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Lexmark Optra 1200 (5050-001) Laser Printer Service Manual

1. General Information 5050 001 Operational Theory This printer makes a color image by overlapping each color toner in dot units and fusing them to the paper The process is divided into two steps The first step is the electrophotographic process which forms the image on the PC The second step consists of Feeding Transferring Fusing which feeds the paper transfers the image to the paper and fuses the toner Electrophotographic Process As the photoconductor drum rotates it is electrically charged the image is exposed to the PC drum the image is developed with toner the image is transferred to the paper and the PC drum is cleaned 1 8 Service Manual 5050 001 Electrical Charge Exposure sells DE x LA n RE Transfer Developme General Information 1 9 5050 001 Photoconductor Drum The photoconductor drum uses aluminum as the base material and a layer of organic photo conductor OPC on the surface A characteristic of this layer is that only the part that the light shines on becomes conductive Electrical Charge Unit The charge roller of the electrical charge unit evenly charges the surface of the drum The static latent image forms on the photo sensitive drum HVU1 1 10 Service Manual 5050 001 Exposure Assembly The exposure
2. REAR SIDE 14 6 FRONT SIDE LEFT SIDE 6 2 5 4 Service Manual 8 _ 67 2 lt p mee 43 Co 40 RIGHT SIDE 5050 001 Electrical Components OHP sensor Cover Safety switch Output bin full Ur sensor actuator Output bin full MPF pa Thermostat sensor Paper exit sensor Face up down Po Sensor Belt thermister Belt up down BUD sensor Paper remaining sensor Registration sensor Humidity sensor Cassette size sensor Connector Locations 5 5 5050 001 Sensors Drum gear sensor Color Drum gear sensor BK Toner sensor Operation panel Drum drive gear sensor BK ee drive gear sensor Color Connector Locations 5 6 5050 001 Power Supply Board 614 MPS E 5 g q je o g INTERLOCK SWITCH J D on T D OT di w oO J n 9 is ral 2 o O 8 Loz Z Connector Locations 5 7 5050 001 High Voltage Unit 1 Board 614 HVU1 1 4 C2 CM02 14 CI CMO3 2 CMOS E48 JE48 ve m i eS 40 39 14 Es CM04 Connector Locations 5050 001
3. m a a a ma ma al alal oadl ols sa ga 4ala a al al a a a al lal a a al al a 29 11G0334 Second Harness 30 11G0199 Locking Wire Saddle 31 11G0420 Locking Wire Saddle 32 11G0336 Edging Saddle 35 11G0340 Mini Bushing 39 11G0531 Interface Card Connector Mounting Bracket 40 11G0573 Interface Connector Bracket 41 11G0532 Option Junction Cable 42 11G0705 Bracket 43 11G0706 Installation Sheet 44 11G0659 Heater Drive Board 230 Volt 45 11G0660 Resistor Heater Drive Board 230 Volt 47 11G0708 AC Cable Rear 48 11G0709 HPVDO Harness 49 11G0710 HBVDO Harness Parts Catalog 7 31 5050 001 Assembly 7 cont 7 32 Parts Catalog 5050 001 Assembly 7 cont Electrical Ref ie Units Description 7 6 11G0310 L Paper Size Board A P611 PSZ 7 11G0311 1 Paper Size Bracket 8 11G0312 1 Size Sensor Plate 9 11G0313 1 High Voltage Unit 2 P614 HVU2 10 11G0314 1 Hvt Bracket 11 11G0315 1 Plate Holder 12 11G0316 1 Plate Feeder 13 11G0317 1 Hv Cable 14 11G0318 1 Power Switch 15 11G0319 1 Power Switch Cable 16 11G0320 1 Switch Holder 17 11G0321 1 Transfer Belt Power Connector Holder 24 11G0328 1 OPEL Cable 25 11G0329 1 HVU2 Harness P614 HVU2 30 11G0199 4 Locking Wire Saddle 33 11G0338 1 Paper Size Harness Asm 614 PSZ 34 11G0339 1 H
4. Ref ue Units Description 6 34 11G0435 1 Solenoid Spring 35 11G0293 1 Clutch Lever 36 11G0294 1 Solenoid Bracket 37 11G0295 1 Cassette Support Plate 38 11G0296 1 Paper Feed Ground Plate 39 11G0297 1 Carrying Gear 40 11G0298 1 Idler Gear 41 11G0299 1 Idler Gear 35 42 11G0300 1 W Gear 21 x 39 43 11G0301 1 Idler Gear 38 46 11G0701 2 MPF Guide 47 11G0702 1 Pad 48 11G0703 1 Clamp NS 11G0575 1 OHP Sheet Detect Sensor Also order 11G0576 NS 11G0576 1 OHP Sheet Detect Sensor Also order 11G0575 NS 11G0577 1 Screw Parts Packet 6 Parts Catalog 7 29 5050 001 Assembly 7 Electrical Parts Catalog 5050 001 Assembly 7 Electrical Part G Ref Number Units Description 7 1 11G0305 MPS Power Supply P611 MPS 115 Volt 1 11G0541 MPS Power Supply P611 MPS E 230 Volt 2 11G0306 Interlock Rod Lever Bracket 3 11G0307 Interlock Rod Lever 4 11G0308 Insulation Sheet MPS 5 11G0309 Sealed Plate MPS 15 11G0319 Power Switch Cable 18 11G0322 Fan Power Supply 19 11G0323 Fan Main 20 11G0324 Printer Controller Board P614 PRCONT 21 11G0325 EEPROM Printer Controller Board 22 11G0326 High Voltage Unit 1 P614 HVU1 23 11G0327 HVU Bracket 26 11G0330 IF Power Cable Asm 27 11G0331 Power Cable Asm 28A 11G0332 28B 11G0704 VDOL Wire Harness 115 Volt PBVDOF Wire Harness 230 Volt
5. 2 30 Optional Paper Feed Service Check 2 31 Paper Jam Service Check 4sscisssusssussssasessus 2 31 Paper Carrying Service Check 2 33 Paper Exit FU FD Service Check 2 35 Paper Low Empty Tray 1 2 3 Service Check 2 36 Paper Tray Missing Size Service Check 2 36 Remove Paper Sensor Service Check 2 37 Power Supply Service Check oics0cis0e0320959 0040cs4ed 2 37 Marks on Paper Service Check 2 38 Image Quality Troubleshooting 2 39 Print Quality Probleisindse dca Geen sciseenieceewece ess 2 39 Sensor Service CHECK 222 4c4ciiaesdcacsavesadsacceeedia 2 46 BET EE EE 3 1 Power On Self Test Sequence 3 1 Using the Operator Panel cccscectseetsecetaeewtewewsan 3 2 Operator Panel BUtHtOns sssssssssssssssssssssesesenses 3 3 Printing the Menu Settings 622ss02sssuuseumesenmamse 3 4 Operator Menu Disabled 2 2c00cceeccceecceeececeecen 3 4 Menu Overview 2 sus scemessauesenessedesemmasedaenses 3 4 Diagnostic Mode sisssisaississsasssasesast assssnss 3 6 Diagnostic Menu Group sssssussssussseumsenmasenanten 3 6 Setting Printer top Margin 4 s4ssssissssusssessacesen 3 10 Color Calibration of Printer 424 444ssussssuassumasseuas 3 13 PHA TESS sssssasssasssssansassasssnesssnssssastaaes 3 15 Input Output Source Print Tests
6. MPF Solenoid 9 Remove the registration sensor and the connector of the remaining paper sensor and cut the cable tie Repair Information 4 55 5050 001 10 Press and slide the paper cassette support plate and remove the paper feed base 4 screws Cassette Support Plate 11 Remove the turn guide 4 screws Paper Feed Base Turn Guide 4 56 Service Manual 5050 001 12 Remove the paper feed clutch and the paper feed solenoid 13 Remove the paper carrying roller Paper Carrying Roller OHP Sensor Removal 1 Remove the rear cover front cover and right side cover 2 Remove the MPF 3 Remove connector CN132 and harness from the printer control board 4 Remove the OHP sensor photo sensor from the sensor stay Repair Information 4 57 5050 001 Remove the front sub cover Cut the cable tie and remove the front frame Remove the transfer belt unit Remove the turn guide Remove connector CN131 and harness from the control board Remove the OHP sensor LED 1 screw NN ui 4 58 Service Manual 5050 001 Paper Exit Sensor Removal 1 Remove the rear cover 2 Remove the connector 3 Remove the paper exit photo interrupter Be sure the actuator works correctly after you reassemble Output Bin Full Sensor Removal Remove the rear cover
7. 4 Remove the E ring and MPF clutch ED ai Assembly Note Put conductive grease on the contact portion between the shaft of the resist roll and the resist roller ground plate Repair Information 4 25 5050 001 F Pad Removal 1 Remove the MPF roller 2 Remove the pad by releasing 2 latches F Pad Clean the paper feed roller surface with a cloth dampened with alcohol Registration Sensor Removal 1 Remove the MPF roller 2 Remove the connector and lift out the sensor 4 26 Service Manual 5050 001 MPF Paper Empty Sensor Removal 1 Remove the front cover 2 Remove the connector and lift out the sensor from the MPF sensor bracket see Humidity Sensor Removal 1 Remove the rear cover and the right side cover 2 Remove the connector and remove the humidity sensor 1 black screw Repair Information 4 27 5050 001 Printer Controller 614 PRCONT Removal 1 Remove the rear cover and the right side cover 2 Remove the connector and the printer control board 6 screws Ly o gt dl H iig TE TA S MTA JEg ENS OF gr no Dit E Se Installation Notes Be sure to take the EEPROM U107 from the old board and install i
8. 5050 001 Index A abbreviations 1 3 adjustment procedures 4 3 adjustments and procedures following parts replacement 2 1 attendance messages 2 13 belt unit drive frame BUD motor BUD sensor removal 4 12 belt up or down BUD 1 23 button test 3 17 C calibrating the transparency sensor 3 24 cleaning assembly 1 13 clearing paper jams 1 27 clearing the error log 3 26 color calibration of printer 3 13 color print unit missing service check 2 28 Covers 7 2 cross section of printer D developer assembly 1 11 diagnostic menu group 3 6 diagnostic mode 3 6 disk test clean 3 21 DRAM memory test 3 17 drive board removal 4 64 drive 1 de motor service check 2 28 drive 1 removal 4 50 drive 2 and FUD solenoid removal 4 29 drive 2 stepper motor service check 2 29 drum drive gear sensor removal 4 51 1 6 5 2 E electrical charge unit 1 10 electronic board layout 5 4 electro photographic process 1 8 engine board removal 4 14 exiting diagnostic mode 3 27 exposure assembly 1 11 F F pad removal 4 26 fuser assembly 1 19 fuser heat roller and gear H gear 30 removal 4 44 fuser heater removal 4 42 fuser pawl removal 4 39 fuser press roller removal fuser removal 4 30 fuser service check 2 27 fuser thermostat fuse and thermistor removals 4 34 4 37 H handling PWBs with MOISICS 4 1 handling the drum cartridge 4 2 head controller removal 4 21 heater drive board 230 V removal
9. ju Registrtion roller General Information 1 17 5050 001 Separation Assembly The paper separates from the transfer belt at the drive roller section of the belt assembly The electric charge on the paper is then eliminated by the discharge brush Drive Roller a Paper JT i scharge Brush RSS an CS 1 18 Service Manual 5050 001 Fuser Assembly The press roller presses the paper with toner against the heated fuser roller which fuses and fixes the toner to the paper The separator pawl separates the paper from the fuser roller Thermostat A g TX Separator r Roller hk Press Roller Exit Unit The fused paper is ejected from the printer The exit sensor checks the state of the paper while the flap performs the change over of paper exit direction face down face Up As the paper leaves the fuser it pushes down the exit link which turns on the exit sensor on the printer controller The printer controller detects a paper jam if the exit sensor is not turned on within the prescribed time or when it continues to be turned on past the prescribed time Face down face up switching for paper exit is performed by switching the flap lever manual or by command from the interface controller automatic General Information 1 19 5050 001 When automatic switching is set default the face up face down F
10. gt Rear Cover Left Side Cover 2nd CN Cover DT Right Side Cover 4 62 Service Manual 5050 001 Size Sensor Board P611 PSZ Removal 1 Remove the rear cover and the left side cover 2 Remove the connector and the paper size board bracket 2 screws 3 Remove the size sensor board from the bracket 2 screws Repair Information 4 63 5050 001 Drive Board P614 2 3 DRIV Removal 1 Remove the rear cover and the right side cover 2 Remove the connector from the drive board 8 Remove the drive board and the bracket 2 screws 4 Remove the drive board from the bracket 4 screws KA JE O Paper Feed Motor 2 PM42 Removal 1 Remove the rear cover and the right side cover 2 Remove the harness from the motor 3 Remove the motor 2 screws 4 64 Service Manual 5050 001 Paper Feed Roller Removal 1 Remove the rear cover and the right side cover 2 Move the plunger of the paper feed clutch solenoid out of the way to make the clutch move freely Turn the paper feed roller and remove the screw 3 Remove the paper feed roller from the shaft If the roller has oil on it clean it with a cloth dampened with alcohol ai hg EN D E Paper F
11. 022002c20esneeeseeewsn 3 15 Prat Quay Pages t2c0ccngcsasoosadctcunoweeed Bou actean 3 16 LOD Hardware T st ss sssassauuseuuseedaseumasedaac 3 17 BUUGN TEST sis siisscssssmisessssansarasessscrmatess 3 17 DRAM Memory Test 44 scsi sssnassenneemaussasa 3 17 Std Parallel Wrap Test and Parallel X Wrap Test 3 18 Serial Wrap Tests 4 44 ssuassouassmausedasseua odae 3 19 Quick Disk Test 5 usa scanner s sut ee se 3 20 Disk Test Cl a ss sisssacisusassuussenmseumaseaae 3 21 Setting the Page Count saasasuamasakesann makan as name 3 23 Viewing the Permanent Page Count 3 23 Viewing and Resetting the Drum Counters 3 24 Calibrating the Transparency Sensor 3 24 Viewing the Error Log 444ssusscuvsamsessmsesmsens 3 25 Clearing the Error Log 424 44ussuasssuasemmasseua 3 26 US NoOR US ss sous ses messes se ke hk ee 3 27 Exiting Diagnostics Mode 22 22 ssssssesasseuassau 3 27 iv Service Manual 5050 001 Test Pit lassestases skesasa svake anse eee ew woes 3 28 TeSt PD Z ssmrsanmssanarsne Piamans sew R ie 3 29 Repair Information 4 444ssscsisssssscssmsuneusn 4 1 Precautions for Disassembly and Cleaning 4 1 Handling the Printed Circuit Boards with MOS ICs 4 1 Precautions for Handling the Drum Cartridge 4 2 Pans NOLO MP os cduwe eet doed eSak 4 3 Adjustment Procedur s aus sesaussmeonsemessamensanusse 4 3 Transfer
12. High Voltage Unit 2 Board P614 HVU2 CNOUT1 Oo 1 21 2 IG CNOUT2 wo LU B ql fl TL JF12 JF JF78 hv I O Cc ol O r 1Z LIS O FR JW1 3 L ON9 OL Connector Locations 5 9 5050 001 Optional Paper Feed Controller Board P614 2 3 DRIV Connector Locations 1 4 g i I 2 1 CN903 CN904 19 O CN901 DE SIS KR o m 2 a S am N o lt A Sia N 2 D 3 O 2 3 S a 3 ST Q 8 2 8 co t 2 Z N N O N P614 2 3DRIV 5 10 5050 001 Printhead Controller Board P614 HD CONT D CN207 KL 24 N a U201 SS r 36 v a 37 144 37 oO a gt 72 109 72 i 73 108 BLACK EEP ROM v 14 k d CN210 1 CM208 KR 36 v 44 73 108 U208 36 Vv 36 37 144 37 72 109 72 73 108 P614 73 HDCONT U209 YELLOW CYAN EEP ROM EEP ROM 2 CN209 312 24 2 U231 CN202 MR MAGENTA EEP ROM N al CN206 YR 251 24 25 Connector Locations 5 11 5050 001 Printer Controller Board P614 PRCONT E 1 2 40 181 em
13. 1 2 Remove the connector from the paper full sensor harness 3 Remove the paper exit unit 4 Remove the paper exit cover Be careful not to drop the exit flame from the exit cover Repair Information 4 59 5050 001 5 Pull out the exit unit from the exit cover Be careful of the output bin sensor harness 6 Remove the paper full sensor from the exit cover 4 60 Service Manual 5050 001 RIP Controller Card Removal 1 Be sure the printer power is off and the power cord is unplugged If the rear output bin is attached to the back of the printer lift it straight up and remove it from the printer Disconnect all cables from the back of the printer Loosen the six thumbscrews on the system board faceplate at the back of the printer Slide the system board completely out of the printer and place it on a level surface Paper Face Up Face Down FUD Delivery Sensor Removal Pon gt Remove the rear cover Remove the connector Remove the photo interrupter Be sure to check the actuator after you reassemble Repair Information 4 61 5050 001 Optional Paper Feeder Removal Procedures Outer Cover Removal 1 Remove the second cover 2 Remove the screw and take off the latch of the upper side and remove the rear cover 1 silver screw 8 Remove the right side cover 3 silver screws Remove the left side cover 3 silver screws 5 Remove the front cover 2 screws
14. Be sure to use the fuse listed in the parts catalog Do not forget to install the ground wire or ground plate to ensure positive conduction Install the screw with a toothed washer in the right position at reassembly Handling the Printed Circuit Boards with MOS ICs The following precautions must be observed when handling circuit boards with MOS Metal Oxide Semiconductor ICs During Transportation Storage During transportation or when in storage new circuit boards must not be indiscriminately removed from their protective conductive bags Do not store or place circuit boards in a location exposed to direct sunlight When it becomes absolutely necessary to remove a board from its conductive bag or case always place it on its conductive mat in an area as free as possible from static electricity Do not touch pins of the ICs with your bare hands Repair Information 4 1 5050 001 During Replacement Before you unplug connectors from the circuit boards be sure the power cord has been unplugged from the power outlet When you remove a board from its conductive bag or case do not touch the pins of the ICs or the printed pattern Place it in position by holding only the edges of the board Before you plug connectors into the board be sure the power cord has been unplugged from the power outlet During Inspection e Avoid checking the IC directly with a multimeter use connectors on the board Never create
15. High Voltage Unit 1 The printed paper has black print Be sure the high voltage unit 1 is prop erly connected If you still have a problem replace the high voltage unit 1 11G0326 Right Sub frame If you still have the problem replace the right sub frame contacts Photoconductor Drum Set If you still have a problem after replacing the right sub frame be sure the PC drum has clean con tacts If necessary replace the PC drum set Missing Colors Possible Cause Action Toner Cartridge Unit Be sure the toner cartridge and the PC drum unit are properly seated Be sure the contacts on the print unit are clean Be sure the print unit is installed in the correct position Run a print test If the problem remains switch the print unit with another color and run a test print If the new color prints replace the failing toner cartridge High Voltage Unit 2 If you still have the problem check the connector on the high voltage Replace the high voltage unit if you still have the problem 11G0313 LED Printhead Unit Replace the printhead if you still have the problem LED Printhead Controller Board If you still have the problem replace the LED printhead controller board 11G0555 Diagnostic Information 2 43 5050 001 Possible Cause Action High Voltage Unit 1 If you still have the problem replace the high voltage unit 1 11G0326
16. Yellow 931 Magenta 932 Cyan 933 Black Printhead Error 1 Be sure all cables to the printhead controller board are correctly seated 2 Replace the appropriate color printhead and printhead EEPROM 3 If you still have the problem replace the printhead controller board 11G0555 4 Do the printhead adjustments See Chapter 3 Diagnostic Aids 939 COMM Error Printer Controller Board Replace the printer controller board 11G0324 941 Code ROM Error Replace the EEPROM code controller solid state drive J10 on the RIP control card Diagnostic Information 2 5 5050 001 Error Message or Symptom Action 942 Font ROM Error Replace the EEPROM code controller solid state drive J10 11G0607 on the RIP control card 943 RIP Controller Board Font The font and RIP controller card Error 11G0604 are incompatible 944 RIP Controller Card Error Replace the RIP controller card 945 11G0604 Be sure to move the 946 solid state drive memory and option 947 cards from the old card to the new 950 one 953 954 955 NVRAM Failure Replace the RIP controller card 11G0604 RIP Controller Card 960 Memory Error DRAM Replace memory SIMM J1 or J3 on the RIP controller card These must be in a set of 2 and must be 50 NS EDO SIMMS 961 Memory Error Option Replace memory SIMM J4 or J5 on DRAM the RIP controller card These must be in a set of t
17. 1234567 Calibrating the Transparency Sensor If you replace the printer controller board you must re calibrate the transparency sensor This sensor must be calibrated for both Paper and Transparency The senor is located in the MP Feeder so these calibrations must be done from the MP Feeder To calibrate the sensor for paper the user selects Paper Sensor Cal Paper 3 24 Service Manual 5050 001 After the user selects Paper the printer requests that paper be loaded The paper must be loaded into the MP Feeder Sensor Cal Insert Paper Press Go for the calibration to begin The operator panel displays that it is performing the calibration Sensor Cal Performing Cal When the engine has completed the Sensor Calibration for paper the operator panel returns to the Sensor Calibration menu Sensor Cal Paper Press Menu gt or Menu lt to calibrate the sensor for Transparency These same steps should be followed for transparencies The transparency must be loaded in the MP Feeder After the sensor has been calibrated for both paper and transparencies the calibration is complete Viewing the Error Log The Error Log aids the Customer Engineer by providing a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error is displayed in position 1 and the oldest error is displayed in position 12 a
18. 5050 001 Assembly 6 Feeder Parts Catalog 7 26 5050 001 Assembly 6 Feeder Ref dr Units Description 6 1 11G0304 1 Paper Feed Unit 2 11G0268 1 Registration Roller Asm 3 11G0269 1 Registration Clutch 4 11G0270 2 Auxiliary Roller 5 11G0271 2 Paper Feed Roll Asm 6 11G0272 1 Paper Feed Shaft 7 11G0273 1 Guide Stay Sheet 8 11G0274 1 Ground Plate Guide 9 11G0275 1 Sensor Stay 10 11G0219 1 Photo Interrupter Registration Sensor 11 11G0276 1 Registration Sensor Lever 12 11G0277 1 Registration Sensor Spring 13 11G0553 1 MPF Sensor Lever 14 11G0556 1 Bracket Sensor MPT 15 11G0243 1 Photo Interrupter MPF Paper Detect Sensor 16 11G0278 1 Upper Guide Stay 17 11G0279 1 Paper Feed Base 18 11G0280 2 Noise cut Roller 19 11G0281 1 MPF Clutch 20 11G0282 1 MPF Roller 21 11G0285 1 Turn Guide 22 11G0283 1 MPF Friction Pad 23 11G0284 1 Friction Pad Spring 24 11G0286 4 Idler Roller 25 11G0287 4 Roller Guide 26 11G0288 2 Roller Spring 27 11G0302 2 Roller Spring 28 11G0289 1 Carrying Roller 29 11G0303 2 Metal Bushing 30 11G0290 1 Bushing 31 11G0140 1 Bushing 32 11G0291 1 Paper Feed Clutch 33 11G0292 1 Paper Feed Solenoid 1 Parts Catalog 7 27 5050 001 Assembly 6 cont Feeder Parts Catalog 7 28 5050 001 Assembly 6 cont Feeder
19. Black A Asm 614 dss 20 11G0505 1 Paper Face Up Face Down Sensor Cable 22 11G0215 1 Paper Exit Guide 23 11G0138 1 Bushing 24 11G0513 1 Paper Face Up Face Down Sensor Lever 25 11G0516 L Torsion Spring 26 11G0216 L Paper Exit Shaft Lower 27 11G0140 2 Bushing 28 11G0220 1 Gear 29 11G0217 1 Sensor Spring 30 11G0218 1 Sensor Lever 31 11G0219 2 Photo Interrupter Belt Up Down BUD Sensor 55 11G0243 2 Photo Interrupter Paper Detect 69 11G0257 1 Drive Unit 1 70 11G0256 1 Dc Motor Drive 1 71 11G0581 1 Drum Drive Gear Sensor 72 11G0259 1 Dc Motor Cable Asm 75 11G0258 1 Drive Unit 2 76 11G0260 1 Stepper Motor Drive 2 77 11G0262 1 Rubber Mount 78 11G0261 1 Solenoid Bracket 79 11G0534 1 Thermistor Cable 80 11G0340 1 Bushing 81 11G0535 1 Face Up Face Down FUD Solenoid Bracket 82 11G0536 1 Face Up Face Down FUD Solenoid Actuator 83 11G0537 1 Face Up Face Down FUD Solenoid Spring 84 11G0538 1 Face Up Face Down FUD Solenoid Parts Catalog 7 23 5050 001 Assembly 5 cont 7 24 Parts Catalog 5050 001 Assembly 5 cont Ref i Units Description 5 85 11060626 2 Setting Label MR 86 11G0627 2 Setting Label Cr 87 11G0628 2 Setting Label Yr 88 11G0629 2 Setting Label Bkr 95 11G0699 1 Exit Sensor Cover 96 11G0700 1 Face Up Down Sensor Cover NS 11G0725 1 Exit Sensor Grid NS 11G0540 1 Screw Parts Packet 5 Parts Catalog 7 25
20. Only 4 to 6 0 displayed if a parallel port is available via PCI slot 1 Par Strobe Adj Only 4 to 6 0 displayed if a parallel port is available via PCI slot 2 MAINTENANCE MENU 80 Maint Cnt 0 to 1048675 Diagnostic Aids 3 9 5050 001 Reset 80 Maint Yes No ERROR LOG Display Log Clear Log US Non US Defaults e US e Non US EXIT DIAGNOSTICS See Exiting Diagnostics Mode on page 3 27 Setting Printer top Margin The purpose of this function is to adjust the leading edge margin for each tray It is the top margin of how the page is printed For A4 or letter it is on the leading long edge of the page that the margin is being adjusted K Top Margin Adjust Print Tests The purpose of this function is to adjust the leading edge margin for each tray It is the top margin of the direction the page is printed For A4 or letter it is on the leading long edge of the page that the margin is being adjusted What is being adjusted is the time from when the leading edge of the paper reaches the print registration rollers and when the printer starts putting toner on the paper You must adjust both the CMY and K top margins The K Top Margin must be adjusted first To make this adjustment Note Before adjusting the margins be sure the printer is set to the graphic print mode in the Print Quality Menu The Print Quality Menu is a sub menu of the Color Menu Sele
21. Transfer Belt Unit If you still have the problem replace the transfer belt unit 11G0202 Partial Darkness or Lightness Possible Cause Action Photoconductor Drum Unit Check the PC drum for exposure to strong light Transport Belt Waste Toner Bottle Transport Belt Unit Check the underside of the transport belt for toner buildup Uneven Printing Possible Cause Action Photoconductor Drum Check for condensation or dirt on the photoconductor drum LED Head Clean any dirt off the exposure sur face of the LED head Transfer Belt Unit Be sure the transfer belt is clean and not damaged Replace parts as nec essary Periodic Dirt Possible Cause Action Fuser Heat Roll Check for dirt or damage to the fuser heat roll Fuser Press Roll Check for dirt or damage to the fuser press roll Fuser Oil Roll Check for dirt or damage to the fuser oil roll 2 44 Service Manual 5050 001 Possible Cause Action Photoconductor Drum Check for scratches on the surface and replace if necessary White Spots Possible Cause Action Condensation Check the LED head and photoconductor drum surface for condensation Let it dry naturally Printhead Unit Firmly install the PC drum unit into DS TS the toner cartridge and the print unit into the printer Belt Unit Check the belt unit for
22. negative and right positive Y controls the vertical plane and by adjusting the value for Y you move the color radar image up negative and down positive These values are determined by examining the left side of the radar page Values for X are 1 600th of an inch and Y values are 1 2400th of an inch Theta controls the skew or angle of rotation To get the correct reading adjust X and Y before Theta Examine the left side radar images for their deviation from black Look at all the radar images along the left and make a judgment on the value of the adjustment When the color is correctly adjusted the color radar image should lay directly on the black radar image Press the Menu button until the color you want to adjust displays and then press Select Change the displayed value and press Select You should see message displayed that the value is Saved Press the Menu button until X Adjustment Print Tests displays and press Select Look at the color and the value you have changed and see if this is acceptable If so go to the next adjustment If it is not acceptable go back to the color and adjust it again Repair Information 4 7 5050 001 12 When all the values are acceptable for all colors exit diagnostics Example of the Adjustment Here is a sample of the magenta radar image Looking down the left side for both X and Y you can see the X value is close to correct It may be a little to the righ
23. oO I R Lever Insulation Sheet Sealed Plate Note Be sure the I R lever works correctly after you reassemble Repair Information 4 47 5050 001 Size Sensor Board P611 PSZ Removal Remove the rear cover the front cover and the left side cover Remove the power supply board Remove the HDRV board 230 V only Remove the connector and the PSZ bracket 2 screws Remove the P611 PSZ assembly size sensor board from the bracket 2 screws O1 OO D Toner Remaining Sensor Drum Gear Sensor Removal 1 Remove the HVU1 2 Remove the right sub cover 2 screws 3 Remove the right sub frame toner drum gear sensor 4 screws 4 Unsnap and remove the sub frame toner drum gear sensor cover 5 Remove one black mounting screw and lift out the toner remaining sensor 4 48 Service Manual 5050 001 Subframe Repair Information 4 49 5050 001 Drive 1 Removal 1 Remove the right sub frame toner drum gear sensor unit 2 Remove the belt unit 3 Remove the lock cover 1 screw Lock Cover 4 Remove the 6 outside mounting screws and 2 screws from inside the frame Remove drive 1 Installation Note When you connect the terminals be sure to connect them to the correct position After the terminals are connected firmly insert the insulating cover 4 50 Service Manual 5050 001 Drum Drive Gear Sensor P614 DGS Removal 1 Remove the gear
24. 2 11G0151 1 Paper Exit Unit 3 11G0131 1 Paper Exit Cover 4 11G0150 1 Discharge Brush 5 11G0134 6 Roller Fitting Plate Upper 6 11G0135 8 Paper Exit Roller 7 11G0132 1 Feed Guide 8 11G0133 1 Paper Delivery Flap 9 11G0137 1 Paper Exit Shaft Upper 10 11G0140 2 Bushing 11 11G0138 1 Bushing C 12 11G0139 1 Lock Spring 13 11G0141 1 Paper Exit Frame 14 11G0143 1 Ground Plate Paper Exit 15 11G0144 2 Pulley 16 11G0145 1 Belt 17 11G0147 6 Lower Roller Fitting Plate 19 11G0561 1 Clutch Lever Paper Delivery Flap 20 11G0507 1 Clutch Lever Spring 21 11G0508 1 Paper Delivery Flap Plate Shaft 22 11G0146 1 One Way Clutch Gear 20 23 11G0511 1 Screw stopper 24 11G0136 1 Harness Cover 25 11G0515 1 Paper Exit Feeder Base 1 26 11G0518 1 Paper Exit Feeder Base 2 27 11G0142 1 Switch Spring 28 11G0563 1 Photo Interrupter Remove Paper 29 11G0521 1 Paper Exit Feeder Rod 30 11G0523 1 Paper Exit Feeder Spring 31 11G0527 1 Paper Exit Feeder Lever 32 11G0528 1 Sensor Cable Remove Paper NS 11G0566 1 Screw Parts Packet 2 Parts Catalog 7 7 5050 001 Assembly 3 Upper Unit Parts Catalog 5050 001 Assembly 3 Upper Unit Ref s Units Description 3 1 11G0152 1 Head Frame 7 11G0159 4 LED Head Asm LED Head EEPROM 7 11G0719 4 LED Head Asm LED Head EEPROM Level 2 8 11G0160 4 Head Spring L
25. 2 22 Service Manual 5050 001 Message Action 88 color Toner The printer has detected that the specified toner Empty cartridge is completely out of toner You must install a new toner cartridge before you can continue printing If this message does not reset after you replace all the toner cartridges replace the toner remaining sensor 11G0207 in the right sub frame 91 Fan Error 1 Be sure connector C193 is properly connected to the RIP controller card RIP Controller 2 Replace the fan 11G0606 if necessary Board Fan 3 If you still have a problem replace the RIP controller card 11G0604 2xx Paper Jam The printer has detected a paper jam in the area Open Top Cover specified in the message In some cases the Open Top Cover message alternates with the Paper Jam message to remind you to open the top cover and remove jammed paper from inside the printer You must remove all the paper from the entire paper path Close the top cover and press Go to clear the message If the message does not clear go to the Paper Jam Service Check on page 2 30 Symptom Table Symptom Action You cannot print color Make sure the Color Correction menu item is not set to Black amp White Make sure the color print units are completely installed in the printer Make sure the RIP controller card is completely inserted in the printer and the thumbscrews are securely tightened Go to the Transp
26. 3 11G0606 1 Fan 4 11G0607 1 16MB Solid State Drive 4 11G0714 1 20MB Solid State Drive Japan 5 11G0608 2 16MB SIMM EDO 50ns 5 11G0609 2 32MB SIMM EDO 50ns 6 11G0611 1 Bracket Riser Card 7 11G0612 1 Tray Controller Card 8 11G0613 2 Screw Fan 9 11G0614 6 Screw Thumb 10 11G0615 2 Nut Fan Parts Catalog 7 37 5050 001 Assembly 9 Fuser Parts Catalog 7 38 5050 001 Assembly 9 Fuser Ref es Units Description 9 1 11G0603 1 Fuser Oil Roll 2 11G0542 1 Fuser 230 Volt 2 11G0375 1 Fuser 115 Volt 2 11G0722 1 Fuser 100 Volt Japan 3 11G0342 1 Fuser Cover 4 11G0619 1 Caution Label Fuser Cover 5 11G0343 1 Lock 6 11G0344 1 Lock Screw 7 11G0345 1 Fuser Guide 8 11G0346 2 Release Lever 9 11G0347 2 Screw 10 11G0549 1 614 Heater 230 Volt 10 11G0348 1 614 Heater 115 Volt 10 11G0723 1 614 Heater 100 Volt Japan 11 11G0349 1 611 Thermostat Asm 11 11G0724 1 611 Thermostat Asm Level 2 12 11G0551 1 611 Fuse Asm 13 11G0214 4 Stopper Screw 14 11G0351 1 Terminal 15 11G0352 1 Cord Retainer 16 11G0353 1 614 Thermistor Asm 17 11G0354 1 Paper Feed Guide 18 11G0355 1 Fuser Lower Cover 19 11G0356 1 Discharge Brush 20 11G0357 1 Arm L 21 11G0358 2 Bushing P 22 11G0359 1 Press Roller 23 11G0360 1 Arm R 24 11G0514 1 Press Roller Guide 25 11G0661 1 Guide Roller Asm 26 11G036
27. 4 45 humidity sensor removal HVU1 board layout 5 8 HVU1 removal 4 29 HVU2 board layout 5 9 HVU2 removal 4 46 image quality troubleshooting 2 38 initial check 2 2 input output source print tests 3 15 L LCD hardware test 3 17 LED head light quantity adjustment 4 27 Index l 1 5050 001 4 5 LED head removal 4 10 LEDs cleaning 2 40 light quantity 3 14 lubricants and cleaners 6 2 maintenance approach 1 1 maintenance kit 6 1 marks on paper service check 2 37 menu overview 3 4 MPF paper empty sensor removal 4 27 mpf removal 4 23 multipurpose feeder 1 16 O ohp sensor removal 4 57 operational theory 1 8 operator menu disabled 3 4 operator panel buttons 3 3 operator panel removal 4 22 optional paper feed controller board layout 5 10 optional paper feed service check 2 30 optional paper feeder removal procedures 4 62 options 1 5 outer cover removal 4 62 output bin full sensor removal 4 59 over head projector OHP mode 1 26 overhead projection sheet detection sensor adjustment 4 6 P paper carrying service check 2 32 paper cassette feeder 1 16 paper exit fu fd service check 2 34 paper exit sensor removal 4 59 paper feed assembly removal 4 53 paper feed clutch solenoid and transfer belt removal 4 67 paper feed motor 2 removal 4 64 l 2 Service Manual paper feed roller removal 4 24 4 65 paper feed transfer and fusing 1 14 paper FUD delivery sensor removal 4 61 paper handling 5
28. 43 5050 001 Assembly 11 Optional Feeder Base Parts Catalog 7 44 5050 001 Assembly 11 Optional Feeder Base Ref ek Units Description 11 2 11G0397 1 Rear Cover 2 3 11G0107 1 Second Connector Cover 5 11G0129 1 Rubber Plate 24 11G0411 2 Mini Bushing B 25 11G0412 1 Spring Hook 26 11G0193 2 Lock Cover A 27 11G0192 2 Lock Cover B 28 11G0196 1 Bottom Frame Cover 29 11G0191 1 Cassette Ground Plate 30 11G0195 2 Cassette Rail 31 11G0310 1 Paper Size Board P611 PSZ 32 11G0311 1 Paper Size Board Bracket 33 11G0312 1 Paper Size Sensor Plate 34 11G0201 4 Foot 35 11G0188 1 Second Connector Bracket 36 11G0413 1 Drive Frame Out 2 42 11G0415 1 Motor Harness Parts Catalog 7 45 5050 001 Assembly 11 cont Parts Catalog 5050 001 Assembly 11 cont Ref Gr Units Description 11 37 11G0421 1 Drive Frame In 2 38 11G0422 1 Gear Idler 62 39 11G0423 1 Gear S37xs24 40 11G0424 1 Gear H97xs34 41 11G0414 1 Paper Feed Motor Pm42 Optional Feeder 42 11G0415 1 Motor Harness 43 11G0416 2 Pcb Bracket 44 11G0417 1 Paper Feeder Driver Board P614 2 3 DRIV 45 11G0418 1 Side Cover R2 46 11G0419 1 Second Harness Asm 47 11G0420 1 Locking Wire Saddle 48 11G0425 1 Bottom Frame 2 Parts Catalog 7 47 5050 001 Assembly 11 cont Optional Feeder Base 7 48 Pa
29. 50 foot serial cable General Information 1 5 5050 001 Printer Supplies Supply Toner cartridges Description cartridges Black magenta cyan or yellow Approximate yield 6 500 pages each 5 coverage Photoconductors coating roll together e Black photoconductor with fuser e Cyan magenta and yellow photoconductors packaged 13 000 pages each Transparencies A4 and letter size Cross Section of Printer oo N DO a BB WO YP mi sut D 13 14 15 16 17 Fuser Roller Press Roller Heater Fuser Oil Roller Paper Exit Sensor Lever Belt Drive Roller Belt Thermistor Transfer Belt Transfer Sheet Cleaning Blade Charging Roller Photoconductor Drum LED Printhead Development Roller Developer Supply Roller Developer Doctor Blade Developer Agitator 1 6 Service Manual 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Absorption Roller Registration Upper Roller Metal Registration Roller Rubber Registration Sensor Registration Sensor Lever MPF Roller Feeder Friction Stop Pad MPF Assembly Paper Carrying Roller Paper Noise Cut Roller Pick up Paper Feed Roller Paper Remaining Detection Lever Paper Remaining Detection Sensors Transport Belt Blade Transport Belt Waste Bottle Belt Unit Drive Motor Interface RIP Controller Card 5050 001 DG Av 43 G204 06 7 GS N N
30. Assembly 5 cont Base 2 7 20 Parts Catalog 5050 001 Assembly 5 cont Base 2 Ref ie Units Description 5 31 11G0219 2 Photo Interrupter Belt Up Down BUD Sensor 39 11G0267 1 Changing Shaft 44 11G0232 2 Bushing 45 11G0233 1 Hook Shaft 46 11G0234 2 Hook 47 11G0235 1 Interlock Lever Rear 48 11G0236 1 Interlock Lever Bracket 49 11G0239 1 Link Base 50 11G0238 1 Open Spring 51 11G0237 1 Open Button 52 11G0242 1 Link 53 11G0241 1 Hook Spring 54 11G0240 1 Release Hook Lever 56 11G0558 1 Photo Interrupter Paper Detect 59 11G0246 1 Paper Detect Sensor Harness Asm 60 11G0247 1 Mpf Clutch Lever 61 11G0248 1 Mpf Clutch Spring 62 11G0249 1 Solenoid 2 Paper Feed 63 11G0250 1 Solenoid Bracket 64 11G0251 1 Belt Up Down BUD Frame Unit 67 11G0254 1 Belt Up Down BUD Motor 68 11G0255 1 Belt Up Down BUD Harness Asm Parts Catalog 7 21 5050 001 Assembly 5 cont Parts Catalog 5050 001 Assembly 5 cont Base 2 Ref ek Units Description 5 5 11G0543 1 Sub Frame Asm Rm 6 11G0544 1 Sub Frame Asm Rc 7 11G0545 1 Sub Frame Asm Ry 8 11G0206 4 Sub Frame Asm Rk 9 11G0207 4 Toner Sensor A Asm 611 Tn 10 11G0548 1 Drum Sensor Color A Asm 614 dss 11 11G0550 1 Drum Sensor
31. Belt Tracking Adjustment 4 3 Thermistor Rank Adjustment 4 5 LED Head Light Quantity Adjustment 4 5 Top Margin for Color Mod 422 ssuusssdassuuessauusaus 4 5 Top Margin for Black and White Mode 4 6 Overhead Projection Sheet Detection Sensor Adjustment 4 6 Printhead Adjustments X Y and Theta 4 6 Removal Procedures 424 2 sous muscu kake anne an 4 10 LED Head Removal ssscsssssssasessunesessesemaencses 4 10 Transfer Belt Unit Removal 2222200200002 eetsewessvewees 4 11 Paper Remaining Sensor Removal 4 12 Belt Unit Drive Frame BUD Motor BUD Sensor Removal 4 12 Engine Board PG14 ENG BB Removal 4 14 Cover Removals 2200 cause somaesuaesmassenasemame 4 15 Head Controller Board P614 HDCONT Removal 4 21 Operator Panel Removal 44e ssiusseuunseuamses 4 22 MPF Removal ss Sousse sise east ss oedema nd band 4 23 Paper Feed Roller Removal 4 24 MPF R le i626 ccd dee be eens eens cms seu Sin sme 4 25 F Pad Removal 42 sus s nmssdussanesedassesasddans 4 26 Registration Sensor Removal 4 26 MPF Paper Empty Sensor Removal 4 27 Humidity Sensor Removal 4 27 Printer Controller 614 PRCONT Removal 4 28 AVUI U Removal sisi ss me cence cccneecaaa cana sacs
32. Macintosh UNIX 1 4 Service Manual 5050 001 Options Option Optional drawer Description Support unit and 250 sheet tray up to two drawers may be installed underneath the printer 250 sheet tray Replacement tray Memory e 32MB option two 16MB memory cards e 64MB option two 32MB memory cards e Maximum installed memory 128MB Hard disk option 2 5 inch hard disk to store fonts forms job statistics and spooled jobs Hard disk adapter ribbon cable For installing compatible Lexmark or third party hard disks MarkNet S internal network adapters Adapters available to support the following topologies e Ethernet 10BaseT and 10Base2 e Ethernet 10 100BaseTX Token Ring connects the printer to a Token Ring network via DB9 or RJ45 Tri port adapter Provides support for the following interfaces e Serial RS 232C RS 422A which can also be configured to support a class 1 fax modem e High speed Infrared local connections LocalTalk network connection Parallel port adapter Provides additional parallel port Infrared adapter For use with the tri port adapter receives infrared beam from an IrDA compatible workstation Serial interface adapter Converts the printer s parallel port to a serial port Parallel cables High speed bidirectional 10 foot and 20 foot 1284 B parallel cables 9 8 foot 1284 A C parallel cable Serial cable
33. Right Heater Plate 5 Remove the fuser roller 6 Remove gear H Fuser roller 4 44 Service Manual 5050 001 Heater Drive Board 230 V Only 1 Remove the rear cover front cover and left side cover 2 Remove the HK bracket 2 screws 3 Remove the connector 4 Remove the HDRV board from the HK bracket 2 screws Repair Information 4 45 5050 001 HVU 2 Removal 1 Remove the rear cover the front cover and the left side cover 2 Remove the connector and HVT bracket 8 Remove the HVU 2 from the HVT bracket 6 screws Power Supply Switch Removal 1 Remove the rear cover the front cover and the left side cover 2 Remove the 2 switch mounting screws and pull out the switch 3 Remove each terminal and the switch from the switch holder 4 46 Service Manual 5050 001 Installation Note When you connect the terminals be sure to connect them to the correct position Also after the terminals are connected firmly insert the insulating cover Power Supply Board P614 MPS Removal 1 Remove the rear cover the front cover and the left side cover 2 Remove the connectors on the board 3 Remove the ground wire green yellow gray 117 V only 1 screw 4 Remove the I R lever B S tight 3x6 2 screws Remove the shield plate S tight 3x6 8 screws 6 Remove the insulating sheet and power supply board S tight 3x6 5 screws 7 Remove the connector of the main switch cable
34. a problem replace the paper size Detection detection board 11G0310 Board Diagnostic Information 2 35 5050 001 Remove Paper Sensor Service Check FRU Action 1 Remove Paper Check the operation of the paper full lever and Lever actuator shaft Replace as necessary 2 Paper Full Check the sensor for operation Check for Sensor approximately 5 V from CN109 pin 2 to GND when the sensor is activated Replace if necessary Power Supply Service Check FRU Action 1 Voltage Be sure the switch is on and the power cord is firmly plugged into the printer Be sure the correct voltage is present at the outlet 2 Power Cord Check the power cord for continuity 3 e Fuse e Switch The power supply fuses may be blown Unplug the machine and check fuse F1 on the power supply for continuity If the fuse is good check the power switch connector for continuity 4 Power Supply The power supply may be defective Check the dc power of the power supply Check pins 7 and pin 5 on connector CN604 Pin 7 yellow should read 4 8 V to 5 3 V Pin 5 red should read 22 V to 26 V Replace if necessary 11G0305 115 V 11G0541 230 V 2 36 Service Manual 5050 001 Marks on Paper Service Check If you have evenly spaced marks on the paper measure the distance between the marks and locate the symptom below Check the assembly for dirt or da
35. chapter for more information Parallel The standard parallel interface is the active communication link Parallel x The specified parallel interface is the active communication link Serial x The specified serial interface is the active communication link Network x The specified network interface is the active communication link LocalTalk x The LocalTalk interface is the active communication link Infrared x The infrared interface is the active communication link Fax The Fax interface is the active communication link Diagnostic Information 2 11 5050 001 Message Cancelling Job Meaning The printer is processing a request to cancel the print job Resetting the Printer The printer is deleting any print jobs in progress and restoring all print settings to the user defaults Flushing Buffer The printer is flushing corrupted print data and discarding the current print job Printing Menu Settings A list of the user default settings and the installed options is printing To cancel the print job press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select Printing Font List A list of available fonts for the selected printer language is printing To cancel the print job press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appea
36. i 17 08 I CN111 A 1 2 39 8 CN120 Zz 2 O gt N Zz CN121 2 oO D 5 3 5l CN131 Zz 5 CN102 CN132 B 3 amp CN135 a 1 3 EJ 1 Zz U103 Connector Locations CN107 ere our y 22 CM117 on 807 CN124 1 I 15 l JA Th 2 CN127 CN125 CN118 er ql o CM133 N jt Z oj z a Oo N h z ra OS oJ E in Lu N Tie Zz O ior 5 Q S oO rr 2 3 Z o m Zz 10 Ta CN134 2 12 5 12 5050 001 Size Sensor Board P611 PSZ SWA01 Q SW402 Z O sw403 P611 PSZ Connector Locations 5 13 5050 001 RIP Controller Card l J7 Sen C1iQ R229 R230 C193 C204 a Of ge C2074 I A14 C208N 1 C209 i C2117 I R129 Eri Ole jem sm RP14 8 R146 1 Co i g g g Q
37. k N Photoconductor Drum LED Printhead w 14 15 16 17 Development Roller Developer Supply Roller Developer Doctor Blade Developer Agitator 5 2 Service Manual 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Absorption Roller Registration Upper Roller Metal Registration Roller Rubber Registration Sensor Registration Sensor Lever MPF Roller Feeder Friction Stop Pad MPF Assembly Paper Carrying Roller Paper Noise Cut Roller Pick up Paper Feed Roller Paper Remaining Detection Lever Paper Remaining Detection Sensors Transport Belt Blade Transport Belt Waste Bottle Belt Unit Drive Motor Interface Controller 5050 001 aD 43 42X14 46 47 15 Connector Locations 5050 001 Electronic Board Layout No Name No Name 1 Main Fan 8 Operator Panel 2 Power Supply Fan 9 HVU1 3 Power Supply 10 Printer Controller Board 4 Paper Size Detection Board 11 Printhead Controller Board 5 Paper Size Detection Board 12 Drive Unit 1 2nd Paper Feeder Option 6 Power Switch 13 Drive Unit 2 7 HVU2 14 RIP Controller Board
38. operator panel menus press Go before you send a job to print Menu gt and lt Menu Press the Menu gt or lt Menu button to e Enter the menus from the ready state Scroll to the next Menu gt or the previous lt Menu menu menu item or value Increase or decrease a numerical value for a menu item setting e Display the Job Menu or the Supplies Menu while the printer is busy Select Press the Select button to e Select the menu shown on the second line of the display and view the available menu items e Select the menu item shown on the second line of the display and view the available values and the current user default setting for that menu item e Save the value displayed on the second line of the display as the new user default setting e Clear certain messages from the display Return Press the Return button to back up to the previous level of the menu structure without selecting a new menu item or value Stop Press the Stop button when the printer displays the Busy or Waiting message to temporarily stop all activity The message Not Ready is then displayed until you press Go to continue printer activity For example if you need to load paper in a tray while a job is printing press Stop and wait for the printer motors to idle before removing the tray from the printer Reinsert the loaded tray and then press Go Diagnostic Aids 3 3 5050 001 Printing the Menu Settings
39. power indicator blinks indicating the test is in process The printer continually runs the same test until cancelled from the control panel by pressing Return or Stop Each time the test finishes the screen is updated with the result If the test passes then the Pass Count increments by 1 However if the test fails then a signal error is displayed for approximately 3 seconds and then the Fail Count increments by 1 Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final test results are displayed Press Return or Stop to exit the test Serial Wrap Tests The Serial Wrap Test is used to check the operation of the serial port hardware using a wrap plug Each serial signal is tested To perform the wrap test follow these steps e Disconnect the serial interface cable and install the serial wrap plug Select HARDWARE TESTS from the Diagnostics Menu Select the appropriate Serial Wrap Test Serial 1 Wrap Serial 2 Wrap The following screen is displayed and the printer begins testing the serial hardware for the first time Serial X Wrap PHARE FHH Terminology The X indicates which serial port is being tested 1 optional serial port 1 2 optional serial port 2 Diagnostic Aids 3 19 5050 001 P represents the number of times the test has passed finished successfully Initially 000000 is displayed for The maximu
40. press Return or Stop Button Test The Button Test is used to verify the operation of each button on the operator panel When Button Test is selected the following screen is displayed OP OP OP OP OP OP While a button is pressed CL Closed is displayed Likewise while a button is not pressed OP Open is displayed If the wrong message is displayed then the button is malfunctioning To exit the button test press Return or Stop The previous menu screen is displayed when the button is released DRAM Memory Test The DRAM Memory Test is used to check the validity of DRAM both standard and optional DRAM The test involves writing patterns of data to DRAM to verify that each bit in memory can be set and read correctly When this test is selected from the operator panel the following screen is displayed and the printer begins testing DRAM memory for the first time DRAM Memory Test PH F HHHH Terminology P represents the number of times the memory test has passed finished successfully Initially 000000 is displayed for The maximum pass count is 999 999 Diagnostic Aids 3 17 5050 001 F represents the number of times the memory test has failed finished with errors Initially 00000 is displayed for The maximum fail count is 99 999 The power indicator blinks indicating the memory test is in process The printer continually runs the same test until cancelled fr
41. rear cover If the message will not reset check the two actuating rods contacting the power supply interlock switch Activate the interlock switch with the power on and replace the power supply 11G0305 115 V 11G0541 230 V if the message does not reset Insert Tray x Insert the tray indicated tray 1 2 or 3 Go to the Paper Tray Missing Size Service Check on page 2 35 Change tray The printer is requesting a different size or type media than what it detects is in the identified tray tray 1 2 3 or the multipurpose feeder The message displays either the custom media name defined using the MarkVision utility the media size or the media size and type it is looking for To clear the message e If the correct paper type is loaded in the tray but the Paper Type setting was not changed from the operator panel press Go to continue printing Press Select to ignore the request and print on the media already installed in the tray Load media of the requested size and type in the tray indicated e If you re printing on larger paper make sure the Size Detection setting is correct e Cancel the print job Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select Diagnostic Information 2 13 5050 001 Message Load tray Action The printer is trying to feed paper from a source it detects is empty t
42. replace the operator panel 99A0001 If the diamonds remain check the pairs of SIMMs in J1 and J3 and the riser card 11G0605 for proper installation If you still have the problem replace the operator panel If this does not fix the problem replace the ROM solid state drive 11G0607 If you still have a problem replace the RIP controller card 11G0604 If your machine beeps 5 times and the screen is blank or all diamonds replace the operator panel Foggy print Black pages Blank print White spots Poor reproduction Incorrect color image registration Dirt on back of paper Low image density White and black lines and bands Go to Print Quality Problems on page 2 38 Diagnostic Information 2 25 5050 001 Symptom Action Evenly spaced marks on the paper or a single mark in the same place on every page Go to the Marks on Paper Service Check on page 2 37 Poor fusing Go to the Fuser Service Check on page 2 27 Toner scatter on front or back of paper Check the following Excessive toner buildup Clean off the toner and run a test print Transfer belt assembly Transfer belt toner waste bottle Fuser separation pawl Paper Jam 201 clears but the fuser and exit rollers do not rotate while the printer resets Go to the Drive 2 Stepper Motor Service Check on page 2 29 Paper will not feed from MPF Be sure you have pap
43. scratches or nicks Be sure there is no toner buildup on the belt Replace the belt unit if it is damaged 11G0202 Sensor Service Check 1 2 When a paper jam or malfunction occurs identify the sensor that is probably responsible for the problem Probe the connector with a test meter Test the LED between signal pin 5 V and GND Change the state of the selected sensor and see if the signal is approximately 5 V For example When a paper jam occurs and you think the paper exit sensor is responsible Check it as follows 1 2 3 Remove the paper jam Access the sensor signal Use a sheet of paper to move the actuator so that the sensor is blocked Check the meter for changes in the reading between signal pin 5 V pin and GND If the sensor is not working correctly and the actuator is not damaged replace the failing sensor Diagnostic Information 2 45 5050 001 6 If this does not correct the problem replace the printer controller board 7 If both the sensor and actuator are working correctly replace the indicated part in the service check you were working in 2 46 Service Manual 5050 001 3 Diagnostic Aids Note When trouble shooting or prior to making any adustment to print quality always be sure of the following The printer is installed on a level rigid surface The OPCs are never exchanged Do not exchange a black OPC for a color OPC as they will have different surface
44. setting printer top margin 3 10 setting the page count 3 23 size sensor board layout 5 13 size sensor board removal 4 48 4 63 standard features 1 4 status messages 2 10 symptom table 2 23 T thermistor rank 3 15 thermistor rank adjustment 4 5 tools 1 1 top margin for black and white mode adjustment 4 6 4 52 4 26 top margin for color mode adjustment 4 5 transfer assembly 1 12 transfer belt 1 21 transfer belt tracking adjustment 4 3 transfer belt unit removal 4 11 transport belt bud service check 2 29 U using the operator panel 3 2 V viewing and resetting the drum counters 3 24 viewing the error log 3 25 viewing the permanent page count 3 23 Index l 3 5050 001 l 4 Service Manual
45. sure e Exit Flap connector CN122 is properly connected to the Clutch Lever printer controller board e Gears e Fuser Exit Upper Roller Paper Exit FU FD Service Check FRU Action FU FD Sensor Actuator If the paper is not exiting to the back paper face up tray or the face down tray check the sensors 2 34 Service Manual 5050 001 2 Flap Check the paper flap vane that directs the paper to the proper tray Replace if necessary 3 FU FD Check the FU FD solenoid for continuity Also be Solenoid sure connector CN122 is properly connected to the printer controller board 4 Gear Check the gears and the metal actuating cam for e Cam wear or damage Replace as necessary Paper Low Empty Tray 1 2 3 Service Check FRU Action 1 Actuator Check the actuators and sensors for proper e Sensor operation Tray 1 connector CN106 pin 9 and pin 12 to GND Tray 2 and 3 CN903 pin 2 and pin 5 to GND Paper Tray Missing Size Service Check FRU Action 1 Actuator Check the paper size indicator for proper operation e Sensor Check the size detection fingers for proper operation Replace parts as necessary Do a sensor check for the paper size detection board It should be approximately 5 V when activated Tray 1 CN108 pins 11 12 and 13 to GND e Tray 2 and 3 CN904 pins 1 2 and 3 to GND 2 Paper Size If you still have
46. the Diagnostic Aids chapter Transfer Belt Tracking Adjustment Make this adjustment whenever you replace the transfer belt unit or when the belt is not tracking properly As you check and make this adjustment Be careful not to scratch or leave fingerprints on the belt Do not expose the photosensitive drum kit to direct light To check belt tracking 1 Enter the diagnostic mode 2 Select Transfer Belt Adjustment 3 Select the time you want the belt to run seconds and let the belt run After the belt stops check for a minimum clearance between the belt and the right hand stopper If the belt tracks against either the right or left stopper you need to make the adjustment Repair Information 4 3 5050 001 Absorption Roller Absorption Roller Stopper Stopper To make the adjustment 1 Be sure the transfer belt unit is installed correctly and the 6 mounting screws are tight 2 Insert an allen wrench into the hole in the offset collar Use the wrench as a lever to rotate the collar clockwise or counter clockwise and adjust belt tracking Rotate the collar one click at a time and recheck the adjustment Adjust for minimum clearance at the front left corner of the belt unit without the belt tracking against the right stopper 4 4 Service Manual 5050 001 e Ifthe belt tracks too far to the right rotate the collar clockwise ifthe belt tracks too far to the l
47. y a D I nl a a oojoo cic J5 J4 193 J1 J10 q j R28 i 9 R27 R17 GJ x JT47 JT37 J2 r 5 14 Service Manual 5050 001 6 Preventive Maintenance Maintenance Kit After printing approximately 100 000 pages the message 80 Scheduled Maintenance appears on the printer display This message indicates that it s time to replace the following parts Fuser Unit Belt Unit Paper Feed Rollers 2 Routine replacement of these parts ensures peak printer performance and helps prevent print quality problems and paper feed problems resulting from worn parts The parts are contained in the maintenance kits listed below Maintenance Kit Part number Printer power supply 11G0601 115 V 750 W 11G0602 220 V 750 W The printer can be used until you are able to schedule a service call The Maintenance status message appears on the display until the printer is serviced Preventive Maintenance 6 1 5050 001 Periodic Maintenance This table lists the parts to be periodically cleaned by the servicer Part Name Method Paper Feed Unit e Paper Feed Roller MPF Roll If there is dust or dirt remove it and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Registration Unit Registration Roller Upper and Lower If there is dust or dirt remove it and wipe the surface lightly with a dry cloth If it is still dirty clean with
48. 1 2 From the printer operator panel press the Menu gt or lt Menu button to enter the menus Continue to press and release Menu gt or lt Menu until you see TESTS MENU Press the Select button TESTS MENU is then displayed on the first line and Print Menus is on the second line Press Select again to print the page The message Printing Menu Settings is displayed The printer returns to Ready status after the menu settings page prints Operator Menu Disabled If the operator has disabled the menu and you want to run operator print tests turn the machine off then press Go and Stop as you turn the machine on Menu Overview Menus or menu items in italic are displayed only when the required option is installed Capitalized menu items for example PAPER SIZE have submenus SUPPLIES MENU lt color gt Toner lt color gt PC Drum Tray 1 Status Tray 2 Status Tray 3 Status MAINTENANCE MENU Maint Status COLOR MENU Color Correction Print Quality Toner Saver PAPER MENU Paper Source PAPER SIZE PAPER TYPE CUSTOM TYPES Output Bin Substitute Size Configure MP Size Detection FINISHING MENU Copies Blank Pages Collation Separator Sheets Separator Source Multipage Print Multipage Order Multipage View Multipage Border TESTS MENU Print Menus Print Fonts Print Directory Print Demo Color Samples Factory Defaults Format Flash Format Disk Job Acct Stat Hex Trace
49. 1 paper jam service check 2 30 paper low empty tray 1 2 3 service check 2 35 paper path for color pages 1 25 paper path for mono pages 1 25 paper remaining sensor removal 4 12 4 66 paper tray missing size service check 2 35 parallel wrap test part numbers 2 1 parts not to be touched 4 3 periodic maintenance 6 2 photoconductor drum 1 10 post card mode 1 27 power on self test sequence 3 1 power supply board layout 5 7 power supply board removal 4 47 power supply service check 2 36 power supply switch removal 4 46 precautions for disassembly and cleaning 4 1 print modes 1 26 print quality pages 3 16 print quality problems 2 38 print tests 3 15 printer controller board layout 5 12 printer controller removal 4 28 printer messages 2 3 printer supplies 1 6 printhead adjustment 3 13 printhead adjustments 4 6 printhead controller board layout 5 11 printing from the multipurpose feeder 1 28 printing the menu settings 3 4 Q quick disk test 3 20 3 18 5050 001 R registration 1 17 2 41 registration roller removal registration sensor removal removal procedures 4 10 remove paper sensor service check 2 36 RIP controller card layout 5 14 RIP controller card removal 4 61 S safety information ix second paper feed 1 26 sensor locations 5 6 sensor service check 2 45 separation assembly 1 18 serial number 1 2 serial wrap test 3 19 service checks 2 27 service error message table 2 4
50. 11G0565 1 Screw Parts Packet 3 Parts Catalog 7 13 5050 001 Assembly 4 Base 1 Parts Catalog 7 14 5050 001 Assembly 4 Base 1 Ref ee Units Description 4 1 11G0176 1 Top Frame 2 11G0177 1 Side Frame L 3 11G0178 1 Power Supply Bracket A 4 11G0179 1 Power Supply Stay 5 11G0180 1 Power Supply Bracket B 6 11G0181 1 Front Stay USA 6 11G0691 1 Front Stay Non USA 7 11G0182 1 Front Frame B 8 11G0183 1 Front Frame 9 11G0184 1 Bottom Frame 10 11G0185 1 Side Frame R 11 11G0186 L HVU1 Mounting Stay 12 11G0187 1 Fan Stay 13 11G0618 1 Cable Tie 14 11G0188 1 Second Connector Bracket 15 11G0189 1 Hinge Frame 17 11G0191 1 Cassette Ground Plate 18 11G0192 2 Lock Cover B 19 11G0193 2 Lock Cover A 20 11G0194 2 Release Lower Plate 21 11G0195 2 Cassette Rail 22 11G0196 1 Bottom Frame Cover 23 11G0197 1 Registration Roller Ground Plate 24 11G0198 1 Mpf Ground Plate 25 11G0517 1 Locking Saddle 26 11G0199 3 Locking Wire Saddle 27 11G0201 4 Foot 28 11G0519 1 Torsion Bearing R 29 11G0520 1 Torsion Bearing L 30 11G0522 2 Torsion Bearing Nut 31 11G0526 1 Controller Card Mounting Plate NS 11G0617 1 Screw Parts Packet 4 Parts Catalog 7 15 5050 001 Assembly 4 cont 7 16 Parts Catalog 5050 001 Assembly 4 cont Ref e
51. 1G0128 1 Mpf Asm 18 11G0113 1 Mpf Side Location L 19 11G0114 1 Mpf Side Location R 20 11G0115 1 Mpf Tray L 21 11G0623 1 Label Paper Size Mpf 22 11G0116 1 Sub Tray 23 11G0117 2 Mpf Rack 24 11G0118 1 Mpf Pinion 25 11G0119 1 Mpf Lock Lever 26 11G0120 1 Tray Lock Spring 27 11G0122 1 Mpf Spring 28 11G0123 1 Mpf Cover Parts Catalog 7 3 5050 001 Assembly 1 cont Covers 7 4 Parts Catalog 5050 001 Assembly 1 cont Covers Ref es Units Description 1 29 11G0121 2 Mpf Holder 30 11G0524 1 Bracket Rh Mpf Tray 31 11G0525 1 Bracket Lh Mpf Tray 34 11G0631 1 Rear Paper Exit Tray Asm 36 11G0651 2 Screw Mtg Rear Paper Exit Tray 38 99A0001 1 Operator Panel Asm 39 99A0630 1 Bezel Operator Panel 39 99A0541 1 Bezel Operator Panel Japan NS 11G0567 1 Rating Plate Low 115 Volts NS 11G0568 1 Rating Plate High 230 Volts NS 11G0718 1 Rating Label 100 Volts Japan NS 11G0623 2 Cushion Exit Tray NS 11G0569 1 Screw Parts Packet 1 NS 11G0622 1 Label Instruction Mpt NS 11G0732 1 MPF Wire Extension Parts Catalog 7 5 5050 001 Assembly 2 Paper Exit Parts Catalog 5050 001 Assembly 2 Paper Exit Ref ie Units Description 2 1 11G0149 1 Paper Exit Cover H
52. 2 Remove the left rear and right rear sub covers Repair Information 4 31 5050 001 3 Remove the thermistor harness connector 4 32 Service Manual 5050 001 5 Remove the 3 black fuser mounting screws 6 Lift the fuser out of the printer When you reinstall the fuser be careful not to damage the fuser exit sensor actuator Repair Information 4 33 5050 001 Fuser Thermostat Fuse and Thermistor Removals 1 Remove the fuser cleaner Release Lever S J 2 Remove the 2 release levers and stopper screws 3 Unlatch the center of the fuser guide slide it to the right and remove the fuser guide 4 34 Service Manual 5050 001 Thermal Fuse Ip 2 QD 4 Remove the temperature fuse silver screw with washer Thermoswitch Repair Information 4 35 5050 001 5 Remove 1 screw and the terminal 6 Remove the thermistat switch from the terminal 1 silver screw with washer Thermistor 7 Remove the thermistor 1 silver screw with washer 4 36 Service Manual 5050 001 Fuser Press Roller Removal 1 Remove the fuser cleaner and the fuser guide 2 Remove the lock screw wave washer and washer 3 Slide the fuser cover toward the driving side and remove the fuser cover to the upper side Lock Fuser Cover le Lock 4 Remove the press spring by loosening 2 of the
53. 3 4 Service Manual 5050 001 JOB MENU Cancel Job Reset Printer Print Buffer SETUP MENU Printer Language Power Saver Resource Save Download Target Print Timeout Wait Timeout Auto Continue Jam Recovery Page Protect Print Area Display Language Alarm Control Printer Usage Timing Adj Job Buffer Size Job Accounting Job Acct Limit PCL EMUL MENU Font Source Font Name Point Size Pitch Symbol Set Orientation Lines per Page A4 Width TRAY RENUMBER Auto CR after LF Auto LF after CR POSTSCRIPT MENU Print PS Error Font Priority Image Smoothing PARALLEL MENU STD PARALLEL PARALLEL OPT 1 PARALLEL OPT 2 PCL SmartSwitch PS SmartSwitch NPA Mode Parallel Buffer Job Buffering Advanced Status Protocol Honor Init Parallel Mode 1 Parallel Mode 2 SERIAL MENU SERIAL OPTION 1 SERIAL OPTION 2 PCL SmartSwitch PS SmartSwitch NPA Mode Serial Buffer Job Buffering RS 232 RS 422 RS 422 Polarity Serial Protocol Robust XON Baud Data Bits Parity Honor DSR Diagnostic Aids 3 5 5050 001 NETWORK MENU NETWORK OPTION 1 INFRARED MENU Infrared Port LOCALTALK MENU LocalTalk Port NETWORK OPTION 2 PCL SmartSwitch PCL SmartSwitch PCL SmartSwitch PS SmartSwitch PS SmartSwitch PS SmartSwitch NPA Mode NPA Mode NPA Mode Infrared Buffer LocalTalk Buffer Network Buffer Job Buffering Job Buffering Job Buffering Window Size NPA Hosts NETWORK x SETUP Transmi
54. 4 29 Drive 2 U and Face Up Face Down FUD Solenoid Removal 4 29 Fuser Removal 2 200222 cceceeseees see dan make ma 4 30 Fuser Thermostat Fuse and Thermistor Removals 4 34 Fuser Press Roller Removal sacs sesssessesanmsnses 4 37 Fuser Pawl Removal ssuassususauasssumesaumessuaeusa 4 39 Fuser Heater Removal 4 42 Fuser Heat Roller and Gear H Gear 30 Removal 4 44 Heater Drive Board 230 V Only 4 45 HVU 2 Removal s avasaavusauemsanus sees eens enews ee 4 46 5050 001 Power Supply Switch Removal 4 46 Power Supply Board P614 MPS Removal 4 47 Size Sensor Board P611 PSZ Removal 4 48 Toner Remaining Sensor Drum Gear Sensor Removal 4 48 Drive 1 Removal oi sisi sissssissssissauniessrs saisesss 4 50 Drum Drive Gear Sensor P614 DGS Removal 4 51 Registration Roller Removal 4 52 OP Sensor HeMOVAl u sdctagestedes T ged 4 57 Paper Exit Sensor Removal 2 dass sasssossnaonasragest 4 59 Output Bin Full Sensor Removal sis vsassceen dene eee mes 4 59 RIP Controller Card Removal 04 4 20vumesrema 4 61 Paper Face Up Face Down FUD Delivery Sensor Removal 4 61 Optional Paper Feeder Removal Procedures 4 62 Guter Cover RSMmoval 2c c lt e0endade tenesevteeneauewmamaut 4 62 Size Sensor Board P611 PSZ Removal 4 63 Drive
55. 5 1 Heat Roller 27 11G0366 1 Gear 30 Parts Catalog 7 39 5050 001 Assembly 9 cont Fuser 7 40 Parts Catalog 5050 001 Assembly 9 cont Fuser Ref ek Units Description 9 28 11G0367 1 Fuser Frame 29 11G0368 1 Heater Plate L 30 11G0369 2 Bushing Holder 31 11G0564 2 Bearing Holder 32 11G0370 2 Compression Spring 33 11G0371 1 Gear Holder 34 11G0372 1 Heater Plate R 35 11G0373 1 Idler Gear 18 36 11G0374 1 Stay Bracket 38 11G0711 1 Paw Bracket 39 11G0662 1 Pawl Spring 40 11G0663 1 Separation Pawl NS 11G0570 1 Heat Resist Cable Tie NS 11G0572 1 Screw Parts Packet 9 Parts Catalog 7 41 5050 001 Assembly 10 Cassette Parts Catalog 7 42 5050 001 Assembly 10 Cassette Part Ref Number Units Description 10 1 18A1413 1 Tray Cassette Assembly 2 11G0376 1 Tray Plate with Cork 3 11G0378 1 Side Location R 4 11G0379 1 Click R 5 110380 1 Lower Plate Push Lever R 6 11G0381 2 Lever Lock 7 11G0382 2 Lock Spring 8 11G0383 2 Push Up Spring 12 11G0387 1 Rear Location Plate 13 11G0388 1 Side Lock 14 11G0389 1 Side Location L 15 11G0390 1 Click L 16 11G0391 1 Lower Plate Push Lever L 17 11G0392 2 Rack 18 11G0118 1 Pinion 19 11G0393 1 Instruction Label NS 11G0616 1 Screw Parts Packet 10 Parts Catalog 7
56. 760 mm and the width is about 320 mm The belt is conductive and has no seams Be careful not to scratch the belt or leave fingerprints on it when you replace the assembly If toner remains on the belt in a scratch or on a finger print it will create dirty spots on the back side of the paper If you do find a stain on the belt wipe it off with a dry cloth or alcohol General Information 1 21 T ke ates _ 5050 001 Belt Up or Down BUD During monochrome printing only the black transfer and development functions operate An electromagnetic clutch in drive 1 operates to pull the transfer belt down as the paper passes under the color PC drums A cam on the changing shaft moves the belt up and down through gears from the belt unit drive motor on the unit frame The position of the belt is detected by a photo sensor from the cam position General Information 1 23 5050 001 BUD Motor 1 24 General Information 5050 001 Paper Path for Mono Pages Transport Belt Paper Path for Color Pages Transport Belt General Information 1 25 5050 001 Second Paper Feed Up to two additional paper feeders can be used under this printer The operation of the optional paper feeder is the same as the base printer cassette feeder except t
57. 9 11G0161 4 Head Cover L 10 11G0162 4 Pressure Base L 11 11G0502 4 Head Spring R 12 11G0163 4 Head Cover R 13 11G0164 4 Pressure Base R 18 11G0503 1 Head cable M 115 V 18 11G0720 1 Head Cable M 100 V Japan 19 11G0504 1 Head cable M 115 V 19 11G0652 1 Head Cable M 230 V 20 11G0506 1 Head cable C 115 V 20 11G0653 1 Head Cable C 230 V 21 11G0509 2 Head cable C 115 V 21 11G0654 1 Head Cable C 230 V 22 11G0510 2 Head cable Y 115 V 22 11G0655 1 Head Cable Y 230 V 22 11G0721 1 Head Cable Y 100 V Japan 23 11G0512 1 Head cable K 115 V 23 11G0656 1 Head Cable K 230 V 24 11G0670 1 MLFG Harness 25 11G0671 1 HDFG Harness 26 11G0672 1 YLFG Harness 27 11G0673 1 DLFG Harness 32 11G0620 1 Nylon Clip 33 11G0657 1 KRCFFC Cable 115 V 33 11G0658 1 KRCFFC Cable 230 V 34 11G0677 1 CRFG Harness 48 11G0688 1 MCT Harness 49 11G0689 1 YTFG Harness 50 11G0690 1 KTFG Harness Parts Catalog 7 9 5050 001 Assembly 3 cont 7 10 Parts Catalog 5050 001 Assembly 3 cont Upper Unit Ref oe Units Description 3 2 11G0153 1 Hinge Stay 2 3 11G0154 1 Damper Right 4 11G0155 1 Damper Left 14 11G0555 1 LED Printhead Controller Board P614 Hdcont 16 11G0167 1 Insulator Shield sheet 17 11G0168 1 Sealed Plate 18 11G0665 1 Head Cable
58. Adjustment to Gear Only may decrease the time necessary to complete the calibration but you may notice inconsistent color registration on your printed pages You cannot remove paper jammed in the fuser Make sure the printer s top cover is completely open Opening the top cover all the way releases the fuser roll so you can easily remove jammed paper Go to the Paper Carrying Service Check on page 2 32 You cannot clear the paper jam message To clear the paper jam messages you must remove all paper from the printer s paper path Check both inside the printer as well as the paper source you were using Open and close the top cover and press Go If the message does not clear go to the Paper Jam Service Check on page 2 30 2 24 Service Manual 5050 001 Symptom Action Paper jam in pick up assembly Go to the Paper Carrying Service Check on page 2 32 Fuser failure Go to the Fuser Service Check on page 2 27 No paper pick up from multipurpose tray Go the Paper Carrying Service Check on page 2 32 No paper pick up from upper or lower cassette Go to the Optional Paper Feed Service Check on page 2 30 Registration roller does not rotate Go to the Drive 1 DC Motor Service Check on page 2 28 Operator panel does not operate properly Go to the Diagnostic Aids chapter and run the LCD and Button tests If the tests fail
59. Board P614 2 3 DRIV Removal 4 64 Paper Feed Motor 2 PM42 Removal 4 64 Paper Feed Roller Removal avcccnnsdsas serena dex ones 4 65 Paper Remaining Sensor Removal 4 66 Paper Feed Clutch Solenoid and Transfer Roller Removal 4 67 Connector Locations issii is eccscedeses neneke s 5 1 Paper Handling 22 seececeetseeeiemersseeseewereweee en 5 1 Cross Section of Printer s scsssssssssssseseseusesesesse 5 2 Electronic Board Layout cect eect sees ssgesememseuamces 5 4 Electrical Components 2s4224scssssssssessesessnec 5 5 SGNSOSssietenes seve dcawereneateneve sees eeeeeeeew den 5 6 Power Supply Board 614 MPS E 5 7 High Voltage Unit 1 Board 614 HVU1 5 8 High Voltage Unit 2 Board P614 HVU2 5 9 Optional Paper Feed Controller Board P614 2 3 DRIV 5 10 Printhead Controller Board P614 HD CONT 5 11 Printer Controller Board P614 PRCONT 5 12 Size Sensor Board P611 PSZ sise scssssssssenans 5 13 RIP Controller Card sisssssassssussmassenaseumassrasme 5 14 Preventive Maintenance 6 1 Maintenance Kit 2 sisissssscsncossuesesasesseseessess 6 1 Periodic Maintenance 22 2 c0cccee ets e ts ew ete eeawe ween 6 2 Lubricants and Cleaners 245ssssussesssscsesenences 6 2 Parts Catalog 22442 scuaceduussumssegassumescaums on 7 1 Howto Use This Pa
60. Diagnostic Aids chapters Diagnostic Information 2 1 5050 001 Printer Controller Board Printer Control EEPROM U107 If you replace the printer controller board remove EEPROM U 107 and install it on the new board Also check the printhead adjustment If you change the EEPROM the following items must be checked and adjusted in the service mode LED Head Light Quantity Belt Thermistor Rank e Margins Top K and C e Printhead Adjustments X Y and Theta OHP Sheet Sensor e Counters RIP Controller Card If you replace the RIP controller card be sure to move the solid state drive memory and option cards from the old card to the new one Transfer Belt Transfer belt tracking Transfer belt thermistor rank e Printhead adjustments X Y and Theta e Margins Top K and C LED Printhead Controller Board or LED Printhead e LED printhead light quantity e Printhead adjustments X Y and Theta e Margins Start Initial Check Before you start troubleshooting check the following 2 2 Service Manual 5050 001 Installation Environment The power supply line voltage is plus or minus 10 of the rated line voltage The machine is securely installed on a level surface in a well ventilated place The room temperature is between 10 and 32 C 50 and 90 F and the relative humidity between 20 and 80 e Avoid sites generating ammonia gas high temperature or high humidity near water fauc
61. G0297 1 Carrying Gear 11 11G0431 1 Carrying Roller 2 12 11G0280 2 Noise cut Roller 13 11G0432 1 Paper Feed Guide 2 14 11G0433 2 Roller Spring 15 11G0434 2 Roller Guide 2 16 11G0286 2 Idle Roller 17 11G0296 1 Paper Feed Ground Plate 18 11G0295 1 Cassette Plate 19 11G0249 1 Solenoid 2 Paper Feed 20 11G0293 1 Clutch Lever 21 11G0435 1 Solenoid Spring 22 11G0294 1 Solenoid Bracket NS 11G0562 1 Screw Parts Packet 12 Parts Catalog 7 51 5050 001 Assembly 13 Optional Features Ref se Units Description 11G0601 1 Maintenance Kit Low Voltage 11G0602 1 Maintenance Kit High Voltage 11G0727 1 Maintenance Kit Japan 11G0632 1 Machine Return Packaging Material 11G0733 1 Hard Disk 11G0610 1 Cable Hard Disk 99A0422 1 Ethernet 10BaseT and 10Base2 99A0421 1 Ethernet 10 100BaseT 99A0420 1 Token Ring Connects via DB9 or RJ45 99A0560 1 Tri port Adapter 99A0467 1 Parallel Port Adapter 99A0424 1 Infrared Adapter 99A0545 1 Serial Interface Adapter 99A0702 2 Printer Stand Caster Non Locking 99A0703 2 Printer Stand Caster Locking 99A0704 1 Printer Stand Grommet Wire 99A0705 2 Printer Stand Lock Cam 99A0706 1 Printer Stand Storage Shelf 99A0707 1 Printer Stand Door Assembly Cabinet 99A0710 1 Printer Stand Filler Rear Top Piece 99A0711 1 Printer Stand Table Assembly Large 99A0712 1 Printer Stand Table Assembly Small 7 52 Service Manual
62. Lift the engine board bracket Be careful not to damage the harness 3 Remove the connector 4 Remove the engine board from the bracket Engine Board Interface Card 4 14 Service Manual 5050 001 Cover Removals Paper Exit Cover Top Cover Left Side Cover Rear Cover Left Rear Sub Cover Left Front Sub Cover Right Front Sub Cover Right Side Cover Front Cover 4 15 Repair Information 5050 001 1 Open the paper exit cover and remove the screw in the right rear sub cover Place a screwdriver between the right side cover and the sub cover then move the sub cover toward the center of the printer and lift it out 2 Remove left rear sub cover mounting screw and remove the cover 4 16 Service Manual 5050 001 3 Push the latch to lift the top cover remove the 5 black mounting screws and remove the top cover 4 Remove the second paper cassette connector cover on the bottom of the rear cover 5 Remove the rear paper exit tray if it is installed Remove the 2 rear paper exit tray mounting studs 7 Remove the 3 silver screws from the upper latch and rear cover OO Upper Latches 8 Lift the cover over the top latches and lift back 9 Loosen the cable tie and remove the face down stacker sensor harness connector if it is installed Repair Informa
63. M 230 V 18 11G0720 1 Head Cable M 100 V Japan 19 11G0504 1 Head cable M 115 V 19 11G0652 1 Head Cable M 230 V 20 11G0506 1 Head cable C 115 V 20 11G0653 1 Head Cable C 230 V 21 11G0509 2 Head cable C 115 V 21 11G0654 1 Head Cable C 230 V 22 11G0510 2 Head cable Y 115 V 22 11G0655 1 Head Cable Y 230 V 23 11G0512 1 Head cable K 115 V 23 11G0656 1 Head Cable K 230 V 24 11G0670 1 MLFG Harness 25 11G0671 1 HDFG Harness 26 11G0672 1 YLFG Harness 27 11G0673 1 DLFG Harness 29 11G0675 1 STFG Harness 30 11G0676 1 DFG Harness 32 11G0620 3 Nylon Clip 33 11G0657 1 KRCFFC Cable 115 V 34 11G0677 1 CRFG Harness 44 11G0684 1 Sheet Selected 45 11G0685 1 FLFG Harness 48 11G0688 1 MCT Harness 49 11G0689 1 YTFG Harness Parts Catalog 7 11 5050 001 Assembly 3 cont 7 12 Parts Catalog 5050 001 Assembly 3 cont Ref ek Units Description 3 5 11G0501 2 Bracket Ground Plate 6 11G0157 2 Ground Plate Head Frame 26 11G0672 1 YLFG Harness 27 11G0673 1 KLFG Harness 28 11G0674 1 FRFG Harness 37 11G0678 1 Top Cover Spring 38 11G0679 2 Cover 39 11G0680 3 FFC Spring A 40 11G0681 1 FFC Spring B 41 11G0339 1 Ground Plate 42 11G0682 2 Side Ground Plate 43 11G0683 2 Ground Plate 45 11G0685 1 FLFG Harness 46 11G0686 1 FTFG Harness 48 11G0688 1 MCT Harness 49 11G0689 1 YTFG Harness 50 11G0690 1 KTFG Harness NS
64. RAM Viewing the Permanent Page Count The permanent page count setting cannot be modified using the operator panel It can only be viewed using the Diagnostics menus When Permanent Page Count is selected the following screen is displayed Perm Page Count 1234567 Diagnostic Aids 3 23 5050 001 Viewing and Resetting the Drum Counters The drum counters increment when a page is printed The drum counter for a particular plane only increments if that color is printed It increments by 1 for Letter A4 A5 B5 and envelopes It increments by 1 2 for Legal and B4 It increments by 2 for 11 x 17 and A3 The counters are used to track printer usage The current value of the drum counter may be viewed in the Diagnostic menus by selecting Drum Count menu However this value is not viewable from the Ready menu The following screen illustrates the operator panel when the cyan drum counter is displayed The leftmost digit 1 in this example will blink indicating it is the first digit to be changed To change the value press either Menu gt or Menu lt until the value you want is displayed Press Select to move to the next digit The next digit 2 in this example will blink Continue modifying each digit using this method To skip a digit and keep its current value press Select When Select is pressed after the final digit 7 in this example the new page count is stored in NVRAM Cyan Drum Count
65. Saver message replaces the Ready message on the display When Power Saver is displayed your printer is ready to receive and process data When Power Saver is displayed you can Press Go to quick start the printer e Press Menu gt or lt Menu to enter the menus Engine Warming The printer is warming the fuser to prepare for printing Performing Self Test The printer is running the normal series of start up tests it performs after it is turned on Busy The printer is processing or printing data The light on the operator panel flashes while this message is displayed If a job name has been defined the name replaces the Busy message on the display To cancel the print job press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select Waiting The printer has received a page of data to print but is waiting for an End of Job or Form Feed command or for additional data To print the contents of the print buffer press Go To cancel the print job press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select Not Ready The printer is not ready to receive or process data because someone selected Stop when another message was displayed Press Go to take the printer out of the Not Ready state To cancel the print job press Menu g
66. UD solenoid is turned on by a signal from the printer controller and the spring clutch transfers power from the exit roller to the flap The flap is then switched by a cam mechanism on the exit roller m rS A z 1 20 Service Manual 5050 001 Transfer Belt The positive charged absorption roller charges the paper as it enters the transfer belt The belt rotates at the same speed as the photoconductor drum Toneris transferred to the paper in the order of magenta cyan yellow and black As the paper passes each photoconductor drum the static from the transfer belt pulls toner away from the drum A little waste toner sticks to the transfer belt as it passes the drum This toner is scraped off and collected in the transfer belt waste toner bottle Temperature changes can affect the registration of colors To compensate for these changes the temperature of the belt drive roller is monitored and the timing of the LED head writing is adjusted accordingly The transfer belt unit should be replaced approximately every 100 000 pages When you replace a transfer belt you must set the thermistor resistance settings for temperature control You must also make the print adjustments There are two printhead adjustments the margin adjustment and the color image registration adjustment Make these adjustments in the service mode The length of the transfer belt is about
67. V Cable Asm 36 11G0529 1 Rh Cable 37 11G0530 1 Humidity Sensor Housing 38 11G0571 1 Sensor Humidity 45 11G0660 1 Resistor Heater Drive Board 230 Volt 46 11G0707 1 AC Cable Front Parts Catalog 7 33 5050 001 Assembly 7 cont 7 34 Parts Catalog 5050 001 Assembly 7 cont Ref ek Units Description 7 NS 11G0562 1 Screw Parts Packet 7 NS 11G0726 L Insulator Sheet HVT NS 11D0328 1 Power Cord U S Canada APG LV LAD LV NS 11D0333 1 Power Cord Denmark NS 11D0334 1 Power Cord Europe England NS 11D0334 1 Power Cord France NS 11D0334 1 Power Cord Germany NS 11D0335 1 Power Cord Italy NS 11D0334 1 Power Cord Spain NS 11D0336 1 Power Cord Swiss French NS 11D0336 1 Power Cord Swiss German NS 11D0336 1 Power Cord Swiss ltalian NS 11D0337 1 Power Cord U K NS 11D0338 1 Power Cord Israel NS 11D0339 1 Power Cord South Africa NS 11D0334 1 Power Cord Belgium NS 11D0330 1 Power Cord Argentina NS 11D0331 1 Power Cord Brazil NS 11D0332 1 Power Cord Chile NS 11D0329 1 Power Cord Peru Parts Catalog 7 35 5050 001 Assembly 8 I F Controller 7 36 Parts Catalog 5050 001 Assembly 8 I F Controller Ref ek Units Description 8 1 11G0604 1 RIP Controller Card 2 11G0605 1 Riser Card
68. a soft cloth and alcohol Charge Exposure Unit LED Head If there is dust or dirt remove it and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Transfer Unit Transfer Belt If there is dust or dirt remove it and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Fuser Unit e Heat Roller e Fuser Oil Roller Clean with a soft cloth silicon oil or alcohol Outer Covers Use a synthetic detergent and a damp cloth Lubricants and Cleaners Alcohol or Clean Plastic rubber and Follow Isopropyl external parts manufacturer s directions Lubricating Oil Apply between gears and shafts 10 oil Grease Lubricating Apply to gears 423 grease 6 2 Service Manual 5050 001 7 Parts Catalog How to Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description AR As Required in the Units column indicates that the quan tity is not the same for all machines NP Non Procurable in the Units column indicates that the part is non procurable and that the individual parts or the next higher assembly should be ordered NR Not Recomme
69. a I ENS TK a EE ene mes X Stepping Motor DC Motor Electromagnetic Clutch Drive 2 Drive 1 General Information 1 15 5050 001 Paper Cassette Feeder The printer controller sends a signal to the paper feed solenoid which turns on and drives the paper feed roller connected to drive 1 by a spring clutch The paper in the cassette is picked one sheet at a time amme He Multipurpose Feeder After it receives a signal from the printer controller the MPF solenoid turns on and drives the MPF roller connected to drive 1 by a spring clutch The paper in the multipurpose feeder is picked up one sheet at a time 1 16 Service Manual 5050 001 Registration Paper feed stops temporarily at the registration roller to make the top edge of the paper parallel to the photosensitive drum and to adjust feed timing with the toner image on the photosensitive drum In parallel to the photosensitive drum the rubber registration roller presses against the metal registration upper roller The registration clutch controls the registration roller The registration sensor photo interrupter detects paper as it feeds through senses paper jams and stops paper feed and also starts the electrophotographic process Registration sensor
70. a closed circuit across IC pins with a metal tool e When it is absolutely necessary to touch the ICs and other electrical components on the board be sure to ground your body Precautions for Handling the Drum Cartridge The following precautions must be observed when handling the drum cartridge During Transportation Storage Use the specified carton whenever moving or storing the drum cartridge The storage temperature is in the range between 20 C and 40 C Handling The PC drum in the drum cartridge exhibits greatest light fatigue after being exposed to strong light over an extended period of time Never therefore expose it to direct sunlight Cover the PC when you remove it from the printer Use care not to contaminate the surface of the PC drum with oil base solvent fingerprints and other foreign matter e Do not scratch the surface of the PC drum 4 2 Service Manual 5050 001 Parts not to be touched Any part where the mounting screws are painted red such as the printhead must not be removed disassembled or adjusted Adjustment Procedures The transfer belt tracking adjustment is the only mechanical adjustment in this printer The other adjustments are in the form of printer setup settings entered into the printer from the diagnostic mode This section describes these adjustments and lists the menus and values for each To make the adjustment you will be directed to the appropriate page in
71. ached the fuser If the fuser or exit rollers do not turn during POR go to the Drive 2 Stepper Motor Service Check on page 2 29 FRU Action 1 Registration Check these parts for wear or damage Replace as Roller necessary Be sure all guide surfaces in the paper Clutch path are free of dirt Registration Roller Check the registration roller clutch for continuity Absorption Roller Be sure connector CN104 on the printer controller Transfer Belt board is connected properly Unit Rear Paper Feed Guide Diagnostic Information 2 33 5050 001 The paper has exited the registration roll and entered the fuser FRU Action e Transfer Belt Unit Rear Paper Guide Discharge Brush e Fuser Roller e Fuser Press Roller Remove any buildup of toner Replace and damaged or worn parts Fuser Separation Pawl Be sure the separation pawls do not have any toner built up on the tips Replace any damaged or worn parts The paper has entered the fuser and exited the printer FRU Action e Fuser Roller Remove any toner buildup and replace any worn or e Fuser Press damaged parts Roller e Fuser Separation Pawl Fuser Exit Be sure the exit FU FD solenoid energizes in the Lower roller correct position for either face down or face up e Exit Guide delivery Replace any damaged or worn parts e FU FD Flap Solenoid Do a continuity check of the solenoid Be
72. ains four large square blocks of each primary color located in the top 1 3 of the page used to show ghosting These pages are the same as the Print Quality Pages If Continuous is selected the pages will be printed until the Stop button is pressed The Print Test pages can only be printed on A4 or Letter While the page is printing the following message is displayed The Power indicator also blinks while the page is printing lt Input Source gt Printing If Single is selected no buttons are active while the Print Test pages are printing However if Continuous is selected Return or Stop can be pressed to cancel the test While the test is being cancelled the following message is displayed lt Input Source gt Cancelling Print Quality Pages Execution of this diagnostic function causes the printer to print the Print Quality Test Pages These pages can also be printed with a POR key sequence however when printed with this method the toner cartridge lockout functionality is enabled These pages are the same as the Print Test pages As the pages are printed the printer posts Prt Quality Pgs Printing 3 16 Service Manual 5050 001 Once started this operation cannot be cancelled Furthermore all key presses are ignored while this message is posted LCD Hardware Test Selecting this test will cause the printer to continually execute the LCD display test To cancel the test
73. all paper from the entire paper path Top Output Bin Multi Purpose Feeder Rear Output m Bi g 3 a gi dd o gt gt Trays 1 2 3 D After you have cleared all the paper close the printer s top cover and press Go to clear the message If you feel you have cleared all the paper from the paper path but the paper jam message is still displayed open and close the top cover and press Go again The Jam Recovery setting in the Setup Menu determines whether the printer reprints the jammed page General Information 1 27 5050 001 When clearing a jam open the top cover completely and clear all paper from the entire paper path Make sure you also clear paper jammed in the paper tray Close the top cover and press Go The following table lists the paper jam messages Message To locate the jam 200 Paper Jam Open Top Cover 201 Paper Jam Open Top Cover 202 Paper Jam Open Top Cover 24x Paper Jam Check Tray x 250 Paper Jam Check MP Feeder Printing From the Multipurpose Feeder Because the multipurpose feeder does not have auto size sensing you must select the correct paper size and type from the printer operator panel or from MarkVision before you send a job to print Paper must be loaded before any paper pickup attempt is made 1 28 Service Manual 5050 001 2 Diagnostic Information The diagnostic information in this cha
74. assembly uses an LED head to form an electrostatic image by emitting light onto the charged drum The length of time the light is on is contained in non volatile memory EEPROM in the printer controller because the light emitting time of each LED is different in every head When the LED head is replaced the light emitting time must be reset If you replace the LED head be sure to also replace the EEPROM Developer Assembly The toner agitator stirs the toner in the cartridge The toner supply roller provides toner to the development roller The doctor blade is pressed to the development roller which is conductive rubber Doctor Blade LED ms D Tel As the development roller rotates toner feeds between the developer roller and the doctor blade This friction charges the toner negatively As the toner comes in contact with the photoconductor drum it sticks to the electrostatic latent image General Information 1 11 5050 001 Photoconductor Drum Dark Area Light Area Transfer Assembly Paper is held to the transfer belt electrostatically The belt rotates at the same speed as the photoconductor drum The absorption roller applies a positive charge to the paper The toner formed on the photoconductor drum transfers to the paper because of the positive charge from the transfer sheet under the transfer belt Photoconductor Drum Paper Transfer Sheet Transfer Belt 406 1 12 Serv
75. cover 2 Remove the rear cover front cover and right side cover 3 Remove the printer controller board and high voltage unit 1 4 Remove the drum drive gear sensor from drive 1 1 screw Repair Information 4 51 5050 001 Registration Roller Removal 1 Remove the rear cover the front cover and the right side cover 2 Remove the right front sub cover 3 Remove the connector from printer controller board 4 Remove the lead line from the wire saddle 5 Remove the registration roll 4 black screws Be careful of the lead line 6 Remove the registration clutch from the registration roller 1 E ring I D K Registration Clutch When you reassemble put conductive grease on the contact portion between the shaft of the registration roll unit and registration roller ground plate 4 52 Service Manual 5050 001 Paper Feed Assembly Removal 1 Remove the rear cover front cover and right side cover 2 Remove the MPF 3 Remove the transfer belt assembly 4 Remove the 2 screws 5 Remove the front sub cover 2 screws 6 Cut the cable tie off and remove the front frame 4 screws Repair Information 4 53 5050 001 Front Frame Front Sub Cover 7 Remove the connector from the printer controller board and harness Printer Controller us 4 54 Service Manual 5050 001 8 Remove the MPF solenoid 1 screw o
76. creen press Return or Stop Files will be Lost Go Stop Once Go is selected the following screen is displayed to indicate the cleaning phase of the test has begun This screen is periodically updated to indicate the percentage of the cleaning phase which is Diagnostic Aids 3 21 5050 001 complete and number of bad blocks which have been found The Power indicator also blinks while the cleaning phase is in progress Cleaning Disk Bad 000000 00 When the cleaning phase of the test is complete the following screen is displayed to indicate the testing phase of the test has begun Again the screen is periodically updated to indicate the percentage of the testing phase which is complete and the number of bad blocks which have been found The Power indicator also blinks while the testing phase is in progress Testing Disk Bad 000000 00 The cleaning or testing phase can be cancelled at any time by pressing Return or Stop If either phase is cancelled the following message is displayed momentarily before returning to the DEVICE TESTS screen Disk Test Clean Cancelling Once both phases complete one of the following screens is displayed If fewer than 2 000 bad blocks are detected then the following screen is displayed This screen indicates the number of bad blocks xxxxx and usable blocks yyyyyy on the disk Press Go Return or Stop to return to the DEVICE TESTS scre
77. ct the Diagnostic Mode Select Printer Setup Select K Top Margin Adjust Input the values Ron 3 10 Service Manual 5050 001 To verify the margin values are correct you must print the Quick Test page From the Tray X test screen press Select While the page is printing the following message is displayed The Power indicator also blinks while the page is printing Quick Test Printing The printer will attempt to print the Top Margin page from the default paper source However if the default source only supports envelopes then the page will be printed from Tray 1 The page consists of alignment diamonds When you change the value for that tray you will see the K alignment diamonds move up and down the page The test page also contains the page count setting printer serial number and code levels The Test Page can only be printed for the trays that are installed The Menus to change the values show up even if the tray is not installed This allows the service person to set these values to the factory values even if a customer does not have that tray installed The Test page should be printed on Letter or A4 paper only To exit the Registration menu press Return CMY Top Margin Adjust Print Tests The purpose of this function is to adjust the leading edge margin for each tray It is the top margin of how the page is printed For A4 or letter it is the leading long edge of the page that the margin is being adj
78. d check for 10K ohms conductance of the belt thermistor 3 Replace the belt unit 11G0202 4 If you still have the problem replace the printer controller board 11G0324 986 OHP Sensor Error 1 Be sure connector CN 132 is properly connected to the printer controller board 2 Replace the OHP sensor 3 If you still have a problem replace printer controller EEPROM U107 4 If you still have a problem replace the printer controller board 2 8 Service Manual 5050 001 Error Message or Symptom Action 992 Engine Error Abnormal Humidity Sensor 1 Be sure connector CN121 is properly connected to the printer controller board Also be sure the connector on the humidity sensor card is plugged in correctly 2 Replace the humidity sensor 11G0571 8 If you still have the problem replace the printer controller board 993 Engine ROM RAM Printer Controller Error 1 Try to recover by turning power off and on 2 Replace the U107 EEPROM 11G0325 on the printer controller board 3 If you still have the problem replace the printer controller board 11G0324 4 If you still have the problem replace the RIP controller card 11G0604 Diagnostic Information 2 9 5050 001 Status Messages Message Ready Meaning The printer is ready to receive and process data Power Saver When your printer is in power saver mode the Power
79. deve quindi adottare le precauzioni necessarie Sicherheitshinweise e Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen e Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen x Service Manual 5050 001 Pautas de Seguridad e Este producto se ha dise ado verificado y aprobado para cumplir los mas estrictos estandares de seguridad global usando los componentes especificos de Lexmark Puede que las caracteristicas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio La informacion sobre el mantenimiento de este producto esta dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de dafios personales durante el desmontaje y la reparaci n de la maqu
80. e Units Description 4 32 11G0692 5 PCB Guide 33 11G0693 1 Ground Spring LV 34 11G0694 1 Ground Spring RV 35 11G0695 1 Cover Spring 36 11G0696 1 Spring 37 11G0697 1 Cover Bracket Spring R Parts Catalog 7 17 5050 001 Assembly 5 Base 2 Parts Catalog 7 18 5050 001 Assembly 5 Base 2 Ref s Units Description 5 1 11G0202 L Transfer Belt Unit 2 11G0203 1 Belt toner Waste Bottle 3 11G0204 1 Transfer Cover 4 11G0205 1 Gear Cover 12 11G0208 4 Sub Frame Asm Lm 13 11G0554 4 Sub Frame Asm Lc 14 11G0557 4 Sub Frame Asm Ly 15 11G0560 4 Sub Frame Asm Lk 16 11G0209 1 Paper Carrying Guide 17 11G0210 1 Paper Carrying Guide Film 18 11G0211 1 Paper Discharge Brush 19 11G0212 1 Belt Thermistor Harness 21 11G0214 2 Stopper Screw 27 11G0140 2 Bushing 32 11G0221 1 Link Holder 33 11G0222 1 Link Arm 34 11G0223 1 Link Spring 35 11G0224 L Interlock Rod Front 36 11G0225 1 Interlock Rod Rear 37 11G0226 1 Spring Cover 38 11G0227 1 Interlock Lever Spring Rear 55 11G0243 2 Photo Interrupter Paper Detect 57 11G0245 1 Paper Detect Lever 58 11G0244 1 Power Supply Cover 89 11G0266 2 Setting Label MI 90 11G0265 2 Setting Label CI 91 11G0264 2 Setting Label YI 92 11G0263 2 Setting Label Bkl 93 11G0539 1 Stay Sub Frame L 94 11G0698 4 Separation Pawl Parts Catalog 7 19 5050 001
81. e following and check parts as indicated Jam 200 Check the paper registration sensor by actuating the sensor lever flag and look for a change of voltage at pin 2 to ground on connector CN110 on the printer controller board Look for approximately 5 V If it works properly go to the Paper Carrying 2 30 Service Manual 5050 001 Service Check on page 2 32 If it does not work properly replace the actuator or sensor If that doesn t correct the problem replace the printer controller board Jam 201 Remove the cartridges Check the registration sensor and the paper exit sensor Actuate the sensor lever flag and look for a change of voltage at pin 2 to ground on connectors CN110 and CN124 on the printer controller board Look for approximately 5 V If it works properly go to the Paper Carrying Service Check on page 2 32 If it does not work properly replace the actuator or sensor If that doesn t correct the problem replace the printer controller board If the fuser exit rollers do not turn go to the Drive 2 Stepper Motor Service Check on page 2 29 Jam 202 Check the paper exit sensor by actuating the sensor lever flag and looking for a change of voltage at pin 2 to ground on connector CN124 on the printer controller board Look for approximately 5 V If it works properly go to the Paper Carrying Service Check on page 2 32 If it does not work properly replace the actuator or sensor If that doesn t co
82. e from Lexmark You must have a trained service technician install the maintenance kit The message appears when the printer maintenance counter determines 100 000 pages have printed Failure to replace the maintenance kit items will not interrupt printer operation but can result in unsatisfactory printer performance 84 Black PC Life Warning This message alerts you that you can print approximately 100 pages before the Black PC Drum Exhausted message appears If you do not have a black photoconductor kit order it now Press Go to clear the message and continue printing The Supplies status message is then displayed with the Ready Power Saver Busy and Waiting messages unless another status message of higher priority is posted until you replace the photoconductor If this message does not reset after replacing all photoconductor units clean or replace the drum sensor 11G0550 black in the right sub frame 2 20 Service Manual 5050 001 Message Action 84 Color PC Life This message alerts you that you can print Warning approximately 100 pages before the Color PC Drums Exhausted message appears If you do not have new color photoconductors order them now The cyan magenta and yellow photoconductors come packaged together You cannot order them separately Press Go to clear the message and continue printing The Supplies status message is then displayed with the Ready Power Saver Busy and Wai
83. e printer controller board 11G0324 ak 981 Switch Error Abnormal FU FD Switching 1 Be sure connector CN133 is properly connected to the controller board 2 Be sure the FUD sensor actuator is working properly 3 Do a sensor test Check for approximately 5 V on connector CN133 pin 2 to GND as you actuate the flag in the sensor 4 Replace the FUD actuator sensor If the sensor is good go to the Paper Exit FU FD Service Check on page 2 34 Diagnostic Information 2 7 5050 001 Error Message or Symptom Action 983 Gear Sensor Abnormal Gear Sensor Color Black 1 Be sure CN123 and CN126 are properly connected to the printer controller board 2 Clean the gear drum sensor 3 Replace the drum drive gear sensor 11G0581 If you still have the problem go to the Drive 1 DC Motor Service Check on page 2 28 984 Gear Sensor Abnormal Drum Gear Sensor Yellow Black 1 Be sure CN125 and CN127 are properly connected to the printer controller board 2 Clean the gear drum sensor 3 Replace the drum gear sensor 11G0581 4 If you still have the problem go to the Drive 1 DC Motor Service Check on page 2 28 985 Thermistor Error Belt Thermistor Open 1 Be sure the thermistor connector under the transfer guide is properly connected Also be sure CN107 is properly connected to the printer controller board 2 Unplug the connector an
84. ective Press Go to clear the message and continue printing You must install a different disk before you can perform any disk functions 62 Disk Full There is not enough space available to hold the resources you want to store on disk Press Go to clear the message and continue processing Downloaded fonts and macros not previously stored in flash memory or disk are deleted Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the second line Press Select 63 Unformatted The hard disk installed in your printer has not been Disk formatted You must format the disk before you can download resources to it Press Go to clear the message If the error message remains the disk may be defective and need replacing To format the disk select Format Disk from the Tests Menu Diagnostic Information 2 19 5050 001 Message 70 79 Network Action Reserved for messages relating to the optional internal network adapter INA installed in your printer For more information refer to the online documentation included on the printer CD under Network Printing 80 Scheduled Maintenance The printer requires replacement of routine maintenance items such as the fuser transport belt and roller set to maintain top performance and avoid print quality and paper feed problems These items are in a maintenance kit availabl
85. eed Clutch Repair Information 4 65 5050 001 Paper Remaining Sensor Removal 1 Remove the rear cover the right side cover and the left side cover 2 Remove the front stay 2 plate 5 screws Front Stay 2 3 Remove the connector and lift out the photo interrupter Photo Interrupter PE20 4 66 Service Manual 5050 001 Paper Feed Clutch Solenoid and Transfer Roller Removal 1 Remove the rear cover the right side cover and the left side cover 2 Remove the front stay 2 plate 5 screws 3 Remove the connector and lead line of the solenoid 4 Remove the 4 screws Press the cassette support plate in and slide the paper feed base out of the machine Remove the paper feed base to the upper side Paper Feed Solenoid Repair Information 4 67 5050 001 6 Remove the paper feed guide 2 black screws 7 Remove the paper carrying roller Paper Carrying Roller Paper Feed Guide 4 68 Service Manual 5050 001 5 Connector Locations Paper Handling Top output bin Rear output bin Multipurpose feeder 250 sheet standard drawer 250 sheet optional drawers Connector Locations 5 1 5050 001 Cross Section of Printer Fuser Roller Press Roller Heater Fuser Oil Roller Paper Exit Sensor Lever Belt Drive Roller Belt Thermistor Transfer Belt oo M OO a F OA DY Transfer Sheet Oo Cleaning Blade Charging Roller
86. eft rotate the collar counter clockwise Offset collar Hole Thermistor Rank Adjustment Make this adjustment whenever you replace the transfer belt unit or when you replace the EEPROM on the printer controller board See Thermistor Rank on page 3 15 LED Head Light Quantity Adjustment Make this adjustment whenever you replace the LED Head or the EEPROM on the printer controller board See Light Quantity on page 3 14 Top Margin for Color Mode Make this adjustment whenever you replace the following parts Repair Information 4 5 5050 001 Transfer Belt Unit LED Head e EEPROM Printer Controller Printer Controller Board You must set the top margin for each cassette and the MPF See CMY Top Margin Adjust Print Tests on page 3 11 Top Margin for Black and White Mode Make this adjustment whenever you replace the following parts Transfer Belt Unit LED Head EEPROM Printer Controller Printer Controller Board You must set the top margin for each cassette and the MPF See K Top Margin Adjust Print Tests on page 3 10 Overhead Projection Sheet Detection Sensor Adjustment Make this adjustment whenever you replace the OHP sensor or the printer controller board EEPROM See Calibrating the Transparency Sensor on page 3 24 Printhead Adjustments X Y and Theta Note When trouble shooting or prior to making any adustment to print quality always be sure of the fol
87. en xxxxx Bad Blocks yyyyyy Usable If more than 2 000 bad blocks are detected then the following screen is displayed This screen indicates the number of bad blocks xxxxxx The disk cannot be recovered because too many bad 3 22 Service Manual 5050 001 blocks exist on the disk Press Go Return or Stop to return to the DEVICE TESTS screen xxxxx Bad Blocks Replace Disk If the bad block count is 6 digits long i e the whole disk is bad then the s is dropped from blocks to make room for the sixth digit Setting the Page Count The printer s page count can be changed via the Diagnostics menus This menu is used by the service technician to reset the Page Count setting whenever the engine card is replaced The engine card contains the printers NVRAM memory When Page Count is selected from the PRINTER SETUP menu the current page count is displayed as follows Page Count 1234567 The leftmost digit 1 in this example will blink indicating it is the first digit to be changed To change the value press either Menu gt or Menu lt until the value you want is displayed Press Select to move to the next digit The next digit 2 in this example will blink Continue modifying each digit using this method To skip a digit and keep its current value press Select When Select is pressed after the final digit 7 in this example the new page count is stored in NV
88. enta 24 to 24 0 Yellow 24 to 24 0 Test Print Radar Test PRINT TESTS Tray 1 Single Continuous Diagnostic Aids 3 7 5050 001 Only displayed if a flash or disk option is installed Tray 2 if installed Single Continuous Tray 3 if installed Single Continuous MP Feeder Single Continuous Top Output Single Continuous Back Output Single Continuous Prt Quality Pgs Single Continuous HARDWARE TESTS LCD Test Test Button Test Test DRAM Memory Test Test Std Parallel Wrap Test Parallel 1 Wrap Test Parallel 2 Wrap Test Serial 1 Wrap if Test available Serial 2 Wrap if v available DEVICE TESTS Quick Disk Test See Quick Disk Test on page 3 20 Disk Test Clean See Disk Test Clean on page 3 21 PRINTER SETUP Defaults e US e Non U S 3 8 Service Manual 5050 001 LIGHT QUANTITY 0 to 45 0 e Cyan e Magenta Yellow e Black Thermistor Rank 0 to 4 0 Transfer Belt Adj 30 Seconds 240 Sensor Cal e Paper Transparency Cyan Drum Cnt 0 to 65535 Magenta Drum Cnt 0 to 65535 Yellow Drum Cnt 0 to 65535 Black Drum Cnt 0 to 65535 Page Count 0 to 9999999 Perm Page Count 0 to 9999999 Serial Number XXXXXXXX printer serial number where x A Zor0 9 Par S Strobe Adj 4 to 6 0 Par 1 Strobe Adj
89. er in the MPF Be sure the MPF paper present sensor connector CN110 is connected to the printer controller board Do a sensor test Check for approximately 5 V between pin 2 and Gnd on connector CN110 as you actuate the flag to the sensor Replace the parts as necessary If the paper still does not feed go to the Paper Carrying Service Check on page 2 32 2 26 Service Manual 5050 001 Service Checks Fuser Service Check When you work on the fuser be sure to reposition it to the original mounting position Also be sure the exit sensor and FUD sensors are not damaged when you replace the fuser FRU Action e Fuser The fuser may not be fusing correctly or not fusing Heater at all e Fuser Thermostat Disconnect the fuser heater cable CN602 from the e Fuser power supply Check for continuity of the heater Thermal 11G0348 115 V 11G0549 230 V thermostat Fuse 11G0349 and thermal fuse The thermostat must equal 240K Ohms at 25 degrees C room temperature Replace the failing part Power Supply With the paper exit cover interlock activated check for approximately 120 V or approximately 240 V on connector CN602 pin 1 and 2 e Fuser Be sure connector CN119 is securely pugged into Thermistor the printer controller board e Printer Controller If the problem remains unplug connector CN119 Board and short pins 1 and 2 on the connector together with the power on If an error code dis
90. essasesassesenseses 1 10 Exposure Assembly sssaussucusaumassamesaumassuenuss 1 11 Developer Assembly 4424ssssusssusesausesenensas 1 11 Transfer Assembly 4ccsssusssuassscasenmmseuamses 1 12 Cleaning Assembly 4sssssssssssssusssassismssssass 1 13 Paper Feed Transfer and Fusing 1 14 Print MOdGS 4 sis sus sssussssussauesasessadesxssuss 1 26 Clearing Paper Jams 4 244ssuuussuussauesausessueuss 1 27 Printing From the Multipurpose Feeder 1 28 Diagnostic Information 2 1 Parn NUMBERS ai no cee uen ge Se ae die ae ge she na mae 2 1 Adjustments and Procedures Following Parts Replacement 2 1 Slat masmamscanassmeus ontarsneet owns sewed saura sead nas 2 2 Initial Check ss sssssssessssessssessesessuseseseesest 2 2 Printer M SSages 44e cmussmmassmansenasesmasentases 2 3 Service Error Message Table 2 4 Status Messages 22 sous cs cucusauussenasanmmsenmsmca 2 11 Attendance Messages scsi ssssssasesenence 2 14 Symptom T ble sus ssammsesdasesauredasseaases da 2 24 Service CHECKS ssccisssessesessusess sanesassesanencses 2 28 Fuser Service Check s4suussuuussuussauessumaessueusan 2 28 Color Print Unit Missing Service Check 2 29 Drive 1 DC Motor Service Check 2 29 Drive 2 Stepper Motor Service Check 2 30 5050 001 Transport Belt BUD Service Check
91. ets kettles humidifiers cold spaces near open flames and dusty areas e Avoid sites exposed to direct sunlight Print Paper Checks Be sure the recommended paper for this printer is being used e Check the paper for dampness Make a trial print with paper from a newly opened package and check the result Printer Messages The printer displays three types of messages service messages status messages and attendance messages Service messages indicate a problem that requires a service technician Status messages provide information about the current state of the printer They require no action Attendance messages alert the operator to printer problems that require operator intervention Diagnostic Information 2 3 5050 001 Service Error Message Table Error Message or Symptom Action 900 Software Error Unrecoverable software error Refer to the operator manual 910 Motor Error 1 Be sure motor connector CN501 is connected properly to the PC DC Drive 1 Motor Failure motor drive 1 2 Be sure printer controller board connector CN105 is connected properly 3 Be sure there is no abnormal load on the toner or drum unit 4 Replace the toner unit or the drum unit if necessary 5 Replace the DC motor drive 1 11G0256 6 If you still have a problem go to the Drive 1 DC Motor Service Check on page 2 28 918 Fan Error 1 Be sure motor connector CN115 is connected properly on the Main Bod
92. he Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select Remove Paper Top Output The top output bin is full Remove the stack of paper and press Go Go to the Remove Paper Sensor Service Check on page 2 36 2 14 Service Manual 5050 001 Message Action Print Jobs on Disk Jobs that were spooled to the optional hard disk before the printer was last turned off have not yet printed Press Go to print the jobs Press Return or Stop to delete the jobs from the disk without printing them Files Will be Lost You have changed the Job Buffer Size setting from the Go Stop operator panel and the printer must reformat the hard disk to activate the change If you press Go all files currently stored on the disk will be deleted Press Return or Stop to cancel this operation Invalid Font Data The printer has detected an incompatibility between the font data and the firmware You must download compatible font data to flash memory before the printer can return to the ready state Invalid Network x The code in the specified network adapter has not Code been programmed or is invalid You must download valid code to the network adapter before the printer can return to the ready state 30 color Print Unit The specified print unit Cyan Magenta Yellow or Missing Black is not installed in the printer Insert the print unit and close the top cove
93. he DEVICE TESTS screen Quick Disk Test Test Passed 3 20 Service Manual 5050 001 If the test fails the Power indicator is turned on solid and the following message is displayed Press Go Return or Stop to return to the DEVICE TESTS screen Quick Disk Test Test Failed Disk Test Clean This test causes the file system to scan the disk for bad sectors and remove these blocks from the addressable space This test destroys all data on the disk and should not be attempted on a good disk Normally this test will only be used when the disk contains bad data and is therefore unusable The test is actually executed in two distinct phases a writing or cleaning phase and a verifying or testing phase During the cleaning phase the printer writes a 0x00 to each byte location on the disk During the testing phase the data written is verified This can be an extremely lengthy test however the test length depends on the disk size For example each phase of this test executed on a 540MB hard disk takes approximately 14 minutes to complete This test leaves the disk unformatted The servicer or user must reformat the disk using the Format Disk menu operation To run this test select Disk Test Clean from the DEVICE TESTS menu The following message is displayed to warn the customer that all disk contents will be lost To continue on with the test press Go To exit the test immediately and return to the DEVICE TESTS s
94. he job again Replace the affected toner cartridge Replace the photoconductors If only black print appears light you can replace just the black photoconductor If one of the colors prints too light replace all three of the color photoconductors If you still have the problem go to Partial Darkness or Lightness on page 2 44 Colored lines streaks or smudges appear on the printed page or print appears blurred or unclear Replace the photoconductors If the problem only occurs when printing black you can replace just the black photoconductor and fuser coating roll If the problem occurs when printing one of the colors replace all three of the color photoconductors If you still have the problem go to Black Line on page 2 42 2 38 Service Manual 5050 001 Problem Toner specks appear on the page N L Action Replace the fuser coating roll If it is not time to order a black photoconductor kit which includes a fuser coating roll order a separate fuser coating roll P N 12A1706 Toner colors the background of the page N L Be sure the affected print unit is completely installed in the printer The page has 100 coverage of one color Be sure the system board is completely inserted in the printer and the thumbscrews are securely tightened Refer to the Setup Guide or installation instructions Be sure the affected print unit is comple
95. he optional paper feeder has its own motor to drive paper to the printer paper path Print Modes The 3 print modes for this printer are 1 Normal mode for normal printing 2 Overhead projector transparency mode 3 Post card mode The modes are switched by commands from the interface controller Overhead Projector OHP Mode This mode improves the color print on transparencies If the color image on a transparency is not smooth light will not penetrate it and it will appear black when projected 1 26 Service Manual 5050 001 Processing speed is reduced 75 in OHP mode The fuser temperature is set at 20 degrees higher than normal printing This is to improve the smoothness of the toner image by ensuring the toner melts enough in the fuser When you load transparencies in the multipurpose feeder the printer recognizes this type of media you have loaded and automatically makes these adjustments However waiting for the printer to sense the presence of transparencies may further delay the job We recommend always selecting the correct Paper Type before sending a job to print Post Card Mode In this mode the fuser temperature is also set 20 degrees higher and the setting of transfer voltage switches according to the humidity Clearing Paper Jams When a jam occurs the Paper Jam message on the operator panel display indicates where to find the jammed paper You must clear the paper from this area but you must also clear
96. ic process using LED printheads Print 600 dpi Maximum print speed 12 ppm letter and A4 paper Color 12 ppm Mono Fonts 1 75 resident scalable fonts e PostScript Level 2 emulation 39 Optra compatible plus 36 additional e PCL emulation 45 LaserJet compatible plus 30 additional 2 PCL bitmap fonts e LinePrinter e POSTNET Barcode 3 FontVision font manager utility with 110 fonts 4 World class international font support 77 symbol sets including support for e Canadian French Brazilian Portuguese Cyrillic and Greek Paper input e 250 sheet tray e Multipurpose feeder Paper output e Top output bin 250 sheets collated Rear output bin 100 sheets uncollated Paper sizes supported A4 A5 JIS B4 JIS B5 A3 letter legal 11 x 17 Printer memory 32MB two 16MB 50 ms EDO SIMMS Some printer models may ship with more memory Flash memory 4MB for permanent storage of fonts logos and forms Interface Parallel standard Centronics protocol that complies with bidirectional IEEE 1284B Internal solutions ports e 2 ports for network adapters tri port adapters or parallel port adapters e 1 connector for hard disk e 2 pairs of memory connectors Printer software MarkVision utility that lets you manage your printer from your computer Supported in the following environments Windows 95 Windows NT 4 0 Windows 3 1x OS 2 Warp
97. ice Manual 5050 001 Cleaning Assembly The cleaning blade scrapes off the remaining toner on the photoconductor drum after the toner image has been transferred to the paper Cleaning Blade A rotating coil in the waste toner conveyance assembly conveys the scraped off toner to the waste toner bag Waste Toner Bag Waste Tor General Information 1 13 5050 001 Paper Feed Transfer and Fusing Two drives perform the entire paper feed in this printer drive 1 and drive 2 There is a separate motor in the second paper feeder to drive the paper feed Drive 1 Drive 1 consists of a brush less de motor and gear unit Drive 1 carries paper from the paper feed unit to the registration unit and also drives the electrophotographic process The motor starts running after it receives an ON signal from the printer controller The motor then sends a synchronizing signal to the printer controller When monochrome mode is selected clutch 2 interrupts the electrophotographic process for color printing Do not disassemble the gears in drive 1 because the phase adjustment has been preset Do not turn the PC when it is out of the machine as the gears will lose timing to work as a matched set Drive 2 Drive 2 consists of a hybrid stepping motor and gear assembly It drives the fuser and exit assembly There is no synchronizing signal for this motor 1 14 Service Manual 5050 001 Drum Drive Gear GA dre p
98. ina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a e Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem n o ser sempre bvias A Lexmark n o respons vel pela utiliza o de outros componentes de substitui o e As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Safety Information Xi 5050 001 Informaci de Seguretat e Aquest producte esta dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi e La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de se
99. is allows the service person to set these values to the factory values even if a customer does not have that tray installed The Test page should be printed on Letter or A4 paper only To exit the Registration menu press Return 3 12 Service Manual 5050 001 Color Calibration of Printer Printhead Adjustment X Y and Theta Test Print Pages Printing the color calibration pages allows a service person to align the Cyan Magenta and Yellow planes with the Black plane The planes must be adjusted in three different directions the X direction the Y direction and the Theta direction These values must be adjusted for each plane View the page in the portrait position when you check these adjustments The X Y and Theta adjustment must be checked with the radar test page found in the X Adjustment menu Test Print sub menu Printhead Adjustment X Position Adjustment Horizontal Modification of this setting allows the users to adjust the color offset of a color image for the line direction X Changing this parameter by 1 unit moves the image 1 600 of an inch The X position can be set from 80 to 80 A positive offset moves the plane up the page A negative offset moves plane down the page Note Modification of the X position adjustment setting causes the entire plane to move up down on the page Y Position Adjustment Vertical Modification of this setting allows the users to adjust the color offset of a color image f
100. isplayed with the Ready Power Saver Busy and Waiting messages unless another status message of higher priority is posted until you replace the photoconductors If this message does not reset after replacing all photoconductor units clean or replace the drum sensor 11G0548 in the right sub frame 84 color PC Abnormal You have installed a defective photoconductor You must replace the specified photoconductor before you can continue printing If this message does not reset after replacing all photoconductor units clean or replace the drum sensor 11G0548 in the right sub frame 88 color Toner Low The printer has detected that the toner supply in the specified cartridge is low After printing approximately 250 more pages the printer will display the 88 color Toner Empty message and cease operating until the toner cartridge is replaced If you do not have the necessary supplies order them now Press Go to clear the message The Supplies status message is then displayed with the Ready Power Saver Busy and Waiting messages unless another status message of higher priority is posted until you replace the toner cartridge The 88 color Toner Low message is also displayed each time you turn the printer on and each time you open and close the top cover If this message does not reset after you replace all the toner cartridges clean or replace the toner remaining sensor 11G0207 in the right sub frame
101. l Inc registered in the United States and or other countries Other trademarks are the property of their respective owners O Copyright Lexmark International Inc 1998 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 U S P N 12G0169 Japan P N 11F0867 5050 001 Contents Safety Information 445 444s2uusscuaussuuassaem enus ix Maloy NOUS seede SSG ix General Information 1 1 Maintenance Approach ccsecceteces eee tennessee eens 1 1 TOOLS cccsecesseeateaeaseatasacescaaeaaceescaacaae 1 1 Serial Number ss ss dssssuumssauussuesseduessumeesdunssu 1 2 ADDIEVIGUONS 2c ssssscesmissacesacesssseosssciestessas 1 3 Standard Features ssucssueusamessemessmunesmeemseun 1 4 OPTIONS EE kareka ture 1 5 Printer Supplies sas ssuussdmussunssadersuuessdoersus 1 6 Cross Section of Print r sisssssssssssessssssasssassasss 1 6 Operational Theory sus sssssssssaueuseuessanassauss 1 8 Electrophotographic PrOCeSS 4 ssccsssmsussesvsssesses 1 8 Photoconductor Drum 24 samss mussumssamarsuuusadaasma 1 10 Electrical Charge Unit scsssssssssas
102. log is cleared and then the empty log is displayed as indicated below 1 000 2 000 3 000 4 000 3 26 Service Manual 5050 001 Select No to exit the Clear Log menu Pressing Return or Stop also exits the Clear Log menu US Non US This setting is used by the printer to determine whether US Non US factory defaults should be selected Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal user mode press EXIT DIAGNOSTICS Diagnostic Aids 3 27 Print Quality Test Page 3 28 Service Manual Print Quality Test Page Diagnostic Aids 3 29 5050 001 3 30 Service Manual 5050 001 4 Repair Information Precautions for Disassembly and Cleaning Observe the following precautions whenever you service the printer Be sure to unplug the printer from the outlet before attempting to service the printer To reassemble the printer reverse the order of disassembly unless otherwise specified Do not operate the printer anytime during disassembly If it is absolutely necessary to run the printer with its covers removed use care not to allow your clothing to be caught in revolving parts such as the gears rollers and fan motor Never touch the terminals of electrical parts or high voltage parts such as the high voltage unit Be sure to handle the fuser carefully as it remains hot for a while after the printer stops running Always unplug connectors by holding the connector housing
103. lowing The printer is installed on a level rigid surface The OPCs are never exchanged Do not exchange a black OPC for a color OPG as they will have different surface phase counts Radar Page is always used when adjusting print registration Make this adjustment if you replace the LED head sub frame transfer belt or EEPROM on the printer controller board 4 6 Service Manual 5050 001 The X Y and Theta adjustment must be checked with the radar test page found in the X Adjustment menu Test Print sub menu This adjustment depends on the combination of 3 settings for color registration X Y and Theta Follow the procedure closely as the adjustment is critical For additional information see Color Calibration of Printer on page 3 13 1 2 3 Press the Menu button until X Adjustment Print Tests 10 11 Press Return and Go as you turn on the printer Release the buttons when you see Performing Self Test on the display Press the Menu button until X Adjustment displays Select X Adjustment displays and press Select This will print the 3 color registration pages These pages are the same for X Y Theta and for the 3 colors and are available under the X Adjustment Y Adjustment and the THETA Adjustment There are 3 adjustments for each color registration X Y and Theta Adjust X and Y first then adjust Theta X controls the horizontal plane By adjusting X you move the radar image left
104. m pass count is 999 999 F represents the number of times the test has failed finished with errors Initially 00000 is displayed for The maximum fail count is 99 999 The power indicator blinks indicating the test is in process The printer continually runs the same test until cancelled from the operator panel by pressing Return or Stop Each time the test finishes the screen is updated with the result If the test passes then the Pass Count increments by 1 However if the test fails then a signal error message is displayed for approximately 3 seconds and then the Fail Count increments by 1 Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final test results are displayed Press Return or Stop to exit the test Quick Disk Test Selecting this test runs a disk test that performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good then the saved data is written back to the disk The following message is displayed while the test is running The Power indicator also blinks while the test is in progress Quick Disk Test Testing If the test passes the Power indicator is turned on solid and the following message is displayed Press Go Return or Stop to return to t
105. mage and clean as necessary Run a test print to verify the problem has been corrected The indicated assemblies are replaced by the customer at prescribed intervals If you remove the transfer belt do not turn it upside down Toner will fall from the waste toner box onto the transfer sheets and roller s inside the belt This will cause lower transfer efficiency and washed out colors Distance between marks FRU 31 4 mm Absorption Charge Roller 75 4 mm Fuser Upper Roller 80 1 mm Fuser Lower Roller 763 4 mm Transfer Belt 44 mm Upper Registration Roller 81 7 mm Lower Registration Roller 37 7 mm Supply Roller cartridge 58 7 mm Developer Roller cartridge 94 2 mm PC Diagnostic Information 2 37 5050 001 Image Quality Troubleshooting Print Quality Problems Problem Print is too light or printed images or characters have voids or dropouts N L Action Be sure you re using recommended paper or other media Use media from a new package Be sure you have selected the correct Paper Type setting for the media you re using Be sure the affected print unit is completely installed in the printer Set Toner Saver Off from the Color Menu Clean the head LEDS If you suspect a toner cartridge is low on toner remove the appropriate print unit and gently shake it back and forth to distribute the toner evenly Reinsert the print unit and try printing t
106. moval Open the top cover and remove the toner cartridge and PC drum Be sure to set them away from bright light 1 2 Head Cover Pressure Base Remove the left and right head covers Remove the left and right pressure bases 3 black screws Be careful of the LED head because nothing is supporting it at this time Remove the black right hand head spring and the gold left hand head spring Disconnect the ground wire and the flat cable on both ends of the head from the connector Remove the LED head Do not remove or loosen the pins on either end of the LED head because the head will be out of focus when you reinstall it Set the head aside and place a sheet of paper over the transfer belt to protect it Do the print position top margin K and C adjustments for each paper supply tray and enter the LED head quantity in the service mode When you replace the head also replace the EEPROM on the printhead controller board which corresponds to the head Head Spring Head eee A Head Spring Pressure Base 4 10 Service Manual 5050 001 Transfer Belt Unit Removal Never turn the transfer belt unit upside down 1 Hold the top of the printer and press the upper unit release button to open it 2 Remove the 4 toner cartridges and PC drum sets Place them in a safe place away from bright light 3 Remove the transfer cover and gear c
107. nd line Press Select Diagnostic Information 2 17 5050 001 Message 54 Serial Option x Error Action The printer has detected a protocol error on the specified serial interface Make sure the serial interface parameters are set up correctly and you are using an appropriate serial cable Press Go to clear the message and continue printing The job may not print correctly Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the second line Press Select 54 Std Par ENA Connection Lost An external network adapter ENA that was once connected to the standard parallel port is no longer responding The printer only recognizes the missing connection when the printer power is first turned on e Make sure the cable connecting the ENA and the printer is securely attached Turn the printer off and then on again to see if the printer recognizes the connection Press Go to clear the message The printer erases any reference to the ENA and then resets 54 Par x ENA Connection Lost An external network adapter ENA that was once connected to the specified parallel port is no longer responding The printer only recognizes the missing connection when the printer power is first turned on e Make sure the cable connecting the ENA and the printer is securely attached Turn the printer off and then on again to see if the printe
108. nded in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the Description column indicates that the part is contained in a parts packet A part reference within a circle indicates an assembly or a bill of material An assembly is complete A bill of material contains unassembled parts Parts Catalog 7 1 5050 001 Assembly 1 Covers 7 2 Parts Catalog 5050 001 Assembly 1 Covers Ref ee Units Description 1 1 11G0101 1 Top Cover 115 V 1 11G0650 1 Top Cover 230 V 1 11G0716 1 Top Cover 100 V Japan 2 11G0102 1 Paper Stopper 3 11G0104 1 Side Cover Asm L 4 11G0103 1 FC Cover 5 11G0129 4 Rubber Plate 6 11G0105 1 Sub Cover LF 7 11G0546 1 Sub Cover LR 8 11G0547 1 Rear Cover L 230volt 8 11G0106 L Rear Cover L 115volt 8 11G0717 1 Rear Cover L 100volt Japan 9 11G0107 1 Second CN Cover 10 11G0108 1 Side Cover R 11 11G0109 1 Sub Cover R 12 11G0552 1 Sub Cover R 13 11G0110 1 Front Sub Cover 14 11G0111 1 Front Cover Asm 15 11G0112 1 Latch 17 1
109. oe Optra Color 1200 5050 001 Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index LEXMARK 5050 001 Edition July 2005 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22 035 3 740 New Circle Road N W Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark FontVision MarkVision and Optra are trademarks of Lexmark Internationa
110. om the control panel by pressing Return or Stop Each time the test finishes the screen is updated with the result If the test passes then the Pass Count increments by 1 However if the test fails then a failure message is displayed for approximately 3 seconds and then the Fail Count increments by 1 DRAM Error Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final test results are displayed Press Return or Stop to exit the test Std Parallel Wrap Test and Parallel X Wrap Test The Parallel Wrap Test is used to check the operation of the parallel port hardware using a wrap plug Each parallel signal is tested To perform the wrap test follow these steps e Disconnect the parallel interface cable and install the parallel wrap plug Select HARDWARE TESTS from the Diagnostics Menu Select Parallel Wrap to initiate the Parallel Wrap Test The following screen is displayed and the printer begins testing the parallel hardware for the first time Parallel Wrap PH FE Terminology P represents the number of times the test has passed finished successfully Initially 000000 is displayed for The maximum pass count is 999 999 3 18 Service Manual 5050 001 F represents the number of times the test has failed finished with errors Initially 00000 is displayed for The maximum fail count is 99 999 The
111. or Service Check FRU Action e DC Motor If the motor does not attempt to turn and you Drive Unit 1 receive a 910 error code replace the driver 1 de e Printer motor 11G0256 Controller Board Be sure the toner and dc drum units are not causing an overload on the dc motor If the motor turns but the paper carrying section of the machine does not rotate check the drive 1 unit gear train for damage Be sure the clutch on the gear train engages for color printing Replace the drive 1 unit if necessary 11G0257 If this does not correct the problem replace the printer controller board 11G0324 2 28 Service Manual 5050 001 Drive 2 Stepper Motor Service Check FRU Action Drive 2 Stepper Motor Be sure connector C112 on the printer controller board is firmly connected If you still have the problem replace the drive 2 stepper motor 11G0260 Drive 2 Stepper Motor Unit If the drive 2 stepper motor rotates and the fuser and exit rolls do not rotate replace the drive 2 stepper motor unit 11G0258 Transport Belt BUD Service Check FRU Action BUD Check the transfer belt BUD sensor Replace the Sensors sensor or the actuator if necessary BUD Actuator BUD Motor Be sure connector CN106 is firmly connected Replace the BUD unit if necessary 11G0254 BUD Lift Cams Check and replace the BUD lift cam shaft if necessary 11G0267 Printer If yo
112. or the EEPROM for the engine controller the Thermistor rank value must be set according to the color of the lead line color To set this value 1 Select Diagnostic Mode 2 Select Printer Setup 3 Select Thermistor Setup 4 Enter the value from the following table Standard Thermistor Rank Color of Connector Resistance Value K Ohms 0 Blue 9 057 1 Black 9 515 2 Red 10 000 3 Yellow 10 51 4 Green 11 06 Transfer Belt Adjustment This menu allows you to select how long you would like to run the transfer belt for testing Whenever you replace a transfer belt you have to run the transfer belt to make sure that it is tracking correctly Print Tests Input Output Source Print Tests The Diagnostic PRINT TESTS menu is used to verify that the printer can print on media from each of the installed input sources Each of the installed sources is listed as an option within this menu For each source the user has 2 choices Single print Print Test pages once Diagnostic Aids 3 15 5050 001 e Continuous continue printing Print Test pages until Return or Stop is pressed The first page Print Test contains seven vertical columns of black cyan magenta yellow red green and blue The columns are shaded from 0 to 100 coverage The second page contains a matrix of blocks outlined in primary colors which are used to show vertical and horizontal misalignment This page also cont
113. or the page direction Y Changing this parameter by 1 unit moves the image 1 dot unit The X position can be set from 128 to 127 A positive offset moves the plane to the right of the page negative offset moves the plane to the left the page Note Modification of the y position adjustment setting causes the entire plane to move side to side see Summary Notes on page 4 9 Diagnostic Aids 3 13 5050 001 Theta Position Adjustment Alignment of the curve of the horizontal position over the length of the line Modification of this setting allows the users to adjust the color offset of a color image for the line direction and page direction X and Y Changing this parameter by 1 unit moves the image 1 dot unit The theta position can be set from 128 to 127 A positive offset moves the plane down the page from left side to right side of the page A negative offset moves the plane up the page from left side to the right side of the page Light Quantity If you replace one or more of the printheads or the EEPROM for the engine controller the Light Quantity value must be set to the value that is marked on the printhead To set this value 1 Select Diagnostic Mode 2 Select Printer Setup 3 Select Light Quantity Enter the value from the label on the printhead LED Head K Label 3 14 Service Manual 5050 001 Thermistor Rank If you replace the transfer belt unit
114. ort Belt BUD Service Check on page 2 29 Transparencies curl Make sure you re using the recommended excessively Lexmark transparencies Also be sure the paper delivery is set to the rear exit Diagnostic Information 2 23 5050 001 Symptom Action Transparencies jam If the last transparency jams as you try to feed it from tray 1 place the cardboard sheet with the cutout included in the transparencies box in the bottom of tray 1 before loading transparencies The printer seems slow to print If you set Print Quality to 1200 Image Quality it may take longer to print some complex jobs or jobs formatted for larger paper Select another Print Quality setting if you need the job to print faster If you set the Paper Type to Transparency or Card Stock the printer increases the fuser temperature and slows printing to 3 ppm to improve the print quality After printing on these media the printer requires additional time to cool the fuser after you select another Paper Type setting such as Plain Paper or Letterhead If Printer Usage is set to Maximum Yield the printer must adjust the photoconductors as it prepares to print a color page after printing a mono page The printer performs this same calibration each time you turn the printer on and each time you open and close the top cover Depending on the types of jobs you print these adjustments may significantly slow print time Setting Timing
115. over 4 black screws 4 Remove the paper carrying guide 2 screws Paper Carrying Guide Transfer Cover ro A 9 g Bel gt i Gear Cover 5 Disconnect connector 2P 6 Lift the front part of the transfer belt unit first then lift the transfer belt unit out of the machine 6 black screws S Connector LD SS oy SSS y Repair Information 4 11 5050 001 Installation Notes 1 After you replace the belt do the transfer belt adjustments Run tests in the service mode Enter the thermistor rank value and adjust the print position top margin K and C in the service mode Check the belt tracking 2 Check and adjust the printhead adjustments X Y and Theta position in the service mode if necessary Paper Remaining Sensor Removal 1 Remove the belt unit 2 Remove the connector and the sensor The sensor is a snap fit type Photointerrupter Belt Unit Drive Frame BUD Motor BUD Sensor Removal 1 Remove the belt unit Do not turn it upside down 2 Remove the 3 screws and pull it from the front 4 12 Service Manual 5050 001 3 Remove the UD frame 4 Remove the connector and remove the BUD sensor from the UD frame Repair Information 4 13 5050 001 5 Disconnect the BUD motor connector and remove the 2 mounting screws Remove the motor BUD Motor Engine Board PG14 ENG BB Removal 1 Remove the belt unit Do not turn it upside down 2
116. phase counts Radar Page is always used when adjusting print registration Power On Self Test Sequence 1 2 le ONO Power on Printer and RIP controller check e ROM and RAM e Fuser thermistor Printer hardware check e Paper jam Printer cartridge unit Toner supply Paper cassette present Fuser temperature check Temperature regulated Ready Printer controller e RIP controller Printer condition e Motor Fan e Heater DC motor drive 1 Feeding paper Print Stepper motor drive 2 Paper exit Stop Diagnostic Aids 3 1 5050 001 Using the Operator Panel The operator panel on your printer has a 2 line by 16 character liquid crystal display LCD five buttons and one indicator light The light indicates whether the printer power is on and whether the printer is idle or busy processing a job Indicator Light State Indicates Off Printer power is off On Printer is on but idle Flashing Printer is busy processing a job Use the five operator panel buttons to open a menu scroll through a list of values select printer settings and clear error messages 3 2 Service Manual Select Return 5050 001 Operator Panel Buttons Button Go Function Press the Go button to e Exit printer menus and return the printer to the ready state e Clear certain messages from the display If you ve changed printer settings from the
117. plays replace the printer controller board If no error displays replace the Thermistor 11G0353 Springs Be sure the two large springs that hold the fuser rollers together are securely in place e Fuser Roll Be sure the fuser roll and the press roller are not e Press Roller dirty or damaged Replace as necessary e Separation Be sure the detach fingers are not dirty damaged Pawl or out of position Replace as necessary e Detach Fingers Fuser position Be sure the fuser mounting guides are adjusted for proper paper exit tracking Replace as necessary Diagnostic Information 2 27 5050 001 Color Print Unit Missing Service Check When you replace the PC drum unit all three color units must be replaced at the same time FRU Action Color Print Check for dirt or damage to the sensing contacts on Unit the right side of the cartridge assembly Clean or replace the PC drum unit if necessary The toner and PC drum unit must be installed as a unit Right Side Check the sensing contacts on the right side sub Sub frame Unit frame assembly Clean or replace the affected right side sub frame High Voltage If you still have the problem replace the high Unit 1 voltage unit 1 11G0326 High Voltage If you still have the problem replace the high Unit 2 voltage unit 2 11G0313 Printer If you still have the problem replace the printer Controller controller board 11G0324 Board Drive 1 DC Mot
118. pletely closed and both sides are snapped shut You may need to replace the fuser 11G0375 115 V 11G0542 230 V 2 40 Service Manual 5050 001 Problem Toner adheres to the back of the page Action Remove the fuser coating roll from under the printer s rear cover and wipe it with a dry lint free cloth If you still have the problem go to Periodic Dirt on page 2 44 Quality of printed transparencies is inadequate Be sure you re using the recommended Lexmark transparencies Be sure you re loading transparencies properly When printing transparencies always set the Paper Type to Transparency Set the Color Correction menu item to Vivid Avoid getting fingerprints on transparencies before printing Print on the page is skewed N L Be sure the width guides in the paper tray or the multipurpose feeder fit snugly against the media you loaded Be sure the paper you load in the trays fits under the two corner tabs at the front of the tray A white gap is noticeable between color fills due to poor color registration Be sure all four corners of the printer are resting on a level surface Turn the printer off and back on The printer calibrates the photoconductors and drive gears which may improve registration If the Printer Usage menu item is set to Maximum Yield make sure the Timing Adjustment menu item is
119. printer is processing the job but the memory used to store pages is full Press Go to clear the message and continue printing Some data may not print or may not print correctly e Cancel the print job Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select To reduce the complexity of the job e Reduce the number of graphics or images ona page e Delete unnecessary downloaded fonts or macros e Change the Print Quality setting Install additional printer memory to avoid future Memory Full errors 39 Complex Page The text graphics and print information on the page require more memory to print than what you have installed in your printer Press Go to clear the message and continue printing Some data may not print or may not print correctly e Cancel the print job Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select To avoid another Complex Page error e Set Page Protect On from the Setup Menu and resend the job Reduce the complexity of the page by using fewer fonts macros and graphics Install additional printer memory 2 16 Service Manual 5050 001 Message 52 Flash Full Action There is not enough space available to hold the resources you want to store in flash memory Press Go to clear the mes
120. pter leads you to the failing part Before you replace an entire assembly determine if just the defective part is available in the parts catalog Use the error code tables symptom table service checks and the diagnostic aids chapter to determine the symptom and repair the failure You may find that the removal procedures in the Repair Information chapter will help you identify parts After you complete the repair perform the appropriate tests to verify the repair If an error is displayed locate it in the following Service Error Message Table Status Messages Table or Attendance Messages Table and take the appropriate action If an error message appears while you are working on the printer go to the error message table and take the indicated action Part Numbers Some of the message tables and service checks list the part number of the part you are asked to replace Adjustments and Procedures Following Parts Replacement Note When trouble shooting or prior to making any adustment to print quality always be sure of the following The printer is installed on a level rigid surface The OPCs are never exchanged Do not exchange a black OPC for a color OPG as they will have different surface phase counts Radar Page is always used when adjusting print registration Whenever you replace any of the following parts be sure to perform the required adjustments or procedures The adjustments are in the Repair Information and
121. r recognizes the connection Press Go to clear the message The printer erases any reference to the ENA and then resets 56 Std Parallel Port Disabled Data was sent to the standard parallel port but the port has been disabled from the Parallel Buffer menu item Press Go to clear the message The printer discards the data sent to the parallel port Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the second line Press Select 2 18 Service Manual 5050 001 Message Action 56 Parallel Port x Data was sent to the specified parallel port but the Disabled port has been disabled from the Parallel Buffer menu item Press Go to clear the message The printer discards the data sent to the parallel port Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the second line Press Select 56 Serial x Port Data was sent to the specified serial port but the port Disabled has been disabled from the Serial Buffer menu item e Press Go to clear the message The printer discards the data sent to the serial port Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the second line Press Select 61 Defective Disk The hard disk installed in your printer is def
122. r to clear the message 33 Tray x The printer has detected a tray with the rear paper Configuration Error guide in the wrong position When loading A4 and letter size paper make sure you place it in the tray with the long edge of the sheet next to the front of the tray Position the rear paper guide correctly for the paper size then insert the tray in the printer 35 Res Save Off The printer lacks the memory needed to enable the Deficient Memory Resource Save function This message usually indicates that too much memory is allocated for one or more of the printer link buffers To disable Resource Save and continue printing press Go To enable Resource Save after you get this message e Set the link buffer for each interface to Auto then exit the menus to activate the link buffer changes When the Ready message is displayed enable Resource Save from the Setup Menu e Or install additional printer memory Diagnostic Information 2 15 5050 001 Message 37 Insufficient Collation Area Action The printer memory or optional hard disk if installed does not have the space necessary to collate the print job Press Go to print the portion of the job already stored and begin collating the rest of the job e Cancel the print job Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select 38 Memory Full The
123. ray 1 2 3 or the multipurpose feeder The message displays either the custom media name defined using the MarkVision utility the media size or the media size and type it is looking for To clear the message Load media of the requested size and type in the tray indicated e If you re printing on larger paper make sure the Size Detection setting is correct e Cancel the print job Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select Go to the Paper Low Empty Tray 1 2 3 Service Check on page 2 35 Load Manual You have sent a request for a manual feed job to the printer and the printer is ready for you to insert a single sheet or envelope into the multipurpose feeder The message displays either the custom media name defined using the MarkVision utility the media size or the media size and type it is looking for To clear the message Load media of the requested size and type in the multipurpose feeder e Press Select or Go to ignore the manual feed request and print on media already installed in one of the paper sources If the printer finds a tray that has media of the correct size and type it feeds media from that tray If the printer cannot find a tray with the correct media size and type it prints on whatever media is installed in the default paper source e Cancel the print job Press Menu gt or lt Menu T
124. rrect the problem replace the printer controller board 24X Paper Jam Be sure the option paper tray 2 and 3 are plugged in correctly and go to the Paper Carrying Service Check on page 2 32 Paper Jam Be sure there is no paper jammed in the MPF then go to step 1 of the Paper Carrying Service Check on page 2 32 Diagnostic Information 2 31 5050 001 Paper Carrying Service Check The paper is being picked up and carried to the registration roll FRU Action e Paper Size Be sure the paper cassette has the size guides and Guide the side locator locks are working properly e Side Location Replace parts as necessary Plates e Paper Feed Roller MPF e Paper Feed Rolls MPF tray 1 2 3 e Carrying Roller Tray 1 2 3 Friction Stop Pad MPF Be sure the paper feed rollers are free of dirt and not damaged Be sure the stop friction pad is free of dirt and not damaged Replace parts as necessary Gears Be sure the paper feed gears are not damaged e Paper Feed Solenoid e Paper Feed Clutch Be sure the paper feed solenoid activates the paper feed clutch and the clutch engages properly Check the failing paper feed solenoid for continuity Also check connector CN101 and CN102 MPF on the printer controller board and CN906 on the option paper feed driver board 2 32 Service Manual 5050 001 The paper has stopped at the registration roller or has not re
125. rs Catalog cadwsiseeteeenvsnrawaeemaams 7 1 Assembly CONS essuie sr bee te beds wong 7 2 vi Service Manual 5050 001 Assembly 2 Paper EXIt 24466460 ucssesesassesesenc n 7 6 Assembly 3 Upper Unit sssscssusessuesssumessmmessuemesme 7 8 Assembly 4 Base saasnisasasasaava seven nese ened 7 14 Assembly 5 Bas 2 si sanke dan 7 18 Assembly 6 Feeder 44ssssssscsassasss ssesaasssas 7 26 AsSoinbN 7 EISCHICAl 124i snmimensisensasemvasssunsseuse 7 30 Assembly 8 VF Controler 2225 sussssssossscsstscpeseec 7 36 APSEN PN FIS s oder assure muesdoimecade 7 38 Assembly 10 Cassetles cccccncctdedeaeneenesdnee nae seas 7 42 Assembly 11 Optional Feeder Base 7 44 Assembly 12 Optional Feeder Paper Feed 7 50 Assembly 13 Optional Features 7 52 vii 5050 001 viii Service Manual 5050 001 Safety Information Safety Notice This product is designed tested and approved to meet strict global safety standards with the use of specific Lexmark components The safety features of some parts may not always be obvious Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Profes
126. rs on the second line Press Select Printing Directory List A list of all the files stored in flash memory or on the hard disk is printing To cancel the print job press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select Printing Job Accounting Stat A report of the accumulated statistics for the most recent print jobs is printing Clearing Job Accounting Stat The printer is deleting all job statistics stored on the optional disk Restoring Factory Defaults The printer is restoring factory defaults Formatting Flash The printer is formatting the flash memory Do not turn the printer off while this message is displayed Programming Flash The printer is storing resources in flash memory Do not turn the printer off while this message is displayed Formatting Disk The printer is formatting the hard disk Do not turn the printer off while this message is displayed 2 12 Service Manual 5050 001 Message Programming Disk Meaning The printer is storing resources on the hard disk Do not turn the printer off while this message is displayed Network Card Busy The network adapter is being reset The Network x Setup menu is not available while this message is displayed Attendance Messages Message Close Top Covers Action Close the printer s top cover and
127. rts Catalog 5050 001 Assembly 11 cont Optional Feeder Base Ref s Units Description 11 1 11G0396 1 Top Frame 2 4 11G0398 1 Side Cover L 2 5 11G0129 1 Rubber Plate 6 11G0399 4 Ground Plate Second 7 11G0400 4 Lock 2 8 11G0401 2 Lock Shaft 2 9 11G0402 1 Lock Link 10 11G0403 1 Lock Lever 11 11G0404 1 Lock Spring 2 12 11G0245 1 Paper Detect Lever 13 11G0243 1 Photo Interrupter Paper Detect Sensor 14 11G0558 1 Photo Interrupter Paper Detect Sensor 16 11G0405 1 Second Photo Interrupter Harness 18 11G0194 2 Release Lower Plate 19 11G0407 1 Sub Frame L 2 20 11G0408 1 Front Stay 2 21 11G0409 1 Front Cover 2 22 11G0410 1 Sub Frame R 2 23 11G0340 2 Mini Bushing A NS 11G0578 1 Rating Plate NS 11G0618 1 Cable Tie NS 11G0579 1 Screw Parts Packet 11 NS 11G0625 1 Lever Stopper Parts Catalog 7 49 5050 001 Assembly 12 Optional Feeder Paper Feed 7 50 Parts Catalog 5050 001 Assembly 12 Optional Feeder Paper Feed Ref ek Units Description 12 1 11G0426 1 Paper Feed Base 2 2 11G0270 2 Auxiliary Roller 3 11G0271 2 Paper Feed Roller 4 11G0272 1 Paper Feed Shaft 5 11G0290 1 Bushing B 6 11G0140 1 Bushing 8a 7 11G0291 1 Paper Feed Clutch 8 11G0430 1 Idle Gear 27 9 11G0303 2 Metal Bushing 8 10 11
128. rvei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients xii Service Manual 5050 001 TEA APER Lexmark TF FRB AH SLR R MAKE ALS LET BET ETER HARE REPRE EA Lexmark TA e AP AE MANE ERS AER MEET AE HA e AP ARH BBR WEERA RnS RE S R EURE ARR EDEN TAR HERDER HU TE ME ot AFS Oo H R ESA Lexmark HY 2 amp 2 ABA UJA 24249 NA HF Ho PSS M HAEYYON Solttorseiict ah Ho oMMS SAL HAS g c Lexmark MS mA F ASH ch st AAS AA ggd e AZo Bet RI PE AAAS ME AHA 28x80 AAS Hoe ul ASAE MES aat o Z H S ASD SUIS JF UYA 348 HALL SAS AS Tao JEU Ae HEX 7187 Ol AMS SASH Best de AAS SES SYA Safety Information xiii 5050 001 xiv Service Manual 5050 001 1 General Information Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the error code charts symptom index and service checks to determine the symptom and repair the failure You may find that the removals in the Repair Information chapter will help you identify parts After you complete the repair perform tests as needed to verify the repair Tools The removal and adjustment procedures described in this manual require the following tools and equipment Magnetic tip Phillips screwdrivers large and small Flat blade screwdrivers Analog volt ohmmeter a digital volt onmmeter may also be used Needle no
129. sage and continue processing Downloaded fonts and macros not previously stored in flash memory or disk are deleted e Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the second line Press Select 53 Unformatted Flash The flash memory installed in your printer has not been formatted You must format the flash memory before downloading resources Press Go to clear the message To format flash memory select Format Flash from the Tests Menu 54 Parallel Error The printer has detected a protocol error on the standard parallel interface Check the cable connection between the printer and the computer and make sure the cable is not defective Press Go to clear the message and continue printing The job may not print correctly Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the second line Press Select 54 Parallel Option x Error The printer has detected a protocol error on the specified parallel interface Check the cable connection between the printer and the computer and make sure the cable is not defective Press Go to clear the message and continue printing The job may not print correctly Reset the printer Press Menu gt or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Reset Printer appears on the seco
130. screws and sliding the paper feed guide toward the bottom Repair Information 4 37 5050 001 5 Open the guide retainer 6 Remove the press roller 4 38 Service Manual 5050 001 Fuser Pawl Removal Be careful not to damage the edge of the pawl or the fuser roll 1 Remove the fuser oiler roller fuser guide and fuser cover 2 Remove the press spring 3 Remove the 2 stopper screws and the guide stay Repair Information 4 39 5050 001 4 Remove idler gear 18 Idler Gear 18 5 Pull out the pawl holder stay and remove it 5 screws Be careful not to damage the fuser roller surface 4 40 Service Manual 5050 001 6 Remove the pawl from the holder stay Be careful to not lose the spring Repair Information 4 41 5050 001 Fuser Heater Removal Be careful not to damage the heater glass Do not touch the lamp with your fingers Wipe with alcohol if it is necessary to clean 1 Remove the fuser guide and the fuser cover 2 Remove the harness from the terminal 2 silver screws with washers 8 Cut off the cable tie on the cord retainer a Cord Retainer gt g 4 42 Service Manual 5050 001 4 Remove the left heater plate from the left side Repair Information 4 43 5050 001 Fuser Heat Roller and Gear H Gear 30 Removal Remove the fuser heater Remove the guide stay Remove the pawl holder stay Remove the right heater plate ROD
131. se pliers Tweezers C ring pliers Magnifier 10 times or equivalent 6 angle wrench 1 5 mm When you make voltage readings always use frame ground unless another ground is specified General Information 1 1 5050 001 Serial Number Lower the multipurpose feeder and refer to the label on the right The serial number is also listed on the menu settings page you can print from the Tests Menu 1 2 Service Manual 5050 001 Abbreviations ASIC Application Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read Only Memory EP Electrophotographic Process ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LAN Local Area Network LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PICS Problem Isolation Charts PIXEL Picture Element POR Power On Reset POST Power On Self Test PQET Print Quality Enhancement Technology RIP Raster Image Processor ROS Read Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement VAC Volts alternating current VDC Volts direct current General Information 1 3 5050 001 Standard Features addressability Feature Description Print method Dry electrophotograph
132. set to Gear and Drum Diagnostic Information 2 41 5050 001 No Image Possible Cause Action Moist Paper Be sure the printer is not in a damp environment and the paper is not curled or wavy due to moisture If necessary inform the customer about correct storage LED Head Be sure the LED head cable is securely connected to the head controller board and LED head assembly If the problem remains replace the LED head High Voltage Unit 2 Be sure all the connectors to the high voltage unit 2 are securely connected If the problem remains replace the high voltage unit 2 11G0313 Printer Controller Board Be sure all connectors are securely connected to the printer controller board If the problem remains replace the printer controller board 11G0324 Printhead Controller Board If you still have the problem replace the printhead controller board 11G0555 Black Line Possible Cause Action Photoconductor Drum Clean any dirt from the PC surface Replace it if it is scratched Fuser Detach Pawl Fuser Roller Surface Fuser Thermistor Surface Fuser Thermostat Surface Remove any toner buildup Replace scratched parts LED Head Clean the LED printhead Print a sheet of blank document Replace the LED printhead if a black line appears on the paper 2 42 Service Manual 5050 001 Black Print Possible Cause Action
133. sional service personnel should understand this and take necessary precautions Consignes de S curit e Ce produit a t con u test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de l utilisation d autres pi ces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Safety Information ix 5050 001 Norme di sicurezza e prodotto stato progettato testato e approvato in conformit a severi standard di sicurezza e per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non responsabile per l utilizzo di parti di ricambio di altri produttori e Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato Il personale di assistenza autorizzato
134. ss connectors O1 D Repair Information 4 21 5050 001 8 Remove the head controller board from the mounting board 6 screws Operator Panel Removal 1 Remove the front cover 4 silver screws 2 Remove the connector and ground wire 3 Remove the 2 screws from the operator panel mounting bracket 4 22 Service Manual 5050 001 MPF Removal 1 Remove the front cover 2 Remove the right MPF plate 2 screws 3 Remove the left MPF plate 2 screws Repair Information 4 23 5050 001 4 Remove the bearing stoppers from each side of the MPF U Release and turn the bearing position clips 90 degrees toward the front MPF Holder Paper Feed Roller Removal 1 Remove the rear cover and the right side cover 2 Move the plunger of the paper feed clutch solenoid out of the way to make the clutch move freely Turn the paper feed roller and remove the screw 3 Remove the paper feed roller from the shaft If the roller has oil on it clean it with a cloth dampened with alcohol en TI Paper Feed Clutch 4 24 Service Manual 5050 001 MPF Roller 1 Remove the front cover 2 Remove the MPF U 3 Remove the bearing stoppers from each side of the MPF U Release and turn the bearing position clips 90 degrees toward the front
135. ssuming 12 or more errors have occurred If fewer than 12 errors have occurred then the oldest error is displayed in the position before the empty log entries begin Empty log entries are identified with an error number of 000 Occupied log entries contain the error number for the message that is displayed on the operator panel For example 925 is contained in the log when a 925 Service Error occurs If an error occurs after the log is full the oldest error in the log is discarded to make room for the new error Diagnostic Aids 3 25 5050 001 The following error messages are stored in the error log All 2xx paper jam messages All 9xx service messages To view the error log select the Display Log operation from the Diagnostics ERROR LOG menu The entire error log cannot be displayed on a single screen Four error log entries are displayed per screen Therefore the entire error log takes up three screens To move forward in the log press Menu gt To move backward in the log press Menuc Here is an example of the error log screens 1 200 2 920 3 928 4 922 5 250 6 990 7 230 8 230 9 953 10 000 11 000 12 000 To exit the error log press Return or Stop Clearing the Error Log To clear the error log select the Clear Log operation from the ERROR LOG menu The printer displays the following message Clear Log Yes Select Yes to confirm that you really want to clear the log The error
136. t The Y value for magenta is incorrect The magenta radar image is too far above the black In the case of Y increase the value for Y to move the magenta image down the page This may not seem intuitive but increasing the value increases the timing delay thus moving the image down the page The images may be off by different amounts Make the best overall judgment using all the radar images on the left side When the Y value is correctly adjusted the magenta radar image should look like the following example The Theta adjustment is done in the same manner as the Y except theta values are taken from the right side of the test pages 4 8 Service Manual 5050 001 Summary Notes X and Y values are taken from the left side Theta is taken from the right Increasing values for X drives the color radar right Increasing values for Y and Theta drive the color radar image down the page Do both the X and Y before attempting Theta Use a loop or magnifying glass to make the job easier Yellow is very difficult When you make the yellow adjustment swap the cyan toner cartridge and photoconductor with the yellow cartridge and photo conductor Run through the procedure making the correct adjustments to the yellow X Y and Theta adjustment Remember to swap the supplies position back to the correct position when you finish Repair Information 4 9 5050 001 Removal Procedures LED Head Re
137. t or lt Menu The Job Menu is displayed Press Menu gt or lt Menu until Cancel Job appears on the second line Press Select 2 10 Service Manual 5050 001 Message Ready Hex Meaning Hex Trace diagnostic mode is active and the printer is ready to receive data Use Hex Trace to isolate the source of a print job problem With Hex Trace selected all data sent to the printer is printed in hexadecimal and character representation Control code strings are printed not executed To exit Hex Trace mode turn the printer off or reset the printer To reset the printer press Menu gt or lt Menu The Job Menu is displayed and Reset Printer appears on the second line Press Select Locking Menus Someone has locked the menus While the menus are locked users cannot change the printer default settings from the operator panel Unlocking Menus Someone has unlocked the menus Users can now change the printer default settings from the operator panel Menus Disabled Menus have been locked or disabled To unlock press the Stop and Go buttons as you POR the machine Supplies At least one of the printer supplies needs attention You may have a paper tray that is low on paper or a toner cartridge or photoconductor that needs replacing Press Menu gt or lt Menu to open the Supplies Menu Maintenance It s time to replace the fuser transport belt and roller set See the Preventive Maintenance
138. t Delay LocalTalk Name Max Baud Rate LocalTalk Addr LocalTalk Zone FAX MENU Fax Port Fax Baud Fax Data Bits Fax Parity Fax Buffer Diagnostic Mode To access the diagnostics printer settings and operations 1 Turn off the printer 2 Press and hold the Go and Return buttons 3 Turn on the printer Release the buttons after the Performing Self Test message displays Diagnostic Menu Group The Diagnostic Menu Group contains multiple menus They are displayed in the operator panel in the order shown in the table The names of the top level menus are capitalized Intermediate Menu Top level Menu Printer Setting or Value List Printer Operation CMY TOP MAR ADJ Tray 1 16 to 15 0 Tray 1 Test Test Tray 2 16 to 15 0 3 6 Service Manual 5050 001 Tray 2 Test Test Tray 3 16 to 15 0 Tray 3 Test Test MP Feeder 16 to 15 0 MP Feeder Test K TOP MAR ADJ Tray 1 16 to 15 0 Tray 1 Test Test Tray 2 16 to 15 0 Tray 2 Test Test Tray 3 16 to 15 0 Tray 3 Test Test MP Feeder 16 to 15 0 MP Feeder Test Test X POSITION ADJ Cyan 80 to 80 0 Magenta 80 to 80 0 Yellow 80 to 80 0 Test Print Radar Test Y POSITION ADJ Cyan 128 to 127 0 Magenta 128 to 127 0 Yellow 128 to 127 0 Test Print Radar Test THETA POSITION ADJ Cyan 24 to 24 0 Mag
139. t on the new board e If you change the EEPROM the LED light quantity total counter printing position margins and printhead adjustments X Y and Theta should be readjusted in the service mode 4 28 Service Manual 5050 001 HVU1 U Removal Remove the printer controller board Remove the harness from the wire saddle Remove the connector Remove the 7 mounting screws Remove HVU1 U from the HVU bracket 9 screws apron Drive 2 U and Face Up Face Down FUD Solenoid Removal 1 Remove the printer controller 2 Remove the harness from the wire saddle 3 Remove the mounting bracket stay 1 black screw Repair Information 4 29 5050 001 4 Remove the FUD solenoid from the mounting bracket stay 2 black screws Fuser Removal Before you remove the fuser mark its position with a pencil so you can install it to the same place 4 30 Service Manual 5050 001 You can also note the position of the fuser on the embossed scale on the bottom of the fuser frame Identification of high low voltage fuser can be determined by either a red low or a blue high wire for the fuser connector After you install the fuser run a test print If there is a wrinkle or scrape on the bottom of the page reposition the fuser 1 Be sure to unplug the machine
140. tely installed in the printer Replace the photoconductors If the page is black you can replace just the black photoconductor If the page is another color replace all three of the color photoconductors If this does not fix the problem go to Black Print on page 2 43 Diagnostic Information 2 39 5050 001 Problem Light lines or streaks appear on the printed page L Action Clean the LEDs Make sure the affected print unit is completely installed in the printer Remove the affected print unit and gently shake it back and forth to distribute the toner evenly Reinsert the print unit and try printing the job again Replace the affected toner cartridge Replace the photoconductors If the problem only occurs when printing black you can replace just the black photoconductor If the problem occurs when printing one of the colors replace all three of the color photoconductors If you still have the problem go to Uneven Printing on page 2 44 The page is blank Be sure the affected print unit is completely installed in the printer Replace the affected toner cartridge If you still have the problem go to No Image on page 2 42 Toner smears or rubs off the page Be sure you re using recommended paper or other media Be sure you have selected the correct Paper Type setting for the media you re using Be sure the top cover is com
141. ting messages unless another status message of higher priority is posted until you replace the photoconductor If this message does not reset after replacing all photoconductor units clean or replace the drum sensor 11G0548 in the right sub frame 84 Black PC Drum The black photoconductor has reached the end of its Exhausted 13 000 page life You may want to replace the photoconductor now If the print quality is still acceptable press Go to clear the message and continue printing The Supplies status message is then displayed with the Ready Power Saver Busy and Waiting messages unless another status message of higher priority is posted until you replace the photoconductor When you replace the black photoconductor make sure you also install the new fuser coating roll that is included in the black photoconductor kit If this message does not reset after replacing all photoconductor units clean or replace the drum sensor 11G0550 in the right sub frame Diagnostic Information 2 21 5050 001 Message 84 Color PC Drums Exhausted Action The three color photoconductors have reached the end of their 13 000 page life You may want to replace the photoconductors now When you do replace them replace all three cyan magenta and yellow at the same time If the print quality is still acceptable press Go to clear the message and continue printing The Supplies status message is then d
142. tion 4 17 5050 001 10 Open the paper exit cover and remove the paper exit unit by sliding it toward the rear To remove the front cover 1 Remove the paper cassette and open the MPF 2 Remove the 4 silver mounting screws and unlatch the upper part of the front cover 3 Remove the operator panel connector and remove the front cover 4 18 Service Manual 5050 001 To remove the left side cover 1 Remove the 4 silver mounting screws and remove the left side cover 2 Remove the 2 screws that mount the left side sub cover Repair Information 4 19 5050 001 To remove the right side cover 1 Remove the 4 silver screws that mount the right side cover 2 Remove the 2 screws that mount the right side sub cover WAYA YIP a I LA WY EG V7 I DD X T 4 20 Service Manual 5050 001 Head Controller Board P614 HDCONT Removal Remove the top cover Remove the harness connector from the HDCONT board Remove the 3 flat cables from the HDCONT board Remove the grounding wires from the shield plate Remove the 4 black mounting screws and lift the shield plate from the HDCONT board 6 Remove the remaining flat cable from the HDCONT board 7 Remove the other 4 flat cables and 3 harne
143. u still have the problem replace the printer Controller controller board 11G0324 Board Diagnostic Information 2 29 5050 001 Optional Paper Feed Service Check If you have a 24XX error code the last number in the code indicates the affected tray Check the option connection cable for proper connection to the printer or other paper feeder If you have two optional feeders you can connect the non working one directly to the printer to check for a cable or drive card problem FRU Action 1 Drive Motor If the drive motor works go to the Paper Carrying Service Check on page 2 32 If the drive motor does not work check for 8 Ohms resistance between pins 1 to 3 and 2 to 4 Replace the motor if necessary 11G0414 2 Gears If the motor turns but the drive gears do not replace the gears as necessary If this does not correct the problem replace the optional feed driver board Paper Jam Service Check Be sure the customer is using the correct paper If the machine is turned on and error code 200 201 202 24X or 250 is displayed do the following before going to the Paper Carrying Service Check You must clear all paper from the entire paper path Open and close the top cover and the rear cover then press Go If you still get an error run a single sheet of paper through the machine note the error code and the position of the paper in the printer Locate the error code from th
144. usted What is being adjusted is the time from when the leading edge of the paper reaches the print registration rollers and when the printer starts putting toner on the paper You must adjust both the CMY and K top margins The K Top Margin must be adjusted first Diagnostic Aids 3 11 5050 001 To make this adjustment Note Before adjusting the margins be sure the printer is set to the graphic print mode in the Print Quality Menu The Print Quality Menu is a sub menu of the Color Menu Select the Diagnostic Mode Select Printer Setup Select CMY Top Margin Adjust Input the values RON To verify the margin values are correct you must print the Quick Test page From the Tray X test screen press Select While the page is printing the following message is displayed The Power indicator also blinks while the page is printing Quick Test Printing The printer will attempt to print the Top Margin page from the default paper source However if the default source only supports envelopes then the page will be printed from Tray 1 The page consists of alignment diamonds When you change the value for that tray you will see the CMY alignment diamonds move up and down the page The test page also contains the page count setting printer serial number and code levels The Test Page can only be printed for the trays that are installed The Menus to change the values show up even if the tray is not installed Th
145. wo and must be 50 NS EDO SIMMS 964 Emulation Error Contact Technical Support for assistance Download emulation CRC failure 965 Emulation Error Contact Technical Support for assistance Download emulation outdated Time stamps indicate the download emulation and RIP code are incompatible 97X INA Failure Be sure the RIP controller riser card and the INA are properly installed Replace the INA If you still have a problem replace the RIP controller card 11G0604 2 6 Service Manual 5050 001 Error Message or Symptom Action 977 Network Card Error The system processor has detected an INA is installed but cannot communicate with it The X after the card indicates which one has the problem Network card 1 always refers to the INA in the bottom slot and Network card 2 always refers to the INA in the top slot Be sure the RIP controller card riser card is properly installed 980 Switch Error Transfer Belt or Belt Up Down BUD Sensor Problem 1 Be sure connector CN106 is connected to the printer controller board 2 Be sure the BUD sensor actuator is working properly Clean the BUD sensor Firmly connect the connector Do a sensor test Check for approximately 5 V on pin 2 to GND of connector CN106 as you actuate the flag in the sensor Replace the actuator or sensor if necessary 6 Replace the BUD motor unit 11G0251 7 If you still have the problem replace th
146. y Fan Alarm printer controller board 11G0323 2 Replace the fan if necessary 3 If you still have a problem replace the printer controller board 919 Fan Error 1 Be sure motor connector CN116 is connected properly on the Power Supply Fan Alarm printer controller board 2 Replace the fan 11G0322 3 Replace the printer controller board 11G0324 2 4 Service Manual 5050 001 Error Message or Symptom Action 920 Fuser Error Fuser Heater Trouble 1 Remove the fuser heater cable from the power supply CN602 and check it for continuity If there is no continuity in the heater wire replace the fuser heater and the fuser oil coating roller If there is no continuity in the thermostat or it does not equal 240K Ohms at 25 degrees C room temperature replace the fuser thermostat and the fuser oil coating roller If the thermal fuse is open replace it 2 If there is continuity and the thermostat is good replace the power supply If this doesn t fix the problem replace the printer controller board 923 Fuser Error Fuser Thermistor Open 1 Be sure thermistor connector CN119 is connected properly to the printer controller board 2 Short pins 1 and 2 of connector CN119 and turn the power on 3 If an error displays replace the printer controller board If an error does not display replace the fuser thermistor and the fuser oil coating roller 93X 930

Lexmark Optra 1200 (5050-001) Laser Printer Service Manual

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