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Lexmark Optra Color 1200, Service Manual

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Lexmark Optra Color 1200 Service Manual Download Page 161

Repair Information

4-47

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, 120 V only).

4. Remove the I/R lever: B, (2 screws).

5. Remove the shield plate, (7 screws).

6. Remove the insulating sheet and power supply board, (5 

screws).

7. Remove the connector of the main switch cable.

Be sure the I/R lever works correctly after you reassemble.

Size Sensor Board (P611-PSZ) Removal 

1. Remove the rear cover, the front cover, and the left side cover.

2. Remove the power supply board.

3. Remove the HDRV board (230 V only).

4. Remove the connector and the PSZ bracket, (2 screws).

5. Remove the P611-PSZ assembly (size sensor board) from the 

bracket, (2 screws).

Summary of Contents for Optra Color 1200

Page 1: ...M Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start...

Page 2: ...c 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 o...

Page 3: ...embly 1 11 Transfer Assembly 1 12 Cleaning Assembly 1 13 Paper Feed Transfer and Fusing 1 14 Print Modes 1 26 Clearing Paper Jams 1 27 Printing From the Multipurpose Feeder 1 28 Diagnostic Information...

Page 4: ...e Operator Panel 3 1 Operator Panel Buttons 3 3 Printing the Menu Settings 3 3 Operator Menu Disabled 3 4 Menu Overview 3 4 Diagnostic Mode 3 6 Diagnostic Menu Group 3 6 Setting Printer top Margin 3 1...

Page 5: ...lt Unit Removal 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 4 15 Head Controller Board P614 HD...

Page 6: ...DRIV Removal 4 64 Paper Feed Motor 2 PM42 Removal 4 64 Paper Feed Roller Removal 4 65 Paper Remaining Sensor Removal 4 66 Paper Feed Clutch Solenoid and Transfer Roller Removal 4 67 Connector Location...

Page 7: ...7 10 Assembly 5 Base 2 7 12 Assembly 6 Feeder 7 18 Assembly 7 Electrical 7 22 Assembly 8 I F Controller 7 26 Assembly 9 Fuser 7 28 Assembly 10 Cassette 7 32 Assembly 11 Optional Feeder Base 7 34 Asse...

Page 8: ...assembly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t con u test et approuv pour respecter les...

Page 9: ...di adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu...

Page 10: ...ran 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 s...

Page 11: ...fessionals 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 servei d aquest producte El personal professional h...

Page 12: ...apter 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...

Page 13: ...1 2 Service Manual 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...

Page 14: ...rea 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 O...

Page 15: ...and Greek Paper input 250 sheet tray Multipurpose feeder Paper output Top output bin 250 sheets collated Rear output bin 100 sheets uncollated Paper sizes supported A4 A5 JIS B4 JIS B5 A3 letter legal...

Page 16: ...following topologies Ethernet 10BaseT and 10Base2 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 int...

Page 17: ...ller Rubber 4 Fuser Oil Roller 21 Registration Sensor 5 Paper Exit Sensor Lever 22 Registration Sensor Lever 6 Belt Drive Roller 23 MPF Roller 7 Belt Thermistor 24 Feeder Friction Stop Pad 8 Transfer...

Page 18: ...General Information 1 7 5050 001...

Page 19: ...lectrophotographic 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 Electropho...

Page 20: ...General Information 1 9 5050 001...

Page 21: ...ayer 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 elec...

Page 22: ...ced 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...

Page 23: ...ectrostatically 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...

Page 24: ...mbly The cleaning blade scrapes off the remaining toner on the photoconductor drum after the toner image has been transferred to the paper A rotating coil in the waste toner conveyance assembly convey...

Page 25: ...e 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 interr...

Page 26: ...General Information 1 15 5050 001...

Page 27: ...per feed roller connected to drive 1 by a spring clutch The paper in the cassette is picked one sheet at a time Multipurpose Feeder After it receives a signal from the printer controller the MPF solen...

Page 28: ...ming 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 c...

Page 29: ...vice Manual 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 discharg...

Page 30: ...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 co...

Page 31: ...itching is set default the face up face down FUD 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 s...

Page 32: ...ive 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...

Page 33: ...General Information 1 22 5050 001...

Page 34: ...ns 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 gear...

Page 35: ...General Information 1 24 5050 001...

Page 36: ...General Information 1 25 5050 001 Paper Path for Mono Pages Paper Path for Color Pages...

Page 37: ...tor 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...

Page 38: ...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...

Page 39: ...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 MarkVisio...

Page 40: ...e 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 a...

Page 41: ...quantity Printhead adjustments X Y and Theta Margins Start Initial Check Before you start troubleshooting check the following Installation Environment The power supply line voltage is plus or minus 10...

Page 42: ...ntion Service Error Message Table Error Message or Symptom Action 900 Software Error Unrecoverable software error Refer to the operator manual 910 Motor Error DC Drive 1 Motor Failure 1 Be sure motor...

Page 43: ...t 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 ther...

Page 44: ...3 954 RIP Controller Card Error Replace the RIP controller card 11G0604 Be sure to move the solid state drive memory and option cards from the old card to the new one 955 NVRAM Failure RIP Controller...

Page 45: ...rk 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 Tran...

Page 46: ...page 2 34 983 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...

Page 47: ...eck 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 connecto...

Page 48: ...eplace the humidity sensor 11G0571 3 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 Repla...

Page 49: ...his 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 or Menu The Job Menu is displayed Press Menu or Menu until...

Page 50: ...rator 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...

Page 51: ...ancel Job appears 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 or Menu The...

Page 52: ...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 m...

Page 53: ...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 i...

Page 54: ...he printer can return to the ready state 30 color Print Unit Missing The specified print unit Cyan Magenta Yellow or Black is not installed in the printer Insert the print unit and close the top cover...

Page 55: ...il Cancel Job appears on the second line Press Select To reduce the complexity of the job Reduce the number of graphics or images on a page Delete unnecessary downloaded fonts or macros Change the Pri...

Page 56: ...rallel 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...

Page 57: ...ain 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 E...

Page 58: ...the second line Press Select 61 Defective Disk The hard disk installed in your printer is defective Press Go to clear the message and continue printing You must install a different disk before you ca...

Page 59: ...en 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 perf...

Page 60: ...replacing all photoconductor units clean or replace the drum sensor 11G0548 in the right sub frame 84 Black PC Drum Exhausted The black photoconductor has reached the end of its 13 000 page life You m...

Page 61: ...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...

Page 62: ...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 t...

Page 63: ...just 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 t...

Page 64: ...ter and run the LCD and Button tests If the tests fail 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 installatio...

Page 65: ...ottle 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 fr...

Page 66: ...heck for approximately 120 V or approximately 240 V on connector CN602 pin 1 and 2 3 Fuser Thermistor Printer Controller Board Be sure connector CN119 is securely pugged into the printer controller bo...

Page 67: ...lem replace the high voltage unit 1 11G0326 4 High Voltage Unit 2 If you still have the problem replace the high voltage unit 2 11G0313 5 Printer Controller Board If you still have the problem replace...

Page 68: ...he drive 2 stepper motor rotates and the fuser and exit rolls do not rotate replace the drive 2 stepper motor unit 11G0258 FRU Action 1 BUD Sensors BUD Actuator Check the transfer belt BUD sensor Repl...

Page 69: ...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 the foll...

Page 70: ...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...

Page 71: ...ng 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 3 Ge...

Page 72: ...r Service Check on page 2 29 FRU Action 1 Registration Roller Clutch Registration Roller Absorption Roller Transfer Belt Unit Rear Paper Feed Guide Check these parts for wear or damage Replace as nece...

Page 73: ...aged or worn parts FRU Action 1 Fuser Roller Fuser Press Roller Fuser Separation Pawl Remove any toner buildup and replace any worn or damaged parts 2 Fuser Exit Lower roller Exit Guide FU FD Flap Sol...

Page 74: ...ce as necessary FRU Action 1 Actuator Sensor Check the actuators and sensors for proper operation Tray 1 connector CN106 pin 9 and pin 12 to GND Tray 2 and 3 CN903 pin 2 and pin 5 to GND FRU Action 1...

Page 75: ...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 Fuse Switch The power supply fuses may...

Page 76: ...y 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 wi...

Page 77: ...istribute the toner evenly Reinsert the print unit and try printing the job again Replace the affected toner cartridge Replace the photoconductors If only black print appears light you can replace jus...

Page 78: ...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...

Page 79: ...r 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 af...

Page 80: ...Vivid Avoid getting fingerprints on transparencies before printing Print on the page is skewed Be sure the width guides in the paper tray or the multipurpose feeder fit snugly against the media you lo...

Page 81: ...lem 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 co...

Page 82: ...le 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 co...

Page 83: ...Bottle Transport Belt Unit Check the underside of the transport belt for toner buildup Possible Cause Action Photoconductor Drum Check for condensation or dirt on the photoconductor drum LED Head Cle...

Page 84: ...per to move the actuator so that the sensor is blocked 4 Check the meter for changes in the reading between signal pin 5 V pin and GND 5 If the sensor is not working correctly and the actuator is not...

Page 85: ...anual 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 w...

Page 86: ...ure check Temperature regulated 5 Ready Printer controller RIP controller Printer condition Motor Fan Heater 6 DC motor drive 1 7 Feeding paper 8 Print 9 Stepper motor drive 2 10 Paper exit 11 Stop Us...

Page 87: ...t Use the five operator panel buttons to open a menu scroll through a list of values select printer settings and clear error messages State Indicates Off Printer power is off On Printer is on but idle...

Page 88: ...button to Select the menu shown on the second line of the display and view the available menu items Select the menu item shown on the second line of the display and view the available values and the...

Page 89: ...hine 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 color Toner color...

Page 90: ...nt 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 PAR...

Page 91: ...lized NETWORK MENU NETWORK OPTION 1 NETWORK OPTION 2 PCL SmartSwitch PS SmartSwitch NPA Mode Network Buffer Job Buffering NETWORK x SETUP INFRARED MENU Infrared Port PCL SmartSwitch PS SmartSwitch NPA...

Page 92: ...est 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...

Page 93: ...ngle 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 available Test Serial 2 Wrap if av...

Page 94: ...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 Z or 0 9 Par S Strobe Ad...

Page 95: ...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 o...

Page 96: ...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...

Page 97: ...ow 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...

Page 98: ...to 127 A positive offset moves the plane to the right of the page A negative offset moves the plane to the left the page Note Modification of the y position adjustment setting causes the entire plane...

Page 99: ...Enter the value from the label on the printhead Thermistor Rank If you replace the transfer belt unit or the EEPROM for the engine controller the Thermistor rank value must be set according to the co...

Page 100: ...s menu For each source the user has 2 choices Single print Print Test pages once Continuous continue printing Print Test pages until Return or Stop is pressed The first page Print Test contains seven...

Page 101: ...following message is displayed 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 sequenc...

Page 102: ...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...

Page 103: ...parallel signal is tested To perform the wrap test follow these steps Disconnect the parallel interface cable and install the parallel wrap plug Select HARDWARE TESTS from the Diagnostics Menu Select...

Page 104: ...using a wrap plug Each serial signal is tested To perform the wrap test follow these steps Disconnect the serial interface cable and install the serial wrap plug Select HARDWARE TESTS from the Diagnos...

Page 105: ...e 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 proc...

Page 106: ...plete 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 foll...

Page 107: ...cted 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 screen If mo...

Page 108: ...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...

Page 109: ...ill 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 s...

Page 110: ...tains 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 assuming 12 or more errors have occu...

Page 111: ...g 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 Select Yes to confirm that you re...

Page 112: ...Diagnostic Aids 3 27 5050 001 Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal user mode press EXIT DIAGNOSTICS...

Page 113: ...3 28 5050 001 Print Quality Test Page...

Page 114: ...Diagnostic Aids 3 29 5050 001 Print Quality Test Page...

Page 115: ...fter the printer stops running Always unplug connectors by holding the connector housing Be sure to use the fuse listed in the parts catalog Do not forget to install the ground wire or ground plate to...

Page 116: ...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...

Page 117: ...l be directed to the appropriate page in 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...

Page 118: ...sert 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...

Page 119: ...is 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 14 LED Head Light Quantity Adjustment Make this a...

Page 120: ...ee 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 Se...

Page 121: ...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 2400 of an inch 6 Theta contro...

Page 122: ...ncrease 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 of...

Page 123: ...he 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...

Page 124: ...ld left hand head spring 4 Disconnect the ground wire and the flat cable on both ends of the head from the connector 5 Remove the LED head Do not remove or loosen the pins on either end of the LED hea...

Page 125: ...e 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 cover 4 black screws 4 Remove the paper carr...

Page 126: ...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...

Page 127: ...Repair Information 4 13 5050 001 3 Remove the UD frame 4 Remove the connector and remove the BUD sensor from the UD frame...

Page 128: ...nd remove the 2 mounting screws Remove the motor Engine Board PG14 ENG BB Removal 1 Remove the belt unit Do not turn it upside down 2 Lift the engine board bracket Be careful not to damage the harness...

Page 129: ...Repair Information 4 15 5050 001 Cover Removals...

Page 130: ...r 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...

Page 131: ...onnector cover on the bottom of the rear cover 5 Remove the rear paper exit tray if it is installed 6 Remove the 2 rear paper exit tray mounting studs 7 Remove the 3 silver screws from the upper latch...

Page 132: ...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 c...

Page 133: ...Repair Information 4 19 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...

Page 134: ...4 20 Service Manual 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...

Page 135: ...tor from the HDCONT board 3 Remove the 3 flat cables from the HDCONT board 4 Remove the grounding wires from the shield plate 5 Remove the 4 black mounting screws and lift the shield plate from the HD...

Page 136: ...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...

Page 137: ...Repair Information 4 23 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...

Page 138: ...the front 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 f...

Page 139: ...move the bearing stoppers from each side of the MPF U Release and turn the bearing position clips 90 degrees toward the front 4 Remove the E ring and MPF clutch Assembly Note Put conductive grease on...

Page 140: ...oval 1 Remove the MPF roller 2 Remove the pad by releasing 2 latches Clean the paper feed roller surface with a cloth dampened with alcohol Registration Sensor Removal 1 Remove the MPF roller 2 Remove...

Page 141: ...sor Removal 1 Remove the front cover 2 Remove the connector and lift out the sensor from the MPF sensor bracket Humidity Sensor Removal 1 Remove the rear cover and the right side cover 2 Remove the co...

Page 142: ...the connector and the printer control board 6 screws Installation Notes Be sure to take the EEPROM U107 from the old board and install it on the new board If you change the EEPROM the LED light quant...

Page 143: ...ness from the wire saddle 3 Remove the connector 4 Remove the 7 mounting screws 5 Remove HVU1 U from the HVU bracket 9 screws Drive 2 U and Face Up Face Down FUD Solenoid Removal 1 Remove the printer...

Page 144: ...001 4 Remove the FUD solenoid from the mounting bracket stay 2 black screws 5 Remove the Drive 2 7 black screws Fuser Removal Before you remove the fuser mark its position with a pencil so you can ins...

Page 145: ...e 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 scrap...

Page 146: ...4 32 Service Manual 5050 001 3 Remove the thermistor harness connector 4 Remove the harness connector from the power supply board...

Page 147: ...Repair Information 4 33 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...

Page 148: ...5050 001 Fuser Thermostat Fuse and Thermistor Removals 1 Remove the fuser cleaner 2 Remove the 2 release levers and stopper screws 3 Unlatch the center of the fuser guide slide it to the right and rem...

Page 149: ...Repair Information 4 35 5050 001 4 Remove the temperature fuse silver screw with washer...

Page 150: ...4 36 Service Manual 5050 001 5 Remove 1 screw and the terminal 6 Remove the thermistat switch from the terminal 1 silver screw with washer 7 Remove the thermistor 1 silver screw with washer...

Page 151: ...er 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 4 Remove the press spring by...

Page 152: ...4 38 Service Manual 5050 001 5 Open the guide retainer 6 Remove the press roller...

Page 153: ...050 001 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...

Page 154: ...4 40 Service Manual 5050 001 4 Remove idler gear 18 5 Pull out the pawl holder stay and remove it 5 screws Be careful not to damage the fuser roller surface...

Page 155: ...Repair Information 4 41 5050 001 6 Remove the pawl from the holder stay Be careful to not lose the spring...

Page 156: ...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 silv...

Page 157: ...Repair Information 4 43 5050 001 4 Remove the left heater plate from the left side 5 Hold the insulator and pull it out from the heat roller...

Page 158: ...anual 5050 001 Fuser Heat Roller and Gear H Gear 30 Removal 1 Remove the fuser heater 2 Remove the guide stay 3 Remove the pawl holder stay 4 Remove the right heater plate 5 Remove the fuser roller 6...

Page 159: ...tion 4 45 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 bra...

Page 160: ...r 2 Remove the connector and HVT bracket 3 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 swi...

Page 161: ...re green yellow gray 120 V only 4 Remove the I R lever B 2 screws 5 Remove the shield plate 7 screws 6 Remove the insulating sheet and power supply board 5 screws 7 Remove the connector of the main sw...

Page 162: ...sor 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...

Page 163: ...Repair Information 4 49 5050 001 6 Remove the drum gear sensor 2 black screws...

Page 164: ...move the belt unit 3 Remove the lock cover 1 screw 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...

Page 165: ...m Drive Gear Sensor P614 DGS Removal 1 Remove the gear 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 dr...

Page 166: ...ctor 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 regis...

Page 167: ...ssembly 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 cabl...

Page 168: ...4 54 Service Manual 5050 001 7 Remove the connector from the printer controller board and harness...

Page 169: ...Repair Information 4 55 5050 001 8 Remove the MPF solenoid 1 screw 9 Remove the registration sensor and the connector of the remaining paper sensor and cut the cable tie...

Page 170: ...4 56 Service Manual 5050 001 10 Press and slide the paper cassette support plate and remove the paper feed base 4 screws 11 Remove the turn guide 4 screws...

Page 171: ...aper feed solenoid 13 Remove the 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 printe...

Page 172: ...5 Remove the front sub cover 6 Cut the cable tie and remove the front frame 7 Remove the transfer belt unit 8 Remove the turn guide 9 Remove connector CN131 and harness from the control board 10 Remov...

Page 173: ...paper exit photo interrupter Be sure the actuator works correctly after you reassemble Output Bin Full Sensor Removal 1 Remove the rear cover 2 Remove the connector from the paper full sensor harness...

Page 174: ...4 60 Service Manual 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...

Page 175: ...from the printer 3 Disconnect all cables from the back of the printer 4 Loosen the six thumbscrews on the system board faceplate at the back of the printer 5 Slide the system board completely out of t...

Page 176: ...uter 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 3 Remove the right side cover 3 silver screws 4 Remove...

Page 177: ...4 63 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 th...

Page 178: ...side cover 2 Remove the connector from the drive board 3 Remove the drive board and the bracket 2 screws 4 Remove the drive board from the bracket 4 screws Paper Feed Motor 2 PM42 Removal 1 Remove the...

Page 179: ...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...

Page 180: ...anual 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 3 Remove the connector and lift out the phot...

Page 181: ...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 pape...

Page 182: ...4 68 Service Manual 5050 001 6 Remove the paper feed guide 2 black screws 7 Remove the paper carrying roller...

Page 183: ...Connector Locations 5 1 5050 001 5 Connector Locations Paper Handling...

Page 184: ...hermistor 24 Feeder Friction Stop Pad 8 Transfer Belt 25 MPF Assembly 9 Transfer Sheet 26 Paper Carrying Roller 10 Cleaning Blade 27 Paper Noise Cut Roller 11 Charging Roller 28 Pick up Paper Feed Rol...

Page 185: ...Connector Locations 5 3 5050 001...

Page 186: ...n 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 2nd Paper Feeder Option...

Page 187: ...Connector Locations 5 5 5050 001 Electrical Components...

Page 188: ...Connector Locations 5 6 5050 001 Sensors...

Page 189: ...Connector Locations 5 7 5050 001 Power Supply Board 614 MPS E...

Page 190: ...Connector Locations 5 8 5050 001 High Voltage Unit 1 Board 614 HVU1...

Page 191: ...Connector Locations 5 9 5050 001 High Voltage Unit 2 Board P614 HVU2...

Page 192: ...Connector Locations 5 10 5050 001 Optional Paper Feed Controller Board P614 2 3 DRIV...

Page 193: ...Connector Locations 5 11 5050 001 Printhead Controller Board P614 HD CONT...

Page 194: ...Connector Locations 5 12 5050 001 Printer Controller Board P614 PRCONT...

Page 195: ...Connector Locations 5 13 5050 001 Size Sensor Board P611 PSZ...

Page 196: ...5 14 Service Manual 5050 001 RIP Controller Card...

Page 197: ...er 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...

Page 198: ...n with 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...

Page 199: ...rable and that the individual parts or the next higher assembly should be ordered NR Not Recommended in the Units column indicates that the part is procurable but not recommended for field replacement...

Page 200: ...Parts Catalog 7 2 5050 001 Assembly 1 Covers...

Page 201: ...0108 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 NS 11G0622 1 Label Instruction Mpt 17 11G0128 1 Mpf A...

Page 202: ...Parts Catalog 7 4 5050 001 Assembly 1 cont Covers...

Page 203: ...567 1 Rating Plate Low 115 Volts NS 11G0568 1 Rating Plate High 230 Volts 34 11G0631 1 Rear Paper Exit Tray Asm 35 11G0623 2 Cushion Operator Panel 37 11G0569 1 Screw Parts Packet 1 38 99A0001 1 Opera...

Page 204: ...Parts Catalog 7 6 5050 001 Assembly 2 Paper Exit...

Page 205: ...ound Plate Paper Exit 15 11G0144 2 Pulley 16 11G0145 1 Belt 17 11G0147 6 Lower Roller Fitting Plate 18 11G0148 6 Paper Exit Roller Lower 19 11G0561 1 Clutch Lever Paper Delivery Flap 20 11G0507 1 Clut...

Page 206: ...Parts Catalog 7 8 5050 001 Assembly 3 Upper Unit...

Page 207: ...Base R 14 11G0555 1 LED Printhead Controller Board P614 Hdcont 16 11G0167 1 Insulator Shield sheet 17 11G0168 1 Sealed Plate 18 11G0503 1 Head cable M 115 V 18 11G0665 1 Head Cable M 230 V 19 11G0504...

Page 208: ...Parts Catalog 7 10 5050 001 Assembly 4 Base 1...

Page 209: ...0618 1 Cable Tie 14 11G0188 1 Second Connector Bracket 15 11G0189 1 Hinge Frame 16 11G0190 3 Ground Plate 17 11G0191 1 Cassette Ground Plate 18 11G0192 2 Lock Cover B 19 11G0193 2 Lock Cover A 20 11G0...

Page 210: ...Parts Catalog 7 12 5050 001 Assembly 5 Base 2...

Page 211: ...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 1...

Page 212: ...Parts Catalog 7 14 5050 001 Assembly 5 cont Base 2...

Page 213: ...237 1 Open Button 52 11G0242 1 Link 53 11G0241 1 Hook Spring 54 11G0240 1 Release Hook Lever 55 11G0243 2 Photo Interrupter Paper Detect 56 11G0558 1 Photo Interrupter Paper Detect 57 11G0245 1 Paper...

Page 214: ...Parts Catalog 7 16 5050 001 Assembly 5 cont...

Page 215: ...own 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 85 11G0626 2 Setting Label...

Page 216: ...Parts Catalog 7 18 5050 001 Assembly 6 Feeder...

Page 217: ...1G0277 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 Pape...

Page 218: ...Parts Catalog 7 20 5050 001 Assembly 6 cont Feeder...

Page 219: ...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...

Page 220: ...Parts Catalog 7 22 5050 001 Assembly 7 Electrical...

Page 221: ...315 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 Holde...

Page 222: ...Parts Catalog 7 24 5050 001 Assembly 7 cont Electrical...

Page 223: ...oard 230 V NS 11G0660 1 Resistor Heater Drive Board 230 V 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 Cor...

Page 224: ...Parts Catalog 7 26 5050 001 Assembly 8 I F Controller...

Page 225: ...G0604 1 RIP Controller Card 2 11G0605 1 Riser Card 3 11G0606 1 Fan 4 11G0607 1 16MB Solid State Drive 5 11G0608 2 16MB SIMM EDO 50ns 5 11G0609 2 32MB SIMM EDO 50ns 6 11G0611 1 Bracket Riser Card 7 11G...

Page 226: ...Parts Catalog 7 28 5050 001 Assembly 9 Fuser...

Page 227: ...Heater 230 Volt 10 11G0348 1 614 Heater 115 Volt 11 11G0349 1 611 Thermostat Asm 12 11G0551 1 611 Fuse Asm 230 Volt 12 11G0350 1 611 Fuse Asm 115 Volt 13 11G0214 4 Stopper Screw 14 11G0351 1 Terminal...

Page 228: ...Parts Catalog 7 30 5050 001 Assembly 9 cont Fuser...

Page 229: ...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 37 11G05...

Page 230: ...Parts Catalog 7 32 5050 001 Assembly 10 Cassette...

Page 231: ...1 Click R 5 11G0380 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 Loca...

Page 232: ...Parts Catalog 7 34 5050 001 Assembly 11 Optional Feeder Base...

Page 233: ...Lever 13 11G0243 1 Photo Interrupter Paper Detect Sensor 14 11G0558 1 Photo Interrupter Paper Detect Sensor NS 11G0625 1 Lever Stopper 16 11G0405 1 Second Photo Interrupter Harness 17 11G0406 1 Cable...

Page 234: ...Parts Catalog 7 36 5050 001 Assembly 11 cont Optional Feeder Base...

Page 235: ...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...

Page 236: ...Parts Catalog 7 38 5050 001 Assembly 12 Optional Feeder Paper Feed...

Page 237: ...Feed Clutch 8 11G0430 1 Idle Gear 27 9 11G0303 2 Metal Bushing 8 10 11G0297 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 R...

Page 238: ...Parts Catalog 7 40 5050 001 Assembly 13 Optional Features...

Page 239: ...nce Kit High Voltage 11G0632 1 Machine Return Packaging Material 99A0459 1 Hard Disk 11G0610 1 Cable Hard Disk 99A0422 1 Ethernet 10BaseT and 10Base2 99A0421 1 Ethernet 10 100BaseT 99A0420 1 Token Rin...

Page 240: ...1 8 Wiring Diagram A wiring diagram for this printer is available as a PostScript file on this CD ROM disk Print file 5050_001 PS in the DIAGRAM directory Files are available for either letter or A4 p...

Page 241: ...er motor service check 2 29 drive board removal 4 64 drum drive gear sensor removal 4 51 E electrical charge unit 1 10 electronic board layout 5 4 electro photographic process 1 8 engine board removal...

Page 242: ...belt removal 4 67 paper feed motor 2 removal 4 64 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 1 paper jam service ch...

Page 243: ...e 2 3 setting printer top margin 3 10 setting the page count 3 23 size sensor board layout 5 13 size sensor board removal 4 47 4 63 standard features 1 4 status messages 2 10 symptom table 2 23 T ther...

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