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Part number index

I-9

  

7002-xxx

Part number index

P/N

Description

Page

1319128

Parallel wrap plug

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-159

, 

3-10

40X0001

Fuser wiper cover assembly

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-3

, 

7-7

40X0009

TLI/ID/serial number label—blank

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-5

, 

7-7

40X0021

Cartridge holddown spring

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0024

Right frame extension

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-11

40X0025

Left frame extension

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-11

40X0026

Contact, RSF ground

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-11

40X0027

Upper redrive deflector

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0028

Upper diverter spring

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0030

Redrive assembly, 500 in/500 out

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0032

Transfer deflector with brush

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0033

Machine mounting pad

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0034

Signature button contact assembly with cable

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15

, 

7-45

40X0036

Toner sensor assembly

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0039

Developer support roller

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0040

Upper paper feed deflector

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0042

Inner paper feed deflector

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0043

Input sensor

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0044

Gear guard

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0045

ESD shield with label

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-15

40X0046

Paper size sensing board assembly

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -7-13

, 

7-44

40X0048

Paper switch activate spring

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0049

Gear release link

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0050

Counterbalance spring

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-5

, 

7-7

40X0051

Standard bin level sensor

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0052

Standard bin level sensor bracket

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0054

Main fan with cable, 500-sheet output

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13

, 

7-51

40X0058

Output paper level flag

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0059

Extension guide

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-13

40X0060

External ground clip

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-11

40X0061

Laser printhead cable assembly

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-24

, 

7-44

40X0062

Printhead assembly (includes all cables)

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-24

40X0065

Frame extension, nut plate

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-11

40X0066

Pick arm assembly—500-sheet

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-25

40X0069

Parts packet, bellcrank assembly for—500-sheet tray

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-25

40X0070

Pick roll assembly

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-59

, 

7-61

, 

7-70

40X0070

Pick tires, pick roll assembly

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-25

40X0072

Paper out flag—500-sheet tray

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-25

40X0074

Paper size/autocompensator cable

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25

, 

7-44

40X0076

Pick roll assembly

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-27

40X0077

Multipurpose feeder paper out flag

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-27

40X0079

Multipurpose feeder lower deflector assembly

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-27

40X0084

Paper feed alignment assembly paper feed

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-29

40X0085

Reference ground clip

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-29

40X0086

Parts packet (reference adjust)

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-29

40X0098

Tray assembly—500-sheet tray

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-31

40X0099

Side restraint

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31

40X0100

115 V Maintenance kit

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

40X0101

220 V Maintenance kit

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

40X0103

Pass thru plate—500-sheet tray

 

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -  7-31

40X0105

Restraint pad

 

 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31

Summary of Contents for X642E

Page 1: ...xx Table of Contents Start Diagnostics Safety and Notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Edition February 27 2007 ...

Page 2: ...ay be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you Lexmark Lexmark with diamond design MarkNet and MarkVisio...

Page 3: ...edia sizes 1 9 Print media types 1 11 Print media weights 1 11 Selecting print media 1 13 Paper 1 13 Paper characteristics 1 13 Transparencies 1 14 Envelopes 1 14 Labels 1 15 Card stock 1 16 Storing print media 1 16 Avoiding jams 1 16 Tools required 1 17 Acronyms 1 18 Diagnostic information 2 1 Start 2 1 Symptom tables 2 1 Service errors 8xx xx and 9xx xx s 2 1 User status and attendance messages ...

Page 4: ...ice check 2 112 294 03 Error code service check 2 113 298 01 Error code service check models X644e X646e 2 115 298 02 Error code service check 2 115 842 xx Error code service check 2 115 843 xx Error code service check 2 116 845 00 Error code service check 2 117 848 00 Error code service check 2 118 848 01 Error code service check 2 118 900 xx Error code service check 2 118 900 90 Error code servi...

Page 5: ...heck printer 2 156 Paper size sensing service check 2 158 Parallel port service check 2 159 Print quality service check 2 160 Scan quality service check 2 165 Signature button assembly service check 2 170 System board service check 2 170 Toner sensor service check 2 171 Transfer roll service check 2 172 Diagnostic aids 3 1 Accessing service menus 3 1 Diagnostics Menu 3 2 Entering Diagnostics Menu ...

Page 6: ...3 21 EVENT LOG 3 21 Display Log 3 21 Print Log 3 22 Clear Log 3 22 SCANNER TESTS 3 23 ASIC Test 3 23 Feed Test 3 23 Scanner Manual Registration 3 23 Sensor Tests 3 23 Configuration menu CONFIG MENU 3 24 Entering Configuration Menu 3 24 Available menus 3 24 Maintenance Page Count 3 25 Reset Maintenance Counter 3 25 Print Quality Pages 3 26 SIZE SENSING 3 26 Panel Menus 3 27 PPDS Emulation 3 27 Fact...

Page 7: ...er solenoid adjustment 4 2 Gap adjustment 4 2 Printhead assembly adjustment printer 4 2 Paper alignment assembly adjustment 4 3 Scanner registration 4 4 Automatic Scanner Registration 4 4 Manual registration 4 5 Removal procedures 4 6 Scanner ADF and flatbed removals 4 6 ADF front cover removal 4 6 ADF pick assembly removal 4 7 ADF rear cover removal 4 7 ADF top cover removal 4 9 Scanner left side...

Page 8: ... removal 4 71 Left cover handle holder removal 4 72 Right cover handle holder removal 4 72 Left and right frame extensions 4 73 Pass thru plate 4 74 Bevel gear removal 4 75 Developer drive assembly removal 4 77 Developer drive coupler kit removal 4 78 ESD cover removal 4 78 Fuser assembly removal 4 79 Fuser exit sensor removal 4 82 Fuser exit sensor flag and spring removal 4 83 Fuser lamp removal ...

Page 9: ...rs ADF 5 2 Connections 5 3 System board 5 3 Autoconnect 5 8 Fuser board 5 9 High voltage power supply 5 9 Interface card 5 10 USB card 5 10 Low voltage power supply 5 11 Operator panel card UICC 1 model X642e 5 12 Operator panel card UICC 1 models X644e X646e 5 14 LCD inverter board IUCC 2 5 16 Scanner control card 5 17 Motor driver board 5 23 Flatbed interconnect card 5 26 Modem card 5 31 Prevent...

Page 10: ...bling diagram 2 7 44 Assembly 26 Cabling diagram 3 7 45 Assembly 27 Cabling diagram 4 model X642e 7 46 Assembly 28 Cabling diagram 4 models X644e X646e 7 48 Assembly 29 Cabling diagram 5 7 50 Assembly 30 Cabling diagram 6 model X642e 7 52 Assembly 31 Cabling diagram 6 models X644e X646e 7 54 Assembly 32 Cabling diagram 7 7 56 Assembly 33 Cabling diagram 8 model X642e 7 57 Assembly 34 Cabling diagr...

Page 11: ...r Bestätigung erfüllt Laserprodukte der Klasse I gelten als unschädlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Länge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daß im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durc...

Page 12: ...láser de Clase I 1 Los productos láser de Clase I no se consideran peligrosos La impresora contiene en su interior un láser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al niv...

Page 13: ...minelt er en 5 milliwatt galliumarsenid laser som arbejder på bølgelængdeområdet 770 795 nanometer Lasersystemet og printeren er udformet således at mennesker aldrig udsættes for en laserstråling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchap...

Page 14: ...som farlige Skriveren inneholder internt en klasse IIIb 3b laser som består av en gallium arsenlaserenhet som avgir stråling i bølgelengdeområdet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I nivå under vanlig bruk vedlikehold som utføres av brukeren eller foreskrevne serviceoperasjoner Avís sobre el Làser Segons ha esta...

Page 15: ...Laser notices xv 7002 xxx Japanese Laser Notice ...

Page 16: ...xvi Service Manual 7002 xxx Korean Laser Notice ...

Page 17: ...entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez Débr...

Page 18: ...bre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo con la que ...

Page 19: ...stà orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu treballant és perill...

Page 20: ...ns uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Conventions Note A note provides additional information Warning A warning identif...

Page 21: ...e error codes user status messages user error messages service checks and diagnostic aids to determine the MPF problem and repair the failure After you complete the repair perform tests as needed to verify the repair See Start on page 2 1 Model name Configuration Machine type Lexmark X644e Network 7002 001 Lexmark X642e Network 7002 003 Lexmark X642e Network modem 7002 005 Lexmark X644e Network mo...

Page 22: ...trol panel Multipurpose feeder Tray 1 integrated tray or standard tray Model X644e or X646e MFP Standard Model X644e or X646e MFP With duplex and drawer Model X642e MFP Standard Model X642e MFP With duplex and drawer CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other ...

Page 23: ... optional Lexmark MarkNet Professional N800 Series internal print server makes the server the active network connection and disables the standard Ethernet port Lexmark PrintCryption card Forms card single byte and Simplified Chinese Media handling operations 250 and 500 sheet paper trays of A4 letter A5 B5 Executive folio statement and legal size 250 and 400 sheet universally adjustable trays 250 ...

Page 24: ...um mono 600 x 300 dpi color with final resolution 300 x 300 dpi Scan area flatbed 8 5 in x 14 in 216 mm x 355 6 mm maximum 8 5 in x 14 in 216 mm x 355 6 mm maximum Scanner ADF ADF type Simplex ADF with C path Single pass duplex ADF with C path ADF optical resolution 600 x 600 dpi maximum 600 x 600 dpi maximum Document capacity 50 sheets assuming 20 lb 75 g m2 50 sheets assuming 20 lb 75 g m2 Media...

Page 25: ...ory MB One slot 100 pin DDR SDRAM unbuffered DIMMs 128 256 and 512 available Maximum MB 640 768 768 Optional flash memory MB 32 and 64 available Hard disk N A N A 20GB Note One firmware card and one flash memory card are supported Either slot supports both card types Dimension Measurement Left 12 in 30 5 cm Right 8 in 20 3 cm Front 20 in 50 8 cm Rear 8 in 20 3 cm Top 12 in 30 5 cm Allow clearance ...

Page 26: ...6 lb 2 7 kg 500 Sheet drawer 5 2 in 134 mm 15 7 in 398 mm 19 0 in 520 mm 7 lb 3 2 kg 2 000 Sheet drawer 15 0 in 381 mm 15 7 in 398 mm 18 0 in 457 mm 31 lb 14 1 kg Envelope option closed position 7 72 in 196 mm 4 lb 1 8 kg Envelope option support fully extended 12 28 in 312 mm 4 lb 1 8 kg MFP Stand with Cabinet 31 5 in 800 mm 22 4 in 569 mm 24 5 in 622 mm 64 lb 29 0 kg Low Profile MFP Stand 22 8 in...

Page 27: ...regions 198 to 259 V ac extreme Notes Using a power converter or inverter is not recommended All models are ENERGY STAR qualified All models ship with Power Save Mode on The default timeout to power saver is 30 minutes for models X644e X646e and 45 minutes for model X642e Printing states Lexmark X642e Lexmark X644e Lexmark X646e Off 0 W 05 W 05 W Idle average power Power Saver on 30 W 20 W 20 W Po...

Page 28: ...valent to 10 300 meters 0 to 34 000 feet Storage environment unpacked Temperature 0 to 40 C 32 to 104 F Relative humidity 5 to 80 Acoustics All measurements are made in accordance with ISO 7779 and conform with ISO 9296 Mode Emission sound pressure level dBA Declared sound power level Bels Bystander position average LpAm Standing Operator Position LpAm LpAm Printing 56 N A 7 0 Copying 57 62 7 2 Sc...

Page 29: ...nt media The following tables provide information on standard and optional sources for both input and output trays and bins Print media sizes Print media weights Media weights supported in optional output bins Note If you use a print media size not listed select the next larger size Print media sizes Legend indicates support 250 sheet tray 500 sheet tray 250 UAT 400 UAT Multipurpose feeder 2000 sh...

Page 30: ...4 mm 3 875 x 8 87 in 10 Envelope 104 8 x 241 3 mm 4 12 x 9 5 in DL Envelope 110 x 220 mm 4 33 x 8 66 in B5 Envelope 176 x 250 mm 6 93 x 9 84 in C5 Envelope 162 x 229 mm 6 38 x 9 01 in Other Envelope1 98 4 x 162 mm to 176 x 250 mm 3 87 x 6 38 in to 6 93 x 9 84 in Legend indicates support 250 sheet tray 500 sheet tray 250 UAT 400 UAT Multipurpose feeder 2000 sheet drawer option Envelope feeder optio...

Page 31: ...dia Type Print media weight Integrated tray and optional 500 sheet drawer Multipurpose feeder and optional 250 sheet drawer Envelope feeder Paper Xerographic or business paper 60 to 176 g m2 grain long 16 to 47 lb bond 60 to 135 g m2 grain long 16 to 36 lb bond n a Card stock maximum grain long 1 Index Bristol 163 g m2 90 lb 120 g m2 67 lb Tag 163 g m2 100 lb 120 g m2 74 lb Cover 176 g m2 65 lb 13...

Page 32: ...otton content maximum weight 24 lb Sulfite wood free or up to 100 cotton bonds Not recommended 60 to 105 g m2 16 to 28 lb bond 2 3 60 to 105 g m2 16 to 28 lb bond 3 Note 28 lb envelopes are limited to 25 cotton content 1 Grain short is preferred for papers over 135 g m2 2 Includes envelopes fed from the multipurpose feeder only 3 28 lb bond envelopes are limited to 25 cotton content 4 Printing lab...

Page 33: ...n long in the integrated and optional 500 sheet trays and paper weights from 60 to 135 g m2 16 to 36 lb bond grain long in the multipurpose feeder and optional 250 sheet trays Paper lighter than 60 g m2 16 lb might not be stiff enough to feed properly causing jams For best performance use 75 g m2 20 lb bond grain long paper When using paper narrower than 182 x 257 mm 7 2 x 10 1 in make sure the we...

Page 34: ...g using with the MFP before buying large quantities When printing on envelopes To achieve the best possible print quality use only high quality envelopes that are designed for use in laser printers Set the Paper Size Type in the Paper menu to MP Feeder Manual Env or Env Feeder depending on the source you are using Set the paper type to Envelope and select the correct envelope size from the operato...

Page 35: ...et trays or the optional 250 or 500 sheet drawers For vinyl labels set the Paper Type to Labels the Labels Texture to Smooth and the Label Weight to Heavy or set the Paper Type to vinyl labels and the texture and weight to normal Do not load labels with paper or transparencies in the same source mixing print media can cause feeding problems and print quality problems Do not use label sheets with a...

Page 36: ...ines to avoid paper feeding problems and uneven print quality Store paper in an environment where the temperature is approximately 21 C 70 F and the relative humidity is 40 Store cartons of paper on a pallet or shelf rather than directly on the floor If you store individual packages of paper out of the original carton make sure they rest on a flat surface so the edges do not buckle or curl Do not ...

Page 37: ...of print media you have loaded Make sure the guides are not placed too tightly against the stack of print media If a jam occurs clear the entire media path Tools required Flat blade screwdrivers various sizes Phillips screwdrivers various sizes 7 32 inch open end wrench 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Pa...

Page 38: ...n of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LES Lexmark Embedded Solution applications LVPS Low Voltage Power Supply MDC Motor Driver Control MFP Multifunction Printer MPF Multipurpose Feeder NVRAM Nonvolatile Random Access Memory OPT Optical Sensor PC Photoconductor PIN Personal Identification Number PJL Printer Job Language POR Power On Reset POST Power On Self Test PP Par...

Page 39: ...the display unless invoked and then Power Saver displays If a user status message is displayed go to User status displays on page 2 38 User attendance messages are indicated by a two or three digit error code that provides the user with information that explains a problem with a print cartridge paper jam option port and so on If a user error message displays go to User attendance messages on page ...

Page 40: ...ion or print driver apply only to the job being sent to the MFP Changes made to print fax copy and e mail settings from an application override changes made from the operator panel If a setting cannot be changed from the application use the MFP operator panel MarkVision Professional or the Web pages Changing a setting from the MFP operator panel MarkVision Professional or the Web pages makes that ...

Page 41: ...the MFP to the home screen When in any other menu while the MFP is Ready it cancels all changes that have not been submitted and returns the MFP to the home screen 7 Start Press to initiate the current job indicated on the operator panel From the home screen press it to start a copy job with the default settings If pressed while a job runs through the scanner the button has no effect 8 Stop Press ...

Page 42: ...k Graphics PNG png file PiCture eXchange PCX pcx file and PC Paintbrush File Format dcx file files The USB direct interface can also be used to scan a document to a USB flash memory device using the PDF TIFF or JPEG formats 12 Home only on model X642e Returns the LCD to the home screen 13 Help Tips only on model X642e Accesses the context sensitive Help feature 14 Menu only on model X642e Accesses...

Page 43: ...sage including how to clear it Icon Button Tips Tips is a context sensitive Help feature For models X644e and X646e all menus have a Tips icon on the touchscreen panel For model X642e there is a Tips button on the operator panel below the touchscreen panel See Help Tips only on model X642e on page 2 4 FTP Touch to access the File Transfer Protocol FTP menus A document can be scanned directly to an...

Page 44: ...ed the PIN entry screen clears and the Lock Device button is replaced with the Unlock Device button Note If an invalid PIN is entered Invalid PIN appears A pop up screen appears with the Continue button Touch Continue The home screen returns with the Lock Device button Unlock Device Models X644e and X646e This button appears on the screen when the MFP is locked The operator panel buttons and short...

Page 45: ...he current user default setting For model X642e To save the value as the new user default setting touch Submit Back For all models touch Back to return to the previous screen and all the settings for the scan job made on Sample screen one are lost For models X644e and X646e when the Back button is shaped like this no other navigation is possible from this screen except to go back If any other choi...

Page 46: ...n Once Continue is touched the original screen appears Custom Allows for creating a custom button based on the user s needs Cancel Touch Cancel to cancel an action or a selection Touch to cancel out of a screen and return to the previous screen Select Touch to select a menu The next screen appears showing menu items Touch to select a menu item The next screen appears showing values Done Allows spe...

Page 47: ...the Software and Documentation CD Paper Menu Default Source Paper Size Type Configure MP Envelope Enhance Substitute Size Paper Texture Paper Weight Paper Loading Custom Types Custom Names Custom Bin Name only X644e X646e Universal Setup Bin Setup X644e X646e only Settings General Settings Copy Settings Fax Settings E mail Settings FTP Settings Print Settings Security Set Date and Time Reports Men...

Page 48: ...l right cover assembly removal on page 4 64 Operator panel one button does not work Replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 64 Operator panel LED does not come on while MFP operates normally Go to Operator panel right cover assembly service check on page 2 154 Paper feed problems printer or integrated 500 sheet paper tray Go to Pape...

Page 49: ...ge 2 131 A blue screen on the touchscreen The MFP does not come to a Ready state Go to 843 xx Error code service check on page 2 116 A clicking noise coming from the back of the MFP between the scanner and the printing unit Go to 843 xx Error code service check on page 2 116 Scanner scan quality Symptom Action Vertical streaks or lines on image Go to Vertical streaks or lines on image on page 2 16...

Page 50: ...ion symptoms Symptom Action Paper feed problem with Duplex Go to Duplex option service check on page 2 127 Paper jams at Paper Removal Tray Go to Duplex option service check on page 2 127 Paper skews in the Duplex Option Go to Duplex option service check on page 2 127 Paper fails to pass from lower option through the Duplex Option Go to Duplex option service check on page 2 127 Envelope feeder sym...

Page 51: ...he last screen displays the original message displays Printed error codes Additional information is available by printing the error log See Print Log on page 3 22 Service error codes 8xx xx Error code Sub codes Display text Description Action 842 xx Service Scanner This error indicates that a scanner communications failure Go to 842 xx Error code service check on page 2 115 843 xx Service Scanner ...

Page 52: ...terface violation by Paperport device These errors indicate an unrecoverable system software error Replace the system board See System board and inner shield removal models X644e X646e on page 4 131 906 xx RIP interface driver error These errors indicate an unrecoverable system software error Replace the system board See System board and inner shield removal models X644e X646e on page 4 131 910 xx...

Page 53: ... xx Cold fuser service check on page 2 132 920 04 Hot roll too cool when heating to desired temperature after slope change standby control only Fuser page count between 0 and 99 999 Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Low wattage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 132 920 06 Fuser is no...

Page 54: ... to 920 xx Cold fuser service check on page 2 132 920 14 Hot roll too cool when heating to desired temperature after slope change Fuser page count between 100 000 and 199 999 Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 132 920 16 Fuser...

Page 55: ...xx Cold fuser service check on page 2 132 920 24 Hot roll too cool when heating to desired temperature after slope change Fuser page count between 200 000 and 299 999 Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 132 920 26 Fuser is not ...

Page 56: ...check on page 2 132 920 34 Hot roll too cool when heating to desired temperature after slope change Fuser page count between 300 000 and 399 999 Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 132 920 36 Fuser is not increasing in temperat...

Page 57: ...x Cold fuser service check on page 2 132 920 44 Hot roll too cool when heating to desired temperature after slop change Fuser page count between 400 000 and 499 999 Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 132 920 46 Fuser is not in...

Page 58: ...ld fuser service check on page 2 132 920 54 Hot roll too cool when heating to desired temperature after slope change Fuser page count more than 500 000 Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Low voltage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check on page 2 132 920 56 Fuser is not increasing in t...

Page 59: ... hot roll Go to 920 xx Cold fuser service check on page 2 132 920 94 Hot roll too cool when heating to desired temperature after slope change Fuser page count not available Bad thermistor circuit or cabling Noisy thermistor signal Fuser not receiving AC power Poor supply line voltage Excessive load on the fuser Low voltage or incorrect lamp Incorrect hot roll Go to 920 xx Cold fuser service check ...

Page 60: ...page count between 0 and 99 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 134 922 07 Fuser has taken too long to reach desired temperature after increasing interrupt gap Fuser page count between 0 and 99 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling F...

Page 61: ...oor supply line voltage Go to 922 xx Cold fuser check on page 2 134 922 22 Hot roll took too long to reach the beginning lamp detection temperature Fuser page count between 200 000 and 299 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 134 922 23 Hot roll reached final lamp...

Page 62: ... circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 134 922 34 Hot roll timed out in trying to reach the final lamp detection temperature Fuser page count between 300 000 and 399 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Co...

Page 63: ...d not roll over to steady state control in time Fuser page count between 400 000 and 499 999 The control code has been lost Go to 922 xx Cold fuser check on page 2 134 922 46 Hot roll did not reach operating temperature in time new enhanced control Fuser page count between 400 000 and 499 999 Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Po...

Page 64: ...ser page count stopped at 500 000 to preserve data Low wattage or incorrect lamp Bad thermistor circuit or cabling Fuser not receiving sufficient AC power Poor supply line voltage Go to 922 xx Cold fuser check on page 2 134 922 57 Fuser has taken too long to reach desired temperature after increasing interpage gap Fuser page count stopped at 500 000 to preserve data Low wattage or incorrect lamp E...

Page 65: ...22 xx Cold fuser check on page 2 134 923 01 Fuser over temperature Fuser page count between 0 and 99 999 Short in the thermistor circuit Noisy thermistor signal Fuser is actually overheating due to hardware faults Go to 923 xx Hot fuser service check on page 2 135 923 11 Fuser over temperature Fuser page count between 100 000 and 199 999 Short in the thermistor circuit Noisy thermistor signal Fuse...

Page 66: ...istor check failure Fuser page count between 300 000 and 399 999 Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor actually open Go to 924 xx Hot fuser service check on page 2 136 924 41 Open thermistor check failure Fuser page count between 400 000 and 499 999 Noisy thermistor signal Intermittent connection Thermistor cable not connected or thermistor ac...

Page 67: ...ed and found error Fuser page count between 300 000 and 399 999 115 V lamp in 220 V printer Lamp has excessive wattage Go to 925 xx Hot fuser service check on page 2 137 925 32 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fuser page count between 300 000 and 399 999 Attempting to POR machine after receiving a 925 01 Go to 925 xx Hot fuser service check on page ...

Page 68: ...Go to Main fan service check on page 2 119 927 01 Main fan stalled External blockage of fan Fan may not turn due to internal fan problem Go to Main fan service check on page 2 119 927 02 Cartridge fan stalled Loose connector External blockage of the fan preventing it from turning Bad fan Go to Cartridge fan service check on page 2 119 927 03 Main fan took too long to ramp up Loose connector Extern...

Page 69: ...o first HSYNC received Check printhead Check cables and connectors Check system board Go to Printhead service check on page 2 165 934 00 Mirror motor lost lock Check printhead Check cables and connections Check system board Go to Printhead service check on page 2 165 936 00 Mirror moor not up to speed Check printhead Check system board Go to Printhead service check on page 2 165 936 10 No hall eff...

Page 70: ...s Defective motor Paper jams Go to Main drive service check on page 2 153 936 91 Stall detected during speed control Motor is type 1 Defective cable Check cable connections Defective motor Paper jams Go to Main drive service check on page 2 153 937 4 Overspeed detected during speed control Motor is type 0 Faulty motor sensor Faulty system board Go to Main drive service check on page 2 153 937 41 O...

Page 71: ... check to make sure the LVPS to system board cable is installed correctly If correct replace the LVPS assembly See Low voltage power supply removal on page 4 109 947 00 PQET RAM test incomplete PQET RAM test did not complete PQET RAM test failed MARCH0 PQET RAM test failed MARCH1 PQET RAM test busy failure PQET failed to pass RAM tests on the system board Replace the system board See System board ...

Page 72: ...acing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer ...

Page 73: ... inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a machine it cannot be used in another machine It must be returned to the manufacturer Go to 950 30 through 95...

Page 74: ...stalled in a printer it cannot be used in another printer It must be returned to the manufacturer 955 00 Code CRC CRC failure or ECC code failure on the system board Replace the system board See System board and inner shield removal models X644e X646e on page 4 131 956 00 System board This error indicates a system board processor failure Replace the system board See System board and inner shield r...

Page 75: ... command received by device Invalid command received by the specified device 984 00 Invalid command parameter received by device Invalid command parameter received by the specified device 990 00 General device equipment check Indicates an equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Service errors 980 thru 984 devic...

Page 76: ... at this time Try again after the current job is complete Invalid or incorrect password An incorrect password is entered Touch Continue to return to the screen to enter a correct password Invalid PIN An incorrect Personal Identification Number PIN is entered Touch Continue to return to the screen to enter a correct PIN Job cannot be deleted A job in the job list is touched but it cannot be cancele...

Page 77: ...wer Saver message replaces the Ready message Send a job to print Press any operator panel button Printing The MFP is printing a job Printing page x A sheet of print media moves through the MFP to be printed x represents the number of the sheet being printed Even though a duplex two sided sheet has two sides called pages it only counts as one sheet Printing page x copy a b A sheet of print media mo...

Page 78: ...rs automatically when the cover or door over the toner cartridge is opened or if the MFP power is turned off and then on Replace the toner cartridge If it is not replaced the MFP issues the message again when the door or cover is closed Tray x Empty x represents the number of the tray The tray has no print media installed 1 Remove the tray The message clears 2 Install print media in the tray accor...

Page 79: ...ave a dial tone Queued for sending The scanning process of a fax job completed but it is not sent yet because another fax job is being sent or received As this one job waits for its turn this message appears for three seconds Receive complete The MFP has received an entire fax job Receiving page n The MFP receives page n of the fax job where n is the number of the page received Sending page n The ...

Page 80: ... with print media currently in the tray Change src to size Lets the user override the current print media source for the remainder of the print job The formatted page prints as is on the print media installed in the tray This may cause clipping of text or images Touch Use current src to ignore the message and print on the print media loaded in the tray Touch Continue which continues the job if the...

Page 81: ...actions may be taken If the option was temporarily removed or not connected properly reattach or reconnect it Accept the configuration change which notifies the printer the option has been hot unplugged removed with the power on Note This action is not available if the printer is in Diagnostics Mode or running diagnostics If the device is experiencing a hardware problem turn the printer off and on...

Page 82: ...the hard disk are deleted Disk Full Scan Job Canceled Model X646e only The scan job cancels or stops due to insufficient hard disk space Note The scanner finishes scanning currently committed pages in the ADF but data is lost when the job cancels itself Touch Continue to clear the message Insert Cartridge or Close Door This message displays when the printer front door is open or the print cartridg...

Page 83: ...ses but before the job prints Sometime during processing the optional tray is removed Install the optional tray specified by x The message clears Touch Cancel Job if needed Touch Reset Active Bin to reset the active bin for a linked set of bins If the message cannot be cleared go to Input tray s service check on page 2 147 Load manual feeder with Custom String Occurs when the MFP receives a manual...

Page 84: ...ad manual feeder with type size Occurs when the MFP receives a manual feed request for a specific size and type of print media when none is loaded into the multipurpose feeder Touch Continue if print media is in the multipurpose feeder The job continues Touch Continue if there is no print media in the multipurpose feeder All requests for additional pages are automatically overridden and print medi...

Page 85: ...sing between the time the job processes and when it prints Sometime during processing the optional envelope feeder is removed Touch Cancel Job to clear the message and continue without using the optional envelope feeder Install the optional envelope feeder Reattach Bins x y Bins x y Bins 1 to 5 Bins 2 to 6 or Bins 6 to 10 This messages displays for the following conditions The specified output bin...

Page 86: ... Bin 1 Bin 2 or Bin 3 This messages displays for the following conditions The specified output bin may have been removed from the printer possibly to clear a paper jam or to remove the option The option may be attached to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions ...

Page 87: ...ower on reset of the MFP Touch Yes to restore the held jobs to the hard disk and make them available The jobs data remains on the hard disk however the job control information is stored in the MFP memory Touch Quit to stop restoring held jobs before all jobs are restored Unrestored jobs remain on the hard disk and are retrievable again only at the next power on reset Note A pop up screen appears t...

Page 88: ...upported Print Cartridge Error 32 displays when the top cover is closed and an unsupported print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is supported Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print then they are not reprinted once a good...

Page 89: ... the hard disk and are inaccessible 37 xx Insufficient memory some Held Jobs were lost Held jobs are deleted in order to process the current job The message appears once per job Touch Continue to clear the message and continue printing To avoid this error in the future for other jobs install more memory Touch Cancel Job to cancel the current job if needed 38 xx Memory full The MFP is processing da...

Page 90: ... the data currently being downloaded Touch Continue to clear the message and continue the print job Install flash memory with more storage capacity Download the data Touch Cancel Job to cancel the current job if needed Touch Reset Active Bin to change to another linked bin 53 xx Unformatted flash detected The MFP detects unformatted flash memory Touch Continue to clear the message and continue pri...

Page 91: ...ded outlet 5 Turn the MFP on 56 xx Parallel port x disabled A status request occurs over the parallel port but the parallel port is disabled Touch Continue The MFP discards any data received on the parallel port Touch Reset Active Bin to reset the active bin for a linked set of bins 56 xx Serial port x disabled The MFP receives data across a serial port but the port is disabled Touch Continue The ...

Page 92: ...n the MFP on 59 xx Incompatible duplex An unsupported optional duplex unit is attached to the MFP Remove the optional duplex unit The MFP ceases normal functions until the optional duplex unit is removed Touch Continue to clear the message once the optional duplex unit is removed 59 xx Incompatible envelope feeder An unsupported optional envelope feeder is attached to the MFP Remove the optional e...

Page 93: ...aintenance advised Service is required to maintain printer performance Replace the maintenance items and if necessary reset the printer maintenance counter For more information go to Scheduled maintenance on page 6 1 81 xx Engine Code CRC Failure This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check POR the MFP to clear the message The micro...

Page 94: ...ge Explanation Parallel Standard Parallel Port if available Serial Standard Serial Port if available Serial x Serial Port is attached to PCI connector x where x 1 2 or 3 Network x Network card x is attached to PCI connector x where x 1 2 or 3 LocalTalk x LocalTalk Card x is attached to PCI connector x where x 1 2 or 3 Infrared Standard Infrared port if available Infrared x Infrared Port x is attac...

Page 95: ...Paper jam leaving page over sensor Fan media and stack flat in tray or MPF Check for anything in the paper path that might cause the paper to jam Check cartridge for obstructions If clearing a paper jam does not fix the problem go to Input sensor service check on page 2 146 200 02 Input sensor covered too long Multi sheet feed that is shingled Tray size sensing wrong size Paper jam leaving page ov...

Page 96: ...es input sensor Printhead lock signal not working Printhead control not working Check printhead to system card connections Check printhead motor system Go to Printhead service check on page 2 165 200 11 Printhead motor fell out of lock after page arrives at input sensor Paper pre staged in path Lock signal went away Check printhead to system card connections Check printhead motor system Go to Prin...

Page 97: ... on page 4 79 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 138 201 01 Main motor identification failed Main drive motor identification failed Fuser page count between 0 and 99 999 Main motor not working Check motor connections to motor and system board If no problem is found go to Main drive service check on page 2 153 201 02 Page did not re...

Page 98: ...heck fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 79 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 138 201 11 Main drive motor identification failed Fuser page count between 100 000 and 199 999 Main drive motor not working Check motor to system board connections Replace ...

Page 99: ...ild up Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 79 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 138 201 21 Main drive motor identification failed Fuser page count between 200 000 and 299 999 Main drive motor not working Check motor connections to motor and sys...

Page 100: ...Check fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 79 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 138 201 31 Main drive motor identification failed Fuser page count between 300 000 and 399 999 Main drive motor not working Check the motor connections to motor and system...

Page 101: ...p Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 79 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 138 201 41 Main drive motor identification failed Fuser page count between 400 000 and 499 999 Main drive motor not working Check the motor connections to motor and ...

Page 102: ...oner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 79 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 138 201 51 Main drive motor identification failed Fuser page count more than 500 000 Main drive motor not working Check the connections to the motor and ...

Page 103: ...guide for toner build up Check the fuser for wear or contamination If a problem is found replace the fuser assembly See Fuser assembly removal on page 4 79 The fuser exit sensor may not be functioning properly Go to Fuser exit sensor service check on page 2 138 201 91 Main drive motor identification failed Fuser page count is not available Main drive motor not working Check the connections to the ...

Page 104: ...rly Go to Fuser narrow media sensor service check on page 2 139 202 00 Paper jam at fuser exit or redrive area Fuser page count between 0 and 99 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over t...

Page 105: ...rive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output option s that may be installed for ...

Page 106: ... count between 0 and 99 999 202 09 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between 202 10 Paper jam around fuser or redrive area Fuser page count between 100 000 and 199 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any ar...

Page 107: ...Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may...

Page 108: ...irtual page timed out waiting for the last page of the job to be safe in the stapler accumulator Fuser page count between 100 000 and 199 999 202 20 Paper jam around fuser exit or redrive area Fuser page count between 200 000 and 299 999 Paper may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are ...

Page 109: ...sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be i...

Page 110: ...9 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between 200 000 and 299 999 202 30 Paper jam around the fuser exit or redrive area Fuser page count between 300 000 and 399 999 Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are fo...

Page 111: ...e the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be inst...

Page 112: ... 39 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between 300 000 and 399 999 202 40 Paper jam around the fuser exit or redrive area Fuser page count between 400 000 and 499 999 Page may be jammed in fuser exit or redrive Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found...

Page 113: ...ure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be in...

Page 114: ...9 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count between 400 000 and 499 999 202 50 Paper jam around the fuser exit or redrive area Fuser page count stopped at 500 000 to preserve data Page may be jammed in the fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination I...

Page 115: ...ke sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may b...

Page 116: ...500 000 202 59 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count more than 500 000 202 90 Paper jam around the exit or redrive area Fuser page count is not available Page may be jammed in fuser exit or redrive area Make sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace th...

Page 117: ...sure the redrive door is complete closed Check the fuser for any signs of wear or contamination If any are found replace the fuser assembly See Fuser assembly removal on page 4 79 Turn media over to reduce W curl Check upper redrive diverter and diverter spring for any signs of damage a loose spring or binding parts Repair the redrive as necessary Check any installed output options s that may be i...

Page 118: ...page count is not available 202 99 Virtual page timed out waiting for last page of job to be safe in the stapler accumulator Fuser page count is not available 231 00 Paper did not arrive at the duplex input sensor but did leave the printer exit sensor Duplex rear door not fully latched Printer diverter not functioning correctly Duplex feed system not working correctly Printer and duplex not aligne...

Page 119: ...ailable go to 233 xx Jam displays on page 2 128 234 00 Paper did not arrive at duplex exit sensor Duplex rear door not fully latched Duplex feed system not working correctly Severely skewed media coming from the printer Check the media coming from the printer to the duplex option is not damaged or skewed If the media is not damaged or skewed try another duplex option if available If not available ...

Page 120: ... There may be other jams in the paper path Duplex jam access tray is not fully latched Printer PTO not driving duplex feed rolls Duplex feed system not working correctly Make sure the duplex jam access tray is installed correctly Make sure the power takeoff shaft and spring are correctly installed and operating properly Try the duplex option again If it fails try another duplex option if available...

Page 121: ... Try the duplex option again If it fails try another duplex option if available If one is not available replace the duplex option 238 06 Duplex doublefeed and exit sensors covered Media left in the duplex and Continue selected Sensor is having mechanical or electrical problems Remove any sheets from the duplex option Try the duplex option again If it fails try another duplex option if available If...

Page 122: ...stem Replace the duplex option 239 11 Sheet picked from duplex never made it to the input sensor Slow or delayed feed from the duplex unit Mechanical feed error due to belt slipping Timing error due to feed system Input sensor not working correctly Check duplex sensor cables for correct installation If no problem is found with the cables replace the duplex option 241 00 Paper jam near tray 1 241 0...

Page 123: ...over Reduce amount of media loaded in tray 1 Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 105 241 12 Page was not properly picked from tray 1 Failure to feed possible causes include Edge locking Worn or contaminated pick tires Overfilling of tray past the fill line Fan media Turn media over Reduce amount of media loaded in tray 1 Replace pick tires Se...

Page 124: ...aminated pick tires Overfilling of tray past fill line Failed sensor If source is tray 3 possible cause include Paper path bind when feeding from tray 2 though tray 1 Damaged PTO shaft Clear all jams Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 105 Check and or replace input sensor 242 05 Option tray pass thru sensor never became uncovered Paper jam o...

Page 125: ...eplace tray motor Check replace sensor s Replace entire option 243 03 Jam declared by smart device Homing allowed to stop Fault reported by options tray 3 Paper jam Motor failure Sensor failure Clear all media jams Check replace tray motor Check replace sensor s Replace entire option 243 04 Option tray pass thru sensor never became covered Failure to feed Possible causes include Edge locking Worn ...

Page 126: ...ensors faulty Reinstall tray Check sensors 244 00 Paper jam near tray 4 Tray removed Sensors faulty Clear media jams Check sensor 244 02 Jam declared by a smart device Immediate stop Fault reported by options tray 4 Paper jam Motor or motor cable failure Sensor failure Clear all media jams Check motor cables Check replace tray motor Check replace sensor s Replace entire option 244 03 Jam declared ...

Page 127: ...ushed to the output bin Failure to feed Possible causes include Edge locking Worn or contaminated pick tires Overfilling of tray past fill line Could also be a failed pass thru sensor Clear media jams Replace pick tires See Integrated tray autocompensator pick roll assembly removal on page 4 105 Check replace input sensor 244 17 One or more trays location above the source tray have been removed Tr...

Page 128: ...egrated tray autocompensator pick roll assembly removal on page 4 105 Check replace input sensor 245 13 Paper over tray 5 pass thru sensor on warm up Paper left in path Failed pass thru sensor Clear media jams Check replace pass thru sensor 245 15 Late feed from a tray interfered with the pick retry 245 1 6 16 Failed to feed from tray 5 Pages in the paper path have been flushed to the output bin F...

Page 129: ... in the paper path have been flushed to the output bin Paper jam around the multipurpose feeder Check for jam in tray Check the pick assembly and controller card 260 00 Paper jam near the envelope feeder 260 01 Jam declared by a smart device Immediate stop 260 02 Jam declared by a smart device Homing allowed stop 260 05 Envelope feeder pass thru sensor never became uncovered 260 06 Envelope feeder...

Page 130: ...Paper may be stuck in the ADF at the first scan sensor or the first scan sensor may be malfunctioning Check for any media or obstruction over the first scan sensor If no problem is found go to 290 10 Error code service check on page 2 102 291 00 Static Jam Second Scan Sensor Paper may be stuck in the ADF at the second scan sensor or the second scan sensor is not operating properly Check for any me...

Page 131: ...ing Verify the exit sensor is operating properly If the problem persists and the exit sensor seems to be operating properly go to 294 02 Error code service check on page 2 112 295 03 ADF Exit Jam Sensor On The exit sensor may not be operating properly or malfunctioning Verify that the exit sensor is operating properly If the problem persists and the exit sensor seems to be operating properly go to...

Page 132: ... unplugged or loose Check the cables on the rear of the scanner to make sure they are plugged in and fastened securely If no problem is found with the cables go to 298 02 Error code service check on page 2 115 User attendance messages paper jams and paper handling errors 2xx xx Code Sub code Description Possible causes Action ...

Page 133: ...t be working correctly When the sensor flag is made it does not return to the correct position 202 06 Error code service check The spring on the fuser exit sensor flag may not be working correctly When the sensor flag is made it does not return to the correct position FRU Action 1 Fuser narrow media sensor flag and spring Remove the fuser narrow media sensor See Fuser narrow media sensor removal o...

Page 134: ...heet of paper over the sensor This is easier to perform by first removing the pick arm assembly If the sensor fails the test go to step 3 3 Interval sensor cable interval sensor to CN10 on the MDC card Check to make sure the interval sensor cable is correctly installed at the sensor and atCN10 on the motor driver card If the cable is not installed correctly reinstall the cable If installed correct...

Page 135: ... replace the interval sensor If this does not fix the problem replace the complete ADF assembly Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 FRU Action Interval sensor reflective type normally closed Connector CN10 motor driver card Pin number Sensor closed uncovered Sensor open covered CN10 Pin 7 0 V dc 0 ...

Page 136: ...lace the solenoid assembly which contains both springs See ADF pick assembly removal on page 4 7 If no problem is found go to step 4 4 Pickup arm solenoid Turn the power off disconnect CN5 on the motor driver card Measure the resistance between C5 1 and CN5 2 The resistance should measure approximately 41 0 ohms If correct go to step 5 If incorrect disconnect the solenoid from the solenoid cable o...

Page 137: ...page 4 4 8 Interval sensor electrical checks Turn the power off and reconnect CN10 to the motor driver card Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open paper over the sensor If the voltages are incorrect replace the interval sensor If this does not fix the problem replace the complete ADF assembly Note Whenever the complete ADF...

Page 138: ... select Sensor Tests Check the first scan sensor for correct operation Note Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation If the sensor fails the test go to step 3 3 First scan sensor cable first scan sensor to CN10 on the MDC card Check to make sure the interval sensor cable is correctly installed at the sensor CN10 ...

Page 139: ...7 7 Scan motor belt Check the scan motor drive belt for any signs of wear or damage or the belt is off the gear If the belt is off the gear reinstall If the belt is worn or damaged replace the belt If no problem is found Replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced is necessary to perform the scanner registrati...

Page 140: ...t Sensor Tests Check the first scan sensor for correct operation Note Check the first scan sensor by manually feeding a sheet of paper through the ADF and checking the sensor for correct operation If the sensor fails the test go to step 3 3 First scan sensor cable first scan sensor to CN10 on the MDC card Check to make sure the first scan cable is correctly installed at the sensor CN10 on the moto...

Page 141: ... the first scan sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 FRU Action First scan sensor Connector CN10 motor driver card Pin number Sensor closed uncovered Sensor open covered CN10 Pin ...

Page 142: ...ry to defeat the jam tray sensor by placing a piece of paper in the sensor to turn off the jam tray message on the display or you can manually feed a piece of paper through the ADF If the sensor fails the test go to step 3 3 Second scan sensor cable second scan sensor to CN9 on the MDC card Check to make sure the first scan cable is correctly installed at the sensor CN9 on the SCC scanner control ...

Page 143: ...g edge of the media was detected by the first scan sensor but never detected by the trailing edge Clear any media that may be in the ADF Enter Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS load some sheets of paper in the ADF paper tray and select Feed Tests If the error continues at or near the same point go to step 2 2 Area around the first scan sensor Check the area ar...

Page 144: ...roken or damaged parts If any problems are found replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 Note To help isolate a problem with the ADF feed system you can run the Feed Test from the SCANNER TESTS in the Diagnostics Menu Put ...

Page 145: ...blem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 FRU Action 1 ADF upper top cover Check the ADF upper top cover to make sure it closes properly and does not come loose or pop up while the ADF is scanning FRU Action Second scan...

Page 146: ...re the voltages shown in the table below If the voltages are incorrect turn the power off disconnect the cable attached to CN10 on the motor driver card and measure the voltages in the table below If the voltages are incorrect replace the motor driver card If the voltages are correct replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF ass...

Page 147: ...ver the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 If the flag operates correctly go to step 3 3 ADF exit sensor Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the ADF exit sensor for correct operation Note You can check the ADF exit sensor by moving the exit...

Page 148: ...he problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 FRU Action 1 ADF jammed media Check for any signs of media or other debris that might be present in the ADF assembly around the exit sensor flag Remove any media or debris...

Page 149: ...Tests Check the ADF exit sensor for correct operation Note You can check the ADF exit sensor by moving the exit sensor flag or by manually feeding a sheet of paper through the ADF If the sensor fails the test go to step 4 4 Motor driver card Turn the power off and disconnect CN9 on the motor driver card Measure the voltages in the table below If incorrect replace the motor driver card If the error...

Page 150: ...te ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 If the flag operates correctly go to step 3 3 ADF exit sensor Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Sensor Tests Check the ADF exit sensor for correct operation Note You can check the ADF exit sensor by moving the exit sensor flag o...

Page 151: ...activated If the voltages are incorrect replace the ADF exit sensor If this does not fix the problem replace the complete ADF assembly See ADF complete assembly removal on page 4 15 Note Whenever the complete ADF assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 FRU Action 1 ADF jammed media Check for any signs of media or other debris that m...

Page 152: ... card Measure the voltages in the table below If incorrect replace the motor driver card If the voltage is correct go to step 5 5 ADF exit sensor electrical checks Turn the power off and reconnect CN9 to the motor driver card Measure the voltages in the table below with the sensor in normal operation sensor closed and with the sensor open sensor flag activated If the voltages are incorrect replace...

Page 153: ...y If ADF CCD assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 FRU Action 1 MDC cable Check the cable for correct connections to the flatbed interface connector on the rear of the flatbed scanner assembly and to the motor driver card If incorrect install the cable correctly If correct replace the following FRUs in the order shown MDC cable Fl...

Page 154: ... If the flatbed CCD assembly is replaced it is necessary to perform scanner registration See Scanner registration on page 4 4 4 Flatbed CCD scan motor cable Flatbed interface card Check for correct installation of the CCD scan motor cable to both the motor and to the flatbed interface card at CN2 Enter the Diagnostics Menu turn on MFP while holding 3 and 6 select SCANNER TESTS and select Feed Test...

Page 155: ...tbed CCD assembly a few inches to the right of home 2 Bend the bracket upwards 1 2 mm 3 Move the flatbed CCD assembly back to the home position and check for clearnace between the bracket and the edge of the flatbed CCD assembly If this does not fix the problem got to step 7 7 Flatbed scanner assembly If the 843 00 error code continues to be displayed replace the complete flatbed scanner assembly ...

Page 156: ...Remove the modem installed in the printer FRU Action 1 Printer POR Turn the printer off and on several times If Error Code 900 continues to display go to step 2 2 System board Turn the machine off and on several times waiting a few minutes between power on and power off If Error Code 900 continues to display go to step 3 3 Factory defaults Restore factory defaults See EP Defaults on page 3 20 This...

Page 157: ...Fan will not run when trying to print Main fan System board Measure the voltage at J4 1 on the system board The voltage should measure approximately 2 5 V dc If incorrect replace the main fan See Main fan removal on page 4 111 If that does not fix the problem replace the system board See System board and inner shield removal models X644e X646e on page 4 131 4 Main fan blades do not turn Measure th...

Page 158: ...erface card FRU Action 1 Interface card If the interface card been recently replaced go to step 3 If the card has not been replaced go to step 2 2 Operator panel board If the operator panel board has been recently replaced go to step 4 If the operator panel board has not been replaced contact your next level of support 3 Interface card Replace the current interface card assembly with the original ...

Page 159: ...d with the part number in the table below This error code indicates a mismatch between the system board and the interface card Model Board bar code Corresponds to P N Lexmark X642e 003 004 005 006 M010 6030 40X3310 Lexmark X644e X646e 001 002 011 012 101 102 111 112 M010 6000 40X2722 FRU Action 1 Interface card assembly If the interface card assembly has been recently replaced go to step 3 If the ...

Page 160: ...e card Measure the voltages shown in the table below If incorrect replace the motor driver card If correct go to step 3 3 ADF paper length sensor Turn the power off and reconnect CN8 to the motor driver card Measure the voltages in the table below If the voltages are incorrect replace the paper length sensor If this does not fix the problem replace the ADF paper tray assembly If the problem persis...

Page 161: ...ing the paper width guides on the paper tray in and out If only one or two of the sensor widths does not operate properly replace the ADF paper tray assembly If none of the sensors operate correctly replace the ADF paper tray If this does not fix the problem replace the motor driver card FRU Action 1 Charge roll assembly Check the charge roll for correct installation toner buildup marks cuts or ot...

Page 162: ...ed or missing 3 Flatbed cover closed and closing sensors Turn the power off disconnect the cable to CN7 and measure the voltages at CN7 on the card The voltages should measure as shown in the table below If any of the voltages are incorrect replace the motor driver card If the voltages are correct go to step 4 4 Flatbed cover closing closed sensors cable Check continuity of the flatbed cover closi...

Page 163: ...ck the cover closed switch for proper mechanical operation If incorrect repair as necessary Disconnect the cover closed switch cable from J8 at the system board and measure the voltage at J8 3 It measures approximately 5 V dc If the voltage is incorrect replace the system board If the voltage is correct check the voltage at J8 1 If the voltage measures greater than 1 0 V dc replace the system boar...

Page 164: ... power supply removal on page 4 109 6 Features or option installed on the interface card assembly Warning Observe all the ESD precautions and turn the printer off before any feature or option cards are removed or replaced Remove one option feature at a time to help isolate the failing part Replace the faulty part 7 LVPS fuse F1 primary power Unplug the AC line cord remove the LVPS from the printer...

Page 165: ...ly removal on page 4 107 23x xx jam code Jam location 231 xx Media did not arrive at the duplex input sensor but did leave the fuser exit sensor 232 xx Media did not clear the duplex input sensor but did leave the printer fuser exit sensor 233 xx Media failed to make the duplex double feed sensor during turnaround 234 xx Media did not arrive at the duplex exit sensor 235 xx A piece of media is ove...

Page 166: ...r objects that might cause a paper jam If none are found replace the duplex option assembly FRU Action 1 Duplex input sensor If the paper reaches the duplex input sensor but does not clear the sensor make sure the sensor is connected to the duplex system board If connected correctly check for correct operation of the sensor If a problem is found and cannot be corrected replace the duplex option as...

Page 167: ...ope feeder and continue with step 3 3 Autoconnect on the envelope feeder Check for damage to the connector or contacts If you find damage replace the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc J1 7 measures 24 V dc If any of the voltages are incorrect replace the a...

Page 168: ...the envelope feeder option FRU Action 1 DC feed motor assembly Check the motor and motor cable for loose wires or poor connections Make sure the motor cable is connected to the envelope system board If correct replace the envelope feeder option FRU Action 1 Clutch latch assembly Check the clutch latch assembly to make sure it moves freely If correct replace the envelope feeder option FRU Action 1 ...

Page 169: ... signs of glue Make sure the flaps are not interleaved If the envelopes meet the guidelines and are properly loaded go to step 2 2 Deflector Check the deflector gap adjustment The adjustment may be too wide If the deflector gap adjustment is correct go to step 3 If not replace the envelope feeder option 3 Restraint roll bias spring Check for a missing broken or incorrectly installed restraint roll...

Page 170: ...ure the correct type of lamp is installed voltage and wattage Verify that the fuser to fuser lamp cable is installed correctly to the fuser top cover assembly If incorrect install correctly if correct go to step 2 2 AC line voltage CAUTION When taking measurements for AC power observe all safety precautions Check the AC line voltage to make sure it is within operating specification If incorrect in...

Page 171: ...embly must be replaced 6 Fuser top cover assembly thermistor thermistor cable Fuser to system board DC cable Check to make sure that the thermistor is installed correctly to J5 on the fuser control card If installed correctly check the cable for any signs of damage If any problems are found replace the fuser top cover assembly If no problem is found check the fuser to system board DC cable for cor...

Page 172: ...S to fuser AC cable plug in the line cord turn the printer on and measure the voltage between CN1 1 and CN1 3 on the connector see the connector locations at Low voltage power supply on page 5 11 If incorrect replace the LVPS assembly see Low voltage power supply removal on page 4 109 if correct go to step 4 4 LVPS LVPS fuser AC cable CAUTION When taking measurements for AC power observe all safet...

Page 173: ...Check for any signs of overheating in the fuser assembly Check the hot roll hot roll bearings and the area around the thermistor for any signs of excessive heat If a problem is found replace the thermistor If no problem is found go to step 2 2 Fuser top cover assembly thermistor Turn the printer off and disconnect the fuser to system board cable from J10 on the system board Check the resistance be...

Page 174: ...esistance measures infinity open circuit replace the fuser top cover assembly 3 Fuser to system board cable System board Fuser assembly Reconnect the thermistor cable to J5 on the fuser board Disconnect the fuser to system board cable from J10 on the system board and measure the resistance between J10 3 and J10 4 on the cable If the resistance measures infinity open circuit check the continuity of...

Page 175: ...ld be displayed 2 AC power source Check the AC power source to make sure it meets specifications If the AC power source does not meet specifications inform the customer If it meets specifications go to step 3 3 Fuser lamp Turn the printer off and allow the fuser assembly to cool After the fuser assembly cools down turn the printer on If you receive the same error code replace the fuser lamp See Fu...

Page 176: ...he installation is found install the cable correctly If damage to the cable or connectors is found replace the cable 3 Fuser exit sensor flag Make sure the sensor flag is not binding and is operating properly If the sensor is operating properly go to step 4 If it is not operating properly repair or replace the sensor assembly See Fuser exit sensor removal on page 4 82 4 Fuser assembly Fuser exit s...

Page 177: ...mage to the cable or the connectors is found replace the cable 3 Fuser narrow media sensor flag Make sure the sensor flag is not binding and is operating properly If the sensor is operating properly go to step 4 If the sensor is not operation properly repair or replace the sensor assembly See Fuser narrow media sensor removal on page 4 88 4 Fuser assembly Fuser narrow media sensor cable Fuser boar...

Page 178: ... The voltage should measure approximately 50 V dc If incorrect go to step 3 If incorrect go to step 4 3 LVPS Measure the voltage at CN2 18 on the LVPS The voltage should measure approximately 50 V dc If incorrect replace the LVPS assembly See Low voltage power supply removal on page 4 109 If correct replace the system board See System board and inner shield removal model X642e on page 4 130 or Sys...

Page 179: ...ord If defective replace the cord If not defective check the AC input and output receptacles and wiring harness in the HCIT Repair or replace the receptacles or AC wiring harness as required Note Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lock washer are tightened FRU Action 1 high capacity feeder autoconnect mechanical chec...

Page 180: ...able is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board FRU Action 1 Pass thru sensor and flag assembly The tray x option system board did not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the ap...

Page 181: ...tion system board FRU Action 1 Lower limit switch Lower limit switch cable Check continuity of the lower limit switch If incorrect replace the switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High capacity feeder control board Disconnect the lower limit switch cable and check the voltage at J2 1 orange The vo...

Page 182: ...and pin 2 Yellow The resistance measures between approximately 7 5 and 10 5 ohms If incorrect replace the motor assembly If correct replace the high capacity feeder option system board FRU Action 1 DC drive motor assembly high capacity feeder system board Check the voltages at J1 on the high capacity system board The voltages measure approximately as follows If any of the voltages are incorrect di...

Page 183: ...ges measure approximately 5 V dc If incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board 2 Elevator top optical sensor cable Elevator top optical sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly FRU Action 1 High capacity feeder option...

Page 184: ...tch If incorrect replace the switch FRU Action 1 DC motor assembly Make sure all the motor plate mounting screws are tight 2 Idler pulley DC motor assembly Make sure the idler pulley is not binding on the pulley shaft Check the pulley for wear Check the idler pulley shaft on the motor mounting plate for damage or contamination 3 Drive pulley Check the drive pulley for wear binds or damage to the p...

Page 185: ...gnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power takeoff shaft and spring bevel gear feed roll gear drive roll assembly wear plate drive shaft bearings and skewed backup roll...

Page 186: ...install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer Check the interface card for correct installation and for any signs of damage If the card is damaged replace the interface card See Interface card assembly removal on page 4 107 FRU Action ...

Page 187: ...k continuity of the UICC 8 pin cable If correct go to step 3 If incorrect replace the cable 3 Operator panel left cover assembly Replace the operator panel left cover assembly See Operator panel left cover assembly removal on page 4 61 If this does not fix the problem replace the operator panel right cover assembly See Operator panel right cover assembly removal on page 4 64 FRU Action 1 LCD inver...

Page 188: ...al on page 4 64 If the voltages at CN1 1 and CN1 2 are correct replace the inverter card If this does not fix the problem replace the touchscreen display See LCD touchscreen removal models X644e and X646e on page 4 67 FRU Action LCD Touchscreen display Connector CN1 LCD inverter card Display dark Display lit CN1 1 Power 12 V dc 12 V dc CN1 2 Power 12 V dc 12 V dc CN1 3 Ground 0 V dc 0 V dc CN1 4 G...

Page 189: ... touchscreen display and Submit the new setting Measure the voltage at CN1 5 The voltage should measure approximately 0 to 1 5 V dc Enter 50 on the touchscreen display and Submit Measure the voltage at CN1 5 The voltage should measure approximately 2 7 V dc Enter 100 on the touchscreen display and Submit Measure the voltage at CN1 5 The voltage should measure approximately 5 0 V dc If the voltages...

Page 190: ...ct go to step 4 4 Inverter card assembly Operator panel right cover assembly Enter the following Menus Settings General Settings and Screen Brightness on the touchscreen display Enter 22 on the touchscreen display and Submit the new setting Measure the voltage at CN1 5 The voltage should measure approximately 0 to 1 5 V dc Enter 50 on the touchscreen display and Submit Measure the voltage at CN1 5...

Page 191: ...for any loose or worn parts in the developer drive assembly main drive gearbox or fuser Repair as necessary 2 Main drive motor assembly excessive noise gears ratcheting and so on A service error code 936 Transport Motor may be displayed Check the voltage at J20 6 on the system board It measures approximately 5 V dc when the motor is not running and goes to 0 V dc when the motor is running If incor...

Page 192: ... correct installation to J1 on UICC card 3 and to J14 on UICC card 1 operator panel card If installed correctly go to step 2 2 UICC card 1 to UICC card 3 cable UICC 8 pin cable Check continuity of the UICC 8 pin cable If correct go to step 3 If incorrect replace the cable 3 Operator panel left cover assembly Replace the operator panel left cover assembly See Operator panel left cover assembly remo...

Page 193: ... disk board are correctly installed Run the Quick Disk Test on page 3 16 from the Device Test on the Diagnostics menu when a problem is suspected either with the hard disk system board or with the hard disk Note The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If a problem still exists replace the hard disk board The Disk Test Clean o...

Page 194: ... fails to display Remove Paper Standard Bin message Output Bin Sensor Test fails Check the voltage at J6 1 It measures 5 V dc when the flag is in the sensor and 0 V dc when the flag is out of the sensor If the voltage does not change replace the sensor cable assembly If this does not fix the problem replace the system board 2 Output bin sensor flag Make sure the correct flag is installed Check the...

Page 195: ...down If the pick roll turns but does not pick paper check the roll for signs of wear oil or grease on the surface of the pick roll or slick spots If you find a problem replace the pick roll assembly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications FRU Action 1 Pass thru sensor Check the pass thru sensor for correct installati...

Page 196: ... X X 3 4 PSIZE3 SW2 X X X 4 FRU Action 1 Tray 1 Check Tray 1 for damaged or broken autosize fingers Check for anything that would prevent the autosize fingers from activating the paper activate springs and ITC switches If a problem is found repair or replace the tray assembly If no problem is found go to step 2 2 Integrated card autocompensator cable Check for correct installation of the cable at ...

Page 197: ...ivate spring is not bent or broken Replace the spring if damaged If the spring is not damaged go to step 3 3 System board ITC cable Set the tray for the paper size that is not recognized and install the tray in the printer Select the paper size and corresponding paper switch from table below If the voltage on J26 does not change go to step 4 If the voltage changes recheck the printer If Tray 1Miss...

Page 198: ...e can cause problems Incorrect characters could print and the copy may not fit the page correctly Measure all voltages from the connector to printer ground All voltages measured during the print cycle are measured with the controller board removed while running the print test Print quality all black page Service tip An all black page is generally caused by a problem in the high voltage system or a...

Page 199: ...n If the contact is bent or damaged replace the contact Note Inspect the HVPS PC drum contact on the board for damage or contamination 3 HVPS Check the fuse on the HVPS If open replace the HVPS Check the voltages at J22 on the system board Measure the following voltages from connector J22 to printer ground Printer Idle J15 5 measures 24 V dc Printer Printing J15 5 measures 24 V dc If the voltages ...

Page 200: ...nds of the shaft or replace the transfer roll assembly 3 High voltage contacts Check the high voltage contacts on the right side frame to ensure they are clean and not bent deformed or pitted If incorrect replace the contact 4 System board HVPS connector Check the following voltages at J15 on the system board Measure the voltages from J15 to printer ground If J15 1 voltage is incorrect check the c...

Page 201: ...see if enough force is being applied to the charge roll by applying slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample See if the problem changes or goes away If this fixes or changes the problem then check the springs and charge roll link arm assemblies for binds or defective parts Replace as necessary 2 Charge ro...

Page 202: ...vel changes 1 In Ready state press Menu 2 Select Settings and press Select 3 Select Quality Menu and press Select 4 Select Print Resolution and press Select 5 Select 1200 dpi 6 Press Back until Ready appears 7 Print a test page if you want to print an internal test page Print Fonts is the only internal 1200 dpi document If printing in 1200 dpi is correct and not light but other printing at other d...

Page 203: ... ADF CCD flatbed contact glass or flatbed CCD Service error code Explanation 1 Error code 931 xx No first HYSNC Signal Error Code 932 Lost HYSNC These errors usually indicate a failure in the HYSNC signal to the printhead Check the continuity of the cables connected to J2 and J4 on the system board If incorrect replace the defective cable The voltage at J4 1 measures approximately 5 V dc If incorr...

Page 204: ...or is missing replace the lower exit guide assembly See Lower exit guide assembly removal on page 4 47 If no problem is found with the lower exit guide assembly go to step 5 5 ADF frontside bracket assembly strip Check the ADF frontside bracket assembly for any signs of damage to the front flatbed white strip If damaged replace the complete ADF assembly See ADF complete assembly removal on page 4 ...

Page 205: ...lable to clean the glass if any contamination is found on the glass If after cleaning the problem persists go to step 9 9 ADF frontside bracket assembly strip Check the ADF frontside bracket assembly for any signs of damage to the front flatbed white strip If damaged replace the complete ADF assembly See ADF complete assembly removal on page 4 15 If no problem is found check the front flatbed whit...

Page 206: ...em is found go to step 4 4 Flatbed interconnect board CN5 to scanner control card J28 cable models X644e X646e Check the cable to make sure it is properly connected to both the flatbed interconnect card and to the scanner control card If it is properly installed check the cable for any signs of damage bent pins or so forth If any damage is found replace the complete ADF scanner assembly See ADF co...

Page 207: ...moval on page 4 47 3 ADF assembly This can be caused by the shock of the media being released from the first scan roller Replace the complete ADF assembly See ADF complete assembly removal on page 4 15 4 Pick mechanism Separator arm This can be caused by the shock of paper release from the feed separator roller Replace the following FRUs in the order listed Pick mechanism See ADF pick assembly rem...

Page 208: ...ing any one of the following components Flatbed interconnect card ICC System board assembly Interface card assembly Only replace one component at a time Replace the required component and perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR afte...

Page 209: ...rtion of the front harness cable to make sure it is properly seated into the toner sensor If correct at both the sensor and system board J15 check the continuity of the cable If incorrect replace the cable 3 Toner sensor The toner sensor cable is part of the front harness and part of connector J15 on the system board Check the voltage at J15 11 It reads approximately 5 V dc If incorrect replace th...

Page 210: ...transfer arm assembly spring for proper operation 3 Right transfer arm assembly Check the right transfer arm assembly to make sure it is fastened and locked in the down position If the arm is not locked down make sure the arm is not broken and locks into the EP frame correctly Check the right transfer arm assembly spring for proper operation For any background problems ensure the contact to the HV...

Page 211: ...p consists of menus settings and operations that are used to diagnose various printer problems Note While the Diagnostics menu group is active all host interfaces are offline See Diagnostics Menu on page 3 2 for more information Configuration Menu 1 Turn off the printer 2 Press and hold the 2 and 6 buttons simultaneously for about 10 seconds 3 Turn on the printer 4 Release the buttons after 10 sec...

Page 212: ...ck Test on page 3 6 PRINT TESTS Tray 1 See Input source tests on page 3 7 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed MP Feeder Envelope Feeder if installed Printing Print Quality Test Pages See Printing Quality Pages on page 3 7 HARDWARE TESTS Panel Test See Panel Test on page 3 8 Button Test See Button Test on page 3 8 DRAM Test See DRAM Test on page 3 9 CACHE...

Page 213: ...ray 5 if installed Envelope Feeder MP Feeder Sensor Tests See Sensor Test input tray on page 3 14 Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Envelope Feeder MP Feeder OUTPUT BIN TESTS See OUTPUT BIN TESTS on page 3 14 Feed Tests Standard Bin Sensor Tests Standard Bin BASE SENSOR TEST See BASE SENSOR TEST on page 3 15 Toner Sensor Input Sensor Standard Bi...

Page 214: ...lel strobe adjustment Par x Strobe Adj on page 3 19 PAR 1 STROBE ADJ if additional parallel options are installed EP SETUP EP Defaults See EP Defaults on page 3 20 Fuser Temp See Fuser Temperature Fuser Temp on page 3 20 Fuser Page Count See Fuser Page Count on page 3 20 Warm Up Time See Warm Up Time on page 3 20 Transfer See Transfer on page 3 21 Print Contrast See Print Contrast on page 3 21 Cha...

Page 215: ...crement causes approximately 4 pels shift at 600 dpi A positive change moves the image down the page and increases the top margin A negative change moves the image up and decreases the top margin Left Margin 25 to 25 A positive change moves the image right and a negative change moves the image left No compression occurs Right Margin 10 to 10 A positive change moves the image right and a negative c...

Page 216: ...ack to cancel and return to the Diagnostics Menu For model X642e touch Submit to save all changed values The device prints a Quick Test page from the appropriate paper tray While the Quick Test page prints Printing Alignment Page appears on the LCD Quick Test The Quick Test contains the following information Margin settings Alignment diamonds at the top bottom and each side Horizontal lines for sk...

Page 217: ...rn is printed If Continuous is selected the test pattern is printed only on the first envelope Note The Print Test Page always prints on one side of the paper regardless of the duplex setting or the presence of a duplex option Touch Back to return to PRINT TESTS Printing Quality Pages The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartri...

Page 218: ...the following Hardware Tests from this menu Panel Test Button Test DRAM Test CACHE Test Parallel 1 Wrap if available models X644e X646e Serial Wrap if available models X644e X646e Panel Test This test automatically toggles each pixel of the touchscreen through every contrast level beginning with the darkest and on to the brightest This test continues until you press Stop Button Test The Button Tes...

Page 219: ...e the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display To stop the test before completion turn the MFP off CACHE Test This test is used to verify the printer processor cache To run the CACHE Test 1 Touch to select CACHE TEST from HARDWARE TESTS The message CACHE Test Testing displays Then the message Resetting Prin...

Page 220: ...power indicator goes on solid and the final results display To stop the test before completion press Stop Serial Wrap test The serial wrap tests are used to check the operation of the serial port hardware using a wrap plug Use Serial 1 Wrap if a serial port is available through PCI slot 1 and Serial 2 Wrap if the serial port is available through PCI slot 2 To perform the Serial Wrap tests 1 Discon...

Page 221: ...back side of a duplexed sheet The single test stops automatically when a single duplex sheet is printed and the continuous test continues until you press Stop Top Margin duplex This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page Therefore be sure to set the top margin in REGISTRATION before setting the duplex ...

Page 222: ...light blinks and the message Motor Test Testing displays 2 When the motor stops the results are displayed AA 00 indicates success and any other value indicates failure BB average PWM for the high speed portion of the test The results should be in the range of 20 through 3F inclusively hex CC average PWM for the low speed portion of the test The results should be in the range of 3A through 5D inclu...

Page 223: ...eeding and the message Duplex Feed 2 Feeding displays The message Duplex Feed 2 Clear Paper displays when the paper reaches the duplex paper stop position 2 and the power indicator turns on solid 2 Remove the media from the duplex unit and clear the message on the operator panel by touching Back or pressing Stop INPUT TRAY TESTS Feed Tests input tray This test lets the servicer observe the paper p...

Page 224: ...can be actuated by hand however a sheet of paper can be used to cover the pass thru sensor When the sensor is closed Closed displays when the sensor is open Open displays 5 Press Stop to exit the test OUTPUT BIN TESTS Feed Tests output bins Use these tests to verify that media can be fed to a the standard output bin No information is printed on the media fed to the output bin because the printhead...

Page 225: ...ally actuate the bin sensor by moving the flag in and out of the sensor and the display changes The following screen is displayed Bin Empty empty or Bin Empty full 4 Press Stop to exit the test BASE SENSOR TEST This test is used to determine if the sensors located inside the printer are working correctly To run the Base Sensor Test 1 Select BASE SENSOR TEST from the DIAGNOSTICS menu The following ...

Page 226: ...d 2 Press Stop to return to the Device Tests menu Disk Test Clean Warning This test destroys all data on the disk and should not be attempted on a good disk Also note that this test may run approximately 1 hours depending on the disk size To run the Disk Test Clean Test 1 Touch to select Disk Test Clean from the Device Tests menu Contents will be lost Continue message displays to warn the user tha...

Page 227: ... turns on solid and either the message Flash Test Test Passed or Flash Test Test Failed displays 3 Touch Back or press Stop to return to DEVICE TESTS PRINTER SETUP The triangles pointing up or down indicate whether there are additional menus Touch the up or down arrows to display these additional menus Note If you make changes touch Submit to make the change effective Defaults US Non US defaults c...

Page 228: ...d cannot be changed Touch Back to return to Diagnostics Menu Envelope Enhance This setting affects the level of the fuser solenoid To set Envelope Enhance 1 The current value is displayed setting s current value The values are Low Medium and High The default is Medium 2 Touch or to change the value Touch Back to return to Diagnostics Menu Engine Setting 1 through 4 Warning Do not change these sett...

Page 229: ... are displayed Use keys to type the numbers for the two configuration IDs Use the left arrow to move over a digit from the right of the number toward the left When the numbers are correct touch Submit If you have a question touch the question mark icon To exit without changing the numbers touch Back Note Be sure to touch Submit or the number will not be changed Submitting Selection displays follow...

Page 230: ...s adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media The fuser temperature can be adjusted to Normal Lower Lowest The default is Normal Touch Back to return to Diagnostics Menu Fuser Page Count The fuser page count can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu Warm ...

Page 231: ...ing problems However increasing this value also results in slower overall performance measured in pages per minute The range of values is 0 to 255 and the default value is 0 Touch Back to return to Diagnostics Menu EVENT LOG Display Log The event log provides a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error displays in positi...

Page 232: ...information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis To print the event log Touch to select Print Log from EVENT LOG Clear Log Use Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Touch to select Clear Log from the Event Log menu 2 Touch to s...

Page 233: ...n Feed Test Testing displays Press 4 to exit the test 4 Touch Back to return to the Diagnostics Menu Scanner Manual Registration Note Do not change these settings unless requested to do so by your next level of support Sensor Tests The following tests are available ADF cover Open ADF Exit Sensor ADF Interval ADF Jam Removal ADF Paper Present FB Cover Open Home Sensor SCAN_QRY_PAPER_SIZE_ADF_LONG S...

Page 234: ...7 Factory Defaults See Factory Defaults on page 3 28 Energy Conserve See Energy Conserve on page 3 28 Min Copy Memory See Min Copy Memory on page 3 29 Format Fax Storage See Format Fax Storage on page 3 29 ADF Edge Erase See ADF Edge Erase on page 3 29 FB Edge Erase See FB Edge Erase on page 3 30 Automatic Scanner Registration See Automatic Scanner Registration on page 3 30 EVENT LOG print log onl...

Page 235: ... for the part number To view the maintenance page count touch to select Maint Cnt Value from the Configuration Menu The value is displayed and cannot be changed Touch Back to return to the main Configuration Menu Reset Maintenance Counter After scheduled maintenance the servicer needs to reset the page counter To reset the maintenance page count to zero 1 Touch to select Reset Maintenance Counter ...

Page 236: ...ler code level engine code level operator panel code level smart option code levels font versions and so on Values for the QUALITY MENU settings used to print the pages The print quality test consists of four pages Page one contains a mixture of graphics and text Pages two and three only contain graphics Page four is blank If duplex is turned on the pages are duplexed The Print Quality Test pages ...

Page 237: ...Enable The default is Enable 3 Touch Submit to save your change Touch Back to exit without changing the value PPDS Emulation This menu item allows the user to enable or disable PPDS emulation data stream When this setting is enabled the following settings are also changed SmartSwitch settings for each port are turned off The printer language is changed to PPDS Emulation Users can still switch lang...

Page 238: ...electing one of these settings immediately takes effect The MFP restarts and returns to Ready state Restoring Factory Defaults and then Resetting the Device are displayed Energy Conserve This menu controls what values appear on the Power Saver menu If Off is selected in Energy Conserve menu then Disabled appears in the Power Saver menu and Power Saver can be turned off If On is set in Energy Conse...

Page 239: ... Format Fax Storage from the Configuration Menu Formatting Fax Flash DO NOT POWER OFF appears on the LCD while the format operation is active Note If an advanced password has been established you must enter this password in order to change the setting ADF Edge Erase The ADF Edge Erase and FB Edge Erase settings specify in millimeters the size of a border around the scanned image that will be erase...

Page 240: ...uch Submit to save the change Touch Back to cancel and return to the Configuration Menu Automatic Scanner Registration To perform the Automatic Scanner Registration 1 Obtain two pieces of colored paper A4 or letter for the automatic registration Use a light blue sheet or other solid color paper Note Always store the colored sheets so they do not become creased or torn The sheets can be used if you...

Page 241: ...n Menu 2 Touch to print the log Printing Event Log displays on the touchscreen 3 Touch Back to return to EVENT LOG Note An event log printed from the CONFIG MENU will not contain debug information or secondary codes for 900 service errors However the event log printed from DIAGNOSTICS mode does include this information Paper Prompts When a tray is out of the indicated paper size a prompt is sent t...

Page 242: ...o cancel and return to the Configuration Menu Disk Encryption Model X646e only If a hard disk is installed Disk Encryption selects whether the data on the disk is encrypted or not The values are Disable and Enable This setting determines if the printer encrypts the information that it writes to the hard disk The values are Disable and Enable Warning If the value is changed from Enable to Disable o...

Page 243: ... graphics depending on the process selected and then begins the second stage of the process The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100 After completion the panel returns to Disk Encryption Wipe Disk This setting provides you with a tool for erasing the contents of a disk Warning Wipe Disk removes a disk s data in such a way...

Page 244: ...tandby Mode is on the printer begins functioning in Standby Mode when it remains idle for an amount of time The Standby Mode enables the printer To consume less energy than when operating in normal mode but not as little as when operating in Power Saver To return to the Ready state more quickly than when operating in Power Saver To change this setting 1 Touch to select Require Standby from the Con...

Page 245: ... will repeat The range is 1 100 with a default of 15 times per second To change this setting 1 Touch to select Key Repeat Initial Delay from the Configuration Menu 2 Touch to increase the value or to decrease the value 3 Touch Submit to save the change Touch Back to cancel and return to the Configuration Menu Wiper Message To change this setting 1 Touch to select Wiper Message from the Configurati...

Page 246: ...r like the D roll this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness High normal force is one of the most significant contributors to double feeding paper The pick arm is counterbalanced by an extension spring located on the pick arm to reduce weight in the rest state This spring is factory set to exert no more...

Page 247: ...ial interface transmit signal serial interface receive signal and two ground pins The duplex option receives the 24 V dc from the printer for the duplex motors and also converts the voltage to 5 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and base of the printer The ground connection is automat...

Page 248: ...to clear the message and resume printing The MFP prints a new copy of the page that jammed if Jam Recovery is set to On or Auto however the Auto setting does not guarantee the page will print Identifying jams If the MFP jams the appropriate jam message will be displayed on the touch screen Print status message bar See the diagram on Access doors and trays on page 3 39 for an overview of the paper ...

Page 249: ...mbers in following the illustration indicate the numbers that can appear on the operator panel and designate the general area of a paper jam Doors and trays Path and locations Models X644e X646e shown CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations a...

Page 250: ...er 1 Remove the paper from the multipurpose feeder 2 Flex fan and restack the media and place it into the multipurpose feeder 3 Load the print media 4 Slide the side guide toward the inside of the tray until it lightly rests against the edge of the media Message What to do 200 and 201 Paper Jam Remove Cartridge Open the bottom then top front covers remove the print cartridge and then remove the ja...

Page 251: ... the jammed envelope has entered the MFP and cannot be pulled out remove the envelope feeder a Lift the envelope feeder out of the MFP and then set it aside b Remove the envelope from the MFP Note If you cannot remove the envelope the print cartridge will have to be removed See 200 and 201 Paper Jam Remove Cartridge on page 3 46 for more information c Reinstall the envelope feeder Make sure it sna...

Page 252: ...3 42 Service Manual 7002 xxx 4 Load the envelope feeder 5 Adjust the guide 6 Lower the envelope weight 7 Touch Continue 1 2 ...

Page 253: ...and 24x jams Paper jams in these areas can occur on the incline surface of a tray or across more than one tray To clear these areas 1 Open the MFP paper tray and remove any jammed media 2 Open the duplex tray To remove the media pull up ...

Page 254: ...ly one way try the other way CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations also must have a printer stand or printer base More information is available on our Lexmark Web site at www lexmark com multifunctionprinters ...

Page 255: ...nt media is neat and aligned 5 Touch Continue CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations also must have a printer stand or printer base More information is available on our Lexmark Web site at www lexmark com multifunctionprinters ...

Page 256: ... the print cartridge aside Note Do not leave the cartridge exposed to light for extended periods Note The print media may be covered with unfused toner which can stain garments and skin 5 Pull the print media up and toward you Warning If the print media does not move immediately when you pull stop pulling You need to access the print media from the MFP rear door CAUTION The inside of the MFP may b...

Page 257: ...ear Door 1 If the paper is exiting the MFP pull the media straight out and then touch Continue Otherwise continue with step 2 2 Open the MFP rear door 2 1 CAUTION The inside of the MFP may be hot Allow the MFP to cool before touching any internal components CAUTION Do not use any pointed objects to remove the paper This could cause personal injury or damage to the MFP ...

Page 258: ...a 4 Close the rear door 5 Touch Continue 23x Paper Jam Open Duplex Rear Door 1 Open the duplex rear door 2 Remove the jammed media Depending on the media location pull the media either up or down 3 Close the duplex rear door Make sure it snaps into place ...

Page 259: ...tinue Clearing ADF jams 290 291 292 and 294 Scanner Jams 1 Remove all original documents from the ADF 2 Open the ADF top cover and remove any jammed pages 3 Open the ADF cover and remove any jammed pages 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 ...

Page 260: ...3 50 Service Manual 7002 xxx 4 Open the lower entrance guide and remove any jammed pages 5 Close the lower exit guide 6 Close the ADF cover ...

Page 261: ...ctricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrica...

Page 262: ...o the printhead assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots It is necessary to perform a registration adjustment before lock...

Page 263: ...e reference adjustment screw out far enough to allow the alignment assembly to be removed from the MFP It is not necessary to completely remove the screw 4 Install the new alignment assembly Turn the reference screw clockwise with a 7 mm nut driver or M3 Allen wrench until it touches the back of the reference plate and tighten the nut with a 5 5 mm wrench The reference adjustment screw can be adju...

Page 264: ... 1 Enter the Configuration menu a Turn off the printer b Press and hold the 2 and 6 buttons simultaneously c Turn on the printer d Release the buttons after 10 seconds 2 Scroll through the menus using the down arrow and select Automatic Scanner Registration from the Configuration menu 3 Place a colored piece of paper in the ADF making sure the edge guides are properly adjusted Place another piece ...

Page 265: ...ned as correctly as possible If the process fails again contact the next level of support 6 Verify the results by running a copy of a quick test page created during MFP registration See Print tests on page 3 6 for more information Manual registration Note Manual registration should be performed only after automatic registration is performed The primary purpose of manual registration is to fine tun...

Page 266: ...val 1 Open the ADF top cover 2 Remove the two screws A 3 Release the ADF front cover latch B on the right side under the scanner and then release the latch B on the left side CAUTION Remove the power cord from the MFP or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the MFP CAUTION Use the handholds on the side o...

Page 267: ...Repair information 4 7 7002 xxx ADF pick assembly removal 1 Grasp the pick assembly and gently push the shaft to the right to free the left side ADF rear cover removal 1 Remove the two screws A A ...

Page 268: ...he square notches For models X644e X642e there are two cables and notches and for model X642e there is a single cable Replacement note When replacing the ADF rear cover be sure to align the cables C in the notches and press the square portions of the cables into the holes Model X642e Model X644e X646e ...

Page 269: ...front cover removal on page 4 6 2 Remove the ADF rear cover See ADF rear cover removal on page 4 7 3 Open the ADF top cover 4 Remove the shoulder screw A on the front 5 Remove the shoulder screw B on the rear with a long shank screwdriver Models X644e X646e shown 6 Remove the ADF top cover A ...

Page 270: ...4 10 Service Manual 7002 xxx Scanner left side cover removal 1 Remove the two screws A 2 Slide the cover toward the rear to unlatch the cover and remove Note Model X644e X646e shown A ...

Page 271: ...he cover out first and lift away to remove Scan cover flatbed removal 1 Remove the glass holder assembly See Scanner flatbed glass holder assembly removal on page 4 50 2 Remove the flatbed contact glass See Flatbed contact glass removal on page 4 31 3 Remove the three screws A A ...

Page 272: ...4 12 Service Manual 7002 xxx 4 Lift the scan cover flatbed Scanner right side cover removal Scanner right side cover removal 1 Remove the screw A A ...

Page 273: ...ion 4 13 7002 xxx 2 Slide cover back to release tab B ADF attach screws removal 1 Open the document cover 2 Remove the two ADF attach screws A by turning them by hand Note Do not remove the screws toward the rear B A ...

Page 274: ...carefully supporting the unit 5 Open the lower exit guide assembly 6 Remove the four screws A and the two small screws B securing the ADF CCD module assembly 7 Remove the ADF jam tray sensor C from the mounting bracket to protect it from being bumped or damaged during removal of the ADF CCD module assembly 8 Remove the ADF CCD module assembly and disconnect the ADF CCD to scan control cable D Rein...

Page 275: ...rews See ADF attach screws removal on page 4 13 Note Do not remove the two screws in the back 3 Lift the ADF up and make sure you clear the two rear screws The hinge is slotted to allow the ADF to come off and leave the screws in place Note Whenever the complete ADF assembly is replaced it is necessary to perform the scanner registration See Scanner registration on page 4 4 A A Model X642e Models ...

Page 276: ...mbly removal 1 Remove the ADF pick assembly See ADF pick assembly removal on page 4 7 2 Remove the document tray assembly See Document tray assembly removal on page 4 23 3 Remove the three screws A 4 Lift the cover Replacement note Be sure to align the tabs A ...

Page 277: ...lass See Flatbed contact glass removal on page 4 31 3 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 4 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 5 Push the CCD belt tension spring to take tension from the belt 6 Unhook the belt from the motor shaft ...

Page 278: ...from the holes in the right side This allows you to remove the flatbed CCD module from the shafts 9 Carefully lay the flatbed CCD module on the scan frame being careful not to touch the card lamp or mirrors 10 Disconnect the CCD belt from the retainer F in the flatbed CCD module assembly 11 Remove the CCD belt E F ...

Page 279: ...ass See Flatbed contact glass removal on page 4 31 3 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 4 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 5 Push the CCD belt tension spring toward the motor to take tension from the belt 6 Unhook the belt from the motor shaft ...

Page 280: ... 20 Service Manual 7002 xxx 7 Unhook the main CCD guide shaft A from the hole in the right side and slide it out of the way This allows you to access the spring 8 Remove the CCD belt tension spring A A B ...

Page 281: ...See Scan cover flatbed removal on page 4 11 2 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 3 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 4 With pliers pull firmly to remove the actuator A A ...

Page 282: ... Scan cover flatbed removal on page 4 11 2 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 3 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 4 With pliers pull firmly to remove the actuator A A ...

Page 283: ...ssembly removal 1 Remove the ADF front cover See ADF front cover removal on page 4 6 2 Remove the ADF rear cover See ADF rear cover removal on page 4 7 3 Remove the two screws A 4 For modelsX644e X646e disconnect the connector B B Models X644e X646e ...

Page 284: ...val on page 4 11 2 Remove the flatbed contact glass See Flatbed contact glass removal on page 4 31 3 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 4 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 5 Push the flatbed CCD toward the motor to take tension from the belt 6 Unhook the belt from the mo...

Page 285: ... the holes in the right side This allows you to remove the flatbed CCD module from the shafts 9 Carefully lay the flatbed CCD module on the scan frame being careful not to touch the card lamp or mirrors 10 Disconnect the flatbed CCD ribbon cable B from the flatbed CCD module ...

Page 286: ...11 Remove the screw C from the flatbed CCD ribbon cable clamp 12 Remove the printer left side cover See Printer left side cover removal on page 4 56 13 Remove the seven screws D from the SCC and HDD shield Models X644e X646e shown ...

Page 287: ...om to remove the scanner control card shield and the hard disk shields 15 Disconnect the flatbed CCD ribbon cable from the scanner control card E 16 Remove the toroid from the cable and set aside for reinstallation 17 Disconnect the flatbed CCD ribbon cable from the IF interface card E E Model X642e Models X644e X646e X646e shown ...

Page 288: ... See Scan cover flatbed removal on page 4 11 2 Remove the flatbed contact glass See Flatbed contact glass removal on page 4 31 3 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 4 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 5 Push the CCD belt tension spring to take tension from the belt 6 Unho...

Page 289: ... all the way to the left There is a slot in the frame to allow the flatbed CCD module assembly to be lifted out 8 Unhook the main CCD guide shafts E from the holes in the right side This allows you to remove the flatbed CCD module assembly from the shafts A ...

Page 290: ... Manual 7002 xxx 9 Disconnect the flatbed CCD ribbon cable B from the flatbed CCD module 10 Disconnect the CCD belt from the retainer C in the flatbed CCD module assembly 11 Remove the flatbed CCD module assembly C ...

Page 291: ...er assembly See Scanner flatbed glass holder assembly removal on page 4 50 3 Remove the upper glass holder See Upper glass holder removal on page 4 53 4 Slide the glass to the left and lift it 5 Lift the glass and place it on a clean dry cloth CAUTION While the glass edge is beveled handle it carefully to avoid cutting your hand ...

Page 292: ...l 7002 xxx Flatbed white cushion removal 1 Open the document cover 2 Peel the Velcro attached pad from one corner To replace the flatbed white cushion place the cushion on the document glass and close the document cover ...

Page 293: ... a printer it cannot be used in another printer It must be returned to the manufacturer Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 Illustrations represent models X644e X646e Unless there is an indication the procedure is the same Differences are shown side by side 1 Remove the scan cover flatbed See Scan cover flatbed removal...

Page 294: ...move the two screws D from the left bottom and right bottom 9 Disconnect all connectors E There are either four or three depending on model 10 Remove the four screws F 11 Remove the card C B D C D E F E F Models X644e X646e Model X642e ...

Page 295: ...over flatbed See Scan cover flatbed removal on page 4 11 2 Remove the flatbed contact glass See Flatbed contact glass removal on page 4 31 3 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 4 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 5 Remove the three screws A that attach the hinge support b...

Page 296: ...ve the two screws C from the left side and right side 8 Remove the two screws D from the left bottom and right bottom Note Some models may look different Model X646e is shown 9 Remove the two screws E from the sensor assembly cover C B D C D E E Models X644e X646e Model X642e ...

Page 297: ...or you need to replace Note There are three sensors in models X644e X646e There is only one in model X642e 11 Disconnect the sensor cable G at the sensor and remove the sensor Note Only remove one sensor at a time to make it easier to reinstall the right cable G G F F Models X644e X646e Model X642e ...

Page 298: ...mplete assembly removal on page 4 15 2 Remove the printer left side cover See Printer left side cover removal on page 4 56 3 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 4 Remove the seven screws A from the SCC and HDD shield 5 Loosen the screws for the printer outer shield and slide shield to the left to allow enough room to remove the scanner control card s...

Page 299: ...ables B 7 Remove the two screws C from the left side 8 Remove the two screws D that attaches the ground bracket to the SCC HDD shield Note The ground bracket is only on models X644e and X646e B B Models X644e X646e X646e shown Model X642e Model X646e shown ...

Page 300: ...ver removal on page 4 12 10 Remove the two screws from the right side E 11 Pull the scan unit forward to unhook the unit from the printer and lift the scan unit from the printer Installation note Remove any clear protective covers from the scanner registration strip and the flatbed white cushion after installation E ...

Page 301: ...11 2 Remove the flatbed contact glass See Flatbed contact glass removal on page 4 31 3 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 4 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 5 Remove the three screws A that attach the hinge support bracket to the rear scan bracket 6 Remove the two screw...

Page 302: ...left bottom and right bottom 9 Push the flatbed CCD toward the motor to take tension from the CCD belt 10 Unhook the CCD belt from the motor shaft 11 Carefully lay the flatbed CCD module on the scan frame being careful not to touch the card lamp or mirrors C B D C D ...

Page 303: ...Repair information 4 43 7002 xxx 12 Remove the three screws E that attach the FB scan motor assembly to the frame 13 Remove the flatbed scan motor assembly E ...

Page 304: ...left side cover See Printer left side cover removal on page 4 56 2 Remove the six screws A from the SCC and HDD shield 3 Loosen the screws for the printer outer shield and slide the shield to the left to allow enough room to remove the scanner control card shield and the hard disk shield 4 Disconnect the two cables B ...

Page 305: ...Repair information 4 45 7002 xxx 5 Remove the four screws C 6 Remove the hard disk ...

Page 306: ...ontact glass removal on page 4 31 3 Remove the scanner right side cover See Lift the scan cover flatbed Scanner right side cover removal on page 4 12 4 Remove the scanner left side cover See Scanner left side cover removal on page 4 10 5 Remove the screw A 6 Remove the sensor and bracket B 7 Disconnect the cable C from the sensor 8 Unclip the home sensor D from the bracket ...

Page 307: ...t cover removal on page 4 6 2 Remove the flatbed white cushion See Flatbed white cushion removal on page 4 32 3 Open the document cover 4 Press the latch A to open the lower exit guide assembly 5 Remove the two screws B and remove the metal plate C Set the plate aside 6 Remove the screw D on the ADF frame 7 Remove the lower exit guide assembly Installation note Be sure to route the cable through t...

Page 308: ...or in front of the other spring 3 Remove the cable from the cable guide 4 Disconnect the connector C and remove the pickup solenoid assembly Scanner control card removal Illustrations represent models X644e X646e Unless there is an indication the procedure is the same Differences are shown side by side 1 Remove the printer left side cover See Printer left side cover removal on page 4 56 2 Remove t...

Page 309: ...hield and slide the shield to the left to allow enough room to remove the scanner control card shield and the hard disk shield 4 Disconnect all the cables B 5 Remove the four screws B 6 Tilt the card to remove the scanner control card Model X642e Models X644e X646e X646e shown ...

Page 310: ...embly removal 1 Open the document cover 2 Remove the two screws A 3 Carefully pry up the inner edge Warning Do not use tools that can scratch the glass Warning Be careful not to touch the calibration strip A on the underside of the scanner flatbed glass holder A ...

Page 311: ...mation 4 51 7002 xxx 4 Lift to release the three tabs C Warning Place the scanner flatbed glass holder assembly on a clean dry cloth to protect the glass from scratches Warning Do not touch the calibration strip D ...

Page 312: ...val 1 Open the ADF top cover 2 Remove the ADF pick arm assembly See Document tray assembly removal on page 4 23 3 Unsnap and remove the paper guide A 4 Remove the clip B 5 Remove the reverse roller C 6 Slide the separator assembly torque limiter D off the shaft A B C D ...

Page 313: ...Repair information 4 53 7002 xxx Upper glass holder removal 1 Open the document cover 2 Slide the upper glass holder to the left to unlatch 3 Lift the upper glass holder to remove ...

Page 314: ...moval 1 Squeeze the two latches together and pull up 2 Remove the fuser wiper cover assembly 3 Remove the fuser wiper cover assembly CAUTION Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer CAUTION Use the handholds on the side of the printer Make sure your finge...

Page 315: ...sub cover removal 1 Remove flatbed scanner assembly See Flatbed scan assembly removal on page 4 38 2 Remove screw A from right side frame holding upper sub cover 3 Pull up on the right side of the upper sub cover 4 Remove the upper sub cover ...

Page 316: ... scan assembly See Flatbed scan assembly removal on page 4 38 2 Raise the upper tray cover and lift to release the latches 3 Remove the upper tray cover Printer left side cover removal 1 Open the upper and lower front covers 2 Press the two left door latch buttons A and open the left door ...

Page 317: ...Repair information 4 57 7002 xxx 3 Release the top hinge from the latch B 4 Lift the door to release the bottom from the pin B and remove the door ...

Page 318: ...y open lift and free the left side 2 Remove the redrive door Printer right cover removal 1 Remove the upper sub cover See Upper sub cover removal on page 4 55 2 Open the upper and lower front covers 3 Remove the print cartridge 4 Remove the right front cover mounting screw A ...

Page 319: ...mation 4 59 7002 xxx 5 Remove the redrive door See Redrive door on page 4 58 6 Remove the right rear cover mounting screw C 7 Remove the two redrive screws D 8 Press the two latches to remove the redrive assembly C ...

Page 320: ...e front of the right cover 10 Pull up and out on the right cover to release the three cover retainers E at the bottom Note When replacing the right side cover make sure the three cover retainers E are correctly located in the appropriate slots in the right side frame D E ...

Page 321: ... models X644e X646e Unless there is an indication the procedure is the same 1 Remove the printer left side cover See Printer left side cover removal on page 4 56 2 Open the printer upper front cover 3 Remove the two screws A Note Model X644e shown 4 For model X642e disconnect the cable B Model X642e ...

Page 322: ...4 62 Service Manual 7002 xxx 5 For model X642e remove the screw C that attaches the ground cable 6 Remove the operator panel left cover assembly ...

Page 323: ...Repair information 4 63 7002 xxx Installation note Be sure the latches C on the back of the operator panel left cover are fastened into the upper front cover hinge slots ...

Page 324: ...cover 2 Remove the two screws A 3 Lift the operator panel right cover assembly carefully to access the cables Warning Be careful not to tear or break the small ribbon cable from its connector B 4 Disconnect the four cables C from the UI control card 5 Remove the operator panel right cover assembly A C B C ...

Page 325: ...Repair information 4 65 7002 xxx Installation note Be sure the latches D on the top of the operator panel right cover are fastened into the upper front cover hinge slots ...

Page 326: ...er 2 Use a small screwdriver or other small tool to carefully release the two tabs A under the touchscreen bezel Warning Be careful not to scratch or mar the touchscreen bezel 3 For model X642e disconnect the UICC 3 cable B 4 Remove the touchscreen bezel A A Models X644e X646e Model X642e B ...

Page 327: ...3 Lift the operator panel right cover assembly carefully to access the cables Warning Be careful not to tear or break the small ribbon cable from its connector B 4 Disconnect the cables C from the UI control card CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the produc...

Page 328: ...e cable D from the LCD inverter card assembly 7 Remove the touchscreen bezel See Touchscreen bezel removal on page 4 66 8 Press the two tabs E that limit range of motion and rotate the LCD touchscreen up until it disconnects 9 Set the LCD touchscreen aside Warning Avoid touching or placing pressure on the touchscreen Do not handle roughly or drop D ...

Page 329: ...ct the ground cable You might want to use a pair of pliers and a small flat blade screwdriver LCD touchscreen removal model X642e 1 Remove the bezel See Touchscreen bezel removal on page 4 66 2 Remove the two screws A from the right side cover A ...

Page 330: ...reful not to tear or break the small ribbon cable B from its connector 4 Disconnect the cables C from the UI CC 5 Remove the operator panel left side cover See Operator panel left cover assembly removal on page 4 61 6 Use a screwdriver to lift the lock and disconnect the cable D from the LCD inverter card assembly B C D ...

Page 331: ...wer front cover assembly removal 1 Open the multipurpose tray to a position that allows the left and right tray hinge slots A to align with the D shape mounting posts B Pull upward on each tray hinge to remove the tray from the two mounting posts Warning Be careful not to break or stress the hinges 2 Remove the multipurpose tray lower front cover assembly E E ...

Page 332: ...on page 4 126 3 Remove the two screws A holding the top of the left handle holder in place 4 Use the tab B to lift out the left handle holder Right cover handle holder removal 1 Remove the right side cover See Printer right cover removal on page 4 58 2 Remove the two screws A holding the top of the right handle holder in place 3 Lift out the right handle holder ...

Page 333: ...move the ADF and flatbed scanner assemblies See Flatbed scan assembly removal on page 4 38 2 Remove the toner cartridge 3 Turn the printer on its back 4 Remove the two screws A holding the right frame extension 5 Remove the two screws B securing the left frame extension ...

Page 334: ...See Redrive assembly removal on page 4 128 2 Remove the screw A securing the pass thru plate 3 Carefully remove the plate until it is loose 4 Remove the fuser to system board DC cable B secured through the plate Note Note the routing of the fuser card to system board DC cable ...

Page 335: ...oor 2 Remove the inner shield 3 Remove the gear guard 4 Remove the power takeoff shaft and spring A through the bottom of the printer 5 Place your thumb on the top of the gear and press firmly down and away Note You need to exert firm pressure to snap the bevel gear out ...

Page 336: ...rtion and press or pull into position Note You should hear two distinct snaps If you only hear one the bevel gear is only partially engaged and you should continue to press until the second snap is heard Very firm pressure is required 5 Install the power takeoff shaft and spring 6 Install the gear guard 7 Install the inner shield CAUTION Do not brace your hands below the bevel gear itself When the...

Page 337: ... one long screw B securing the developer drive assembly 3 Remove the developer drive assembly 4 Remove the developer drive coupler kit See Developer drive coupler kit removal on page 4 78 Installation 1 Place the developer coupler into the main motor drive shaft 2 Place the developer drive shaft on the developer drive 3 Align the developer drive shaft with the coupler 4 Be sure to replace the scre...

Page 338: ... page 4 77 2 Remove the shaft drive and coupler ESD cover removal 1 Open the multipurpose tray and remove the tray from the two mounting posts See Multipurpose feeder lower front cover assembly removal on page 4 71 2 Carefully lift the latch on the left A and remove the ESD cover Note Be careful not to stress the hinge on the right B ...

Page 339: ...ly cover See Fuser wiper cover assembly removal on page 4 54 2 Remove the redrive assembly See Redrive assembly removal on page 4 128 3 Remove the fuser mounting screws A 4 Disconnect the fuser to LVPS AC cable B from the fuser lamp connector C CAUTION Unplug the printer before you begin ...

Page 340: ... lamp AC and the DC cable 6 Pull the cables free and remove the fuser Installation notes 1 When you reinstall the fuser be sure to route the fuser to LVPS AC cable A through the channel B on the right side frame above the LVPS under the clip C over the LVPS and through the notch in the frame D 2 Route the fuser lamp cable through the opening in the fuser E ...

Page 341: ...Repair information 4 81 7002 xxx 3 Connect the fuser to LVPS AC cable to the fuser lamp connector F at the LVPS Note Be sure to connect the fuser to system board DC cable after replacing the LVPS ...

Page 342: ...ser control board 3 Remove the screw B securing the cover containing the fuser exit sensor flag and spring 4 Release the two clips C holding the sensor in the bracket 5 Unplug the fuser exit sensor cable from the sensor Installation 1 Move the fuser exit sensor flag out of the way to clip the sensor securely into the cover 2 Connect the fuser exit sensor cable ...

Page 343: ...or cover into the clips 4 Replace the screw securing the sensor cover Note Make sure the flag moves properly Fuser exit sensor flag and spring removal 1 Remove the fuser exit sensor See Fuser exit sensor removal on page 4 82 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C until the fuser exit sensor cover releases the flag and spring ...

Page 344: ...4 84 Service Manual 7002 xxx Spring replacement 1 Place the spring on the left pin A 2 Set the tang B on the flag ...

Page 345: ...tate the bent end C of the spring to add tension place the pins between the sensor cover arms and rest the bent end against the sensor cover frame Note After replacing the sensor flag and spring make sure the flag moves freely and returns ...

Page 346: ...p cover assembly 3 Remove the two screws A from the right side fuser lamp contact cover Warning Take care when removing the screw as the lamp is under spring tension When the contact is released damage to the lamp or contact may occur 4 Remove the left lamp contact assembly CAUTION The fuser and the fuser lamp may be hot You may need to allow them to cool before handling them A 202 ...

Page 347: ...emoving the lamp from the fuser Grip the lamp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp Use the following table to identify and install the correct lamp Description P N Fuser Lamp 115 V 40X0122 Fuser Lamp 220 V 40X0123 ...

Page 348: ...o the fuser 3 With a thumbnail release the catches B holding the sensor cover to the lower exit guide assembly C in place Note You may need to move the narrow media flag out of the way to remove the sensor 4 Disconnect the fuser narrow media cable at the sensor 5 Release the catches holding the sensor in the cover Note Hold the narrow media flag out of the way to remove the sensor from the cover ...

Page 349: ...e way to clip the sensor securely into the cover 2 Connect the fuser narrow media cable 3 Snap the bottom fastener of the sensor cover into place in the lower exit guide assembly and rock the cover up until the top fastener snaps securely 4 Replace the screw securing the sensor cover ...

Page 350: ...nsor See Fuser narrow media sensor removal on page 4 88 2 Note the position of the spring A in relation to the flag B 3 Carefully ease the right arm C of the sensor cover just far enough apart to release the flag and spring Spring replacement 1 Place the spring on the left pin A 2 Set the tang B on the flag ...

Page 351: ...3 Rotate the bent end C of the spring to add tension place the pins between the sensor cover arms and rest the bent end against the sensor cover frame Note After replacing the sensor flag and spring make sure the flag moves properly A ...

Page 352: ...move the right side cover See Printer right cover removal on page 4 58 4 Disconnect the fuser to LVPS AC cable A from the fuser lamp connector on the fuser and remove the cable through the cable retainer B and the lower rectangular opening C in the fuser frame 5 Remove the pass thru plate See Pass thru plate on page 4 74 6 Disconnect the LVPS to system board DC cable D from the LVPS CAUTION Unplug...

Page 353: ...VPS E Note The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal 8 Remove the fuser to LVPS AC cable Installation 1 Plug in the fuser to LVPS AC cable A into the LVPS 2 Route the cable through the channel B on the right side frame above the LVPS under the clip C over the LVPS and through the notch in the frame D ...

Page 354: ...l 7002 xxx 3 Route the cable through the lower rectangular opening E 4 Connect the fuser to LVPS AC cable to the fuser lamp connector F Note Be sure to connect the fuser to system board DC cable after replacing the LVPS ...

Page 355: ... assembly See Fuser assembly removal on page 4 79 2 Note the thermistor cable routing A and disconnect the thermistor cable at the fuser control board 3 Disconnect the AC fuser lamp cable B from the top right side of the fuser cover CAUTION Unplug the printer before you begin ...

Page 356: ... fuser lamp contact cover D 5 Release the latch E and remove the cover 6 Remove the screw F on the left side and the screw G on the right side that attach the fuser upper cover assembly to the fuser frame 7 Remove screw H that attaches the side fuser lamp contact to the fuser top cover F G H ...

Page 357: ...ly removal on page 4 132 3 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 101 4 Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right side from its mounting 5 Remove the screw that attaches the transfer plate ground wire to the center pan 6 Remove the fuser transfer plate 7 Remove the screw that attaches the deflec...

Page 358: ...ner shield removal models X644e X646e on page 4 131 2 Remove the developer drive 3 Disconnect the gear release link A from the hole in charge roll link B Note Lift the upper front cover to make it easier to remove the link 4 Rotate the link to disconnect the link from the main drive assembly 5 Remove the gear release link ...

Page 359: ...ect the HVPS cable from the HVPS at connector A 4 Disconnect the transfer roll cable B from the HVPS board Warning Use care when disconnecting the cable from the transformer on the HVPS The cable and connector can be easily damaged CAUTION There is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must...

Page 360: ...4 100 Service Manual 7002 xxx 5 Remove the HVPS mounting screws C 6 Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS ...

Page 361: ... 4 138 3 Remove the MPF lower deflector assembly See MPF lower paper deflector on page 4 117 4 Place the printer on its side 5 Gently pry the inner paper deflector from the left and right mounting posts A located on the bottom of the printer and remove the deflector 6 Disengage the two latches B on the upper part of the deflector from the upper edge of the frame C and lift to remove A B C C ...

Page 362: ...on page 4 138 2 Loosen the MPF lower front cover See Multipurpose feeder lower front cover assembly removal on page 4 71 3 Remove the inner paper deflector Inner paper deflector assembly removal on page 4 101 4 Disconnect the input sensor cable A from the input sensor B 5 Release the input sensor from its mounting and remove ...

Page 363: ...ge 4 15 2 Remove the flatbed scanner assembly See Flatbed scan assembly removal on page 4 38 3 Remove the paper tray 4 Remove the left door See Printer left side cover removal on page 4 56 5 Remove the outer shield See Printer outer shield removal on page 4 126 6 Place the printer on its back 7 Disconnect the cannot motor cable A from the system board J24 ...

Page 364: ...te the larger loop attaches to the side frame 9 Remove the C clip D that rests against the right side frame from the autocompensator pivot shaft 10 Disconnect the autocompensator sensor cable E from the assembly 11 Remove the autocompensator assembly mounting screw F 12 Slide the shaft to the right and push the shaft from the outside of the frame 13 Remove the integrated tray autocompensator assem...

Page 365: ...Remove the integrated tray and look underneath the printer for the autocompensator arm Pull the arm down 2 Press on the end of the tab A and pull the pick roll off the arm Repeat this step for the pick roll on the other side Next gently release the autocompensator arm Discard the used pick rolls ...

Page 366: ... the pick roll and align it with the tab on the arm There are two arrows on each pick roll Make sure the bottom arrow faces you as you align the recessed area with the tab 3 Push the pick roll onto the arm with the tab aligned Repeat this step on the other side to install the other pick roll 4 Gently release the autocompensator arm Insert integrated tray ...

Page 367: ...noperable Warning Never install and remove components listed above as a method of troubleshooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 Note Any time the interface card assembly is repl...

Page 368: ...cover removal on page 4 56 2 Remove the operator panel left side cover See Operator panel left cover assembly removal on page 4 61 3 Remove the two cables A 4 Remove the two screws B Note For model X642e you may need to carefully use a screw to disconnect the LCD display HV cable C Models X644e X646e Model X642e Model X642e ...

Page 369: ...ee Printer right cover removal on page 4 58 3 Remove the pass thru plate See Pass thru plate on page 4 74 4 Remove the LVPS mounting screws A from the rear of the center pan 5 Disconnect the LVPS to system board cable The cable is difficult to disconnect There are catches B that firmly hold latches on the LVPS card connector C CAUTION Unplug the printer before you begin ...

Page 370: ...mbly far enough out from the right side of the printer to disconnect the fuser to LVPS AC lamp cable D Warning The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal 7 Remove the low voltage power supply ...

Page 371: ...e the flatbed scanner assembly See Flatbed scan assembly removal on page 4 38 3 Remove the printer left side cover See Printer left side cover removal on page 4 56 4 Open the left side cover 5 Remove the outer shield See Printer outer shield removal on page 4 126 6 Remove the two screws A securing the upper plenum 7 Remove the upper plenum ...

Page 372: ...nual 7002 xxx 8 Clip the cable tie B Note Be careful not to damage any of the cables Note the location of the cable tie for later replacement 9 Disconnect the main fan to the system board C at J4 10 Remove the main fan ...

Page 373: ...shield removal models X644e X646e on page 4 131 2 Remove the screw securing the gear guard A 3 Remove the power take off shaft and spring See Power takeoff shaft and spring removal on page 4 126 4 Remove the developer drive assembly See Developer drive assembly removal on page 4 77 5 Lift and remove the cables from the cable hooks B ...

Page 374: ... drive assembly 10 Remove the main drive assembly Warning Whenever the main drive assembly is removed from the printer it must be handled very carefully Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come in contact with the grease in the gears Note Be sure the ...

Page 375: ... 1 Remove the two screws A on the rear of the MFP 2 Disconnect the cable B from the scanner control card 3 Remove the cable from the slot in the frame C 4 With a flathead screwdriver open the cable clamp D and remove the cable and the modem A C D B ...

Page 376: ...r deflector See MPF lower paper deflector on page 4 117 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 138 5 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 101 6 Remove the MPF solenoid assembly See MPF solenoid assembly removal on page 4 119 7 Remove the C clip A 8 Remove the washer and set it aside 9 Remove the MPF a...

Page 377: ...02 xxx Installation note Note the order of C clips bushing and washer when you reinstall MPF lower paper deflector 1 Remove the MPF lower cover 2 Remove the four screws securing the MPF lower paper deflector 3 Remove the defector ...

Page 378: ...ce Manual 7002 xxx MPF pick tire removal 1 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 138 2 Release the pick roll retaining tab A and slide the pick roll off the shaft A ...

Page 379: ... cover assembly removal on page 4 71 3 Remove the MPF lower paper deflector See MPF lower paper deflector on page 4 117 4 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 138 5 Remove the C clip A on the left side 6 Press the clips on the end of the shaft to remove the MPF tires B 7 Remove the C clip C on the shaft B C ...

Page 380: ...shing D Note The bushing fits into a detent E in the frame of the MPF arm assembly 9 Loosen the paper alignment screws F 10 Remove the C clip securing the MPF solenoid assembly on the shaft Note This C clip is very difficult to locate and remove F ...

Page 381: ...to the right until the left end of the shaft is clear of the frame and slide the MPF solenoid assembly from the shaft Installation note Be careful not to lose the washer H that is between the MPF solenoid assembly and the C clip It belongs to the MPF arm assembly H ...

Page 382: ...mbly See Upper paper deflector assembly removal on page 4 138 2 Remove the inner paper deflector assembly See Inner paper deflector assembly removal on page 4 101 3 Release the input paper sensor from its mounting and remove 4 Remove the left door 5 Remove the paper alignment assembly mounting screws A ...

Page 383: ...ocate the paper alignment assembly reference adjustment screw B through the left frame and remove the screw 7 Remove the paper alignment assembly Note Do the Paper alignment assembly adjustment on page 4 3 when you reinstall the assembly B ...

Page 384: ...iper cover assembly See Fuser wiper cover assembly removal on page 4 54 4 Remove the two screws A attaching the upper plenum and remove the upper plenum 5 Remove the screws from the upper cover See Upper cover removal printer on page 4 133 Note It is not necessary to remove the cover from the printer 6 Lift the left rear corner of the printer upper top cover to access the flag B and remove the fla...

Page 385: ...r shield See System board and inner shield removal models X644e X646e on page 4 131 2 Remove the paper size sensing board mounting screw A 3 Disconnect the paper size sensing board cable B from the board 4 Remove the paper size sensing board from the latch C 5 Remove the paper size sensing board C A B ...

Page 386: ...ve the power takeoff shaft and spring A through the bottom of the printer Printer outer shield removal 1 Remove the printer left door See Printer left side cover removal on page 4 56 2 Loosen the outer shield mounting screws A and remove the shield by sliding up A 202 A 202 ...

Page 387: ...See Upper cover removal printer on page 4 133 4 Disconnect the printhead cable A from the printhead assembly 5 Remove the four printhead mounting screws B and remove the printhead Note Do the Printhead assembly adjustment printer on page 4 2 whenever you remove or replace the printhead assembly or loosen the mounting screws CAUTION The laser scanning unit is not a serviceable FRU Replace the entir...

Page 388: ... xxx Redrive assembly removal 1 Remove the redrive door assembly 2 Remove the redrive exit cover 3 Remove the redrive assembly mounting screws A 4 Release the redrive assembly mounting latches B and remove the redrive assembly ...

Page 389: ... 58 4 Remove outer system board shield See Printer outer shield removal on page 4 126 5 Disconnect signature button cable from connector J14 on the system board 6 On models 200 210 400 410 remove the two screws A securing the blower duct 7 Remove the signature button contact assembly mounting screw B 8 Remove the assembly signature button contact assembly Note Be sure to route the cable in the sam...

Page 390: ...ng components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 1 Remove the outer shield See Printer outer shield removal on page 4 126 2 Disconnect all cables from the system board Note Sometimes cables may...

Page 391: ...shooting components Once a component has been installed in a printer it cannot be used in another printer It must be returned to the manufacturer Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 1 Remove the outer shield See Printer outer shield removal on page 4 126 2 Disconnect all cables from the system board Note Sometimes cabl...

Page 392: ...e and remove the toner sensor Transfer roll assembly removal Warning Be careful when handling the transfer roll Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 1 Open the upper front cover and remove the print cartridge 2 Unsnap the transfer roll assembly from the left pivot arm 3 Lift the transfer roll assembly toward the left and remove it from the pri...

Page 393: ... 4 Remove the right cover See Printer right cover removal on page 4 58 5 Remove the upper tray cover See Upper tray cover removal paper support on page 4 56 6 Remove the upper sub cover See Upper sub cover removal on page 4 55 7 Remove the fuser wiper cover See Fuser wiper cover assembly removal on page 4 54 8 Remove the two screws A attaching the upper plenum and remove the upper plenum 9 Remove ...

Page 394: ...7002 xxx 10 Remove the two screws D from the top of the right side 11 Remove the two screws E from the top of the left side 12 For those models with a hard disk X646e remove the hard disk See Hard disk removal on page 4 44 ...

Page 395: ...e the screw F through the back of the shield or from the position shown 14 Unlatch the front right and front left cover posts and remove the upper cover Note Make sure the paper bin full sensor G clears the opening will lifting the upper cover ...

Page 396: ...removal models X644e and X646e on page 4 67 7 Remove printer left side cover See Printer left side cover removal on page 4 56 8 Remove printer right side cover See Printer right cover removal on page 4 58 9 Remove the printer upper cover See Upper cover removal printer on page 4 133 10 Remove the C clips A from the upper front cover hinge assembly left and right hinge pins and remove the pins Note...

Page 397: ...e from the hinge arm 15 Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket 16 Lift the left pivot arm from the bracket and move the upper cover hinge assembly toward the left to clear the right upper cover pivot arm from the mounting bracket 17 Remove the upper front cover hinge assembly D ...

Page 398: ... cover are easily stressed or broken 2 Lift the left side to release the small tab A on the left and the MPF flag B and slide the upper paper deflector assembly to the right to unlatch the hooks C on the right Note Be careful not to put too much stress on the small tab A on the right 3 Lift to remove the upper paper deflector assembly Installation note Make sure the MPF flag B is in place ...

Page 399: ... side cover removal on page 4 56 2 Remove the operator panel left cover See Operator panel left cover assembly removal on page 4 61 3 Remove the USB cable A from the USB board assembly 4 Remove the two screws B securing the USB board assembly Note Models X644e X646e shown 5 Remove the USB card B A ...

Page 400: ...4 140 Service Manual 7002 xxx ...

Page 401: ...Locations and connections 5 1 7002 xxx 5 Locations and connections Locations Sensors flatbed Model X642e Models X644e X646e ...

Page 402: ...5 2 Service Manual 7002 xxx Sensors ADF Model X642e Models X644e X646e ...

Page 403: ...Locations and connections 5 3 7002 xxx Connections System board Models X644e X646e Model X642e ...

Page 404: ... 2 VIDEO 1 CN 3 Ground 4 LADJ2 5 VIDEO 0 CN 6 VIDEO 0 CN 7 Ground 8 5PHEAD 9 LPOW 10 Ground 11 LADJ CN 12 LPOW FB 13 LENA J3 Printhead HSYNC mirror motor 1 Ground 2 HSYNC CN 3 HSYNC ID 4 5 V dc 5 6 7 8 9 10 11 12 J4 Main fan 1 FANSTALL 2 Ground 3 MAINFAN J5 Cartridge fan 1 CARTFANSTAIL 2 Ground 3 CARTFAN J6 Hopper full output bin sensor 1 HOP FULL 2 Ground 3 HOP LED ...

Page 405: ... dc 7 THUMPRET 8 EXIT SNS 9 3 3 V dc 10 I2C CLK L5 11 I2C DAT L5 J14 Signature button 1 SM Cart 2 Ground J15 HVPS 1 ATSERVO 2 TXENABLE 3 XFR 4 24 V dc switched 5 CHARGE 6 Ground 7 DEV 8 Ground input sensor 9 INPUTSENSX 10 5 V dc switched Cartridge toner wheel sensor 11 5 V dc 12 TONER WHEELX 13 Ground System board see System board on page 5 3 connector pins Connector Pin no Signal ...

Page 406: ...HALL 1 3 BLDC_HALL 2 4 BLDC FG 5 Ground 6 5 V dc switched 7 BLDC WIND 8 BLDC WIND 1 9 BLDC WIND 2 J21 Autoconnect front bottom 1 Ground 2 5 V dc fused 3 Ground 4 24 V dc PTC OPT J23 MPF pick solenoid 1 MPFPick 2 24V dc J24 Autocomp motor 1 24 V dc 2 AUTOCOMP J25 Autoconnect bottom front 1 Ground 2 24VPTCOPT System board see System board on page 5 3 connector pins Connector Pin no Signal ...

Page 407: ...DER 10 5V dc J27 LVPS 1 5 V dc 2 5 V dc 3 5 V dc 4 Ground 5 Ground 6 Ground 7 Ground 8 Ground 9 Ground 10 Ground 11 24 V dc RAW 12 Ground 13 24 V dc RAW 14 24 V dc RAW 15 ZEROXING R 16 24 V dc RAW 17 HEAT 18 HEAT 19 Ground 20 L FAN DRV J28 MPF paper out 1 MPF POUT 2 Ground 3 MPF LED System board see System board on page 5 3 connector pins Connector Pin no Signal ...

Page 408: ...I 3 USB DI 4 Ground 5 Ground Printhead fan 1 24V dc 2 PH FAN Connector Pin no Signal static Bottom autoconnect 1 24 V dc 2 0 V dc 3 5 V dc 4 0 V dc 5 0 V dc 6 0 V dc Front autoconnect 1 0 V dc 2 0 V dc 3 0 V dc 4 5 V dc 5 0 V dc 6 24 V dc System board see System board on page 5 3 connector pins Connector Pin no Signal ...

Page 409: ... supply Fuser Board not a FRU Connectors J1 System board J2 Narrow media sensor J3 N A J4 Solenoid J5 Exit sensor J6 Thermistor Connector CN no Signal CN1 System board 1 Developer PWM 2 24 V dc Return 3 Charge PWM 4 24 V dc IN 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO OUT ...

Page 410: ...5 10 Service Manual 7002 xxx Interface card USB card Connector Pin no Signal J1 A1 to B62 N A J2 A1 to B62 N A Connector Pin no Signal CN2 1 5 Signals J2 USB signals ...

Page 411: ...ctor CN pin no Signal CN1 Fuser lamp AC 1 AC fuser lamp 2 Not used 3 AC fuser lamp CN2 DC output 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc ...

Page 412: ...anel card connector pins model X642e Connector CN pin no Signal J3 to touchscreen display 1 X DRIVE 5 V dc IN 2 X Y DRIVE 3 Y X DRIVE 4 Y X 5 V dc IN J5 Not used J7 Not used J10 to J15 on scanner control card 1 24 V dc 2 24 V dc 3 Ground 4 Ground 5 TXD 6 TXD 7 TXD232 N 8 RXD232 N 9 Ground 10 Ground 11 CLKTX 12 CLKTX Model X642e ...

Page 413: ... 5 V dc IN 2 BUTTON ADMIN 5 V dc default ground when pushed 3 Ground 4 Vo contrast wheel output 5 Vo contrast wheel output 6 Ground 7 VEE 24 V dc 8 VEE 24 V dc J15 1 5 V dc IN 2 BUTTON HOME 3 BUTTON HELP 5 V dc default ground when push Go 4 Ground J18 to CN1 on LCD inverter card 1 5 V dc BACKLIGHT CONTROL 2 Ground Operator panel card connector pins model X642e continued Connector CN pin no Signal ...

Page 414: ...Part of operator panel right cover assembly Operator panel card connector UICC 1 pins model X644e X646e Connector CN pin no Signal J3 to touchscreen display 1 X DRIVE 5 V dc IN 2 X Y DRIVE 3 Y X DRIVE 4 Y X 5 V dc IN J5 Not used 1 4 Signal J7 Not used 1 14 Signal Models X644e X646e ...

Page 415: ...Ground 10 Ground 11 CLKTX 12 CLKTX 13 NC TX2 14 NC TX2 15 NC TXI 16 NC TXI 17 MASTER RESET N 18 Ground J12 to touchscreen display 1 32 Signal J13 to CN1 on inverter card 1 12 V dc 2 12 V dc 3 Ground 4 Ground 5 BACKLITE CONTROL 6 PWM DIM 7 Ground 8 Ground Operator panel card connector UICC 1 pins model X644e X646e continued Connector CN pin no Signal ...

Page 416: ...panel card Model X642e 1 5 V dc BL 2 Ground CN1 to J13 on operator panel card Model X644e X646e 1 12 V dc 2 12 V dc 3 Ground 4 Ground 5 BACKLITE CONTROL Lamp on off control 6 PWM DIM Bright adjust 7 Ground 8 Ground CN2 to touchscreen display 1 HV DO NOT MEASURE 2 Not used 3 Not used 4 Not used 6 HV DO NOT MEASURE Model X642e Models X644e X646e ...

Page 417: ...or CN pin no Signal J1 to CN1 on flatbed interface card 1 MDC DET 2 25 V dc IN 3 25 V dc IN 4 25 V dc IN 5 Ground 6 nTOP FB 7 nTOP ADF 8 Ground 9 nSTART LINE 10 Ground 11 MDC TXD 12 MDC RXD 13 Ground 14 nADF Present 15 nCOVER CLOSED 16 Ground 17 FAN ON 18 FAN BACK 19 Ground Models X644e X646e Models X642e ...

Page 418: ... 1 Ground 2 MDC RXD 3 MDC TXD 4 5 V dc J5 Not used 1 Ground 2 VXADF RXD1 3 VXADF TXD1 4 5 V dc J7 To hard disk assembly model X646e only 1 12 V dc 2 Ground 3 Ground 4 5 V dc J12 to hard disk model X646e only 1 5 V dc 2 Ground 3 Signal 4 Signal 5 Signal 6 Signal 7 Signal 8 Signal 9 Signal 10 Signal 11 Signal 12 Signal 13 Signal 14 Signal 15 Signal 16 Signal Scanner control card connector pins conti...

Page 419: ... Signal 27 Signal 28 Signal 29 Signal 30 Ground 31 Signal 33 5 V dc 34 Ground 35 Signal 36 Signal 37 Signal 38 Signal 39 Signal 40 Ground J13 to J59 on modem card 1 5 V dc 2 Ground 3 3 3 V dc 4 3 3 V dc 5 Signal 6 Signal 7 Signal 8 Signal 9 Ground 10 Signal 11 Signal 12 Signal 13 Signal 14 Signal 15 Signal Scanner control card connector pins continued Connector CN pin no Signal ...

Page 420: ...P IRQ 24 IO WRITE 25 IO READ 26 MOD CS 27 Ground 28 MOD RDY 29 MOD PRES 30 RESET N J15 to operator panel card 1 MASTER RESET N 2 Ground 3 TX1 4 TX1 5 TX2 6 TX2 7 CLKTX 8 CLKTX 9 Ground 10 Ground 11 UITXD 12 UIRXD 13 TX0 14 TX0 15 Ground 16 Ground 17 24 V dc 18 24 V dc Scanner control card connector pins continued Connector CN pin no Signal ...

Page 421: ...ound 9 Ground 10 Ground 11 Ground 12 Signal 13 Signal 14 Ground 15 Signal 16 Signal 17 Ground 18 Signal 19 SDI 20 SEN 21 Signal 22 Ground 23 Signal 24 Signal 25 Ground 26 Signal 27 Signal 28 Signal 29 Signal 30 CCD CLAMP 31 CCD RESET 32 CCD PHRASE 33 CCD TRANSFER 34 CCD BW SELECT 35 24 V dc IN 36 Ground Scanner control card connector pins continued Connector CN pin no Signal ...

Page 422: ...12 ADFR CCD RESET 13 Ground 14 ADFR CCD CLAMP 15 Ground 16 ADFR CCD CLK 17 Ground 18 ADFR AFE RSAMP 19 Ground 20 ADFR AFE VSAMP 21 Ground 22 ADFR AFE D 23 ADFR AFE D 24 Ground 25 ADFR AFE D 26 ADFR AFE D 27 Ground 28 ADFR AFE D 29 ADFR AFE D 30 Ground 31 ADFR AFE D 32 ADFR AFE D 33 Ground 34 ADFR AFE SEN 35 ADFR AFE SCK 36 ADFR AFE SD1 Scanner control card connector pins continued Connector CN pin...

Page 423: ...F feed motor 1 A 2 25 V dc 3 Na 4 B 5 25 V dc 6 VBB CN3 to ADF scan motor 1 OUT A 2 25 V dc 3 OUT nA 4 OUT B 5 OUT nB 6 25 V dc CN5 to pick arm solenoid 1 SOL ON 2 25 V dc CN6 to flatbed interconnect card C1 Ground C2 Ground 1 MDC ON 2 25 V dc 3 25 V dc 4 nTOP ADF 5 nSTART LINE 6 MDC TXD 7 Ground 8 nCOVER CLOSED 9 OUT A 10 OUT A ...

Page 424: ...C RXD 25 nADF PRESENT 26 Ground 27 OUT nA 28 OUT nA 29 OUT nB 30 OUT nB 31 Ground 32 nFLAT LENGTH2 33 nHOME 34 FAN ON 35 5 V dc 36 Ground CN7 to cover closed and cover closing sensors 1 5 V dc IN 2 nCOVER CLOSING 3 Ground 4 5 V dc IN 5 nCOVER CLOSED 6 Ground CN8 to paper tray sensor 1 Ground 2 ADF WIDTH1 3 ADF WIDTH2 4 Ground 5 nADF LENGTH 6 5 V dc IN Motor drive board connector pins continued Con...

Page 425: ... n2ND SCAN 7 Ground 8 nADF COVER 9 5 V dc IN CN10 to jam remove sensor ADF paper present sensor interval sensor first scan sensor 1 Ground 2 nJAM REMOVE 3 5 V dc IN 4 Ground 5 nADF PRESENT 6 5 V dc IN 7 Ground 8 nADF INTERVAL 9 5 V dc IN 10 Ground 11 5 V dc IN 12 n1ST SCAN Motor drive board connector pins continued Connector CN pin no Signal ...

Page 426: ...Connector Pin no Signal J1 to CN6 on ADF motor drive card C1 Ground C2 Ground 1 MDC ON 2 25 V dc 3 25 V dc 4 nTOP ADF 5 nSTART LINE 6 MDC TXD 7 Ground 8 nCOVER CLOSED 9 OUT A 10 OUT A 11 OUT B 12 OUT B 13 Ground 14 nFLAT LENGTH1 15 nFLAT LENGTH3 16 Ground 17 FAN BACK Models X644e X642e Model X642e ...

Page 427: ...DC RXD 25 nADF PRESENT 26 Ground 27 OUT nA 28 OUT nA 29 OUT nB 30 OUT nB 31 Ground 32 nFLAT LENGTH2 33 nHOME 34 FAN ON J1 to CN6 on ADF motor drive card continued 35 5 V dc 36 Ground J2 to CN2 on ADF CCD module models X644e X646e 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Flatbed interconnect card connector pins continued Connector Pin no Signal ...

Page 428: ...8 Ground 9 nSTART LINE 10 Ground 11 MDC TXD 12 MDC RXD 13 Ground 14 nADF PRESENT 15 nCOVER CLOSED 16 Ground 17 FAN ON 18 FAN BACK 19 Ground 20 nRESET 21 3 3 V dc 22 Ground 23 Signal 24 Signal CN2 Flatbed scan motor 1 OUT A 2 25 V dc 3 out nA 4 OUT B 5 25 V dc 6 OUT nB Flatbed interconnect card connector pins continued Connector Pin no Signal ...

Page 429: ...NGTH2 6 5 V dc IN 7 Ground 8 nFLAT LENGTH3 9 5 V dc IN CN4 home sensor 1 Ground 2 nHOME 3 5 V dc IN CN5 C1 Ground C2 Ground 1 CCD ON 2 POWER SAVER 3 24 V dc IN 4 Ground 5 Ground 6 Ground 7 Ground 8 Ground 9 Ground 10 Ground 11 Ground 12 Signal 13 Signal 14 Ground Flatbed interconnect card connector pins continued Connector Pin no Signal ...

Page 430: ...gnal 19 SDI 20 SEN 21 Signal 22 Ground 23 Signal 24 Signal 25 Ground 26 Signal 27 Signal 28 Signal 29 Signal 30 CCD CLAMP 31 CCD RESET 32 CCD PHASE 33 CCD TRANSFER 34 CCD BW SE LECT 35 24 V dc IN 36 Ground Flatbed interconnect card connector pins continued Connector Pin no Signal ...

Page 431: ...dem card 1 5 V dc 2 Ground 3 3 3 V dc 4 3 3 V dc 5 Signal 6 Signal 7 Signal 8 Signal 9 Ground 10 Signal 11 Signal 12 Signal 13 Signal 14 Ground 15 Signal 16 Signal 17 Signal 18 Signal 19 Signal 20 Signal 21 Signal 22 Ground 23 DSP IRQ 24 IO WRITE 25 IO READ 26 MOD CS 27 Ground 28 MOD RDY 29 MOD PRES 30 RESET N ...

Page 432: ...5 32 Service Manual 7002 xxx ...

Page 433: ... area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication specifications No requirements for this printer Scheduled maintenance Maintenance kit The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval It is necessary to replace the fuser assembly transfer roller charge roll and pick tires at this...

Page 434: ...lowing with the cloth or swab Flatbed contact glass Flatbed white cushion Front flatbed white strip Glass slit in flatbed glass holder see step 4 4 Remove the flatbed glass holder and clean both sides of the glass slit See Upper glass holder removal on page 4 53 Warning Be careful not to touch the white calibration strip A on the underside of the scanner flatbed glass holder All models ...

Page 435: ...e cushion See Flatbed white cushion removal on page 4 32 6 Press the release lever to open the lower exit guide 7 Use the cloth or swab to clean the ADF CCD glass and back ADF white strip with the cloth or swab 8 Close the lower exit guide 9 Close the document cover Models X644e X646e ...

Page 436: ...6 4 Service Manual 7002 xxx ...

Page 437: ... Index column indicates that the part is procurable but is not pictured in the illustration NA Not available in the parts description column indicates the part is shown for identification purposes only and is not available as a FRU Model information used in the parts catalog Asm Index Part number Units mach OR Units option Units kit or pkg Description Model name Configuration Machine type Parts ca...

Page 438: ...7 2 Service Manual 7002 xxx Assembly 1 Covers printer model X642e ...

Page 439: ...w M3x10 3 Screw Sunk head 1 9 40X3303 1 1 Operator panel right cover assembly X642e includes Operator panel right cover Dial numeric pad key Control 1 Stop key Control 2 Go key Control 3 Clear key Hook operator panel right assembly Compression spring LCD operator panel cap UICC 1 card assembly Screw M3x8 2 Screw M3x8 2 10 40X0493 1 1 Multipurpose tray assembly 11 40X3301 1 1 LCD mono touchscreen d...

Page 440: ...7 4 Service Manual 7002 xxx Assembly 1 continued Covers printer model X642e ...

Page 441: ...ts kit or pkg Description 1 15 40X3304 1 1 LCD mono touchscreen inverter card X642e 16 40X0009 1 1 TLI ID serial number label blank 17 40X0470 1 1 Left cover assembly 18 40X0472 1 1 Left side cover NS 5 10 Parts packet cable ties PP 40X0174 NS 40X0050 2 1 Counterbalance spring NS 40X5651 1 1 Vent cover ...

Page 442: ...7 6 Service Manual 7002 xxx Assembly 2 Cover printer models X644e and X646e ...

Page 443: ... 1 Right hinge spring 1 9 40X0496 1 1 Operator panel right cover assembly X644e X646e includes Stop button 1 Go button 1 Clear button 1 LED cap 1 Dial number pad User interface control card assembly Compression spring Operator panel right cover Operator panel right side hook 10 40X0493 1 1 Multipurpose tray assembly 11 40X0494 1 1 LCD touchscreen display assembly X644e X646e 12 40X3313 1 1 Cover b...

Page 444: ...7 8 Service Manual 7002 xxx Assembly 3 Covers ADF scanner ...

Page 445: ... 1 Complete ADF assembly X644e X646e 2 40X3296 1 1 Complete ADF assembly X642e 3 40X0451 1 1 Document tray assembly X644e X646e 4 40X3297 1 1 Document tray assembly X642e 5 40X0452 1 1 ADF top cover assembly 6 40X0463 1 1 ADF scan cover 7 40X0465 1 1 ADF rear cover 8 40X0464 1 1 ADF front cover 9 1 1 Parts packet sensors PP 40X0481 ...

Page 446: ...7 10 Service Manual 7002 xxx Assembly 4 Frame 1 ...

Page 447: ...0X0065 4 1 Frame extension nut plate 2 40X0225 1 1 Right side hand holder 3 4 4 Parts packet PP 40X0165 4 40X0024 1 1 Right frame extension 5 40X0026 1 1 Right side frame ground contact 6 40X0025 1 1 Left frame extension 7 40X0060 1 1 External ground clip 8 40X0231 1 1 Left side hand holder 9 40X0285 1 1 Frame clip ...

Page 448: ...7 12 Service Manual 7002 xxx Assembly 5 Frame 2 ...

Page 449: ...1 Parts packet PP 40X0165 7 40X0048 1 1 Paper switch activate spring 8 40X0046 1 1 Paper size sensing board assembly 9 40X0049 1 1 Gear release link 10 40X0054 1 1 Main fan with cable 500 sheet output 11 40X0051 1 1 Standard bin level sensor 12 40X0052 1 1 Standard bin level sensor bracket 13 40X0058 1 1 Output paper level flag 14 40X0264 1 1 Standard bin level sensor cable 15 40X0232 1 1 Redrive ...

Page 450: ...7 14 Service Manual 7002 xxx Assembly 6 Frame 3 ...

Page 451: ...1 HVPS input sensor toner sensor cable assembly 7 40X0036 1 1 Toner sensor assembly 8 40X0306 1 1 High voltage contact kit including Charge roll contact 1 Doc TAR Dev contact 3 PC drum contact 1 Screw 5 Screw block 4 9 40X0213 1 1 Tray bias assembly 10 40X0021 2 1 Cartridge holddown assembly 11 40X0040 1 1 Upper paper feed deflector 12 40X0042 1 1 Inner paper feed deflector 13 40X0039 2 1 Develope...

Page 452: ...7 16 Service Manual 7002 xxx Assembly 7 Scanner automatic document feeder ADF pickup Asm Index Part number Units mach Units kit or pkg Description 7 1 40X0453 1 Pickup assembly ...

Page 453: ...art number Units mach Units kit or pkg Description 8 1 40X4656 1 1 Upper entrance guide kit including A Separator roller with hub B Torque limiter C Upper entrance guide D Sub ADF separator guide E Snap ring 2 40X4658 1 1 Sub ADF separator guide 3 40X4657 1 1 Entrance guide ...

Page 454: ...r ADF lower exit guide assembly Asm Index Part number Units mach Units kit or pkg Description 9 1 40X0460 1 1 Lower exit guide assembly X644e X646e 1 40X3311 1 1 Lower exit guide assembly X642e 2 40X0458 1 1 ADF CCD module assembly X644e X646e only ...

Page 455: ...g Description 10 1 40X0482 1 1 Belts including A Timing belt 52M194 B Timing belt 52M172 C Timing belt motor 52M292 D Timing belt second transport 52M152 E Timing belt first transport 52M132 Note Belt P N stamped on belt F Timing belt knob 52M172 2 40X0461 1 1 Feed motor ADF feed 3 40X0462 1 1 ADF scan motor assembly ...

Page 456: ...7 20 Service Manual 7002 xxx Assembly 11 Scanner ADF sensors ...

Page 457: ... arm assembly solenoid 2 40X0481 1 4 Parts packet sensors A Second scan sensor B Paper present C Interval sensor D First scan sensor E ADF top cover open F Flatbed cover open G Jam access door Note There are four different sensors in the parts packet some of the same sensors are used in different locations 3 40X0486 1 1 Motor driver card ...

Page 458: ...7 22 Service Manual 7002 xxx Assembly 12 Scanner flatbed ...

Page 459: ... assembly 8 40X3312 1 1 Flatbed interconnect card assembly X642e 9 40X0485 1 1 Flatbed interconnect card assembly X644e X646e 10 40X0490 1 1 Belt tension spring 11 40X0479 1 1 Flatbed CCD drive belt 12 40X0480 1 1 Flatbed scan motor including flatbed scan motor to flatbed interconnect card cable 13 40X0491 1 1 Flatbed paper size sensor assembly assembly includes 3 sensors X644e X646e 13 40X0491 1 ...

Page 460: ...r Units mach Units kit or pkg Description 13 1 40X0061 1 1 Laser printhead cable assembly 2 Parts packet PP 40X0165 printhead mounting screw 3 40X0062 1 1 Printhead assembly includes all cables CAUTION The printhead is not a serviceable FRU Do not disassemble the printhead ...

Page 461: ...1 1 Pick arm assembly 500 sheet 2 40X0069 1 1 Parts packet bellcrank assembly for 500 sheet tray Bellcrank 1 Spring 1 3 40X0070 2 2 Pick tires pick roll assembly 4 40X0072 1 1 Paper out flag 500 sheet tray 5 40X0215 1 1 Paper low out sensor card assembly 500 sheet 6 Parts packet PP 40X0165 hanger 7 40X0074 1 1 Paper size autocompensator cable ...

Page 462: ...7 26 Service Manual 7002 xxx Assembly 15 Paper feed multipurpose feeder ...

Page 463: ...r assembly 2 40X0310 1 1 Multipurpose feeder pick arm assembly with solenoid 3 40X0076 1 1 Pick roll assembly 4 40X0077 1 1 Multipurpose feeder paper out flag 5 1 Parts packet PP 40X0165 lower deflector mounting screw 8 mm 5 1 Parts packet PP 40X0165 lower deflector mounting screw 12 mm 5 1 Parts packet PP 40X0165 frame mounting screw NS 1 Parts packet PP 40X0165 pick roll shaft clip ...

Page 464: ...7 28 Service Manual 7002 xxx Assembly 16 Paper feed alignment ...

Page 465: ... 1 1 Paper feed alignment assembly paper feed 2 1 Parts packet PP 40X0165 clip ref ground mounting screw 3 40X0085 1 1 Reference ground clip 4 40X0086 1 1 Parts packet reference adjust Screw paper reference adjust 1 Washer paper reference adjust 1 Nut paper reference adjust 1 NS 1 1 Parts packet PP 40X0165 alignment asm mounting screw ...

Page 466: ...7 30 Service Manual 7002 xxx Assembly 17 Integrated 500 sheet paper tray ...

Page 467: ...number Units mach Units kit or pkg Description 17 1 40X0098 1 1 Tray assembly 500 sheet tray 2 40X0099 1 1 Side restraint 3 40X0182 4 1 Wear strip 4 40X0103 1 1 Pass thru plate 500 sheet tray 5 40X0183 1 1 Wear plate 500 sheet tray 6 40X0105 2 1 Restraint pad 7 40X0106 1 1 Back restraint ...

Page 468: ...7 32 Service Manual 7002 xxx Assembly 18 Drives Main drive and developer drive ...

Page 469: ... shaft 500 sheet 3 40X0112 1 1 Power takeoff shaft spring 4 40X0113 1 1 Bevel gear with grease packet and washer Bevel gear 1 Instruction sheet 1 Grease packet 1 washer 1 5 40X0114 1 1 Developer drive assembly 6 40X0115 Parts packet developer drive Developer drive shaft 1 shaft coupler gear 55 1 7 3 Parts packet PP 40X0165 developer drive ground screw NS 4 Parts packet PP 40X0165 gearbox mounting ...

Page 470: ...7 34 Service Manual 7002 xxx Assembly 19 Hot roll fuser ...

Page 471: ...40X0121 1 Fuser cover assembly kit including Thermistor 1 Thermostat 1 Left and right fuser lamp contact assemblies 1 5 Parts packet fuser mounting screw PP 40X0254 6 40X0239 1 Exit sensor flag spring kit including Spring 1 Flag 1 7 40X0236 1 1 Exit narrow media sensor cover 8 Parts packet PP 40X0165 9 40X0125 1 1 Exit sensor 10 40X0230 1 1 Exit sensor cable 11 40X0238 1 1 1 Narrow media flag spri...

Page 472: ...7 36 Service Manual 7002 xxx Assembly 20 Transfer charging ...

Page 473: ...assembly dual 3 40X0129 1 Parts kit right side charge roll link assembly 4 40X0130 1 1 Transfer roll assembly 5 40X0131 1 1 Transfer roll assembly right arm 6 40X0132 1 1 Transfer roll right spring 7 40X0133 1 1 Transfer pivot shaft 8 40X0134 1 1 Transfer roll left spring 9 40X0135 1 1 Transfer roll left arm NS 1 Parts packet PP 40X0165 charge roll screw NS 1 Parts packet PP 40X0165 C clip pivot s...

Page 474: ...7 38 Service Manual 7002 xxx Assembly 21 Electronics power supplies ...

Page 475: ...nds Cyprus Dominica Falkland Islands Gambia Ghana Gibraltar Grenada Guyana Hong Kong Iraq Ireland Isle of Man Jordan Kenya Kuwait Lebanon Liberia Malawi Malaysia Malta Mauritius Montserrat Nigeria Oman Pakistan Pitcairn Island UK Qatar Scotland Seychelles Sierra Leone Singapore St Kitts and Nevis St Lucia St Vincent and Grenadines Sudan Tanzania Trinidad and Tobago Uganda United Arab Emirates Unit...

Page 476: ...7 40 Service Manual 7002 xxx Assembly 22 Electronics card assemblies ...

Page 477: ...520 1 1 Interface card assembly 5 40X0510 1 1 Hard disk 4 pin power cable X646e 6 40X3310 1 1 System board assembly X642e Board ID M010 6030 6 40X2722 1 1 System board assembly network X644e X646e Board ID M010 6000 7 40X3477 1 1 Bar code card assembly X642e 7 40X2792 1 1 Bar code card assembly X644e X646e 7 40X2529 1 1 IPDS SCS TNe card assembly X644e X646e 7 40X2793 1 1 PRESCRIBE card assembly X...

Page 478: ...kg Description 23 1 40X0150 1 1 Outer shield 2 Parts packet PP 40X0165 INA cover mounting screw 2 Parts packet PP 40X0165 outer shield mounting screw 2 Parts packet PP 40X0165 inner shield mounting screw 3 40X0149 1 1 Inner shield assembly 4 40X0153 1 1 INA flat cover blank 5 40X0152 1 1 Ethernet shield blank ...

Page 479: ...mbly 24 Cabling diagram 1 Asm Index Part number Units mach Units kit or pkg Description 24 1 40X0223 1 1 HVPS input sensor toner sensor cable assembly 2 40X0160 1 1 MPF sensor cable 3 40X0264 1 1 Standard bin level sensor cable 1 3 2 ...

Page 480: ...bly 25 Cabling diagram 2 Asm Index Part number Units mach Units kit or pkg Description 25 1 40X0061 1 1 Laser printhead cable assembly 2 40X0074 1 1 Paper size autocompensator cable 3 40X0046 1 1 Paper size sensing board assembly 2 3 1 ...

Page 481: ... number Units mach Units kit or pkg Description 26 1 40X0034 1 1 Signature button contact assembly with cable 2 40X0156 1 1 Bottom front autoconnect cable assembly 3 40X0223 1 1 HVPS input sensor toner sensor cable assembly 4 40X0224 1 1 LVPS to system board cable assembly ...

Page 482: ...7 46 Service Manual 7002 xxx Assembly 27 Cabling diagram 4 model X642e ...

Page 483: ...C 2 card cable 8 pin 1C USB cable 1 1D Cover open switch cable from system board 1E LCD display to operator panel card cable 14 pin ribbon 1F Operator panel cable from SCC 1G Operator panel card to bezel card cable 4 pin 1H LCD display to operator panel card cable 4 pin 1J LCD display to LCD inverter card cable 2 pin 2 40X0162 1 1 System board to fuser board cable assembly 3 40X0163 1 1 Fuser AC l...

Page 484: ...7 48 Service Manual 7002 xxx Assembly 28 Cabling diagram 4 models X644e X646e ...

Page 485: ...ver open switch cable 1 1C Operator panel cable to SCC card 1 See full description of upper front cover hinge assembly on page 7 7 2 40X0511 1 1 Inverter 32 pin cable operator panel card to LCD inverter card 3 40X0512 1 1 32 pin cable LCD display to operator panel cable 4 40X0162 1 1 System board to fuser board cable assembly 5 40X0163 1 1 Fuser AC lamp to LVPS cable assembly 6 40X0226 1 1 Fuser c...

Page 486: ...7 50 Service Manual 7002 xxx Assembly 29 Cabling diagram 5 1 2 3 3 3 4 5 ...

Page 487: ... number Units mach Units kit or pkg Description 29 1 40X0310 1 1 Multipurpose feeder pick arm assembly with solenoid 2 40X0159 1 1 Main drive motor cable assembly 3 40X0249 1 1 EP DC fan assembly 4 40X0054 1 1 Main fan with cable 500 sheet output 5 40X0161 1 1 Ground cable ...

Page 488: ...7 52 Service Manual 7002 xxx Assembly 30 Cabling diagram 6 model X642e ...

Page 489: ...1 1 Parts packet sensors home sensor 3 40X0487 1 1 Flatbed CCD ribbon cable 4 40X0507 1 1 Modem 30 pin cable 5 NA 1 1 Flatbed interconnect card CN1 to SCC card cable J15 NOT AVAILABLE AS A FRU 6 NA 1 1 Flatbed interconnect card CN4 to home sensor cable NOT AVAILABLE AS A FRU 7 40X0480 1 1 Flatbed scan motor including flatbed scan motor to flatbed interconnect card cable 8 NA 1 1 Flatbed paper size...

Page 490: ...7 54 Service Manual 7002 xxx Assembly 31 Cabling diagram 6 models X644e X646e ...

Page 491: ...LE AS A FRU 3 40X0481 1 1 Parts packet sensors home sensor 4 40X0487 1 1 Flatbed CCD ribbon cable 5 40X0509 1 1 Hard disk IDE 50 pin cable X646e 6 40X0510 1 1 Hard disk 4 pin power cable X646e 7 40X0507 1 1 Modem 30 pin cable 8 NA 1 1 Scanner control card J1 to flatbed interconnect card CN1 cable NOT AVAILABLE AS A FRU 9 NA 1 1 Scanner control card J28 to flatbed interconnect card CN5 NOT AVAILABL...

Page 492: ...s kit or pkg Description 32 1 40X0481 1 1 Parts packet sensors A Second scan sensor B Jam access door sensor C First scan sensor D Interval sensor 2 40X0456 1 1 Pickup arm assembly solenoid 3 40X0486 1 1 Motor driver card 4 NA 1 1 Paper present sensor cable NOT AVAILABLE AS A FRU 1A 2 1B 1C 1D 3 4 ...

Page 493: ...scan sensor C Flatbed cover closed sensors cover closing cover closed D ADF paper length sensor 2 NA 1 1 Feed motor cable NOT AVAILABLE AS A FRU 3 40X0506 1 1 MDC to flatbed interconnect card 36 pin cable 4 NA 1 1 Flatbed cover open sensor cable NOT AVAILABLE AS A FRU 5 N A 1 1 Transport motor cable NOT AVAILABLE AS A FRU 6 N A 1 1 Paper length sensor cable includes paper width sensor assembly X64...

Page 494: ... sensors cover closing cover closed D ADF paper length sensor 2 NA 1 1 Feed motor cable NOT AVAILABLE AS A FRU 3 40X0502 1 1 ADF CCD to flatbed interconnect card 36 pin cable X644e X646e 4 40X0506 1 1 MDC to flatbed interconnect card 36 pin cable 5 NA 1 1 Flatbed cover open sensor cable NOT AVAILABLE AS A FRU 6 N A 1 1 Transport motor cable NOT AVAILABLE AS A FRU 7 N A 1 1 Paper length sensor cabl...

Page 495: ...ring 4 56P4129 1 1 Paper out arm 250 sheet 5 3 3 Parts packet screws PP 99A0263 auto comp mounting 5 4 4 Parts packet screws PP 99A0263 6 40X3232 1 1 Pick arm assembly 7 56P1228 1 1 Bellcrank 250 sheet paper tray 8 99A1929 2 1 Bellcrank spring 250 sheet paper tray 9 40X0070 2 2 Pick roll assembly 10 40X3234 1 1 Bin low sensor with cable 11 40X3233 1 1 Option pass thru sensor 12 99A0272 1 1 Drive s...

Page 496: ...tion Units kit or pkg Description 36 1 40X3231 1 1 Tray assembly option 250 sheet 2 40X3235 1 1 Side restraint 250 sheet tray 3 56P1279 1 4 Wear strips 4 56P4230 1 1 Clip 250 sheet pass thru 5 99A0121 1 1 Plate 250 sheet tray wear 6 99A0120 1 2 Restraint pad 7 40X3236 1 1 Back restraint 250 sheet tray ...

Page 497: ... 1 Pick arm assembly 500 sheet 4 56P1228 1 1 Bellcrank spring arm 5 56P2540 1 1 Bellcrank spring 500 sheet option tray 6 40X0070 1 2 Pick roll assembly 7 40X3244 1 1 Option pass thru sensor 8 99A0275 1 1 Power takeoff spring 9 99A0447 1 1 Drive shaft 500 sheet 10 40X3245 1 1 Bin low sensor with cable 11 40X3247 1 1 Base assembly 500 sheet 12 56P4145 1 1 Paper out arm 500 sheet drawer 13 99A0063 1 ...

Page 498: ...its option Units kit or pkg Description 38 1 56P4150 1 1 Complete tray assembly 500 sheet 2 56P4137 1 1 Side restraint 500 sheet tray 3 99A0292 1 4 Wear strips 4 56P4196 1 1 Pass thru plate 5 56P4195 1 1 Plate 500 sheet wear 6 99A0120 1 2 Restraint pad 7 56P4147 1 1 Back restraint 500 sheet tray ...

Page 499: ...Parts catalog 7 63 7002 xxx Assembly 39 Duplex option Asm Index Part number Units option Units kit or pkg Description 39 1 56P4102 1 1 Duplex assembly 500 sheet ...

Page 500: ...7 64 Service Manual 7002 xxx Assembly 40 Envelope feeder 1 ...

Page 501: ...Parts catalog 7 65 7002 xxx Assembly 40 Envelope feeder Asm Index Part number Units option Units kit or pkg Description 40 1 40X3248 1 1 Complete envelope option ...

Page 502: ...7 66 Service Manual 7002 xxx Assembly 41 High capacity feeder 1 ...

Page 503: ...tion assembly A4 2 99A1818 1 1 Wear dimple strip 3 99A0681 4 1 Wear strip 4 40X3254 1 1 Front door assembly 5 56P4157 1 2 Door hinge 6 4 1 Parts packet nuts PP 99A0676 6 32 hinge mounting nut 7 4 1 Parts packet washers PP 99A0677 hinge mounting flat washer 8 4 1 Parts packet washers PP 99A0677 hinge mounting star washer 9 40X3252 1 1 2000 sheet option control card assembly 10 99A0658 2 2 Door magn...

Page 504: ...sembly 42 High capacity feeder 2 Asm Index Part number Units option Units kit or pkg Description 42 1 99A0654 1 1 Paper low switch 2 Parts packet nuts PP 99A0676 3 40X3262 1 1 AC external jumper cord 4 40X2669 1 1 Power supply board ...

Page 505: ...Parts catalog 7 69 7002 xxx Assembly 43 High capacity feeder 3 Asm Index Part number Units option Units kit or pkg Description 43 1 99A0275 1 1 Power takeoff spring 2 99A0272 1 1 Drive shaft 250 sheet ...

Page 506: ...eeder 4 Asm Index Part number Units option Units kit or pkg Description 44 1 3 Parts packet screws PP 99A0263 auto comp assembly mounting screw 2 40X3255 1 1 Pick arm assembly 2000 sheet 3 40X0070 2 2 Pick roll assembly 4 40X3233 1 1 Option pass thru sensor ...

Page 507: ...et NS 40X1377 1 1 MarkNet 8030 Fiber Ethernet NS 40X1378 1 1 MarkNet 8050 wireless print server 802 11g US NS 40X1562 1 1 MarkNet 8050 wireless print server 802 11g non US NS 40X0291 1 1 Parallel 1284 B interface card NS 40X0290 1 1 RS232C serial interface card NS 40X2529 1 1 IPDS SCS TNe card assembly X644e X646e NS 56P4116 1 1 Universal adjustable tray assembly 400 sheet NS 40X3478 1 1 Forms car...

Page 508: ...7 72 Service Manual 7002 xxx ...

Page 509: ...3 8 buttons accessing service menus 3 1 Button Test 3 8 upper front cover including buttons 7 7 upper front panel button kit 7 7 C cable diagrams 7 43 7 44 7 45 7 46 7 48 7 50 cabling diagrams 7 52 7 56 7 57 CACHE Test 3 9 Configuration ID 3 19 configuration menu accessing 3 1 3 24 ADF Edge Erase 3 29 Automatic Scanner Registration 3 30 available menus 3 24 Disk Encryption 3 32 Energy Conserve 3 2...

Page 510: ...ial wrap tests 3 10 INPUT TRAY TESTS Feed Test 3 13 Sensor Test 3 14 OUTPUT BIN TESTS Feed Test 3 14 Sensor Tests 3 15 PRINT TESTS input source 3 7 Prt Quality Pgs 3 7 PRINTER SETUP Configuration ID 3 19 Defaults 3 17 Edge to Edge 3 19 engine settings 3 18 Envelope Enhance 3 18 Model Name 3 18 Page Count 3 18 Par x Strobe Adj 3 19 Perm Page Count 3 18 Serial Number 3 18 REGISTRATION 3 5 Quick Test...

Page 511: ...moval 4 97 fuser wiper cover assembly parts catalog 7 3 7 7 removal 4 54 G gap adjustment 3 21 4 2 gear release link removal 4 98 H handle left cover 4 72 7 11 right cover 4 72 7 11 hard disk parts catalog 7 40 removal 4 44 Help button service check 2 154 high voltage power supply HVPS connectors 5 9 parts catalog 7 38 removal 4 99 high capacity feeder service check 2 141 high capacity input tray ...

Page 512: ... 1 1 2 7 1 X642e cabling diagram parts catalog 7 46 operator panel 2 2 X644e X646e cabling diagram parts catalog 7 48 operator panel 2 2 modem card connectors 5 31 parts catalog 7 40 status messages 2 40 motor driver board connectors 5 23 MPF arm assembly 4 116 MPF lower paper deflector 4 117 MPF solenoid assembly 4 119 multipurpose feeder parts catalog 7 26 removal 4 71 N narrow media sensor See ...

Page 513: ...ls integrated tray autocompensator 4 105 pick tire integrated tray autocompensator pick roll 4 105 MPF 4 118 power takeoff shaft and spring 4 126 PPDS Emulation 3 27 preventive maintenance 6 1 print quality pages 3 7 3 26 print registration 3 5 printhead adjustment 4 2 parts catalog 7 24 removal 4 127 service check 2 165 Q quality printer all black page 2 160 background 2 162 banding 2 163 black b...

Page 514: ...r support 4 56 USB card 4 139 scanner ADF and flatbed ADF attach screws 4 13 ADF CCD module assembly 4 14 ADF complete assembly 4 15 ADF front cover 4 6 ADF pick assembly 4 7 ADF rear cover 4 7 ADF top cover 4 9 ADF upper entrance guide assembly 4 16 CCD belt tension spring 4 19 CCD beth removal 4 17 cover closed actuator 4 22 cover closing actuator 4 21 document tray assembly 4 23 flatbed CCD mod...

Page 515: ...ace card 2 148 LCD touchscreen contrast control model X642e 2 149 LCD touchscreen display models X644e X646e 2 149 main drive 2 153 main fan 2 119 network card 976 xx 2 155 network card 977 xx 2 155 operator panel Help and Home buttons model X642e 2 154 operator panel Menu button X642e 2 154 operator panel right cover assembly 2 154 options 2 155 output bin sensor 2 156 paper feed 2 156 paper size...

Page 516: ...assembly parts catalog 7 36 removal 4 132 service check 2 172 U UICC 1 model X642e operator panel card 2 149 2 154 5 12 model X644e X646e operator panel card 5 14 UICC 2 LCD inverter board 5 16 unique tools 1 17 upper front cover hinge assembly removal 4 136 upper paper deflector 4 138 upper sub cover removal 4 55 upper tray cover removal 4 133 USB card connectors 5 10 location 2 4 removal 4 139 u...

Page 517: ...unterbalance spring 7 5 7 7 40X0051 Standard bin level sensor 7 13 40X0052 Standard bin level sensor bracket 7 13 40X0054 Main fan with cable 500 sheet output 7 13 7 51 40X0058 Output paper level flag 7 13 40X0059 Extension guide 7 13 40X0060 External ground clip 7 11 40X0061 Laser printhead cable assembly 7 24 7 44 40X0062 Printhead assembly includes all cables 7 24 40X0065 Frame extension nut pl...

Page 518: ...0X0159 Main drive motor cable assembly 7 51 40X0160 MPF sensor cable 7 43 40X0161 Ground cable 7 51 40X0162 System board to fuser board cable assembly 7 47 7 49 40X0163 Fuser AC lamp to LVPS cable assembly 7 47 7 49 40X0165 Parts packet 7 11 7 13 7 15 7 24 7 25 7 27 7 29 7 33 7 35 7 37 7 39 7 42 40X0171 Cartridge shipping package empty 7 71 40X0174 Parts packet cable ties 7 5 7 7 40X0179 Nyogel 74...

Page 519: ...ay assembly X644e X646e 7 9 40X0452 ADF top cover assembly 7 9 40X0453 Pickup assembly 7 16 40X0456 Pickup arm assembly solenoid 7 21 7 56 40X0457 Complete flatbed scanner assembly X644e X644e 7 23 40X0458 ADF CCD module assembly X644e X646e 7 18 40X0460 Lower exit guide assembly X644e X646e 7 18 40X0461 Feed motor ADF feed 7 19 40X0462 ADF scan motor assembly 7 19 40X0463 ADF scan cover 7 9 40X04...

Page 520: ...56MB memory option 7 71 40X1510 512MB memory option 7 71 40X1512 Japanese font card 7 71 40X1513 Simplified Chinese font card 7 71 40X1514 Traditional Chinese font card 7 71 40X1515 Korean font card 7 71 40X1562 MarkNet 8050 wireless non US 7 71 40X1564 32MB Flash card 7 71 40X2529 IPDS SCS TNe card assembly X644e X646e 7 41 7 71 40X2590 Fuser assembly w 220 V lamp 7 35 40X2591 Fuser assembly w 10...

Page 521: ... code card assembly X644e X646e 7 71 40X4243 LVPS AIO 115 V ac 7 39 40X4244 LVPS AIO 220 V ac 7 39 40X4275 High voltage power supply 7 39 40X4656 Upper entrance guide kit 7 17 40X4657 Entrance guide 7 17 40X4658 Sub ADF separator guide 7 17 56P1228 Bellcrank spring arm 7 61 56P1228 Bellcrank 250 sheet paper tray 7 59 56P1279 Wear strips 7 60 56P2540 Bellcrank spring 500 sheet option tray 7 61 56P4...

Page 522: ...I 14 Service Manual 7002 xxx 99A1818 Wear dimple strip 7 67 99A1929 Bellcrank spring 250 sheet paper tray 7 59 ...

Page 523: ...Lexmark X644e X646e Wiring diagram AIO printer ...

Page 524: ...Lexmark X642e Wiring diagram AIO scanner ...

Page 525: ...Lexmark X644e X646e Wiring diagram AIO scanner ...

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