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4022-XXX Service Manual and repair guide
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LexmarkTM W812 4022-XXX
· 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.
4022-XXX
Edition: October 2002
The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION "AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Optra Forms is a trademark of Lexmark International, Inc. PostScript is a registered trademark of Adobe Systems Incorporated. Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 2002. All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550. U.S.A. U.S.A. P/N 12G9161
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Table of Contents
Laser Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Preparing for shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Overview of Print Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Paper Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Generating Print Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Transmission of Driving Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Driving Power Transmission to Paper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Driving Power Transmission to Roll Registration Metal and Rubber . . . . . . . 1-14 Driving Power Transmission to Drum and Transfer Roller . . . . . . . . . . . . . . . . 1-15 Driving Power Transmission to Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . 1-16 Driving Power Transmission to Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Printer Component Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 250-Sheet Paper Tray/Cassette Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Pick/Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame and Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 1-19 1-24 1-27 1-30 1-32
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Operator Panel Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-2 2-2 2-2 2-2
User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Service Error Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Service Check Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Service Checks Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 How to Use the Service Checks Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
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How to Follow a Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Notes on Using Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Symptom Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Inoperative Printer Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Erratic Printer Operation Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Blank, Erratic, or Inoperative Operator Panel Service Check . . . . . . . . . . . . . 2-16 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Using Diagnostic Test Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Light (Undertoned) Prints Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Blank Prints Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Black Prints Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Vertical Band Deletions Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Horizontal Band Deletions Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Vertical Streaks Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Horizontal Streaks Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 Spot Deletions Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 Background Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Toner on Back of Print Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Skewed Image Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Damaged Prints Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Unfused Image or Image Easily Rubs Off of Page Service Check . . . . . . . . . 2-33 Repetitive Marks on Each Page Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-34 Lead Edge Registration is Not Correct Service Check . . . . . . . . . . . . . . . . . . 2-35 Side-to-Side Registration is Not Correct Service Check . . . . . . . . . . . . . . . . . 2-36 Electrical Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Using the Operator Panel Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Entering Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Exiting Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 LCD Hardware Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 DRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 DRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Parallel Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Duplex Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
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Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Storage Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing the Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 3-17 3-17 3-17 3-18
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Viewing and Resetting the Maintenance Page Count . . . . . . . . . . . . . . . . . . . 3-22 Setting Printer Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Notations in the Removals and Replacement Procedures . . . . . . . . . . . . . . . . 4-1 Front Cover Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Left Cover Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Top Cover Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Card Cage Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Duplex Output Feed Roller Assembly and Clutch Removal . . . . . . . . . . . . . . . 4-9 Engine Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Fuser Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 HVPS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 HVPS Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Left Cartridge Guide Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Lower Duplex Out Guide Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 LVPS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Main Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 MPF Input Paper Feed Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 MPF Paper Present Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 MPF Pick Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 MPF Pick Roll Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 MPF Separator Pad Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
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MPF Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 MPF Tray Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Optional 250-Sheet Pick Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Optional 500-Sheet Pick Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Optional 500-Sheet Separator Pad/Lift Plate Assembly Removal . . . . . . . . . . 4-28 Paper Size Dial and Card Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Paper Tray Lift Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Printhead Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Rear Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Right Cartridge Guide Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 RIP Controller Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Toner Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Transfer Guide Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Transfer Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Tray 1 Present Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 Tray 1 Pick Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Tray 1 Pick Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Tray 1 Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Upper Duplex Out Guide Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Upper Card Cage Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 250-Sheet Separator Pad Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
P/J Location Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Harness Route Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Printer Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Wiring Diagram Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 General Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Engine Board <-> LVPS <-> Interlock SW and Fan (1/3) . . . . . . . . . . . . . . . . 5-18 Engine Board <-> LVPS <-> Interlock SW and Fan (1/3) . . . . . . . . . . . . . . . . 5-19 Engine Board <-> LVPS <-> Interlock SW and Fan (3/3) . . . . . . . . . . . . . . . . 5-20 Engine Board <-> Fuser Assembly and LVPS (1/2) . . . . . . . . . . . . . . . . . . . . 5-20 Engine Board <-> Printhead and Toner Cartridge (1/3) . . . . . . . . . . . . . . . . . . 5-22 Engine Board <-> Printhead and Toner Cartridge (3/3) . . . . . . . . . . . . . . . . . . 5-24 Engine Board <-> HVPS <-> Toner Cartridge (BCR and Mag. Roll), Transfer Roller and Detack Saw (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Engine Board <-> HVPS <-> Toner Cartridge (BCR and Mag. Roll), Transfer Roller and Detack Saw (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Engine Board <-> HVPS <-> Clutch Registration, Sensor Registration and Sensor Option1 (1/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Engine Board <-> Solenoid T1/MPF, Sensor LP/MPF NP/FDR LP/FDR NP, Clutch Turn, and SW D2X (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Engine Board <-> Solenoid T1/MPF, Sensor LP/MPF NP/FDR LP/FDR NP, Clutch Turn, and SW D2X (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Engine Board <-> LVPS <-> Main Motor (1/1) . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Engine Board <-> Sensor Toner (1/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
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Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
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Laser Notices
Laser Advisory Label
Caution - Laser radiation when open. Avoid exposure to beam. The following laser label may be affixed to this printer as shown.
Printhead Label
Label
HVPS Cover
Laser Notices
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210 C / 410 F
Label Fuser Asm
Laser Notices
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1. Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.
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Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher 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 durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.
Avis relatif à l'utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I. Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d'un laser de Classe IIIb (3b) (arséniure de gallium d'une puissance nominale de 5 milliwatts) émettant sur des longueurs d'onde comprises entre 770 et 795 nanomètres. L'imprimante et son système laser sont conçus pour impossible, dans des conditions normales d'utilisation, d'entretien par l'utilisateur ou de révision, l'exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .
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Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825-1. I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all'arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d'onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.
Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos 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 nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.
Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1. Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.
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Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.
Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt 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 Subchapter J määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä. VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.
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Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke å betrakte 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 estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d'IEC 60825-1. Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d'arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d'ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d'un nivell de classe I durant una operació normal, durant les tasques de manteniment d'usuari ni durant els serveis que satisfacin les condicions prescrites.
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Japanese Laser Notice
Chinese Laser Notice
Laser Notices
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Korean Laser Notice
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Safety Information
· The safety of this product is based on testing and approvals of the original design · ·
and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.
Consignes de Sécurité
· La sécurité de ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées. Les consignes d'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.
· ·
Norme di sicurezza
· La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e · ·
dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.
Sicherheitshinweise
· Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des
ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.
· ·
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Pautas de Seguridad
· La seguridad de este producto se basa en pruebas y aprobaciones del diseño · ·
original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. La información sobre 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.
Informações de Segurança
· A segurança deste produto baseia-se em testes e aprovações do modelo original e · ·
de componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
Informació de Seguretat
· La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny
original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. La informació pel manteniment d'aquest producte està 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.
· ·
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Preface
This manual contains maintenance procedures for service personnel only. It is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions. 2. Diagnostic Information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs). 3. Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems. 4. Repair Information provides instructions for making printer adjustments and removing and installing FRUs. 5. Connector Locations 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.
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1. General Information
The LexmarkTM W812 printer is a mid-range mono laser printer available in two models:
· 4022-100 is a base model of the W812 with 16MB of standard memory and USB/ ·
parallel port connectors. 4022-110 is a network model of the W812 with 32 MB of standard memory and USB/ Ethernet 10BaseT/100BaseTX network port connectors.
Product features include:
· · · · · ·
A3 support 26 ppm Memory expandable up to an additional 256MB Optional 250-sheet drawer Optional 500-sheet drawer Optional Unit
The product supports the following operating systems:
· · · · · · ·
Windows 95/98/Me Windows NT 4.0 Windows 2000 Windows XP Macintosh OS 8.6-9.x Macintosh OS X (10.1.2) UNIX/Linus
Maintenance Approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error message, service checks, and diagnostic aids to determine the printer problem and repair the failure. After you complete the repair, perform tests as needed to verify the repair.
Tools Required
The removal and replacement procedures described in this manual require the following tools and equipment:
· · · · · · ·
Flat-blade screwdriver #1 Phillips screwdriver #2 Phillips screwdriver Needlenose pliers Diagonal pliers Spring hook Analog or digital multimeter
General Information
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Acronyms
BCR CM CSU DIMM DRAM EDO EP EPROM ESD FG FRU GB HVPS LASER LCD LD LED LVPS MROM NVRAM OEM PC POR POST RIP ROM SDRAM SRAM UPR V ac V dc TTL Bias Charge Roll Charging and Metering Customer Setup Dual Inline Memory Module Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Erasable Programmable Read-Only Memory Electrostatic Discharge Frame Ground Field Replaceable Unit Gigabyte High Voltage Power Supply Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Laser Diode Light-Emitting Diode Low Voltage Power Supply Masked Read Only Memory Nonvolatile Random Access Memory Original Equipment Manufacturer Photoconductor Power-On Reset Power-On Self Test Raster Imaging Processor Read-Only Memory Synchronous Dynamic Random Access Memory Static Random Access Memory Used Parts Return Volts alternating current Volts direct current Transistor-Transistor Logic
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Preparing for shipping
When a printer is first installed, two transfer roll stops (bright orange in color) are removed before the toner cartridge can be installed. These transfer roll stops prevent roll from coming loose during shipping. Whenever the printer is to be shipped, reinstall the stops.
Left
Transfer Roll Stop
Right
Transfer Roll Stop
Transfer Roll Assembly
Transfer Roll Assembly
General Information
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Principles of Operation Overview of Print Process
The printer provides a electrophotographic process function to print image on paper with video signals sent from the controller board to the engine board. The electrophotographic process consists of the following seven steps. 1. Charge - Equally assigns negative charge on the drum surface by the bias charge roll. 2. Exposure - The laser scanner scans the drum surface and generates an invisible electrostatic latent image on the drum surface using super-fine laser beams modulated according to signals sent from the controller. 3. Development - Draws toner toward an electrostatic latent image on the drum surface and creates a visible toner image. 4. Transcription - Transcribes a toner image from the drum surface to paper. 5. Exfoliation - Cast off paper from the drum surface by partially neutralizing charge on paper. 6. Fusing - Permanently fuses a toner image by heat and pressure. 7. Cleaning - Eliminates the remaining toner from the drum surface.
Paper Enters
1. Charge
2. Exposure
3. Development
4. Transfer
5. Detack
6. Fusing
Paper Exits
Xerographic cycle 7. Cleaning
Cycle repeats for the next print
Rotating the drum, the drum surface passes six steps (charge, exposure, development, transcription, exfoliation, and cleaning), creates a toner image, and transcribes the created image on paper. Paper passes three steps (transcription, exfoliation, and fusing) by the paper transfer mechanism. When paper is positioned as shown in image, toner image is transcribed from the drum surface to paper, and then fused.
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The illustrations show the major components directly related to the print process and paper transfer.
Back-up Roll
Hot Roll
6 FUSING
Cleaning Blade
5 DETACK
7 CLEANING
BCR
1 CHARGE
Detack Saw Transfer Roller
4 TRANSFER
Drum
2 EXPOSURE
Laser Beam
CM Blade Mag.Roll Paper
3 DEVELOPMENT
General Information
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Fuser Assembly
Heat Roll
Front
Pressure Roll Drum Transfer Roller Mag. Roll Toner Cartridge Printhead
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In the exposure step, thin laser beam scans the drum surface which was negatively charged in the charging step of the previous process. The laser beam emitted by the laser diode of the printhead scans from end to end of the drum through the rotating polyhedron mirror (Polygon Mirror: 6 or 12 sides) and lens. Radiation from the laser beam is adjusted according to the video signal from the controller. The laser beam irradiated to the drum excites the electron going toward the conductor and generates a pair of electronic holes in the light transmission layer. As the electronic holes move to the surface of the light transmission layer when the electron moves toward the body in the drum along the electric field, the negative charge at that part decreases and invisible electrostatic latent image is generated. Toner is absorbed to the electrostatic latent image and developed. Toner absorbed to the drum is attracted by the positive electric charge supplied by Transfer Roller and transcribed on the paper and the drum goes to the separating and cleaning process. In the cleaning step, residual toner is removed from the drum surface as the surface is prepared for the next cycle. The toner is scraped off the drum surface by the cleaning blade. Note: The toner rubbed off in the cleaning step is collected in the recovery toner compartment separated from the unused toner. The transcription ratio is 90% or more, but it varies depending on the image cover range and environment conditions such as the temperature and humidity. The used toner cannot be reused. Note: At the starting time for each print process, the entire drum surface is scanned with laser beams, and the charge remaining on the drum surface from the preceding print step is removed completely. Note: At the starting and ending times of the continuous print process, the negative highvoltage is applied to the Transfer Roller. If residual toner is on the Transfer Roller surface in the preceding print step, it is returned onto the drum surface to clean the Transfer Roller surface.
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Paper Transfer
Paper is supplied from tray 1 or chute MPF, and carried to the printer along the paper route shown in the illustration. The optional duplex assembly has an individual motor (bracket assembly motor duplex) to transfer paper.
Tray 1
MPF
Roll Assembly Tray 1
Roll Assembly MPF
Roll Pinch Registration (lower)
Roll Pinch Registration (upper)
Roll Registration Metal Roll Registration Rubber Chute Assembly Transfer Transfer Roller Drum Toner Cartridge Heat Roll Pressure Roll
Roll Assembly Decurler Roll Pinch
Roll Assembly Exit Roll Pinch Fuser Assembly
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The illustration below shows the major components directly related to the paper route and paper transfer. See "Options" for the major components related to the paper route and paper transfer when the optional devices (Tray 2, Tray 3, and Duplex) are attached to the printer.
Exit Sensor
Roll Pinch Exit
Exit Roll
Heat Roll
Front
Pressure Roll Drum Transfer Roller Roll Registration Metal Roll Registration Rubber
Sensor Registration
Roll Assembly Tray 1
Roll Assembly MPF
Generating Print Image
The printers attached to the network, the network interface card (NIC) of the printer connected to network receives packet signals from a network client or server in a bit stream, and decomposes the received packet signals into a data format for the layer where data is sent to the controller. The controller processes the data sent from the NIC in the same way as of the data received from the host computer through a parallel port. Data received from the NIC or parallel port is called host data. The controller board buffers host data in the lustered bit image or converts host data of the page description language (PDL) into the lustered bit image data. The controller board sends the lustered bit image data to the engine board line by line each time laser beams are scanned. The signal that transfers image data (/VDO signal) is converted into an LVDS signal by the engine board, and sent to the printhead as a P.DATA+P.DATA signal. The printhead
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converts the signal into laser beams, and radiated as super fine laser beams. The laser beams are turned on and off according to a video signal. Laser beams, that are emitted from the surface of the rotating polygon mirror, are collectively irradiated on the drum surface of the EP cartridge. An electrostatic latent image is then generated on the drum surface.
Transmission of Driving Power
The driving power is generated by the Motor Assembly (component of the Main Drive Assembly), and transferred to the printer components, that requires the mechanical driving power, through the gear and gear train in the Main Drive Assembly. As shown in the following illustrations, the driving power is distributed to the toner cartridge, chute assembly transfer, Roll Assembly MPF, Roll assembly tray 1, optional feeder, and fuser assembly through the gear in the drive assembly. The driving power transmitted to the chute assembly transfer drives the roll registration metal and roll registration rubber. The driving power transmitted to the toner cartridge drives the drum, and it is transmitted to the Transfer Roller of the chute assembly transfer. The driving power transmitted to the fuser assembly drives the heat roll, and it is further transmitted to the roll assembly exit by the gear decurler.
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Motor Assembly
Gear 2 Gear 3 Gear 4 Gear 15 Gear 16
Clutch Registration
Gear 5 Gear 10 Gear 11 Gear 12 Gear 13 Gear 14 Gear 8 Gear 9 Gear 6 Gear 7
Gear Clutch
Main Drive Assembly
Drum Gear (EP Cartridge)
Gear Registration (Roll Registration Rubber) Gear Registration Rubber Gear Registration Metal Chute Asm Transfer
Gear 40
Clutch Turn /Gear Turn (Roll Asm Turn /Shaft Turn 14) Gear 24 Turn R
Gear IDL HR
Transfer Roller
Gear 40 Pick Up T1
Gear HR
Gear Decurler Gear 23 MSI (to Feeder Asm Opt) Clutch Assembly Spring Gear 40 Pick Up MSI
Gear Idler
Gear Exit Fuser Assembly
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Front
Gear Idler Dup In Clutch Asm Spring Gear Idler Gear Exit Fuser Assembly Gear Decurler Gear HR Gear IDL HR Gear 9 Gear 8 Gear 7 Gear 6 Motor Asembly Gear 5 Gear 10 Gear 11 Drive Assembly Clutch Turn /Gear Turn (Roll Asm Turn /Shaft Turn 14) Gear 24 Turn R (to Feeder Asm Opt) Gear 23 MPF Gear 40 Pick Up MPF Gear 40 Gear 40 Pick Up T1 Gear 4 Gear 3 Gear 2 Drum Gear (EP Cartridge)
Gear 12
Gear 13 Gear 16 Gear 14 Gear 15
Gear Clutch Clutch Registration
Gear Registration (Roll Registration Rubber) Gear Registration Rubber
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Driving Power Transmission to Paper Feeder
The driving power generated by the motor assembly is transmitted from the gear 14 of the main drive assembly to the roll assembly MPF and roll assembly tray 1 via the gear 40. Each time the solenoid MPF or solenoid T1 functions, the gear 40 pick up MPF or solenoid T1 is pulled by the spring pick up or spring pick up T1, and rotates by one turn, engaging with gear 14 in the gear 23 MPF or main drive assembly. After one turn ends, the system releases the engagement with the gear 14 in the gear 23 MPF or main drive assembly. When the roll assembly MPF or tray 1 driven by the gear 40 pick up MPF or solenoid T1 rotates by one turn, a sheet of paper is supplied from the tray assembly MPF or cassette assembly 250 to the printer.
Front
Motor Assembly
Gear 5 Gear 10 Gear 11 Drive Assembly Gear 12 Gear 13 Gear 14 Gear 23 MPF Gear 40 Gear 40 Pick Up T1 Gear 40 Pick Up MPF
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Driving Power Transmission to Roll Registration Metal and Rubber
The driving power generated by the motor assembly is transmitted from gear 16 to the clutch registration in the main drive assembly. When the clutch registration functions, the driving power is transmitted to the gear registration by the gear clutch to drive the roll registration rubber. The driving power is then transmitted from the right gear registration rubber of the roll registration rubber to the gear registration metal to drive the roll registration metal.
Front
Motor Assembly
Gear 5 Gear 10 Gear 11 Drive Assembly Gear 12 Gear 13 Gear 14 Gear 23 MPF Gear 40 Gear 40 Pick Up T1 Gear 40 Pick Up MPF
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4022-XXX
Driving Power Transmission to Drum and Transfer Roller
The driving power generated by the motor assembly is transmitted from gear 4 of the main drive assembly to the drum of the toner cartridge. The driving power is then transmitted from the drum to the Transfer Roller. The connection of the shaft of gear 4 (that transmits the driving power) with the drum is controlled by the cover open cam driven by opening and closing the top cover. The driving power is not transmitted to the toner cartridge unless the top cover is closed.
Front
Drum Gear (EP Cartridge)
Gear 4 Transfer Roller Gear 3 Gear 2 Motor Assembly
Main Drive Assembly
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Driving Power Transmission to Fuser Assembly
The driving power generated by the motor assembly is transmitted from gear 9 of the main drive assembly to the fuser assembly. The connection of gear 8 and gear 9 (that transmit the driving power) with the fuser assembly is controlled by the cover open cam driven by opening and closing the top cover. The driving power is transmitted only when the top cover is closed.
Gear Idler Dup In
Clutch Assembly Spring
Gear Idler
Gear Exit
Front
Fuser Assembly
Gear Decurler Gear HR Gear IDL HR Gear 9 Gear 8 Gear 7 Gear 6 Motor Assembly Gear 5
Main Drive Assembly
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Driving Power Transmission to Roll Assembly
The driving power generated by the motor assembly is transmitted from gear 11 of the main drive assembly to the clutch turn, The driving power drives the duplex output feed roll reinserted to print the second side of paper transferred from the duplex assembly. The driving power is then transmitted to the feeder assembly option 250 or feeder assembly 500 by gear 24 turn R attached to the right of the duplex output feed roll or shaft turn 14.
Front
Motor Assembly
Gear 5 Gear 10 Gear 11
Main Drive Assembly
Clutch Turn (Duplex Output Feed Roll /Shaft Turn 14) Gear 24 Turn R (to Feeder Assembly Option)
Printer Component Function 250-Sheet Paper Tray/Cassette Assembly
Guide Paper Left, Guide Paper Right - Adjusts to the left and right to fit to different paper sizes. These components hold paper at the specified positions on the left and right respectively.
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Guide End - Adjusts forward and backward to fit to different paper sizes. These components hold paper at the specified positions forward and backward respectively. The size of paper in the cassette must be transmitted to the printer control unit as a set value by the dial paper size. Plate Lift L Plate Lift R - Mounted at the end of the cassette, the plate lifts are pushed up when the cassette is inserted into the printer. Lift Plate - The force for pushing up the lift plate is supplied by the springs connected to the plate lift. Pushing up the lift plate assures the contact between the supplied paper and pick rolls. Separator Pad - Applies the friction force to the lower side of paper preventing multiple sheets from being picked simultaneously by the pick roll. This component is to be replaced each 100,000 sheets.
Plate Lift L
Lift Plate Separator Pad
Guide Paper L
Plate Lift R
Guide Paper R Guide End
Front
Paper Tray/Cassette Assembly
Lift Plate
Plate Lift L and R
Front
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Paper Pick/Feed
Tray Present Switch - When the 250 sheet paper tray is inserted to the specified position, the end of the tray presses the tray present switch, and the printer recognizes the tray is inserted. Tray 1 Empty Flag - When sheets of paper in the 250 sheet paper tray are used up, the end of the tray 1 empty flag drops in the opening of the lift plate, and the flag shades the tray empty sensor. Tray 1 Empty Sensor - Senses whether paper is set in the 250 sheet paper tray at the position of the tray 1 empty flag, and converts the sensing result into an electric signal. When the sensor receives the light, the NO PAPER1 signal (paper setting state) is set low. MPF Empty Flag - When sheets of paper are used up in the MPF tray, the end of the drops in the opening in the center of the MPF tray, and the flag shades the sensor. MPF Empty Sensor - Senses whether paper is set in the MPF tray at the position of the MPF actuator, and converts the sensing result into an electric signal. When the sensor receives the light, the NO PAPER MPF signal (paper setting state) is set low. MPF Separator Pad - Applies the friction force to the lower side of paper and prevents multiple sheets from being picked simultaneously. This component is to be replaced each time 100,000 sheets are printed. Tray 1 Pick Roll - Supplies paper from the 250-paper tray to the printer. The rotation is always stopped by the tray 1 solenoid; however, when the solenoid is energized, this unit turns once to supply paper. The pick roll is to be replaced each time 100,000 sheets are printed. MPF Pick Roll - Supplies paper from the MPF tray to the printer. The rotation is always stopped by the MPF solenoid; however, when the solenoid is energized, this unit turns once to supply paper. The pick roll is to be replaced each time 100,000 sheets are printed.
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MPF Pick Roll
Tray 1 Pick Roll
Tray Present Switch
MPF Separator Flag MPF Empty Flag
MPF Empty Sensor
Tray 1 Empty Sensor
Tray 1 Empty Flag
Front
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MPF Empty Flag
MPF Empty Sensor
MPF Pick Roll
Tray 1 Pick Roll
Front
Tray 1 Present Switch Tray 1 Empty Sensor Tray 1 Empty Flag
Optional Feeder Drive Gear - Transmits the driving power generated by the main drive assembly to the optional 250- or 500-sheet optional feeder. Duplex Output Feed Roll Clutch - Determines a timing for supplying paper from the duplex assembly to the lower paper guide assembly. When paper is supplied from the optional feeder, this clutch is also energized, and the driving power is transmitted to the optional feeder. Duplex Output Feed Roll Assembly - The driving power is transmitted to this unit by energizing the duplex output feed roll clutch, and this unit transfers paper from the duplex assembly to the lower paper guide assembly. Duplex Output Sensor Flag - An actuator sensing that paper is present at the duplex output feed roll assembly. Duplex Output Sensor - Senses whether paper is present at the duplex output feed roll assembly.
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Front
Duplex Output Feed Roll Clutch Duplex Output Sensor Duplex Output Feed Roll Assembly Duplex Output Sensor Flag
Transfer Roller - The Transfer Roller is driven by the drum gear, coming into contact with the drum of the toner cartridge. The Transfer Roller applies the positive charge onto the back of paper when paper moves between the Transfer Roller and drum. A negatively charged toner image is drawn by the positive charge on the backside of paper, and transcribed from the drum surface to the paper face. Metal and Rubber Registration - Roll rotation is controlled by the registration roller clutch, and paper is positioned with an image of the drum surface. Detack Blade - Applies the negative charge to the back of paper to partially neutralize the positive charge, and cast off paper from the drum surface. Varistor - Installed between the frame and Transfer Roller, this component helps reduce noise that can alter the voltage level on the Transfer Roller. Toner Low Sensor - Residual toner in the toner cartridge is measured with the electromagnetic sensor and a warning for replacement is issued (optional).
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Detack Blade Rubber Registration Roll
Transfer Roller
Varistor Metal Registration Roll
Registration Sensor
Front
Registration Sensor Flag
Registration Sensor Flag
Registration Sensor
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Toner Low Sensor
Front
Fuser
The fuser assembly contains a fusing component and a component for ejecting printed paper from the printer. It also has a function that reverse-inserts paper to the duplex assembly when the optional duplex assembly is attached to the printer.
Hot Roll - A metallic coating tube that is heated by the internal lamp to heat paper passing between this roll and the backup roll. Using this heat, toner is fixed to the paper. Backup Roll - A metallic shaft coated with rubber that applies pressure to paper between this roll and the hot roll. Temperature Sensor - A thermistor of which resistance changes as the temperature changes. This sensor, in contact with the surface of the hot roll, monitors its temperature. The surface temperature of the hot roll is held in the specified range by turning on and off the power of the lamp using a signal sent from this sensor. This signal is also used to prevent overheating. Thermostat - Connected to the lamp in series, this unit prevents overheating. When overheating of the fuser cannot be prevented via the temperature sensor, the thermostat cuts off power to the lamp.
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Hot Roll Fingers - Peels the front edge of paper from the hot roll so that paper does not wind round the hot roll. Fuser Diode - A negative charge may build up on the lamp. The charge may alter image quality during fusing. The fuser diode flows the charge to the frame ground. Fuser Exit Sensor - Detects whether paper arrives at, or is ejected from, the exit area in the rear of the Fuser. When the sensor receives the light (paper setting state), the /EXIT is set low.
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Fuser Diode
Temperature Sensor Assembly Fuser Assembly
Thermostat
Lamp
Fuser Exit Sensor Flag
Hot Roll Fingers Fuser Exit Sensor
Backup Roll
Hot Roll
Front
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Chute Change Direction Duplex Assembly Fuser Assembly
Front
Fuser Exit Roll Fuser Exit Sensor
Hot Roll Backup Roll Hot Roll Fingers Hot Roll
Fuser Exit Sensor Flag
Chute Change Direction Duplex Assembly
Fuser Exit Roll
Duplex Sensor Flag
Front
Duplex Sensor
Frame and Drive
Main Drive Assembly - Consists of the motor assembly that generates the mechanical driving power of the printer and optional feeders and gears (that transmit the driving power to each portion in the printer). Registration Roller Clutch - An electromagnetic clutch that provides the driving power to the registration rolls.
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The clutch functions at a specified time after the arrival of paper is detected by the registration sensor, and rotates the registration rolls. Cover Open Link and Cam - A mechanism that controls the transmission of the driving power from the main drive assembly to the fuser assembly. When the top cover is opened, the cam presses down gear 8 and gear 9 in the main drive assembly to cut off the connection with the gear IDL HR in the fuser assembly As the respective parts to which gear 8 and gear 9 are attached move up and down, the shaft of gear 4 moves to the left and right via the cam mechanism, and the driving power is connected to, or disconnected from, the toner cartridge drum.
Cover Open Link
Cover Open Cam
Rear
Main Drive Assembly
Registration Roller Clutch
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Top Cover
Fuser Assembly Cover Open Link Cover Open Cam Main Drive Assembly
Gear IDL HR
Gear 8
Gear 9
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Top Cover
Front
Cover Open Link Cover Open Cam Toner Cartridge
Main Drive Assembly Gear 4
Cover Open Cam Gear 4
Cover Open Link Main Drive Assembly Toner Cartridge
Front
Right
Xerographics
The toner cartridge consists of the following five major components. Drum: An aluminum cylinder coated with optical conductive materials. This coating is charged via the HVPS and discharges when exposed to light. BCR (Bias Charge Roll): Evenly applies a charge on the drum surface, and erases a pattern (remained in the preceding step) of which charge reduces.
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Developer Roll: Supplies the drum with toner from the agitator. CM Blade (Charging and Metering Blade): Applies the negative charge to toner on the developer roll. Cleaning Blade: Takes away toner remaining on the drum surface after the image is transferred to the paper. The toner cartridge is equipped with a circuit for turning on and off the printhead power. If the toner cartridge is not mounted in the printer, the 5 V dc power circuit for generating a laser is disconnected from the printer.
Toner Cartridge
Cartridge Present Cable
Front
The printhead consists of the three components: Laser Diode (LD), Scanner Assembly, and printhead card assembly. The LD Assembly generates laser beams. The generated laser beams are set on and off by a print data signal. The light source of laser is a semiconductor laser diode of the nominal maximum output 4 mW. The Scanner Assembly consists of a 6- or 12-side Polygon Mirror and Scanner Motor. The Polygon Mirror is fixed to the shaft of the Scanner Motor.
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The Scanner Motor rotates the Polygon Mirror at a specified speed. The rotating mirror reflects laser beams onto the rotating drum surface through the lens and mirror, and scans laser beams from an end to another on the drum surface. One scan operation is performed for each side of the Polygon Mirror. The Scanner Motor is driven by a 3-phase full-wave current linear signal. The current of the coil for each phase is switched by the amplifier matrix, within the printhead card assembly, using a signal sent from the phase detector terminal of the Motor. A latent image of one line is generated by turning on and off laser beams and scanning them from one end to another on the drum surface. A flat image is generated by repeating the scanning of laser beams while the drum is rotating. The resolution in the scanning direction (from the right to the left) is determined by the motor speed and LD pulse rate. The resolution in the paper path direction (from the top to the bottom) is determined depending on the rotation speed of the scanner motor. (As the scanning speed is higher, the next line is scanned more quickly.)
Paper Path 600 dots/inch
600 scans/inch
Electrical
Interlock Switch - A safety switch that stops the supply of 24V dc power from the LVPS to the engine card while the top cover is open. Fan - Ventilates the inside of the printer to prevent overheating. LVPS - Generates a low DC voltage (5V and 3.3V for logical circuit, 5 V-LD for laser diode and 24 V for solenoid and clutch) from the ac power. The LVPS, that consists of the fan control circuit and fuser lamp switch circuit, functions with a signal sent from the engine card assembly. HVPS - Generates AC and DC high voltage to supply the charger (BCR), developing unit Transfer Roller, and (Detack Blade).
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Engine Card Assembly - Controls all the printer operations according to signals from RIP card sensors and switches. The engine card has 7 major functions: 1. 2. 3. 4. 5. 6. 7. Communication with RIP card Communication with optional feeders Communication with optional duplex assembly Information reception from printer sensors and switches Printhead, fuser, and main drive assembly control Control of print process Distribution dc power from LVPS to other electric parts
Tray 1 Paper Size Card Assembly - Contains a size switch to set the size of paper supplied in tray 1.
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HVPS
LVPS
Fan Interlock Switch
HVPS
RIP Card Assembly
Engine Card Assembly
Front
Tray 1 Paper Size Card Assembly
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Top Cover Assembly
Interlock Switch
Top Cover Assembly
Front
Interlock Switch
Gene