Lexmark W812 Service Manual
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Lexmark W812 Service Manual

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TM
Lexmark
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.

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Summary of Contents for Lexmark W812

  • Page 1 Lexmark 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.
  • Page 2 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.

  • Page 3: Table Of Contents

    4022-XXX Table of Contents Laser Notices ............ix Safety Information .
  • Page 4 4022-XXX How to Follow a Service Check ........2-11 Notes on Using Service Checks .
  • Page 5 4022-XXX Input Tray Tests ........... . 3-13 Input Tray Feed Test .
  • Page 6 4022-XXX MPF Solenoid Removal ......... . 4-24 MPF Tray Assembly Removal .
  • Page 7 4022-XXX Preventive Maintenance ............Safety Inspection Guide .
  • Page 8 4022-XXX viii...

  • Page 9: Laser Notices

    4022-XXX 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...
  • Page 10 4022-XXX 210 C 410 F Fuser Asm Label 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.
  • Page 11 4022-XXX 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...
  • Page 12 4022-XXX 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.
  • Page 13 4022-XXX 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.
  • Page 14 4022-XXX 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...
  • Page 15 4022-XXX Japanese Laser Notice Chinese Laser Notice Laser Notices...
  • Page 16 4022-XXX Korean Laser Notice Service Manual...

  • Page 17: Safety Information

    4022-XXX 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.
  • Page 18 4022-XXX 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. •...
  • Page 19 4022-XXX Safety Information...

  • Page 20: Preface

    4022-XXX 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.

  • Page 21: General Information

    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: •...

  • Page 22: Acronyms

    4022-XXX Acronyms Bias Charge Roll Charging and Metering Customer Setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Frame Ground Field Replaceable Unit Gigabyte HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display...

  • Page 23: Preparing For Shipping

    4022-XXX 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 Right Transfer Roll Stop...

  • Page 24: Principles Of Operation

    4022-XXX 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.
  • Page 25 4022-XXX The illustrations show the major components directly related to the print process and paper transfer. Back-up Hot Roll Roll Cleaning CLEANING FUSING Blade CHARGE DETACK Drum Laser Beam Detack Saw Transfer Roller EXPOSURE TRANSFER CM Blade DEVELOPMENT Mag.Roll Paper General Information...
  • Page 26 4022-XXX Front Fuser Assembly Heat Roll Pressure Roll Toner Cartridge Printhead Drum Transfer Roller Mag. Roll Service Manual...
  • Page 27 4022-XXX 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.

  • Page 28: Paper Transfer

    4022-XXX 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 Roll Assembly Tray 1 Roll Assembly MPF...

  • Page 29: Generating Print Image

    4022-XXX 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.

  • Page 30: Transmission Of Driving Power

    4022-XXX 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.
  • Page 31 4022-XXX Motor Assembly Gear 2 Gear 5 Gear 3 Gear 6 Gear 10 Gear 4 Gear 11 Gear 7 Gear 15 Gear 12 Gear 16 Gear 13 Gear 8 Gear 9 Gear 14 Clutch Registration Gear Clutch Main Drive Assembly Clutch Turn Drum Gear Gear Registration...

  • Page 32: Service Manual

    4022-XXX Front Clutch Asm Gear Idler Gear Exit Gear Idler Spring Dup In Drum Gear (EP Cartridge) Fuser Assembly Gear Decurler Gear HR Gear 4 Gear IDL Gear 3 Gear 2 Gear 9 Gear 8 Gear 7 Gear 6 Gear 23 MPF Motor Asembly Gear 40 Pick Up...

  • Page 33: Driving Power Transmission To Paper Feeder

    4022-XXX 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.

  • Page 34: Driving Power Transmission To Roll Registration Metal And Rubber

    4022-XXX 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.

  • Page 35: Driving Power Transmission To Drum And Transfer Roller

    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.

  • Page 36: Driving Power Transmission To Fuser Assembly

    4022-XXX 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.

  • Page 37: Driving Power Transmission To Roll Assembly

    4022-XXX 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.
  • Page 38 4022-XXX 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.

  • Page 39: Paper Pick/Feed

    4022-XXX 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.
  • Page 40 4022-XXX MPF Pick Roll Tray 1 Pick Roll Tray Present Switch MPF Separator Flag MPF Empty Flag MPF Empty Sensor Tray 1 Empty Flag Tray 1 Empty Sensor Front 1-20 Service Manual...
  • Page 41 4022-XXX MPF Empty Sensor MPF Empty Flag MPF Pick Roll Tray 1 Pick Roll Front Tray 1 Present Switch Tray 1 Tray 1 Empty Empty Flag Sensor Optional Feeder Drive Gear - Transmits the driving power generated by the main drive assembly to the optional 250- or 500-sheet optional feeder.
  • Page 42 4022-XXX Front Duplex Output Feed Roll Clutch Duplex Output Duplex Output Feed Roll Assembly Sensor 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.
  • Page 43 4022-XXX Detack Blade Rubber Registration Roll Transfer Roller Varistor Metal Registration Roll Registration Sensor Front Registration Sensor Flag Registration Registration Sensor Sensor Flag 1-23 General Information...

  • Page 44: Fuser

    4022-XXX 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.
  • Page 45 4022-XXX 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.
  • Page 46 4022-XXX Fuser Diode Temperature Sensor Assembly Fuser Assembly Thermostat Lamp Fuser Exit Hot Roll Fingers Sensor Flag Fuser Exit Sensor Backup Roll Hot Roll Front 1-26 Service Manual...

  • Page 47: Frame And Drive

    4022-XXX Chute Change Direction Fuser Assembly Duplex Front Assembly Fuser Exit Roll Fuser Exit Sensor Hot Roll Fuser Exit Sensor Flag Backup Roll Hot Roll Fingers Hot Roll Chute Change Direction Duplex Assembly Fuser Exit Roll Front Duplex Sensor Duplex Flag Sensor Frame and Drive...
  • Page 48 4022-XXX 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...
  • Page 49 4022-XXX Top Cover Fuser Assembly Cover Open Gear IDL Link Cover Open Main Drive Assembly Gear 9 Gear 8 1-29 General Information...

  • Page 50: Xerographics

    4022-XXX Top Cover Front Cover Open Link Toner Cover Cartridge Open Main Drive Assembly Gear 4 Cover Open Cam Cover Open Link Main Drive Assembly Gear 4 Toner Cartridge Right Front Xerographics The toner cartridge consists of the following five major components. Drum: An aluminum cylinder coated with optical conductive materials.
  • Page 51 4022-XXX 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.

  • Page 52: Electrical

    4022-XXX 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.
  • Page 53 4022-XXX 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. Communication with RIP card 2. Communication with optional feeders 3. Communication with optional duplex assembly 4.
  • Page 54 4022-XXX LVPS HVPS Interlock Switch HVPS RIP Card Assembly Engine Card Assembly Tray 1 Paper Size Card Assembly Front 1-34 Service Manual...
  • Page 55 4022-XXX Top Cover Assembly Interlock Switch Top Cover Assembly Interlock Switch Front 1-35 General Information...
  • Page 56 4022-XXX 1-36 Service Manual...

  • Page 57: Diagnostic Information

    4022-XXX 2. Diagnostic Information Start 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. Make sure your fingers are not under the printer when you lift or set the printer down.

  • Page 58: Status Screen

    4022-XXX Status Screen The status screen provides the operator with information on the current state of the printer. This screen includes the capability to display a warning message. Ready Ready <warning> Ready Screen The above is a representation of the operator panel display when the printer is in the Ready state.

  • Page 59: User Error Messages

    4022-XXX User Error Messages User Error Message Explanation 200 Paper Jam Paper is jammed in or behind any of the paper trays or Open Top Cover multipurpose feeder. 200 Paper Jam Check Trays 201 Paper Jam Open Top Cover 201 Paper Jam Check Trays 202 Paper Jam Paper is jammed underneathe the toner cartridge.
  • Page 60 4022-XXX User Error Message Explanation 35 Res Save Off Deficient The printer lacks the memory needed to enable Memory Resource Save. This message usually indicates too much memory is allocated for one or more of the printer link buffers. Press Go to disable Resource Save and continue printing.
  • Page 61 4022-XXX User Error Message Explanation 39 Complex Page The page may not print correctly because the print information on the page is too complex. Press Go to clear the message and continue printing the job. The job may not print correctly. Press Menu to open the Job Menu and cancel the current job.
  • Page 62 4022-XXX User Error Message Explanation 54 Std Par ENA Connection The printer has lost the connection to an external print Lost server (also called an external network adapter or ENA). 54 Par <x> ENA Connection Make sure the cable connecting the ENA and the printer Lost is securely attached.
  • Page 63 4022-XXX User Error Message Explanation 63 Unformatted Disk The printer detects an unformatted hard disk. Press Go to clear the message and continue printing. Format the disk before performing any disk operations. To format the disk, select Format Disk from the Utilities Menu. If the error message remains, the hard disk may be defective and require replacing.

  • Page 64: Service Error Code Table

    4022-XXX Service Error Code Table Second Line Description/Action Code Message RIP Software Unrecoverable RIP software error. May be the result of a code malfunction, or failure of the RIP controller board. Engine Flash An attempt was made to program the flash memory on the engine board, and the programming failed.
  • Page 65 4022-XXX Second Line Description/Action Code Message Memory Error The RAM in slot 1 on the RIP board is bad. Replace the failing RAM card. Memory Error The RAM in slot 2 on the RIP board is bad. Replace the failing RAM card.

  • Page 66: Service Check Table

    4022-XXX Service Check Table Symptom Action Inoperative printer Go to “Inoperative Printer Service Check” on page 2-14. Erratic printer operation Go to “Erratic Printer Operation Service Check” on page 2-15. Blank, erratic, or inoperative operator panel Go to “Blank, Erratic, or Inoperative Operator Panel Service Check”...

  • Page 67: Service Checks Flowchart

    4022-XXX Service Checks Flowchart How to Use the Service Checks Flowchart • Follow your problem to the individual Primary Service Check that corresponds to your error code, printer operation problem, or print image problem. • Follow the instructions presented in the Service Check. •...

  • Page 68: Notes On Using Service Checks

    4022-XXX Notes on Using Service Checks 1. Unless indicated otherwise, the instruction “switch on printer main power” means for you to switch on printer power and let the printer proceed through power-on diagnostics and warm-up until it is online and ready to print. 2.

  • Page 69: Symptom Service Checks

    4022-XXX Symptom Service Checks Before entering the service checks: 1. Is the AC power provided at the electrical outlet within specifications for this printer; either 110 V ac or 220 V ac? 2. Is the ac power cord in good condition; neither frayed nor broken? 3.

  • Page 70: Inoperative Printer Service Check

    4022-XXX Inoperative Printer Service Check Before beginning this service check, remove all attached options to see if the problem goes away. If it does, isolate the failing option by attaching each one, one at a time and testing the printer. Step Actions and Questions AC POWER CORD INSPECTION...

  • Page 71: Erratic Printer Operation Service Check

    4022-XXX Step Actions and Questions LVPS 24V CHECK Go to step 8 Replace the LVPS. Check for DC voltage between FG and the following jack locations with cables plugging into each jack removed: J101-5 J103-1 J106-1 Is there approximately 24V between each of the pins and RIP CARD ASSEMBLY CHECK Replace the RIP Card...

  • Page 72: Blank, Erratic, Or Inoperative Operator Panel Service Check

    4022-XXX Step Actions and Questions AC POWER CORD REPLACEMENT Go to step 6 Problem solved Replace the AC Power Cord. Monitor printer operation. Does the printer display erratic operation? RIP CARD ASSEMBLY REPLACEMENT Go to step 7 Problem solved Replace the RIP Card Assembly with a new one. Monitor printer operation.

  • Page 73: Paper Feed Service Check

    4022-XXX Step Actions and Questions ENGINE RIP CARD ASSEMBLY REPLACEMENT Replace the Problem Engine Card solved Replace the Engine RIP Card Assembly. Assembly Is the problem still present? The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely.

  • Page 74: Print Quality Service Checks

    4022-XXX Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.
  • Page 75 4022-XXX Step Actions and Questions IMAGE DEVELOPMENT INSPECTION Go to step 4 Replace the HVPS. Go to Remove the Left Cover. “HVPS Generate a Test Print and switch off printer power halfway Removal” on through the print cycle. page 4-13. Open the Top Cover.

  • Page 76: Blank Prints Service Check

    4022-XXX Blank Prints Service Check The entire image area is blank. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions CONTROLLER OR HOST SOFTWARE ISOLATION Troubleshoot Go to step 2 or replace the Generate a Test Print. RIP Card Assembly or reload the print driver...

  • Page 77: Black Prints Service Check

    4022-XXX Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.

  • Page 78: Vertical Band Deletions Service Check

    4022-XXX Step Actions and Questions IMAGE DEVELOPMENT INSPECTION Replace the Go to step 5 Transfer Remove the Left Cover. Roller. Go to Generate a Test Print and switch off printer power halfway “Transfer through the print cycle. Roller Open the Top Cover. Removal”...
  • Page 79 4022-XXX THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PRINTHEAD WINDOW INSPECTION Go to step 2 Remove the paper scrap Remove the EP Cartridge. or clean the Inspect the Printhead Window for a scrap of paper or other Printhead contamination that may have lodged in front of it and could be window...

  • Page 80: Horizontal Band Deletions Service Check

    4022-XXX Horizontal Band Deletions Service Check There are areas of the image that are extremely light or are missing entirely. These missing areas form lines or bands that run horizontally across the page. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PAPER INSPECTION Replace with...

  • Page 81: Vertical Streaks Service Check

    4022-XXX Vertical Streaks Service Check There are black lines running vertically along the page. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PAPER PATH INSPECTION Go to step 2 Remove contamination Inspect the paper path, between feed and exit, for contamination or obstructions.

  • Page 82: Horizontal Streaks Service Check

    4022-XXX Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.

  • Page 83: Spot Deletions Service Check

    4022-XXX Step Actions and Questions FUSER INSPECTION Replace the Go to step 5 Fuser Generate another Test Print and switch off printer power when Assembly. Go the print is halfway through the Fuser. “HVPS Open the Top Cover and remove the Toner Cartridge. Cover Examine the paper areas before the image enters the Fuser Removal”...

  • Page 84: Background Service Check

    4022-XXX Step Actions and Questions IMAGE TRANSFER INSPECTION Replace the Go to step 4 Transfer Generate a Black Test Print and switch off printer power Roller. Go to halfway through the print cycle. “Transfer Open the Top Cover and remove the Toner Cartridge. Roller Open the Drum Shutter.

  • Page 85: Toner On Back Of Print Service Check

    4022-XXX Step Actions and Questions IMAGE TRANSFER INSPECTION Replace the Go to step 4 Transfer Inspect the page generated in step 2. Roller. Go to Before Transfer was the drum clean and without “Transfer noticeable background toner, but there was background Roller visible on the paper after Transfer? Removal”...
  • Page 86 4022-XXX Step Actions and Questions PAPER PATH INSPECTION Go to step 4 Thoroughly clean the Remove the paper trays. paper path, Remove the Toner Cartridge. from Feeders Use a flashlight to inspect the entire paper path, from Feeder to the Output to Output Tray, for any loose toner.

  • Page 87: Skewed Image Service Check

    4022-XXX Skewed Image Service Check The image is either twisted on the page or is not parallel to the sides of the page. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PAPER FEED INSPECTION Go to step 2 Reload the paper and reinstall the...

  • Page 88: Damaged Prints Service Check

    4022-XXX Step Actions and Questions The following printer FRUs and areas are associated with this specific problem. One or more of these FRUs or areas may have failed partially or completely. If you cannot isolate this problem using the steps in this service check, replace each FRU or troubleshoot each area listed below, one at a time, until you isolate and solve the problem.

  • Page 89: Unfused Image Or Image Easily Rubs Off Of Page Service Check

    4022-XXX Step Actions and Questions PAPER PATH INSPECTION - FEED TO REGISTRATION Replace the Go to step 5 Pick Rollers Generate a Test Print. and Separator Open the Top Cover just before the lead edge of the sheet of Pads from the paper reaches the Registration Rolls.

  • Page 90: Repetitive Marks On Each Page Service Check

    4022-XXX Step Actions and Questions FUSER ASSEMBLY REPLACEMENT Go to step 4 Problem solved Replace the Fuser Assembly. Go to “HVPS Cover Removal” on page 4-14. Run a half dozen Test Prints. Does the image rub off? The following printer FRUs and areas are associated with this specific problem.

  • Page 91: Lead Edge Registration Is Not Correct Service Check

    4022-XXX Lead Edge Registration is Not Correct Service Check The printed image is not centered on the page. The lead edge margin of the printed image is either too narrow or too wide, and either cuts off the lead edge of the printed image or starts the lead edge of the printed image too far into the page.

  • Page 92: Side-To-Side Registration Is Not Correct Service Check

    4022-XXX Side-to-Side Registration is Not Correct Service Check The printed image is not centered on the page. The side margins are not equal and the image is cut off on either the right side or the left side. THE PRINTER DISPLAYS NO ERROR CODE. Step Actions and Questions PAPER TRAY INSPECTION...

  • Page 93: Electrical Interference

    4022-XXX Electrical Interference Something is generating electrical noise that may be interfering with the normal operation of the printer. The interference generator may be either external or internal to the printer. If you are using a parallel connection, make sure it is fully shielded and grounded at both ends.
  • Page 94 4022-XXX Step Actions and Questions ENGINE CARD ASSEMBLY REPLACEMENT Go to step 9 Problem solved Replace the Engine Card. Go to “Engine Card Removal” on page 4-10. Is the Electrical Noise problem still present? MAIN DRIVE ASSEMBLY REPLACEMENT Go to step 10 Problem solved Replace the Main Drive Assembly.

  • Page 95: Diagnostic Aids

    4022-XXX 3. Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Use the Diagnostic Mode to run the various tests. Use the Configuration Mode to change various printer settings. Using the Operator Panel Diagnostics Menu Entering Diagnostic Mode Press and hold Go and Return as you turn on the printer to access Diagnostic Mode.
  • Page 96 4022-XXX Intermediate Menu, Top-level Menu Printer Setting, or Value List Operation Parallel Wrap Go to “Parallel Wrap Test” on page 3-8. Only displayed if the printer is configured with a standard parallel port. Parallel 1 Wrap Go to “Parallel Wrap Test” on page 3-8.
  • Page 97 4022-XXX Intermediate Menu, Top-level Menu Printer Setting, or Value List Operation Input Tray Tests Feed Test Only installed paper sources are displayed. Tray 1 Tray 2 Tray 3 MP Feeder Single Continuous For additional information, go to “Input Tray Feed Test” on page 3-13.

  • Page 98: Print Tests

    4022-XXX Intermediate Menu, Top-level Menu Printer Setting, or Value List Operation Par 1 Strobe Adj -4 to 6 (0) Only displayed if a parallel port is available using PCI slot 1. Par 2 Strobe Adj -4 to 6 (0) Only displayed if a parallel port is available using PCI slot 2.
  • Page 99 4022-XXX contains envelopes, then the envelope print test pattern is printed on the first envelope and subsequent envelopes are blank. Note: The Print Test page can be printed on any paper size. However, more than one sheet of some media sizes (A5 for example) may be required. Note: The Print Test page is always single-sided, regardless of the Duplex setting or the presence of the duplex unit.

  • Page 100: Print Quality Pages

    4022-XXX Print Quality Pages Execution of this diagnostic function causes the printer to print the Print Quality Test Pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. While the printer is in diagnostics, the toner cartridge lockout functionality is disabled. These pages can also be printed using the Configuration Menu Group;...

  • Page 101: Hardware Tests

    4022-XXX Hardware Tests LCD Hardware Test Selecting this test causes the printer to continually execute the LCD display test. To cancel the test, press Return or Stop. Button Test Use the Button Test to verify the operation of each button on the operator panel. When you select the Button Test the following screen is displayed.

  • Page 102: Dram Error

    4022-XXX DRAM Error Once the maximum pass count or fail count is reached, the test is stopped and the final test results are displayed. Press Return or Stop to exit the test. ROM Memory Test Use the ROM Memory Test to check the validity of the RIP code and fonts. When you select this test from the operator panel, the following screen is displayed and the printer begins testing ROM memory for the first time.
  • Page 103 4022-XXX The following screen is displayed and the printer begins testing the parallel hardware for the first time. Parallel Wrap P:###### F:##### Terminology: • P:###### represents the number of times the test has passed (finished successfully). Initially 000000 is displayed for ######. The maximum pass count is 999,999.

  • Page 104: Serial Wrap Test

    4022-XXX Serial Wrap Test Use the Serial Wrap Test to check the operation of the serial port hardware using a wrap plug. Each serial signal is tested. To perform the wrap test: Disconnect the serial interface cable, and install the serial wrap plug. Select HARDWARE TESTS from the Diagnostics Menu.
  • Page 105 4022-XXX • Receive Status Interrupt Error • Status Error • Receive Data Interrupt Error • Transmit Data Interrupt Error • Transmit Empty Error • Threshold Error • Receive Data Ready Error • Break Interrupt Error • Framing Error • Parity Error •...

  • Page 106: Duplex Tests

    4022-XXX Duplex Tests Duplex Quick Test Use the Duplex Quick Test to verify that the duplex Top Margin is set correctly. This test prints a duplexed version of the Quick Test page that can be used to adjust the Top Margin for the back of the page.

  • Page 107: Input Tray Tests

    4022-XXX Input Tray Tests Input Tray Feed Test The Feed Test operation within the INPUT TRAY TESTS menu is used by the manufacturing line and service engineers to observe the paper path as media is being fed through the printer. The top cover (used to access the print cartridge) cannot be opened during the feed test.

  • Page 108: Base Sensor Test

    4022-XXX Base Sensor Test Use the Base Sensor Test to determine whether or not the sensors located inside the printer are working correctly. To run the test, select Base Sensor Tests from the top level menu in diagnostics. The following sensors are displayed in the bottom level menu: •...

  • Page 109: Storage Device Tests

    4022-XXX Storage Device Tests Quick Disk Test Selecting this test runs a disk test that performs a non-destructive read/write on one block per track on the disk. The following message is displayed while the test is running. The Power indicator also blinks while the test is in progress.

  • Page 110: Flash Test

    4022-XXX Once Go is selected, the following screen is displayed to indicate the operation has begun. Disk Test/Clean Testing... If the test passes, then the following message is displayed. Press Go, Return, or Stop to return to the DEVICE TESTS screen. Disk Test/Clean Test Passed If the test fails, then the following message is displayed.

  • Page 111: Printer Setup

    4022-XXX Printer Setup Defaults The EP Defaults menu is used to restore each of the printer settings contained in the EP SETUP menu to their factory default value. To restore the EP SETUP settings to factory defaults, select Restore. To exit the menu without restoring the settings to factory defaults, select Do Not Restore.

  • Page 112: Configuration Id

    The CE should get the appropriate ID from the table listed below. After a valid ID is set using either method (that is invalid IDs are ignored), the printer automatically PORs to activate the new setting. Common Configuration ID’s for the Lexmark W812: Operator Panel Operating Voltage...

  • Page 113: Error Log

    4022-XXX Error Log Viewing the Error Log The Error Log aids the Customer Engineer by providing a history of printer errors. It contains the 12 most recent errors that have occurred. The most recent error is displayed in position 1, and the oldest error is displayed in position 12 (assuming 12 or more errors have occurred).

  • Page 114: Clearing The Error Log

    4022-XXX Clearing the Error Log To clear the error log, select the Clear Log operation from the ERROR LOG menu. The printer displays the following message. Clear Log =Yes Select Yes to confirm that you really want to clear the log. The error log is cleared and then the empty log is displayed as shown.
  • Page 115 4022-XXX Intermediate Menu, Printer Value List Setting or Printer Operation Prt Quality Pgs No selections exist for this operation. Pressing Select initiates this operation. Go to “Print Quality Pages” on page 3-6. Panel Menus Disable Only displayed when the PJL Enable* PASSWORD Environment variable is set to zero.

  • Page 116: Viewing And Resetting The Maintenance Page Count

    4022-XXX Viewing and Resetting the Maintenance Page Count The maintenance page counter is incremented when a page is printed and incremented by two when a duplex sheet is printed. The counter is used to track printer usage. When the counter reaches 100,000, the printer posts a maintenance intervention and a status indicator on the display.

  • Page 117: Setting Printer Registration

    4022-XXX Setting Printer Registration This setting is in the Configuration Menu to allow easier access for customers. This setting also allows separate Left Margin settings for each paper tray. (The Top Margin setting is the same for all trays.) The range of valid settings for both the Top and Left margins are -50 to +50, where one unit represents 1/300 of an inch.
  • Page 118 4022-XXX 3-24 Service Manual...

  • Page 119: Repair Information

    4022-XXX 4. Repair Information Removals Directions in the procedures are indicated as follows: This chapter contains the Removal and Replacement Procedures for select parts of the printer. Do the following steps before you begin any Removal and Replacement Procedure: 1. Switch off the printer power and disconnect the power cord from the AC electrical outlet.
  • Page 120 4022-XXX • The notation “(Figure x)” points to the illustration that corresponds to the removal and replacement procedure you are performing. • Bold arrows in an illustration show direction of movement when removing or replacing a component. • Callouts in an illustration point to the specific removal and replacement component and also to associated and adjacent components that are related to the removal and replacement of the specific component.

  • Page 121: Front Cover Assembly Removal

    4022-XXX Front Cover Assembly Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the operator panel. 4. Use a screwdriver to push down the upper two hooks of the front cover assembly. Tilt the top of the front cover assembly forward. 5.

  • Page 122: Left Cover Assembly Removal

    4022-XXX Left Cover Assembly Removal 1. Open the top cover. 2. Remove the right cover. 3. Remove the upper card cage cover. 4. Remove the operator panel. 5. Remove the two screws that secure the left cover. 6. Slide the left cover assembly toward the rear, and remove it. Service Manual...

  • Page 123: Rear Cover Removal

    4022-XXX Rear Cover Removal 1. Remove the top cover. 2. Remove the five screws which secure the rear cover. 3. Slide the rear cover up, then remove the cover. Repair Information...

  • Page 124: Right Cover Removal

    4022-XXX Right Cover Removal 1. Open the top cover. 2. Move the right cover backward while pressing the button on the top of the upper card cage cover. 3. Move the top of the right cover rightward, and remove the tow lower hooks from the frame assembly.

  • Page 125: Top Cover Assembly Removal

    4022-XXX Top Cover Assembly Removal 1. Remove the hinge screw. 2. Press the latch button, and open the top cover assembly. 3. Shift the left of the top cover assembly backward, and move it to the right. Remove the top cover. Repair Information...

  • Page 126: Card Cage Cover Removal

    4022-XXX Card Cage Cover Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the operator panel. 4. Remove the seventeen screws which secure the card cage cover. 5. Remove card cage cover. Service Manual...

  • Page 127: Duplex Output Feed Roller Assembly And Clutch Removal

    4022-XXX Duplex Output Feed Roller Assembly and Clutch Removal 1. Remove the main drive assembly. 2. Remove the card cage cover. 3. Remove the controller card. 4. Remove the lower duplex out guide assembly and mounting bracket. 5. Remove the two screws which secure the power switch bracket to the frame, and remove the bracket.

  • Page 128: Engine Card Removal

    4022-XXX Engine Card Removal 1. Remove the card cage cover. 2. Remove the RIP controller card. 3. Remove all the connectors on the engine card. 4. Remove four screws securing the engine card. 5. Remove the engine card. 4-10 Service Manual...

  • Page 129: Fan Removal

    4022-XXX Fan Removal 1. Remove the rear plate. 2. Remove the fan cable from P106 on the LVPS. 3. Remove the two screws which secure the fan to the frame. 4. Remove the fan. 4-11 Repair Information...

  • Page 130: Fuser Assembly Removal

    4022-XXX Fuser Assembly Removal 1. Open the top cover. 2. Lift up the right and left fuser latches. 3. Slide the fuser forward and remove. Note: Whenever the fuser assembly is replaced, be sure to reset the maintenance page count. Go to “Viewing and Resetting the Maintenance Page Count”...

  • Page 131: Hvps Removal

    4022-XXX HVPS Removal 1. Remove the HVPS cover. 2. Remove all the connectors on the HVPS. 3. Remove the four screws which secure the HVPS to the frame. 4. Remove the HVPS. 4-13 Repair Information...

  • Page 132: Hvps Cover Removal

    4022-XXX HVPS Cover Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the operator panel assembly. 4. Remove the left cover. 5. Remove the four screws which secure the HVPS cover. 6. Remove the cover. 4-14 Service Manual...

  • Page 133: Left Cartridge Guide Assembly Removal

    4022-XXX Left Cartridge Guide Assembly Removal 1. Open the top cover and remove the toner cartridge. 2. Remove the transfer roller. 3. Remove the two screws which secure the left cartridge guide assembly to the frame. 4. Remove the left cartridge guide assembly. 4-15 Repair Information...

  • Page 134: Lower Duplex Out Guide Assembly Removal

    4022-XXX Lower Duplex Out Guide Assembly Removal 1. Remove the rear cover. 2. Remove the two screws which secure the lower duplex out guide assembly to the frame. 3. Pull out the lower duplex out guide assembly. 4-16 Service Manual...

  • Page 135: Lvps Removal

    4022-XXX LVPS Removal 1. Remove the rear plate. 2. Remove the fan. 3. Remove all the connectors on the LVPS. 4. Remove the four screws which secure the LVPS to the frame. 5. Remove the LVPS. 4-17 Repair Information...

  • Page 136: Main Drive Assembly Removal

    4022-XXX Main Drive Assembly Removal 1. Remove the fuser. 2. Remove the HVPS cover. 3. Remove the cable from P105 on the LVPS. 4. Remove the registration clutch cable from the clamp on the main drive assembly. 5. Remove the five screws which secure the main drive assembly to the frame. 6.

  • Page 137: Mpf Input Paper Feed Assembly Removal

    4022-XXX MPF Input Paper Feed Assembly Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the operator panel. 4. Remove the front cover assembly. 5. Remove the left cover. 6. Remove the HVPS cover. 7.

  • Page 138: Mpf Paper Present Flag Removal

    4022-XXX MPF Paper Present Flag Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the operator panel. 4. Remove the printhead. 5. Rotate the MPF paper present flag to its upper position. 6. Deflect the left end of the flag forward (A) and slide the flag to the left (B). 7.

  • Page 139: Mpf Pick Roll Removal

    4022-XXX MPF Pick Roll Removal 1. Open the top cover. 2. Remove the toner cartridge. 3. Compress the roll locks and slide rollers A and B away from the center. 4. Slide pick rolls (C and D) away from the center, and then lift and remove. Note: When installing pick rolls, note the orientation as shown in the illustration.

  • Page 140: Mpf Pick Roll Assembly Removal

    4022-XXX MPF Pick Roll Assembly Removal 1. Remove the left cover. 2. Remove the HVPS cover. 3. Remove the MPF pick up spring connected to the MPF pick up gear. 4. Unlatch the MPF pick up gear (A) and then slide off the shaft. 5.

  • Page 141: Mpf Separator Pad Assembly Removal

    4022-XXX MPF Separator Pad Assembly Removal 1. Remove MPF input paper feed assembly. 2. Pry the MPF separator pad assembly away from MPF input paper feed assembly. Note: Be careful not to lose the springs located under the MPF separator. 4-23 Repair Information...

  • Page 142: Mpf Solenoid Removal

    4022-XXX MPF Solenoid Removal 1. Remove the HVPS cover. 2. Disconnect the solenoid cable from P132 on the HVPS. 3. Remove the MPF pickup spring connected to the MPF pick up gear. 4. Remove the screw that secures the MPF solenoid and remove the solenoid. 4-24 Service Manual...

  • Page 143: Mpf Tray Assembly Removal

    4022-XXX MPF Tray Assembly Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the operator panel. 4. Remove the front cover assembly. 5. Remove the two screws which secure the MPF tray to the frame. 6.

  • Page 144: Operator Panel Removal

    4022-XXX Operator Panel Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the screw which secures the rear left of the operator panel. 4. Lift the right of the operator panel a little, and disconnect the operator panel cable. 5.

  • Page 145: Optional 250-Sheet Pick Roller Removal

    4022-XXX Optional 250-Sheet Pick Roller Removal 1. Remove the optional 250 sheet feeder assembly from the printer. 2. Compress the roller (A and B) locks and slide rollers A and B away from the center. 3. Slide pick rollers (C and D) away from the center, then lift and remove. Note: When installing pick rollers, note the orientation as shown in the illustration.

  • Page 146: Optional 500-Sheet Separator Pad/Lift Plate Assembly Removal

    4022-XXX Optional 500-Sheet Separator Pad/Lift Plate Assembly Removal 1. Remove the optional 500-sheet tray from the feeder assembly. 2. Remove any paper in the tray and place the tray upside down on a table. 3. While holding the metal plate down, remove the three screws as shown in the illustration.
  • Page 147 4022-XXX Bottom Rear Right Front 4-29 Repair Information...

  • Page 148: Paper Size Dial And Card Assembly Removal

    4022-XXX Paper Size Dial and Card Assembly Removal 1. Remove the card cage cover. 2. Remove the two screws which secure the dial bracket to the frame and remove the bracket. 3. Remove all the connectors on the paper size card assembly. 4.

  • Page 149: Paper Tray Lift Plate Removal

    4022-XXX Paper Tray Lift Plate Removal 1. Remove the 250-sheet paper tray. 2. Remove the dust cover from the paper tray, and remove paper. 3. Unsnap lift plate levers from the paper tray. 4. Depress hinge tab and remove right rear lift plate. 5.

  • Page 150: Printhead Assembly Removal

    4022-XXX Printhead Assembly Removal 1. Remove the right cover. 2. Remove the upper card cage cover. 3. Remove the operator panel. 4. Remove the card cage cover. 5. Remove printhead cables P11 and P22 from the engine card. 6. Remove the four screws which secure the printhead to the frame. 7.

  • Page 151: Rear Plate Removal

    4022-XXX Rear Plate Removal 1. Remove the top cover. 2. Remove the rear cover. 3. Remove the screw which secures the rear plate to the frame. 4. Lift the rear plate to remove it. 4-33 Repair Information...

  • Page 152: Right Cartridge Guide Assembly Removal

    4022-XXX Right Cartridge Guide Assembly Removal 1. Remove the transfer roller. 2. Remove the two screws which secure the right cartridge guide assembly. 3. Disconnect the cable from P29 on the engine card. 4. Remove the right cartridge guide assembly. RIP Controller Card Removal 1.

  • Page 153: Toner Sensor Removal

    4022-XXX Toner Sensor Removal 1. Remove the transfer guide assembly. 2. Insert a screwdriver in front of the toner sensor to unlatch the sensor. 3. Lift sensor and remove. 4-35 Repair Information...

  • Page 154: Transfer Guide Assembly Removal

    4022-XXX Transfer Guide Assembly Removal 1. Remove the top cover. 2. Remove the fuser assembly. 3. Remove the transfer roller. 4. Remove the right cover. 5. Remove the upper card cage cover. 6. Remove the operator panel. 7. Remove the rear cover. 8.
  • Page 155 4022-XXX 16. Lift the right side of the transfer guide assembly to release; then lift the transfer guide assembly and remove from printer. 4-37 Repair Information...

  • Page 156: Transfer Roller Removal

    4022-XXX Transfer Roller Removal 1. Open the top cover. Warning: When performing the following procedure, do not touch the roll surface of the transfer roller and window (laser beam output part) of the printhead. Warning: When removing the transfer roller from the transfer guide assembly, confirm that the roll part of the transfer roller is not damaged.

  • Page 157: Tray 1 Present Switch Removal

    4022-XXX Tray 1 Present Switch Removal 1. Remove the duplex and paper tray options, if installed. 2. Place the printer upside down. 3. Remove the four screws that secure the lower duplex out guide assembly bracket, and remove the bracket. 4.

  • Page 158: Tray 1 Pick Roll Removal

    4022-XXX Tray 1 Pick Roll Removal 1. Remove tray 1 and any optional trays. 2. Turn the printer upside down. 3. Compress the roll locks and slide rolls A and B away from center. 4. Slide pick rolls (C and D) away from center, and then lift and remove. Note: When installing pick rolls, note orientation as shown in the illustration.

  • Page 159: Tray 1 Pick Roller Assembly Removal

    4022-XXX Tray 1 Pick Roller Assembly Removal 1. Remove the top cover. 2. Remove the fuser assembly. 3. Remove the transfer roller. 4. Remove the HVPS cover. 5. Remove the rear plate. 6. Remove the card cage cover. 7. Remove the main drive assembly. 8.

  • Page 160: Tray 1 Solenoid Removal

    4022-XXX Tray 1 Solenoid Removal 1. Remove the HVPS cover. 2. Remove the tray 1 pick up spring connected to the tray 1 pick up gear. 3. Disconnect the solenoid cable from P134 on the HVPS. 4. Remove the screw securing the tray 1 solenoid and remove the solenoid. 4-42 Service Manual...

  • Page 161: Upper Duplex Out Guide Assembly Removal

    4022-XXX Upper Duplex Out Guide Assembly Removal 1. Remove the main drive assembly. 2. Remove the card cage cover. 3. Remove the controller card. 4. Remove the duplex output feed roller assembly and clutch. 5. Disconnect all cables from the upper duplex out guide assembly. 6.

  • Page 162: Upper Card Cage Cover Removal

    4022-XXX Upper Card Cage Cover Removal 1. Open the top cover assembly. 2. Remove the right cover. 3. Pull up the right fuser latch. 4. Remove the two screws securing the upper card cage cover. 5. Remove the upper card cage cover. 4-44 Service Manual...

  • Page 163: 250-Sheet Separator Pad Assembly Removal

    4022-XXX 250-Sheet Separator Pad Assembly Removal 1. Unlock the tray extension locks, and then fully slide out the tray extension. 2. Place the paper tray upside down on the table. 3. Remove the five screws from the bottom of the paper tray. 4.
  • Page 164 4022-XXX 4-46 Service Manual...

  • Page 165: Connector Locations

    4022-XXX 5. Connector Locations P/J Location Table Use the table and diagrams in this section to locate specific P/J connectors within the printer. 1. Locate the P/J connector number in the first column of the table. 2. Locate the corresponding coordinate, such as B-5 in the second column. 3.
  • Page 166 4022-XXX Connector Mounting Parts Connection Destination Coordinate Connected To Other End Connected To J-25 LVPS A-23 LVPS K-23 LVPS J-27 LVPS K-23 LVPS Duplex Output 1071 Clutch J-22 LVPS RIP Controller Board K-23 LVPS F-47 Printhead Engine Board F-47 Printhead Printhead F-47 Printhead...
  • Page 167 4022-XXX Connector Mounting Parts Connection Destination Coordinate Connected To Other End Connected To F-47 Printhead Engine Board 241A I-182 Duplex Cable Engine Board H-48 Photo Sensor Engine Board G-48 Photo Sensor Engine Board G-149 Photo Sensor Engine Board K-22 LVPS Engine Board D-22 LVPS...
  • Page 168 4022-XXX P/J Connector Position Coordinate Diagram Service Manual...
  • Page 169 4022-XXX Connector Locations...
  • Page 170 4022-XXX RIP Controller Card Service Manual...
  • Page 171 4022-XXX Connector Locations...
  • Page 172 4022-XXX Service Manual...
  • Page 173 4022-XXX Connector Locations...

  • Page 174: Harness Route Diagram

    4022-XXX Harness Route Diagram 5-10 Service Manual...
  • Page 175 4022-XXX Engine to Fuser Cable Cover Interlock Switch Cable Power Inlet Registration Cable Cooling Fan Clutch with Cable Cable Main Drive Assembly with Cable Rear 5-11 Connector Locations...
  • Page 176 4022-XXX Tray 1 Solenoid with Cable Duplex Clutch Cable MFP Solenoid with Cable Duplex Cable Tray 1 Solenoid with Cable Duplex Output Front Photo Sensor Cable 5-12 Service Manual...
  • Page 177 4022-XXX HVPS Transfer HVPS Detack Cable Cable HVPS Detack Cable HVPS Transfer Cable Registration Sensor Cable Toner Sensor Front Cable 5-13 Connector Locations...
  • Page 178 4022-XXX LVPS to Controller Board Cable Engine Board to LVPS Cable HVPS Cable Engine to LVPS Cable LVPS to Controller Board Cable Engine Cable HVPS Cable Front Standard Tray Empty Sensor Cable 5-14 Service Manual...

  • Page 179: Printer Wiring Diagrams

    4022-XXX Printer Wiring Diagrams Wiring Diagram Notations This section contains a Master Wiring Diagram for the printer. The Master Wiring Diagram shows the interconnections of the major subsystems within the printer. The remainder of this section divides the Master Wiring Diagram into individual block diagrams (BD) to better illustrate the electrical relationships between components and assemblies.

  • Page 180: General Wiring Diagram

    4022-XXX General Wiring Diagram Engine Board PRINTHEAD Scanner Solenoid HVPS Clutch Regi Solenoid Sensor Toner Sensor LP Sensor MSI Sensor Regi PWBA Feeder Sensor Option1 P/J173 P/J172 Sensor FDR NP P/J1721 P/J1731 Sensor P/J153 FDR LP SW DX2 Fuser PWBA Size MSI Future Option...
  • Page 181 4022-XXX 5-17 Connector Locations...

  • Page 182: Engine Board <-> Lvps <-> Interlock Sw And Fan (1/3)

    4022-XXX Engine Board <−> LVPS <−> Interlock SW and Fan (1/3) FUSER ASM P/J152 P/J151 P/J272 LVPS ENGINE BOARD P/J271 P/J27 3.3V FUSER CONTROL /HEAT ON P/J10 P/J101 P/J10 P/J101 3.3VDC FMLOCK SUPPLY /FAN FAST /FAN SLOW 24V INT OPEN Interlock SW 24VDC 24V RTN...

  • Page 183: Engine Board <-> Lvps <-> Interlock Sw And Fan (1/3)

    4022-XXX Engine Board <−> LVPS <−> Interlock SW and Fan (1/3) Signal names for Engine Board <−> LVPS route Signal Name Explanation FMLOCK A signal that transmits the fan alarm signal to the engine board. /FAN FAST A signal that changes the fan rotation speed, and instructs to set the fan rotation speed to high.

  • Page 184: Engine Board <-> Lvps <-> Interlock Sw And Fan (3/3)

    4022-XXX Engine Board <−> LVPS <−> Interlock SW and Fan (3/3) • Cutting off the 24V dc power by the Interlock switch When the Cover Popup is opened, the contact of the Interlock SW is also opened, and the 24V dc power circuit from the LVPS to the Engine Board is then opened. As a result, the supply of the power from the PWBA Engine Board to the Motor, Clutch, and Solenoid is stopped.
  • Page 185 4022-XXX Engine Board <−> Fuser Assembly and LVPS (2/2) Signal names for Engine Board <−> Fuser Assembly route Signal Name Explanation A signal sent from the exit sensor. This signal is set low when the exit sensor /EXIT receives the light. A temperature monitor signal (analog signal) sent from the temperature sensor (thermistor).

  • Page 186: Engine Board <-> Printhead And Toner Cartridge (1/3)

    4022-XXX Engine Board <−> Printhead and Toner Cartridge (1/3) ENGINE P/J221 P/J22 PRINTHEAD BOARD XP DATA+ XP DATA- P/J11 P/J111 /PCONT /LDENB Vref P/J112 LD +5V /SOS /SOS P/J114 Scanner 24V RTN/SG /ROSMOT ON 24V RTN ROSMOTCLK P/J113 /SOS P/J29 J292 P293 LD +5V...
  • Page 187 4022-XXX Engine Board <−> Printhead and Toner Cartridge (2/3) Signal names for Engine Board <−> Printhead route Signal Name Explanation XP DATA + Print image data DATA+ > DATA-: Lights on. XP DATA - DATA+ < DATA-: Lights off. /PCONT Sample/hold circuit.

  • Page 188: Engine Board <-> Printhead And Toner Cartridge (3/3)

    4022-XXX Engine Board <−> Printhead and Toner Cartridge (3/3) • Safety switch functions of toner cartridge LD +5V The toner cartridge contains the power circuit for LD +5V. The LD +5V circuit is established by inserting the toner cartridge. If the toner cartridge is not attached to the printer, the LD +5V circuit is opened, and the radiation of laser beams stops.
  • Page 189 4022-XXX <−> <−> Engine Board HVPS Toner Cartridge (BCR and Mag. Roll), Transfer Roller and Detack Saw (2/3) <−> Signal names for Engine Board HVPS route Signal Name Explanation DBAC An off-time variable pulse signal that supplies an oscillation source to generate ac components for the DB (development bias).

  • Page 190: And Detack Saw (3/3)

    4022-XXX Engine Board <−> HVPS <−> Toner Cartridge (BCR and Mag. Roll), Transfer Roller and Detack Saw (3/3) CAUTION: High voltage is applied to the CR (JP001/JP002), DB (JP003/JP004), TR (P/J136 to P/J1361), and DTS (P/J135 to P/J1351); therefore, do not touch them during power-on and do not come into contact with the electric conductor.
  • Page 191 4022-XXX Pin numbers and voltage levels for Engine Board ↔ HVPS ↔ Clutch Registration and Sensor Registration Signal Direction M: Engine Engine Clutch/ High HVPS Signal Name Board, Trigger Board Sensor level level C: Clutch S: Sensor M → C P13-2 P131-19/ P1331-4 /REGI CLUTCH ON...

  • Page 192: Turn, And Sw D2X (1/3)

    4022-XXX Engine Board <−> Solenoid T1/MPF, Sensor LP/MPF NP/ FDR LP/FDR NP, Clutch Turn, and SW D2X (1/3) P/J13 P/J131 Solenoid T1 ENGINE HVPS P/J134 BOARD /FEED1 ON /FEED1 ON Solenoid MSI P/J132 /FEED MSI ON /FEED MSI ON 3.3V Sensor LP P/J25 P/J251...
  • Page 193 4022-XXX Engine Board <−> Solenoid T1/MPF, Sensor LP/MPF NP/FDR LP/FDR NP, Clutch Turn, and SW D2X (2/3) Signal names for Engine Board <−> Solenoid T1/MPF, Sensor LP/MPF NP/FDR LP/FDR NP, Clutch Turn, SW DX2 and PWBA Size MPF route Signal name Explanation /FEED1 ON A solenoid T1 control signal.

  • Page 194: Turn, And Sw D2X (3/3)

    4022-XXX Engine Board <−> Solenoid T1/MPF, Sensor LP/MPF NP/ FDR LP/FDR NP, Clutch Turn, and SW D2X (3/3) Pin numbers and voltage levels for Engine Board <−> Solenoid T1/MPF, Sensor LP/MPF NP/FDR LP/FDR NP, Clutch Turn, SW D2X and PWBA Size MPF route Signal direction M:Engine Board PWB: HVPS/...

  • Page 195: Engine Board <-> Lvps <-> Main Motor (1/1)

    4022-XXX Engine Board <−> LVPS <−> Main Motor (1/1) LVPS P/J105 P/J10 Engine P/J101 Board Motor Drive 24VDC CUTOFF Signal names for Engine Board <−> LVPS <−> Main Motor route Signal Name Explanation A and B Clockwise stepping driving power of main motor. /A and /B Counterclockwise stepping driving power of main motor.

  • Page 196: Engine Board <-> Sensor Toner (1/1)

    4022-XXX Engine Board <−> Sensor Toner (1/1) Sensor Toner Engine P/J19 Board 24V RTN /NO TONER Signal names for Engine Board <−> Sensor Toner route Signal Name Explanation /NO TONER A signal sent from the sensor toner. When toner is used up in the toner car- tridge, this signal is set low.

  • Page 197: Preventive Maintenance

    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply • Possible safety exposure from any non-Lexmark attachments Scheduled Maintenance The operator panel displays the message “80 Scheduled Maintenance” at each 100K page count interval. It is necessary to replace the fuser assembly at this interval to maintain the print quality and reliability of the printer.
  • Page 198 4022-XXX Service Manual...

  • Page 199: Parts Catalog

    4022-XXX 7. Parts Catalog How to Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.
  • Page 200 4022-XXX Assembly 1: Covers Service Manual...

  • Page 201: Index

    4022-XXX Assembly 1: Covers Asm- Part Units Description Index Number 56P0956 Screw, Shoulder 56P0822 Cover Assembly, Top 56P0958 Kit Assembly, Bin Full Sensor 56P0823 Cover, Upper Card Cage 56P0825 Cover, Right 56P0834 Cover Assembly, Rear 56P0826 Cover Assembly, Front 56P0827 Cover Assembly, Left 56P0833 Cable, Operator Panel...
  • Page 202 4022-XXX Assembly 2: Standard 250 Sheet Paper Tray Service Manual...
  • Page 203 4022-XXX Assembly 2: Standard 250-Sheet Paper Tray Asm- Part Units Description Index Number 56P0835 Tray Assembly, 250-Sheet Paper 56P0836 Pad Assembly, 250-Sheet Separator Parts Catalog...
  • Page 204 4022-XXX Assembly 3: Paper Pick/Feed Service Manual...
  • Page 205 4022-XXX Assembly 3: Paper Pick/Feed Asm- Part Units Description Index Number 56P0867 Bearing, MPF Separator Pad 56P0838 Pad Assembly, MPF Separator 56P0837 Feed Assembly, Input Paper 56P0802 Sensor, Photo (Tray 1 Empty) 56P0840 Cable, Tray 1 Empty Sensor 56P0839 Flag, Tray 1 Empty 56P0800 Kit, Pick Roll (contains 2) 56P0841...
  • Page 206 4022-XXX Assembly 4: Duplex Paper Feed Service Manual...
  • Page 207 4022-XXX Assembly 4: Duplex Paper Feed Asm- Part Units Description Index Number 56P0868 Guide Assembly, Upper Duplex Out 56P0802 Sensor, Photo (Duplex Sensor 2) 56P0869 Flag, Duplex Output Sensor 56P0870 Roll Assembly, Duplex Output Feed 56P0872 Gear, Optional Feeder Drive 56P0803 Bearing, Feed Roll (Right) 56P0877...
  • Page 208 4022-XXX Assembly 5: Main Paper Feed 7-10 Service Manual...
  • Page 209 4022-XXX Assembly 5: Main Paper Feed Asm- Part Units Description Index Number 56P0878 Roll Assembly, Transfer 56P0882 Stop, Transfer Roll Assembly (for shipping purposes only) 56P0883 Guide Assembly, Transfer 56P0880 Guide Assembly, Duplex to Registration 56P0879 Guide Assembly, Registration Paper 56P0881 Sensor, Toner Low 56P0802...
  • Page 210 4022-XXX Assembly 6: Fuser 7-12 Service Manual...
  • Page 211 4022-XXX Assembly 6: Fuser Asm- Part Units Description Index Number 56P0886 Latch, Left Fuser 56P0888 Cable, Fuser 100 V/120 V 56P0961 Cable, Fuser 220 V 56P0887 Latch, Right Fuser 56P0968 Fuser Assembly, 100 V Complete 56P0884 Fuser Assembly, 120 V, Complete 56P0885 Fuser Assembly, 220 V, Complete 7-13...
  • Page 212 4022-XXX Assembly 7: Main Drive 7-14 Service Manual...
  • Page 213 4022-XXX Assembly 7: Main Drive Asm- Part Units Description Index Number 56P0889 Spring, Cover Open Link 56P0890 Link, Cover Open 56P0891 Cam, Cover Open 56P0809 Foot, Rubber 56P0894 Cable, Registration Clutch 56P0893 Clutch, Registration Roller 56P0892 Drive Assembly, Main 7-15 Parts Catalog...
  • Page 214 4022-XXX Assembly 8: Printhead 7-16 Service Manual...
  • Page 215 4022-XXX Assembly 8: Printhead Asm- Part Units Description Index Number 56P0896 Guide Assembly, Right Cartridge 56P0951 Cable, Printhead Video 56P0881 Sensor, Toner Low 56P0897 Printhead, Complete Laser 56P0895 Guide Assembly, Left Cartridge 7-17 Parts Catalog...
  • Page 216 4022-XXX Assembly 9: Electronics 7-18 Service Manual...
  • Page 217 4022-XXX Assembly 9: Electronics Asm- Part Units Description Index Number 56P0899 Cable, Paper Size Card 56P0807 Dial, Paper Size 56P0806 Knob, Paper Size Dial 56P0898 Card Assembly, Paper Size 56P0916 Grommet, Cable 56P0863 Clamp, Cable 56P0904 Cable, HVPS 56P0903 Power Supply, High Voltage 56P0905 Cable, HVPS Detack 56P0906...
  • Page 218 4022-XXX Assembly 9 (cont.): Electronics 7-20 Service Manual...
  • Page 219 4022-XXX Assembly 9 (cont.): Electronics Asm- Part Units Description Index Number 56P0918 Cable, Power Inlet 56P1218 Cable, LVPS to RIP Card Assembly 56P0954 Card Assembly, RIP Riser 56P0910 Switch, Cover Interlock 56P0953 Card Assembly, RIP (Network) 56P0952 Card Assembly, RIP 56P0912 Cable, Engine to LVPS 56P0913...
  • Page 220 4022-XXX Assembly 10: Optional 250-Sheet Feeder 7-22 Service Manual...
  • Page 221 4022-XXX Assembly 10: Optional 250-Sheet Feeder Asm- Part Units Description Index Number 10-1 56P0808 Feeder Assembly, Optional 250-Sheet 56P0919 Cover, Optional 250 Front 56P0920 Cover, Optional 250 Left Side 56P0921 Cover, Optional 250 Right Side 56P0811 Screw, Optional Interconnect 56P0810 Cable, Optional Interconnect 56P0802 Sensor, Photo...
  • Page 222 4022-XXX Assembly 10 (cont.): Optional 250-Sheet Feeder 7-24 Service Manual...
  • Page 223 4022-XXX Optional 250-Sheet Feeder Assembly 10 (cont.): Asm- Part Units Description Index Number 10-1 56P0815 Clutch, Optional Feedroll 56P0800 Kit, Pick Roll (contains 2) 56P0817 Joint, Optional Feeder 56P0809 Foot, Rubber 56P0816 Solenoid, Optional 250/500 Roller 56P0925 Guide Assembly, Optional 250 Paper 56P0924 Roll Assembly, Optional 250 Pick 56P0814...
  • Page 224 4022-XXX Assembly 11: Optional 500-Sheet Feeder 7-26 Service Manual...
  • Page 225 4022-XXX Assembly 11: Optional 500-Sheet Feeder Asm- Part Units Description Index Number 11-1 56P0813 Feeder Assembly, Optional 500-Sheet (LTR) 56P0962 Feeder Assembly, Optional 500-Sheet (A4) 56P0812 Clamp, Optional Sensor 56P0929 Flag, Optional 500 (Paper Empty) 56P0802 Sensor, Photo (Paper Empty) 56P0928 Cover, Optional 500 Right 56P0811...
  • Page 226 4022-XXX Assembly 11 (cont.): Optional 500-Sheet Feeder 7-28 Service Manual...
  • Page 227 4022-XXX Optional 500-Sheet Feeder Assembly 11 (cont.): Asm- Part Units Description Index Number 11-1 56P0813 Feeder Assembly, Optional 500-Sheet (LTR) 56P0962 Feeder Assembly, Optional 500-Sheet (A4) 56P0802 Sensor, Photo (Paper Empty) 56P0814 Roll Assembly, Optional Feed 56P0815 Clutch, Optional Feedroll 56P0932 Roll, Optional 500 Pick 56P0804...
  • Page 228 4022-XXX Assembly 12: Optional 500-Sheet Tray 7-30 Service Manual...
  • Page 229 4022-XXX Assembly 12: Optional 500-Sheet Tray Asm- Part Units Description Index Number 12-1 56P0934 Tray Assembly, 500-Sheet (LTR) 56P0963 Tray Assembly, 500-Sheet (A4) 56P0938 Cover, Optional 500 Tray Upper 56P0937 Plate Assembly, Optional 500 Lift 56P0935 Guide Assembly, Optional 500 Tray Right 56P0960 Kit Assembly, Optional 500 Spring 56P0936...
  • Page 230 4022-XXX Assembly 13: Duplex Unit 7-32 Service Manual...
  • Page 231 4022-XXX Assembly 13: Duplex Unit Asm- Part Units Description Index Number 13-1 56P0939 Duplex Assembly, Complete 56P0940 Door Assembly, Duplex Upper Access 56P0942 Cover, Duplex Left Side 56P0943 Cover, Duplex Right Side 56P0946 Roll Assembly, Upper Duplex Feed 56P0947 Switch, Duplex Upper Door Open 56P0947 Switch, Duplex Lower Door Open 56P0941...
  • Page 232 4022-XXX Assembly 14: Miscellaneous/Options Asm- Part Units Description Index Number 56P0694 Card Assembly, 4MB DIMM 56P0695 Card Assembly, 8MB DIMM 56P0696 Card Assembly, 16MB DIMM 56P0697 Card Assembly, 32MB DIMM 56P0698 Card Assembly, 64MB DIMM 56P0699 Card Assembly, 128MB DIMM 99A1757 Card Assembly, 2MB Flash DIMM 99A1758...
  • Page 233 4022-XXX Index Skewed Image 2-31 Spot Deletions 2-27 Acronyms Toner on Back of Print 2-29 Unfused Image or Image Easily Rubs Off of Page 2-33 Base Sensor Tests 3-14 Vertical Band Deletions 2-22 Button Test Vertical Streaks 2-25 Service Checks Flowchart 2-11 Service Error Code Table Clearing the Error Log...
  • Page 234 4022-XXX MPF Solenoid 4-24 MPF Tray Assembly 4-25 Input Tray Tests Operator Panel 4-26 Input Tray Feed Test 3-13 Optional 250-Sheet Pick Roller Removal 4-27 Optional 500-Sheet Pick Roller Removal 4-27 Optional 500-Sheet Separator Pad/Lift Plate As- LCD Hardware Test sembly Removal 4-28 Paper Size Dial and Card Assembly...
  • Page 235 4022-XXX 56P0811 7-23, 7-27 56P0812 7-23, 7-27 User Error Messages 56P0813 7-27, 7-29 Using the Operator Panel Diagnostics Menu 56P0814 7-25, 7-29 56P0815 7-25, 7-29 56P0816 7-25, 7-29 Viewing and Resetting the Maintenance Page Count 56P0817 7-25, 7-29 3-22 56P0822 Viewing the Error Log 3-19 56P0823...
  • Page 236 4022-XXX 56P0879 7-11 56P0938 7-31 56P0880 7-11 56P0939 7-33 56P0881 7-11, 7-17 56P0940 7-33 56P0882 7-11 56P0941 7-33 56P0883 7-11 56P0942 7-33 56P0884 7-13 56P0943 7-33 56P0885 7-13 56P0944 7-33 56P0886 7-13 56P0945 7-33 56P0887 7-13 56P0946 7-33 56P0888 7-13 56P0947 7-33 56P0889...

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