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Lexmark Optra TM W810
Laser Printer

4023-001




· 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.
4023-001



Edition: March 2001
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.
A form for reader's comments is provided at the back of this publication. If the form has
been removed, comments may be addressed to Lexmark International, Inc., Department
D22/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may
use or distribute any of the information you supply in any way it believes appropriate
without incurring any obligation to you. You can purchase additional copies of publications
related to this product by calling 1-800-553-9727. In other countries, contact your point of
purchase.
Lexmark, MarkNet, MarkVision, Optra and OptraImage are trademarks of Lexmark
International, Inc., registered in the United States and/or other countries.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 1999, 2000, 2001.
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. P/N: 12G3978
4023-001


Table of Contents

Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Printer (Main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Printer/Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Printer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
General Description of Each Section . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Paper Feed Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Printhead Unit (Exposure Section) . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Imaging Cartridge (Charging, Development Section) . . . . . . . . . 1-9
Image Transfer Section (Release Section) . . . . . . . . . . . . . . . . . 1-9
Fusing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Cleaning Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Paper Exit Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
General Flow for Printing Process . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Paper Feed Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Taking Up Paper­Tray 1 (1st Paper Cassette) . . . . . . . . . . . . . 1-11
Tray 1 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1st Cassette Tray 1 Paper Size Detection . . . . . . . . . . . . . . . . . 1-15
Tray 2 (2nd Paper Cassette) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Taking up Paper­Tray 2 (2nd Paper Cassette) . . . . . . . . . . . . . 1-16
Tray 2 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Edge Guide and Trailing Edge Stop. . . . . . . . . . . . . . . . . . . . . . 1-20
Paper Lifting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Cassette-in-Position Detection. . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Paper Near Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Paper Separating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Paper Take-Up Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Printhead Unit (Exposure section) . . . . . . . . . . . . . . . . . . . . . . . . . 1-28




iii
4023-001

Imaging Cartridge (Charging/Development Section) . . . . . . . . . . . .1-28
Development Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
Toner Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
Image Transfer Section (Release Section) . . . . . . . . . . . . . . . . . . .1-34
Optical Erase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
Fusing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Temperature Control Using The Thermistor . . . . . . . . . . . . . . . .1-36
Thermostat (TS1) and Heater Lamp Fuse (TF1). . . . . . . . . . . . .1-36
Fusing Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Fusing PPM Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Paper Exit Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
Paper Path Through Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
Detection of a New Imaging Cartridge . . . . . . . . . . . . . . . . . . . . . . .1-39
Right Door Interlock Switch (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
Duplex Unit Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
Switchback Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
Transport and Duplex Paper Take-Up Mechanism . . . . . . . . . . .1-43
Paper Deck 2500-Sheet (LCC) Option . . . . . . . . . . . . . . . . . . . . . .1-45
Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-45
Vertical Transport Drive Mechanism . . . . . . . . . . . . . . . . . . . . . .1-45
Paper Take-Up Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-47
Paper Take-Up Retry Control . . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
Paper Separating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . .1-53
Paper Pressure Releasing Mechanism . . . . . . . . . . . . . . . . . . . .1-53
Paper Take-Up Roll Retracting Mechanism . . . . . . . . . . . . . . . .1-54
Edge Guides and Trailing Edge Stop . . . . . . . . . . . . . . . . . . . . .1-54
Paper Size Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-55
LCC-in-Position Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-56
Lifting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-57
Paper Near Empty Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59
Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59
Paper Dehumidifying Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . .1-60




iv Service Manual
4023-001

Mailbox/Transport Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Paper Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
Paper Transport Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
Paper Entrance Switching Mechanism . . . . . . . . . . . . . . . . . . . 1-64
Paper Transport Mechanism (Horizontal Transport Unit) . . . . . 1-64
Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
Paper Full Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
Paper Output Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67
Finisher Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
Paper Transport Path Switching Mechanism . . . . . . . . . . . . . . . 1-69
Paper Transport Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70
Punch Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71
Finisher Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
CD Aligning Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
Shifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
Finisher Tray Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 1-76
Paper Holding Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
Elevator Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
Stapling Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
Horizontal Transport Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Print Quality Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Paper Feed Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Other Printer Malfunction Symptom Table . . . . . . . . . . . . . . . . . 2-31
LCC 2500-Sheet Tray 4 Symptom Table . . . . . . . . . . . . . . . . . . 2-32
Mailbox Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Finisher Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Printer Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
No Power Service Check (923) . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Fuser (Abnormal Temperature) Service Check (923) . . . . . . . . 2-34
Fuser (Temperature Low) Service Check (920/922) . . . . . . . . . 2-35
Toner Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Black Page Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
White Spots Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Toner Smudges On Backside Service Check . . . . . . . . . . . . . . 2-37
Low Image Density Service Check . . . . . . . . . . . . . . . . . . . . . . 2-38


v
4023-001

Foggy Background Service Check . . . . . . . . . . . . . . . . . . . . . . .2-39
White/Black Lines Service Check . . . . . . . . . . . . . . . . . . . . . . . .2-40
Offset Image Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
Blank Print Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Image Space Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
Paper Feed Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
Paper Feed Pickup Tray 1 (250-Sheet) Service Check . . . . . . .2-44
Paper Feed Pickup Tray 2&3 (500-Sheet) Service Check . . . . .2-44
Paper Feed Synchronizing Roll/Registration Service Check . . .2-45
Paper Feed Fuser/Exit Service Check . . . . . . . . . . . . . . . . . . . .2-46
Paper Feed In Duplex Service Check . . . . . . . . . . . . . . . . . . . .2-46
Paper Feed In Horizontal Transport Service Check . . . . . . . . . .2-48
Paper Feed Mailbox Service Check . . . . . . . . . . . . . . . . . . . . . .2-48
Paper Feed Finisher Service Check . . . . . . . . . . . . . . . . . . . . . .2-50
Paper Feed LCC (2500-Sheet Tray 4) Service Check . . . . . . . .2-51
Paper Feed Hole Punch Service Check . . . . . . . . . . . . . . . . . . .2-52
Finisher Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
Finisher Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
Finisher Elevator Tray Service Check (993) . . . . . . . . . . . . . . . .2-53
Finisher Tray Drive Service Check (994) . . . . . . . . . . . . . . . . . .2-54
Finisher Shift Plate Drive Service Check (995) . . . . . . . . . . . . . .2-54
Finisher Paper Aligning Service Check (996) . . . . . . . . . . . . . . .2-54
Finisher Stapler Drive Service Check (997) . . . . . . . . . . . . . . . .2-56
Finisher Paper Holding Tray Drive Service Check (998). . . . . . .2-56
Finisher Upper Entrance Service Check . . . . . . . . . . . . . . . . . . .2-57
Mailbox Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
Mailbox Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . .2-58
Mailbox Bin 1­10 Service Check. . . . . . . . . . . . . . . . . . . . . . . . .2-59
Mailbox Transport Drive Service Check (935). . . . . . . . . . . . . . .2-59
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Operator Menu Disabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . . . . . . .3-1
Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Quick Test Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Diagnostics­Print Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Output Bin Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Finisher Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14


vi Service Manual
4023-001

Base Printer Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Mailbox Internal Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Disassembly and Cleaning Precautions. . . . . . . . . . . . . . . . . . . . 4-1
Handling the Printed Circuit Boards with MOS ICs . . . . . . . . . . . 4-1
Image Cartridge/PC (I/C) Handling Precautions . . . . . . . . . . . . . 4-2
Parts Not To Be Touched. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Printer (Main) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Mailbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Resetting Maintenance Counters . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Resetting Hole Punch Counter. . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Resetting Fuser Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Resetting Transfer Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Printer Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Pre-disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Outer Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
1st Cassette/250-Sheet (Tray1) Paper Take-Up
Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
250-Sheet Cassette (Tray 1) Paper Take-Up
Rolls Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
250-Sheet Cassette (Tray 1) Paper Take-Up
Rolls Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
500-Sheet Cassette (Tray 2 and 3) Vertical Transport
Roller/Rolls Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
500-Sheet Cassette (Tray 2 and 3) Paper Lifting
Springs Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
500-Sheet Cassette (Tray 2 and 3) Paper Size
Detecting Board (PWB-S2) Removal . . . . . . . . . . . . . . . . . . . . . 4-20
Image Transfer Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Image Cartridge/PC (I/C) Thermistor (TH2) Removal . . . . . . . . 4-22
Image Transfer Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Synchronizing Roller Sensor (PC2) Removal . . . . . . . . . . . . . . 4-23
Pre-transfer Guide Plate Register Plate (PWB-R2) Removal . . 4-24
Synchronizing Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Cooling Fan Motor (M3) and I/C Filter Removal . . . . . . . . . . . . 4-26


vii
4023-001

Fusing Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Paper Exit Sensor (PC3) and Actuator Removal . . . . . . . . . . . .4-27
Heater Lamp Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Heater Lamp (H1) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
Fusing Roller Thermistor (TH1) Removal . . . . . . . . . . . . . . . . . .4-29
Fusing Roller Thermostat (TS1) Removal . . . . . . . . . . . . . . . . . .4-30
Paper Exit Full Sensor (PC12) Removal . . . . . . . . . . . . . . . . . . .4-31
Eraser Duct Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-32
Erase Lamp (LA1) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
Fuser Frame Resistor Board (PWB-R1) Removal . . . . . . . . . . .4-34
1st Cassette Paper Empty Sensor (PC4) Removal. . . . . . . . . . .4-35
Image Cartridge/PC (I/C) Cooling Fan Motor (M9) Removal . . .4-36
High Voltage Unit (HV1) Removal . . . . . . . . . . . . . . . . . . . . . . . .4-37
Printer Main Engine Board (PWB-A) Removal . . . . . . . . . . . . . .4-38
Printhead Unit Assembly (PH) Removal . . . . . . . . . . . . . . . . . . .4-40
Right Door Switch (S3) Removal. . . . . . . . . . . . . . . . . . . . . . . . .4-43
Power Supply Unit (PU1) Removal . . . . . . . . . . . . . . . . . . . . . . .4-44
CPM (Power Supply Safety) Switch and PWB-L Removal . . . . .4-45
Power Unit Cooling Fan Motor (M4) Removal. . . . . . . . . . . . . . .4-46
Ozone Fan Motor (M8) and Ozone Filter Removal . . . . . . . . . . .4-47
1st Paper Cassette (Tray 1) Paper Size Detecting
Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Bottle Cover Sensor (PC10) Removal. . . . . . . . . . . . . . . . . . . . .4-49
Agitating Motor (M10) Removal. . . . . . . . . . . . . . . . . . . . . . . . . .4-50
Main Hopper Motor (M6) and Sub Hopper
Motor (M7) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51
Transport Motor (M2) Removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-52
Image Cartridge/PC (I/C) Drive Motor (M1) Removal . . . . . . . . .4-53
Right Door Interlock Switch (S2) Removal . . . . . . . . . . . . . . . . .4-54
Toner Detecting Read Switch (S4) Removal. . . . . . . . . . . . . . . .4-55
1st Cassette (Tray 1) Paper Near Empty
Sensor (PC5) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57
1st Cassette (Tray 1) Set Sensor (PC6) Removal . . . . . . . . . . .4-58
1st Cassette (Tray 1) Paper Take-Up
Solenoid (SL1) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59
Double Feed Detection Sensor
Board (PWB-H) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60
500-Sheet Cassette (Tray 2 and 3) Control
Board (PWB-A2) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62
500-Sheet Cassette (Tray 2 and 3) Paper
Take-Up Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-63




viii Service Manual
4023-001

500-Sheet Cassette (Tray 2 and 3) Paper Empty
Sensor (PC22) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
500-Sheet Cassette (Tray 2 and 3) Paper Near
Empty Sensor (PC25) Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
500-Sheet Cassette (Tray 2 and 3) Right Door
Detecting Sensor (PC23) Removal . . . . . . . . . . . . . . . . . . . . . . 4-66
500-Sheet Cassette (Tray 2 and 3) Paper Take-Up
Solenoid (SL2) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
Duplex Unit Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Duplex Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
Duplex Unit Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
Paper Deck 2500-Sheet Tray 4 (LCC) Removal Procedures . . . . . 4-70
Exterior Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
Paper Take-Up Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
Paper Take-Up Rolls Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
Feed Roll, Separator Roll and Torque Limiter
Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
Paper Take-Up Roll Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Feed Roll and Separator Roll Cleaning . . . . . . . . . . . . . . . . . . . 4-80
Vertical Transport Roller/Rolls Cleaning . . . . . . . . . . . . . . . . . . 4-81
Roll with a Torque Limiter Cleaning . . . . . . . . . . . . . . . . . . . . . . 4-81
Finisher Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
External Covers Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Punch Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
Stapler Unit Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
Rear Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
Front Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
Front Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
Mailbox Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Storage Unit Cover Removals . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
Horizontal Transport Unit Cover Removal . . . . . . . . . . . . . . . . . 4-92
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Printer with Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Printer Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Electrical Components (cont.) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Printer Main Engine Board PWB-A . . . . . . . . . . . . . . . . . . . . . . . 5-8
RIP Controller Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
High Voltage Board (HV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Power Unit (PU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Network Interface Card (NIC). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11



ix
4023-001

Paper Cassettes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Fixed Paper Size Cassette (Tray 1 only). . . . . . . . . . . . . . . . . . .5-12
Universal Cassette (Tray 2,3 and 500-Sheet Option) . . . . . . . . .5-12
Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Paper Cassette Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Paper Cassette Electrical Components. . . . . . . . . . . . . . . . . . . .5-14
Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Duplex Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Duplex Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Duplex Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Paper Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Paper Deck Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . .5-19
Paper Deck Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
Paper Deck Electrical Components. . . . . . . . . . . . . . . . . . . . . . .5-21
Finisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
Finisher Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Finisher Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
Finisher Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . .5-26
Finisher Main Board PWB-A . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-28
Mailbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29
External View (Front: When Connected To Printer) . . . . . . . . . .5-29
External View (Rear: When Connected To Printer). . . . . . . . . . .5-29
Mailbox External View (Each Section) . . . . . . . . . . . . . . . . . . . .5-30
Mailbox Horizontal Transport Unit: Cross-Sectional View . . . . . .5-30
Mailbox Horizontal Transport Unit: Electrical Components . . . . .5-31
Mailbox Horizontal Transport Unit: Mechanical Components . . .5-31
Mailbox Storage Unit: Cross-Sectional View . . . . . . . . . . . . . . . .5-32
Mailbox Storage Unit: Electrical Components . . . . . . . . . . . . . . .5-33
Mailbox Storage Unit: Mechanical Components . . . . . . . . . . . . .5-34
Mailbox Storage Unit: Main Board PWB-A . . . . . . . . . . . . . . . . .5-34
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Assembly 1: Printer Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Assembly 2: Printer Frames (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Assembly 3: Printer Frames (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Assembly 4: Printer Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12


x Service Manual
4023-001

Assembly 5: Printer Fuser (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Assembly 6: Printer Fuser (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Assembly 7: Printer Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Assembly 8: Printer Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Assembly 9: Printer Electrical Components . . . . . . . . . . . . . . . . . . 7-26
Assembly 10: Printer Paper Take-up . . . . . . . . . . . . . . . . . . . . . . . 7-28
Assembly 11: Printer Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Assembly 12: Printer Paper Tray . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Assembly 13: 500 Sheet Unit Housing . . . . . . . . . . . . . . . . . . . . . . 7-38
Assembly 14: 500 Sheet Unit Paper Take-up . . . . . . . . . . . . . . . . . 7-42
Assembly 15: 500 Sheet Unit Paper Tray Unit (A) . . . . . . . . . . . . . 7-46
Assembly 16: 500 Sheet Unit Paper Tray Unit (B) . . . . . . . . . . . . . 7-48
Assembly 17: Printer Controller Card . . . . . . . . . . . . . . . . . . . . . . . 7-50
Assembly 18: Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Assembly 19: Paper Deck Housing. . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Assembly 20: Paper Deck Paper Take-up (A) . . . . . . . . . . . . . . . . 7-58
Assembly 21: Paper Deck Paper Take-up (B) . . . . . . . . . . . . . . . . 7-62
Assembly 22: Paper Deck Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
Assembly 23: Paper Deck Paper Tray (A) . . . . . . . . . . . . . . . . . . . 7-70
Assembly 24: Paper Deck Paper Tray (B) . . . . . . . . . . . . . . . . . . . 7-72
Assembly 25: Finisher Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-74
Assembly 26: Finisher Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-76
Assembly 27: Finisher Paper Transport (A) . . . . . . . . . . . . . . . . . . 7-80
Assembly 28: Finisher Paper Transport (B) . . . . . . . . . . . . . . . . . . 7-82
Assembly 29: Finisher Paper Aligning. . . . . . . . . . . . . . . . . . . . . . . 7-86
Assembly 30: Finisher Assistance Tray . . . . . . . . . . . . . . . . . . . . . 7-92
Assembly 31: Finisher Elevator Tray. . . . . . . . . . . . . . . . . . . . . . . . 7-96
Assembly 32: Finisher Punch Unit . . . . . . . . . . . . . . . . . . . . . . . . 7-100
Assembly 33: Finisher Stapler Unit/Finisher Tray . . . . . . . . . . . . . 7-102
Assembly 34: Finisher/Mailbox Horizontal Transfer (A) . . . . . . . . 7-106
Assembly 35: Finisher/Mailbox Horizontal Transfer (B) . . . . . . . . 7-108
Assembly 36: Mailbox Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-112
Assembly 37: Mailbox Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-114
Assembly 38: Mailbox Paper Transport (A). . . . . . . . . . . . . . . . . . 7-118
Assembly 39: Mailbox Paper Transport (B). . . . . . . . . . . . . . . . . . 7-122
Assembly 40: Mailbox Paper Transport (C) . . . . . . . . . . . . . . . . . 7-124
Assembly 41: Mailbox Paper Transport (D) . . . . . . . . . . . . . . . . . 7-126
Assembly 42: Mailbox Paper Transport (E). . . . . . . . . . . . . . . . . . 7-128
Assembly 43: Mailbox Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-130
Assembly 44: Optional Features (No illustration) . . . . . . . . . . . . . 7-132
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1



xi
4023-001




xii Service Manual
4023-001

Notices and Safety Information

Laser Notices
The following laser notice labels may be affixed to this printer as
shown:




Notices and Safety Information xiii
4023-001


Laser Notice
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.

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.


Laser German
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 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 French

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 relatives aux produits laser de Classe I.



xiv Service Manual
4023-001

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 .


Avvertenze sui prodotti laser Italian
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.

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 Spanish
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 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


Notices and Safety Information xv
4023-001

la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.


Declaração sobre Laser Portugese

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.

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.




Laserinformatie Dutch

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.

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.




xvi Service Manual
4023-001


Lasermeddelelse Danish
Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 60825.

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.




Notices and Safety Information xvii
4023-001


Huomautus laserlaitteesta Finnish

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 60825 -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.

LUOKAN 1 LASERLAITE

VAROITUS! Laitteen käyttäminen muulla kuin tässä
käyttöohjeessa mainitulla tavalla saattaa altistaa käyttäjän
turvallisuusluokan 1 ylittävälle näkymättömälle lasersäteilylle.

KLASS 1 LASER APPARAT

VARNING! Om apparaten används på annat sätt än i denna
bruksanvisning specificerats, kan användaren utsättas för osynlig
laserstrålning, som överskrider gränsen för laserklass 1.

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.




xviii Service Manual
4023-001


Laser-notis Swedish

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.

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 Norwegian

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.

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.




Notices and Safety Information xix
4023-001


Avís sobre el Làser Catalàn

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.

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.


Japanese Laser Notice




xx Service Manual
4023-001


Chinese Laser Notice




Korean Laser Notice




Notices and Safety Information xxi
4023-001


Safety Information
· This product is designed, tested and approved to meet strict
global safety standards with the use of specific Lexmark
components. The safety features of some parts may not always
be obvious. Lexmark is not responsible for the use of other
replacement parts.
· The maintenance information for this product has been
prepared for use by a professional service person and is not
intended to be used by others.
· There may be an increased risk of electric shock and personal
injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precautions.


Consignes de Sécurité French

· Ce produit a été conçu, testé et approuvé pour respecter les
normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. Les caractéristiques de
sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres
pièces de rechange.
· 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.




xxii Service Manual
4023-001


Norme di sicurezza Italian

· Il prodotto è stato progettato, testato e approvato in conformità
a severi standard di sicurezza e per l'utilizzo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune parti
non sempre sono di immediata comprensione. Lexmark non è
responsabile per l'utilizzo di parti di ricambio di altri produttori.
· 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 German

· Dieses Produkt und die zugehörigen Komponenten wurden
entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder
Haftung für dieses Produkt 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.


Pautas de Seguridad Spanish

· Este producto se ha diseñado, verificado y aprobado para
cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede que
las características de seguridad de algunas piezas no sean



Notices and Safety Information xxiii
4023-001

siempre evidentes. Lexmark no se hace responsable del uso de
otras piezas de recambio.
· 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 Portugese

· Este produto foi concebido, testado e aprovado para satisfazer
os padrões globais de segurança na utilização de componentes
específicos da Lexmark. As funções de segurança de alguns
dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de
substituição.
· 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 Catalàn

· Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de Lexmark. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Lexmark no es responsabilitza de l'us
d'altres peces de recanvi.
· 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.



xxiv Service Manual
4023-001

El personal professional ha d'estar-ne assabentat i prendre les
mesures convenients.


Chinese




Korean




Notices and Safety Information xxv
4023-001




xxvi Service Manual
4023-001

1. General Information

Maintenance Approach
The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the error code charts,
symptom index, and service checks to determine the symptom and
repair the failure. You may find that the removals in the Repair
Information chapter will help you identify parts.

After you complete the repair, perform tests as needed to verify the
repair.


Tools
The removal and adjustment procedures described in this manual
require the following tools and equipment:

· Magnetic tip Phillips screwdrivers, large and small
· Flat-blade screwdrivers
· Analog volt ohmmeter (a digital volt ohmmeter may also be
used)
· Needle nose pliers
· Tweezers, C-ring pliers

When you make voltage readings, always use frame ground unless
another ground is specified.




General Information 1-1
4023-001


Serial Number
The serial number is located in the bottom left corner of the label
illustrated below:




1-2 Service Manual
4023-001


Abbreviations
ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable Read-
Only Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Network
LASER Light Amplification by Stimulated Emission
of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PICS Problem Isolation Charts
PIXEL Picture Element
POR Power-On Reset
POST Power-On Self Test
PQET Print Quality Enhancement Technology
RIP Raster Image Processor
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
VAC Volts alternating current
VDC Volts direct current




General Information 1-3
4023-001


Standard Features
Printer (Main)

Feature Description

Print speed 35 ppm (letter/A4) High Speed Printing
Power supply AC120V, AC220­240V ±10%
Power 1200W
consumption 45W or less (low power)
Temperature 10 to 35°C
Controller Lexmark Controller (High Performance)
RIP page Hard disk option can be partitioned to be used for
storage intermediate RIP page storage
Printer MarkvisionTM for network and/or desktop printer
management management
software
Operator panel Operator panel access for menus
Universal Drawer 250 sheet 11x17/A3/letter/legal/A4
500 sheet input Two (2) 500 sheet input drawers (11x17/A3/letter/legal/
drawers A4)
Copy collation Multiple copy collation in the printer RAM
Dimensions 1.75 ft. (535 mm) Width x 2.06 ft. (628 mm) Depth x 1.40
ft. (428 mm) Height
Printing system Electrostatic dry powdered imaging system +
Imaging cartridge
Two-component imaging cartridge
Exposure system Laser diode + polygon mirror scanning
Paper feeding Six-way system Tray 1 (multipurpose) (250 sheets)
system
Charging system Comb electrode with scorotron system
Development MTHG system
Density ATDC sensor
correction
Density control Developing bias adjusting system



1-4 Service Manual
4023-001


Feature Description

Image transfer Roller transform system
system
PC drum Organic photoconductor (OPC)
Cleaning system Blade system
Separating Paper separator
system
Fusing system Heat roller fusing system
Paper exit Printer
system Face down (300 sheets maximum A4/C/Letter C)
Mailbox
2000 sheets
Finisher
2500 sheets
500 sheets standard bin
2000 sheets finisher bin




General Information 1-5
4023-001

Options

Optra W810
Option Description
Versions*

EDO DRAM 32MB EDO Memory A,B,C
Memory
Options: 64MB EDO Memory
Hard disk Hard disk option A,B,C
Hard disk adapter cable
Tri-port interface Serial, LocalTalk and IR A,B,C
card
MarkNetTM S Token-ring B,C
Adapters Ethernet (10BT/100BTx)
Ethernet (10BT/2)
Ethernet (10BT/100BTx) SCSI
Coax/twinax adapter for SCS
Parallel Parallel/USB A,B,C
connector
Paper handling 500 sheet input tray and drawer A,B,C

2500 sheet input tray (worldwide)

2000 sheet mailbox

2500 sheet finisher (3 and 4 hole
punching capability, 5k stapling capacity)
OptraImageTM Ethernet 10/100, SCSI A,B,C
scanner and fax
Supplies Photoconductor kit A,B,C
Toner cartridge
Staples
Cables 10-foot parallel cable A,B,C
20-foot parallel cable
50-foot serial cable
10-foot 1284 A-C parallel cable


*Versions are:
A­W810
B­W810n
C­W810dn




1-6 Service Manual
4023-001


Printer/Options
Parts Identification




General Information 1-7
4023-001


Printer Configuration
The following diagram shows the major parts of the printer and
paper path. The printer consists of the paper feed section, printhead
unit (exposure section), imaging cartridge (charging section and
development section), image transfer section, fusing section,
cleaning section and paper exit section.




1 Paper Exit Roller 12 Double Feed Sensor
2 Paper Exit Sensor (PS3) 13 Tray1 (1st Paper Cassette)
3 Lower Fusing Roller 14 1st Paper Cassette Near Empty Sensor
(PC5)
4 Upper Fusing Roller (Heater Lamp) 15 1st Paper Cassette Empty Sensor (PC4)
5 Image Transfer Roller 16 ATDC Sensor
6 Synchronizing Roller 17 Sleeve Roller
7 Synchronizing Roller Sensor (PC2) 18 PC Drum Charger
8 Manual Unit 19 PC Drum
9 Tray2 (2nd Paper Cassette) 20 Imaging Cartridge
10 2nd Paper Cassette Near Empty Sensor 21 Print Head Unit (PH)
(PC25)
11 2nd Paper Cassette Empty Sensor (PC22) 22 Laser Beam




1-8 Service Manual
4023-001


General Description of Each Section
Paper Feed Section
Paper feeds from tray 1 (1st paper cassette), tray 2 or 3 (500-sheet
paper cassette). When the printer receives a print command, the
transport motor M2 turns, paper take-up solenoid turns ON, and the
paper take-up roller in the 1st paper cassette feeds a sheet of paper.
The synchronizing roller sensor (PC2) detects the fed paper and the
paper is then fed to the synchronizing roller for printing. When paper
trays (500-sheet cassette (tray 2 or 3), 250-sheet universal cassette
(tray 1)), or 2500-sheet drawer is installed, paper feeds from the
respective paper source.

Printhead Unit (Exposure Section)
The laser diode in the printhead unit emits a laser beam. The
scanning beam creates an electrostatic latent image on the surface
of the PC drum in the imaging cartridge.

Imaging Cartridge (Charging, Development Section)
The imaging cartridge consists of the charging section and
development section. The I/C drive motor (M1) drives the moving
parts of the imaging cartridge.

Image Transfer Section (Release Section)
The toner image on the PC drum transfers to the paper when
passing over the transfer roll. The paper electrostatically releases
from the PC drum.

Fusing Section
Using a heated roller, the fusing section permanently fixes the toner
image onto the paper. A heat sensitive element (thermistor) attached
to the upper fusing roller controls the fusing temperature.

Cleaning Section
The cleaning blade removes excess toner from the paper and
transfers the toner to the waste toner box.



General Information 1-9
4023-001

Paper Exit Section
After the paper passes the fusing section, the paper exit roller ejects
the paper out the top of the printer. The paper exit sensor (PC3)
senses the ejection of the paper.

Optional manual and duplex unit installed:

The duplex unit switchback motor pulls the trailing edge of the
printed paper inside the duplex unit. The duplex unit transport motor
then feeds the paper to the manual unit where the paper remains
until the second print command.


General Flow for Printing Process
Print command The motor in the printhead unit starts
turning.
Polygon Motor ON
Cleaning The transfer roller becomes negatively
charged to prevent the negatively-charged
toner from sticking to the PC Drum.
Starting processing The I/C (imaging cartridge) drive motor (M1)
starts turning.
Paper take-up The transport motor (M2) starts turning.

The paper take-up solenoid turns on to feed
paper.
Laser emission A laser beam is emitted at constant power.
Scanning the image data A laser beam scans the surface of the PC
drum to produce a latent electrostatic image.
Paper feeding
The sychronizing roller sensor (PC2) detects
the presence of paper. The sychronizing
clutch then turns on which turns on the
sychronizing roller for feeding paper.
Developing the image data Toner is applied to the PC drum to produce a
visible toner image.
Transfer the image data The toner image on the surface of the PC
drum is transferred onto the paper.
Fusing the toner The toner is permanently fixed onto the
paper.
Cleaning Excess toner and electric potential on the
PC drum are eliminated.
Paper ejection The paper ejects.




1-10 Service Manual
4023-001


Paper Feed Section
Taking Up Paper­Tray 1 (1st Paper Cassette)
Power is transmitted from the transport motor (M2) as follows to take
up paper from the 1st paper cassette:

1. The transport motor (M2) turns counterclockwise.
2. The idle gear turns clockwise and the 1st cassette paper take-
up solenoid (SL1) turns ON.
3. The paper take-up roller turns counterclockwise and paper is
taken up.




1 PC Drum 5 Synchronizing Roller
2 Image Transfer Roller 6 Paper Take-Up Roller
3 Transport Motor (M2) 7 Paper
4 Synchronizing Roller
Sensor (PC2)




General Information 1-11
4023-001

Tray 1 Sensors




1 1st Cassette Paper Near Empty Sensor (PC5) 5 Synchronizing Roller Sensor (PC2)
2 1st Cassette Set Sensor (PC6) 6 Double Feed Sensor
3 1st Cassette Paper Take-up Solenoid (SL1) 7 Paper Take-up Roller
4 Separator Pad 8 1st Paper Cassette Empty Sensor (PC4)


1st Cassette Tray 1 Set Sensor (PC6)

PC6 (1) sensor detects installation of the 1st paper cassette in tray
1.




.
1 1st Cassette Set Sensor (PC6)
2 1st Paper Cassette




1-12 Service Manual
4023-001

1st Cassette Tray 1 Paper Empty Sensor (PC4)

PC4 (1) detects paper empty status of the 1st paper cassette.

.




1 1st Paper Cassette Empty Sensor (PC4)
2 Paper


1st Cassette Tray 1 Paper Near Empty Sensor (PC5)

PC5 detects when the 1st cassette is near empty.




1 1st Paper Cassette Near Empty Sensor (PC5)
2 Paper
3 Paper Lifting Plate




General Information 1-13
4023-001

1st Cassette Tray 1 Double Feed Sensor

The double feed sensor (located on the double feed detecting
sensor board (PWB-H)) detects the possibility of double feed. This
sensor uses a photo reflector.

The double feed sensor detects whether the leading edge of paper
to be taken up next runs 10 mm or more from the paper nip point. If
paper runs 10 mm or more, double feeding may occur if the paper is
taken up in the normal printing interval. To avoid this, the printer
prolongs the printing intervals as long as the double feed sensor
detects a double feed status. This results in the reduction of the
number of sheets fed per minute.




Light reflects: Output=L Light does not reflect: Output=H
1 Paper
2 Paper Take-up Roller
3 Double Feed Sensor


1st Casse