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Assembly 36: Options and miscellaneous

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Assembly 36: Options and miscellaneous AsmIndex NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS Part number 40X1508 40X1509 40X1510 40X1454 40X1455 40X1514 40X1513 40X1512 40X1515 40X0290 40X3522 40X4743 40X3521 40X4741 40X3523 40X4742 40X3524 40X4744 40X4754 40X0291 40X2610 40X1592 40X1593 40X1594 40X1376 40X1377 40X1378 40X1562 7371549 7370563 7370564 7370565 7370566 Units/ option 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Units/ FRU 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description 128MB SDRAM card assembly 256MB SDRAM card assembly 512MB SDRAM card assembly 32MB Flash DIMM card assembly 64MB Flash DIMM card assembly Traditional Chinese font DIMM card assembly Simplified Chinese font DIMM card assembly Japanese font card assembly Korean font card assembly card assembly RS-232 serial interface card IPDS/SCS card assembly-1xx/3xx only IPDS/SCS card assembly-2xx/4xx only Bar code card assembly-1xx/3xx only Bar code card assembly-2xx/4xx only Lexmark Forms card assembly-1xx/3xx only Lexmark Forms card assembly-2xx/4xx only PrintCryption™ card assembly-1xx/3xx only PrintCryption card assembly-2xx/4xx only PRESCRIBE card assembly-2xx/4xx only Adapter, parallel 1284-B Hard Disk, 40GB with/adapter (formatted) MarkNet N7020e ENA adapter MarkNet N7000e ENA adapter MarkNet N7000e ENA adapter (requires parallel) MarkNet N8020 Gigabit Ethernet adapter MarkNet N8030 Fiber Ethernet adapter MarkNet N8050 wireless print server, 802.11g, U.S. MarkNet 8050 wireless print server, 802.11g, non-U.S. Screw type 323, parts packet, 40X1633 Screw type 324, parts packet, 40X1635 Screw type 232, parts packet, 40X1676 Screw type 102, parts packet, 40X1639 Screw type 312/322/412/423, parts packet, 40X1691 Screw type 484, parts packet, 40X1632 Screw, 500-sheet tray, parts packet, 40X1665 Screw type 121, parts packet, 40X1780 Relocation package kit assembly-printer Relocation package kit assembly-output expander Relocation package kit assembly-5-bin mailbox Relocation package kit assembly-500 drawer Relocation package kit assembly-duplex 5061 Parts catalog 7-71

Section	Page
Table of contents	3
Notices and safety information	11
Laser notice	11
Preface	20
1. General information	21
Models	21
Tools required for service	21
Options and features	22
Printer specifications	24
Power and performance	27
Media specifications	29
Media input and output capacities	29
Media sizes	30
Media guidelines	37
Web oiler upgrade kit and replacements	40
Upgrade kit	40
Acronyms	41
2. Diagnostic information	43
Start	43
POR (Power-On Reset) sequence	44
Symptom tables	45
Symptom table—base printer	45
Symptom table—500-sheet drawer option	46
Symptom table—HCIT 2000-sheet option	46
Symptom table—output expander option	47
Symptom table—5-bin mailbox option	47
Symptom table—StapleSmart finisher	47
Service error code and paper jam message table	49
Service checks	56
100.01 ITU error service check	56
100.02 ITU error service check	59
122.01 error code service check	60
122.02 error code service check	61
122.03 error code service check	61
122.04 error code service check	62
122.05 and 122.06 error code service check	63
122.07, 122.14, and 122.15 error code service check	64
122.08 error code service check	65
122.10 error code service check	65
122.11 error code service check	66
122.12 error code service check	66
122.13 error code service check	66
148.xx error code service check	67
150.xx error code service check	68
151.xx error code service check	68
152.xx error code service check	69
153.xx error code service check	69
177.xx error code service check	70
200.03 paper jam service check	70
200.04 paper jam service check	71
200.05 paper jam service check	71
200.06 paper jam service check	72
200.07 paper jam service check	72
200.16 paper jam service check	72
200.21, 200.28, and 200.29 paper jam service check	73
200.93 paper jam service check	73
200.96 paper jam service check	75
201.xx and 202.xx paper jam service check	75
230.xx paper jam service check	77
241.xx paper jam service check	78
242.xx paper jam service check	79
243.xx paper jam service check	83
244.xx paper jam service check	88
250.xx paper jam service check	89
271.xx paper jam service check	91
272.xx paper jam service check	92
282.98 paper jam service check	93
900.xx RIP Software Error service check	93
925.02 error code service check	96
926.01 error code service check	96
927.03 error code service check	97
930.09 error code service check	97
940.xx error code service check	98
941.xx error code service check	100
942.xx error code service check	102
943.xx error code service check	104
956.xx service error service check	106
982.xx error service check	106
990.01 error service check	107
5-bin mailbox option service check	109
500-sheet drawer option service check	113
AC and DC power service check	116
Autocompensator service check	118
Black only retract (BOR) service check	120
Close door/HVPS/printhead interlock switch service check	121
Duplex option service check	123
Envelope feeder option service check	125
HCIT 2000-sheet option service check	126
Fuser drive assembly noise check	129
Operator panel LCD/status LED/buttons service check	130
Output expander option service check	132
Print quality service check	135
Second transfer roll service check	151
StapleSmart finisher service check	153
Tray 1 service check	157
Tray 1 media size sensing service check	158
User operator panel, menus, and messages	159
Understanding the printer operator panel	159
Operator panel buttons	159
Menu map	161
User attendance messages	166
3. Diagnostic aids	179
Diagnostic procedures	179
Printhead diagnostics	179
Print quality defect locator chart	181
Partial Print Test	182
HCIT standalone test mode	183
Accessing service menus	184
Diagnostics mode	185
Entering Diagnostics mode	185
Diagnostic mode menus	185
Exiting the Diagnostics mode	187
REGISTRATION	188
ALIGNMENT MENU	189
MISC TESTS	191
PRINT TESTS	192
HARDWARE TESTS	193
DUPLEX TESTS	197
INPUT TRAY TESTS	198
OUTPUT BIN TESTS	199
FINISHER TESTS	201
BASE SENSOR TEST	202
DEVICE TESTS	203
PRINTER SETUP	204
EP SETUP	206
ERROR LOG	207
EXIT DIAGNOSTICS	208
Configuration Menu	209
Entering Config Menu	209
Exiting the Config Menu	209
Reset Fuser Cnt	210
Black Only Mode	210
Prt Quality Pgs	210
Color Trapping	210
Tray Insert Msg	210
SIZE SENSING	210
Panel Menus	211
PPDS Emulation	211
Demo Mode	211
Factory Defaults	211
Energy Conserve	211
EVENT LOG	211
Auto Color Adjust	212
Paper Prompts	212
Env Prompts	212
Font Sharpening	212
Jobs On Disk	213
Disk Encryption	213
Exit Config Menu	213
Paper jams	214
Identifying jams	214
Access doors and trays	214
Understanding jam messages	215
Clearing the entire paper path	216
4. Repair information	229
Handling ESD-sensitive parts	229
Screw identification table	230
Removal procedures	234
Operator panel bezel removal	235
Lens removal	237
Front cover rear pivot cover removal	238
Front cover or front cover backplate assembly removal	239
Redrive cap removal	240
Top cover assembly removal	241
Front lower left cover removal	245
Paper path access door removal	246
Front left handle cover assembly removal	247
Front lower right cover removal	247
Front right handle cover assembly removal	249
Rear cover removal	250
Lower right door assembly removal	252
Left lower cover removal	252
Lower jam access door assembly removal	253
Redrive door removal	254
Autocompensator pick assembly removal	255
BOR drive assembly removal	262
Cartridge contact assembly removal	263
Cartridge drive assembly removal	266
Developer HVPS board removal	267
Friction buckler and buckler housing removal	268
Front right light shield removal	270
Fuser assembly removal	272
Fuser bottom duct removal	274
Fuser drive assembly removal	274
Fuser fan removal	275
Fuser top duct removal	275
Inner system board shield removal	276
ITU assembly removal	277
ITU drive assembly removal	280
LVPS assembly removal	281
Media size sensing assembly removal	283
Media size sensing board removal	286
Multipurpose feeder (MPF) removal	287
Multipurpose feeder (MPF) autocompensator or side restraints removal	290
Multipurpose feeder (MPF) motor removal	292
Nip relief handle removal	293
Operator panel assembly removal	296
Outer system board shield removal	297
Pick rolls removal	298
Printhead removal and adjustments	300
Rear bellcrank removal (cyan, magenta, yellow)	307
Rear bellcrank (black) removal	309
Redrive assembly removal	310
Registration motor removal	311
Rib housing removal	312
RIP fan removal	314
S2/narrow media/transparency/multipurpose feeder cable removal	315
S2/narrow media/transparency/multipurpose feeder sensors removal	316
Second transfer roll removal	316
System board removal	317
Transfer HVPS board removal	319
Transfer plate assembly removal	322
Vacuum transport belt (VTB) removal	323
Vacuum transport belt (VTB) fan removal	325
Waste container door removal	325
Waste container latch removal	326
Web oiler fuser assembly and card removal and replacement	327
5. Connector locations	333
Locations	333
Printer boards	333
Printer motors	334
Printer sensors	335
Cartridge contact assembly pin locations (cyan, magenta and yellow)	336
Cartridge contact assembly pin locations (black)	337
System board cabling reference	338
Connectors	339
System board	339
Autoconnect—top	350
Autoconnect—bottom	351
Transfer high voltage power supply (HVPS)	352
Developer high voltage power supply (HVPS) board	354
Low voltage power supply (LVPS)	355
Media size sensing board	357
High-capacity input tray (HCIT)	358
StapleSmart finisher	360
6. Preventive maintenance	363
Safety inspection guide	363
Scheduled maintenance	363
Standard fusers	363
ITU Maintenance kits	363
Lubrication specifications	364
Lubrication for replacement motors	364
Fuser drive assembly	364
Cartridge drive assembly	365
ITU drive assembly	365
7. Parts catalog	367
How to use this parts catalog	367
Assembly 1: Covers	368
Assembly 1.1: Covers	370
Assembly 2: Cartridge mounting	372
Assembly 3: Fuser assembly	373
Assembly 3.1: Fuser (web oiler)	374
Assembly 4: Fuser drive	376
Assembly 5: Vacuum transport belt (VTB) assembly	377
Assembly 6: Transfer	378
Assembly 7: Printheads	379
Assembly 8: Paper feed output (redrive)	380
Assembly 9: Paper feed input	381
Assembly 10: Media size sensing	382
Assembly 11: Paper feed transport	383
Assembly 12: Multipurpose feeder (MPF)	384
Assembly 13: 500-Sheet integrated tray	386
Assembly 14: Autocompensator assembly	387
Assembly 15: ITU assembly	388
Assembly 16: ITU drive assembly	389
Assembly 17: ITU loading	390
Assembly 18: Waste toner	392
Assembly 19: BOR drive assembly	393
Assembly 20: Cartridge contact assembly	394
Assembly 21: Cartridge drive assembly	395
Assembly 22: Electronics	396
Assembly 22.1: Electronics	398
Assembly 22.2: Electronics	400
Assembly 22.3: Electronics	401
Assembly 23: Electronics—cabling interconnections 1	402
Assembly 24: Electronics—cabling interconnections 2	404
Assembly 25: Electronics—cabling interconnections 3	406
Assembly 26: Electronics—cabling interconnections 4	407
Assembly 27: Output expander	408
Assembly 27.1: Output expander	410
Assembly 28: 5-Bin mailbox	412
Assembly 28.1: 5-Bin mailbox	414
Assembly 29: 500-Sheet drawer option	416
Assembly 29.1: 500-Sheet drawer option	418
Assembly 30: Duplex option	420
Assembly 30.1: Duplex option	422
Assembly 31: High-capacity input tray (HCIT)	424
Assembly 31.1: High-capacity input tray (HCIT)	426
Assembly 32: StapleSmart finishe	428
Assembly 32.1: StapleSmart finisher	429
Assembly 32.2: StapleSmart finisher	430
Assembly 32.3: StapleSmart finisher	431
Assembly 33: Envelope option	432
Assembly 34: Outdoor media tray option	434
Assembly 35: Banner option	435
Assembly 36: Options	436
Appendix A—Service tips	439
Identifying the printheads	439
Redrive belt routing	440
Duplex option deflector button replacement	441
Appendix B—Print quality samples	443
Print tests	443
Print Quality Pages—Title page (total of five)	443
Print Quality Pages—Page 1 (total of five)	444
Print Quality Pages—Page 2 (total of five)	445
Print Quality Pages—Page 3 (total of five)	446
Print Quality Pages—Page 4 (total of five)	447
Registration and alignment	448
Quick Test Page	448
Printhead mechanical alignment test page	449
Printhead electronic alignment test page—Magenta (one of two)	450
Printhead electronic alignment test page—Magenta (two of two)	451
Index	453
Part number index	461
Repeating defect locator	471
Wiring diagrams	472
System board—left side	472
System board—right side	473

Match case Limit results 1 per page

Parts catalog

7-71

5061

Assembly 36: Options and miscellaneous

Asm-

Index

Part

number

Units/

option

Units/

FRU

Description

40X1508

128MB SDRAM card assembly

40X1509

256MB SDRAM card assembly

40X1510

512MB SDRAM card assembly

40X1454

32MB Flash DIMM card assembly

40X1455

64MB Flash DIMM card assembly

40X1514

Traditional Chinese font DIMM card assembly

40X1513

Simplified Chinese font DIMM card assembly

40X1512

Japanese font card assembly

40X1515

Korean font card assembly card assembly

40X0290

RS-232 serial interface card

40X3522

IPDS/SCS card assembly—1xx/3xx only

40X4743

IPDS/SCS card assembly—2xx/4xx only

40X3521

Bar code card assembly—1xx/3xx only

40X4741

Bar code card assembly—2xx/4xx only

40X3523

Lexmark Forms card assembly—1xx/3xx only

40X4742

Lexmark Forms card assembly—2xx/4xx only

40X3524

PrintCryption™ card assembly—1xx/3xx only

40X4744

PrintCryption card assembly—2xx/4xx only

40X4754

PRESCRIBE card assembly—2xx/4xx only

40X0291

Adapter, parallel 1284-B

40X2610

Hard Disk, 40GB with/adapter (formatted)

40X1592

MarkNet N7020e ENA adapter

40X1593

MarkNet N7000e ENA adapter

40X1594

MarkNet N7000e ENA adapter (requires parallel)

40X1376

MarkNet N8020 Gigabit Ethernet adapter

40X1377

MarkNet N8030 Fiber Ethernet adapter

40X1378

MarkNet N8050 wireless print server, 802.11g, U.S.

40X1562

MarkNet 8050 wireless print server, 802.11g, non-U.S.

Screw type 323, parts packet, 40X1633

Screw type 324, parts packet, 40X1635

Screw type 232, parts packet, 40X1676

Screw type 102, parts packet, 40X1639

Screw type 312/322/412/423, parts packet, 40X1691

Screw type 484, parts packet, 40X1632

Screw, 500-sheet tray, parts packet, 40X1665

Screw type 121, parts packet, 40X1780

7371549

Relocation package kit assembly—printer

7370563

Relocation package kit assembly—output expander

7370564

Relocation package kit assembly—5-bin mailbox

7370565

Relocation package kit assembly—500 drawer

7370566

Relocation package kit assembly—duplex