Lexmark X644E Service Manual - Page 4

iv

Service Manual

7002-xxx

Scanner—scan quality

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

High-capacity feeder (2000-sheet) symptoms

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

Paper tray symptoms

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Duplex option symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Envelope feeder symptoms

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Messages and error codes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

Sub error codes for 8xx, 9

xx,

and 2

xx

error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

User status displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

User attendance messages

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

User line 2 link messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

Check device connection messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56

User attendance messages—paper jams and paper handling errors (2

xx

.

xx

) . . . . . . . . . . . . . . . . . .2-57

Service checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95

202.03 Error code service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-95


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-96


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-98


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-100


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-102


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-104


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-105


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-106


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-107

293 Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-108


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-110


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-113

298.01 Error code service check—models X644e/X646e

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115

842.xx Error code service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118



. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118

927.xx Fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119

Main fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119

Cartridge fan service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119

950.00 through 950.29 EPROM mismatch failure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-120

950.30 through 950.60 EPROM mismatch failure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121

ADF paper length sensor service check—models X644e/X646e . . . . . . . . . . . . . . . . . . . . . . . . . . .2-122

ADF paper width sensor service check—models X644e/X646e . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123

Charge roll service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-123

Cover closed sensors service check—flatbed

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-124

Cover closed switch/cable service check—printer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-125

Dead machine service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-125

Duplex option service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-127

Envelope feeder service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-129

Flatbed size sensor service check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-131

Fuser service checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-132

920.xx—Cold fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-132

922.xx—Cold fuser check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-134

923.xx—Hot fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-135



Lexmark X644E Service Manual - Page 4

Service Manual, Messages and error codes, Service checks

Page 4 highlights

Section	Page
Table of contents	3
Laser notices	11
Laser notice	11
Laser	11
Avis relatif à l’utilisation de laser	11
Avvertenze sui prodotti laser	12
Avisos sobre el láser	12
Declaração sobre Laser	12
Laserinformatie	13
Lasermeddelelse	13
Huomautus laserlaitteesta	13
Laser-notis	14
Laser-melding	14
Avís sobre el Làser	14
Japanese Laser Notice	15
Korean Laser Notice	16
Consignes de sécurité	17
Norme di sicurezza	17
Sicherheitshinweise	18
Pautas de Seguridad	18
Informações de Segurança	18
Informació de Seguretat	19
Preface	20
1. General information	21
Maintenance approach	21
Configured models	22
Options	23
Specifications	24
General	24
Resolution	24
Data streams	24
Memory configuration	25
Recommended operating clearances	25
Dimensions	26
Power requirements	27
Electrical specifications	27
Environment	28
Acoustics	28
Media specifications	29
Paper and specialty media guidelines	29
Supported print media	29
Print media sizes	29
Print media types	31
Print media weights	31
Selecting print media	33
Paper	33
Paper characteristics	33
Transparencies	34
Envelopes	34
Labels	35
Card stock	36
Storing print media	36
Avoiding jams	36
Tools required	37
Acronyms	38
2. Diagnostic information	39
Start	39
Symptom tables	39
Service errors (8xx.xx and 9xx.xx’s)	39
User status and attendance messages	39
Additional information	39
Understanding the MFP operator panel	40
MFP operator panels	40
Home screen and Home screen buttons	42
Buttons and touchscreen icon buttons	42
Menus	47
Symptom tables	48
Printer symptoms	48
Scanner-ADF symptoms	49
Scanner-flatbed symptoms	49
Scanner-scan quality	49
High-capacity feeder (2000-sheet) symptoms	49
Paper tray symptoms	50
Duplex option symptoms	50
Envelope feeder symptoms	50
Messages and error codes	51
Service error codes	51
Sub error codes for 8xx, 9xx, and 2xx error codes	51
User status displays.	76
User attendance messages	80
User line 2 link messages	94
Check device connection messages	94
User attendance messages-paper jams and paper handling errors (2xx.xx)	95
Service checks	133
202.03 Error code service check	133
202.06 Error code service check	133
290.00 Error code service check	134
290.01 Error code service check	136
290.02 Error code service check	138
290.10 Error code service check	140
291.00 Error code service check	142
291.01 Error code service check	143
291.02 Error code service check	144
292.00 Error code service check	145
293 Error code service check	146
294.00 Error code service check	147
294.01 Error code service check	148
294.02 Error code service check	150
294.03 Error code service check	151
298.01 Error code service check-models X644e/X646e	153
298.02 Error code service check	153
842.xx Error code service check	153
843.xx Error code service check	154
845.00 Error code service check	155
848.00 Error code service check	156
848.01 Error code service check	156
900.xx Error code service check	156
900.90 Error code service check	156
927.xx Fan service check	157
Main fan service check	157
Cartridge fan service check	157
950.00 through 950.29 EPROM mismatch failure	158
950.30 through 950.60 EPROM mismatch failure	159
ADF paper length sensor service check-models X644e/X646e	160
ADF paper width sensor service check-models X644e/X646e	161
Charge roll service check	161
Cover closed sensors service check-flatbed	162
Cover closed switch/cable service check-printer	163
Dead machine service check	163
Duplex option service check	165
Envelope feeder service check	167
Flatbed size sensor service check	169
Fuser service checks	170
920.xx-Cold fuser service check	170
922.xx-Cold fuser check	172
923.xx-Hot fuser service check	173
924.xx-Hot fuser service check	174
925.xx-Hot fuser service check	175
Fuser exit sensor service check	176
Fuser narrow media sensor service check	177
High-capacity feeder input tray service check	179
Input sensor service check	184
Input tray(s) service check	185
Interface card service check	186
LCD touchscreen contrast control service check-model X642e	187
LCD touchscreen display service check-models X644e/X646e	187
Main drive service check	191
Operator panel Help and Home buttons service check-model X642e	192
Operator panel Menu button service check-model X642e	192
Operator panel right cover assembly service check	192
Options service check	193
Flash memory option(s)	193
DRAM memory option(s)	193
Hard disk option	193
Output bin sensor standard tray service check	194
Paper feed service check-printer	194
Paper size sensing service check	196
Parallel port service check	197
Print quality service check	198
Scan quality service check	203
Signature button assembly service check	208
System board service check	208
Toner sensor service check	209
Transfer roll service check	210
3. Diagnostic aids	211
Accessing service menus	211
Diagnostics Menu	212
Entering Diagnostics Menu	212
Available tests	212
Registration (printer)	215
Quick Test	216
PRINT TESTS	217
Input source tests	217
Printing Quality Pages	217
HARDWARE TESTS	218
Panel Test	218
Button Test	218
DRAM Test	219
CACHE Test	219
Parallel Wrap test	220
Serial Wrap test	220
DUPLEX TESTS	221
Quick Test (duplex)	221
Top Margin (duplex)	221
Sensor Test (duplex)	222
Motor Test (duplex)	222
Duplex Feed 1	223
Duplex Feed 2	223
INPUT TRAY TESTS	223
Feed Tests (input tray)	223
Sensor Test (input tray)	224
OUTPUT BIN TESTS	224
Feed Tests (output bins)	224
Sensor Test (standard output bin)	225
BASE SENSOR TEST	225
DEVICE TESTS	226
Quick Disk Test	226
Disk Test/Clean	226
Flash Test	227
PRINTER SETUP	227
Defaults	227
Printed Page Count	228
Permanent Page Count	228
Serial Number	228
Envelope Enhance	228
Engine Setting 1 through 4	228
Model Name	228
Configuration ID	229
Edge to Edge	229
Parallel strobe adjustment (Par x Strobe Adj)	229
EP SETUP	230
EP Defaults	230
Fuser Temperature (Fuser Temp)	230
Fuser Page Count	230
Warm Up Time	230
Transfer	231
Print Contrast	231
Charge Roll	231
Gap Adjust	231
EVENT LOG	231
Display Log	231
Print Log	232
Clear Log	232
SCANNER TESTS	233
ASIC Test	233
Feed Test	233
Scanner Manual Registration	233
Sensor Tests	233
Configuration menu (CONFIG MENU)	234
Entering Configuration Menu	234
Available menus	234
Maintenance Page Count	235
Reset Maintenance Counter	235
Print Quality Pages	236
SIZE SENSING	236
Panel Menus	237
PPDS Emulation	237
Factory Defaults	238
Energy Conserve	238
Min Copy Memory	239
Format Fax Storage	239
ADF Edge Erase	239
FB Edge Erase	240
Automatic Scanner Registration	240
EVENT LOG	241
Paper Prompts	241
Envelope Prompts	242
Jobs On Disk	242
Disk Encryption	242
Wipe Disk	243
Font Sharpening	244
Require Standby	244
LES Applications	244
Key Repeat Initial Delay	245
Key Repeat Rate	245
Wiper Message	245
Exit Configuration Menu	245
Theory	246
Autocompensator operation	246
Autoconnect system, paper tray options, envelope feeder-electrical	247
Autoconnect cabling and connectors	247
Duplex Option	247
Option microcode	247
Paper feed jams	248
Identifying jams	248
Access doors and trays	249
Understanding jam messages	250
Clearing jams	250
250 Paper Jam Check MP Feeder	250
260 Paper Jam Check Env Feeder	251
23x and 24x jams	253
200 and 201 Paper Jam Remove Cartridge	256
202 Paper Jam Open Rear Door	257
23x Paper Jam Open Duplex Rear Door	258
Clearing ADF jams	259
290, 291, 292, and 294 Scanner Jams	259
4. Repair information	261
Handling ESD-sensitive parts	261
Adjustment procedures	262
Fuser solenoid adjustment	262
Gap adjustment	262
Printhead assembly adjustment-printer	262
Paper alignment assembly adjustment	263
Scanner registration	264
Automatic Scanner Registration	264
Manual registration	265
Removal procedures	266
Scanner ADF and flatbed removals	266
ADF front cover removal	266
ADF pick assembly removal	267
ADF rear cover removal	267
ADF top cover removal	269
Scanner left side cover removal	270
Front flatbed cover removal	271
Scan cover (flatbed) removal	271
Scanner right side cover removal	272
ADF attach screws removal	273
ADF CCD module assembly removal (models X644e/X646e)	274
ADF complete assembly removal	275
ADF upper entrance guide assembly removal	276
CCD belt removal	277
CCD belt tension spring removal	279
Cover closing actuator removal	281
Cover closed actuator removal	282
Document tray assembly removal	283
Flatbed CCD ribbon cable removal	284
Flatbed CCD module assembly removal	288
Flatbed contact glass removal	291
Flatbed white cushion removal	292
Flatbed interconnect card removal	293
Flatbed paper length sensor assembly removal	295
Flatbed scan assembly removal	298
Flatbed scan motor assembly removal	301
Hard disk removal	304
Home sensor removal	306
Lower exit guide assembly removal	307
Pickup solenoid assembly removal	308
Scanner control card removal	308
Scanner flatbed glass holder assembly removal	310
Separator assembly torque limiter removal	312
Upper glass holder removal	313
Printer removals	314
Fuser wiper cover assembly removal	314
Upper sub cover removal	315
Upper tray cover removal (paper support)	316
Printer left side cover removal	316
Redrive door	318
Printer right cover removal	318
Operator panel left cover assembly removal	321
Operator panel right cover assembly removal	324
Touchscreen bezel removal	326
LCD touchscreen removal-models X644e and X646e	327
LCD touchscreen removal-model X642e	329
Multipurpose feeder/lower front cover assembly removal	331
Left cover handle holder removal	332
Right cover handle holder removal	332
Left and right frame extensions	333
Pass thru plate	334
Bevel gear removal	335
Developer drive assembly removal	337
Developer drive coupler kit removal	338
ESD cover removal	338
Fuser assembly removal	339
Fuser exit sensor removal	342
Fuser exit sensor flag and spring removal	343
Fuser lamp removal	346
Fuser narrow media sensor removal	348
Fuser narrow media flag and spring removal	350
Fuser to LVPS AC cable removal	352
Fuser top cover removal	355
Fuser transfer plate removal	357
Gear release link removal	358
High voltage power supply removal	359
Inner paper deflector assembly removal	361
Input sensor removal	362
Integrated tray autocompensator assembly removal	363
Integrated tray autocompensator pick roll assembly removal	365
Interface card assembly removal	367
LCD inverter card assembly removal	368
Low voltage power supply removal	369
Main fan removal	371
Main drive assembly removal	373
Modem removal	375
MPF arm assembly removal	376
MPF lower paper deflector	377
MPF pick tire removal	378
MPF solenoid assembly removal	379
Paper alignment assembly removal	382
Paper bin full sensor flag removal	384
Paper size sensing board removal	385
Power takeoff shaft and spring removal	386
Printer outer shield removal	386
Printhead removal	387
Redrive assembly removal	388
Signature button contact assembly removal	389
System board and inner shield removal-model X642e	390
System board and inner shield removal -models X644e/X646e	391
Toner sensor removal	392
Transfer roll assembly removal	392
Upper cover removal (printer)	393
Upper front cover hinge assembly removal	396
Upper paper deflector assembly removal	398
USB card	399
5. Locations and connections	401
Locations	401
Sensors-flatbed	401
Sensors-ADF	402
Connections	403
System board	403
Autoconnect	408
Fuser board	409
High voltage power supply	409
Interface card	410
USB card	410
Low voltage power supply	411
Operator panel card (UICC #1)-model X642e	412
Operator panel card (UICC #1)-models X644e/X646e	414
LCD inverter board (IUCC #2)	416
Scanner control card	417
Motor driver board	423
Flatbed interconnect card	426
Modem card	431
6. Preventive maintenance	433
Safety inspection guide	433
Lubrication specifications	433
Scheduled maintenance	433
Maintenance kit	433
Cleaning the scanner glass, cushions, and strips	434
7. Parts catalog	437
How to use this parts catalog	437
Assembly 1: Covers-printer (model X642e)	438
Assembly 2: Cover-printer (models X644e and X646e)	442
Assembly 3: Covers-ADF scanner	444
Assembly 4: Frame 1	446
Assembly 5: Frame 2	448
Assembly 6: Frame 3	450
Assembly 7: Scanner automatic document feeder (ADF)-pickup	452
Assembly 8: Scanner ADF-paper feed	453
Assembly 9: Scanner ADF-lower exit guide assembly	454
Assembly 10: Scanner ADF-motors and belts	455
Assembly 11: Scanner ADF-sensors	456
Assembly 12: Scanner-flatbed	458
Assembly 13: Printhead	460
Assembly 14: Paper feed-autocompensator	461
Assembly 15: Paper feed-multipurpose feeder	462
Assembly 16: Paper feed-alignment	464
Assembly 17: Integrated 500-sheet paper tray	466
Assembly 18: Drives-Main drive and developer drive	468
Assembly 19: Hot roll fuser	470
Assembly 20: Transfer/charging	472
Assembly 21: Electronics-power supplies	474
Assembly 22: Electronics-card assemblies	476
Assembly 23: Electronics-shields	478
Assembly 24: Cabling diagram 1	479
Assembly 25: Cabling diagram 2	480
Assembly 26: Cabling diagram 3	481
Assembly 27: Cabling diagram 4-model X642e	482
Assembly 28: Cabling diagram 4-models X644e/X646e	484
Assembly 29: Cabling diagram 5	486
Assembly 30: Cabling diagram 6-model X642e	488
Assembly 31: Cabling diagram 6-models X644e/X646e	490
Assembly 32: Cabling diagram 7	492
Assembly 33: Cabling diagram 8-model X642e	493
Assembly 34: Cabling diagram 8-models X644e/X646e	494
Assembly 35: Optional 250-sheet paper drawer	495
Assembly 36: Optional 250-sheet paper tray	496
Assembly 37: Optional 500-sheet paper drawer	497
Assembly 38: Optional 500-sheet paper tray	498
Assembly 39: Duplex option	499
Assembly 40: Envelope feeder	500
Assembly 41: High-capacity feeder 1	502
Assembly 42: High-capacity feeder 2	504
Assembly 43: High-capacity feeder 3	505
Assembly 44: High-capacity feeder 4	506
Assembly 45: Options	507
Index	509
Part number index	517
Wiring diagrams	523
AIO scanner—X642e	524