Lexmark X125

All-In-One
4412-00X

• 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.
4412-00X

Edition: November 2002

The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS
PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore, this
statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at
ServiceInfoAndTraining@Lexmark.com. 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 and Lexmark with diamond design 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. 2002.
All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

P/N 12G9185
4412-00X

Table of Contents

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printer Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Facsimile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Power and Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . 2-1
POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Carrier Transport Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-7
CIS Assembly Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Scanner Motor with Gear Assembly Service Check . . . . . . . 2-10
Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . 2-11
Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Paper Path Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Scan/Copy Quality Service Check . . . . . . . . . . . . . . . . . . . . 2-18
Fax/Telephone Communication Service Check . . . . . . . . . . 2-19
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Theory of Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Scanner Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Drive Feed Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Contact Image Sensor (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Document Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

iii
4412-001

Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
General Precautions on Removals. . . . . . . . . . . . . . . . . . . . . .4-3
CIS White Roller Assembly Removal . . . . . . . . . . . . . . . . . . . .4-4
Top Cover Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . .4-5
Rollers (Drive Feed Roller Assembly, Exit Shaft) Removal . . .4-6
CIS (Contact Image Sensor) Removal . . . . . . . . . . . . . . . . . . .4-7
Scanner Motor with Gear Assembly Removal . . . . . . . . . . . . .4-9
Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Line Interface Board Removal . . . . . . . . . . . . . . . . . . . . . . . .4-12
Operator Panel Assembly Removal . . . . . . . . . . . . . . . . . . . .4-13
Printer Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
ASF Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Maintenance Station Removal . . . . . . . . . . . . . . . . . . . . . . . .4-17
Carrier Assembly with Belt Removal . . . . . . . . . . . . . . . . . . .4-18
System Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Mid Frame Assembly with Exit Rollers Removal . . . . . . . . . .4-20
Large Feed Roller Assembly with Gear Removal . . . . . . . . .4-21
Paper Feed Motor Assembly with Gears Removal . . . . . . . .4-22
Carrier Transport Motor Removal. . . . . . . . . . . . . . . . . . . . . .4-23
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
System Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Line Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
How to Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

iv Service Manual
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Safety Information

• The safety of this product is based on testing and approvals of

the original design and specific components. The manufacturer
is not responsible for safety in the event of use of unauthorized
replacement parts.
• The maintenance information for this product has been
prepared for use by a professional service person and is not
intended to be used by others.
• There may be an increased risk of electric shock and personal
injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precautions.

Consignes de Sécurité
• La sécurité de ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des
composants particuliers. Le fabricant n'assume aucune
responsabilité concernant la sécurité en cas d'utilisation de
pièces de rechange non agréées.
• Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement à un personnel de maintenance
qualifié.
• Le démontage et l'entretien de ce produit pouvant présenter
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

Safety Information v
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Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione
del progetto originale e dei componenti specifici. Il produttore
non è responsabile per la sicurezza in caso di sostituzione non
autorizzata delle parti.
• Le informazioni riguardanti la manutenzione di questo prodotto
sono indirizzate soltanto al personale di assistenza autorizzato.
• Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise
• Die Sicherheit dieses Produkts basiert auf Tests und
Zulassungen des ursprünglichen Modells und bestimmter
Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird
vom Hersteller keine Verantwortung oder Haftung für die
Sicherheit übernommen.
• Die Wartungsinformationen für dieses Produkt sind
ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
• Während des Auseinandernehmens und der Wartung des
Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

vi Service Manual
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Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y
aprobaciones del diseño original y componentes específicos.
El fabricante no es responsable de la seguridad en caso de uso
de piezas de repuesto no autorizadas.
• La información sobre el mantenimiento de este producto está
dirigida exclusivamente al personal cualificado de
mantenimiento.
• Existe mayor riesgo de descarga eléctrica y de daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações
do modelo original e de componentes específicos. O fabricante
não é responsável pela segunrança, no caso de uso de peças
de substituição não autorizadas.
• As informações de segurança relativas a este produto
destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.
• Risco de choques eléctricos e ferimentos graves durante a
desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

Safety Information vii

4412-00X

Informació de Seguretat
• La seguretat d'aquest producte es basa en l'avaluació i
aprovació del disseny original i els components específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
• La informació pel manteniment d’aquest producte està
orientada exclusivament a professionals i no està destinada
a ningú que no ho sigui.
• El risc de xoc elèctric i de danys personals pot augmentar
durant el procés de desmuntatge i de servei d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.

viii Service Manual

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Safety Information ix
4412-00X

Preface

This manual and contains maintenance procedures for service

personnel. It is divided into the following chapters:

1. General Information contains a general description of the

printer and the maintenance approach used to repair it. Special
tools and test equipment are listed in this chapter, as well as
general environmental and safety instructions.
2. Diagnostic Information contains an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).
3. Diagnostic Aids contains tests and checks used to locate or
repeat symptoms of printer problems.
4. Repair Information provides instructions for making printer
adjustments and removing and installing FRUs.
5. Connector Locations uses illustrations to identify the
connector locations and test points on the printer.
6. Preventive Maintenance contains the lubrication specifications
and recommendations to prevent problems.
7. Parts Catalog contains illustrations and part numbers for
individual FRUs.

x Service Manual
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1. General Information

The Lexmark™ X125 All-In-One (4412-00X) is a letter quality print,

fax, copy, and scan machine. The printhead uses small heater plates
and nozzles to control ink flow and the formation of characters on
the print media. The printhead assembly and ink supply are
combined into a single unit. Print cartridges are available as a
customer replaceable supply item. Dual printheads provide color
and true black printing without changing printheads. The number
and size of inkjets or nozzles, in the printhead, determines the
overall quality and capability of the printer. The black cartridge has a
total of 208 nozzles and installs on the right. The color cartridge has
a total of 192 nozzles and installs on the left. The printer is capable
of printing in both directions from either cartridge.

General Information 1-1

4412-00X

Specifications
Printer Engine

Technology Thermal Inkjet

2-pin and printhead swapping

type

Speed Color 8 ppm at Draft Mode

Mono 16 ppm at Draft Mode

Resolution Color 600 X 600 dpi (1200 X 2400

dpi addressable)

Mono 600 X 600 dpi (1200 X 2400

dpi addressable)

Printing Width 203 mm

Feeding Method Automatic 100 sheets of 20 lb cut sheets

(Max 10 mm)

Manual Tray No

Emulation Host Based Printing (GDI)

Printer Driver Windows 98/ME, Windows

2000/Windows XP

Interface USB Interface

Printhead

Babbage Mono Standard Birch Color

Printhead 208 nozzles 192 nozzles

Ink Type Pigment Dye

Ink Color Black Color

Ink Yield About 600 sheets About 200 sheets

1-2 Service Manual

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Facsimile

General Compatibility ITU-G3

Scan Method CIS

Scan Width Maximum 216 mm, Effective 210 mm

Scan Resolution 600 X 1200 dpi

Scan Speed 6 seconds

Feeding Method Sheet Feed

ADF 30 sheets of 20 lb

Guide Document Input Guide

Stacker Document Output Stacker/Paper

Stacker

Paper Tray Bin Type (without Manual Tray)

Modem Speed 33.6 Kbps

Coding Method MH, MR, MMR, Error Correction Mode

LCD 2 lines of 16 characters each

Scanning Resolution and Standard: 200 X 100 dpi

Type Fine: 200 X 200 dpi (default)
Super Fine: 300 X 300 dpi
Color: 200 X 200 dpi

(Standard: Low quality, Fine: High

quality compression)

Contrast Darkest/Darken/Normal
Lighten/Lightest

Memory Capacity 1 Mbyte

Back-up Time 15 sec (Continuous power failure,

typically 1-2 minutes)

Confidential No

Forced Memory TX Yes

Memory RX Automatic reception when paper empty.

General Information 1-3

4412-00X

Telephone Speed Dial 70 locations

Chain Dial No

On-Hook Dial Yes, 1-Key

Last Number Redial Yes, 1-Key

Auto Redial Yes

Hold and Mute No

Pause Yes, use Redial Key

Ringer Volume S/W Option Setting (4 steps)

Tone/Pulse Select S/W Option Setting

DRPD USA: Yes, Other Countries: Yes

Report and TX/RX Journal Yes

List
Image TCR Yes, reduction of first page sent by
Memory TX

System Data Yes

Telephone Number Yes

List

Self Test Yes

Copy Multipage Copy Up to 99 pages

Grayscale 256 levels

Reduction and 25% - 200%

Enlargement (Reference is the top center of
document.)

Telephone Answering I/F Yes

I/F
Extension Phone 1-jack, extension phone transfer

Others Sensors Paper Jam

Real-Time Clock No

RTI Yes

1-4 Service Manual

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Scanner

Compatibility TWAIN

Technology Platen CIS

Light Source for Color CIS RGB LEDs (Line Order Control)

Power and Size

Power Source 110V-240V / 50Hz-60Hz

Dimensions 440.6 X 319.6 X 205.4 mm

Weight (Packed) 15.3 lbs (Packed Weight)

Abbreviations

ASF Auto Sheet Feed

B/M Bill of Material
CIS Contact Image Sensor
EOF End of Form
ESD Electrostatic Discharge
FPC Flat Printhead Cable
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LCD Liquid Crystal Display
LVPS Low Voltage Power Supply
OEM Original Equipment Manufacturer
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

General Information 1-5

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1-6 Service Manual

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2. Diagnostic Information

Start
Power-On Self Test (POST) Sequence

1. Power Up Please Wait is displayed on the LCD.

2. Carrier moves to the left and the paper feed motor runs then
stops.
3. Carrier returns to the right.
4. Ready, ANS/FAX, and the Date and Time display when POST is
complete.

If your printer completes POST with no errors, go to the “Symptom

Tables” on page 2-3. Locate the symptom and take the indicated
action.

If your printer does not complete POST, locate the symptom in the
following table and take the indicated action.

Diagnostic Information 2-1

4412-00X

POST Symptom Table

Symptom Action

LCD or operator Go to the “Power Service Check” on page 2-15. If okay,

panel buttons do go to the “Operator Panel Problems” on page 2-3.
not work and no
motors run

Paper feed Go to the “Paper Feed Service Check” on page 2-12.

gears do not
turn

Carrier does not Go to the “Carrier Transport Service Check” on

move page 2-7.

Carrier slams Go to the “Carrier Transport Service Check” on

side frame page 2-7.

CIS light does Go to the “CIS Assembly Service Check” on page 2-9.
not turn on

2-2 Service Manual

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Symptom Tables
Locate the symptom in the following tables and take the appropriate
action.

Carrier Transport Problems

Symptom Action

• No carrier movement Go to the “Carrier Transport

• Slow carrier movement Service Check” on page 2-7.
• Carrier stops
• Carrier slams side frame

Maintenance Station Problems

Symptom Action

Maintenance station: Go to the “Maintenance Station

Service Check” on page 2-11.
• Fails to cap the printheads
• Fails to clean the printheads

Operator Panel Problems

Symptom Action

• Buttons do not work Check operator panel cable

• LCD does not display connection at P9 on the system
board. Run the “Power-On Self
Test (POST) Sequence” on
page 2-1. If the LCD or buttons fail,
check connection P9. If the problem
remains, replace the operator panel
assembly. Go to the “Operator
Panel Assembly Removal” on
page 4-13.

If the problem still exists, replace the

system board. Go to the “System
Board Removal” on page 4-19.

Diagnostic Information 2-3

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Symptom Action

Document scan sensor does not Check operator panel cable

detect document connector P9 on the system board. If
okay, go to the “Scanner Motor
with Gear Assembly Service
Check” on page 2-10. If the
scanner motor is working correctly,
replace the operator panel assembly.
Go to the “Operator Panel
Assembly Removal” on page 4-13.

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Printer Communication Problem

Symptom Action

Not able to print Self Test Page Check the USB cable and system
board cable connections. If okay,
replace system board. Go to the
“System Board Removal” on
page 4-19.

Scanner Problems

Symptom Action

Light does not turn on Go to the “CIS Assembly Service

Check” on page 2-9.

• Scanned images are faded, or Go to the “Scan/Copy Quality

colors are dull, blurry or fuzzy. Service Check” on page 2-18.
Images are slanted or crooked
and the straight lines in the
image appear to be jagged or
uneven.
• Blank copies

• Scanner motor does not run Go to the “Scanner Motor with

• Document sensor does not Gear Assembly Service Check”
work on page 2-10.

Go to the “Operator Panel

Problems” on page 2-3.

• CIS white roller assembly slips Go to the “Paper Path Service

• Paper does not feed correctly Check” on page 2-14.

Diagnostic Information 2-5

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Paper Feed Problems

Symptom Action

• Fails to pick paper Go to the “Paper Feed Service

• Picks more than one sheet of Check” on page 2-12.
paper
• Picks paper but fails to feed
• Paper jams
• Paper fails to exit
• Noisy paper feed

Envelopes fail to feed Go to the “Paper Feed Service

Check” on page 2-12.

Paper skews Go to the “Paper Path Service

Check” on page 2-14.

Power Problems

Symptom Action

No power in machine, motors do Go to the “Power Service Check”

not operate on page 2-15.

Print Quality Problems

Symptom Action

• Voids in characters Go to the “Print Quality Service

• Light print Check” on page 2-16.
• Prints off the page
• Fuzzy print
• Carrier moves but no print
• Printhead dries prematurely
• Colors print incorrectly
• Vertical alignment off

• Ink smearing Go to the “Paper Feed Service

• Vertical streaks on paper Check” on page 2-12.
• Print lines crowded

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Service Checks
Carrier Transport Service Check

FRU Action

1 System Board Check the carrier transport motor connector P4. If

connected, check for approximately 29 volts on
Carrier Transport pins 1 and 2 or at the wire connections located on
Motor the rear of the carrier transport motor. If voltage is
incorrect, replace the system board. If voltage is
correct, check the motor for shorts.

2 Carrier Transport Check the motor for binds, or loose motor pulley.
Motor
A noisy or chattering motor, or a motor that fails to
turn, can be caused by:

• An open or short in the motor

• An open or short in the motor driver
on the system board
• A bind in the carrier transport
mechanism
With the carrier transport motor cable (P4)
disconnected from the system board, check for 0
to 16 ohms between the following pins on the
motor:

P4-1 and P4-2

If the readings are incorrect, replace the print

engine. Go to the “Carrier Transport Motor
Removal” on page 4-23.

3 Carrier Guide Rod Clean the carrier rod.

Note: Lubricate the rod and the carrier rod bearing

surfaces with grease P/N 99A0394.

Diagnostic Information 2-7

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FRU Action

4 Encoder Strip Check the encoder strip for proper installation.

Also, check it for wear, dirt, and grease. Replace if
Carrier Assembly needed.
with Belt
Be sure all printhead connectors are fully seated.
Check the cables for damage.

If the encoder strip and all connections are okay,

but the carrier still slams the side frame, replace
the carrier assembly with belt. Go to the “Carrier
Assembly with Belt Removal” on page 4-18. If
problem remains, replace the system board. Go to
the “System Board Removal” on page 4-19.

5 Carrier Transport Check for worn, loose or broken parts. Check for
Belt obstructions blocking carrier movement. If pulley
Idler Pulley assembly is damaged, replace.
Assembly
Lubricate carrier to carrier frame engagement with
grease P/N 99A0394.

6 Maintenance A problem with the maintenance station can cause

Station carrier movement problems at the right margin. Go
to the “Maintenance Station Removal” on
page 4-17.

7 Access Door If the carrier does not move toward the cartridge
Sensor load position when the access door is opened,
verify that power is on. If the carrier still does not
move, check connector P11 pin 1 for
approximately 3 volts, with the door open. If the
voltage is correct, replace the sensor. Disconnect
P11 from the system board before removing
sensor. If the voltage is incorrect, replace the
system board. Go to the “System Board
Removal” on page 4-19.

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CIS Assembly Service Check

The CIS lamp does not light when scanning is in process.

FRU Action

1 CIS Assembly If light does not come on during the

scanning process, check connector
P2 on the system board. If the
connection is okay, check for a
voltage reading of approximately 4
volts from ground to P2-2 pin. If
voltage is correct, replace the CIS
assembly. Go to the “CIS (Contact
Image Sensor) Removal” on
page 4-7. If voltage is incorrect,
replace the system board. Go to the
“System Board Removal” on
page 4-19.

Diagnostic Information 2-9

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Scanner Motor with Gear Assembly Service Check

Motor will not run.

FRU Action

1 Scanner Motor with Gear Check scanner motor for shorts.

Assembly Disconnect connector P6 from the
system board and check for
approximately 6 ohms between the
following pins on the motor
connector.
P6-1 and P6-2

If the ohms reading is incorrect,

replace the scanner motor assembly.
If the motor does not come on during
the scanning process, check
connector P6 on the system board. If
the connection is okay, check for
voltage reading of approximately 29
volts at pins
P6-1
P6-2
P6-3
P6-4

If voltage is correct, replace the

scanner motor with gear assembly.
Go to the “Scanner Motor with
Gear Assembly Removal” on
page 4-9. If voltage is incorrect,
replace the system board. Go to the
“System Board Removal” on
page 4-19.

2 Document Scanner Sensor To check the document scanner

sensor, insert a sheet of paper or
press the sensor to see if the
scanner motor is working. Go to
“Operator Panel Problems” on
page 2-3.

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Maintenance Station Service Check

The maintenance station has three functions:

1. Wipes the printhead nozzles to clean them of dirt.

2. Provides a place for printheads to fire all nozzles, keeping them
clear prior to printing.
3. Seals the printhead when it is not being used to prevent the
nozzles from drying.

FRU Action

1 Maintenance As the carrier moves to the right over the

Station Assembly maintenance station, a slot on the bottom of the
carrier engages a tab on the sled of the
maintenance station causing the cap to rise and
seal the printhead. Carrier movement to the left
uncaps the printhead. The wiper cleans the
printhead nozzles as the carrier leaves the
maintenance station. The wiper cleans the
printhead only when the carrier is moving to the
left. Do not wipe the printhead nozzles when the
carrier is moving to the right. After the cleaning
operation is complete, a tab on the maintenance
station engages a tab on the carrier, causing the
wiper to lower.

Check the maintenance station for worn or broken

parts. Replace if needed. Go to the “Maintenance
Station Removal” on page 4-17.

Worn wipers cause degraded print quality just after

a maintenance cleaning. Check for loose or worn
wipers.

Worn caps cause the printhead nozzles to dry and

clog. Check for loose or worn caps.

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Paper Feed Service Check

If your machine does not have paper jam problems, continue with
the service check. If your machine does have a paper jam, examine
it for the following before you begin the service check:

• Check the entire paper path for obstructions.

• Be sure there is not too much paper in the sheet feeder.
• Be sure the correct type of paper is being used.
• Check for static in the paper.

FRU Action

1 System Board Run the “Power-On Self Test (POST) Sequence”

on page 2-1. Replace parts as needed. To check
the paper feed motor, disconnect the paper feed
connector P5 and check for approximately 4 ohms
between pins 1 and 4. If the reading is incorrect,
replace the paper feed motor assembly with gears.
Go to the “Paper Feed Motor Assembly with
Gears Removal” on page 4-22. If the reading is
correct, replace the system board. Go to the
“System Board Removal” on page 4-19.

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FRU Action

2 Paper Feed Motor A noisy or chattering motor or a motor that fails to

turn, can be caused by:

• An open or short in the motor

• An open or short in the motor driver on the
system board
• A bind in the paper feed mechanism
With the paper feed motor cable P5 disconnected
from the system board, check for approximately 4
ohms between the following pins on the motor:

Pin 1 to Pin 4

If the readings are incorrect, replace the paper

feed motor assembly with gears. Go to the “Paper
Feed Motor Assembly with Gears Removal” on
page 4-22.

Although the paper feeds in a forward direction

only, the paper feed motor turns in two directions.
If the paper feed motor turns in one direction only,
replace the system board. Go to the “System
Board Removal” on page 4-19.

Binds in the paper feed motor or gear train can

cause intermittent false paper jam errors. Remove
the paper feed motor and check the shaft for binds.
Also check for a loose or worn motor gear.

3 Auto Sheet Check the pick roller for wear.

Feeder Assembly

4 Mid Frame Check the following for wear:

Assembly
• Small Feed rollers
• Large Feed roller
• Exit roller
• Star rollers
If the mid frame assembly needs to be replaced,
go to the “Mid Frame Assembly with Exit
Rollers Removal” on page 4-20.

5 End-of-Forms Check for binds or damage.

Flag and Spring

Diagnostic Information 2-13

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Paper Path Service Check

Examine the machine for the following before you begin this service
check:

• Check the entire paper path for obstructions.

• Be sure the correct type of paper is being used.
• Be sure the printer is installed on a flat surface.

FRU Action

1 Large and Small Check for wear and binds.

Feed Rollers

2 Small Feed Roller Check for damage or disconnected springs.

Springs

3 Auto Sheet Check the pick roller for wear.

Feeder Assembly

4 Mid Frame Asm Check the following for wear:

• Exit roller
• Star rollers

5 End-of-Forms Check for binds or damage.

Flag

6 White Roller Check for correct installation. Check gear and

Assembly bushings for damage. If damaged, replace. Go to
the “CIS White Roller Assembly Removal” on
page 4-4.

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Power Service Check

FRU Action

1 Power Supply Plug the machine into an outlet. Check for

approximately 30 V dc at P1 pin 3. Check
connector (CON1) at the power supply. If voltage is
incorrect, replace the power supply.

2 Printhead Cables Unplug the printer. Disconnect the printhead

Paper Feed Motor cables and plug in the printer. Look for a symptom
Carrier Transport change. Check the failing part for shorts and
Motor replace as necessary.
Operator Panel
Repeat this procedure for the carrier transport
motor, paper feed motor, and operator panel.

3 System Board If the symptom has not changed, replace the

system board. Go to the “System Board
Removal” on page 4-19.

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Print Quality Service Check

FRU / Function Action

1 Printhead Be sure the machine contains good print

Cartridge cartridges.

2 Color Printhead Cross contamination of color inks results in

Cartridge Cross incorrect colors printed, as when green prints for
Contamination yellow, (when yellow and blue are mixed in the
printhead cartridge). This problem resolves quickly
as the printhead cartridge is used.

If cross contamination occurs, check the following:

• The maintenance station wiper for damage.

• The printhead nozzle plate was resealed with
tape.

3 Carrier Assembly Reseat the printhead cables in the system board

and check the following parts for wear or damage:

• Printhead Cartridge Latch

• Latch Spring
• Carrier

4 System Board Print the self test page. To enter the self test page,
Carrier press Setup and then Menu button until “Print
Assembly Report” is displayed. Press Options button until
“Self Test” is displayed. Then press the to print the
self test page. Look for a break in the diagonal line
of the nozzle test pattern. A broken line indicates
one or more print nozzles are not working. Run the
test again to verify the failure.

Check the gold-plated contacts on the end of the

printhead carrier cable for dirt, wear, and damage.
Use only a clean dry cloth to clean the contacts. If
a problem is found with contacts on the carrier,
replace the carrier. Go to the “Carrier Assembly
with Belt Removal” on page 4-18.

If the symptom remains, replace the system board.

Go to the “System Board Removal” on
page 4-19.

5 Maintenance Intermittent nozzle failures can be caused by worn

Station parts in the maintenance station. Go to the
“Maintenance Station Removal” on page 4-17,
and then return to this check.

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FRU / Function Action

6 Paper Feed Ink smudging and smearing can be caused by

paper problems or problems in the paper feed
area.

Check the following:

• Correct type of paper is being used. Also check

the paper for curl or wrinkles.
• Feed rollers for wear, dirt, or looseness.
• Gears for wear or binds.
• Paper path for obstructions.

7 Carrier Transport Blurred print and voids can be caused by problems

in the carrier transport area. Check the following:

• Carrier transport belt for wear.

• Carrier guide rod for wear or dirt. If dirty, clean
and lubricate.
• Carrier to carrier frame engagement should be
lubricated with grease P/N 99A0394.
• Idler pulley parts for wear, damage, or
looseness.

8 Alignment Uneven vertical lines can be adjusted by

performing the printhead alignment adjustments in
the maintenance mode. The user is directed,
through the “Setting up System in User Mode”
on page 3-3, to perform the printhead alignment
adjustments, when replacing a printhead cartridge.

Diagnostic Information 2-17

4412-00X

Scan/Copy Quality Service Check

FRU / Function Action

1 Scanned images Check the lighter/darker settings to see if it is

are faded, or correct.
colors are dull,
blurry, or fuzzy. • From the operator panel
Images are • From the Scan & Copy Control Program
slanted or
crooked and the
straight lines in Check to see if there is any dust or debris on the
the image appear glass lens of the CIS. This may cause a poor
to be jagged or image.
uneven.

2 Blank copies If there are blank copies found, make sure that the
original document is facing down.

Check the print cartridges to see if they need to be

cleaned or replaced.

3 Scanning error Ensure the USB cable is correctly installed.

Ensure the USB cable is proper for USB

specification, version 1.1.

Start the system after twain driver is reinstalled.

If error still occurs, replace the system board. Go

to the “System Board Removal” on page 4-19.

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Fax/Telephone Communication Service Check

FRU / Function Action

1 Line Interface No dial tone

Board or System
Board Verify correct dialing method (tone or pulse). Are
TEL and LINE connections reversed? Verify phone
Cannot make number and availability of other fax machine.
telephone
connection to Before dialing, press Speaker so you can hear the
other fax. dialing process. You should hear the ring and a 0.5
second 1000 Hz calling tone from your machine, a
1 second pause, then the 3 second 2100 Hz fax
response tone and a 1650 Hz - 1850 Hz “warbling”
handshaking tone from the called machine.

Check the connectors on the line interface board

P1 and P2. If okay, check connector CN15 located
on the system board. If problem still exists, replace
the line interface board. Go to the “Line Interface
Board Removal” on page 4-12. If this does not
correct the problem, replace the system board. Go
to the “System Board Removal” on page 4-19.

2 Cannot receive Are TEL and LINE connections reversed? Is a

faxes telephone on the same line off the hook? Is the
machine connected to the wrong telephone line?

Check for a damaged line cord to the machine.

Check telephone and line cord connections.

Diagnostic Information 2-19

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3. Diagnostic Aids

Theory of Mechanism
Scanner Mechanism
The scanner mechanism consists of components which feed, scan,
and eject the documents that are to be copied or transmitted to a
remote facsimile unit. These components and their functions are
explained below.

Drive Feed Roller Assembly

The drive feed roller assembly, consisting of various rollers, rubber
pad, and springs, automatically separates and feeds the pages of a
document over the scanning area and stacks them on the document
exit tray.

Documents up to 15 pages can be placed in the drive feed roller

assembly for scanning. The leading edge of the document moves
the document detect sensor lever when the operator slides the stack
into the drive feed roller assembly. The scan motor starts to rotate
when the document detect sensor detects the leading edge of the
document. The roller feeds the first page of the document into the
feeder.

The scan motor stops when the leading edge of the page actuates
the document scan sensor. The page is now in the scan position.

The drive feed roller assembly rubber pad prevents multiple sheets
from being fed. A spring provides force that the pad places on the
document pages for proper separation.

The scan motor is turned on when the machine is ready to scan the
document and drives the feed roller at a speed determined by the
resolution selected. The scan motor stops after a set period of time
when the trailing edge of the page releases the document scan
sensor. If another page is detected as the trailing edge of the page
releases the document scan sensor, the next page feeds to the scan
position. The exit roller pushes the page out onto the document exit
tray where it is stacked.

Diagnostic Aids 3-1

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Contact Image Sensor (CIS)

The contact image sensor unit consist of LEDs, rod lens array, and a
photo sensor. The LEDs illuminate the document to be scanned
when the leading edge is detected by the document scan sensor.
The LEDs turn off when the document exits the scanner mechanism.

The LEDs illuminate the document to obtain an image from the

document through the rod lens array, where the image is translated
into voltage levels.

Document Sensors
There are two document sensors in the scanner mechanism; the
document detect and the document scan sensor. The document
detect sensor, detects whether or not a document is loaded, and the
document scan sensor detects the scan position of the document.
The scanner mechanism consists of components which feed, scan,
and eject the documents that are to be copied or transmitted to a
remote facsimile unit.

Service Mode

In service mode (tech) mode, the technician checks the machine

and performs various tests to isolate the cause of a malfunction.

To enter the service mode, press Menu, #, 1, 9, 3, 4 in sequence,

and the LCD briefly displays T. The machine has entered service
(tech) mode. While in service mode, the machine still performs all
normal operations. To return to normal user mode, press Menu, #, 1,
9, 3, 4 in sequence again, or turn the power off and then on by
unplugging and plugging the power cord.

Options changed while in service mode do not remain changed

unless you clear the machine memory.

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Setting up System in User Mode

Setup Item Default

Date Jan/01/01 Month - Day - Year Jan/01/01

Time 12:00:00P Hour - Minute - AM/PM 12:00 PM

Print Report Fax Confirm

Transmit Log
Receive Log
Speed Send List
Self Test

Maintenance Cartridge Clean

Cartridge Align
Scanner Init

Paper Size Letter/A4/Legal Letter

Ringer Volume Off/Low/Medium/High Medium

Fax Print Letter Quality/ Letter Quality

Draft Quality

Fax Forwarding Off/Forward/ Forward Off

and Print

Fax Receive Mode FAX/TEL/ANS/FAX/ ANS/FAX

DRPD

Setup DRPD Learn

Auto Journal Yes / No

Dial Mode Pulse / Tone

Default Setting Fax Type

Copy Size
Copy Collate
Copy Contrast
Copy Type
Copy Paper Type

Diagnostic Aids 3-3

4412-00X

Setting up System in Service Mode

Setup Item Default

CIS Test Red, Green, and Blue

maximum and minimum
peak levels

Aging Test Scanner Aging/

Printer Aging

Print Report Fax Confirm

Transmit Log
Receive Log
Speed Send List
Self Test
Protocol Dump
ASF Test
System Data
NVRAM Dump
CIS Pattern

Maintenance Cartridge Clean

Cartridge Align
Scanner INIT

Program Download

Message Confirm On/Off/Error On-Error

Remote RCV Code (0-9) 9

EMC Mode Yes/No Yes

Auto Reduction On/Off Vertical Only On

Retry Interval (1-7) 3

Retry Count (0-2) 2

Answer on Rings (1-7) 1

Print RTI Yes / No

Modem Test FSK/2400/4800/7200/

9600/12000/14400 bps/
21600 bps/26400 bps/
28800 bps/31200 bps/
33600 bps/1100/1650/
1850/2100 Hz

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Setup Item Default

DTMF Test

ROM Test

Modem Speed Item FSK/2400/4800/7200/ 33600 bps

(1-6) 9600/112000/14400/
33600/12000/9600/
7200/4800/2400

Set TX Level (1-15) 12

Set RX Level (40-50) 43

Pause Time (1-9) 3

CIS Test

The test adjusts the light of CIS. It is already set at CIS Test to get
optimum quality.

Warning: Shading profile must be made after downloading a new

firmware. If not, the system will not work properly.

1. Load all white document in scanner unit.

2. Press Setup and ‘CIS Test Press Start’ is displayed.
3. Press Start and ‘Shading...’ is displayed.
4. After scanning, shading waveform is printed.
5. After shading waveform has printed, press Stop.
6. Turn off system and turn on.

Aging Test

Scanner Aging - Scanner part aging

Printer Aging - Printer part aging.

Print Report

1. Press Setup.
2. Press Menu until ‘Print Report’ is displayed.
3. Press Options to select the log you want to print.
4. Press Start or Setup to print the report.

Diagnostic Aids 3-5

4412-00X

Maintenance

1. Press Setup.
2. Press Menu until ‘Maintenance’ displays.
3. Press Options to select, cartridge clean, cartridge align and
scanner init.
4. Press Start after you select.

Program Download

1. Press Setup.
2. Press Menu four times until ‘Program Download Press Start’ is
displayed.
3. Press Start.
4. Download your new firmware files from PC.
Note: Be sure the USB cable is connected to the PC when you are
running this test. If cable is not connected, it may cause a fatal error.

Message Confirm

A message confirmation report shows whether the transmission was

successful or not and how many pages were sent.

1. Press Setup.
2. Press Menu five times until ‘Message Confirm, Report, On
Report, Off Report, Error’ is displayed.
3. Press Options to print a confirmation report automatically each
time you send a fax (On). Press Options to turn this feature off.
Press Options to print only when an error occurs and the
transmission was not successful. Press Start or Setup to set
the time you want to select.

Auto Journal

A journal shows specific information concerning transmission or

reception activities, the time and dates of up to 40 of the most recent
transmissions or receptions.

1. Press Setup.
2. Press Menu until ‘Auto Journal’ displays in the top line of the
LCD.

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4412-00X

3. Press Options to print the journal automatically after every 40

transmissions or receptions (Yes). Press Options to print
journal manually (No).

Remote RCV Code

The remote receive code lets you initiate fax received from an
extension phone plugged into the EXT jack. If you pick up the
extension phone and hear fax tones, enter the remote receive code
and the fax starts receiving. The password is preset to 9.

1. Press Setup.
2. Press Menu until ‘Remote RCV Code’ displays on the top line.
3. Enter the code you want, 0 to 9 on the number keypad.

Dial Mode

Select the type of dial system your fax machine is connected to.

1. Press Setup.
2. Press Menu until ‘Dial Mode’ displays in the top line of the LCD.
3. Press Start or setup when Tone Message is displayed if the fax
machine is connected to a tone (Touch Tone) dial line.
4. Press Start or Setup when Pulse Message is displayed if the
fax machine is connected to a pulse (Rotary) dial line.

ECM (Error Correction Mode)

This mode compensates for poor line quality and ensures accurate,
error-free transmission with another ECM-equipped facsimile
machine. If the line quality is poor, transmission time may be
increased when ECM is enabled.

1. Press Setup.
2. Press Menu until ‘ECM Mode’ displays.
3. Press Start or Setup when Yes is displayed to turn on the Error
Correction Mode. Press Start or Setup when No is displayed to
turn off the Error Correction Mode.

Diagnostic Aids 3-7

4412-00X

Auto Reduction

When receiving a document as long or longer than the paper

installed in your machine, the machine can reduce the data in the
document to fit into your recording paper size.

Turn on this feature if you want to reduce an incoming page that may
otherwise need to be divided into two pages with only a small portion
on the second page. If the fax machine cannot reduce the data to fit
one page with the feature enabled, the data is divided and printed in
actual size on two or more sheets.

1. Press Setup.
2. Press Menu until ‘Auto Reduction’ displays. To turn only the
vertical reduction feature On, press Start or Setup when On is
displayed. The machine reduces an incoming page containing
overflow data only in vertical. Press Start or Setup when Off is
displayed to turn this feature on.

Discard Size

When receiving a document as long as, or longer than, the paper

installed in your fax machine, you can set the fax machine to discard
any excess image at the bottom of the page to fit into the recording
paper size. If the receiving page is outside the margin you set, it
prints on two sheets of paper at the actual size. If the data is within
the margin, and the Auto Reduction feature is turned on, it reduces
to fit into the appropriate size paper (Discard does not take place). If
the Auto Reduction feature is turned Off or fails, the data within the
margin is discarded.

1. Press Setup.
2. Press Menu until ‘Discard Size’ displays in the top line of the
LCD.
3. Enter the length using the numbers on the keypad.

Retry Interval

1. Press Setup.
2. Press Menu until ‘Retry Interval’ displays.
3. Enter the number of minutes (from 1 to 7) using the numbers on
the keypad.

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Retry Count

1. Press Setup.
2. Press Menu until ‘Retry Count’ displays.
3. Enter the number of attempts (from 1 to 2) to redial the number.
If you enter 0, the machine does not redial.

Answer On Rings

You can select the number of times your machine rings before
answering an incoming call. If you are using your machine as both a
telephone and a fax machine, we suggest you set the ring count to at
least 4 to give you time to answer.

1. Press Setup.
2. Press Menu until ‘Answer On Rings’ displays.
3. Enter a number from 1 through 7 on the keypad.

Print RTI (Receive Terminal ID)

This feature lets the machine automatically print the receive terminal
ID (if registered), page number, and the date and time of the
reception at the bottom of each page on the received document.

1. Press Setup.
2. Press Menu until ‘Print RTI’ displays.
3. Press Start for yes to print RTI, or press Cancel for no.

Diagnostic Aids 3-9

4412-00X

Modem Test

The modem sends various transmit signals on the telephone line.

You can check the following:

– FSK
– Tones: 1100Hz, 1650Hz, 1850Hz, 2100Hz
– G3 training: 33600, 31200, 28800, 26400, 21600, 14400,
12000, 9600, 7200, 4800, 2400 bps
1. Press Setup.
2. Press Menu until ‘Modem Test’ displays.

DTMF Test

This feature lets the user or tester verify that the phone keypad
buttons are working correctly.

1. Press Setup.
2. Press Menu until “DTMF Test” displays.
3. Press Start.

To test each button, press each button one at a time. There is a

different tone for each button. Each pressed button displays a
corresponding number or symbol in the LCD. If any button fails,
replace the operator panel.

ROM Test

Display ROM version and checksum.

1. Press Setup.
2. Press Menu until ‘ROM Test’ displays.
3. Press Start or Setup.

Modem Speed

Default=33600 bps

Select baud rate of 33600, 28800, 14400, 12000, 9600, 7200, 4800
or 2400 bps. The lower the baud rate, the larger the acceptable error
rate. T30 protocol has a fixed speed of 300 bps in the protocol mode.
When the TX speed is set to 33600 or 28800 bps, the RX speed is
either V.34 V.17 or V.33. When the TX speed is set to 14400 or

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12000 bps, the RX speed is either V.17 or V.33. When the TX speed
is set to 9600 or 7200 bps, the RX speed is V.29 or V.27. When the
TX speed is set to 4800 or 2400 bps, the RX speed is V.27.

1. Press Setup.
2. Press Menu until ‘Modem Speed’ displays.
3. Press Options to select the TX speed you want. Press Start or
Setup.

Set TX Level

Default=12 dBm

FCC requires that the transmission level be less than -9 dBm. From -
9 dBm to -15 dBm is acceptable. You can set the transmission level
between 0 and -15 dBm in 1 dBm steps using the operator panel
keypad. Accuracy is +0/-3 dBm.

1. Press Setup.
2. Press Menu until ‘Set TX Level’ displays.
3. Enter a number from 1 through 15 on the keypad.

Set RX Level

Default=-43 dBm

Reception level may be too low due to cable losses. If set to -43
dBm, reception sensitivity is between 0 and -43 dBm.

1. Press Setup.
2. Press Menu until ‘Set RX Level’ displays.
3. Enter a number from 40 through 50 on the keypad.

Pause Time

Default=3 seconds

This sets the length of the pause time from 1 through 9 seconds.

1. Press Setup.
2. Press Menu until ‘Pause Time’ displays.
3. Enter a number from 1 through 9 on the keypad.

Diagnostic Aids 3-11

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4. Repair Information

This chapter explains how to make adjustments to the printer and

how to remove defective parts.
Note: Read the following before handling electronic parts.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to
electrostatic discharge (ESD). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic boards:
• Keep the ESD-sensitive part in its original shipping container (a
special “ESD bag”) until you are ready to install the part into the
machine.
• Make the least-possible movements with your body to prevent
an increase of static electricity from clothing fibers, carpets, and
furniture.
• Put the ESD wrist strap on your wrist. Connect the wrist band to
the system ground point. This discharges any static electricity in
your body to the machine.
• Hold the ESD-sensitive part by its edge; do not touch its pins. If
you are removing a pluggable module, use the correct tool.
• Do not place the ESD-sensitive part on the machine cover or on
a metal table; if you need to put down the ESD-sensitive part for
any reason, first put it into its special bag.
• Machine covers and metal tables are electrical grounds. They
increase the risk of damage because they make a discharge
path from your body through the ESD-sensitive part. (Large
metal objects can be discharge paths without being grounded.)
• Prevent ESD-sensitive parts from being accidentally touched by
other personnel. Install machine covers when you are not
working on the machine, and do not put unprotected ESD-
sensitive parts on a table.
• If possible, keep all ESD-sensitive parts in a grounded metal
cabinet (case).
• Be extra careful in working with ESD-sensitive parts when cold
weather heating is used because low humidity increases static
electricity.

Repair Information 4-1

4412-00X

Adjustments
The user is directed, in the Printer Control program, to perform the
bidirectional alignment adjustments after replacing a print cartridge.

Removal Procedures
The following procedures are arranged according to the name of the
printer part discussed.

CAUTION: Unplug the power cord before removing any parts.

Releasing Plastic Latches

Many of the parts are held in place with plastic latches. The latches
break easily; release them carefully. To remove such parts, press the
hook end of the latch away from the part to which it is latched.

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Removals
General Precautions on Removals
When you disassemble and reassemble components, use extreme
caution. The close proximity of cables to moving parts makes proper
routing a must. If components are removed or replaced, any cables
disturbed must be replaced as close as possible to their original
positions. Before removing any component from the machine, note
the cable routing.

When servicing the machine:

• Check to verify that documents are not stored in memory.

• Move the printer cartridge to far right to cap the nozzle.
• Unplug the power cord.
• Use a flat and clean surface.
• Replace only with authorized components.
• Do not force plastic-material components.
• Make sure all components are in their proper position.

Repair Information 4-3

4412-00X

CIS White Roller Assembly Removal

1. Open the operator panel.
2. Push the bushing on both ends of the roller slightly inward, and
then rotate it until it reaches the slot as shown. Lift the roller out.
Note: If the roller is dirty. If dirty, wipe it with a soft cloth
dampened with water. If the roller is heavily worn, replace it with
a new one.

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Top Cover Assembly Removal

1. Open the operator panel and open the print cartridge
compartment cover. Remove the white roller assembly. Remove
the six screws as shown.

2. Remove the three screws as shown and remove the top cover
assembly.

Repair Information 4-5

4412-00X

Rollers (Drive Feed Roller Assembly, Exit Shaft)

Removal
1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Take out the rollers from the base assembly.

Note: Clean the surface of the rollers with ethyl alcohol. After wiping
them, you must dry them completely.

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CIS (Contact Image Sensor) Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Remove the drive feed roller. See “Rollers (Drive Feed Roller
Assembly, Exit Shaft) Removal” on page 4-6.
3. Remove one screw securing the CIS assembly and unplug the
CIS harness. Remove the CIS assembly.

Repair Information 4-7

4412-00X

4. Turn the CIS assembly over. Remove one screw to release the
CIS from the bracket.
Note: Be careful not to lose the springs.

Note: Check the glassy surface of the CIS for any stain or scratch. If
stained, wipe off with ethyl alcohol. If it is heavily stained or
scratched, replace it.

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Scanner Motor with Gear Assembly Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Unplug the motor connector from the system board. Make sure
the harness is released from hooks securing the harness as
shown.

Repair Information 4-9

4412-00X

3. Remove two screws as shown and remove the scan motor

assembly.

4. Remove the two screws securing the motor to the motor

bracket.

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Power Supply Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Remove screw from left side and the ground wire on the right.
3. Disconnect connector CON1 from power supply.
4. Lift up and remove.

Repair Information 4-11

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Line Interface Board Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Remove the one screw securing the ground wires to the
bracket.

3. Unplug the line interface connector from the line interface

board.
4. Remove the screw from the ground wire on the power supply.
5. Pull the snaps as shown to unlock the line interface board from
the system board. Push up on the line interface board.
6. Unplug all the connectors from the line interface board and
remove it.

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Operator Panel Assembly Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Disconnect the operator panel cable from the system board.
3. Release harness from harness hook.
4. Remove the two ground strap screws.
5. Turn the tie stopper 90 degrees as shown and remove from
operator panel assembly.
6. Release ground strap cable hooks.
7. Release opposite operator panel hinge.

Repair Information 4-13

4412-00X

Printer Unit Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Remove the paper support extension.
3. Release lower paper guide tabs.
4. Release upper paper guide tab.
5. Remove the paper guide.
6. Remove the paper deflector.

7. Remove three screws securing the printer unit, and unplug the
eight connectors from the system board. Remove the printer
unit.

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8. Remove ground strap screw.

Note: When you reassemble the unit, do not pinch or short the wire
harness.

ASF Assembly Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Remove paper support extension.
3. Release lower paper guide tabs.
4. Release upper paper guide tab.
5. Remove paper guide.
6. Remove paper deflector.
7. Release cables from guides located on ASF assembly.
8. Remove two screws.
9. Remove power supply. See“Power Supply Removal” on
page 4-11.
10. Remove the three screws from the ASF assembly.

Repair Information 4-15

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11. Remove ASF assembly.

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Maintenance Station Removal

1. Remove the printer unit.
2. Remove one screw.
3. Release two tabs from the rear of the maintenance station and
remove the maintenance station.

Repair Information 4-17

4412-00X

Carrier Assembly with Belt Removal

1. Remove the printer unit. See “Printer Unit Removal” on
page 4-14.
2. Disconnect the carrier cables from the system board.
3. Release tab on carrier cable guide.
4. Release carrier cable guide from frame.
5. Remove pulley stopper.
6. Depress the belt tensioner and remove the belt from the carrier
motor.
7. Remove two carrier springs that secure the shaft.
8. Remove the carrier shaft.
9. Remove the carrier assembly.

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System Board Removal

1. Remove the top cover assembly. See “Top Cover Assembly
Removal” on page 4-5.
2. Remove two screws securing the system board.
3. Unplug all connectors.
4. Pull the sensor lever toward you and remove the system board.

Repair Information 4-19

4412-00X

Mid Frame Assembly with Exit Rollers Removal

1. Remove the top cover. See “Top Cover Assembly Removal”
on page 4-5.
2. Remove the carrier assembly.
3. Remove the maintenance station.
4. Remove the encoder strip.
5. Remove two screws from friction roller assembly.
6. Remove exit roller assembly.
7. Release four springs on small feed roller assembly.
8. Press down and remove each lower portion section of the small
feed roller assembly.
9. Release tabs in upper portion of small feed roller assembly.
10. Remove upper portion of small feed roller assembly.
11. Push up on mid frame assembly to release from large feed
roller.
12. Remove mid frame assembly.

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Large Feed Roller Assembly with Gear Removal

1. Remove the printer unit. See “Printer Unit Removal” on
page 4-14.
2. Remove the mid frame assembly. See “Mid Frame Assembly
with Exit Rollers Removal” on page 4-20.
3. Remove the maintenance station.
4. Remove the feed roller bearing from the main frame. Pull the
feed roller as shown and remove.

Repair Information 4-21

4412-00X

Paper Feed Motor Assembly with Gears Removal

1. Remove the printer unit. See “Printer Unit Removal” on
page 4-14.
2. Remove the large feed roller assembly. See “Large Feed
Roller Assembly with Gear Removal” on page 4-21.
3. Remove the two screws and remove the paper feed motor
assembly.

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Carrier Transport Motor Removal

1. Remove the top cover assembly. Go to the “Top Cover
Assembly Removal” on page 4-5.
2. Manually move the carrier to the center of the machine.
3. Remove the idler pulley assembly spring cover retainer.
4. Press the idler pulley and remove the belt from the carrier
transport pulley.
5. Disconnect connector (P4) from the system board.
6. Remove the two screws from the carrier transport motor and
remove.

Repair Information 4-23

4412-00X

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5. Connector Locations
System Board

Units Description

P1 Power Supply

P2 CIS

P4 Carrier Motor

P5 Paper Feed Motor

P6 Scanner Motor

P7 Carrier Cable

P8 Line Interface Board

P9 Operator Panel

P10 Speaker

P11 Door Switch

Connector Locations 5-1

4412-00X

Line Interface Board

Units Description

P1 System Board

5-2 Service Manual

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Power Supply

Units Description

CON1 System Board

Connector Locations 5-3

4412-00X

5-4 Service Manual

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6. Preventive Maintenance

This chapter contains the lubrication specifications. Follow these

recommendations to prevent problems and maintain optimum
performance.

Lubrication Specifications
Lubricate only when parts are replaced or as needed, not on a
scheduled basis. Use grease P/N 99A0394 to lubricate the following:

• All gear mounting studs.

• The left and right ends of the large feed roller at the side frames.
• The carrier to carrier frame engagement.
• The carrier guide rod and carrier guide rod bearings.

Preventive Maintenance 6-1

4412-00X

6-2 Service Manual

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7. Parts Catalog

How to Use This Parts Catalog

• SIMILAR ASSEMBLIES: If two assemblies contain a
majority of identical parts, they are shown on the same list.
Common parts are shown by one index number. Parts
peculiar to one or the other of the assemblies are listed
separately and identified by description.
• NS: (Not Shown) in the Asm-Index column indicates that the
part is procurable but is not pictured in the illustration.
• PP: in the parts description column indicates the part is
available in the listed parts packet.
• NA: Not available as a FRU.

Parts Catalog 7-1

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Assembly 1: Main Assembly

7-2 Service Manual

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Assembly 1: Main Assembly

Asm- Part
Units Description
Index Number
1-1 NA 1 Support, Paper Extension
2 56P1151 1 Guide, Paper
3 NA 1 Deflector, Paper
4 56P1154 1 Cover, Top Assembly
5 NA 1 CIS White Roller Assembly
6 56P1155 1 Tray, Paper Exit Assembly
7 56P1156 1 Tray, Scan Exit Assembly
8 NA 1 Screw/Rings Parts Packet
9 56P1160 1 Panel, Operator Assembly

Parts Catalog 7-3

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Assembly 2: Base Unit

7-4 Service Manual

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Assembly 2: Base Unit

Asm- Part
Units Description
Index Number
2-1 NA 1 Phone Line Cord
2 NA 1 Power Line Cord
3 56P1157 1 Board, Line Interface
3 56P1180 1 Board, Line Interface (EMEA)
3 56P1181 1 Board, Line Interface (Taiwan)
3 56P1182 1 Board, Line Interface (PRC)
4 56P1158 1 Power Supply
5 56P1161 1 Base Assembly
6 56P1164 1 Motor, Scanner with Gear Assembly
7 56P1165 1 Motor, Carrier Assembly
8 NA 1 Shaft, Exit
9 12G6941 1 Drive Feed Roller Assembly
10 NA 1 Strap, Operator Panel Door
11 NA 1 Spring, Ground
12 NA 1 Sensor, Access Door
13 NA 1 Latch, Operator Panel Door
14 56P1162 1 Contact, Image Sensor (CIS)
15 NA 1 Spring, CIS
16 NA 1 IPR-Bracket CIS
17 56P1179 1 Cable CIS

Parts Catalog 7-5

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Assembly 3: Engine

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Assembly 3: Engine
Asm- Part
Units Description
Index Number
3-1 56P1167 1 ASF Assembly
2 12G6961 1 Small Feed Roller Assembly with EOF and
Springs
3 56P1159 1 System Board
4 NA 1 Main Frame Assembly with Encoder Clip
5 56P1169 1 Cable, Transport Carrier Motor
6 56P1168 1 Motor, Carrier Transport
7 NA 1 Spring, Carrier Shaft Retainer
8 12G6956 1 Maintenance Station Assembly
9 NA 1 Bearing, Feed Roller
10 12G6962 1 Feed Roller, Large with Gear
11 NA 1 Frame, Mid Assembly with Exit Rollers
12 NA 1 Carrier Belt
13 12G6968 1 Strip, Encoder
14 56P1170 1 Carrier Assembly with Belt
15 56P1173 1 Clip, Encoder
16 NA 1 Shaft, Carrier
17 NA 1 Stopper Pulley
18 12G6958 1 Pulley, Idle Assembly
19 12G6963 1 Motor, Paper Feed Assembly with Gears

Parts Catalog 7-7

4412-00X

7-8 Service Manual

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Index

A Plastic Latches 4-2

POST 2-1
Abbreviations 1-5 Power Supply 5-3
Adjustments 4-2 Preventive Maintenance 6-1
Aging Test 3-5 Print Report 3-5
Answer On Rings 3-9 Print RTI 3-9
Auto Journal 3-6 Problems
Auto Reduction 3-8 Carrier Transport 2-3
Maintenance Station 2-3
C
Operator Panel 2-3
CIS Test 3-5 Paper Feed 2-6
Connector Locations 5-1 Power 2-6
Contact Image Sensor 3-2 Print Quality 2-6
Printer Communication 2-5
D Scanner 2-5
Diagnostic Aids 3-1 Program Download 3-6
Diagnostic Information 2-1
Dial Mode 3-7 R
Discard Size 3-8 Remote RCV Code 3-7
Drive Feed Roller 3-1 Removal Procedures 4-2
DTMF Test 3-10 Removals
ASF Assembly 4-15
E Carrier Assembly 4-18
ECM 3-7 Carrier Transport Motor 4-23
ESD-Sensitive Parts 4-1 CIS White Roller 4-4
Contact Image Sensor 4-7
G Large Feed Roller 4-21
Line Interface Board 4-12
General Information 1-1
Maintenance Station 4-17
L Mid Frame Assembly 4-20
Operator Panel 4-13
Line Interface Board 5-2 Paper Feed Motor 4-22
Lubrication Specifications 6-1 Power Supply 4-11
Printer Unit 4-14
M Rollers 4-6
Maintenance 3-6 Scanner Motor 4-9
Message Confirm 3-6 System Board 4-19
Modem Speed 3-10 Top Cover Assembly 4-5
Modem Test 3-10 Repair Information 4-1
Retry Count 3-9
P Retry Interval 3-8
Parts Catalog 7-1 ROM Test 3-10
Pause Time 3-11

Index I-1
4412-00X

S 56P1155 7-3
56P1156 7-3
Safety Information v 56P1157 7-5
Service Checks 56P1158 7-5
Carrier Transport 2-7 56P1159 7-7
CIS Assembly 2-9 56P1160 7-3
Maintenance Station 2-11 56P1161 7-5
Paper Feed 2-12 56P1162 7-5
Paper Path 2-14 56P1164 7-5
Power 2-15 56P1165 7-5
Print Quality 2-16 56P1167 7-7
Scan/Copy Quality 2-18 56P1168 7-7
Scanner Motor 2-10 56P1170 7-7
Service Mode 3-2, 3-4 56P1173 7-7
Set RX Level 3-11 56P1179 7-5
Set TX Level 3-11 56P1180 7-5
Specifications 56P1181 7-5
Facsimile 1-3 56P1182 7-5
Power and Size 1-5
Printer Engine 1-2
Printhead 1-2
Scanner 1-5
Symptom Table (POST) 2-2
Symptom Tables 2-3
System Board 5-1

T
Theory of Mechanism
Contact Image Sensor 3-2
Document Sensors 3-2
Drive Feed Roller Assembly 3-1
Scanner 3-1

U
User Mode 3-3

Part Numbers
12G6941 7-5
12G6956 7-7
12G6958 7-7
12G6961 7-7
12G6962 7-7
12G6963 7-7
12G6968 7-7
56P1151 7-3
56P1154 7-3

I-2 Service Manual