Lexmar X422 Laser User manual

7001–001

Lexmark™ X422 Laser

Lexmark and Lexmark with diamond

design are trademarks of Lexmark

International, Inc., registered in the

United States and/or other countries.

• Table of Contents

• Index

• Safety and Notices

• Trademarks

• Start Diagnostics

• Safety and Notices

Edition: April 2004

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.

References in this publication to products, programs, or services do not imply that the

manufacturer intends to make these available in all countries in which it operates. Any

reference to a product, program, or service is not intended to state or imply that only that

product, program, or service may be used. Any functionally equivalent product, program,

or service that does not infringe any existing intellectual property right may be used

instead. Evaluation and verification of operation in conjunction with other products,

programs, or services, except those expressly designated by the manufacturer, are the

user’s responsibility.

Lexmark, Lexmark with diamond design, MarkNet, MarkVision, and Optra are trademarks

of Lexmark International, Inc., registered in the United States and/or other countries.

ImageQuick, Optra Forms, and PictureGrade are trademarks of Lexmark International,

Inc.

Other trademarks are the property of their respective owners.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are

commercial computer software and documentation developed exclusively at private

expense.

7001–001

U.S.A. P/N 12G9352

iii

7001-001

Table of Contents

Laser notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxii

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

MFP identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

MFP features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Fonts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Memory and user flash memory . . . . . . . . . . . . . . . . . . . . . . . 1-4

Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Print area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Data streams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Paper handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

MFP speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Resolution and print quality. . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

RIP card specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Scanner features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Copier specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Fax specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Attendance and status messages . . . . . . . . . . . . . . . . . . . . . . . 2-2

Operator panel overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Power–on self test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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

iv Service Manual

7001-001

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18

ADF service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-19

Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20

Cover interlock switch service check . . . . . . . . . . . . . . . . . . .2-21

Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . .2-22

E-mail service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Low voltage power supply (LVPS) service check. . . . . . . . . .2-24

Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Cold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

Hot fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28

Continuity check on HVPS/cartridge . . . . . . . . . . . . . . . . . . .2-29

Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Network printing service check . . . . . . . . . . . . . . . . . . . . . . .2-31

Operator panel service check. . . . . . . . . . . . . . . . . . . . . . . . .2-32

Paper feed service checks. . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

RIP card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46

Scanner/copier service check . . . . . . . . . . . . . . . . . . . . . . . .2-47

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

USB service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48

Solving print quality problems . . . . . . . . . . . . . . . . . . . . . . . . . .2-49

Using print quality test pages. . . . . . . . . . . . . . . . . . . . . . . . .2-49

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Menu descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Entering the diagnostics menu. . . . . . . . . . . . . . . . . . . . . . . . .3-1

Entering the configuration menu . . . . . . . . . . . . . . . . . . . . . . .3-1

Configuration and Diagnostic Menu. . . . . . . . . . . . . . . . . . . . .3-2

Configuration Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Diagnostic mode menu settings. . . . . . . . . . . . . . . . . . . . . . . .3-6

SE Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Hex Trace mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Flashing firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

System shutdown for flashing or other soft resets . . . . . . . . .3-15

Flashing sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Ways to flash the machine. . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

7001-001

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Paper feed adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Printhead alignment adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-2

Printhead registration adjustment . . . . . . . . . . . . . . . . . . . . . . 4-4

Scanner calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Scanner registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

MFP cover removals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

3–pin and 2–pin connectors removal . . . . . . . . . . . . . . . . . . 4-19

Bracket, opener shutter removal. . . . . . . . . . . . . . . . . . . . . . 4-20

Bracket, paper detect (input sensor) removal. . . . . . . . . . . . 4-21

Cartridge coupling assembly removal. . . . . . . . . . . . . . . . . . 4-22

Charge roll removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

D–roll tray 1 feed removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

D–roll (tray 1) shaft assembly removal . . . . . . . . . . . . . . . . . 4-26

Door latches (right side) removal . . . . . . . . . . . . . . . . . . . . . 4-28

Duplex tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . 4-29

Fuser assembly, fuser paper exit guide,

Fuser exit sensor, and fuser lamp removal. . . . . . . . . . . . . . 4-30

HVPS card removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

LVPS card removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Lower (MPF) housing assembly removal . . . . . . . . . . . . . . . 4-41

Lower (MPF) housing assembly - paper sensor removal . . . 4-42

Main drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Main drive motor assembly removal . . . . . . . . . . . . . . . . . . . 4-45

Motor assembly (stepper) removal . . . . . . . . . . . . . . . . . . . . 4-46

MPF roller assembly removal . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Pick pad removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Printhead removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Rear exit door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Reference plate assembly removal. . . . . . . . . . . . . . . . . . . . 4-56

RIP card cage (with card in place) removal . . . . . . . . . . . . . 4-58

Smart button sensor removal . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Terminal assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Tray damper and spring removal . . . . . . . . . . . . . . . . . . . . . 4-65

Transfer roll assembly and left transfer support bearing removal.

4-66

Upper (MPF) housing assembly (with paper flag) removal. . 4-66

vi Service Manual

7001-001

Scanner cover removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67

Scanner ADF removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Scanner ADF motor removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-78

Scanner assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-79

Scanner CCD carriage removal . . . . . . . . . . . . . . . . . . . . . . 4-82

Scanner CCD timing belt removal. . . . . . . . . . . . . . . . . . . . . 4-84

Scanner control unit card removal . . . . . . . . . . . . . . . . . . . . 4-86

Scanner document tray assembly. . . . . . . . . . . . . . . . . . . . . 4-87

Scanner flatbed motor assembly removal. . . . . . . . . . . . . . . 4-88

Scanner ADF pick roller assembly removal . . . . . . . . . . . . . 4-91

Scanner R1 idler removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92

Scanner R2 idler removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Cables (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Scanner cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

High voltage power supply (HVPS) . . . . . . . . . . . . . . . . . . . . . . 5-8

Low voltage power supply (LVPS) . . . . . . . . . . . . . . . . . . . . . . . 5-9

RIP card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

RIP card assembly (continued) . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

SCU connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Scanner sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

Laser notices vii

7001-001

Laser notices

The following laser notice labels may be affixed to this MFP as

shown:

Laser advisory label

viii Service Manual

7001-001

Laser Notice

The printer is certified in the U.S. to conform to the requirements of

DHHS 21 CFR Subchapter J for Class I (1) laser products, and

elsewhere is certified as a Class I laser product conforming to the

requirements of IEC 60825-1.

Class I laser products are not considered to be hazardous. The

printer contains internally a Class IIIb (3b) laser that is nominally a 5

milliwatt gallium arsenide laser operating in the wavelength region of

770-795 nanometers. The laser system and printer are designed so

there is never any human access to laser radiation above a Class I

level during normal operation, user maintenance, or prescribed

service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die

Anforderungen der Bestimmung DHHS (Department of Health and

Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).

In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,

der die Anforderungen der IEC (International Electrotechnical

Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des

Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es

sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen

der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der

Drucker sind so konzipiert, daßim Normalbetrieb, bei der Wartung

durch den Benutzer oder bei ordnungsgemäßer Wartung durch den

Kundendienst Laserbestrahlung, die die Klasse Iübersteigen würde,

Menschen keinesfalls erreicht.

Laser notices ix

7001-001

Avis relatif àl’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux

provisions DHHS 21 CFR alinéa J concernant les produits laser de

Classe I (1). Pour les autres pays : cette imprimante répond aux

normes IEC 60825-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits

non dangereux. Cette imprimante est équipée d’un laser de Classe

IIIb (3b) (arséniure de gallium d’une puissance nominale de 5

milliwatts) émettant sur des longueurs d’onde comprises entre 770

et 795 nanomètres. L’imprimante et son système laser sont conçus

pour impossible, dans des conditions normales d’utilisation,

d’entretien par l’utilisateur ou de révision, l’exposition àdes

rayonnements laser supérieurs àdes rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante ècertificata negli Stati Uniti per essere conforme

ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di

classe 1 ed ècertificata negli altri Paesi come prodotto laser di

classe 1 conforme ai requisiti della norma CEI 60825-1.

I prodotti laser di classe non sono considerati pericolosi. La

stampante contiene al suo interno un laser di classe IIIb (3b)

all’arseniuro di gallio della potenza di 5mW che opera sulla

lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema

laser e la stampante sono stati progettati in modo tale che le

persone a contatto con la stampante, durante il normale

funzionamento, le operazioni di servizio o quelle di assistenza

tecnica, non ricevano radiazioni laser superiori al livello della

classe 1.

xService Manual

7001-001

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los

requisitos para los productos láser de Clase I (1) establecidos en el

subcapítulo J de la norma CFR 21 del DHHS (Departamento de

Sanidad y Servicios) y, en los demás países, reúne todas las

condiciones expuestas en la norma IEC 60825-1 para productos

láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La

impresora contiene en su interior un láser de Clase IIIb (3b) de

arseniuro de galio de funcionamiento nominal a 5 milivatios en una

longitud de onda de 770 a 795 nanómetros. El sistema láser y la

impresora están diseñados de forma que ninguna persona pueda

verse afectada por ningún tipo de radiación láser superior al nivel de

la Clase I durante su uso normal, el mantenimiento realizado por el

usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora estácertificada nos E.U.A. em conformidade com os

requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a

Classe I (1) de produtos laser. Em outros locais, estácertificada

como um produto laser da Classe I, em conformidade com os

requisitos da norma IEC 60825-1.

Os produtos laser da Classe I não são considerados perigosos.

Internamente, a impressora contém um produto laser da Classe IIIb

(3b), designado laser de arseneto de potássio, de 5 milliwatts

,operando numa faixa de comprimento de onda entre 770 e 795

nanómetros. O sistema e a impressora laser foram concebidos de

forma a nunca existir qualquer possiblidade de acesso humano a

radiação laser superior a um nível de Classe I durante a operação

normal, a manutenção feita pelo utilizador ou condições de

assistência prescritas.

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