Lexmark MS81 Series User manual

Lexmark MS81x, MS71x Printer
Machine Type 4063-2xx, -4x0, -63x, -83x
Service Manual
•Start diagnostics
•Maintenance
•Safety and notices
•Trademarks
•Index
October 18, 2012 www.lexmark.com

Product information
Product name:
Lexmark MS71x and MS81x Series
Machine type:
4063
Model(s):
2xx, 4x0, 63x, 83x
Edition notice
October 18, 2012
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.
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.
Trademarks
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other
countries.
PrintCryption is a trademark of Lexmark International, Inc.
Mac and the Mac logo are trademarks of Apple Inc., registered in the U.S. and other countries.
PCL® is a registered trademark of the Hewlett-Packard Company. PCL is Hewlett-Packard Company’s designation of a set of printer commands
(language) and functions included in its printer products. This printer is intended to be compatible with the PCL language. This means the
printer recognizes PCL commands used in various application programs, and that the printer emulates the functions corresponding to the
commands.
All other trademarks are the property of their respective owners.
© 2012 Lexmark International, Inc.
All rights reserved.
P/N 12G3023
4063

Table of contents
Product information.....................................................................................2
Edition notice...............................................................................................2
Notices and safety information..................................................................17
Laser notices............................................................................................................................................17
Safety.......................................................................................................................................................20
Preface.......................................................................................................25
Service manual conventions....................................................................................................................25
General information...................................................................................27
Printer configurations.............................................................................................................................28
Paper guidelines......................................................................................................................................30
Paper characteristics......................................................................................................................................... 30
Selecting paper ................................................................................................................................................. 31
Selecting preprinted forms and letterhead ......................................................................................................31
Using recycled paper and other office papers.................................................................................................. 31
Storing paper .................................................................................................................................................... 33
Data security notice.................................................................................................................................33
Tools required for service........................................................................................................................33
Diagnostic information...............................................................................35
Troubleshooting overview.......................................................................................................................35
Performing the initial troubleshooting check ................................................................................................... 35
Error code number key ..................................................................................................................................... 36
Power‑on Reset (POR) sequence.............................................................................................................36
Using Safe Mode.....................................................................................................................................37
Fixing print quality issues........................................................................................................................37
Initial print quality check .................................................................................................................................. 38
Gray background on prints ............................................................................................................................... 38
Printer is printing blank pages .......................................................................................................................... 39
Printer is printing solid black pages .................................................................................................................. 40
Repeating defects ............................................................................................................................................. 41
Shadow images appear on prints ..................................................................................................................... 41
Skewed print..................................................................................................................................................... 42
Streaked horizontal lines appear on prints....................................................................................................... 43
Streaked vertical lines appear on prints ........................................................................................................... 45
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Toner rubs off ................................................................................................................................................... 46
Paper jams...............................................................................................................................................46
Understanding jam numbers and locations...................................................................................................... 47
200–201 paper jams ......................................................................................................................................... 49
Sensor (input) static jam service check............................................................................................................. 53
Sensor (input) early arriving jam service check ................................................................................................ 53
Sensor (input) never‑ or late‑arriving jam service check.................................................................................. 54
Sensor (input) late-leaving or did-not-clear jam service check......................................................................... 56
Main drive motor control jam service check .................................................................................................... 57
Printhead motor control jam service check...................................................................................................... 58
Fuser drive motor control jam service check.................................................................................................... 58
Sensor (input) miscellaneous jam 1 service check............................................................................................ 58
Sensor (input) miscellaneous jam 2 service check............................................................................................ 59
Sensor (input) miscellaneous jam 3 service check............................................................................................ 59
202 paper jams ................................................................................................................................................. 60
Sensor (fuser exit) static jam service check ...................................................................................................... 62
Sensor (fuser exit) late-leaving jam service check ............................................................................................ 62
Sensor (fuser exit) late-arriving jam service check ........................................................................................... 63
Sensor (narrow media) late arriving jam service check .................................................................................... 64
Sensor (narrow media) static jam service check............................................................................................... 65
Sensor (fuser exit) miscellaneous jam service check ........................................................................................ 66
Fuser ID chip control jam service check............................................................................................................ 66
203 paper jams ................................................................................................................................................. 67
Upper redrive motor control jam service check ............................................................................................... 68
230 paper jams ................................................................................................................................................. 68
Sensor (duplex path) static jam service check .................................................................................................. 71
Sensor (duplex path) early arriving jam service check...................................................................................... 72
Sensor (duplex path) never‑ or late‑arriving jam service check .......................................................................73
Sensor (duplex path) late leaving jam service check ........................................................................................ 74
Duplex control jam service check ..................................................................................................................... 75
Sensor (duplex path) miscellaneous jam service check .................................................................................... 75
Sensor (input) never-arriving jam (exiting duplex) service check..................................................................... 76
235–239 paper jams ......................................................................................................................................... 76
24x paper jams.................................................................................................................................................. 77
Media feeder motor control service check....................................................................................................... 79
Media tray 1, tray pulled jam ........................................................................................................................... 80
Media feeder motor tray lift error service check ............................................................................................. 81
Sensor (input) never-arriving jam from tray 1 service check............................................................................ 81
250 paper jams ................................................................................................................................................. 82
Sensor (input) never-arriving jam from MPF media tray service check............................................................84
41y.xx paper jams ............................................................................................................................................. 86
43y.xx paper jams ............................................................................................................................................. 87
451 paper jams ................................................................................................................................................. 88
455–457 paper jams ......................................................................................................................................... 89
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User attendance messages (0-99.99)......................................................................................................92
User attendance messages (0‑99.99) ............................................................................................................... 92
Toner level sensing error check ........................................................................................................................ 97
Toner cartridge smart chip error service check ................................................................................................ 97
Imaging unit smart chip service check.............................................................................................................. 98
Fuser unit smart chip service check.................................................................................................................. 99
Printer hardware errors (100-199.99).....................................................................................................99
Printer hardware error messages(100‑199.99) .............................................................................................. 100
Printhead ID service check.............................................................................................................................. 104
Printhead service check .................................................................................................................................. 104
Fuser drive motor service check ..................................................................................................................... 105
Fuser service check ......................................................................................................................................... 105
LVPS service check .......................................................................................................................................... 106
Toner level sensing service check ................................................................................................................... 106
Main drive motor service check...................................................................................................................... 107
Media feeder service check ............................................................................................................................ 107
Redrive motor service check........................................................................................................................... 108
Duplex motor service check............................................................................................................................ 108
Toner add motor service check ...................................................................................................................... 109
Main cooling fan service check ....................................................................................................................... 109
Cartridge cooling fan service check ................................................................................................................ 110
LVPS cooling fan service check ....................................................................................................................... 110
HVPS cooling fan service check....................................................................................................................... 111
Miscellaneous cooling fan service check ........................................................................................................ 111
Firmware and/or system electronics errors (900-999.99)....................................................................111
9xx error messages ......................................................................................................................................... 112
System software error service check.............................................................................................................. 115
NVRAM mismatch failure service check ......................................................................................................... 120
Input/output option hardware errors...................................................................................................121
3xx error messages (300‑399.99) ................................................................................................................... 121
250/550-sheet transport motor failure service check.................................................................................... 126
250/550-sheet media feeder failure service check ........................................................................................ 128
250/550-sheet controller board failure service check.................................................................................... 130
HCIT lift drive motor failure service check...................................................................................................... 131
HCIT lift plate failure service check................................................................................................................. 133
HCIT transport motor failure service check .................................................................................................... 135
HCOE failure service check ............................................................................................................................. 137
Mailbox failure service check.......................................................................................................................... 138
Output expander failure service check ........................................................................................................... 139
Input/output option paper jam errors..................................................................................................141
Input option jam error messages (242‑245.99) .............................................................................................. 141
250/550-sheet media tray option jam service check...................................................................................... 152
HCIT jam service check ................................................................................................................................... 154
HCIT source jam service check........................................................................................................................ 156
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4xx error messages (400‑499.99) ................................................................................................................... 158
Sensor (mailbox pass through) jam service check .......................................................................................... 167
Mailbox diverter jam service check ................................................................................................................ 170
HCOE diverter jam service check .................................................................................................................... 172
Sensor (HCOE pass through) jam service check.............................................................................................. 173
Sensor (finisher pass through) jam service check........................................................................................... 175
Finisher left tamper jam service check ........................................................................................................... 177
Finisher right tamper jam service check ......................................................................................................... 179
Finisher ejector jam service check.................................................................................................................. 181
Finisher diverter jam service check ................................................................................................................ 182
Finisher paddle jam service check .................................................................................................................. 183
Finisher tray holder jam service check ........................................................................................................... 185
Stapler carriage jam service check.................................................................................................................. 186
Output expander jam service check ...............................................................................................................188
Sensor (media in stapler) jam service check................................................................................................... 190
Symptoms..............................................................................................................................................191
Base printer symptoms................................................................................................................................... 191
Network service check.................................................................................................................................... 191
Dead machine service check........................................................................................................................... 194
Option tray symptoms .................................................................................................................................... 195
250/550-sheet media type error service check .............................................................................................. 196
250/550-sheet tray undetected service check ............................................................................................... 198
HCIT incorrect media error service check....................................................................................................... 199
HCIT media type error service check .............................................................................................................. 201
HCIT undetected service check....................................................................................................................... 203
HCIT media low undetected service check ..................................................................................................... 204
Finisher side door error service check ............................................................................................................ 206
Mailbox incorrect bin exit service check......................................................................................................... 208
Finisher cartridge error service check ............................................................................................................ 209
Finisher undetected service check.................................................................................................................. 211
Finisher bin error service check ..................................................................................................................... 212
Finisher door undetected service check ........................................................................................................ 213
Stapler carriage failure service check ............................................................................................................. 215
Finisher bin media present error service check.............................................................................................. 216
Output expander error service check ............................................................................................................. 218
Service menus..........................................................................................219
Using the printer control panel.............................................................................................................219
Menus list..............................................................................................................................................220
Diagnostics menu..................................................................................................................................220
Entering diagnostics mode ............................................................................................................................. 221
REGISTRATION ................................................................................................................................................ 221
PRINT TESTS .................................................................................................................................................... 222
Print Quality Pages (Prt Quality Pgs) .......................................................................................................... 222
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HARDWARE TESTS .......................................................................................................................................... 222
Panel Test ................................................................................................................................................... 222
Button Test................................................................................................................................................. 223
DRAM Test.................................................................................................................................................. 223
Serial Wrap Test ......................................................................................................................................... 224
USB HS Test Mode...................................................................................................................................... 224
DUPLEX TESTS ................................................................................................................................................. 225
Quick Test................................................................................................................................................... 225
Top Margin ................................................................................................................................................. 226
Sensor Test ................................................................................................................................................. 226
Motor Test.................................................................................................................................................. 226
Duplex Feed 1............................................................................................................................................. 227
Duplex Feed 2............................................................................................................................................. 227
INPUT TRAY TESTS .......................................................................................................................................... 227
Feed Tests .................................................................................................................................................. 227
Sensor Tests ............................................................................................................................................... 228
OUTPUT BIN TESTS ......................................................................................................................................... 228
Feed Tests .................................................................................................................................................. 228
Feed To All Bins .......................................................................................................................................... 228
Sensor Test ................................................................................................................................................. 229
Diverter Test............................................................................................................................................... 229
FINISHER TESTS ............................................................................................................................................... 229
Staple Test.................................................................................................................................................. 229
Hole Punch Test.......................................................................................................................................... 230
Feed Test (finisher)..................................................................................................................................... 230
Finisher Sensor Test ................................................................................................................................... 230
BASE SENSOR TEST.......................................................................................................................................... 231
DEVICE TESTS .................................................................................................................................................. 231
Quick Disk Test ........................................................................................................................................... 231
Disk Test/Clean........................................................................................................................................... 232
Flash Test.................................................................................................................................................... 232
PRINTER SETUP ............................................................................................................................................... 232
Defaults ...................................................................................................................................................... 232
Printed Page Count..................................................................................................................................... 233
Permanent Page Count (Perm page count)................................................................................................ 233
Processor ID................................................................................................................................................ 233
Engine Setting [x] ....................................................................................................................................... 234
Edge to Edge............................................................................................................................................... 234
Parallel Strobe Adjustment (Par 1 Strobe Adj) ........................................................................................... 234
EP SETUP......................................................................................................................................................... 234
EP Defaults ................................................................................................................................................. 234
Fuser Temperature (Fuser Temp)............................................................................................................... 234
Fuser Page Count ....................................................................................................................................... 235
Warm Up Time ........................................................................................................................................... 235
Transfer ...................................................................................................................................................... 235
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Print Contrast ............................................................................................................................................. 235
Charge Roll ................................................................................................................................................. 235
Gap Adjust.................................................................................................................................................. 236
Automatic Darkness Adjust (Auto Dark Adj) .............................................................................................. 236
REPORTS ......................................................................................................................................................... 236
Menu Settings Page.................................................................................................................................... 236
Installed Licenses........................................................................................................................................ 237
EVENT LOG...................................................................................................................................................... 237
Display Log ................................................................................................................................................. 237
Print Log ..................................................................................................................................................... 237
Clear Log..................................................................................................................................................... 237
Exit Diags......................................................................................................................................................... 238
Configuration menu..............................................................................................................................238
Entering configuration mode.......................................................................................................................... 239
Roller Kit Counter Value.................................................................................................................................. 239
Reset Roller Kit Counter.................................................................................................................................. 239
Print Quality Pages.......................................................................................................................................... 240
Reports ........................................................................................................................................................... 240
Menu Settings Page.................................................................................................................................... 240
Event Log .................................................................................................................................................... 240
Size sensing..................................................................................................................................................... 240
Panel Menus ................................................................................................................................................... 241
PPDS Emulation .............................................................................................................................................. 241
Download Emuls ............................................................................................................................................. 241
Safe Mode....................................................................................................................................................... 241
Factory Defaults.............................................................................................................................................. 242
Energy Conserve ............................................................................................................................................. 242
Paper Prompts ................................................................................................................................................ 242
Envelope Prompts........................................................................................................................................... 243
Action for Prompts.......................................................................................................................................... 243
Jobs on Disk .................................................................................................................................................... 244
Disk Encryption ............................................................................................................................................... 244
Erase All Information on Disk.......................................................................................................................... 244
Wipe All Settings............................................................................................................................................. 245
Font Sharpening.............................................................................................................................................. 245
Require Standby.............................................................................................................................................. 245
A5 Loading ...................................................................................................................................................... 245
UI Automation ................................................................................................................................................ 246
LES Applications .............................................................................................................................................. 246
Key Repeat Initial Delay .................................................................................................................................. 246
Key Repeat Rate.............................................................................................................................................. 246
Wiper Message ............................................................................................................................................... 247
Clear Supply Usage History ............................................................................................................................. 247
Clear Custom Status........................................................................................................................................ 247
USB Speed....................................................................................................................................................... 247
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Automatically Display Error Screens............................................................................................................... 248
USB PnP .......................................................................................................................................................... 248
Entering invalid engine mode................................................................................................................248
Entering recovery mode........................................................................................................................248
Accessing the Network SE menu...........................................................................................................249
Service Engineer menu..........................................................................................................................249
Accessing the service engineer (SE) menu...................................................................................................... 249
Service engineer (SE) menu ............................................................................................................................ 249
Repair information...................................................................................251
Removal precautions.............................................................................................................................251
Handling ESD‑sensitive parts .......................................................................................................................... 251
Controller board/control panel replacement ................................................................................................. 252
eSF solutions backup ...................................................................................................................................... 252
Ribbon cable connectors ................................................................................................................................ 253
Zero Insertion Force (ZIF) connectors ........................................................................................................ 253
Horizontal top contact connector .............................................................................................................. 254
Horizontal bottom contact connector........................................................................................................ 257
Vertical mount contact connector ............................................................................................................. 260
Horizontal sliding contact connector ......................................................................................................... 263
Low Insertion Force (LIF) connector........................................................................................................... 266
Adjustments..........................................................................................................................................267
Media aligner roller adjustment ..................................................................................................................... 269
Polygon printhead mechanical registration adjustment ................................................................................ 270
Removal procedures.............................................................................................................................272
Base printer - cover removals...............................................................................................................273
Left cover removal .......................................................................................................................................... 273
Rear lower cover removal............................................................................................................................... 276
Top cover removal .......................................................................................................................................... 278
Right cover removal........................................................................................................................................ 278
Rear door removal .......................................................................................................................................... 280
Base printer- front removals.................................................................................................................281
Duplex exit diverter removal .......................................................................................................................... 282
Front door removal......................................................................................................................................... 284
Inner guide deflector removal ........................................................................................................................ 285
Laser printhead removal................................................................................................................................. 286
Left inner cover removal................................................................................................................................. 291
Media aligner roller removal .......................................................................................................................... 293
Media turn guide removal .............................................................................................................................. 295
Media vertical guide removal ......................................................................................................................... 296
MPF feeder lift plate removal......................................................................................................................... 298
MPF pick roller removal.................................................................................................................................. 301
MPF tray removal ........................................................................................................................................... 303
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Right inner cover removal .............................................................................................................................. 304
Sensor (input) removal ................................................................................................................................... 305
Sensor (toner density) removal ...................................................................................................................... 307
Transfer roller left arm with cable removal.................................................................................................... 308
Transfer roller right arm removal ................................................................................................................... 309
Transfer roller removal ................................................................................................................................... 312
Base printer - rear removals..................................................................................................................314
Duplex motor removal.................................................................................................................................... 314
Fuser removal ................................................................................................................................................. 316
Fuser access door removal ............................................................................................................................. 318
Left frame pivot removal ................................................................................................................................ 319
Output bin sensor cover removal ................................................................................................................... 320
Right frame pivot removal .............................................................................................................................. 321
Sensor (rear door interlock) removal.............................................................................................................. 322
Base printer - top removals...................................................................................................................322
Sensor (standard bin full) removal ................................................................................................................. 323
Standard bin cover removal............................................................................................................................ 324
Upper redrive removal.................................................................................................................................... 325
Base printer - bottom removals............................................................................................................327
Duplex front flap removal............................................................................................................................... 328
Duplex rear flap removal ................................................................................................................................ 329
Left frame extension removal......................................................................................................................... 330
Media tray removal ........................................................................................................................................ 332
Pick roller assembly removal .......................................................................................................................... 333
Right frame extension..................................................................................................................................... 334
Sensor (duplex path) removal......................................................................................................................... 335
Sensor (tray 1 media out) removal ................................................................................................................. 336
Separator roller assembly removal................................................................................................................. 338
Base printer - left removals...................................................................................................................339
Controller board removal ............................................................................................................................... 340
Controller board access cover removal .......................................................................................................... 341
Controller board access shield removal.......................................................................................................... 342
Fuser drive motor removal ............................................................................................................................. 342
Main cooling fan removal ............................................................................................................................... 344
Main drive motor removal.............................................................................................................................. 345
Media feeder removal .................................................................................................................................... 347
PCBA housing removal.................................................................................................................................... 348
Sensor (control panel interlock) removal ....................................................................................................... 350
Sensor (pick roller position) removal.............................................................................................................. 351
Toner add motor removal............................................................................................................................... 352
Base printer - right removals.................................................................................................................353
Cartridge cooling fan removal ........................................................................................................................ 354
Duplex cooling fan removal ............................................................................................................................ 355
HVPS removal ................................................................................................................................................. 356
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LVPS removal .................................................................................................................................................. 357
Control panel removals.........................................................................................................................360
4.3‑inch tilting display removal....................................................................................................................... 360
7‑inch tilting display removal.......................................................................................................................... 363
Control panel removal (2.4‑inch screen) ........................................................................................................ 366
Control panel removal (4.3‑inch screen, 7‑inch screen)................................................................................. 372
Control panel board (2.4‑inch tilting display) removal ................................................................................... 378
Control panel board (4.3‑inch tilting display) removal ................................................................................... 381
Control panel board (7‑inch tilting display) removal (MS812de) ................................................................... 384
Control panel front cover removal ................................................................................................................. 387
Control panel latch removal ........................................................................................................................... 389
Control panel left bezel removal .................................................................................................................... 390
Left control panel hinge removal.................................................................................................................... 391
Right control panel hinge removal.................................................................................................................. 394
250/550-sheet media tray option removals..........................................................................................397
250/550-sheet media tray and drawer assembly removal............................................................................. 397
Media tray separation roller removal............................................................................................................. 398
Media tray assembly removal......................................................................................................................... 398
Media tray front cover removal...................................................................................................................... 398
Drawer pick roller removal ............................................................................................................................ 399
Sensor (pick roll position) removal ................................................................................................................399
Drawer assembly rear cover removal............................................................................................................. 400
Drawer assembly left cover removal .............................................................................................................. 401
Drawer controller PCBA removal.................................................................................................................... 402
Drawer upper interface cable removal........................................................................................................... 403
Drawer lower interface cable removal ........................................................................................................... 404
Drawer media feeder removal ....................................................................................................................... 405
Drawer transport motor removal ................................................................................................................... 407
Sensor (drawer pass through) removal .......................................................................................................... 408
Sensor (pick) removal ..................................................................................................................................... 410
High capacity input tray option removals.............................................................................................413
HCIT and drawer assembly removal ............................................................................................................... 413
HCIT removal .................................................................................................................................................. 414
HCIT drawer assembly removal ...................................................................................................................... 414
HCIT separator roll assembly removal ............................................................................................................ 415
HCIT media guide removal.............................................................................................................................. 415
HCIT front cover removal................................................................................................................................ 416
HCIT pick arm assembly removal.................................................................................................................... 418
HCIT drawer assembly rear cover removal..................................................................................................... 419
HCIT drawer assembly left cover removal ...................................................................................................... 420
HCIT drawer assembly right cover removal.................................................................................................... 422
HCIT controller PCBA removal ........................................................................................................................ 424
HCIT top cover assembly removal .................................................................................................................. 425
HCIT lift drive motor removal ......................................................................................................................... 427
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HCIT drawer assembly interface cable removal ............................................................................................. 429
Sensor (HCIT media low) with flag removal.................................................................................................... 430
Sensor (pick roll position) removal ................................................................................................................. 431
Sensor (HCIT pick) removal............................................................................................................................. 433
HCIT media feeder removal ............................................................................................................................ 434
Output expander option removals........................................................................................................437
Output expander assembly removal............................................................................................................... 437
Output expander top cover removal .............................................................................................................. 437
Output expander rear door removal .............................................................................................................. 438
Output expander sensor cover removal ......................................................................................................... 440
Sensor (media bin full) with flag removal ....................................................................................................... 440
Output expander right cover removal ............................................................................................................ 441
Output expander left cover removal .............................................................................................................. 443
Output expander controller PCBA removal .................................................................................................... 445
Lower interface cable removal ....................................................................................................................... 446
Upper interface cable removal ....................................................................................................................... 446
Spring with string removal.............................................................................................................................. 448
High capacity output expander option removals..................................................................................450
High capacity output expander assembly removal......................................................................................... 450
HCOE top cover removal................................................................................................................................. 450
HCOE rear door removal................................................................................................................................. 451
HCOE sensor cover removal ........................................................................................................................... 452
Sensor (HCOE media bin full) with flag removal............................................................................................. 453
HCOE right outer cover removal..................................................................................................................... 453
HCOE left cover removal................................................................................................................................. 455
HCOE controller PCBA removal....................................................................................................................... 457
HCOE lower interface cable removal .............................................................................................................. 459
HCOE upper interface cable removal.............................................................................................................. 460
Staple finisher option removals............................................................................................................461
Staple finisher assembly removal ................................................................................................................... 461
Stapler rear door removal............................................................................................................................... 462
Stapler right cover removal ............................................................................................................................ 464
Sensor (cartridge door interlock) removal...................................................................................................... 466
Stapler door close limit switch removal.......................................................................................................... 466
Stapler carriage assembly removal................................................................................................................. 469
Stapler left cover removal .............................................................................................................................. 470
Stapler cartridge access door removal ........................................................................................................... 472
Stapler top cover removal .............................................................................................................................. 472
Stapler spring with string removal.................................................................................................................. 474
Media stack flap (right) removal..................................................................................................................... 475
Media stack flap (left) removal....................................................................................................................... 476
Standard output bin LED removal................................................................................................................... 479
Sensor (finisher bin media present) removal.................................................................................................. 480
Tamper motor (right) removal........................................................................................................................ 481
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Tamper motor (left) removal.......................................................................................................................... 481
Tamper drive belt removal ............................................................................................................................. 482
Paddle drive motor removal ........................................................................................................................... 483
Stapler lower interface cable removal............................................................................................................ 484
Stapler controller PCBA removal .................................................................................................................... 486
Sensor (bin full send) removal ........................................................................................................................ 487
Sensor (bin full receive) removal .................................................................................................................... 488
Mailbox option removals......................................................................................................................490
Mailbox assembly removal ............................................................................................................................. 490
Mailbox top cover removal............................................................................................................................. 490
Mailbox rear door removal............................................................................................................................. 490
Mailbox right cover removal........................................................................................................................... 492
Mailbox spring with string removal ................................................................................................................ 493
Mailbox solenoid removal .............................................................................................................................. 494
Mailbox left cover removal............................................................................................................................. 496
Mailbox controller PCBA removal................................................................................................................... 497
Sensor (mailbox divert motor) removal.......................................................................................................... 499
Mailbox lower interface cable removal .......................................................................................................... 500
Mailbox upper interface cable removal.......................................................................................................... 502
Mailbox divert motor removal........................................................................................................................ 502
Mailbox media bin full flag removal ...............................................................................................................504
Sensor (mailbox bin full receive) removal ...................................................................................................... 505
Mailbox belt removal...................................................................................................................................... 508
Mailbox output bin LED assembly removal .................................................................................................... 510
Component locations...............................................................................515
Connectors............................................................................................................................................515
Controller board....................................................................................................................................515
Maintenance............................................................................................523
Inspection guide....................................................................................................................................523
Scheduled maintenance........................................................................................................................525
Fuser maintenance kits................................................................................................................................... 525
Replacing fuser maintenance kits............................................................................................................... 525
Identifying the type of fuser used in the printer ........................................................................................ 526
Resetting the Roller Kit counter...................................................................................................................... 527
Preventive maintenance.......................................................................................................................528
Device‑specific preventive maintenance........................................................................................................ 528
Lubrication specification.......................................................................................................................528
Cleaning the printer..............................................................................................................................528
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Parts catalog............................................................................................530
Legend...................................................................................................................................................530
Assembly 1: Covers................................................................................................................................533
Assembly 2: Paper path.........................................................................................................................535
Assembly 3: Fusers................................................................................................................................537
Assembly 4: Electronics.........................................................................................................................539
Assembly 5: Drive motors.....................................................................................................................543
Assembly 6: Duplex...............................................................................................................................545
Assembly 7: Frame................................................................................................................................547
Assembly 8: Control panel.....................................................................................................................549
Assembly 9: Paper tray..........................................................................................................................553
Assembly 10: Input options...................................................................................................................555
Assembly 11: 250-sheet tray option......................................................................................................557
Assembly 12: 550-sheet tray option......................................................................................................559
Assembly 13: High capacity input tray option 1....................................................................................561
Assembly 14: High capacity input tray option 2....................................................................................563
Assembly 15: Output options................................................................................................................565
Assembly 16: Output expander option.................................................................................................567
Assembly 17: High capacity output expander option............................................................................569
Assembly 18: Staple finisher option 1...................................................................................................571
Assembly 19: Staple finisher option 2...................................................................................................573
Assembly 20: Mailbox option 1.............................................................................................................575
Assembly 21: Mailbox option 2.............................................................................................................577
Assembly 22: Miscellaneous.................................................................................................................579
Assembly 23: Power cords....................................................................................................................581
Appendix A: Printer specifications............................................................583
Power specifications..............................................................................................................................583
Operating clearances.............................................................................................................................584
Acoustics...............................................................................................................................................584
Environment..........................................................................................................................................585
Processor...............................................................................................................................................585
Appendix B: Options and features............................................................587
Available internal options.....................................................................................................................587
Input options supported.......................................................................................................................587
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Output options supported.....................................................................................................................587
Physical specifications (options)............................................................................................................588
Options configurations..........................................................................................................................588
Appendix C: Theory of operation..............................................................589
Models MS81x and MS71x paper path rollers and sensors..................................................................590
Models MS81x and MS71x sensors.......................................................................................................591
Functions of main components - need a new title................................................................................591
Media tray assembly....................................................................................................................................... 591
Rear media guide............................................................................................................................................ 591
Side media guide............................................................................................................................................. 591
Media tray.............................................................................................................................................592
Media feeder .................................................................................................................................................. 592
Sensor (media size) ......................................................................................................................................... 592
Sensor (pick roller position) ............................................................................................................................ 592
Multi-purpose feeder (MPF).................................................................................................................592
MPF pick roller................................................................................................................................................ 593
MPF pick solenoid........................................................................................................................................... 593
Registration...........................................................................................................................................593
Sensor (input) ................................................................................................................................................. 594
Duplex...................................................................................................................................................594
Sensor (duplex path)....................................................................................................................................... 594
Transfer.................................................................................................................................................594
Transfer roller ................................................................................................................................................. 594
Printhead...............................................................................................................................................595
Fuser components.................................................................................................................................596
Heat belt (belt fuser)....................................................................................................................................... 597
Heat belt (hot roll fuser) ................................................................................................................................. 597
Pressure roll.................................................................................................................................................... 597
Heater lamp (hot roll fuser) ............................................................................................................................ 597
Thermistor ...................................................................................................................................................... 597
Sensor (fuser exit)........................................................................................................................................... 598
Sensor (narrow media) (hot roll fuser only) ................................................................................................... 598
Exit.........................................................................................................................................................598
Sensor (standard bin full)................................................................................................................................ 598
Drive......................................................................................................................................................599
Main drive motor assembly ............................................................................................................................ 599
Fuser drive motor assembly ........................................................................................................................... 599
Toner add motor assembly............................................................................................................................. 599
Redrive motor assembly ................................................................................................................................. 599
Sensors..................................................................................................................................................600
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Electrical components and controller...................................................................................................600
Sensor (control panel door interlock)............................................................................................................. 601
Sensor (rear door interlock)............................................................................................................................ 601
Main cooling fan ............................................................................................................................................. 601
Cartridge cooling fan....................................................................................................................................... 601
Duplex cooling fan .......................................................................................................................................... 601
Fuser cooling fan (hot roll printer only).......................................................................................................... 601
LVPS board assembly ...................................................................................................................................... 602
HVPS board assembly ..................................................................................................................................... 602
Controller board ............................................................................................................................................. 602
Xerographic and print cartridge components.......................................................................................602
Supported paper sizes, types, and weights...........................................................................................606
Paper types and weights supported by the printer ........................................................................................ 606
Paper sizes supported by the printer.............................................................................................................. 607
Paper sizes, types, and weights supported by the optional finishers.............................................................608
Output options theory...........................................................................................................................610
Output expander theory................................................................................................................................. 610
High capacity output expander theory ........................................................................................................... 611
Mailbox theory................................................................................................................................................ 612
Staple finisher theory...................................................................................................................................... 613
Appendix D: Acronyms.............................................................................615
Acronyms...............................................................................................................................................615
Index........................................................................................................617
Part number index...................................................................................625
Part name index.......................................................................................635
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Notices and safety information
Laser notices
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, 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 10 milliwatt gallium arsenide laser operating in the wavelength of 787-800 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-Hinweis
Der Drucker wurde in den USA zertifiziert und entspricht den DHHS-Vorschriften 21 CFR, Kapitel I, Unterkapitel J für
Laserprodukte der Klasse I (1); andernorts ist er als Laserprodukt der Klasse I zertifiziert, das den IEC 60825-1-
Anforderungen entspricht.
Laserprodukte der Klasse I werden nicht als gefährlich eingestuft. Der Drucker enthält im Inneren einen Laser der
Klasse IIIb (3b), und zwar einen 10-Milliwatt-Gallium-Arsenid-Laser, der im Wellenlängenbereich von 787 bis 800
Nanometern arbeitet. Das Lasersystem und der Drucker sind so konstruiert, dass unter normalen Betriebsbedingungen,
bei der Wartung durch den Benutzer oder bei den vorgeschriebenen Wartungsbedingungen Menschen keiner
Laserstrahlung ausgesetzt sind, die die Werte für Klasse I überschreitet.
Avis relatif à l'utilisation du laser
L'imprimante est certifiée conforme aux exigences de la réglementation des Etats-Unis relative aux produits laser (DHHS
21 CFR, Chapter I, Subchapter J for Class I (1)). Pour les autres pays, elle est certifiée conforme aux exigences des normes
IEC 60825-1 relatives aux produits laser de classe I.
Les produits laser de Classe I ne sont pas considérés comme dangereux. L'imprimante contient un laser de classe IIIb
(3b), laser arséniure de gallium 10 milliwatts opérant sur une longueur d'onde de l'ordre de 787 à 800 nanomètres. Le
système laser ainsi que l'imprimante ont été conçus de manière à ce que personne ne soit exposé à des rayonnements
laser dépassant le niveau de classe I dans le cadre d'un fonctionnement normal, de l'entretien par l'utilisateur ou de la
maintenance.
Avvertenze sui prodotti laser
La stampante è certificata negli Stati Uniti come stampante conforme ai requisiti DHHS 21 CFR, Capitolo I, Sottocapitolo
J per i prodotti laser di Classe I (1), mentre in altri paesi è certificata come prodotto laser di Classe I conforme ai requisiti
IEC 60825-1.
I prodotti laser di Classe I non sono considerati pericolosi. La stampante contiene un laser di Classe IIIb (3b), che è
nominalmente un laser ad arseniuro di gallio a 10milliwatt funzionante a una lunghezza d'onda di 787-800 nanometri.
Il sistema laser e la stampante sono stati progettati in modo da impedire l'esposizione a radiazioni laser superiori al
livello previsto dalla Classe I durante le normali operazioni di stampa, manutenzione o assistenza.
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Aviso de láser
Esta impresora se ha certificado en EE. UU. de conformidad con los requisitos de DHHS 21 CFR, capítulo I, subcapítulo
J, para los productos láser de Clase I (1), y en otros países está certificada como un producto láser de Clase I de acuerdo
con los requisitos de IEC 60825-1.
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene un láser interno de Clase IIIb (3b) que
nominalmente es un láser de arseniuro de galio de 10 milivatios que funciona en una longitud de onda de 787-800
nanómetros. El sistema láser y la impresora se han diseñado para que ningún individuo acceda nunca a las radiaciones
láser por encima del nivel de Clase I durante su uso normal, ni en tareas de mantenimiento o intervenciones de servicio
técnico prescritas.
Aviso sobre laser
A impressora foi certificada nos EUA por estar em conformidade com os requisitos do DHHS 21 CFR, capítulo I,
subcapítulo J, para produtos a laser de Classe I (1) e, nos demais países, foi certificada como produto a laser de Classe
I em conformidade com os requisitos da IEC 60825-1.
Os produtos a laser de Classe I não são considerados perigosos. A impressora contém, internamente, um laser de Classe
IIIb (3b) que é um laser de arsenieto de gálio de 10 miliwatts operando no comprimento de onda de 787-800
nanômetros. O sistema do laser e a impressora foram projetados para que jamais haja acesso humano à radiação do
laser acima do nível da Classe I durante a operação normal ou a manutenção pelo usuário ou sob as condições de
manutenção prescritas.
Laserinformatie
Deze printer is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS 21 CFR,
hoofdstuk 1, paragraaf J voor laserproducten van klasse I (1). Elders is de printer gecertificeerd als een laserproduct
van klasse I dat voldoet aan de vereisten van IEC 60825-1.
Laserproducten van klasse I worden geacht geen gevaar op te leveren. De printer bevat intern een laser van klasse IIIb
(3b), een galliumarsenide laser met een nominaal vermogen van 10 milliwatt en een golflengtebereik van 787-800
nanometer. Het lasersysteem en de printer zijn zodanig ontworpen dat gebruikers nooit blootstaan aan laserstraling
die hoger is dan het toegestane niveau voor klasse I-apparaten, tijdens normaal gebruik, onderhoudswerkzaamheden
door de gebruiker of voorgeschreven servicewerkzaamheden.
Lasererklæring
Denne printer er certificeret i USA i henhold til kravene i DHHS 21 CFR, afsnit I, underafsnit J, for Klasse I-laserprodukter
(1) og certificeret andetsteds som et Klasse I-laserprodukt i henhold til kravene i IEC 60825-1.
Klasse I-laserprodukter anses ikke for at være farlige. Printeren indeholder internt en klasse IIIb (3b)-laser, der nominelt
er en 10 milliwatt galliumarsenid-laser, som fungerer i bølgelængdeområdet 787-800 nanometer. Lasersystemet og
printeren er udviklet på en sådan måde, at der ikke er en direkte laserstråling, der overskrider Klasse I-niveauet under
normal brug, brugers vedligeholdelse eller de foreskrevne servicebetingelser.
Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR, Chapter I, Subchapter J -standardin mukaiseksi luokan I (1) -
lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
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Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 10
mW:n galliumarsenidilaser ja toimii 787–800 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön, ylläpidon tai
huollon aikana.
Lasermeddelande
Skrivaren är certifierad i USA enligt kraven i DHHS 21 CFR, avsnitt I, underavsnitt J för laserprodukter av klass I (1) och
i andra länder är den certifierad som en laserprodukt av klass I som uppfyller kraven i IEC 60825-1.
Laserprodukter av klass I anses inte vara skadliga. Skrivaren innehåller en klass IIIb (3b)-laser, vilket är en 10 mW
galliumarseniklaser som arbetar inom en våglängd på 787–800 nm. Lasersystemet och skrivaren är utformade så att
människor aldrig utsätts för laserstrålning över klass I-nivå under normala förhållanden vid användning, underhåll eller
service.
Lasermerknad
Skriveren er sertifisert i USA for samsvar med kravene i DHHS 21 CFR, kapittel I, underkapittel J for laserprodukter av
klasse I (1), og er andre steder sertifisert som et laserprodukt av klasse I som samsvarer med kravene i IEC 60825-1.
Laserprodukter av klasse I anses ikke som helseskadelige. Skriveren inneholder en intern laser av klasse IIIb (3b) som
nominelt er en 10 milliwatt galliumarsenid-laser, og som opererer i bølgelengder på 787-800 nanometer. Lasersystemet
og skriveren er utformet slik at mennesker ikke utsettes for laserstråling utover nivået i klasse I under normal drift,
vedlikehold eller foreskrevet service.
Avís sobre el làser
Als EUA, la impressora està certificada de conformitat amb els requisits del capítol I, apartat J del CFR 21 del Departament
de Salut i Serveis Humans per a productes làser de classe I (1) i a la resta de països està certificada com a producte làser
de classe I d'acord amb els requisits de la norma IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. A l'interior de la impressora hi ha un làser de classe IIIb (3b)
que nominalment es un arsenur de galió de 10 mil·liwatts que funciona a una longitud d'ona de 787-800 nanòmetres.
El sistema làser y la impressora s'han dissenyat amb l'objectiu d'impedir l'accés humà de la radiació làser superior al
nivell de classe I durant un funcionament normal, el manteniment per part de l'usuari o les condicions de servei
prescrites.
レーザーに関する通知
本機は、米国においてクラス I（1）レーザー製品に対する DHHS 21 CFR、Chapter I、Subchapter J の要件に準
拠し、その他の国では IEC 60825-1 の要件に準拠するクラス I レーザー製品として認可されています。
クラス I レーザー製品は、危険性がないとみなされています。 本機には、クラス IIIb（3b）レーザーが内蔵
されています。これは、787 ～ 800 ナノメートルの波長で動作する定格 7 ミリワットのガリウムヒ素レーザ
ーです。 レーザーシステムとプリンタは、通常の操作、ユーザーによるメンテナンス、または所定のサー
ビス条件の下で、ユーザーがクラス I レベルを超えるレーザー放射に絶対にさらされないように設計されて
います。
레이저 관련 공지
이 프린터는 미국에서 DHHS 21 CFR, Chapter I, Subchapter J 의 요구 사항을 준수하는 클래스 I(1) 레이저 제품으
로 승인되었으며 이외 지역에서 IEC 60825-1 의 요구 사항을 준수하는 클래스 I 레이저 제품으로 승인되었습니다.
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Class I 레이저 제품은 위험한 제품으로 간주되지 않습니다. 프린터에는 655-675 나노미터의 파장 영역에서 작동
하는 공칭 7 밀리와트 갈륨 비소 레이저인 클래스 IIIb(3b) 레이저가 내부에 포함되어 있습니다. 레이저 시스템
과 프린터는 정상적인 작동, 사용자 유지 관리 또는 사전 설명된 서비스 조건에는 사람에게 클래스 I 수준 이상
의 레이저 방사가 노출되지 않도록 설계되었습니다.
激光注意事项
本打印机在美国认证合乎 DHHS 21 CFR Chapter I，Subchapter J 对分类 I（1）激光产品的标准，而在其他地区则
被认证是合乎 IEC 60825-1 的分类 I 激光产品。
一般认为分类 I 激光产品不具有危险性。本打印机内部含有分类 IIIb（3b）的激光，在操作过程中会产生额定
7 毫瓦的砷化镓激光，其波长范围在 787-800nm 之间。本激光系统及打印机的设计，在一般操作、使用者维护
或规定内的维修情况下，不会使人体接触分类 I 以上等级的辐射。
雷射聲明
本印表機係經過美國核可，符合 DHHS 21 CFR，Chapter I，Subchapter J 規定的 I (1) 級雷射產品激光注意事项；
在美國以外的地區，為符合 IEC 60825-1 規定的 I 級雷射產品。
根據 I 級雷射產品的規定，這類產品不會對人體造成傷害。本機所採用之 IIIb (3b) 級雷射只會產生 7 百萬分之
一瓦特 (milliwatt)、波長 787 至 800 億分之一米 (nanometer) 的鎵砷放射線 (gallium arsenide laser)。使用者只要
以正確的方法操作及維護保養，並依照先前所述之維修方式進行修護，此印表機與其雷射系統絕不會產生 I 級
以上的放射線，而對人體造成傷害。
Safety
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.
CAUTION—POTENTIAL INJURY
The lithium battery in this product is not intended to be replaced. There is a danger of explosion if a lithium
battery is incorrectly replaced. Do not recharge, disassemble, or incinerate a lithium battery. Discard used
lithium batteries according to the manufacturer's instructions and local regulations.
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.
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