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MS81x
Lexmark MS81x User Manual
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Output expand
er controlle
r PCBA removal
1
Remove the left cover
. See
“Outpu
t expand
er le
ft cove
r remo
val” o
n page 4
52
.
2
Disc
onnect
all th
e cab
les (J
7,
J10, J3, J1, J2, J14, J6, J4 an
d J5) from the con
troller PCBA.
3
Remove the three s
crews (A), then remo
ve the controller PCBA.
4063
Rep
air
info
rmatio
n
454
453
455
Table of Contents
Default Chapter
1
Service Manual
1
Product Information
2
Edition Notice
2
Table of Contents
3
Notices and Safety Information
17
Laser Notices
17
Safety
20
Preface
25
Service Manual Conventions
25
General Information
27
Printer Configurations
28
Fully Configured Model
29
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
34
Diagnostic Information
35
Troubleshooting Overview
35
Performing the Initial Troubleshooting Check
35
Error Code Number Key
36
Power-On Reset (POR) Sequence
36
Power‑On Reset Sequence
36
Using Safe Mode
37
Fixing Print Quality Issues
37
Initial Print Quality Check
38
Gray Background on Prints
39
Printer Is Printing Blank Pages
40
Printer Is Printing Solid Black Pages
41
Repeating Defects
41
Shadow Images Appear on Prints
42
Skewed Print
43
Streaked Horizontal Lines Appear on Prints
44
Streaked Vertical Lines Appear on Prints
46
Toner Rubs off
47
Paper Jams
47
Understanding Jam Numbers and Locations
48
200-201 Paper Jams
50
Sensor (Input) Static Jam Service Check
54
Sensor (Input) Early Arriving Jam Service Check
54
Sensor (Input) Never- or Late-Arriving Jam Service Check
56
Sensor (Input) Late-Leaving or DID-Not-Clear Jam Service Check
57
Main Drive Motor Control Jam Service Check
59
Printhead Motor Control Jam Service Check
59
Fuser Drive Motor Control Jam Service Check
60
Sensor (Input) Miscellaneous Jam 1 Service Check
60
Sensor (Input) Miscellaneous Jam 2 Service Check
61
Sensor (Input) Miscellaneous Jam 3 Service Check
61
202 Paper Jams
61
Sensor (Fuser Exit) Static Jam Service Check
64
Sensor (Fuser Exit) Late-Leaving Jam Service Check
64
Sensor (Fuser Exit) Late-Arriving Jam Service Check
65
Sensor (Narrow Media) Late Arriving Jam Service Check
66
Sensor (Narrow Media) Static Jam Service Check
67
Sensor (Fuser Exit) Miscellaneous Jam Service Check
68
Fuser ID Chip Control Jam Service Check
68
203 Paper Jams
69
Upper Redrive Motor Control Jam Service Check
69
230 Paper Jams
70
Sensor (Duplex Path) Static Jam Service Check
73
Sensor (Duplex Path) Early Arriving Jam Service Check
74
Sensor (Duplex Path) Never- or Late-Arriving Jam Service Check
74
Sensor (Duplex Path) Late Leaving Jam Service Check
75
Duplex Control Jam Service Check
76
Sensor (Duplex Path) Miscellaneous Jam Service Check
77
Sensor (Input) Never-Arriving Jam (Exiting Duplex) Service Check
78
235-239 Paper Jams
78
24X Paper Jams
79
Media Feeder Motor Control Service Check
81
Media Tray 1, Tray Pulled Jam
82
Media Feeder Motor Tray Lift Error Service Check
83
Sensor (Input) Never-Arriving Jam from Tray 1 Service Check
83
250 Paper Jams
84
Sensor (Input) Never-Arriving Jam from MPF Media Tray Service Check
86
41Y.XX Paper Jams
88
43Y.XX Paper Jams
89
451 Paper Jams
90
455-457 Paper Jams
91
User Attendance Messages (0-99.99)
94
Toner Level Sensing Error Check
99
Toner Cartridge Smart Chip Error Service Check
99
Imaging Unit Smart Chip Service Check
100
Fuser Unit Smart Chip Service Check
101
Printer Hardware Errors (100-199.99)
101
Printer Hardware Error Messages(100-199.99)
102
Printhead ID Service Check
106
Printhead Service Check
106
Fuser Drive Motor Service Check
107
Fuser Service Check
107
LVPS Service Check
108
Toner Level Sensing Service Check
108
Main Drive Motor Service Check
109
Media Feeder Service Check
109
Redrive Motor Service Check
110
Duplex Motor Service Check
110
Toner Add Motor Service Check
111
Main Cooling Fan Service Check
111
Cartridge Cooling Fan Service Check
112
LVPS Cooling Fan Service Check
112
HVPS Cooling Fan Service Check
113
Miscellaneous Cooling Fan Service Check
113
Firmware And/Or System Electronics Errors (900-999.99)
113
9Xx Error Messages
114
System Software Error Service Check
117
NVRAM Mismatch Failure Service Check
122
Input/Output Option Hardware Errors
123
3Xx Error Messages (300-399.99)
123
250/550-Sheet Transport Motor Failure Service Check
128
250/550-Sheet Media Feeder Failure Service Check
130
250/550-Sheet Controller Board Failure Service Check
132
HCIT Lift Drive Motor Failure Service Check
133
HCIT Lift Plate Failure Service Check
135
HCIT Transport Motor Failure Service Check
137
HCOE Failure Service Check
139
Mailbox Failure Service Check
140
Output Expander Failure Service Check
141
Input/Output Option Paper Jam Errors
143
Input Option Jam Error Messages (242-245.99)
143
250/550-Sheet Media Tray Option Jam Service Check
154
HCIT Jam Service Check
156
HCIT Source Jam Service Check
159
4Xx Error Messages (400-499.99)
161
Sensor (Mailbox Pass Through) Jam Service Check
171
Mailbox Diverter Jam Service Check
174
HCOE Diverter Jam Service Check
175
Sensor (HCOE Pass Through) Jam Service Check
177
Sensor (Finisher Pass Through) Jam Service Check
179
Finisher Left Tamper Jam Service Check
181
Finisher Right Tamper Jam Service Check
182
Finisher Ejector Jam Service Check
184
Finisher Diverter Jam Service Check
185
Finisher Paddle Jam Service Check
186
Finisher Tray Holder Jam Service Check
188
Stapler Carriage Jam Service Check
189
Output Expander Jam Service Check
191
Sensor (Media in Stapler) Jam Service Check
193
Symptoms
194
Base Printer Symptoms
194
Network Service Check
194
Dead Machine Service Check
197
Option Tray Symptoms
198
250/550-Sheet Media Type Error Service Check
199
250/550-Sheet Tray Undetected Service Check
201
HCIT Incorrect Media Error Service Check
202
HCIT Media Type Error Service Check
204
HCIT Undetected Service Check
206
HCIT Media Low Undetected Service Check
207
Finisher Side Door Error Service Check
209
Mailbox Incorrect bin Exit Service Check
211
Finisher Cartridge Error Service Check
212
Finisher Undetected Service Check
214
Finisher bin Error Service Check
215
Finisher Door Undetected Service Check
216
Stapler Carriage Failure Service Check
218
Finisher bin Media Present Error Service Check
219
Output Expander Error Service Check
221
Service Menus
223
Using the Printer Control Panel
223
Menus List
224
Diagnostics Menu
224
Entering Diagnostics Mode
225
Registration
225
Print Tests
226
Print Quality Pages (Prt Quality
226
Hardware Tests
226
Panel Test
226
Button Test
227
DRAM Test
227
Serial Wrap Test
228
USB HS Test Mode
228
Duplex Tests
229
Quick Test
229
Top Margin
230
Sensor Test
230
Motor Test
230
Duplex Feed 1
231
Duplex Feed 2
231
Input Tray Tests
231
Feed Tests
231
Sensor Tests
232
Output bin Tests
232
Feed Tests
232
Feed to All Bins
232
Sensor Test
233
Diverter Test
233
Finisher Tests
233
Staple Test
233
Hole Punch Test
234
Feed Test (Finisher)
234
Finisher Sensor Test
234
Base Sensor Test
235
Device Tests
235
Quick Disk Test
235
Disk Test/Clean
236
Flash Test
236
Printer Setup
236
Defaults
236
Printed Page Count
237
Permanent Page Count (Perm
237
Processor ID
237
Engine Setting [X]
238
Edge to Edge
238
Parallel Strobe Adjustment (Par 1 Strobe Adj)
238
Ep Setup
238
EP Defaults
238
Fuser Temperature (Fuser Temp)
238
Fuser Page Count
239
Warm up Time
239
Transfer
239
Charge Roll
239
Print Contrast
239
Automatic Darkness Adjust (Auto Dark Adj)
240
Gap Adjust
240
Menu Settings Page
240
Reports
240
Clear Log
241
Display Log
241
Event Log
241
Installed Licenses
241
Print Log
241
Exit Diags
242
Configuration Menu
242
Entering Configuration Mode
243
Reset Roller Kit Counter
243
Roller Kit Counter Value
243
Event Log
244
Menu Settings Page
244
Print Quality
244
Reports
244
Size Sensing
244
Download Emuls
245
Panel Menus
245
PPDS Emulation
245
Safe Mode
245
Energy Conserve
246
Factory Defaults
246
Paper Prompts
246
Action for Prompts
247
Envelope Prompts
247
Disk Encryption
248
Erase All Information on Disk
248
Jobs on Disk
248
A5 Loading
249
Font Sharpening
249
Require Standby
249
Wipe All Settings
249
Key Repeat Initial Delay
250
Key Repeat Rate
250
LES Applications
250
UI Automation
250
Clear Custom Status
251
Clear Supply Usage History
251
USB Speed
251
Wiper Message
251
Automatically Display Error Screens
252
USB Pnp
252
Entering Invalid Engine Mode
252
Entering Recovery Mode
252
Accessing the Network SE Menu
253
Service Engineer Menu
253
Accessing the Service Engineer (SE) Menu
253
Service Engineer (SE) Menu
253
Repair Information
255
Removal Precautions
255
Handling ESD-Sensitive Parts
255
Controller Board/Control Panel Replacement
256
Esf Solutions Backup
256
Ribbon Cable Connectors
257
Zero Insertion Force (ZIF) Connectors
257
Horizontal Top Contact Connector
258
Horizontal Bottom Contact Connector
261
Vertical Mount Contact Connector
264
Horizontal Sliding Contact Connector
267
Low Insertion Force (LIF) Connector
270
Adjustments
271
Media Aligner Roller Adjustment
272
Polygon Printhead Mechanical Registration Adjustment
274
Removal Procedures
277
Base Printer - Cover Removals
277
Left Cover Removal
277
Rear Lower Cover Removal
280
Top Cover Removal
282
Right Cover Removal
283
Rear Door Removal
285
Base Printer- Front Removals
286
Duplex Exit Diverter Removal
286
Front Door Removal
288
Inner Guide Deflector Removal
289
Laser Printhead Removal
291
Left Inner Cover Removal
295
Media Aligner Roller Removal
297
Media Turn Guide Removal
299
Media Vertical Guide Removal
300
MPF Feeder Lift Plate Removal
302
MPF Pick Roller Removal
305
MPF Tray Removal
308
Right Inner Cover Removal
309
Sensor (Input) Removal
310
Sensor (Toner Density) Removal
312
Transfer Roller Left Arm with Cable Removal
313
Transfer Roller Right Arm Removal
314
Transfer Roller Removal
317
Base Printer - Rear Removals
319
Duplex Motor Removal
320
Fuser Removal
322
Fuser Access Door Removal
324
Left Frame Pivot Removal
325
Output bin Sensor Cover Removal
326
Right Frame Pivot Removal
327
Sensor (Rear Door Interlock) Removal
328
Base Printer - Top Removals
328
Sensor (Standard bin Full) Removal
329
Standard bin Cover Removal
330
Upper Redrive Removal
331
Base Printer - Bottom Removals
333
Duplex Removal
333
Duplex Front Flap Removal
335
Duplex Rear Flap Removal
336
Left Frame Extension Removal
337
Media Tray Removal
339
Media Size Actuator Removal
340
Pick Roller Assembly Removal
342
Right Frame Extension
343
Sensor (Duplex Path) Removal
344
Sensor (Tray 1 Media Out) Removal
345
Separator Roller Assembly Removal
347
Base Printer - Left Removals
348
Controller Board Removal
349
Controller Board Access Cover Removal
350
Controller Board Access Shield Removal
351
Fuser Drive Motor Removal
351
Main Cooling Fan Removal
353
Main Drive Motor Removal
354
Media Feeder Removal
356
PCBA Housing Removal
357
Sensor (Control Panel Interlock) Removal
359
Sensor (Pick Roller Position) Removal
360
Toner Add Motor Removal
361
Base Printer - Right Removals
362
Cartridge Cooling Fan Removal
363
Duplex Cooling Fan Removal
364
HVPS Removal
365
LVPS Removal
366
Control Panel Removals
369
4.3-Inch Tilting Display Removal
369
7-Inch Tilting Display Removal
372
Control Panel Removal (2.4-Inch Screen)
375
Control Panel Removal (4.3-Inch Screen, 7-Inch Screen)
381
Control Panel Board (2.4-Inch Tilting Display) Removal
387
Control Panel Board (4.3-Inch Tilting Display) Removal
390
Control Panel Board (7-Inch Tilting Display) Removal (Ms812De)
393
Control Panel Front Cover Removal
396
Control Panel Latch Removal
398
Control Panel Left Bezel Removal
399
Left Control Panel Hinge Removal
400
Right Control Panel Hinge Removal
403
250/550-Sheet Media Tray Option Removals
406
250/550-Sheet Media Tray and Drawer Assembly Removal
406
Media Tray Separation Roller Removal
407
Media Tray Assembly Removal
407
Media Tray Front Cover Removal
407
Drawer Pick Roller Removal
408
Sensor (Pick Roll Position) Removal
408
Drawer Assembly Rear Cover Removal
409
Drawer Assembly Left Cover Removal
410
Drawer Controller PCBA Removal
411
Drawer Upper Interface Cable Removal
412
Drawer Lower Interface Cable Removal
413
Drawer Media Feeder Removal
414
Drawer Transport Motor Removal
416
Sensor (Drawer Pass Through) Removal
417
Sensor (Pick) Removal
419
High Capacity Input Tray Option Removals
422
HCIT and Drawer Assembly Removal
422
HCIT Removal
423
HCIT Drawer Assembly Removal
423
HCIT Separator Roll Assembly Removal
424
HCIT Media Guide Removal
424
HCIT Front Cover Removal
425
HCIT Pick Arm Assembly Removal
427
HCIT Drawer Assembly Rear Cover Removal
428
HCIT Drawer Assembly Left Cover Removal
429
HCIT Drawer Assembly Right Cover Removal
431
HCIT Controller PCBA Removal
433
HCIT Top Cover Assembly Removal
434
HCIT Lift Drive Motor Removal
436
HCIT Drawer Assembly Interface Cable Removal
438
Sensor (HCIT Media Low) with Flag Removal
439
Sensor (Pick Roll Position) Removal
440
Sensor (HCIT Pick) Removal
442
HCIT Media Feeder Removal
443
Output Expander Option Removals
446
Output Expander Assembly Removal
446
Output Expander Top Cover Removal
446
Output Expander Rear Door Removal
447
Output Expander Sensor Cover Removal
449
Sensor (Media bin Full) with Flag Removal
449
Output Expander Right Cover Removal
450
Output Expander Left Cover Removal
452
Output Expander Controller PCBA Removal
454
Lower Interface Cable Removal
455
Upper Interface Cable Removal
456
Spring with String Removal
458
High Capacity Output Expander Option Removals
460
High Capacity Output Expander Assembly Removal
460
HCOE Top Cover Removal
460
HCOE Rear Door Removal
461
HCOE Sensor Cover Removal
462
Sensor (HCOE Media bin Full) with Flag Removal
463
HCOE Right Outer Cover Removal
463
HCOE Left Cover Removal
465
HCOE Controller PCBA Removal
467
HCOE Lower Interface Cable Removal
469
HCOE Upper Interface Cable Removal
470
Staple Finisher Option Removals
471
Staple Finisher Assembly Removal
471
Stapler Rear Door Removal
472
Stapler Right Cover Removal
474
Sensor (Cartridge Door Interlock) Removal
476
Stapler Door Close Limit Switch Removal
476
Stapler Carriage Assembly Removal
479
Stapler Left Cover Removal
480
Stapler Cartridge Access Door Removal
482
Stapler Top Cover Removal
482
Stapler Spring with String Removal
484
Media Stack Flap (Right) Removal
485
Media Stack Flap (Left) Removal
486
Standard Output bin LED Removal
489
Sensor (Finisher bin Media Present) Removal
490
Tamper Motor (Right) Removal
491
Tamper Motor (Left) Removal
491
Tamper Drive Belt Removal
492
Paddle Drive Motor Removal
493
Stapler Lower Interface Cable Removal
494
Stapler Controller PCBA Removal
496
Sensor (bin Full Send) Removal
497
Sensor (bin Full Receive) Removal
498
Mailbox Option Removals
500
Mailbox Assembly Removal
500
Mailbox Top Cover Removal
500
Mailbox Rear Door Removal
500
Mailbox Right Cover Removal
502
Mailbox Spring with String Removal
503
Mailbox Solenoid Removal
504
Mailbox Left Cover Removal
506
Mailbox Controller PCBA Removal
507
Sensor (Mailbox Divert Motor) Removal
509
Mailbox Lower Interface Cable Removal
510
Mailbox Upper Interface Cable Removal
512
Mailbox Divert Motor Removal
512
Mailbox Media bin Full Flag Removal
514
Sensor (Mailbox bin Full Receive) Removal
515
Mailbox Belt Removal
518
Mailbox Output bin LED Assembly Removal
520
Component Locations
525
Connectors
525
Controller Board
525
Maintenance
533
Inspection Guide
533
Scheduled Maintenance
535
Fuser Maintenance Kits
535
Replacing Fuser Maintenance Kits
535
Identifying the Type of Fuser Used in the Printer
536
Resetting the Roller Kit Counter
537
Preventive Maintenance
538
Device-Specific Preventive Maintenance
538
Lubrication Specification
538
Cleaning the Printer
538
Parts Catalog
540
Legend
540
Assembly 1: Covers
543
Assembly 2: Paper Path
545
Assembly 3: Fusers
547
Assembly 4: Electronics
549
Assembly 5: Drive Motors
553
Assembly 6: Duplex
555
Assembly 7: Frame
557
Assembly 8: Control Panel
559
Assembly 9: Paper Tray
563
Assembly 10: Input Options
565
Assembly 11: 250-Sheet Tray Option
567
Assembly 12: 550-Sheet Tray Option
569
Assembly 13: High Capacity Input Tray Option 1
571
Assembly 14: High Capacity Input Tray Option 2
573
Assembly 15: Output Options
575
Assembly 16: Output Expander Option
577
Assembly 17: High Capacity Output Expander Option
579
Assembly 18: Staple Finisher Option 1
581
Assembly 19: Staple Finisher Option 2
583
Assembly 20: Mailbox Option 1
585
Assembly 21: Mailbox Option 2
587
Assembly 22: Miscellaneous
589
Assembly 23: Power Cords
593
Appendix A: Printer Specifications
595
Power Specifications
595
Operating Clearances
596
Acoustics
596
Environment
597
Processor
597
Appendix B: Options and Features
599
Available Internal Options
599
Input Options Supported
599
Output Options Supported
599
Physical Specifications (Options)
600
Options Configurations
600
Appendix C: Theory of Operation
601
Models Ms81X and Ms71X Paper Path Rollers and Sensors
602
Models Ms81X and Ms71X Sensors
603
Functions of Main Components - Need a New Title
603
Media Tray Assembly
603
Rear Media Guide
603
Side Media Guide
603
Media Tray
604
Media Feeder
604
Sensor (Media Size)
604
Sensor (Pick Roller Position)
604
Multi-Purpose Feeder (MPF)
604
MPF Pick Roller
605
MPF Pick Solenoid
605
Registration
605
Sensor (Input)
606
Duplex
606
Sensor (Duplex Path)
606
Transfer
606
Transfer Roller
607
Printhead
608
Fuser Components
609
Heat Belt (Belt Fuser)
610
Heat Belt (Hot Roll Fuser)
610
Pressure Roll
610
Heater Lamp (Hot Roll Fuser)
611
Thermistor
611
Sensor (Fuser Exit)
611
Sensor (Narrow Media) (Hot Roll Fuser Only)
611
Exit
611
Sensor (Standard bin Full)
612
Drive
612
Main Drive Motor Assembly
612
Fuser Drive Motor Assembly
612
Toner Add Motor Assembly
613
Redrive Motor Assembly
613
Sensors
614
Electrical Components and Controller
614
Sensor (Control Panel Door Interlock)
615
Sensor (Rear Door Interlock)
615
Main Cooling Fan
615
Cartridge Cooling Fan
615
Duplex Cooling Fan
615
Fuser Cooling Fan (Hot Roll Printer Only)
615
LVPS Board Assembly
616
HVPS Board Assembly
616
Controller Board
616
Xerographic and Print Cartridge Components
616
Supported Paper Sizes, Types, and Weights
620
Paper Types and Weights Supported by the Printer
620
Paper Sizes Supported by the Printer
621
Paper Sizes, Types, and Weights Supported by the Optional Finishers
622
Output Options Theory
624
Output Expander Theory
624
High Capacity Output Expander Theory
625
Mailbox Theory
626
Staple Finisher Theory
627
Appendix D: Acronyms
629
Acronyms
629
Index
631
Repeating Defects Shadow Images Appear on Prints
634
Part Number Index
639
Part Name Index
649
4
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Lexmark MS81x Specifications
General
Brand
Lexmark
Model
MS81x
Category
Printer
Language
English
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