4038 PDF

4038-001
Lexmark X215 MFP

Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
Table of Contents
Index
Safety and Notices
Trademarks
Start Diagnostics
Edition: June 2003
The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS
PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore, this
statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at
ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the
information you supply in any way it believes appropriate without incurring any obligation
to you. You can purchase additional copies of publications related to this product by
calling 1-800-553-9727. In other countries, contact your point of purchase.
Lexmark, and Lexmark with diamond design are trademarks of Lexmark International,
Inc., registered in the United States and/or other countries.
Other trademarks are the property of their respective owners.
2003 Lexmark International, Inc.
All rights reserved.
UNITED STATES GOVERNMENT RIGHTS
This software and any accompanying documentation provided under this agreement are
commercial computer software and documentation developed exclusively at private
expense.
U.S.A. P/N 12G9321
4038-001
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Table of contents
Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Machine features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Print materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Cleaning the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cleaning the outside of the machine. . . . . . . . . . . . . . . . . . . . 1-5
Cleaning the inside of the machine. . . . . . . . . . . . . . . . . . . . . 1-6
Cleaning the scan unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleaning the photoconductor drum. . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Error message table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Paper feed problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Printing and copying problems . . . . . . . . . . . . . . . . . . . . . . . 2-13
Scanning problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Faxing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Print quality checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Configuration modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Clear All Memory mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Dial mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Error Rate mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Modem Speed mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Park CCD module mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Print Properties mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Send Level mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
System Settings Report mode . . . . . . . . . . . . . . . . . . . . . . . . 3-7
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Machine tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
DRAM Memory test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Modem Protocol Log test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Modem test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Motor, Fan, Solenoid test . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Operator Panel Button test. . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Operator Panel test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Printhead test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Print Quality Pages test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
ROM Memory test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Scanner CCD Module and Motor test . . . . . . . . . . . . . . . . . .3-16
Sensor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Customizing settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Content. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Darkness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Automatic document feed (ADF) removals . . . . . . . . . . . . . .4-16
CCD module assembly removal . . . . . . . . . . . . . . . . . . . . . . .4-18
Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
HVPS contact removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32
LVPS / HVPS card removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
Main drive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . .4-36
Main paper feed roller removal. . . . . . . . . . . . . . . . . . . . . . . .4-38
Main feed roller solenoid removal . . . . . . . . . . . . . . . . . . . . .4-41
Manual paper feed sensor actuator removal . . . . . . . . . . . . .4-44
Modem card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49
Paper empty sensor actuator removal . . . . . . . . . . . . . . . . . .4-51
Paper feed sensor actuator removal . . . . . . . . . . . . . . . . . . .4-53
Paper tray feed roller removal . . . . . . . . . . . . . . . . . . . . . . . .4-55
Paper tray pick roller assembly removal . . . . . . . . . . . . . . . .4-56
Paper tray solenoid removal. . . . . . . . . . . . . . . . . . . . . . . . . .4-60
Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-62
Scanner assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-63
Scanner card assembly removal . . . . . . . . . . . . . . . . . . . . . .4-67
Scanner assembly cushion removal. . . . . . . . . . . . . . . . . . . .4-70
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Scanner assembly hinge removal . . . . . . . . . . . . . . . . . . . . . 4-71
System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
Transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
EP rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
HVPS / LVPS card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Modem card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Operator panel card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Scanner card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
System board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
ADF paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Printer engine paper path/paper jams. . . . . . . . . . . . . . . . . . 5-15
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Assembly 1: Scanner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly 2: Main assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly 3: Frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
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Laser notices vii
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Laser notices
The following laser notice labels may be affixed to this printer as
shown.
Laser advisory label
With the middle cover removed, the laser advisory label is affixed to
the top of the printhead.
viii Service Manual
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Class 1 Laser Statement label
The Class 1 laser label is located on the rear of the machine.
Example:
Laser notices ix
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Laser notice
The printer is certified in the U.S. to conform to the requirements of
DHHS 21 CFR Subchapter J for Class I (1) laser products, and
elsewhere is certified as a Class I laser product conforming to the
requirements of IEC 60825-1.
Class I laser products are not considered to be hazardous. The
printer contains internally a Class IIIb (3b) laser that is nominally a 5
milliwatt gallium arsenide laser operating in the wavelength region of
770-795 nanometers. The laser system and printer are designed so
there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed
service condition.
Laser
Der Drucker erfllt gem amtlicher Besttigung der USA die
Anforderungen der Bestimmung DHHS (Department of Health and
Human Services) 21 CFR Teil J fr Laserprodukte der Klasse I (1).
In anderen Lndern gilt der Drucker als Laserprodukt der Klasse I,
der die Anforderungen der IEC (International Electrotechnical
Commission) 60825-1 gem amtlicher Besttigung erfllt.
Laserprodukte der Klasse I gelten als unschdlich. Im Inneren des
Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es
sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Lnge 770-795 Nanometer ausstrahlt. Das Lasersystem und der
Drucker sind so konzipiert, da im Normalbetrieb, bei der Wartung
durch den Benutzer oder bei ordnungsgemer Wartung durch den
Kundendienst Laserbestrahlung, die die Klasse I bersteigen wrde,
Menschen keinesfalls erreicht.
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Avis relatif lutilisation de laser
Pour les Etats-Unis : cette imprimante est certifie conforme aux
provisions DHHS 21 CFR alina J concernant les produits laser de
Classe I (1). Pour les autres pays : cette imprimante rpond aux
normes IEC 60825-1 relatives aux produits laser de Classe I.
Les produits laser de Classe I sont considrs comme des produits
non dangereux. Cette imprimante est quipe dun laser de Classe
IIIb (3b) (arsniure de gallium dune puissance nominale de 5
milliwatts) mettant sur des longueurs donde comprises entre 770
et 795 nanomtres. Limprimante et son systme laser sont conus
pour impossible, dans des conditions normales dutilisation,
dentretien par lutilisateur ou de rvision, lexposition des
rayonnements laser suprieurs des rayonnements de Classe I .
Avvertenze sui prodotti laser
Questa stampante certificata negli Stati Uniti per essere conforme
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di
classe 1 ed certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norma CEI 60825-1.
I prodotti laser di classe non sono considerati pericolosi. La
stampante contiene al suo interno un laser di classe IIIb (3b)
allarseniuro di gallio della potenza di 5mW che opera sulla
lunghezza donda compresa tra 770 e 795 nanometri. Il sistema
laser e la stampante sono stati progettati in modo tale che le
persone a contatto con la stampante, durante il normale
funzionamento, le operazioni di servizio o quelle di assistenza
tecnica, non ricevano radiazioni laser superiori al livello della classe
1.
Laser notices xi
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Avisos sobre el lser
Se certifica que, en los EE.UU., esta impresora cumple los
requisitos para los productos lser de Clase I (1) establecidos en el
subcaptulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los dems pases, rene todas las
condiciones expuestas en la norma IEC 60825-1 para productos
lser de Clase I (1).
Los productos lser de Clase I no se consideran peligrosos. La
impresora contiene en su interior un lser de Clase IIIb (3b) de
arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanmetros. El sistema lser y la
impresora estn diseados de forma que ninguna persona pueda
verse afectada por ningn tipo de radiacin lser superior al nivel de
la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situacin de servicio tcnico.
Declarao sobre Laser
A impressora est certificada nos E.U.A. em conformidade com os
requisitos da regulamentao DHHS 21 CFR Subcaptulo J para a
Classe I (1) de produtos laser. Em outros locais, est certificada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 60825-1.
Os produtos laser da Classe I no so considerados perigosos.
Internamente, a impressora contm um produto laser da Classe IIIb
(3b), designado laser de arseneto de potssio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795
nanmetros. O sistema e a impressora laser foram concebidos de
forma a nunca existir qualquer possiblidade de acesso humano a
radiao laser superior a um nvel de Classe I durante a operao
normal, a manuteno feita pelo utilizador ou condies de
assistncia prescritas.
xii Service Manual
4038-001
Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een
laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 60825-1.
Laserprodukten van klasse I worden niet als ongevaarlijk
aangemerkt. De printer is voorzien van een laser van klasse IIIb
(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met
een golflengte van 770-795 nanometer. Het lasergedeelte en de
printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelling mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.
Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren
indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5
milliwatt galliumarsenid laser, som arbejder p blgelngdeomrdet
770-795 nanometer. Lasersystemet og printeren er udformet
sledes, at mennesker aldrig udsttes for en laserstrling over
Klasse I-niveau ved normal drift, brugervedligeholdelse eller
obligatoriske servicebetingelser.
Laser notices xiii
4038-001
Huomautus laserlaitteesta
Tm kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -mrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 60825-1 -mrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia kyttjlle.
Kirjoittimessa on sisinen luokan IIIb (3b) 5 milliwatin
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometri.
Laserjrjestelm ja kirjoitin on suunniteltu siten, ett kyttj ei
altistu luokan I mrityksi voimakkaammalle steilylle kirjoittimen
normaalin toiminnan, kyttjn tekemien huoltotoimien tai muiden
huoltotoimien yhteydess.
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina
nkymttmlle lasersteilylle. l katso steeseen.
VARNING! Osynlig laserstrlning nr denna del r ppnad och
sprren r urkopplad. Betrakta ej strlen.
Laser-notis
Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21
CFR, underparagraf J fr laserprodukter av Klass I (1). I andra
lnder uppfyller skrivaren kraven fr laserprodukter av Klass I enligt
kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hlsovdliga. Skrivaren har en
inbyggd laser av Klass IIIb (3b) som bestr av en laserenhet av
gallium-arsenid p 5 milliwatt som arbetar i vglngdsomrdet 770-
795 nanometer. Lasersystemet och skrivaren r utformade s att det
aldrig finns risk fr att ngon person utstts fr laserstrlning ver
Klass I-niv vid normal anvndning, underhll som utfrs av
anvndaren eller annan freskriven servicetgrd.
xiv Service Manual
4038-001
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,
underkapittel J, for klasse I (1) laserprodukter, og er i andre land
godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC
60825-1.
Klasse I-laserprodukter er ikke betrakte som farlige. Skriveren
inneholder internt en klasse IIIb (3b)-laser, som bestr av en
gallium-arsenlaserenhet som avgir strling i blgelengdeomrdet
770-795 nanometer. Lasersystemet og skriveren er utformet slik at
personer aldri utsettes for laserstrling ut over klasse I-niv under
vanlig bruk, vedlikehold som utfres av brukeren, eller foreskrevne
serviceoperasjoner.
Avs sobre el Lser
Segons ha estat certificat als Estats Units, aquesta impressora
compleix els requisits de DHHS 21 CFR, apartat J, pels productes
lser de classe I (1), i segons ha estat certificat en altres llocs, s un
producte lser de classe I que compleix els requisits dIEC 60825-1.
Els productes lser de classe I no es consideren perillosos. Aquesta
impressora cont un lser de classe IIIb (3b) darsenir de gal.li,
nominalment de 5 mil.liwats, i funciona a la regi de longitud dona
de 770-795 nanmetres. El sistema lser i la impressora han sigut
concebuts de manera que mai hi hagi exposici a la radiaci lser
per sobre dun nivell de classe I durant una operaci normal, durant
les tasques de manteniment dusuari ni durant els serveis que
satisfacin les condicions prescrites.
Laser notices xv
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Japanese Laser Notice
Chinese Laser Notice
xvi Service Manual
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Korean Laser Notice
Safety information xvii
4038-001
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: When you see this symbol, there is a
danger from hazardous voltage in the area of the
product where you are working. Unplug the product
before you begin, or use caution if the product must
receive power in order to perform the task.
Consignes de scurit
La scurit de ce produit repose sur des tests et des
agrations portant sur sa conception d'origine et sur des
composants particuliers. Le fabricant n'assume aucune
responsabilit concernant la scurit en cas d'utilisation de
pices de rechange non agres.
Les consignes d'entretien et de rparation de ce produit
s'adressent uniquement un personnel de maintenance
qualifi.
Le dmontage et l'entretien de ce produit pouvant prsenter
certains risques lectriques, le personnel d'entretien qualifi
devra prendre toutes les prcautions ncessaires.
ATTENTION : Ce symbole indique la prsence
d'une tension dangereuse dans la partie du produit
sur laquelle vous travaillez. Dbranchez le produit
avant de commencer ou faites preuve de vigilance si
l'excution de la tche exige que le produit reste sous
tension.
xviii Service Manual
4038-001
Norme di sicurezza
La sicurezza del prodotto si basa sui test e sull'approvazione
del progetto originale e dei componenti specifici. Il produttore
non responsabile per la sicurezza in caso di sostituzione non
autorizzata delle parti.
Le informazioni riguardanti la manutenzione di questo prodotto
sono indirizzate soltanto al personale di assistenza autorizzato.
Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona pi
elevato. Il personale di assistenza autorizzato deve, quindi,
adottare le precauzioni necessarie.
ATTENZIONE: Questo simbolo indica la presenza
di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare
cautela se il prodotto deve essere alimentato per
eseguire l'intervento.
Sicherheitshinweise
Die Sicherheit dieses Produkts basiert auf Tests und
Zulassungen des ursprnglichen Modells und bestimmter
Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird
vom Hersteller keine Verantwortung oder Haftung fr die
Sicherheit bernommen.
Die Wartungsinformationen fr dieses Produkt sind
ausschlielich fr die Verwendung durch einen
Wartungsfachmann bestimmt.
Whrend des Auseinandernehmens und der Wartung des
Gerts besteht ein zustzliches Risiko eines elektrischen
Schlags und krperlicher Verletzung. Das zustndige
Fachpersonal sollte entsprechende Vorsichtsmanahmen
treffen.
ACHTUNG: Dieses Symbol weist auf eine
gefhrliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor
den Arbeiten am Gert den Netzstecker des Gerts,
bzw. arbeiten Sie mit groer Vorsicht, wenn das
Produkt fr die Ausfhrung der Arbeiten an den
Strom angeschlossen sein mu.
Safety information xix
4038-001
Pautas de Seguridad
La seguridad de este producto se basa en pruebas y
aprobaciones del diseo original y componentes especficos.
El fabricante no es responsable de la seguridad en caso de uso
de piezas de repuesto no autorizadas.
La informacin sobre el mantenimiento de este producto est
dirigida exclusivamente al personal cualificado de
mantenimiento.
Existe mayor riesgo de descarga elctrica y de daos
personales durante el desmontaje y la reparacin de la
mquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.
PRECAUCIN: este smbolo indica que el voltaje
de la parte del equipo con la que est trabajando es
peligroso. Antes de empezar, desenchufe el equipo
o tenga cuidado si, para trabajar con l, debe
conectarlo.
Informaes de Segurana
A segurana deste produto baseia-se em testes e aprovaes
do modelo original e de componentes especficos. O fabricante
no responsvel pela segunrana, no caso de uso de peas
de substituio no autorizadas.
As informaes de segurana relativas a este produto
destinam-se a profissionais destes servios e no devem ser
utilizadas por outras pessoas.
Risco de choques elctricos e ferimentos graves durante a
desmontagem e manuteno deste produto. Os profissionais
destes servios devem estar avisados deste facto e tomar os
cuidados necessrios.
CUIDADO: Quando vir este smbolo, existe a
possvel presena de uma potencial tenso perigosa
na zona do produto em que est a trabalhar. Antes
de comear, desligue o produto da tomada elctrica
ou seja cuidadoso caso o produto tenha de estar
ligado corrente elctrica para realizar a tarefa
necessria.
xx Service Manual
4038-001
Informaci de Seguretat
La seguretat d'aquest producte es basa en l'avaluaci i
aprovaci del disseny original i els components especfics.
El fabricant no es fa responsable de les qestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
La informaci pel manteniment daquest producte est
orientada exclusivament a professionals i no est destinada
a ning que no ho sigui.
El risc de xoc elctric i de danys personals pot augmentar
durant el procs de desmuntatge i de servei daquest producte.
El personal professional ha destar-ne assabentat i prendre
les mesures convenients.
PRECAUCI: aquest smbol indica que el voltatge
de la part de l'equip amb la qual esteu treballant s
perills. Abans de comenar, desendolleu l'equip
o extremeu les precaucions si, per treballar amb
l'equip, l'heu de connectar.
Safety information xxi
4038-001

xxii Service Manual
4038-001
Preface
This manual contains maintenance procedures for service
personnel. It is divided into the following chapters:
1. General information contains a general description of the
printer and the maintenance approach used to repair it. Special
tools and test equipment are listed, as well as general
environmental and safety instructions.
2. Diagnostic information contains an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).
3. Diagnostic aids contains tests and checks used to locate or
repeat symptoms of printer problems.
4. Repair information provides instructions for making printer
adjustments and removing and installing FRUs.
5. Connector locations uses illustrations to identify the connector
locations and test points on the printer.
6. Preventive maintenance contains the lubrication specifications
and recommendations to prevent problems.
7. Parts catalog contains illustrations and part numbers for
individual FRUs.
Definitions
Note: A note provides additional information.
Warning: A warning identifies something that might damage the
product hardware or software.
CAUTION: A caution identifies something that might cause a
servicer harm.
General information 1-1
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1. General information
The Lexmark X215 MFP is a compact multifunction printer that
offers scanning, printing, copying, and faxing.
Machine features
Print speeds up to 17 ppm
Print resolution up to 600 x 600 dpi
Paper tray capacity up to 250sheets
Front output bin 150sheet capacity
Manual bypass paper feeder one page at a time
Automatic document feeder
(ADF)
30sheet capacity
Compatible with various
operating systems
Windows 98, Windows NT 4.0,
Windows 2000, and Windows XP
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4038-001
Print materials
Always use print materials that meet the guidelines for use with this
machine. Using print materials not recommended may cause paper
jams or print quality problems.
Selecting print materials
Size (mm/in.)
Input source/capacity
1
Paper tray
Bypass
feeder
Plain paper
Letter (215.9 x 279/8.5 x 11)
A4 (210 x 297/8.27 x 11.69)
Folio (215.9 x 330.2/8.5 x 13)
Legal (215.9 x 355.6/8.5 x 14)
Executive (184.2 x 266.7/7.25 x 10.5)
B5 (182 x 257/7.2 x 10)
Yes/250 Yes/1
A5 (148 x 210/5.83 x 8.27)
A6 (105 x 148/4.13 x 5.88)
No/0 Yes/1
Envelopes
No.9 (98.4 x 225.4/3.88 x 8.88)
No.10 (104.8 x 241.3/4.12 x 9.5)
DL (110 x 220/4.33 x 8.66)
C5 (162 x 229/6.38 x 9.02)
C6 (114 x 162/4.49 x 6.38)
B5 (176 x 250/6.93 x 9.84)
No.7 3/4 (98.4 x 190.4/3.88 x 5.83)
No/0 Yes/1
Labels
2
Letter (215.9 x 279/8.5 x 11)
A4 (210 x 297/8.27 x 11.69)
No/0 Yes/1
Transparency films
2
Letter (215.9 x 279/8.5 x 11)
A4 (210 x 297/8.27 x 11.69)
No/0 Yes/1
4038-001
Paper and speciality media guidelines
When selecting or loading paper, envelopes, transparencies, or
other specialty media, keep these guidelines in mind:
Attempting to print on damp, curled, wrinkled, or torn paper can
cause paper jams and poor print quality.
Use only high quality, copier grade paper. Avoid paper with
embossed lettering, perforations, or texture that is too smooth or
too rough.
Store paper in its ream wrapper until ready to use. Place
cartons on pallets or shelves, not on the floor. Do not place
heavy objects on top of the paper, whether it is packaged or
loose. Keep it away from moisture, or other conditions that could
cause it to wrinkle or curl.
During storage, you should use moisture-proof wrap, such as a
plastic container or bag, to prevent dust and moisture from
contaminating your paper.
Always use paper and other materials that conform with those
listed in Selecting print materials on page 1-2.
Use only well-constructed envelopes with sharp, well creased
folds.
Do not use envelopes with clasps and snaps.
Do not use envelopes with windows, coated lining, self-
adhesive seals, or other synthetic materials.
Do not use damaged or poorly made envelopes.
Card stocks
2
A6 card (105 x 148/4.13 x 5.88)
Post Card (101.6 x 152.4/4 x 6)
Hagaki (100 x 148/3.94 x 5.83)
No/0 Yes/1
1
Maximum capacity may be reduced depending on paper thickness.
2
Media must be fed one sheet at a time through manual bypass.
Size (mm/in.)
Input source/capacity
1
Paper tray
Bypass
feeder
1-4 Service Manual
4038-001
Load specialty media one sheet at a time.
Use only materials recommended for use with laser printers.
To prevent specialty media, such as transparencies and label
sheets, from sticking together, remove each sheet from the
output tray as it is printed.
Place transparencies on a flat surface after removing them from
the machine.
Do not leave transparencies in the paper tray for long periods of
time. Dust and dirt may accumulate on the film, resulting in
spotty printing.
To avoid smudging caused by fingerprints, handle
transparencies and coated paper carefully.
To avoid fading, do not expose the printed transparencies to
prolonged sunlight.
Store unused materials at temperatures between 59
o
F and 86
o

F (15
o
C to 30
o
C). The relative humidity should be between
10% and 70%.
The laser printing process heats paper to high temperatures of
180 C (356 F). Use only paper able to withstand these
temperatures without discoloring, bleeding, or releasing
hazardous emissions. Check with the manufacturer or vendor to
determine whether the paper chosen is acceptable for laser
printers.
Verify that label adhesive materials can tolerate a fusing
temperature of 180
o
C (356
o
F) for 0.1 second.
Make sure there is no exposed adhesive material between
labels. Exposed areas can cause labels to peel off during
printing, which can cause paper jams. Exposed adhesive can
also damage machine components.
Do not load a sheet of labels through the machine more than
once. The adhesive backing is designed for only one pass
through the machine.
Note: Do not use labels that are separating from the backing sheet
or are wrinkled, bubbled, or damaged.
4038-001
Cleaning the machine
To maintain print quality, follow these cleaning procedures each time
the toner cartridge is replaced or if print quality problems occur.
Do not put water directly onto any part of the machine.
Do not use ammonia-based cleaners or volatile solvents,
such as thinner, on the printer.
While cleaning the inside of the machine, be careful not to
touch the transfer roller located under the toner cartridge. Oil
from your fingers can affect print quality.
Cleaning the outside of the machine
Wipe the outside surface of the machine with a soft, clean, lint-free
cloth. If you dampen the cloth slightly with water, be careful not to let
any water drip onto or inside the machine.
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4038-001
Cleaning the inside of the machine
During the printing process, paper, toner, and dust particles can
accumulate inside the machine. This buildup can cause print quality
problems, such as toner specks or smearing.
1. Turn the machine off, unplug the power cord, and then wait for
the machine to cool down.
2. Open the front cover and remove the toner cartridge.
CAUTION: Do not touch the photoconductor drum located on the
bottom of the toner cartridge.
3. Place the toner cartridge on a clean, dry surface.
4038-001
4. With a dry, lint-free cloth, wipe away any dust and spilled toner
from the toner cartridge area and the toner cartridge cavity.
Warning:
To prevent damage to the toner cartridge, do not expose it to
light for more than a few minutes. Cover it with a piece of paper,
if necessary.
Do not touch the black transfer roller.
5. Reinsert the toner cartridge and close the cover.
6. Plug in the power cord and turn the machine on.
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Cleaning the scan unit
Keeping the scan unit clean helps ensure the best possible copies.
1. Slightly dampen a soft, lint-free cloth or paper towel with water.
2. Open the document cover.
3. Wipe the surfaces of the document glass and ADF until they are
clean and dry.
4. Wipe the underside of the white document cover and white
sheet until it is clean and dry.
5. Close the document cover.
4038-001
Cleaning the photoconductor drum
If there are streaks or spots on your print, the photoconductor drum
may require cleaning. The operator panel menu includes a Clean
Drum option that may help to improve the print quality.
To clean the photoconductor drum:
1. Make sure paper is loaded.
2. Press Menu until MACHINE SETUP appears on the top line of
the display, and then press Select.
3. Press the scroll button until CLEAN DRUM appears on
the bottom line of the display, and then press Select.
The machine prints out a cleaning page. Toner particles on the
photoconductor surface are affixed to the paper.
If the problem persists, repeat these steps.
If the photoconductor drum has been cleaned several times and the
problem is still unresolved, install a new toner cartridge.
Maintenance approach
The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the error messages, and
diagnostic aids to determine the printer problem and repair the
failure. After you complete the repair, perform tests as needed to
verify the repair.
Tools
The removal and adjustment procedures require the following tools
and equipment:
Analog or digital multimeter
Pliers: diagonal and needle-nose
Screwdrivers: #1 and #2 Phillips
Cotton swab
When you make voltage readings, always use frame ground unless
another ground is specified.
or
1-10 Service Manual
4038-001
Abbreviations
ADF Automatic document feed
BPS Bits per second
CCD Charge-coupled device
CCITT International consultative committee on telephone
and telegraphy
dB Decibel
DPI Dots per inch
DRAM Dynamic random access memory
EP Electrophotographic process
ESD Electrostatic discharge
FRU Field replaceable unit
HSYNC
HVPS High voltage power supply
Kbps Kilobits per second
LCD Liquid crystal display
LED Light-emitting diode
LSU Laser scan unit
LVPS Low voltage power supply
OPC Optical photoconductor drum
PC Photoconductor
PTL Pretransfer LED
RH Relative humidity
ROM Read only memory
USB Universal serial bus
V ac Volts alternating current
V dc Volts direct current
Diagnostic information 2-1
4038-001
2. Diagnostic information
Start
CAUTION: NEVER manually actuate or disable the top cover
interlock switch and the printhead shutter actuator at the same time.
To perform some of the service checks and tests, such as
troubleshooting paper feed problems, you need to actuate the top
cover interlock switch with the covers opened or removed and power
applied to the machine. It is important for personal safety that you
DO NOT, FOR ANY REASON, disable the printhead shutter actuator
when power is on.
Remove power from the printer before you connect or
disconnect any cable or electronic board or assembly
for personal safety and to prevent damage to the printer.
Use the error message table, and symptom table in this chapter to
determine the corrective action necessary to repair a malfunctioning
printer.
The LCD on the operator panel can indicate an error message. See
the Error message table on page 2-2 to determine the meaning
of the message and what corrective action to take.
If the printer does not have an error message, go to the Symptom
table on page 2-10. Locate the symptom and take appropriate
action to correct the problem.
2-2 Service Manual
4038-001
Error message table
Clearing display messages:
Display Meaning Solution
Bypass Jam Paper was sensed at
the manual bypass
sensor, but not at the
main paper feed/toner
cartridge present
sensor.
Load paper in the
manual bypass or
remove the jam from
the manual bypass.
Make sure the main
paper feed/toner
cartridge present
sensor actuator is
not broken,
improperly installed
or stuck with paper
debris.
Perform the Sensor
test on page 3-16
to check proper
operation of the
sensor.
If the sensor works
properly, the problem
is likely associated
with the system
board.
If the paper path and
sensor actuator are
clear and working
properly, and the
problem persists,
replace the HVPS/
LVPS.
Note: This sensor is
a component of the
HVPS/LVPS.
4038-001
Document Jam Paper was sensed at
the ADF registration
ADF scan sensor.
Make sure the ADF
scan sensor actuator
is not broken,
or stuck with paper
debris.
sensor actuator are
clear and working
properly, replace the
scanner assembly.
Door Open Front or rear cover is
not securely latched.
Close the front toner
cartridge access
cover until it locks.
If the message does
not clear, perform the
Sensor test on
page 3-16 to check
proper operation of
the switch.
If the switch works
with the system
board.
If the switch does not
work in the test,
make sure the cover
open actuator is
working properly.
When the cover
closes, the cover
should push the
actuator, causing the
cover open switch on
the HVPS/LVPS to
close.
Note: This process
is viewable with the
right cover removed.
If all moving parts
appear to be working
correctly, and the
messages does not
clear, replace the
HVPS/LVPS.
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4038-001

Fuser Error
Problem in the fuser
unit.
Make sure CN1 and
CN7 on the HVPS/
LVPS are properly
connected.
Check CN1 on the
HVPS/LVPS for
proper voltage.
If the voltage is
correct, replace the
fuser.
Otherwise, replace
the HVPS/LVPS.
Load Bypass No document loaded in
the manual bypass.
Load print media into
the manual bypass and
try again.
LSU Error A problem in the LSU
(laser scanning unit).
Make sure all cables
are properly
connected to the
printhead.
If correct, replace the
printhead.
Memory Full Collated copy is too
large for memory.
Reduce the number of
pages in the job.
No Cartridge Toner cartridge not
installed.
Install the toner
cartridge.
No Paper No paper in the paper
tray.
If paper exists in the
paper tray but this
message is
displayed, make sure
the paper empty
sensor actuator is
not broken or
improperly installed.
If the actuator is
working properly,
replace the HVPS/
LVPS.
4038-001

Open Heat Error
The printer senses that
the thermistor isnt
connected or faulty.
Make sure the
thermistor is properly
connected to CN7 on
the HVPS/LVPS.
If the problem
persists replace the
fuser.

Overheat
The fuser unit has
overheated.
Replace the fuser.
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4038-001
Paper Jam 0 Paper was sensed at
the paper tray empty
manual bypass.
Go to the paper path
diagram Printer
engine paper path/
paper jams on
page 5-15 to see the
region where a paper
jam may occur.
Remove any
obstructions and
other paper debris.
Make sure the
manual bypass
sensor actuator is
not broken,
or stuck with paper
debris.
Perform the Sensor
test on page 3-16
to check proper
operation of the
sensor.
If the sensor works
with the system
board.
sensor actuator are
clear and working
properly, and the
problem persists,
replace the HVPS/
LVPS.
a component of the
HVPS/LVPS.
4038-001
Paper Jam 1 The fuser exit sensor
sensed the leading
edge of the page but
never sensed the
trailing edge.
diagram Printer
engine paper path/
paper jams on
jam may occur.
Remove any
obstructions and
other paper debris.
Perform the Sensor
test on page 3-16
to check proper
operation of the
sensor.
If the sensor works
with the system
board.
Make sure the fuser
exit sensor isnt stuck
with debris or
improperly installed.
sensor actuator are
clear and working
properly, replace the
HVPS/LVPS.
a component of the
HVPS/LVPS.
2-8 Service Manual
4038-001
Paper Jam 2 Paper was sensed at
the main paper feed/
toner cartridge present
fuser exit sensor.
diagram Printer
engine paper path/
paper jams on
jam may occur.
Remove any
obstructions and
other paper debris.
Perform the Sensor
test on page 3-16
to check proper
operation of the
sensor.
If the sensor works
with the system
board.
Make sure the fuser
exit sensor actuator
is not broken,
or stuck with paper
debris.
sensor actuator are
clear and working
properly, and the
problem persists,
replace the HVPS/
LVPS.
a component of the
HVPS/LVPS.
Power Failure Power interruption and
the machines memory
is not saved.
Restart the print job.
4038-001
Time/Date prompt Prompt appears when
the machine is powered
on.
Use the numeric
keypad to enter the
two-digit month and
day, and the four-digit
year. For example,
01-23-2003.
Enter the current
time. The default
clock setting is 12-
hour.
Press the asterisk (*)
to select AM or PM,
and then press
Select.
Note: If the machine
is unplugged for
longer than 15
minutes, or turned off
for longer than an
hour, when the power
is turned back on, the
machine prompts you
to reset the correct
date and time.
Toner Empty Toner cartridge has run
out.
Install a new toner
cartridge.
Toner Low Toner is nearly empty. Remove the toner
cartridge and gently
shake it. This
temporarily
reestablishes printing.
2-10 Service Manual
4038-001
Symptom table
Symptom Reference
Paper feed problems See Paper feed problems on
page 2-11.
Printing and copying problems See Printing and copying
problems on page 2-13.
Scanning problems See Scanning problems on
page 2-18.
Faxing problems See Faxing problems on
page 2-19.
Print quality problems See Print quality checks on
page 2-21.
Dead machine (no power) See Dead machine on
page 2-32.
Fan noisy or not working See Cooling fan on page 2-30.
Main motor noisy or does not
move
See Main drive motor on
page 2-31.
4038-001
Paper feed problems
Symptom Possible cause and solution
Paper jam Clear the paper jam.
Paper sticks together Ensure that there is not too much paper in
the paper tray. Depending on the thickness
of your paper, the paper tray can hold up to
250sheets of paper.
Make sure the correct type of paper is used.
See Selecting print materials on
page 1-2 for more information.
Remove paper from the paper tray and flex
or fan the paper.
Humid conditions may cause some paper to
stick together.
Multiple sheets do not feed Different types of paper may be stacked in
the paper tray. Load paper of only one type,
size, and weight.
When loading paper, do not force the paper
down into the machine.
If multiple sheets have caused a paper jam,
clear the paper jam.
Paper skews or buckles Ensure there is not too much paper in the
paper tray. Depending on the thickness of
your paper, the paper tray can hold up to
250sheets.
Make sure the paper guide lightly touches
the paper and does not cause the paper to
bow in the paper tray.
Make sure you are using the correct type of
paper. See Selecting print materials on
2-12 Service Manual
4038-001
Paper does not feed. Paper is not loaded correctly. Remove paper
from the tray and reload it correctly.
There is too much paper loaded. Remove
excess paper from the tray.
The paper is too thick. Use only paper that
meets specifications.
Remove any obstructions.
If the problem persists in the ADF, replace
the ADF pick roller/separator pad assembly.
If the problem persists in the paper tray,
replace the paper tray pick roller assembly.
Paper keeps jamming. There is too much paper loaded. Remove
excess paper from the tray. If printing on
special materials, use the manual bypass.
An incorrect type of paper is being used.
Use only paper that meets specifications.
See Selecting print materials on
There may be debris inside the machine.
Open the front cover and remove the debris.
If the problem persists in the ADF, replace
the ADF pick roller/separator pad assembly.
If the problem persists in the paper tray,
replace the paper tray pick roller assembly.
Transparencies stick
together in the paper exit.
Use only transparencies specially designed for
a laser printer. Remove each transparency as
it exits the machine.
Envelopes skew or fail to
feed correctly.
Ensure that the manual bypass guides are
against both sides of the envelopes.
Symptom Possible cause and solution
4038-001
Printing and copying problems
Problem Possible cause Solution

Machine does
not print
Machine is not receiving
power.
Check the power cord
connections.
Check the power switch
and the power source.
Machine is busy scanning. Wait until scanning is
complete before using the
printer.
Machine is not selected as
the default printer.
Select Lexmark X215 as
your default printer in
Windows.
Front or rear covers are not
closed.
Close the covers.
Paper jam. Clear the paper jam.
No paper loaded. Load paper.
Toner cartridge is not
installed.
Install the toner cartridge.
Connection cable between
the computer and the
machine is not connected
properly.
Disconnect the printer
cable, and then reconnect
it.
Connection cable between
the computer and the
machine is defective.
If possible, attach the
cable to another
computer that is working
properly and print a job.
Try a new printer cable.
Port setting is incorrect. Check the Windows
printer setting to make
sure that the print job is
sent to the correct port,
for example, LPT1.
If the computer has more
than one port, make sure
that the machine is
attached to the correct
one.
2-14 Service Manual
4038-001
Configuration incorrect. Ensure the printer settings
are correct.
Machine is malfunctioning. Check the message on the
operator panel to determine
if the machine is indicating
a system error.
Print job is
extremely slow
Job may be very complex. Reduce the complexity of
the page.
Adjust the print quality
settings.
If using Windows 98/Me,
the spool setting may be set
incorrectly.
1. Click Start Settings
Printers.
2. Right-click the
Lexmark X215 printer
icon.
3. Click Properties.
4. From the Details tab, click
Spool Settings.
5. Select the spool setting
you want.
Half the page is
blank
Page orientation setting
may be incorrect.
Change the page
orientation in your program.
Paper size and the paper
size settings do not match.
Ensure that the paper size
in the printer driver settings
matches the paper in the
tray.
Machine prints,
but the text is
wrong, garbled,
or incomplete
Printer cable is loose or
defective.
Disconnect the printer
cable, and then
reconnect it.
Try a print job that you
have already printed
successfully.
If possible, attach the
cable and the machine to
another computer and try
another print job.
Try a new printer cable.
Wrong printer driver
selected.
Check the programs printer
selection menu to ensure
that your machine is
selected.
4038-001
Software program is
malfunctioning.
Try printing a job from
another program.
Operating system is
malfunctioning.
Exit Windows and restart
the computer.
Turn the machine off and
then back on again.
Illustrations
print incorrectly
in Adobe
Illustrator
The setting in the software
program is wrong.
Print the document with
Download as Bit Image
selected in the Advanced
Options window of the
graphic properties.
Error occurs
repeatedly
when printing
with the USB
connection
When the USB mode is set
to FAST, some users may
experience poor USB
communication.
Change the USB mode to
SLOW.
1. Press Menu.
2. Press the scroll button
( ) until MACHINE
SETUP appears on the
top line of the display,
and then press Select.
until USB appears on the
bottom line of the display,
and press Select.
until SLOW appears on
the bottom line of the
display, and press
Select.
5. To return to the Ready
prompt, press
Stop/Clear.
LCD does not
turn on
Machine is not receiving
power.
Check that the machine
is plugged into a properly
grounded electrical
outlet.
Ensure that there is
power to the outlet and
that the machine power
switch is in the On
position.
Go to Dead machine
on page 2-32 for more
information.
or
2-16 Service Manual
4038-001
Copies are too
light or too dark
If the original is light,
press Darkness to
darken the background of
the copies.
If the original is dark,
press Darkness to
lighten the background of
the copies.
Smears, lines,
marks, or spots
on copies
Document glass or
document cover is dirty.
If defects appear on the
original, press Darkness
to lighten the background
of your copies.
If no defects appear on
the original, clean the
document glass and
underside of the
document cover.
Copy image is
skewed
Original document not
positioned correctly.
Ensure the original is
positioned correctly on
document glass or that
ADF paper guides are
aligned.
Check that paper is
loaded correctly.
Blank copies Original document not
positioned correctly.
Ensure that the original is
facedown on the document
glass or faceup in the ADF.
Image rubs off
the copy easily.
Ensure the correct media
type is selected.
Replace paper with a
fresh supply.
In high humidity areas,
do not leave paper in the
machine for extended
periods of time.
4038-001
Frequent jams Check/adjust paper
guides.
Fan the stack of paper,
and then turn it over in
the paper tray.
Replace paper with a
fresh supply.
Ensure the paper is the
proper paper weight.
20 lb. (75 g/m
2
) bond
paper is recommended.
Check for paper or pieces
of paper remaining in the
machine after a jam is
cleared.
Fewer copies
from the toner
cartridge than
expected.
Originals contain
pictures, solids, or heavy
lines.
Originals are forms,
newsletters, books, and
so on.
The machine is turned on
and off frequently.
The document cover is
left open while copies are
made.
Ensure document cover is
closed when making
copies.
2-18 Service Manual
4038-001
Scanning problems
Problem Possible cause and solution
Scanner does not work. Machine may be busy printing. Wait until
printing completes before using the scanner.
Make sure the document to be scanned is
facedown on the document glass, or faceup
in the Automatic Document Feeder.
Check that the USB or parallel cable is
connected properly.
Check that the USB or parallel cable is not
defective. Swap the cable with a known
good cable. If necessary, replace the cable.
If using a parallel cable, ensure that it is
compliant with the IEEE-1284 standard.
Make sure that the scanner job is sent to the
correct port (for example, LPT1 or USB).
Scans very slowly. Check if the machine is printing receiving
data. Scan the document after the current
job is completed.
Graphics are scanned more slowly than text.
Communication speed becomes slow in
scan mode because of the large amount of
memory required to analyze and reproduce
the scanned image.
Set your computer to ECP printer mode
through BIOS setting. It helps to increase
the speed. For details on how to set BIOS,
refer to your computer user documentation.
4038-001
Faxing problems

Machine is not working, no
display, and buttons are
not working
Unplug the power cord and plug it in again.
Ensure that there is power to the electrical
outlet.
No dial tone Check that the phone line is connected
properly.
Check that the phone socket in the wall is
working by plugging in another phone.
Numbers stored in the
memory do not dial
correctly
Make sure that the numbers are stored in the
memory correctly. Print a phonebook list.
Document does not feed Make sure that the document is not wrinkled
and you are putting it in correctly.
Check that the document is the correct size,
not too thick or too thin.
Make sure that the ADF cover is firmly
closed.
Faxes are not received
automatically
Make sure Receive mode is set to Automatic
on the FAX SETUP menu.
Make sure that there is paper loaded.
Check that the display does not show
MEMORY FULL.
Machine does not send Make sure that the document is loaded in
the ADF or on the document glass.
Make sure the fax machine you are sending
to can receive faxes.
2-20 Service Manual
4038-001
Incoming fax has blank
spaces or is received with
a poor quality
Fax machine sending the fax may be faulty.
Fax machine sending the fax may have a
dirty document glass. Clean the document
glass.
Noisy phone line can cause line errors.
Check machine by making a copy.
Toner cartridge may be empty. Replace the
toner cartridge.
Some of the words on a
incoming fax are stretched
Fax machine sending the fax had a temporary
jam.
There are lines on
documents sent
Check your scan glass for marks and clean it.
Machine dials a number,
but fails to make a
connection with another
fax machine
The other fax machine may be turned off, out
of paper, or cannot answer incoming calls. Ask
the receiving fax recipient to solve the problem.
Documents are not stored
in memory
There may not be enough memory to store the
document. If the display shows a MEMORY
FULL message, delete any documents you no
longer need from the memory, and then
restore the document.
Blank areas appear at the
bottom of each page or on
other pages, with only a
small strip of text printed at
the top
The wrong paper settings may have been
chosen.
4038-001
Print quality checks
Problem Possible causes
Straight thin black
vertical line and band
Dark black vertical
bands
The drum inside the toner cartridge has
probably been scratched.
Toner cartridge failure.
Foreign material between transfer/charge/
development rollers.
Deformed transfer roller.
Vertical white streak
Faded areas
The toner supply is low. Before changing
the cartridge, try redistributing the toner or
cleaning the photoconductor drum first.
Note: If dense paper is used or processing
a lot of graphics, the cartridge may need
changing more often.
Paper may not meet specifications (too
moist or too rough). See Paper and
speciality media guidelines on page 1-3
for more information.
If the entire page is light, adjust the
darkness and content. See Customizing
settings on page 3-18 for more
information.
A combination of faded or smeared defects
may indicate that the toner cartridge needs
cleaning. See Cleaning the
photoconductor drum on page 1-9 for
more information.
Printhead failure.
Fuser failure.
Foreign material on printhead lens.
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2-22 Service Manual
4038-001
Dark or blurry horizontal
stripes
Check the toner cartridge installation.
Toner cartridge may be defective.
Bad or dirty voltage contacts.
Toner smear Clean inside printer. See Cleaning the
inside of the machine on page 1-6 for
more information.
Check paper type and quality. See
Selecting print materials on page 1-2
Fuser failure.
Dark or blurry black
spots occur periodically
White spots occur
periodically
Paper may not meet specifications (too
moist or too rough). See Paper and
speciality media guidelines on page 1-3
Check paper path for debris. See
Cleaning the inside of the machine on
Transfer roller failure.
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4038-001
Background scatter Paper may be damp. Try printing with a
different batch of paper.
Note: Paper does absorb moisture. Open
paper packages when ready for use.
If background scatter occurs on an
envelope, change printing layout to avoid
printing over areas with overlapping seams
on the reverse side.
If background scatter covers the entire
surface area of a printed page, adjust the
print resolution through a software program
or the printer properties.
Misformed characters Paper stock may be too slick causing
characters to be improperly formed and
producing hollow images. See Selecting
print materials on page 1-2 for more
information.
Scanner unit may be defective causing
characters to be improperly formed and
producing a wavy effect.
Inspect the CCD unit for proper operation
and movement.
Ensure the belt, which moves the CCD unit,
is properly installed.
Page skew Check paper type and quality. See
Ensure paper or other material is loaded
correctly.
Ensure the guides are not too tight or too
loose against the paper stack. See
A
A
a
B
b
C
c
A
a
B
b
C
c
A
a
B
b
C
c
A
a
B
b
C
c
A
a
B
b
C
c
2-24 Service Manual
4038-001
Curl or wave Check paper type and quality. See
Note: High temperature and humidity can
cause paper curl.
Turn over the stack of paper and rotate 180
in the tray.
Wrinkles and creases Ensure the paper is loaded properly.
Check the paper type and quality. See
Turn over the stack of paper and rotate 180
in the tray.
Back of printout is dirty Clean transfer roller. See Cleaning the
machine on page 1-5 for more
information.
Check for leaking toner. Clean inside the
printer. See Cleaning the inside of the
machine on page 1-6 for more
information.
Fuser failure (dirty).
Printed image is light, with
no residual image
Toner save mode on.
Bad or dirty voltage contacts.
HVPS failure.
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4038-001
Black or dark image Check that toner cartridge is installed
properly.
Bad or dirty high voltage contacts.
HVPS failure.
Loose toner Clean the inside of the printer. See
Cleaning the inside of the machine on
Check paper type and quality. See
Check that correct media type is selected.
Fuser failure.
Character voids White areas, within the parts of characters,
that should be solid black.
If transparencies are used, try another type
of transparency.
Check that the printing is on the correct
surface. Remove the paper and turn over in
tray.
Check that paper meets paper
specifications. See Selecting print
materials on page 1-2 for more
information.
Print density is uneven
from left to right
Improper transfer roller installation.
A
a b c C B A
a b c C B A
a b c C B A
a b c C B A
a b c C B A
2-26 Service Manual
4038-001
Background appears in
print area
Gray background
Check for recommended paper weight
(recycled or poor quality paper). See
Check machine environment.
Note: Very dry (low humidity) or humid
(higher than 80% relative humidity (RH))
conditions can increase background
shading.
Dirty transfer roll.
Transfer roll failure or improperly installed.
HVPS failure.
Residual image occurs at
75 mm intervals
Engine board failure.
75 mm intervals when
printing card stock or
transparencies
Software not set to card stock or transparency
mode.
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4038-001
Residual image occurs in
the black image printing at
37 mm intervals
64 mm intervals
Fuser temperature maintained too high.
Check for toner buildup on hot roller and
thermistor surface.
Clean or replace fuser if necessary.
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7
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2-28 Service Manual
4038-001
Blank page prints Redistribute the toner.
If necessary, replace the toner cartridge.
Ensure the printed file doesnt have blank
pages.
Bad or dirty high voltage contacts; inspect
and clean contacts.
Replace the LVPS/HVPS.
Replace the system board.
Blank page prints
One or several blank
pages print
When printer is powered
on, several blank pages
print
Pick roller solenoid failure.
System board failure.
4038-001
If an abnormal image prints periodically, check the following parts:
No.
Distance
between
repeated
marks
Related
printer
components
Type of
abnormal
image
Replace
1 75.5 mm OPC drum White or black
spots/voids
Toner cartridge
2 37.7 mm Charge roller Black spots Toner cartridge
3 37.0 mm Supply roller Horizontal shock
lines
Toner cartridge
4 35.2 mm Developer
roller
Horizontal shock
lines
Toner cartridge
5 45.3 mm Transfer roller Back side
contamination
Transfer roller
6 64.1 mm Hot roll White or black
spots/voids
Fuser
7 75.5 mm Back-up roller Back side
contamination
Fuser
Toner Cartridge
Fuser
1
2
3
4
5
6
7
2-30 Service Manual
4038-001
Service checks
Cooling fan
FRU Action

Cooling fan,
LVPS/HVPS,
system board
Perform the Motor, Fan,
Solenoid test on page 3-10 to
see if the fan turns on.
If the fan turns on, the problem is
likely associated with the system
board.
If the fan does not turn on, make
sure the cooling fan cable is
properly seated in CN3 on the
LVPS/HVPS.
Disconnect the fan, and check
CN31 for +24 V dc.
If the voltage is present, replace
the cooling fan.
If the voltage is not present,
replace the LVPS/HVPS.
4038-001
Main drive motor
Document cover open switch
FRU Action

Main drive motor,
system board,
LVPS/HVPS
Perform the Motor, Fan,
Solenoid test on page 3-10 to
see if the main drive motor turns
on.
If the motor works but is noisy,
replace the main drive assembly.
If the motor works correctly in this
test but not during normal printing,
the problem may be associated
with a faulty system board.
If the motor does not work at all
during this test, make sure the
motor cable is properly
connected.
If connections are correct and the
problem persists, replace the main
drive assembly.
If the problem persists, replace
the LVPS/HVPS.
FRU Action
Document cover
switch,
operator panel
First, make sure the document
cover open switch cable is
properly seated in CN1 on the
operator panel.
Disconnect the cable from CN1 on
the operator panel and check
CN11 for +5 V dc.
If the voltage is present, the
document cover switch is faulty.
replace the operator panel.
2-32 Service Manual
4038-001
Dead machine
FRU Action
Line voltage Check the AC line voltage to make
sure it is correct.
LVPS/HVPS to system
board cable
Ensure the cable connecting the
LVPS/HVPS to the system board is
properly seated.
LVPS/HVPS Check the following voltages on CN2
of the LVPS/HVPS:
pin 3, +5 V dc
pin 4, +5 V dc
pin 5, Ground
pin 6, Ground
pin 7, +12 V dc
pin 8,9,10,11, Ground
pin 12, +24 V dc
If any of the voltage measurements
are not correct, replace the LVPS/
HVPS.
4038-001
Operator panel, scanner card assembly
FRU Action
Operator panel
scanner card assembly
Perform the Operator Panel
test on page 3-12 to check for
proper operation of the LCD
screen, LED(s) and key buttons.
If the operator panel does not
work at all, check the following on
the scanner card:
CN21, Ground
CN22, +5 V dc
replace the scanner card.
If the voltage is present, check for
continuity of the operator panel
cable.
If continuity is missing in any part
of the cable, replace the cable.
Otherwise, replace the operator
panel.
2-34 Service Manual
4038-001
Diagnostic aids 3-1
4038-001
3. Diagnostic aids
Configuration modes
Clear All Memory mode
The Clear All Memory setting is used to reset all settings back to
factory defaults.
Note: Page counts are not reset when Clear All Memory is
performed.
To adjust Clear All Memory:
1. Press Menu, #, 1, 9, 3, 4.
The LCD displays TECH.
2. Press Menu, and then Select.
3. Select Data Setup.
4. Select Clear All Memory.
5. Select the country where the machine is located and press
Select to save the setting.
6. Press Return to go back to TECH screen.
7. Press Menu, #, 1, 9, 3, 4 to exit TECH mode.
3-2 Service Manual
4038-001
Dial mode
The Dial mode setting allows the modem card to be changed
between pulse or tone dial modes.
To adjust Dial mode:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Dial mode.
5. Use the arrow keys to select the desired dial mode.
6. Press Select to save the setting.
Error Rate mode
The Error Rate setting is a level used to automatically lower the
modem speed when errors occur. Whenever the error rate exceeds
this setting the baud rate of the modem card automatically drops to
2400 bps.This setting can be set at 5% or 10%.
To adjust the Error Rate:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Error Rate.
5. Select the desired error rate value (5% or 10%) and press
Select to save the setting.
Diagnostic aids 3-3
4038-001
Modem Speed mode
The Modem Speed setting is used to select the modem speed. The
possible choices are:
4.8
9.6
12.0
14.4
28.8
33.6 Kbps.
To adjust the Modem Speed:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Modem Speed.
5. Select the desired modem speed value and press Select to
save the setting.
3-4 Service Manual
4038-001
Park CCD module mode
This function parks the CCD module in the middle of the flatbed to
prevent damage to the CCD module during shipping. Perform this
function whenever the printer is to be shipped.
To park the CCD module:
1. Press Menu, #, 1, 9, 3, 4.
The LCD screen displays TECH.
3. Select Machine Test.
4. Select Move CCD.
The CCD module parks in the shipping position.
5. At this point, the printer can be powered off and packaged for
shipping.
Note: Once the power is turned back on, the CCD module
returns to a normal position.
6. To return the CCD module without powering off the machine, lift
the document cover and then lower document cover.
Diagnostic aids 3-5
4038-001
Print Properties mode
Settings to adjust for a print job include:
Orientation - the direction information is printed on a page.
2-UP or 4-UP - multiple pages printed on one sheet.
Scale - the size information is printed on a page.
Fit to Page - used to fit a document to a selected paper size.
Watermark - text printed over an existing document.
Overlay - specific text or images printed on multiple documents,
such as the text or images that make up a letterhead.
Odd/Even pages and Manual feed - used to print on both
sides of the paper.
Access Print Properties using the program or the Printers folder.
Note:
Accessing Print Properties from the program, any settings
changed are in effect only while using the current program.
Accessing Print Properties from the Printers folder, any settings
changed are permanent.
3-6 Service Manual
4038-001
Print settings description
From this tab: Change these settings:
Layout Orientation - select how the document is oriented on the
printed page.
Layout - select the type of layout for the document.
Paper Copies - select the number of copies to print.
Type - select the type of paper to use.
Make sure that Type is set to Printer Default. If you load
specialty media, select the corresponding paper type.
For more information see the Users Guide.
Source - select the paper input source (front input tray or
manual bypass).
The Manual Feed source is used when printing
specialty media. Load one sheet at a time into the
manual bypass.
If the paper source is set to Auto Select, the machine
automatically picks up print materials from the manual
bypass first, and then the paper tray.
Size - select the size of paper to use.
Graphics Resolution - select the quality of the output (600 dots per
inch (dpi) for normal quality or 300 dpi for draft quality).
Extras Watermark - select the text to print over an existing
document.
Overlay- select a one-page document containing text or
graphics to print over another document.
Diagnostic aids 3-7
4038-001
Send Level mode
The Send Level setting adjusts the transmission signal level of the
modem card. Typically, this level should be under 12dB.
Note: The Send Level is set at the factory at an optimal setting. Do
not arbitrarily adjust.
To adjust Send Level:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Send Level.
5. Key in desired send level (915) and press Select.
System Settings Report mode
This function prints a listing of all configuration settings, code version
levels, and page counts.
To print a System Settings report:
1. Press Menu, #, 1, 9, 3, 4.
3. Select Report.
4. Select System Data.
5. A system settings page prints.
3-8 Service Manual
4038-001
Machine tests
DRAM Memory test
The DRAM Memory test checks all DRAM memory on the system
board.
To enter the DRAM Memory test:
1. Press Menu, #, 1, 9, 3, 4.
4. Select DRAM Test.
The test runs automatically.
If the test passes, the LCD screen displays OK.
If the test fails, an error message displays.
Replace the system board if the DRAM Memory test fails.
5. Press Return to exit the test.
Diagnostic aids 3-9
4038-001
Modem Protocol Log test
The Modem Protocol log prints the sequence of the CCITT group 3
T.30 protocol during the most recent sending or receiving operation.
This report is used to check for send and receive errors.
To perform the Modem Protocol log:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Report.
5. Select Protocol.
A Modem Protocol log page prints.
Modem test
The Modem test causes the modem to send various transmit signals
on the telephone line. The signals are audible through the speaker.
To enter the Modem test:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Modem Test.
5. Select the baud rate to test.
6. Press Select to begin the test.
7. Press Return to end the test.
8. Press Stop/Clear twice to exit the test.
3-10 Service Manual
4038-001
Motor, Fan, Solenoid test
This test checks the following components:
Main drive motor
Paper tray pickup solenoid
Cooling fan
Main feed roller/bypass solenoid
Pretransfer LED
To enter the Motor, Fan, Solenoid test:
1. Press Menu, #, 1, 9, 3, 1.
2. Select Diagnostic.
3. Press Select for Mtr Fan Sol.
Each component is listed one at a time. The first component
is the main drive motor.
4. To test the component, press 1.
5. To turn off the component test and proceed to the next
component test, press 2.
The test can be exited at any time by pressing Return.
Note: If a component was activated when Return is pressed,
that component remains activated while another test can run
concurrently.
6. Press Stop/Clear to exit the Diagnostic Test mode.
Diagnostic aids 3-11
4038-001
Operator Panel Button test
The Operator Panel Button test checks all key buttons on the
operator panel.
To enter the Operator Panel Button test:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Switch Test.
5. Press the desired key button(s), one at a time, to perform the
test.
As a key button is pressed, the LCD screen displays the name
of the key button.
6. Press Stop/Clear twice to exit the test.
3-12 Service Manual
4038-001
Operator Panel test
To perform the Operator Panel test:
1. Press Menu, #, 1, 9, 3, 8.
2. Press, Select
3. Select LCD LED Key.
4. Press any key to begin the LCD test.
Each pel of the LCD panel is illuminated, starting from left to
right. Once all pels have been illuminated, press any key. All
LEDs now illuminate.
5. Press Menu to perform the LED test.
The light contrast LED turns off. By continuing to press any
key, each LED turns off. When the last LED is turned off, the
Key Button test begins.
6. Press each key button prompted by the LCD screen to verify
that each button is working.
Note: If you press a button other than the one prompted, a
series of beeps is audible.
After each key button has been pressed, the LCD screen
indicates that the test is complete.
If any of the LCD pels do not illuminate, any of the LEDs do
not illuminate, or any of the key buttons do not work, replace
the operator panel.
4038-001
Printhead test
The Printhead test checks the following components:
Printhead motor
Printhead HSYNC
Laser diode
To enter the Printhead test:
1. Press Menu, #, 1, 9, 3, 1.
3. Press Menu, and then select LSU test.
4. Press Select.
Each component is listed one at a time. The first component is
the printhead (LSU) motor.
5. To test the component, press 1.
The LCD screen displays Ready once the component passes
the test.
6. To turn off the component test and proceed to the next
component test press 2.
concurrently.
7. Press Stop/Clear to exit the Diagnostic test mode.
3-14 Service Manual
4038-001
Print Quality Pages test
This function prints a variety of test pages used to verify print quality.
There are seven different test patterns.
To perform the Print Quality Pages test:
1. Press Menu, #, 1, 9, 3, 4.
4. Select Pattern Test.
5. Select the pattern to print, or select All to print all test patterns.
Select the number of pages to be printed per test at the print no.
prompt.
Pattern Description
1 Graphics / image quality
2 Graphics / image quality
3 Horizontal lines
4 White page
5 Dot array (fine)
6 Dot array (coarse)
7 Vertical lines
4038-001
ROM Memory test
The ROM Memory test checks the ROM memory in the printer.
To enter the ROM Memory test:
1. Press Menu, #, 1, 9, 3, 4.
4. Select ROM Test.
The test runs automatically.
If the test passes, the flash and engine code levels are
displayed on the LCD screen.
If the test fails, replace the system board.
5. Press Return to exit the test.
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4038-001
Scanner CCD Module and Motor test
This test is used to check for proper movement of the CCD module
from one side of the flatbed scanner to the other.
To perform the scanner CCD tests:
1. Press Menu, #, 1, 9, 3, 8.
2. Press the right arrow key to select scanner.
3. Press Select.
4. Press Start to begin the test.
During this test the CCD module moves continuously from
side to side.
If the CCD does not move smoothly, or not at all, check that
the belt is properly installed between the motor pulley and
CCD module.
Ensure the CCD module is installed correctly.
If the CCD module strikes the left side of the scanner, the
CCD module is not sensing its home position. This can be
caused by a faulty CCD module cable, or the home position
sensor which is part of the CCD module assembly.
5. Press Stop, at any time, to stop the test.
Sensor test
The Sensor test checks the following components:
Main paper feed/toner cartridge present sensor
Fuser exit sensor
Toner cartridge access cover open sensor
Paper tray empty sensor
Manual bypass sensor
4038-001
To enter the Sensor test:
1. Press Menu, #, 1, 9, 3, 1.
3. Press Menu, and then select Sensor Test.
4. Press Select.
5. Each sensor is tested one at a time.
The first sensor checked is the main paper feed/toner cartridge
present.
6. Manually actuate the sensor flag while pressing 1 on the
operator panel.
The LCD screen briefly posts On or Off depending on the
position of the sensor actuator when 1 is pressed.
7. Press 2 to move to the next sensor to be tested.
concurrently.
8. Press Stop/Clear to exit the Diagnostic test mode.
Note: While the toner cartridge is removed, the main paper feed/
toner cartridge present sensor posts an On message when the
actuator is fully up or down. With the cartridge installed, an Off
message is posted. This sensor detects both paper jams and
cartridge present.
Note: There are two tests on the Lexmark X215 MFP LCD that are
not used in servicing this printer.
Heat test
HVPS test
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4038-001
Customizing settings
All the copy options (content, darkness, number, scale, and
advanced) using the operator panel buttons can be temporarily
modified. Settings remain in effect until a predefined time-out period
is expired.
Note:
Make all of your selections before pressing Start.
Press Stop/Clear while modifying the copy settings cancels all
settings for the current job and returns them to their default
status.
Content
The content setting is used to improve copy quality. Choose from the
following settings:
Text - use for documents containing mostly text.
Mixed - use for documents with mixed text and graphics.
Photo - use when the originals are photographs.
To select, press Content repeatedly.
Each time you press Content, the LED labeled with the selected
mode lights up.
Note: When you copy a document with color in the background
using the Mixed mode, the machine automatically removes the
background color. If you want to include the background color in your
copy, load the document about 5 mm away from the edges of the
scanning bed, or change the darkness setting.
4038-001
Darkness
The darkness setting is used for an original document containing
paint markings or dark images:
Light - works well with dark print.
Normal - works well with standard typed or printed documents.
Dark - works well with light print or faint pencil markings.
To adjust the darkness, press Darkness repeatedly.
Each time you press the button, the LED labeled with the selected
mode lights up.
Number
Select number of copies from 1 to 99.
1. Press Number.
2. Enter the number of copies to print using the numeric keypad.
3. Press Select.
The selected number appears on the display.
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Scale
Original documents copied from the document glass, can be
reduced or enlarged from 25% to 400%.
Original documents copied from the ADF, can be reduced or
enlarged from 25% to 100%.
To scale a document to a predefined copy size:
1. Press Scale.
The default setting appears on the bottom line of the display.
2. Press a scroll button ( ) repeatedly until the copy size is
displayed.
3. Press Select.
To customize the copy size:
1. Press Scale.
2. Press a scroll button ( ) until CUSTOM:25400% (or
CUSTOM:25100%) appears on the bottom line of the display.
3. Press Select.
4. Enter the size using the numeric keypad.
5. Press Select.
The selected number appears on the display.
or
or
4038-001
Advanced
The advanced option, copies images onto a page in a variety of
layouts.
The advanced settings available when a document is loaded in the
ADF include:
Off - turns off the advanced copy features.
Collation - controls the sequence in which multiple page
documents are printed.
2Up - prints two copied documents on a single page.
4Up - prints four copied documents on a single page.
The advanced settings available when a document is loaded in the
scanner bed include:
Off - turns off the advanced copy features.
Auto Fit - automatically reduces or enlarges the original image
so the resulting copy fits on the paper.
2Side - prints two copied documents on a single page. When
using the scanner bed, the 2Side feature is especially useful
when copying both sides of an original document.
Note: Auto Fit and 2Side can be selected only when the paper
size is letter, legal, or A4.
To select the advanced setting:
1. Press Advanced repeatedly until the desired setting appears.
2. Press Select.
3-22 Service Manual
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Repair information 4-1
4038-001
4. Repair information
Removals
Covers
Cartridge access cover removal
1. Remove the paper tray.
2. Open the access cover.
4-2 Service Manual
4038-001
3. Press in on one side of the access cover to release it.
4. Release the other side of the access cover and remove.
4038-001
Middle cover removal
1. Remove the scanner and scanner card assembly. See
Scanner assembly removal on page 4-64, and Scanner
card assembly removal on page 4-68 for more information.
2. Slip the cables out of the middle cover (A) (scanner to system
board).
3. Remove six screws (A) in the middle cover.
4-4 Service Manual
4038-001
4. From the front of the printer, pull both the middle cover legs
away from the printer to release tabs.
5. Lift up to remove the middle cover.
4038-001
Rear cover removal
1.Remove four screws (A).
4-6 Service Manual
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2. Pull the rear cover to remove.
4038-001
Scanner assembly document cover removal
1. Remove the left side cover. See Left side on page 4-12 for
more information.
2. Remove the ground screw on the drive assembly. See
Scanner assembly removal on page 4-64 for more
information.
3. Disconnect the scanner assembly cable (A) (CN3).
4-8 Service Manual
4038-001
4. Unthread the cable (A) from the scanner document cover.
4038-001
5. Open the document cover.
4-10 Service Manual
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6. Lift the document cover until the hinges catch (A).
4038-001
7. Tilt back and lift off the scanner document cover.
4-12 Service Manual
4038-001
Side cover removals
Left side
1. Remove the rear cover. See Rear cover removal on
2. Disconnect the speaker cable (A).
A
4038-001
3. Slide the cover toward the rear of the printer to release.
4-14 Service Manual
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4. Tilt away from printer.
5. Lift to remove the left side cover.
4038-001
Right side
1. Remove the rear cover. See Rear cover removal on
2. Slide the cover toward the rear of the printer to release.
4-16 Service Manual
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3. Tilt away from printer.
4. Lift to remove the right side cover.
4038-001
Automatic document feed (ADF) removals
ADF Pick roller
1. Open ADF access cover.
2. Rotate the pick roller bearing (A) to release from the ADF
housing.
4-18 Service Manual
4038-001
3. Lift the pick roller and slide out.
ADF Pad
1. Remove the ADF pick roller. See Automatic document feed
(ADF) removals on page 4-17 for more information.
2. Grab both sides of the ADF pad and lift.
4038-001
CCD module assembly removal
1. Remove the scanner assembly and operator panel. See
Scanner assembly removal on page 4-64, and Operator
panel removal on page 4-50 for more information.
2. Remove four screws (A).
3. Slip a flat blade screwdriver under one side then the other to
release the tabs.
4-20 Service Manual
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4. Lift off glass housing to remove.
4038-001
5. Use a flat blade screwdriver to gently pry open the CCD module
assembly housing to release the belt.
4-22 Service Manual
4038-001
6. Pry the shaft loose on both ends and slide out.
4038-001
7. Release the ribbon cable from slots (A).
4-24 Service Manual
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8. Disconnect the ribbon cable (A) from the CCD.
9. Remove the CCD assembly.
4038-001
Card cage removal
1. Remove the left, right and rear covers. See Left side on
page 4-12, Right side on page 4-15, and Rear cover
removal on page 4-5 for more information.
2. Remove two screws (A) at the rear of the printer.
3. Place the printer front side down on a flat surface
4-26 Service Manual
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4. Remove 10 screws (A) in card cage.
4038-001
Note: Hold the card cage as you remove the last screw; as the cage
can fall.
4-28 Service Manual
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5. Lift the card cage to remove.
4038-001
6. Disconnect all cables on the system board.
See reinstallation note.
4-30 Service Manual
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Reinstallation note: Make note of the cable locations (A) for the
cartridge fuse (CN4) and main paper feed cable (CN6) as these
pin connectors can be interchanged. This reversal could cause the
printer to malfunction.
4038-001
Fan removal
1. Remove the right side cover. See Right side on page 4-15
2. Disconnect the fan cable from the LVPS/HVPS.
3. Pull the fan straight out to remove.
4-32 Service Manual
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Fuser removal
1. Remove the card cage. See Card cage removal on
2. Remove four screws (A).
3. Pull the fuser straight out to remove.
4038-001
HVPS contact removal
1. Remove the right side cover. See Right side on page 4-15
2. Remove the screw in the cover to the HVPS contacts.
3. Remove the cover.
4. Using needle nose pliers, remove the HVPS contact(s).
4-34 Service Manual
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LVPS / HVPS card removal
2. Disconnect the cable (CN2) on the LVPS/HVPS card.
4038-001
3. Remove seven screws (A).
Note: The bracket securing the LVPS/HVPS card must be removed
to reveal the last screw holding the LVPS/HVPS card.
4-36 Service Manual
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4. Remove the LVPS/HVPS card.
4038-001
Main drive assembly removal
1. With the left side cover removed. See Left side on page 4-12
2. Remove six screws (A) across the top and bottom of the main
drive assembly.
4-38 Service Manual
4038-001
3. Pull the main drive assembly out a little and disconnect the drive
motor cable (A).
4. Lift out the main drive assembly to remove.
4038-001
Main paper feed roller removal
1. Remove the middle cover and main drive assemblies. See
Middle cover removal on page 4-3 and Main drive
assembly removal on page 4-37 for information.
2. Remove the three screws (A) and the gear plate.
3. Remove the four gears.
4-40 Service Manual
4038-001
4. Remove the two screws (A).
5. Lift the metal plate and remove.
4038-001
6. Lift the metal shaft (registration roller) with both bearings
attached.
Reinstallation note: When installing the four gears, make sure
the arms of the solenoids are in the correct position.
7. Pry up the main paper feed roller and remove.
4-42 Service Manual
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Main feed roller solenoid removal
1. With the card cage and main drive assembly removed. See
Card cage removal on page 4-25 and Main drive
assembly removal on page 4-37 for more information.
2. Remove the gear plate (A).
4038-001
3. Remove the pick roller gear.
4. Remove one screw.
4-44 Service Manual
4038-001
5. Remove the main feed roller solenoid.
4038-001
Manual paper feed sensor actuator removal
1. With the paper tray feed roller removed. See Paper tray feed
roller removal on page 4-56 for more information.
2. Flex the tab with your thumb and pry up the end of the actuator.
4-46 Service Manual
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3. Lift and remove from the printer.
Note: Ensure the spring remains on the actuator.
Reinstallation note: Verify the spring is in the correct orientation
and flexes the actuator.
4038-001
Modem card removal
1. With the card cage removed. See Card cage removal on
2. Disconnect the modem ribbon cable (CN3).
4-48 Service Manual
4038-001
3. Remove two screws (A).
4. Using needle nose pliers, squeeze the standoff to release the
modem card.
4038-001
5. Remove the modem card.
4-50 Service Manual
4038-001
Operator panel removal
1. Remove three screws (A) on the underside of the operator
panel.
2. Rotate the top portion of the operator panel up.
4038-001
3. Disconnect the operator panel cables (CN1 and CN2).
4. Remove the operator panel.
4-52 Service Manual
4038-001
Paper empty sensor actuator removal
2. Deflect the tab to the side of the actuator to release.
4038-001
3. Remove the paper empty sensor actuator.
4-54 Service Manual
4038-001
Paper feed sensor actuator removal
1. Remove the paper tray pick roller assembly and paper empty
sensor actuator. See Paper tray pick roller assembly
removal on page 4-57 and Paper empty sensor actuator
2. Deflect the right side of the actuator to release.
4038-001
3. Lift and remove the paper feed sensor actuator.
4-56 Service Manual
4038-001
Paper tray feed roller removal
1. Remove the paper tray pick roller. See Paper tray pick roller
assembly removal on page 4-57 for more information.
2. Pull down to release from bushings (A).
3. Remove the paper tray feed roller.
4038-001
Paper tray pick roller assembly removal
1. Remove the main drive assembly. See Main drive assembly
2. Remove the paper tray.
3. Remove the three screws (A) securing the gear plate and
remove the plate.
4-58 Service Manual
4038-001
4. Remove the pick roller gear.
5. With the card cage removed. See Card cage removal on
4038-001
6. With a flat blade screwdriver, lift the tab (A) on the right bushing.
4-60 Service Manual
4038-001
7. While holding the tab up, push the pick roller to the right until the
shaft (A) is released on the left side.
8. Remove the pick roller.
4038-001
Paper tray solenoid removal
1. Remove the card cage and main drive assembly. See Card
cage removal on page 4-25 and Main drive assembly
2. Remove the screw from the solenoid.
4-62 Service Manual
4038-001
3. Remove the paper tray solenoid.
4038-001
Printhead removal
1. Remove the middle cover. See Middle cover removal on
2. Remove four screws (A) from the printhead.
3. Lift the printhead.
4. Disconnect two connectors.
5. Remove the printhead.
4-64 Service Manual
4038-001
Scanner assembly removal
1. Remove the left, right and rear covers. See Left side on
page 4-12, Right side on page 4-15, and Rear cover
2. Remove the ground screw from the main drive assembly.
3. Disconnect the following cables from the scanner card:
4038-001
cable (A) (CN3)
cable (A) with toroid (CN6)
4-66 Service Manual
4038-001
cable (A) (CN2)
4038-001
ribbon cable (A) (CN1)
4. Remove two screws in rear of printer.
4-68 Service Manual
4038-001
5. Remove the scanner assembly.
Scanner card assembly removal
1. Remove the left side cover. See Left side on page 4-12 for
more information.
2. Disconnect all cables from the scanner card.
4038-001
3. Remove two screws (A) from the card.
4-70 Service Manual
4038-001
4. Lift out the scanner card to remove.
4038-001
Scanner assembly cushion removal
Pull the scanner cushion away to release from adhesive.
4-72 Service Manual
4038-001
Scanner assembly hinge removal
1. With the scanner document cover removed. See Scanner
assembly document cover removal on page 4-7 for more
information.
2. Lay the scanner document cover upside down.
3. Remove three screws (A) from the hinge.
4. Tilt back through catches and lift out.
4038-001
System board removal
1. Remove the modem card. See Modem card removal on
2. Disconnect the LVPS/HVPS cable (CN14).
3. Remove the modem card ribbon cable (CN1).
4-74 Service Manual
4038-001
Note: See reinstallation note.
4. Remove five screws (A).
4038-001
5. Remove the system board.
6. Remove the modem card standoff from the system board.
Reinstallation note: Reinstall the modem card standoff and ribbon
cable on the new system board.
4-76 Service Manual
4038-001
Transfer roll removal
1. Open the cartridge access cover.
2. Remove the toner cartridge.
Note: Place toner cartridge on a flat surface and cover with
paper to prevent light getting to the developer. Prolonged
exposure of light to the green PC drum can damage the
cartridge.
3. Pry up the transfer roll (A) on the right end.
4038-001
4. Using a pair of needle nose pliers, grab the right end of the shaft
and move to the right.
Note: Touching the roller may cause print quality problems.
5. Once the left side of the transfer roll is released, still holding
with pliers, remove from the printer.
4-78 Service Manual
4038-001
Locations 5-1
4038-001
5. Locations
Front view
ADF release
knob
Scanning
bed
Document
output tray
Document
cover
Paper output
extension
Document
guide
Automatic
Document
feeder (ADF)
Document
input tray
Operator
panel
Front
output tray
Front
cover
Paper
tray
Manual
bypass
5-2 Service Manual
4038-001
Rear view
Telephone
line connector
USB connector
Parallel connector
Rear
cover
Power
switch
AC power
cord connector
Locations 5-3
4038-001
EP rollers
1 OPC drum
2 Charge roller
3 Supply roller
4 Developing roller
5 Transfer roller
6 Heat roller
7 Pressure roller
Toner Cartridge
Fuser
1
2
3
4
5
6
7
5-4 Service Manual
4038-001
Operator panel
1
2
3
4
5
6
7
8
9
*
0
#
R
e
t
u
r
n
M
e
n
u
S
e
l
e
c
t
C
o
p
y
F
a
x
N
u
m
b
e
r
R
e
s
o
l
u
t
i
o
n
P
h
o
n
e
b
o
o
k
R
e
d
i
a
l
/
P
a
u
s
e
L
i
g
h
t
T
e
x
t
S
c
a
l
e
A
d
v
a
n
c
e
d
M
i
x
e
d
P
h
o
t
o
D
a
r
k
N
o
r
m
a
l
F
a
x
C
o
p
y
D
a
r
k
n
e
s
s
C
o
n
t
e
n
t
1
2
3
4
9
5
8
7
6
Locations 5-5
4038-001
C
o
p
y
Content Selects the output type for the current copy job. Select
from Text, Mixed, or Photo quality.
Darkness Adjusts the brightness of the current copy job to the
selected value.
Number Selects the number of copies that you want to make.
Scale Adjusts the size of content on the page.
Advanced Accesses special copy features such as Collate, 2-Up,
and 4-Up.
Resolution Adjusts the resolution of a faxed document.
F
a
x
Phonebook Accesses and stores fax numbers as shortcuts and
groups.
Redial/Pause Redials the most recently used fax number. Also used
to enter programmed delays when entering shortcuts.
Telephone icon Starts a dial tone (used to send a fax manually).
1
2
3
4
5
6
7
8
9
Display Displays the current status and prompts during an
operation.
Toner Low
indicator
Turns on when the toner cartridge is near empty.
Numeric
keypad
Used to enter a menu number, to dial a fax number, or
to enter alphanumeric characters.
Stop/Clear Stops an operation at any time.
Menu Enters menu functions and scrolls through menu items.
Scroll buttons Scrolls through the options available for the selected
menu item.
Select Confirms the selection on the display.
Return Sends you back to the previous menu level or exits the
menu.
Start Starts a job.
5-6 Service Manual
4038-001
HVPS / LVPS card
C
N
2
1
OP104
OP103
OP101
OP102
CN3
CN1
C/O
Switch
1
Locations 5-7
4038-001
Function name
Name on
card
# of pins Pin # Signal
Fuser CN1 2 1
2
110 / 220 /
240 V ac
Neutral
System board CN2 26 3, 4
7
12
5,6,8,9,10,
11
+5 V dc
+12 V dc
+24 V dc
Ground
Cooling fan CN3 3 1 +24 V dc
Cover open
switch
C/O Switch
Manual bypass
sensor
OP101
Main paper feed
/ toner cartridge
present sensor
OP103
Fuser exit
sensor
OP102
Paper tray
empty
OP104
5-8 Service Manual
4038-001
Modem card
Function name
Name on
card
System board CN3 14 10
2, 12
+5 V dc
Ground
1
CN3
CN1
Locations 5-9
4038-001
Operator panel card
Function name
Name on
card
Document cover
sensor
CN1 3 1
3
+5 V dc
Ground
Scanner card CN2 6 2
1
+5 V dc
Ground
CN2
1
CN1
CN3
1
1
5-10 Service Manual
4038-001
Scanner card
1
CN2
1
CN6 1
CN1
CN4
1
CN5 CN3
1 1
Locations 5-11
4038-001
Function name
Name on
card
CCD module CN1 24 19
22
1,3,5,7,12,
20,24
+5 V dc
+24 V dc
Ground
Operator panel CN2 6 2
1
+5 V dc
Ground
ADF CN3 16 3
2,4
1,11,13,15
+5 V dc
+24 V dc
Ground
System board CN4 26 1,2,3
8,9,10,18,
19,20,22,
24,26
+5 V dc
Ground
System board CN5 26 1,2,3,4,5
8,9,10,18,
19,20,22,
24,26
+24 V dc
Ground
CCD module
motor
CN6 4
5-12 Service Manual
4038-001
System board
CN13
1
CN20
C156
CN10
CN8
CN9
CN7
1
1
1
1
CN14
1
CN4
CN12
CN6
CN5
CN2
CN1
1
1
1
1
CN3
1
1
1
Locations 5-13
4038-001
Function name
Name on
card
HVPS/LVPS CN1 26 3,4
7
12
5,6,8,9,10,
11
+5 V dc
+12 V dc
+24 V dc
Ground
Paper tray
solenoid
CN2 3 3 +24 V dc
Pre-transfer LED CN3 2 1 +3.3 V dc
Toner cartridge
fuse
CN4 2
Main drive motor CN5 4
Main paper feed
/ bypass
solenoid
CN6 2 1 +24 V dc
Fuser thermistor CN7 2
Scanner card CN8 26 1,2,3,4,5
10,15,16,
17,18,20,
21,22,24,26
+24 V dc
Ground
Speaker CN9 2
Scanner card CN10 26 1,2,3,
8,9,10,18,
19,20,22,
24,26
+5 V dc
Ground
Printhead CN12 11 5
7
4,8,9,11
+24 V dc
+5 V dc
Ground
Not used CN13
Modem card CN14 14 10
2,12
+5 V dc
Ground
5-14 Service Manual
4038-001
ADF paper path
CCD-Module
Exit roller
Document sensor
Pickup roller ADF roller ADF-Idle roller
Scan sensor
Registration
sensor
Feed roller
White-sheet
Locations 5-15
4038-001
Printer engine paper path/paper jams
PTL
P
I
C
K
/
R
CR
DR
SR
TR FR
OPC
Bypass jam
BR
Fuser
Printhead
Paper jam 0 Paper jam 2
Paper jam 1
Main paper feed/toner
cartridge present sensor
Manual bypass sensor Empty sensor
Fuser
exit sensor
5-16 Service Manual
4038-001
Preventive maintenance 6-1
4038-001
6. Preventive maintenance
The Lexmark X215 MFP does not require preventive maintenance.
6-2 Service Manual
4038-001
Parts catalog 7-1
4038-001
7. Parts catalog
How to use this parts catalog
SIMILAR ASSEMBLIES: If two assemblies contain a majority of
identical parts, they are shown on the same list. Common parts
are shown by one index number. Parts peculiar to one or the
other of the assemblies are listed separately and identified by
description.
NS: (Not Shown) in the Asm-Index column indicates that the
part is procurable but is not pictured in the illustration.
PP: (Parts Packet) in the Description column indicates the part
is contained in a parts packet.
7-2 Service Manual
4038-001
Assembly 1: Scanner assembly
1
2
3
4
5
6
7
8
9
10
11
Parts catalog 7-3
4038-001
Assembly 1: Scanner assembly
Index P/N Units Description
11 56P1931 1 Cover asm, ADF access
2 56P1923 1 Kit asm, ADF pick roll/pad
3 56P1922 1 Roller, ADF idler
4 56P1983 1 Scanner, complete
5 56P1936 1 Overlay, main
6 56P1935 1 Overlay, menu/select/return
7 56P1934 1 Panel asm, operator
8 56P1932 1 Cushion, document cover
9 56P1933 2 Hinge, document cover
10 56P1941 1 Cable, CCD
11 56P1940 1 Module asm, CCD
7-4 Service Manual
4038-001
Assembly 2: Main assembly
1
2
4
5
12
15
14
6
7
9
13
18
16
17
19
21
8
10
11
20
3
Parts catalog 7-5
4038-001
* Note: Whenever a part is replaced in a machine with serial
number below S8374290, all three parts must be replaced at the
same time.
Assembly 2: Main assembly
21 56P1914 1 Cover asm, rear
2 56P1902 1 Printhead, complete
3 56P1916 1 Cable, main drive motor
4 56P1915 1 Fan, cooling
5 56P1913 1 Cover, right
6 56P1904 1 Card asm, LVPS/HVPS - 110 V
7 56P1906 1 Cable, system to power supply
8 56P1918 1 Card asm, modem (Americas)
8 56P1986 1 Card asm, modem (West Europe)
8 56P1987 1 Card asm, modem (S. Africa)
8 56P1988 1 Card asm, modem (Asia)
8 56P1989 1 Card asm, modem (Australia)
9 56P1984 1 Cable, modem card to system
10 56P1919 1 Standoff, modem card
11 *56P2416 1 Card asm, system
12 56P1908 1 Cover asm, middle
13 56P1911 1 Tray asm, paper
14 56P1910 1 Cover asm, cartridge access
15 56P1909 1 Extender, output bin
16 *56P2418 1 Cable, scanner to system
17 *56P2417 1 Card asm, scanner
18 56P1901 1 Drive asm, main
19 56P1912 1 Cover, left, w/speaker
20 56P1985 1 Cable, main drive ground
21 56P1903 1 Cable, printhead
7-6 Service Manual
4038-001
Assembly 3: Frame assembly

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Parts catalog 7-7
4038-001
Assembly 3: Frame assembly
31 56P1963 1 LED, pre-transfer
2 56P1965 1 Bearing, left transfer roller
3 56P1966 1 Spring, transfer roll bearing
4 56P1917 1 Roller asm, transfer
5 56P1967 1 Bearing, right transfer roller
6 56P1964 1 Lens, pre-transfer LED
7 56P1979 1 Fuser, complete, 110 V
8 56P1968 1 Roller, registration
9 56P1970 2 Spring, registration roller
10 56P1969 2 Bearing, registration roller
11 56P1953 2 Spring, cartridge latch
12 56P1948 4 Contact, high voltage
13 56P1949 1 Cover, HV contact
14 56P1950 1 Latch, paper tray
15 56P1951 1 Actuator, cover open
16 56P1947 2 Foot, rubber
17 56P1952 1 Latch, right cartridge
18 56P1954 1 Latch, left cartridge
19 56P1958 1 Contact, transfer roll
20 56P1957 1 Actuator, manual paper feed
21 56P1959 1 Roller, main paper feed
22 56P1955 1 Actuator, paper feed
23 56P1956 1 Actuator, paper empty
24 56P1960 5 Bearing, feed roller
25 56P1961 1 Roller, paper tray feed
26 56P1962 1 Roller asm, paper tray pick
27 56P1978 1 Gear, roller idler
28 56P1976 2 Coupling, shaft
29 56P1977 1 Gear, registration roller
30 56P1973 1 Gear asm, pick roll
31 56P1972 1 Solenoid, main paper feed
32 56P1971 1 Solenoid, paper tray pick roll
7-8 Service Manual
4038-001
Assembly 3 (cont.): Frame assembly
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Parts catalog 7-9
4038-001
Assembly 3 (cont.): Frame assembly
33 56P1975 1 Clutch asm, main paper feed
NS 1339526 1 Line cord, US, Canada, Mexico, Costa
Rica, Guatemala, Panama, Puerto Rico,
Honduras, Nicaragua, El Salvador,
Dominican Republic
NS 1339527 1 Line cord, Australia, New Zealand
NS 1339528 1 Line cord, Hong Kong, Malaysia,
Singapore, Ireland, UK
NS 1339529 1 Line cord, Austria, Belgium, Czech/Slav,
Finland, France, Germany, Greece,
Hungary, Iceland, Italy, Luxembourg,
Netherlands/Holland, Norway, Poland,
Portugal, Russia, Spain, Sweden, Turkey,
Brazil (HV) Paraguay
NS 1339531 1 Line cord, Switzerland
NS 1339532 1 Line cord, Sri Lanka, South Africa
NS 1339533 1 Line cord, Chile, Uruguay
NS 1339534 1 Line cord, Denmark
NS 1339544 1 Line cord, Argentina
NS 1339548 1 Line cord, Brazil (LV)
NS 43H5545 1 Line cord, China
NS 7372151 1 Packaging, field relocation
7-10 Service Manual
4038-001
Index-1
4038-001
Index
A
abbreviations 1-10
abnormal image prints 2-29
back side contamination 2-29
black spots 2-29
horizontal shock lines 2-29
white or black spots/voids 2-29
Adobe Illustrator
illustrations print incorrectly 2-15
C
card stocks 1-2
cleaning the machine 1-5
inside 1-6
outside 1-5
photoconductor drum 1-9
scan unit 1-8
clear all memory 3-1
configuration modes 3-1
clear all memory 3-1
dial mode 3-2
error rate 3-2
modem speed 3-3
park CCD module 3-4
print properties 3-5
send level 3-7
system settings report 3-7
contrast
for copying 3-19
customizing settings 3-18
advanced 3-21
content 3-18
darkness 3-19
number 3-19
scale 3-20
D
dial mode 3-2
DRAM memory test 3-8
drum
clean 1-9
E
envelopes 1-2
error message 2-2
bypass jam 2-2
door open 2-3
fuser error 2-4
jam 2-3
load bypass 2-4
LSU error 2-4
memory full 2-4
no cartridge 2-4
no paper 2-4
open heat error 2-5
overheat 2-5
paper jam 2-6
paper jam 1 2-7
paper jam 2 2-8
power failure 2-8
time/date prompt 2-9
toner empty 2-9
toner low 2-9
error rate 3-2
F
faxing problems 2-19
#s in memory dial incorrectly 2-19
blank areas at bottom of page 2-20
buttons not working 2-19
docs not stored in memory 2-20
document does not feed 2-19
does not send 2-19
fax received with poor quality 2-19
incoming fax blank spaces 2-19
incoming fax stretched words 2-20
lines on documents sent 2-20
no dial tones 2-19
no display 2-19
not connected to another fax 2-20
not received automatically 2-19
not working 2-19
Index-2 Service Manual
4038-001
L
labels 1-2
Laser notices vii
class 1 label viii
laser notices
advisory label vii
locations 5-1
ADF paper path 5-14
cross-section of machine 5-3
engine paper path/paper jams 5-15
front view 5-1
HVPS/LVPS card 5-6
modem card 5-8
operator panel 5-4
operator panel card 5-9
rear view 5-2
scanner card 5-10
system board 5-12
M
machine tests 3-8
DRAM memory 3-8
modem 3-9
modem protocol log 3-9
motor, fan, solenoid 3-10
operator panel button 3-11
operator panel test 3-12
print quality pages 3-14
printhead test 3-13
ROM memory 3-15
scanner CCD and motor 3-16
sensor 3-16
maintenance approach 1-9
modem protocol log test 3-9
modem speed 3-3
modem test 3-9
motor, fan, solenoid test 3-10
O
operator panel button test 3-11
operator panel test 3-12
P
paper feed problems 2-11
blank copies 2-16
copies too dark 2-16
copies too light 2-16
copy image skewed 2-16
envelopes skew 2-12
frequent jams 2-17
half of page is blank 2-14
illustrations print incorrectly 2-15
image rubs off easily 2-16
LCD does not turn on 2-15
low copies from cartridge 2-17
machine does not print 2-13
marks, spots on copies 2-16
multiple sheets do not feed 2-11
paper does not feed 2-12
paper keeps jamming 2-12
paper skews or buckles 2-11
paper sticks together 2-11
print job slow 2-14
repeated error with USB 2-15
smears, lines on copies 2-16
text garbled 2-14
text incomplete 2-14
text wrong 2-14
transparencies stick together 2-12
park CCD module 3-4
part number index X-5
photoconductor drum
cleaning 1-9
plain paper 1-2
print materials 1-2
paper 1-3
selecting 1-2
speciality media 1-3
print properties 3-5
extras 3-6
graphics 3-6
layout 3-6
paper 3-6
Index-3
4038-001
print quality checks 2-21
back of printout dirty 2-24
back side contamination 2-29
background in print area 2-26
background scatter 2-23
black or dark image 2-25
black spots 2-29
black spots/voids 2-29
black vertical band 2-21
blank page prints 2-28
blurry horizontal stripes 2-22
character voids 2-25
curl or wave 2-24
dark horizontal stripes 2-22
dark spots periodically 2-22
faded areas 2-21
gray background 2-26
horizontal shock lines 2-29
image occurs at intervals 2-26
loose toner 2-25
misformed characters 2-23
page skew 2-23
print density uneven 2-25
printed image light 2-24
thin black vertical line 2-21
toner smear 2-22
vertical white streak 2-21
white spots periodically 2-22
white spots/voids 2-29
wrinkles and creases 2-24
print quality pages test 3-14
printhead test 3-13
R
removals 4-1
ADF, pad 4-17
ADF, pick roller 4-16
card cage 4-24
CCD module assembly 4-18
covers, cartridge access 4-1
covers, left side 4-11
covers, middle 4-3
covers, rear 4-5
covers, right side 4-14
covers, scanner assembly 4-7
fan 4-30
fuser 4-31
HVPS contact 4-32
LVPS/HVPS card 4-33
main drive assembly 4-36
main feed roller solenoid 4-41
main paper feed roller 4-38
manual paper feed sensor 4-44
modem card 4-46
operator panel 4-49
paper empty sensor actuator 4-51
paper feed sensor actuator 4-53
paper tray feed roller 4-55
paper tray pick roller asm 4-56
paper tray solenoid 4-60
printhead 4-62
scanner assembly 4-63
scanner assembly cushion 4-70
scanner assembly hinge 4-71
scanner card assembly 4-67
system board 4-72
transfer roll 4-75
ROM memory test 3-15
S
safety information xvii
scan unit
cleaning 1-8
scanner CCD module/motor test 3-16
scanning problems 2-18
does not work 2-18
very slow 2-18
sensor test 3-16
service checks 2-30
cooling fan 2-30
dead machine 2-32
document cover open switch 2-31
main drive motor 2-31
oper panel, scanner card asm 2-33
T
tools 1-9
transparency films 1-2
U
USB connection
error occurs repeatedly 2-15
Index-4 Service Manual
4038-001
Part number index-5
4038-001
Part number index
P/N Description Page
1339526 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339527 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339528 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339529 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339531 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339532 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339533 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339534 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339544 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
1339548 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
43H5545 Line cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
56P1901 Drive asm, main . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1902 Printhead, complete . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1903 Cable, printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1904 Card asm, LVPS/HVPS - 110 V . . . . . . . . . . . . . . . . 7-5
56P1906 Cable, system to power supply . . . . . . . . . . . . . . . . 7-5
56P1908 Cover asm, middle . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1909 Extender, output bin . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1910 Cover asm, cartridge access . . . . . . . . . . . . . . . . . . 7-5
56P1911 Tray asm, paper . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1912 Cover, left, w/speaker . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1913 Cover, right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1914 Cover asm, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1915 Fan, cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1916 Cable, main drive motor . . . . . . . . . . . . . . . . . . . . . 7-5
56P1917 Roller asm, transfer . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1918 Card asm, modem (Americas) . . . . . . . . . . . . . . . . . 7-5
56P1919 Standoff, modem card . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P1922 Roller, ADF idler . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1923 Kit asm, ADF pick roll/pad . . . . . . . . . . . . . . . . . . . . 7-3
56P1931 Cover asm, ADF access . . . . . . . . . . . . . . . . . . . . . 7-3
56P1932 Cushion, document cover . . . . . . . . . . . . . . . . . . . . 7-3
Part number index-6 Service
4038-001
56P1933 Hinge, document cover . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1934 Panel asm, operator . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1935 Overlay, menu/select/return . . . . . . . . . . . . . . . . . . 7-3
56P1936 Overlay, main . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1940 Module asm, CCD . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1941 Cable, CCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1947 Foot, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1948 Contact, high voltage . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1949 Cover, HV contact . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1950 Latch, paper tray . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1951 Actuator, cover open . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1952 Latch, right cartridge . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1953 Spring, cartridge latch . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1954 Latch, left cartridge . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1955 Actuator, paper feed . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1956 Actuator, paper empty . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1957 Actuator, manual paper feed . . . . . . . . . . . . . . . . . . 7-7
56P1958 Contact, transfer roll . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1959 Roller, main paper feed . . . . . . . . . . . . . . . . . . . . . 7-7
56P1960 Bearing, feed roller . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1961 Roller, paper tray feed . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1962 Roller asm, paper tray pick . . . . . . . . . . . . . . . . . . . 7-7
56P1963 LED, pre-transfer . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1964 Lens, pre-transfer LED . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1965 Bearing, left transfer roller . . . . . . . . . . . . . . . . . . . 7-7
56P1966 Spring, transfer roll bearing . . . . . . . . . . . . . . . . . . . 7-7
56P1967 Bearing, right transfer roller . . . . . . . . . . . . . . . . . . 7-7
56P1968 Roller, registration . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1969 Bearing, registration roller . . . . . . . . . . . . . . . . . . . . 7-7
56P1970 Spring, registration roller . . . . . . . . . . . . . . . . . . . . . 7-7
56P1971 Solenoid, paper tray pick roll . . . . . . . . . . . . . . . . . . 7-7
56P1972 Solenoid, main paper feed . . . . . . . . . . . . . . . . . . . 7-7
56P1973 Gear asm, pick roll . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1975 Clutch asm, main paper feed . . . . . . . . . . . . . . . . . 7-9
56P1976 Coupling, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1977 Gear, registration roller . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1978 Gear, roller idler . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1979 Fuser, complete, 110 V . . . . . . . . . . . . . . . . . . . . . 7-7
Part number index-7
4038-001
56P1980 Fuser, complete, 220 V . . . . . . . . . . . . . . . . . . . . . . 7-7
56P1983 Scanner, complete . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
56P1984 Cable, modem card to system . . . . . . . . . . . . . . . . . 7-5
56P1985 Cable, main drive ground . . . . . . . . . . . . . . . . . . . . . 7-5
56P1986 Card asm, modem (West Europe) . . . . . . . . . . . . . . 7-5
56P1987 Card asm, modem (S. Africa) . . . . . . . . . . . . . . . . . . 7-5
56P1988 Card asm, modem (Asia) . . . . . . . . . . . . . . . . . . . . . 7-5
56P1989 Card asm, modem (Australia) . . . . . . . . . . . . . . . . . 7-5
56P1990 Fuser, complete, 240 V . . . . . . . . . . . . . . . . . . . . . . 7-7
56P2416 Card asm, system . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P2417 Card asm, scanner . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
56P2418 Cable, scanner to system . . . . . . . . . . . . . . . . . . . . 7-5
7372151 Packaging, field relocation . . . . . . . . . . . . . . . . . . . . 7-9
Part number index-8 Service
4038-001

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