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4048-1xx Lexmark T430 Service Manual

1. Connector Name of Pins Pin Signal To controller CN1 connects 8 2 Ground card to J19 on the controller card 4 24 V dc 7 5 V dc C Charge roll Terminal DC Photoconductor Contact T Transfer roll Contact DEV Development Contact roll TAR Toner adder roll Contact Dr B Doctor blade Contact 5 8 Service Manual 4048 1 xx 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems and maintain optimum performance Safety inspection guide This guide is to aid you in identifying unsafe conditions AN If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items e Damaged missing or altered parts especially in the area of the on off switch and the power supply e Damaged missing or altered covers especially in the area of the top cover and the power supply cover e Possible safety exposure from any non Lexmark attachments Lubrication specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts
2. Lex Qui Pri Pa Repair information 4 3 4048 1 xx 5 After obtaining a properly adjusted image on the paper tighten all three screws 6 After adjusting the printhead if necessary adjust registration of the left right top and bottom margins See REGISTRATION on page 3 4 Note Printhead misalignment results in skewed horizontal lines but a consistent margin top to bottom of page Paper feed misalignment results in entire image rotated on the paper See Adjusting paper feed alignment skew on page 4 5 4 4 Service Manual 4048 1xx Adjusting paper feed alignment skew When a reference feed assembly is removed it requires realignment Use a long shank 6 inches Phillips screwdriver to adjust the rear screw holding the assembly in place It is accessed through the hole in the main drive assembly It is between the controller card cage and the main motor board Adjust the screw counterclockwise which rotates paper counterclockwise in the printer path image clockwise and vice versa Verify alignment by printing the Quick Test page 1 Enter the Diagnostic Menu See Entering Diagnostic Mode on page 3 2 2 Select Print Tests from the Diagnostic Menu 3 Select Tray 1 4 Select Single The Quick Test prints Repair information 4 5 4048 1 xx Lubrication Several FRUs must be lubricated when installed The follo
3. 7 13 56P2324 Drawer cable assembly 7 15 56P2325 Main drive motorassembly 7 5 56P2326 Drive assembly 4 6 7 5 56P2327 Exit gear drive assembly 4 7 7 5 56P2328 Right guide assembly 7 11 56P2329 Transfer roll assembly 6 2 7 11 1 8 Service Manual 4048 1xx 56P2330 Fuser assembly 110 V 6 2 7 9 56P2331 Fuser assembly 220 V 6 2 7 9 56P2332 Fuser assembly 100 V 6 2 7 9 56P2333 110 V maintenance kit 6 2 7 22 56P2334 Paper feed drive bushing 7 5 56P2335 Main harness cable assembly 7 13 56P2336 Output full and fuser exit cable assembly 7 15 56P2337 220 V maintenance kit 6 2 7 22 56P2338 100 V maintenance kit 6 2 7 22 56P2339 Power supply 100 V 7 13 56P2340 Left guide assembly 7 11 7 13 56P2341 Customer replaceable CRU charge roll 7 11 7 22 56P2342 Language overlay group 7 3 56P2343 Clear bezel withlogo 7 3 56P2344 Tray assembly 250 s
4. 2 16 Service Manual 4048 1xx User attendance messages continued Message Explanation 37 Insufficient Collation Area This message displays when the printer memory is insufficient to perform the Flash Memory Defragment operation Note This message is posted prior to the actual start of the defragment operation The printer code determines if enough printer memory is available to complete the defragment operation The user should not be concerned with losing resources stored in the flash option The following actions may be taken Press Go to clear the message Press Menu until Busy Waiting appears The following actions are available Cancel Job Reset Printer 37 Insufficient Defrag Memory This message displays when the printer memory is fragmented Defragmentation is required and additional memory is required to complete the task Press Go to clear the message Defragmentation will not continue and no changes are made to memory and no resources are lost e Press Menu until Busy Waiting appears The following functions may be available Cancel Job Reset Printer The user may clear memory for a defragmentation by Deleting fonts macros and other data in RAM Installing additional memory Diagnostic information 2 17 4048 1xx User attendance messages continued Message Explanation 37 Insufficient Memory Held Jobs may be lost
5. 7 21 56P3305 PRESCRIBE card assembly 7 21 70G0478 Power cord 7 17 7370971 Field relocation kit 7 22 99A0394 Lubricant Nyogel 744 4 6 6 1 6 2 7 5 7 8 99A0462 Lubricant IBM 23 4 6 99A0545 External serial adapter 7 21 4048 1 xx I 10 Service Manual x s EB 3 5 Sle i amp lsezzz a Y SS m S430 19 Printhead Lexmark T430 Wiring diagram 110Vac di Mirror Motor Sensor Exit Tray Full Sensor Exit Sensor E Frame V connector Li T2 3 4 5 6 Gnd 5V dc Loeis Is KBEN OI 7TeIs 4 3 1 J5 o J6 MPF Solenoid 5V XPRT 24Vdc Le TeT5 4 3 2T BLIEBEN EISE 5 MPF Paper 2 H Sensor Gnd I Toner Low oL Low Voltage Sensor Power Supply CN1 Feed Bin Full j u LLL Frame
6. Diagnostic information 2 57 4048 1 xx Problem Action The Toner Low message appears Solid black areas on transparencies or paper contains white streaks Remove the print cartridge and gently shake it from side to side to redistribute the toner Replace the cartridge Choose a different fill pattern in your software application Try a different type of paper Paper designed for copiers gives the best quality Remove the print cartridge and gently shake it from side to side to redistribute the toner Replace the cartridge Faint images or repetitive spots appear on the page Select a different media type or form type setting from your printer driver Try a different type of paper Paper designed for copiers gives the best quality Replace the print cartridge Pages are blank The print cartridge may be out of toner or defective Replace the cartridge You may have a software error Try turning the printer off and back on Check the photoconductor circuit for continuity Check the printhead The media skews or buckles Don t overfill tray 1 or the optional tray 2 see media capacities in the media types and sizes table in the User s Reference Make sure the paper guides are flush against the edges of the media The paper sticks together printer feeds multiple sheets of paper Remove the paper from tray 1 or the optional tray 2 and fan the paper
7. Diagnostic information 2 59 4048 1 xx Problem Action Unexpected characters print or characters are missing Make sure you are using the correct printer driver Select hex trace mode to determine what the problem is To turn on hex trace 1 Select UTILITIES MENU from the READY MENU 2 Select Hex Trace To exit Hex Trace select Reset Printer from the JOB MENU or turn the printer off Restore factory defaults See Factory Defaults on page 3 24 for more information Make sure the parallel cable or USB cable is firmly plugged in at the back of the printer 2 60 Service Manual 4048 1 xx 3 Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem Additional service menus Several service menus are available by selecting particular keys during POR Diagnostics 1 Press and hold Go The Diagnostics Mode group Mode and Return contains the settings and 2 Turn on the printer Operations used while 3 Release the buttons manufacturing and servicing the whenPerforming Printer self Test See Diagnostics Mode on displays page 3 2 for more information Configuration 1 Press and hold The Configuration Menu group Menu Select and Return contains a set of menus settings 2 Turn on the printer and operations which are 3 Release the buttons infrequently required by a us
8. Optional drawers Note When two optional drawers are installed the first must be a 250 sheet drawer 250 sheet drawer e 500 sheet drawer The 500 sheet drawer supports the following sizes A4 JIS B5 folio letter legal and executive Maximum number of media input sources 4 4 Maximum input sheet capacity excluding 1000 1000 envelopes Maximum sheet capacity excluding envelopes 150 150 V Indicates associated capability is supported Assumes 20 Ib xerographic paper 1 8 Service Manual Input media sources 4048 1 xx gt x x c gt o o e o 85 3 au g du x UT 5 hi 5 x o Oo lt za lt me 9 Supported input sizes 52 a9 S 9 7 E 25 2a zo 2 c 2c aT to 5 0 0 Lv i5 I 1 a S 8 N i o Letter 4 V V v V 11x17 Legal A4 A3 A5 Folio V YA Statement JIS B4 JIS B5 V Executive 4 Universal WA 7 3 4 envelope V 9 envelope V 10 envelope VA DL envelope V C5 envelope 4 B5 envelope YA Other envelope V 4 Size supported without size sensing General information 1 9 4048 1 xx Output media Supported output sizes Letter 150 sheet standard bin V 20 sheet rear exit v A4 v V Legal 11x17 A3 Folio Statement A5 JIS B4 JIS B5 Executive Universal 7 3 4 envelope 9 envelope 10 enve
9. 5 Open the rear cover and remove the second screw down from the top left corner B mm TT FM LL je LI mO 6 Pull the top of the right cover away from the printer slightly 4 12 Service Manual 4048 1xx 7 Unlatch the cover from the frame behind the front of tray C 8 Remove the cover The MPF door may need to be lifted slightly for the side cover to clear Repair information 4 13 4048 1 xx Left side cover removal 1 Open the front cover and the MPF door 2 Disengage the two latches A located in the front and top 3 Swing the left side cover away from the printer 4 14 Service Manual 4048 1xx Rear cover removal 1 Remove the paper tray 2 Remove the right side cover See Right side cover removal on page 4 12 3 Remove the left side cover See Left side cover removal on page 4 14 4 Disconnect the sensor cable in line connector A below the lower left corner of the controller cage Note Be sure to reconnect the sensor cable when reinstalling the rear cover The printer fails to operate without this connection Repair information 4 15 4048 1 xx 5 Open the exit tray rear door 6 Remove the five remaining screws B There are a total of six 7 Lift the top cover slightly with one hand while pulling out on the rear cover Installation notes Handle carefully Do not touch the rollers When reinstalling the rear cover position t
10. 7 15 56P0667 Door latch niemeer aeri na ee es 7 7 56P0668 Parts packet screws and E rings 7 7 7 11 56P0669 Pivothinge ssseseseeleeee ee 7 11 4048 1xx 56P0672 Tray body bracket includes 4 7 7 56P0676 Fuser exit spring lisi 7 9 56P0682 Output full sensor cable 7 15 56P0694 4MB SDRAM DIMM 7 21 56P0695 8MB SDRAM DIMM 7 21 56P0696 16MB SDRAM DIMM 7 21 56P0697 32MB SDRAM DIMM 7 21 56P0698 64MB SDRAM DIMM 7 21 56P0699 128MB SDRAM DIMM 7 21 56P1417 16MB flash card assembly 7 21 56P1418 32MB flash card assembly 7 21 56P1427 Optra Forms 32 MB flash card assembly 7 21 56P1428 Optra Forms 16 MB flash card assembly 7 21 56P 1429 Simplified Chinese font card assembly 7 21 56P 1430 Traditional Chinese font card assembly 7 21 56P1438 Japanese font card assembly 7 21 56P2231 Korean font card assembly 7 21 56P2300 Left cover assembly 7 3 56P2301 Reareritdoorassembly 7 3 56P2302
11. 917 Transfer roll The most likely cause is a faulty HVPS It may also indicate a problem in the transfer roll area Go to Transfer roll service check on page 2 44 920 Fuser error Indicates that the fuser is below temperature when printing Go to Fuser service check on page 2 40 922 Fuser error Fuser failed to reach standby temperature Verify line voltage to the fuser Go to Fuser service check on page 2 40 2 6 Service Manual 4048 1xx Service error codes 9xx continued Error Description Action 923 Fuser error Fuser is too hot during printing or when printer is idle Go to Fuser service check on page 2 40 924 Fuser error An open circuit has been detected in the fuser thermistor circuit Check cabling and connectors Go to Fuser service check on page 2 40 929 Toner sensor The toner sensor is not operating properly the developer drive assembly is not operating properly or the print cartridge is defective Go to Sensor Test on page 3 12 931 Printhead no first Check for unplugged printhead faulty hysnc cabling or faulty printhead 932 Printhead lost hsyncs Replace the printhead 934 Mirror motor lost lock Replace the printhead 935 Mirror motor unable to Faulty printhead cabling or connector reach operating speed 936 Transport motor initial Indicates a problem with the main drive lock failure motor or a jam occurred durin
12. Don t overfill tray 1 or the optional tray 2 see media capacities in the media types and sizes chart in the User s Reference 2 58 Service Manual 4048 1xx Problem Action The paper fails to feed from tray 1 or tray 2 Remove the paper from tray 1 and fan the paper Make sure tray 1 is selected from the printer driver Do not overfill the tray The paper fails to feed from the optional tray 2 or tray 3 Make sure the printer recognizes the optional trays POR the printer and check the cables Make sure the optional tray 2 is selected from the printer driver Remove the paper from the optional tray 2 and fan the paper Make sure the tray is pushed all the way in Make sure the metal plate is pressed down before inserting the tray into the printer Note Once the tray is inserted the metal plate springs up so the paper can feed into the printer Make sure the paper does not exceed the stack height indicator Make sure the paper is under both corner bucklers see loading paper in the User s Reference The Load Paper displays even though there is paper loaded in the optional tray 2 or tray 3 Make sure the tray is pushed all the way in Press Go The printer does not print after a paper jam has been cleared Press Go or open and close the printer front cover to restart the printer Make sure the print cartridge is installed properly
13. Main motor service check FRU Action Main motor Main motor cable Controller card assembly With the printer on verify 24 V dc on pin 7 at J10 on the controller card assembly If the voltage is correct check the main motor cable for continuity f continuity exists on each wire replace the main motor f continuity does not exist on one or more of the wires replace the motor cable If the voltage is not correct verify 24 V dc on pins 1 and 2 on J17 f voltage is correct replace the controller card f the voltage is not correct check the LVPS Note Always check printhead alignment after replacing the controller card assembly See Printhead assembly adjustment on page 4 2 for hardware alignment of the printhead 2 42 Service Manual 4048 1 xx Operator panel service check Warning Never replace both the operator panel and controller card at the same time Otherwise some critical settings will be permanently lost Inspect the operator panel cable for damage Make sure the cable is plugged in securely Run POST and check for proper operation See Power On Reset POR sequence on page 2 2 FRU Action Operator panel If the buttons do not depress or click when Operator panel cable pressed replace the operator panel Controller card If the operator panel does not illuminate turn assembly the printer off and unplug J5 on the controller car
14. RAM Data 00 Error RAM Data 55 Error 3 8 Service Manual 4048 1 xx DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error False Init Fail Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Failing Interrupt Error Clear Autofeed Fail Error 6 Once the maximum count is reached the test stops The power indicator goes on solid and the final results display 7 Press Return or Stop to exit the test DUPLEX TESTS Quick Test This test is used to verify that the duplex Top Margin is set correctly This test prints a duplexed version of the Quick Test page that can be used to adjust the Top Margin for the backside of the duplexed page Since you are measuring the margin on the back of a duplex sheet to the front make sure you adjust the Top Margin for a single sheet See REGISTRATION on page 3 4 Use either letter or A4 paper to run the test Quick Test Printing lt media width gt If wider or narrower paper is used media width appears with either W for wide or N for narrow paper To run the Duplex Quick Test 1 Select Duplex Tests from Diagnostics Mode 2 Select Quick Test Diagnostic aids 3 9 4048 1xx 3 Select Single to print a single duplex page or Continuous to continue printing until Return or Stop is pressed The printer attempts
15. Display Log Print Log Clear Log Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode Diagnostic aids 3 3 4048 1 xx REGISTRATION To set print registration 1 Select REGISTRATION from the Diagnostics menu The Top margin sign value pair blinks This indicates it is the margin value being changed T SXX B SXXxX L Sxx Resxx 2 To select the margin value to be changed press Select until the margin value pair you want to change is blinking The print registration range is Variable Description Value S sign blank for positive values for negative values B Bottom margin 20 to 20 Each increment causes approximately 0 55 mm shift in the bottom margin T Top margin 16 to 16 L Left margin 25 to 25 R Right margin 10 to 10 3 To change the margin value press Menu When the value you want displays press Select to save the value To verify the margin values are correct you must print the Quick Test page Press Go to print the test page While printing Quick Test Printing displays Once the Quick Test page completes printing the registration screen displays again 4 To exit press Return 5 Test the setting by printing the Quick Test page for all the source see PRINT TESTS on page 3 5 Select all the available sources To test the Duplex sources see DUPLEX TESTS on page 3 9 Print the Quick Test Page on
16. Netherlands Norway Paraguay Poland Portugal Romania Russia and CIS Slovak countries Slovenia Spain Sweden Syria Turkey Yugoslavia Serbia and Montenegro HV Power cord Israel HV Power cord Switzerland HV Power cord Lybia Pakistan South Africa HV Power cord Chile Uruguay HV Power cord Denmark HV Power cord PR China HV Power cord Brazil LV Power cord Argentina Power cord U S HV RPQ Parts catalog 7 17 4048 1 xx Assembly 9 Sensors 7 18 Service Manual Assembly 9 Sensors 4048 1xx Asm Pan Units Description index numbers 9 1 56P0645 1 Photo sensor locations found A Paper path exit flag B Fuser exit sensor C Paper path below cartridge D Paper path duplex E Paper path MPF F Paper path below cartridge 2 56P0653 1 Toner level sensor 3 56P2350 1 Cartridge signature button switch Parts catalog 7 19 4048 1 xx Assembly 10 Options 7 20 Service Manual Assembly 10 Options 4048 1xx mu pi Units Description 10 1 56P2346 1 Drawer assembly 250 T2 and base 2 56P2344 1 Tray assembly 250 sheet T2 3 56P2347 1 Drawer assembly 500 T3 and base 4 56P2345 1 Tray assembly 500 sheet T3 NS 56P0694 1 4MB SDRAM DIMM NS 56P0695 1 8MB SDRAM DIMM NS 56P0696 1 16MB SDRAM DIMM NS 56P0697 1 32MB SDRAM DIMM NS 56P0698 1 64MB SDRAM DIMM NS 56P0699 1 128MB SDRAM DIMM NS 56P2361 1 256MB PC100 kit DIMM NS 56P
17. See Operator panel service check on page 2 43 or Controller card service check on page 2 38 Operator panel light does not light or is very dim See Controller card service check on page 2 38 Diagnostic information 2 5 4048 1 xx Messages and error codes Service error codes Service error codes are generally non recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition Service error codes 9xx Error Description Action 900 RIP software Server firmware problem Contact the next level of support 902 General engine An unrecoverable system software error software failure Reset the printer POR If the problem continues replace the controller card 910 DC exit motor stall The load on the exit motor is too high or there is a cabling problem First check for 911 DC exit motor jams and then move the exit rollers located between the rear door and fuser 912 DC exit motor below while observing the DC motor If the speed torque is too high isolate the problem to the redrive and repair or replace as 913 DC exit motor over necessary If the torque seems normal speed check the cabling for continuity and replace the motor with cabling 914 DC pick motor no Verify motor is plugged into controller encoder feedback card correctly Also check load condition see service error 910 above
18. This menu item only displays if a downloaded emulator is installed To disable downloaded emulations 1 Select Download Emuls from CONFIG MENU 2 Select Disable The printer performs POR and starts as if the downloaded emulations were not loaded To reactivate downloaded emulations restart the printer Demo Mode This menu item lets you turn demo mode on or off 1 Select Demo Mode from CONFIG MENU 2 Select Activate to turn the demo mode on or Deactivate to turn demo mode off Factory Defaults This menu lets you restore the printer settings to their factory default values 1 Select Factory Defaults from the Configuration Menu 2 Select either Restore Base or Restore Network Restore Network is only available if an integrated network adapter is installed 3 24 Service Manual 4048 1 xx NARROW MEDIA The narrow media sensor automatically detects media which is less than 6 77 in long 72 mm and imposes maximum speed restrictions This setting also reduces speed for narrow paper less than 8 in 203 mm not narrow enough for the sensor to detect Reducing the speed prevents damage to the fuser Menu item Selections Plain Width Normal or Narrow Card Stock Width AA Transprncy Width Labels Width Bond Width Letterhead Width Preprinted Width Colored Width Envelope Width Custom x Width x 1 6 Energy Conserve Select On to allow access to the Power Saver menu If you sel
19. This message displays when there is not enough memory available to continue processing a job and Print and Hold feature is in use The printer frees memory by deleting the oldest Reserve Print and Verify Print jobs It deletes only the amount needed to continue the incoming job Some or all of the jobs may not be restored If while printing the current job it runs out of memory again another message is not posted Press Go to clear the message Some of the Print and Hold jobs on the disk will not be restored They remain on the disk but cannot be accessed e Press Menu until Busy Waiting appears The function Reset Printer may be available 38 Memory Full This message displays when the printer is processing an incoming job and there is insufficient memory available to continue processing the job The following actions may be taken Press Go to clear the message Perform the defragment operation Simplify the print job Delete fonts macros and other data in RAM Install additional memory e Press Menu to display Busy Waiting The following functions may be available Cancel Job Reset Printer 39 Complex Page This message displays when the page is too complex to print The following actions may be taken Press Go to clear the message and continue the job Some data loss may occur Simplify the print job and reprint if necessary e Press Menu until Busy Waiting appears The foll
20. if not already removed 2 Remove the print cartridge 3 Tilt the printer onto its back 4 Remove the five screws A holding the bottom pan 5 Remove the bottom pan Repair information 4 25 4048 1 xx Fuser assembly removal 1 Unplug the printer A N 2 Remove the left side cover See Left side cover removal on page 4 14 3 Remove the right side See Right side cover removal on page 4 12 4 Remove the rear cover See Rear cover removal on page 4 15 5 Disconnect the thermistor and exit sensor cables A at the printer frame to the right of the fuser 6 Disconnect the fuser from the LVPS B on the left side and free the cables from the printer frame 4 26 Service Manual 4048 1xx 7 Using a long shank Phillips screwdriver remove the four screws C which fasten the fuser metal frame to the printer frame 8 Carefully slide the fuser out while pressing the duplex diverter Non duplex models do not have the diverter The front cover door must be closed to remove the fuser Repair information 4 27 4048 1 xx Installation notes During reassembly of the fuser keep the front door closed to prevent separation of the roller in the fuser Be sure to route the cables through the frame and through the cable retainer D 4 28 Service Manual 4048 1xx Fuser paper exit guide assembly removal AA 1 Unplug the printer 2 Remove the left side cover See Left
21. or controller card HVPS assembly See Controller card service Controller card check on page 2 38 and verify 24 V dc on assembly pin 5 at J1 and 5 V dc on pin 7 at J3 Verify Cartridge contacts ground on pin 4 at J1 and on pin 6 at J3 If assembly these are not correct replace the controller card See Controller card assembly removal on page 4 50 If the voltages are correct check the printhead cable for continuity f the cable has continuity replace the printhead See Printhead removal on page 4 46 f the cable does not have continuity replace the cable With the cartridge removed and the printer off check continuity between HVPS DC designation on outer side of card and the PC pin inside the printer The PC pin is directly above the transfer roll gear Replace the cartridge contacts as necessary See High voltage power supply HVPS on page 5 8 Verify input voltages of 24 V dc pin 4 and 5 V dc pin 7 f incorrect verify the continuity of the cable Replace if necessary Note Pins 1 8 on the HVPS correspond to pins 4 11 respectively of J19 on the controller card e f correct replace the HVPS only after verifying all the above items 2 50 Service Manual 4048 1xx Black page Note Incorrect laser exposure or incorrect charging of the photoconductor by the charge roll causes an all black page FRU Action HVPS contacts Check the contacts for contamina
22. tray s service check on page 2 64 2 14 Service Manual 4048 1xx User attendance messages continued Message Explanation Load lt input source gt lt type gt lt size gt Input source Tray 1 Tray 2 Tray 3 or MP Feeder Type Bond Cardstock Colored Envelope Labels Ltrhead Plain Preprint Trnsprncy Size letter legal B5 A4 A5 Exec Univ Folio or Stmt The following actions may be taken Load media in the indicated source e Press Menu until Busy Waiting displays Select one of the following Cancel Job Reset Printer If the message cannot be cleared go to Input tray s service check on page 2 64 No Jobs Found Retry When a PIN personal identification number is added to a Confidential Print job and there are no jobs associated with the PIN number The following actions may be taken Press Go to enter another PIN Press Return or Stop to exit the PIN entry operation Res Reduced lt warning gt This message displays only when the Resolution Reduction setting is enabled The following actions may be taken Press Stop to take the printer offline No more data is processed but the printer processes all the paper currently in the paper path Press Menu to access the Busy Waiting menu group Select one of the following Cancel Job Reset Printer 31 Missing or Defective Cart The cartridge may be missing and the front door clos
23. until you are ready to install the part into the printer Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the printer Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the printer cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 4048 1 xx Adjustments Printhead assembly adjustment The printhead needs to be co
24. 26 This code indicates that media has activated the input sensor however the printhead fell out of lock condition or expected a stable lock too soon The media may have also reached the input sensor early 200 84 xx 2F xl Xe X9 Laser servo never started due to potential conflict with the transfer servo x1 bit 0 transfer servo started bit 1 transport started x2 x3 transfer servo count value Possible cause is slow or missing transport motor positional feedback 200 2 28 Service Manual Sub error codes continued First 6 bytes sub error code data xx can be any value Explanation 4048 1 xx Possible error message 84 xx 30 00 00 00 Input sensor never became uncovered from page ahead while trying to feed media out of path during warm up Paper originally detected at option tray pass thru sensor Clear the media or debris from the printer Enter Diagnostics and perform the Base Sensor test to verify the proper function of the input sensor See Entering Diagnostic Mode on page 3 2 and BASE SENSOR TEST on page 3 14 200 84 00 08 Paper at input sensor when not expected during printing Possible cause is multiple sheets picked 200 84 00 10 The main motor driver failed to detect a specific motor after two tries Possible causes for this error are The main drive motor has stalled An incorrect main drive motor gearbox assembly has been i
25. 60825 1 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p belgelaengdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Laser notices xi 4048 1 xx Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan IIIb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Al katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r la
26. DE SS RY xiv Service Manual 4048 1xx Korean Laser Notice SHEE 158 olx ASSO CHSt DHHS 21 CFR Subchapter 39 FNS Ato wes oO oA 215900 319 9 ejod 1EC 825 TAS p le 158 Aly BORA 9035S BOS LIC 158 HoH ASSES OMS HOP HFHH PIAS 5 PASE AS ofato alo X aA 770 795 Lj n E 9 IHA SScbe Class Il 3b ajo z amp yoy Zt 9i amp ur amp alo xi ABD zaye AA AS Sol RA E SLE AAS MYA Eno A 7 2 Class FELY alo x HEA Ao Ach 422 T gem So YEHCH Laser notices XV 4048 1 xx xvi Service Manual 4048 1 xx 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 s curit a s curit de ce produit repose sur des tests et des agr
27. Hot fuser service check on page 2 41 Fuser heater does not activate See Cold fuser service check on page 2 41 Toner not fused to the paper See Poor fusing of image on page 2 53 Blank page See Blank page on page 2 50 Black page See Black page on page 2 51 Heavy background See Heavy background on page 2 52 Light print See Light print on page 2 54 White or black lines or bands See White or black lines or bands on page 2 54 Toner on back of page See Toner on back of page on page 2 55 Paper jams See Paper feed service checks on page 2 45 Main motor noisy or does not move See Main motor service check on page 2 42 Paper never picks See Paper never picks on page 2 48 Paper feeds continuously See Paper picks during POST and or continuously on page 2 46 Skewed paper See Note regarding alignment on page 4 64 or Paper feed service checks on page 2 45 2 4 Service Manual 4048 1 xx Symptom Action Printer not communicating with host Paper wrinkled or bent See Paper trees wrinkles See Parallel port service check on page 2 49 stacks poorly or curls on page 2 49 Top cover will not close See Cover interlock switch service check on page 2 37 Operator panel button does not respond
28. Print cartridge Average yield Approximate coverage Lexmark Return Program 6 000 5 print cartridges 12 000 5 Regular cartridges without Lexmark 6 000 5 Return Program terms and 12 000 5 conditions Fonts Fonts options All models PCL bitmapped 2 PCL scalable 89 PostScript scalable 91 PPDS bitmapped 5 PPDS scalable 39 Note Additional fonts can be downloaded to the printer RAM or optional user flash 1 6 Service Manual 4048 1 xx Media and paper handling Media The following table shows the supported media media weights and media textures which together provide optimal print quality across a variety of media Media supported All models Paper v Card stock Transparency Labels Envelope SISIS S S Bond Media weights S Heavy Normal Light Media textures Rough Normal Smooth Note V Indicates media is supported General information 1 7 4048 1 xx Standard and optional paper sources Models Media sources 101 102 111 Standard Standard input sources 2 2 e Integrated 250 sheet tray 1 1 The 250 sheet drawer supports the following sizes A4 A5 JIS B5 folio letter legal executive and statement Multipurpose feeder 1 1 Standard output destination 150 sheet sensing 1 1 bin Duplex standard in models 101 and 102 only VA X Options Maximum of optional drawers 2 2
29. Rear cover assembly 4 7 6 2 7 8 56P2303 MPF door cover assembly 7 3 56P 2304 Stack control flags output tray full flags 7 5 56P2305 Front cover assembly 7 3 56P2306 Top cover assembly 7 3 56P2307 Right cover assembly 7 3 56P2308 Backup feed roller assembly top front and rear 7 5 56P2309 Reference feed CBM 7 5 56P2310 Main tray assembly 250 7 7 56P2311 Lower MPF housing assembly 6 2 7 8 56P2312 Upper MPF housing assembly 7 8 56P2313 Paper feed solenoid 7 15 56P2314 Controller card assembly non network 7 13 56P2315 Controller card assembly network 7 13 56P2316 Motor cableassembly 7 15 56P2317 Operator panel cable assembly 7 15 56P2318 Printhead cable assembly 7 13 56P2319 Printhead assembly 7 7 56P2320 Power supply 110 V 1 ee 7 13 56P2321 Powersupply 220V 7 13 56P2322 High voltage power supply 7 13 56P2323 Fuser cooling fan
30. V1 connector Gnd O Thermistor Doctor Blade Toner Adder Roll Print Cartridge Developer Roll Photo Conductor 1 12151415161713 H12151415161713 High Voltage Power Supply M I Solenoid AC Inlet OI OI OI o o 13 4 5 6 7 8 9 5161778 Tray 2 Bottom view Gnd 24Vdc ex Duplex Sensor Paper In Sensor Narrow Media Sensor
31. ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence AN d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension Safety information xvii 4048 10x Norme di sicurezza e 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 e 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 piu elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo i
32. exit sensor never actuated from the sheet going through the fuser before the next page begins feeding x12media size 202 89 XX OD The fuser exit sensor bounced Check the exit sensor for correct operation Check the sensor cable to J16 on the controller card Also the controller card may be failing 202 89 00 00 00 OE 00 Exit sensor never changed state from sheet ahead of page heading toward exit sensor when feeding out media detected during warm up 202 89 00 00 00 OF 00 Trailing edge never cleared exit sensor when feeding out media that was detected during warm up 202 2 30 Service Manual Sub error codes continued First 6 bytes sub 4048 1 xx x1 source x2 x3 timeout value Possible errorcode data Explanation error xx can be any message value 8D 00 00 The fuser exit sensor was never activated 201 by the leading edge of the media fed through the printer This error can be displayed after a 201 paper jam This can be caused by a defective fuser exit sensor assembly Note Enter the diagnostic tests menu select Base Sensor Tests select Output Sensor Test and check the fuser exit sensor for correct operation If the test fails check the cable connection to J16 on the controller card 8D 00 01 00 User pressed Go or Continue after an 201 00 00 8D xx 00 jam but never opened the top cover Need to open cover and
33. panel diagram 1 3 parts catalog 7 3 removal 4 22 service checks 2 43 operator panel cable 4 20 7 15 options memory 1 5 paper sources 1 8 parts catalog 7 20 output tray full flags parts catalog 7 5 removal 4 18 P packaging 7 22 page count 3 16 Panel Menus 3 23 paper feed alignment 4 5 paper flag MPF 4 66 paper handling options 1 7 paper jams 2 22 3 27 Paper Prompts 3 26 parallel port service check 2 49 Parallel Wrap 3 8 parts catalog cables 7 16 charging 7 10 covers 7 2 electronics 7 16 electronics and cables 7 12 electronics and cables l 7 14 frame 7 6 fuser 7 9 howtouse 7 1 miscellaneous 7 22 multipurpose feeder MPF 7 8 options 7 20 paperfeed 7 4 sensors 7 18 permanent page count 3 16 power cords 7 17 power on reset POR 2 2 power on self test POST 2 3 PPDS Emulation 3 23 l 4 Service Manual Print Contrast 3 17 print quality 1 4 2 56 black page 2 51 blank page 2 50 2 58 does not print 2 59 faintimages 2 58 heavy background 2 52 light or blurred characters 2 56 light print 2 54 Load Paper displays 2 59 media skews 2 58 multiple feeds 2 58 paper fails to feed 2 59 paper sticks 2 58 poor fusing 2 53 solid black areas 2 58 streaks 2 57 Toner Low does not display 2 57 Toner Low message 2 58 toner on back of page 2 55 toner smudges 2 57 unexpected characters print 2 60 variation in image density 2 53 white or black lines or bands 2 54 white streaks 2 58 print quality pag
34. side cover removal on page 4 14 3 Remove the right side See Right side cover removal on page 4 12 4 Remove the rear cover See Rear cover removal on page 4 15 5 Using a long shank Phillips screwdriver remove the four screws A which fasten the fuser metal frame to the printer frame Repair information 4 29 4048 1 xx 6 Carefully slide the fuser out far enough to reach the screw that holds the exit guide B Remove the screw Note Insert the screwdriver through the top cover to access the screw with the minimum fuser movement 4 30 Service Manual 4048 1xx 7 Ease the guide back and forth while sliding it to the left and into the opening in the metal frame to allow the right side to disengage from the frame 8 Swing the right side out enough to clear the metal frame 10 Remove the exit guide assembly Repair information 4 31 4048 1 xx Installation notes During reassembly of the fuser exit guide assembly keep the front door closed to prevent separation of the roller in the fuser Be sure to route the cables through the frame and through the cable retainer C 4 32 Service Manual 4048 1xx Fuser exit sensor removal 1 Remove the fuser paper exit guide See Fuser paper exit guide assembly removal on page 4 29 2 Use your right index finger to push the tangs A of the sensor out of the metal frame 3 Disconnect the sensor from the cable and remov
35. supply LVPS 100 V 110 V or 220 V A Unplug the power cord and verify that the cable is correct and functioning Replace if necessary With the power cord unplugged remove the HVPS fan and disconnect the 8 pin CN2 connector from the LVPS Pin 8 is the topmost pin of the connector Verify pins 2 5 and 6 are ground Replug the power cord and turn the printer on CAUTION Be careful to not ground pins to cage while testing Verify pin 4 is 5 V dc Verify pins 7 and 8 are 24 V dc If any one of these is incorrect replace the LVPS If these are correct check the controller card operator panel and wiring Note A dead machine implies no power beyond the LVPS If the printer behaves dead but has correct power from the LVPS unplug all connectors from the controller card except J18 power from LVPS Turn the printer on If the printer does not beep 5 times replace the controller card If it does beep turn the power off and plug in other devices such as sensors and operator panel one at a time Turn the printer back on and observe any beeps and or operator panel messages This technique may be repeated to help isolate a faulty component or short Diagnostic information 2 39 4048 1xx High voltage power supply HVPS service check FRU Action HVPS Check continuity between the HVPS and the Cartridge charge roll Dr B doctor blade TAR toner adder roll the developer roll a
36. the LCD display test 2 Press Return or Stop to cancel the test Button Test 1 Select Button Test from Diagnostics Mode With no buttons pressed several occurrences of 0P Open appear on the display OP OP OP OP OP OP 2 To test the proper operation of each button press each button on the operator panel one at a time and a CL Closed displays in place of an OP 3 Press Return or Stop to cancel the test 3 6 Service Manual 4048 1 xx DRAM Test The purpose of this test is to check the validity of DRAM both standard and optional The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly To run the SDRAM Memory Test 1 Select DRAM Test from the menu The power indicator blinks indicating the test is in progress DRAM Test XXXMb P HBHHHHE F HBEHHHE XXxMB represents the amount of installed DRAM memory in MB P HHHHHE represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F 4HHHHE represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 2 Once the maximum pass count or fail count is reached the test stops the power indicator is turned on solid and the final results display If the test fails the message DRAM Error displays for approxim
37. the left side of the cover to release it from the hinge 5 Move the cover to the left to separate the right pivot 4 8 Service Manual 4048 1 xx Front cover removal 1 Open the front cover 2 Remove the two screws holding the front cover to the hinge arm A A 3 Unlatch the ends of the hinge arms Repair information 4 9 4048 1 xx 4 Remove the screw B from the operator panel cable cover and remove the cable cover 5 Disconnect the operator panel cable C from the operator panel r 6 Remove the front cover with the operator panel attached If replacing the front cover remove the operator panel See Operator panel assembly removal on page 4 22 4 10 Service Manual 4048 1 xx Top cover assembly removal 1 Remove the front cover See Front cover removal on page 4 9 2 Remove the two screws as shown A 3 Remove the E clips from both hinges that connect the left and right guides to the top cover B 4 Remove the stud hinges A 5 Open the rear exit door 6 Remove the two screws as shown C lt a C 7 Remove the top cover being careful not to damage the output tray full flags when you remove the cover Repair information 4 11 4048 1 xx Right side cover removal Remove the paper tray Open the front cover Open the MPF door Remove the screw below the front cover which fastens the side cover to the frame A A OO N A
38. to print the Quick Test Page from the default paper source If the default paper source only supports envelopes then the page is printed from Tray 1 4 Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet If adjustment is necessary see Top Margin on page 3 10 5 Press Return or Stop to exit the test Top Margin Print the duplex Quick Test to verify the margin on the backside of the duplex page aligns with the front side See Quick Test on page 3 9 Since this test aligns against the front page make sure the front page is aligned the front side of a duplex page is facedown in the output bin See REGISTRATION on page 3 4 The Duplex Top Margin offset range is 16 to 16 and the default is zero Adjustment of this setting lets you shift up or down the position of the Top Margin Changing this parameter by one unit moves the margin 0 25mm A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin 3 10 Service Manual 4048 1 xx Sensor Test This test is used to determine whether or not the duplex sensors and switches are working correctly 1 Select Sensor Test from the Duplex Tests menu 2 Manually actuate each of the duplex sensors Sensor Test Testing When the sensor switch is closed CL closed displays wh
39. voltage contacts are clean If the cartridge is installed correctly and the problem persists try a new cartridge The cartridge may be nearing end of life HVPS card Check the cartridge contacts for correct Controller card installation and contamination where contact is assembly made with the print cartridge and HVPS card Cartridge contacts Clean as necessary assembly If this does not correct the problem replace the HVPS If that does not correct the problem replace the controller card assembly Note Always check printhead alignment after replacing the controller card assembly See Printhead assembly adjustment on page 4 2 for hardware alignment of the printhead Partial blank image white spots no periodic pattern FRU Action Print cartridge not a FRU Remove the print cartridge and gently shake the assembly to evenly distribute the toner If the print cartridge is low try a new one Fuser assembly Check springs at each end of the fuser backup roller to ensure adequate and even pressure is applied to the fuser belt Replace the fuser if necessary Paper not a FRU Make sure recommended paper is being used 2 52 Service Manual 4048 1 xx Variation in image density horizontally across page FRU Action Print cartridge The charge roll may have unbalanced pressure Right guide assembly against the PC drum Check for equal forces at Left guide assembly both ends of th
40. 1 Remove the left side cover See Left side cover removal on page 4 14 2 Remove the four screws that fasten the top cover to the frame See Top cover assembly removal on page 4 11 3 Remove the screw A and remove the inner shield 4 Loosen the five screws B in the controller card cage cover and slide the cover to the rear and remove it 0 4 48 Service Manual 4048 1xx 5 Disconnect all cables from the controller card assembly 6 Remove the three screws C in the controller card and one at the front face of the cage 7 Gently pull the bottom of the cage out and lift up and off the two posts at the top Repair information 4 49 4048 1 xx Controller card assembly removal Warning Never replace both the operator panel and controller card at the same time Otherwise some critical settings will be permanently lost 1 Remove the left side cover See Left side cover removal on page 4 14 2 Remove the screw A and remove the inner shield 3 Loosen the five screws B in the controller card cage cover and slide the cover to the rear and remove it a 4 50 Service Manual 4048 1xx 4 Disconnect all cables and extract the ones from the right side and bottom of the cage 5 Remove the four screws on the face of the card D and three screws on the back holding the USB and parallel port connectors E 6 Remove the card by rotating the front of the controller card fro
41. 1417 1 16MB flash card assembly NS 56P1418 1 32MB flash card assembly NS 56P1427 1 Optra Forms 32 MB flash card assembly NS 56P1428 1 Optra Forms 16 MB flash card assembly NS 56P3304 1 ImageQuick card assembly T430 NS 56P3305 1 PRESCRIBE card assembly NS 56P1429 1 Simplified Chinese font card assembly NS 56P1430 1 Traditional Chinese font card assembly NS 56P 1438 1 Japanese font card assembly NS 56P2231 1 Korean font card assembly NS 12G9833 1 MarkNet X2011e Ethernet 10 100 BaseTX NS 12G9832 1 MarkNet X2012e Ethernet 10 100 BaseTX 10Base2 NS 12G9831 1 MarkNet X2031e Ethernet 10 100 BaseTX NS 12G9830 1 MarkNet X2030t Token Ring NS 99A0545 1 External serial adapter NS 1329605 1 High speed bidi parallel cable 10 ft NS 1427498 1 High speed bidi parallel cable 20 ft NS 12A2405 1 USB cable 2 m NS 1038693 1 Serial cable 50 ft Parts catalog 7 21 4048 1xx Assembly 11 Miscellaneous ai eke Units Description NS 7370971 1 Field relocation kit NS 56P2333 1 110 V maintenance kit NS 56P2337 1 220 V maintenance kit NS 56P2338 1 100 V maintenance kit NS 56P2364 1 Maintenance kit parts group see Maintenance kit parts group on page 6 3 NS 56P2341 1 Customer replaceable CRU charge roll 7 22 Service Manual Index Numerics 2 pin connector parts 7 15 removal 4 46 2xx paper jams 2 22 2 23 3 pin connector parts 7 15 removal 4 46 3x 9x attendance messages 2 16 2 21 9xx servic
42. 3 17 Fuser Temp 3 17 Gap Adjust 3 17 Print Contrast 3 17 Transfer 3 17 Error Log Clear Log 3 20 Display Log 3 18 PrintLog 3 19 Exit Diagnostics 3 20 Hardware Tests Button Test 3 6 DRAM Test 3 7 LCD Test 3 6 Parallel Wrap 3 8 Input Tray Tests Feed Test 3 12 Sensor Test 3 12 Print Tests MP Feeder 3 5 Prt Quality Pgs 3 6 Tray1 3 5 Tray 2 3 5 Tray3 3 5 Printer Setup Configuration ID 3 16 Defaults 3 15 Edge to Edge 3 16 Page Count 3 16 Par S Strobe Adj 3 16 Perm Page Count 3 16 duplex assembly parts catalog 7 5 tray removal 4 24 Duplex Feed 1 3 11 duplex input sensor Sensor Test 3 11 E Edge to Edge 3 16 Energy Conserve 3 25 Env Prompts 3 26 EP defaults 3 17 errorcodes 2 6 error log Clear Log 3 20 Display Log 3 18 Print Log 3 19 Print Log configuration menu 3 26 error messages disconnected cables 2 34 paper jams 2 22 service error codes 2 6 sub error codes 2 24 user attendance messages 2 11 ESD sensitive parts 4 1 exit drive assembly lubrication 4 7 parts catalog 7 5 removal 4 59 exit drive motor parts catalog 7 5 removal 4 58 F factory defaults 3 24 fan cooling 4 82 LVPS 4 76 7 13 Feed Test 3 12 field relocation kit 7 22 flash memory options 7 21 specifications 1 5 test 3 14 Flash Test 3 14 Registration 3 4 fonts 1 6 Download Emuls 3 24 DRAM Test 3 7 1 2 Service Manual fuser assembly parts catalog 7 9 removal 4 26 service check 2 40 Fuser Temp 3 17 G Gap Adjust 3 17 H hig
43. 4 3 Remove the inner shield A 4 Loosen the five screws B to slide the controller card cage cover to the rear to remove EE 4 70 Service Manual 4048 1xx 5 Disconnect the MPF cable on the right side of the controller card C and the toner level sensor D EET y AS 6 Remove the three screws E on the front of the lower body MPF assembly and gently remove the assembly Repair information 4 71 4048 1 xx Backup feed roller assembly removal 1 Using a flat bladed screw driver and springhook release the spring A from the metal anchor Note A third assembly is below the upper MPF housing When one assembly needs replacing replace all three assemblies one ata time The assembly with the black roller should be installed in the back farthest from the door 4 72 Service Manual 4048 1xx MPF pick roller assembly removal 1 Remove the left side cover and inner shield See Left side cover removal on page 4 14 2 Remove the roller cover one screw See Lower MPF housing assembly removal on page 4 70 3 Pull the latch A away from the shaft and slide the gear off Repair information 4 73 4048 1 xx 4 Remove two screws B holding the roller assembly and one screw C facing the front of the printer x r gt 5 Remove the roller assembly Note Push the MPF plate down to give clearance Warning When reinstalling replace the two screws B first and t
44. 4048 1 xx Charge roll removal Warning Handle the charge roll only at the ends and with clean dry hands Otherwise use a piece of paper between the charge roll and your fingers 1 Grasp the charge roll on the right end Hold the front cover as closed as possible while unsnapping the charge roll in the direction of the arrow The arrow is located to the right of the charge roll assembly 2 After the right side is unsnapped from the bearing slide the roll from the left side bearing 4 38 Service Manual 4048 1 xx Right guide removal 1 Remove the top cover See Top cover assembly removal on page 4 11 2 Remove the HVPS See HVPS card removal on page 4 75 3 Remove the charge roll See Charge roll removal on page 4 38 4 Remove two screws in the right guide above and behind the HVPS 5 Unsnap the three latches of the right guide 6 Remove the right guide Repair information 4 39 4048 1 xx Left guide removal 1 Remove the controller card cage See Controller card cage with card in place removal on page 4 48 2 Remove the charge roll See Charge roll removal on page 4 38 3 Remove the top cover assembly See Top cover assembly removal on page 4 11 4 Remove the three screws as shown A 5 Press the three latches B while separating the left guide from the frame 6 Remove the HVPS See HVPS card removal on page 4 75 4 40 Service Manual 4048 1xx
45. 45 Parallel poit Service Check ae idi eder edo RE PRELA bts 2 49 PI COKE s ideis isa uo inti dira nice dua us a tus 2 50 Solving print quality problems sucum rer dere dew Rm 2 56 Diagnose Sls oce sana EA dE UE d RUE E Bak ok undo AAA 3 1 Auditiohal Service MENUS sa add ep be edob dor boda PR od eq doe dici 3 1 Dagnosics Ya ada sorai dados ida s Pa iod qua ed Roe 013 semana 3 2 Entering Diagnostic Mode a acd aaa eam ec o RAO dd dod 3 2 REGISTRATION s 23 233 2 5 38 22er era Pur hese Sab Eve ina Eck eee 3 4 PRINT TESTS ndara notice qiia maquis eec asap dise IAA 3 5 HARDWARE TESTS sux usu nom actae RE wb Eurum REN DS RR 3 6 DUPLEX TESIS uenti tma reir greens ns tale das iia 3 9 INPUT TRAY TEST Soe sch ssis amis mes sm msa Rub sa D EUER RE 3 12 BASE SENSOR TES os 222 Squid quise prada ds ie IIIA 3 14 DEVICE TEST Sr sects chews eee id bee Demos DERERRREIP TES 3 14 PRINTER SETUP 1222 25 CBE DERE dur dada aada Gia tx Reus 3 15 EP SETUP i23222222225 5ce ckxagbpaiedab Rd dd Rede deris 3 17 ERROR LOG udo ii 3 18 Configuration MOfil II nx RR REG RA eee 3 21 Entering CONFIG MENU 2s zioxuaiwbrc bcnc ma kde d bs 3 21 Maint Cot Val B IIIA NIA 3 22 Reset Maint Gb es exe x ix RES rates AES ERE Qoseaees 3 22 PS UA IA 3 23 Panel Mi wantd am RO ean ama an 3 23 PAIN 3 23 Download AINA 3 24 Demo Se AA Aa vain 3 24 mae ka WA AA aa udin dared ace ERE REPE 3 24 NARROW MEDIA 3 25 IA YE AA AAA AAA Kuna Ed Rad Rd id 3 25 UA CT TP 3 25 Paper PLOmpl
46. 7 1339534 Powercord llle 7 17 1339548 Powercord llle 7 17 1427498 High speed bidirectional parallel cable 20 ft 7 21 43H5545 Power cord 7 17 56P0615 MPF paper feed cover cap 7 8 56P0624 Cover switch cable assembly 7 15 56P0625 Interlock cover switch 7 15 56P0629 Cartridge contactassembly 7 7 56P0634 Paper feed gear 7 5 56P0638 Cartridge coupling 7 5 56P0639 Guide bracket 7 5 56P0640 Charge roll 6 2 7 11 56P0645 Photo sensor 7 5 7 15 7 19 56P0649 Fuser ezitcableassembly 7 15 56P0651 Duplex assembly 101 102 7 5 56P0653 Toner level Sensor 7 15 7 19 56P0655 Paper sensor bracket 7 5 56P0657 Paper feed assembly 7 5 56P0660 Paper guide roller 7 7 56P0661 Tray damper 0 eee ee 7 7 56P0662 Base feet 0 0 0 0c ee ee ees 7 7 56P0665 3 pin connector 7 15 56P0666 2 pin connector
47. 7 Disconnect the single conductor cable spade connector D Note Removal of the printhead is not necessary but gives better visibility and access Illustrations are with the printhead removed See Printhead removal on page 4 46 8 Remove the cable from the retainers between the printer right side and the left guide 9 Remove the left guide Repair information 4 41 4048 1 xx Cartridge signature button sensor removal 1 Remove the gear train assembly See Main drive assembly removal on page 4 55 2 Remove the two screws and the bracket coupling assembly 3 To protect the charge roll from touching either remove it see Charge roll removal on page 4 38 or cover it with a sheet of paper 4 Remove the screw holding the cartridge signature button sensor A 5 Remove the two screws in the cable cover retainer B 6 Remove the sensor Note Unplug the thermistor cable to remove the cartridge signature button sensor Both share the same connector at J18 4 42 Service Manual 4048 1xx Transfer roll assembly Note Do not touch the transfer roll except on the ends 1 Unlatch and lift the left transfer support bearing 2 Unlatch and lift the right transfer support bearing 3 Remove the transfer roll Note After reinstalling the transfer roll use a thin screwdriver to push the copper tab on the right side fully into the slot Note Always check the bottom margin following a tr
48. 8 1xx Controller card assembly connectors see card assembly on page 5 2 Controller Connector Name of pins Pin Signal J20 Paper Duplex Paper input narrow media duplex 9 5 V dc Ground 5 V dc Ground o AJO 5 V dc o Ground J21 TRAY 2nd drawer interface 5 V dc 5 V dc 5 V dc 5 V dc Ground 24 V dc o oO AJ OJN 5 V dc 5 6 Service Manual Low voltage power supply LVPS CAUTION 100 1 10 220 V ac E E 4048 1 xx U CTT BOO Connector Name Pins Pin Signal Controller CN1 5 1 Ground card LVPS control 110 220 CN2 8 2 Ground Volts 4 5 V dc 5 Ground 6 Ground 7 24 V dc 8 24 V dc Heater CN3 2 1 100 110 220 Vac 2 100 110 220 Vac On off switch CN4 S W 2 1 110 220 V ac 2 110 220 V ac Locations and connections 5 7 4048 1xx High voltage power supply HVPS INSIDE Toward Printer b 4 a
49. Eb Ea deb 4 25 Fuser assembly ramova su sa doa 3 ceva savas dodo akis i AR RC d f 4 26 Fuser paper exit guide assembly removal 4 29 Fuser exit sensor removal IIIA itenni 4 33 Cartridge contact assembly removal lesse 4 34 Tray damper and spring removal saa xc uk m aan RR ER sisas 4 35 DooridetchPTelmoVvel s aaogco dcicenges ri nS Dad ia iEn do r8 at a rna 4 36 Paper guide roller removal ax x cacxim aca canes mr ka wa a an a 4 37 Charos Tol Iove ig ctansie o quos ppt e tiP bio epp ERES 4 38 Right gulde remowval aux caca arx mk i Gc RC ii aaa eae 4 39 bett ejhitele TORIO Mella a 25 379 4 75 2 1 2t E07 Ravi aaa aime ees 4 40 Cartridge signature button sensor removal 4 42 Tanso rral SS ecard doas IIIA 4 43 Bracket paper detect input sensor removal 4 44 D roll feed removal tray 1 lleeeellreserrnene 4 44 D roll shaft assembly removal tray 1 serere 4 45 3 pin and 2 pin connectors removal 3 auch nic m n Rn 4 46 ErititheadFemg al ooa edere iei dina dus iate Geste cane Evene 4 46 Controller card cage with card in place removal 4 48 Controller card assembly removal eee 4 50 MPF gear remoVval amp aau socakcacio ie sce dod REOR Ro an EO UD ne eee 4 52 Main drive motor assembly removal e eee aens 4 53 Main drive assembly removal 4a cx nca acm hcec in n 4 55 Exitd ve molor feimoMel a ave
50. Error codes 956 957 and 959 are controller card failures Perform a power on reset POR If this does not fix the problem replace the controller card 960 RAM soldered on the card is bad Indicates a DRAM Memory Error on the controller card Replace the controller card 961 RAM in slot 1 is bad If another SDRAM memory DIMM is available turn the power off and switch the DIMM If the memory card now works correctly replace the failing DIMM If this does not fix the problem replace the controller card If another DIMM is not available replace the memory option first and then the controller card if necessary Diagnostic information 2 9 4048 1 xx Service error codes 9xx continued The engine is experiencing unreliable communications to the specified device Error Description Action 964 Download emulation Perform the following CRC failure Checksum 1 Disable the downloaded emulations failure detected in the See Download Emuls on emulation header or page 3 24 emulation file 2 Reprogram the downloaded emulations If the problem persists replace the emulation card 975 Unrecognizable A failure with the network port network port If the printer is a network model replace 7 the controller card See Controller card 976 Software error in assembly removal on page 4 50 network port 978 Bad checksum while programming network port 979 Flash pa
51. F gear clears the drive gear bracket Repair information 4 55 4048 1 xx 5 Pull the latch C away from the shaft and slide the gear off the shaft 6 Remove the cables from the two cable clamps on the right side of the gear drive 4 56 Service Manual 4048 1xx 7 Remove the six screws D in the gear train assembly 8 Disconnect the drive motor cable 9 Remove the two screws E and the plastic bearing at the upper right corner of the main drive motor This allows more movement for the gear assembly v 10 Gently lift and work the gear train assembly out Repair information 4 57 4048 1 xx Exit drive motor removal 1 Remove the left side cover See Left side cover removal on page 4 14 2 Loosen the five screws A in the controller card cage cover and slide the cover to the rear and remove it 3 Disconnect the exit motor cable at J6 upper right side of controller card 4 Remove the two screws B The controller card cage does not have to be removed N SSS ij iN Q N AD 5 Slide the motor out 4 58 Service Manual 4048 1 xx Exit drive assembly removal 1 Remove the controller card cage See Coniroller card cage with card in place removal on page 4 48 2 If replacing the drive assembly remove the exit drive motor See Exit drive motor removal on page 4 58 3 Remove three screws A and the screw holding the ground strap B A B 4 Remove t
52. KIT MOTOR redrive motor 917 POST J19 HVPS high voltage power supply and fan 924 POST J18 THERM thermistor and smart chip 929 Print multiple J12 MPF SENSOR pages multipurpose feeder sensor and toner sensor 931 POST J3 LSU laser printhead 935 POST Ji MMTR mirror motor 936 POST J10 MAIN MOTOR transport motor 940 POST J13 LVPS low voltage power supply control Close Door POST J2 CO cover open switch Load MP Pick paper from J9 MPF Feeder multipurpose feeder solenoid 2 34 Service Manual 4048 1 xx Error or message Condition Check Connector name if cable is required to connection ae and description unplugged obtain error at Load Tray 1 Pick paper from J14 FD tray1 feed tray1 solenoid Paper Jam Print a page from J20 PAPER DUPLEX any source input sensor narrow media sensor and duplex sensor Remove Paper POST J16 EXIT exit sensor Standard Bin and bin full sensor Option tray is not Attempt to select J21 TRAY option available option tray in tray PAPER SOURCE menu Diagnostic information 2 35 4048 1 xx Service checks Service checks involve measuring voltages of the LVPS HVPS and controller card assembly Continuity and resistance verifications are done on cables and components as required Note When looking at the printed side of a printed circuit board connectors are designated with J followed by a numbe
53. Manual 4048 1 xx MPF paper sensor removal See the MPF paper sensor installation on page 4 69 for information about installing the FRU 1 Remove the MPF door cover See MPF door cover removal on page 4 8 2 At the lower right assembly hinge use a flat blade screwdriver to separate the metal plate from the plastic housing Repair information 4 67 4048 1 xx 3 Support the left side with the left hand while separating the left hinge Note There is a loaded compression spring A on the left side and under the metal plate Note the location before removing the spring 4 Rotate the metal plate until you can access the sensor B 5 Push the latches underneath the sensor and housing and disconnect the cable to the sensor e 4 68 Service Manual 4048 1xx MPF paper sensor installation To verify the spring is correctly reinstalled 1 Reinstall the metal plate Make sure the compression spring A is in the proper location and captured at its ends 2 Release the solenoid latch A 3 Rotate the main motor counterclockwise until the gear arm engages the solenoid latch The metal plate B raises and lowers as the latch engages and releases the drive to rotate Repair information 4 69 4048 1 xx Lower MPF housing assembly removal 1 Remove the MPF door cover See MPF door cover removal on page 4 8 2 Remove the left side cover See Left side cover removal on page 4 1
54. PC 850 PPDS code page 437 850 Units of measure Inches Millimeters Where input sources do not have size sensing capabilities Warning Changing the Defaults setting causes the printer to reset the printer NVRAM to factory settings Diagnostic aids 3 15 4048 1xx Page Count Reset the page count when an engine card is replaced To reset the page count 1 Select Page Count from the PRINTER SETUP menu Page Count 1234567 2 The leftmost number blinks Use Menu to increase or decrease the number and press Select to move to the next digit to the right Continue until the correct number displays To skip a number without changing it press Select When Select is pressed after the last digit the number is saved Perm Page Count This menu option lets you view the permanent page count The permanent page count cannot be changed by the operator panel Select Perm Page Count and the value is displayed Configuration ID The configuration ID is used to communicate characteristics of certain areas of the printer that cannot be determined by hardware sensors The configuration ID was originally set when the printer is manufactured and is located on the printer label Edge to Edge When Edge to Edge is set to On text and graphics are printed with all margins set to the physical edges of the page This features does not work in PPDS emulation Par S Strobe Adj This setting adjusts the factory s
55. S ABE PAST EVE MME at z A CED EN SERERE BESS IESU A PSP DU RU fe E E n eV B A RIXA UMAN T f FARE I TRI fr D Wie AMARA SIN WHER PE RP m KER SES FAR ETE WEARER im D FELD 4k RAET m UAE FLYER IT ESS IN ZI Sis Safety information xxi 4048 10x 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 Locations and connections 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 fo
56. Select the sensor to test The following sensors may be tested Toner toner optical sensor Input input sensor Output exit sensor Narrow Media narrow media sensor Front Door upper front door sensor The selected sensor is displayed with OP for open or CL for closed You can actuate the sensors to toggle between open and closed DEVICE TESTS This menu is only displayed if flash memory is installed Flash Test This test causes the file system to write and read data on the flash to test the flash Warning This test destroys all data on the flash The flash will be unformatted at the end of the test Format Flash is available from the Utilities menu To run the Flash Test 1 Select Flash Test from the DEVICE TESTS menu The power indicator blinks while the test is running Files will be Lost Go Stop 3 14 Service Manual 4048 1xx 2 Select Go to continue Select Stop or Return to exit Flash Test Testing The results are displayed and the power indicators turns on solid Flash Test Flash Test Test Passed Test Failed 3 Press Go Return or Stop to return to the DEVICE TESTS menu PRINTER SETUP Defaults Selections are U S or Non U S This setting affects the following defaults Printer setting U S value Non U S value Default paper size Letter A4 Envelope size 10 Envelope DL Envelope Fax paper size Letter A4 PCL Symbol Set PC 8
57. Ssa s sauna d bai ddr bad Ead aedi dd RAE dd 3 26 ENY BIOS IIIA 3 26 aie Wok ew tee PEE 3 26 Exit Contig Mens as ism err orsus REUS dum Sus ted S EO PUR rS 3 26 Paperia ss darse AAA WAMA diga qd aus ers dig ate adsum 3 27 iv Service Manual 4048 1xx Repair information III UWA 4 1 Handling ESB SamgillVe Pans eacus IAA 4 1 ka 3 hid case dk ana E CERT CR REOR ee ae C DE dia 4 2 Printhead assembly adjustment ies 4 2 Adjusting paper feed alignment Skew e eee e eee 4 5 MUDIE elder new Eri Rt ee omer cir Serica Peer ee f 4 6 Floasselnblya ka acaba url CE wind aden a eke d Kanes 4 7 heinoval BIOCediles x 515 a a adiar tod Gur t6 diss xus Rus FE d ake ne 4 8 MPF d orcovel FemoVal x24 2405944454423 44 564 Eb daha a 4 8 Front COVO Temas eai eodd Sopa qt a te Qiu be SEO 4 9 Top covel assembly FemoVala aue caca aede kos rds nd ERR Ld Ea 4 11 Right Side cover removal x sius nenat unana gps Nosti dod 4 12 Let SIGECOVERTOMMOWAl 2 2152 2A d 2 ddsra ric dd aa 4 14 Rear cover removal s saux sceau ce o Ro mac aci e a dar we aca rd RO 4 15 Bear exib door removal us sess eratmichen iere acd aaa 4 17 Output tray full flag removal ax ssim onem trmt cnim mmm es mms 4 18 Operator panel cable removal 20 0 0s cece eee eee eee 4 20 Operator panel assembly removal 2 0ee cece eee eee eee 4 22 Duplex tray assembly removal nee eee eee 4 24 Bottom Pan Felmovala a aca dene ad ene da E Reds eda
58. This can only occur after a replacement of one of the two parts and the replaced part is faulty Replace the controller card or the operator panel Warning Always replace only one at a time with a POR between 951 Controller card The secure NVRAM was not detected on the controller card Replace the controller card 952 NV failure n Recoverable error Reset POR the printer 953 NVRAM chip failure Indicates the NVRAM chip has failed Replace the controller card 954 NVRAM CRC failure Indicates the NVRAM experienced a CRC failure Replace the controller card 2 8 Service Manual 4048 1xx Service error codes 9xx continued Error Description Action 955 Code CRC loc Replace the controller card Where lt loc gt CRC Failure or ECC Failure on the controller card 956 Controller card Error codes 956 957 and 959 are controller card failures Perform a power on reset POR If this does not fix the problem replace the controller card 957 ASIC failure Error codes 956 957 and 959 are controller card failures Perform a power on reset POR If this does not fix the problem replace the controller card 958 NAND failure Before proceeding perform a power on reset POR to see if the ECC error correction code can reflash NAND If this does not fix the problem replace the controller card 959 SRAM failure
59. U MAS Laser notices Vii 4048 1 xx Laser notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class Illb 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 level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem f3 amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse Illb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der L nge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daB im Normalbetrieb bei der Wartung durch den Benutzer oder bei o
60. Use IBM no 10 oil P N 1280443 approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease PN 99A0462 approved equivalent Shell Darina 1 or P N 99A0394 to lubricate appropriate areas of the printer Preventive maintenance 6 1 4048 1 xx Scheduled maintenance The operator panel displays the message 80 Scheduled Maintenance ata fixed page count interval It may be necessary to replace the fuser assembly transfer roller charge roll and pick tires at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers Maintenance kits Description Part number 110 V maintenance kit 56P2333 220 V maintenance kit 56P2337 100 V maintenance kit 56P2338 After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message See Reset Maint Cnt on page 3 22 Maintenance kit contents Description Part number Tray 1 paper feed roll 56P2352 Transfer roll assembly 56P2329 Charge roll 56P0640 Fuser assembly See note below Rear cover assembly 56P2302 Lower MPF housing assembly 56P2311 Lubricant Nyogel 744 99A0394 Maintenance kit parts group 56P2364 Note The 110 V maintenance kit P N 56P2333 contains P N 56P2330 fuser assembly The 220 V kit P N 56P2337 contains P N 56P2331 fuser assemb
61. able 2 36 Service Manual 4048 1xx Cover interlock switch service check Note Make sure a print cartridge is installed and the cover closes all the way fully engaging the cover open switch lever FRU Action Cover interlock switch Disconnect the cover interlock cable from the interlock switch Push the cover interlock switch to the closed position and verify continuity between the bottom and middle terminals Open the switch and verify continuity between the bottom and top terminals The top and middle terminals should indicate discontinuity at all times e If the switch is good verify 5 V dc on the middle spade of the cable and ground on the top spade of the cable f voltage is not present see Controller card service check on page 2 38 Replace the switch if faulty Diagnostic information 2 37 4048 1 xx Controller card service check Warning Never replace both the operator panel and controller card at the same time Otherwise some critical settings will be permanently lost FRU Action Controller card assembly Check for 5 V dc and 24 V dc from the LVPS card to the controller card assembly 1 Turn the printer off 2 Disconnect the LVPS cable from the controller card at J17 3 Turn the printer on 4 Verify 24 V dc from the cable connector sockets 1 and 2 and 5 V dc at socket 5 If voltages are not present or incorrect see Low voltage po
62. acm a ko on m RR omo o e era QR WR e 6 2 Maintenance Kil parts group 2a etr rei hh nr E 6 3 Parts cataloQ i iaa naa IIIA 7 1 Howto use Wis parte catalog SIA 7 1 Assembly 1 COVEIS ssp iceh eden Sus UR ios o9 sinus Teo Sm RUE ts ame e 7 2 PSSSMNY 2 Papel IBBQ iii AE 7 4 Assembly FU IIIA IIIA KIE 7 6 Assembly 4 Multipurpose feeder MPF wananananzanana 7 8 PSSOMOly D PUSBI se b du bk d dean Ede d XR p waded edida needa date 7 9 ASSEMON C2 CHA iii a 7 10 Assembly 7 Electronics and cables 1 cases ca cuca mr urn cai 7 12 Assembly 8 Electronics and cables 2 l sss 7 14 Assembly 9i Sens0lS aa ssiecesci nerizdcreiadbiigddke Ru nsisdrs 7 18 Assembly TO DJDIIORS xau Exundodui doa dupl ius iot acrid arius doin leew 7 20 ld ded etntdinsine dead enna ob AA PANA MUTU wane l 1 Part number index zx5 s 353 ad IIIA eed eed l 7 vi Service Manual 4048 1xx Laser notices The following laser notice labels may be affixed to this printer as shown Laser advisory label 5mW 780nm 800nm DANGER INVISIBLE LASER RADIATION WHEN OPEN AVOID DIRECT EXPOSURE TO BEAM VORSICHT UNSICHTBARE LASERSTRAHLUNG WENN ABDECKUNG GEOFFNET UND SICHERHEITSVERRIEGELUNG BERBR CKT NICHT DEM STRAHL AUSSETZEN DANGER RAYON LASER INVISIBLE LORS DE LOUVER TURE EVITER LEXPOSITION DIRECTE PELIGRO RADIACION LASER INVISIBLE AL ABRIR EVITAR LA EXPOSICION DIRECTA AL HAZ fe BR MbeceL venomman E ARMRYASRUSSCRBLTFE
63. ansfer roll replacement See REGISTRATION on page 3 4 Repair information 4 43 4048 1 xx Bracket paper detect input sensor removal 1 Remove the print cartridge to expose latches in the bracket Leave the door open 2 Remove the duplex tray assembly see Duplex tray assembly removal on page 4 24 or bottom pan in the simplex model see Bottom pan removal on page 4 25 3 Disconnect the cable to the sensor or remove the sensor and cable together 4 Unlatch the bracket by pushing from inside the printer and pulling from the duplex side D roll feed removal tray 1 1 Remove the duplex tray See Duplex tray assembly removal on page 4 24 In a non duplex printer remove the bottom plate See Bottom pan removal on page 4 25 2 Disconnect extension spring A from the D roll 3 Using a flat blade screwdriver as a wedge between the D roll and bearing wall force the D roll to unsnap from the shaft 4 Disengage the D roll from the shaft B until the D roll can be rotated to allow clearance for removal um 4 44 Service Manual 4048 1xx D roll shaft assembly removal tray 1 1 Remove the left side cover See 2 Remove the gear train assembly See 3 Remove the screw and solenoid A 4 With the printer on its back remove the D roll See Note Slowly remove the shaft B while facing the D roll end see page 4 44 Capture the small washer and the bearing The bearing mu
64. antenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de dafios personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje A N 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 Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas e As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a AN poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a ta
65. ately three seconds and the failure count increases by 1 Turn the power off if you want to stop the test before it completes Diagnostic aids 3 7 4048 1 xx Parallel Wrap This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select HARDWARE TESTS from Diagnostics Mode 3 Select Parallel Wrap 4 Select Parallel Wrap Parallel 1 Wrap Parallel 2 Wrap or Parallel 3 Wrap The power indicator blinks indicating the test is in progress The test runs continuously until canceled Parallel Wrap P HBHHHHE F HEHHHE P HHHHHE represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F JHHHHF represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Each time the test finishes the screen updates If the test passes the pass count increases by 1 however if the test fails a message displays for approximately three seconds One of the following failure messages may display Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Error Host Busy Error RAM Data FF Error RAM Data AA Error
66. card assembly Note Always check printhead alignment after replacing the controller card assembly See Printhead assembly adjustment on page 4 2 for hardware alignment of the printhead Paper occasionally picks or picks multiple sheets at once FRU Action Paper feed roll Check the paper feed roll D roll or pick roll for Paper feed assembly wear Verify that the extension spring is working properly Replace as necessary During a paper pick the paper feed assembly is released by the solenoid Verify the plastic end of the shaft is not worn allowing the shaft to be released without the solenoid being activated Replace the paper feed assembly as necessary Note We recommend that the paper feed roll be replaced when the paper feed assembly is replaced Also see Paper picks during POST and or continuously on page 2 46 2 48 Service Manual 4048 1 xx Paper trees wrinkles stacks poorly or curls FRU Action Fuser assembly This problem is most likely due to a worn backup roller A worn backup roller causes the printer to run hotter than required for the media being printed Excessive heat can cause paper treeing problems poor stacking or excessive curl Parallel port service check 1 Perform a print test to make sure the printer prints correctly See Prt Quality Pgs on page 3 6 for more information 2 Be sure the printer cable is designed for bidi
67. cat en altres llocs s un producte laser de classe que compleix els requisits d IEC 60825 1 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un l ser de classe IIIb 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci l ser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Laser notices xiii 4048 1xx Japanese Laser Notice L 3X icBiy 535535 IZO7ZULZS i KBCEADHHS 21 CFR97 v 75 1 07241 1 ORHUEdULIVv v 8 cooks NTE EAIKEEACIEIEC82950HSEtmNIIUL ZZT AlOov VY amp kc s cmaS Er coETY 22X1I0v Y 8Wpiifsl amp tEd7zvcxxoncozxv co 7Zyr sZ i7zHnb 3b OL P AARMELTOEF CO LF ENT T9ISFJA F OMACL BH SL UDybhOAVUDAUMILWMERRITSL P CT TOL WATACTULS ii HE OH 2 FOAVFPVYAL HR ESM BW TH AMI FALTOVANVELLOL ik HIN ZCLORMWEABHANTHET Chinese Laser Notice FT El ELE SE IU GEA S DHHS 21 CFR Subchapter I X 4r 25 I 1 8t J6 77 d B9 tH E mE th Hb pe WD HR UA Ee IEC 825 ER EE SE TBO d RAD RAS ETE A TT ED DLA ah amp A oP 28 Hb 3b HIE ERENBHSFES SRAGRRAM REG Hw Ki EE 770 795 nm Z SRI AKARRITNP MRI RHR VE ABSAPRMEANABHAT TAEA fh ET
68. ce messages continued Message Explanation Install Tray x Tray x Tray 2 or Tray 3 DE Cance T OD This message is displayed when a paper handling option has been hot unplugged The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed The following actions may be taken Install the option e Press Menu until Busy Waiting displays Select one of the following Cancel Job Reset Printer If the message cannot be cleared check connections and then POR the printer with the option attached If the message persists check the cables starting at the controller card Load lt input source Input source Tray 1 Tray 2 Tray 3 or MP lt custom type name gt Feeder Custom type name is a user defined media type The following actions may be taken Load media in the indicated source Press Menu until Busy Waiting displays Select one of the following Cancel Job Reset Printer If the message cannot be cleared go to Input tray s service check on page 2 64 Load lt input source Input source Tray 1 Tray 2 Tray 3 or MP size Feeder Size Letter Legal B5 A4 A5 Exec Univ Folio or Stmt The following actions may be taken Load media in the indicated source e Press Menu until Busy Waiting displays Select one of the following Cancel Job Reset Printer If the message cannot be cleared go to Input
69. ce the photo sensor and or the stack control flag as necessary Photo sensors paper path Make sure the sensors are working properly A stuck or incorrectly installed sensor causes this error The operator panel indicates 200 Paper Jam 201 Paper Jam 202 Paper Jam or 23x Paper Jam For a 200 or 201 message look under the cartridge A 201 is posted if the paper stops between the input sensor under the cartridge and the exit sensor at the fuser A 202 indicates a jam in the rear door Errors 231 235 237 and 238 indicate jams in the duplex If the printer functions correctly in the simplex but posts these errors in duplex check the sensor cable for continuity and replace the cable or sensor s as necessary Paper picks during POST and or continuously FRU Action Paper feed assembly Paper feed solenoid Check the pick mechanism for wear The solenoid releases the shaft of the D roll allowing it to engage with a gear on the main drive There is a step in the plastic part of the shaft that rests against the solenoid arm This error occurs if the step is worn or damaged so the solenoid cannot stop the rotation Replace the paper feed assembly if necessary Make sure the spring on the solenoid is properly installed If the spring is improperly installed or missing the pick roller will continuously pick paper Replace the solenoid as necessary 2 46 Service Manual 4048 1xx Paper pick
70. che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Laser notices ix 4048 1 xx Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los demas paises reune todas las condiciones expuestas en la norma IEC 60825 1 para productos laser de Clase 1 Los productos laser de Clase no se consideran peligrosos La impresora contiene en su interior un laser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora estan disefiados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est c
71. clear any media under cartridge before continuing 8D 00 02 00 Exit sensor never made by leading edge 201 00 00 of paper when feeding out media that was detected during warm up 8D x1 03 x2 Page arrived at fuser too soon and feed 201 X3 x4 time was too quick Possibly staged media caused a quick pick 8E xx 00 x1 Sheet coming from duplex unit never 237 x2 x3 made it to the input sensor Diagnostic information 2 31 4048 1 xx Sub error codes continued First 6 bytes sub rror code data po 3 ee Explanation error xx can be any message value 8E xx 02 X1 This error can be caused by the input 243 x2 sensor not being activated by a page that was known to have been picked x1 size x2 media source Ensure the correct source has been selected and the media is feeding from that source Enter Diagnostics and go to INPUT TRAY TESTS Select Sensor Test and the tray to test to verify the function of the pass thru sensor TP Tray present P pass thru See Sensor Test on page 3 11 8E xx 06 xl The second pick failed from the MPF 250 when paper was detected to be in the Source x12media source 8E xx 09 xl The second pick from the MPF or Tray 1 250 failed When other sheets were committed to the paper path x1 media source 8E 00 OD x1 00 Paper reached the input sensor after 200 00 engine timed out and was feeding the paper ahead to the output tray x1 media source 8E x1 11 x2 Took too lo
72. d Verify pin 4 is ground Turn the printer on and verify 5 V dc on pins 2 and 5 Also verify 3 3 V dc on pins 6 and 7 If any of the voltages fail replace the controller card See Controller card assembly removal on page 4 50 If all of the voltages are correct verify the continuity of the operator panel cable If the cable fails continuity replace it See Operator panel cable removal on page 4 20 Otherwise replace the operator panel See Operator panel assembly removal on page 4 22 If the operator panel display is erratic during POST replace the following FRUs one at a time in the order shown Controller card assembly Note Always check printhead alignment after replacing the controller card assembly See Printhead assembly adjustment on page 4 2 for hardware alignment of the printhead Operator panel Operator panel cable Diagnostic information 2 43 4048 1 xx Transfer roll service check FRU Action Transfer assembly roll Check the springs in the left and right transfer roll bearings The bearing assemblies should support the transfer roll applying even pressure to the PC drum The roll should rotate evenly and smoothly Replace the transfer roll assembly if the springs or bearings indicate damage or lack of proper function Inspect the transfer roll for signs of wear damage or contamination Replace the assembly as necessary Note Do not vacuum t
73. daba a ass a S a Ea a a hid Dudes 1 11 Diagnostic information is 00 cece eee eee n nh 2 1 Slat UE 2 1 Power On Reset POR sequence sananzazannana 2 2 ovmplom Tables ELEWA 2 3 POST symptom TaDle ede ss omeo end scm pes rpaeE diee Suus 2 3 Printer symptom LASS 2 52 dnm a 78 Gn pk RU URS E dm eda IR al a rad E 2 4 Messages arid error Codes essei rumes em mmn Ex m FUR P 2 6 GBIVIDG ENO COMES vore eetatale A quiu potis a wr bsp te Iis d 2 6 User attendance messages ask ki eara i o Roxas ca ER CORO 2 11 Paper jami MESSAGSS use ura d cara oca ndn areis xci DR BU RR RR S Ec UIS On 2 22 SUHET OOd S cassis esser kirdbt b pee bd Rx AAA 2 24 Disconnects on the controller card 423a tack koca ka inima 2 34 Service Cheki ase sees a ne 4r RREESRARR ER RI ane a REESE 2 36 Gooling fan service Check ux Lisa ime Ra dde dx ane dt Rua d 2 36 Cover interlock switch service check 2 37 Controler cardi Service Check auci ead eui bord donnees hates 2 38 Dead machine service check KA leeren 2 39 Low voltage power supply LVPS service check 2 39 4048 1xx High voltage power supply HVPS service check 2 40 EA IAA We C TEE 2 40 M llvmotor Sorvibo ChE K as ad 1o ebd oPR Ed ERE ea Rh dade 2 42 Opetatorpariel senice CheCK ccc ot cctechtdea ceto ok b cee bs 2 43 Transfer roll service CHECK uaa dena Kat d eei E Eh ard 2 44 Paper feed service checks cg 2 0c cence eese nnn 2
74. dciraaan d 687 cta pc bo d adr Qe 4 58 Exit drive assembly removal cossec 43 4 bach iweb dark EN mad 4 59 Fiauchet drive remove 22 6 23 35 x 478 Ru i0E alla d Rao b brad 4 60 Reference feed assembly removal esee ees 4 62 4048 1xx Cartridge coupling assembly removal 2 20 e cece eee eee 4 65 Upper MPF housing assembly with paper flag removal 4 66 MPF paper sensor TefmoVala a osa dear ed doce ha RI ba RE 4 67 Lower MPF housing assembly removal sese 4 70 Backup feed roller assembly removal eese 4 72 MPF pick roller assembly removal eese 4 73 HVPS card romoval sa sacas crane neeeenes ce he nif zgebofbi 4 75 VPS UE EIA 4 76 UPI SEA AA 4 77 Inner link and outer link assembly removal lese 4 78 Cooling fal temgy al s sed ussuu erts chere tees i nme sda 4 82 Locations and connections 000 cece eee enn 5 1 ExteliorlooatIgS nti sanded V Coa beUo V oec Da ok a CA RO hal hese 5 1 US aua cinta dba DER S ug S du i RUE ERIS Sa BUE cae A 5 2 Conkrollencard ASSEMBLY ia sinum eid pb s ESN EEEE A iren s 5 2 Low voltage power supply LVPS 0e esse eee ence eens 5 7 High voltage power supply HVPS lesser 5 8 Preventive maintenance WA Rx eee CALCARE A 6 1 Safety Ihispectlon QUIdO sssctrsce ruiteeivieme icu Rea e RII DaRxg a 6 1 Liipricsuor SHENG IIIA 6 1 Scheduled MAINTENANCE IIIA aaa 6 2 Maintenance KIIB a
75. designated on the printed circuit card by either a white triangle a number 1 or both The pin numbers follow chronologically to the opposite end of the connector Voltages shown on the following pages are made with the printer turned on CAUTION Voltages are expose Controller card assembly d 2 Network Card Lx J8 3 if 77 Base Card Quv92 NOILdO Quv2 NOILdO Uv Tuvuuu UUUUUU VUUVUUUUU nnnnn 5 2 Service Manual 4048 1 xx Controller card assembly connectors see Controller card assembly on page 5 2 Connector Name of Pin Signal pins J1 MMTR Mirror motor 5 4 Ground 5 24 V dc J2 CO Cover 3 2 5 V de 3 Ground J3 LSU LSU printhead 10 3 Ground 6 Ground 7 5 V dc cover closed 9 Ground J4 DIMM SDRAM 100 1 Ground 12 Ground 21 3 3 V dc 26 Ground 36 Ground 42 3 3 V dc 47 Ground 50 3 3 V dc 51 Ground 56 3 3 V dc 62 Ground 71 3 3 V dc 76 Ground 81 3 3 V dc Locations and connections 5 3 4048 1xx Controller card assembly connectors
76. e Repair information 4 33 4048 1 xx Cartridge contact assembly removal 1 Remove the HVPS See HVPS card removal on page 4 75 2 Remove the cartridge contact assemblies A Note The lower right cartridge contact to the transfer roll is a different color from the others Be sure to reinstall this one in the same location 4 34 Service Manual 4048 1xx Tray damper and spring removal 1 Remove the right side cover See Right side cover removal on page 4 12 2 Remove the tray damper spring from the printer frame post A runes 1 EE n A 3 Rotate the lever counterclockwise as far as possible and lift out Repair information 4 35 4048 1 xx Door latch removal 1 Remove the right side cover See Right side cover removal on page 4 12 2 Remove the two screws A Nida 2 Sis WT oe PPP reves wa ees CET gt bd gt fe eo 00 3 Remove the left side cover See Left side cover removal on page 4 14 4 Remove the latch on the left side 4 36 Service Manual 4048 1xx Paper guide roller removal 1 Remove the HVPS See HVPS card removal on page 4 75 2 Remove the print cartridge 3 Remove the upper body MPF assembly See Upper MPF housing assembly with paper flag removal on page 4 66 4 Unsnap the latch which is part of the roller hub A 5 Remove the paper guide roller Repair information 4 37
77. e This action is not available if the printer is in Diagnostics Mode or running diagnostics e If the device is experiencing a hardware problem turn the printer off and on Close Door Close the upper front door 2 12 Service Manual 4048 1xx User attendance messages continued Message Explanation Delete All Jobs When the user has selected the Print and Go Stop Hold Delete All Jobs selection this message is displayed The following actions may be taken Press Go to confirm the selection All jobs are deleted Press Return or Stop to cancel the delete operation Insert tray Tray Tray 1 or Tray 2 The printer does not detect the presence or absence of a tray but that paper was not picked Replace the tray and press Go Note This situation usually occurs when the tray is refilled during a job To refill a tray during a printing session press Stop and wait for pages to reach the output bin before refilling the tray The following actions may be taken Insert the requested tray e Press Menu until Busy Waiting displays The following selections are available Cancel Job Reset Printer If the message cannot be cleared verify whether the paper is being picked If so and the paper advances to activate the input sensor this message would indicate a sensor problem Otherwise check the pick tires and pick mechanism Diagnostic information 2 13 4048 1 xx User attendan
78. e 4 39 transfer rollassembly 4 43 tray 1 D roll shaft assembly 4 45 tray 1 feed D roll 4 44 tray damper and spring 4 35 upper MPF housing assembly 4 66 resolution 1 4 S safety information xvii safety inspection guide 6 1 scheduled maintenance 6 2 Sensor Test 3 11 3 12 sensors cartridge signature button 4 42 duplex input sensor 3 11 exit sensor 3 14 fuser exit removal 4 33 input sensor 3 14 MPF paper sensor removal 4 67 narrow media sensor 3 14 paper detect input and bracket removal 4 44 paper sensor MPF removal 4 67 parts catalog 7 18 pass thru sensor 3 13 toner optical sensor 3 14 tray present sensor 3 13 upper front door sensor 3 14 serial number 1 2 service checks controller card 2 38 cooling fan 2 36 cover interlock switch 2 37 dead machine 2 39 fuser cold fuser 2 41 hot fuser 2 41 4048 1 xx high voltage power supply HVPS 2 40 low voltage power supply LVPS 2 39 main motor 2 42 operator panel 2 43 paper feed 2 45 parallel port 2 49 print quality 2 50 transfer roll 2 44 service error codes 2 6 specifications connectivity 1 1 data streams 1 5 fonts 1 6 inputsizes 1 9 lubrication 6 1 media 1 7 memory 1 5 models 1 1 operator panel 1 3 options 1 8 output sources 1 10 print area 1 6 resolution 1 4 standard trays 1 8 supplies 1 6 start 2 1 sub error codes 2 24 supplies 1 6 symptoms POST symptoms 2 3 printer symptoms 2 4 T test pages duplex quick test 3 9 input source 3 5 input t
79. e charge roll If one side has a much lower force than the other check the spring of the guide assembly Replace the faulty guide assembly either right or left If force seems similar try a new cartridge Transfer assembly roll Check the springs and bearings at both ends of the transfer roller The bearing assemblies should support the transfer roller applying even pressure to the PC drum Replace the transfer roll assembly if either spring shows signs of damage or fatigue See Transfer roll assembly on page 4 43 Inspect the transfer roller for signs of wear or damage and replace if necessary Note Cleaning or vacuuming the transfer roll is not recommended An uneven distribution of debris on the transfer roll can cause cyclic variation in image density or banding Poor fusing of image FRU Action Fuser The fuser may not be operating at the proper temperature to fuse the toner to the paper See Cold fuser service check on page 2 41 Make sure recommended paper is being used Diagnostic information 2 53 4048 1xx Light print FRU Action Print cartridge not a FRU Make sure the print cartridge is installed correctly and is not low on toner If the problem continues install a new cartridge Transfer roller HVPS contact transfer roller HVPS card Check the transfer roller for signs of toner buildup and contamination Inspect the HVPS contac
80. e errors 2 6 2 10 1565 Emul Error 2 23 A acronyms 1 11 adjustments lubrication 4 6 paper feed alignment 4 5 printhead assembly 4 2 reassembly 4 7 alignment paper feed 4 5 printhead 4 2 bottom pan removal Button Test 3 6 C cable bad connections 2 34 cables 7 12 7 14 7 16 cartridge contact assembly parts catalog 7 7 4 25 removal 4 34 cartridge coupling assembly parts 7 5 removal 4 65 charge roll removal 4 38 tests 3 17 4048 1 xx Config Menu Demo Mode 3 24 description 3 1 Download Emuls 3 24 Energy Conserve 3 25 entering 3 21 Env Prompts 3 26 Error Log Print Log 3 26 Exit Config Menu 3 26 Factory Defaults 3 24 Maint Cnt Value 3 22 Narrow Media 3 25 Panel Menus 3 23 Paper Prompts 3 26 PPDS Emulation 3 23 Prt Quality Pgs 3 23 Reduced Curl 3 26 Reset Maint Cnt 3 22 configuration ID 3 16 connectors controller card assembly 5 2 HVPS 5 8 LVPS 5 7 controller card card and cage removal card removal 4 50 connections 5 2 disconnects 2 34 service check 2 38 cooling fan parts catalog 7 13 removal 4 82 service check 2 36 symptoms 2 3 covers locations 1 2 parts catalog 7 2 removals 4 8 D data streams 1 5 defaults 3 15 Demo Mode 3 24 4 48 4048 1 xx Diagnostics Mode Base Sensor Test 3 14 description 3 1 Device Tests Flash Test 3 14 Duplex Tests Duplex Feed 1 3 11 Quick Test 3 9 Sensor Test 3 11 Top Margin 3 10 entering 3 2 EP Setup Charge Roll 3 17 EP Defaults
81. e failure See Diagnostic information on page 2 1 for the location of each section See the Repair information on page 4 1 to help identify parts After completing the repair perform tests as needed to verify the repair General information 1 1 4048 1 xx Special tools Long Phillips screwdriver approximately 6 inch shank Slotted screwdriver Small Phillips screwdriver Spring hook When taking voltage readings always use the printer frame as ground unless another ground is specified Printer identification Paper support 4 Front cover MPF door assembly Right side cover Serial number Look for the serial number label on the inside front cover of the printer 1 2 Service Manual 4048 1 xx Printer features and specifications Operator panel The operator panel consists of a two line display and six buttons Menu is two buttons Display General information 1 3 4048 1 xx Resolution and print quality JET PictureGrade print resolution print darkness and toner saver can all be set independently of each other through the data stream Control panel menus let a user independently set PictureGrade and print resolution The IET setting is selected when a print resolution is selected using the Quality Menu Toner saver and print darkness settings are set when a toner darkness is selected using the Quality Menu Print Quality sett
82. ecaution for personal safety and to prevent damage to the printer This chapter contains the codes and diagnostic tools to aid in providing corrective action for a malfunctioning printer To determine the corrective action to repair a printer look for the following information Does the POR stop Check the Power On Reset POR sequence on page 2 2 POST symptom table on page 2 3 Do you have a symptom rather than an error message Check the Symptom tables on page 2 3 f you have an error message or user message check the following Service error codes on page 2 6 User attendance messages on page 2 11 Additional information Service checks on page 2 36 Solving print quality problems on page 2 56 Diagnostic information 2 1 4048 1 xx Power On Reset POR sequence The following is an example of the events that occur during the POR sequence when the printer is turned on 1 2 Nos Diamonds are displayed on the operator panel While code is being loaded into DRAM dots scroll across the operator panel A screen is displayed with the memory and processor speed A typical example of this message is 32 Mb 366 Mhz Performing Self Test is displayed Busy is displayed Close Door will be posted if the cover is open Any cartridge errors such as Defective Cartridge are posted Applicable maintenance messages are posted For e
83. eceived on the parallel port Press Menu until Busy Waiting appears and select Reset Printer 56 Standard USB Port Disabled Displayed when status is requested over the USB port but the port has been disabled Once the error has been displayed for the first time reporting of further errors is suppressed until the menus are entered or the printer is reset The following actions may be taken Press Go to clear the message The printer discards any data received on the USB port e Press Menu until Busy Waiting appears and select Reset Printer 58 Too Many Trays Attached This error code displays when too many input trays are attached to the printer Remove the extra trays 2 20 Service Manual 4048 1xx User attendance messages continued Message Explanation 58 Too Many Flash Options 59 Incompatible Tray x This error displays when too many flash options are installed in the printer The following options may be taken Turn off the printer and remove the extra flash options Press Go to clear the message The extra flash options are ignored An incompatible tray is installed For Tray x x 2 or 3 Remove the incompatible tray and press Go to clear the message Note If the user installed the incompatible device to satisfy a Check Device Connections reattach message the user should reinstall an associated compatible option or hot unplug the option 80 Schedu
84. ect Off an additional item appears in the Power Saver menu Disable lets you enable or disable Power Saver from the customer menu ERROR LOG See ERROR LOG on page 3 18 for a more detailed description The error log printed from the Diagnostics Mode contains additional debug information for 9xx errors than the error log printed from the Configuration Menu You can also view or clear the log from the Diagnostics Mode Diagnostic aids 3 25 4048 1xx Print Log Additional diagnostic information is available when you print the error log This report can also be printed from the Diagnostics Mode See Print Log on page 3 19 Also the error log printed from the Diagnostics Mode contains additional debug information for 9xx errors than the error log printed from the Configuration Menu Because you can clear error logs you can view the contents of this log may not match the contents when you view the error log To print the error log 1 Select Print Log from the Error Log menu 2 Press Return to exit the Error Log menu Paper Prompts Setting Paper Prompts controls which tray a change prompt is directed to when paper is sensed to be the wrong size Selections include Auto MP Feeder and Manual Paper Env Prompts Setting Env Prompts controls which tray a change prompt is directed to when envelopes are sensed to be the wrong size Selections include Auto MP Feeder and Manual Env Reduced Curl Use this setting to reduce pap
85. ed Return the cartridge Or the cartridge may be defective Replace the cartridge Diagnostic information 2 15 4048 1xx User attendance messages continued Message Explanation 32 Unsupported Error 32 displays when the top cover is closed Print Cartridge and an unsupported print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is supported Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print then they are not reprinted once a good print cartridge is inserted Replace the cartridge 34 Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size loaded in the tray Make sure the Paper Size setting is correct for the size paper that is being used The following actions may be taken Press Go to clear the message and continue printing e Press Menu until Busy Waiting displays Select one of the following Cancel Job Reset Printer 35 Res Save Off The printer lacks sufficient memory to enable Deficient Memory Resource Save The following actions may be taken Press Go to clear the message The printer disables Resource Save Install additional memory Set link buffers to Auto return to Ready and enable Resource Save and reset the link buffers
86. en the sensor switch is open OP open displays Sensor Test Input 0P Input refers to the duplex input sensor in the duplex unit 3 Press Return or Stop to exit the test Duplex Feed 1 This test feeds a blank sheet of paper to the duplex paper stop position 1 To run the Duplex Feed 1 Test 1 Select Duplex Feed 1 from the Duplex Test menu The power indicator blinks while the paper is feeding Duplex Feed 1 Feeding 2 When the paper reaches the duplex paper stop position 1 the power indicator turns on solid and a message appears Duplex Feed 1 Clear Paper 3 Remove the paper and press Go Return or Stop to end the test Diagnostic aids 3 11 4048 1xx INPUT TRAY TESTS Feed Test This test is used to determine if the input tray sensors are working correctly Observe the paper path as blank media is being fed through the printer The upper front door cannot be opened during the feed test To observe the paper path open MPF door cover to access the multipurpose feeder Any media that meets the specifications for the printer can be used for this test To run the Input Tray Feed Test 1 Open the MPF door Note Do not open the front cover 2 Select the Feed Test from the Input Tray Test menu 3 Select the input source Only installed sources display but may include Tray 1 Tray 2 Tray 3 MP Feeder 4 Select Single to feed a single blank sheet or Continuous to feed blank
87. en the printer input and Remove Cartridge exit sensor Remove the print cartridge to clear the paper path 202 Paper Ja The exit sensor is either covered during POR or Open Rear Door covered too long Open the rear door to access the jam area 231 Paper Ja A piece of media did not arrive at the duplex Remove Trayl input sensor but did leave the printer exit Pull Down Lever Sensor At Printer Rear 235 Paper Jam A piece of media is over the duplex sensor after Remove Trayl a sheet has been picked from the duplex Pull Down Lever At Printer Front 237 Paper Jam A piece of media did not reach the printer input Check Duplex sensor after leaving the duplex unit 2 22 Service Manual 4048 1xx Paper jam messages continued Message Explanation 238 Paper Jam Check Duplex A piece of media is most likely jammed in the duplex area Remove tray 1 and pull down the lever to access the jam area If the paper is not in the duplex area then check the rear of the printer by opening the rear door 239 Paper Jam Remove Tray 1 Pull Down Lever At Printer loc 242 Paper Jam Check Tray 2 A paper jam has occurred in the duplex unit Indicates a load problem with the exit motor also serves as a duplex motor High load could be from using non specified too heavy media in duplex paper path obstructions high frictional forces in the redrive unit rear cover or a worn motor loc can be Front or Rear Tra
88. enu 2 Press Return to exit the Error Log menu Diagnostic aids 3 19 4048 1 xx Clear Log 1 Select Clear Log from the Error Log menu Clear Log Yes 2 Press Yes to confirm Select No to exit without clearing the log 1 000 2 000 3 000 4 000 3 Press Return to exit the Clear Log menu after clearing the log Exit Diagnostics Select Exit Diagnostics to exit the Diagnostic Mode and return to normal mode 3 20 Service Manual 4048 1xx Configuration Menu Entering CONFIG MENU 1 Turn the printer off 2 Press and hold the Select and Return buttons 3 4 Release the buttons when Performing Self Test displays Turn the printer on on the operator panel The menu items appear on the operator panel in the order shown Maint Cnt Value Reset Maint Cnt Prt Quality Pgs Panel Menus PPDS Emulation Download Emuls Demo Mode Factory Defaults NARROW MEDIA Energy Conserve ERROR LOG Paper Prompts Env Prompts Reduced Curl Exit Config Menu Select Exit Config Menu to exit the Configuration Menu and return to normal mode Diagnostic aids 3 21 4048 1 xx Maint Cnt Value This menu lets you view the maintenance count value It only displays if Maintenance Warning and Intervention function is enabled in the configuration ID The maintenance interval is determined by page count Select Maint Cnt Value from the CONFIG MENU Maint Cnt Value 1234567 Press Return to exit Re
89. er whenPerforming Generally the options made Self Test available in this menu group are displays used to configure a printer for operation See Configuration Menu on page 3 21 for more information Diagnostic aids 3 1 4048 1 xx Diagnostics Mode To run the printer diagnostic tests described in this chapter you must put the printer in Diagnostics Mode Entering Diagnostic Mode FON Turn the printer off Press and hold the Go and Return buttons Turn the printer on Release the buttons when Performing Self Test displays on the operator panel The tests are displayed on the operator panel in the order shown REGISTRATION PRINT TESTS Tray 1 Tray 2 displays only if installed Tray 3 displays only if installed MP Feeder Prt Quality Pages HARDWARE TESTS LCD Test Button Test DRAM Test Parallel Wrap displays in some configurations DUPLEX TESTS Quick Test Top Margin Sensor Test Duplex Feed 1 INPUT TRAY TESTS Feed Test Sensor Test BASE SENSOR TEST Toner Input Output Narrow Media Front Door 3 2 Service Manual 4048 1 xx DEVICE TESTS only displays if flash is installed Flash Test PRINTER SETUP Defaults Page Count Perm Page Count Serial Number Engine Setting 1 Engine Setting 2 Engine Setting 3 Engine Setting 4 Model Name Configuration ID Edge to Edge Par S Strobe Adj EP SETUP EP Defaults Fuser Temp Transfer Print Contrast Charge Roll Gap Adjust ERROR LOG
90. er curl problems The printer engine speed is reduced when this setting is turned on Only use this for paper Settings are Off and On and the default is Off Exit Config Menu Select Exit Config Menu to exit the Configuration Menu and return to normal mode 3 26 Service Manual 4048 1 xx Paper jams Most paper jams are caused by improper print media or incorrect loading of the media Note To clear the Paper Jam error message you must remove all jammed print media from the entire paper path The following illustration shows the path that print media travels through the printer The path varies depending on the input source trays and multipurpose feeder and output bin you are using See Paper jam messages on page 2 22 for more information 24x Paper jam Note To avoid tearing print media pull all jams out gently and slowly Use both hands and even pressure if possible Diagnostic aids 3 27 4048 1 xx 3 28 Service Manual 4048 1 xx 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual precautions such as turning off power before removing logic cards Keep the ESD sensitive part in its original shipping container a special ESD bag
91. ernational Inc Lexington KY 40550 U S A P N 12G9436 4048 1xx Table of Contents Lasot HnollO8S s cada Pdoktib ede dd ERA ERR Edd did d FRA Ed RRRRA MRS vii Safety information itas co ted tercexe adus a Eds baba Pads Pus xvii Prefacg siseksskanksaphbE SQ EEAR RE ERR RARE AR ADR ORE Eur ab d xxii De Og da desi d cdeipatiteia Ert beris E E d Es E eed e xxii General information 5ii usciekhibeseiir kabkagg bah sin bd Rd Pis 1 1 Motels 2 54 sik aru Eun m dux deine E eia RR Ra PEE bad esas 1 1 Maipterianmee appeals 13 3 8 602 adi caos RR UAR anan ka teenie Ra s 1 1 Special TO0lS AI IIIA 1 2 Prifteridenuicaon sagesse true tr gps Rok eR E NE ERR thee ee 1 2 Printer features and specifications leeren 1 3 Operator panels sessi esq E nmm sk ema Edo v BR PU GR OU 1 3 Resolution and print qualiby 4 4 5222 2 enam nnnm na inan 1 4 Memory and user flash memory iss casam nd ee RR RR Ran 1 5 Primer dels Steams ai Sch musta LR aep Ret ace aa 1 5 alti 2252204088 cbt 2c cnheeerereewsacetaseesizadenedae 1 6 UW riri vita sh iol echt iea helen T D tino 1 6 FOS 08 dando dase UT 1 6 Media and paper handling 24x ia ka Era ak ER na i QR ea egw ea 1 7 Mr ccna ed cae ama ed enna dae seca s eacdaeaceseseanedes 1 7 Standard and optional paper sources lessls 1 8 Input media SoUfeeS i ia ndurde a e doa 9 ERR EA o3 CR Rd doi do 1 9 Outpit MEd acct o shi tris Re AA medien e rE s uU RU RUNI S 1 10 ACON uu Saone safer aua aa
92. ertificada como um produto laser da Classe em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe nao sao considerados perigosos Internamente a impressora cont m um produto laser da Classe IIIb 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um nivel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas X Service Manual 4048 1 xx Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 Laserprodukten van klasse 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 l laserprodukt i overenstemmelse med kravene i IEC
93. es 3 6 printer identification 1 2 printhead adjustment 4 2 parts catalog 7 7 removal 4 46 printhead cable parts catalog 7 13 Prt Quality Pgs CONFIG MENU 3 23 Diagnostic Mode 3 6 diagnostics 2 56 Q Quick Test 3 4 Quick Test duplex 3 9 R ratchet drive assembly lubrication 4 6 parts 7 5 removal 4 60 rear cover assembly lubrication 4 7 removal 4 15 reassembly 4 7 reference feed assembly parts 7 5 removal 4 62 registration 3 4 removals 2 pin connector 4 46 3 pin connector 4 46 bottom pan non duplex 4 25 cartridge contact assembly 4 34 cartridge coupling assembly 4 65 cartridge signature button sensor 4 42 charge roll 4 38 controller card 4 50 controller card and cage 4 48 cooling fan 4 82 covers front 4 9 left side 4 14 MPF door cover 4 8 rear 4 15 rear exit door 4 17 right side 4 12 top cover assembly 4 11 door latch 4 36 duplex tray assembly 4 24 exit drive assembly 4 59 exit drive motor 4 58 fuser assembly 4 26 fuser exit sensor 4 33 fuser paper exit guide 4 29 HVPS card 4 75 left guide 4 40 lower MPF housing assembly 4 70 LVPS card 4 77 LVPS fan 4 76 main drive assembly 4 55 main drive motor assembly 4 53 MPF paper sensor 4 67 MPF pick roller assembly 4 73 operator panel assembly 4 22 operator panel cable 4 20 4048 1 xx output tray full flags 4 18 paper detect bracket 4 44 paper guide roller 4 37 printhead 4 46 ratchet drive 4 60 reference feed assembly 4 62 right guid
94. etting for the amount of time strobe is sampled to determine that valid data is available on the parallel port Incrementing this value by one means the strobe is sampled 50 nanoseconds longer The range of values are between 4 and 6 in increments of one A value of zero indicates no change is made from the factory setting 3 16 Service Manual 4048 1 xx EP SETUP EP Defaults Restores all EP settings to factory default values Selections are Restore and Do Not Restore Fuser Temp Changing this setting can reduce paper curl or melting of some letterhead images Selections are Normal default Lower and Lowest Transfer Selections are Low Medium default and High Print Contrast Selections are Low Medium default and High Charge Roll Selections are Low Medium default and High Gap Adjust Adjusts the minimum gap between sheets during printing This setting reduces speed pages per minute but can be used to reduce curl of printed media and improve stacking in the output bin Range is 0 default to 255 Adjusting by one results in 9 mm of increased gap Diagnostic aids 3 17 4048 1xx ERROR LOG Display Log The error log provides a history of printer errors It contains the 12 most recent errors that have occurred on the printer The most recent error displays in position 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error
95. for continuity across the fuser heater pins 1 and 3 or outer pins If there is no continuity replace the fuser assembly See Fuser assembly removal on page 4 26 If there is continuity follow these steps 1 Reconnect the fuser heater cable 2 Replug and turn the printer on Measure the voltage between the connectors on the back of the switch It should match the line voltage 3 If line voltage is not present replace the LVPS Make sure the fuser thermistor is correctly connected to the controller card J18 Fuser assembly If the fuser heater comes on and a fuser failure error code displays be sure the thermistor is firmly seated in connector J18 on the controller card assembly The thermistor cable goes through the frame by way of a connector Unplug the printer and disconnect the thermistor cable from the controller card J18 Measure the resistance of the thermistor The resistance measures approximately 240K to 400K ohms when cool approximately 40 C or 104 F and 1 5K to 3K ohms hot immediately after running a printout Replace the fuser assembly as necessary Hot fuser service check FRU Action Fuser assembly Unplug the printer and measure the resistance of the thermistor The resistance measures 240K to 400K ohms when cool approximately 40 C or 104 F and 1 5K to 3K ohms hot Replace the fuser assembly as necessary Diagnostic information 2 41 4048 1xx
96. g the motor ramp up to speed 937 Transport motor lost Faulty motor or a jam occurred after lock motor ramp up to speed Possible problem with the main drive 939 RIP engine The RIP processor cannot communicate communications with the engine processor Replace the controller card Go to Controller card assembly removal on page 4 50 If the problem persists contact the next level of support Diagnostic information 2 7 4048 1 xx Service error codes 9xx continued Error Description Action 940 LV Power Supply A The low voltage power supply zero crossover test failed Check the LVPS for correct installation Make sure the connector on the LVPS assembly is firmly seated with the connector on the interconnect card connector This error may also be caused by a noisy AC input power source Be sure the correct LVPS has been installed If all the above are correct replace the LVPS assembly 941 Controller card This error indicates an open fuse in line to tray 2 POR the printer to reset the fuse Check for 24 V dc on J21 pin 6 If correct the fuse is okay If incorrect remove the drawer and check resistance between pin 6 and 5 of the tray If the resistance is less than 50 ohms replace the drawer 950 Controller card There is a mismatch between the variables in the EPROM on the operator panel card and those in the secure NVRAM on the controller card
97. h voltage power supply HVPS card removal 4 75 connectors 5 8 parts catalog 7 13 service check 2 40 input sensor removal 4 44 L Laser notices ivii LCD Test 3 6 locations duct cover assembly 5 1 flags 5 1 front cover 5 1 MPF door 5 1 low voltage power supply LVPS card removal 4 77 connectors 5 7 fan removal 4 76 parts catalog 7 13 service check 2 39 lubrication drive assembly 4 6 exit drive assembly 4 6 exit gear drive assembly 4 7 MPF pick rollassembly 4 7 ratchet drive 4 6 ratchet drive assembly 4 6 rear cover assembly 4 7 lubrication specifications 6 1 4048 1 xx main drive assembly lubrication 4 6 parts catalog 7 5 removal 4 55 main drive motor assembly parts catalog 7 5 removal 4 53 service check 2 42 maintenance handling ESD sensitive parts 4 1 lubrication 4 6 maintenance kit 6 2 maintenance kit parts group 6 3 preventive 6 1 maintenance approach 1 1 maintenance kits 6 2 media input sources 1 9 options 1 8 output sources 1 10 paper sources 1 8 memory options 1 5 messages paper jam messages 2 22 service error codes 2 6 user attendance messages 2 11 models 1 1 MPF pick roll assembly lubrication 4 7 multipurpose feeder MPF door cover removal 4 8 housing assembly removal 4 70 input tray tests 3 5 locations 5 1 lower housing assembly removal 4 70 parts catalog 7 8 roller assembly removal 4 73 upper housing assembly removal 4 66 N network controller card 7 13 4048 1 xx O operator
98. he assembly Be careful to avoid dropping the ratchet drive gears from the back of the exit drive assembly 5 If the exit drive is being replaced remove the motor assembly and install it on the new drive Note Reinstall the ratchet drive before you reinstall the assembly Note Be sure to reattach the ground strap B when you reinstall the assembly Repair information 4 59 4048 1 xx Ratchet drive removal 1 Remove the exit drive assembly See Ratchet drive removal on page 4 60 2 Gently remove the ratchet drive A from the back of the exit drive assembly 3 Remove the bushing B from the exit drive assembly 4 60 Service Manual 4048 1xx Installation 1 Place the printer on the right side 2 Install the bushing C aligning it with the slots 3 Insert the ratchet Repair information 4 61 4048 1 xx 4 Complete the installation of the exit drive Reference feed assembly removal 1 Remove the gear train assembly See Main drive assembly removal on page 4 55 2 Remove the three screws A fastening the assembly plate to the frame 3 Remove the MPF door cover See MPF door cover removal on page 4 8 4 Remove the lower body MPF assembly See MPF paper sensor removal on page 4 67 4 62 Service Manual 4048 1xx 5 Remove the two screws B holding the upper body MPF assembly and carefully lift the assembly out Note A sensor flag is attached below the
99. he fuser exit guide fingers so they are not bound by the rear cover A bind causes jams Be sure the spring contacts on the left side of the rear cover make good contact with the LVPS cage 4 16 Service Manual 4048 1xx Rear exit door removal 1 Open the rear exit door 2 Use your index finger or flatblade screwdriver to disengage the left facing the back of printer hinge A from the rear cover 3 Swing the left side out to clear the printer and then move the door to the left to disengage the right hinge Repair information 4 17 4048 1 xx Output tray full flag removal 1 Open the front cover 2 Remove the two screws A holding the front top cover A 3 Remove the two screws B from the rear 4 Lift the rear part of the top cover to clear the output tray full flags You do not have to disconnect the top cover from the left and right guides 4 18 Service Manual 4048 1xx 5 Press the side of the flag to unclip the flag from the frame eae 6 Repeat to remove the other flag Repair information 4 19 4048 1 xx Operator panel cable removal 1 Remove the left side cover See Left side cover removal on page 4 14 2 Remove the inner shield A 3 Loosen the five screws B slide the controller card cage cover toward the rear and remove 4 Disconnect the cable from the controller card C i C 5 Withdraw the cable through the cage and frame 6 Remove the
100. he roll Note Always check the bottom margin following a transfer roll replacement See REGISTRATION on page 3 4 2 44 Service Manual 4048 1 xx Paper feed service checks Paper picks and advances approximately four inches FRU Action Reference feed Turn printer off and remove the print cartridge assembly and left side cover Backup roller assembly With a left finger rotate the main motor Paper feed gear counterclockwise while using a right finger to Drive assembly resist gear movement in the reference feed assembly located in the paper path below the cartridge e f the gear motion cannot be stopped look for obstructions in the paper path such as debris or damage e f the gear motion can be stopped while continuing to rotate the drive motor one of the following units has to be replaced Check or replace the FRUs in the following order Backup roller assemblies Reference feed assembly Drive assembly When the reference feed assembly is replaced it has to be adjusted See Adjusting paper feed alignment skew on page 4 5 for more information Diagnostic information 2 45 4048 1xx Paper jam error indication during POST FRU Action Stack control flags Photo sensor If the exit sensor flag is not resting within the paper exit sensor during POST the printer indicates Remove Paper Standard Bin Make sure the flag is operating freely and correctly Repla
101. heet T2 7 21 56P2345 Tray assembly 500 sheet T8 7 21 56P2346 Drawer assembly 250 T2 and base 7 21 56P2347 Drawer assembly 500 T3 and base 7 21 56P2348 Fuser lift outer link assembly 7 11 56P2349 Fuser lift inner link 7 11 56P2350 Cartridge signature button switch 7 15 7 19 56P2351 Entrance guide assembly with brush 7 7 56P2352 Paper feedroll 6 2 7 5 56P2353 Operator panel assembly 7 3 56P2354 Operator panel cable cover 7 3 56P2355 Fuser paper exit guide assembly 7 9 56P2356 Operator panel assembly Japan 7 3 56P2357 LVPS fan and housing assembly 7 13 56P2358 MPF paperpickgear 7 8 56P2359 MPF pick rollassembly 4 7 7 8 56P2360 Exit drive motor 7 5 56P2361 256MB PC100 kit DIMM 7 21 56P2363 Ratchet drive 4 6 7 5 56P2364 Maintenance kit parts group 6 2 7 22 56P2365 Paper guide bracket 7 5 56P3304 ImageQuick cardassembly
102. hen the front screw C 4 74 Service Manual 4048 1xx HVPS card removal 1 Remove the right side cover See Right side cover removal on page 4 12 2 Disconnect the HVPS cable at the top left corner of the board 3 Remove the four screws A 4 Disconnect the charge roll cable spade connector 5 Remove the HVPS card Repair information 4 75 4048 1 xx LVPS fan removal Remove the right side cover See Right side cover removal on page 4 12 2 Disconnect the fan A 3 Remove the two screws B 1 t H E uti A TAY TS L4 E 4 Remove the LVPS fan 4 76 Service Manual 4048 1xx LVPS card removal AA 1 Unplug the printer 2 Remove the right side cover See Right side cover removal on page 4 12 3 Remove the LVPS fan See LVPS fan removal on page 4 76 4 Disconnect all cables attached to the LVPS card The fuser connector has a latch on the back side If it cannot be reached complete steps 5 and 6 first 5 Remove the four screws A EA A t4 Lam m 6 Remove the LVPS Repair information 4 77 4048 1 xx Inner link and outer link assembly removal Note Links are shown in light color for visibility They are actually dark in color 1 Remove the controller card cage See Controller card cage with card in place removal on page 4 48 Remove the fuser See Fuser assembly removal on page 4 26 Remove the charge rol
103. ing All models Print resolution 300 dpi 600 dpi 1200 Image Quality 2400 Image Quality 1200 dpi SSNSS Image Enhancement Technology IET 2 bits pel 4 bits pel Toner saver SISISS Print darkness PictureGrade 4 X Indicates print quality setting is supported 1 4 Service Manual 4048 1 xx Memory and user flash memory Each model has a standard amount of memory RAM soldered on the controller card and a certain number of 100 pin DIMM slots available for installing additional memory or user flash memory options Models Memory 101 and 111 102 Standard memory 32MB 64MB Standard flash memory None None Memory options 8MB DIMM V V 16MB DIMM V V 32MB DIMM V V 64MB DIMM V V 128MB DIMM V V 256MB DIMM V V Maximum of memory DIMM 1 1 Maximum possible memory 288MB 320MB Flash memory options 16MB V V 32MB V V Maximum of flash memory options 1 1 Maximum possible flash memory 32MB 32MB 4 Indicates option is supported Printer data streams Data streams All models PCL 6 emulation V PostScript 3 emulation PPDS NININ PDF version 1 3 General information 1 5 4048 1xx Print area The following print area settings are available Print area option All models Normal v Fit to page x Edge to edge r4 Supplies
104. is discarded Identical errors in consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the error log 1 Select Display Log from the Error Log menu The error log is displayed on three screens but only four entries are shown at a time To move to the next screen press Menu For example 1 200 2 920 3 928 4 922 5 250 6 990 7 230 8 230 9 953 10 000 11 000 12 000 In this example the last error was a 200 error In positions 10 11 and 12 no codes were recorded 2 Press Return to exit the error log 3 18 Service Manual 4048 1 xx Print Log Additional diagnostic information is available when you print the error log Some of the additional information includes Detailed printer information including model and serial number Time and date stamps Page counts for each error Model and Error Log Information Page Serial number kamari T1 Printer information 4 Page count Panel display when error occurred Sub error codes Next error code The printed error log can be faxed to Lexmark or your next level of support for verification or diagnosis This report can also be printed from the Configuration Menu Because you can clear error logs the contents of this log may not match the contents when you view the error log To print the error log 1 Select Print Log from the Error Log m
105. l See Charge roll removal on page 4 38 Remove the remaining screws fastening the top cover and tilt the cover forward onto the front cover Remove the screw behind the card cage which holds the outer link assembly and the inner link together Remove the screw behind the card cage which fastens the link guide to the left guide assembly 4 78 Service Manual 4048 1xx 7 Use a flat blade screwdriver to wedge the charge roll arm from the left guide assembly and remove the inner link Repair information 4 79 4048 1 xx 8 Remove the bellcrank while holding the link guide 4 80 Service Manual 4048 1xx 9 Remove the inner link The outer link can also be removed Note The outer link assembly is disconnected and must be reconnected at reassembly A diagram of the linkages is shown left guide Outer link assembly Repair information 4 81 4048 1 xx Cooling fan removal 1 Remove the top cover See Top cover assembly removal on page 4 11 2 Remove the right side cover See Right side cover removal on page 4 12 3 Disconnect the fan cable 4 Remove the two screws A 5 Remove the fan 4 82 Service Manual 4048 1 xx 5 Locations and connections Exterior locations Paper support Right side Flags Front cover MPF door 4 assembly Operator Locations and connections 5 1 4048 1 xx Connectors Note Pin number 1 is
106. led Maintenance Replace the fuser assembly transfer roller charge roll and pick rolls at this recommended interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit For more information see Scheduled maintenance on page 6 2 81 Engine Code CRC Failure This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check Press Go to clear the message The microcode data is discarded and must be re transmitted from the host 88 Toner Low This message displays when toner low occurs and the toner low alarm is activated Press Go to clear this message Diagnostic information 2 21 4048 1 xx Paper jam messages Repeating jams or jam messages can be caused by any of the following Faulty pick solenoids or worn cams of the solenoids Faulty flags or springs Worn backup rollers at the reference guide Improperly adjusted reference guide Debris in the paper path Paper not of the specified length Paper jam messages Message Explanation 200 Paper Jam The input sensor under print cartridge is Remove Cartridge covered too long or is covered during POR or when Go is pressed after clearing a different jam or problem The exit sensor could also be covered Remove the print cartridge and open the rear door to remove the media 201 Paper Jam Paper is jammed betwe
107. letter or A4 paper 3 4 Service Manual 4048 1xx PRINT TESTS Tray 1 Tray 2 Tray 3 or MP Feeder Input source print tests can verify that the printer can print on media from the installed input sources Only installed sources appear in the menu To run the input source test 1 Select PRINT TESTS from Diagnostics Mode 2 Select the input source from the sources displayed on the Feed Test menu All installed sources are listed Menu selections Description Tray 1 Standard tray Tray 2 Optional tray Tray 3 Optional tray MP Feeder Multipurpose feeder If installed 3 Select either Single feeds one sheet of blank media from the selected source or Continuous continues feeding blank media from the selected source until Return or Stop is pressed 4 Press Return or Stop to exit the test Diagnostic aids 3 5 4048 1 xx Prt Quality Pgs To print the Print Quality pages 1 Select PRINT TESTS from Diagnostics Mode 2 Select Prt Quality Pgs 3 Press Select Four pages print Additional button presses are ignored until the pages have printed If duplex is selected the pages print front and back The first page is a mix of graphics and text The second two pages are graphics and the last page is blank The Print Quality pages can also be printed from the Configuration Menu HARDWARE TESTS LCD Test 1 Select LCD Test from Diagnostics Mode The LCD test continually executes
108. lope DL envelope C5 envelope B5 envelope SIESISISISISISINSIS Other envelope V S ISI ISIS SN IN IS Size supported but results may be unacceptable 1 10 Service Manual 4048 1 xx Acronyms ASIC C CRC DC DEV DIMM DRAM ECC EPROM FRU GND HVPS IET KB LCD LSU LVPS MPF NAND NVRAM PIN PJL POR POST PPDS RAM RIP SDRAM SRAM T TAR USB Vac Application Specific Integrated Circuit Charge Roll Cyclic Redundancy Check Direct Current Developer Roll Dual In line Memory Module Dynamic Random Access Memory Error Checking and Correction Erasable Programable Read Only Memory Field Replaceable Unit Ground High Voltage Power Supply Image Enhancement Technology Kilobyte Liquid Crystal Display Laser Scanning Unit Low Voltage Power Supply Multipurpose Feeder Not And Gate Nonvolatile Random Access Memory Personal Identification Number Printer Job Language Power On Reset Power On Self Test Personal Printer Data Stream Random Access Memory Raster Image Processor Synchronous Dynamic Random Access Memory Static Random Access Memory Transfer Roll Toner Adder Roll Universal Serial Bus Volts Alternating Current General information 1 11 4048 1 xx 1 12 Service Manual 4048 1 xx 2 Diagnostic information Start CAUTION Unplug power from the printer before connecting or disconnecting any cable assembly or electronic card This is a pr
109. ly The 100 V kit P N 56P2338 contains P N 56P2332 fuser assembly 6 2 Service Manual 4048 1 xx Maintenance kit parts group The maintenance kit parts group P N 56P2364 includes the following items MPF rubber pick roll Metal plate for tray 1 with pad Metal plates for optional 250 sheet trays with pads Rubber pick rolls for optional 250 sheet trays Metal plate for 500 sheet tray with pad Rubber pick roll for 500 sheet tray Preventive maintenance 6 3 4048 1 xx 6 4 Service Manual 4048 1xx 7 Parts catalog How to use this parts catalog Abbreviations used in the parts catalog include the following NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration 101 102 or 111 FRUs may be identified by model numbers The following table lists the models and their descriptions a as Description 4048 101 Duplex non network 4048 102 Duplex network 4048 111 Simplex non network Parts catalog 7 1 4048 1 xx Assembly 1 Covers 7 2 Service Manual Assembly 1 Covers 4048 1 xx mu er Units Description 1 1 56P2302 1 Rear cover assembly 2 56P2301 1 Rear exit door assembly 3 56P2306 1 Top cover assembly 4 56P2307 1 Right cover assembly 5 56P2305 1 Front cover assembly 6 56P2303 1 MPF door cover assembly 7 56P2342 1 Language overlay group 8 56P2353 1 Operator panel as
110. m the cage and sliding the card to the right Repair information 4 51 4048 1 xx MPF gear removal 1 Remove the left side cover See Left side cover removal on page 4 14 N Remove the inner shield Co Lift the solenoid arm A to release the gear 5 Rotate the main motor B counterclockwise until the gear clears the main motor drive bracket C 5 Pull the latch D away from the shaft and slide the gear off the shaft 4 52 Service Manual 4048 1 xx Main drive motor assembly removal 1 Remove the left side cover See Left side cover removal on page 4 14 2 Remove the screw A and remove the inner shield Repair information 4 53 4048 1 xx 3 Disconnect the cable B to the card for the drive motor 4 Remove the four screws C holding the metal base plate to the gear train assembly 5 Remove the motor assembly Note Be very careful when reinstalling the motor Do not allow the motor drive shaft to touch the mating gears until the shaft is fully inserted Install one screw and confirm the motor is seated against the drive plat before installing the remaining screws 4 54 Service Manual 4048 1xx Main drive assembly removal 1 Remove the controller card cage See Coniroller card cage with card in place removal on page 4 48 2 Remove the inner shield by removing the screw A 3 Release the solenoid latch B 4 Rotate the drive motor until the MP
111. me 4048 1xx mus iN Units Description 3 1 56P2319 1 Printhead assembly 2 56P0629 1 Cartridge contact assembly includes 5 3 56P0662 1 Base feet 4 56P0661 1 Tray damper 5 56P0668 1 Parts packet screws and E rings 6 56P2310 1 Main tray assembly 250 7 56P0667 1 Door latch includes 3 8 56P0660 1 Paper guide roller 9 56P0672 1 Tray body bracket includes 4 10 56P2351 1 Entrance guide assembly with brush Parts catalog 7 7 4048 1 xx Assembly 4 Multipurpose feeder MPF sate HN Units Description 4 1 56P2312 1 Upper MPF housing assembly 2 56P2311 1 Lower MPF housing assembly 3 56P0615 1 MPF paper feed cover cap 4 56P2359 1 MPF pick roll assembly 5 56P2358 1 MPF paper pick gear order lubricant to use with this gear P N 99A0394 7 8 Service Manual 4048 1 xx Assembly 5 Fuser E de Units Description 5 1 56P2330 1 Fuser assembly 110 V 1 56P2331 1 Fuser assembly 220 V 1 56P2332 1 Fuser assembly 100 V 2 56P2355 1 Fuser paper exit guide assembly 3 56P0676 1 Fuser exit spring Parts catalog 7 9 4048 1 xx Assembly 6 Charging ame Inside frame 7 10 Service Manual Assembly 6 Charging 4048 1 xx ASM Fan Units Description index numbers 6 1 56P0640 1 Charge roll Note Customer replaceable unit is a different part number order CRU P N 56P2341 2 56P0668 1 Parts packet screws and E rings 3 56P0669 1 Piv
112. media Refer to the Card Stock amp Label Guide available on the Lexmark Web site at www lexmark com If the customer is printing on transparencies card stock or labels be sure to check the Paper Type in the printer driver or operator panel If the media has an uneven surface adjust the driver or printer Paper Weight and Paper Texture The print cartridge may be defective Replace it 2 56 Service Manual 4048 1xx Problem Action Toner smudges appear on the front or back of the page Make sure the paper is straight and unwrinkled Check for loose toner in the printer Clean the printer e If the problem persists replace the cartridge Vertical or horizontal streaks appear on the page Replace the print cartridge Toner smears or rubs off the page Try a different kind of paper Papers designed for copiers give the best quality e f you are printing on special media such as card stock or labels be sure you select the correct paper type in the printer driver Change the media texture setting You can download the latest driver from the Lexmark Web site www lexmark com The print is getting light but Toner Low does not display The message does not display if a print cartridge with less than a 6 000 page yield is installed Remove the cartridge and gently shake it from side to side to redistribute the toner Replace the cartridge
113. nd the photoconductor DC Check as follows 1 Turn printer off 2 Remove the right side cover See Right side cover removal on page 4 12 for more information 3 Remove the print cartridge 4 Check from C on the HVPS to the bearing on the left side of the charge roll See page 5 8 for more information Check from the Dr B TAR developer roll D transfer roll T and photoconductor DC respectively to the corresponding pin on the right side frame where the print cartridge makes its contacts If any show discontinuity remove the HVPS and check the cartridge contact assemblies springs for continuity and damage If the charge roll and the cable at C show discontinuity replace the left guide assembly See High voltage power supply HVPS on page 5 8 for testing the board ol Fuser service check When toner is partially fused to the paper it is usually caused by low fuser temperature The line voltage to the printer must be within the following limits 90 V ac 120 V ac for nominal 100 V model printer 100 V ac 127 V ac for the nominal 110 V model printer 200 V ac 240 V ac for the nominal 220 V model printer 2 40 Service Manual 4048 1xx Cold fuser service check FRU Action Fuser assembly Unplug the printer and disconnect the fuser LVPS heater cable from the LVPS card connector CN3 See Low voltage power supply LVPS on page 5 7 for more information Check
114. ndica la presenza A N 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 urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende Vorsichtsma3nahmen treffen ACHTUNG Dieses Symbol weist auf eine AN gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein mu xviii Service Manual 4048 1 xx Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del dise o original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas e La informaci n sobre el m
115. ng to ramp up DC redrive 239 X3 x4 motor 8E 00 15 x1 Excessive PWM for the DC redrive motor 239 00 x2 8E xx 16 00 Page detected over tray pass thru at 200 00 00 warm up and tried to feed out but did not reach the input sensor in time 8F xx 00 x1 Duplex sensor was never made by 231 x2 00 leading edge of page x1 x2 timeout value 2 32 Service Manual 4048 1xx Sub error codes continued First 6 whi oe Possible Se gara Explanation error xx can be any message value 8F xx 01 00 Duplex sensor covered paper not 238 00 00 expected paper in duplex during warm up 8F xx 02 xl Duplex sensor never changed state when 235 x2 00 sheet left duplex possible sticky sensor x1 x2 timeout value Diagnostic information 2 33 4048 1xx Disconnects on the controller card Always print a page from each paper source following a repair action The following table is an aid to find a problem with a cable connection Error or message Condition Check Connector name if cable is required to connection ir and description unplugged obtain error at No backlight and POST No power J17 LVPS low no text on the delivered to voltage power operator panel controller card supply No backlight no POST J5 OP PANEL text on operator operator panel panel and 5 Go to Dead beeps machine service check on page 2 39 second note 914 POST J6 E
116. nstalled 200 84 00 31 00 00 00 Trailing edge never cleared input sensor when feeding out media that was detected during warm up Clear the media or debris from the printer Enter Diagnostics and perform the Base Sensor test to verify the proper function of the exit sensor See Entering Diagnostic Mode on page 3 2 and BASE SENSOR TEST on page 3 14 200 Diagnostic information 2 29 4048 1 xx Sub error codes continued First 6 bytes sub error code data xx can be any value Explanation Possible error message 89 00 01 A 89 XX 03 The exit sensor at the fuser is activated by a piece of media indicating there is a piece of media in the machine during POST Check for media in the exit of the fuser assembly or redrive assembly Feed a sheet of paper and if the same error occurs after clearing the fuser or the same error occurs when no media is present check the exit sensor assembly Turn the printer off enter the diagnostic tests menu and select the base sensor test Select output sensor and check the sensor for correct operation The fuser exit sensor did not detect the trailing edge of the media going through the fuser assembly e This failure can be caused by a broken fuser exit sensor flag This may also be caused by erratic operation of exit sensor flag or exit sensor or a defective piece of media 202 202 89 XX 04 xl The fuser
117. oe Lexmark T430 4048 1xx Service Manual e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index LEXMARK 4048 1xx Edition October 2004 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining 9 Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase References in this publication
118. opes lt size gt 7 4 Envelope 9 Envelope 10 Envelope DL Envelope C5 Envelope B5 Envelope or other Envelope Diagnostic information 2 11 4048 1xx User attendance messages continued Message Explanation Change lt input source gt lt type gt lt size gt This message displays when the user should change the media installed in one of the input options e lt input source gt Tray 1 Tray 2 Tray 3 or MP feeder e lt type gt Bond Card stock Colored Envelope Labels Ltrhead Plain Preprint or Transparency lt size gt letter legal B5 A4 Executive Universal A5 Folio or Statement For envelopes lt size gt 7 4 Envelope 9 Envelope 10 Envelope DL Envelope C5 Envelope B5 Envelope or other Envelope Check Tray x Connection Tray x Tray 2 or Tray 3 This messages displays for the following conditions The specified device may have been removed from the printer possibly to clear a paper jam or to uninstall the option The option may be attached to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions may be taken e If the option was temporarily removed or not connected properly reattach or reconnect it Press Go to execute a configuration change which notifies the printer the option has been hot unplugged removed with the power on Not
119. ot hinge quantity 2 4 56P2328 1 Right guide assembly 5 56P2329 1 Transfer roll assembly 6 56P2340 1 Left guide assembly 7 56P2349 1 Fuser lift inner link 8 56P2348 1 Fuser lift outer link assembly Parts catalog 7 11 4048 1 xx Assembly 7 Electronics and cables 1 7 12 Service Manual 4048 1 xx Assembly 7 Electronics and cables 1 mus ges Units Description 7 1 56P2357 1 LVPS fan and housing assembly 2 56P2335 1 Main harness cable assembly including wiring to the following locations VPS fan fuser fan HVPS Main fan LVPS power VPS control Paper input sensor duplex 3 56P2320 1 Power supply 110 V 3 56P2321 1 Power supply 220 V 3 56P2339 1 Power supply 100 V 4 56P2322 1 High voltage power supply 5 56P2340 1 Left guide assembly only the end of the cable shown 6 56P2314 1 Controller card assembly non network 101 111 6 56P2315 1 Controller card assembly network 102 7 56P2318 1 Printhead cable assembly 8 56P2323 1 Fuser cooling fan Parts catalog 7 13 4048 1 xx Assembly 8 Electronics and cables 2 7 14 Service Manual 4048 1xx Assembly 8 Electronics and cables 2 d d AR Units Description 8 1 56P0624 1 Cover switch cable assembly 2 56P2317 1 Operator panel cable assembly 3 56P0625 1 Interlock cover switch 4 56P0645 6 Photo sensor included with P N 56P2311 lower MPF housing 5 Available only with P N 56P2311 6 and 8 56P2313 2 Pa
120. owing selections are possible Cancel Job Reset Printer 2 18 Service Manual 4048 1xx User attendance messages continued Message Explanation 40 Unsupported A firmware card containing network code is Firmware Card installed on a non network printer or a non network card is installed on a network printer Press and hold Go while powering the printer The unsupported card will be ignored Remove the card 41 Unsupported A firmware card containing unsupported code is Firmware Card detected Press and hold Go while powering the printer The unsupported card will be ignored Remove the card 50 PPDS This message displays when the PPDS Font Error interpreter has encountered a font error Note This error may only occur when the printer is formatting PPDS print data The following actions may be taken Press Go to clear the message and continue processing the job Press Menu until Busy Waiting appears The following are available Cancel Job Reset Printer 51 Defective This message displays when the printer detects Flash a defective flash This error may occur at power on or during flash format and write operations Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved 52 Flash Full This message displays when there is not enough free space in the flash memory to hold the resources tha
121. per feed solenoid 7 56P0653 1 Toner level sensor 9 56P2324 1 Drawer cable assembly 10 56P2316 1 Motor cable assembly 11 56P2336 1 Output full and fuser exit cable assembly 12 Double 3 pin connector available only with P N 56P2336 13 56P2350 1 Cartridge signature button switch attached cable shown 14 56P0682 1 Output full sensor cable 15 56P0665 1 3 pin connector 16 56P0666 1 2 pin connector 17 56P0645 1 Photo sensor 18 56P0649 1 Fuser exit cable assembly Parts catalog 7 15 4048 1 xx Assembly 8 cont Electronics and cables Il 7 16 Service Manual 4048 1xx Assembly 8 cont Electronics and cables II Asm index Part numbers Units Description 8 19 19 19 19 19 19 19 19 19 19 19 19 70G0478 1339528 1339529 1339530 1339531 1339532 1339533 1339534 43H5545 1339548 11D0330 1339520 1 ck aa ua ai ai Power cord US Bolivia Canada Caribbean countries Columbia Costa Rica Dominican Republic Ecuador EI Salvador Guatemala Honduras Japan Mexico Nicaragua Panama Peru Puerto Rico Saudi Arabia Taiwan The Virgin Islands Venezuela AP LV Power cord Bahrein Cyprus Iraq Ireland Kuwait Oman Qatar UAE UK Yemen HV Power cord Austria Belgium Bosnia Bulgaria Catalan Croatia Czech Egypt Albania Euro English and other East Finland France Germany Greece Hungary Iceland Iran Italy Jordan Lebanon Macedonia
122. r Pin 1 is designated on the board by an adjacent 1 or triangle Pin numbers index sequentially to the opposite end of the connector See Controller card assembly on page 5 2 for more information The controller card passes 5 V dc and 24 V dc from the LVPS to its clients Therefore when either voltage is missing as an output on the controller card be sure to verify the inputs from the LVPS J17 Sockets 1 and 2 at 24 V dc and socket 5 at 5 V dc Cooling fan service check FRU Action Cooling fan fuser Make sure the plugs of the cooling fan cables Cooling fan LVPS are properly seated Both fans are connected to the same 24 V dc on pin 1 at J19 on the controller Pin 2 is ground for both fans Therefore if one fan functions and the other does not either the fan or the cable is faulty Turn the printer off and disconnect the cooling fan cable at the suspect cooling fan Turn the printer on Within approximately 15 seconds the controller card assembly should apply 24V dc to the fan See Controller card assembly on page 5 2 for more information f voltage is present reconnect the fan to verify the fan is faulty If it is replace the fan f voltage is not present disconnect the cable from the controller card J19 and check for continuity on each cable Ifthe cable is good see Controller card service check on page 2 38 for more information Ifthe cable is damaged replace the c
123. r 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 CAUTION When you see this symbol there is a AN 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 xxii Service Manual 1 General information The Lexmark T430 4048 1xx laser printer is a monochrome laser printer designed for individual users or small workgroups 4048 1 xx Models There are three models differing on standard features including standard memory For information on standard and optional memory see Memory and user flash memory on page 1 5 Models Standard features 101 102 111 Duplex V V Parallel interface connector VA v V 1284 B connector Parallel mode 2 V VA USB port y J Ethernet adapter integrated x V 4 Indicates attachment is part of the factory shipped configuration X Indicates attachment is not part of the factory shipped configuration Maintenance approach The diagnostic information leads you to the correct field replaceable unit FRU or part Use the error code charts symptom index and service checks to determine the symptom and repair th
124. ray feed 3 12 print quality pages 3 23 Prt Quality Pgs 3 6 Quick Test 3 4 tests Device Tests 3 14 Duplex Tests 3 9 EP Setup 3 17 1 6 Service Manual Hardware Tests 3 6 Input Tray Tests 3 12 Narrow Media 3 25 Print Tests 3 5 Printer Setup 3 15 Quick Test page 3 4 Registration 3 4 tools 1 2 Top Margin 3 10 top margin 3 4 Transfer 3 17 transfer roll assembly parts catalog 7 11 removal 4 43 service check 2 44 U upper MPF housing assembly removal 4 66 user attendance messages 2 11 W wiring diagram end of book 4048 1 xx Part number index P N Description Page 1038693 Serial cable 50 ft 7 21 11D0330 Power cord 7 17 12A2405 USB cable 2M 0 0 e 7 21 12G9830 MarkNet X2030t Token Ring 7 21 12G9831 MarkNet X2031e Ethernet 10 100 BaseTX 7 21 12G9832 MarkNet X2012e Ethernet 10 100 BaseTX 10Base2 7 21 12G9833 MarkNet X2011e Ethernet 10 100 BaseTX 7 21 1329605 High speed bidirectional parallel cable 10 ft 7 21 1339520 Power cord ai ee A 7 17 1339528 Power cord 7 17 1339529 POWEF COI eae WAA ene aee are d eam EE v 7 17 1339530 POWer Cord uere eer ce a c IA ADR ee Vra 7 17 1339531 Powercord AAA Ki N a SE TA 7 17 1339532 Power cord llle 7 17 1339533 POWEFr COA e ek Reap o Chee ae es dc 7 1
125. rdnungsgem er Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht viil Service Manual 4048 1 xx Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 1 relatives aux produits laser de Classe I Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe IIlb 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe 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 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIIb 3b all arseniuro di gallio della potenza di 5mW
126. rectional printing 3 Be sure the user application is set up correctly 4 An extra long parallel cable may require some adjustment in the Par S strobe See Par S Strobe Adj on page 3 16 Some computers assume the printer samples data on the trailing edge of the strobe This printer samples data on the leading edge by default This process can be switched by turning Parallel Mode 2 off To change this setting a Select PARALLEL MENU from the Ready Menu b Select Parallel Mode 2 Selections are On and Off If the printer fails to print on command from the host verify the following a Internal print test page prints correctly b The user application printer driver is set up correctly c The host computer has been restarted d The bidirectional parallel cable is connected correctly and is functional If the printer still fails to print correctly replace the controller card assembly Note Always check printhead alignment after replacing the controller card assembly See Printhead assembly adjustment on page 4 2 Diagnostic information 2 49 4048 1xx Print quality service checks Blank page FRU Action Print cartridge Remove the print cartridge and gently shake not a FRU the assembly to evenly distribute the toner Ensure clean electrical contacts on the right side of the cartridge Printhead Blank pages can be caused by a defective Printhead cable printhead assembly HVPS
127. refa necess ria Safety information xix 4048 10x Informacio de Seguretat La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades e La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar r9 r2 a elec lee 9 teal le al Ep Te au ee ee A ae eee ee FHS WAS AWA s 9 HS AGS ALA 8 SLE EAS lee TA HT eee es Al aa At Al Gl TH o 2z H A gE Af 2st A 9 A L E 10L X Loan og T mu ENES ASTHA RHE CF PINAY 58 EUS ASUS HSU UU 2 amp 48 Ste WAS LEA oe UL ea eS FA ale Ta Aya ee 9 91 HA Ol L Cf At 1 OF 2044 HOA HL Tla H TE H T2 15 v7 PS HS XX Service Manual 4048 1 xx Rene ARF ih FS BEE VL OR EY ERR XE n SU BG AR AE d Uh Jj ASAE IU ERR TE DEC POSEE ARTE TA SI AK di ED fei AS DUDEN A
128. rrectly positioned after it has been removed Align it to the frame or use the same position as the removed printhead Skew is caused by a sheet being fed through the printer while misaligned The entire image is rotated relative to the print media edges However a misaligned printhead causes the horizontal lines to appear skewed while the vertical lines remain parallel to the vertical edges Skew Printhead misalignment To align the printhead 1 Enter the Diagnostic Menu See Entering Diagnostic Mode on page 3 2 and print the Quick Test To print the test a Select Print Tests from the Diagnostic Menu b Select Tray 1 c Select Single The Guick Test prints 4 2 Service Manual 4048 1xx 2 Fold the printed test page on the left side so that a few millimeters of grid lines wrap around the outside of the fold 3 Fold a second vertical fold near the center so that the left side top edge aligns with the right side top edge Correct paper fold 4 If the grid lines of the paper on the right side extend below the grid lines of the left side adjust the printhead clockwise relative to the printer and recheck See the left side of the figure below Adjust the printhead counterclockwise if the left side grid lines extend below the right side See the right side of the figure below Adjust printhead Adjust printhead clockwise counterclockwise
129. rts failed while programming network port 980 lt device gt Comm Service errors 980 through 984 lt device gt can be one of the following Engine Duplex or Tray x x 1 2 or 3 2 10 Service Manual 4048 1 xx User attendance messages User attendance messages Message Explanation Change Cartridge Invalid Refill Remove the print cartridge and install a new cartridge Change lt input source custom type name gt Change lt input source lt custom string This message displays when the user should change the media installed in one of the input options e input source Tray 1 Tray 2 Tray 3 or MP feeder Custom Type name gt Custom 1 through Custom 6 using the MarkVision utility When the printer is prompting for one of the custom types which has been named by the user then only the custom type name is displayed on line 2 The name may be truncated to fit the display This message displays when the user should change the media installed in one of the input options e input source Tray 1 Tray 2 Tray 3 or MP feeder e custom string gt a user definable name Change lt input source lt size gt This message displays when the user should change the media installed in one of the input options e lt input source gt Tray 1 Tray 2 Tray 3 or MP feeder lt size gt letter legal B5 A4 Executive Universal A5 Folio or Statement For envel
130. s but stops half way through the printer FRU Action Input paper feed sensor Make sure the input paper feed sensor is Controller card working properly assembly Check for a broken or stuck flag on the input paper feed sensor Make sure the cable is seated on the controller card assembly J20 Verify 5 V dc on pins 1 4 7 and ground on pins 3 6 and 9 See Locations and connections on page 5 1 for more information f correct replace the input paper feed sensor e If the voltage is not correct replace the controller card assembly Note Always check printhead alignment after replacing the controller card assembly See Printhead assembly adjustment on page 4 2 for hardware alignment of the printhead Diagnostic information 2 47 4048 1 xx Paper never picks FRU Action Paper tray Make sure the paper tray and paper are correctly positioned Check the input tray for missing or broken parts Replace the tray as necessary Paper feed solenoid Make sure solenoid is installed correctly and Controller card its cable is plugged into the controller card assembly assembly at J15 See Locations and connections on page 5 1 for more information Verify approximately 55 ohms in the solenoid If not correct replace the solenoid Verify the solenoid has the spring in place and functions mechanically If this is true and the resistance is correct replace the controller
131. screw in the front cover holding the cable cover 7 Remove the cable cover 4 20 Service Manual 4048 1xx 8 Disconnect the cable from the operator panel card Repair information 4 21 4048 1 xx Operator panel assembly removal Warning Never replace both the operator panel and controller card at the same time Otherwise some critical settings will be permanently lost 1 Remove the operator panel cable See Operator panel cable removal on page 4 20 2 Lift the front cover unclip the clear bezel from the bottom of the cover and lift from the bezel from the operator panel 3 Set aside the language overlay 4 22 Service Manual 4048 1xx 4 Press each of the four tabs A while gently prying up the same corner of the operator panel assembly B until the panel is free 5 Remove the operator panel assembly Repair information 4 23 4048 1 xx Duplex tray assembly removal 1 Disconnect the computer and power cables at the back of the printer if not already removed 2 Remove the print cartridge 3 Tilt the printer on its back 4 Remove the five screws A holding the bottom panel 5 Swing the right side away from the printer and disconnect the paper input sensor cable 6 Remove the duplex assembly 4 24 Service Manual 4048 1xx Bottom pan removal This removal is for a model 4048 111 without a duplex unit 1 Disconnect the computer and power cables at the back of the printer
132. see Controller card assembly on page 5 2 Connector Name of pins Pin Signal J4 DIMM continued SDRAM 100 86 Ground 92 3 3 V dc Ground J5 OP PANEL Operator panel 5 V dc Ground N AJP 3 3 V dc J6 Exit motor Exit motor Ground 5 V dc 24 V dc a AJO 24 V dc J7 USB USB connector USB power 5 V dc USB cable attached J9 MPF MPF solenoid 24 V measured to ground 24 V measured to ground J10 MAIN MOTOR Main motor a Ground Ground 24 V dc o NI O 5 V dc J12 MPF SN Sensor MPF toner 5 V dc Ground 5 V dc Oo o Ground 5 4 Service Manual 4048 1 xx Controller card assembly connectors see Controller card assembly on page 5 2 Connector Name of Pin Signal pins J13 LVPS LVPS control 5 5 Ground J14 FD Paper feed solenoid 2 1 24 V dc only during tray 1 pick J16 EXIT Fuser exit tray full 6 1 5 V dc sensor 3 Ground 4 5 V dc 6 Ground J17 LVPS LVPS DC power 6 1 24 V dc 2 24 V dc 3 Ground 4 Ground 5 5 V dc 6 Ground J18 THERM Thermistor Smart 5 1 2 5 V dc m 2 Ground 5 Ground J19 HVPS HVPS 11 1 24 V fans 2 Ground fans 5 Ground 7 24 V dc Locations and connections 5 5 404
133. sembly 8 56P2356 1 Operator panel assembly Japan 9 56P2343 1 Clear bezel with logo 10 56P2354 1 Operator panel cable cover 11 56P2300 1 Left cover assembly Parts catalog 7 3 4048 1 xx Assembly 2 Paper feed 7 4 Service Manual Assembly 2 Paper feed 4048 1 xx Asm Part Units Description index numbers 2 1 56P2304 1 Stack control flags output tray full flags 2 56P0651 1 Duplex assembly 101 102 3 56P2365 1 Paper guide bracket 4 56P2352 1 Paper feed roll 5 56P0655 2 Paper sensor bracket one per package 6 56P0645 1 Photo sensor one per package 7 56P2309 1 Reference feed CBM 8 56P0657 1 Paper feed assembly 9 56P0634 1 Paper feed gear 10 56P2308 1 Backup feed roller assembly top front and rear 11 56P2326 1 Drive assembly Order a lubricant to use with these gears P N 99A0394 FRU Nyogel 744 See page 4 6 12 56P2334 1 Paper feed drive bushing 13 56P2325 1 Main drive motor assembly 14 56P0638 1 Cartridge coupling 15 56P2363 1 Ratchet drive Order a lubricant to use with these gears P N 99A0394 FRU Nyogel 744 See page 4 6 16 56P2327 1 Exit gear drive assembly Order a lubricant to use with these gears P N 99A0394 FRU Nyogel 744 See page 4 6 17 56P2360 1 Exit drive motor 18 56P0639 1 Guide bracket Parts catalog 7 5 4048 1 xx Frame Assembly 3 ISS NS AN RUNS IN Sy N S BN IK p b S yY 7 6 Service Manual Assembly 3 Fra
134. serprodukter av Klass 1 andra lander uppfyller skrivaren kraven for laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass IIIb 3b som best r av en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren ar utformade sa att det aldrig finns risk for att n gon person uts tts f r laserstralning Over Klass I niva vid normal anv ndning underh ll som utf rs av anvandaren eller annan f reskriven serviceatgard xii Service Manual 4048 1 xx Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse I laserprodukt i samsvar med kravene i IEC 60825 1 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i bolgelengdeomradet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse l niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe 1 i segons ha estat certifi
135. set Maint Cnt When 80 Scheduled Maintenance appears and the maintenance kit is installed see Scheduled maintenance on page 6 2 this number should be reset To reset the counter 1 Select Reset Maint Cnt from the CONFIG MENU Reset Maint Cnt Reset 2 Press Select to reset the counter to zero Press Return to cancel 3 22 Service Manual 4048 1xx Prt Quality Pgs To print the Print Quality Pages 1 Select Prt Quality Pgs from CONFIG MENU 2 Press Select Four pages print Additional button presses are ignored until the pages have printed If duplex is selected the pages print front and back The first page is a mix of graphics and text The second two pages are graphics and the last page is blank The Print Quality Pages can also be printed from the Diagnostics Mode Panel Menus If no password is set Panel Menus lets you restrict access to the Ready Menu Group When a password is set by an administrator this menu item does not appear 1 Select Panel Menus from the Diagnostics Mode 2 Select Disable to make menus in the Ready Menu Group inaccessible To change the setting select Panel Menus and select Enable to make the menus available PPDS Emulation This menu lets you turn on PPDS emulation if desired 1 Select PPDS Emulation from CONFIG MENU 2 Select Activate to enable PPDS emulation and Deactivate to turn it off Diagnostic aids 3 23 4048 1 xx Download Emuls
136. sheets until you press Return or Stop The selected input source appears on the display lt input source Feeding Sensor Test This test is used to determine if the input tray sensors are working correctly 1 Select the Sensor Test from the Input Tray Test menu 2 Select the input source Only installed sources display but may include Tray 1 Tray 2 Tray 3 MP Feeder lt input source gt Testing 3 12 Service Manual 4048 1xx 3 A list of sensors appears depending upon the input source selected For example if tray 2 were selected Tray 2 TP 0P P 0P TP refers to tray present sensor P refers to pass thru sensor OP indicates the sensor is open CL indicates the sensor is closed Not all sources have the same set of sensors The table below indicates which sources should display which sensors Source Tray present TP Pass thru sensor P Tray 1 Yes No Tray 2 Yes Yes Tray 3 No Yes Multipurpose feeder Yes No 1 Only available when tray 2 is installed Only available when tray 3 is installed 3 Only available if tray is 250 sheet drawer 4 Press Return or Stop to exit the test Diagnostic aids 3 13 4048 1xx BASE SENSOR TEST Base sensor test is used to determine if the sensors inside the printer are working correctly To run the Base Sensor Test 1 Select BASE SENSOR TEST from the Diagnostics Mode 2
137. sor and flag x12media size 200 84 xx 02 xl KE Paper is over the input sensor too long x12media size x2 source Possible causes are Multi sheet feeding Paper size is not the same as expected The media feeding from the source is slipping or media is slipping before exiting the input sensor 200 84 xx 03 xl The measured gap between sheets of media at the input sensor is too small to meet video requirements x1 time by which the gap was too small 200 2 26 Service Manual 4048 1xx Sub error codes continued First 6 bytes sub error code data xx can be any value Explanation Possible error message 84 xx 04 84 xx 05 xl There was media at the input sensor too The input sensor was covered activated during POST Clear the media or debris from the printer Run the base sensor test input sensor from the diagnostic tests menu to test the input sensor and flag for correct operation early There was not enough time between printhead start and the printhead mirror motor to lock Possible causes for this error are Paper might be pre staged in the paper Source tray Paper is picking too fast due to faulty paper feed assembly A defective input sensor 200 84 xx OF xl X2 x3 The option tray pass thru sensor was never deactivated x12media size x2 media source and x3 media source where paper jam was detected Check
138. st be removed and the new one reinserted through the opening adjacent to its operating location Repair information 4 45 4048 1 xx 3 pin and 2 pin connectors removal 1 Remove the controller card cage See Controller card cage with card in place removal on page 4 48 2 Remove the rear cover See Rear cover removal on page 4 15 3 Unplug the wires on both sides of the connectors 4 Unsnap connectors and remove toward the controller card side Printhead removal 1 Open the front cover 2 Remove the two screws fastening the top cover to the printer frame A A 3 Open the rear exit tray and remove the upper left and right Screws fastening the top cover to the printer frame B E 4 46 Service Manual 4048 1xx 4 Lift the rear part of the top cover to clear the output tray full flags You do not have to disconnect the top cover from the left and right guides to access the printhead 5 Use a sharp pencil or other tool to mark the position of the printhead on the frame for re alignment at installation 6 Remove the three screws holding the printhead C 7 Remove the printhead 8 Disconnect the printhead cables D Note When reinstalling the printhead check the alignment of the printhead to the frame and perform the Printhead assembly adjustment on page 4 2 before reinstalling the top cover Repair information 4 47 4048 1 xx Controller card cage with card in place removal
139. t transfer roller or T for contamination Inspect the HVPS card for contamination where it contacts the cartridge contact assemblies If all components appear free of contamination replace the following FRUs one at a time in the order shown Transfer roller Note Always check the bottom margin following a transfer roll replacement See REGISTRATION on page 3 4 Cartridge contact assembly HVPS card White or black lines or bands FRU Action Print cartridge Paper feed drive gears Banding appears as light or dark horizontal lines on a uniformly gray page or on a page with a large area of graphics Banding is primarily due to a variation in the speed of the paper as it feeds through the printer especially in the developer and transfer process Inspect the cartridge and paper feed components especially the drive gears for signs of wear debris binds or damage Replace drive as necessary 2 54 Service Manual 4048 1 xx Toner on back of page FRU Action Print cartridge Inspect the overall paper path for signs of not a FRU spilled toner Gently clean the contaminated areas with a soft cloth Fuser assembly The fuser belt can deposit toner on the back of the paper if toner is building up on the belt edges This buildup may transfer to the backup roller later transferring to the back of the paper Inspect the belt and backup roller for signs of contamination and replace f
140. t have been requested to be written to flash The following actions may be taken Press Go to clear the message and continue processing the job e Press Menu until Busy Waiting appears The following are available Cancel Job Reset Printer Diagnostic information 2 19 4048 1xx User attendance messages continued Message Explanation 53 Unformatted Flash This message displays when the printer detects an unformatted flash at power on Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the flash is formatted 54 Std Network Software Error This error displays when a network port is detected but the printer cannot establish communications with it Press Go to clear the message The printer disables all communications to the network interface 55 Unsupported Flash in Slot x An unsupported flash option is installed in the solutions port Turn off the printer and remove the unsupported flash option in the specified slot 56 Std Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset The following actions may be taken Press Go to clear the message The printer discards any data r
141. te down the information 2 Continue pressing Return and Select until each screen of information is obtained When the last screen displays the original message displays Printed error codes Additional information is available by printing the error log See Print Log on page 3 19 2 24 Service Manual 4048 1 xx Values In the table below the values for common variables are listed below e media source 10 Multipurpose tray MPT 11 Tray 1 12 Tray 2 13 Tray 3 80 Duplex unit e media size 1 Letter 2 Legal 3 B5 4 A4 5 Executive 6 A5 7 Custom size 9 7 in envelope A 9 Envelope B 10 Envelope C 8 661 in Envelope D C5 Envelope E B5 Envelope F Legal envelope Diagnostic information 2 25 4048 1xx Sub error codes First 6 bytes sub error code data xx can be any value Explanation Possible error message 84 xx 00 xl X2 x3 This code indicates that the input sensor is still actuated from the first sheet and the second sheet is ready to arrive at the sensor x12media size x2 media source Check the printer input sensor and flag for correct operation The flag should operate freely Check for debris in the area of the input sensor Check the area of the transfer roll and input to the fuser for anything that might cause the paper to remain over the input sensor 200 84 xx 01 x1 The video signal never started within 2 inches after actuating the input sensor Check input sen
142. the pass thru sensor and flag for correct operation Check to see if paper has cleared the pass thru area of the option where the paper jam occurred 243 84 xx 18 There is media over the Tray 2 pass thru sensor during warm up If no media is present check the pass thru sensor flag and cables e Try running the Input Tray Tests for Tray 2 and see if Tray 2 is feeding paper correctly and all the sensors are working correctly Make sure the paper size setting is correct for the size paper in the tray 242 Diagnostic information 2 27 4048 1 xx Sub error codes continued First 6 bytes sub error code data xx can be any value Explanation Possible error message 84 xx 20 xl X2 The imaged page is not the expected page x12media size x2 media source Check the pass thru sensor to make sure it is operating properly If no problem is found it may still be necessary to try a new pass thru sensor 200 84 xx 22 xl x2 00 This code indicates that the media activated the input sensor before the printer EP was ready x1 leading edge of media state x2 trailing edge of media state 200 84 xx 23 xl X2 x3 The transfer servo never started x12media size x2 leading edge of media state x3 trailing edge state Possible causes Slow or missing main motor positional feedback Paper too fast to input sensor Gap too small on interpage servo 200 84 xx
143. tion and correct installation Replace as necessary Controller card Ensure the HVPS to controller card and charge assembly roll cables are correctly installed HVPS cable Check continuity of the charge roll cable HVPS from C printed on outside HVPS to the Left guide assembly bushing at the right side of the charge roll If continuity fails replace the left guide assembly which includes this cable Check continuity from the charge roll left side bushing to the right side shaft If continuity fails remove the charge roll and clean the left side shaft and bushing See High voltage power supply HVPS on page 5 8 and check that the voltage measurements are 24 V dc on socket 4 and 5 V dc on socket 7 on the HVPS The pins sockets are numbered from left to right when facing the installed HVPS The front door can be opened to check voltages If incorrect verify the continuity of the cable Replace if necessary Note Pins 1 8 on the HVPS correspond to pins 4 11 respectively of J19 on the controller card f correct replace the HVPS only after verifying all the above items Diagnostic information 2 51 4048 1 xx Heavy background Poor development or poorly charged toner particles cause excessive background This is more noticeable as the print cartridge nears end of life FRU Action Print cartridge Make sure the print cartridge is correctly not a FRU installed and the high
144. to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Lexmark Lexmark with diamond design MarkNet and MarkVision are trademarks of Lexmark International Inc registered in the United States and or other countries ImageQuick Optra Forms and PrictureGrade are trademarks of Lemark International Inc PCL is a registered trademark of the Hewlett Packard Company PostScript is a registered trademark of Adobe Systems Incorporated Other trademarks are the property of their respective owners 2004 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark Int
145. upper body d B 6 Remove the screw C and inside cover which is adjacent to the assembly plate C 7 Remove the MPF pick roller assembly See Repair information 4 63 4048 1xx 8 Remove the reference feed assembly through the front of the printer Installation note When a reference feed reference edge assembly is removed reinstallation requires alignment Use a long shank approximately 6 inches Phillips screwdriver to adjust the rear screw holding the assembly in place Access the adjusting screw through the hole in the main drive assembly between the controller card cage and the main motor board Adjusting the screw counterclockwise rotates the paper counterclockwise in the printer path resulting in the image appearing clockwise on the paper 4 64 Service Manual 4048 1xx Cartridge coupling assembly removal 1 Remove the left cover See Left side cover removal on page 4 14 2 Remove the controller card cage See Controller card cage with card in place removal on page 4 48 3 Remove the two screws A 4 Remove the bracket Note The print cartridge coupling may need to be compressed during removal Repair information 4 65 4048 1 xx Upper MPF housing assembly with paper flag removal 1 Open the front cover 2 Remove two screws A holding the assembly A 3 Carefully lift the assembly out Note A sensor flag is attached below the housing 4 66 Service
146. user assembly as necessary Transfer roller A transfer roller contaminated with toner can cause toner to transfer to the back of printed pages Inspect the transfer roller for contamination and replace as necessary Note Always check the bottom margin following a transfer roll replacement See REGISTRATION on page 3 4 Diagnostic information 2 55 4048 1 xx Solving print quality problems To print the Print Quality Pages 1 Enter Diagnostic Mode a b c d Turn the printer off Press and hold the Go and Return buttons Turn the printer on Release the buttons when Performing Self Test displays on the operator panel 2 Select PRINT TESTS from Diagnostics mode 3 Select Prt Quality Pgs Four pages print Additional button presses are ignored until the pages have printed If duplex is selected the pages print front and back The first page is a mix of graphics and text The second two pages are graphics and the last page is blank The Print Quality Pages can also be printed from the Configuration Menu See Prt Quality Pgs on page 3 23 Problem Action Light or blurred The print cartridge may be getting low on characters toner To use the remaining toner remove the cartridge and shake the cartridge back and forth Reinstall the cartridge and press Go Change the Toner Darkness setting to a value greater than 8 Make sure you are using recommended print
147. wer supply LVPS service check on page 2 39 Note With all cables connected the printer should complete POST within approximately 12 15 seconds in the following sequence a The operator panel light comes on b Diamonds display from left to right c Dots display left to right d The memory size and processing speed temporarily display e The operator panel displays Performing Self Test f Ready displays If immediately following power on the operator panel lights are on but the printer does not go through steps a and b above replace the controller card assembly Note Always check printhead alignment after replacing the controller card assembly See Printhead assembly adjustment on page 4 2 for hardware alignment of the printhead Note U S versus non U S and the printer configuration ID can be reset This affects default measurements and paper size This can be changed See Defaults on page 3 15 in the Diagnostics Mode See Diagnostics Mode on page 3 2 for more information 2 38 Service Manual 4048 1 xx Dead machine service check Note Check the AC line voltage The voltage should be within the following limits 90 V ac 120 V ac for nominal 100 V model printer 100 V ac 127 V ac for the nominal 110 V model printer 200 V ac 240 V ac for the nominal 220 V model printer Low voltage power supply LVPS service check FRU Action Low voltage power
148. wing diagrams indicate the units requiring lubricant and show where to place it Place a drop size or less at each location and then rotate the gears or mechanism to evenly distribute the lubricant Use Nyogel 744 P N 99A0394 or IBM 23 P N 99A0462 Note Be careful to not spread the grease to other parts of the printer P N 56P23637 Ratchet drive Lubricate the teeth of all the gears in the drive assembly except the indicated gear P N 56P2326 Drive assembly Lubricate all gears except this one 4 6 Service Manual 4048 1 xx P N 56P2359 MPF pick roll assembly Y Sall V SIS i P N 56P2327 Exit gear drive assembly P N 56P2302 Rear cover assembly Reassembly Ensure all cables are reconnected when reassembling the printer The printer may not detect a disconnected sensor in some areas without extensive running Note Always print a page from each paper source to verify reassembly Repair information 4 7 4048 1 xx Removal procedures Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed Remove the print cartridge and paper tray before you perform removal procedures Unless otherwise stated reinstallations are in reverse order of removal MPF door cover removal 1 Remove the tray 2 Open the front cover 3 Open the MPF door to where the latches are just clear of the printer about 15 4 Lift
149. xample 80 Scheduled Maintenance 9 Applicable toner low messages are posted The printer displays Ready 2 2 Service Manual 4048 1 xx Symptom tables POST symptom table These symptoms may appear during the POST Power on Self Test See Power On Reset POR sequence on page 2 2 for the sequence when a printer is turned on Symptom Action The main motor cooling fan and fuser do not come on See Cover interlock switch service check on page 2 37 POST completes except display is incomplete or erratic POST complete except display does not function See Operator panel service check on page 2 43 See Operator panel service check on page 2 43 Main motor does not come on See Main motor service check on page 2 42 Fan does not come on See Cooling fan service check on page 2 36 Fuser heater does not come on See Cold fuser service check on page 2 41 Fuser heater never turns off See Hot fuser service check on page 2 41 The paper feed picks and tries to feed paper See Paper feed service checks on page 2 45 Diagnostic information 2 3 4048 1 xx Printer symptom table Symptom Action Dead machine no power Fan noisy or not working See Dead machine service check on page 2 39 See Cooling fan service check on page 2 36 Fuser parts melted See
150. y 2 pass thru sensor is covered during warm up Try opening Tray 2 If the tray is difficult to remove then you may have to remove the tray above or below the tray to remove the jammed pages 243 Paper Jam Check Tray 3 Media picked from tray 3 made it through the tray 2 pass thru sensor but failed to make the input sensor in time 250 Paper Jam Check MP Feeder Media in the multipurpose feeder was picked two attempts if necessary but did not make it to the input sensor 1565 Emul Error Load Emul Option The emulation version on the card does not function with the printer code The correct version must be downloaded Diagnostic information 2 23 4048 1 xx Sub error codes The sub error codes are helpful troubleshooting a paper path problem Each status byte has a different level of troubleshooting value for each area of the printer The following table displays up to 8 status bytes of data Some or all of these bytes may be used to help diagnose a printer problem These status bytes are designed to help isolate paper jams and paper feed problems in the base printer DU XX XX XX XX DU XX XX XX XX To identify the bytes Byte 1 Byte 2 Byte 3 Byte 4 DU XX XX XX XX DU XX XX XX XX Byte 5 Byte 6 Byte 7 Byte 8 Displayed error codes When a 9xx or 2xx error displays 1 Press and hold Return and press Select to enter for sub error codes The first screen of information displays Wri

4048-1xx Lexmark T430 Service Manual

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