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Lexmark T420 (4048-00x) Series Laser Printer Service Manual

1. Function Name on Card of Pins Pin Signal Name ToRIP J16 CN1 8 2 Ena 4 24 V de 7 5 V de Charge C Terminal 1 roll 5 12 Service Manual 4048 00x 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 The purpose of this inspection guide is to aid you in identifying unsafe conditions 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 Damaged missing or altered parts especially in the area of the on off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover 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 Use IBM no 10 oil P N 1280443 approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease approved
2. Diagnostic Information 2 7 4048 00x Printer Error Secondary Light Patterns To obtain the secondary light pattern quickly press Continue twice o o g 2 E gt 2 E Attendance Condition a 2 o 5 O gt e ES E Oo 5 c Qa VU LS O O O O O O Complex Page O e O O O O Insufficient Collation Area O O e O O e Defective Flash O O O O e O Network Interface Error O O O e O Resource Save Off Deficient Memory O O O e O PPDS Font Error O O O 0 Insufficient Defrag Memory O O O e O ENA Connection Lost 0 O O 0 Memory Full O O O O O O Short Paper O O O O O O Flash Full O O 0 Too Many Flash Options O 0 O O 0 0 Engine Code Failure 2 8 Service Manual 4048 00x Service Information Light Patterns Service Condition Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Service Error Note A double press of Continue causes a secondary light pattern which indicates further information on the type of printer error See Service Error Codes on page 2 11 for more information Diagnostic Information 2 9 4048 00x Service Error Secondary Light Patterns Quickly press and release Continue twice to obtain the secondary light pattern
3. y ES Jos UE OE N IN US NG IT SIE YO UE VER LE SE 7 20 Service Manual 4048 00x Assembly 8 Sensors and Locations Asm Index Part Numbers Units Description 8 1 5 8 8 2 5 8 7 56P0645 56P0655 56P0653 56P0652 1 Sensor Photo Locations Paper Path Exit Flag Paper Path below Cartridge Paper Path Duplex Paper Path MPF Paper Path below Cartridge Fuser Exit Sensor O1 R ND Bracket Paper Sensor Sensor Toner Level Sensor Smart Button Parts Catalog 7 21 4048 00x Assembly 9 Options 7 22 Service Manual 4048 00x Assembly 9 Options Asm Part Index Numbers 9 1 56P0674 9 2 56P0609 9 3 56P0675 9 4 56P0678 NS 56P0694 NS 56P0695 NS 56P0696 NS 56P0697 NS 56P0698 NS 56P0699 NS 99A1757 NS 99A1758 NS 99A1759 NS 99A1774 NS 99A1683 NS 99A1684 NS 99A1685 NS 99A1686 NS 56P1248 NS 56P1250 NS 56P1251 NS 12G9833 Units Description Drawer Assembly 250 Sheet Tray 250 Sheet Drawer Assembly 500 Sheet Tray 500 Sheet DIMM 4MB SDRAM DIMM 8MB SDRAM DIMM 16MB SDRAM DIMM 32MB SDRAM DIMM 64MB SDRAM DIMM 128MB SDRAM DIMM 2MB Flash DIMM 4MB Flash DIMM 8MB Flash DIMM 16MB Flash DIMM Optra Forms 2MB Flash DIMM Optra Forms 4MB Flash DIMM Optra Forms 8MB Flash DIMM Optra Forms 16MB Flash DIMM Japanese 8MB Font DIMM Simplified Chinese Font DIMM Traditional Chi
4. im o 2 a Q g E sS Q E Service Condition S 1 3 51 8 5 gt V D o D S 5 amp s 2 14 F q a Ww a O O O O O Software Error 90x O O O O Transfer Roll Error 91x O O O O Fuser Toner Sensor Error 92x O O O Printhead Transport Motor Error 93x O O O O Controller Card 94x O O O NVRAM ROM NAND Error 95x O O RAM Memory Error 96x O Network Error 97x O Paper Port Communication Error 98x Note There are many tertiary codes following these secondary codes The following pages show these codes 2 10 Service Manual 4048 00x Obtaining Information about Printer Service Error Codes All lights flashing simultaneously on the panel designates a printer service error as a primary code Double press Continue to see the secondary codes double press Continue again to see the tertiary codes double press Continue the third time to return to the primary code All secondary codes have a flashing Ready Data light but not the Toner Low light All tertiary codes have a flashing Toner Low light but not a Ready Data light All lights flashing simultaneously as a result of sending data to the printer may indicate a code problem Call Lexmark Customer Service at 1 800 539 6275 for assistance 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 condi
5. L Interface violation by RIP 904 L Paper port link drive error 903 L General engine software error 902 Note If the alarm control is turned on the alarm does sound when this error occurs 2 12 Service Manual 4048 00x Transfer Roll Error Indicates a problem in the transfer roll area Check the cable from the HVPS CN1 to the controller card J3 Also check the voltage at pin 4 of J3 Primary Code Secondary Code Tertiary Codes J Ready Data J Ready Data Ready Data 3 Toner Low Toner Low He Toner Low XV Load Load Load Remove Paper Remove Paper Remove Paper 3 Paper Jam Paper Jam Loi Paper Jam LE Error Error Lo Error Eog Press Continue he Press Continue os Press Continue 917 Note Ifthe alarm control is turned on the alarm does sound when this error occurs Diagnostic Information 2 13 4048 00x Fuser Error Indicates a problem with the fuser See the Fuser Service Check on page 2 34 for more information Primary Code Secondary Code pos Ready Data 3 Toner Low Loi Load Remove Paper ie Paper Jam os Error os Press Continue 3 Ready Data Toner Low Load Remove Paper Paper Jam 3 Error Press Continue Tertiary Codes O Ready Data 38 Loi we LE JE LE Toner Low O Load Remove Paper O O O O RE Paper Jam 3 x
6. Press Continue Invalid command parameter received by specified device 984 Invalid command received by specified device 983 Communications error detected by specified device 982 L Engine protocol violation detected by the specified device 981 _ Engine experiencing unreliable communications to specified device 980 Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead 2 24 Service Manual 4048 00x Power On Operations To access the printer operations for the 4048 1 Turn off the printer 2 Press and hold the buttons in the following table for the operation needed 3 Turn on the printer Hold the buttons until the lights cycle on the operator panel Operation Power on action Enter Configuration 1 Power on with top cover open and Continue Menu mode pressed 2 Close cover once the error light is displayed Print the Print Quality Top cover open with Continue pressed Cartridge test pages Lockout function enabled Enter Diagnostics 1 Power on with top cover open and Cancel mode pressed 2 Close cover once the error light is displayed Print the Print Quality Top cover open with Cancel pressed Cartridge test pages Lockout function disabled Reset NVRAM and 1 Power on with top cover open and both enter Norma
7. 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 Diagnostic Information 2 43 4048 00x Paper Picks but Stops Half Way Through the Printer FRU Action Input Paper Feed Sensor RIP Card Assembly Make sure the input paper feed sensor is working properly Check for a broken or stuck flag on the input paper feed sensor Make sure the cable is seated on the RIP card assembly J23 Verify 5 V de on pins 1 4 7 and ground on pins 3 6 and 9 See Locations on page 5 1 for more information e If correct replace the input paper feed sensor If the voltage is not correct replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead 2 44 Service Manual 4048 00x 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 RIP Card Assembly correctly and its cable is plugged into the RIP card assembly See Locations on page 5 1 for more information e Verify approximately 40 ohms in the solenoid If
8. O Press Continue Continue Cancel printer toolkit to modify settings The operator panel may be used for Determining printer status See Status Information Light Patterns on page 2 3 for more information e Reviewing printer settings See Power On Self Test POST on page 2 26 for more information Changing printer settings See Power On Operations on page 2 25 for more information e Utilizing diagnostic tools See Power On Operations on page 2 25 for more information e Obtaining information about printer service errors See Service Error Codes on page 2 11 for more information 2 2 Service Manual 4048 00x Light Patterns The following symbols are used in the status attendance and service information tables x 00 Light is off Light is on solid Light is blinking Light is blinking slowly Status Information Light Patterns em o q o E E Status a 4 e 5 O gt P TG TD 5 q o o o 2 lo E E X F am A wu a O O O O O Ready O O O O Demo Ready x O O O O O Hex Trace Ready O O O O O Busy O O O O 0 Waiting O O O O O O Ready with Toner Low Warning O O O O O Demo Ready with Toner Low Warning x O O O O O Hex Trace Ready with Toner Low Warning O O O Busy with Toner Low Warning O O O Waiting with Toner Low Warning O O O O Flushing
9. Unplug the power cord and verify that the cable is correct and functioning Replace if necessary With the poser cord unplugged disconnect the 8 pin and 5 pin connectors from the LVPS On the 8 pin connector pin 1 is closest to the HVPS 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 e Verify pin 4 is 5 V de e Verify pins 7 and 8 are 24 V dc e Verify pin 1 of the 5 pin connector also closest to the HVPS is 5 V dc If any one of these are incorrect replace the LVPS Diagnostic Information 2 33 4048 00x Fuser Service Check When toner is partially fused to the paper it is usually caused by low fuser temperature Warning Avoid handling the lamp as much as possible as it is easily broken Be careful not to touch the glass housing with bare hands as skin contains acids that can weaken the glass The line voltage to the printer must be within the following limits e 100 V ac 127 V ac for the nominal 110 V model printer e 200 V ac 240 V ac for the nominal 220 V model printer 2 34 Service Manual 4048 00x Cold Fuser Service Check FRU Action Fuser Lamp Unplug the printer and disconnect the Lamp Cable fuser lamp cable from the LVPS card LVPS connector CN3 See Power Supply LVPS on page 5 11 for more information Check for continuity across the fuser lamp Pi
10. 1 2 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information Remove the left side cover See Left Side Cover Removal on page 4 14 for more information Remove the RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information Remove the inner cover one 1 screw Remove the roller MPF gear by lifting the latch in the center of the hub and sliding it out D Free the cables from the attached retainers Remove the six 6 screws in the gear train assembly A B and C Remove the two screws holding the bearing at the upper right corner of the PWB Lift up gently and work the gear train assembly out Remove the paper feed drive gear 4 44 Service Manual 4048 00x Repair Information 4 45 4048 00x Reference Plate Assembly Removal 1 2 3 Remove the print cartridge Remove the gear train assembly See Main Drive Assembly Removal on page 4 44 for more information Remove the three screws Located between the main gear drive and the assembly plate Remove the MPF cover See Lower Front Cover Multipurpose Feeder Cover Removal on page 4 6 for more information Remove the upper body MPF assembly See Upper MPF Housing Assembly with Paper Flag Removal on page 4 49 for more information Remove the lower body MPF assembly See Lower MPF Housing Assembly Pape
11. 4 11 56P0622 1 Cable Assembly Printhead Parts Catalog 7 9 4048 00x Assembly 4 cont Electronics and Cables 7 10 Service Manual 4048 00x Assembly 4 cont Electronics and Cables a ne er Units Description 4 1 56P0624 1 Cable Assembly Cover Switch 4 2 56P0621 1 Cable Assembly Operator Panel 4 3 56P0625 1 Switch Interlock Cover 4 4 and 5 Sensor and Cable Included with P N 56P0611 lower MPF housing 4 6 and 8 56P0616 2 Solenoid Paper Feed 4 7 56P0653 1 Sensor Toner Level 4 9 56P0631 1 Cable Assembly Drawer 4 10 56P0617 1 Card Assembly RIP 4 10 56P0619 1 Card Assembly Network RIP 4 11 56P0664 1 Cable Assembly Output Full and Fuser Exit 4 12 56P0652 1 Sensor Smart Button 4 13 56P0682 1 Sensor Cable Output Full 4 14 56P0665 1 Connector 3 Pin 4 15 56P0666 1 Connector 2 Pin 4 16 56P0645 1 Sensor Photo NS 56P0649 1 Cable Assembly Fuser Exit NS 56P0620 1 Cable Assembly Motor Parts Catalog 7 11 4048 00x Assembly 4 cont Electronics and Cables This page left intentionally blank 7 12 Service Manual 4048 00x Assembly 4 cont Electronics and Cables Asm Part Index Numbers NS 70G0478 1 Power Cord Bolivia Canada Caribbean Countries Columbia Costa Rica Dominican Republic Equador El Salvador Guatemala Honduras Japan Mexico Nicaragua Peru Panama Puerto Rico Saudi Arabia Taiwan The Virgin Islands Venezuela US AP LV
12. 7 13 7 13 7 13 7 13 7 13 7 13 7 13 7 13 7 13 7 23 7 13 7 3 5 3 7 3 5 3 7 3 7 3 7 3 7 3 7 17 7 3 7 3 7 17 7 23 7 3 5 3 7 6 7 11 7 5 7 5 4 5 T9 7 11 7 9 7 11 7 15 7 9 7 11 7 11 7 9 7 17 7 11 7 11 7 9 56P0627 56P0628 56P0629 56P0630 56P0631 56P0632 56P0633 56P0634 56P0635 56P0636 56P0637 56P0638 56P0639 56P0640 56P0641 56P0642 56P0643 56P0644 56P0645 56P0646 56P0647 56P0648 56P0649 56P0650 56P0651 56P0652 56P0653 56P0654 56P0655 56P0656 56P0657 56P0658 56P0659 56P0660 56P0661 56P0662 56P0663 56P0664 56P0665 56P0666 56P0667 56P0668 56P0669 56P0670 56P0671 56P0672 56P0673 79 7 9 7 17 7 9 7 11 7 19 4 4 7 15 7 15 4 5 7 15 4 5 7 15 4 4 7 15 Flo 7 15 7 7 7 7 1 9 7 7 7 7 7 7 7 11 7 15 7 21 7 19 7 19 719 7 11 ra 7 15 7 11 7 21 7 11 7 21 7 15 7 15 7 21 7 19 7 15 7 17 7 17 7 17 7 17 7 17 7 9 7 11 7 11 7 11 7 17 7 7 7 17 7 7 7 24 7 19 7 17 7 19 4048 00x 56P0674 7 23 56P0675 7 23 56P0676 7 19 56P0677 7 15 56P0678 7 23 56P0679 7 3 56P0680 7 3 56P0682 7 11 56P0693 7 15 56P0694 7 23 56P0695 7 23 56P0696 7 23 56P0697 7 23 56P0698 7 23 56P0699 7 23 56P1248 7 23 56P1250 7 23 56P1251 7 23 70G0478 7 13 99A0545 7 23 99A1683 7 23 99A1684 7 23 99A1685 7 23 99A1686 7 23 99A1757 7 23 99A1758 7 23 99A1759 7 23 99A1774 7 23 l 6 Service Manual
13. O Error 3 3 3k Press Continue Incorrect fuser lamp installed 925 Open circuit in thermistor path 924 L Fuser too hot during printing or idle 923 Fuser failed to reach standby temperature 922 Fuser below standby temperature at idle 921 Fuser below temperature when printing 920 Note If the alarm control is turned on the alarm does sound when this error occurs 2 14 Service Manual 4048 00x Fan Stalled This error indicates a printer fan stall Primary Code Secondary Code Tertiary Codes Loi Ready Data 3 Toner Low LE Load Remove Paper 3 Paper Jam Loi Error Eog Press Continue Loi Ready Data Toner Low Load Remove Paper Paper Jam 3 Error Press Continue os Ready Data O Toner Low O Load Remove Paper 38 Paper Jam Lo Error we Press Continue Toner Sensor Error 927 Indicates a problem with either the toner sensor or print cartridge Primary Code Secondary Code Tertiary Codes te Ready Data he Ready Data Ready Data 3 Toner Low Toner Low Lo Toner Low PE Load Remove Paper os Paper Jam PE Error PE Press Continue Load Remove Paper Paper Jam LE Error Press Continue we Load Remove Paper Paper Jam Error LE Press Continue 929 Note lf the alarm contro
14. Toner Low JE Load Remove Paper 3 Paper Jam 3 Error ae Press Continue e Ready Data O Toner Low O Load Remove Paper 3 Paper Jam Error se Press Continue O 0 oo Ready Data LE Toner Low Load Remove Paper LE Paper Jam Error Press Continue Note L NVRAM chip failure 954 L NVRAM CRC failure 952 Ifthe alarm control is turned on the alarm does sound when this error occurs Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead 2 20 Service Manual 4048 00x RIP Card Error ROM NAND Indicates a failed RIP card assembly Replace the RIP card Primary Code 3 Ready Data oe Toner Low Load Remove Paper Lo Paper Jam se Error se Press Continue Secondary Code JE Ready Data Toner Low Load Remove Paper LE Paper Jam Error LE Press Continue Tertiary Codes Ready Data LE Toner Low Loi Load Remove Paper Paper Jam Error O OO ME OXEO de Mk OO OO XO O SE we Press Continue L SRAM failure 959 LNAND failure 958 ASIC failure 957 L Processor failure 956 L Code ROM or NAND failed Cyclic Redundancy Check CRC 955 Note The alarm is not activated for this error Alw
15. and toner saver can all be set independently of each other through the data stream e Control panel menus allow a user to independently set PQET PictureGrade and print resolution e The IET setting is implicitly selected when a particular print resolution is selected using the Quality Menu e Toner saver and print darkness settings are implicitly set when a particular toner darkness is selected using the Quality Menu Print Quality Setting Base Model Network Model Print resolution 300 dpi 600 dpi 1200 IQ dpi NAS SSS Image Enhancement Technology IET 2 Bits Pel PQET Toner saver Print darkness PictureGrade SSR SES Note V Indicates print quality setting is supported 1 4 Service Manual 4048 00x Print Area The following print area settings are available Print Area Option Base Model Network Model Normal Y Y Fit to page Y Y Edge to edge Y Y General Information 1 5 4048 00x Print Media The following table shows the supported media media weights and media textures which together are used to select a technology operating point to provide optimal print quality across a variety of media Media Base Model Network Model Media Operating Poin ts Paper Card stock Transparency Labels Envelope Cotton paper Bond SISISISISISINS SS EYES Media Weig
16. assist ncia prescritas X Service Manual 4048 00x 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 laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse I laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p b lgel ngdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig uds ttes for en laserstr ling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Laser Notices Xi 4048 00x Huomautus laserlaitteesta T m kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja mu
17. 00x HVPS Card Removal 1 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information 2 Remove the right side cover See Right Side Cover Removal on page 4 13 for more information Disconnect the HVPS cable Remove the four screws A Disconnect the charge roll cable Remove the HVPS card noo PR OW N E E la P y A UN 4 56 Service Manual 4048 00x LVPS Card Removal 1 Unplug the printer 2 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information 3 Remove the right side cover See Right Side Cover Removal on page 4 13 for more information 4 Disconnect all cables attached to the LVPS card 5 Remove the three screws B 6 Remove the LVPS A Repair Information 4 57 4048 00x Cooling Fan Removal 1 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information 2 Remove the right side cover See Right Side Cover Removal on page 4 13 for more information 3 Disconnect the fan cable 4 Remove the two screws A 5 Remove the fan 4 58 Service Manual 4048 00x 5 Locations nm Duct cover Asm Front cover SS SS Cover MPF Asm MPF door Locations 5 1 4048 00x Cables CD 5 2 Service Manual 4048 00x Reference Description 1 Cable Assembly Cover Switch 2 Display and
18. Fuser parts melted See Hot Fuser Service Check on page 2 37 Fuser lamp doesn t light See Cold Fuser Service Check on page 2 35 Toner not fused to the paper See Poor Fusing of Image on page 2 53 Blank page See Blank Page on page 2 48 Black page See Black Page on page 2 50 Heavy background See Heavy Background on page 2 51 Light print See Light Print on page 2 53 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 54 Paper jams See Paper Feed Service Checks on page 2 41 Main motor noisy or does not move See Main Motor Service Check on page 2 37 Paper never picks See Paper Never Picks on page 2 45 Paper feeds continuously See Paper Picks During POST and or Continuously on page 2 43 Paper skew See the Note regarding alignment on page 4 47 or Paper Feed Service Checks on page 2 41 Diagnostic Information 2 27 4048 00x Symptom Action Printer not communicating with host See Parallel Port Service Check on page 2 47 Paper wrinkled or bent See Paper Trees Wrinkles Stacks Poorly Or Curls on page 2 46 Top cover will not close See Cover Interlock Switch Service Check on page 2 30 Operator panel button do
19. Left Side Cover Removal on page 4 14 for more information 4 Turn the printer to face rear cover Open the paper tray trim A 6 Disconnect the sensor cable inline connector below the lower left corner of the controller cage Note Replug the sensor cable on re assembly The printer fails to detect tray full and will not duplex properly without this q connection 1 ERST IS RN al 1 a H al 7 Open the exit tray rear door B 4 16 Service Manual 4048 00x 8 Remove the six screws A 9 Lift the top cover slightly with one hand while pulling out on the rear cover Note When reinstalling the rear cover be sure to position the fuser exit guide fingers such that they are not bound by the rear cover If a bind occurs a jam will occur Repair Information 4 17 4048 00x Rear Exit Door Removal 1 Open the rear exit door 2 Use your index finger or screwdriver to disengage the left facing back of printer hinge from the rear cover A With your opposite hand apply force to remove the door away from the printer 4 18 Service Manual 4048 00x Duplex Tray Assembly Removal RON Remove the paper tray Disconnect all cables on the back of the printer Tilt the printer on its back Remove the five screws A Work the right side loose first disconnect the paper input sensor cable Remove the duplex assembly Repair Information 4 19 4048 0
20. MarkNet MarkVision Optra and Prebate are trademarks of Lexmark International Inc registered in the United States and or other countries Optra Forms and PictureGrade are trademarks of Lexmark International Inc Other trademarks are the property of their respective owners O 2002 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 International Inc Lexington KY 40550 U S A P N 12G9119 4048 00x Table of Contents Laser NONGOS cornisa vii sarety Inlomaton sarao ir xvii Pr fab siiiisssrmasissesrennsssassenassssssens sess xxii General Information 1 1 Maintenance Approach an a a e qd m 1 1 Spacal TOO sas pacer ab sense ae b de 1 1 JE LA gt sur aaa au 1 2 Printer Identification sus eps sds ideas ces 1 2 dias A dead 1 3 Memory and User Flash Memory 1 3 Resolution and Pant Quail a 1 4 PU MEG ee 1 5 PN Med seede ds 1 6 Pinter Data Streams asia ea 1 7 FONG arrasa irradian T AA 1 8 Paper Handling use en ee bes 1 8 CONNGOUIMY ehren 1 10 Pinter Sedan danse dedans amet 1 11 RIP Gard Specific an
21. NS 1339528 1 Power Cord Bahrein Cyprus Iraq Ireland Kuwait Oman Qatar UAE UK Yemen HV NS 1339529 1 Power Cord Austria Belgium Bosnia Bulgaria Catalan Czech Croatia Egypt Albania Euro English and other East Finland France Germany Greece Hungary Iceland Iran Italy Jordan Lebanon Macedonia Netherlands Norway Paraguay Poland Portugal Romania Russia and CIS Slovak Countries Slovenia Spain Sweden Syria Turkey Yugoslavia Serbia and Units Description Montenegro HV NS 1339530 1 Power Cord Israel HV NS 1339531 1 Power Cord Switzerland HV NS 1339532 1 Power Cord Lybia Pakistan South Africa HV NS 1339533 Power Cord Chile Uruguay HV 4 NS 1339534 1 Power Cord Denmark HV NS 43H5545 1 Power Cord PR China HV NS 1339548 1 Power Cord Brazil LV NS 11D0330 1 Power Cord Argentina NS 1339520 1 Power Cord U S HV RPQ Parts Catalog 7 13 4048 00x Assembly 5 Paper Feed 7 14 Service Manual 4048 00x Assembly 5 Paper Feed Asm Part Index Numbers 5 1 56P0677 5 2 56P0651 5 3 56P0645 5 4 56P0618 5 5 56P0656 5 6 56P0655 5 7 56P0657 5 8 56P0654 5 9 56P0634 5 10 56P0693 Units Description Flags Stack Control Assembly Duplex Sensor Photo Spring D Roll Roll Paper Feed Bracket Paper Sensor Assembly Paper Feed Plate Assembly Gear Paper Feed X A A a a a a Roller Asm Reference Backup Top Fron
22. Primary Code Secondary Code Tertiary Codes LE Ready Data Loi Toner Low Load Remove Paper roi Paper Jam LE Error xe Press Continue 38 Ready Data Toner Low Load Remove Paper LE Paper Jam Error Press Continue Ready Data LE Toner Low Load Remove Paper Paper Jam Error Press Continue 2 18 Service Manual 940 4048 00x Engine Circuitry Failure Controller Card This error indicates a failure in the engine circuitry portion of the controller card Primary Code Secondary Code XE Ready Data LE Toner Low XE Load Remove Paper 3 Paper Jam LE Error LE Press Continue 3 Ready Data Toner Low Load Remove Paper 3 Paper Jam Error Press Continue Tertiary Codes Remove Paper LE 3 LE Ready Data Toner Low 3 LE Load xe Paper Jam roi Error Es LE Press Continue L 947 Delay line calibration failure 949 Pel clock check failure 948 PQET RAM test incomplete PQET RAM test did not complete PQET RAM test failed MARCHO PQET RAM test failed MARCH1 PQET RAM test busy failure Diagnostic Information 2 19 4048 00x NVRAM Failure This lighting sequence indicates a problem in the NVRAM Replace the RIP card assembly Primary Code Secondary Code Tertiary Codes Lei Ready Data 3
23. and holding Continue until the lights cycle We recommend this sheet be run and checked anytime Diagnostics mode is entered It provides instructions in the manipulation of the menu 2 Set edge to edge printing on off Off is the default and normal setting which allows the printer graphics and printing engine to set the margins accordingly When edge to edge is set on the printer graphic and printing engine shift all four margins to the physical edges of the paper 3 Print the Print Quality Pages These are the same pages that are run in the Configuration mode Note The toner cartridge lockout function is disabled in this mode In the Configuration mode the lockout function is enabled which means the pages cannot be printed unless the toner cartridge has a machine class ID that matches the machine class ID held in NVRAM on the RIP card Note The next two items run continuously until interrupted by pressing Cancel or powering off The printed page comes from printer ROM and is useful for printhead alignment and skew measurements 4 Print simplex from tray 1 MPF or tray 2 if installed 5 Print duplex from tray 1 MPF or tray 2 if installed 3 6 Service Manual 4048 00x 10 Print history pressing Continue prints the service error history report Defaults allows the printer to be set for U S or non U S after the RIP card has been replaced Configuration ID allows the printer to have th
24. black page FRU Action HVPS Contacts Check the contacts for contamination and correct installation Replace as necessary RIP Card Assembly Controller Card HVPS Cable HVPS Left Guide Assembly Ensure the HVPS to RIP card and charge roll cables are correctly installed Check continuity of the charge roll cable from C printed on outside HVPS to the bushing at the right side of the charge roll If continuity fails replace the left guide assembly 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 12 and check the voltage measurements e If the 24 V dc and 5 V dc input voltages are correct replace the HVPS Ifthe voltages are not correct see RIP Card Service Check on page 2 31 e Check continuity on the HVPS RIP card cable 2 50 Service Manual 4048 00x Heavy Background Poor development or poorly charged toner particles cause excessive background This is more noticeable as the toner cartridge nears end of life FRU Action Toner Cartridge not a FRU Make sure the toner cartridge is correctly installed and the high voltage contacts are clean If the cartridge is installed correctly and the problem persists try a new cartridge HVPS Contacts HVPS Card RIP C
25. code below with four flashing lights indicates a problem in the drive assembly Primary Code Secondary Code Tertiary Codes 3 Ready Data Loi Toner Low xe Load Remove Paper Eod Paper Jam Eos Error xe Press Continue 3 Ready Data Toner Low Load Remove Paper Paper Jam re Error 3 Press Continue Ready Data Loi 3 Toner Low Load Remove Paper ae Paper Jam BER Loi Error LE Press Continue O L Transport motor lost lock 937 L Transport motor initial lock failure 936 Note lf the alarm control is turned on the alarm does sound when this error occurs Diagnostic Information 2 17 4048 00x RIP to Engine Communication Failure Controller Card This error indicates that the RIP processor cannot communicate with the engine processor Primary Code Secondary Code Tertiary Codes LE Ready Data roi Toner Low LE Load Remove Paper LE Paper Jam LE Error LE Press Continue 38 Ready Data Toner Low Load Remove Paper Paper Jam He Error He Press Continue Ready Data LE Toner Low Load Remove Paper Paper Jam Error Loi Press Continue 939 RIP to Engine Communication Failure Controller Card This error indicates a failure in the zero crossing signal which is used for fuser control It may indicate the wrong LVPS has been installed
26. front cover and remove the toner cartridge 2 Grasp the charge roll on the left end and push the bearing and roll away from each other Warning Handle the charge roll with clean dry hands and only at the ends 3 After the left side is removed from the bearing slide the roll from the right side bearing Repair Information 4 27 4048 00x Right Guide Removal 1 2 3 Remove the toner cartridge Remove the top cover See To completely remove the top cover on page 4 11 for more information Remove the HVPS See HVPS Card Removal on page 4 56 for more information Remove the charge roll See Charge Roll Removal on page 4 27 for more information Remove two screws in the right guide above and behind the HVPS Unsnap the three latches of the right guide Remove the right guide Left Guide Removal Remove the toner cartridge Remove the top cover See To completely remove the top cover on page 4 11 for more information Remove the RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information Remove the charge roll See Charge Roll Removal on page 4 27 for more information 4 28 Service Manual 4048 00x 5 Remove the three screws A and B one holding the link guide bracket arm to the left guide 6 Remove the left stud hinge on the top cover See step 6 on page 4 11 for more information 7 Remove
27. 0x Fuser Assembly Fuser Paper Exit Guide Fuser Exit Sensor and Fuser Lamp Removal 1 Unplug the printer 2 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information 3 Remove the rear cover See Rear Cover Removal on page 4 16 for more information 4 To remove the fuser assembly release the two latches and remove the cooling fan duct A 5 To replace only the paper exit guide or exit sensor remove one screw B to lift off the exit guide 6 Disconnect the spring on the left side 7 Swing out for clearance to replace ZZ my 4 20 Service Manual 4048 00x 8 Unplug the fuser lamp exit sensor and thermistor cables B Note It may be easier to unplug the fuser lamp once the fuser is loosened 9 Remove the four screws A Note Removing the lower left screw requires a long screwdriver approximately a 6 inch shank 10 Remove the fuser 11 To replace the fuser lamp remove the two screws at each end and very carefully extract the lamp from the heater roll Warning Do not touch the glass of a good lamp it causes premature failure Repair Information 4 21 4048 00x Terminal Assembly Removal 1 Remove the HVPS See HVPS Card Removal on page 4 56 for more information 2 Remove the terminal assemblies A Note The lower right terminal to the transfer roll is gold in color 4 22 Service Manual 4048 00x Tray Da
28. 1 or the optional tray 2 and fan the paper e Don t overfill tray 1 or the optional tray 2 see media capacities in the media types and sizes chart in the User s Guide The paper fails to feed from tray 1 Remove the paper from tray 1 and fan the paper e Make sure tray 1 is selected from the printer driver e Do not overfill the tray Diagnostic Information 2 59 4048 00x Problem Action The paper fails to feed from the optional tray 2 e Make sure the optional tray 2 is selected from the printer driver Remove the paper from the optional tray 2 and fan the paper e Make sure the tray is pushed all the way in e Make sure the metal plate is pressed down before inserting it into the printer Note Once the tray is inserted the metal plate springs up so the paper can feed into the printer e 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 Guide 2 60 Service Manual 4048 00x Problem Action The Load Paper light is on even though there is paper loaded in the optional tray 2 Ready Data Toner Low 3 Load Remove Paper Paper Jam Error 3 Press Continue Make sure the tray is pushed all the way in Press Continue The printer does not print after a paper jam has been cleared Press Continue or open and cl
29. 2 56 Service Manual 4048 00x Problem Action The print is getting light but the Toner Low light is not on ie Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue The Toner Low light does not come on if the standard 5 000 page print cartridge is installed Remove the print cartridge and gently shake it from side to side to redistribute the toner Replace the print cartridge The Toner Low light is on 3 Ready Data LE Toner Low Load Remove Paper Paper Jam Error Press Continue Remove the print cartridge and gently shake it from side to side to redistribute the toner Replace the print cartridge Solid black areas on transparencies or paper contains white streaks e Choose a different fill pattern in your software application Try a different type of paper Paper designed for copiers gives the best quality e Remove the print cartridge and gently shake it from side to side to redistribute the toner Replace the print cartridge Faint images or repetitive spots appear on the page e Select a different media type or form type setting from your printer driver e Try a different type of paper Paper designed for copiers gives the best quality Replace the print cartridge Diagnostic Information 2 57 4048 00x Problem Action Pages are blank The print ca
30. 8 00x Printer Diagnostics Caeady Data Oraner Lew JLaad temore Paper Oraper Jum Otrrer Printer Diagnostics Tale page explains hou te access the printer mera ad change values Mens are represented by Hendy Data toner Lov cad tenove Paper and Paper dem Light Sequences Mens items md thelr values are indicated py Error and Press Continue Iipat sequences Use the illustration 16 help you find the meru and valut pou want te change the Error and Press Continue Lights show the current value of the mens iten I Press ad release Carcel te advance Trogi the mena and menu item to the one you need 2 Dress and release Continue to advance to the value you mend 3 Press arc hold Continue until ail of the Lights cycle to perform the furian or to save the value To return te the Home menu press and halg Cancel until all of the Lights cycle 3 Turn the printer aff to esit the menus Menus menu items and values mm y Light ot Lipe Miri valse arma Continue Th 5 i 5 3 gs Est 7 HEr fa HHH Gta cosh DEEE EH cerda ib sia o i ia i Diagnostic Aids 3 5 4048 00x Printer Diagnostics Mode The Printer Diagnostics mode is for service use only Its manipulation is the same as the Configuration mode The following functions can be performed in the Diagnostics mode See Configuration Menu Group or Diagnostic Menu Group on page 3 2 for more information 1 Print diagnostic instructions and menu settings by pressing
31. Diagnostic Information 2 3 4048 00x k 2 o 2 E 2 E E Status Q 4 5 oO lu S s la Q Q D o o 1 F J a m a O O O O O O Canceling Job Resetting Printer Activating Changes All lights cycling Restarting Printer O O O O O O Diagnostics Memory Test O O O O O O Programming System Code DO NOT POWER OFF Note The Error and Press Continue lights cycle through four different patterns to indicate progress during programming O O O Programming System Code Partially Complete Download System Code Data O O O 0 O Invalid Engine Code Invalid Network Code Note A double press of Continue causes a secondary light pattern which indicates further information on the type of invalid code status exists See Invalid Code Secondary Light Patterns on page 2 5 2 4 Service Manual 4048 00x Invalid Code Secondary Light Patterns m o o 2 g E E E 5 Status 4 e 5 3 5 3 3 9 c o o 2 Q Q E 2 x E 4 A LU a O O O O O O Invalid Engine Code O O O O Invalid Network Code Attendance Information Light Patterns nu v Q ke a g E gt 2 E 5 Attendance Condition QA 2 o 5 o gt x Ko Ko oO oO q o Q Q o E E 12 F par a uu a O O O O O O Load Paper Tray 1 Tray 2 or MPF O O O O L
32. I 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 I 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der L nge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht viii Service Manual 4048 00x 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 Ib 3b ars n
33. Note Pin number 1 is 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 J5l y J1 O mb B E J2E om E ae To J4 y NU Ds 3 J6 o 5 A Pm el ka Ge ESTER m Jet E J22 Je3 J12 E J18 15 1 Jiz VE J441 J10 J8 J37 gt O vuvusy uy 2 po UU ue O 5 8 Service Manual 4048 00x Function Name on Card of Pins Pin Signal Name Mirror J1 MMTR 5 4 Gnd motor 5 24 V Cover J2 CO 3 2 5 V 3 Gnd LSU J3 LSU 8 1 5 Gnd 6 5 V 7 Gnd SDRAM J4 DIMM 2 100 6 21 31 3 3 V 42 50 71 81 92 3 3V 56 1 12 26 Gnd 36 47 51 62 76 Gnd 86 97 USB J5 USB 4 1 USB power connector 3 3V SDRAM J6 DIMM 1 100 6 21 31 3 3 V 42 50 71 81 92 3 3V 56 1 12 26 Gnd 36 47 51 62 76 Gnd 86 97 Operator J7 OP PANEL 6 1 Gnd panel lights 5 5 V MPF J8 MPF 2 1 2 24 V during solenoid MPF pick Main motor J10 MAIN 7 1 6 Gnd MOTOR 7 24 V dc Ex
34. RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information 2 Remove the rear cover See Rear Cover Removal on page 4 16 for more information 3 Unplug the wires on both sides of the connectors 4 Unsnap connectors and remove to the left side 4 38 Service Manual 4048 00x Printhead Removal 1 2 gt Remove the top cover See Top Cover Assembly Removal on page 4 8 Disconnect the printhead cable Note Mark alignment of the printhead at the screw areas with the printhead to keep the same alignment upon reinstallation Remove the four screws A Remove the printhead Check alignment of the printhead before reinstalling the top cover Adjust as necessary See Printhead Assembly Adjustment on page 4 2 for more information Repair Information 4 39 4048 00x RIP Card Cage with card in place Removal 1 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 2 Loosen the six screws in the controller cage cover and slide the cover off 3 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information 4 Disconnect all cables from the RIP card assembly 5 Remove the inner cover 6 Remove the three screws through the RIP card and one only through the cage A 7 Gently pull the bottom of the cage out and lift up and off the two posts at the top 4 40 Servi
35. SS Service Manual pi AE Taser 4048 00x e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index LEXMARK 4048 00x Edition February 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 Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark Lexmark with diamond design
36. ar and remove 4 Disconnect the MPF cable on the right side of the RIP card and the toner level sensor 5 Remove the three screws A on the front of the lower body MPF assembly and gently remove the assembly 4 52 Service Manual 4048 00x MPF Roller Assembly Removal 1 Remove the upper body MPF assembly See Upper MPF Housing Assembly with Paper Flag Removal on page 4 49 for more information Remove the MPF cover See Lower Front Cover Multipurpose Feeder Cover Removal on page 4 6 for more information Remove the left side and inner covers See Left Side Cover Removal on page 4 14 for more information Remove the roller cover one 1 screw See Lower MPF Housing Assembly Removal on page 4 52 for more information Remove the lower body MPF assembly See Lower MPF Housing Assembly Removal on page 4 52 for more information CAUTION The lower body MPF assembly remains electrically connected since it is not being replaced Use care with the cable Rotate the unit upside down to reduce stress on the cable Repair Information 4 53 4048 00x 6 Remove the MPF gear using your thumbnail to release the latch and slide the gear from the shaft 4 54 Service Manual 4048 00x 7 Remove two screws A holding the roller assembly and one screw facing the front of the printer 8 Remove the roller assembly Repair Information 4 55 4048
37. ard Assembly Cartridge Contacts Assembly Check the contacts for correct installation and contamination where contact is made with the toner cartridge and HVPS card Clean as necessary If this does not correct the problem replace the following FRUs one ata time in the order shown HVPS card e RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Diagnostic Information 2 51 4048 00x Partial Blank Image White Spots no periodic pattern FRU Action Toner Cartridge not a FRU Remove the toner cartridge and gently shake the assembly to evenly distribute the toner If the toner cartridge is low try a new one Fuser Backup Roll Springs not a FRU Fuser Assembly Check springs at each end of the backup roller springs and backup roller to ensure adequate and even pressure is applied to the fuser hot roll Replace the fuser if necessary Paper Make sure recommended paper is being used Variation in Image Density Horizontally Across Page FRU Action Toner Cartridge The charge roll may have an unbalanced pressure against the PC drum Check for equal forces at both ends of the charge roll Try a new toner cartridge Transfer Roll Bearings Transfer Assembly Roll Check the springs and bearings at both ends
38. ays check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Diagnostic Information 2 21 4048 00x RAM Memory Error This error indicates RAM failure Remove DIMM s and re POR the printer If the error persists replace the card If the error subsides check each DIMM independently Replace faulty DIMM Primary Code Secondary Code LE Ready Data Loi Toner Low LE Load Remove Paper Loi Paper Jam LE Error LE Press Continue he Ready Data Toner Low Load Remove Paper he Paper Jam xe Error Press Continue Tertiary Codes Ready Data Los PE he LE Toner Low Load Remove Paper O Paper Jam 3 E Error O 3 O HE Press Continue RAM in slot 3 is bad 963 RAM in slot 2 is bad 962 RAM in slot 1 is bad 961 RAM soldered on the board is bad 960 Note The alarmis not activated for this error 2 22 Service Manual 4048 00x Network Error Indicates an error in the network circuitry Replace the RIP card assembly Primary Code Secondary Code Eos Ready Data XE Ready Data os Toner Low Toner Low XE Load O Load Remove Paper Remove Paper JE Paper Jam PE Paper Jam xk Error Eos Error IE Pre
39. cable included with P N s 56P0601 and 56P0602 front cover 3 Switch Interlock Cover 4 and 5 Sensor and Cable Included with P N 56P0611 6 and 7 Solenoid Paper Feed 7 Sensor Toner Level 9 Cable Assembly Drawer 10 Card Assembly RIP 10 Card Assembly Network RIP 11 Cable Assembly Output Full and Fuser Exit 12 Sensor Smart Button 13 Sensor Cable Output Full 14 Connector 3 Pin 15 Connector 2 Pin 16 Sensor Photo Locations 5 3 4048 00x Cables continued RIO XI OED 5 4 Service Manual 4048 00x Reference Description 1 Power Supply 110 V 1 Power Supply 220 V 2 7 8 9 Cable Assembly Main Harness Locations HVPS Fan LVPS Power LVPS Control NS Paper In Duplex OPNP Fuser PS High Volt Guide Assembly Left oa AJ Cable Assembly LVPS to Fuser Fan Cooling 10 Card Assembly RIP 10 Card Assembly Network RIP 11 Cable Assembly Printhead Locations 5 5 4048 00x Sensors 5 6 Service Manual 4048 00x Reference Description Paper Path Exit Flag Paper Path below Cartridge Paper Path Duplex Paper Path MPF Paper Path below Cartridge Sensor Toner Level Sensor Smart Button NI BR wo ND Sensor Fuser Exit Locations 5 7 4048 00x RIP Card Assembly
40. ce Manual 4048 00x RIP Card Assembly Removal 1 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information Loosen the six screws in the controller cage cover and slide the cover off Remove the inner cover Disconnect all cables from the RIP card assembly Extract all cables from the cage except those at the top rear portion of the card Remove three screws through the RIP card and one only through the cage A Remove three screws at the ports at the back of the cage Carefully remove the RIP card Repair Information 4 41 4048 00x Main Drive Motor Assembly Removal 1 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information Disconnect the cable to the PWB Remove the four screws holding the metal base plate to the gear train assembly Remove the motor assembly A G o 4 42 Service Manual 4048 00x Motor Assembly Stepper Removal 1 2 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information Remove the left side cover See Left Side Cover Removal on page 4 14 for more information Remove the RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information Remove three screws B Lift the stepper motor out Repair Information 4 43 4048 00x Main Drive Assembly Removal
41. de 4 24 D roll tray 1 feed 4 35 tray 1 shaft assembly 4 36 duplex tray assembly 4 19 fuser assembly 4 20 fuser exit sensor 4 20 fuser lamp 4 20 fuser paper exit guide 4 20 guide entrance 4 32 left 4 28 right 4 28 locations high voltage power supply HVPS 5 12 power supply LVPS 5 11 RIP card assembly 5 8 lower MPF assembly 4 52 main drive assembly 4 44 motors main drive assembly 4 42 stepper 4 43 MPF roller assembly 4 53 paper guide roller 4 26 printhead 4 39 rear exit door 4 18 reference plate assembly 4 46 sensor MPF paper sensor 4 50 smart button 4 31 terminal assembly 4 22 transfer roll assembly left transfer bearing 4 33 tray damper 4 23 spring 4 23 upper MPF assembly 4 49 Resolution 1 4 Right Guide Removal 4 28 Right Side Cover Removal 4 12 4 13 RIP Card Assembly Removal 4 41 RIP Card Cage Removal 4 40 RIP Card Specifications 1 11 Roll Tray 1 Feed Removal 4 35 S Safety Information 1 xvii Safety Inspection Guide 6 1 Serial Number 1 2 Service Checks cooling fan 2 29 cover interlock switch 2 30 dead machine 2 33 fuser 2 34 cold fuser 2 35 hot fuser 2 37 LVPS power supply 2 33 main motor 2 37 operator panel 2 38 paper feed 2 41 2 42 2 43 2 44 2 45 2 46 parallel port 2 47 print quality 2 48 bands 2 54 black lines 2 54 black page 2 50 heavy background 2 51 light print 2 53 partial blank image 2 52 poor fusing of image 2 53 toner on back of page 2 54 variation 2 52 white l
42. e ID set to match the label after the RIP card has been replaced Par S strobe adjustment for the parallel port can be set to four additional settings in addition to the default setting Pull up resistors are only enabled indicating parallel mode 1 is not supported Parallel mode 2 is supported and can be turned off or on in the configuration mode Adjustments may have to be made if an unusually long parallel cable is being used Network settings for Mark History History mode Optra Forms mode and Meditech mode can be set A service error history report network can be printed Dump NVRAM prints a hex dump of the NVRAM partition and the re init NVRAM resets the network NVRAM to the factory defaults Note When a controller card is changed in a network printer print the menu and network sheets After POR press Continue If the Printer Type under Integrated Network Option Settings does not match the Name under Appletalk go into the printer diagnostics mode and reinitialize NVRAM Reinit NVRAM Verify that the names match after reprinting the network sheet Diagnostic Aids 3 7 4048 00x Continuity Check on HVPS Cartridge Continuity between the HVPS and the charge roll Dr B blade TAR toner adder roll the developer roll and the photoconductor DC can be checked as follows 1 Turn printer off 2 Remove the right side cover See Right Side Cover Removal o
43. e Manual 4048 00x 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 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 b lgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Avis 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 I 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 60825 1 Els productes l ser de classe no es consideren perillosos Aquesta impressora cont un l ser de classe Illb 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 le
44. e RIP card J22 Measure the resistance of the thermistor The resistance measures approximately 245K ohms when cool approximately 40 C and 2K 3K ohms hot Replace the fuser assembly as necessary 2 36 Service Manual 4048 00x Hot Fuser Service Check Make sure the correct voltage lamp is installed The voltage rating is stamped on one of the lamp contacts FRU Action Fuser assembly Unplug the printer and measure the resistance of the thermistor The resistance measures approximately 245K ohms when cool approximately 40 C and 2K 3K ohms hot Replace the fuser assembly as necessary Main Motor Service Check FRU Action Main Motor Verify 24 V de on pin 7 at J10 on Main Motor Cable the RIP card assembly e If the voltage is correct check the main motor cable for continuity e f the voltages are not correct see Low Voltage Power Supply LVPS Service Check on page 2 33 or replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead If continuity exists on each wire replace the main motor If continuity does not exist on one or more of the wires replace the motor cable Diagnostic Information 2 37 4048 00x Operator Panel Service Check Inspect the operator panel cable for damage Make sure the cable
45. e cable is damaged replace the cable Diagnostic Information 2 29 4048 00x Cover Interlock Switch Service Check Note Make sure a toner cartridge is installed and the cover closes all the way 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 de on the middle spade of the cable and ground on the top spade of the cable If voltage is not present see RIP Card Service Check on page 2 31 Replace the switch if faulty 2 30 Service Manual 4048 00x RIP Card Service Check FRU Action RIP Card Assembly Check for 24 V dc from the LVPS card to the RIP card assembly Turn the printer off Disconnect the LVPS cable from the RIP card at J20 e Turn the printer on Verify 24 V dc from the cable pins 1 and 2 e If voltages are not present or incorrect see the Low Voltage Power Supply LVPS Service Check on page 2 33 Diagnostic Information 2 31 4048 00x FRU Action RIP Card Assembly continued NOOB Note With all cabl
46. e top two lights are on Press Continue for three seconds The print quality test pages print See Using Print Quality Test Pages on page 2 62 for more information Problem Action Light or blurred characters The print cartridge may be getting low on toner Remove the print cartridge e Shake it from side to side to redistribute the toner e Reinstall it Make sure you are using recommended print media see media types and sizes in the User s Guide e Use MarkVision to define the custom type setting for media type media texture or media weight e The print cartridge may be defective Replace it Diagnostic Information 2 55 4048 00x Problem Action Toner smudges appear on the front or back of the page e Make sure the paper is straight and unwrinkled e 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 BCDEN BCDE BCDE Replace the print cartridge Toner smears or rubs off the page e Try a different kind of paper Paper designed for copiers gives the best quality e If you are printing on special media such as card stock or labels be sure you select the correct paper type in the printer driver e Change the media texture setting You can download the latest driver from the Lexmark Web site www lexmark com
47. ensor to function The sensor is also required for duplexing Repair Information 4 5 4048 00x Removal Procedures Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed Be sure to remove the print cartridge before you perform removal procedures Cover Removals Lower Front Cover Multipurpose Feeder Cover Removal 1 Open the front cover 2 Open the MPF front cover to where the latches are clear about 15 3 Lift the left side of the cover to release it from the hinge 4 Remove the lower front cover 4 6 Service Manual 4048 00x Front Cover Removal 1 Open the front cover 2 Disconnect the cable from the display panel A 3 Remove the four screws B 4 Remove the front cover Es 7 yr Repair Information 4 7 4048 00x Top Cover Assembly Removal 1 Remove the toner cartridge 2 Remove the two 2 screws in front A EE 7 em Te A 3 Open the rear exit door 4 Remove the two screws in the rear A 4 8 Service Manual 4048 00x 5 Remove the duct assembly in the top cover Repair Information 4 9 4048 00x 6 Carefully lift the rear edge of the top cover to clear the exit flags and rotate the front cover hinge until the cover is in a vertical position 4 10 Service Manual 4048 00x To completely remove the top cover 7 Open the front cover 8 Remove the E clips from both hinges that co
48. entrance guide A 3 Remove the duplex unit See Duplex Tray Assembly Removal on page 4 19 for more information Unsnap the two latches holding the entrance guide Remove the entrance guide Check the printhead alignment and adjust as necessary See Printhead Assembly Adjustment on page 4 2 for more information Oo OR 4 32 Service Manual 4048 00x Transfer Roll Assembly and Left Transfer Support Bearing Removal Note Do not touch the transfer roll except on the ends 1 Remove the toner cartridge 2 Unlatch and lift the left side support bearing 3 Unlatch and lift the right transfer support bearing 4 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 Repair Information 4 33 4048 00x 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 19 for more information 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 4 34 Service Manual 4048 00x D Roll Tray 1 Feed Removal 1 Remove the left cover and inner cover for the MPF gearing See Left Side Cover Removal on page 4 14 for more in
49. equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas of the printer Preventive Maintenance 6 1 4048 00x 6 2 Service Manual 4048 00x 7 Parts Catalog How to Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description AR As Required in the Units column indicates that the quantity is not the same for all machines NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts description column indicates the part is contained in a parts packet Parts Catalog 7 1 4048 00x Assembly 1 Covers 7 2 Service Manual 4048 00x Assembly 1 Covers Asm Part Index Numbers 1 1 56P0608 1 2 56P0607 1 3 56P0680 1 4 56P0603 1 5 56P0604 1 6 56P0605 1 7 56P0601 Units Description Cover Assembly Rear Door Assembly Rear Exit Flap Paper Holder Cover Assembly Duct Cover Assembly Top Cover Assembly Right X A a a a a Cover Assembly Front with Display without logo 1 7 56P0602 1 Cover Assembly Front with Display with logo 1 8 56P0610 1 Cover Assembly MPF Door 1 9 56P0679 1 Overlays Language 1 10 56P0600 1 Cover A
50. er front top front top rear as shown in the picture above 4 Lift cover out of the bottom slots Repair Information 4 13 4048 00x Left Side Cover Removal 1 Open the front cover and the MPF cover 2 Disengage the two latches located in the front and top A 3 Swing the left side cover away from the printer 4 14 Service Manual 4048 00x Note With only the left side cover and inner cover removed the following items can also now be removed and replaced MPF gear see Multipurpose Feeder MPF on page 7 4 for more information Toner level sensor see Electronics and Cables on page 7 8 for more information Motor with PWB see Paper Feed on page 7 14 for more information Door latches see Frame on page 7 16 for more information Paper feed solenoid see Electronics and Cables on page 7 8 for more information RIP card cage cover see Electronics and Cables on page 7 8 for more information Memory see Options on page 7 22 for more information Connector cable for second drawer option see Electronics and Cables on page 7 10 for more information RIP card PCB see Electronics and Cables on page 7 8 for more information Repair Information 4 15 4048 00x Rear Cover Removal 1 Remove the paper tray 2 Remove the right side cover See Right Side Cover Removal on page 4 12 for more information 3 Remove the left side cover See
51. es connected the printer should complete POST within approximately 12 15 seconds in the following sequence All operator panel lights on solid momentarily Lights then flash on and off sequentially After lights quit flashing the Ready Data light turns on solid The cooling fan comes on The fuser lamp comes on The drive motor runs The printhead motor runs The printer cycles down into standby mode ready If immediately following power on the operator panel lights are active but the printer does not go through steps 1 and 2 above replace the RIP card assembly Note Always check printhead alignment after replacing the RIP 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 See Printer Diagnostics Mode on page 3 6 for more information If some lights are on or flashing see Status Information Light Patterns on page 2 3 to determine a course of action 2 32 Service Manual 4048 00x Dead Machine Service Check Note Check the AC line voltage The voltage should be within the following limits 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 Supply Card LVPS 110 V and 220 V
52. es not respond See Operator Panel Service Check on page 2 38 or RIP Card Service Check on page 2 31 Operator panel lights do not light or are very dim See RIP Card Service Check on page 2 31 2 28 Service Manual 4048 00x Service Checks Service checks involve measuring voltages of the LVPS HVPS and RIP card assembly Continuity and resistance verifications are done on cables and components as required Note When looking at the printed side of a PCB connectors are designated with J followed by a number Pin 1 is designated on the PCB by an adjacent 1 or triangle Pin numbers index sequentially to the opposite end of the connector See RIP Card Assembly on page 5 8 for more information Cooling Fan Service Check FRU Action Cooling Fan Make sure the cooling fan motor cable plug is properly seated Turn the printer off and disconnect the cooling fan cable at the cooling fan Turn the printer on Within approximately 15 seconds the RIP card assembly should apply 24V dc to the fan See RIP Card Assembly on page 5 8 for more information e If voltage is present replace the cooling fan e If voltage is not present disconnect the cable from the RIP card J22 and check for continuity and shorts connector sockets 1 and 2 Ifthe cable is good see the RIP Card Service Check on page 2 31 for more information Ifth
53. ety Inspection Guide 2 4444suesssuvesmmessuenssue 6 1 Lubrication Specifications sssssssssssescssuseseneusae 6 1 Parts Catalog cooccociccncrran aan en en aa 7 1 How to Use This Parts Catalog asus 7 1 INGEN 222 ee 1 1 4048 00x vi Service Manual 4048 00x 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 GE FFNET 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 oreer vasoeman AERMSESAUNESERBUT FEU MAS Laser Notices vii 4048 00x Laser Notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class I 1 laser products and elsewhere is certified as a Class 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
54. formation Remove the duplex tray See Duplex Tray Assembly Removal on page 4 19 for more information Disconnect extension spring B from the D roll Release the latch on the paper feed solenoid It is located behind the lower right corner of the main drive assembly Rotate the main drive motor counterclockwise until the D roll clears the adjacent rib Using a slotted screwdriver as a wedge between the D roll and bearing wall force the D roll to unsnap from the shaft Slide the D roll off the tray 1 feed shaft A d Tur S Repair Information 4 35 4048 00x D Roll Tray 1 Shaft Assembly Removal 1 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 2 Remove the inner cover 3 Remove the MPF gear 4 Remove the gear train assembly See Main Drive Assembly Removal on page 4 44 for more information 4 36 Service Manual 4048 00x 5 Remove the solenoid B A B 6 With the printer on its back remove the D roll See D Roll Tray 1 Feed Removal on page 4 35 for more information Note Slowly extract the shaft while facing the D roll end Capture the small washer and the bearing The bearing must be removed and reinserted through the opening adjacent to its operating location A See page page 4 35 for more information Repair Information 4 37 4048 00x 3 Pin and 2 Pin Connectors Removal 1 Remove the
55. he assembly to evenly distribute the toner Ensure clean electrical contacts on the right side 2 48 Service Manual 4048 00x FRU Action Printhead Blank pages can be caused by a Printhead Cable defective printhead assembly high HVPS voltage power supply or RIP card RIP Card Assembly assembly See RIP Card Service Cartridge Contacts Assembly Check on page 2 31 and verify the required voltages and proper ground at connectors J1 and J3 With the cartridge removed and the printer off check continuity between HVPS DC designation on outside of card and the PC pin inside the printer The PC pin is directly above the transfer roll gear If the voltages are correct check the printhead cable for continuity e If the cable measures continuity replace the printhead e If the cable does not measure continuity replace the cable See High Voltage Power Supply HVPS on page 5 12 and verify the voltages e If the 24 V dc and 5 V de input voltage measurements are correct replace the HVPS e If the voltages are incorrect replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Diagnostic Information 2 49 4048 00x Black Page Note Incorrect laser exposure or incorrect charging of the photoconductor by the charge roll causes an all
56. he 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 e Use of this symbol throughout the service manual indicates the presence of hazardous voltage in the repair work area Unplug the printer before proceeding or proceed with caution if repair work requires power Consignes de S curit e La s curit de ce produit repose sur des tests et des agr 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 pieces de rechange non agr es e Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifie 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 Safety Information xvii 4048 00x Norme di sicurezza e Lasicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produtto
57. he menu 3 2 printer diagnostics 3 5 printer setting configuration 3 4 Door Latches Right Side Removal 4 24 D Roll Tray 1 Shaft Assembly Removal 4 36 Duplex Tray Assembly Removal 4 19 E Entrance Guide Removal ESD Sensitive Parts 4 1 F Factory Defaults restoring 2 62 Flash Memory 1 3 Fonts 1 8 Front Cover Removal 4 7 Fuser Assembly Removal Fuser Exit Sensor Removal Fuser Lamp Removal 4 20 Fuser Paper Exit Guide Removal 4 20 4 32 4 20 4 20 H Handling ESD Sensitive Parts 4 1 HVPS Card Removal 4 56 l Invalid Code Secondary Lights 2 5 L Laser Notices 1 vii Left Guide Removal 4 28 Left Side Cover Removal 4 14 Left Transfer Support Bearing Removal 4 33 Lower MPF Housing Assembly Paper Sensor Removal 4 50 Lower MPF Housing Assembly Removal 4 52 Lower Front Cover Removal 4 6 Lubrication 4 3 Lubrication Specifications 6 1 LVPS Card Removal 4 57 4048 00x Main Drive Assembly Removal 4 44 Main Drive Motor Assembly Removal 4 42 Maintenance Approach 1 1 Memory 1 3 flash memory 1 3 Motor Assembly Stepper Removal 4 43 MPF Roller Assembly Removal O Operator Panel 1 12 diagnostics 2 2 light patterns 2 3 attendance information 2 5 service information 2 9 status information 2 3 menu definition 3 1 service checks 2 38 4 53 P Paper Guide Roller Removal Paper Handling 1 8 options 1 9 Paper Jam Secondary Lights 2 7 Parts Catalog 7 1 cables 7 10 charging 7 6 co
58. hment is not part of the model factory shipped configuration 1 10 Service Manual 4048 00x Printer Speed Speed Base Model Network Model Pages minute in 300 dpi 22 22 Pages minute in 600 dpi 22 22 Pages minute in 1200 22 22 Image Quality Time to first print 10 seconds 10 seconds Automatic power saver 8 8 RIP Card Specifications Feature Base Model Network Model Processor 9221 9221 Processor Bus frequency 200 100 MHz 200 100 MHz Synchronous DRAM 2 64 Mbit 2 128 Mbit NAND flash 1 64 Mbit 1 64 Mbit Processor internal bus 32 Bit 32 Bit width capability RIP SRAM OKB OKB L1 Cache instruction 8KB 8KB 8KB 8KB data General Information 1 11 4048 00x Supplies Print Cartridge Average Yield Approximate Coverage Prebate print 5 000 5 cartridges 10 000 5 Regular cartridges 5 000 5 without Prebate terms and conditions 10 000 5 Operator Panel The 4048 00x operator panel consists of six lights and two buttons The operator panel is used to indicate status as well as an input to modify some printer settings All models have the same operator panel Ready Data light is on Toner Low light is off Load Remove Paper light is blinking Paper Jam light is blinking slowly Error light is off Press Continue light is off Continue button Cancel button Note Printer settings such as paper source paper size and
59. hts Heavy Normal Light Media Textures Rough Normal Smooth Note V Indicates media is supported 1 6 Service Manual 4048 00x Printer Data Streams Data Streams Base Model Network Model PCL 6 emulation Y Y PostScript Level 2 Y emulation PPDS Note V Indicates data stream is supported e PCL 6 emulation includes the PCL 5e and PCL XL interpreters and is fully compatible with Hewlett Packard s LaserJet 5 Family Furthermore the printer PCL emulation is backward compatible with the Optra T 610 612 614 616 and other members of Lexmark s Optra family of laser printers e 4048 00x supports version 3010 of the Adobe definition of PostScript 3 and the interpreter is backward compatible with the Optra T 610 612 614 616 and other members of Lexmark s Optra family of laser printers e PPDS is backward compatible with Optra T 610 612 614 616 and Lexmark s Optra family of laser printers The PPDS interpreter is inactive as a factory default It must be activated using a PJL command or operator panel operation before it can be used General Information 1 7 4048 00x Fonts Fonts Options Base Model Network Model PCL bitmapped 2 2 PCL scalable 90 90 PS scalable 89 89 PPDS bitmapped 5 5 PPDS scalable 39 39 Paper Handling Paper Handling Base Model Network Model Standard Standard input sources 2 2 I
60. ice Check FRU Action Transfer Assembly Roll Transfer Bearing 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 both the transfer roll bearing assemblies if the springs or bearings indicate damage or lack of proper function Inspect the transfer roll for signs of wear or damage and replace as necessary 2 40 Service Manual 4048 00x Paper Feed Service Checks Paper Picks and Advances Approximately 4 Inches FRU Action Plate Assembly reference edge Turn printer off and remove the print Paper Feed Gear cartridge and left side cover Drive Assembly With a left finger rotate the main motor counterclockwise while using a right finger to resist gear movement in the plate assembly reference edge in the paper path below the cartridge If the gear motion can be stopped while continuing to rotate the drive motor one of the units has to be replaced The paper feed gear is most likely the failing part Remove the drive assembly for further inspection Replace the faulty unit When the plate assembly is replaced it has to be adjusted See Adjusting Paper Feed Alignment on page 4 3 for more information Diagnostic Information 2 41 4048 00x Paper Jam Error Indication During POST FRU Action S
61. ines 2 54 white spots 2 52 RIP card 2 31 transfer roll 2 40 4048 00x Service Error Codes 2 11 engine circuitry error 2 19 engine flash error 2 12 engine software error 2 12 fan stalled error 2 15 fuser error 2 14 network error 2 23 NVRAM failure 2 20 paper communication failure 2 24 printhead error 2 16 RAM memory error 2 22 RIP card error 2 21 RIP software error 2 11 RIP software illegal trap 2 11 RIP to engine communication error 2 18 toner sensor error 2 15 transfer roll error 2 13 transport motor error 2 17 Service Error Secondary Lights 2 10 Service Information Light Patterns 2 9 Smart Button Sensor Removal 4 31 Special Tools 1 1 Status Information Light Patterns 2 3 Supplies 1 12 Symptom Tables 2 26 POST 2 26 printer 2 27 T Terminal Assembly Removal 4 22 Top Cover Assembly Removal 4 8 Transfer Roll Assembly Removal 4 33 Tray Damper and Spring Removal 4 23 U Upper MPF Housing Assembly Removal 4 49 l 4 Service Manual 4048 00x Part Numbers 1038693 11D0330 12A2405 12G9830 12G9831 12G9832 12G9833 1329605 1339520 1339528 1339529 1339530 1339531 1339532 1339533 1339534 1339548 1427498 43H5545 56P0600 56P0601 56P0602 56P0603 56P0604 56P0605 56P0606 56P0607 56P0608 56P0609 56P0610 56P0611 56P0612 56P0613 56P0614 56P0615 56P0616 56P0617 56P0618 56P0619 56P0620 56P0622 56P0623 56P0624 56P0625 56P0626 7 24 7 13 7 23 7 23 7 23 7 23 7 23 7 23
62. ir Special Tools Long Phillips screwdriver approximately 6 inch shank Slotted screwdriver Small Phillips screwdriver When taking voltage readings always use the printer frame as ground unless another ground is specified General Information 1 1 4048 00x Serial Number Look for the serial number label on the inside front cover of the printer Printer Identification Flap j Duct cover Asm Front cover Flags Cover MPF Asm MPF door 1 2 Service Manual 4048 00x Printer Features Memory and User Flash Memory Each model has a standard amount of memory RAM soldered on the system card and a certain number of 100 pin DIMM slots available for installing additional memory or user flash memory options Memory Base Model Network Model Standard memory 16MB 32MB Standard flash memory None None Memory options 8MB DIMM e 16MB DIMM e 32MB DIMM e 64MB DIMM e 128MB DIMM Maximum of memory DIMM NI SSSSS DI SSSSS Maximum possible memory 272MB 288MB Flash memory options e 2MB DIMM 4MB DIMM 8MB DIMM e 16MB DIMM ISIS ISIS Maximum of flash memory DIMMs Maximum possible flash memory 16MB 16MB Note Indicates option is supported General Information 1 3 4048 00x Resolution and Print Quality Note e IET PQET PictureGrade print resolution print darkness
63. is plugged in securely Run POST and check each light for proper operation FRU Action Front Cover If more than one light does not turn on or an individual light stays on solid during POST check the operator panel cable for continuity Replace if defective Ifthe cable has continuity replace the front cover Ifthe buttons do not depress or click when pressed replace the front cover 2 38 Service Manual 4048 00x FRU Action Front Cover If all lights are dim and operate Operator Panel Cable erratically during POST or come on RIP Card Assembly and stay on solid during POST replace the following FRUs one ata time in the order shown RIP card assembly Front cover e Operator panel cable Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead If none of the lights come on make sure the cable is properly connected to the operator panel and the RIP card assembly Check the LVPS Disconnect the cable and check it for continuity Replace if necessary If the cable indicates continuity verify 5 V dc at pin 5 on J7 See Locations on page 5 1 for more information e If the voltages are not correct replace the RIP card assembly If these voltages are correct replace the front cover Diagnostic Information 2 39 4048 00x Transfer Roll Serv
64. it motor J12 EX_MT 4 1 2 24 V during motor run Sensor J14 MPF SN 6 1 5 V MPF toner 3 Gnd 4 5 V 6 Gnd Locations 5 9 4048 00x Function Name on Card of Pins Pin Signal Name LVPS J15 LVPS 5 5 Gnd control Paper feed J16 FD 2 1 2 24 V during solenoid tray 1 pick 2nd drawer J17 TRAY2 6 5 Gnd interface 6 24 V Fuser exit J19 P EXIT 6 1 5 V tray full 3 Gnd sensor 4 5 V 6 Gnd LVPS DC J20 POWER 6 1 2 24 V power 3 4 Gnd 5 5 V 6 Gnd Thermistor J21 THERM 5 2 5 Gnd Smart IC HVPS J22 HVPS 11 1 24 V fan 2 Gnd fan 5 Gnd 7 24 V Sensor J23 Paper IN 9 1 4 7 5 V paper Duplex 3 6 9 Gnd input narrow duplex 5 10 Service Manual 4048 00x Power Supply LVPS CAUTION 110 220 V ac EHNCHON Name on Card of Pins Pin Signal Name 110 220 CN1 1 5 V de Volts CN2 1 2 5 6 Gnd 3 4 5 V dc 7 8 24 V de Heater CN3 1 2 110 220 Vac On off CN4 S W 1 2 110 220 Vac switch Locations 5 11 4048 00x High Voltage Power Supply HVPS INSIDE Toward Printer ES a G
65. iure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres Limprimante 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 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 00x Avisos sobre el l ser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos l ser de Clase I 1 establecidos en el subcap tulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s
66. l function menu See Configuration Menu Group or Diagnostic Menu Group on page 3 2 for more information Press Cancel and wait for the Ready Data light Press Cancel again and wait for the Toner Low light Press Cancel again and wait for both Ready Data and Toner Low lights Press and hold Continue until lights cycle Three pages print to help you evaluate print quality The first page has registration marks the second page is gray and the third page is black Once the paper exits into the output bin the printer returns to the Ready state Use the test pages to isolate problems such as print too light toner streaks and so on See the Troubleshooting tables in the User s Guide for solutions to these problems To return the printer online POR the printer 2 62 Service Manual 4048 00x 3 Diagnostic Aids Operator Panel Menu Definition The operator panel settings and operations are divided in two menu groups Configuration Menu Group The Configuration Menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used to configure a printer for operation Access to the Configuration Menu group is gained by way of a POR key sequence See Power On Operations on page 2 25 for more information Diagnostic Menu Group The Diagnostic Menu group contains the settings and
67. l ha d estar ne assabentat i prendre les mesures convenients ok apar e EMSS HA SAS SA 748 Go Met HSE Zr okt Mo SE ASUCH te F517 Wal TES Sor SPAS HEHH re Ho HAS XX SESC S eo LOI E MEO BS KA HS MAE NE MBA SN Sle ASI HO S E bl MEE AEE AAA T MACH HES AMA Bula AS arme SAS HHG ARE ds gado HELICE HE AHA JIER E O MAS SA ofA Best oft 21 S Zlob ES SHA E xx Service Manual 4048 00x ZERM AP a FY 0 PE DA IGOR i ATE EDS In N MIKE RANE A tio I ERA STARTE EA NYE PE TT o ASPE AED EN YEE MINTE SH EX MN EE PES HE ERZAN NTE RAT IT T HR LEE PI HINE AERP IE EN i AE T Safety Information xxi 4048 00x 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 in this chapter as well as general environmental and safety instructions Diagnostic Information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUS Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Repair Information provides instructions for making printer adjustments and removing and installing FRU
68. l is turned on the alarm does sound when this error occurs Diagnostic Information 2 15 4048 00x Printhead Error Indicates a problem with the printhead Check cables to the printhead Replace the printhead as necessary See Printhead Assembly Adjustment on page 4 2 for realignment procedures Primary Code Secondary Code LE Ready Data we Toner Low LE Load Remove Paper dE Paper Jam Lo Error LE Press Continue te Ready Data Toner Low Load Remove Paper Paper Jam Eog Error he Press Continue Tertiary Codes 1 0 Ready Data 38 LE os LE we 3 Toner Low Load Remove Paper 38 Eos Paper Jam x Error XO O Loi Press Continue Ae Mirror motor not at operating speed 935 Verify 24 V dc on pin 5 of J7 Mirror motor lost lock 934 L Mirror motor locked no hsync received 933 Printhead lost hsync 932 Printhead no first hsync 931 Printhead wrong printhead installed 930 Note If the alarm control is turned on the alarm does sound when this error occurs 2 16 Service Manual 4048 00x Transport Motor Error Indicates a problem with the main drive motor system The problem could be the motor the RIP card the cabling or the drive assembly Check the cable connectors The tertiary
69. l mode Continue and Cancel buttons pressed 2 Close cover once the error light is displayed Diagnostic Information 2 25 4048 00x Power On Self Test POST When you turn the printer on it performs a Power On Self Test Check for correct POST functioning of the base printer by observing the following symptoms Symptom Tables POST Symptom Table Symptom Action The main motor cooling fan and fuser do not come on See the Cover Interlock Switch Service Check on page 2 30 POST completes except one or more lights do not come on See the Operator Panel Service Check on page 2 38 None of the lights come on See the Operator Panel Service Check on page 2 38 Main motor does not come on See the Main Motor Service Check on page 2 37 Fan does not come on See the Cooling Fan Service Check on page 2 29 Fuser lamp does not come on See the Cold Fuser Service Check on page 2 35 Fuser lamp never turns off See the Hot Fuser Service Check on page 2 37 The paper feed picks and tries to feed paper See the Paper Feed Service Checks on page 2 41 2 26 Service Manual 4048 00x Printer Symptom Table Symptom Action Dead machine no power See Dead Machine Service Check on page 2 33 Fan noisy or not working See Cooling Fan Service Check on page 2 29
70. lag is attached below Repair Information 4 49 4048 00x Lower MPF Housing Assembly Paper Sensor Removal 1 Remove the lower front MPF door See Lower Front Cover Multipurpose Feeder Cover Removal on page 4 6 for more information 2 Remove the feed roll cover one screw 3 At the lower right assembly hinge separate the metal plate from the plastic housing 4 50 Service Manual 4048 00x 4 Support the left side with the left hand while separating the left hinge Note In the next step note a loaded compression spring A on the left side and under the metal plate 5 Rotate the metal plate until the sensor can be accessed 6 Disconnect the cable to the sensor and remove the sensor by pushing on the latches underneath the sensor and housing 7 Install the new sensor and reconnect the cable 8 Reinstall the metal plate Make sure the compression spring is in the proper location and captured at its ends 9 Rotate the metal plate to keep the spring positioned Reconnect the left hinge and then the right hinge Repair Information 4 51 4048 00x Lower MPF Housing Assembly Removal 1 Remove the lower front MPF door See Lower Front Cover Multipurpose Feeder Cover Removal on page 4 6 for more information 2 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 3 Loosen the six screws in the RIP card cover Slide the cover toward the re
71. ment may not be needed Always check the printhead alignment after replacing the RIP card assembly Settings on the original RIP card may not be the same as on the new card Only a horizontal line adjustment can be made margins cannot be adjusted Contact the next support level or call Lexmark 1 800 539 6275 for assistance To perform the registration check and adjustment ROD Turn the printer off Open the front door Press and hold Cancel while turning the printer on Hold Cancel until the lights have cycled on and off approximately nine seconds Close the door when the Error light comes on Wait for the four top lights to stay on Press and release Cancel once and wait for the lights to change to Ready Data Press and release Cancel again and wait for Toner Low light Press and release Cancel again and wait for both Ready Data and Toner Low lights Press and hold Continue until lights cycle Once the printer starts press Cancel These sheets continuously print if not canceled Use the sheets to check the margins and alignment 4 2 Service Manual 4048 00x 11 Adjust the printhead as necessary If a horizontal line is clockwise on the paper adjust the printhead counterclockwise 12 After obtaining a properly adjusted image on the paper tighten all four screws Note Printhead misalignment results in skewed horizontal lines but a consistent margin top to bottom of page Pape
72. mper and Spring Removal 1 Remove the right side cover See Right Side Cover Removal on page 4 12 for more information 2 Remove the tray damper spring from the printer frame post A 3 Rotate the lever counterclockwise as far as possible and lift out Repair Information 4 23 4048 00x Door Latches Removal 1 Remove the right side cover See for more information 2 Remove the two screws A and replace the latches 3 Remove the left side cover See for more information hd E 4 Remove one latch on left side 4 24 Service Manual 4048 00x Bracket Opener Shutter Removal 1 do Remove the HVPS See HVPS Card Removal on page 4 56 for more information Remove the toner cartridge Unsnap the latches from the frame Remove the opener shutter bracket Note The bracket can be removed with possible latch breakage by wedging a screwdriver or similar tool between the bracket and the frame Repair Information 4 25 4048 00x Paper Guide Roller Removal 1 2 3 Remove the HVPS See HVPS Card Removal on page 4 56 for more information Remove the toner cartridge Remove the upper body MPF assembly See Upper MPF Housing Assembly with Paper Flag Removal on page 4 49 for more information Unsnap the latch which is part of the roller hub A Remove the paper guide roller 4 26 Service Manual 4048 00x Charge Roll Removal 1 Open the
73. n page 4 12 for more information 3 Remove the toner cartridge 4 Check from C on the HVPS to the bearing on the left side of the charge roll See page 5 12 for more information 5 Check from the Dr B TAR DEV T and DC photoconductor respectively to the corresponding pin on the right side frame where the toner 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 12 for testing the PCB 3 8 Service Manual 4048 00x 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 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 an
74. nese Font MarkNet X2011e Ethernet 10 100 sa aa aC a a a 2 2 2 2 2 aa a a 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 Adapter External Serial NS 1329605 1 Cable High Speed Bidirectional Parallel 10 ft NS 1427498 1 Cable High Speed Bidirectional Parallel 20 ft NS 12A2405 1 Cable USB 2 Meter Parts Catalog 7 23 4048 00x Assembly 9 Options Asm Part Alde index N mbers Units Description NS 1038693 1 Cable Serial 50 ft NS 56P0670 1 Kit Repack 7 24 Service Manual 4048 00x Index A Acronyms 1 14 Adjusting Paper Feed Alignment 4 3 Adjustments 4 2 paper feed alignment 4 3 printhead assembly 4 2 Attendance Information Lights 2 5 Bracket Opener Shutter Removal 4 25 Bracket Paper Detect Input Sensor Removal 4 34 C Cartridge Coupling Assembly Removal 4 48 completely remove top cover 4 11 Configuration Menu Group 3 2 changing settings 3 3 moving around the menu 3 2 printer diagnostics 3 5 printer setting configuration 3 4 printing graphical aids 3 3 Connectivity 1 10 Connector Removals 3 Pin and 2 Pin 4 38 Continuity Check HVPS cartridge 3 8 Cooling Fan Removal 4 58 D Data Streams 1 7 Diagnostic Information 2 1 Diagnostic Menu Group 3 2 changing settings 3 3 graphical aids 3 3 moving around t
75. nnect the charge roller and top cover B 9 Remove the stud hinges 10 Disconnect the cable A 11 Remove the top The front cover remains attached to the top cover p nl a A Repair Information 4 11 4048 00x Right Side Cover Removal 1 2 Remove the paper tray Remove the front right screw and same side rear screw from the top cover See Top Cover Assembly Removal on page 4 8 for more information Note If you do not have an appropriate screwdriver to access the front right screw remove the two screws holding the right side of the front cover to the hinge Move the front cover just enough to access the screw Open the MPF Lift the top cover just enough to grasp the top of the right side cover with your right hand B While pulling out on the top of the right side cover use your left hand to release the two latches top front and lower front A 4 12 Service Manual 4048 00x Note The MPF door may need to be lifted slightly for the side cover to clear 6 Release the top rear latch if necessary Swing the cover out and lift it from the base Right Side Cover Removal There may be an occasion where you have to completely remove the top cover instead of just lifting it to access the screw and latches 1 Remove the paper tray 2 Remove the top cover assembly See Top Cover Assembly Removal on page 4 8 for more information 3 Release the three latches low
76. not correct replace the solenoid e Verify the solenoid has the spring in place and functions mechanically If this is true and the resistance is correct replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Diagnostic Information 2 45 4048 00x Paper Occasionally Picks or Picks Multiple Sheets at Once FRU Action Paper Feed Roll D Roll at Tray 1 Spring Paper Feed Assembly Check the paper feed roll D roll pick roll for wear Replace as necessary Verify that the extension spring is working properly If not replace the spring If the paper feed roll shaft rotates freely replace the paper feed assembly Note We recommend that the paper feed roll be replaced when the paper feed assembly is replaced 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 curl 2 46 Service Manual 4048 00x Diagnostic Information 2 47 4048 00x Print Quality Service Checks Blank Page FRU Action Toner Cartridge Remove the toner cartridge and gently shake t
77. ns 1 and 2 If there is continuity go to step 1 If there is no continuity go to step 2 Step 1 Continuity Reconnect the fuser lamp cable at CN3 Replug and turn the printer on Measure the voltage at connector CN4 on the LVPS It should match the line voltage e If line voltage is not present replace the LVPS Make sure the fuser thermistor is correctly connected to the RIP card J22 If the problem persists disconnect the thermistor cable from the RIP card assembly and check for 4 V to 5 V dc See Locations on page 5 1 for more information e If the voltage is incorrect see RIP Card Service Check on page 2 31 Step 2 No Continuity Unplug the printer and check the lamp cable for continuity e If correct replace the lamp e If incorrect replace the lamp cable Diagnostic Information 2 35 4048 00x Make sure the correct voltage lamp is installed The voltage rating is stamped on one of the lamp contacts FRU Action Fuser assembly If the fuser lamp comes on and a fuser failure error code displays be sure the thermistor is contacting the hot roll and the thermistor cable is firmly seated in connector J22 on the RIP card assembly The thermistor cable goes through the frame by way of a connector Check for excessive toner buildup on the surface of the thermistor Clean as necessary Unplug the printer and disconnect the thermistor cable from th
78. ntegrated 250 sheet tray The 250 sheet drawer supports the following sizes A4 A5 JIS B5 folio letter legal executive and statement e Multipurpose feeder Standard output destination 150 sheet sensing bin Standard duplex Envelope conditioning 1 8 Service Manual 4048 00x Paper Handling Base Model Network Model Universal paper size e Minimum bitmap width and length e Maximum bitmap width e Maximum bitmap length Y 64800 183600 306000 Y 64800 183600 306000 Options Maximum of optional drawers Optional drawers 250 sheet drawer 500 sheet drawer The 500 sheet drawer supports the following sizes A4 JIS B5 folio letter legal and executive as as Maximum of media input sources Maximum input sheet capacity excluding envelopes 850 850 Maximum sheet capacity excluding envelopes 150 150 Note Y Indicates associated capability is supported Assumes 20 Ib xerographic paper General Information 1 9 4048 00x Connectivity Attachments Base Model Network Model Standard parallel Y Y interface Parallel interface connector is a 1284 B connector Parallel mode 2 Standard USB interface Standard Ethernet 10 x 100 Base TX Note v Indicates attachment is part of the model factory shipped configuration X Indicates attac
79. oad Paper Manual Feed O O O O Load Paper Tray 1 for Side 2 Manual Duplex O O O O O O Remove Paper from Output Bin O O O O O O Insert Tray 1 O O O O O O Top Cover Open Cartridge Missing O O O O Defective or Unsupported Print Cartridge O O O O Change Cartridge Invalid Refill Diagnostic Information 2 5 4048 00x k o o a g E O adi 2 gt E E 5 Attendance Condition Q 9 u 5 O Ge Re os p Ss D o 5 0 Q Q o 1 E a a u a O Oo O O O Toner Low Intervention O O O O O Offline O O O O Paper Jam Note A double press of Continue causes a secondary light pattern which indicates further information on the type of paper jam See Paper Jam Secondary Light Patterns on page 2 7 O O O O O Printer Error Note A double press of Continue causes a secondary light pattern which indicates further information on the type of printer error See Printer Error Secondary Light Patterns on page 2 8 2 6 Service Manual 4048 00x Paper Jam Secondary Light Patterns im o o Ly A o g E gt 2 E Attendance Condition a 4 2 O gt pa e A Oo Oo 2 YN SIS SISIE EIS 1 4 a uu a O O O O O O Paper Jam Input Sensor O O O O O O Paper Jam Exit Sensor O O O O e Paper Jam Duplex Sensor O O O O O O Paper Jam Fuser Exit Sensor O O O O O Paper Jam Multipurpose Feeder Sensor
80. of the transfer roller The bearing assemblies should support the transfer roller applying even pressure to the PC drum Replace both bearing assemblies if either spring shows signs of damage or fatigue Inspect the transfer roller for signs of wear or damage and replace as necessary 2 52 Service Manual 4048 00x Poor Fusing of Image FRU Action Fuser Lamp 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 35 Make sure recommended paper is being used Light Print FRU Action Toner Cartridge Make sure the toner cartridge is installed correctly and is not low on toner If the problem continues install a new toner cartridge Transfer Roller Check the transfer roller for signs of HVPS Contact Transfer Roller toner buildup and contamination HVPS Card Inspect the HVPS contact transfer roller for contamination Inspect the HVPS card for contamination where it meets the HVPS contacts If all components appear free of contamination replace the following FRUS one at a time in the order shown Transfer roller e HVPS contact transfer roller e HVPS card Diagnostic Information 2 53 4048 00x White or Black Lines or Bands FRU Action Toner Cartridge Paper Feed Drive Gears Banding appears as light or dark horizontal lines on a uniformly gray page or
81. 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 toner cartridge and paper feed components especially the drive gears for signs of wear debris binds or damage Toner on Back of Page FRU Action Print Cartridge Inspect the overall paper path for signs of spilled toner Gently clean the contaminated areas with a soft cloth or compressed air Fuser Assembly The fuser hot roll can cause toner on the back of the paper if toner is building up on the hot roll This buildup may transfer to the backup roller later transferring to the back of the paper Inspect the hot roll and backup roller for signs of contamination and replace fuser 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 2 54 Service Manual 4048 00x Solving Print Quality Problems Note To run the print quality test pages Turn the printer off and open the door e Turn the printer on while pressing Continue e Continue to press and hold Continue until lights finish cycling When the Error light stays on close the door and wait until the four top lights are on Press Cancel until th
82. operations used while manufacturing and servicing the printer See Power On Operations on page 2 25 for more information The top four lights are on home state when the printer is in either Configuration or Diagnostic mode The only items that can be changed have one or both Error and Continue lights on e Press and release Cancel to advance through the menus e Press and release Continue to advance through the values for a menu item until you find the one you want e Press and hold Continue until all lights cycle to save the value for a menu item e Press and hold Cancel until all lights cycle to go to the home state Diagnostic Aids 3 1 4048 00x Configuration Menu Group or Diagnostic Menu Group Correct entry of either mode is indicated with the four top lights on Press and hold Continue about 4 seconds for the printer to produce a page similar to the ones on page 3 4 and page 3 5 depending on which mode is entered Note For information on how to enter the configuration or diagnostic modes see Power On Operations on page 2 25 Moving Around the Menu Referring to page 3 4 and page 3 5 menu items are designated by the non indented items listed along the left edge of the page Bottom as printed from printer Note These items are un shaded and have the four light pattern indications printed Press and release Cancel to move sequentially from one of the menu items to another e Pre
83. orientation may not be selected or modified by the operator panel Instead users must utilize an application print driver and or the printer toolkit to modify settings through the host computer A printer settings page can be printed by briefly pressing Continue when only the Ready Data light is on 1 12 Service Manual 4048 00x Options See Options on page 7 22 for a list of options available for the T420 n printer General Information 1 13 4048 00x Acronyms C CCW CW DC DEV DIMM DRAM FRU GND HVPS IDE IET INA KB LED LSU LVPS MHz MPF NAND NVRAM PCB PCL 6 PJL POR POST PPDS PQET PS PWB RIP ROM RS TAR USB Vac Charge Roll Counterclockwise Clockwise Direct Current Developer Roll Dual Inline Memory Module Dynamic Random Access Memory Field Replaceable Unit Ground High Voltage Power Supply Integrated Development Environment Image Enhancement Technology Internal Network Adapter Kilobyte Light Emitting Diode Laser Scanning Unit Low Voltage Power Supply Megahertz Multipurpose Feeder Not And Gate Nonvolatile Random Access Memory Printed Circuit Board Printer Command Language Printer Job Language Power On Reset Power On Self Test Personal Printer Data Stream Print Quality Enhancement Technology PostScript Printed Wiring Board Raster Image Processor Read Only Memory Recommended Standard Transfer Roll Toner Adder Roll Universal Serial Bus Volts Al
84. os an su 1 11 STP 1 12 Operar PE 1 12 O jolie po RS u 1 13 Fe rene ira canina 1 14 Diagnostic Information 2 1 TT 2 1 Operator PAn6l sassasasasadsis as sasddds sakene dis 2 2 Light P ttems ou um 000 1 2 BR aa a 2 3 Status Information Light Patterns 2 3 Attendance Information Light Patterns 2 5 Obtaining Information about Printer Service Error Codes 2 11 Service Error COd S eociommocinmrr anna anna en 2 11 Power On Operations comoocccnrrmrcra ners cece 2 25 Power On Self Test POST z40s 2 002000 2 26 Symptom Tables ssssisscsosscssssasessessssases 2 26 4048 00x Service Checks ss sissssesasresnsrsassenssrssssteasax 2 29 Cooling Fan Service Check 42 uaa ss u0 un samen 2 29 Cover Interlock Switch Service Check 2 30 RIP Card Service Check ss cssssmmsadsdascunasreaaa 2 31 Dead Machine Service Check 2 33 Low Voltage Power Supply LVPS Service Check 2 33 Fuser Service Check ceca 2 34 Main Motor Service Check 2 37 Operator Panel Service Check 2 38 Transter Roll Service Check sus a a 2 40 Paper Feed Service Checks 2 41 Parallel Port Sento Check ass 2 47 Print Quality Service CNeCKS 22 se ei messe 2 48 Solving Print Quality Problems ss uud an 2 55 Restoring Factory Defaults ssa ses en ee 2 62 Using F
85. ose the printer cover to restart the printer Make sure the print cartridge is installed properly 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 See Configuration Menu Group or Diagnostic Menu Group on page 3 2 for more information Restore factory defaults See Restoring Factory Defaults on page 2 62 for more information Make sure the parallel cable or USB cable is firmly plugged in at the back of the printer Jobs are not printing and the Error light is on solid Make sure the print cartridge is installed properly Make sure the printer top cover is closed Make sure the top cover is activating the switch Diagnostic Information 2 61 4048 00x Restoring Factory Defaults Sometimes resetting the printer to the original factory default settings solves formatting problems 1 4 Enter the configuration mode See Configuration Menu Group or Diagnostic Menu Group on page 3 2 for more information Press and release Cancel The Ready Data light is on Press Continue until lights flash The factory defaults are reset To return the printer online POR the printer Using Print Quality Test Pages To help isolate print quality problems like streaking print test pages using the print quality test pages setting 1 ww Enter the specia
86. pa ses re ne todas las condiciones expuestas en la norma IEC 60825 1 para productos l ser de Clase I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase Illb 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 est n dise ados 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 Declarac o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamentac o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe Illb 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 n vel de Classe I durante a opera o normal a manuten o feita pelo utilizador ou condi es de
87. r feed misalignment results in entire image rotated on the paper See adjusting paper feed alignment for more information Adjusting Paper Feed Alignment When a reference plate reference edge assembly is removed it requires alignment 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 RIP card cage and the main motor PCB Adjust the screw counterclockwise which rotates paper counterclockwise in the printer path image clockwise and vice versa Lubrication Several FRUs must be lubricated when installed The following diagrams indicate which units and where to place the lubricant 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 Repair Information 4 3 4048 00x FR SUE US TEW yp UG P N 56P0633 P N 56P0637 4 4 Service Manual 4048 00x Pam EN W N ef Sat DS P N 56P0635 P N 56P0636 Re assembly Ensure all cables are re connected when re assembling the printer The printer may not detect a disconnected sensor in some areas without extensive running For example the tray full sensor has a connector in the left cover and has to be disconnected to remove the rear cover The tray would have to be full for the s
88. r Sensor Removal on page 4 50 for more information Remove one screw in the cover adjacent to the assembly plate Note Remove the reference plate assembly through the front of the printer A 4 46 Service Manual 4048 00x When a reference plate reference edge assembly is removed reinstallation requires alignment 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 between the RIP card cage and the main motor PCB Adjusting the screw counterclockwise rotates paper counterclockwise in the printer path image clockwise and vice versa Repair Information 4 47 4048 00x Cartridge Coupling Assembly Removal 1 2 3 Remove the toner cartridge Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information Remove the left cover See Left Side Cover Removal on page 4 14 for more information Remove the RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information Remove the two screws A Remove the bracket Note The toner cartridge coupling may need to be compressed u removal N Xy 4 48 Service Manual 4048 00x Upper MPF Housing Assembly with Paper Flag Removal 1 Open the front cover 2 Remove two screws holding the assembly 3 Carefully lift the assembly out Note A sensor f
89. re 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 e Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona amp pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie 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 ausschlie lich 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 zust ndige Fachpersonal sollte entsprechende Vorsichtsma nahmen treffen xviii Service Manual 4048 00x Pautas de Seguridad e 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 mantenimiento de este producto est dirigida exclusivamente al pe
90. rnt Quality Test Pages susanne pas da 2 62 Diagnostic A OS 050 dr dais 3 1 Operator Panel cormocrrmarr rr anna anna 3 1 Menu Definition scsi ccssssesssmessssessesesssssses 3 1 Configuration Menu Group or Diagnostic Menu Group 3 2 Printer Diagnostics Mode 2660 200s200cee cece ee ecen 3 6 Continuity Check on HVPS Cartridge 3 8 Repair Intormaton as un da dead de 4 1 Handling ESD Sensitive Parts casuais sra ee gt 4 1 Fe Ps ER ata Pedido adia db Duas De 4 2 Printhead Assembly Adjustment 4 2 Adjusting Paper Feed Alignment 4 3 ep 4 3 Re EE ee 4 5 Removal Procedures score berede ane 4 6 Cover Remo AB in 4 6 Rear Exit Door REMOVAL 4 sssssssisasessasenausx 4 18 Duplex Tray Assembly Removal 4 19 Fuser Assembly Fuser Paper Exit Guide Fuser Exit Sensor and Fuser Lamp Removal 4 20 Terminal Assembly Removal 4 22 Tray Damper and Spring Removal 4 23 Door Latches Removal 26cecceseceeesseenseaans 4 24 Bracket Opener Shutter Removal 4 25 Paper Guide Roller Removal 4 26 Charge Roll Removal sazzz22222222220200002220055 4 27 iv Service Manual 4048 00x Right Guide Removal ssssssssissssssssessessssnsss 4 28 Left Guide Removal sssssssassaussaumasssemsss 4 28 Smart Button Sensor Removal 4 31 En
91. rsonal cualificado de mantenimiento e Existe mayor riesgo de descarga el ctrica y de da os 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 Informac es de Seguranca e 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 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 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 Safety Information xix 4048 00x Informaci de Seguretat La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components especifics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades e Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e Elrisc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge de servei d aquest producte El personal professiona
92. rtridge 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 e Check the printhead The operator panel lights do not come on when the printer is turned on e The lights may take a few seconds to come on e Make sure the power cord is firmly plugged in at the back of the printer and at the electrical outlet The top cover does not close Make sure the print cartridge is positioned correctly The printer is on but nothing prints e Make sure the print cartridge is installed properly e Make sure the parallel or USB cable is firmly plugged into the connector on the back of the printer Press Continue with a brief button press to print a test page to determine whether the problem is with the printer or the computer If you can print a test page the problem is in the computer or the software application If you cannot print a test page the problem is in the printer 2 58 Service Manual 4048 00x Problem Action The media skews or buckles e Don t overfill tray 1 or the optional tray 2 see media capacities in the media types and sizes table in the User s Guide e Make sure the paper guides are flush against the edges of the media The paper sticks together printer feeds multiple sheets of paper e Remove the paper from tray
93. s Locations uses illustrations and tables to identify the locations and test points on the printer Preventive Maintenance contains the lubrication specifications and recommendations to prevent problems Parts Catalog contains illustrations and part numbers for individual FRUs xxii Service Manual 4048 00x 1 General Information The Lexmark T420 n laser printer is a monochrome laser printer designed for single users or small workgroups There are two models The T420 Base printer with 16MB of memory standard a parallel port and a USB port The T420 Network printer with 32MB of memory standard an integrated Ethernet adapter a parallel port and a USB port The purpose of this chapter is to provide an overview of the capabilities of the printer and available options for each of the T420 models Note Unless otherwise noted all references to the Lexmark T420 n laser printer are intended to refer equally to both the T420 Base and the T420 Network models Maintenance Approach The diagnostic information in this manual 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 the 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 repa
94. s condicions prescrites Laser Notices xiii 4048 00x Japanese Laser Notice LT 53004 LOF7 7 KETADHHS 21 CFRYTF TS DIFAI 1 D EMAELEAL Y BE TS 8 EMEA Atos EXXELUATILIEC 8250445211275 ALOV V WMECHSCEMMPMANTIET FIAILOV V WHEE SREB LARA TUNEL CO P L RPSAED 3b DL HF TR LTVET CO LEE HENTTO 7957 77 72 3 OBHC BH 537937 RORY D MEU MHT LDL PCS COLA YVAFREFUVI H EOS 2 FOXTVTFFIYAR KH ESM BW TI MEDI FAIDVNSNVELED L TF ik HomanaldtaohkuvaisdiHantv E T Chinese Laser Notice FT EN OL ae E EA ES DHHS 21 CFR Subchapter IN 59 2 I 1 RIT RYH MATABA META UE A IEC 825 AJ Ar V DE TI BOL m RUAKERE A FT ED OLA ah A oy NI 3b BM FEET TS JE 5 ETER NN fil Bist HKEE 770 795 nm 2H ABOGRA MAT ENLAI ET GE ME E GER EGET BONE A ES IE ALT REE AR HE fh EI DI TEATER xiv Service Manual 4048 00x Korean Laser Notice axie 188 4014 ASSO CHEF DHHS 21 CFR Subchapter 3 TAS Arsh Ves u o ISSO 12 19 etol E IEC 825 TIS tse 158 WA ABSA 2138 SCIE LICE isa alo ASSES OMS Noz HFHH 2 HHS 5 PASS 28 ofato gjo BA 770 795 poje el mep ol SSste Class II 3b JoINSE LEO 27 USH E alo AAMT BREE YA As Soltt Fi Er S EE TIE MEIA SEHON 719 Class TES AO EH ol Aol AC 428 913 MASON VE Laser Notices XV 4048 00x xvi Service Manual 4048 00x Safety Information e The safety of this product is based on testing and approvals of the original design and specific components T
95. ss Continue pe Press Continue Tertiary Codes O Ready Data EE RE SE BE RE BE Toner Low o oo O O O O Load Remove Paper Eos x XK Paper Jam Error Eos He xe Press Continue Flash parts failed while programming port 979 Bad checksum while 973 programming port 978 ao Unrecoverable software error in network port 975 971 Unrecognizable network port 974 970 Note Ifthe alarm control is turned on the alarm does sound when this error occurs Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Diagnostic Information 2 23 4048 00x Paper Port Communication Failure Indicates an error communicating with tray 2 if installed Remove tray 2 and recheck If the error doesn t recur replace tray 2 If the error recurs replace the RIP card assembly Primary Code Secondary Code LE Ready Data XE Ready Data XE Toner Low Toner Low LE Load he Load Remove Paper Remove Paper 3 Paper Jam Paper Jam LE Error Error LE Press Continue Press Continue Tertiary Codes Ready Data LE Loi LE oe LE Toner Low O O Load Remove Paper ZE Paper Jam 3 FE Error 34 O ae O
96. ss and hold Cancel to jump to home state top four lights on e Press and release Continue to move through the values of the item with values This action rotates only through the possible values of the selected menu item Note Menu items with values have either or both the Error or Press Continue lights on Menu items without values have neither Error nor Press Continue lights on 3 2 Service Manual 4048 00x Changing Settings or Printing Graphical Aids Select the desired item by pressing and releasing Cancel If the item has values press and release Continue to select the desired value Press and hold Continue to Activate printing Three pages are in the Print Quality Pages Instructions for either the Configuration or Diagnostics mode occupy one page Continuous Cont Prt printing can be halted by pressing Cancel Reset defaults After resetting factory defaults the operator panel returns to home state four top lights on Settings are retained in NVRAM as well as ROM Record selected settings After setting new values the operator panel returns to home state Settings are retained in NVRAM Exceptions are Hex Trace and Demo Mode Activate e Select Hex Trace On or Demo Mode Activate The printer automatically POR s and returns with Ready Data flashing slowly Files sent to the printer are printed in Hex Trace e Press and hold Cancel to leave Hex Trace The printer returns
97. ssembly Left Parts Catalog 7 3 4048 00x Assembly 2 Multipurpose Feeder MPF 4048 00x Assembly 2 Multipurpose Feeder MPF Asm Part Index Numbers Units Description 2 1 56P0612 1 Housing Assembly Upper MPF 2 2 56P0611 1 Housing Assembly Lower MPF 2 3 56P0615 1 Cap MPF Paper Feed Cover 2 4 56P0613 1 Assembly Roller MPF 2 5 56P0614 1 Gear MPF Paper Pick Parts Catalog 7 5 4048 00x Assembly 3 Charging 7 6 Service Manual 4048 00x Assembly 3 Charging G ne as Units Description 3 1 56P0640 1 Roll Charge 3 2 56P0668 1 Parts Pack Screws and E Rings 3 3 56P0669 1 Hinge Pivot quantity 2 3 4 56P0642 1 Guide Assembly Right 3 5 56P0643 1 Assembly Transfer Roll 3 6 56P0644 1 Bearings Transfer Roll 3 7 56P0641 1 Guide Assembly Left Parts Catalog 7 7 4048 00x Assembly 4 Electronics and Cables 7 8 Service Manual 4048 00x Assembly 4 Electronics and Cables a a as Units Description 4 1 56P0626 1 Power Supply 110 V 4 1 56P0627 1 Power Supply 220 V 4 2 7 8 56P0663 1 Cable Assembly Main Harness Locations 2 HVPS 7 Fan 8 LVPS Power 9 LVPS Control NS Paper In Duplex 4 3 56P0628 1 PS High Volt 4 4 56P0641 1 Guide Assembly Left 4 5 56P0650 1 Cable Assembly LVPS to Fuser 4 6 56P0630 1 Fan Cooling 4 10 56P0617 1 Card Assembly RIP 4 10 56P0619 1 Card Assembly Network RIP
98. t and Rear 5 11 56P0633 5 12 56P0632 5 13 56P0638 5 14 56P0637 5 15 56P0635 5 16 56P0636 5 17 56P0639 Assembly Drive Motor Assembly Main Drive Coupling Cartridge Drive Ratchet Assembly Motor Gears Spur Guide Link X A a a Order a lubricant to use with these gears P N 99A0394 FRU Nyogel 744 See page 4 3 for more information Parts Catalog 7 15 4048 00x Assembly 6 Frame 7 16 Service Manual 4048 00x Assembly 6 Frame Ga ee Take Units Description 6 1 56P0606 1 Duct Air 6 2 56P0623 1 Assembly Printhead 6 3 56P0629 1 Assembly Cartridge Contacts quantity 5 6 4 56P0662 Feet Base 6 5 56P0661 6 6 56P0668 6 7 56P0609 6 8 56P0667 6 9 56P0660 6 10 56P0659 6 11 56P0672 6 12 56P0658 Damper Tray Parts Pack Screws and E Rings Assembly Tray 1 Latch Door Qty 3 Roller Paper Guide Bracket Shutter Bracket Body Tray X A A a a Guide Entrance Parts Catalog 7 17 4048 00x Assembly 7 Fuser 7 18 Service Manual 4048 00x Assembly 7 Fuser G ae ai Units Description 7 1 56P0648 1 Assembly Fuser 110 V 7 1 56P0671 1 Assembly Fuser 220 V 7 2 56P0673 1 Fuser Assembly Paper Guide 7 3 56P0676 1 Spring Fuser Exit 7 4 56P0646 1 Lamp Fuser 110 V 7 4 56P0647 1 Lamp Fuser 220 V Parts Catalog 7 19 4048 00x Assembly 8 Sensors VE
99. tack Control Flags Photo Sensor If the exit sensor flag is not resting within the paper exit sensor during POST the printer indicates Load Remove Paper Make sure the flag is operating freely and correctly Replace the photo sensor and or the stack control flag as necessary Photo Sensors paper path Make sure the input paperfeed sensor is working properly A stuck or incorrectly installed sensor causes this error Printer indicates Paper Jam and Press Continue If the secondary code indicates additionally Ready Data check under the cartridge for paper damaged flags or malfunctioning sensors Toner Low check under the cartridge and or inside the rear door for jammed paper Load Remove Paper check for a damaged flag malfunctioning sensor at the fuser exit or a paper jam inside the rear door Flashing Ready Data check for paper jam in the MPF ora malfunctioning MPF sensor Flashing Toner Low check the sensor in the duplex path for a jam or a malfunction 2 42 Service Manual 4048 00x Paper Picks During POST and or Continuously FRU Action Paper Feed Assembly Check the pick roller clutch for wear Paper Feed Solenoid The solenoid interacts with the clutch controlling motion of the pick roller If the cam surface of the pick roller clutch assembly is worn the solenoid may not stop the D roll pick roll from rotating Replace the paper feed assembly if necessary
100. ternating Current 1 14 Service Manual 4048 00x 2 Diagnostic Information Start CAUTION Unplug power from the printer before connecting or disconnecting any cable assembly or electronic card This is a precaution 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 The lights on the operator panel indicate the status of the printer anytime it is powered on When the printer experiences a problem requiring operator intervention it indicates the source by blinking one or more lights See Status Information Light Patterns on page 2 3 for more information When all six lights blink simultaneously a service may need to be performed See Service Error Codes on page 2 11 for more information If the printer does not indicate a service error code nor complete POST without an error but there is a symptom see Symptom Tables on page 2 26 for more information Diagnostic Information 2 1 4048 00x Operator Panel The 4048 00x operator panel consists of six indicator lights and two buttons Note Traditional printer settings such as paper source paper size and orientation may not be selected or modified using the operator panel Users must either utilize an application print driver and or the O Ready Data O Toner Low Load Remove Paper O Paper Jam O Error
101. the HVPS See HVPS Card Removal on page 4 56 for more information Repair Information 4 29 4048 00x 8 Disconnect the single conductor wire spade connector D Note Removal of the LSU printhead is not necessary but gives better visibility and access Illustrations are with the LSU removed See Printhead Removal on page 4 39 for more information 9 Remove the wire from the retainers between the printer s right side and the left guide 10 Unsnap the three latches C of the left guide while prying the assembly from the frame See page page 4 29 for more information 11 Remove the left guide 4 30 Service Manual 4048 00x Smart Button Sensor Removal 1 Remove the toner cartridge 2 Remove the gear train assembly See Main Drive Assembly Removal on page 4 44 for more information 3 Remove the two screws and the bracket coupling assembly 4 For additional clearance remove the charge roll See Charge Roll Removal on page 4 27 for more information 5 Remove the screw holding the smart button sensor A 6 Remove the two screws in the cable cover retainer 7 Remove the sensor by pushing from inside the printer Note Unplug the thermistor cable to remove the smart button sensor Repair Information 4 31 4048 00x Entrance Guide Removal 1 Remove the LSU printhead See Printhead Removal on page 4 39 for more information 2 Remove the two screws A holding the
102. tion RIP Software Error Illegal Trap Contact the next level of support or call Lexmark 1 800 539 6275 for assistance Primary Code Secondary Code Tertiary Codes LE Ready Data LE Ready Data Ready Data 3 Toner Low Toner Low He Toner Low J Load Load Load Remove Paper Remove Paper Remove Paper 3 Paper Jam Paper Jam Paper Jam Loi Error Error Error Loi Press Continue Press Continue Press Continue Note The alarmis not actuated for this error 900 Diagnostic Information 2 11 4048 00x Engine Flash or Engine Software Error The first error message below 901 indicates the flash into which the engine code is programmed is bad Either the flash cannot be erased or the program failed when programming was attempted The remaining errors 902 906 indicate an unrecoverable engine software error Replace the RIP card Primary Code Secondary Code 3 Ready Data 3 Ready Data ee Toner Low Toner Low 3 Load O Load Remove Paper Remove Paper o Paper Jam Paper Jam XE Error Error 3 Press Continue Press Continue Tertiary Codes Ready Data xe LE Xk Eos od Toner Low O Load Remove Paper O 7 Eos Eos Paper Jam Xe os 3 Error Eos ZE O Press Continue L RIP interface driver error 906 Interface violation by paper port device 905
103. to ready state Ready Data light on Select Demo Mode Activate The Ready Data light comes on solid and the Press Continue light flashes A demo page prints each time Continue is pressed After returning to Demo Mode Deactivate see note the printer returns to Ready Data automatically after a few seconds Note After using Hex Trace return to the printer Configuration group by powering the printer off and on See Configuration Menu Group or Diagnostic Menu Group on page 3 2 for more information The printer cannot be returned to the menu home state using the operator panel Diagnostic Aids 3 3 4048 00x Printer Settings Configuration Printer Settings Configuration This page explains how to access the printer menus and change values Menus are represented by Ready Data Toner Low Load Remov Paper Paper Jam light sequences Menu items and their values are indicated by Error and Press Continue light sequences Use the illustration to help you find the menu and value you want to 1 Press and release Cancel to advance through the menus and to the items you need e Light On 2 Press and release Continue to advance to the value you need O Ught ort 3 Press and hold Continue until all of the lights cycle to perform the function or to save the value Light Blinking 4 To retum to the Home menu press and hold Cancel until all of the lights cycle Valve 5 Tum the printer off to exit the menus 3 4 Service Manual 404
104. trance Guide Removal 4 32 Transfer Roll Assembly and Left Transfer Support Bearing Re o EE EE EN T 4 33 Bracket Paper Detect Input Sensor Removal 4 34 D Roll Tray 1 Feed Removal 4 35 D Roll Tray 1 Shaft Assembly Removal 4 36 3 Pin and 2 Pin Connectors Removal 4 38 Piinthead Removal ce eceess a ee orero aea 4 39 RIP Card Cage with card in place Removal 4 40 Main Drive Motor Assembly Removal 4 42 Motor Assembly Stepper Removal 4 43 Main Drive Assembly Removal 4 44 Reference Plate Assembly Removal 4 46 Cartridge Coupling Assembly Removal 4 48 Upper MPF Housing Assembly with Paper Flag Removal 4 49 Lower MPF Housing Assembly Paper Sensor Removal 4 50 Lower MPF Housing Assembly Removal 4 52 MPF Roller Assembly Removal 4 53 HYPO CAN ROMOV sans aan ara acing 4 56 LVPS Gard Removal zu u nda 4 57 Cooling Fan Removal cero nn 4 58 Locations s oviscsinsaria sarria AA 5 1 Cables 00 0 anna 5 2 Cables continued 2u0u 04H HH 5 4 ee 5 6 RIP Card Assembly sissssisssesasessasesassesmectess 5 8 Power Supply LYPS accus suuusamassamesaumassuausan 5 11 High Voltage Power Supply HVPS 5 12 Preventive Maintenance 6 1 Saf
105. ualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan I laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan Illb 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 DHHS 21 CFR underparagraf J f r laserprodukter av Klass I 1 I andra l nder uppfyller skrivaren kraven f r laserprodukter av Klass I 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 p 5 milliwatt som arbetar i v gl ngdsomr det 770 795 nanometer Lasersystemet och skrivaren r utformade s att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass I niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd xii Servic
106. vers 7 2 electronics 7 8 frame 7 16 fuser 7 18 how to use 7 1 multipurpose feeder MPF 7 4 options 7 22 paperfeed 7 14 sensors 7 20 POST symptom table 2 26 Power On Operations 2 25 Power On Self Test POST Preventive Maintenance 6 1 Print Area 1 5 4 26 2 26 l 2 Service Manual Print Media 1 6 operating points textures 1 6 weights 1 6 Print Quality 1 4 solving problems 2 55 using test pages 2 62 Printer Diagnostics Mode 3 6 Printer Error Secondary Lights 2 8 Printer Features 1 3 connectivity 1 10 data streams 1 7 fonts 1 8 media 1 6 operating points textures 1 6 weights 1 6 memory 1 3 operator panel 1 12 paper handling 1 8 print area 1 5 print quality 1 4 resolution 1 4 RIP card specifications speed 1 11 supplies 1 12 user flash memory 1 3 Printer Identification 1 2 Printer Speed 1 11 Printer symptom table 2 27 Printhead Assembly Adjustment 4 2 R Rear Cover Removal Rear Exit Door Removal Re assembly 4 5 Reference Plate Assembly Removal 4 46 Removals 4 6 1 6 1 6 1 11 4 16 4 18 bracket opener shutter 4 25 bracket paper detect 4 34 card HVPS 4 56 LVPS 4 57 RIP card 4 41 RIP card and cage 4 40 4048 00x cartridge coupling assembly 4 48 charge roll 4 27 connectors 2 pin 4 38 3 pin 4 38 cooling fan 4 58 cover front 4 7 left side 4 14 lower front 4 6 MPF 4 6 rear 4 16 right side 4 12 top 4 11 top cover assembly 4 8 door latches right si
107. y 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 00x Adjustments Printhead Assembly Adjustment The printhead needs to be adjusted after it has been removed When reinstalling the new printhead tighten the four screws enough to contact the printhead frame An adjustment is required before tightening the screws Note Adjust the printhead so that its body is parallel to the cross brace of the printer frame Further adjust

Lexmark T420 (4048-00x) Series Laser Printer Service Manual

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