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4037-05E
Reference Handbook
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Lexmark 4037-05E, 4033, 4047-05E, 4047-05W Reference Handbook

First Edition (March, 1996)
The following paragraph does not apply to the United Kingdom or 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.
A form for reader’s comments is provided at the back of this publication. If the form has been removed, comments may be addressed to Lexmark International, Inc., Department F95/035-3, 740 New Circle Road, Lexington, Kentucky 40511, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.
Lexmark, MarkNet, MarkVision, Optra and WinWriter are trademarks of Lexmark International, Inc.
IBM and ExecJet are registered trademarks of the International Business Machines Corporation in the United States and/or in other countries. ExecJet is under license from International Business Machines Corporation.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 1996. 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., Greenwich, CT 06836.
Contents
4026-0XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Power-On Self Test (Post). . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Service Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Diagnostics Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Printer Diagnostic Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Service Diagnostic Test Page . . . . . . . . . . . . . . . . . . . . . . 1-16
User Mode Print Test Page . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Hex Trace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Restoring Factory Defaults. . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
4027-04W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Customer Test Page (From WPS) . . . . . . . . . . . . . . . . . . . 2-10
Customer Test Page (Stand Alone) . . . . . . . . . . . . . . . . . . 2-10
Developed Image Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
WPS.INI File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
4033 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Power Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Reset, LAN Connected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Symptoms after Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Sample Print Test (Models 20X and 30X) . . . . . . . . . . . . . . 3-5
Wrap Test for Adapter Ports. . . . . . . . . . . . . . . . . . . . . . . . . 3-5
LAN Connection Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Printer and LAN checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Printer checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
LAN checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Contents
iii
4037 / 4047-05E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Power-on Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Print Test (Main Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Developed Image Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Diagnostics Print Test 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Diagnostics Print Test 2. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Page Count Display Or Initialize . . . . . . . . . . . . . . . . . . . . 4-10
Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Button Lockout Mode (4047 Only). . . . . . . . . . . . . . . . . . . 4-12
LCD Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Print Head Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Print Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-14
Advanced Setup Menu (Early 4037 Models Only). . . . . . . 4-15
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Fastbytes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Hex Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4039-1XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Failures With Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Alphabetical List of Diagnostic Aids. . . . . . . . . . . . . . . . . . . 5-9
Operator Panel Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Network Connections and Checks . . . . . . . . . . . . . . . . . . 5-20
LAN Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Laser Printer Reference Handbook
iv
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Envelope Restraint Spring . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Paper Restraint Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Printhead Skew - Level 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Printhead Skew - Level 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
4040 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Diagnostic Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Error Code/Message Tables . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Operator Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Diagnostic Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Interlock Override. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Diagnostics Mode Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Envelope Feeder Separation Guide and Lower Separation Roll-
er Gap Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Paper Drawer Cassette Side Registration Adjustment. . . . 6-27
Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
System Board Connector Signals . . . . . . . . . . . . . . . . . . . 6-28
Paper Deck Switches, Sensors, Clutches, Solenoid, Motors. . .
6-37
Paper Deck Printed Circuit Boards. . . . . . . . . . . . . . . . . . . 6-37
Paper Deck Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Option Controller Interface Connectors . . . . . . . . . . . . . . . 6-41
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
Contents
v
4047-05W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Customer Test Page (From WPS). . . . . . . . . . . . . . . . . . . 7-10
Customer Test Page (Stand Alone). . . . . . . . . . . . . . . . . . 7-10
Developed Image Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Service Diskette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Diagnostics Test Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Diagnostics Test Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Envelope Print Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Hex Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Set Page Count. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Printhead Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Print Registration Adjustment . . . . . . . . . . . . . . . . . . . . . . 7-16
Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
4049-XXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . 8-10
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . 8-13
Diagnostics Mode Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Auto Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Auto Clean Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Auto Clean Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17
Disk Test/Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Duplex Feed 1 Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18
Duplex Feed 2 Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Envelope Enhance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Envelope Print Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Fuser Temperature And Warm-Up Time. . . . . . . . . . . . . . 8-21
Laser Printer Reference Handbook
vi
LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Maintenance Kit Count. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Memory Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22
Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Paper Feed Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Parallel Confidence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Print Test 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
Print Test 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Print Test 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27
Top Margin and Duplex Quick Tests . . . . . . . . . . . . . . . . . 8-28
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Wrap Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28
Developed Image Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
LAN Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Print Test Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30
Print Test with RIP Board Removed. . . . . . . . . . . . . . . . . . 8-31
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
Contents
vii
5045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1
Diagnostic/Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . 9-3
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . . 9-7
Diagnostics Mode Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
Disk Test/Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
LCD Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Memory Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Permanent Page Count. . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Print Test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Print Test 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Print Test 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Wrap Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
Density Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
LAN Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Attendance/Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
Service Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Screen/Color Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Toner Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Ordering Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Handling The Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Optional Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Using Print Density Adjustment (PDA)Panel. . . . . . . . . . . 9-22
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
Temperature/Humidity Sensor. . . . . . . . . . . . . . . . . . . . . . 9-23
117 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Print Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Laser Printer Reference Handbook
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Optra E
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1-1
Notes:
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1-2

4026-0XX

Diagnostics

Start

CAUTION: interlock switch and the printhead shutter actuator at the same
. To perform some of the servic e checks and tests, such as
time
troubleshooting paper feed problems, you need to actuate the top cover interlock switch with the covers opened or removed and power applied to the machine. It is important for personal safety that you
FOR ANY REASON
is on. Remove power from the printer before you connect or disconnect any
cable or electronic board or assembly for personal safety and to prevent damage to the printer.
Use the service error code, user error message, symptom table, service checks, and diagnostic aids to determine the corrective action necessary to repair a malfunctioning pr int er.
The lights on the operator panel can indicate either a user error message or service error message. When a service error occurs the printer stops printing and all operator panel LEDs blink in a continuous patt e rn, indicating a se rvice e rror, until the pri n t e r is powe r e d o ff. If all operator panel LEDs are blinking, go to the “Service Error Codes” on page 1 -5.
When a user error message occurs, one or two operator panel LEDs are on solid or blinking. Go to the “User Error Message Table” on page 1 -8.
If your machine does not have a service error code and does not complete POST, go to the “POST Symptom T able” on page 1-11. If your machine completes POST without an error, and you have a symptom, go to the “Symptom Table” on page 1-12. Locate your symptom and take the appropriate action.
If a service error code appears while you are working on the machine, go to the “Service Error Codes” on page 1-5 and take the indicated action for that error.
If your printer did not successfully complete POST, locate the symptom in the “POST Symptom Table” on page 1-11 and take the appropriate action.
NEVER
manually actuate or disable the top cover
DO NOT,
, disable the printhead shutter actuator when power
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1-3
If the printer completes all these steps and no error indications are displayed, the printer has successfully completed the POST. If the printer has completed POST without an error and a symptom exists, go to the “Symptom Table” on page 1-12.

Power-On Self Test (Post)

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The printer performs the following Power-On Self Test when powered on:
1. All LEDs come on solid.
2. The fan turns on for 2 seconds.
3. All the LEDs turn off.
4. The engine board checks the status of the cover interlock switch.
5. The LEDs begin to turn on then off continuously.
6. The fan turns off.
7. The engine board checks the status of the paper exit sensor.
8. The engine board checks the status of the thermistor.
9. The fuser lamp turns on. The printer may be idle for up to 40 seconds as the fuser warms
to operating temperature. Printer idle time is shorter if the fuser is already warm.
10. The polygon motor (printhead motor) turns on.
11. The main motor turns on.
12. The paper feed gears turn.
13. The print cartridge drive gear engages.
14. The paper feed take-up shaft and D-roll assembly rotates to home position. (The paper feed lift plate assembly is in the down position).
15. All the LEDs turn off.
16. Model 4026-06A, 06D - The Ready LED turns on solid and the Data LED blinks. Go to Step 17.
Model 4026-06B, 06E - The Ready LED turns on solid and the Data LED blinks.
• The controller board checks flash ROM installation.
• The controller board verifies that flash is formatted.
• The controller board attempts to format flash if unformatted.
• The Data LED blinks du ring format.
• The printer continues POST after format is complete.
• If format fails, a “Flash Memory Failure” error displays.
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1-4
17. The main drive motor turns off.
18. The polygon motor (printhead motor) turns off.
19. The Data LED turns off.
20. The Ready LED stays on solid.
If the printer completes all these steps and no error indications are displayed, the printer has successfully completed the POST.

Service Error Codes

When a service error occurs the printer stops printing and all operator panel LEDs blink in a continuous pattern, indicating a service error, until the printer is powered off.
Press and release the operator panel button to display the service error code. Locate the blinking LEDs in the following table and take the indicated action.
Blinking Operator Panel LED Action
Software Service Error Code Run the Printer Diagnostic Test to
diagnose between the ROM SIMM and the control ler board. If no other error cod e displays after the test completes, replace the controller board.
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Fuser Failure Error Refer to t he Cold Fus er Service
Check in the Service Man ual.
Mirror Motor Error The Polygon Mirror Motor is not
rotating during printing. Replace the engine board. If t his does not c orrect the problem, replace the printhead assembly.
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1-5
Blinking Operator Panel LED Action
Laser Diode Failure Replace the printhead assem bly. If
this does not correct the problem, replace the engine board.
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Controller Card Failure Replace Controller board
Optional Memory Error Replace the op ti onal memory SI MM.
If this does not correct the problem , replace the controller board.
Fan Failure Error Refer to the Fan Service Check in
the Service Manual.
ROM Checksum Error Replace the ROM SIMM. If thi s does
not correct the problem, replace the controller board.
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1-6
Blinking Operator Panel LED Action
Base Memory Error Replace Controll er board
NVRAM Fai lure Error Replace Controller board
ASIC Register Failure Error Replace Controller board
ASIC SRAM Fail ure Er ror Replace Controll er boar d
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Flash Memory Failure Error Replace the ROM SIMM w/Flas h. If
this does not cor rect the problem, replace the controller board.
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1-7
Blinking Operator Panel LED Action
Font Checksum Fail ure Error Replace the ROM SIMM . If thi s does
not correct the problem, replace the controller board.
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Engine Board Communications Failure Error
Controller SRAM Failure Error Replace Controller board
Replace the engine boar d. If this does not correct the problem, replace the controller board.
User Error Message Table
When a user error message occurs the printer stops printing and one or two operator panel LEDs are on solid or blinking until the printer is powered off. Locate the printer’s LED Status in the following table and take the indicated action.
User Error Message
LED Status Action
Paper Jam Paper Jam on solid Open cover and clear any
paper jams. Close the top cover. If the error message is still present , refer to the Paper Feed Service Check in the Service Manual.
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1-8
User Error Message
Load Manual Paper /Envel ope
LED Status Action
Load Paper blinks and Press Button on solid
Load media into the manual slot and push the oper ator panel button to resume printing or do a front panel reset by pressing and holding the operator panel button for more than three seconds.
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Load Paper/Load Env elo pe
Top Cover Open Error on solid Close the top cover. If the
Memory Full/ Complex Page/ Resolution Reduction Warning/Data Transmission Error
Load Paper on solid and Press Button on soli d
Error on solid and Press Button on solid
Load media in the appropriate pap er tr ay and push the operator panel button to r esum e printing or do a front panel reset by pressing and hol ding the operator panel button for more than three seconds.
error LED remains on solid and POST does not continue, refer to t he Cover Interlock Service Check in the Service Manual.
The printer memory is full or the page is too complex to print. The printer is forced to reduce the resol ution of a formatted page to 300 dpi before pri nting, or the printer is unable to maintain the required data transfer rate. Refer to the “User Secondary Error Message” Table in the Service Manual.
Flash Memory Full Error blinks and
Press Button on solid
This condition only occurs when the Flash SIMM is installed. (4026-06B, 06E) Refer to the “User Secondary Error Message” Table in the Service Manual.
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1-9
User Secondary Error Message Table
Press and release the operator panel button two times to display the user secondary error LED status. Each press and release action must be performed within a half second. Locate the printer’s LED status in the following table and take the indicated action.
4026-0XX
User Error Message
LED Status Action
Complex P age Ready, Error, and
Press Button on solid
Memory Full Ready, Data,
Error, and Press Button on solid
Resolution Reduction
Ready, Data blinking and the Error , Press But ton on solid
Switch the printing mode to a differ ent pri nting mode using the Lexmark driver for Windows, or push the operator panel button to resume printing, or do a front panel reset b y pre ssing and holding the oper ator panel button for more than three seconds.
Change the pri nting mode to Quick Print Plus or reduce the complexity of the job or the resolution, or push the operator panel button to resume printing, or do a front panel reset b y pre ssing and holding the oper ator panel button for more than three seconds.
Switch from the GL/2 or raster mode to Quick Print Plus mode using the Lexmark driv er f or Windows , or press the operator panel button to resume printing, or do a front panel reset by pressing and holding the operator button for more than three seconds.
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1-10
User Error Message
Data Transmission Error
LED Status Action
Data, Error, and Press Button on solid
Switch to Print Accelerator using the Lexmark driver for Windows if 2MB of memory or more is installed, or switch to the GL/2 printing mode using the Lexmark driver for Windows, or push the operator panel button to resume printing, or do a front panel reset b y pressing and holding the oper ator panel button for more than three seconds.
4026-0XX
Flash Memory Full Error blinking and
Press Button on solid
This condition only occurs when the Flash memory is full.
POST Symptom Tabl e
Symptom Action
POST completes e xcept one or more LEDs do not come on.
None of the LEDs come on. Refer to t he Operator Panel Service
The printer is dead (No LEDs come on, no motor turns)
The fan does not come on. Refer to the Fan Service Check in t he
The fuser l am p does not c om e on. Refer to the Cold Fuser Service
The polyg on motor does n ot come on.
Refer to the Ope rator Panel Service Check in the Service Man ual.
Check in the Service Man ual. Refer to the Low Voltage Power
Supply Service Check in the Service Manual.
Service Manual.
Check in the Service Man ual. Replace the printhead assembly. If
this does not fix the problem, repl ace the engine board.
The main drive motor does not come on.
Refer to the Main Drive Motor Service Check in the Service Man ual.
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1-11
Symptom Action
The paper feed gears do not turn. Refer to the Paper Feed Service
Check in the Service Manual.
The paper feed solenoid picks
4026-0XX
and tries to feed paper. The toner/print cartridge gear s do
not tur n .
Refer tot he Paper Fe ed Service Check in the Service Manual.
Refer t o the Main Driv e Motor Service Check in the Service Manual.
Symptom Table
Locate your symptom in the following table and take the appropriate action
Symptom Action
Dead printer Refer to the Lo w Voltage Power
Supply Service Check in the Service Manual.
Fan not w orki ng Refer to the Fan Se rvice Check in the
Service Manual.
Fan noisy Refer to the Fan Service Check in the
Service Manual.
Fuser parts melted Refer t o the Col d Fuser Service
Check in the Service Manual.
Fuser Lamp doesn’t light Refer to the Cold Fuser Service
Check in the Service Manual.
Toner not fused to the paper Refer to the Cold Fuser Service
Check in the Service Manual.
Blank page Refer to the Print Quality Service
Check in the Service Manual.
Black page Refer to the Print Quality Service
Check in the Service Manual.
High or heavy background Refer to the Print Quality Service
Check in the Service Manual.
Offset print (image ar ound characters)
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1-12
Refer to the Print Quality Service Check in the Service Manual.
Symptom Action
Poor image (charact ers washed out)
Paper jams Refer to the Paper Feed Service
Main Drive Motor noisy Refer t o the Main Drive Motor Service
Main Drive Motor does not move Refer to the Main Dri ve M otor Service
Main Drive Motor runs backward Replace the Engine board. Paper is not picked or never
leaves the primary tray
Paper is not picked or never leaves the optional paper tray (Tray 2)
Paper feeds continuously Refer to t he Paper Feed Servi ce
Paper fails to exit printer or st ack in output bin
Paper skew Refer to t he Paper Feed Servi ce
Refer to the Print Quality Service Check in the Service Man ual.
Check in the Service Man ual.
Check in the Service Man ual.
Check in the Service Man ual.
Refer to t he Paper Feed Frame Assembly S ervice Ch eck in the Service Manual.
Refer to the Optional Pape r Tray 2 Service Check in the Service Manual.
Check in the Service Man ual. Refer to the Paper Feed Service
Check in the Service Man ual.
Check in the Service Man ual.
4026-0XX
Toner on the back of the page Refer to t he Transfer Assem bly
Service Check in the Service Manual.
Po or pri nt quality Refer to the Print Quality Service
Check in the Service Man ual.
Incorrect characters print Refer to the Print Quality Service
Check in the Service Man ual.
Printer not communicating with host
White or black lines or bands Refer to the Print Quality Service
Paper wrinkled or bent Refer to the Paper Feed Service
Refer to the Parallel Port Service Check in the Service Man ual.
Check in the Service Man ual.
Check in the Service Man ual.
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1-13
Symptom Action
Top cov er wi ll not close Refer to the Cov er Interlock Service
Check in the Service Manual.
Light print Refer to the Print Quality Service
4026-0XX
Check in the Service Manual.
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1-14

Diagnostics Aids

Printer Diagnostic Test

The following tests run sequentially when performing this test:
Standard Memor y Test Optional Memor y Test Microcode Check LED Test Read/Write ASIC Register Test Read/Write ASIC SRAM Test Read/Write controller board SRAM Test
Perform the following steps to run the Printer Diagnostic Test:
1. Tur n t he prin ter off.
2. Open the top cover.
3. Press and hold the operator panel button as you turn on the printer. Release the button once the printer’s indica tor lights come on.
4. Wait until the Error LED (top cover open indication) comes on.
5. Close the top cover.
6. The Ready LED comes on solid and the Data LED blinks. (This is the printer Busy Mode indication).
7. If all the diagnostic tests run correctly, the Ready LED goes off and the Data LED continues to blink. If a test fails, the error light pattern for the service error code displays on the operator panel.
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1-15

Service Diagnostic Test Page

The service diagnostic test page includes registration marks to aid in adjusting print registration and also includes the installed printer base code level. The service test page displays the user default v alues for t he following:
4026-0XX
Top M argin Offset Left Margin Offset Printer Page Count Permanent Page Count Print Da rk n es s Setting PQET Setting (on/off) Tone r Saver (on/off) Print Re s olu t ion
Perform the following steps to print the Service Diagnostic Test Page:
1. Tur n the pr inter off.
2. Open the top cover.
3. Press and hold the operator panel button as you turn on the printer.
4. Wait until the Error LED comes on solid.
5. Close the top cover.
6. The Ready LED is on solid and the Data LED blinks continuously.
7. When the test is complete the Ready LED goes off and the Data LED continues to blink.
8. Press the operator panel button briefly.
9. The Ready and Data LEDs blink and the Service Diagnostic T est Page prints. The test page requires several seconds to start printing.
10. When the test page has finished printing the Ready LED comes on solid and Data LED goes off.
Note:
automatically exits the diagnostic mode and returns to the normal mode.
After the diagnostic test page prints, the printer
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1-16
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1-17

User Mode Print Test Page

The User Mode Print Test Page displays the user default values, installed options, printer features, various typefaces, and the installed printer base code level.
1. Be sure the Ready LED is on solid (printer is in the ready state).
4026-0XX
2. Press and release the operator panel button.
3. The Ready and Data LEDs blink continuously.
4. The test page prints and the operator panel Ready LED comes on solid and the Data light turns off.
5. The printer returns to the ready state.
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1-18

Configuration Mode

The configuration mode gives the ability to set the following printer functions through the operator panel:
Hex Trace NPA Mode (Parallel) Parallel Protocol Advanced Status PPDA Activated Auto CRLF/LFCR
Perform the following steps to enter the configuration mode:
1. Tur n t he prin ter power off.
2. Open the top cover.
3. Turn the printer power on.
4. Top Cover Open (Error LED on) is displayed on the operator panel.
5. Double-click the operator panel button.
Note:
solid. The Data, Load Paper, Paper Jam, Er ror and Press Button are off.
Note:
mode. Repeat the steps to re-access the configuration mode.
Configuration Mode Operator Panel Overlay
The following overlay indicates the operator panel LED and button designations when in the configuration mode.
The printer is in the configuration mode. The Ready LED is on
Closing the top cover causes the printer to exit the configuration
4026-0XX
Hex Trace NPA Mode Parallel Protocol Advance St a tus CRLF/LFCR Off/On/Auto
Press three secon ds to save
4026-0XX
1-19
Operator Panel Configuration Mode Button Definition
Term Description Result
Brief Button Press Press the operator
4026-0XX
Long Button Press Press and hold the
Double-Click Button Press
panel but ton n o longer than three seconds.
operator panel button for more than three seconds.
Press and release t he operator panel button two times. E ac h press and release action must be performed within a half second.
This action moves through the configurat ion mode value list.
This action sel ects and save s the value for the menu it em displayed. To indicate that the setting i s save d, it is displayed on the operator pane l.
This action moves through the configurat ion mode value list.
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1-20

Hex Trace

Use Hex Trace to isolate the cause of print problems. When a job is printed, the printer operator panel displays the Hex Trace indication, (Ready LED blinking), showing that the printer remains in the Hex Trace mode. Tu rn the printer power off or do a front panel reset (long button press) to exit the Hex Trace mode.
Perform the following steps to enter the Hex Trace mode:
1. Enter the configuration mode.
2. Do a brief button press.
3. The Ready LED is on and the Press Button (Off/On/Auto) is on or off indicating the value selected. A brief button press causes the printer to cycle through the valid settings for Hex Trace and the Press Button LED turns on or off.
Operator Panel LED Status Action
4026-0XX
Off/On/Auto LED and Hex Trace LED is off
Off/On/Auto LED and Hex Trace LED is on
A long button pr ess causes the printer to exit configurat ion mode and enter the normal printi ng mode or a demo printing mode. A double-click button press causes the next menu item, NPA mode, to display
A long button pr ess causes the printer to e xi t the config urat ion mode and enter Hex Trace mode. A double-click button press causes the next menu item, NPA mode, to display .
4. Press and hold the button until the Saved setting indication, (all LEDs on solid) is posted.
5. When the Error LED comes on, close the top cover.
6. The printer completes POST with the Ready LED blinking indicating the printer is in the Hex Trace mode.
7. Do a double-click to proceed to the next mode. Do an operator panel reset or turn the printer off to exit the Hex Trace mode.
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1-21

Restoring Factory Defaults

Restoring factory defaults returns the printer settings to the original factory sett ing s.
Perform the following steps to invoke factory defaults:
1. Turn the printer power off.
4026-0XX
2. Open the top cover.
3. Tur n t he printer power on. The printer star ts POST.
4. The operator panel Error LED comes on solid.
5. Press and hold the operator panel button until all the LEDs are on solid indicating the printer is restoring factory defaults.
6. Release the button. The printer indicates the operation is complete by turning all the LEDs off except the Error LED.
7. The configuration mode can be selected by doing a brief button press or closing the top cover which causes the printer to enter either the normal mode or the demo mode.
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1-22

Connectors

Low Voltage Power Supply
Connector Pin No. Signal CN1 Engine Board
CN2 Fuser Lamp/ Thermal Fuse
1 +24 V dc 2GND 3GND 4 +5 V dc 5FUSER LAMP* 1HEAT N 2 NO CONNECTION 3HEAT L
High Voltage Power Supply
Connector Pin No. Signal CN1 Engine Board
T
TRET
1HV C 2HV T* 3 HV SEL 2* 4 HV SEL 1* 5HV B 6 BIAS MON 7GND 8 +24 V dc T HV to TRANSFER CORONA
CHARGE
TRET HV to TRANSFER CORONA
HOUSING
4026-0XX
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1-23
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