Lexmark E460dn, E460dw, 4513-630, 4513-63W, 4513-6EW Service Manual

• Tabl e of conte n t s

• Start diagnostics

Revision Date: July 1, 2013

Lexmark™ E460dn

Lexmark E460dw

4513-630

4513-63W

4513-6EW

• Safet y and notices

• Trademarks

• Index

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries .

Edition: July 1, 2013 The following paragraph does not apply to any country where such provisions are inc onsistent 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; there fore, this statement ma y not apply to you.

This publication could include tec hnical inaccuraci es or typographical er rors. Changes are period ically made to the information herein; these changes wil l 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 D22X/002-1, 740 West New Circle Road, Lexington, Kentuck y 40550 , U.S.A or e-mail at ServiceI nfoAndTr ai ning@Lex mark.com. Lexmar k may use or dist ribu te any of the information you supply in any way it believes appropriate wi thout incurring any obligation to you.

References i n this publication to products, programs, or services do not i mp ly that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only t hat produ ct, pr ogra m, or serv ice may be used. Any funct ional ly equi valent pro duct, progr am, or servi ce that does not infringe any existing intellectual property right may be used instea d. Eval uation and verifi cation of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s respons ibility.

Lexmark, Lexmark wit h diamond design and MarkVision are trademarks of Lexmark Internation al, Inc., register ed in t he United States and/or other countries.

PCL® is a registered trademark of the Hewlett-Packard Company. All other trademarks are the property of their respective owners.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private ex pense.

4513-630, -63W, -6EW

P/N 12G9813

4513-630, -63W, -6EW

Table of contents

Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Lithium warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi

Change history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v-xvi

Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Print quality settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Connectivity and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Media trays and supply capaci ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Types of print media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Tips on preventing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Paper path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Diagnostics information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service errors (9xx.xx’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

User status and attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Overview of the operator panel and menu s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Diagram of the printer menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Messages and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Cartridge error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Paper jam error codes (200-series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

POST symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Controller board service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Cover interlock switch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Dead machine service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

LVPS/HVPS service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Main motor servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Media feed clutch service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Paper feed service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Paper jam error indication during POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Media picks but st ops halfway through the pri nter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Media never picks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

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Media occasionally mispicks or pi cks multiple sheets at once . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Media skews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Media “trees,” wrinkles, stacks poorly, or curls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30

Parallel or USB port servi ce check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 3 0

Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Blank page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Black page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32

Heavy background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 32

Partial blank image/white spots (no repeat ing pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Variation in image density horizontally across page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Poor fusing of image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33

Light print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

White or black lines or bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34

Toner on back of page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 3 4

Solving print quality problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 3 5

Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38

Service software service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41

Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Tray 2 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42

Diagnostic aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -2

Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Maintenance Count Value (Maint Cnt Valu e) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Reset Maintenance Count Value (Reset Maint Cnt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Reset Photoconductor Mainte nance Counter (Reset PC Cnt) . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Action For Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Font Sharpening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

Exit Configuration Menu (Exit Config Menu) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Entering Diagnostics menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Margins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Quick Test page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Input sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Print Quality Pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3- 8

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Top Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Left Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

iv Service Manual

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Duplex Feed 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Output bin tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Feed Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Base Sensor Test (B. Sensor Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Printed Page Count (Page Count ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Permanent Page Count (Per m Page Count) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Service Tag (only on some printers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Engine Setting 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Edge to Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Par S Strobe Adj (parallel str obe adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

EP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Fuser Temperature (Fuser Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Gap Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Automatic Darkness Adjustment (Auto Dark Adj) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Exit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Printhead assembly el ectronic adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Printhead assembly mechanical adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Repair information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensiti ve parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

ACM pick tire roller removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Bezel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Controller board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Cover open sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Door mount removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Duplex removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Duplex/main moto r gear drive interface remo val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Front access door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Left print cartridge guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Left side cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Lower front cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

LVPS/HVPS removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Main motor gear drive removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Manual feed clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

Manual feed solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Media ACM ASM feeder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Media feed clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Media manual input sensor re mov al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Table of contents v

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Multipurpose feeder (MPF) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 9

Multipurpose feeder (MPF) feed clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52

Nameplate removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-55

Paper input and duplex sensor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-56

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57

Rear door and rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-58

Rear exit guide assembly with sensor and reversing sol enoid removal . . . . . . . . . . . . . . . . . . .4-60

Right side cover assembl y removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 6 2

Toner level sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-64

Top cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 5

Transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-67

Upper front guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68

Wear strip (tray 1 and 250-sheet tray 2) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-69

Wear strip (550-sheet tray 2) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7 0

Locations and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Rear view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Lexmark E460dn controller board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Lexmark E460dw control ler board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Lexmark E460dn, E460dw cont roller board connector pin values . . . . . . . . . . . . . . . . . . . . . . . .5-4

Preventive mainte nan ce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication spec if ications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Maintenance kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 3: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 4: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 5: Power cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

Part number index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-3

vi Service Manual

Notices and safety information

The following laser notice labels may be affixed to this printer.

Laser no tice

The printer is certified in the U.S. to conform to the requi rements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.

Class I laser products are not considered to be hazardous. The printer contains internall y a Clas s IIIb (3b) laser that is nomin all y a 7 milliwatt gallium arseni de laser operating i n the wavelength region of 655-675 nanom eters. The laser system and pri nter are designed so there i s never any human access to las er radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amt li cher Bestätigung der USA die Anfor derungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). I n anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfül lt .

4513-630, -63W, -6EW

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befind e t si ch ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 7 Milliwatt handelt, der Wellen der Länge 655-675 Nanometer ausstr ahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetr ieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbes tr ahlung, die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis: cette imprimante est ce rt if iée conforme aux provi sions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les aut res pays : cette imprim ante répond aux normes IEC 6082 5-1 relatives aux produits laser de Classe I.

Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un l aser de Classe IIIb (3b) (arséniur e de gallium d’une puissance nominal e de 7 milliwatts ) émettant sur des longueurs d’onde comprises entre 655 et 675 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampant e è certificata negli Stati Unit i per essere conforme ai requisit i del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificat a negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti del la norma CEI 60825-1.

I prodotti laser di classe non sono consider at i pericol osi. La st ampant e contie ne al suo interno un laser d i classe IIIb (3b) all’arseniuro di gall io della potenza di 7mW che opera sul la lunghezza d’ond a com presa tra 655 e 675 nanometri. Il sistema laser e la stampante sono stati proget tati 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 radi azioni laser superi ori al livello della classe 1.

Notices and safet y information vii

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Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el su bcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanid ad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su int eri or un láser de Clase IIIb (3b) de arseniuro de gali o de funcionami ento nominal a 7 m ilivatios en una longitud de onda de 655 a 675 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ni ngún ti po de radiación láser superior al nivel de la Clase I dur ante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servici o técnico.

Declaração sobre Laser

A impressora e stá cer tific ada n os E.U.A . em conf ormidade com os r equisi tos da regu lamentaç ão DHHS 21 CFR Subcapítulo J para a Clas se I (1) de produt os laser . Em outr os locai s, est á cer tific ada co mo um produ to laser da Classe I, em conformidade com os requisitos da norma IEC 60825-1.

Os produtos lase r da Class e I não são cons id erados per igosos . Inte rnamen te, a impress ora contém um produ to laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 7 mill iwatts ,operando numa faixa de comprimento de onda entre 655 e 675 nanómetros. O sistema e a impressora laser foram concebido s de forma a nunca existir qualquer possiblidade de acesso humano a radiaç ão laser superior a um nível de Classe I durante a operação nor m al, a manutenção feita pel o utilizador ou condições de assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eis en vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 7 milliwatt met een golflengte van 655-675 nanometer. Het laser gedee lte en de print er zijn zo ontworp en dat bij normaal gebr uik, bi j onder houd of repar atie conform de voorschriften, nooi t bl ootstelling mogelijk is aan laserstr aling boven een niveau zoals voorgeschr even is voor klasse 1.

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der

nominelt er en 7 milli watt galliumarsenid laser, som arbejder på bølgelængdeområdet 655-675 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved nor m al dr ift, brugervedl igeholdelse ell er obligatoriske servi cebetingels er.

viii Service Manual

Laserilmoitus

Tämä tulostin on sertif ioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuot teeksi ja muualla IEC 60825- 1 -st andardin mukaiseksi luokan I lasertuotteeksi.

Luokan I laser tuot teit a ei pi detä hai tall isi na. Tul ostimen sisäl l ä on luok an III b (3b) laser, joka o n ni mellist eholt aan 7 mW:n galliumarsenidilaser ja toimii 655 - 675 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulost in ovat rakenteelt aan sellaisia, et tä käyttäjä ei joudu altt iiksi luokkaa 1 suur em m all e säteilylle nor m aalin käytön, ylläpidon tai huollon aikana.

Huomautu s las er laitteesta

Tämä kirjoi tin on Yh dysval loiss a luokan I (1) las erlai ttei den DHHS 21 CFR Subc hapt er J -määr ity ksen mukai nen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 7 milliwatin gal liumarsenid il aser, joka toimii aalt oalueella 655 - 675 nanom etriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käytt äjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirj oittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen.

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VARNING! Osynlig laserst rålning när denna del är öppn ad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.

Laserprodukter i Klass I anses ej hälsovådliga. Skriva ren har en inbyggd laser av Klas s II Ib (3b) som består av en laserenhet av gal lium-arsenid på 7 mil li watt som arbetar i våglängdsområdet 655-675 nanom eter. Lasersystem et och skrivaren är utfo rmade så att det aldrig finns risk för att någon pe rson utsätts för laserstrå lning över Klass I-nivå vid normal användning, underhåll som utför s av användaren eller annan föreskriv en serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for k lasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laser produkt i samsvar med krav ene i I EC 60825-1.

Klasse I-laserprodukte r er ikke å betrakte so m farlige. Skriveren inneholder inter nt en klasse IIIb (3b)-laser, s om består av en gallium-arsenlaserenhet som avgir stråli ng i bølgelengdeomr ådet 655-675 nanometer . Lasersystem et og skrive ren er utformet slik at personer aldri utsett es for la serstrål i ng ut over klasse I-n ivå under vanlig bruk, vedlikehold som utføres av brukeren, ell er fo reskrevne serviceoperasjoner.

Notices and safety information ix

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Avís sobre el Làser

Segons ha estat cert ificat als Estats Units, aquesta impressor a compleix els requi sits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat cer tificat en alt res llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1.

Els productes l àser de classe I no es consideren perillosos. Aquesta impressora con té un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 7 mil.liwats, i funciona a la regió de longi tud d’ ona de 655-675 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operaci ó normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Notices and safety information xi

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xii Service Manual

Lithium warn ing

CAUTION

This product cont ains a lithi um battery. THERE IS A RISK OF EXPL OSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations.

Safety information

• The safety of this product is based on testing and approvals of the original design and speci fi c

components. The man ufacturer is not res ponsible for safety in the event of use of unauthorized replacement parts.

• The maintenance inf ormation for this product has been prepared for use by a professional ser vice person

and is not intended to be used by others.

• There may be an increased risk of electric shock and personal injury during disassembly and servicing of

this product. Professional service personnel should understand this and take necessary precautions.

• CAUTION: When you see this symbol, there i s a danger from hazardous volta ge i n the area of the

product where you a re work ing. Unp lug th e product be fore y ou begin, or us e cau tion i f th e product must receive power in order to perform the task.

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Consignes de sécurité

• La sécurité de ce pro duit repose sur des tests et des

agréations por tant sur sa conception d' origine et sur des composants particuliers. Le fabricant n'assume aucune respon sabilité concernant la sécurité en cas d'ut ilisation de piè ces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent unique me nt à un personnel de

maintenance qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel

d'entretien qualifié devra prendre toutes les précautions nécessaires.

• ATTENTION : Ce symbole indique la présence d'une tension dangereuse dans la partie du

produit sur laquelle vous travaillez. Débranchez le produit avant de commencer ou fai tes preuve de vigilance si l' exécution de la tâche exi ge que le produit reste sous tension.

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti

specifici. Il produttore non è resp onsabile per la sicur ezza in caso di sostituzione non autorizzata delle parti.

• Le informazion i riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al pers onale di

assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzat o deve, quindi, adott are le precauzioni necessarie.

• ATTENZIONE: Questo simbolo indi ca la presenza di tensione pericolosa nell' area del prodotto.

Scollegare il pr odotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.

Lithium warning -xiii

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Sicherheitshinweise

• Die Sicherheit di eses Produkts basiert auf Tests und Zulassungen des ursprünglichen Mode ll s und

bestimmter Baut eil e. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind ausschl ießlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des Geräts besteht ein zus ätzliches Risiko eines

elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die i n diesem

Bereich des Produkts auf tret en kann. Zieh en Sie vor den Arbeit en am Gerät den Netzsteck er des Geräts, bzw. arbeiten Sie mit große r Vor sicht, wenn das Produkt für die Ausführung der Arbeiten an den Strom angeschlossen sein muß.

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes

específico s. El fabri cante no es responsabl e de la seguridad en caso de uso de piezas de repuesto no autorizadas.

• La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal

cualificado de mantenimiento.

• Existe mayor riesgo de de scarga e léc trica y de dañ os pe rsonal es du rante e l desmont aj e y la r eparaci ón de

la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

• PRECAUCIÓN: este símbolo indica que el voltaje de la parte del equipo con la que está

trabajando es peligroso. Antes de empez ar, desenchufe el equipo otenga cuidado si, para trabajar con él, debe conectarlo.

Inform a çõ es de Segurança

• A segurança deste produto baseia-se em testes e aprovações do modelo ori ginal e de componentes

específico s. O fabr icante não é responsá vel pela segunrança, no caso de uso de peças de substit uição não autorizadas.

• As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não

devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.

Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• CUIDADO: Quando vir este símbolo, existe a possível presença de um a potencial tensão

perigosa na zona do produto em que está a trabalhar . Ant es de com eçar, desligue o produt o da tomada eléctr ica ou seja cu ida doso caso o pr oduto t enha de estar liga do à c orrent e eléc tric a para realizar a taref a necessária.

-xiv Service Manual

Informació de Seguretat

• La seguretat d'aquest producte es basa en l' avaluació i aprovació del disseny original i els components

específics . El fabricant no es fa responsable de les qüestions de seguretat si s'u ti litzen peces de recanvi no autoritzades.

• La informació pel ma nteniment d’aquest producte està orient ada exclusivament a professionals i no està

destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei

d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures con venients.

• PRECAUCIÓ: aquest símbol indica que el voltatge de la part de l'equip amb la qual esteu

treballan t és perill ós. Abans de començ ar, desendol leu l' equip oextremeu les precaucion s si, per treballar am b l'equip, l'heu de connect ar.

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Safety informa tion -xv

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CAUTION

A caution identifies something that might cause a servicer harm.

CAUTION

This type of caution i ndicates there is a danger from hazardous voltage in t he area of the product where you are working. Unplug the product befor e you begin, or use caution i f th e product must recei ve power in order to perform the task.

Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General infor m a ti o n contains a general description of the printer and the maintenance approach used to

repair it. Speci al tools and test equip me nt, as well as general environmental and safety instructions, are discussed.

2. Diagnostic information contains an error indicator table, sym ptom tables, and service checks used to

isolate failing field replaceable units (FRUs).

3. Diagnostic aids con tai ns tests and checks used to locate or repeat symp toms of printer probl ems .

4. Repair infor ma t io n provides instructions for making printer adjustments and removing and i nstalling

FRUs.

5. Connector locations uses il lustrations to identify the connector locations and test poi nts on the printer.

6. Preventive maintenance contains the lubrication specif ications and recomme ndations to prevent

problems.

7. Parts catalog cont ains illustrations and part numbers for individual FRUs.

Change history

Revision date Updates

2013/07/01 Updated “Media ACM ASM feeder removal” on page 4-39. 2012/08/08 Changed all cross-references that call for the left side cover removal procedures. 2011/10/28 Added this warning: “Warni ng: Do not strip the insulation off the red and black wires. The

2011/9/14 Revised the media feed clutch assembly removal procedure in “Media feed clutch

Conventions

Note: A note provides additional information. Warning: A warning identi fi es something that might damage the product hardware or software.

There are several types of caution statements:

connectors will not work if the insulation is removed,” in step 8 of “Media feed clutch

removal” on page 4-42.

-xvi Service Manual

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CAUTION

This type of caution i ndicates a hot surface.

CAUTION

This type of caution i ndicates a tipping hazar d.

Conventions -xvii

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-xviii Service Manual

1. General in formation

The Lexmark™ E460dn and E460dw are m onochrome laser printers designed for single users or small

workgroups. This book contains information on E460dn and E460dw. For more information on E260d and E260dn, see the 4513-220, -230 service manual. 4513-420, -430 service manual.

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For information on E360d and 360dn, see the

minute on letter-size media (29 ppm on A4, 25ppm on legal).

Maintenance approach

The diagnostic information in this manual leads to the correct field replaceable unit (FRU) or part. Use the error code charts, sympt om index, and service checks to determine the symptom and repair the failure. See

“Diagnostics i nformation” on page 2-1 for more information. See “Repair information” on page 4-1 to help

identify parts. After completing the repair, perform tests as needed to verify the repair.

General information 1-1

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1 2 3

Back

Stop

Overview of the operator panel

The control panel consists of these items:

• A 4-line, liquid crystal display ( APA) th at can show both graphics and text

• Eight buttons: Back , Menus , Stop , Select , and Navigation (up arrow , down

arrow , left arrow , and right arrow )

• Keypad

• Indicator light

1-2 Service Manual

Specifications

Memory

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Item

Standard memory 64MB 64MB Maximum memory 576MB 576MB Optional memory

128MB ✔✔ 256MB ✔✔ 512MB ✔✔

Optional flash memory

64MB ✔✔ 256MB ✔✔

Optional font cards (DBCS) ✔✔ Option slots

Memory slots 1 1 Flash memory/option card 2¹ 2¹ ¹ Both slots are acti ve for either a 256MB Flash memory car d, a fo nt card, or a DLE. Multiple Flash , fo nt, or DLE cards

are not supporte d.

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Print quality setti ngs

Item

Print resolution

1200 Image qualit y¹ ✔✔ 2400 Image qualit y² ✔✔ 600 X 600 dpi ✔✔ 1200 X 1200 dpi³ ✔✔ ¹ 1200 Image quality is def ined as 600 dpi with 2 bit IET (Image Technology) default mo de for all models. ² 2400 Image quality is def ined as 600 dpi with 4 bit IET. ³ True 1200 dpi at 1/2 the rated speed

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General information 1-3

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Connectivity and compatibility

Item

Data stream emulation s

Host based printing ✔✔ PCL 5e and PCL 6 ✔✔ PostScript 3 ✔✔ PPDS migration tool ✔✔ PDF v1.6 ✔✔ XPS¹ ✔✔ HTML (including DBCS) ✔✔ Direct image ✔✔ Compatibility Windows/Macintosh/Linux Windows/Macintosh/Linux

Standard local connec ti ons

Parallel ✔ x USB* ✔✔

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Lexmark E460dw

Standard network connect ions

Ethernet (10/100 Base Tx) ✔✔ Wireless ethernet 802.11b/g/n x ✔

Optional local connections

Optional network connections: external print server support

*All models are USB 2.0 Certified devices supporting Hi-Speed data transfer. ¹ Includes the HD photo image format ² Includes support for the following graphics formats: TIFF, TIF, JPG, GIF, PNG, BMP, PCX, AND DCX

✔✔

1-4 Service Manual

Media trays and supply capacity

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Item

Available input trays

Integrated 250-sheet tray ✔✔ 50-sheet MP feeder ✔✔ 1-sheet manual feed slot xx

Optional input sources

250-sheet drawer ✔✔ 550-sheet drawer ✔✔

Maximum input sheet capacity 850

Manual/integrated print duplex Integrated Integrated

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(excluding envelopes)

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850

(excluding envelopes)

Envelope conditioning x x

Available output trays

Standard 150-sheet sensing bin ✔✔

Toner and photoconductor

Toner cartridge 1,500 standard pages SWE¹

3,500 standard pages SWE¹

High toner cartri dge 9,000 standard pages¹ 9,000 standard pages¹

Photoconductor kit Up to 30,000 ² Up to 30,000 ² ¹ Declared value in accordance with ISO/IEC 1975 2 ² Up to 30,000 pages, based on an average of 3 pages per job and approximately 5% coverage per page. Yields may

vary based on customer usage.

7,000 standard pages SWE¹

15,000 standard pages¹

General information 1-5

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Types of print media

Note: Ensure trays are properly loaded. Never mix media types wit hin a tray.

Source Sizes Types Weight Input capacity* (sheets)

Input tray 1 (250-sheet tray)

2nd Drawer option (250/550-sheet

drawer)

Multipurpose feeder

A4, A5, A6,JIS¹-B5, letter, legal , executive, oficio (Mexico)², folio², statement

A4, A5, JIS¹-B5, letter, legal, executive, oficio (Mexico )², folio², statement

A4, A5, A6,JIS¹-B5, letter, legal , executive, oficio (Mexico)², folio², statement

Plain paper, recycled, l abels, bond, letterhead, preprinted , colored paper, light paper, heavy paper, rough/cotton, custom type [x]

Plain paper, transparency, recycled, l abels, bond, letterhead, preprinted , colored paper, light paper, heavy paper, rough/cotton, custom type [x]

Card stock*** • 120-163 g/m²

60-90 g/m² (16-24 lb)

60-163 g/m² (16-43 lb)

(16-43 lb) Index Bristol

• 75-163 g/m² (46-100 lb) Tag

• 250 paper

• 50 labels**

• 250 paper

• 550 paper

• 50 labels**

• 50 paper

• 15 lables**

• 10 transparencies

7 ¾, 9, 10, DL, C5, B5, other

Duplex A4, lett er, le g al , of ic io

(Mexico )², folio²

* Capacity for 20 lb print media, unless otherwise noted. ** Use for occasional printing only. *** Grain short is recommended. Use rear exit for best results.

¹Japanese Indust ry Standard ² If a source supports size sensing and is activated, then neither the “oficio” value nor the “folio” value appears in that

source’s list of supported me dia sizes. These values only appear in a source’s list of supported medi a sizes either when the source is non- size sensing or when the source’s size sensing har dware is deactivated and t hen the device is power cycled.

Envelopes Rough envelopes

Plain paper, recycled, bond, letterhead, preprinted , colored paper, light paper, heavy paper, custom type [x]

75 g/m² (20 lb) 7

60-90 g/m² (16-24 lb)

1-6 Service Manual

Tips on preventing jams

Paper path

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A Paper path A – B 125. 3 mm B Manual feed sensor B – C 9.0 mm C Upper end feed rol ls C – D 59.8 mm D Input sensor D – E 44.9 mm E Transfer roll E – F 112.7 mm F Fuser F – G 21.4 mm G Fuser exit rolls G – H 114.8 mm H Fuser exit sensor H – I 7.5 mm

I Exit rolls I – J 17.0 mm

J Exit sensor/narrow media sensor I – K 211.7 mm K Duplex unit K – L 93.4 mm L Duplex sensor L – M 8.4 mm

M Auto compensat or

General information 1-7

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Most paper jams can be avoided by correctly lo ading paper and specialty media in the printer. The following hints can help prevent paper jams:

• Use only the recommended print media.

• Do not overload th e print med ia sourc es. Mak e sure the st ack heig ht does not exceed the maximu m height

indicated by t he stack line on the labels in the sources.

• Do not load wrinkled, creased, damp, or curled print media.

• Flex, fan, and strai ghten pr int media before loa ding it. If jams do occur with t he print media,th en try feeding

one sheet at a time through the manual feeder.

• Do not mix print media sizes, weights, or types in the same print media source.

• Push all trays in firmly after loading them.

Note: Make sure the media stack is below the maximum media fill indicators on the 250-shee t tray before

pushing the tray into the printer.

• Make sure paper guides are positioned before loading the paper or specialty media.

• Do not remove trays while a job is printing.

• Before loading transparencies, fan the stack to prevent sheets from sticking together.

• Do not use envelopes tha t: – Have excessive curl – Are stuck together – Are damaged in any way – Contain windows, holes, perforations, cutouts, or embo ssm ents – Have metal clasps, string ties, or metal folding bars – Have postage st am ps att ached – Have any exposed adhesive when the flap is in the sealed position

• Use only recommended m edia. Refer to th e Card Stock & Label Guide available on the Lexmark Web site

at www.lexmark. com for more information abou t whi ch m edia provides optimum results for the current printing envir onm ent.

Tools

The removal and adjust m ent procedures require the following tool s and equipment:

• Spring hook

• Needle nose pliers

• Volt-ohmmeter

• #1 and #2 Phillips screwdr iv e r

• Slotted screwdriver

1-8 Service Manual

Acronyms

ACM Autocompensator Mechanism (or paper feed) ADC Analog-to-digital Converter ASIC Application Specific Integrated Circuit CBM Complete Bill Of Material DEV Development Roll (of print cartridge/photoconductor

DIMM Dual In-Line Memory Module ENA External Network Adapter FRU Field Replaceable Unit HBP Host Based Printing HVPS High Voltage Power Supply LCD Liquid Crystal Dio de LED Light Emitting Diode LSU Laser Scanning Unit LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory PC Photoconductor PCL Printer Control Language POR Power-On Reset POST Power-On Self Test PPDS Personal Printer Data Stream PRC People’s Republic of China TAR Toner Add Roll SDR Synchronous Dynamic RAM SWE Shipped With Equipment USB Universal Serial Bus V ac Volts alternating current V dc Volts direct current

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system)

General information 1-9

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1-10 Service Manual

2. Diagnostics information

Start

CAUTION: Unplug power from the printe r bef ore connecting or disconnecting any cable,

assembly, or el ectr onic car d. Thi s is a pr eca ution f or per sonal sa fety an d to prevent damage to t he printer.

Use the service error code, user status message, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessar y to re pair a malfunctioni ng pri nter. They will lead you to solutions or servi ce checks, including use of various tests.

Sympto m tables

If your machine compl etes t he “Power– On Self Test (POST) sequenc e” on page 2-1 without an error and you have a symp to m , th en go to “Messages and error codes” on page 2-5. Locate your symptom, and take the appropriate action.

Servi ce erro r s (9xx.x x’s)

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If a service error code appears while you are wor king on the machi ne, then go to “Mess ages and error codes”

on page 2-5, and take the indicated action for that error.

Service error codes are indicated by a three-digit error code followed by a period and additional numbers in the format XXX.YY. In most cases, five digits are shown.

User status and attendance messages

•

User status messages provi de the user wi th information on the current status of the printer. Ready disp lays on the first line of the display unless invoked, and then Power Saver displays. If a user stat us me ssage is displayed, then go to “Messages and error codes” on page 2-5.

• User attendance messages are indicated by a two- or three-digit error code that provides the user with

information that explains a problem wi th a print cart ri dge, paper j am , option, port , and so on. I f a user error message displays, then go to “User attendance messages” on page 2-5 and “Paper jam error codes

(200-series )” on page 2-9.

Power–On Self Test (POST) sequence

The following is an example of the events that oc cur dur ing the POR sequence when the printer is turned on.

1. Diamonds are displayed on the operator panel.

2. While code is being loaded into DRAM, dots scroll across the operator panel.

3. A screen is displayed with the memory and processor speed. A typical exam ple of this message is:

*64MB

4. Performing Self Test is displayed.

5. Busy is displayed.

6. Close Door will be display ed if the cover is open.

7. Any cartridge errors, such as Defective Cartridge, are di splayed.

8. Applicable maintenance messages are displayed.

9. Applicable toner low messages are displ ayed.

10. The printer displays Ready.

Diagnostics information 2-1

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1 2 3

button

Back

button

KeypadSelect

button

LCD

display

Stop

button

Navigation

buttons

Indicator

light

Back

Stop

Overview of the operator panel and menus

The operator panel on your printer is a 4-line, back-lit, grays cale display that can show bot h graphics and text. The Back, Menu, and Stop buttons are located to the left of the display, the navigat ion buttons are locat ed below the display, and the numeric pad is located to the right of the display .

The use of the buttons and the layout of the display panel are described in the following table.

Operator panel

Button Function

Back Press and release to return to the previous screen.

Menus Press and release to open the menus. The menus are available only when

Stop • Press once t o return to the previ ous display screen while in the menus.

Navigation

the printer is in the Ready state. Pressing also returns the operator panel to the top level menu scree n if

pressed while in a menu.

• Press twice to exit the menus and return to t he Ready state.

• Pre ss to stop print er activity.

• Press to cancel a print job. Stopping will display momentarily. Stopped will then displ ay to offer a list of sett ings that may be selected.

Up arrow and Down arrow buttons

Press or to scroll through menus, menu items, or printer options.

Left arrow and Right arrow buttons

2-2 Service Manual

Press or to increase or decrease a value or to scroll through text that rolls to another screen.

Select button

Press and release to open a menu, to display the available values or settings, or to save th e displayed value as the new user default setting.

Note: When a new setting is save d as the def ault s etting, it remai ns in effect unt il new settings are saved or until factory defaults are restored. Settings chosen from a software program can also change or override the user default settings selected from the operator panel.

+ 154 hidden pages

Lexmark E460dn, E460dw, 4513-630, 4513-63W, 4513-6EW Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual