Lexmark Optra Service Manual

Lexmark Optra™ Series

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4049-XXX

• Index

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

4049-XXX

Third Edition (November, 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, THEIMPLIEDWARRANTIESOF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow
disclaimer of express or implied warranties in certain transactions, therefore,
this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors.
Changes are periodically made to the information herein; these changes will be
incorporated in later editions of the publication. Improvementsor changes in the
products or the programs described in this publication may be made at any
time. Publications are not stocked at the address given below; requests for
publications should be made to your point of purchase.

Comments may be addressed to Lexmark International, Inc., D22A/035-3, 740
New Circle Road NW, Lexington, Kentucky 40550, 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 is a trademark of Lexmark International, Inc., registered in the United
States and/or other countries.

©Copyright Lexmark International, Inc. 1995, 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 DFARS252.227-7013 and in applicable FAR provisions:
Lexmark International, Inc., Lexington, KY 40550.

4049-XXX

Table of Contents

NoticesandSafetyInformation...........................ix

LaserNotice....................................... ix

Laser..............................................x

Avisrelatifàl’utilisationdelaser.........................x

Avvertenzesuiprodottilaser .......................... xi

Avisossobreelláser................................. xi

DeclaraçãosobreLaser.............................. xii

Laserinformatie..................................... xii

Lasermeddelelse ...................................xiii

Huomautuslaserlaitteesta............................xiii

Laser-notis....................................... xiv

Laser-melding..................................... xiv

AvíssobreelLàser.................................. xv

Japanese Laser Notice...............................xv

ChineseLaserNotice............................... xvi

KoreanLaserNotice................................ xvi

Trademarks....................................... xvii

SafetyInformation..................................xviii

Preface ............................................xxiii

GeneralInformation...................................1-1

PowerConsumption................................ 1-2

Options.......................................... 1-2

Maintenance Approach.............................. 1-3

Tools Required For Service .......................... 1-3

Abbreviations..................................... 1-4

iii

4049-XXX

DiagnosticInformation ................................2-1

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

Power-OnSelfTest(POST) ........................ 2-10

SymptomTable.................................. 2-11

Banding ..................................... 2-12

Background.................................. 2-12

BlackPage .................................. 2-13

BlankPage.................................. 2-14

BlurredorFuzzyPrint.......................... 2-15

DeadMachine................................ 2-15

Duplex...................................... 2-16

Fan(927Error)............................... 2-18

Fuser Theory . ................................ 2-19

Fuser: 920, 921, or 922 Error .................... 2-19

Fuser:923or924Error......................... 2-20

Honeycomb.................................. 2-20

HorizontalVoidorStreak........................ 2-20

LANProblems................................ 2-21

LightPrint ................................... 2-21

NetworkCard977Errors........................ 2-21

NetworkWrapTests........................... 2-22

OutputBinSensor............................. 2-22

Operator Panel Problem . ....................... 2-22

Paper Feed Problem, 500-Sheet Option or 200-Sheet Second

Drawer,Non-Rt............................... 2-23

Paper Feed, Base Printer ....................... 2-23

Paper Feed, Duplex Unit . ....................... 2-25

Paper Feed Problem, Envelope+ Feeder/

100-Sheet Auxiliary Feeder...................... 2-26

Paper Feed Problem, 200-Sheet Second Drawer, Rt . . 2-26

Paper Feed Problem, Dual Rear Feeder............ 2-27

MachineLevelInformation: ...................2-27

Paper Feed Problem, High Capacity Feeder......... 2-29

Printhead.................................... 2-30

Paper Size Sensing Problem..................... 2-31

RegularlySpacedMarks........................ 2-32

ResidualImage............................... 2-32

Random Marks ............................... 2-32

Skew, all edges ............................... 2-33

Skew,topandbottomonly...................... 2-33

Stalled (diamonds on display) .................... 2-34

VerticalVoidorStreak.......................... 2-34

iv Service Manual

4049-XXX

DiagnosticAids ......................................3-1

Diagnostics Mode .................................. 3-1

Diagnostics Mode Menu Structure . ................. 3-1

Diagnostics Mode Tests . . . .......................... 3-3

AutoClean.................................... 3-3

Auto Clean Frequency . .......................... 3-3

AutoCleanDelay............................... 3-4

ButtonTest.................................... 3-4

ChargeRoll ................................... 3-4

Defaults...................................... 3-5

DiskTest/Clean................................ 3-5

DuplexFeed1Test............................. 3-6

DuplexFeed2Test............................. 3-6

Envelope Enhance .............................. 3-7

EnvelopePrintTest............................. 3-7

ErrorLog ..................................... 3-8

FlashTest..................................... 3-8

FuserTemperatureAndWarm-UpTime............. 3-8

FuserTemperature...........................3-9

FuserWarm-UpTime.........................3-9

LCDTest..................................... 3-9

Maintenance Kit Count. ......................... 3-10

MemoryTests................................. 3-10

PageCount .................................. 3-10

Paper Feed Tests.............................. 3-10

Parallel Confidence . . . ......................... 3-11

Permanent Page Count ......................... 3-11

PrintContrast................................. 3-11

PrintRegistration.............................. 3-12

PrintTest1................................... 3-13

PrintTest2................................... 3-13

PrintTest3................................... 3-14

QuickDiskTest............................... 3-14

QuickTest................................... 3-14

SensorTest.................................. 3-15

TopMarginandDuplexQuickTests............... 3-15

Transfer..................................... 3-16

WrapTests................................... 3-16

v

4049-XXX

OtherTests..................................... 3-17

DevelopedImageTest ......................... 3-17

LANInformation............................... 3-17

PrintTestPage............................... 3-18

PrintTestwithRIPBoardRemoved............... 3-18

RepairInformation....................................4-1

Handling ESD-Sensitive Parts ........................ 4-1

Adjustments...................................... 4-2

Envelope Restraint Spring On

The Envelope+ Feeder Adjustment. . ............... 4-2

Paper Restraint Spring On T he 100-Sheet

Auxiliary Feeder Adjustment ...................... 4-2

Envelope+ Feeder Magnet And

100-Sheet Auxiliary Feeder Magnet Adjustment. ...... 4-3

Dual Rear Feeder Gear Alignment Adjustment. . ...... 4-4

FuserDriveGearBacklashAdjustment ............. 4-5

Fuser Solenoid Adjustment ....................... 4-7

Paper Feed Magnet Adjustment ................... 4-8

Printhead Skew Adjustment ...................... 4-9

RemovalProcedures.............................. 4-10

Covers...................................... 4-10

RightCoverRemoval .......................... 4-10

FrontCoverRemoval .......................... 4-10

LeftCoverRemoval............................ 4-12

TopCoverRemoval............................ 4-12

14 in. 200-Sheet Paper Tray Top Cover ............ 4-14

14 in. 500-Sheet Paper Tray Top Cover ............ 4-14

D-rollAssemblyRemoval....................... 4-14

DriveMotorRemoval........................... 4-14

EngineBoardRemoval......................... 4-15

ExitSensorBoardRemoval ..................... 4-16

Fan/RedriveRemoval.......................... 4-17

FuserRemoval............................... 4-18

FuserInputGuideRemoval...................... 4-19

FuserLampRemoval.......................... 4-20

Fuser/SensorCableRemoval.................... 4-21

Fuser Solenoid Removal. ....................... 4-22

FuserShroudAssemblyRemoval................. 4-23

HVPSRemoval............................... 4-24

INAorHardDiskRemoval ...................... 4-26

Input Sensor Board Removal .................... 4-26

LowerFrameAssemblyRemoval................. 4-28

vi Service Manual

4049-XXX

Removal Procedures (continued)

LVPSRemoval................................ 4-29

LVPSCoverRemoval .......................... 4-30

Operator Panel Removal ........................ 4-31

Paper Feed Rollers Removal ..................... 4-31

Paper Feed Magnet Assembly Removal ............ 4-32

Paper Size Switch Removal...................... 4-33

Printhead Removal............................. 4-34

RIPBoardandInnerEMCShieldRemoval.......... 4-35

TonerSensorRemoval ......................... 4-35

Torquer Motor Removal ......................... 4-35

TransferRollRemoval.......................... 4-36

TransferRollHousingRemoval................... 4-37

Upper Frame Removal. ......................... 4-38

Duplex Option Top Cover And Table Cover Removal . . 4-39

DuplexOptionExitCardAndCoverRemoval........ 4-40

Duplex Option Bottom Cover

AndEntrySensorCardRemoval.................. 4-41

DuplexOptionSystemCardAndMotorRemoval..... 4-42

Dual Rear Feeder - Edge Guide Asm. .............. 4-43

Dual Rear Feeder - Gear Plate Asm. ............... 4-43

Dual Rear Feeder - Right Cover. . . ................ 4-43

200-Sheet Second Drawer, Rt .................... 4-44

High Capacity Feeder Paper Feed Rollers........... 4-45

High Capacity Feeder Cover ..................... 4-47

ConnectorLocations ..................................5-1

MajorAssemblyLocations........................... 5-1

GearTrain.................................... 5-2

HVPS........................................ 5-3

TransferRollerHousing.......................... 5-3

Engine Board Connectors ........................ 5-4

RIPBoard..................................... 5-6

BoardInstallationHardware....................... 5-7

MirrorMotor/FanCable.......................... 5-7

Operator Panel/Output Bin Sensor Cable ............ 5-8

Printhead Connector Locations . . . ................ 5-10

Duplex Autoconnect Cable....................... 5-10

Printer Ground Straps . ......................... 5-11

High Capacity Feeder Board Connectors............ 5-12

vii

4049-XXX

Preventive Maintenance ...............................6-1

SafetyInspectionGuide............................. 6-1

LubricationSpecifications........................... 6-1

Scheduled Mechanical Maintenance................... 6-3

Printhead Window Cleaning Procedure. . ............... 6-4

CleaningTheTransferRoller......................... 6-4

PartsCatalog ........................................7-1

HowToUseThisPartsCatalog................... 7-1

Covers........................................7-2

LowerFrame...................................7-4

UpperFrame...................................7-6

Printhead......................................7-8

Paper Feed . . .................................7-10

Paper Feed Alignment Gears .....................7-14

Paper Feed Drive ..............................7-16

Standard Paper Tray (200-Sheet) . . . ...............7-18

Paper Tray (500-Sheet). . ........................7-20

Base for Paper Drawer (500-Sheet) . ...............7-22

Second Paper Drawer, (200-Sheet) . ...............7-24

Optional Paper Drawer (500-Sheet) . ...............7-26

Fuser........................................7-28

Electronics....................................7-32

TransferRoll..................................7-36

DuplexOption.................................7-38

Envelope+ and 100-Sheet Auxiliary Feeder ..........7-40

Dual Rear Feeder ..............................7-42

High Capacity Feeder . . . ........................7-44

Options ......................................7-46

Miscellaneous .................................7-47

Index ...............................................X1

viii Service Manual

4049-XXX

Notices and Safety Information

References in this publication to products, programs, or services do
not imply that the manufacturerintends to make these availablein all
countries in which it operates. Any reference to a product, program,
or service is not intended to state or imply that only that product, pro­gram, or service may be used. Any functionally equivalent product,
program, or service that does not infringe any existing intellectual
property rights may be used instead. Evaluation and verification of
operation in conjunction with other products, programs, or services,
except those expressly designated by the manufacturer, are the
user’s responsibility.

Laser Notice

The printer is certified in the U.S. to conform to the requirements of
DHHS 21 CFR Subchapter J for Class I (1) laser products, and else­where is certified as a Class I laser product conforming to the
requirements of IEC 825.

Class I laser products are not considered to be hazardous. The
printer contains internally a Class IIIb (3b) laser that is nominally a 5
milliwatt gallium arsenide laser operating in the wavelengthregion of
770-795 nanometers. The laser system and printer are designed so
there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed
service c ondition.

Notices and Safety Information ix

4049-XXX

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die
Anforderungen der Bestimmung DHHS (Depar tment of Health and
Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).
In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,
der die Anforderungen der IEC (International Electrotechnical
Commission) 825 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des
Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es
sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der
Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung
durch den Benutzer oder bei ordnungsgemäßer Wartung durch den
KundendienstLaserbestrahlung, die die Klasse I übersteigen würde,
Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux
provisions DHHS 21 CFR alinéa J concernant les produits laser de
Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 825 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 laser de Classe
IIIb (3b) (arséniure de gallium d’une puissance nominale de 5
milliwatts) émettant sur des longueurs d’onde comprises entre 770
et 795 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 .

x Service Manual

4049-XXX

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di
classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della nor m a CEI 825.

I prodotti laser di classe non sono considerati pericolosi. La
stampante contiene al suo interno un laser di classe IIIb (3b)
all’arseniuro di gallio della potenza di 5mW che opera sulla
lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema
laser e la stampante sono stati progettati in modo tale che le
persone a contatto con la stampante, durante il normale
funzionamento, le operazioni di servizio o quelle di assistenza
tecnica, non ricevano radiazioni laser superiori al livello della classe

1..

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
subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las
condiciones expuestasen la norma IEC 825 para productos láser de
Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La
impresora contiene en su interior un láser de Clase IIIb (3b) de
arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanómetros. El sistema láser y la
impresora están diseñados de forma que ninguna persona pueda
verse afectadapor ningún tipo de radiación láser super ior al nivelde
la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.

Notices and Safety Information xi

4049-XXX

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os
requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a
Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 825.

Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um produto laser da Classe IIIb
(3b), designado laser de arseneto de potássio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795
nanómetros. O sistema e a impressora laser foram concebidos de
forma a nunca existir qualquer possiblidade de acesso humano a
radiação laser superior a um nível de Classe I durante a operação
normal, a manutenção feita pelo 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 eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 825.

Laserprodukten van klasse I worden niet als ongevaarlijk
aangemerkt. De printer is voorzien van een laser van klasse IIIb
(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met
een golflengte van 770-795 nanometer. Het lasergedeelte en de
printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelling mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.

xii Service Manual

4049-XXX

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 825.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren
indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5
milliwatt galliumarsenid laser, som arbejderpå bølgelængdeområdet
770-795 nanometer. Lasersystemet og printeren er udformet
således, at mennesker aldrig udsættes for en laserstråling over
Klasse I-niveau ved normal dr ift, brugervedligeholdelse eller
obligatoriske servicebetingelser.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.
Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei
altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen
normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden
huoltotoimien yhteydessä.

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

VARNING! Osynlig laserstrålning när denna del är öppnad och
spärren är urkopplad. Betrakta ej strålen.

Notices and Safety Information xiii

4049-XXX

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 825.

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en
inbyggd laser av Klass IIIb (3b) som består av en laserenhet av
gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770­795 nanometer.Lasersystemet och skrivaren är utformade så att det
aldrig finns risk för att någon person utsätts för laserstrålning över
Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,
underkapittel J, for klasse I (1) laserprodukter, og er i andre land
godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC

825.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en
gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet
770-795 nanometer. Lasersystemet og skriveren er utformet slik at
personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne
serviceoperasjoner.

xiv Service Manual

4049-XXX

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora
compleix els requisits de DHHS 21 CFR, apartat J, pels productes
làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 825.

Els productes làser de classe I no es consideren perillosos. Aquesta
impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,
nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona
de 770-795 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 operació nor mal, durant
les tasques de manteniment d’usuari ni durant els serveis que
satisfacin les condicions prescrites.

Japanese Laser Notice

Notices and Safety Information xv

4049-XXX

Chinese Laser Notice

Korean Laser Notice

xvi Service Manual

4049-XXX

Trademarks

Optra and Lexmark are trademarks of Lexmark International, Inc.,

registered in the United States and/or other countries.

AppleTalk and LocalTalk are trademarks of Apple Computer, Inc.,
registered in the United States and other countries.

PCL is a registered trademark of the Hewlett-Packard Company.
PCL 5 is Hewlett-Packard Company’s designation of a set of printer
commands (language) and functions included in its printer products.
This printer is designed and manufactured byLexmark International,
Inc., to be compatible with the PCL 5 language. This means the
printer recognizes PCL 5 commands used in various applications
programs, and that the printer emulates the functions corresponding
to the commands.

Details relating to compatibility are included in the 4049 Technical
Reference manual.

Other trademarks are the property of their respective owners.

Notices and Safety Information xvii

4049-XXX

Safety Information

•

This product is designed, tested and approved to meet strict
global safety standards with the use of specific Lexmark
components. The safety features of some parts may not always
be obvious. Lexmark is not responsible for the use of other
replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precautions.

Consignes de Sécurité

•

Ce produit a été conçu, testé et approuvé pour respecter les
normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. Les caractéristiques de
sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres
pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement 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.

xviii Service Manual

4049-XXX

Norme di sicurezza

•

Il prodotto è stato progettato, testato e approvato in conformità a
severi standard di s icurezza e per l’utilizzo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune par ti
non sempre sono di immediata comprensione. Lexmark non è
responsabile per l’utilizzo di parti di ricambio di altri produttori.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise

•

Dieses Produkt und die zugehörigen Komponenten wurden
entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder
Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

Notices and Safety Information xix

4049-XXX

Pautas de Seguridad

•

Este producto se ha diseñado, verificado y aprobado para
cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede que
las características de seguridad de algunas piezas no sean
siempre evidentes.Lexmark no se hace responsable del uso de
otras piezas de recambio.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Informações de Segurança

•

Este produto foi concebido, testado e aprovado para satisfazer
os padrões globais de segurança na utilização de componentes
específicos da Lexmark. As funções de segurança de alguns
dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de
substituição.

• 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.

xx Service Manual

4049-XXX

Informació de Seguretat

•

Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de Lexmark. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Lexmark no es responsabilitza de l'us
d'altres peces de recanvi.

• La informació pel manteniment d’aquest producte està

orientada 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 convenients.

Notices and Safety Information xxi

4049-XXX

xxii Service Manual

4049-XXX

Preface

This manual is divided into the following chapters:

• “General Information” contains a general description of the

printer, available options, and the maintenance approach used
to repair it. Special tools and test equipment are listed in this
chapter.

• “Diagnostic Information” contains error code table, symptom

table, and service checks used to isolate failing field replaceable
units (FRUs).

• “Diagnostic Aids” contains tests and checks used to locate or

repeat symptoms of printer problems.

• “Repair Information” provides instructions for making printer

adjustments and removing and installing FRUs.

• “Connector Locations” uses illustrations to identify the major

components and test points on the printer.

• “Preventive Maintenance” contains safety inspection guidelines,

lubrication specifications, and maintenance information to
prevent problems and maintain optimum performance.

• “Parts Catalog” contains illustrations and part numbers for

individual FRUs.

Preface xxiii

4049-XXX

1. General Information

The Optra™ Laser Printers are designed to attach to IBM-compati­ble PC’s and to most computer networks. There are multiple models,
all with standard PostScript Level 2 emulation and PCL 5 emulation.

+

From a service standpoint models Lxi

+

, model Lxi is the same as Lx, and model Rn+is the same as R+.

Lx
Models Lxi

+

,Lxn+, Lxi, and Rn+are not mentioned elsewhere in this

manual.

plus

The

models have a different ROM SIMM, RIP board, and top
cover,and all have a maximum speed of 16 ppm. There are no other
hardware differences. Processing speed and efficiency have been
improved, and scheduled maintenance has been eliminated.

and Lxn+are the same as

1-1

4049-XXX

Power Consumption

R/L/Rt/R+/Rt

Power Saver Mode 21W 20W
Printing (average) 260W 310W
Max. AC draw 110V 6.8A 9.8A
Max. AC draw 220V 3.4A 5.0A

+

Rx/Lx/Lx

+

Options

The following options are available. Some options are not available
in every country. Contact your point of purchase foroptions available
in your country.

Memory upgrade options of 2MB, 4MB, 8MB, 16MB and 32MB
Flash memor y options of 1MB, 2MB and 4MB
Integrated network options

Token-Ring
Ethernet
AppleTalk
SCS

IPDS
200 and 500-sheet paper trays of A5, letter, and legal size.
500-sheet second drawer (with letter-size paper tray)
Envelope+ feeder
100-sheet auxiliary feeder
Duplex option
Font cards (bitmapped or scalable fonts)
100MB Hard Disk
Dual Rear Feeder
Stat Alert Light
High Capacity Feeder (1500 sheets)

General Information 1-2

4049-XXX

Maintenance Approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the error code charts,
symptom index, service checks, and diagnostic aids to determine
the symptom and repair the failure. Begin with “Start” on page 2-1.

This printer can be serviced without being connected to a host com­puter.

After you complete the repair, perform tests as needed to verify the
repair.

Tools Required For Service

Flat-blade screwdriver
#1 Phillips screwdriver
#2 Phillips screwdriver

5.5 mm nut driver
8 mm wrench
Needlenose pliers
Diagonal pliers
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Serial wrap plug 1329048
Twinax/serial debug cable 1381963
Coax/serial debug cable 1381964

1-3

4049-XXX

Abbreviations

ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable Read-

Only Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Network
LASER Light Amplification by Stimulated Emission

of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PICS Problem Isolation Charts
PIXEL Picture Element
POR Power-On Reset
POST Power-On Self Test
PQET Print Quality Enhancement Technology
RIP Raster Image Processor
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
VAC Volts alternating current
VDC Volts direct current

General Information 1-4

4049-XXX

2. Diagnostic Information

Start

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.

Two-digit codes are messages for the user, but if they recur fre­quently or at inappropriate times they may be symptomatic of a ser­vice problem.

Use the service error code, symptom table, service checks, and
diagnostic aids to determine the corrective action necessary to
repair a malfunctioning printer.

2-1

4049-XXX

Refer to the diagnostics Error log for the last six machine errors.

Error Code Explanation

20 Paper Jam The input sensor was not unmade in

time.

21 Paper Jam The exit sensor was not made in

time after the input sensor was
made.

22 Paper Jam The exit sensor was not unmade in

time.

23 Paper Jam Jam at the duplex unit. Paper is

either not leaving the duplex entry
sensor in time or not making or
unmaking the duplex exit sensor in
time. See “Duplex” on page 2-16

24 Short Paper The defined paper size is too short

to print data as formatted.

25 Incorrect Manual Feed Input sensor made at wrong time.

May be due to the paper feeding
manually while motors running and
previous page in path.

26 Duplex Tray Missing Duplex unit is installed butpaper tray

is not sensed.

27 Change Envelope/Paper Envelopes/paper loaded are wrong

28 Load Envelope/Paper Input sensor not made after pick

29 Output Bin Full The output bin sensor has not been

size.

attempt. Tray is empty or not
installed, paper jam in entry throat,
or printer is requesting a manual
feed.

unmade.See “Output Bin Sensor” on

page 2-22.

Diagnostic Information 2-2

4049-XXX

Error Code Explanation

30 Top Cover Open or Print
Cartridge Missing

32 Wrong Print Cartridge
installed

37 Insufficient Collation Mem­ory

38 Memory Full Memory used to store pages is full.

39 Complex Page Page too complex to print.To verify

Make sure the spring-mounted pin
on the printhead shroud is installed
properly andthat it is detected by the
ramp on the print cartridge as the
cover closes. The pin should enter
the tower on the HVPS and depress
the cover switch.

The installed print cartridge is not
supported by the Optra printer.

Memoryistoofulltocollatetheprint
job.

To verify that the printer recognizes
all the installed memory, go to the
user menus and print the “Print
Menus” test page. Make sure the
memory shown on the printout
matches the installed memory.

that the printer recognizes all the
installed memory, go to the user
menus and print the “Print Menus”
test page. Make sure the memory
shown on the printout matches the
installed memory.

43 Font Card Not Supported Font card format not supported by

printer.

44 Defective Font Card Defective font card installed in font

slot.

47 Font Card Removed While
Printing

51 Defective Flash The printer detects a defective Flash

52 Flash Full Not enough flash memory for data

53 Unformatted Flash Flash problem at POR or while

Printer needs data on removed card.

SIMM. If the error recurs replace the
Flash SIMM.

requested to be stored.

attempting to write.

2-3

4049-XXX

Error Code Explanation

54 Serial Error Framing or parity error on serial.
56 Serial Port Disabled or,Par-

allel Port Disabled

57 Check Duplex Connection The duplexunit has been electrically

58 Duplex Not Attached Duplex is no longer connected, and

59 Duplex Cover Open Top cover of duplex unit is sensed

62 Disk Full Not enough disk space for data that

63 Unformatted Disk Format the disk.
64 Defective Disk The printer will ignore a disk it

Data has been sent to a port which
has been disabled in the Setup
Menu. The port can be reactivated
by entering the customer setup
menu and selecting Serial Setup or
Parallel Setup, Serial Buffer or Paral­lel Buffer,and changing the setting
from Disabled to Auto.

disconnected from the printer but the
printer top cover is not open. Check
theauto-connect plugson the duplex
unit and the printer.

printer top cover is closed.

open.

has been requested to be written to
disk.

senses as defective. Run the Quick
Disk Test. If the test fails, the disk is
defective or the data on track 1 is
bad. If the Quick Disk Test passes
but the disk does not work, run the
Disk Test/Clean (2 hour test).
Replace the disk if instructed by the
operator panel.

7X Network Card Codes These user codes are documented

in various network card user manu­als. See “Network Wrap Tests” on

page 2-22

80 Scheduled Maintenance Printer has reached 200,000 prints

without maintenance count reset.
Refer to “Scheduled Mechanical

Maintenance” on page 6-3.

Diagnostic Information 2-4

4049-XXX

Error Code Explanation

81 Engine Code CRC Microcode to be programmed into

the engine board during a machine
upgrade has failed a CRC check.
The microcode data will be dis­carded and must be retransmitted

from the host computer.
88 Toner Low Toner sensor detects low toner.
90X Software Error Unrecoverable software error. If one

of these errors appeared during

POST, o r while the printer was idle

(not printing or receiving data), or

whiletryingtoprintoneoftheinter-

nal test pages, replace the RIP

Board. If the error appeared while

sending a job from the host com-

puter to the printer, turn the printer

off, then turn it on and try again. If

the error appears again, callthe next

level service support for assistance.
917 Transfer Roll Error Cannot start servo operation. Verify

correct cable connections from the

engine board to the HVPS. Make

sure there is continuity between the

transfer roller and its contact on the

HVPS; replace the transfer roll if the

continuity is correct. If there is no

continuity, make sure the HVPS con-

tact returns to its upward limit when

depressed, and make sure the left

bearing of the transfer roll is making

proper contact. If the error persists,

replace the HVPS and cable.
918 Transfer Roll Error Servo Failure. Verify correct cable

connections from the Engine board

to the HVPS. Make sure there is

continuity between the transfer roller

and its contact on the HVPS; replace

the transfer roll if the continuity is

correct. If there is no continuity,

make sure the HVPS contact returns

to its upward limit when depressed,

and make sure the left bearing of the

transfer roll is making proper con-

tact.

2-5

4049-XXX

Error Code Explanation

920 Fuser Error Fuser is below temperature while

printing. See “Fuser: 920, 921, or

922 Error” on page 2-19.

921 Fuser Error Fuser is below standby temperature

when idle. See “Fuser: 920, 921, or

922 Error” on page 2-19.

922 Fuser Error Fuser failed to reach standby tem-

perature. See “Fuser: 920, 921, or

922 Error” on page 2-19.

923 Fuser Error Fuser is too hot while printing or

when idle. See “Fuser: 923 or 924

Error” on page 2-20.

924 Fuser Error Open detected in thermistor circuit.

See “Fuser: 923 or 924 Error” on

page 2-20.

927 Fan Stalled See “Fan (927 Error)” on page 2-18.
928 Erase Lamps Erase lamp assembly missing or dis-

connected.
931 Printhead Error No first hsync. See “Printhead” on

page 2-30.

932 Printhead Error Lost hsync.See “Printhead” on page

2-30.

934 Printhead Error Lost lock condition. See “Printhead”

on page 2-30.

935 Printhead Error Mirror motor unable to reach operat-

ing speed. See “Printhead” on page

2-30.

941 ROM SIMM ROMSIMM failedCRC;code dataor

font data. Run the diagnostic Mem-

ory Test for ROM. Replace the SIMM

if the test fails or the problem recurs

after POR; replace the RIP Board if

the SIMM does not fix the problem.
944 RIP Board RIP processor failure. Replace the

RIP Board.

Diagnostic Information 2-6

4049-XXX

Error Code Explanation

945 RIP Board ASIC 1 failure. Replace the RIP

Board.

946 RIP Board ASIC 2 failure. Replace the RIP

Board.

947 Engine Board Engine ASIC RAM failure. Replace

the engine board.

948 Engine Board Engine ASIC electronics failure.

Replace the engine board.

950 RIP Board SRAM failure. Replace the RIP

951 Engine Board PQET SRAM failed verification test.

952 Engine Board Unable to zero PQET SRAM.

953 Engine Board NVRAM failure. Replace the engine

954 Engine Board Printhead crystal not functioning cor-

960 Memory Error Bad or missing DRAM in the base

961 Memory Error Bad DRAM in the optional DRAM

970 Network Card 1 Network card 1 processor failure.

Board.

Replace the engine board.

Replace the engine board.

board.

rectly. Replace the engine board.

DRAM slot. Reseat the DRAM and
run the diagnostic Memory Test for
DRAM. POR the printer. If the test
fails or the problem recurs, replace
the DRAM SIMM.

slot. Reseat the DRAM and run the
diagnostic Memory Testfor DRAM.
POR the printer.If the test failsor the
problem recurs, replace the DRAM
SIMM.

Replace network card 1.

970 Network Card 2 Network card 2 processor failure.

Replace network card 2.

971 Network Card 1 Network card 1 RAM failure.

Replace network card 1.

2-7

4049-XXX

Error Code Explanation

971 Network Card 2 Network card 2 RAM failure.

Replace network card 2.
972 Network Card 1 Network card 1 ROS/FLASH failure.

Replace network card 1.
972 Network Card 2 Network card 2 ROS/FLASH failure.

Replace network card 2.
973 Network Card 1 Network card 1 EEPROM/NVRAM

failure. Replace network card 1.
973 Network Card 2 Network card 2 EEPROM/NVRAM

failure. Replace network card 2.
974 Network Card 1 Network card 1/ Network interface

error. Replace network card 1.
974 Network Card 2 Network card 2/Network interface

error. Replace network card 2.
976 Network Card 1 Network card 1 software error.Verify

that the network card is installed and

grounded correctly. If this error

returns after a POR, there is a soft-

ware or microcode incompatibility

problem. Do not replace the card.

Contact your next level of support.
976 Network Card 2 Network card 2 software error.Verify

that the network card is installed and

grounded correctly. If this error

returns after a POR, there is a soft-

ware or microcode incompatibility

problem. Do not replace the card.

Contact your next level of support.
977 Network Card 1 Network card 1 is installed but is not

communicating with the RIP Board.

See “Network Card 977 Errors” on

page 2-21.

977 Network Card 2 Network card 2 is installed but is not

communicating with the RIP Board.

See “Network Card 977 Errors” on

page 2-21.

978 Network Card 1 General network 1 card hardware

error. Replace network card 1.

Diagnostic Information 2-8

4049-XXX

Error Code Explanation

978 Network Card 2 General network 2 card hardware

error. Replace network card 2.

979 Network Card 1 General network 1 card software

error. Verify that the network card is
installed and grounded correctly. If
this error returns after a POR, there
is a software or microcode incompat­ibility problem. Do Not replace the
card. Contact your next levelof sup­port.

979 Network Card 2 General network 2 card software

error. Verify that the network card is
installed and grounded correctly. If
this error returns after a POR, there
is a software or microcode incompat­ibility problem. Do Not replace the
card. Contact your next levelof sup­port.

990 Duplex Option Duplex error.See “Duplex” on page

2-16.

991 Duplex System Card Fail­ure

993 Duplex Comm. Failure Communications between the

Duplex system board failure.
Replace the duplex system board.

duplex unit and the printer have
failed. See “Duplex” on page 2-16.

2-9

4049-XXX

Power-On Self Test (POST)

When you turn the printer on, it performs a Power-On Self Test.
Check for correct POST functioning by observing the following:

1. One and one half rows of pels appear on the display and then
clear.

2. Diamonds fill the display and then clear.

3. The fuser lamp and the fan turn on. [Performing Self Test]
appears on the display.

Note:

warms to operating temperature. Printer idle time is shorter if
the fuser is already warm.

Note:

on for about five seconds just before the Ready screen appears.

4. The ready screen appears on the display.

Note:

5. The dr ive motor and the mirror motor start. The fan starts to run
at high speed.

6. The drive motor runs for approximately ten seconds. The fan
runs at high speed, then switches to low speed.

If the printer completes all these steps and no error messages are
displayed, the printer has successfully completed the POST.

The printer may be idle for up to 60 seconds as the fuser

If the duplex unit is installed, the duplexdrive motor turns

Diagnostics menu appears if you are in diagnostic mode.

Diagnostic Information 2-10

4049-XXX

Symptom Table

Symptom Go To

Dead Machine “Dead Machine” on page 2-15.
Machine Hangs Displaying

Diamonds
Repeats a pattern of 5 beeps

and a pause.
Operator Panel “Operator Panel Problem” on page

Paper Feed, Base Printer “Paper Feed, Base Printer” on page

Paper Feed, Duplex Unit “Paper Feed, Duplex Unit” on page

Paper Feed Problem, 500­Sheet Option or 200-Sheet
Second Drawer, Non-Rt

Paper Feed Problem, Enve­lope+ Feeder/100-Sheet Auxil­iary Feeder

Paper Feed Problem, Dual
Rear Feeder

Paper Feed Problem, 200­Sheet Second Tray, Rt

Machine Hangs Displaying Dia­monds Service Check.

“Operator Panel Problem” on page
2-22.

2-22.

2-23.

2-25.
“Paper Feed Problem, 500-Sheet

Option or 200-Sheet Second
Drawer, Non-Rt” on page 2-23 or
“Paper Feed Problem, 200-Sheet
Second Drawer, Rt” on page 2-26.

“Paper Feed Problem, Envelope+
Feeder/ 100-Sheet Auxiliary Feeder”
on page 2-26.

“Paper Feed Problem, Dual Rear
Feeder” on page 2-27.

“Paper Feed Problem, 200-Sheet
Second Drawer, Rt” on page 2-26.

Paper Feed Problem, High
Capacity Feeder

Automatic Paper Size Sensing
Problem

LAN Problems “LAN Problems” on page 2-21.
Blank Page “Blank Page” on page 2-14.
Black Page “Black Page” on page 2-13.
Random Marks “Random Marks” on page 2-32.

“PaperFeedProblem, HighCapacity
Feeder” on page 2-29

Automatic Paper Size Sensing Prob­lem Service Check.

2-11

4049-XXX

Symptom Go To

Regularly Spaced Marks “Regularly Spaced Marks” on page

2-32.

Skew, all edges “Skew, all edges” on page 2-33.
Skew, top and bottom only “Skew,top and bottom only” on page

2-33.

Light Print “Light Print” on page 2-21.
Blurred or Fuzzy Print “Blurred or Fuzzy Print” on page

2-15.

Residual Image “Residual Image” on page 2-32.
Honeycomb “Honeycomb” on page 2-20.
Background “Background” on page 2-12.
Horizontal Void or Streak “Horizontal Void or Streak” on page

2-20.

Vertical Void or Streak “Vertical Void or Streak” on page

2-34.

Banding “Banding” on page 2-12.

Banding

Banding appears as light and dark horizontal lines on a page that is
supposed to be uniformly gray. It is due to variation in the speed of
the paper as it moves from roll to roll during developmentor transfer.
It is undetectable when printing text and is most noticeable on fine
dot or horizontal line patterns such as the second page of Print
Test 2 or Print Test 3. Inspect the gear train and the paper feed roll­ers for wear, damage, dirt, or binds.

Background

Areas that are supposed to stay blank are getting small amounts of
toner deposited on them. Clean the erase lamps and the printhead
window.

Verify that all the erase lamps are working by powering on or off with
the top cover open. Verify that there is +24VDC on engine board

Diagnostic Information 2-12

4049-XXX

J9-1 and between +15 and +20VDC on engine board J9-2. Shorting
engine board J9-2 to ground should turn on all the erase lamps.
Check the erase lamp cable continuity. Replace the transfer roll
housing if the voltage and the cable are good.

Inspect the contacts on the HVPS; make sure each spring-loaded
contact returns when pressed and released.

Rough Paper mode can cause background on some papers; if
Rough Paper mode is on, turn it off and run the print test again.

Printing on coated paper or using refilled print cartridges can also
cause background.

Run the Print Test with the RIP Board removed and check the follow­ing voltages; then stop the test and check the voltages again:

Connector

Voltage while
Printing

Voltage while Idling

J13-1 Less than 5 VDC 0 VDC
J13-2 Less than 5 VDC 0 VDC
J13-3 (Fluctuates

0VDC
between pages)
+1.5 VDC

J13-8 Less than 1 VDC +6 VDC

If any voltages are not correct replace the engine board.
If no problem is found, enter the diagnostics mode and change the

Charge Roll setting.
Users who run large jobs with very dense graphics in high humidity

environments may get some print quality improvement from increas­ing the Transfer setting; users with more normal jobs will see no dif­ference.

Make sure the HVPS contacts to the transfer roll housing are in good
condition.

Black Page

Black output is usually caused by an incorrect high voltage in the
printing process, resulting in toner development on the entire photo-

2-13

4049-XXX

conductor drum. Check the condition of each HVPS contact and
make sure they spring back when pressed. Check the continuity of
the HVPS cable.Make sure the following voltages are correct; if they
are not, replace the engine board.

Connector Voltage

J13-5 to J13-4 +24 VDC
J13-6 to J13-4 +24 VDC

Run the Print Test with the RIP Board removed. Make the following
voltage checks while printing and again while idling. If the voltages
are not correct, replace the engine board.

Connector

Voltage while
Printing

Voltage while
Idling

J13-1 to J13-4 +4.5 VDC 0 VDC
J13-2toJ13-4 +4VDC 0VDC

If no other trouble is found replace the HVPS.

Blank Page

Inspect the printhead shutter for proper operation and make sure the
actuator on top of the cartridge is present and extends into the print­head shroud when the printer top cover is closed. A failed printhead
will cause a 931 Service e rror rather than blank output.

Check the continuity of the HVPS cable. The HVPS and transfer roll
contacts should be clean and spring back when pressed. Make sure
the transfer roll contact under the left bearing is making contact with
the HVPS.

Diagnostic Information 2-14

4049-XXX

Run the Print Test with the RIP Board removed. Make the following
voltage checks:

Connector

Voltage while
Printing

J13-1 to J13-4 Less than 5

Voltage while
Idling

0VDC

VDC

J13-2 to J13-4 Less than 5

0VDC

VDC

J13-3 to J13-4 (Fluctuates

0VDC
between
pages) +1.5
VDC

J13-8 to J13-4 Less than 1

+6 VDC
VDC

If the voltages are not correct replace the engine board.

Blurred or Fuzzy Print

This can be caused by a damaged gear train or by paper slippage in
the feed roll or transfer roll. Also see Banding.

Inspect the HVPS contacts; make sure each spring-loaded contact
returns when pressed and released. Inspect the transfer roll housing
contacts for damage or contamination. Check the gear train for dam­age, binds, or wear.

When using the 100-sheet auxiliary feeder, some blurring mayoccur
at the point where the feeder’s friction rollers release the paper.

Dead Machine

Possible causes: no voltagereaching the printer, LVPS failure, blown
LVPS fuse, failure of the On/Off switch or switch linkage, or a
shorted electrical component.

Check for the indicated voltages at the LVPS connection to the
engine board. If no voltages are present, remove the LVPS cover
and check fuse F1 and the power switch before replacing the LVPS.

If some voltages are present but all are not correct, disconnect all
cables except the LVPS from the engine board. POR and verify that

2-15

4049-XXX

the LVPS voltages are correct. Turn the power back off and, one at a
time, reconnect the engine board cables, powering on in between
each connection and checking the voltages. The connection which
causes the voltages to be wrong indicates which component is bad.
Repair or replace the failing component or cable as necessary.

Duplex

The duplex unit should home — the front shafts should turn and the
input deflector should move — immediately when you install the
duplex unit with the printer already powered on, or just before the
[Ready] screen is displayed when you POR the printer with the
duplex unit installed. This means the duplex unit and the printer are
communicating and thus the printer engine board, duplex unit sys­tem board, and the cables between them are all good.

If the duplex unit does not home immediately but homes after 5 or 6
seconds, the duplex unit is receiving +34 VDC from the printer but is
not communicating with the printer. The duplex unit homes on its
own as a signal that it is functional.

If the duplex unit does not home at all, it is either damaged or is not
receiving +34 VDC from the printer.

To check the connection from the printer engine board to the duplex
system board, removethe printer RIP Board. Removethe duplex top
cover and table cover, and reinstall the duplex unit. Engine board J3­2 should have continuity with the duplex system board J5-1, J3-3
with J5-2, and so on. With power on, you should have the following
voltages:

Connector Voltage to Ground

Engine Board J3-3 +34 VDC

J3-5 +5 VDC
J3-7 +5 VDC

Duplex System
Board

J5-2 +34 VDC

J5-4 +5 VDC
J5-6 +5 VDC

Diagnostic Information 2-16

4049-XXX

If you do not find a cable or voltage problem replace the duplex sys­tem board. If this does not fix the problem, replace the printer engine
board.

A 993 error indicates that communication between the printer and
duplex unit had been established but has been lost. Check the cable
as above; if the error persists replace the duplex system board.

23 Paper Jams: Examine the paper path in the duplex unit and in
the fuser exit area for paper or other obstructions. Make sure the
duplex unit is positioned correctly on the printer, and that the gear at
the bottom of the duplex unit meshes with the gear on the top of the
paper tray. Check that the paper is fed with no skew or binds from
the duplexer into the metal channel at the right edge of the tray
cover. The tray roller should move the paper forward when the tray
gear is turned, but allow the paper to be pulled by the D-roll when it
picks. Make sure the belt to the duplex DC motor is in place. Make
sure the duplex table cover (floor) is correctly snapped in place at its
front and rear and that the gear block assembly is correctly snapped
into the bottom cover. Run duplex diagnostics tests #1 and #2 to
make sure there is no slippage in the paper path. Make sure the
flags of the duplex unit i nput and exit sensors move freely.

While the 23 is displayed, press and hold the Return button while
pressing the second button from the top, and note the 7th and 8th
digits from the left. If they are 01 or 03, there is a problem with the
duplex input sensor signal. Remove the duplex top cover and table
cover and reinstall the duplex unit on the printer. Measure the volt­age on J5-12 of the duplex system board; it should fluctuate from 0
to +5 VDC as you toggle the sensor. Check the sensor cable conti­nuity. If the sensor and the cable are good, replace the duplex sys­tem board.

If the 7th and 8th digits are 04, there is an exit sensor problem.
Remove the duplex top cover and table cover and reinstall the
duplex unit on the printer. Remove the paper tray so you can reach
the sensor. Measure the voltage on J5-8 of the duplex board; it
should fluctuate from 0 to +5 VDC as you toggle the sensor. Check
the sensor cable continuity. If the sensor and the cable are good,
replace the duplex system board.

2-17

4049-XXX

Fan (927 Error)

The fan should run continuously when the printer is powered up,
unless the printer is in Power Savermode. Check that the fanrotates
freely when spun manually and that the cable connections to the fan
are OK. The voltage at engine board J 2-7 should be approximately
+24 VDC when the top cover is up. Short J2-7 to ground (J2-6) to
test the fan; if the fan does not run, check the continuity of the fan
cable before replacing the fan. A bad fan can pull down the +24 V
line even if it runs; check that J2-8 has between +21 and +26 VDC
when the fan is running. If the voltage is under 21 VDC, replace the
fan; if the voltage is correct and there is still a 927 error, replace the
engine board.

Diagnostic Information 2-18

4049-XXX

Fuser Theory

The fuser lamp operates off line voltage from the LVPS. The ther­mistor is in contact with the fuser hot roll. The system board reads
the thermistor resistance and toggles a TRIAC in the LVPS which
cycles the lamp on and off to maintain the proper hot roll tempera­ture. Inside the fuser shroud there is a thermal fuse which is in
series with the lamp; if the TRIAC fails and leaves the lamp on con­tinuously, the fuse melts and shuts off power to the lamp.

The thermistor output voltage is proportional to the fuser tempera­ture and is on engine board J8-4. The voltage cycles from approxi­mately 2.0 to 2.3 VDC as the lamp goes on and off during idle, and
will be around 2.7 VDC during continuous printing when the Fuser
Temperature is set to Normal. In Power Saver mode the lamp is left
off until a job is printed.

The engine board signalto the LVPS TRIACis on J4-16. The voltage
is 0 VDC when the lamp is to be on and +5 VDC when the lamp is to
be off. The lamp can be tested by briefly connecting this pin to
ground.

Fuser: 920, 921, or 922 Error

A 922 error during a POR caused by low line voltage can usually be
cleared by doing another POR.

If the fuser lamp is lighting very dimly, check for a 220 V lamp
installed in a 110 V machine.

Check all the connectors to the exit sensor card and the lamp power
connections at the left end of the fuser. Make sure the thermistor is
making contact with thehot roll. Check the continuity of the lamp, the
thermal fuse, and the fuser power cable. Check the thermistor resis­tance at engine board J8-3 to J8-4; it should be from 100K Ohms to
260K Ohms when cold; it may be as low as 2.3K Ohms when hot but
increases quickly as the fuser cools. There should be no connection
from either pin to ground.

If the thermal fuse is open, the fuser and the fuser wiper may be
damaged. Before replacing the fuser and the fuser wiper, check the
voltage at engine board J4-16 as you POR again. It should stay at 0
until the 922 Error is displayed and then go to +5 VDC; if it does not,
replace the engine board, the fuser, and the fuser wiper. Next, mea-

2-19

4049-XXX

sure the voltage to the fuser lamp during a POR; it should be line
voltage until the 922 Error is displayed, if it does not, replace the
LVPS, the fuser, and the fuser wiper.

If the voltage to the fuser lamp is the not the same as the line volt­age, replace the LVPS.

If the lamp, fuser power cable, thermal fuse, thermistor and lamp
voltage are OK, check J4-16 to see if the engine board is sending
the correct signal to the TRIAC. At POR this signal should go to +5
VDC and then immediately drop to 0 VDC until the fuser is warm; if it
does not, replace the engine board. If the signal is OK, replace the
LVPS.

Fuser: 923 or 924 Error

Check the connection and continuity of the cable from the fuser exit
sensor board to engine board J8. Check the thermistor condition
and connection.

Check the thermistor resistance at engine board J8-3 to J8-4. It
should be from 100K Ohms to 260K Ohms when cold; it may be as
low as 2.3K Ohms when hot, but increase quickly as the fuser cools.

Honeycomb

(Areas of the page are covered by faint 6 mm circles.)
This print defect is usually caused by the print cartridge. If it is not

the problem, verify that the tab on the transfer roll housing is touch­ing the contact on the HVPS; the transfer roll housing should have
continuity to ground. Make sure the HVPS ground lead to the side
frame is in place and making good contact.

Horizontal Void or Streak

This is usually due to the cartridge not being installed correctly.
Check the printhead area for obstructions, and check the mechani­cal workings of the pr int cartridge and printhead shutter. If nothing is
found see “Blank Page” on page 2-14 and follow those instructions.

Diagnostic Information 2-20

4049-XXX

LAN Problems

You cannot find a printer or network problem, but jobs still do not
print.

If the network card checks out successfully, the problem may be with
the hardware or software outside of the network card. Below are
some suggestions to the customer for checking hardware and soft­ware for possible problems. Refer the customer to the LaserPrinter
Network Printer Utility Guide to find the problem.

• Make sure the network protocol you want is enabled from the

printer operator panel.

• Verify proper print queue and printer driver configuration.

• Verify the adapter port has been associated.

• Verify correct installation of the software utility.

• Single route broadcast not supported across network bridge, if

bridge is used.

• Server problem;check print server installation and configuration

using the appropriate system guide to operations.

Light Print

Light print is frequently caused by a worn out print cartridge. Clean
the transfer roll by powering on and off two or three times, leaving
the printer on for about two minutes each time. Other causes are the
same as for “Blank Page”. See “Blank Page” on page 2-14.

Make sure Print Darkness on the customer menu is set to Normal or
Dark. Increasing the diagnostics mode Print Contrast setting will
darken print further.

PostScript emulation output may appear lighter than PCL emulation
output or a test print; this is not a defect. Verify on the Print Test that
the print is too light before performing service.

Network Card 977 Errors

All network card errors are recorded as 977 in the error log. If there
are 977 errors in the log, POR several times and take the appropri­ate action for the displayed error code.

2-21

4049-XXX

If the displayed error is 977, verify that the network card is installed
and grounded correctly. Remove the network card and check for +5
VDC at pin B24 of RIP board J6 or J12 (whichever the network card
was connected to). If the voltage is incorrect replace the engine
board; if there is +5 VDC replace the network card.

Network Wrap Tests

Token-Ring with Shielded Twisted-Pair Cable: Disconnect the

LAN cable from the electr ical outlet, leaving it connected to the
printer network card.

Ethernet 10BASE2: Attach a 50 Ohm BNC terminator cap to each
end of the T-connector. The customer may be able to provide this
cap.

There is no wrap test for Token-Ring with Unshielded Twisted-Pair
cable or for Ethernet 10Base -T.

POR the printer. If the printer completes POR successfully, the
printer, network card, and the port to the LAN are working correctly.

see

If the customer still has a problem printing,

page 2-21.

“LAN Problems” on

Output Bin Sensor

Examine the bin area for obstructions or damage. Run the diagnos­tic sensor test.

Make sure the plastic bails and guide are in good condition and that
they guide the sensor flag out of and into the sensor as paper
passes into the bin. On the sensor, the voltage from pin 2 to pin 3
(pin 1 is the bottom pin) should change from 0 to +5 VDC as the sen­sor is blocked and unblocked.Pin 1 should always measure +5 VDC.

Replace the sensor, the sensor card or the operator panel/bin sen­sor cable as necessary.

Operator Panel Problem

Note:

the menus by powering on the printer with the Return button and the
top button pressed. Repeat the POR procedure to disable the
menus again after service.

If the printer is in “Menus Disabled” mode, you can activate

Diagnostic Information 2-22

4049-XXX

Possible causes: failed LCD or operator panel card, cable or con­nector problem, or engine board problem.

Replace the operator panel if POR stops with half rows of pels dis­played.

Run the diagnostic tests for the LCD and for the buttons. If only
some buttons or pels work, replace the operator panel.

If the printer beeps 5 times at POR, or if the operator panel is blank:
check for +5 VDC at pin 4 of the cable connector at the operator
panel, and also at engine board J1-4. Replace the operator panel or
the cable if they are the problem. If the voltage at the engine system
board is incorrect, check that the LVPS is providing +5 VDC at J4-7,
J4-9, and J4-11, and replace the LVPS if its output voltages are
wrong.

Paper Feed Problem, 500-Sheet Option or 200-Sheet Second Drawer, Non-Rt

Remove the module and inspect the tray, the module D-roll and the
gear train. Make sure the gear train is meshing with the drive gear at
the bottom of the printer. Look for other mechanical problems or
damage. Make sure the printer and module auto-connectors mate
properly when the module is installed.

Check for +34 VDC at engine board J15-2. You can test the torquer
motor by shorting engine board J15-1 to ground (J15-3).

Paper Feed, Base Printer

Note:

torquer motor or a solenoid.

Run the print test or the diagnostic paper feed test and carefully
examine the area of the problem.

If paper is not feeding, make sure the paper is in the tray correctly
and is not damaged or stuck together. With 500-sheet trays, make
sure the tension wheel is set high enough to give good contact
between the D-roll and the paper stack.

If paper is not feeding, make sure the gear train is rotating. The main
motor should be on during most of POR and during any attempt to

2-23

The printer paper pick mechanism may have either a

4049-XXX

feed paper. Remove the RIP board and run Print Test with RIP
Board Removed. During the test check for 19±2 Vdc on the engine
board J6-1, J6-2, J6-3, and J6-4. If the voltage is wrong, replace the
engine board.

Remove the motor and gear assembly from the printer and recon­nect it to the engine board. Reconnect all the other engine board
connectors and reinstall at least one engine board mounting nut to
make sure the engine board is grounded. POR the printer. If the
motor does not run during POR replace the motor. If the motor is
OK, look for a bind elsewhere in the gear train.

Intermittent problems may be caused by a thermal problem in the
motor. Run an extended print test; if the gear train stops suddenly
replace the motor.

If paper is not feeding or is feeding continuously with no gaps
between pages, remove the paper tray and the RIP board. Press
switches 1 and 3 on the paper size switch assembly. Watch the D­roll as you run the Print Test with RIP Board Removed. One of the
following will occur:

• The D-roll will make one complete revolution and stop with the

flat side down. This indicates that the mechanism is working
correctly. If the flat side is not facing down, or if the printer had
error code 20 or 28, turn the D-roll, if it rotates easily more than
10°, either the D-roll or gear 11 is damaged and should be

replaced.

• The D-roll will turn continuously:

a. Torquer: There is a possible short to ground of the lead

between the torquer gear and engine board J14-2, or the
timing marks on the torquer gear and the D-roll gear are mis­aligned. Examine the condition of the torquer leads and
replace the torquer motor if necessary.The timing marks are
visible when the engine board is removed. If no problem is
found, replace the engine board.

b. Solenoid: There is a possible short to ground of the lead

between the solenoid and engine board J14-2, or the sole­noid is out of adjustment. Examine the condition of the sole­noid leads. Adjust the solenoid air gap (see “Paper Feed

Magnet Adjustment” on page 4-8) or replace the solenoid if

necessary. If no problem is found, replace the engine board.

• The D-roll will not move at all. Either the engine board signal is

Diagnostic Information 2-24

4049-XXX

incorrect or the torquermotor or solenoid is defective.Adjust the
solenoid air gap (see “Paper FeedMagnet Adjustment” on page

4-8). On torquer machines, make sure the torquer gear is not

slipping on the shaft. Engine board J14-1 should always be +34
VDC; J14-2 should be +34 VDC when the torquer or solenoid is
not picking. Short engine board pin J14-2 to ground and listen
carefully for the torquer or solenoid; it will move slightly and
make a noise. If it does, replace the engine board.

• The D-roll will move slightly but will not complete an entire revo-

lution. This indicates a bind or defect in the gear train, or a mis­alignment of the torquer motor gear timing marks.

If paper is jamming, clean the paper path of obstructions or repair
any damaged parts. Very thin or thick paper, labels, transparencies,
or card stock has a higher jam rate than regular xerographic paper.
Check the condition of the paper in the tray and verify that the tray is
installed correctly. If the paper feeds but stops undamaged in the
paper path run the input and exit sensor test. Check for +5 VDC at
the input sensor (engine board J9-6) and exit sensor (engine board
J8-6) with paper present. Check continuity on the cable before
replacing a sensor.

If paper is curling badly enough to cause a problem feeding or stack-

see

ing,

“Fuser Temperature And Warm-Up Time” on page 3-8.

Paper Feed, Duplex Unit

Check that all gears and belts are working correctly both in the
duplex unit and on the tray top cover, and that the gear on the tray
top cover correctly engages the gear on the duplex unit.

If paper is jamming in the table cover area, make sure the table
cover is properly installed. Run diagnostics Duplex Test 1 to make
sure the paper is feeding far enough into the duplex unit before
reversing. Examine the condition of all rollers.

If paper is stopping or jamming as it is fed back across the top of the
paper tray, run diagnostics Duplex Test 2 to make sure there is no
slippage in the paper path. Make sure the paper tray top cover is not

see

damaged. Cold paper curl can also cause jams here;

Temperature And Warm-Up Time” on page 3-8.

2-25

“Fuser

4049-XXX

If paper is jamming at the front exit of the printer, inspect the duplex
exit selector switch and the linkage to the printer exit deflector.
Check the switch by removing the duplex top cover and table cover
and reinstalling the duplex unit in the printer. Check for +5 VDC at
duplex system board J15-10. The voltage will change from 0 VDC to
+5 VDC as the selector lever is moved.

see

Also

“23 Paper Jams” on page 2-17.

Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Auxiliary Feeder

Check for the following: paper or envelope jammed in the feed path;
missing hold-down weight; adjustable guide out of position; feeder
cable loose, disconnected, or plugged in the wrong connector;
feeder incorrectly installed; worn or damaged rollers or gears;
warped or damaged envelopesused; envelopes improperly installed
(envelope flaps must rest against the paper edge guide); envelopes
other than 20 or 24 pound used in the Envelope+ Feeder; paper
other than 20 or 24 pound used in the 100-sheet auxiliary feeder;
envelopes interleaved with paper.

Run the diagnostics Envelope Feed test and make sure the feed
magnet is being energized. If not, check the resistance of the mag­net at J10-1 to J10-2 on the feeder cable; the resistance should be
from 105 Ohms to 155 Ohms. If the magnet is good, reconnect the
cable and monitor the voltage between the two pins of the connector
while running the Envelope Feed test; if the voltage does not
increase momentarily as the magnet is picked, replace the engine
board.

Check the adjustment of the feeder magnet. If paper is being bent or
double-fed, check the adjustment of the feeder restraint spring.

Paper Feed Problem, 200-Sheet Second Drawer, Rt

Run the Paper Feed Test and select “Tray 2”. If Tray 2 is not on the
Paper Feed Test menu, make sure the jumper at J16 on the engine
board is in place and that Tray 2 is properly connected at J17 on the
engine board.

If paper is not being picked, check for +34 VDC at J17-1 and J17-2
on the engine board. Test the torquer by shorting J17-1 to J17-4; the

Diagnostic Information 2-26

4049-XXX

torquer moves slightly and makes a noise. With the power off there
should be 88 ohms between J17-1 and J17-2, and neither should
have continuity to ground.

Remove the module and inspect the tray, the D-roll and the gear
train. Make sure the gear train is meshing with the drive gear at the
bottom of the printer. Check all mechanical areas and electrical con­nections.

The Print Test with the RIP Board Removed can be run from the sec­ond tray by disconnecting J14 and shorting J14-2 to J17-1.

Paper Feed Problem, Dual Rear Feeder

Run the diagnostics Paper Feed for Feeder 1 and Feeder 2.

Machine Level Information:

Early level printers do not support the Dual Rear Feeder without an
upgrade.If the feeder is not being recognized by the printer,print the
Print Menus test page and make sure the "Base" code level is at
least 32.00, and the "Engine" code level is at least 43.42.

On the early machines engine board connector J5 is wired differ­ently. These machines require the J5/J10 external adapter box in
order to support the Dual Rear Feeder. On the Print Menus test
page, machines which require the adapter havean "Engine Card" of
12 or 16; machines not requiring the adapter have 12 A or 16 A.

Upgrade kits containing code upgrades and the adapter box are
available through normal marketing channels.

No paper feed: If the Dual Rear Feeder is recognized by the printer,
Feeder 1 (front tray) and Feeder 2 (rear tray) will be shown on the
Paper Source menu and on the diagnostics Paper Feed Test menu.
If it is not, check the printer code levels (see Note above) and test
the torquer.

J5-8 and J5-10 are inaccessible. J5-8 may be measured on test
point RXD and J5-10 may be measured on test point TXD.

2-27

4049-XXX

J16

1

1

1

J3

J1

J4

J17

1

J2

1

RXD
TXD

J5

J5-1 carries the pick signal for Feeder 1, J5-8 carries the pick signal
for Feeder 2, and J5-10 is +34 VDC. When the feeder is connected,
all three pins have +34 VDC. For early level machines using the
external J5/J10 adapter box, J5-8 and J5-10 are +34 VDC, J5-1 is 0
VDC, and J10-1 and J10-2 are +34 VDC. For all machines, if the J5­10 and J10-1 voltages are incorrect replace the engine board. If the
other voltages are wrong, continue with this service check.

To test the torquers, short J5-1 (Feeder 1) or the J5-8 test point
(Feeder 2) to ground; the torquer rotates slightly and makes a noise.
Turn the power off and disconnect the feeder connector. There
should be 88 ± 10 ohms between pins 1 and 10, and between pins 8
and 10. Reconnect the feeder and make sure neither J5-1, nor the
J5-8 test point, nor the J5-10 test point has continuity to ground.

Skews or Jams: Check for worn, dirty, or damaged rolls, gears, or
envelope bucklers; obstructions in the paper path, correct paper/
envelopes properly installed; edge guides and flip doors properly
positioned; and paper load shafts installed parallel to the frame.

Gear chatter or continuous paper feed: Remove the right cover
and verify that the gear alignment marks are centered in the win­dows of the gear plate when the torquer is in its detent position.
Refer to “Dual Rear Feeder Gear Alignment Adjustment” on page

4-4. Continuous feed may also be caused by a short to ground of J5-

1 (Feeder 1) or J5-8 (Feeder 2).

Diagnostic Information 2-28

4049-XXX

Paper Feed Problem, High Capacity Feeder

The paper feed rollers should be replaced every 200,000 prints or
whenever feeding becomes unreliable. Clean rollers with alcohol or
waterat every service call.

The feeder receives a pick signal from the printer, and will not do a
test feed without the printer installed. Paper can be manually picked
by rotating the paper feed rollers by hand, or by removing the upper
paper feed motor screw, pivoting the motor downward, and rotating
the gear.

For all paper feed problems: Verify that the printer designator
switch on the rear of the high capacity feeder is set to the correct
printer model being used. Make sure the paper is undamaged, shin­gled correctly, properly installed in the tray, and is the correct weight
(16 to 24 lb.) and size (letter or A4). Letter paper size and A4 paper
size model feeders are available. Paper sizes are not interchange­able between the two models. Make sure that all paper in the tray is
the same type and has not been run through the printer before.
Envelopes and transparencies are not supported in the high capac­ity feeder.

Jams: Make sure the printer is installed correctly on the feeder.
Check for obstructions in the printer throat. Make sure the paper in
the tray does not have excessive curl. Look between the printer and
feeder to make sure the paper is entering the printer correctly.

Failure to feed: Check the printer Paper Source menu for a “Tray 2”
indication to be sure the printer detects the high capacity feeder.
Check the condition of the feed rollers and clean with alcohol or
water; replace if necessary. Make sure the feed motor i s connected
and functioning. The motor winding resistance is 36 ohms ±2 ohms
for the following pins: 1-4, 1-6, 2-3, and 2-5. No pin should have con­tinuity to the motor case and no pin should havea short to any other
pin.

Multiple feeds: This is often due to environmental factors or the
customer's choice of papers. Make sure the paper is undamaged
and that the corner bucklers are in good condition and free to move
up and down with the paper stack.

Tray does not raise/lower properly: Elevator motion can be tested
by opening and closing the door, with or without the printer installed.

2-29

4049-XXX

The elevator mechanism and switches can be inspected by remov­ing the cover, positioning it near the feeder, reconnecting the power
supply and door switch cables, and reconnecting the line cord.
Check the tray height and door switches, and all cable connections.
If the tray does not move at all check the elevator motor and the
upper and lower limit switches. Inspect the gears, belts, and shafts
for mechanical damage or blockage. The motor winding resistance
is 36 ohms ±2 ohms for the following pins: 1-4, 1-6, 2-3, and 2-5. No
pin should have continuity to the motor case and no pin should have
a short to any other pin.

If the elevator raises normally but immediately reverses when the
upper limit switch is made, the paper out switch is not working. If the
elevator behaves normally but the printer does not become Ready,
the signal from the feeder ready switch is not reaching the printer.

Dead unit: Check the printer Paper Source menu for a “Tray 2” indi­cation to be sure the printer detects the high capacity feeder. Check
feeder power supply input and output voltages. If the output is cor­rect (pin 1: +24 VDC, pin 2: GND, pin 3: +5 VDC, pin 4: GND)
replace the circuit board. When replacing the circuit board, check
the A4/U.S. jumper to verify that the correct paper size is selected.
Be sure to plug each cable into the correct board connector. Plug­ging a cable into the wrong board connector can damage the new
board or other components.

Printhead

Note:

that can be replaced or adjusted.
Verify the presence of the following voltages: +24 VDC at engine

board J2-1, +5 VDC at engine board J11-4, and +5 VDC at engine
board J12-8. If these voltages are not correct, replace the engine
board.

Verify the continuity of the fan/mirror motor cable, the hsync cable,
and the laser cable.

934 and 935 errors: Check engine board J2-5 during a POR; the
voltage should be between +2 VDC and +4 VDC for about seven
seconds after the main motor turns on. If the voltage is incorrect,
replace the engine board. If the voltage is correct, check the continu-

The printhead is a sealed unit. It contains no internal parts

Diagnostic Information 2-30

4049-XXX

ity of the fan/mirror motor cable.Replace the printhead if the cable is
good.

Paper Size Sensing Problem

(The printed area does not fit on the page, or the paper size cannot
be changed from the operator panel.)

Make sure the paper tray and its stops are undamaged. Make sure
the cable to the paper size switch is connected correctly. With the
paper tray removed, the resistance of the paper size switch should
be infinite. With the tray installed, the resistance of the switch varies
with the paper size.

For Tray 1, remove the front cover, disconnect the cable from the
sensor and measure the resistance between the two pins on the
sensor board.

For 500-Sheet Option or 200-Sheet Second Drawer, Non-Rt,
remove the RIP Board, disconnect J15 from the engine board, and
measure between J15-3 and J15-4 on the cable.

For 200-Sheet Tray 2, Rt, remove the RIP board, disconnect J17
from the engine board, and measure between J17-3 and J17-4 on
the cable.

If the readings do not match the following within 5% replace the
paper size sensor.

Tray installed and set to:

A5 1.4K Ohms
B5 2.0K Ohms

10.5” 3.0K Ohms
11” 4.7K Ohms
A4 8.0K Ohms
13” or 14” 17.8K Ohms (legal tray)

2-31

4049-XXX

Regularly Spaced Marks

This is caused by a defect on one of the rolls or gears in the print
process. The damaged part can be determined by the spacing of the
marks according to the following table. Find and replace the dam­aged part.

Component Print Defect Spacing on Page

PC Drum (part of print cartridge) 125.7 mm
Transfer Roll 53.1 mm
Fuser Hot Roll 78.9-79.2 mm
Fuser Backup Roll 69.1 mm
Charge Roll (part of print car-

tridge)
Developer Roll (part of print car-

tridge)
Prealigner Feed Roller 68.5 mm
Auxiliary Feed Roller 68.5 mm

37.1-37.7 mm

40.0mm

Spacings other than the ones listed could be caused by damage or a
bind in the gear train.

Residual Image

Residual image--the “walking” of a leftover image down the page--is
probably the result of failed erase lamps not discharging the photo­conductor,or of a failed cleaner inside the print cartridge. It can also
be caused by a failedfuser hot roll retaining toner and redepositing it
on the page. Check that the erase lamp voltage at engine board J9­1 is +24 VDC and that the cable has continuity.

To test the erase lamps, jumper engine board J9-2 to ground.

Random Marks

Random marks are nearly always due to a mechanical problem or
due to foreign matter loose in the printer or in the print cartridge.

Diagnostic Information 2-32

4049-XXX

Inspect and clean the inside of the printer carefully and correct any
problems found.

Skew, all edges

If the test print frame is parallel to all edges of the page but the mar­gins are not all the same width. “Print Registration” on page 3-12.

If the test print frame is not parallel to the left and right edges of the
paper, the paper has skewed in the paper path. Check the paper
path for obstructions. Make sure the paper in the tray is undamaged
and loaded properly, and the tray side restraint is properly adjusted.
Check the prealigner, drive, and auxiliary r ollers, springs, and
backup rollers for dirt, wear, or damage; refer to the parts catalog for
repair kits for broken bellcrank spring attachment hooks on the side­frame. Make sure all the bellcrank assemblies pivot freely. Check the
gear train for damage or binds.

Skew, top and bottom only

If the test print frame is parallel to the left and right edges of the
paper but not parallel to the top and bottom, the printhead skew
needs to be adjusted. See “Printhead Skew Adjustment” on page

4-9.

2-33

4049-XXX

Stalled (diamonds on display)

Check the continuity of the cable from J1 on the engine board to the
operator panel. Nextreseat the ROM and memory SIMMs and POR.
This condition can also occur if the RIP and engine board are not
seated or their connectors are damaged.

If the problem is still present, replace one at a time the:

1. ROM SIMM

2. Engine board

3. RIP Board

Vertical Void or Streak

Do a developed image test to determine if the defect is occurring
before or after the transfer process.

If you see the defect on the photoconductor, check the operation of
the printhead shutter and clean the printhead window with a lint-free
cloth folded over a cotton swab; do not use a bare swab and do not
use any cleaning fluids or water on the printhead window. Inspect
the HVPS contacts.

If the image on the photoconductor is good, inspect the fuser rolls
and transfer roll. Make sure the left transfer roll bearing is contacting
the contact from the HVPS. Make sure the HVPS contacts are clean
and spring back when pressed.

Diagnostic Information 2-34

4049-XXX

3. Diagnostic Aids

Diagnostics Mode

To run the remainder of the printer diagnostic tests described in this
chapter, you must put the printer in Diagnostics mode.

To enter Diagnostics mode:

1. Turn the printer off.

2. Press and hold the Ready and Return buttons. Then turn the
printer on. The printer performs the Power-On Self Test.

3. Release the buttons when [Performing Self Test] is displayed.

4. You can exit Diagnostics mode without a POR by selecting
[Reset Printer].

Diagnostics Mode Menu Structure

The following is the Diagnostics mode menu structure, The indented
items are submenus availableunder the main menu items, which are
in capital letters on the operator panel. Menu items referring to
options will only be present if those options are installed. Menuswith
more than four items will use [MORE] on the fourth operator panel
button to access the next screen of selections.

PRINT TESTS

PrintTest1
PrintTest2
PrintTest3
Envelope Print Test

PRINT REGISTRATION

Left Margin
Top Margin
Bottom Margin
Quick Test

HARDWARE TESTS

LCD Test
Sensor Tests

Toner Low

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4049-XXX

Output Bin
Input
Exit

Cover Open
Button Test
Parallel Confidence
Wrap Tests

Parallel

Serial
Memory Tests

DRAM

ROM

PAGE COUNTS

Page Count
Permanent Page Count
Maintenance Count

PAPER FEED TESTS

Tray 1
Tray 2
Tray 3
Feeder
Feeder 1
Feeder 2
Manual

DUPLEX TESTS

Top Margin
Duplex Quick Test
Duplex Feed 1
Duplex Feed 2

DEVICE TESTS

Disk Test/Clean
QuickDiskTest
Flash Test

PRINTER SETUP

Fuser Temperature
Warm-Up Time

Diagnostic Aids 3-2

4049-XXX

Envelope Enhance
Auto Clean
Auto Clean Frequency
Auto Clean Delay
Transfer
Print Contrast
Charge Roll
Defaults

ERROR LOG
RESET PRINTER

Diagnostics Mode Tests

Auto Clean

Auto Clean needs to be turned on if there is an unacceptable
amount of toner being deposited on the back of the page. When
Auto Clean is on, after printing the number of pages specified in
Auto Clean Frequency, the printer will pause the number of seconds
specified in Auto Clean Delay. This pause minimizes the toner accu­mulating on the fuser cleaner.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Auto Clean].

4. Select [On] or [Off].

5. Press Return to return to the Diagnostics mode main menu.

Auto Clean Frequency

This can be set from 10 to 255 pages with a default of 50.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Auto Clean Frequency].

4. Select [+] or [-] to display the frequency desired.

5. Select [Save].

6. Press Return to return to the Diagnostics mode main menu.

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4049-XXX

Auto Clean Delay

This can be set from 1 to 60 seconds with a default of 1.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Auto Clean Delay].

4. Select [+] or [-] to display the delay desired.

5. Select [Save].

6. Press Return to return to the Diagnostics mode main menu.

Button Test

To test the operator panel buttons:

1. Enter Diagnostics mode.

2. Select [HARDWARE TESTS].

3. Select [Button Test].

4. Press each button. [Closed] is displayed until the button is
released. Then [Open] is displayed.

5. Press Return to return to the Diagnostics mode main menu.

Charge Roll

This setting varies the charge roll bias. It is used to reduce back­ground on the output. In general, if there is background and the envi­ronment is hot and humid, change the setting to low; if the
environment is cool and dry, change the setting to high. If the back­ground is not reduced, try changing the setting the other way.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Charge Roll].

4. Select [High], [Medium] or [Low].

5. Press Return to return to the Diagnostics mode main menu.

Diagnostic Aids 3-4

4049-XXX

Defaults

Allows setting the following defaults to U.S. or Non-U.S. values.

U.S. NON-U.S.

Letter size paper A4 paper
# 10 envelopes DL envelopes
Symbol Set Roman-8 Symbol Set PC-850

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Defaults].

4. Select [U.S.] or [NON U.S.].

5. Press Return to return to the Diagnostics mode main menu.

Disk Test/Clean

This is a two hour test (three hours for 100MB drives) that should be
performed only on a disk that contains bad data and is therefore
unusable.

This test destroys all data on the disk by doing a multi-pass write/
read on every blockof the disk. Bad blocks are flagged and removed
from use. If over 2000 bad blocks are found, the test stops and the
display indicates the disk must be replaced.

A message describing test progress is displayed during the test.

1. Enter Diagnostics mode.

2. Select [DEVICE TESTS].

3. Select [Disk Test/Clean].

4. Select [CONTINUE] to start the test, or [CANCEL] to return to
Diagnostics mode main menu.

5. Select [CANCEL] to interrupt the test.

6. Press Return to return to the Diagnostics mode main menu.

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4049-XXX

Duplex Feed 1 Test

This test checks for slipping paper problems. It verifies that the
paper is entering the duplex unit far enough for the trailing edge to
clear the selector fingers before the paper reverses direction.

1. Enter Diagnostics mode.

2. Select [DUPLEX TESTS].

3. Select [Duplex Feed 1].

4. Select [Tray 1], or [Tray 2].

Note:

Paper feeds all the way into the duplex unit and stops.

5. The message [Clear Paper] appears on the display.

6. Slide the tray extension all the way out until it stops.

7. Push a small screwdriver through the lower end of one of the
ventilation slots and through the sheet of paper fed in under the
slot.

8. Open the cover and remove the sheet of paper.

9. Measure the distance from the mark on the paper to the trailing
edge of the paper.If the mark, or hole, is more than 85 mm from
the trailing edge, there is a paper slipping problem with the
duplex unit paper feed.

Duplex Feed 2 Test

This test verifies that paper feeds through the duplex unit properly
and tests the stop point of the page as it feeds back over the top of
the duplex paper tray.

1. Enter Diagnostics mode.

2. Select [DUPLEX TESTS].

3. Select [Duplex Feed 2].

4. Select [Tray 1] or [Tray 2].

Note:

feeds out and stops on top of the paper tray.

5. The message [Clear Paper] appears on the display.

6. Open the printer top cover.

7. If you are doing the test with legal size paper, open the top
cover of the duplex unit.

Paper feeds all the way into the duplex unit and then

Diagnostic Aids 3-6

4049-XXX

8. Carefully remove the duplex unit from the printer without dis­turbing the position of the paper on the top of the duplex tray.

9. Without changing the position of the page, hold it to the top of
the paper tray and remove the paper tray.

10. Measure from the leading edge of the page to the leading edge
of the paper stack in the tray. This measurement should be
75 mm or less. If it is larger than 75 mm, there is a drive prob­lem in the duplex unit or in the tray top cover.

11. Select [CONTINUE].

12. Perform the test several times to verify that the measurement is
accurate.

13. Press Return to return to the Diagnostics mode main menu.

Envelope Enhance

Use this procedure to set the fuser solenoid power level to low,
medium, or high. Increase the levelto reduce envelope wrinkling, or
decrease the level to reduce solenoid noise.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Envelope Enhance].

4. Select [Low], [Medium], or [High].

5. Press Return to return to the Diagnostics mode main menu.

Envelope Print Test

Use Envelope Print Test to test the Envelope+ or Auxiliary feeder.
Envelope Print Test generates one printout: a page of ripple print.

Printing will occur only on the first page or envelope.

1. Enter Diagnostics mode.

2. Select [PRINT TESTS].

3. Select [Envelope Print Test].

4. Select [Single] or [Continuous].

5. Select [CANCEL] to stop continuous print.

6. Press Return to return to the Diagnostic mode main menu.

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4049-XXX

Error Log

The error log records the last six “2X Paper Jam” or “9XX Service”
errors. In a full log, position 6 is the oldest error. If more than six
errors are received, the oldest error is discarded. If the same error
occurs consecutively it is recorded only once.

All 97X Network Card errors are logged as 977.

1. Enter Diagnostics mode.

2. Select [ERROR LOG].

3. Select [CLEAR] and then [CONTINUE] to clear the error log.

4. Press Return to return to the Diagnostics mode main menu.

Flash Test

This test writes to and reads from the flash memory. It destroys all
datastoredintheflashSIMM.

1. Enter Diagnostics mode.

2. Select [DEVICE TESTS].

3. Select [Flash Test].
The operator panel will display [Passed] or [Failed].

4. Press Return to return to the Diagnostics mode main menu.

Fuser Temperature And Warm-Up Time

These settings allow adjustment of the fuser to correct problems with
paper curl or melting letterheads.

Paper curl in which the top and bottom of the page curl away from
the printed side (hot paper curl) can be corrected by reducing the
fuser temperature. Reduce the setting from Normal to No Boost; if
necessary, reduce the setting further to Low Temperature. Verify that
the toner is being adequately fused to the paper at the new tempera­ture setting.

Paper curl in which the edges of the paper curl toward the printed
side (cold paper curl) can be corrected by increasing the fuser
warm-up time. Use the lowest setting that corrects the problem.
Setting “0” is the factory default and is the shortest warm-up time.

Diagnostic Aids 3-8

4049-XXX

Setting “5” increases warm-up time by 90 seconds; lower settings
increase the time proportionately less. Settings other than “0” may
reduce throughput. Use the [+] or [-] key to change the number and
then select [SAVE].

Melting letterheads may be prevented by reducing the fuser
temperature as described above for paper curl.

Fuser Temperature

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Fuser Temperature].

4. Select [Normal], [No Boost], Or [Low Temperature].

5. Press Return to return to the Diagnostics mode main menu.

Fuser Warm-Up Time

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Warm-Up Time].

4. Select a setting of “0” through “5”. Use the + or - key to change
the number. 0 is the shortest fuser warm-up (factory setting). 5
is the longest fuser warm-up.

5. Press Return to return to the Diagnostics mode main menu.

LCD Test

To test the operator panel display:

1. Enter Diagnostics mode.

2. Select [HARDWARE TESTS].

3. Select [LCD Test].

4. Select [Single] or [Continuous].

5. The display goesthrough a continuous sequence of turning pels
on and off.

6. Press Return to stop continuous LCD test.

7. Press Return to return to the Diagnostics mode main menu.

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4049-XXX

Maintenance Kit Count

This non-displayed counter must be reset after the maintenance kit
is replaced to prevent the [80 Scheduled Maintenance] message
from displaying when the machine is turned on.

1. Enter Diagnostics mode.

2. Select [PAGE COUNTS].

3. Select [Maintenance Count].

4. Select [Reset] to set the count back to “0”.

5. Press Return to return to the Diagnostics mode main menu.

Memory Tests

1. Enter Diagnostics mode.

2. Select HARDWARE TESTS].

3. Select [Memory Test].

4. Select either [DRAM] or [ROM].

5. Select [Single] or [Continuous].

6. The display will indicate [PASSED], or [FAILED].

7. Select [CANCEL] to stop continuous memor y test.

8. Press Return to return to Diagnostics mode main menu.

Page Count

To view or set the page count:

1. Enter Diagnostics mode.

2. Select [PAGE COUNTS].

3. Select [Page Count].

4. Choose any number between 0000000 and 9999999 by Select­ing [Next] to movethe cursor under each digit. Select [+] or [-] to
select the number you want in each digit.

5. Select [SAVE] to save the page count displayed.

Paper Feed Tests

This test allows you to observe the drive gear train and feed paper
through the printer to check for broken gear teeth, watch the paper
path, or check the erase lamps.You may want to remove the gear
cover before starting this test so you can observe the motor gears.

Diagnostic Aids 3-10

4049-XXX

Note: “Feeder” refers to the Envelope+ or 100-Sheet Auxiliary

feeder. “Feeder 1” and “Feeder2” refer to the front and rear bins
of the Dual Rear Feeder.

1. Enter Diagnostics mode.

2. Select [PAPER FEED TESTS].

3. Select [Tray 1], [Tray 2], [Tray 3],[Feeder],[Feeder 1], [Feeder 2],
or [Manual].

4. Select [Single] or [Continuous].

5. Select [CANCEL] to stop continuous.

6. Press Return to return to the Diagnostics mode main menu.

Parallel Confidence

This test requires specific PC software and is to be implemented
with the assistance of Lexmark Technical Support. It can be used to
diagnose parallel port interface problems.

Permanent Page Count

The permanent page count can be displayed only. It cannot be mod­ified or reset by the customer or servicer.

1. Enter Diagnostics mode.

2. Select [PAGE COUNTS].

3. Select [Permanent Page Count].

4. Press Return to return to the Diagnostics mode main menu.

Print Contrast

This setting varies the developer bias to vary the print darkness. If
the Print Darkness setting on the customer menu does not allow the
darkness to be set correctly, this setting can increase or decrease
the entire darkness range.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Print Contrast].

4. Select [Low], [Medium], or [High].

5. Press Return to return to the Diagnostics mode main menu.

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4049-XXX

Print Registration

Use Print Test 1 or the Quick Test to evaluate print registration.
Adjust the registration so the tips of the diamonds are at the top and
bottom edges of the page and the printout is centered left to right.

Verify that the top margin is correct before adjusting the bottom mar­gin.

1. Enter Diagnostics mode.

2. Select [PRINT REGISTRATION].

3. Select one of the following: [Left Margin], [Top Margin], [Bottom
Margin].

4. The value of the margin you selected is shown.

5. Margins:

• Left Margin can be set between -23 and +23. Changing the

number by one moves the margin 1/75 inch. Moving the
number in a positive direction moves the margin toward the
right and negative moves the margin to the left.

• Top Margin can be set between -20 and +20. Changing the

number by one moves the margin by 1/75 inch. Moving the
number in a positive direction moves the margin down the
page and widens the top margin. Moving the number in a
negative direction moves the text up the page and narrows
the top margin.

• Bottom Margin can be set between -20 and +20. Moving

the number in a positive direction moves the margin down
and narrows the bottom margin. Moving the number in a
negative direction moves the text up the page and leaves a
wider bottom margin.

6. Select [+] to movethe number in a positive direction or select [-]
to move the number in a negative direction. Select [SAVE] to
save your settings when they are correct.

7. Select [Quick Test] to check your settings.

8. Press Return to return to the Diagnostics mode main menu.

Diagnostic Aids 3-12

4049-XXX

PrintTest1

Print Test 1 generates one printout similar to the test page and will
not duplex.

This test prints from the user-selected default paper source if the
default source is a tray, or from Tray 1 if the default source is a
feeder. You can change the default source by selecting Paper
Source in the Paper Menu. After running the test, reset the default
source to the customer’s selection.

To run Print Test 1:

1. Enter Diagnostics mode.

2. Select [PRINT TESTS].

3. Select [Print Test 1].

4. Select [Single] or [Continuous].

5. Select [CANCEL] to stop continuous print.

6. Press Return to return to the Diagnostics mode main menu.

PrintTest2

Print Test 2 generates two printouts: a page similar to the test page,
and a fine dot pattern which can be used to evaluate banding or
other print quality problems.

Print Test 2 will duplex if the duplex option is installed.
This test prints from the user-selected default paper source if the

default source is a tray, or from Tray 1 if the default source is a
feeder. You can change the default source by selecting Paper
Source in the Paper Menu. After running the test, reset the default
source to the customer’s selection.

To run Print Test 2:

1. Enter Diagnostics mode.

2. Select [PRINT TESTS].

3. Select [Print Test 2].

4. Select [Single] or [Continuous].

5. Select [Cancel] to stop continuous print.

6. Press Return to return to the Diagnostic mode main menu.

3-13

4049-XXX

Print Test 3

This test generates 2 printouts: a solid black page, and a dot pattern
that can be used to evaluate print quality. Print Test 3 will not duplex.

This test prints from the user-selected default paper source if the
default source is a tray, or from Tray 1 if the default source is a
feeder. You can change the default source by selecting Paper
Source in the Paper Menu. After running the test, reset the default
source to the customer’s selection.

1. Enter Diagnostics mode.

2. Select [PRINT TESTS].

3. Select [Print Test 3].

4. Select [Single] or [Continuous].

5. Select [Cancel] to stop continuous print.

6. Press Return to return to the Diagnostics mode main menu.

Quick Disk Test

This is a one minute test which performs a non-destructive write/
read on one block per track on the disk. It tests the printer-to-disk
communications, and the disk hardware and circuitry, but does only
incidental testing of the disk surface itself.

The Quick Disk Test does not destroy data on the disk; existing data
is read and stored prior to the testing of each track, and then rewrit­ten after the track is tested.

1. Enter Diagnostics mode.

2. Select [DEVICE TESTS].

3. Select [Quick Disk Test].

4. The display will indicate [Test Passed] or [Test Failed].

5. Press Return to return to the Diagnostics mode main menu.

Quick Test

The Quick Test is activated by pressing Ready from any screen
while in Diagnostics mode, as well as being an entry under [PRINT
REGISTRATION]. It provides a simple page alignment pattern that
prints faster than the other print tests.

Diagnostic Aids 3-14

4049-XXX

Sensor Test

1. Enter Diagnostics mode.

2. Select [HARDWARE TESTS].

3. Select [Sensor Test].

4. Select one of the following sensor tests: Toner Low, Output Bin,
Input, Exit, or Cover Open.

5. When the sensor is blocked, [Open] is displayed. Otherwise,
[Closed]is displayed.

6. Press Return to return to the Diagnostics mode main menu.

Top Margin and Duplex Quick Tests

The Top Margin and Duplex Quick Test are used together to adjust
the duplexfront-to-back registration. Makesure the non-duplex page
registration is correct before adjusting the duplex top margin.

1. Enter Diagnostics mode.

2. Select [DUPLEX TESTS].

3. Select [Top Margin].

4. Select [+] or [-] to raise or lower the back image 0.01 inches per
increment.

5. Press Return to return to the Diagnostics mode main menu.

The Duplex Quick Test is used to verify the Duplex Top Margin.

1. Enter Diagnostics mode.

2. Select [DUPLEX TESTS].

3. Select [Duplex Quick Test].

4. Press Return to return to the Diagnostics mode main menu.

There is some variation in the image position from sheet to sheet.
Print three or four test pages at each setting.

3-15

4049-XXX

Transfer

This setting varies the transfer voltage offset slightly. In normal envi­ronments it does not result in a visible difference in the printout. In
extreme environments with unusual papers, this setting may be
helpful. Do not change this setting unless replacing the transfer roll
assembly did not correct the problem.

1. Enter Diagnostics mode.

2. Select [PRINTER SETUP].

3. Select [Transfer].

4. Select [Low], [Medium], or [High].

5. Press Return to return to the Diagnostics mode main menu.

Wrap Tests

The Wrap Tests check the circuits used to communicate with the
host computer.

Note:

directional communication. Contact Lexmark Technical Support for
instructions on running the Parallel Confidence Test.

To run the Wrap Test:

The Parallel wrap test does not test all signals used for bi-

1. Turn the printer off.

2. Disconnect the interface cable.

3. Install the wrap plug in one of the interface cable connectors.

Note:

parallel test or install the 25-pin serial wrap plug part no.
1329048 for the serial test.

4. Enter Diagnostics mode.

5. Select [HARDWARE TESTS].

6. Select [Wrap Test].

7. Select [Parallel] for the parallel port or [Serial] for the 25 pin
serial port.

8. Select [Single] or [Continuous].

9. Select [CANCEL] to stop continuous.

Install the parallel wrap plug part no. 1319128 for the

Diagnostic Aids 3-16

4049-XXX

A [Passed] message indicates the printer connection to the printer
cable connector is good.

A [Failed] message indicates a defective RIP board.

Note:

10. Press Return to return to the Diagnostics mode main menu.

11. Turn the printer off, and remove the wrap plug from the interface

Ignore the number displayed after a failure is displayed.

connector.

Other Tests

Developed Image Test

Use the DevelopedImage Test to isolate print quality problems. You
might have to practice this procedure several times to get the timing
correct.

To run the Developed Image Test:

1. Open the front exit tray.

2. Print the test page.

3. As soon as the leading edge of the paper is visible coming out
the front exit slot, turn off the printer.

4. Remove the print cartridge and look at the image on the photo­conductor.

LAN Information

The printer may be connected to one of the following LAN types:

Token-Ring
Ethernet 10BASE-T
Ethernet 10BASE2
LocalTalk

The printer test page indicates to which type of LAN the printer is
connected.The Network external connectors are shown below.

3-17

4049-XXX

Token Ring Ethernet 10Base2 Ethernet 10BaseT LocalTalk

Print Test Page

You can run the Print Test even if the printer is not attached to a
computer. Use this test to check print and graphics quality and the
version numbers of printer microcode. This test prints from the user­selected default paper tray.

To run the Print Test:

1. Turn the printer on.

2. Select [MENUS].

3. Select [TESTS MENU].

4. Select [Print Test Page].

5. Select either [Single] for one page or [Continuous] for continu­ous test pages.

6. Select [Stop] when you want the continuous test to end.

Print Test with RIP Board Removed

Most meter measurements required during printer service will be on
the engine board connectors, which are inaccessible with the RIP
board in place. The printer has a service mode which allows you to
test the printer without the RIP board installed. This verifies that the
motors, sensors, printhead, and electrophotographic process are
working correctly.In this mode, the operator panel has minimal func­tion; service codes are not displayed and most error-handling is dis­abled (during normal operation these functions are handled by the
RIP board).

Remove the RIP board and the inner EMC shield together and
poweron the printer. The operator panel has one button active which
starts and stops the print test. The test consists of horizontal lines
spaced about an inch apart down the page. This is a continuous
print test; to print a single page press the start button twice.

Diagnostic Aids 3-18

4049-XXX

4. Repair Information

This chapter explains how to make adjustments to the printer and
how to remove defective FRUs.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to
electrostatic discharge (ESD). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual pre­cautions, such as turning off power before removing logic boards:

• Keep the ESD-sensitive part in its original shipping container (a

special “ESD bag”) until you are ready to install the part into the
machine.

• Make the least-possible movements with your body to prevent

an increase of static electricity from clothing fibers, carpets, and
furniture.

• Put the ESD wrist strap on your wrist. Connect the wrist band to

the system ground point. This discharges anystatic electricity in
your body to the machine.

• Hold the ESD-sensitive part by its edge connector shroud

(cover); do not touch its pins. If you are removing a pluggable
module, use the correct tool.

• Do not place the ESD-sensitive part on the machine cover or on

a metal table; if you need to put down the ESD-sensitive part for
any reason, first put it into its special bag.

• Machine covers and metal tables are electrical grounds. They

increase the risk of damage because they make a discharge
path from your body through the ESD-sensitive part. (Large
metal objects can be discharge paths without being grounded.)

• PreventESD-sensitive parts from being accidentally touched by

other personnel. Install machine covers when you are not work­ing on the machine, and do not put unprotected ESD-sensitive
parts on a table.

• If possible, keep all ESD-sensitive parts in a grounded metal

cabinet (case).

• Be extra careful in working with ESD-sensitive parts when cold-

weather heating is used because low humidity increases static
electricity.

4-1

4049-XXX

Adjustments

Envelope Restraint Spring On The Envelope+ Feeder Adjustment

1. Loosen the mounting screw [A].

2. Position the spring [B] so it clears the separator roller by

1.9 ± 0.2 mm ( 0.075 ± 0.008 in.).

3. Tighten the mounting screw.

Paper Restraint Spring On The 100-Sheet Auxiliary Feeder Adjustment

1. Loosen the mounting screw [A].

2. Position the spring [B] so it clears the separator roller by

1.0 ± 0.2 mm ( 0.040 ± 0.008 in.).

3. Tighten the mounting screw.

Repair Information 4-2

4049-XXX

Envelope+ Feeder Magnet And 100-Sheet Auxiliary Feeder Magnet Adjustment

1. Hold the armature [A] in the closed (coil active) position.

2. Loosen the mounting screw [B], and rotate the magnet assem­bly so the armature clears the clutch gear by 0.30 ± 0.20 mm
(0.012 ± 0.008 in.).

3. Tighten the screw.

4. Check the adjustment on both sides of the gear.

4-3

4049-XXX

Dual Rear Feeder Gear Alignment Adjustment

Remove the right side cover of the feeder. The gear timing marks
should be centered in the windows of the gear plate. If the timing
mark is too far clockwise the gears will chatter during a POR. If the
mark is too far counterclockwise, extra sheets may feed at random
times, or paper may feed continuously after the first page is fed.

To adjust:

1. Remove the mounting screw at the front of the torquer.

2. Loosen the mounting screw at the rear of the torquer.

3. Pivot the torquer up to disengage it from the gear.

4. Turn the torquer to its detented position.

5. Position the gear so the timing mark [A] is centered in the win­dow.

6. Pivot the torquer down, install the front screw and tighten the
rear screw, keeping the timing centered in the window.

Repair Information 4-4

4049-XXX

Fuser Drive Gear Backlash Adjustment

Fuser drive gear backlash is adjusted so that when gear #2 is held
still, there is a slight amount of backlash in the fuser gear. Print qual­ity can be affected if the gears are too tight.

1. Remove the fuser cover.

2. Locate gear #2. It is the white adjustable gear mounted to the
side frame below the fuser gear.

3. Rotate the adjustable gear in one direction to check for back­lash.

To adjust backlash:

1. Loosen the nut on the idler stud.

2. Move the idler stud downward in its slot.

3. Insert a 0.95 mm (.037 in.) feeler gage between the gear shoul­ders from the front of the machine. You may need to use an
angled or very small feeler gauge.

4. With the nut snug but not tight, tap the idler upward until the
gage is snug between the gear shoulders.

5. Tighten the locking nut.

6. Check the clearance again; tightening may have altered the
adjustment. Be sure the fuser gear can be rotated slightly when
gear #2 is held still.

4-5

4049-XXX

Fuser Gear

Idler Gear

Right Sideplate

0.95 ± 0.15

.037 ± .006

Stud

Nut

Repair Information 4-6

4049-XXX

Fuser Solenoid Adjustment

Note:

adjustment and should be at room temperature.

.

The fuser solenoid must be mounted on the fuser for this

1. Loosen screw [A].

2. Remove the rubber washer.

3. Rotate shaft [B] (eccentric) to obtain 4.2 mm ± 0.2 mm (0.165
in. ± 0.008 in.) air gap.

4. Tighten screw [A].

5. Replace the rubber washer.

4-7

4049-XXX

Paper Feed Magnet Adjustment

1. Remove thesystem board. The magnet isaccessed through the
holes in the right frame.

2. With the armature latched on the cam step check for0.60 mm ±

0.07 mm (0.024 in. ± 0.003 in.) between the foam pad and the
magnet pole piece. If adjustment is required, continue.

3. Keep the armature latched and loosen the magnet mounting
screw [A].

4. Insert the feeler gauge.

5. Rotate the magnet against the feeler gauge.

6. Tighten the mounting screw.

7. The gauge should pass between the foam pad and the magnet
pole piece with moderate resistance.

Repair Information 4-8

4049-XXX

Printhead Skew Adjustment

1.

+

,Rt,Rt+,andRx:Removethepluginthetopcover.

R, R

+

Open the paper exit stop. Unlatch and remove

L, Lx, and Lx

:

the spring-loaded exit stacker.

2. Loosen the screws [A].

3. Run Print Test 1 or the Quick Test on the Diagnostics Menu.

4. Move the pointer [B] to eliminate the skew. Moving the pointer
toward the left raises the left adjustment point on the printout.
Each mark is equivalent to one dot of the skew adjustment
points.

5. Tighten the screws, and verify the adjustment.

4-9

4049-XXX

Removal Procedures

When there is artwork to support a procedure, it follows the text.

Covers
Right Cover Removal

1. Turn the printer off.

2. Remove all external trays.

3. Open the top cover.

4. Depress the latch and open the right cover.

5. Remove the E-clip from the rear pivot pin and lift the cover off
the rear pivot pin.

Front Cover Removal

1. Unplug the power cord.

2. Remove the paper tray.

3. Open the top cover.

4. Open the right cover.

5. Release the latches [B]. You can reach the lower latches
through the paper tray opening.

6. Lift the right side of the cover to disengage the latch [D].

7. Slide the cover to the right to disengage the bracket from the
posts.

8. Pull the front cover forward and disconnect the ground strap
from the frame on the left side.

Repair Information 4-10

4049-XXX

4-11

4049-XXX

Left Cover Removal

1. Unplug the power cord.

2. Open the top cover and remove the print cartridge.

3. Remove the front cover.

4. Locate the latch [E] and lift the end to release it.

5. Push the top of the cover to the left.

6. Remove the cover by sliding it to the rear of the machine.

Top Cover Removal

+

1.

L, Lx, and Lx

2. Remove the top cover screws [C].

3. Lift the rear of the cover first, then the front, and lift the cover off.

4. Rest the cover on the machine and disconnect the operator
panel cable.

Remove stacker plate by pulling upward.

:

Repair Information 4-12

4049-XXX

4-13

4049-XXX

14 in. 200-Sheet Paper Tray Top Cover

1. Push the tab where the left corner of the tray cover pivots.

2. Move the left tray cover pivot pin forward and then upward.

3. Remove the cover from the tray.

14 in. 500-Sheet Paper Tray Top Cover

1. Remove the two screws which secure the front trim panel.

2. Slide the trim panel to the rear to expose the tray cover pivot
pins.

3. Lift the cover from the tray.

D-roll Assembly Removal

1. Unplug the power cord.

2. Remove the paper tray.

3. Remove the print cartridge.

4. Remove the fuser input guide.

5. Remove the transfer roll housing assembly.

6. Pull the D-roll firmly to the left to remove it.

Note:

removed for any reason it should be replaced with a new one. It may
take considerable force to install the new D-roll.

The D-roll is designed to be installed only once; if it is

Drive Motor Removal

1. Unplug the power cord.

2. Remove the RIP board and inner EMC shield together.

3. Remove the engine board.

4. Remove the fuser input guide.

5. Remove the transfer housing assembly.

6. Remove the gear coverby releasing the rear latch and lifting up.

7. Remove the motor mounting nuts [B] and screws [D].

8. Work the motor out of the machine.

Repair Information 4-14

4049-XXX

Engine Board Removal

1. Check the page count and write it down so you can set the
count on the new engine board.

2. Turn the printer off.

3. Remove the RIP board and the inner EMC shield together.

4. Disconnect the engine board cable connections.

5. Remove the nut and the three threaded standoffs.

6. Unsnap the board from the plastic standoff.

4-15

4049-XXX

Exit Sensor Board Removal

1. Remove the front cover.

2. Disconnect the fuser/sensor cable.

3. Disconnect the thermistor cable.

4. Disconnect the fuser solenoid cable.

5. Release the latches [A].

6. Pull the sensor board down to remove it.

Repair Information 4-16

4049-XXX

Fan/Redrive Removal

1. Open the top cover.

2. Remove the print cartridge.

3. Remove the top cover.

4. Remove the lower redrive shaft by disengaging the right end to
the rear of the machine.

5. Disconnect the long redrive belt [A] and slip it off the lower
shaft.

+

Disconnect the output bin sensor cable.

6.

L, Lx, and Lx

7. Remove the redrive assembly screws [D].

8. Remove the plenum assembly and screws [B].

9. Unplug the fan cable.The fan [C] can now be removed from the
plenum assembly.

:

4-17

4049-XXX

Fuser Removal

Note:

careful when you remove or replace the fuser unit.

CAUTION:

230°C (302°- 446°F). USE EXTREME CAUTION WHEN REMOV­ING THIS UNIT. BEFORE YOU SERVICE THIS UNIT, ALLOW THE
MACHINE TO COOL FOR 5 MINUTES.

The heater lamp is fragile and maybe damaged if you are not

THE TEMPERATURE OF THE HOT ROLLER IS 150°-

1. Unplug the power cord.

2. Remove the printer cartridge.

3. Through the opening for the paper output, flip the metal ESD
shield up out of the way, and disconnect the exit sensor cable
from the fuser.

4. Remove the fuser cover.

5. Disconnect the power wires [A] from the left side of the fuser.

6. Remove the fuser input guide.

7. Completely loosen the four fuser mounting screws.

8. Lift the fuser out of the machine.

Repair Information 4-18

4049-XXX

Fuser Input Guide Removal

1. Remove the fuser input guide [B] by lifting the rear end of the
guide and unsnapping both sides from the fuser.

2. Lift the fuser input guide upward at both sides near the fuser
and slide the guide toward the rear of the machine to release.

3. Lift the guide out of the machine.

4. Clean the fuser input guide before installing it.

4-19

4049-XXX

Fuser Lamp Removal

CAUTION:

230° C (302-446°F). USE EXTREME CAUTION WHEN REMOV­ING THIS UNIT. BEFORE YOU SERVICE THIS UNIT, ALLOW THE
MACHINE TO COOL FOR 5 MINUTES.

Note:

your hands; skin oils and acids can reduce the life of the heater
lamp. Use a soft cloth to handle the heater lamp at all times if the
lamp is to be reinserted.

1. Remove the fuser.

2. Remove the right lamp bracket [A].

3. Carefully pull the lamp [B] out to the right, using a soft cloth if
the lamp is to be reinserted.

Install the new lamp with the color-coded end away from the
gear.

THE TEMPERATURE OF THE HOT ROLLER IS 150-

The fuser lamp is a glass heater. Do not touch the lamp with

Repair Information 4-20

4049-XXX

Fuser/Sensor Cable Removal

1. Turn the printer off.

2. Remove the RIP board and the inner EMC shield together.

3. Disconnect the cable from the exit sensor board.

4. Remove the front cover.

5. Disconnect the cable from the paper sensor assembly.

6. Remove the cable through the right frame.

4-21