Lexmark Optra K 4046 Service Manual Download | Manualshive

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Second Edition (October 1998)

The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS
PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not
allow disclaimer of express or implied warranties in certain transactions, therefore, this
statement may not apply to you.

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

A form for reader’s comments is provided at the back of this publication. If the form has
been removed, comments may be addressed to Lexmark International, Inc., Department
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 and Optra are trademarks of Lexmark International, Inc., registered in the United
States and/or other countries.

Other trademarks are the property of their respective owners.

© Copyright Lexmark International, Inc. 1998. All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

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Summary of Contents for Optra K 4046

Page 1: ...k OptraTM K Lexmark and Optra are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start Diagnostics Manuals Menu ...

Page 2: ...blications should be made to your point of purchase A form for reader s comments is provided at the back of this publication If the form has been removed comments may be addressed to Lexmark International Inc Department 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 incurrin...

Page 3: ... 2 Service Error Code Table 2 3 User Error Messages 2 5 Symptom Table 2 8 Service Checks 2 9 Cover Open Switch Service Check 2 9 Dead Machine Service Check 2 10 Engine Fan Service Check 2 11 Erase LED Service Check 2 11 Exit Sensor Service Check 2 12 Fuser Service Check 2 13 Image Quality Service Check 2 13 Main Motor Service Check 2 20 Input Sensor Service Check 2 21 Operator Panel Buttons Servic...

Page 4: ... Memory Test 3 6 Parallel Wrap Test 3 7 Serial Wrap Test 3 8 Input Tray Tests 3 10 Input Tray Feed Test 3 10 Input Tray Sensor Test 3 10 Base Sensor Test 3 11 Print Registration 3 11 Printer Setup 3 12 Setting the Page Count 3 12 Viewing the Permanent Page Count 3 13 Setting Configuration ID 3 13 Print Tests 3 14 Print Quality Test Pages 3 14 Printing Menu Settings Page 3 15 Paper Jams Base Printe...

Page 5: ...Supply Board Removal 4 25 Print Density Board Removal 4 26 Printhead Removal 4 27 Printhead Erase LED Assembly Removal 4 27 Process Fan Removal 4 28 Separator Assembly Removal 4 30 Stacker Full Sensor Board Removal 4 31 Transfer Corona Removal 4 32 Locations 5 1 Front and Right Side of Printer 5 1 Rear and Left Side of Printer 5 2 Interior of Printer with Upper Door Open 5 3 Optional Multi Functio...

Page 6: ...Feed Redrive 6 16 Exit Paper Feed Frame 6 18 Fuser 6 20 Paper Tray 250 Sheet 6 22 Optional 450 Sheet Second Paper Tray 6 24 Optional 450 Sheet Second Paper Drawer 2 6 26 Optional 450 Sheet Second Paper Drawer 2 6 28 Optional Multi Function Feeder 6 30 Index x 1 ...

Page 7: ...h 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 else where is certified as a Class I laser product conforming to the requirements of IEC 825 Class I laser products are not considered to...

Page 8: ...viii Service Manual Laser Advisory Label Label is inside printerl Class 1 Laser Statement Label Label is on back of printer ...

Page 9: ...icht 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 u...

Page 10: ...e 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 afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal el mant...

Page 11: ...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 b...

Page 12: ...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 käy...

Page 13: ...son 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 farl...

Page 14: ...ctes 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 normal durant les tasqu...

Page 15: ...Notices and Safety Information xv Chinese Laser Notice Korean Laser Notice ...

Page 16: ...our 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 ...

Page 17: ...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 e...

Page 18: ...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 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 Lexma...

Page 19: ...Notices and Safety Information xix ...

Page 20: ...xx Service Manual ...

Page 21: ... and repair the failure After you complete the repair perform tests as needed to verify the repair Tools The removal and adjustment procedures described in this manual require the following tools and equipment Magnetic tip Phillips screwdrivers large and small Flat blade screwdriver Analog volt ohmmeter a digital volt ohmmeter may also be used Needle nose pliers When you make voltage readings alwa...

Page 22: ...ASER 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 Stor...

Page 23: ...he pick up motor drives the pick up roller in the printer or in the multi function feeder The rotating direction of the motor determines which roller will be selected The paper feed motor drives the paper feed roller The main motor drives the fuser the paper exit roller and the redrive roller ...

Page 24: ...1 4 System Diagram The central processing unit CPU in the main controller controls the entire printer and the data received from the interconnect ...

Page 25: ...per feeder roller print unit fuser exit roller and redrive roller until the paper passes through 4 When the mechanism controller detects the bottom edge of the paper by the paper exit sensor it stops both motors The printer then waits for the next command Paper Feed Drive Mechanism The main motor and the gear train are mounted on the metal frame The power of the pick up motor gear is distributed t...

Page 26: ...1 6 is transmitted to the paper feed roller ...

Page 27: ...ser and the paper eject roller The power of the motor is transmitted to the print unit through gears A B C and D and to the hot roll of the fuser through gears A B C E and F Print Unit The print unit consists of a photoconductive drum OPC drum pre charger assembly developer assembly recycle screw and toner agi tator ...

Page 28: ...he backup roller The hot roll has a halogen lamp hot roll temperature sensor ther mal fuse and supporting parts The back up roller rotates with the hot roll Paper Ejection Paper is ejected either through the rear stacker or the upper exit bin When the stacker is folded down paper exits the rear of the printer and rests on the rear stacker When the stacker is in an upward posi tion it guides paper ...

Page 29: ...General Information 1 9 to the upper exit bin Roller gears receive power from the hot roll gear ...

Page 30: ...1 10 ...

Page 31: ...s and the diagnostic aids chap ter to determine the symptom and repair the failure After you com plete the repair perform the appropriate tests to verify the repair If an error is displayed locate it in the following Operator Error Mes sage Table or the Service Error Message Table and take the appro priate action If an error message appears while you are working on the machine go to the error mess...

Page 32: ...emperature is between 10 and 32 C 50 and 90 F and the relative humidity between 20 and 80 Avoid sites generating ammonia gas high temperature or high humidity near water faucets kettles humidifiers cold spaces near open flames and dusty areas Avoid sites exposed to direct sunlight Print Paper Checks Be sure the recommended paper for this printer is being used Check the paper for dampness Make a tr...

Page 33: ...ed correctly If you don t find a problem replace the controller board If you still have a problem replace the engine board The controller software can also cause this error code Contact your next level for soft ware support 941 RIP Code CRC Replace the controller board 941 RIP Font CRC Replace the controller board 943 RIP Font Version The RIP code and font ROM are incompati ble 944 RIP Card Failur...

Page 34: ...rror Indicates a failure with the Download Emula tion programmed into the code overlay SIMM The specific errors are 964 Download Emulation CRC Failure Checksum failure detected 965 Download Emulation outdated Go to Disabling Download Emulations on page 3 4 975 979 Network Card Indicates a failure with the network card Replace the network card The specific errors are 975 Unrecognizable network card...

Page 35: ...fficult to remove then you may have to remove the tray above or below to remove the jammed pages Insert Tray X The printer is requesting the operator to insert tray X in order to continue printing the job Insert tray X Change Tray X The printer is requesting the operator to insert tray X with a specific type size of paper Insert the correct tray with the paper type size specified If the correct tr...

Page 36: ... 300 dpi to prevent a Memory Full error This message can only occur if the Resolution Reduction setting is turned on Note 1200 dpi pages are not resolution reduced If a 1200 dpi job runs out of memory a Memory Full error is displayed 37 Insufficient Collation Memory This message is displayed when the printer memory used to store pages is too full to collate the print job 38 Memory Full This messag...

Page 37: ...ort has been disabled 56 Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset 61 Defective Disk This error code is displayed when the printer detects a defective disk This error may o...

Page 38: ...atically Symptom Action Engine Fan Failure Go to the Engine Fan Service Check on page 2 11 Process Fan Failure Go to the Process Fan Service Check on page 2 27 Operator panel is unresponsive or doesn t display any or all characters Go to the Operator Panel Dis play Service Check on page 2 22 Paper Feed or Paper Jam Problems Go to the Paper Feed Service Check on page 2 24 Fuser Problems Go to the F...

Page 39: ...e 2 13 Blurred Print Go to Image Quality Service Check on page 2 13 Evenly Spaced Horizontal Marks or Lines Go to Image Quality Service Check on page 2 13 Malfunctions with Options Go to the Options Service Check on page 2 23 Standard Output Bin Problems Go to the Standard Bin Full Sensor Service Check on page 2 27 FRU Action 1 Cover Open Switch Be sure the cover open switch is properly installed ...

Page 40: ...ine Check the exit sensor flag for correct operation The printer will not turn on unless the flag is pass ing through the sensor Check the connector pins on the interconnect board where the power supply plugs in These pins may be bent 4 Controller Board Remove the controller board Turn the printer on If the Ready LED comes on turn off the printer Remove any options plugged into the controller boar...

Page 41: ...ect Replace the FRU causing the change in voltage If the voltage is still incorrect replace the following FRUs in the order shown 1 LVPS 2 Interconnect board 3 HVPS 4 Engine board FRU Action 1 Engine Fan Be sure the engine fan turns on during POST If it does not be sure the fan is connected properly Check the voltage on the engine board between CNF2 1 and CNF2 2 If the voltage is 24 V dc replace t...

Page 42: ...rect position and operation The flag should protrude upward into the paper path and swing to a downward position as the paper passes over it The opposite end of the flag should rest in the exit sensor while the flag is in the upward position and move out of the sensor as the paper pushes the flag Replace the flag if nec essary 2 Power Supply Board The exit sensor is mounted to the power supply boa...

Page 43: ...cable at the LVPS and at the thermal fuse Be sure the lamp is not burned out or broken Check the thermal fuse for conductivity If the ther mal fuse conducts no current replace the fuser If the connections are correct the lamp is good and the thermal fuse is good Replace the following FRUs in the order shown 1 LVPS 2 Engine Board 2 920 Fuser Error Lamp does turn on Check the fuser for signs of exce...

Page 44: ... on the print unit for dirt or damage Clean the wire with the cleaning tool provided with the printer If the wire has come loose from the print unit the customer must replace the print unit 2 HVPS Check the HVPS contacts on the HVPS board and the mating contact springs on the left side of the printer for pitting or incorrect alignment Cables from the pick roller motor and cover open switch can get...

Page 45: ...e cially the PC drum and contacts Also check the precharger wire for damage Clean the wire with the cleaning tool provided with the printer 4 Contact Springs HVPS Check the HVPS contacts on the HVPS board and the mating contact springs on the left side of the printer for pitting or incorrect alignment Cables from the pick roller and cover open switch could also be in the way of the contacts 5 Engi...

Page 46: ...r pit ting cable interference or incorrect installation Clean if necessary Check the voltages on the engine board at the fol lowing locations Printer Idle CNMC B10 24 V dc CNMC B11 17 V dc CNMC A11 20 5 V dc CNMC B12 0 1 V dc Printer Printing CNMC B10 0 1 V dc CNMC B11 0 1 V dc CNMC A11 0 1 V dc CNMC B12 momentarily jumps up to 5 15 V dc If these voltages are not correct replace the engine board I...

Page 47: ...ng is selected for the paper being used Background can also be caused by an incorrect setting on the print darkness control The customer may try to improve the print quality by adjusting the print darkness dial FRU Action 1 Erase LED Assembly Check the erase LED for signs of paper dust toner build up or other contamination Clean with a soft cloth or replace the erase LED assembly When the erase LE...

Page 48: ...cross the corona hous ing Replace the corona if the wire is broken stretched or loose See also the Transfer Corona Service Check on page 2 29 4 Contact Springs Engine Board HVPS Intercon nect Board Check the contact spring and HVPS contact for pit ting cable interference or incorrect installation Clean if necessary Check the voltages on the engine board at the fol lowing locations Printer Idle CNM...

Page 49: ...rona for toner buildup or loose toner Toner in this area can usually be cleaned from the printer Replace the transfer corona if it is excessively contaminated or if you cannot clean it See also the Transfer Corona Service Check on page 2 29 3 Print Unit Check the precharger wire on the print unit for dirt or contamination Clean the print unit with the tool provided with the printer Check the PC dr...

Page 50: ...sed by a gear in the fuser Check the fuser gears for con tamination or damage Replace the fuser if necessary FRU Action 1 Engine Board Main Motor Be sure the main motor cable is connected prop erly Replace it if it is damaged Disconnect the main motor cable and check the voltage on the following connectors on the engine board CNMM 1 24 V dc CNMM 2 24 V dc If the voltages are correct replace the ma...

Page 51: ...or circuit will cause the first copy to exit only partially through the fuser assembly FRU Action 1 Input Sensor Flag Check the input sensor flag for proper position and operation The flag is visible if you open the manual feed tray The position of the flag should be in the paper path such that when printing the paper pushes the flag down Replace the flag if it is dam aged 2 Input Sensor The input...

Page 52: ...it is incorrect replace the engine board If it is correct check the continuity of the operator panel cable If the continuity is not correct replace the cable If the cable is good replace the operator panel FRU Action 1 Operator Panel If the operator panel failed the LCD Test replace it 2 OperatorPanel Cable Be sure the cable is properly connected to the engine board CNOP and the operator panel Che...

Page 53: ...d Run the DRAM Memory Test on page 3 6 If the test fails replace the DRAM SIMM If the problem continues replace the controller board Hard Disk Option Be sure the fixed disk and the fixed disk board are correctly installed Run the Quick Disk Test on page 3 2 The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If the problem remains replac...

Page 54: ...er vice Check on page 2 20 Locate your symptom from the following information and perform the check Pick Roller Fails to Pick Paper FRU Action 1 Pick Roller Check the pick roller for wear scratches or rough spots Replace if necessary 2 Pick Motor Watch the motion of the pick motor as you try to print a test page If the motor does not turn check the print motor connector at the interconnect board I...

Page 55: ...y with little resistance If you slide your hand toward the rear of the printer the pick roller should resist rolling and cause the pick motor to turn FRU Action 1 Paper Path Open the upper door remove the print unit and check for loose debris in the paper path Clean as necessary 2 Input Sensor Go to the Input Sensor Service Check on page 2 21 3 Paper Feed Roll Check the paper feed roll for wear an...

Page 56: ...ffer ent locations and directions and using rough paper and short grain paper can also cause double feeding Parallel Port Service Check Run the Parallel Wrap Test on page 3 7 Use wrap plug P N 1319128 This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately 3 seconds If the test indicates a problem replace the contr...

Page 57: ...r the diagnostic mode and test the standard bin full sensor with the Base Sensor Test on page 3 11 Use the following checks to further isolate the problem 2 Engine Board Disconnect the printhead cable and check the volt age on the engine board at the following locations OPT 1 24 V dc OPT 2 24 V dc OPT 9 Ground OPT 13 Ground OPT 16 5 V dc OPT 19 5 V dc OPT 20 Ground FRU Action 1 Process Fan Be sure...

Page 58: ...e sensor FRU Action 1 Standard Bin Full Sensor Sensor Cable Engine Board Check the flag for damage or improper operation If incorrect replace the sensor Disconnect the sensor cable from the sensor and print a test page If the Remove Paper Standard Bin message does not appear and the test page prints successfully replace the sensor Disconnect the sensor cable from the engine board Attempt another t...

Page 59: ...ge is correct check the voltage at CNTN 3 If it is not ground replace the engine board If the voltages are correct replace the toner sensor FRU Action 1 Transfer Corona Check the transfer corona assembly for signs of toner buildup and contamination Use the cleaning tool provided with the printer to clean the wire Check the wire for damage The wire should be positioned across the corona hous ing Re...

Page 60: ...2 30 ...

Page 61: ...de To enter the Diagnostic Mode 1 Turn the printer off 2 Press and hold the Go and Return buttons 3 Turn the printer on 4 Release the buttons when Performing Self Test displays on the operator panel The tests display on the operator panel in the order shown Device Tests Print Registration Print Tests Hardware Tests Input Tray Tests Base Sensor Tests Printer Setup Error Log Exiting the Diagnostic M...

Page 62: ...e the engine has warmed up the main motor and fans stop turning 10 Ready appears on the display Device Tests Quick Disk Test This test performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the dis...

Page 63: ...ator flashes during the test The test can be can celed anytime during the test by pressing Return or Stop Once the test is complete the busy indicator turns on solid and a message displays xxxx Bad Blocks yyyyyy Usable message displays if fewer than 2000 bad blocks are detected xxxx indicates the num ber of bad blocks and yyyyyy indicates the number of usable blocks xxxx Bad Blocks Replace Disk me...

Page 64: ... without activating any download emulations To Disable the Download Emulation 1 Turn the printer off 2 Press and hold the Go and Menu buttons 3 Turn the printer On and release the buttons once Performing Self Test displays Once the printer is idle the emulation can be downloaded again 4 Program the download emulation into the code overlay SIMM again 5 If these steps do not resolve the problem repl...

Page 65: ... Log Clearing the Error Log To clear the Error Log 1 Select Clear Log from the Error Log menu 2 Select YES to clear the Error Log or NO to exit the Clear Log menu If YES is selected the Empty Error Log displays on the screen 3 Press Return or Stop to exit the Clear Log menu Hardware Tests The following Hardware Tests can be selected from this menu LCD Test Button Test DRAM Memory Test ROM Memory T...

Page 66: ...s indicating the test is in progress 2 Press Return or Stop to exit the test P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum p...

Page 67: ... This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interconnect cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the Hardware Tests menu The busy indicator flashes indicating the test is in progress The test runs continuously until canceled Each t...

Page 68: ... Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug Each signal is tested To run the Serial Wrap Test 1 Disconnect the serial interconnect cable and install the serial wrap plug 2 Select the appropriate Serial Wrap Test from the menu Serial Wrap Serial 1 Wrap The busy indicator flashes indicating the test is running P represents the number of ti...

Page 69: ...reases by 1 Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum cou...

Page 70: ...e selected source until Return or Stop is pressed 4 Press Return or Stop to exit test Input Tray Sensor Test This test is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 Select the Sensor Test from the Input Tray Tests menu 2 Select the input source from the sources displayed on the Sen sor Test Menu Input Tray EM xx Size xxx displays EM Input ...

Page 71: ...Manually toggle the sensors by hand to verify that each sensor switches from open to closed The standard bin sensor requires about six seconds to activate 3 Press Return or Stop to exit the test Print Registration The print registration range is as follows Bottom Margin 7 to 8 Top Margin 20 to 20 Left Margin 23 to 23 Manual Top 20 to 20 To set Print Registration 1 Select Registration from the Diag...

Page 72: ...from the diagnostic menu This is used whenever the engine board is replaced because this board contains the printer s NVRAM Memory where the page count is stored To set the Page Count 1 Select Page Count from the Diagnostic menu The current page count displays The leftmost digit flashes indicating it is the first digit to be changed 2 Press either Menu or Menu until the value you want displays 3 P...

Page 73: ...e Printer Setup menu The current ID displays on the screen The Configuration ID for the 4046 001 is 000303 The ID code for other models with different configurations is on a label located on the con troller board cage Remove the right cover and open the card cage to see the label The leftmost digit flashes indicating that it is the first digit to be changed 2 To change the value press either Menu ...

Page 74: ...t Tests from the Diagnostic menu 2 Select the media source 3 Select Single or Continuous If single is selected no buttons are active during printing If continuous is selected Return or Stop can be selected to cancel the test Check each Test Page from each source to assist in Print Quality and Paper Feed problems Print Quality Test Pages The purpose of this diagnostic function is to allow printing ...

Page 75: ...level margin settings smart option code levels font versions and so on Values for the Quality Menu settings used to print the pages Printing Menu Settings Page Note This test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Select the TESTS MENU 2 Select Print Menus from the TESTS MENU The page contains the following information A list of all the printer settings ...

Page 76: ...ng in the fuser assembly prior to activating the exit sensor flag in time or not at all Error Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at the printer exit sen sor This can be caused by the paper arriving at the sensor too late the paper is jammed in the fuser assembly or is jammed exiting the fuser assembly in the redrive assembly Paper Jams Options Error Mes...

Page 77: ... while after the printer stops running Always unplug connectors by holding the connector housing Be sure to use the fuse of the specified rating Do not forget to install the ground wire or ground plate to ensure positive conduction Install the screw with a toothed washer in the right position at reassembly Instructions for Handling the PWBs with MOS ICs The following precautions must be observed w...

Page 78: ...r elec trical components on the board be sure to ground your body Precautions for Handling the Drum Cartridge The following precautions must be observed when handling the drum cartridge During Transportation Storage Use the specified carton whenever moving or storing the drum cartridge The storage temperature is in the range between 20 C and 40 C Handling The PC drum in the drum cartridge exhibits...

Page 79: ...rtridge be sure to turn the printer off first A highly reflective tool can be dangerous if it is brought into the laser beam path Use utmost care when handling tools around the laser beam If the job requires that the printer be left on take off your watch and ring and wear laser protective goggles which must meet the following laser specifications Max power 5mW Output wavelength 780 810nm ...

Page 80: ...ht side cover 2 Remove the outer shield 3 Disconnect the controller board cable from J4 4 Remove the two parallel port screws 5 Remove the back connector panel cover 3 screws 6 Remove the 5 screws that hold the controller board in place 7 As you remove the controller board tilt the top of the board away from the printer in order to clear the inner shield ...

Page 81: ...Repair Information 4 5 Cover Removal 1 Open the upper door 2 Remove the three screws from the upper cover 3 Remove the rear cover 1 screw ...

Page 82: ...ght side covers 5 Use a screwdriver to release the latches on the left side of the upper cover as you lift the cover upward As you lift the cover disconnect the print density cable and operator panel cable from the operator panel ...

Page 83: ...2 Disconnect the cover open switch connector 3 Disengage the two latches of the left guide and pull the left guide upward to remove it 4 Remove the cover open switch Installation Note When you install the new switch place the switch in the left guide then carefully slide the guide along the metal frame into position ...

Page 84: ...e the engine board from the printer and disconnect the lower control board cable connectors CNCA and CNCB Installation Notes 1 There is a connector on the back side of the engine board which connects the interconnect board When you install the engine board position it so the engine board connector faces the inter connect board connector 2 The white connector with red and blue cables connects to th...

Page 85: ... controller card door assembly 3 Remove the fan shield plate 4 Disconnect the engine fan and pull the cable through the toroid 5 To remove the fan lift it at an angle as you press the lower mounting plate down with a screwdriver Installation Note Install the fan so the air flow arrow is facing up ...

Page 86: ...cess fan plate assembly 2 screws 6 Remove the six gears 7 Remove the right side paper feed frame 8 Remove the exit paper feed roller assembly Installation Note 1 To prevent damage to the pick motor cable and cover open switch cable be sure they are placed above the interconnect card 2 Return the gears to the original position and install the process fan plate assembly to hold them in place 3 Be su...

Page 87: ...s from the rear of the machine and slide the fuser and power sup ply board assembly out the rear of the printer Be careful not to damage the pick motor cable when removing the fuser and power supply board assembly 7 Disconnect the two connectors from the power supply board 8 Turn the fuser assembly bottom side up and remove the six screws from the power supply board lifting the power supply board ...

Page 88: ... Interconnect Board Removal 1 Remove the paper tray 2 Remove the right side cover and the control board cage door 3 Remove the engine board 4 Remove the four screws from the bottom of the printer to remove the interconnect board HVPS assembly ...

Page 89: ...rd observe the order of fastening screws as shown above 2 When you install the high voltage power supply interconnect board assembly be careful the cable does not overlap the four spring electrodes on the bottom left of the printer mechanism 3 As you install the HVPS interconnect board assembly be sure the interconnect board connects into the power supply board Be sure to match the four screw posi...

Page 90: ...oval 1 Remove the right side and upper cover 2 Open the controller board cage door assembly 3 Remove the fan shield plate 4 Remove the engine cooling fan 5 Remove the engine board 6 Remove the main motor assembly 4 screws ...

Page 91: ...Repair Information 4 15 7 Remove four screws and disconnect the cable to remove the main motor ...

Page 92: ...4 16 Multi Function Feeder Board Removal 1 Remove the right side cover 2 Disconnect the cable from the MFF board 3 Remove the board 1 screw ...

Page 93: ...pen the controller board cage door assembly 3 Disconnect the controller board cable and remove the controller board door assembly 4 Remove the engine board 5 Remove the fan shield plate 6 Remove the fixed hinge bracket 7 Remove the 2 mounting screws and pull out the paper feed motor ...

Page 94: ...ector to remove the upper front cover assembly 3 Remove the right and left springs and lift the upper feed roll from the paper feed frame 4 Peel off the two guide sheets Mylar films Be sure to com pletely remove the double sided adhesive tape 5 Use a screwdriver to disengage the bearing phase shift levers at both ends of the lower feed roll and raise the lever upward to ...

Page 95: ...tion 4 19 remove the lower feed roll 6 Use diagonal cutting pliers to cut the hook off the gear at the right end of the lower feed roll 7 Move the lower feed roll to the left and pull out the roller from the left end ...

Page 96: ... left end the end without a D cut of the lower feed roll c Insert the bearings into guide grooves on the base frame with the bearing phase shift levers set upward Turn the bearing levers to the initial state positions to secure the bear ings to the base frame 2 Adhere new guide sheets to the base frame longer one to the left area and shorter one to the right area Be sure there is no clearance betw...

Page 97: ...Repair Information 4 21 ...

Page 98: ...otor Removal 1 Remove the paper tray 2 Remove the left side cover 3 Remove the left paper tray guide assembly 4 Remove the interconnect board and high voltage power supply assembly 5 Remove the pick up motor 2 screws ...

Page 99: ...ove the left side cover 3 Remove the screw from the pick up roller shaft ground plate and remove the ground plate 4 Use a screwdriver to remove the bearing 5 Pull the pick up roller shaft out approximately 50 mm to remove the pick up roller Do not pull the shaft out completely ...

Page 100: ...4 24 Installation Note When you put the pick up roller on the shaft face the tapered rib of the roller toward the pick up motor ...

Page 101: ...move the fuser and power supply board assembly 4 Turn the assembly upside down 5 Remove the six screws that hold the power supply board in place 6 Disconnect the two fuser connectors then the sensor board connector and remove the power supply board Installation Note To prevent damage to the pick motor cable and cover open switch cable be sure they are above the interconnect card ...

Page 102: ...4 26 Print Density Board Removal 1 Remove the control board 2 Remove the fan shield plate Remove the print density board from the bottom of the frame 1 screw ...

Page 103: ...nthead assembly 3 screws Printhead Erase LED Assembly Removal 1 Remove the upper cover 2 Remove the printhead 3 Open the controller card door assembly 4 Disconnect the printhead erase LED assembly cable from the engine card 5 Pull the ends of the printhead erase LED assembly forward to unlatch it from the frame assembly 6 Remove the printhead erase LED assembly ...

Page 104: ...4 28 Process Fan Removal 1 Remove the fuser and power supply assembly 2 Remove the fan from the side of the assembly 2 screws ...

Page 105: ...Repair Information 4 29 Installation Note Install the fan so the air flow arrow is to the outside ...

Page 106: ... down push in the two separator assembly latches and remove the separator assembly Be care ful not lose the spring Installation Note Be sure to install the separator so the rubber sur face is toward the front of the drawer Paper will not feed if the sepa rator is not installed correctly ...

Page 107: ...Repair Information 4 31 Stacker Full Sensor Board Removal 1 Remove the upper cover 2 Remove the cable from the stacker full sensor 3 Remove the board 1 screw ...

Page 108: ...int assembly 3 Use a screwdriver to remove the transfer corona holding block at the left side of the transfer corona 4 Open the latch on the left side of the base frame and use a screwdriver to lift the left side of the transfer corona then pull it toward the left side Be careful not to break the wire ...

Page 109: ...Locations 5 1 5 Locations Front and Right Side of Printer ...

Page 110: ...5 2 Rear and Left Side of Printer ...

Page 111: ...Locations 5 3 Interior of Printer with Upper Door Open ...

Page 112: ...Locations 5 4 Optional Multi Function Feeder and Paper Feeder ...

Page 113: ...Locations 5 5 Sensors ...

Page 114: ...5 6 EP Diagram ...

Page 115: ...Locations 5 7 Engine Board ...

Page 116: ...Locations 5 8 Control Board ...

Page 117: ...Locations 5 9 Power Supply Board ...

Page 118: ...5 10 Interconnect Board ...

Page 119: ...ded for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the Description column indicates that the part is contained in a parts packet A part reference within...

Page 120: ...6 2 Assembly 1 Upper Cover ...

Page 121: ...202 1 Door Top Cover 3 11A4203 1 Hinge Door Outer Left 4 11A4204 2 Hinge Door Inner 5 11A4205 1 Hinge Door Outer Right 6 3 Screw PP 12A4039 7 11A4208 1 Control Panel with English Overlay 7 11A4209 1 Control Panel Overlay W T Kit 8 11A4210 1 Cable Operator Panel 9 11A4211 1 Cable Print Density ...

Page 122: ...6 4 Assembly 2 Covers ...

Page 123: ...nits Description 2 1 11A4207 1 Filter Ozone Top Cover 2 11A4212 1 Cover Left 3 11A4213 1 Cover Right 4 11A4214 1 Cover Rear Center 5 1 Screw PP 12A4039 6 11A4215 1 Stacker Rear 7 11A4216 1 Guide Rear Stacker 8 11A4218 1 Cover Lower Front ...

Page 124: ...6 6 Assembly 3 Electronics ...

Page 125: ...ica Ecuador El Salvador Guatemala Honduras Nicaragua Panama Peru Venezuela Brazil LV HV Mexico 10 1339520 1 Austria Germany Belgium France Netherlands Norway Spain Finland Turkey Iceland Eastern Countries Greece Portugal 10 1339525 1 Denmark 10 1339524 1 Italy 10 1339522 1 Switzerland 10 1339519 1 U K Ireland VAE Bahrain Qatar Jordan Oman Iraq Kuwait Yemen Egypt Sudan 10 1339521 1 Israel 10 133951...

Page 126: ...6 8 Assembly 3 Electronics cont ...

Page 127: ...30 1 Shield Assembly Inner With Insulators 26 12A4041 1 Card Assembly PCI Bus Interconnect 27 2 Screw PP 12A4039 28 2 Screw PP 99A0426 29 2 Screw PP 12A4039 30 11A4341 1 Cover Back Connector Panel 31 99A0236 1 Cover INA Blank 32 6 Screw PP 12A4039 33 11A4401 1 Shield Assembly Outer 34 5 Screw PP 12A4039 35 12A4035 1 Cable Control to Engine 36 11A4337 1 Board Control With Cable 37 11A4334 1 Cable L...

Page 128: ...6 10 Assembly 4 Frame Left Side ...

Page 129: ...0 1 Gear MFF C PP 12A4036 11 1 Gear MFF D PP 12A4036 12 1 Gear MFF E PP 12A4036 13 2 Screw PP 12A4039 14 11A4348 1 Foot Rubber 15 3 Screw PP 12A4039 16 3 Screw PP 12A4039 17 2 Screw PP 12A4039 18 11A4418 1 Guide Print Unit Left 19 11A4419 1 Label Print Unit Left Install 20 11A4423 1 Switch Cover Open 21 11A4400 1 Plate Ground 22 1 Screw PP 12A4039 23 11A4313 1 Guide Assembly Paper Tray Left 24 12A...

Page 130: ...6 12 Assembly 5 Frame Right Side ...

Page 131: ...able Paper Size Sensor 7 1 Screw PP 12A4039 8 11A4407 1 Lever Paper Tray Lock 9 11A4408 1 Spring 10 11A4410 1 Motor Main 11 11A4411 4 Damper Main Motor 12 11A4412 1 Bracket Assembly Main Motor 13 4 Screw PP 12A4039 14 1 Gear Main Motor MA PP 12A4036 15 1 Gear Main Motor MB PP 12A4036 16 11A4413 1 Cable Main Motor 17 4 Screw PP 12A4039 18 11A4414 1 Fan Engine Cooling 19 12A4044 1 Guide Print Unit R...

Page 132: ...6 14 Assembly 6 Input Paper Feed ...

Page 133: ... PP 12A4039 16 12A4047 1 Motor Paperfeed 17 11A4285 1 Bracket Pick Motor Mount 18 1 Gear Pick Motor PP 12A4038 19 2 Screw PP 12A4039 20 11A4286 1 Shaft Assembly Pick Roller 21 1 Gear Pick Roller PP 12A4038 22 11A4287 1 Pick Roller 23 11A4271 2 Bearing Pick Roller 24 11A4289 1 Rack Paper Feed Guide 25 11A4290 1 Guide Paper Left 26 11A4291 1 Guide Paper Right 27 11A4292 1 Gear Paper Feed Guide Rack ...

Page 134: ...6 16 Assembly 7 Printhead and Paper Feed Redrive ...

Page 135: ...229 1 Cover 4 3 Screw PP 12A4039 5 11A4231 1 Label Caution 6 11A4311 1 Paper Feed Redrive Exit Assembly 7 11A4314 2 Roller Redrive 8 11A4315 2 Holder Roller 9 11A4317 1 Guide Roller 10 11A4300 1 Roller Assembly 11 1 Gear 6 Lower PP 12A4038 12 1 Gear 7 upper PP 12A4038 13 11A4319 1 Belt Timing 14 11A4320 1 Cover Gear ...

Page 136: ...6 18 Assembly 8 Exit Paper Feed Frame ...

Page 137: ...00 1 Roller Assembly Exit Paper Feed 10 11A4301 1 Frame Right Side 11 11A4302 1 Frame Left Side 12 6 Screw PP 12A4039 13 11A4303 1 Guide Assembly 14 11A4306 2 Holder Guide Roller 15 11A4314 2 Roller Guide 17 11A4310 1 Switch Assembly 18 1 Gear 1 PP 12A4038 19 1 Gear 2 PP 12A4038 20 1 Gear 3 PP 12A4038 21 1 Gear 4 PP 12A4038 22 1 Gear 5 PP 12A4038 23 11A4255 1 Bracket Fuser Cooling Fan 24 2 Screw P...

Page 138: ...6 20 Assembly 9 Fuser ...

Page 139: ...Parts Catalog 6 21 Ref Part Number Units Description 9 1 11A4321 1 Fuser Assembly 100 120 V 1 11A4322 1 Fuser Assembly 220 240 V ...

Page 140: ...6 22 Assembly 10 Paper Tray 250 Sheet ...

Page 141: ...late Holder PP 12A4037 5 12A4003 1 Plate Paper Lift 6 1 Spring Paper Tray Lift Plate PP 12A4037 7 12A4004 1 Separator Paper 8 1 Spring PP 12A4037 9 12A4005 1 Guide Paper Left 10 12A4006 1 Guide Paper Right 11 12A4007 1 Guide Paper End 12 12A4019 1 Lever Paper Size 13 11A4232 1 Label Size Packet 14 12A4030 1 Extender 250 Sheet Legal 15 12A4032 1 Dust Cover Rear 16 2 Screw PP 12A4039 ...

Page 142: ...6 24 Assembly 11 Optional 450 Sheet Second Paper Tray ...

Page 143: ...Plate Right 4 2 Spring PP 12A4037 5 1 Spring PP 12A4037 6 12A4014 1 Separator Paper 7 1 Spring PP 12A4037 8 12A4015 1 Guide Paper Left 9 12A4016 1 Guide Paper Right 10 12A4017 1 Guide Paper End 11 12A4019 1 Lever Paper Size 12 12A4031 1 Extender 450 Sheet Legal 13 12A4032 1 Dust Cover Rear 14 2 Screw PP 12A4039 15 11A4232 1 Label Size Packet ...

Page 144: ...6 26 Assembly 12 Optional 450 Sheet Second Paper Drawer 2 ...

Page 145: ... Roller 8 11A4331 1 Shaft Pick Roller 9 11A4224 1 Gear Pick Roller 10 11A4287 1 Roller Pick 11 11A4404 2 Bearing Roller 12 11A4336 1 Protector Pick Roller 13 5 Screw PP 12A4039 14 11A4339 1 Cover 450 Sheet Left Side 15 11A4348 2 Foot Rubber 16 11A4403 1 Cover Top Left 17 11A4342 1 Cover Right Side 18 11A4348 2 Foot Rubber 19 11A4407 1 Lever Paper Tray Lock 20 11A4408 1 Spring 21 11A4409 1 Cover To...

Page 146: ...6 28 Assembly 13 Optional 450 Sheet Second Paper Drawer 2 ...

Page 147: ...8 12A4013 1 Bracket Motor Mounting 9 4 Screw PP 12A4039 10 12A4018 1 Motor Pick 11 2 Screw PP 12A4039 12 12A4020 1 Lever Multi switch 13 11A4223 1 Board Paper Size Sensor 14 2 Screw PP 12A4039 15 11A4406 1 Cable Paper Size Sensor 16 11A4338 1 Cable Drawer Interconnect 17 2 Screw PP 12A4039 18 11A4422 1 Board Driver 19 2 Screw PP 12A4039 20 12A4021 1 Lever Sensor FP 21 12A4022 1 Lever Sensor FE 22 ...

Page 148: ...6 30 Assembly 14 Optional Multi Function Feeder ...

Page 149: ...Parts Catalog 6 31 Ref Part Number Units Description 14 1 12A4024 1 Feeder Multi Function ...

Page 150: ...4MB DRAM 99A0518 1 Memory 8MB DRAM 99A0519 1 Memory 16MB DRAM 99A0520 1 Memory 32MB DRAM 99A0724 1 Memory 64MB DRAM 99A0521 1 Memory 1MB Flash 99A0522 1 Memory 2MB Flash 99A0523 1 Memory 4MB Flash 99A0424 1 Infrared Adapter 12A4029 1 Tray Assembly 450 Sheet 12A4028 1 Tray Assembly 250 Sheet 99A0516 1 Card Asm Hard Disk Drive 12A4042 1 SIMM IPDS Board 99A0629 1 Adapter Coax Twin Adapter for SCS 13A...

Page 151: ...ion 12A4036 1 Parts Packet Left Right Frame Gears 12A4037 1 Parts Packet Paper Tray Springs 12A4038 1 Parts Packet Paper Feed Gears 12A4039 1 Parts Packet Screws 99A0426 1 Parts Packet Parallel Connector Mounting Screws 7350166 1 Packaging Printer 12A4040 1 Tool Wire Cleaning ...

Page 152: ...6 34 ...

Page 153: ...rvice check 2 12 exiting the diagnostics mode 3 1 F flash test 3 3 frame assembly left side 6 10 frame assembly right side 6 12 front and right side of printer 5 1 fuser assembly 6 20 fuser removal 4 11 fuser service check 2 13 H hardware tests 3 5 high voltage power supply board and interconnect board removal 4 12 I image quality service check 2 13 initial check 2 2 input paper feed assembly 6 14...

Page 154: ...nt registration 3 11 print tests 3 14 printer operation 1 5 printer setup 3 12 printhead 1 7 printhead and paper feed redrive assembly 6 16 printhead erase LED assembly removal 4 27 printhead removal 4 27 printing menu settings page 3 15 process drive mechanism 1 7 process fan removal 4 28 process fan service check 2 27 Q quick disk test 3 2 R rear and left side of printer 5 2 removal procedures 4...

Page 155: ...e book well organized Yes No 2 Was the content of the book accurate and complete Yes No 3 Was the book easy to use Yes No 4 What can we do to improve the book 5 What is your job title Questions or comments about supplies service applica tions and so on will slow response time considerably Please refer those questions or comments to your authorized dealer or point of purchase Note Please direct all...

Page 156: ...t Along Line POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY ...

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