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2-18

Service Manual

4045-XXX

3

Right Side Charge Roll Arm
and Bushing

Check the right side charge roll arm
and bushing for correct assembly
operation. Check the right charge roll
bushing for signs of wear or
contamination. Excessive
contamination could cause
intermittent charging of the charge
roll. If incorrect, replace the bushing.
Check for continuity from the
bushing to the charge roll high
voltage contact on the right side
frame. If incorrect, replace the right
charge roller arm.

Note:

The screw that attaches the

charge roll lead to the contact must
be secure.

FRU

Action

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Summary of Contents for Optra M410

Page 1: ...0 M412 Lexmark and Lexmark with diamond design 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: ... to Lexmark International Inc Department D22A 032 2 740 West New Circle Road 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 You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Le...

Page 3: ...achine Service Check 2 20 Erase Lamp Service Check 2 22 Fan Service Check 2 23 Fuser Service Check 2 23 Input Sensor Service Check 2 25 Input Tray s Option Service Check 2 26 Main Drive Service Check 2 29 Operator Panel Service Check 2 30 Options Service Check 2 32 Paper Feed Service Check 2 33 Parallel Port Service Check 2 35 Printhead Service Check 2 36 Print Quality Service Check 2 37 Serial Po...

Page 4: ...lenoid Test 3 22 Tray 2 Motor Test 3 23 Mirror Motor Test 3 23 Sensor Monitor Test 3 24 Cooling Fan Fuser Control Test 3 25 Erase Lamp Test 3 26 Reset Test Mode 3 26 Engine Firmware 3 26 Printer Operation 3 27 Electrophotographic Process 3 27 Paper Feeding Transferring and Fusing 3 27 Paper Path Sensor Locations 3 28 Cable Locations 3 29 Repair Information 4 1 Handling ESD Sensitive Parts 4 1 Adju...

Page 5: ...ply 5 2 Engine Board 5 4 Interconnect Board 5 10 Option Tray Board 5 12 Parts Catalog 6 1 Assembly 1 Covers 6 2 Assembly 2 Frame 6 6 Assembly 3 Printhead 6 8 Assembly 4 Paper Feed Multipurpose Unit 6 10 Assembly 5 Paper Feed Alignment 6 12 Assembly 6 Paper Feed Output 6 14 Assembly 7 Main Drive 6 16 Assembly 8 Developer Drive 6 18 Assembly 9 Fuser 6 20 Assembly 10 Transfer 6 24 Assembly 11 Chargin...

Page 6: ...vi Service Manual 4045 XXX ...

Page 7: ...Notices and Safety Information vii 4045 XXX Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown Laser Advisory Label ...

Page 8: ...viii Service Manual 4045 XXX Class 1 Laser Statement Label ...

Page 9: ...lth 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 Galliumars...

Page 10: ... 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 Avis...

Page 11: ...stema 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 v...

Page 12: ...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 ...

Page 13: ...om 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 Avís sobre el Làser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels produ...

Page 14: ...xiv Service Manual 4045 XXX Japanese Laser Notice Chinese Laser Notice ...

Page 15: ...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 ap...

Page 16: ...iguardanti 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 wur...

Page 17: ...onales 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 óbv...

Page 18: ... 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 ...

Page 19: ...Notices and Safety Information xix 4045 XXX Chinese Safety Information Korean Safety Information ...

Page 20: ...xx Service Manual 4045 XXX ...

Page 21: ... computer networks The M410 printer is capable of printing at speeds of 12 pages per minute The M412 is capable of printing at speeds of 17 pages per minute Both models print with a true 600 x 600 dpi resolution or 1200 x 1200 dpi Image Quality resolution Each model of the base printer comes with 4MB of memory and is expandable to 132MB using both SDRAM DIMM slots User flash memory is also availab...

Page 22: ...of purchase for options available in your country 500 Sheet Drawer SDRAM Memory DIMMs 4MB 8MB 16MB 32MB and 64MB Flash Memory DIMMs 2MB 4MB 8MB and 16MB Internal Network Options Token Ring Ethernet 10 100BaseTX 10Base2 T Tri Port Card Hard Disk 2 1GB Coax Twinax Adapter for SCS External Network Adapter Marknet Pro 1 and 3 series compatible ...

Page 23: ...rs Rear Exit sensor Environment Ozone free Blue Angel Energy Star Warm up less than 70 seconds from power on to Ready First page time Tray 1 Less than 12 seconds from standby Tray 2 Less than 13 seconds from standby MPF Less than 12 seconds from standby Dimensions Width 405 mm 15 9 Height 314 mm 12 4 Depth 435 mm 17 1 Height of Tray 2 130 mm 5 1 Footprint 246 square inches Weight 14 8 Kg 32 6 lbs ...

Page 24: ...nd diagnostic aids to determine the printer problem and repair the failure 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 Needlenose pliers Diagonal pliers Spring hook Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax serial debug cable 1...

Page 25: ...er Supply LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply MROM Masked Read Only Memory NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PC Photoconductor POR Power On Reset POST Power On Self Test RIP Raster Imaging Processor ROM Read Only Memory SIMM Single In Line Memory Modu...

Page 26: ...1 6 Service Manual 4045 XXX ...

Page 27: ...e Error Codes on page 2 2 User status messages provide the user with information on the current status of the printer Ready is displayed on the first line of the display unless Power Saver is invoked and then Power Saver is displayed If a user status message is displayed go to the User Status Messages on page 2 5 User error messages are indicated by a two or three digit error code that provides th...

Page 28: ...en the printer is idle Go to the Cold Fuser Service Check on page 2 23 922 Fuser Error Fuser failed to reach standby temperature Go to the Cold Fuser Service Check on page 2 23 923 Fuser Error Fuser is too hot during printing or when printer is idle Go to the Hot Fuser Service Check on page 2 25 924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit Go to the Hot Fuser S...

Page 29: ...C Replace the controller board 941 Controller Font CRC Replace the controller board 943 Controller Font Version Indicates that the controller code and FONT ROM are incompatible 944 Controller Board Failure Replace the controller board 945 Controller Board Failure ASIC Failure Replace the controller board 946 Controller Board Failure SRAM Failure Replace the controller board 947 Engine Board Replac...

Page 30: ... SIMM The specific error is as follows 964 Download Emulation CRC Failure Checksum Failure 965 Download Emulation Outdated The Download Emulation and the controller code are incompatible Go to Download Emulation on page 3 3 965 Emulation Error 975 979 Network Card The following errors indicate a failure with the network card 975 Unrecognizable Network Card Replace Network Card 976 Unrecoverable so...

Page 31: ...ress Select for the values Press Menu until Reset Printer is on the second line of the display Press Select to Reset the printer Busy The printer is busy receiving or processing data or printing data Note The printer indicator light blinks while the printer is processing data Press Stop to take the printer out of Busy The Not Ready message is displayed No more data is processed but the printer pro...

Page 32: ...es Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Printing Directory List A directory of the flash and disk contents is processing or printing because Print Directory is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper currently i...

Page 33: ...ress Menu or Menu to take the printer out of Ready and enter the TESTS MENU Busy state Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Resetting Printer The printer is deleting any print jobs in process and restoring all settings to user defaults No button actions are possible while this message is displayed Formatting Flash Do Not Power Off Th...

Page 34: ...e is displayed Menus Disabled The printer menus have been disabled This occurs when Menu or Menu is pressed while the printer is Ready and Menu Lockout is active The printer display shows this message for one second and then returns to the Ready message No button actions are possible while this message is displayed Activating Menu Changes The printer is reset to activate a printer setting changed ...

Page 35: ...e multipurpose feeder Insert Cartridge or Close Door This message displays when the printer s front door is open or the print cartridge is missing If this message cannot be cleared go to Cover Open Switch Cable Service Check on page 2 19 34 Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size l...

Page 36: ...ed until the flash is formatted 54 Network Software Error This error is displayed when the connection to the network port is lost during power on Press Go to clear the message The printer clears the setting but no communication can exist with the network until the network software is reloaded 56 Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel por...

Page 37: ...ess the Go button to return the printer to the Ready state 62 Disk Full This error code is displayed when there is not enough free space on the disk to hold the resources that have been requested to be written to the disk This message displays for both resource and PostScript Disk operators when the disk is full 63 Unformatted Disk This error code displays when the printer detects an unformatted d...

Page 38: ...The link messages are listed in the following table User Message Explanation Check Configuration ID The printer configuration ID is not set or is invalid This condition can only be cleared when a valid configuration ID is set Go to Setting Configuration ID on page 3 15 Parallel This is the host interface from which the printer is currently drawing data Serial Network LocalTalk Infrared USB Fax ...

Page 39: ...he printer for instance to clear a paper jam Otherwise the device can still be attached to the printer but is experiencing a communications problem not fully connected or having a hardware failure If the device is temporarily removed or not connected properly then reattach it When the option is recognized the printer automatically clears the error and continues If the option is experiencing a hard...

Page 40: ...ars on the display 5 Ready appears on the display 6 The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start 7 The cooling fan turns on and runs full speed 8 The main drive motor turns on 9 The developer drive assembly drives the developer shaft in the toner cartridge 10 The exit rollers turn 11 The printhead mirror motor turns on 12 The cooling fan turns on an...

Page 41: ...ck on page 2 30 Paper feed problems Base printer or Integrated 250 Paper Tray Go to the Paper Feed Service Check on page 2 33 Paper jams at exit of Redrive Assembly Go to the Paper Feed Service Check on page 2 33 Print quality Black page Go to Print Quality All Black Page on page 2 38 Print quality Blank page Go to Print Quality Blank Page on page 2 38 Print quality Light print Go to Print Quality...

Page 42: ...lity Toner on backside of printed page on page 2 47 Print quality Vertical black bands on edge of copy Go to Print Quality Black bands on outer edges of the page on page 2 44 Paper feed problem with 500 sheet paper tray option Go to Input Tray s Option Service Check on page 2 26 Symptom Action ...

Page 43: ... Problems Go to Print Quality Test Pages on page 3 2 and print a test page to help diagnose problems before changing any settings or working on the printer Use the resident diagnostics test provided to help isolate a problem before taking the machine apart or removing any options Charge Roll Service Check Service Tip Close and evenly spaced repetitive marks 47 5 mm apart or spots on the page can b...

Page 44: ... for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the bushing Check for continuity from the bushing to the charge roll high voltage contact on the right side frame If incorrect replace the right charge roller arm Note The screw that attaches the charge roll lead to the contact must be secure FRU Action ...

Page 45: ...mechanical operation If incorrect repair as necessary Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4 6 It measures approximately 5 V dc If the voltage is incorrect replace the engine board If the voltage is correct check for ground at J4 8 If incorrect replace the engine board If the ground is correct check the continuity between J4 6 and J4 7 on t...

Page 46: ...C Line Cord Check the line cord for any signs of damage If correct check the continuity of the line cord and replace if necessary 3 24 V dc at Tray 2 Connector Check for 24 V dc at pin 7 of the tray 2 connector located under the printer If 24 V dc is present at the connector go to step 9 If 24 V dc is not present go to step 4 4 Controller Board Remove the controller board Turn on the printer If th...

Page 47: ...essary safety precautions before applying AC power Measure the voltages on LVPS output connector CN1 If any voltages are incorrect replace the LVPS 9 Engine Board Turn the printer off and disconnect all the cables from the engine board Check for 5 V dc at TP5 test point and 24 V dc at test point TP6 on the engine board If incorrect replace the FRUs in the following order engine board interconnect ...

Page 48: ... front harness to erase lamp assembly for correct installation If incorrect repair as necessary 2 Engine Board Remove the controller board and toner cartridge from the machine Perform the Erase Lamp Test in the Hardware Test Mode The erase lamps turn on The lamps can be observed through the front of the machine with the cover open and print cartridge removed If the lamps do not turn on measure the...

Page 49: ... cleared by turning the machine off and then on again Service Tip Set the Fuser Temperature to NORMAL before starting this service check FRU Action 1 Fan Manually spin the fan and check that it rotates freely Check the cable connection to the engine board J13 for correct installation 2 Engine Board Check the continuity of the cable If incorrect replace the cable Perform the Cooling Fan Test in the...

Page 50: ...contact in the fuser cover 2 LVPS Turn the printer off Disconnect the fuser lamp connectors at the fuser assembly Turn the printer on and check across the cable for line voltage If incorrect remove the LVPS and check both F1 and F2 fuses Remove the LVPS from the printer Replace any open fuses and attach the power cord If the fuses open replace the LVPS If the fuses open after the lamp cables are c...

Page 51: ...ce of the themistor HOT 1K ohms COLD 150K ohms to 475K ohms With the cable connected check the continuity from J8 6 and J8 7 to ground If there is continuity replace the fuser thermistor 2 Engine Board Error code 924 indicates the engine board detects an open circuit in the thermistor circuit for the fuser assembly The voltage on J8 6 on the engine board measures approximately 5 V dc If incorrect ...

Page 52: ...o verify motor and related paper feed components are working properly With the motor on actuate the tray 2 solenoid from the Solenoid Test to feed paper FRU Action 1 Input Sensor Flag Check the input sensor flag for damage and proper operation If a problem is found repair as necessary 2 Engine Board Check for approximately 5 V dc at J2 3 on the engine board If incorrect replace the engine board 3 ...

Page 53: ... Tray 1 Inserted Sensor Check the tray 2 option for correct installation with the base printer Run the Sensor Test in the Hardware Test Mode to verify the printer detects the tray 1 present sensor If the sensor is not detected check the sensor for correct installation and connection at the tray 2 board If the installation is correct replace the sensor FRU Action 1 Paper Path Guides Tray 2 Check th...

Page 54: ...2 28 Service Manual 4045 XXX 4 Tray 2 Motor Use the Tray 2 Motor Test to check the tray 2 motor Replace as necessary FRU Action ...

Page 55: ...ase in the gearbox assembly FRU Action 1 Main Drive Assembly Excessive noise or vibration Remove the controller board and run the Main Motor Test in the Hardware Test Mode If the noise goes away with the toner cartridge removed inform the customer to replace the toner cartridge Determine if the noise is in the main drive assembly fuser developer drive assembly or alignment assembly Look for any lo...

Page 56: ...dc J3 3 Ground J3 4 Ground J3 5 2 5 V dc J3 7 5 V dc J3 9 5 V dc If any voltage is incorrect replace the FRUs in the following order main drive motor assembly engine board FRU Action 1 Operator Panel Assembly If any button fails the Button Test replace the operator panel assembly 2 Engine Board No buttons work Check the voltage at J1 2 The voltage measures approximately 5 V dc with the controller ...

Page 57: ...cable at the engine board J1 and at the operator panel Check the continuity of the operator panel cable If incorrect replace the cable 2 Operator Panel Display blank 5 beeps LED Off Check the voltage at J1 2 on the engine board It measures approximately 5 V dc If incorrect replace the engine board If correct replace the operator panel assembly 3 Operator Panel Display blank 5 beeps LED On Check fo...

Page 58: ...the DRAM DIMM If the problem continues replace the controller board Hard Disk Option Check to make sure the fixed disk and the fixed disk board are correctly installed Run the Quick Disk Test on page 3 17 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk Note The Quick Disk Test is a non destructive test and indicat...

Page 59: ...work card is installed in slot 1 on the interconnect board but cannot establish communications with the network card Paper Feed Service Check If you have a 936 Transport Motor Error go to the Main Motor Test on page 3 22 FRU Action 1 Alignment Assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight Check the alignment assembly ...

Page 60: ...ft plate for proper operation A fatigued lift plate spring can cause paper feed problems near the bottom of the stack FRU Action 1 Pick Roll Check the pick roll for signs of wear and correct installation Replace as necessary 2 Pick Roll Solenoid Check the solenoid for correct operation and installation Use the Solenoid Test in the Hardware Test Mode to check operation Replace as necessary FRU Acti...

Page 61: ...commended paper specifications Parallel Port Service Check Run the Parallel Wrap Test on page 3 10 Note The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug P N 1319128 and invoking the Parallel Diagnostic Test This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately three seco...

Page 62: ...at J5 6 measures approximately 5 V dc If incorrect replace the engine board If correct replace the printhead assembly 2 Error Code 935 Mirror Motor unable to reach operating speed These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the engine board cable or engine board assembly Check the continuity of the mirror motor cable con...

Page 63: ...s so you can return the printer to the original customer printer setup Print Resolution Set to 300 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver Set to OFF PQET Set to OFF An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Meas...

Page 64: ...hey fit securely and are not pitted contaminated or damaged If incorrect replace the contact 2 Engine Board Check the voltages on J9 1 through J9 9 If incorrect replace the HVPS 3 HVPS Cable HVPS Check the continuity of the HVPS cable If incorrect replace the cable assembly If correct replace the HVPS FRU Action 1 Print Cartridge Check the print cartridge for any signs of damage especially the PC ...

Page 65: ... Board If the voltages at J9 are incorrect replace the engine board If the voltages are correct check the HVPS cable for continuity If you measure continuity replace the HVPS 5 Printhead Assembly Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom The printhead used in the printer does not have a mechanical shutter as previous ...

Page 66: ...any feed roller or in the transfer roll bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect feeding from one of the input paper sources Check the high voltage contacts to ensure they are not bent corroded or damaged Replace as necessary ...

Page 67: ...3 Lines spaced 15 6 mm 0 61 inch apart Replace the FRUs in the following order developer drive assembly main drive assembly 4 Lines spaced 47 mm 1 85 inch apart Replace the FRUs in the following order toner cartridge charge roll main drive assembly 5 Lines spaced 38 0 mm 1 50 inches apart Lines spaced 46 5 mm 1 83 inches apart This can be caused by a defective gear in the developer drive assembly ...

Page 68: ...amount of graphics in a humid environment The customer may try to improve the print quality by increasing the transfer setting 9 Lines spaced 112 8 mm 4 45 inches apart Replace the FRUs in the following order alignment assembly main drive assembly 10 Lines spaced 94 mm 3 7 inches apart Replace the FRUs in the following order toner cartridge main drive assembly 11 Lines spaced 45 1 mm 1 78 inches a...

Page 69: ... other attempts fail to correct a background problem 3 Transfer Roll Assembly Check the high voltage contact from the HVPS to the transfer roll Check the transfer arm assembly right side bearing for any signs of contamination pitting or a loose cable to the bearing If any problems are found replace the defective part Check the transfer roll shaft for any signs of contamination wear or pitting on t...

Page 70: ...py and can be wide narrow light or dark FRU Action 1 Charge Roll Linkage Springs If the problem is just on one side of the page check the charge roll linkage spring on that side You can check to see if enough force is being applied to the charge roll by applying a slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample ...

Page 71: ...inter Printing Test Page J9 7 voltage changes from 0 V dc to 4 V dc If the voltage does not vary check the continuity of line J9 7 in the front cable harness If there is no continuity replace the cable harness If there is continuity replace the HVPS If this does not correct the problem replace the engine board Turn the printer Off and check the resistance between J9 9 and printer ground The resist...

Page 72: ... and deposited on the page FRU Action 1 Transfer Roll Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll 2 Right Side Transfer Roll Arm Assembly Check the right side transfer roll arm assembly bearing for any signs of wear or contamination Also check to ensure the transfer cable is firmly attached to the bearing If incorrect rep...

Page 73: ...late the printer from the serial cable and host The test provides failure information on the display for approximately three seconds If the test indicates a problem replace the controller board FRU Action 1 Fuser Assembly Toner is being carried out on the backside of the media This problem is generally caused by a toner buildup on the fuser hotroll or backup roll Check the fuser hotroll and backup...

Page 74: ...2 Left Transfer Arm Assembly Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position If the arm is not locked down check to ensure the arm is not broken and will lock into the EP frame correctly Check the left transfer arm assembly spring for proper operation 3 Right Transfer Arm Assembly Check the right transfer arm assembly to make sure it is fastene...

Page 75: ...guration Mode 1 Turn the printer off 2 Press and hold the Select and Return buttons 3 Turn the printer on 4 Release the buttons when Performing Self Test displays on the operator panel The operator panel will display CONFIG MENU once the printer reaches Configuration Mode 5 Press either of the Menu buttons to scroll throught the CONFIG MENU options 6 Press the Select button to open sub menu option...

Page 76: ...Print Quality Test pages must always be printed on letter legal or A4 paper To run the Print Quality Test Pages in the Configuration Mode 1 Select Prt Quality Pgs from the CONFIG MENU The following is printed on page 1 Margin Settings Contents of the Diagnostic Error Log Printer configuration information printer serial number controller code level engine code level operator panel code level smart ...

Page 77: ...switch settings are turned on Discard Buffered Jobs If the printer is power cycled after jobs have been buffered to the disk then the printer attempts to print all buffered jobs stored on the disk If many jobs have been buffered to the disk then it may take the printer a long time to complete power cycle initialization since each buffered job must be processed during the initialization phase The u...

Page 78: ...set to On then demo mode is entered each time the printer is powered on If the Demo Mode setting is set to Off then normal mode is entered each time the printer is powered on To Activate Deactivate Demo Mode 1 Select Demo Mode from the CONFIG MENU 2 Press the Menu button to locate Activate or Deactivate 3 Press the Select button to store your selection Restore Factory Defaults This operation will ...

Page 79: ...n Mode and return to the normal mode Diagnostic Mode 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 Print Registration Print Tests Hardware Tests Input Tray Tests Base Sensor Test Printer Setu...

Page 80: ...alue you want is displayed press Select to save the value 5 To exit the Registration menu press Return To verify the margin values are correct you must print the Quick Test Page from the registration screen Press Go to print the test page While printing the Quick Test Page the Quick Test Printing message displays Once the Quick Test Page completes printing the Registration screen displays again Th...

Page 81: ...s 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 of the print quality test pages with the toner cartridge lockout function disabled The print quality test consists of three pages Page one contains a mixture of gra...

Page 82: ...u Settings Page Note This test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Perform a normal POR into user mode 2 Select the Utilities menu 3 Select the Print menu from the Utilities menu Hardware Tests The following Hardware Tests can be selected from this menu LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap Serial 1 Wrap if available LCD ...

Page 83: ...d correctly To run the DRAM Memory Test 1 Select DRAM Memory Test from the menu The power indicator blinks indicating the test is in progress 2 Press Return 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 of time the memory test has failed and finished wi...

Page 84: ...owever if the test fails one of the following messages displays for approximately three seconds ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached the test stops with the power indicator on solid The final results display on the screen Parallel Wrap Test This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signa...

Page 85: ...Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum count is reached the test stops The power indicator goes on so...

Page 86: ...however if the test fails one of the following failure messages displays for approximately three seconds and the Fail Count increases 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 42...

Page 87: ...urce or Continuous continues feeding media from the selected source until Return Stop is pressed 4 Press Return Stop to exit test Sensor Test This test is used to determine if the input tray sensors are working correctly To run the Sensor Test 1 Select the Sensor Test from the Input Tray Test menu Input Tray Empty OP Pass OP message displays EM Input Tray Empty Sensor IN Input Tray Inserted Sensor...

Page 88: ... page count 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 blinks indicating it is the first digit to be changed 2 Press either Menu or Menu until the value you want d...

Page 89: ... To set the Configuration ID 1 Select Configuration ID from the Printer Setup menu The current ID displays on the screen The Configuration ID is on a label located inside the printer The label is visible when the top front cover is open The leftmost digit blinks indicating that it is the first digit to be changed 2 To change the value press either Menu or Menu until the value you want is reached P...

Page 90: ...graphics and printing engine shift all four margins top bottom right and left to the physical edges of the page When Edge To Edge is set to Off the printing area is set back to the margin settings Parallel Strobe Adjust This setting lets you adjust the factory setting for the amount of time the strobe is sampled to determine that valid data is available on the parallel port Increasing the value by...

Page 91: ...Log menu The Error log displays on three screens as only four entries display at a time 2 To move to the next screen press Menu to move forward or Menu to move backward 3 Press Return Stop to exit the Error 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 Er...

Page 92: ...to warn the user that all contents on the disk will be lost 2 To exit the test immediately and return to the Device Tests menu press Return Stop To continue with the test press Go If go is selected Disk Test Clean BAD 000000 00 message displays The screen updates periodically indicating the percentage of test completed and the number of bad blocks found 3 The power indicator blinks during the test...

Page 93: ...matted at the end of the test To run the Flash Test 1 Select Flash Test from the Device Tests menu The power indicator blinks while the test is running Flash Test Test Passed message displays if the test passes and the power indicator turns on solid Flash Test Test Failed message displays if the test fails and the power indicator turns on solid Press Go or Return Stop to return to the Device Tests...

Page 94: ...he following menu items are displayed on the operator panel Op Panel Test Main Motor Solenoid Test Tray 2 Motor Mirror Motor Sensor Monitor Cooling Fan status Fuser Ctrl Erase Lamp Reset Test Mode Engine Firmware Note The Operator Panel Test is the first menu item to appear on the operator panel when the printer is powered on in the Hardware Test Mode You can scroll through the menu items to selec...

Page 95: ... If you do not get the expected results replace the operator panel Button Result Menu and PUSH display on the operator panel Menu and PUSH display on the operator panel Select and PUSH display on the operator panel The LED also flashes Return and PUSH display on the operator panel The bottom row of pels turn on Green GO Green and PUSH display on the operator panel The top row of pels turn on Red S...

Page 96: ...Main Mo while the motor is turning 3 Press STOP to turn the main motor off Once the main motor is turned on select either the Tray 1 or MPF solenoid from the Solenoid Test to cause the pick roller to turn Solenoid Test This test lets you actuate the three different pick roller solenoids two within the base printer and one within the Tray 2 option To run the Solenoid Test 1 Select Solenoid Test fro...

Page 97: ...m the menu 2 Press GO to turn the main motor on The operator panel displays Driving T2 Motor while the motor is turning 3 Press STOP to turn the main motor off Once the Tray 2 motor is turned on select the Tray 2 solenoid from the Solenoid Test to cause the pick roller to turn Mirror Motor Test This test lets you turn on the printhead mirror motor To run the Mirror Motor Test 1 Select Mirror Motor...

Page 98: ...w are used in this test Check the corresponding position on the operator panel with the table for the correct signal status Sensor Switch Display Position Signal Status MPF Paper Present Sensor 1 o No paper is present 1 Paper is present Paper Input Sensor 2 o No paper is present 1 Paper is present Paper Exit Sensor 3 o No paper is present 1 Paper is present Cover Open Cartridge Present Switch 4 O ...

Page 99: ...ys on the top line of the operator panel The number displayed on the bottom left of the operator panel is a preset thermistor value corresponding to either standby or printing fuser temperatures depending on whether the cooling fan is set to slow or fast The number displayed on the bottom right of the operator panel is the current thermistor value This value increases from 0 and stabilizes somewha...

Page 100: ...the left menu button once to turn the LEDs on and change the value to 255 Open the front cover and view the LEDs If the LEDs are working properly they should be on 4 Press the right menu button once to turn off the LEDs and change the value back to 0 Press STOP to relock the value Reset Test Mode This function lets you reset any changes made during the test mode To reset test mode select Reset Tes...

Page 101: ...s actuated to allow the appropriate pick roller to turn Paper is then corner fed via a D roll type pick roller and travels along a paper path toward the PC drum and transfer roller An input sensor located before the PC drum detects the leading edge of the paper If the paper is not detected within a certain time from when it was picked a paper jam is detected After the paper passes through the sens...

Page 102: ...3 28 Service Manual 4045 XXX Paper Path Sensor Locations ...

Page 103: ...Diagnostic Aids 3 29 4045 XXX Cable Locations ...

Page 104: ...3 30 Service Manual 4045 XXX ...

Page 105: ...achine 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 ri...

Page 106: ... lines that can be used for skew adjustment page count setting printer serial number code levels and print registration settings 5 Check the Print Test page for any sign of skew by folding the paper in half left edge to right edge Check the horizontal lines at the top left and top right of the test page for equal distance from the top of the page If any adjustment is necessary perform the followin...

Page 107: ...st page and check the margin registration adjustments on the test page These adjustments should be within the range specified in Print Registration on page 3 6 2 Check for skew by folding the paper in half bottom edge to top edge The horizontal lines on the top and bottom of the page should line up If adjustment is necessary turn the adjustment screw A a few turns print a Print Test page and check...

Page 108: ...you are working on the printer with one of the covers removed Also remove the print cartridge before you perform removal procedures Covers Left Side Cover 1 Open the upper door and multipurpose tray 2 Press the two tabs A to open the left side cover 3 Remove the left side cover from the rear hinge ...

Page 109: ...Repair Information 4 5 4045 XXX Right Side Cover 1 Open the upper door and multipurpose tray 2 Remove the screw A located in the front of the right side frame mounted into the cover ...

Page 110: ...4 6 Service Manual 4045 XXX 3 Remove the screw B located at the top rear of the printer 4 Lift the right side cover up and away from the printer ...

Page 111: ...1 Remove the left and right side covers 2 Remove the two screws A from the right side of the top cover 3 Remove the screw B from the left side of the top cover 4 Remove the fuser air duct from the top cover 5 Lift the top cover from the printer ...

Page 112: ...Open the upper door and mulitpurpose tray 2 Spread the charge roller support arms A apart and remove the charge roller Note Make sure the HVPS charge wire is pinched between the bearing and right charge roller arm ensuring good electrical contact ...

Page 113: ...Repair Information 4 9 4045 XXX Controller Board 1 Remove the left side cover 2 Loosen the six screws A and remove the outer EMC shield ...

Page 114: ...rews B and two screws C securing the inner EMC shield 4 Lift the inner EMC shield controller board assembly up and away from the interconnect board 5 Remove the screws D from the controller board 6 Remove the controller board from the inner EMC shield ...

Page 115: ... Remove the top cover 2 Remove the controller board inner EMC shield assembly 3 Disconnect the cooling fan from the engine board 4 Release the two retaining tabs and push the air duct inward approximately 10 mm to provide clearance for fan removal ...

Page 116: ...4 12 Service Manual 4045 XXX 5 Remove the cooling fan ...

Page 117: ...sembly 2 Remove the two screws A and screw B 3 Remove the developer drive assembly Note When you reinstall the developer drive assembly be sure that the developer drive assembly engages with left charge roller arm Be sure that the developer drive assembly wheel aligns with the hub on the main drive assembly ...

Page 118: ...oard 1 Remove the inner EMC shield controller board assembly 2 Disconnect all connectors from the engine board 3 Remove the four screws A from the engine board 4 Lift the engine board from the interconnect board and remove the engine board ...

Page 119: ...nformation 4 15 4045 XXX Fuser 1 Remove the right side cover 2 Disconnect the two LVPS wires A from the fuser 3 Remove the redrive assembly 4 Remove the screw from the inner air duct cover and remove the cover ...

Page 120: ...4 16 Service Manual 4045 XXX 5 Disconnect the thermistor from the printhead mirror motor cable 6 Remove the four fuser mounting screws B and slide the fuser out of the printer ...

Page 121: ...e inner deflector 2 Disconnect the HVPS transfer wire from the HVPS A 3 Disconnect the HVPS cable from the HVPS B 4 Remove the two screws C securing the HVPS and remove the HVPS Note Make sure HVPS contacts D make good electrical contact with the HVPS ...

Page 122: ...4 18 Service Manual 4045 XXX Inner Deflector 1 Open the upper door and multipurpose tray 2 Remove the screw A securing the upper paper deflector and remove the upper paper deflector ...

Page 123: ...Repair Information 4 19 4045 XXX 3 Disconnect the MPF paper sensor remove the four screws B securing the MPF and remove the MPF ...

Page 124: ...ward you Be careful not to damage the input sensor lever D Left Side Frame 1 Remove the redrive assembly 2 Remove the paper alignment assembly 3 Remove the main drive assembly 4 Remove the rear drive assembly 5 Remove the end stop and end stop spring from the left hinge 6 Remove the six screws from the left side frame and remove the frame ...

Page 125: ...Repair Information 4 21 4045 XXX LVPS 1 Remove the right side cover 2 Disconnect the fuser lamp wires from the fuser 3 Remove the screw A from the bottom of the printer ...

Page 126: ... and remove the two screws B from the rear of the printer 5 Slide the LVPS to the right and remove the LVPS Note When you reinstall the LVPS connect the black fuser lamp wire to the rear contact that is labeled black and the other wire to the front contact ...

Page 127: ...ne board shield 3 Remove the gear cover 4 Remove the pick roll solenoid from the main drive assembly 5 Remove the link A from the rear of the main drive assembly 6 Remove screws B securing the main drive assembly 7 Remove the main drive assembly Note Close the front door when you reconnect the link to the main drive assembly ...

Page 128: ...pen the multipurpose tray to a position that allows the left and right tray hinge slots A to align with the rectangular mounting posts B 2 Pull upward on each tray hinge to remove the tray from the two mounting posts Be careful not to break the hinges ...

Page 129: ...ation 4 25 4045 XXX Paper Alignment Assembly 1 Remove the inner deflector 2 Remove the pick roll 3 Remove the paper input sensor 4 Remove the two screws A from the paper alignment assembly located inside the printer ...

Page 130: ...justment screw B from the left side frame 7 Slide the paper alignment assembly to the right and remove it from the printer Note Go to the Adjustment Procedures on page 4 2 and perform the paper alignment adjustment whenever the paper alignment assembly is removed or the screws are loosened ...

Page 131: ... 4 27 4045 XXX Pick Roll 1 Remove tray 1 2 Gain access to the pick roll by positioning the printer on its right side 3 Pull the pick roll from the pick roll shaft in the direction of the arrow A and remove the pick roll ...

Page 132: ...nthead cables from the printhead assembly 3 Remove the three printhead mounting screws A and remove the printhead Note Go to the Adjustment Procedures on page 4 2 and perform the printhead assembly adjustment whenever the printhead is removed or the printhead mounting screws are loosened ...

Page 133: ...r 2 Remove the two lower mounting screws A 3 Open the rear door and remove the two upper mounting screws B 4 Lift the redrive assembly up and away from the rear of the printer 5 Disconnect the cables from the exit and rear door open sensors and remove the redrive assembly ...

Page 134: ... left side 4 Remove the nine screws from the right side frame 5 Lift and remove the right side frame from the printer Transfer Roller 1 Open the upper door and multipurpose tray 2 Remove the print cartridge 3 Unsnap the transfer roller from the left arm 4 Slide the transfer roller to the left removing the roller from the right bearing ...

Page 135: ... XXX 5 Connector Locations Low Voltage Power Supply Connector Pin No Signal CN1 Interconnect Board 1 5 V dc 2 5 V dc 3 Ground 4 24 V dc 5 24 V dc 6 Ground 7 N A 8 5 V dc 9 Ground 10 Ground 11 24 V dc 12 Ground 13 Ground 14 Heat On ...

Page 136: ...X High Voltage Power Supply Connector Pin No Signal CN1 Engine Board 1 Transfer Servo 2 Transfer Current PWM 3 Transfer V Level Enable 4 Transfer V Level PWM 5 Charge Enable 6 Developer Enable 7 Developer PWM 8 24 V dc 9 Ground ...

Page 137: ...Connector Locations 5 3 4045 XXX ...

Page 138: ...ignal J1 Operational 1 SDA 2 5 V dc 3 SCL 4 Ground 5 FPIRQ J2 Paper Input Sensor 1 Paper Input Sensor 2 Ground 3 LED Drive J3 Main Motor 1 24 V dc CVSW 2 24 V dc CVSW 3 Ground 4 Ground 5 MMotor Clock 6 MMotor Enable 7 MMotor CW 8 MMotor Lock 9 5 V dc 10 Ground ...

Page 139: ... Not Used 6 5 V dc 7 Cover Open Switch 8 Ground J5 Printhead 1 Adjust 2 LD Enable 3 Video 4 Ground 5 Ground 6 5 V dc 7 HSYNC J6 RS232C Interface X Not Used J7 Paper Output Sensor Exit Tray O C Sensor 1 Paper Out Sensor 2 Ground 3 LED Drive 4 Exit OC Sensor 5 Ground 6 LED Drive Connector Pin No Signal ...

Page 140: ...r 1 PMotor Clock 2 PMotor Lock 3 PMotor Enable 4 Ground 5 24 V dc 6 5 V dc 7 HTEMP J9 HVPS 1 Transfer Servo 2 Transfer Current PWM 3 Transfer V Level PWM 4 Transfer V Level PWM 5 Charge Enable 6 Developer Enable 7 Developer PWM 8 24 V CVSW 9 Ground Connector Pin No Signal ...

Page 141: ...Tray2 Present Sensor 6 N A 7 24 V dc 8 T2M1ON 9 T2M2ON 10 N A 11 Ground 12 Ground J11 MMF D Roll 1 24 V dc 2 MMF Solenoid 3 24 V dc 4 Tray 1 Solenoid J12 Erase Lamp 1 24 V dc 2 Erase Lamp PWM J13 Fan Motor 1 24 V dc 12 V dc FAN 2 Fan Enable J14 X Not Used J15 Interconnect Board N A N A J16 X Not Used Connector Pin No Signal ...

Page 142: ...5 8 Service Manual 4045 XXX J17 MMF Input Sensor 1 MMF Paper Input Sensor 2 Ground 3 5 V dc Connector Pin No Signal ...

Page 143: ...Connector Locations 5 9 4045 XXX ...

Page 144: ...rd Connector Pin No Signal J21 INA 1 N A J22 Controller Board 1 N A J23 LVPS 1 5 V dc 2 5 V dc 3 5 V dc 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 24 V dc 10 Ground 11 Ground 12 Ground 13 N C 14 Heat On J24 Engine Board 1 N A J25 X Not Used ...

Page 145: ...Connector Locations 5 11 4045 XXX ...

Page 146: ...ay 1 Tray 1 Present Sensor 2 N A 3 Tray 2 Paper Sensor 4 N A 5 Tray 2 Present Sensor 6 N A 7 24 V dc CVSW 8 T2M1ON 9 T2M2ON 10 N A 11 Ground J2 Tray 1 Present 1 Tray 1 Present Sensor 2 Ground 3 LED Drive J3 X Not Used J4 Tray 2 Motor 1 Motor ON 2 Ground J5 Tray 2 Solenoid 1 24 V dc CVSW 2 Solenoid ON ...

Page 147: ...Connector Locations 5 13 4045 XXX ...

Page 148: ...5 14 Service Manual 4045 XXX ...

Page 149: ... Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts description column indicates the part is contained in a parts packet INDENTURE The indenture is marked by a series of dots located before the parts description The indenture indicates the relationship of a part to the next higher assembly For example INDENTU...

Page 150: ...6 2 Service Manual 4045 XXX Assembly 1 Covers ...

Page 151: ...PP 12G0445 1 12 2 Clip PP 12G0445 1 13 12G0427 1 Hinge Right 1 14 12G0260 1 Cover Upper Front M410 1 14 12G3550 1 Cover Upper Front M412 1 15 4 Screw w washer M3x8 PP12G0445 1 16 12G0264 1 Hook Upper 1 17 12G0265 1 Spring Upper Hook 1 18 12G0431 1 Spring MPF Latch 1 19 12G0266 1 Tray MPF Input 1 20 12G0430 1 Latch MPF Tray 1 21 12G0429 1 Cover MPF Latch 1 22 12G0440 1 Panel Asm Operator 110V 1 22 ...

Page 152: ...6 4 Service Manual 4045 XXX Assembly 1 Covers continued ...

Page 153: ...12G0437 1 Bail Optional Front Paper 1 31 12G0438 1 Bail Main Rear Paper 1 32 12G0439 1 Holder Rear Paper Bail NS 12G3701 1 Overlay NLS pack English French German Italian Spanish Danish Dutch Norwegian Swedish Finnish NS 12G3702 1 Overlay XNLS pack Czech Hungarian Polish Russian Turkish NS 12G3703 1 Overlay pack French Canadian ...

Page 154: ...6 6 Service Manual 4045 XXX Assembly 2 Frame ...

Page 155: ...idge 2 12 12G0277 1 Spring IC Locate Arm Right 2 13 12G0275 1 Arm IC Locate Right 2 14 12G3560 1 Sensor Paper Input 2 15 12G0451 1 LED Asm Erase 2 16 12G0281 1 Guide Middle Paper 2 17 12G0282 1 Brush Erase 2 18 12G0296 1 Guide Paper 2 19 12G0295 1 Lever Input Sensor 2 20 12G0280 1 Guide Front Paper 2 21 12G0276 1 Arm IC Locate Left 2 22 12G0278 1 Spring IC Locate Arm Left 2 23 2 Screw M4x8 PP 12G0...

Page 156: ...6 8 Service Manual 4045 XXX Assembly 3 Printhead ...

Page 157: ...Parts Catalog 6 9 4045 XXX Asm Index Part Number Units Description 3 1 3 Screw M4x12 PP 12G0445 3 2 2 Washer PP 12G0445 3 3 12G0298 1 Printhead Complete M410 3 3 12G3551 1 Printhead Complete M412 ...

Page 158: ...6 10 Service Manual 4045 XXX Assembly 4 Paper Feed Multipurpose Unit ...

Page 159: ...er Asm MPF Pick 4 2 4 Screw M4x12 PP 12G0445 4 3 12G0301 1 Feeder Asm MPF 4 4 12G0252 1 Sensor MPF Input 4 5 12G0251 1 Solenoid MPF Pick Roller 4 6 1 Screw M3x8 PP 12G0445 4 7 12G0300 1 Shaft Asm MPF Pick Roller 4 8 12G0302 1 Cover Gear 4 9 1 Screw M4x8 PP 12G0445 4 10 1 Clip PP 12G0445 ...

Page 160: ...6 12 Service Manual 4045 XXX Assembly 5 Paper Feed Alignment ...

Page 161: ...045 XXX Asm Index Part Number Units Description 5 1 12G0303 1 Aligner Asm Paper Feed 5 2 2 Screw M4x8 PP 12G0445 5 3 1 Spring Washer PP 12G0445 5 4 1 Screw Adjustment M3x16 PP 12G0445 5 5 12G0452 1 Spacer Adjustment Screw ...

Page 162: ...6 14 Service Manual 4045 XXX Assembly 6 Paper Feed Output ...

Page 163: ... Screw M3x6 PP 12G0445 6 3 12G0305 1 Bail Rear Door Paper 6 4 12G0252 1 Sensor Rear Door 6 5 12G0309 1 Deflector Paper 6 6 12G0304 1 Door Rear 6 7 12G0306 1 Frame Rear Paper Exit 6 8 12G0310 1 Belt Redrive Roller 6 9 12G0252 1 Sensor Paper Exit 6 10 12G0307 1 Roller Upper Redrive 6 11 2 Screw M4x8 PP 12G0445 ...

Page 164: ...6 16 Service Manual 4045 XXX Assembly 7 Main Drive ...

Page 165: ...21 1 Drive Asm Main M410 7 2 12G3552 1 Drive Asm Main M412 7 3 12G0323 1 Roller Pick 7 4 12G0322 1 Shaft Asm Pick Roller NS 12G3673 1 Clutch Spring Pick Roller 7 5 1 Screw M3x8 PP 12G0445 7 6 12G0443 1 Solenoid Main Pick Roller 7 7 12G0324 1 Coupling Spline Drive 7 8 2 Washer PP12G0445 7 9 1 Clip PP12G0445 ...

Page 166: ...6 18 Service Manual 4045 XXX Assembly 8 Developer Drive ...

Page 167: ...Parts Catalog 6 19 4045 XXX Asm Index Part Number Units Description 8 1 12G0325 1 Drive Asm Developer 8 2 1 Screw M3x25 PP12G0445 8 3 2 Screw M4x12 PP12G0445 ...

Page 168: ...6 20 Service Manual 4045 XXX Assembly 9 Fuser ...

Page 169: ...3x8SW PP 12G0445 9 6 12G0343 1 Contact Fuser Lamp Rear 9 7 12G0347 1 Guide Fuser Paper Exit 9 8 12G0349 1 Spring Exit Sensor Lever 9 9 12G0348 1 Lever Paper Exit Sensor 9 10 12G0328 1 Lamp 115V M410 9 10 12G0329 1 Lamp 220V M410 9 10 12G3562 1 Lamp 115V M412 9 10 12G3563 1 Lamp 220V M412 9 11 12G0339 1 Frame Right Fuser 9 12 12G0330 2 Bushing Hot Roll 9 13 12G0334 2 Clip Gear Retaining 9 14 12G033...

Page 170: ...6 22 Service Manual 4045 XXX Assembly 9 Fuser continued ...

Page 171: ...12G0326 1 Hot Roll Fuser 9 20 3 Screw M3x8 PP 12G0445 9 21 12G0353 1 Thermistor Fuser 9 22 12G0338 1 Frame Left Fuser 9 23 12G0332 1 Gear Hot Roll 9 24 12G0346 1 Gear Fuser Idler 9 25 12G0446 1 Guide Upper Fuser Entry 9 26 12G0342 1 Contact Fuser Lamp Front 9 27 2 Screw M3x5 PP 12G0445 9 28 12G0333 1 Fuse Thermal 9 29 12G0341 1 Contact Lamp to Fuse 9 30 12G0340 1 Cover Fuser 9 31 12G0345 1 Wiper F...

Page 172: ...6 24 Service Manual 4045 XXX Assembly 10 Transfer ...

Page 173: ...Number Units Description 10 1 12G0354 1 Roller Transfer 10 2 12G0358 1 Bushing Right Roller 10 3 12G0355 2 Pin Transfer Roller 10 4 12G0359 2 Spring Transfer Roller 10 5 12G0357 1 Arm Right Transfer Roller 10 6 12G0356 1 Arm Left Transfer Roller ...

Page 174: ...6 26 Service Manual 4045 XXX Assembly 11 Charging ...

Page 175: ...on 11 1 12G0364 2 Pin Charge Roller Arm 11 2 12G0362 1 Arm Right Charge Roller 11 3 12G0358 1 Bushing Right Roller 11 4 12G0360 1 Roller Charge 11 5 12G0363 1 Bushing Left Charge Roller 11 6 12G0365 1 Link Developer Drive Engage 11 7 12G0361 1 Arm Left Charge Roller ...

Page 176: ...6 28 Service Manual 4045 XXX Assembly 12 Electronics ...

Page 177: ... 1 Card Asm LVPS 110V 12 6 12G0372 1 Card Asm LVPS 220V 12 7 12G0376 1 Card Asm HVPS 12 8 12G0366 1 Base Plate HVPS 12 9 12G3567 1 Card Asm Controller RIP M410 12 9 12G3556 1 Card Asm Controller RIP M412 12 9A 2 Screw M4x8 PP 12G0445 12 10 12G0379 1 Card Asm Interconnect 12 11 12G0380 1 Contact Ground 12 12 12G0375 1 Frame Lower LVPS 12 13 12G0378 1 Card Asm Engine M410 12 13 12G3557 1 Card Asm En...

Page 178: ...6 30 Service Manual 4045 XXX Assembly 12 Electronics continued ...

Page 179: ...ntroller Board 12 16A 2 Screw M3x6T PP 12G0445 12 17 9 Screw M4x8 PP 12G0445 12 17A 1 Screw M3x25 PP 12G0445 12 18 12G0384 1 Shield Engine Board 12 19 12G0383 1 Shield Interface Board 12 20 12G0382 1 Cover Controller Bd Shield 12 21 12G0385 1 Cover Blank Bus 12 22 12G0436 1 Cover Internal Gear ...

Page 180: ...6 32 Service Manual 4045 XXX Assembly 12 Electronics continued ...

Page 181: ... Cooling 12 34 12G0416 1 Cable Erase LED NS 1342530 1 Power Cord Set Brazil HV NS 1342534 1 Power Cord Set 8 ft Chile HV NS 1339535 1 Power Cord Set 8 ft U S Canada LV Nicaragua Venezuela Peru LV Bolivia Colombia Costa Rica Ecuador El Salvador Guatemala Honduras Mexico Panama Brazil LV NS 1342536 1 Power Cord Set 6 ft Argentina HV Paraguay HV Uruguay HV APG LV NS 1339537 1 Power Cord Set 8 ft U K ...

Page 182: ...6 34 Service Manual 4045 XXX Assembly 13 250 Sheet Tray ...

Page 183: ...G0313 1 Guide Right Paper 13 3 12G0311 1 Base 250 Sheet Paper Tray 13 4 12G0319 1 Holder Lift Plate 13 5 12G0320 1 Spring Lift Plate Holder 13 6 12G0318 1 Spring Lift Plate 13 7 12G0314 1 Buckler Corner 13 8 12G0316 1 Cover Asm Corner Buckler 13 9 12G0317 1 Pad Pick Roller Friction 13 10 12G0312 1 Plate Lift ...

Page 184: ...6 36 Service Manual 4045 XXX Assembly 14 500 Sheet Tray ...

Page 185: ...Paper Guide 14 3 12G0386 1 Base 500 Sheet Paper Tray 14 4 12G0393 1 Guide Right Paper 14 5 12G0390 1 Holder Lift Plate 14 6 12G0396 1 Spring Lift Plate Holder 14 7 12G0395 1 Spring Lift Plate 14 8 12G0394 1 Pad Pick Roller Friction 14 9 12G0387 1 Buckler Corner 14 10 12G0388 1 Cover Asm Corner Buckler 14 11 12G0389 1 Plate Lift ...

Page 186: ...6 38 Service Manual 4045 XXX Assembly 14 500 Sheet Tray continued ...

Page 187: ...Base 500 Sheet Feeder M412 14 20 12G0250 4 Foot Rubber 14 21 12G0402 1 Lever Asm Tray Bias 14 22 12G0405 1 Spring Tray Bias 14 23 12G0406 1 Guide Paper 14 24 1 Gears Tray 2 Idler PP 12G0448 14 25 12G0409 1 Motor Asm Tray 2 M410 14 25 12G3565 1 Motor Asm Tray 2 M412 14 26 12G0400 1 Shaft Asm 500 Sheet P Roller 14 27 12G0408 1 Card Asm Tray 2 M410 14 27 12G3558 1 Card Asm Tray 2 M412 14 28 12G0444 1...

Page 188: ...ry 4MB Flash DIMM w Optra Forms 15 99A1685 1 Memory 8MB Flash DIMM w Optra Forms 15 99A1686 1 Memory 16MB Flash DIMM w Optra Forms 15 12G1695 1 Card Asm INA Ethernet 10 100BaseTX 15 12G1696 1 Card Asm INA 10Base2 T 15 12G1697 1 Card Asm INA Token Ring 15 99A0560 1 Card Asm Tri port 15 99A0516 1 Adapter Hard Disk 15 99A0459 1 Disk Drive 2 1 GB 15 99A0799 1 Disk Drive 2 1 GB w OptraForms 15 99A0923 ...

Page 189: ...Lamp Test 3 26 Fan Fuser Test 3 25 Main Motor Test 3 22 Mirror Motor Test 3 23 Operator Panel Test 3 21 Reset Test Mode 3 26 Sensor Monitor Test 3 24 Solenoid Test 3 22 Tray 2 Motor Test 3 23 Hardware Tests 3 8 Button Test 3 9 DRAM Memory Test 3 9 LCD Test 3 8 Parallel Wrap Test 3 10 ROM Memory Test 3 10 Serial Wrap Test 3 11 Input Tray Tests 3 13 Panel Menus 3 2 Paper Feed Tests Base Sensor Test ...

Page 190: ... Line 2 Messages 2 11 User Status Messages 2 5 Mirror Motor Test 3 23 O Operator Panel Test 3 21 Option Tray Board 5 12 P Panel Menus 3 2 Paper Feeding Transferring and Fusing 3 27 Paper Path Sensor Locations 3 28 Parallel Strobe Adjust 3 16 Parallel Wrap Test 3 10 Parts Catalog 6 1 Charging 6 26 Covers 6 2 Developer Drive 6 18 Electronics 6 28 Frame 6 6 Fuser 6 20 Main Drive 6 16 Options 6 40 Pap...

Page 191: ...ed 2 33 Parallel Port 2 35 Print Quality 2 37 Printhead 2 36 Serial Port 2 47 Transfer Roll 2 48 Setting Configuration ID 3 15 Setting the Page Count 3 14 Solenoid Test 3 22 Status Messages 2 5 Symptom Tables 2 15 T Tray 2 Motor Test 3 23 U Unique Tools 1 4 User Line 2 Link Messages 2 12 User Line 2 Messages 2 11 User Status Messages 2 5 V Viewing the Permanent Page Count 3 15 Part Numbers 12G0250...

Page 192: ...6 21 12G0331 6 21 12G0332 6 23 12G0333 6 23 12G0334 6 21 12G0335 6 23 12G0336 6 21 12G0337 6 21 12G0338 6 23 12G0339 6 21 12G0340 6 23 12G0341 6 23 12G0342 6 23 12G0343 6 21 12G0344 6 21 12G0345 6 23 12G0346 6 23 12G0347 6 21 12G0348 6 21 12G0349 6 21 12G0350 6 23 12G0351 6 21 12G0352 6 21 12G0353 6 23 12G0354 6 25 12G0355 6 25 12G0356 6 25 12G0357 6 25 12G0358 6 25 6 27 12G0359 6 25 12G0360 6 27 ...

Page 193: ...0429 6 3 12G0430 6 3 12G0431 6 3 12G0436 6 31 12G0437 6 5 12G0438 6 5 12G0439 6 5 12G0440 6 3 12G0441 6 3 12G0443 6 17 12G0444 6 39 12G0446 6 23 12G0449 6 39 12G0450 6 39 12G0451 6 7 12G0452 6 13 12G0453 6 23 12G1695 6 40 12G1696 6 40 12G1697 6 40 12G1860 6 3 6 33 12G3550 6 3 12G3551 6 9 12G3552 6 17 12G3553 6 21 12G3554 6 21 12G3555 6 21 12G3556 6 29 12G3557 6 29 12G3558 6 39 12G3559 6 33 12G3560...

Page 194: ...6 40 99A0459 6 40 99A0516 6 40 99A0560 6 40 99A0629 6 40 99A0799 6 40 99A0923 6 40 99A1683 6 40 99A1684 6 40 99A1685 6 40 99A1686 6 40 99A1752 6 40 99A1753 6 40 99A1754 6 40 99A1755 6 40 99A1756 6 40 99A1757 6 40 99A1758 6 40 99A1759 6 40 99A1774 6 40 ...

Page 195: ...rate 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 applications and so on slow response time considerably Please refer those questions or commen...

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