Lexmark T420 Page 4 Service Manual Download

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Service Manual

4048-00x

Service Checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Cooling Fan Service Check

. . . . . . . . . . . . . . . . . . . . . . . . . .2-29

Cover Interlock Switch Service Check

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

RIP Card Service Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Dead Machine Service Check

. . . . . . . . . . . . . . . . . . . . . . . .2-33

Low Voltage Power Supply (LVPS) Service Check

. . . . . . . .2-33

Fuser Service Check

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

Main Motor Service Check

. . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Operator Panel Service Check

. . . . . . . . . . . . . . . . . . . . . . . .2-38

Transfer Roll Service Check

. . . . . . . . . . . . . . . . . . . . . . . . .2-40

Paper Feed Service Checks

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

Parallel Port Service Check

. . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Print Quality Service Checks

. . . . . . . . . . . . . . . . . . . . . . . . .2-48

Solving Print Quality Problems

. . . . . . . . . . . . . . . . . . . . . . . . . .2-55

Restoring Factory Defaults

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-62

Using Print Quality Test Pages

. . . . . . . . . . . . . . . . . . . . . . . . .2-62

Diagnostic Aids

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

Operator Panel

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

Menu Definition

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

Configuration Menu Group or Diagnostic Menu Group

. . . . . . . .3-2

Printer Diagnostics Mode

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

Continuity Check on HVPS/Cartridge

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

Repair Information

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

Handling ESD-Sensitive Parts

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

Adjustments

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

Printhead Assembly Adjustment

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

Adjusting Paper Feed Alignment

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

Lubrication

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

Re–assembly

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

Removal Procedures

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

Cover Removals

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

Rear Exit Door Removal

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

Duplex Tray Assembly Removal

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

Fuser Assembly, Fuser Paper Exit Guide,
Fuser Exit Sensor, and Fuser Lamp Removal

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

Terminal Assembly Removal

. . . . . . . . . . . . . . . . . . . . . . . . .4-22

Tray Damper and Spring Removal

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

Door Latches Removal

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

Bracket, Opener Shutter Removal

. . . . . . . . . . . . . . . . . . . . .4-25

Paper Guide Roller Removal

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

Charge Roll Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

Summary of Contents for T420

Page 1: ... 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 Safety and Notices ...

Page 2: ... mail at ServiceInfoAndTraining Lexmark com 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 Lexmark Lexmark with diamond design MarkNet MarkVision Optra and P...

Page 3: ... Media 1 6 Printer Data Streams 1 7 Fonts 1 8 Paper Handling 1 8 Connectivity 1 10 Printer Speed 1 11 RIP Card Specifications 1 11 Supplies 1 12 Operator Panel 1 12 Options 1 13 Acronyms 1 14 Diagnostic Information 2 1 Start 2 1 Operator Panel 2 2 Light Patterns 2 3 Status Information Light Patterns 2 3 Attendance Information Light Patterns 2 5 Obtaining Information about Printer Service Error Cod...

Page 4: ...st Pages 2 62 Diagnostic Aids 3 1 Operator Panel 3 1 Menu Definition 3 1 Configuration Menu Group or Diagnostic Menu Group 3 2 Printer Diagnostics Mode 3 6 Continuity Check on HVPS Cartridge 3 8 Repair Information 4 1 Handling ESD Sensitive Parts 4 1 Adjustments 4 2 Printhead Assembly Adjustment 4 2 Adjusting Paper Feed Alignment 4 3 Lubrication 4 3 Re assembly 4 5 Removal Procedures 4 6 Cover Rem...

Page 5: ...ly Stepper Removal 4 43 Main Drive Assembly Removal 4 44 Reference Plate Assembly Removal 4 46 Cartridge Coupling Assembly Removal 4 48 Upper MPF Housing Assembly with Paper Flag Removal 4 49 Lower MPF Housing Assembly Paper Sensor Removal 4 50 Lower MPF Housing Assembly Removal 4 52 MPF Roller Assembly Removal 4 53 HVPS Card Removal 4 56 LVPS Card Removal 4 57 Cooling Fan Removal 4 58 Locations 5...

Page 6: ...vi Service Manual 4048 00x ...

Page 7: ...Laser Notices vii 4048 00x Laser Notices The following laser notice labels may be affixed to this printer as shown Laser advisory label ...

Page 8: ...service condition Laser Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J für Laserprodukte der Klasse I 1 In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gemäß amtlicher Bestätigung erfüllt Laserprodukte...

Page 9: ... par l utilisateur ou de révision l exposition à des rayonnements laser supérieurs à des rayonnements de Classe I Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 6082...

Page 10: ... nivel de la Clase I durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico Declaração sobre Laser A impressora está certificada nos E U A em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I 1 de produtos laser Em outros locais está certificada como um produto laser da Classe I em conformidade com os ...

Page 11: ...ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Lasermeddelelse Printeren er godkendt som et Klasse I laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse I laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b ...

Page 12: ...ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle Älä katso säteeseen VARNING Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad Betrakta ej strålen Laser notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J för laserprodukter av Klass I 1 I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enli...

Page 13: ... 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 productes làser de classe I 1 i segons ha estat certificat en altres llocs és un producte làser de classe I que compleix els requisits d IEC 60825 1 Els productes làser de classe I no es consideren perillosos Aquesta impressora cont...

Page 14: ...xiv Service Manual 4048 00x Japanese Laser Notice Chinese Laser Notice ...

Page 15: ...Laser Notices xv 4048 00x Korean Laser Notice ...

Page 16: ...xvi Service Manual 4048 00x ...

Page 17: ...ary precautions Use of this symbol throughout the service manual indicates the presence of hazardous voltage in the repair work area Unplug the printer before proceeding or proceed with caution if repair work requires power Consignes de Sécurité La sécurité de ce produit repose sur des tests et des agréations portant sur sa conception d origine et sur des composants particuliers Le fabricant n ass...

Page 18: ...na è più elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen Die Wartungsinformationen für die...

Page 19: ...ión de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informações de Segurança A segurança deste produto baseia se em testes e aprovações do modelo original e de componentes específicos O fabricante não é responsável pela segunrança no caso de uso de peças de substituição não autorizadas As informações de segurança relativas a este produt...

Page 20: ...estions de seguretat si s utilitzen peces de recanvi no autoritzades La informació pel manteniment d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures c...

Page 21: ...Safety Information xxi 4048 00x ...

Page 22: ...ontains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems 4 Repair Information provides instructions for making printer adjustments and removing and installing FRUs 5 Locations uses illustrations and tables to identify the locations and tes...

Page 23: ...o the Lexmark T420 n laser printer are intended to refer equally to both the T420 Base and the T420 Network models Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the error code charts symptom index and service checks to determine the symptom and repair the failure See Diagnostic Information on page 2 1 for the location...

Page 24: ...1 2 Service Manual 4048 00x Serial Number Look for the serial number label on the inside front cover of the printer Printer Identification Flags Duct cover Asm Flap Front cover Cover MPF Asm MPF door ...

Page 25: ...tional memory or user flash memory options Note Indicates option is supported Memory Base Model Network Model Standard memory 16MB 32MB Standard flash memory None None Memory options 8MB DIMM 16MB DIMM 32MB DIMM 64MB DIMM 128MB DIMM Maximum of memory DIMM 2 2 Maximum possible memory 272MB 288MB Flash memory options 2MB DIMM 4MB DIMM 8MB DIMM 16MB DIMM Maximum of flash memory DIMMs 1 1 Maximum poss...

Page 26: ...nt resolution The IET setting is implicitly selected when a particular print resolution is selected using the Quality Menu Toner saver and print darkness settings are implicitly set when a particular toner darkness is selected using the Quality Menu Note Indicates print quality setting is supported Print Quality Setting Base Model Network Model Print resolution 300 dpi 600 dpi 1200 IQ dpi Image En...

Page 27: ...General Information 1 5 4048 00x Print Area The following print area settings are available Print Area Option Base Model Network Model Normal Fit to page Edge to edge ...

Page 28: ...ther are used to select a technology operating point to provide optimal print quality across a variety of media Note Indicates media is supported Media Base Model Network Model Media Operating Points Paper Card stock Transparency Labels Envelope Cotton paper Bond Media Weights Heavy Normal Light Media Textures Rough Normal Smooth ...

Page 29: ...f laser printers 4048 00x supports version 3010 of the Adobe definition of PostScript 3 and the interpreter is backward compatible with the Optra T 610 612 614 616 and other members of Lexmark s Optra family of laser printers PPDS is backward compatible with Optra T 610 612 614 616 and Lexmark s Optra family of laser printers The PPDS interpreter is inactive as a factory default It must be activat...

Page 30: ...d 5 5 PPDS scalable 39 39 Paper Handling Base Model Network Model Standard Standard input sources Integrated 250 sheet tray The 250 sheet drawer supports the following sizes A4 A5 JIS B5 folio letter legal executive and statement Multipurpose feeder 2 1 1 2 1 1 Standard output destination 150 sheet sensing bin 1 1 1 1 Standard duplex Envelope conditioning ...

Page 31: ...th 64800 183600 306000 64800 183600 306000 Options Maximum of optional drawers 1 1 Optional drawers 250 sheet drawer 500 sheet drawer The 500 sheet drawer supports the following sizes A4 JIS B5 folio letter legal and executive Maximum of media input sources 3 3 Maximum input sheet capacity excluding envelopes 850 850 Maximum sheet capacity excluding envelopes 150 150 Paper Handling Base Model Netw...

Page 32: ...actory shipped configuration Indicates attachment is not part of the model factory shipped configuration Attachments Base Model Network Model Standard parallel interface Parallel interface connector is a 1284 B connector Parallel mode 2 Standard USB interface Standard Ethernet 10 100 Base TX ...

Page 33: ...in 1200 Image Quality 22 22 Time to first print 10 seconds 10 seconds Automatic power saver 8 8 Feature Base Model Network Model Processor 922T 922T Processor Bus frequency 200 100 MHz 200 100 MHz Synchronous DRAM 2 64 Mbit 2 128 Mbit NAND flash 1 64 Mbit 1 64 Mbit Processor internal bus width capability 32 Bit 32 Bit RIP SRAM 0KB 0KB L1 Cache instruction data 8KB 8KB 8KB 8KB ...

Page 34: ...tead users must utilize an application print driver and or the printer toolkit to modify settings through the host computer A printer settings page can be printed by briefly pressing Continue when only the Ready Data light is on Print Cartridge Average Yield Approximate Coverage Prebate print cartridges 5 000 10 000 5 5 Regular cartridges without Prebate terms and conditions 5 000 10 000 5 5 Ready...

Page 35: ...General Information 1 13 4048 00x Options See Options on page 7 22 for a list of options available for the T420 n printer ...

Page 36: ... Light Emitting Diode LSU Laser Scanning Unit LVPS Low Voltage Power Supply MHz Megahertz MPF Multipurpose Feeder NAND Not And Gate NVRAM Nonvolatile Random Access Memory PCB Printed Circuit Board PCL 6 Printer Command Language PJL Printer Job Language POR Power On Reset POST Power On Self Test PPDS Personal Printer Data Stream PQET Print Quality Enhancement Technology PS PostScript PWB Printed Wi...

Page 37: ...ights on the operator panel indicate the status of the printer anytime it is powered on When the printer experiences a problem requiring operator intervention it indicates the source by blinking one or more lights See Status Information Light Patterns on page 2 3 for more information When all six lights blink simultaneously a service may need to be performed See Service Error Codes on page 2 11 fo...

Page 38: ... panel may be used for Determining printer status See Status Information Light Patterns on page 2 3 for more information Reviewing printer settings See Power On Self Test POST on page 2 26 for more information Changing printer settings See Power On Operations on page 2 25 for more information Utilizing diagnostic tools See Power On Operations on page 2 25 for more information Obtaining information...

Page 39: ...rns Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Status Ready Demo Ready Hex Trace Ready Busy Waiting Ready with Toner Low Warning Demo Ready with Toner Low Warning Hex Trace Ready with Toner Low Warning Busy with Toner Low Warning Waiting with Toner Low Warning Flushing Light is off Light is on solid Light is blinking Light is blinking slowly ...

Page 40: ... different patterns to indicate progress during programming Programming System Code Partially Complete Download System Code Data Invalid Engine Code Invalid Network Code Note A double press of Continue causes a secondary light pattern which indicates further information on the type of invalid code status exists See Invalid Code Secondary Light Patterns on page 2 5 Ready Data Toner Low Load Remove ...

Page 41: ...tatus Invalid Engine Code Invalid Network Code Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Attendance Condition Load Paper Tray 1 Tray 2 or MPF Load Paper Manual Feed Load Paper Tray 1 for Side 2 Manual Duplex Remove Paper from Output Bin Insert Tray 1 Top Cover Open Cartridge Missing Defective or Unsupported Print Cartridge Change Cartridge Invalid Refill ...

Page 42: ...on on the type of paper jam See Paper Jam Secondary Light Patterns on page 2 7 Printer Error Note A double press of Continue causes a secondary light pattern which indicates further information on the type of printer error See Printer Error Secondary Light Patterns on page 2 8 Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Attendance Condition ...

Page 43: ...econdary Light Patterns Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Attendance Condition Paper Jam Input Sensor Paper Jam Exit Sensor Paper Jam Duplex Sensor Paper Jam Fuser Exit Sensor Paper Jam Multipurpose Feeder Sensor ...

Page 44: ...Data Toner Low Load Remove Paper Paper Jam Error Press Continue Attendance Condition Complex Page Insufficient Collation Area Defective Flash Network Interface Error Resource Save Off Deficient Memory PPDS Font Error Insufficient Defrag Memory ENA Connection Lost Memory Full Short Paper Flash Full Too Many Flash Options Engine Code Failure ...

Page 45: ...ta Toner Low Load Remove Paper Paper Jam Error Press Continue Service Condition Service Error Note A double press of Continue causes a secondary light pattern which indicates further information on the type of printer error See Service Error Codes on page 2 11 for more information ...

Page 46: ...following these secondary codes The following pages show these codes Ready Data Toner Low Load Remove Paper Paper Jam Error Press Continue Service Condition Software Error 90x Transfer Roll Error 91x Fuser Toner Sensor Error 92x Printhead Transport Motor Error 93x Controller Card 94x NVRAM ROM NAND Error 95x RAM Memory Error 96x Network Error 97x Paper Port Communication Error 98x ...

Page 47: ...but not the Toner Low light All tertiary codes have a flashing Toner Low light but not a Ready Data light All lights flashing simultaneously as a result of sending data to the printer may indicate a code problem Call Lexmark Customer Service at 1 800 539 6275 for assistance Service Error Codes Service error codes are generally non recoverable except in an intermittent condition when you can POR th...

Page 48: ...or Replace the RIP card Note If the alarm control is turned on the alarm does sound when this error occurs Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error RIP interface driver error 906 Interface...

Page 49: ...er Roll Error Indicates a problem in the transfer roll area Check the cable from the HVPS CN1 to the controller card J3 Also check the voltage at pin 4 of J3 Note If the alarm control is turned on the alarm does sound when this error occurs 917 ...

Page 50: ...ation Note If the alarm control is turned on the alarm does sound when this error occurs Incorrect fuser lamp installed 925 Open circuit in thermistor path 924 Fuser too hot during printing or idle 923 Fuser failed to reach standby temperature 922 Fuser below standby temperature at idle 921 Fuser below temperature when printing 920 ...

Page 51: ...r print cartridge Note If the alarm control is turned on the alarm does sound when this error occurs Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes 927 929 ...

Page 52: ...bly Adjustment on page 4 2 for realignment procedures Note If the alarm control is turned on the alarm does sound when this error occurs Mirror motor not at operating speed 935 Verify 24 V dc on pin 5 of J7 Mirror motor lost lock 934 Mirror motor locked no hsync received 933 Printhead lost hsync 932 Printhead no first hsync 931 Printhead wrong printhead installed 930 ...

Page 53: ...be the motor the RIP card the cabling or the drive assembly Check the cable connectors The tertiary code below with four flashing lights indicates a problem in the drive assembly Note If the alarm control is turned on the alarm does sound when this error occurs Transport motor lost lock 937 Transport motor initial lock failure 936 ...

Page 54: ...g LVPS has been installed Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes 939 Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove...

Page 55: ...e Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Delay line calibration failure 949 Pel clock check failure 948 947 PQET RAM test incomplete PQET RAM test did not complete PQET RAM test failed MARCH0 PQET RAM test failed MARCH1 PQET RAM test ...

Page 56: ...ad alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error NVRAM chip...

Page 57: ...he alarm is not activated for this error Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead SRAM failure 959 NAND failure 958 ASIC failure 957 Processor failure 956 Code ROM or NAND failed Cyclic Redundancy Check CRC 955 ...

Page 58: ... and re POR the printer If the error persists replace the card If the error subsides check each DIMM independently Replace faulty DIMM Note The alarm is not activated for this error RAM in slot 3 is bad 963 RAM in slot 2 is bad 962 RAM in slot 1 is bad 961 RAM soldered on the board is bad 960 ...

Page 59: ...ly Adjustment on page 4 2 for hardware alignment of the printhead Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Primary Code Secondary Code Tertiary Codes Ready Data Press Continue Toner Low Load Remove Paper Paper Jam Error Flash parts failed while programming port 979 Bad checksum while programming port...

Page 60: ...ays check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Invalid command parameter received by specified device 984 Invalid command received by specified device 983 Communications error detected by specified device 982 Engine protocol violation detected by the specified device 981 Engine experiencing u...

Page 61: ...er open and Continue pressed 2 Close cover once the error light is displayed Print the Print Quality test pages Top cover open with Continue pressed Cartridge Lockout function enabled Enter Diagnostics mode 1 Power on with top cover open and Cancel pressed 2 Close cover once the error light is displayed Print the Print Quality test pages Top cover open with Cancel pressed Cartridge Lockout functio...

Page 62: ...0 POST completes except one or more lights do not come on See the Operator Panel Service Check on page 2 38 None of the lights come on See the Operator Panel Service Check on page 2 38 Main motor does not come on See the Main Motor Service Check on page 2 37 Fan does not come on See the Cooling Fan Service Check on page 2 29 Fuser lamp does not come on See the Cold Fuser Service Check on page 2 35...

Page 63: ...48 Black page See Black Page on page 2 50 Heavy background See Heavy Background on page 2 51 Light print See Light Print on page 2 53 White or black lines or bands See White or Black Lines or Bands on page 2 54 Toner on back of page See Toner on Back of Page on page 2 54 Paper jams See Paper Feed Service Checks on page 2 41 Main motor noisy or does not move See Main Motor Service Check on page 2 3...

Page 64: ...rinkles Stacks Poorly Or Curls on page 2 46 Top cover will not close See Cover Interlock Switch Service Check on page 2 30 Operator panel button does not respond See Operator Panel Service Check on page 2 38 or RIP Card Service Check on page 2 31 Operator panel lights do not light or are very dim See RIP Card Service Check on page 2 31 Symptom Action ...

Page 65: ... 5 8 for more information Cooling Fan Service Check FRU Action Cooling Fan Make sure the cooling fan motor cable plug is properly seated Turn the printer off and disconnect the cooling fan cable at the cooling fan Turn the printer on Within approximately 15 seconds the RIP card assembly should apply 24V dc to the fan See RIP Card Assembly on page 5 8 for more information If voltage is present repl...

Page 66: ...witch Push the cover interlock switch to the closed position and verify continuity between the bottom and middle terminals Open the switch and verify continuity between the bottom and top terminals The top and middle terminals should indicate discontinuity at all times If the switch is good verify 5 V dc on the middle spade of the cable and ground on the top spade of the cable If voltage is not pr...

Page 67: ...for 24 V dc from the LVPS card to the RIP card assembly Turn the printer off Disconnect the LVPS cable from the RIP card at J20 Turn the printer on Verify 24 V dc from the cable pins 1 and 2 If voltages are not present or incorrect see the Low Voltage Power Supply LVPS Service Check on page 2 33 ...

Page 68: ...or runs 7 The printer cycles down into standby mode ready If immediately following power on the operator panel lights are active but the printer does not go through steps 1 and 2 above replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead Note U S versus non U S...

Page 69: ...220 V Unplug the power cord and verify that the cable is correct and functioning Replace if necessary With the poser cord unplugged disconnect the 8 pin and 5 pin connectors from the LVPS On the 8 pin connector pin 1 is closest to the HVPS verify pins 2 5 and 6 are ground Replug the power cord and turn the printer on CAUTION Be careful to not ground pins to cage while testing Verify pin 4 is 5 V d...

Page 70: ...void handling the lamp as much as possible as it is easily broken Be careful not to touch the glass housing with bare hands as skin contains acids that can weaken the glass The line voltage to the printer must be within the following limits 100 V ac 127 V ac for the nominal 110 V model printer 200 V ac 240 V ac for the nominal 220 V model printer ...

Page 71: ... cable at CN3 Replug and turn the printer on Measure the voltage at connector CN4 on the LVPS It should match the line voltage If line voltage is not present replace the LVPS Make sure the fuser thermistor is correctly connected to the RIP card J22 If the problem persists disconnect the thermistor cable from the RIP card assembly and check for 4 V to 5 V dc See Locations on page 5 1 for more infor...

Page 72: ...he thermistor cable is firmly seated in connector J22 on the RIP card assembly The thermistor cable goes through the frame by way of a connector Check for excessive toner buildup on the surface of the thermistor Clean as necessary Unplug the printer and disconnect the thermistor cable from the RIP card J22 Measure the resistance of the thermistor The resistance measures approximately 245K ohms whe...

Page 73: ...ly as necessary FRU Action Main Motor Main Motor Cable Verify 24 V dc on pin 7 at J10 on the RIP card assembly If the voltage is correct check the main motor cable for continuity If the voltages are not correct see Low Voltage Power Supply LVPS Service Check on page 2 33 or replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assem...

Page 74: ...ST and check each light for proper operation FRU Action Front Cover If more than one light does not turn on or an individual light stays on solid during POST check the operator panel cable for continuity Replace if defective If the cable has continuity replace the front cover If the buttons do not depress or click when pressed replace the front cover ...

Page 75: ...g the RIP card assembly See Printhead Assembly Adjustment on page 4 2 for hardware alignment of the printhead If none of the lights come on make sure the cable is properly connected to the operator panel and the RIP card assembly Check the LVPS Disconnect the cable and check it for continuity Replace if necessary If the cable indicates continuity verify 5 V dc at pin 5 on J7 See Locations on page ...

Page 76: ...sfer roll bearings The bearing assemblies should support the transfer roll applying even pressure to the PC drum The roll should rotate evenly and smoothly Replace both the transfer roll bearing assemblies if the springs or bearings indicate damage or lack of proper function Inspect the transfer roll for signs of wear or damage and replace as necessary ...

Page 77: ...rclockwise while using a right finger to resist gear movement in the plate assembly reference edge in the paper path below the cartridge If the gear motion can be stopped while continuing to rotate the drive motor one of the units has to be replaced The paper feed gear is most likely the failing part Remove the drive assembly for further inspection Replace the faulty unit When the plate assembly i...

Page 78: ... working properly A stuck or incorrectly installed sensor causes this error Printer indicates Paper Jam and Press Continue If the secondary code indicates additionally Ready Data check under the cartridge for paper damaged flags or malfunctioning sensors Toner Low check under the cartridge and or inside the rear door for jammed paper Load Remove Paper check for a damaged flag malfunctioning sensor...

Page 79: ...with the clutch controlling motion of the pick roller If the cam surface of the pick roller clutch assembly is worn the solenoid may not stop the D roll pick roll from rotating Replace the paper feed assembly if necessary Make sure the spring on the solenoid is properly installed If the spring is improperly installed or missing the pick roller will continuously pick paper Replace the solenoid ...

Page 80: ... feed sensor Make sure the cable is seated on the RIP card assembly J23 Verify 5 V dc on pins 1 4 7 and ground on pins 3 6 and 9 See Locations on page 5 1 for more information If correct replace the input paper feed sensor If the voltage is not correct replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card assembly See Printhead Assembly Adjustment on page...

Page 81: ...ctly and its cable is plugged into the RIP card assembly See Locations on page 5 1 for more information Verify approximately 40 ohms in the solenoid If not correct replace the solenoid Verify the solenoid has the spring in place and functions mechanically If this is true and the resistance is correct replace the RIP card assembly Note Always check printhead alignment after replacing the RIP card a...

Page 82: ... the extension spring is working properly If not replace the spring If the paper feed roll shaft rotates freely replace the paper feed assembly Note We recommend that the paper feed roll be replaced when the paper feed assembly is replaced FRU Action Fuser Assembly This problem is most likely due to a worn backup roller A worn backup roller causes the printer to run hotter than required for the me...

Page 83: ...Diagnostic Information 2 47 4048 00x ...

Page 84: ...ual 4048 00x Print Quality Service Checks Blank Page FRU Action Toner Cartridge Remove the toner cartridge and gently shake the assembly to evenly distribute the toner Ensure clean electrical contacts on the right side ...

Page 85: ... the PC pin inside the printer The PC pin is directly above the transfer roll gear If the voltages are correct check the printhead cable for continuity If the cable measures continuity replace the printhead If the cable does not measure continuity replace the cable See High Voltage Power Supply HVPS on page 5 12 and verify the voltages If the 24 V dc and 5 V dc input voltage measurements are corre...

Page 86: ... Check continuity of the charge roll cable from C printed on outside HVPS to the bushing at the right side of the charge roll If continuity fails replace the left guide assembly Check continuity from the charge roll left side bushing to the right side shaft If continuity fails remove the charge roll and clean the left side shaft and bushing See High Voltage Power Supply HVPS on page 5 12 and check...

Page 87: ...ed correctly and the problem persists try a new cartridge HVPS Contacts HVPS Card RIP Card Assembly Cartridge Contacts Assembly Check the contacts for correct installation and contamination where contact is made with the toner cartridge and HVPS card Clean as necessary If this does not correct the problem replace the following FRUs one at a time in the order shown HVPS card RIP card assembly Note ...

Page 88: ...re is applied to the fuser hot roll Replace the fuser if necessary Paper Make sure recommended paper is being used FRU Action Toner Cartridge The charge roll may have an unbalanced pressure against the PC drum Check for equal forces at both ends of the charge roll Try a new toner cartridge Transfer Roll Bearings Transfer Assembly Roll Check the springs and bearings at both ends of the transfer rol...

Page 89: ... is installed correctly and is not low on toner If the problem continues install a new toner cartridge Transfer Roller HVPS Contact Transfer Roller HVPS Card Check the transfer roller for signs of toner buildup and contamination Inspect the HVPS contact transfer roller for contamination Inspect the HVPS card for contamination where it meets the HVPS contacts If all components appear free of contam...

Page 90: ...s of wear debris binds or damage FRU Action Print Cartridge Inspect the overall paper path for signs of spilled toner Gently clean the contaminated areas with a soft cloth or compressed air Fuser Assembly The fuser hot roll can cause toner on the back of the paper if toner is building up on the hot roll This buildup may transfer to the backup roller later transferring to the back of the paper Insp...

Page 91: ...wo lights are on Press Continue for three seconds The print quality test pages print See Using Print Quality Test Pages on page 2 62 for more information Problem Action Light or blurred characters The print cartridge may be getting low on toner Remove the print cartridge Shake it from side to side to redistribute the toner Reinstall it Make sure you are using recommended print media see media type...

Page 92: ...l or horizontal streaks appear on the page Replace the print cartridge Toner smears or rubs off the page Try a different kind of paper Paper designed for copiers gives the best quality If you are printing on special media such as card stock or labels be sure you select the correct paper type in the printer driver Change the media texture setting You can download the latest driver from the Lexmark ...

Page 93: ... the toner Replace the print cartridge Solid black areas on transparencies or paper contains white streaks Choose a different fill pattern in your software application Try a different type of paper Paper designed for copiers gives the best quality Remove the print cartridge and gently shake it from side to side to redistribute the toner Replace the print cartridge Faint images or repetitive spots ...

Page 94: ...t the back of the printer and at the electrical outlet The top cover does not close Make sure the print cartridge is positioned correctly The printer is on but nothing prints Make sure the print cartridge is installed properly Make sure the parallel or USB cable is firmly plugged into the connector on the back of the printer Press Continue with a brief button press to print a test page to determin...

Page 95: ...f the media The paper sticks together printer feeds multiple sheets of paper Remove the paper from tray 1 or the optional tray 2 and fan the paper Don t overfill tray 1 or the optional tray 2 see media capacities in the media types and sizes chart in the User s Guide The paper fails to feed from tray 1 Remove the paper from tray 1 and fan the paper Make sure tray 1 is selected from the printer dri...

Page 96: ...the paper Make sure the tray is pushed all the way in Make sure the metal plate is pressed down before inserting it into the printer Note Once the tray is inserted the metal plate springs up so the paper can feed into the printer Make sure the paper does not exceed the stack height indicator Make sure the paper is under both corner bucklers see loading paper in the User s Guide Problem Action ...

Page 97: ...racters are missing Make sure you are using the correct printer driver Select hex trace mode to determine what the problem is See Configuration Menu Group or Diagnostic Menu Group on page 3 2 for more information Restore factory defaults See Restoring Factory Defaults on page 2 62 for more information Make sure the parallel cable or USB cable is firmly plugged in at the back of the printer Jobs ar...

Page 98: ...ing 1 Enter the special function menu See Configuration Menu Group or Diagnostic Menu Group on page 3 2 for more information 2 Press Cancel and wait for the Ready Data light 3 Press Cancel again and wait for the Toner Low light 4 Press Cancel again and wait for both Ready Data and Toner Low lights 5 Press and hold Continue until lights cycle Three pages print to help you evaluate print quality The...

Page 99: ...Continue until all lights cycle to save the value for a menu item Press and hold Cancel until all lights cycle to go to the home state Configuration Menu Group The Configuration Menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used to configure a printer for operation Access to the Confi...

Page 100: ... 5 menu items are designated by the non indented items listed along the left edge of the page Bottom as printed from printer Note These items are un shaded and have the four light pattern indications printed Press and release Cancel to move sequentially from one of the menu items to another Press and hold Cancel to jump to home state top four lights on Press and release Continue to move through th...

Page 101: ...te Settings are retained in NVRAM Exceptions are Hex Trace and Demo Mode Activate Select Hex Trace On or Demo Mode Activate The printer automatically POR s and returns with Ready Data flashing slowly Files sent to the printer are printed in Hex Trace Press and hold Cancel to leave Hex Trace The printer returns to ready state Ready Data light on Select Demo Mode Activate The Ready Data light comes ...

Page 102: ...3 4 Service Manual 4048 00x Printer Settings Configuration ...

Page 103: ...Diagnostic Aids 3 5 4048 00x Printer Diagnostics ...

Page 104: ...hics and printing engine to set the margins accordingly When edge to edge is set on the printer graphic and printing engine shift all four margins to the physical edges of the paper 3 Print the Print Quality Pages These are the same pages that are run in the Configuration mode Note The toner cartridge lockout function is disabled in this mode In the Configuration mode the lockout function is enabl...

Page 105: ... turned off or on in the configuration mode Adjustments may have to be made if an unusually long parallel cable is being used 10 Network settings for Mark History History mode Optra Forms mode and Meditech mode can be set A service error history report network can be printed Dump NVRAM prints a hex dump of the NVRAM partition and the re init NVRAM resets the network NVRAM to the factory defaults N...

Page 106: ...dge 4 Check from C on the HVPS to the bearing on the left side of the charge roll See page 5 12 for more information 5 Check from the Dr B TAR DEV T and DC photoconductor respectively to the corresponding pin on the right side frame where the toner cartridge makes its contacts If any show discontinuity remove the HVPS and check the cartridge contact assemblies springs for continuity and damage If ...

Page 107: ...ctricity in your body to the printer 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 printer 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 electrica...

Page 108: ... cannot be adjusted Contact the next support level or call Lexmark 1 800 539 6275 for assistance To perform the registration check and adjustment 1 Turn the printer off 2 Open the front door 3 Press and hold Cancel while turning the printer on 4 Hold Cancel until the lights have cycled on and off approximately nine seconds 5 Close the door when the Error light comes on Wait for the four top lights...

Page 109: ...eference plate reference edge assembly is removed it requires alignment Use a long shank 6 inches Phillips screwdriver to adjust the rear screw holding the assembly in place It is accessed through the hole in the main drive assembly It is between the RIP card cage and the main motor PCB Adjust the screw counterclockwise which rotates paper counterclockwise in the printer path image clockwise and v...

Page 110: ...4 4 Service Manual 4048 00x P N 56P0633 P N 56P0637 ...

Page 111: ...r may not detect a disconnected sensor in some areas without extensive running For example the tray full sensor has a connector in the left cover and has to be disconnected to remove the rear cover The tray would have to be full for the sensor to function The sensor is also required for duplexing P N 56P0635 P N 56P0636 ...

Page 112: ...vers removed Be sure to remove the print cartridge before you perform removal procedures Cover Removals Lower Front Cover Multipurpose Feeder Cover Removal 1 Open the front cover 2 Open the MPF front cover to where the latches are clear about 15 3 Lift the left side of the cover to release it from the hinge 4 Remove the lower front cover ...

Page 113: ...Repair Information 4 7 4048 00x Front Cover Removal 1 Open the front cover 2 Disconnect the cable from the display panel A 3 Remove the four screws B 4 Remove the front cover ...

Page 114: ...4 8 Service Manual 4048 00x Top Cover Assembly Removal 1 Remove the toner cartridge 2 Remove the two 2 screws in front A 3 Open the rear exit door 4 Remove the two screws in the rear A A A ...

Page 115: ...Repair Information 4 9 4048 00x 5 Remove the duct assembly in the top cover ...

Page 116: ...4 10 Service Manual 4048 00x 6 Carefully lift the rear edge of the top cover to clear the exit flags and rotate the front cover hinge until the cover is in a vertical position ...

Page 117: ... remove the top cover 7 Open the front cover 8 Remove the E clips from both hinges that connect the charge roller and top cover B 9 Remove the stud hinges 10 Disconnect the cable A 11 Remove the top The front cover remains attached to the top cover ...

Page 118: ...t have an appropriate screwdriver to access the front right screw remove the two screws holding the right side of the front cover to the hinge Move the front cover just enough to access the screw 3 Open the MPF 4 Lift the top cover just enough to grasp the top of the right side cover with your right hand B 5 While pulling out on the top of the right side cover use your left hand to release the two...

Page 119: ...ght Side Cover Removal There may be an occasion where you have to completely remove the top cover instead of just lifting it to access the screw and latches 1 Remove the paper tray 2 Remove the top cover assembly See Top Cover Assembly Removal on page 4 8 for more information 3 Release the three latches lower front top front top rear as shown in the picture above 4 Lift cover out of the bottom slo...

Page 120: ... 14 Service Manual 4048 00x Left Side Cover Removal 1 Open the front cover and the MPF cover 2 Disengage the two latches located in the front and top A 3 Swing the left side cover away from the printer A ...

Page 121: ...r with PWB see Paper Feed on page 7 14 for more information Door latches see Frame on page 7 16 for more information Paper feed solenoid see Electronics and Cables on page 7 8 for more information RIP card cage cover see Electronics and Cables on page 7 8 for more information Memory see Options on page 7 22 for more information Connector cable for second drawer option see Electronics and Cables on...

Page 122: ... See Left Side Cover Removal on page 4 14 for more information 4 Turn the printer to face rear cover 5 Open the paper tray trim A 6 Disconnect the sensor cable inline connector below the lower left corner of the controller cage Note Replug the sensor cable on re assembly The printer fails to detect tray full and will not duplex properly without this connection 7 Open the exit tray rear door B ...

Page 123: ...rews A 9 Lift the top cover slightly with one hand while pulling out on the rear cover Note When reinstalling the rear cover be sure to position the fuser exit guide fingers such that they are not bound by the rear cover If a bind occurs a jam will occur ...

Page 124: ...r Exit Door Removal 1 Open the rear exit door 2 Use your index finger or screwdriver to disengage the left facing back of printer hinge from the rear cover A With your opposite hand apply force to remove the door away from the printer ...

Page 125: ...embly Removal 1 Remove the paper tray 2 Disconnect all cables on the back of the printer 3 Tilt the printer on its back 4 Remove the five screws A 5 Work the right side loose first disconnect the paper input sensor cable 6 Remove the duplex assembly ...

Page 126: ...on page 4 8 for more information 3 Remove the rear cover See Rear Cover Removal on page 4 16 for more information 4 To remove the fuser assembly release the two latches and remove the cooling fan duct A 5 To replace only the paper exit guide or exit sensor remove one screw B to lift off the exit guide 6 Disconnect the spring on the left side 7 Swing out for clearance to replace A B ...

Page 127: ...fuser is loosened 9 Remove the four screws A Note Removing the lower left screw requires a long screwdriver approximately a 6 inch shank 10 Remove the fuser 11 To replace the fuser lamp remove the two screws at each end and very carefully extract the lamp from the heater roll Warning Do not touch the glass of a good lamp it causes premature failure ...

Page 128: ...ual 4048 00x Terminal Assembly Removal 1 Remove the HVPS See HVPS Card Removal on page 4 56 for more information 2 Remove the terminal assemblies A Note The lower right terminal to the transfer roll is gold in color A ...

Page 129: ...er and Spring Removal 1 Remove the right side cover See Right Side Cover Removal on page 4 12 for more information 2 Remove the tray damper spring from the printer frame post A 3 Rotate the lever counterclockwise as far as possible and lift out ...

Page 130: ...e the right side cover See Right Side Cover Removal on page 4 12 for more information 2 Remove the two screws A and replace the latches 3 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 4 Remove one latch on left side ...

Page 131: ...HVPS Card Removal on page 4 56 for more information 2 Remove the toner cartridge 3 Unsnap the latches from the frame 4 Remove the opener shutter bracket Note The bracket can be removed with possible latch breakage by wedging a screwdriver or similar tool between the bracket and the frame ...

Page 132: ...ard Removal on page 4 56 for more information 2 Remove the toner cartridge 3 Remove the upper body MPF assembly See Upper MPF Housing Assembly with Paper Flag Removal on page 4 49 for more information 4 Unsnap the latch which is part of the roller hub A 5 Remove the paper guide roller ...

Page 133: ...emove the toner cartridge 2 Grasp the charge roll on the left end and push the bearing and roll away from each other Warning Handle the charge roll with clean dry hands and only at the ends 3 After the left side is removed from the bearing slide the roll from the right side bearing ...

Page 134: ... page 4 27 for more information 5 Remove two screws in the right guide above and behind the HVPS 6 Unsnap the three latches of the right guide 7 Remove the right guide Left Guide Removal 1 Remove the toner cartridge 2 Remove the top cover See To completely remove the top cover on page 4 11 for more information 3 Remove the RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for...

Page 135: ...he three screws A and B one holding the link guide bracket arm to the left guide 6 Remove the left stud hinge on the top cover See step 6 on page 4 11 for more information 7 Remove the HVPS See HVPS Card Removal on page 4 56 for more information ...

Page 136: ...sibility and access Illustrations are with the LSU removed See Printhead Removal on page 4 39 for more information 9 Remove the wire from the retainers between the printer s right side and the left guide 10 Unsnap the three latches C of the left guide while prying the assembly from the frame See page page 4 29 for more information 11 Remove the left guide ...

Page 137: ... Remove the two screws and the bracket coupling assembly 4 For additional clearance remove the charge roll See Charge Roll Removal on page 4 27 for more information 5 Remove the screw holding the smart button sensor A 6 Remove the two screws in the cable cover retainer 7 Remove the sensor by pushing from inside the printer Note Unplug the thermistor cable to remove the smart button sensor ...

Page 138: ...ove the two screws A holding the entrance guide 3 Remove the duplex unit See Duplex Tray Assembly Removal on page 4 19 for more information 4 Unsnap the two latches holding the entrance guide 5 Remove the entrance guide 6 Check the printhead alignment and adjust as necessary See Printhead Assembly Adjustment on page 4 2 for more information ...

Page 139: ...e transfer roll except on the ends 1 Remove the toner cartridge 2 Unlatch and lift the left side support bearing 3 Unlatch and lift the right transfer support bearing 4 Remove the transfer roll Note After reinstalling the transfer roll use a thin screwdriver to push the copper tab on the right side fully into the slot ...

Page 140: ... latches in the bracket Leave the door open 2 Remove the duplex tray assembly See Duplex Tray Assembly Removal on page 4 19 for more information 3 Disconnect the cable to the sensor or remove the sensor and cable together 4 Unlatch the bracket by pushing from inside the printer and pulling from the duplex side ...

Page 141: ...e 4 19 for more information 3 Disconnect extension spring B from the D roll 4 Release the latch on the paper feed solenoid It is located behind the lower right corner of the main drive assembly 5 Rotate the main drive motor counterclockwise until the D roll clears the adjacent rib 6 Using a slotted screwdriver as a wedge between the D roll and bearing wall force the D roll to unsnap from the shaft...

Page 142: ...ssembly Removal 1 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 2 Remove the inner cover 3 Remove the MPF gear 4 Remove the gear train assembly See Main Drive Assembly Removal on page 4 44 for more information ...

Page 143: ...l See D Roll Tray 1 Feed Removal on page 4 35 for more information Note Slowly extract the shaft while facing the D roll end Capture the small washer and the bearing The bearing must be removed and reinserted through the opening adjacent to its operating location A See page page 4 35 for more information ...

Page 144: ...he RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information 2 Remove the rear cover See Rear Cover Removal on page 4 16 for more information 3 Unplug the wires on both sides of the connectors 4 Unsnap connectors and remove to the left side ...

Page 145: ...thead cable Note Mark alignment of the printhead at the screw areas with the printhead to keep the same alignment upon reinstallation 3 Remove the four screws A 4 Remove the printhead 5 Check alignment of the printhead before reinstalling the top cover Adjust as necessary See Printhead Assembly Adjustment on page 4 2 for more information ...

Page 146: ...s in the controller cage cover and slide the cover off 3 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information 4 Disconnect all cables from the RIP card assembly 5 Remove the inner cover 6 Remove the three screws through the RIP card and one only through the cage A 7 Gently pull the bottom of the cage out and lift up and off the two posts at the top A ...

Page 147: ...n the controller cage cover and slide the cover off 3 Remove the inner cover 4 Disconnect all cables from the RIP card assembly 5 Extract all cables from the cage except those at the top rear portion of the card 6 Remove three screws through the RIP card and one only through the cage A 7 Remove three screws at the ports at the back of the cage 8 Carefully remove the RIP card ...

Page 148: ...sembly Removal 1 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 2 Disconnect the cable to the PWB 3 Remove the four screws holding the metal base plate to the gear train assembly 4 Remove the motor assembly A ...

Page 149: ... Assembly Removal on page 4 8 for more information 2 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 3 Remove the RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information 4 Remove three screws B 5 Lift the stepper motor out B ...

Page 150: ...age with card in place Removal on page 4 40 for more information 4 Remove the inner cover one 1 screw 5 Remove the roller MPF gear by lifting the latch in the center of the hub and sliding it out D 6 Free the cables from the attached retainers 7 Remove the six 6 screws in the gear train assembly A B and C 8 Remove the two screws holding the bearing at the upper right corner of the PWB 9 Lift up ge...

Page 151: ...Repair Information 4 45 4048 00x ...

Page 152: ...e MPF cover See Lower Front Cover Multipurpose Feeder Cover Removal on page 4 6 for more information 5 Remove the upper body MPF assembly See Upper MPF Housing Assembly with Paper Flag Removal on page 4 49 for more information 6 Remove the lower body MPF assembly See Lower MPF Housing Assembly Paper Sensor Removal on page 4 50 for more information 7 Remove one screw in the cover adjacent to the as...

Page 153: ...se a long shank 6 inches Phillips screwdriver to adjust the rear screw holding the assembly in place It is accessed through the hole in the main drive assembly between the RIP card cage and the main motor PCB Adjusting the screw counterclockwise rotates paper counterclockwise in the printer path image clockwise and vice versa ...

Page 154: ...l on page 4 8 for more information 3 Remove the left cover See Left Side Cover Removal on page 4 14 for more information 4 Remove the RIP card cage See RIP Card Cage with card in place Removal on page 4 40 for more information 5 Remove the two screws A 6 Remove the bracket Note The toner cartridge coupling may need to be compressed during removal ...

Page 155: ...nformation 4 49 4048 00x Upper MPF Housing Assembly with Paper Flag Removal 1 Open the front cover 2 Remove two screws holding the assembly 3 Carefully lift the assembly out Note A sensor flag is attached below ...

Page 156: ... Sensor Removal 1 Remove the lower front MPF door See Lower Front Cover Multipurpose Feeder Cover Removal on page 4 6 for more information 2 Remove the feed roll cover one screw 3 At the lower right assembly hinge separate the metal plate from the plastic housing ...

Page 157: ...al plate until the sensor can be accessed 6 Disconnect the cable to the sensor and remove the sensor by pushing on the latches underneath the sensor and housing 7 Install the new sensor and reconnect the cable 8 Reinstall the metal plate Make sure the compression spring is in the proper location and captured at its ends 9 Rotate the metal plate to keep the spring positioned Reconnect the left hing...

Page 158: ...ormation 2 Remove the left side cover See Left Side Cover Removal on page 4 14 for more information 3 Loosen the six screws in the RIP card cover Slide the cover toward the rear and remove 4 Disconnect the MPF cable on the right side of the RIP card and the toner level sensor 5 Remove the three screws A on the front of the lower body MPF assembly and gently remove the assembly ...

Page 159: ... Remove the left side and inner covers See Left Side Cover Removal on page 4 14 for more information 4 Remove the roller cover one 1 screw See Lower MPF Housing Assembly Removal on page 4 52 for more information 5 Remove the lower body MPF assembly See Lower MPF Housing Assembly Removal on page 4 52 for more information CAUTION The lower body MPF assembly remains electrically connected since it is...

Page 160: ...4 54 Service Manual 4048 00x 6 Remove the MPF gear using your thumbnail to release the latch and slide the gear from the shaft ...

Page 161: ...Repair Information 4 55 4048 00x 7 Remove two screws A holding the roller assembly and one screw facing the front of the printer 8 Remove the roller assembly ...

Page 162: ... See Top Cover Assembly Removal on page 4 8 for more information 2 Remove the right side cover See Right Side Cover Removal on page 4 13 for more information 3 Disconnect the HVPS cable 4 Remove the four screws A 5 Disconnect the charge roll cable 6 Remove the HVPS card ...

Page 163: ...move the top cover See Top Cover Assembly Removal on page 4 8 for more information 3 Remove the right side cover See Right Side Cover Removal on page 4 13 for more information 4 Disconnect all cables attached to the LVPS card 5 Remove the three screws B 6 Remove the LVPS A B A ...

Page 164: ... 1 Remove the top cover See Top Cover Assembly Removal on page 4 8 for more information 2 Remove the right side cover See Right Side Cover Removal on page 4 13 for more information 3 Disconnect the fan cable 4 Remove the two screws A 5 Remove the fan ...

Page 165: ...Locations 5 1 4048 00x 5 Locations Flags Duct cover Asm Flap Front cover Cover MPF Asm MPF door ...

Page 166: ...5 2 Service Manual 4048 00x Cables 3 7 13 5 16 9 15 2 10 6 4 8 1 11 14 12 11 5 ...

Page 167: ...3 Switch Interlock Cover 4 and 5 Sensor and Cable Included with P N 56P0611 6 and 7 Solenoid Paper Feed 7 Sensor Toner Level 9 Cable Assembly Drawer 10 Card Assembly RIP 10 Card Assembly Network RIP 11 Cable Assembly Output Full and Fuser Exit 12 Sensor Smart Button 13 Sensor Cable Output Full 14 Connector 3 Pin 15 Connector 2 Pin 16 Sensor Photo ...

Page 168: ...5 4 Service Manual 4048 00x Cables continued 1 2 3 4 5 6 7 8 9 10 11 ...

Page 169: ...ly 220 V 2 7 8 9 Cable Assembly Main Harness Locations 2 HVPS 7 Fan 8 LVPS Power 9 LVPS Control NS Paper In Duplex 3 Fuser PS High Volt 4 Guide Assembly Left 5 Cable Assembly LVPS to Fuser 6 Fan Cooling 10 Card Assembly RIP 10 Card Assembly Network RIP 11 Cable Assembly Printhead ...

Page 170: ...5 6 Service Manual 4048 00x Sensors 6 1 2 7 3 4 5 8 ...

Page 171: ...7 4048 00x Reference Description 1 Paper Path Exit Flag 2 Paper Path below Cartridge 3 Paper Path Duplex 4 Paper Path MPF 5 Paper Path below Cartridge 6 Sensor Toner Level 7 Sensor Smart Button 8 Sensor Fuser Exit ...

Page 172: ... 1 1 J2 J3 J4 1 J19 1 J20 1 J21 1 J22 1 J23 1 J17 1 1 1 J15 J14 J16 J12 1 1 1 J10 J8 1 1 J7 J5 Note Pin number 1 is designated on the printed circuit card by either a white triangle a number 1 or both The pin numbers follow chronologically to the opposite end of the connector ...

Page 173: ...36 47 51 62 76 86 97 3 3 V 3 3 V Gnd Gnd USB connector J5 USB 4 1 USB power 3 3 V SDRAM J6 DIMM 1 100 6 21 31 42 50 71 81 92 56 1 12 26 36 47 51 62 76 86 97 3 3 V 3 3 V Gnd Gnd Operator panel lights J7 OP PANEL 6 1 5 Gnd 5 V MPF solenoid J8 MPF 2 1 2 24 V during MPF pick Main motor J10 MAIN MOTOR 7 1 6 7 Gnd 24 V dc Exit motor J12 EX_MT 4 1 2 24 V during motor run Sensor MPF toner J14 MPF SN 6 1 3...

Page 174: ... 6 5 6 Gnd 24 V Fuser exit tray full sensor J19 P EXIT 6 1 3 4 6 5 V Gnd 5 V Gnd LVPS DC power J20 POWER 6 1 2 3 4 5 6 24 V Gnd 5 V Gnd Thermistor Smart IC J21 THERM 5 2 5 Gnd HVPS J22 HVPS 11 1 2 5 7 24 V fan Gnd fan Gnd 24 V Sensor paper input narrow duplex J23 Paper IN Duplex 9 1 4 7 3 6 9 5 V Gnd Function Name Name on Card of Pins Pin Signal ...

Page 175: ...ly LVPS Function Name Name on Card of Pins Pin Signal 110 220 Volts CN1 CN2 5 8 1 1 2 5 6 3 4 7 8 5 V dc Gnd 5 V dc 24 V dc Heater CN3 2 1 2 110 220 V ac On off switch CN4 S W 2 1 2 110 220 V ac CN1 CN2 1 1 CN3 CAUTION 110 220 V ac CN4 ...

Page 176: ...5 12 Service Manual 4048 00x High Voltage Power Supply HVPS Function Name Name on Card of Pins Pin Signal To RIP J16 CN1 8 2 4 7 Gnd 24 V dc 5 V dc Charge roll C Terminal 1 ...

Page 177: ...tered parts especially in the area of the on off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause prema...

Page 178: ...6 2 Service Manual 4048 00x ...

Page 179: ...umber Parts peculiar to one or the other of the assemblies are listed separately and identified by description AR As Required in the Units column indicates that the quantity is not the same for all machines 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 parts description column indicates the part is containe...

Page 180: ...7 2 Service Manual 4048 00x Assembly 1 Covers 2 9 1 3 4 5 10 8 6 7 ...

Page 181: ... 1 3 56P0680 1 Flap Paper Holder 1 4 56P0603 1 Cover Assembly Duct 1 5 56P0604 1 Cover Assembly Top 1 6 56P0605 1 Cover Assembly Right 1 7 56P0601 1 Cover Assembly Front with Display without logo 1 7 56P0602 1 Cover Assembly Front with Display with logo 1 8 56P0610 1 Cover Assembly MPF Door 1 9 56P0679 1 Overlays Language 1 10 56P0600 1 Cover Assembly Left ...

Page 182: ...7 4 Service Manual 4048 00x Assembly 2 Multipurpose Feeder MPF 1 3 4 5 2 ...

Page 183: ...rpose Feeder MPF Asm Index Part Numbers Units Description 2 1 56P0612 1 Housing Assembly Upper MPF 2 2 56P0611 1 Housing Assembly Lower MPF 2 3 56P0615 1 Cap MPF Paper Feed Cover 2 4 56P0613 1 Assembly Roller MPF 2 5 56P0614 1 Gear MPF Paper Pick ...

Page 184: ...7 6 Service Manual 4048 00x Assembly 3 Charging 4 5 3 2 1 6 2 3 7 ...

Page 185: ...s Units Description 3 1 56P0640 1 Roll Charge 3 2 56P0668 1 Parts Pack Screws and E Rings 3 3 56P0669 1 Hinge Pivot quantity 2 3 4 56P0642 1 Guide Assembly Right 3 5 56P0643 1 Assembly Transfer Roll 3 6 56P0644 1 Bearings Transfer Roll 3 7 56P0641 1 Guide Assembly Left ...

Page 186: ...7 8 Service Manual 4048 00x Assembly 4 Electronics and Cables 1 2 3 4 5 6 7 8 9 10 11 ...

Page 187: ...0 V 4 2 7 8 9 56P0663 1 Cable Assembly Main Harness Locations 2 HVPS 7 Fan 8 LVPS Power 9 LVPS Control NS Paper In Duplex 4 3 56P0628 1 PS High Volt 4 4 56P0641 1 Guide Assembly Left 4 5 56P0650 1 Cable Assembly LVPS to Fuser 4 6 56P0630 1 Fan Cooling 4 10 56P0617 1 Card Assembly RIP 4 10 56P0619 1 Card Assembly Network RIP 4 11 56P0622 1 Cable Assembly Printhead ...

Page 188: ...7 10 Service Manual 4048 00x Assembly 4 cont Electronics and Cables 3 7 13 5 16 9 15 2 10 6 4 8 1 11 14 12 11 5 ...

Page 189: ... MPF housing 4 6 and 8 56P0616 2 Solenoid Paper Feed 4 7 56P0653 1 Sensor Toner Level 4 9 56P0631 1 Cable Assembly Drawer 4 10 56P0617 1 Card Assembly RIP 4 10 56P0619 1 Card Assembly Network RIP 4 11 56P0664 1 Cable Assembly Output Full and Fuser Exit 4 12 56P0652 1 Sensor Smart Button 4 13 56P0682 1 Sensor Cable Output Full 4 14 56P0665 1 Connector 3 Pin 4 15 56P0666 1 Connector 2 Pin 4 16 56P06...

Page 190: ...7 12 Service Manual 4048 00x Assembly 4 cont Electronics and Cables This page left intentionally blank ...

Page 191: ... Belgium Bosnia Bulgaria Catalan Czech Croatia Egypt Albania Euro English and other East Finland France Germany Greece Hungary Iceland Iran Italy Jordan Lebanon Macedonia Netherlands Norway Paraguay Poland Portugal Romania Russia and CIS Slovak Countries Slovenia Spain Sweden Syria Turkey Yugoslavia Serbia and Montenegro HV NS 1339530 1 Power Cord Israel HV NS 1339531 1 Power Cord Switzerland HV N...

Page 192: ...7 14 Service Manual 4048 00x Assembly 5 Paper Feed 1 2 5 6 7 8 3 4 14 15 17 10 9 11 12 13 16 ...

Page 193: ...r 5 7 56P0657 1 Assembly Paper Feed 5 8 56P0654 1 Plate Assembly 5 9 56P0634 1 Gear Paper Feed 5 10 56P0693 1 Roller Asm Reference Backup Top Front and Rear 5 11 56P0633 1 Assembly Drive 5 12 56P0632 1 Motor Assembly Main Drive 5 13 56P0638 1 Coupling Cartridge 5 14 56P0637 1 Drive Ratchet 5 15 56P0635 1 Assembly Motor 5 16 56P0636 1 Gears Spur 5 17 56P0639 1 Guide Link Order a lubricant to use wi...

Page 194: ...7 16 Service Manual 4048 00x Assembly 6 Frame 1 2 3 9 8 6 5 4 4 7 10 11 12 4 4 8 ...

Page 195: ...head 6 3 56P0629 1 Assembly Cartridge Contacts quantity 5 6 4 56P0662 1 Feet Base 6 5 56P0661 1 Damper Tray 6 6 56P0668 1 Parts Pack Screws and E Rings 6 7 56P0609 1 Assembly Tray 1 6 8 56P0667 1 Latch Door Qty 3 6 9 56P0660 1 Roller Paper Guide 6 10 56P0659 1 Bracket Shutter 6 11 56P0672 1 Bracket Body Tray 6 12 56P0658 1 Guide Entrance ...

Page 196: ...7 18 Service Manual 4048 00x Assembly 7 Fuser 1 2 3 4 ...

Page 197: ... Asm Index Part Numbers Units Description 7 1 56P0648 1 Assembly Fuser 110 V 7 1 56P0671 1 Assembly Fuser 220 V 7 2 56P0673 1 Fuser Assembly Paper Guide 7 3 56P0676 1 Spring Fuser Exit 7 4 56P0646 1 Lamp Fuser 110 V 7 4 56P0647 1 Lamp Fuser 220 V ...

Page 198: ...7 20 Service Manual 4048 00x Assembly 8 Sensors 6 1 2 7 3 4 5 8 ...

Page 199: ...escription 8 1 5 8 56P0645 1 Sensor Photo Locations 1 Paper Path Exit Flag 2 Paper Path below Cartridge 3 Paper Path Duplex 4 Paper Path MPF 5 Paper Path below Cartridge 8 Fuser Exit Sensor 8 2 5 56P0655 1 Bracket Paper Sensor 8 6 56P0653 1 Sensor Toner Level 8 7 56P0652 1 Sensor Smart Button ...

Page 200: ...7 22 Service Manual 4048 00x Assembly 9 Options 1 2 3 4 ...

Page 201: ...1774 1 DIMM 16MB Flash NS 99A1683 1 DIMM Optra Forms 2MB Flash NS 99A1684 1 DIMM Optra Forms 4MB Flash NS 99A1685 1 DIMM Optra Forms 8MB Flash NS 99A1686 1 DIMM Optra Forms 16MB Flash NS 56P1248 1 DIMM Japanese 8MB Font NS 56P1250 1 DIMM Simplified Chinese Font NS 56P1251 1 DIMM Traditional Chinese Font NS 12G9833 1 MarkNet X2011e Ethernet 10 100 BaseTX NS 12G9832 1 MarkNet X2012e Ethernet 10 100 ...

Page 202: ...7 24 Service Manual 4048 00x NS 1038693 1 Cable Serial 50 ft NS 56P0670 1 Kit Repack Assembly 9 Options Asm Index Part Numbers Units Description ...

Page 203: ...settings 3 3 graphical aids 3 3 moving around the menu 3 2 printer diagnostics 3 5 printer setting configuration 3 4 Door Latches Right Side Removal 4 24 D Roll Tray 1 Shaft Assembly Removal 4 36 Duplex Tray Assembly Removal 4 19 E Entrance Guide Removal 4 32 ESD Sensitive Parts 4 1 F Factory Defaults restoring 2 62 Flash Memory 1 3 Fonts 1 8 Front Cover Removal 4 7 Fuser Assembly Removal 4 20 Fus...

Page 204: ...ions 2 25 Power On Self Test POST 2 26 Preventive Maintenance 6 1 Print Area 1 5 Print Media 1 6 operating points 1 6 textures 1 6 weights 1 6 Print Quality 1 4 solving problems 2 55 using test pages 2 62 Printer Diagnostics Mode 3 6 Printer Error Secondary Lights 2 8 Printer Features 1 3 connectivity 1 10 data streams 1 7 fonts 1 8 media 1 6 operating points 1 6 textures 1 6 weights 1 6 memory 1 ...

Page 205: ...embly 4 46 sensor MPF paper sensor 4 50 smart button 4 31 terminal assembly 4 22 transfer roll assembly left transfer bearing 4 33 tray damper 4 23 spring 4 23 upper MPF assembly 4 49 Resolution 1 4 Right Guide Removal 4 28 Right Side Cover Removal 4 12 4 13 RIP Card Assembly Removal 4 41 RIP Card Cage Removal 4 40 RIP Card Specifications 1 11 Roll Tray 1 Feed Removal 4 35 S Safety Information 1 x...

Page 206: ...ftware illegal trap 2 11 RIP to engine communication error 2 18 toner sensor error 2 15 transfer roll error 2 13 transport motor error 2 17 Service Error Secondary Lights 2 10 Service Information Light Patterns 2 9 Smart Button Sensor Removal 4 31 Special Tools 1 1 Status Information Light Patterns 2 3 Supplies 1 12 Symptom Tables 2 26 POST 2 26 printer 2 27 T Terminal Assembly Removal 4 22 Top Co...

Page 207: ...619 7 9 7 11 56P0620 7 11 56P0622 7 9 56P0623 7 17 56P0624 7 11 56P0625 7 11 56P0626 7 9 56P0627 7 9 56P0628 7 9 56P0629 7 17 56P0630 7 9 56P0631 7 11 56P0632 7 15 56P0633 4 4 7 15 56P0634 7 15 56P0635 4 5 7 15 56P0636 4 5 7 15 56P0637 4 4 7 15 56P0638 7 15 56P0639 7 15 56P0640 7 7 56P0641 7 7 7 9 56P0642 7 7 56P0643 7 7 56P0644 7 7 56P0645 7 11 7 15 7 21 56P0646 7 19 56P0647 7 19 56P0648 7 19 56P...

Page 208: ...6P0679 7 3 56P0680 7 3 56P0682 7 11 56P0693 7 15 56P0694 7 23 56P0695 7 23 56P0696 7 23 56P0697 7 23 56P0698 7 23 56P0699 7 23 56P1248 7 23 56P1250 7 23 56P1251 7 23 70G0478 7 13 99A0545 7 23 99A1683 7 23 99A1684 7 23 99A1685 7 23 99A1686 7 23 99A1757 7 23 99A1758 7 23 99A1759 7 23 99A1774 7 23 ...

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