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Lexmark Optra K 1220 Laser Printer

1. Repair Information 4 23 Installation Note When you put the pick up roller on the shaft face the tapered rib of the roller toward the pick up motor Tapered rib Pick up motor 5522 Pick up roller 4 24 Power Supply Board Removal 1 Remove the right side cover and the shield plate 2 Open the controller card door assembly and disconnect the pro cess fan 3 Remove the fuser and power supply board assembly 4 Turn the assembly upside down 5 Remove the six screws that hold the power supply board in place 6 Disconnect the two fuser connectors then the sensor board connector and remove the power supply board Installation Note To prevent damage to the pick motor cable and cover open switch cable be sure they are above the interconnect card Repair Information 4 25 Print Density Board Removal 1 Remove the control board 2 Remove the fan shield plate Remove the print density board from the bottom of the frame 1 screw 4 26 Printhead Removal Remove the upper cover Disconnect the connector from the printhead assembly Remove the printhead cover and the printhead assembly 3 screws Printhead Erase LED Assembly Removal 1 Remove the upper cover 2 Remove the printhead 3 4 Disconnect the printhead erase LED assembly cable from
2. F gt EMI SCA LH DMMENSOT LEO Ol AOA VE 8012 AMO Woh BEM SAIS Class 1 Laser Statement Label Label is on back of printer viii Service Manual Laser Der Drucker erf llt gem B amtlicher Bestatigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J fur Laserprodukte der Klasse 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 825 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert da im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem er Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 825 relatives aux produits laser de Classe I Les produits laser de Classe sont cons
3. oe menm 4 27 Printhead Erase LED Assembly Removal 4 27 Process Fan Removal 4 28 Separator Assembly Removal 4 30 Stacker Full Sensor Board Removal 4 31 Transfer Corona Removal 4 32 Locations si 4 5 1 Front and Right Side of Printer 5 1 Rear and Left Side of Printer 5 2 Interior of Printer with Upper Door Open 5 3 Optional Multi Function Feeder Paper Feeder 5 4 E eo gk T 5 5 EP DGA sous e eds ame p RR 5 6 5 7 CONIC DOAN uu veces VES RES Sean Ss 5 8 Power Supply BOSIQ das sistema 5 9 Interconnect Board isses emm mes 5 10 Parts Catalog saone drame 6 1 How to Use This Parts Catalog 6 1 uad ped a deck b d 6 2 COVES d PRA 6 4 2 alae Gene pd 6 6 Frame Det SIUS dead 6 10 Frame Right Side sous sais see sise etkanda 6 12 Contents v Input Paper sieste mener 6 14 Printhead and Paper Feed Redrive 6 16 Exit Paper Feed 6 18 6 20 Paper Tray 250 Sheet eodd 6 22 Optional 450 Sheet Second Paper Tray
4. 2 1 4 estates acl noe ide aeria 2 2 s e Mr PEE 2 2 Service Error Code 2 3 User Error Messages sius use X Rr Re x ER 2 5 Symptom Table usus bases dox i Roe Sd ex edd wars 2 8 RICE 2 9 Cover Open Switch Service Check 2 9 Dead Machine Service Check 2 10 Engine Fan Service 2 11 Erase LED Service 2 11 Exit Sensor Service 2 12 Fuser Service Check 2 13 Image Quality Service Check 2 13 Main Motor Service 2 20 Input Sensor Service 2 21 Operator Panel Buttons Service Check 2 22 Operator Panel Display Service Check 2 22 Options Service Check 44 2 23 Paper Feed Service Check 2 24 Parallel Port Service Check 2 26 Printhead Service Check 2 26 Process Fan Service 2 27 Serial Port Service Check 2 27 Contents Standard Bin Full Sensor Service Check 2 27 Toner Sensor Service Check 2 29 Transfer Corona Service Check 2 29 Diagnostic AldS 222 222 4 3
5. Quick Disk Test Test Failed message displays if the test failed and the busy indicator turns on solid Press Go Return or Stop to return to the Device Tests menu Disk Test Clean WARNING This test destroys all data on the disk and should not be attempted on a good disk Also note that this test may run approxi mately 1 1 2 hours depending on the disk size To run the Disk Test Clean Test 1 Select Disk Test Clean from the Device Tests menu Files will be lost Go or Stop message displays to warn the user that all contents on the disk will be lost To exit the test immediately and return to the Device Tests menu press Return or Stop To continue with the test press Go e 1001 selected Cleaning Disk BAD 000000 00 mes sage displays The screen updates periodically indicating the percentage of test completed and the number of bad blocks found The busy indicator flashes during the test The test can be can celed anytime during the test by pressing Return or Stop Once the test is complete the busy indicator turns on solid and a message displays e Xxxx Bad Blocks yyyyyy Usable message displays if fewer than 2000 bad blocks are detected xxxx indicates the num ber of bad blocks and yyyyyy indicates the number of usable blocks e Bad Blocks Replace Disk message displays if more than 2000 bad blocks are detected The disk cannot be recovered because too many bad blocks exist
6. To set the Configuration ID 1 Select Configuration ID from the Printer Setup menu The current ID displays on the screen The Configuration ID for the 4046 001 is 000303 The ID code for other models with different configurations is on a label located on the con troller board cage Remove the right cover and open the card cage to see the label The leftmost digit flashes indicating that it is the first digit to be changed 2 To change the value press either Menu or Menu until the value you want is reached Press Select to move to the next digit or press Select again to skip a digit Change each digit as required When the last digit is changed press Select to vali date the Configuration ID If the ID is invalid then INVALID ID message displays on Line 2 before the ID displays again You have to reenter the Configuration ID until a valid ID is verified If the ID is valid then the ID is saved in NVRAM and the printer automatically PORs to activate the new setting Note When the printer PORs it does so in the normal mode Diagnostic Aids 3 13 Print Tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options Each of the installed options is listed in the following order in the menu Tray 1 Tray 2 if installed Multipurpose Feeder if installed For each input source selected you have the following choice Single prints the Prin
7. 6 24 Optional 450 Sheet Second Paper Drawer 2 6 26 Optional 450 Sheet Second Paper Drawer 2 6 28 Optional Multi Function Feeder 6 30 dirais diem aid 1 vi Service Manual Notices and Safety Information References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product pro gram or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property rights may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Laser Notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and else where is certified as a Class laser product conforming to the requirements of IEC 825 Class laser products are not considered to be hazardous The printer contains internally a Class 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so th
8. HVPS printer for pitting or incorrect alignment Cables from the pick roller and cover open switch could also be in the way of the contacts 5 Engine Check the voltages on the engine board at the fol Board lowing locations HVPS Intercon Printer Idle nect Board CNMC B10 24 V dc CNMC B11 17 V dc CNMC A11 20 5 V CNMC B12 0 1 V de Printer Printing CNMC B10 0 1 V CNMC B11 0 1 V CNMC A11 0 1 V CNMC B12 momentarily jumps up to 5 15 V dc If these voltages are not correct replace the engine board If they are correct replace the following FRUs in the order shown 1 HVPS 2 Interconnect Board Diagnostic Information 2 15 Print Quality Light Print FRU Action 1 Transfer Check the transfer corona for dirt or damage Corona Check the contact and contact spring for pitting or contamination Clean or replace as necessary Also see the Transfer Corona Service Check on page 2 29 2 HVPS Check the contact spring and HVPS contact for pit ting cable interference or incorrect installation Clean if necessary Check the voltages on the engine board at the fol lowing locations Printer Idle CNMC B10 24 V CNMC B11 17 V CNMC A11 20 5 V dc CNMC B12 0 1 V de Printer Printing CNMC B10 0 1 V CNMC B11 0 1 11 0 1 CNMC B12 momentarily jumps up to 5 15
9. Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current Mechanical Operation This printer uses three motors to feed paper The pick up motor drives the pick up roller in the printer or in the multi function feeder The rotating direction of the motor determines which roller will be selected The paper feed motor drives the paper feed roller The main motor drives the fuser the paper exit roller and the redrive roller OPC drum Print head Fuser Unit Redrive roller Pick up roller Multi function feeder Paper Feed roller Pick up roller General Information 1 3 iagram System D The central processing unit CPU in the main controller controls the entire printer and the data received from the interconnect yun 4 Aiddns 1emog pueog p1eoq uoisuedx3 49 04 U09 4 euiDu3 uen Jejnduuoo eip AISU9Q i 1S0H o1u09 19 04 U09 JOU 1 4 Printer Operation 1 When the printer receives a printing command the main motor starts to rotate to initialize the print unit including the photocon ductive drum developer cleaning roller and toner agitator and to warm up the fuser The motor in the printhead also starts to rotate to initialize the printhead 2 The pick up motor rotates counterclockwise to pick
10. Assembly 16 Miscellaneous Ref da Units Description 12A4036 1 Parts Packet Left Right Frame Gears 12A4037 1 Parts Packet Paper Tray Springs 12A4038 1 Parts Packet Paper Feed Gears 12A4039 1 Parts Packet Screws 99A0426 1 Parts Packet Parallel Connector Mounting Screws 7350166 Packaging Printer 12A4040 1 Tool Wire Cleaning Parts Catalog 6 33 6 34 4046 Index A abbreviations 1 2 base sensor test 3 11 button test 3 6 C control board 5 8 control board removal 4 12 cover open switch service check 2 9 cover open switch removal 4 7 covers assembly 6 4 D dead machine service check 2 10 diagnostic aids 3 1 diagnostic information 2 1 diagnostic mode 3 1 disabling download emultaions 3 4 disk test clean 3 3 DRAM memory test 3 6 E electronics parts 6 6 engine board 5 7 engine board removal 4 8 engine fan removal 4 9 engine fan service check 2 11 EP diagram 5 6 erase LED service check 2 11 errorlog 3 4 exit paper feed frame assembly 6 18 exit paper feed roller assembly removal 4 10 exit sensor service check 2 12 exiting the diagnostics mode 3 1 F flash test 3 3 frame assembly left side 6 10 frame assembly right side 6 12 front and right side of printer 5 1 fuser assembly 6 20 fuser removal 4 11 fuser service check 2 13 H hardware tests 3 5 high voltage power supply board and interconnect board removal 4 12 image quality serv
11. Before you continue perform the Button Test on page 3 6 FRU Action 1 Operator Panel If any of the buttons failed the Button Test replace the operator panel 2 Engine Board No buttons work Disconnect the operator panel cable from the engine board Turn the power on Check the voltage at CNOP 1 It should measure approximately 5 V dc If it is incorrect replace the engine board If it is correct check the continuity of the operator panel cable If the continuity is not correct replace the cable If the cable is good replace the operator panel Operator Panel Display Service Check Before you continue perform the LCD Test on page 3 5 FRU Action 1 Operator Panel If the operator panel failed the LCD Test replace it 2 Operator Panel Cable Be sure the cable is properly connected to the engine board CNOP and the operator panel Check the condition and continuity of the cable 3 Engine board Disconnect the operator panel cable Check the voltage at CNOP 1 on the engine board It should measure 5 VB dc If it is correct replace the oper ator panel If the voltage is incorrect replace the engine board 2 22 Options Service Check Flash Memory Option Run a copy of the test page to see if the option you are checking is listed The printer does not recognize the option being installed if the option is not listed Be sure
12. Disconnect the main motor cable and check the voltage on the following connectors on the engine 1 24 V 2 24 V If the voltages are correct replace the main motor If the voltages are incorrect replace the engine 2 20 Input Sensor Service Check Error Code 200 Paper Jam Remove Print Unit may display if the input sensor flag is stuck down or defective Error Code 240 Paper Jam Tray or Feeder may display if the input sensor flag is broken or stuck in the upward position Paper jam error codes may be caused by a faulty or worn pick roller Before you continue run the Input Tray Feed Test page 3 10 defective input sensor or circuit will cause the first copy to exit only partially through the fuser assembly FRU Action 1 Input Sensor Flag Check the input sensor flag for proper position and operation The flag is visible if you open the manual feed tray The position of the flag should be in the paper path such that when printing the paper pushes the flag down Replace the flag if it is dam aged 2 Input Sensor The input sensor is mounted on the interconnect board The sensor flag swings through the sensor as the paper makes contact with the flag If it is operating correctly replace the following FRUs in the order shown 1 Interconnect Board 2 Engine Board Diagnostic Information 2 21 Operator Panel Buttons Service Check
13. Holder Roller 9 11A4317 1 Guide Roller 10 11A4300 1 Roller Assembly 11 1 Gear 6 Lower PP 12A4038 12 1 Gear 7 upper PP 12A4038 13 11A4319 1 Belt Timing 14 11A4320 1 Cover Gear Parts Catalog 6 17 Assembly 8 Exit Paper Feed Frame 6 18 Part 27 12A4033 27 12A4034 Fuse 125V 10A Fuse 250V 5 3A Ref Number Units Description 8 2 11A4234 1 Board Power Supply 100 120 V 2 11A4236 1 Board Power Supply 220 240 V 3 5 Screw PP 12A4039 4 1 Screw PP 12A4039 5 11 4253 1 Cover Power Supply Switch 6 11A4254 1 Lever Exit Sensor 7 11A4298 1 Frame Center 8 11A4299 1 Sensor Exit Paper Feed 9 11A4300 1 Roller Assembly Exit Paper Feed 10 11A4301 1 Frame Right Side 11 11 4302 1 Frame Left Side 12 6 Screw PP 12A4039 13 11A4303 1 Guide Assembly 14 11A4306 2 Holder Guide Roller 15 11A4314 2 Roller Guide 17 11A4310 1 Switch Assembly 18 1 Gear 1 PP 12A4038 19 1 Gear 2 PP 12A4038 20 1 Gear 3 PP 12A4038 21 1 Gear 4 12A4038 22 1 Gear 5 12 4038 23 11 4255 1 Bracket Fuser Cooling Fan 24 2 Screw PP 12A4039 25 11A4288 1 Fan Process Cooling 26 2 Screw 12A4039 1 1 Parts Catalog 6 19 Assembly 9 Fuser 455 oy LV OSE 2 5522220 Part Ref Number Units Description 9 1 11A4321 1 Fuser Assembly 100 120 V 1 11A4322 1 Fu
14. Parts Packet in the Description column indicates that the part is contained in a parts packet A part reference within a circle indicates an assembly or a bill of material An assembly is complete A bill of material contains unassembled parts 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 INDENTURE RELATIONSHIP OF PARTS No dot MAIN ASSEMBLY One dot Detail part or subassembly of a main assembly Two dot Detail part or subassembly of a one dot subas sembly Parts Catalog 6 1 Assembly 1 Upper Cover 6 2 Ref as Units Description 1 1 11A4200 1 Cover Assembly Top 2 11A4202 1 Door Top Cover 3 11A4203 1 Hinge Door Outer Left 4 11A4204 2 Hinge Door Inner 5 11A4205 1 Hinge Door Outer Right 6 3 Screw PP 12A4039 7 11A4208 1 Control Panel with English Overlay 7 11 4209 1 Control Panel Overlay W T Kit 8 11A4210 1 Cable Operator Panel 9 11A4211 1 Cable Print Density Parts Catalog 6 3 Assembly 2 Covers 6 4 Part Ref Filter Ozone Top Cover Number 11A4207 11A4212 11A4213 11A4214 11A4215 11A4216 11A4218 Units Description Cover Left Cover Right Cover Rear Center Screw PP 12A4039 Stacker Rear Guide Rear Stacker Cover Lower Front Parts Catal
15. 1 Diagnostic x data edad 3 1 Exiting the Diagnostic Mode 3 1 Power On Self Test POST 3 2 disease dinar vd eM ada Ea teed 3 2 Quick Disk Testa dssdo wen OE REA EG a 3 2 222444 del pda mes 3 3 oma 3 3 Disabling Download Emulations 3 4 bee be qardoeredd d deradobe ad d 3 4 Viewing the Error Log 3 4 Clearing the Etror Logs ia ius asado np 3 5 Lin iaia Ris 3 5 bed db edere dee p dea 3 5 BON IBS quide ides dod qot Een abc dod 3 6 DRAM Memory T6St organe anges me 3 6 ROM Memory Test 3 6 Parallel Wrap Tessin aan 3 7 Setial Wrap estate cd 38 Input Tray Tosi e cance dence thee 3 10 Input Tray Feed 23205540200 E RS ux 3 10 Input Tray Sensor Test 3 10 Base Sensor MOST uu dis siga eer ropa i 3 11 Print Registati some i e qoe rebns 3 11 Printer SOUP ies odd ich dads pudore 3 12 Setting the Page 3 12 Viewing the Permanent Page Count 3 13 Setting Configuration ID 3 13 PHO ROMS PR RTT PT CR 3 14 Print Quality Test Pages 3 14 Printing Menu Settings
16. Background Go to Image Quality Service Check on page 2 13 Toner on Backside of Paper Go to Image Quality Service Check on page 2 13 Random Vertical Streaks Go to Image Quality Service Check on page 2 13 Blurred Print Go to Image Quality Service Check on page 2 13 Evenly Spaced Horizontal Marks or Lines Malfunctions with Options Go to Image Quality Service Check on page 2 13 Go to the Options Service Check on page 2 23 Standard Output Bin Problems Go to the Standard Bin Full Sensor Service Check on page 2 27 Service Checks Cover Open Switch Service Check Run the Base Sensor Tesi on page 3 11 Check the cover open switch for proper operation The display changes from open to closed as the upper door is opened and closed FRU Action 1 Cover Open Be sure the cover open switch is properly installed Switch in the left print unit guide If you still have a problem remove the interconnect board and check the con nection of the cover open switch cable CNCOV2 If it is correct test the continuity of the switch The switch circuit is normally closed When the switch is pressed the circuit opens Diagnostic Information 2 9 2 Intercon nect Board Engine Board Replace these FRUs in the following order 1 Interconnect Board 2 Engine Board Dead Machine Service Check FRU
17. Exit Diagnostics to exit the Diagnostic Mode and return to normal mode Diagnostic Aids 3 1 Power On Self Test POST When you turn the machine on the following POST sequence takes place 10 The Power LED turns Diamonds scroll across the display then clear Performing Self Test appears the display The printhead mirror motor turns on Warming Engine appears on the display and the Busy LED starts flashing The fuser lamp turns on to warm the engine The fuser takes longer to warm up from a cold start than a warm start The process and engine fans turn on The main motor turns on which turns the fuser hot roll backup roll exit rollers and developer gears in the print unit Once the engine has warmed up the main motor and fans stop turning Ready appears on the display Device Tests Quick Disk Test This test performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 2 3 2 Select the Quick Disk Test from the Device Tests menu The busy indicator flashes while the test is in progress Quick Disk Test Test Passed message displays if the test passes and the busy indicator turns on solid
18. Lexmark and Optra are trademarks of Lexmark International Inc registered in the United States and or other countries Other trademarks are the property of their respective owners Copyright Lexmark International Inc 1998 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 Contents Notices and Safety Information vii Laser 22664 x bep EUER a vii Laser Advisory Label tests a viii Class 1 Laser Statement Label viii General Information 1 1 Maintenance Approach 1 1 1 1 ADGIGVIBIONS 2120400226 does mure dor god Run 1 2 Mechanical 1 3 1 4 Pinter ODSIBUOI 1 5 Paper Feed Drive Mechanism 1 5 Process Drive Mechanism 1 7 PAL DDIL 1 7 EU CU Gord ana 1 8 Paper iis css sese RR e oar cua as 1 8 Diagnostic Information
19. Notices and Safety Information xv Safety Information This product is designed tested and approved to meet strict global safety standards with the use of specific Lexmark components The safety features of some parts may not always be obvious Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t concu test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de l utilisation d autres pi ces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Norme di sicurezza prodotto stato progettato testato e approvato in conformit a severi s
20. OPT 20 Ground Process Fan Service Check FRU Action Process Fan Be sure the process fan turns on during POST If it does not be sure the fan is connected properly Check the voltage on the engine board between CNF1 1 and CNF1 2 If the voltage is 24 V dc replace the process fan If the voltage is incorrect replace the engine board Serial Port Service Check Run the Serial Wrap Test on page 3 8 Use wrap plug P N 1319128 This test helps isolate the printer from the serial cable and host The test provides failure information on the display for approxi mately 3 seconds If the test indicates a problem replace the follow ing FRUs in the order shown 1 Tri Port Card or Serial Adapter 2 Controller board Standard Bin Full Sensor Service Check Enter the diagnostic mode and test the standard bin full sensor with the Base Sensor Test on page 3 11 Use the following checks to further isolate the problem Diagnostic Information 2 27 Remove Paper Standard Bin message never appears FRU Action 1 Standard Bin Full Sensor Sensor Cable Engine Board Check the flag for damage or improper operation If incorrect replace the sensor Disconnect the sensor cable from the engine board and check the cable for continuity Check the voltage on the engine board at CNSF 1 It should be 5 V dc If it is incorrect replace the engine board I
21. V If these voltages are not correct replace the engine board If they are correct replace the following FRUs in the order shown 1 Transfer Corona 2 HVPS 3 Interconnect Board 2 16 Print Quality Residual Image Install a new print unit if one is available before you begin this check Residual image can be caused by the photoconductor cleaning mechanism and other parts inside the print unit FRU Action 1 Erase LED Check the erase LED for signs of paper dust toner Assembly build up or other contamination Clean with a soft cloth or replace the erase LED assembly When the erase LEDs work properly each LED turns bright red This is visible with the print unit removed by opening the upper door during the warming engine step in the POST procedure If the erase LEDs do not come on check the voltage at CNERS 1 on the engine board It should measure 24 V dc If it is incorrect replace the engine board If it is correct replace the erase LED assembly Fuser Check the fuser for signs of toner buildup on the hot roll Toner buildup could cause the hot roll to pick up toner and deposit it down the page If buildup is present replace the fuser Print Quality Banding Pri Banding appears as light or dark horizontal lines on a uniformly gray page or on a page with a large area of graphics Banding is prima rily due to a variation in the speed of the paper as it feeds through the
22. comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte esta orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat prendre les mesures convenients xviii Service Manual REAM Lexmark MER ER eh HERD MURR RE ALES HEA ZE TN RET AE re 2 Mh REI Lexmark MAAR ASP m B AS MEAS UE mIRE HA o ANP AIR SRE f E E A AIR JERR AFS ASE SS Lexmark PAY Q59 At Soll 9101 AA Fo Gos AA B ES On els Ho stat HAS X ASA LICH Lexmark St AAS AIX SSC Al So ast hi MMS ME 21848228 AME Holle MBIA ASS AZS Bula AP AIA S22 WAL AAS elg 91810 ATUH MS Ol AAS SISD West ut SAIS a Notices and Safety Information xix xx Service Manual 1 General Information Maintenance Approach The diagnostic information in this manua
23. fan from the engine card and pull it through the toroid Remove the rear cover Remove the rear stacker The power supply board and the fuser could be hot Be careful when you remove them in this step Remove the four screws from the rear of the machine and slide the fuser and power sup ply board assembly out the rear of the printer Be careful not to damage the pick motor cable when removing the fuser and power supply board assembly Disconnect the two connectors from the power supply board Turn the fuser assembly bottom side up and remove the six screws from the power supply board lifting the power supply board from the fuser assembly Disconnect the remaining connector from the power supply board removing the board Remove the two screws securing the process fan to the bracket and remove the fan Repair Information 4 11 High Voltage Power Supply Board and Interconnect Board Removal Remove the paper tray Remove the right side cover and the control board cage door Remove the engine board Remove the four screws from the bottom of the printer to remove the interconnect board HVPS assembly gt D 4 12 5 6 Remove five screws to remove the interconnect board Remove three screws to remove the high voltage power supply board an y i 2 Installation Notes
24. have the problem replace the following FRUs in the order shown 1 LVPS 2 Engine Board Image Quality Service Check Before you troubleshoot a print quality problem do the following Install another print unit if available Use Tray 1 to test for quality of the base printer Select the following settings Be sure to note the original settings so you can return the printer to the original setup Print Resolution Set to 300 dpi print quality problems should be checked at different resolution settings Toner Saver Set to off PQET Set to off Print Darkness Adjust knob to the middle setting Diagnostic Information 2 13 An incorrect printer driver for the installed software can cause prob lems Incorrect characters could print and the copy may not fit the page properly Measure all voltages from the connector to printer ground Be sure to turn the printer off before you make any checks on the transfer corona Locate your symptom below note the possible causes and take the appropriate action Be sure all associated connectors are plugged in correctly Print Quality All Black Page FRU Action 1 Print Unit Check the precharger wire on the print unit for dirt or damage Clean the wire with the cleaning tool provided with the printer If the wire has come loose from the print unit the customer must replace the print unit 2 HVPS 3 Intercon nect Board
25. into the laser beam path Use utmost care when handling tools around the laser beam e If the job requires that the printer be left on take off your watch and ring and wear laser protective goggles which must meet the following laser specifications Max power 5mW e Output wavelength 780 810nm Repair Information 4 3 Removal Procedures Do not disassemble the following parts Printhead Toner Bottle Fuser Transfer Corona Assembly Control Board Removal 4 4 NOOR amp D Remove the right side cover Remove the outer shield Disconnect the controller board cable from J4 Remove the two parallel port screws Remove the back connector panel cover 3 screws Remove the 5 screws that hold the controller board in place As you remove the controller board tilt the top of the board away from the printer in order to clear the inner shield Cover Removal 1 Open the upper door 2 Remove the three screws from the upper cover 3 Remove the rear cover 1 screw Upper door f 1 1 Upper cover AA Repair Information 4 5 4 Remove the left and right side covers 5 Use a screwdriver to release the latches on the left side of the upper cover as you lift the cover upward As you lift the cover disconnect the print density cable and operator panel cable from the operator panel Cover Open Switch Removal 1 Remove the interconnect board and the hi
26. on the disk 4 Press Go or Return or Stop to return to the Device Tests menu Flash Test This test causes the file system to write and read data on the flash to test the flash WARNING This test destroys all data on the flash because the flash is reformatted at the end of the test To run the Flash Test 1 Select Flash Test from the Device Tests menu The busy indicator flashes while the test is running Diagnostic Aids 3 3 2 Flash Test Test Passed message displays if the test passes and the busy indicator turns on solid Flash Test Test Failed message displays if the test fails and the busy indicator turns on solid Press Go or Return or Stop to return to the Device Tests menu Disabling Download Emulations Error Code 964 Download Emulation CRC Failure Checksum fail ure detected in the emulation header or emulation file Error Code 965 Download Emulation Outdated Time stamps indi cate the download emulation and RIP code are incompatible To help resolve Download Emulation problems the following steps are necessary to instruct the printer to POR without activating any download emulations To Disable the Download Emulation 1 2 3 Turn the printer off Press and hold the Go and Menu buttons Turn the printer On and release the buttons once Performing Self Test displays Once the printer is idle the emulation can be downloaded again Program the download emulation
27. power cord has been unplugged from the power outlet During Inspection e Avoid checking the IC directly with a multimeter use connectors on the board Never create a closed circuit across IC pins with a metal tool When it is absolutely necessary to touch the ICs and other elec trical components on the board be sure to ground your body Precautions for Handling the Drum Cartridge The following precautions must be observed when handling the drum cartridge During Transportation Storage Use the specified carton whenever moving or storing the drum cartridge The storage temperature is in the range between 20 C and 40 C Handling e The PC drum the drum cartridge exhibits greatest light fatigue after being exposed to strong light over an extended period of time Never therefore expose it to direct sunlight e Use care not to contaminate the surface of the PC drum with oil base solvent fingerprints and other foreign matter Do not scratch the surface of the PC drum Parts not to be touched Any part where the mounting screws are painted red such as the printhead must not be removed disassembled or adjusted 4 2 Precautions for Handling the Laser Equipment When a service job needs to be performed in the laser beam path such as when working around the printhead and the drum cartridge be sure to turn the printer off first e A highly reflective tool can be dangerous if it is brought
28. screws and pull out the paper feed motor N BR Paper feed motor Repair Information 4 17 Paper Feed Roller Removal 1 Remove the upper cover and the left and right side covers 2 Remove three screws disengage three hooks and disconnect the toner sensor connector to remove the upper front cover assembly 3 Remove the right and left springs and lift the upper feed roll from the paper feed frame 4 Peel off the two guide sheets Mylar films Be sure to com pletely remove the double sided adhesive tape 5 Use a screwdriver to disengage the bearing phase shift levers at both ends of the lower feed roll and raise the lever upward to 4 18 remove the lower feed roll Spring Guide sheets EN Bearing 6 Use diagonal cutting pliers to cut the hook off the gear at the right end of the lower feed roll 7 Move the lower feed roll to the left and pull out the roller from the left end t Paper feed roller Bearing Bearing Gear Repair Information 4 19 Installation Note 1 When you install the lower feed roll a Insert the right end D cut of the lower feed roll into the hole of the right bearing then the hole of a new gear until the gear is caught by the hook b Fit the other bearing to the left end the end without a D cut of the lower feed roll c Insert the bearings into guide grooves on the base frame with the bearing phase shift levers set upward
29. the Open the controller card door assembly engine card Pull the ends of the printhead erase LED assembly forward to unlatch it from the frame assembly Remove the printhead erase LED assembly Repair Information 4 27 Process Fan Removal Remove the fuser and power supply assembly 2 Remove the fan from the side of the assembly 2 screws 1 4 28 Installation Note Install the fan so the air flow arrow is to the outside Air flow Marks Repair Information 4 29 Separator Assembly Removal 1 Remove the paper tray 2 Place the paper tray upside down push in the two separator assembly latches and remove the separator assembly Be care ful not lose the spring es Installation Note Be sure to install the separator so the rubber sur face is toward the front of the drawer Paper will not feed if the sepa rator is not installed correctly M 4 30 Stacker Full Sensor Board Removal 1 Remove the upper cover 2 Remove the cable from the stacker full sensor 3 Remove the board 1 screw Repair Information 4 31 Transfer Corona Removal Be careful the parts could be hot 1 Open the upper door 2 Remove the print assembly 3 Use screwdriver to remove the transfer corona holding block at the left side of the transfer corona 4 Open the latch on the left side of the base frame and use a screwdrive
30. through the redrive roller which forces the paper 1 8 to the upper exit bin Roller gears receive power from the hot roll gear General Information 1 9 2 Diagnostic Information The diagnostic information in this chapter leads you to the failing part Before you replace an entire assembly determine if just the defective part is available in the parts catalog Some diagnostic pro cedures indicate the parts catalog location of the part to be checked by including the assembly number and reference number in paren thesis Some part numbers are also included Use the error code tables symptom table service checks and the diagnostic aids chap ter to determine the symptom and repair the failure After you com plete the repair perform the appropriate tests to verify the repair If an error is displayed locate it in the following Operator Error Mes sage Table or the Service Error Message Table and take the appro priate action If an error message appears while you are working on the machine go to the error message table and take the indicated action Use the Locations chapter to find connector board and pin informa tion The sequence given in the service check is connector board and pin The board uses only a letter for an identifier For example connector CN8A 3 CN8 connector A board 3 the pin Diagnostic Information 2 1 Start Initial Check Before you start troubleshooting check the following Installa
31. 04 1 Clamp 19 11A4283 1 Toroid 20 11A4333 1 Cable Printhead 21 11A4349 1 Plate Fan Shield 22 6 Screw PP 12A4039 23 11A4332 1 Board Engine 24 11A4347 1 Bracket Fixed Hinge 25 11A4330 1 Shield Assembly Inner With Insulators 26 12A4041 1 Card Assembly PCI Bus Interconnect 27 2 Screw 12A4039 28 2 Screw PP 99A0426 29 2 Screw PP 12A4039 30 11A4341 1 Cover Back Connector Panel 31 99 0236 1 Cover INA Blank 32 6 Screw PP 12A4039 33 11A4401 1 Shield Assembly Outer 34 5 Screw PP 12A4039 35 12A4035 1 Cable Control to Engine 36 11A4337 1 Board Control With Cable 37 11A4334 1 Cable Lower Control Board 38 11A4328 1 Cable MFF 39 1 Screw PP 12A4039 40 11A4327 1 Board MFF 41 1 Screw 12A4039 42 11A4325 1 Board Print Density 43 11A4326 1 Knob Density Board Control Parts Catalog 6 9 Assembly 4 Frame Left Side 6 10 Part 18 11A4418 19 11A4419 20 11A4423 21 11 4400 Guide Print Unit Left Label Print Unit Left Install Switch Cover Open Plate Ground Screw PP 12A4039 Guide Assembly Paper Tray Left Spring Cover Open Switch 23 11A4313 24 12A4046 Ref Number Units Description 4 1 12A4047 1 Motor Pick 3 1 Gear Pick Motor PP 12A4036 4 1 Gear Assembly MFF A PP 12A4036 5 11 4345 1 Clip 6 2 Screw PP 12 4039 7 3 Screw PP 12A4039 9 1 Gear MFF B
32. 1 2 When you install the interconnect board observe the order of fastening screws as shown above When you install the high voltage power supply interconnect board assembly be careful the cable does not overlap the four spring electrodes on the bottom left of the printer mechanism As you install the HVPS interconnect board assembly be sure the interconnect board connects into the power supply board Be sure to match the four screw positions Repair Information 4 13 Main Motor Removal os 4 14 Remove the right side and upper cover Open the controller board cage door assembly Remove the fan shield plate Remove the engine cooling fan Remove the engine board Remove the main motor assembly 4 screws v 127 o XI o ML ctr D Le 7 Remove four screws and disconnect the cable to remove the main motor Repair Information 4 15 Multi Function Feeder Board Removal 1 Remove the right side cover 2 Disconnect the cable from the MFF board 3 Remove the board 1 screw 4 16 Paper Feed Motor Removal 1 Remove the right side cover Open the controller board cage door assembly Disconnect the controller board cable and remove the controller board door assembly Remove the engine board Remove the fan shield plate Remove the fixed hinge bracket Remove the 2 mounting
33. 2A4039 15 11A4406 1 Cable Paper Size Sensor 16 11A4338 1 Cable Drawer Interconnect 17 2 Screw PP 12A4039 18 11A4422 1 Board Driver 19 2 Screw PP 12A4039 20 12A4021 1 Lever Sensor FP 21 12A4022 1 Lever Sensor FE 22 12A4023 1 Lever Sensor Parts Catalog 6 29 Assembly 14 Optional Multi Function Feeder 6 30 Ref Part Number Units Description 144 12A4024 Feeder Multi Function Parts Catalog 6 31 Assembly 15 Options Ref 5 Units Description 12A4024 1 Feeder Multi Function 12A4025 1 Drawer 450 Sheet Feeder without Tray 99A0420 1 Card Assembly INA Token Ring 99A0421 1 Card Assembly INA Ethernet 10 100 Base T 99A0560 1 Card Assembly Tri Port 99A0515 1 Disk Drive Hard without Control Card 99A0517 1 Memory 4MB DRAM 99A0518 1 Memory 8MB DRAM 99A0519 1 Memory 16MB DRAM 99A0520 1 Memory 32MB DRAM 99A0724 1 Memory 64MB DRAM 99A0521 1 Memory 1MB Flash 99A0522 1 Memory 2MB Flash 99A0523 1 Memory 4MB Flash 99A0424 1 Infrared Adapter 12A4029 1 Tray Assembly 450 Sheet 12A4028 1 Tray Assembly 250 Sheet 99A0516 1 Card Asm Hard Disk Drive 12A4042 1 SIMM IPDS Board 99A0629 1 Adapter Coax Twin Adapter for SCS 13A0296 1 Cable Twinax 13A0297 1 Cable Coax 99A0545 1 Adapter Serial Port 99A0422 1 Card Assembly INA Ethernet 10 Base 2 10 Base T 6 32
34. 5 EP Diagram Pre Charger Wire Erase LED Developer Asm OPC Drum Paper Path Paper Path Transfer Corona 5 6 Engine Board CNERS 1002 5 en m ME 19 OPT 34 33 CNMM CNOP 5 Locations 5 7 Control Board Locations 5 8 Power Supply Board 00 0 09 0 9 1 CNCOV CNPOW ooo ooo 3 CNHR 1 Locations 5 9 Interconnect Board al CNHV CNCOV2 5 10 6 Parts Catalog How to Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are broken down on the same list Common parts are shown by one index number 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 quan tity is not the same for all machines NP Non Procurable in the Units column indicates that the part is non procurable and that the individual parts or the next higher assembly should be ordered NR Not Recommended in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP
35. 63 Unformatted Disk This error code displays when the printer detects an unformatted disk at power on Press Go to clear the message The disk is marked as bad and normal operation continues Disk operations are not allowed until the disk is formatted 88 Toner Low This error displays when toner low occurs and the toner low alarm is activated Press Go to clear this message 88 Toner Out This error displays when toner is depleted When the toner bottle is refilled printing resumes automatically Symptom Table Symptom Action Engine Fan Failure Go to the Engine Fan Service Check on page 2 11 Process Fan Failure Go to the Process Fan Service Check on page 2 27 Operator panel is unresponsive or Go to the Operator Panel Dis doesn t display any or all characters play Service Check on page 2 22 Paper Feed or Paper Jam Problems Go to the Paper Feed Service Check on page 2 24 Fuser Problems Go to the Fuser Service Check on page 2 13 All Black Page Go to Image Quality Service Check on page 2 13 Blank Page Go to Image Quality Service Check on page 2 13 Light Print Go to Image Quality Service Check on page 2 13 Residual Image 2 8 Go to Image Quality Service Check on page 2 13 Symptom Action Image Banding Go to Image Quality Service Check on page 2 13
36. 7 11A4274 1 Terminal Left Paper Feed Ground 8 11A4276 1 Feed Roll Upper 9 11 4277 2 Lever Lock 10 11A4278 2 Bearing 11 11A4279 2 Spring 12 11A4280 1 Corona Transfer 13 11A4281 1 Left Stop Transfer Corona 14 11A4282 1 Guide Paper Front 15 2 Screw PP 12A4039 16 12A4047 1 Motor Paperfeed 17 11A4285 1 Bracket Pick Motor Mount 18 1 Gear Pick Motor PP 12A4038 19 2 Screw PP 12A4039 20 11A4286 1 Shaft Assembly Pick Roller 21 1 Gear Pick Roller PP 12A4038 22 11A4287 1 Pick Roller 23 11A4271 2 Bearing Pick Roller 24 11A4289 1 Rack Paper Feed Guide 25 11A4290 1 Guide Paper Left 26 11A4291 1 Guide Paper Right 27 11A4292 1 Gear Paper Feed Guide Rack 28 11A4293 1 Washer 29 1 Screw 12A4039 30 11 4295 1 Flag Paper Entry Sensor 31 11A4296 1 Lever Multi Switch 32 3 Screw PP 12A4039 33 11A4220 1 Terminal Ground Corona 34 11A4226 2 Stop Transfer Corona Lower 35 11A4227 1 Terminal Ground Paper Feed Left 36 11A4270 1 Ground Paper Feed Right Parts Catalog 6 15 Assembly 7 Printhead and Paper Feed Redrive Ref AE Units Description 7 1 1144225 1 LED Printhead Erase 2 1144228 1 Printhead 3 11A4229 1 Cover 4 3 Screw PP 12A4039 5 11 4231 1 Label Caution 6 11A4311 1 Paper Feed Redrive Exit Assembly 7 11A4314 2 Roller Redrive 8 11A4315 2
37. Action 1 Line Voltage Check the ac voltage If the line voltage is incorrect inform the customer 2 ACLine Cord Inspect the cord for damage If it is OK check the continuity 3 Power Supply Fuse Remove the power supply Check the continuity of the fuse Install the power supply There is no check you can make of the power sup ply while it is removed from the machine Check the exit sensor flag for correct operation The printer will not turn on unless the flag is pass ing through the sensor Check the connector pins on the interconnect board where the power supply plugs in These pins may be bent 4 Controller Board Remove the controller board Turn the printer on If the Ready LED comes on turn off the printer Remove any options plugged into the controller board and re install the controller board Turn the printer on If the machine powers up normally one of the options is defective Re install each option one at a time to determine which one is defective If the machine did not power up normally when you re installed the controller board replace the con troller board 2 10 5 LVPS Check engine board connector CNMC for the fol Engine lowing voltages Board Intercon CNMC A1 5 V dc nect Board CNMC B16 5 V dc If the voltages are correct check the operator panel cable condition and connection If the voltages are incorrect disconnect all cables fr
38. Engine Board Check the HVPS contacts on the HVPS board and the mating contact springs on the left side of the printer for pitting or incorrect alignment Cables from the pick roller motor and cover open switch can get in the way of the contacts Be sure the HVPS connects to the interconnect board correctly Be sure the interconnect board connects to the engine board correctly If all the connections are correct replace the following FRUs in the order shown 1 HVPS 2 Interconnect Board 3 Engine Board 2 14 Print Quality Blank Page FRU Action 1 Printhead Generally a 935 Printhead Error is posted if the Cable printhead assembly fails Check the connection of the printhead 2 Transfer Check the transfer corona for correct installation or Corona signs of damage Clean the transfer wire with the cleaning tool provided with the printer Check the contact spring that connects to the transfer corona for damage pitting or debris Replace the transfer or center paper feed frame which contains the spring if necessary Also see the Transfer Corona Service Check on page 2 29 3 Print Unit Check the print unit for any signs of damage espe cially the PC drum and contacts Also check the precharger wire for damage Clean the wire with the cleaning tool provided with the printer 4 Contact Check the HVPS contacts on the HVPS board and Springs the mating contact springs on the left side of the
39. PP 12A4036 10 1 Gear MFF C PP 12A4036 11 1 Gear MFF D PP 12A4036 12 1 Gear MFF E PP 12A4036 13 2 Screw PP 1244039 14 11A4348 1 Foot Rubber 15 3 Screw PP 12A4039 16 3 Screw PP 12A4039 17 2 Screw PP 12A4039 1 1 1 1 1 1 1 Parts Catalog 6 11 Assembly 5 Frame Right Side 6 12 Ref dau Units Description 5 1 1144402 1 Gear Box Assembly Main Motor 2 8 Screw PP 12A4039 3 11A4235 1 Guide Assembly Paper Tray Right 4 11A4348 1 Foot Rubber 5 11 4405 1 Board Paper Size Sensor 6 11A4406 1 Cable Paper Size Sensor 7 1 Screw PP 12A4039 8 11A4407 1 Lever Paper Tray Lock 9 11A4408 1 Spring 10 11A4410 1 Motor Main 11 11 4411 4 Damper Main Motor 12 11A4412 1 Bracket Assembly Main Motor 13 4 Screw PP 12A4039 14 1 Gear Main Motor MA PP 12A4036 15 1 Gear Main Motor MB PP 12A4036 16 11A4413 1 Cable Main Motor 17 4 Screw PP 12A4039 18 11A4414 1 Fan Engine Cooling 19 12A4044 1 Guide Print Unit Right 20 11A4417 1 Plate Ground Right Parts Catalog 6 13 Assembly 6 Input Paper Feed 6 14 Ref Su Units Description 6 1 11A4268 1 Frame Paper Feed 2 1144271 2 Bearing Feed Roll 3 11A4269 1 Feed Roll Lower 4 1 Gear Feed Roll PP 12A4038 5 11 4272 1 Strip Mylar Left Guide 6 11 4273 1 Strip Mylar Right Guide
40. Page 3 15 Paper Jams Base Printer 3 16 Paper Jams 5 3 16 Repair Information 4 1 Precautions for Disassembly and Cleaning 4 1 Instructions for Handling the PWBs with MOS ICs 4 1 Precautions for Handling the Drum Cartridge 4 2 Parts not to be touched 4 2 Precautions for Handling the Laser Equipment 4 3 iv Service Manual Removal Precedules aad en RS ed ove 4 4 Control Board Removal Rs 4 4 Cover Hemos oc sno amen as 4 5 Cover Open Switch Removal 4 7 Engine Board Removal 4 8 Engme Fa ess seine deoa bcd 4 9 Exit Paper Feed Roller Assembly Removal 4 10 Fuser Removal 2 da e giae Paw ade winds 4 11 High Voltage Power Supply Board and Interconnect Board ae dot dolus cup ludi dod 4 12 Main Motor Removal 4 14 Multi Function Feeder Board Removal 4 16 Paper Feed Motor Removal 4 17 Paper Feed Roller Removal 4 18 Pick up Motor Removal ems 4 22 Pick up Roller Removal 4 23 Power Supply Board Removal 4 25 Print Density Board Removal 4 26 Printhead Removal
41. Paper Drawer 2 6 26 Part Ref Number Units Description 12 1 12A4025 1 Drawer 450 Sheet Feeder without Tray 2 12A4026 1 Frame Front 3 12A4027 1 Roller Redrive Backup 4 1144323 2 Bushing Redrive Backup Roller 5 11 4329 2 Spring 6 2 Screw PP 12 4039 7 11A4221 1 Bracket Pick Roller 8 11A4331 1 Shaft Pick Roller 9 11 4224 1 Gear Pick Roller 10 11A4287 1 Roller Pick 11 11A4404 2 Bearing Roller 12 11A4336 1 Protector Pick Roller 13 5 Screw PP 12A4039 14 11A4339 1 Cover 450 Sheet Left Side 15 11A4348 2 Foot Rubber 16 11A4403 1 Cover Top Left 17 1144342 1 Cover Right Side 18 11A4348 2 Foot Rubber 19 11A4407 1 Lever Paper Tray Lock 20 11A4408 1 Spring 21 11A4409 1 Cover Top Right 22 11A4420 1 Plate Lower Paper Tray Guide 23 4 Screw PP 12A4039 Parts Catalog 6 27 Assembly 13 Optional 450 Sheet Second Paper Drawer 2 6 28 Part Ref Number Units Description 13 1 11A4421 1 Roller Redrive 2 11A4404 2 Bearing Roller 3 4 Screw PP 12A4039 4 12A4424 1 Spring 5 12A4000 1 Lever Lock 6 12A4009 1 Gear Redrive 7 12A4010 1 Gear Idler 8 12A4013 1 Bracket Motor Mounting 9 4 Screw PP 12A4039 10 12A4018 1 Motor Pick 11 2 Screw PP 12A4039 12 12A4020 1 Lever Multi switch 13 11A4223 1 Board Paper Size Sensor 14 2 Screw PP 1
42. Turn the bearing levers to the initial state positions to secure the bear ings to the base frame 2 Adhere new guide sheets to the base frame longer one to the left area and shorter one to the right area Be sure there is no clearance between the adhesive tape and the positioning edge Guide sheets 4 20 Guide sheets Positioning edges UE lt mE Front Positioning edges Repair Information 4 21 Pick up Motor Removal 4 22 PG moe Remove the paper tray Remove the left side cover Remove the left paper tray guide assembly Remove the interconnect board and high voltage power supply assembly Remove the pick up motor 2 screws Pick up motor Pick up Roller Removal 1 Remove the paper tray 2 Remove the left side cover 3 Remove the screw from the pick up roller shaft ground plate and remove the ground plate 4 Use a screwdriver to remove the bearing 5 Pull the pick up roller shaft out approximately 50 mm to remove the pick up roller Do not pull the shaft out completely FG Plate
43. ble LCD Test To run the LCD Test 1 Select LCD Test from the Diagnostic menu The LCD test con tinually executes the LCD display test 2 Press Return to cancel the test Diagnostic Aids 3 5 Button Test To run the Button Test 1 Select Button Test from the Diagnostic menu With no buttons pressed several OP Open appear on the display 2 Press each button one at a time and a CL Closed displays in place of an OP The proper operation of each button can be checked 3 Press Return or Stop to cancel the test DRAM Memory Test The purpose of this test is to check the validity of DRAM both standard and optional The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly To run the DRAM Memory Test 1 Select DRAM Memory Test from the menu The busy indicator flashes indicating the test is in progress 2 Press Return or Stop to exit the test PuHHHHHE represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display If the test fails the message DRAM Error displays for a
44. cidos en el subcap tulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s pa ses re ne todas las condiciones expuestas en la norma IEC 825 para productos l ser de Clase I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n dise ados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcap tulo J para Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe em conformidade com os requisitos da norma IEC 825 Os produtos laser da Classe n o sao considerados perigosos Internamente a impressora cont m um produto laser da Classe 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de x Service Manual forma a nunca existir qualquer possiblidade de acesso humano a radia
45. customer the print unit must be replaced Print Quality Blurred Print Blurred print is usually caused by a problem in the feed roller main motor gear box assembly or other gears transferring power to the feed rollers Check the gears for contamination of binds Also be sure the paper is feeding correctly from all available input trays Print Quality Evenly Spaced Horizontal Lines or Marks 93mm 3 6 inches Distance Between Lines or Marks Cause and Action This can be caused by the PC drum or the gear driving the PC drum on the print unit Inform the customer the print unit needs to be replaced 55mm 2 2 inches This can be caused by the main motor gear box assembly Replace the gear box assembly Diagnostic Information 2 19 Distance Between Lines or Marks Cause and Action 49mm 1 9 inches This can be caused by the feed roller or gear that turns the feed roller Inspect for damage and replace as necessary 24mm 0 9 inch This can be caused by a gear in the print unit Inform the customer the print unit needs to be replaced 68mm 2 7 inches This can be caused by a gear in the fuser Check the fuser gears for con tamination or damage Replace the fuser if necessary Main Motor Service Check Main Motor board board FRU Action 1 Engine Be sure the main motor cable is connected prop Board erly Replace it if it is damaged
46. d whenever the engine board is replaced because this board contains the printer s NVRAM Memory where the page count is stored To set the Page Count 1 Select Page Count from the Diagnostic menu The current page count displays The leftmost digit flashes indicating it is the first digit to be changed 2 Press either Menu or Menu until the value you want displays 3 Press Select to move to the next digit press Menu or Menu until the value you want displays Continue with each digit until you set the page count You can press Select to skip a digit When you press Select after the final digit the new page count is stored in NVRAM Press Select to save the new page count in NVRAM 5 Press Return to exit the Diagnostic menu gt 3 12 Viewing the Permanent Page Count The Permanent Page Count can only be viewed and cannot be changed To view the Permanent Page Count 1 Select Permanent Page Count from the menu 2 Press Return to exit the diagnostic menu Setting Configuration ID The configuration ID is used to communicate information about cer tain areas of the printer that cannot be determined using hardware sensors The Configuration ID is originally set at the factory when the printer is manufactured however it requires resetting whenever you replace the engine board and can be set on the operator panel However the Configuration ID is the only diagnostic function dis played until a valid ID is entered
47. dicates the printer cannot recognize the network card Error code 976 indicates an unrecoverable software error in the network card Verify the network card is installed correctly and is properly grounded If you find no problem replace the network card If the problem remains replace the controller board Paper Feed Service Check Be sure the size indicator on the paper tray is in the correct position before performing the service check If you have a 936 Transport Motor Error go to the Main Motor Ser vice Check on page 2 20 Locate your symptom from the following information and perform the check Pick Roller Fails to Pick Paper FRU Action 1 Pick Roller Check the pick roller for wear scratches or rough spots Replace if necessary 2 Pick Motor Watch the motion of the pick motor as you try to print a test page If the motor does not turn check the print motor connector at the interconnect board If it is correct disconnect the motor cable and check the impedance of the motor windings across the following motor connector locations CNRM 1 to CNRM 2 approximately 30 Ohms CNRM 3 to CNRM 4 approximately 30 Ohms If incorrect replace the pick motor If correct replace the following FRUs in the order shown 1 Interconnect Board 2 Engine Board 2 24 Pick Roller If the motor is operating correctly check the pick Gear roller gear train The pick roller gear contains a clutch tha
48. e and complete Yes O O 3 Was the book easy to use Yes O O 4 What can we do to improve the book 5 What is your job title Questions or comments about supplies service applica tions and so on will slow response time considerably Please refer those questions or comments to your authorized dealer or point of purchase Note Please direct all requests for copies of publications to your point of purchase Publications are not stocked at the location to which this form is addressed NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape eur Buoy 319
49. ec Service Manual Lexmark Optra K 4046 e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index Manuals Menu LEXMARK Second Edition October 1998 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase A form for reader s comments is provided at the back of this publication If the form has been removed comments may be addressed to Lexmark International Inc Department D22A 035 3 740 New Circle Road NW Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you
50. ed Select either Single feeds one sheet of media from the selected source or Continuous continues feeding media from the selected source until Return or Stop is pressed Press Return or Stop to exit test Input Tray Sensor Test This test is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 3 10 2 Select the Sensor Test from the Input Tray Tests menu Select the input source from the sources displayed on the Sen sor Test Menu Input Tray EM xx Size xxx displays EM Input Tray Empty Sensor Size Input Tray Size Sensor Once this message displays you can manually actuate each sensor To view a valid EM sensor value you must manually press the paper size sensor tabs to select a valid tray size If you do not select a valid tray size the empty tray sensor will display and the size sensor will display When the tray is out of paper the empty tray sensor closes and EM CL displays When the tray contains paper the empty tray sensor is open and EM OP displays 4 Press Return or Stop to exit the test The multipurpose tray does not have a paper low sensor Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly The following sensors can be checked Standard Bin Full Upper Front Door Open Rear Door Open paper guide To run the Base Sensor Test 1 Select the sensor you want fr
51. er cover Open the controller card door assembly Remove the fan shield plate Disconnect the engine fan and pull the cable through the toroid To remove the fan lift it atan angle as you press the lower mounting plate down with a screwdriver ar D Lo Uu Installation Note Install the fan so the air flow arrow is facing up Repair Information 4 9 Exit Paper Feed Roller Assembly Removal ON DOO BR C Remove the right side cover Open the controller board cage door assembly and disconnect the process fan from the engine board Remove the fuser and power supply board assembly Remove the paper feed guide assembly Remove the process fan plate assembly 2 screws Remove the six gears Remove the right side paper feed frame Remove the exit paper feed roller assembly Installation Note 1 To prevent damage to the pick motor cable and cover open switch cable be sure they are placed above the interconnect card 2 Return the gears to the original position and install the process fan plate assembly to hold them in place 3 Be sure to fasten the fan to the plate so the air flow arrow is in the outward direction Gear 5 Gear 4 Gear 5 Gear 1 Gear 3 4 10 Gear 2 Fuser Removal 10 Remove the right side cover Open the controller card door assembly and remove the fan shield plate Disconnect the process
52. er feed motor rotates counterclockwise the power General Information 1 5 is transmitted to the paper feed roller Epicyclic gear train Paper feed roller Redrive roller Paper exit roller ri 127 Process Drive Mechanism The power of the main motor is distributed to the print unit the fuser and the paper eject roller The power of the motor is transmitted to the print unit through gears A B C and D and to the hot roll of the fuser through gears A B C E and Main motor Print unit OPC drum Gear D Gear C Gear E Gear F Print Unit The print unit consists of a photoconductive drum OPC drum pre charger assembly developer assembly recycle screw and toner agi tator General Information 1 7 Gear A receives power from the process drive assembly transmitting the power to the photoconductive drum gear the magnet roll gear B the toner agitator gear C the recycle screw and gear D Fuser The fuser consists of the hot roll assembly and the backup roller The hot roll has a halogen lamp hot roll temperature sensor ther mal fuse and supporting parts The back up roller rotates with the hot roll Paper Ejection Paper is ejected either through the rear stacker or the upper exit bin When the stacker is folded down paper exits the rear of the printer and rests on the rear stacker When the stacker is in an upward posi tion it guides paper
53. ere is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition Notices and Safety Information vii Laser Advisory Label Label is inside printer CAUTION Invisible laser radiation when open and interlock defeated Avoid exposure to beam Radiation laser invisible si le disposit est ouvert et non bloque Eviter l exposition au rayon Unsichtbare laserstrahlung wenn drucker offen und sperre gel st Nicht dem strahl aussetzen Onzichtbare laserstraling wanneer open on niet vergrendeld Vermijd blootstelling aan straal Radiaziori laser invisibili se dispositivo aperto e nor bloccato Evitare l eposizione diretta Radiaci n l ser invisible si la puerta est abierta y el dispositivo no asta bloqueado Evite exponerse a la radiaci n Radia o laser invisive quando a tampa aberta Evite exposigdo aos Avaltaessa ja suojalukitus ohitettaessa olet altina nakymati malle lasers teillle katso s teeseen Osynlig laserstr ining denna del r ppnad och sp rrar ar urkopplace Sir len ar farlig Usynlig laserstraling nar deksel pros og sikkorhedsias brytes Unng eksponering for str len Usynlig laserstr hng ved bning sikkerhedsalbrydere er ude af funktion Undg undseattelse for str ling Radiaci laser invisible si s obre el tancament intern no s correcte Eviteu exposar vos i HERA
54. ervice Check Be sure you turn the printer off before you make any checks on the transfer corona FRU Action 1 Transfer Check the transfer corona assembly for signs Corona of toner buildup and contamination Use the cleaning tool provided with the printer to clean the wire Check the wire for damage The wire should be positioned across the corona hous ing Replace the corona if the wire is broken stretched or loose 2 HVPS Check the HVPS contacts for pitting or cables interfering with the contacts If correct and replacing the transfer corona does not improve the problem replace the FRUs in the following order 1 HVPS 2 Interconnect Board 3 Engine Board Diagnostic Information 2 29 2 30 3 Diagnostic Aids This chapter explains the tests and procedures to identify printer fail ures and verify repairs have corrected the problem To run the printer diagnostic tests described in this chapter you must put the printer in Diagnostic Mode Diagnostic Mode To enter the Diagnostic Mode 1 Turn the printer off 2 Press and hold the Go and Return buttons 3 4 Release the buttons when Performing Self Test displays on the Turn the printer on operator panel The tests display on the operator panel in the order shown Device Tests Print Registration Print Tests Hardware Tests Input Tray Tests Base Sensor Tests Printer Setup Error Log Exiting the Diagnostic Mode Select
55. ess canceled by pressing Return or Stop Each time the test finishes the screen updates with the result If the test passes the Pass Count increases by 1 however if the test fails one of the following failure messages displays for approximately 3 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 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum count is reached the test stops The busy indica tor goes on solid and the final results display Press Return or Stop to exit the test Diagnostic Aids 3 9 Input Tray Tests Input Tray Feed Test This test lets the servicer observe the paper path as media is feed ing through the printer A blank sheet of paper feeds through the printer as the laser turns off during this test The only way to observe the paper path is to open the lower front door that is used to access the multipurpose feeder The paper is placed in the output bin To run the Input Tray Feed Test 1 2 3 4 Select Input Tray Feed Test from the menu Select the input source from the sources displayed on the Feeds Test menu All installed sources are list
56. f it is correct replace the sensor Remove Paper Standard Bin message always appears when attempting printing FRU Action 1 Standard Bin Full Sensor Sensor Cable Engine Board Check the flag for damage or improper operation If incorrect replace the sensor Disconnect the sensor cable from the sensor and print a test page If the Remove Paper Standard Bin message does not appear and the test page prints successfully replace the sensor Disconnect the sensor cable from the engine board Attempt another test page If successful replace the sensor cable If you still have a problem replace the engine board engine board and check the cable for conti nuity Check the voltage on the engine board at CNSF 1 It should be 5 V dc If it is incorrect replace the engine board If it is correct replace the sensor 2 28 Toner Sensor Service Check An Insert Print Unit or Toner or 88 Toner Empty message may appear if the toner sensor cable is not seated correctly or if the cable is defective FRU Action i Toner Sensor Be sure the toner sensor cable is seated properly Check the voltage at CNTN 1 on the engine board If it is not 5 V dc replace the engine board If the voltage is correct check the voltage at CNTN 3 If it is not ground replace the engine board If the voltages are correct replace the toner sensor Transfer Corona S
57. ge 1 Contents of the Diagnostic Error Log Printer configuration information printer serial number control ler code level engine code level operator panel code level margin settings smart option code levels font versions and so on Values for the Quality Menu settings used to print the pages Printing Menu Settings Page Note This test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Select the TESTS MENU 2 Select Print Menus from the TESTS MENU The page contains the following information Alist of all the printer settings contained in the control panel menus and their values Alistof the installed options and features such as RAM memory SIMMs optional input paper trays duplex flash or disk Printer information such as serial number page count installed RAM engine code level RIP code level control panel code Paper Feed Jams Diagnostic Aids 3 15 Paper Jams Base Printer Error Message 200 Paper Jam Remove Print Unit This message indicates that paper is jammed at the printer input sensor This condition can be caused by the paper jamming prior to activating the input sensor flag the sensor not detecting paper over the sensor or paper arriving at the sensor too late Error Message 201 Paper Jam Remove Print Unit This message indicates the paper is jammed between the printer s input and exit sensors This condition can be caused by the paper exiti
58. gh voltage power sup ply 2 Disconnect the cover open switch connector 3 Disengage the two latches of the left guide and pull the left guide upward to remove it 4 Remove the cover open switch Cover open switch Hooks Installation Note When you install the new switch place the switch in the left guide then carefully slide the guide along the metal frame into position Repair Information 4 7 Engine Board Removal 1 Remove the right side cover 2 Open the controller board door assembly 3 Disconnect all connectors from the engine board except for the lower control board cable connectors CNCA and 4 Remove the two screws and disengage the hook on the left side of the card 5 Remove the engine board from the printer and disconnect the lower control board cable connectors CNCA and Installation Notes 1 There is aconnector on the back side of the engine board which connects the interconnect board When you install the engine board position it so the engine board connector faces the inter connect board connector 2 The white connector with red and blue cables connects to the white jumper The blue connector with red and black cables connects to the blue jumper CNF2 4 8 Engine Fan Removal Remove the right side and the upp
59. ice check 2 13 initial check 2 2 input paper feed assembly 6 14 input sensor service check 2 21 input tray feed test 3 10 input tray sensor test 3 10 input tray tests 3 10 interconnect board 5 10 interior of printer with upper door open 5 3 L LCD test 3 5 locations 5 1 main motor removal 4 14 maintenance approach 1 1 mechanical operation 1 3 multi function feeder board removal 4 30 N notices vii O operator panel buttons service check 2 22 operator panel display service check 2 22 optional multi function feeder and Index X 1 paper feeder 5 4 optional multi function feeder assembly 6 30 optional 450 sheet second paper drawer assembly 6 26 6 28 optional 450 sheet second paper tray assembly 6 24 options 6 32 options service check 2 23 paper ejection 1 8 paper feed drive mechanism 1 5 paper jams base printer 3 16 paper jams options 3 16 paper tray assembly 250 sheet 6 22 paperfeed motor removal 4 17 paperfeed roller removal 4 18 parallel wrap test 3 7 parts catalog 6 1 parts packets 6 33 pick up motor removal 4 22 pick up roller removal 4 32 power on self test 3 2 power supply board 5 9 power supply board removal 4 25 precautions for disassembly 4 1 precautions for handling the drum cartridge 4 2 precautions for handling the laser equipment 4 3 print density board removal 4 26 print quality test pages 3 14 print registration 3 11 print tests 3 14 pri
60. id r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres Limprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825 Notices and Safety Information ix prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Avisos sobre el l ser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos l ser de Clase 1 estable
61. into the code overlay SIMM again If these steps do not resolve the problem replace the code overlay SIMM and download the emulation again Error Log Viewing the Error Log The error log is helpful to the servicer by providing a history of printer errors The error log contains the 12 most recent errors that have occurred on the printer The most recent error displays in posi tion 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error is 3 4 discarded Identical errors in consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the Error Log 1 Select Display Log from the Error Log menu The Error log dis plays on 3 screens as only 4 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 or 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 Error Log displays on the screen 3 Press Return or Stop to exit the Clear Log menu Hardware Tests The following Hardware Tests can be selected from this menu LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap if available Serial Wrap if availa
62. l 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 After you complete the repair perform tests as needed to verify the repair Tools The removal and adjustment procedures described in this manual require the following tools and equipment Magnetic tip Phillips screwdrivers large and small Flat blade screwdriver e Analog volt ohmmeter a digital volt onmmeter may also be used Needle nose pliers When you make voltage readings always use frame ground unless another ground is specified General Information 1 1 Abbreviations ASIC CSU DRAM EEPROM EP ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR VAC VDC 1 2 Application Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Electrically Erasable Programmable Read Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Local Area Network Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power On Reset Power On Self Test Print Quality Enhancement Technology Raster Image Processor Read Only Storage
63. l port is not set up correctly 54 Serial Option X Error This error is displayed when a serial error framing or parity is detected on the optional serial port This usually indicates the optional serial port is not set up correctly 56 Standard Serial Disabled This error is displayed when data is sent to the printer across the standard serial port but the port has been disabled 56 Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset 61 Defective Disk This error code is displayed when the printer detects a defective disk This error may occur at power on or during disk format and write operations The following actions may be taken while this message is displayed Press Go to clear the message The disk is marked defective and normal printer operations continue Disk operations are not allowed with a defective disk The Format Disk menu is not shown 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 Diagnostic Information 2 7 User Error Message Explanation
64. lloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 825 maarityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan 16 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Al katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len xii Service Manual Laser notis Denna skrivare ar i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra lander uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 825 Laserprodukter i Klass anses ej halsovadliga Skrivaren har en inbyggd laser av Klass 3b som bestar av en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren ar utformade sa att det aldrig finns risk f r att n gon person uts tts f r laserstr lning ver Klass l niv vid normal anv ndning unde
65. ng the input sensor too late or jamming in the fuser assembly prior to activating the exit sensor flag in time or not at all Error Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at the printer exit sen sor This can be caused by the paper arriving at the sensor too late the paper is jammed in the fuser assembly or is jammed exiting the fuser assembly in the redrive assembly Paper Jams Options Error Message 240 Tray 1 or 242 Tray 2 The paper has not cleared the pass through sensor or reached the pass through sensor of the option above tray 1 or tray 2 If Tray Feeder is displayed the paper may have jammed prior to reaching the input sensor The paper may be in the tray paper feed path from tray to the input sensor or in the Multi function feeder 3 16 4 Repair Information Precautions for Disassembly and Cleaning Observe the following precautions whenever you service the printer Be sure to unplug the printer from the outlet before attempting to service the printer To reassemble the printer reverse the order of disassembly unless otherwise specified The basic rule is not to operate the printer anytime during disas sembly If it is absolutely necessary to run the printer with its covers removed use care not to allow your clothing to be caught in revolving parts such as the gears rollers and fan motor Never touch the terminals of electrical parts or high voltage part
66. nsor Flag Check the exit sensor flag for correct position and operation The flag should protrude upward into the paper path and swing to a downward position as the paper passes over it The opposite end of the flag should rest in the exit sensor while the flag is in the upward position and move out of the sensor as the paper pushes the flag Replace the flag if nec essary 2 Power Supply Board The exit sensor is mounted to the power supply board If the sensor flag is operating correctly replace the power supply board 2 12 Fuser Service Check FRU Action 1 920 Fuser Check the connection of the lamp cable at the Error Lamp LVPS and at the thermal fuse Be sure the lamp is does not come not burned out or broken on Check the thermal fuse for conductivity If the ther mal fuse conducts no current replace the fuser the connections are correct the lamp is good and the thermal fuse is good Replace the following FRUs in the order shown 1 LVPS 2 Engine Board 2 920 Fuser Check the fuser for signs of excessive toner buildup Error Lamp on the hot roll backup roll and thermistor Be sure does turn on the Thermistor is not bent loose or in the wrong position The thermistor should make contact with the hot roll Be sure the resistance of the thermistor is between the range of 50 Ohms hot and 60k Ohms cold If the resistance is out of this range replace the fuser If you still
67. nter operation 1 5 printer setup 3 12 printhead 1 7 printhead and paper feed redrive assembly 6 16 printhead erase LED assembly removal 4 27 printhead removal 4 27 printing menu settings page 3 15 process drive mechanism 1 7 X 2 process fan removal 4 28 process fan service check 2 27 Q quick disk test 3 2 R rear and left side of printer 5 2 removal procedures 4 4 ROM memory test 3 6 S safety information vii sensors 5 5 separator assembly removal 4 30 serial port service check 2 27 serial wrap test 3 8 service checks 2 9 service error code table 2 3 setting configuration ID 3 13 setting the page count 3 12 stacker full sensor board removal 4 31 standard bin full sensor service check 2 27 start 2 2 symptom table 2 8 system diagram 1 4 T toner sensor service check 2 29 tools 1 1 transfer corona removal 4 32 transfer corona service check 2 29 U upper cover assembly 6 2 user error messages 2 5 V viewing the errorlog 3 4 viewing the permanent page count 3 13 Optra K 1220 Laser Printer Readers Service Manual PN 11A4080 Comment 10 98 Form You may use this form to communicate your comments about this publication with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you 1 Did you find the book well organized Yes O No 0 2 Was the content of the book accurat
68. o laser superior um nivel de Classe durante a opera o normal manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 825 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse IIIb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Notices and Safety Information xi Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 825 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder belgeleengdeomradet 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse l niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta kirjoitin on Yhdysva
69. oad the requested type size of paper and insert tray X Remove Paper Standard Bin The printer senses that the standard output bin is full Close Upper Door The upper front door is open Close the door to continue printing Insert Print Unit or Toner The printer senses that either the print unit is not installed or is installed without any toner in the toner reservoir Diagnostic Information 2 5 User Error Message Explanation 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 loaded in the tray For auto size sensing trays this error occurs if the paper stop is in the incorrect position Make sure the Paper Size setting is correct for the size paper that is being used 35 Res Save Off Deficient Memory The printer lacks sufficient memory to enable Resource Save This message usually indicates the user has allocated too much for one or more of the printer s link buffers however modification of other printer settings which affect the amount of available memory may also create this condition Have the user either install additional memory or set each link buffer back to the Auto value 36 Resolution Reduced The resolution of the page has been reduced from 600 dpi to 300 dpi to prevent a Memory Full error This message can only occur if the Resolution Reduction setting is
70. ode Contact your next level for soft ware support 941 RIP Code CRC Replace the controller board 941 RIP Font CRC Replace the controller board 943 RIP Font Version The RIP code and font ROM are incompati ble 944 RIP Card Failure The processor is failing Replace the control ler board 945 RIP Card Failure Indicates an ASIC failure Replace the con troller board 946 RIP Card Failure Indicates SRAM is failing Replace the con troller board 947 Engine Card Replace the engine board 953 NVRAM Failure Indicates the NVRAM chip on the engine board has failed Replace the engine board Diagnostic Information 2 3 Error Code Action 954 NVRAM Failure Indicates the NVRAM chip on the engine board has experienced a CRC failure Replace the engine board 960 RAM Memory Error Replace the controller board 961 RAM Memory Error Indicates a problem with the expanded memory Replace the SIMM If you still have a problem replace the controller board 964 965 Emulation Error Indicates a failure with the Download Emula tion programmed into the code overlay SIMM The specific errors are 964 Download Emulation CRC Failure Checksum failure detected 965 Download Emulation outdated Go to Disabling Download Emulations on page 3 4 975 979 Network Card Indicates a failure with the network card Replace the network card The specific er
71. og 6 5 Assembly 3 Electronics 6 6 Part Ref Number Units Description 3 1 11A4305 1 Plate Ground 2 11A4316 1 Board High Voltage 3 3 Screw PP 12A4039 4 5 Screw PP 12A4039 5 11A4324 1 Board Interconnect 6 4 Screw PP 12A4039 7 11A4294 1 Cover Board Access 8 11A4307 1 Lever Paper Present Sensor 9 11A4312 1 Guide High Voltage Cover 10 1339526 1 Power Cord U S Canada A P LV Bolivia Columbia Costa Rica Ecuador El Salvador Guatemala Honduras Nicaragua Panama Peru Venezuela Brazil LV HV Mexico 10 1339520 1 Austria Germany Belgium France Netherlands Norway Spain Finland Turkey Iceland Eastern Countries Greece Portugal 10 1339525 1 Denmark 10 1339524 1 10 1339522 1 Switzerland 10 1339519 1 U K Ireland Bahrain Qatar Jordan Oman Iraq Kuwait Yemen Egypt Sudan 10 1339521 1 Israel 10 1339517 1 Saudi Arabia 10 1339523 1 South Africa 10 1342534 1 Chile 10 1342536 1 Argentina Paraguay Uruguay 11 11A4219 1 Cover Assembly Upper Front W Toner Sensor 12 3 Screw PP 12A4039 Parts Catalog 6 7 Assembly 3 Electronics cont 6 8 Part Ref Number Units Description 13 11A4335 1 Sensor Assembly Stacker Full 14 1 Screw PP 12A4039 15 11A4340 1 Cable SFS 16 12A4043 1 Baffle Cooling Fan 17 3 Screw PP 12A4039 18 11A43
72. om Base Sensor Test The opera tor panel displays OP for open and CL for closed 2 Manually toggle the sensors by hand to verify that each sensor switches from open to closed The standard bin sensor requires about six seconds to activate 3 Press Return or Stop to exit the test Print Registration The print registration range is as follows Bottom Margin 7 to 8 Top Margin 20 to 20 Left Margin 23 to 23 Manual Top 20 to 20 To set Print Registration 1 Select Registration from the Diagnostic menu 2 The Top margin sign value pair flashes This indicates it is the margin value being changed 3 To select the margin value to be changed press Select until the margin value pair you want to change is blinking 4 To change the margin value press either Menu or Menu Diagnostic Aids 3 11 When the value 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 mes sage displays Once the Quick Test Page completes printing the Registration screen displays again The Quick Test Page should be printed on letter or A4 paper Printer Setup Setting the Page Count This lets the servicer change the page count from the diagnostic menu This is use
73. om the engine board but leave the engine board connected to the interconnect board Measure the following voltages again CNMC A1 5 V dc CNMC B16 5 V dc If the voltages are now correct reconnect each cable until the voltage is incorrect Replace the FRU causing the change in voltage If the voltage is still incorrect replace the following FRUs in the order shown 1 LVPS 2 Interconnect board 3 HVPS 4 Engine board Engine Fan Service Check FRU Action 1 Engine Fan Be sure the engine fan turns on during POST If it does not be sure the fan is connected properly Check the voltage on the engine board between CNF2 1 and CNF2 2 If the voltage is 24 V dc replace the engine fan the voltage is incorrect replace the engine board Erase LED Service Check FRU Action 1 Erase LED Be sure the erase LED cable is correctly connected Assembly to the CNERS connector on the engine board Engine Board Disconnect the LED cable and check CNERS 1 on the engine board for 24 V dc If the voltage is incorrect replace the engine board If the voltage is correct replace the erase LED Diagnostic Information 2 11 Exit Sensor Service Check Error Code 202 Paper Jam Open Rear Door may display if the exit sensor flag is stuck down or defective The printer will not power up if the exit sensor flag is not in the sen sor FRU Action 1 Exit Se
74. pproximately 3 seconds and the failure count increases by 1 ROM Memory Test The ROM Memory Test is used to check the validity of the RIP code and fonts To run the ROM Memory Test 1 Select ROM Memory Test from the menu P and F represent the 3 6 same numbers for DRAM The busy indicator flashes indicating the test is in process The test runs continuously 2 Press Return or Stop to exit the test Each time the test finishes the screen updates with the result If the test passes the Pass Count increases by 1 however if the test fails one of the following messages displays for approximately 3 seconds ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached the test stops with the busy 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 signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interconnect cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the Hardware Tests menu The busy indicator flashes indicating the test is in progress The test runs continuously until canceled Each time the test finishes the screen updates If the test passes the Pass Count increases by 1 however if the test fails one of the following messages displays for approximately 3 seconds Sync Busy Error B
75. printer especially in the developer and transfer process Inspect the paper feed components especially the drive gears for signs of wear dirt binds or damage nt Quality Background Some background problems can be caused by an incorrect paper setting Be sure the correct paper type setting is selected for the paper being used Background can also be caused by an incorrect setting on the print darkness control The customer may try to improve the print quality by adjusting the print darkness dial Diagnostic Information 2 17 Light that enters the machine while some covers are removed may cause background FRU Action 1 Erase LED See the Erase LED Service Check on page 2 11 2 Printhead The printhead is a sealed unit and cannot be cleaned Try a replacement printhead only if all other attempts to correct a background problem fail 3 Transfer Check the transfer corona assembly for signs Corona of toner buildup and contamination Use the cleaning tool provided with the printer to clean the wire Check the wire for damage The wire should be positioned across the corona hous ing Replace the corona if the wire is broken stretched or loose See also the Transfer Corona Service Check on page 2 29 4 Contact Check the contact spring and HVPS contact for pit Springs ting cable interference or incorrect installation Engine Clean if necessary Board HVPS Check the voltages on the engine boa
76. r to lift the left side of the transfer corona then pull it toward the left side Be careful not to break the wire Holding block Transfer unit 4 32 5 Locations Front and Right Side of Printer Stacker full sensor Top Cover Paper Stacker Control Panel Upper door Front cover Slide cover PCI Bus and Ram card slots inside Manual feed slot inside the cover Multi function feeder Paper Tray connector Locations 5 1 Rear and Left Side of Printer 5 2 PCI bus option Rear stacker Centronics parallel interface connector Power switch Power cord connector Interior of Printer with Upper Door Open Print unit Print density dial Locations 5 3 Optional Multi Function Feeder and Paper Feeder Pre charger wire Toner bottle OPC drum Upper cover assembly Print unit Input feed roller Laser unit Eject redrive roller Paper feed roller Paper path Multi function feeder MFF option Rear stacker Exit Paper feed roller Pick up roller Paper tray 1 Paper feeder option Paper tray 2 option Fuser unit Transfer corona unit Locations 5 4 Sensors Rear Door Paper Input Sensor Stacker Sensor Open Switch Cover Open Switch Paper Exit Sensor Paper Size 506 Sensor NII ER Paper Empty Sensor Locations 5
77. rd at the fol Intercon lowing locations nect Board Printer Idle CNMC B10 24 V dc CNMC B11 17 V dc CNMC A11 20 5 V dc CNMC B12 0 1 V dc Printer Printing CNMC B10 0 1 V dc CNMC B11 0 1 V dc CNMC A11 0 1 V dc CNMC B12 momentarily jumps up to 5 15 V dc If these voltages are not correct replace the engine board If they are correct replace the following FRUs in the order shown 1 HVPS 2 Interconnect Board 2 18 Print Quality Toner on the Back Side of a Printed Page FRU Action 1 Fuser Toner is being carried out on the back side of the media The problem is generally caused by a toner buildup on the fuser hot roll or backup roll Check these rolls for any noticeable buildup of toner Replace the fuser if necessary 2 Transfer Corona 3 Print Unit Check the transfer corona for toner buildup or loose toner Toner in this area can usually be cleaned from the printer Replace the transfer corona if it is excessively contaminated or if you cannot clean it See also the Transfer Corona Service Check on page 2 29 Check the precharger wire on the print unit for dirt or contamination Clean the print unit with the tool provided with the printer Check the PC drum on the print unit for loose debris or foreign material Clean the debris from the print unit but do not touch the PC drum sur face If you still have the problem inform the
78. rh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 825 Klasse l laserprodukter er ikke a betrakte som farlige Skriveren inneholder internt en klasse 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i balgelengdeomradet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niva under vanlig bruk vedlikehold som utfgres av brukeren eller foreskrevne serviceoperasjoner Notices and Safety Information xiii Avis sobre el Laser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte laser de classe que compleix els requisits d IEC 825 Els productes laser de classe no es consideren perillosos Aquesta impressora cont un laser de classe 1116 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nanometres El sistema laser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasq
79. rors are 975 Unrecognizable network card 976 Unrecoverable software error in net work card communications 978 Bad checksum while programming net work card 2 4 User Error Messages User Error Message Explanation 200 Paper Jam Remove Cartridge Paper is jammed at the printer Input Sensor Open the printer s upper front door and remove the print cartridge to access the paper jam area 201 Paper Jam Remove Cartridge Paper is jammed between the printer s input and exit sensors Open the printer s upper front door and remove the print cartridge to access the jam area 202 Paper Jam Open Rear Door Paper is jammed at the printer exit sensor Open the printer rear door to access the jam area 240 Paper Jam Check Tray 1 242 Paper Jam Check Tray 2 Paper has jammed as it exits tray 1 or tray 2 Try opening the tray If the tray is difficult to remove then you may have to remove the tray above or below to remove the jammed pages Insert Tray X The printer is requesting the operator to insert tray X in order to continue printing the job Insert tray X Change Tray X The printer is requesting the operator to insert tray X with a specific type size of paper Insert the correct tray with the paper type size specified If the correct tray is inserted and the error message remains press Go to clear the message Load Tray X The printer senses that tray X is empty L
80. s such as the high voltage unit Be sure to handle the fuser carefully as it remains hot for a while after the printer stops running Always unplug connectors by holding the connector housing Be sure to use the fuse of the specified rating Do not forget to install the ground wire or ground plate to ensure positive conduction Install the screw with a toothed washer in the right position at reassembly Instructions for Handling the PWBs with MOS ICs The following precautions must be observed when handling circuit boards with MOS Metal Oxide Semiconductor ICs During Transportation Storage During transportation or when in storage new circuit boards must not be indiscriminately removed from their protective con ductive bags Do not store or place circuit boards in a location exposed to direct sunlight When it becomes absolutely necessary to remove a board from its conductive bag or case always place it on its conductive mat in an area as free as possible from static electricity Do not touch pins of the ICs with your bare hands Repair Information 4 1 During Replacement Before you unplug connectors from the circuit boards be sure the power cord has been unplugged from the power outlet When you remove a board from its conductive bag or case do not touch the pins of the ICs or the printed pattern Place it in position by holding only the edges of the board Before you plug connectors into the board be sure the
81. se ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Notices and Safety Information xvii Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informacoes de Seguranca Este produto foi concebido testado e aprovado para satisfazer os padr es globais de na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem nao ser sempre bvias A Lexmark n o respons vel pela utiliza o de outros componentes de substituic o As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os nao devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Informaci de Seguretat Aquest producte est dissenyat
82. ser Assembly 220 240 V Parts Catalog 6 21 Assembly 10 Paper Tray 250 Sheet 6 22 Ref aia Units Description 10 1 12A4028 1 Tray Assembly 2 12A4001 1 Holder Paper Lift Plate Left 3 12A4002 1 Holder Paper Lift Plate Right 4 2 Spring Lift Plate Holder PP 12A4037 5 12A4003 1 Plate Paper Lift 6 1 Spring Paper Tray Lift Plate PP 12A4037 7 12A4004 1 Separator Paper 8 1 Spring PP 12A4037 9 12A4005 1 Guide Paper Left 10 12A4006 1 Guide Paper Right 11 12A4007 1 Guide Paper End 12 12A4019 1 Lever Paper Size 13 11A4232 1 Label Size Packet 14 12A4030 1 Extender 250 Sheet Legal 15 12A4032 1 Dust Cover Rear 16 2 Screw PP 12A4039 Parts Catalog 6 23 Assembly 11 Optional 450 Sheet Second Paper Tray 6 24 Part Ref Numb r Units Description 11 1 12A4029 1 Tray Assembly 450 Sheet 2 12A4011 1 Holder Plate Left 3 12A4012 1 Holder Plate Right 4 2 Spring PP 12A4037 5 1 Spring PP 12A4037 6 12A4014 1 Separator Paper 7 1 Spring PP 12A4037 8 12A4015 1 Guide Paper Left 9 12A4016 1 Guide Paper Right 10 12A4017 1 Guide Paper End 11 12A4019 1 Lever Paper Size 12 12A4031 1 Extender 450 Sheet Legal 13 12A4032 1 Dust Cover Rear 14 2 Screw PP 12A4039 15 11A4232 1 Label Size Packet Parts Catalog 6 25 Assembly 12 Optional 450 Sheet Second
83. t Test Page once Continuous continue printing the Print Test Page until Return or Stop is pressed The contents of the Print Test Page varies depending on the media installed in the selected input source To run the Print Test Page 1 Select Print Tests from the Diagnostic menu 2 Select the media source 3 Select Single or Continuous e f single is selected no buttons are active during printing e If continuous is selected Return or Stop can be selected to cancel the test Check each Test Page from each source to assist in Print Quality and Paper Feed problems Print Quality Test Pages The purpose of this diagnostic function is to allow printing 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 graphics and text Pages two and three only contain graphics The Print Quality Test pages must always be printed on let ter legal or A4 paper To run the Print Quality Test Pages select Print Quality Pages from the diagnostic menu or follow these steps 3 14 Turn the printer off Press and hold Select and Return Turn on the printer Release the buttons once Performing the Self Test displays The printer performs its normal POR cycle then print one copy of the Print Quality Test pages If you want more than one copy perform these steps again The following is printed on pa
84. t allows rotation in only one direction If it is installed backwards the pick roller cannot pick the paper If the pick roller gear is properly installed but not working correctly replace the gear To determine if the roller gear is positioned cor rectly remove the paper tray and roll the pick roller by hand If you slide your hand toward the front of the printer the roller should rotate freely with little resistance If you slide your hand toward the rear of the printer the pick roller should resist rolling and cause the pick motor to turn Pick Roller Feeds Paper but Stops or Jams at Input Feed Roll FRU Action Paper Path Open the upper door remove the print unit and check for loose debris in the paper path Clean as necessary Input Sensor Go to the Input Sensor Service Check on page 2 21 Paper Feed Check the paper feed roll for wear and replace as Roll necessary Paper Feed Be sure the paper feed motor is connected prop Motor erly Be sure the motor turns when you print a test page If the motor does not turn disconnect the motor cable and check the impedance of the motor wind ings across the following motor connector loca tions CNRM 1 to CNRM 2 approximately 30 Ohms CNRM 3 to CNRM 4 approximately 30 Ohms If incorrect replace the paper feed motor Diagnostic Information 2 25 Failures Occur at or Near the Bottom of the Stack of Paper The paper tray lift pla
85. tandard di sicurezza e per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non responsabile per l utilizzo di parti di ricambio di altri produttori xvi Service Manual Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen Pautas de Seguridad Este producto se ha di
86. te may not be lifting the paper with enough force for the pick roller to move the paper Check the paper tray lift plate spring for proper operation Also check the pick roller for wear scratches or rough spots Double Feeding Paper is usually the primary cause of double feeding Flex the paper before you place it in the tray Edge welded paper is the most com mon cause of double feeding Loading the paper in the tray in differ ent locations and directions and using rough paper and short grain paper can also cause double feeding FRU Action 1 Paper Tray Check the separator pad in the paper tray A worn Separator Pad or incorrectly installed separator may cause mis feeding Parallel Port Service Check Run the Parallel Wrap Test on page 3 7 Use wrap plug P N 1319128 This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately 3 seconds If the test indicates a problem replace the controller board Printhead Service Check FRU Action 1 Printhead Check for wear on the cable Be sure the cable is Cable properly connected Check the continuity of the cable 2 26 FRU Action 2 Engine Board Disconnect the printhead cable and check the volt age on the engine board at the following locations OPT 1 24 Vdc OPT 2 24 Vdc OPT 9 Ground OPT 13 Ground OPT 16 5 Vdc OPT 19 5 Vdc
87. the memory SIMM is installed correctly and is not broken or damaged Run the Flash Test on page 3 3 If the test fails replace the flash SIMM If the problem continues replace the controller board DRAM Memory Option Run a copy of the test page to see if the option you are checking is listed The printer does not recognize the option being installed if the option is not listed Be sure the DRAM SIMM is installed correctly and is not broken or damaged Run the DRAM Memory Test on page 3 6 If the test fails replace the DRAM SIMM If the problem continues replace the controller board Hard Disk Option Be sure the fixed disk and the fixed disk board are correctly installed Run the Quick Disk Test on page 3 2 The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If the problem remains replace the hard disk board The Disk Test Clean on page 3 3 helps restore the disk if the disk contains bad data and is unusable This test is divided into a clean ing and verifying or testing section This can be a very lengthy test depending on the disk size and leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk menu operation This is a destructive type test and should not be performed on a known good disk All the data on the disk is destroyed Diagnostic Information 2 23 Network Card Option Error code 975 in
88. tion Environment The power supply line voltage is plus or minus 10 of the rated line voltage The machine is securely installed on a level surface in a well ventilated place The room temperature is between 10 and 32 C 50 and 90 F and the relative humidity between 20 and 80 Avoid sites generating ammonia gas high temperature or high humidity near water faucets kettles humidifiers cold spaces near open flames and dusty areas Avoid sites exposed to direct sunlight Print Paper Checks Besure the recommended paper for this printer is being used Check the paper for dampness Make a trial print with paper from a newly opened package and check the results 2 2 Service Error Code Table Error Code Action 900 RIP Software Replace the controller board 920 Fuser Error Indicates the fuser is not operating at the correct temperature Go to the Fuser Ser vice Check on page 2 13 935 Printhead Error The mirror motor is not operating correctly Go to the Printhead Service Check on page 2 26 936 Transport Motor Go to the Main Motor Service Check on page 2 20 939 RIP to Engine Comm The controller board and the engine board cannot communicate with each other Be sure each board is installed correctly If you don t find a problem replace the controller board If you still have a problem replace the engine board The controller software can also cause this error c
89. turned on Note 1200 dpi pages are not resolution reduced If a 1200 dpi job runs out of memory a Memory Full error is displayed 37 Insufficient Collation Memory 38 Memory Full This message is displayed when the printer memory used to store pages is too full to collate the print job This message is displayed when the printer memory used to store pages is full 39 Complex Page This message is displayed when the page is too complex to print 51 Defective Flash This message is displayed when the printer detects a defective flash This error may occur at power on or during flash format and write operations Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved 52 Flash Full This message is displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash 2 6 User Error Message Explanation 53 Unformatted Flash This message is displayed when the printer detects an unformatted flash at power on Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the flash is formatted 54 Standard Serial Error This error is displayed when a serial error framing or parity is detected on the standard serial port This usually indicates the seria
90. ues de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Japanese Laser Notice LT st 2 5 21 1 07241 1 D EMALEAL Y 5 0 amp 82508677 5 ALOV V WMECHSCEMMPWMANTIET Z295XI0v v Wiifsl amp tEd7zvcxxoncoxzv co 7Zyr sZ i 72ZzHnb 30 OL P AARMLTOEF CO Li T9ISFJA FY OMACT BH 5LUDybhOAUDAUMILWMERHISL P CHF COL YAFRESP VY HE OH ARM I FALTOVANVELLOL ik HE NSZCLORMWEABHANTHET xiv Service Manual Chinese Laser Notice ph RE TERR i ED ae A DHHS 21 CFR Subchapter I Xj 2 28 I 1 MIT RY bi ru EH Hb X MI SEGA UE 825 1 HE DE THI Bh RUNAR ERE TIED OLA 27 Hb 3b EREHE S EF ER A HU Gt EG ARR 770 795 nm ABOGRAARI VE fH HEIDE ERE BISTRO AA EA PB fh AE I D E SERE REN V Korean Laser Notice 155 al o x ASSO CHSt DHHS 21 CFR Subchapter 39 142 Fs wes ulz 20 9 IEC 825 TAS Sr te 152 old Hez VISES BIOS ict 128 40 ASSES Cast PHYS 5 WS ajo HZA 770 795 LILO EO Class ill 3b AO ME Lysol z ALES BA 45 FA BS BLE HAE MYA 4219 Class 29 80 LEO Ao Ach dos ALES So UECH
91. up paper from the paper tray To print using the multi function feeder the host sends a paper select command When receiving it the pick up motor rotates clockwise to drive the pick up roller of the multi function feeder The paper feed motor starts to rotate to turn the paper feed roller 3 The pick up motor stops turning when the bottom edge of the paper exits the pick roller The paper feed motor and the main motor continue to rotate the paper feeder roller print unit fuser exit roller and redrive roller until the paper passes through 4 When the mechanism controller detects the bottom edge of the paper by the paper exit sensor it stops both motors The printer then waits for the next command Paper Feed Drive Mechanism The main motor and the gear train are mounted on the metal frame The power of the pick up motor gear is distributed to the pick up roller of the paper tray or that of the multi function feeder Selection is determined by the rotating direction of the motor The power of the paper feed motor is distributed to the paperfeed roller Operation 1 When the pick up motor rotates counterclockwise the power is transmitted to the pick up roller of the paper tray through the center gear of the epicyclic gear train 2 When the pick up motor rotates clockwise the power is trans mitted to the pick up roller of the multi function feeder through the circumference gear of the epicyclic gear train 3 When the pap
92. yte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error Diagnostic Aids 3 7 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 False Init Fall 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 busy indica tor goes on solid and the final results display Press Return or Stop to exit the test Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug Each signal is tested To run the Serial Wrap Test 1 2 Disconnect the serial interconnect cable and install the serial wrap plug Select the appropriate Serial Wrap Test from the menu Serial Wrap Serial 1 Wrap The busy indicator flashes indicating the test is running PuHHHHHE represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F3HHHHE represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 3 8 3 This test runs continuously unl

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Lexmark Optra K 1220 Laser Printer

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