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Lexmark E460dn, 4513 Service Manual

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1. Connector Pin Value Value Comments cable plugged cable unplugged if different J2 1 2 3 4 0 V dc Wireless card E460 dw only 5 5 V dc 6 3 3 V dc J4 1 Ground Cartridge 2 17 V dc The front access door must be closed 3 4 3 3 V dc J5 1 3 5 6 3 3 V de Operator panel 2 5 0 V de 4 7 Ground J100 1 gt 0V de 5 V dc Printhead 2 3 5 V dc 4 5 6 7 Ground J7 1 5 V de door closed Open door sensor 0 V dc door open 2 5 V dc 3 Ground J8 1 10 5 V dc LSU 9 2 9 V dc J9 1 24 V dc 0 V dc Cooling fan 2 24 V dc J10 1 24 V dc 24 V dc Duplex solenoid 2 24 V dc 0 V dc J11 1 5V dc Narrow media sensor 2 5 V dc 5V dc 3 Ground J12 1 5 V dc Thermistor 2 Ground J13 1 0 6 V dc Toner level sensor 2 Ground 3 0 V dc J14 1 gt 0V de 5 V dc Fuser exit sensor 2 5 V dc 3 Ground 5 4 Service Manual 4513 630 63W 6EW Connector Pin Value Value Comments cable plugged cable unplugged if different J17 1 4 0 1 V dc 5V dc Main gear drive motor 2 3 6 5 V dc 5 Ground 7 8 9 24 V dc J19 USB port J21 Parallel port J23 1 1 1 V dc 5V dc Manual feed sensor 2 5 V dc 3 Ground J24 1 24 V dc MPF clutch 2 24 V dc 0 V dc J25 1 24 V dc Manual feed solenoid 2 24 V dc 0 V dc J26 1 24 V dc Media feed clutch 2 24 V dc 0 V dc J27 1 4 1 1 V dc 5V dc Input and duplex sensor 2 5 5 V de 3 6 Ground J28 1 4 3 3
2. 5 2 Service Manual 4513 630 63W 6EW Lexmark E460dw controller board D00000 J14 EXI 1 J11 NRW Tmmmmmmmmmmmmmmr goooooo0000o00000 1 J10 DPSOL 1 J9 FAN OOOOOO0000000000000000000000 o o o o o o LOLIO JUHI 1 J7 CO J100 DRV HSYN o mm J28 TRAY2 1 J27 gt IN DPX J2 WRLSS 000000 J5 OP PANEL J26 FED J4 CART J24 MPF Le J23 gt J13 TNR 1 J501 TPS J17 MTR 000000000 1 Locations and connections 5 3 4513 630 63W 6EW Lexmark E460dn E460dw controller board connector pin values Note See the wiring diagram at back of book These values were measured with all connections made plugged or with only one connector at a time unplugged to expose the pins Always disconnect and connect with the printer power off Otherwise the values below may not match
3. eee eee er ee ee 7 8 Tray 2 wear strips 550 sheet tray only mem emma ee es 7 3 Wireless card E460dw 7 5 Antenna 11 inch cable 7 5 Fuser assembly 115 V gt ooo Sse epee eee eee eee ce ee eee 7 5 Fuser assembly 230 V 2 2 ee ee eee eee 7 5 Fuser assembly 100 V 22llc22l2ll22ll22 l222 22l222 22222 2 7 5 Controller board E460dn mm ee 7 5 Controller board E460dw em ee 7 5 LCD operator panel assembly E460dn E460dw eee ee 75 LCD bezel cover E460dn 2 22 eee eee nr em ee 73 MPF tray assembly 2 22 ee eee er lll lll llle ee ea 7 7 Nameplate cover meten eee 7 3 Access door open sensor assembly 2 0 etree eee eee eee eee 7 5 LVPS HVPS card assembly 110 V 100 V 222 eee eee ee 7 5 LVPS HVPS card assembly 220 V nn 7 5 Duplex gear drive CBM ee ee mem emet ee ee 7 Transfer roll bearings gear spring CBM 7 7 Duplex and media sensor assembly 7 5 Manual input sensor assembly 20ers 7 5 Main drive gearbox in motor ee ee
4. 1 Enter Configuration Menu Turn off the printer Turn on the printer while pressing and holding and Release the buttons when Performing Self Test displays The message CONFIG MENU displays Press 3 to Prt Quality Pgs Press to print the pages Four pages print to help evaluate print quality The first page has various fonts and a graphic the second page is gray with graphics the third page is black and the last page is blank 2 Use the test pages to isolate problems such as light or toner streaks See POST symptom table on page 2 19 for solutions to these problems 3 Press to Exit Config Menu and press 7 POLOP To exit configuration turn the printer off Note Refer to the print defects guide at the end of the manual for repeating defects Blank page FRU Action Toner cartridge not a Remove the toner cartridge and gently shake it to evenly distribute the toner RED Check for cartridge damage Blank pages can be caused by a defective printhead assembly LVPS HVPS or controller board A e Printhead errors typically result in printer service errors unless there is blockage of the beam or dust on the lens Check the lens and opening for blockage Blank pages typically are caused by the PC roll not being properly charged Try a Printhead different PC kit LVPS HVPS With the cartridge out check the spring loaded contacts on the right side for fr
5. Service Manual e Table of contents e Start diagnostics e Safety and notices e Trademarks e Index LEXMARK Lexmark E460dn Lexmark E460dw 4513 630 4513 63W 4513 6EW 4513 630 63W 6EW Edition September 29 2008 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 Comments may be addressed to Lexmark International Inc Department D22X 002 1 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining 9 Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all cou
6. Una iE SUE KW FAME TA D o I WER CME m KER fife or RSE TE TE EA EREI ht do DA ruit 4k RAE e UE o UE eT TES BI JM Safety information XV 4513 630 63W 6EW Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 N Po me m General information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment as well as general environmental and safety instructions are discussed Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems Repair information provides instructions for making printer adjustments and removing and installing FRUs Connector locations uses illustrations to identify the connector locations and test points on the printer Preventive maintenance contains the lubrication specifications and recommendations to prevent problems Parts catalog contains illustrations and part numbers for individual FRUs Conventions xvi Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software There are several types of caution statem
7. After obtaining a properly adjusted image on the paper tighten all three screws Note The printhead must be aligned electronically See Printhead assembly electronic adjustment on page 3 18 3 20 Service Manual 4513 630 63W 6EW 4 Repair information Warning Read the following before handling electronic parts Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual precautions such as turning off power before removing logic cards Keep the ESD sensitive part in its original shipping container a special ESD bag until the part is ready to be installed into the printer Make the least possible body movements to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the printer Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If a pluggable module is being removed then use the correct tool Do not place the ESD sensitive part on the MFP cover or on a metal table if the ESD sensitive part needs to be put down for any reason then first put it into its special bag Machine covers and metal tables are electrical grounds They increase th
8. E460dw 8 40X5350 1 1 Controller board E460dn 8 40X5351 1 1 Controller board E460dw 9 40X5320 1 1 Antenna 11 inch cable 10 40X5361 1 LVPS HVPS card assembly 110 V 100 V 10 40X5362 1 LVPS HVPS card assembly 220 V 11 40X5366 1 1 Manual input sensor assembly 12 40X5369 1 1 Manual feed solenoid 13 40X5371 1 1 MPF feed clutch 14 40X5370 1 1 Media feed ACM clutch 15 40X5387 1 LSU E460dn E460dw printhead Parts Catalog 7 5 4513 630 63W 6EW Assembly 3 Frame See instruction sheet in the FRU 7 6 Service Manual Assembly 3 Frame 4513 630 63W 6EW Asm Part Units Units Description Index number mach FRU 3 1 40X5364 1 Transfer roll bearings gear spring CBM 2 40X5372 1 Media exit guide assembly redrive 3 40X5397 1 1 Front mounts 4 40X5396 N A Screws miscellaneous 4 TP2NCX3X6PF Ni 4 TP2C 4 0 8PF Ni 4 M3 0 0 5 6PF Ni 2 M3 0 0 5 4PF Ni 2 M3 5 0 6 6P Ni 5 40X5380 1 1 Complete duplex assembly 6 40X5453 1 1 Media ACM drive assembly 7 40X5451 2 2 Paper feed ACM tires 7 40X5440 1 2 Tray 2 paper feed tires 8 40X5358 1 1 MPF tray assembly 9 40X5383 1 1 Upper front frame assembly 10 40X5368 1 1 Manual feed clutch CBM 11 40X5367 1 1 Main drive gearbox in motor 12 40X5363 1 1 Duplex gear drive CBM NS 40X5400 1 1 110 V maintenance kit NS 40X5401 1 1 220 V maintenance kit NS 40X5402 1 1 100 V maintenance kit Note Kit contains the following Fuser 40X5344 40X5345 or 40X2802 Exit guide
9. ESD sensitive parts 4 1 F fan parts catalog 7 5 service check 2 22 frame parts catalog 7 6 fuser parts catalog 7 5 service check 2 24 Fuser Temp 3 15 G Gap Adjust 3 15 H handling ESD sensitive parts 4 1 History see error log 3 17 L lithium battery v xiii 4 6 locations front views 5 1 rear views 5 1 lubrication specifications 6 1 LVPS HVPS parts catalog 7 5 service check 2 24 maintenance approach 1 1 maintenance kits 6 1 menus accessing service menus 3 1 messages service error codes 2 13 user attendance messages 2 5 Model Name 3 14 models comparison 1 1 diagrams 5 1 operator panels 1 2 trays available 1 5 Index l 1 4513 630 63W 6EW N navigation buttons 2 2 O operator panel LCD 2 2 LED service check 2 26 LED E238 E240 n overview 1 2 P panel control 1 2 paper jams tips on preventing 1 7 parallel port service check 2 28 parts catalog covers 7 2 electronics 7 4 frame 7 6 options 7 8 power on self test POST 2 1 symptoms 2 19 Print Contrast 3 15 print media preventing jams 1 7 trays by model 1 5 types and sizes 1 6 print quality pages using 2 29 print quality problems print media 1 7 service check 2 29 solving 2 33 printer symptom table 2 20 printhead service check 2 36 R registration 3 7 removals covers front access cover 4 6 procedures 4 2 S safety information xiii safety inspection guide 6 1 service checks 2 21 controller card 2 2
10. Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Lithium warning Xiii 4513 630 63W 6EW Sicherheitshinweise e Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen e Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen 0 ACHTUNG Dieses Symbol weist auf eine gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit groBer Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein muB Pautas de Seguridad e La seguridad de este producto se basa en pruebas y aprobaciones del dise o original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas Lainformaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualif
11. 40X0277 1 Power cord 6 foot straight Brazil NS 40X0282 1 Power cord 1 8M straight PRC NS 40X0270 1 Power cord 2 5M straight Japan NS 40X0280 1 Power cord 1 8M straight Korea NS 40X0281 1 Power cord 1 8M straight Taiwan NS 40X0296 1 Power cord 1 8M straight Australia Parts Catalog 7 9 4513 630 63W 6EW 7 10 Service Manual Index A abbreviations 1 9 acronyms 1 9 B buttons accessing service menus 3 1 C Charge Roll diagnostics mode 3 15 compatibility 1 4 configuration ID 3 14 configuration menu accessing 3 1 3 2 available menus 3 2 Demo Mode 3 4 Energy Conserve 3 5 Factory Defaults 3 4 Panel Menus 3 4 PPDS Emulation 3 4 control panel 1 2 controller card service check 2 21 D defaults factory defaults 3 4 diagnostics mode 3 6 accessing 3 1 available tests 3 6 diagnostics mode EP Setup Charge Roll 3 15 EP Defaults 3 15 Fuser Temp 3 15 Gap Adjust 3 15 Print Contrast 3 15 Transfer 3 15 Event Log Clear Log 3 17 Display Log 3 16 Print Log 3 17 Hardware Tests DRAM Test 3 9 Printer Setup Configuration ID 3 14 Edge to Edge 3 14 Engine Settings 3 14 Model Name 3 14 Par S Strobe Adj 3 14 Registration 3 7 DRAM Test 3 9 4513 630 63W 6EW E Edge to Edge 3 14 EP Defaults 3 15 error log clear log diagnostics mode 3 17 display log diagnostics mode 3 16 Print Log 3 17 error messages service error codes 2 13 user attendance messages 2 5
12. Controller board service Diagnostics information 2 23 4513 630 63W 6EW Fuser service check When toner is partially fused to the media it is usually caused by low fuser temperature The line voltage to the printer must be within the following limits e 100 V ac 127 V ac for the 110 V model printer e 200 V ac 240 V ac for the 220 V model printer This printer uses a belt fuser and therefore does not have a lamp Fuser service check FRU Action A Fuser povver cable LVPS HVPS Fuser Unplug the printer and disconnect the fuser cable plug from the LVPS HVPS board connector at CN102 Check for continuity across the fuser by checking across the connector pins If there is continuity then check the LVPS HVPS See LVPS HVPS service check on page 2 24 e If there is no continuity then disconnect the fuser power cable at both ends and check each conductor for continuity Replace cable if necessary e f the cable tests good then replace the fuser Reconnect the cables turn the printer on and at amp 12 check for approximately 5 V dc on pin 1 and ground on pin 2 If line voltage is incorrect on pin 1 then see Controller board service check on page 2 21 for more information A Fuser Disconnect the thermistor cable from J12 on the controller board Measure the resistance across the ends of the thermistor cable Replace the fuser assembly if the resistance is lower than 1K ohm o
13. Network A network interface is the active communication link Network Card Busy An internal print server also called an internal network adapter or INA is being reset Wait for the message to clear Not Ready The printer is not ready to receive or process data Someone pressed to take the printer offline Press Ey to make the printer ready to receive jobs Parallel A parallel interface is the active communication link Performing Self Test The printer is running the series of start up tests it performs after it is turned on Wait for the message to clear Power Saver e Senda job to print e Press E to warm the printer to normal operating temperature and display the Ready message Printing Directory List The printer is processing or printing a directory of all files stored in flash memory Wait for the message to clear Printing Font List The printer is processing or printing a list of all available fonts for the specified printer language Wait for the message to clear Printing Menu Settings The printer is processing or printing the menu settings page Wait for the message to clear Printing Device Statistics The printer is printing statistical information about the printer Wait for the message to clear Printi 5 LI g Quality Test Pages The printer is formatting and printing the Print Quality Test which consists of 4 pages Page 1 contai
14. Once initiated the reset operation cannot be canceled Press EJ or E to return to the Configuration Menu Reset Photoconductor Maintenance Counter Reset PC Cnt This setting resets the photoconductor kit page counter and clears any warnings or photoconductor exhausted messages This operation should be performed only after a new photoconductor unit has been installed Print Quality Pages This setting is a limited version of the Print Quality Pages setting that appears in the Diagnostics menu This setting reports the values of a broad range of printer settings and tests the printer s ability to generate acceptable printed output Press 7 to print the report Printing Quality Test Pages will display Once started the printing cannot be canceled and no buttons are active until the printing completes Diagnostic aids 3 3 4513 630 63W 6EW Reports The Reports menu contains two selections Menu Settings Page and Event Log Menu Settings Page To print the Menu Settings page press M Press to return to the Configuration menu Event Log The event log provides a history of printer errors The event log can only be printed in the Configuration menu Additional options are available in the Diagnostics menu See Reports on page 3 16 To print the event log 1 Select Print Event Log from the Event Log menu 2 Press El to return to the Configuration menu Note An event log printed from the CONFIG MENU will not c
15. Safety irispection guide nisi nao e A d eee dade AE KR Ere 6 1 Lubrication Specil Gall OHS iuga icem dax idee dT Re AAA tea end Sah dd eee 6 1 GEN GEC RIS rotar dep XR Eb Ac SE CR oed EEES RA AA ITE GR ec RUE ia C UK Rc o 6 1 Pants Catalog MESRINE MIN A 7 1 How to use this parts Catalog ama ima resa AAA AAA A Ra 7 1 Assembly 1 COVERS escoiresorrasoro ad are QR RERAsGbiodsR e 7 2 Assembly 2 ElectronicS 42 02 i00805 seer p o iria ii 7 4 Assembly 3 ELMO ciar ADA A 7 6 Assembly 4 Options cioosseooso ri eir dem gos id 7 8 Assembly5 Power COS cocaina rias ia NAR DOES UE BOR RUN A S Poe Pe adus 7 9 lil MEET ETT l 1 Pan number OE AAA l 3 vi Service Manual 4513 630 63W 6EW Notices and safety information The following laser notice labels may be affixed to this printer 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 elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 1 Class laser products are not considered to be hazardous The printer contains internally a Class IIIb 3b laser that is nominally a 7 milliwatt gallium arsenide laser operating in the wavelength region of 655 675 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service c
16. The media fails to feed from Tray 1 Frictional force between tires and media is less than resisting force Remove the media from Tray 1 and fan it Make sure Tray 1 is selected from the printer driver Do not overfill the tray Check the condition of the rubber on the paper feed rolls Replace if worn or contaminated Verify that the ACM clutch is functioning correctly The media fails to feed from the optional Tray 2 Incorrect tray selection or inadequate picking force by tires Make sure the correct tray and media type are selected from the driver Make sure the tray is pushed all the way in Remove the media from the optional Tray 2 fan it and reload Check the rubber on the paper feed tires for dirt or any other debris Replace as necessary Check the paper path in the tray for burrs or debris that may hinder media movement Make sure the media does not exceed the stack height indicator Load Paper displays even though there is media loaded in the optional Tray 2 The input sensor does not sense media after picking Make sure the tray is pushed all the way in Press EJ Check the feed tires See two preceding actions The printer does not print after a paper jam has been cleared The printer is waiting on the next command Clear all jams Press and release FJ or open and close the printer cover to restart the printer Make sure the print cartridge a
17. Utilities Ifa menu settings page cannot be printed then contact the next level of support If a menu settings page can be printed then the problem is one of the following e Computer e Software program e Cable e USB only A failed controller board Replace card Note Test by unplugging USB and plugging it with the printer on If the computer indicates unknown device replace the controller board Toner Low light is on and printing stops If a 3 5K or more page toner cartridge is being used and the Toner Low alarm is set to on then the printer stops printing until the toner cartridge is replaced The Error light alone is on Make sure the front printer cover is closed The Toner Low light is blinking and the Error light is on Make sure the toner cartridge is installed correctly Install a new toner cartridge The media skews or buckles Tray is overfilled or media is too loose Don t overfill Tray 1 or the optional Tray 2 see media capacities in the media types and sizes table in the User s Guide Make sure the paper guides are flush against the edges of the media The media sticks together resulting in the printer feeding multiple sheets The friction between sheets is too high Remove the media from Tray 1 or Tray 2 and fan it Don t overfill Tray 1 or the optional Tray 2 see media capacities in the media types and sizes chart in the User s Reference
18. are available in each output bin Output bin Full sensor Near full sensor Passthru 1 Passthru 2 Level sensor sensor sensor Standard bin v x x x x bin Mailbox x x v v This sensor will register the following levels empty normal near full and full Press M to select this test from the Output bin tests menu and then press FJ again to select the desired output bin Closed will display on the operator panel if the sensor is closed Open will display on the operator panel if the sensor is open If the wrong message is displayed then the sensor is malfunctioning To exit the Sensor Test press E or EY Base Sensor Test B Sensor Test The Base Sensor Test verifies the correct functioning of the following sensors Toner level open Input open Exit open Narrow media open Front door open This test toggles each of these sensors If a sensor does not toggle then the sensor is malfunctioning To exit the Base Sensor Test press E or EQ 3 12 Service Manual 4513 630 63W 6EW Printer Setup Printer Setup displays the following selections Defaults U S Non U S Printed Page Count Perm Page Count Serial Number Engine Setting 1 through 4 Model Name Configuration ID Edge to Edge Par S Strobe Adj displayed only if the printer has a standard parallel port Defaults The value of this setting determines whether the printer uses the U S or Non U S factory de
19. buttons and the layout of the display panel are described in the following table Operator panel Button Function Back Press and release E to return to the previous screen Menus Press and release f to open the menus The menus are available only when the printer is in the Ready state Pressing FJ also returns the operator panel to the top level menu screen if pressed while in a menu Stop Press once to return to the previous display screen while in the menus Press twice to exit the menus and return to the Ready state Press to stop printer activity Press AY to cancel a print job Stopping will display momentarily Stopped Will then display to offer a list of settings that may be selected da Navigation Up arrow and Down arrow buttons Press Eq or fy to scroll through menus menu items or printer options Left arrow and Right arrow buttons Press rj or to increase or decrease a value or to scroll through text that rolls to another screen Select button Press and release to open a menu to display the available values or settings or to save the displayed value as the new user default setting Note When a new setting is saved as the default setting it remains in effect until new settings are saved or until factory defaults are restored Settings chosen from a software program can also change or override the user default settings selected fr
20. cable Pins 1 3 5 and 6 3 3 v Pin2 5v e Pins 4 and 7 GND If these are approximately correct and the operator panel is not functioning then replace the operator panel If any are incorrect then see Controller board service check on page 2 21 Buttons If the buttons do not respond then replace the operator panel There is no test or repair for the faulty switches on the operator panel Paper feed service checks Paper jam error indication during POST FRU Action Fuser exit sensor If the exit sensor flag which is visible at the back of the fuser is in any position other than vertical then the printer will display a paper jam Make sure the flag is operating freely Replace the fuser if the sensor is damaged Input duplex sensor Manual feed sensor Make sure the input paper feed sensors are working properly A stuck or incorrectly installed Sensor causes a paper jam indication Media picks but stops halfway through the printer FRU Action Input duplex sensors under print cartridge assembly Input sensor manual Make sure the input sensors are working properly Check for a broken or stuck flag on the input sensors Clear anything that keeps the flags from rotating freely Make sure the cables are seated on the controller board at J27 input duplex sensor and J23 manual input Check for 5 V dc on pin 2 and 5 at J27 input duplex sensors and pin 2
21. cartridge may be getting low on toner Remove the toner cartridge and print cartridge assembly Shake it from side to side to redistribute the toner Reinstall it and recheck for condition Make sure to use the recommended print media see media types and sizes in the User s Guide Use MarkVision Professional to define the custom type setting for media type media texture or media weight The toner cartridge or photoconductor kit may be defective Replace the photoconductor kit first and recheck Blurred characters Blurred images including characters are usually caused by a defective printhead Vertical white lines See Vertical streaks below Vertical white lines may be caused by the laser beam which may be partially blocked With the printer off clear the path or clean the lens The toner cartridge or fuser may be defective Try a different toner cartridge Inspect the fuser at its entry for debris Toner smudges Make sure the media is straight and unwrinkled appear on the front or Replace the photoconductor kit and recheck before replacing the toner cartridge See back of the page Toner on back of page on page 2 32 for more information Vertical or horizontal Vertical streaks ue appear on the Something could be caught between the photoconductor kit and the fuser Check the paper page path around the fuser entry Try a different toner cartridge Vertical white lines may be caused by the l
22. current reversing page never staged 233 00 Duplex jam while picking from the device 233 01 Page in duplex never picked 233 02 Feed error picking from the duplex 233 03 Paper never reached the input sensor but was detected at the manual feed sensor 234 01 Duplex sensor covered during warm up 235 01 Invalid duplex media 241 00 Paper jam near tray 1 241 10 Second pick attempt failed from Tray 1 241 12 Second pick from manual feeder tray 1 or feeder failed when the media was in the source while other sheets were committed to the paper path 241 16 Failed to feed from tray 1 Pages in the paper path have been flushed to the output bin Diagnostics information 2 11 4513 630 63W 6EW Paper jam error codes 200 series Continued Error Description 241 17 MISIDENTIFIED SMALL GAP JAM Engine detected small gap at the manual feeder sensor attempted to open the gap by stopping the feed rolls trailing edge was seen at the input sensor manual feeder sensor is no longer covered 241 18 MISIDENTIFIED NO GAP JAM Engine detected no gap at the manual feeder sensor attempted to open the gap by stopping the feed rolls trailing edge was seen at the input sensor manual feeder sensor is no longer covered 241 19 Second pick attempt failed from Tray 1 no pages printed since calling a 241 10 or a prior 241 19 242 00 Paper jam near tray 2 242
23. en inbyggd laser av Klass Illb 3b som best r av en laserenhet av gallium arsenid p 7 milliwatt som arbetar i v gl ngdsomr det 655 675 nanometer Lasersystemet och skrivaren r utformade s 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 underh 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 60825 1 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse IIIb 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i b lgelengdeomr det 655 675 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse l niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Notices and safety information ix 4513 630 63W 6EW Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 60825 1 Els productes l ser de classe no es consideren perillosos Aquesta
24. of these items A 4 line liquid crystal display APA that can show both graphics and text e Eight buttons Back El Menus E Stop ES Select M and Navigation x up arrow E down arrow El left arrow El and right arrow EE e Keypad e Indicator light a JE 1 2 Service Manual 4513 630 63W 6EW Specifications Memory tem Pu asa SEW Lexmark E460dw Standard memory 64MB 64MB Maximum memory 576MB 576MB Optional memory 128MB v v 256MB v v 512MB v v Optional flash memory 64MB v v 256MB v v Optional font cards DBCS v v Option slots Memory slots 1 1 Flash memory option card 21 21 1 Both slots are active for either a 256MB Flash memory card a font card or a DLE Multiple Flash font or DLE cards are not supported Print quality settings tem Lexmark E460dn ase Lexmark E460dw Print resolution 1200 Image quality v v 2400 Image quality v v 600 X 600 dpi v v 1200 X 1200 dpi v v 1200 Image quality is defined as 600 dpi with 2 bit IET Image Technology default mode for all models 2400 Image quality is defined as 600 dpi with 4 bit IET 3 True 1200 dpi at 1 2 the rated speed General information 1 3 4513 630 63W 6EW Connectivity and compatibility tom Noon arce Lexmark E460dw Data stream emulations Host base
25. servo gap is smaller than expected for printhead offset target evaluation 200 39 Auto alignment is taking too long to run 200 40 Auto alignment invalid sample count 200 41 Auto alignment ZW adder out of range 200 42 Rogue sheet at manual feed sensor while flushing the paper path prior to declaring the MPF source import 200 43 Paper in the middle of a job at input sensor before interrupt occurred possible causes include bouncy sensor or exceptionally small gap perhaps due to paper pre staged in the source tray 201 00 Paper jam between input and exit sensor 201 01 Transport motor identification failed to identify either motor after two tries 201 02 Exit sensor never made by leading edge of page Also known as internal jam 201 03 Video never started on the page at the input sensor within two inches after hitting the input sensor 201 04 Expected wide page not detected by narrow media sensor possible accordion jam or missing signal HIGH END 201 05 Restart attempted after an internal jam without the cover open close event It is likely that the jam was never cleared 2 10 Service Manual 4513 630 63W 6EW Paper jam error codes 200 series Continued Error Description 201 06 Expected banner sheet assumed wide not detected by narrow media sensor possible accordion jam unsupported narrow banner
26. stable lock time but less than the printhead jitter stable specification Mirror motor fell out of lock condition after media at the input sensor more time elapsed since the printhead than expected stable lock time but less than the printhead jitter stable specification 200 28 First writing line of a page at the developer nip but laser servo cleanup is not complete Likely pre staged media or a fast paper feed 200 29 Printhead drive control out of range due to an external event beyond what the control is designed to handle Probable causes ESD or noise on hsync signal 200 30 Narrow media sensor covered during warm up 200 32 Media more than 14 inches too long over the manual feeder sensor Possible causes include multi sheet feed or pre staged media in the tray 200 33 Page from tray 1 did not reach the input sensor after multiple attempts Page did make it out of the tray at least as far as the manual feeder sensor Possible cause is that the page stalled at the alignment gate 200 34 Timed out waiting for page from tray 1 to reach the input sensor after multiple pick attempts but the page was later detected at the input sensor while waiting for any page s ahead to clear the paper path Possible cause is that the page is delayed at the alignment gate 200 35 Failed to create hsync during auto alignment 200 36 Lost hsyncs during auto alignment 200 37 Timeout on data collection during auto alignment 200 38 Interpage
27. the door is opened too far then it can become disengaged and interfere with the paper tray The tray may go in but will not come out and will render the printer as non serviceable 3 After the ACM pick tires have been pulled out close the duplex door Repair information 4 3 4513 630 63W 6EW 4 Remove the ACM pick tire roller A Note e If the left hub is gray then disconnect the old right and left tire hub assemblies from the ACM and replace with the new right and left tire hub assemblies e ftheleft hub is black then remove the old right and left tires from the ACM hubs and replace with the new tires Do not attempt to remove the hubs 4513 630 63W 6EW Bezel removal 1 Open the front access door 2 Flex the top of the bezel and disconnect the latch A from the upper front cover A 3 Disconnect the bezel from the upper front cover 4 Remove the bezel Repair information 4 5 4513 630 63W 6EW Controller board removal CAUTION A This product contains a lithium battery THERE IS A RISKOF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE Discard used batteries according to the battery manufacturer s instructions and local regulations Warning e Always touch a ground before touching the board Handle the board carefully by the edges Never replace the operator panel and controller board without a successful POR in between e Never repl
28. the paper See LVPS HVPS service check on page 2 24 for more information Try changing the setting to heavier paper or even card stock Media not a FRU Make sure recommended media is being used Check the media settings in the printer driver Diagnostics information 2 31 4513 630 63W 6EW Light print FRU Action Toner cartridge not a FRU Make sure the toner cartridge and photoconductor kit are installed correctly and that the toner cartridge is not low on toner If the problem continues then install a new toner cartridge Recheck condition before replacing photoconductor kit if necessary A Transfer roll LVPS HVPS card Check the transfer roll for signs of toner buildup and contamination Inspect the HVPS contact transfer roll for contamination Verify the high voltage cable is plugged into the LVPS HVPS If all components appear free of contamination then replace the following FRUs one at a time in the order shown e Transfer roll e LVPS HVPS card White or black lines or bands FRU Action Print cartridge assembly not a FRU Developer drive coupling assembly Main motor gear drive 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 primarily due to a variation in the speed of the media as it feeds through the printer especially in the developer and transfer process
29. 01 Took too long to ramp up dc feed motor 242 08 Received lots of dc feed interrupts before losing them 242 10 Second pick attempt failed from Tray 2 242 12 Second pick from manual feeder tray 1 or feeder failed when media was in the source other sheets were committed to the paper path 242 16 Failed to feed from tray 2 Pages in the paper path have been flushed to the output bin 251 00 Paper jam near the manual feeder 251 10 Second pick attempt failed from manual feeder 251 11 Failed to feed from manual feeder Pages in the paper path have been flushed to the output bin 251 12 Second pick from manual feeder tray 1 or feeder failed when media was in the source while the other sheets were committed to the paper path 251 19 Media never reached the input sensor from the manual feeder 2 12 Service Manual 4513 630 63W 6EW Service error codes Service error codes are generally non recoverable except in an intermittent condition when the printer can be put into POR to temporarily recover from the error condition Service error codes 9 xx Error Description 902 XX Engine software service errors 902 00 Engine software error 902 01 Page supervisor timer1 state value is greater than largest defined timer1 state value 902 02 Page supervisor timer2 value is greater than largest defined timer2 state value 9
30. 02 03 TBD 902 04 Attempt to start txport motor when its running 902 05 The signal byte from ps to em was not zero when loaded 902 06 Lost in narrow media tracking 902 07 Timed out waiting for the txport motor to lock before starting the PH 902 08 Page supervisor never received a response from the paper port driver module 902 09 Unknown page supervisor return code 902 10 Failed to switch banks and ran a stub page supervisor state 902 11 Page supervisor attempted to load its mailbox when it was not empty 902 12 Page supervisor received an invalid response from the paper port driver module 902 13 Step EP control still running when attempted to load 902 14 Invalid leading edge step EP control state 902 15 Invalid trailing edge step EP control state 902 16 Timer2 is not spinning when attempted to invoke 902 17 Engine took too long to start 902 18 No page supv was available when InvokePgSupv routine attempted to locate one 902 19 Attempt to enqueue data to notify queue when it is full 902 20 Attempt to dequeue data from notify queue when it is empty 902 21 Timeout waiting for Timer2 to complete trailing edge tracking 902 22 Math overflow while ramping the hot roll fuser 902 23 Tried to fetch a byte from an NVRAM address that we do not have shadowed in RAM 902 24 Cooling state lasted too long 902 25 Txport motor ramp down time out 902 26 Motor timeout on jog the motor 90
31. 1 Remove the rear door cover See Rear door and rear cover removal on page 3 54 A 3 Place the printer on its top with the rear facing you Note Be careful to not mar the finish of the printer 4 Remove the two screws A from the right rear foot assembly A 5 Disconnect the fuser power cable B 4 28 4513 630 63W 6EW 6 Remove the four screws C from the LVPS HVPS shield C 7 Liftthe LVPS HVPS and disconnect the three cables D Repair information 4 29 4513 630 63W 6EW Note Squeeze the clip to remove the cables from their connectors E 8 Disconnect the transfer roll cable F 9 Lift and remove the LVPS HVPS 4 30 4513 630 63W 6EW Main motor gear drive removal 1 Remove the left side cover See Left side cover removal on page 3 24 2 Disconnect the fuser link A from the front access door 3 Place the printer on its right side Note Be careful to not mar the finish of the printer 4 Remove the four screws B from the main motor gear drive Repair information 4 31 4513 630 63W 6EW 5 Lift the gear drive and disconnect the main motor gear drive cable C 6 Remove the main motor gear drive 4 32 4513 630 63W 6EW Manual feed clutch removal 1 Remove the left side cover See Left side cover removal on page 3 24 2 Open the front access door and disconnect the fuser link A 3 Place the printer on its righ
32. 1 cooling fan 2 22 cover interlock switch 2 22 dead machine 2 23 fuser 2 24 LVPS HVPS 2 24 main motor 2 25 operator panel 2 26 paper feed 2 26 paper jam during POST 2 26 paper never picks 2 27 l 2 Service Manual paper picks but stops 2 26 paper picks sheets 2 27 paper trees curls 2 28 parallel port 2 28 print quality 2 29 black page 2 30 blank page 2 29 heavy background 2 30 image density 2 31 light print 2 32 partial blank image 2 31 poor fusing of image 2 31 toner on back of page 2 32 white or black lines 2 32 printhead 2 36 transfer roll 2 36 service error codes 2 13 special tools 1 8 specifications connectivity 1 4 input trays 1 5 memory 1 3 operating systems 1 4 photoconductor capacity 1 5 print media 1 6 toner capacity 1 5 start 2 1 strobe adjustment 3 14 symptom tables 2 19 POST 2 19 printer 2 20 T tools 1 8 Top Margin 3 7 Transfer 3 15 transfer roll parts catalog 7 7 service check 2 36 U user attendance messages 2 5 4513 630 63W 6EW Part number index P N 40X0270 40X0274 40X0275 40X0276 40X0277 40X0278 40X0279 40X0280 40X0281 40X0282 40X0286 40X0287 40X0288 40X0296 40X0297 40X1367 40X1368 40X2855 40X5036 40X5320 40X5344 40X5345 40X5346 40X5350 40X5351 40X5356 40X5357 40X5358 40X5359 40X5360 40X5361 40X5362 40X5363 40X5364 40X5365 40X5366 40X5367 40X5368 40X5369 40X5370 40X5371 40X5372 40X5373 40X5374 40X5375 40X5377 40X5378 40X5379 40X5380 40X5
33. 2 27 Idle EP never finished Diagnostics information 2 13 4513 630 63W 6EW Service error codes 9xx Continued Error Description 902 28 TBD 902 29 TBD 902 30 Smart Chip Memory Manager timeout 902 31 Timeout waiting for a response from paper port driver 902 32 Hsync state invalid 902 33 TBD 902 34 TBD 902 35 NV interface problem 902 36 Low level error on paper port 902 37 Low level error on paper port 902 38 Low level error on paper port 902 39 Low level error on paper port 902 40 Low level error on paper port 902 41 Low level error on paper port 902 42 Number of paper port devices attached exceeds max supported 902 43 Low level error on paper port 902 44 Low level error on paper port 902 45 NULL pointer 902 46 Hot roll fuser control is lost 902 47 Hot roll fuser standby control is lost 902 48 Hot roll fuser new enhanced control is lost 902 49 Hot roll fuser turned off by another process during low line voltage check 902 50 Engine manager sequence ID invalid 902 51 Code detects incompatible hardware Possible Interconnect ID problem or fuser type mismatch 902 52 Belt fuser control is lost 902 53 TBD 902 54 Stack overflow 902 55 Timeout waiting for a page to pick from a source 902 56 Timeout waiting for pa
34. 3 The video never started on the page at the input sensor within two inches after hitting the input sensor 200 04 The media at the input sensor before interrupt occurred not enough time elapsed since the printhead started to expect the printhead mirror motor lock Possible causes include bouncy sensor or exceptionally fast pick perhaps due to media pre staged in the source tray 200 06 Imaged page not expected page bouncy passthru sensor 200 08 Media reached the input sensor before the EP was ready 200 09 Transfer servo never started 200 11 Printhead Driver Mirror motor fell out of lock condition after paper at input sensor not enough time elapsed since printhead start to expect stable lock Paper early at input Mookie finished but lock went away 200 12 Media detected at manual feeder sensor when not expected Possible causes include user insert of media when motor is running or pre staged media in the tray 200 13 The input sensor is covered when the media is not expected media in machine during warm up 200 14 Trailing edge cleared manual feed but did not successfully debounce the sensor Potential causes are a small gap or a bouncy manual feed sensor 200 15 UNRECOVERABLE NO GAP JAM Engine detected no gap at the manual feeder sensor attempted to open the gap by stopping the feed rolls but no trailing edge was ever seen at the input sensor 200 16 Transport motor error detected 200 17 Took too long to
35. 381 40X5382 40X5383 40X5385 40X5387 Description Page Power cord 1 77M straight Japan 2 2 e ee eee eee eee eee 7 9 Power cord 6 foot Switzerland eee 7 9 Power cord 6 foot straight Israel 7 9 Power cord 6 foot South Africa eee eee ee eee eee eee 7 9 Power cord 6 foot straight Brazil 7 9 Power cord 6 foot straight Europe and others 7 9 Power cord 6 foot straight Denmark 7 9 Power cord 1 77M straight Korea nn 7 9 Power cord 1 77M straight Taiwan nn 7 9 Power cord 1 77M straight PRC eee 7 9 Power cord 6 foot United Kingdom e eee ee 7 9 Power cord 6 foot straight Traditional Italy 7 9 Power cord 6 foot Argentina 2 rr rIlIlIlllle 7 9 Power cord 1 8M straight Australiaa 7 9 Power cord 1 77M straight USA Canada 7 9 Parallel cable packaged 3 m E460dn only eee eee eee 7 8 USB cable packaged 2m
36. 40X5372 Tray 1 ACM feed tires 40X5451 Transfer roll CBM 40X5364 NS 7470094 1 Field relocation package assembly Parts Catalog 7 7 4513 630 63W 6EW Assembly 4 Options Asm Part Units Units Description Index number mach FRU NS 40X5972 1 1 Japanese font card assembly NS 40X5970 1 1 Simplified Chinese font card assembly NS 40X5971 1 1 Traditional Chinese font card assembly NS 40X5969 1 1 Korean font card assembly NS 40X5952 1 1 Print cryption card assembly NS 40X5951 1 1 Korean KS KSSM KSP NS 40X5940 1 1 Bar code and forms NS 40X5937 1 1 128MB DIMM NS 40X5938 1 1 256MB DIMM NS 40X5939 1 1 512MB DIMM NS 40X5704 1 1 256MB flash NS 40X1367 1 1 Parallel cable packaged 3 m E460dn only NS 40X1368 1 1 USB cable packaged 2 m 7 8 Service Manual 4513 630 63W 6EW Assembly 5 Power cords Asm Part Units Units Description Index number mach FRU NS 40X0297 1 Power cord 1 8M straight USA Canada NS 40X0278 1 Power cord 6 foot straight Europe and others NS 40X0288 1 Power cord 8 foot straight Argentina NS 40X0286 1 Power cord 8 foot straight United Kingdom NS 40X0275 1 Power cord 6 foot straight Israel NS 40X0274 1 Power cord 6 foot straight Switzerland NS 40X0276 1 Power cord 6 foot straight South Africa NS 40X0287 1 Power cord 6 foot straight Traditional Italy NS 40X0279 1 Power cord 6 foot straight Denmark NS
37. 4453 xx eh cR idee DE RE C ACR EES RA ES EE Da AAA 4 51 Paper input and duplex sensor assembly removal 2 424 224 4 52 Table of contents V 4513 630 63W 6EW Printhead removal ses a nas aa gana a arn ine CROCO ACCRUE EES ana RC A 4 53 Rear door and rear cover removal oocccccccn ee nn nnn nn 4 54 Rear exit guide assembly with sensor and reversing solenoid removal 4 56 Right side cover assembly removal 4 ssh a RAO ROROROR ee 4 58 Toner level sensor removal ick e ER CEA n mes Heme ade A kartoni 4 60 Top cover assembly removal i55 xxssakx asd A RR E RA aL 4 61 Transfer roll removal 4442432422 o aa Rd Picus ede era AA ES EXE E ER RR Ea da 4 63 Upper front guide assembly removal o coooooconcnccn Rn n nnn nnn 4 64 Wear strip tray 1 and 250 sheet tray 2 removal o ooocoococconn eee eee 4 65 Wear strip 550 sheet tray 2 removal oooocccocconcnn eee nnn 4 66 Locations ss MAMA E ERU escassa 5 1 LOCHBOlNS Hei ea ea rada ies Ec RE dear 5 1 EFONEVISW esa ao DS PE deaa AA A A Rm 5 1 a I a dt E 5 1 Lexmark E460dn controller Board mea nina cides nore eer aiaiesseiemaiansesensa essa mia 5 2 Lexmark E460dw controller Board 42222 gamma sack hee RACER RR Seana ua RR QD AUR rama aca ua reina mea 5 3 Lexmark E460dn E460dw controller board connector pin values Le 5 4 Preventive maintenance ssssssssss sss sn 6 1
38. 4513 630 63W 6EW Symptom tables POST symptom table Symptom Action que main motor cooling fan and fuser do not come See Cover interlock switch service check on page 2 22 POST completes but the LCD does not come on See Operator panel service check on page 2 26 Main motor does not come on See Main motor service check on page 2 25 Fan does not come on See Cooling fan service check on page 2 22 Fuser does not cycle See Fuser service check on page 2 24 Fuser does not turn on and off See Fuser service check on page 2 24 The paper feed picks and tries to feed media See Paper feed service checks on page 2 26 Note Investigate any displayed codes before proceeding with these symptoms For example a missing toner cartridge will prevent POST from completing Diagnostics information 2 19 4513 630 63W 6EW Printer symptom table Symptom Action Fan noisy or fan not working See Cooling fan service check on page 2 22 Fuser parts melted See LVPS HVPS service check on page 2 24 Toner not fused to the media See Fuser service check on page 2 24 or Solving print quality problems on page 2 33 Paper jams See Paper feed service checks on page 2 26 Main motor noisy or not moving See Main motor service check on page 2 25 Media skew See Paper feed service checks on page 2 26 Printer not comm
39. 63W 6EW Rear door and rear cover removal 1 Open the rear door 2 Pull the rear door up at an angle disconnect the door from the notch A and remove 4 54 4513 630 63W 6EW 4 Tilt the rear cover and remove Repair information 4 55 4513 630 63W 6EW Rear exit guide assembly with sensor and reversing solenoid removal 1 Remove the top cover See Top cover assembly removal on page 3 61 2 Remove the rear door and rear cover See Rear door and rear cover removal on page 3 54 3 Disconnect the narrow media sensor cable and the reversing solenoid cable A 4 56 4513 630 63W 6EW 5 Remove the solenoid cable C through the opening C D 7 Remove the rear exit guide assembly Note Be careful to not damage the gears during the rear exit guide assembly removal and reinstallation Repair information 4 57 4513 630 63W 6EW Right side cover assembly removal Note Leave the front cover closed when removing the right side cover assembly 1 Remove the one screw A from behind the paper tray 4 58 4513 630 63W 6EW 3 Press the latches C 4 Rotate the right side cover assembly out and remove Repair information 4 59 4513 630 63W 6EW Toner level sensor removal Open the front access door Remove the right side cover See Right side cover assembly removal on page 3 58 Disconnect the toner level sensor cable A from the contro
40. Download valid code to the internal print server Note The network code can be downloaded while this message is displayed Load manual feeder with Custom Type Load manual feeder with Custom String Load manual feeder with size Load manual feeder with size type Load the specified media in the manual feed tray or multipurpose feeder e To ignore the manual feed request and print on media already installed in one of the input sources press gt If the printer finds a tray that has media with the correct media type and size then it feeds media from that tray If the printer cannot find a tray with the correct media type and size then it prints on whatever media is installed in the default input source e Cancel the current job Diagnostics information 2 5 4513 630 63W 6EW User attendance messages Continued Message Action Load src with Custom Type Name Load src with Custom String Load src size Load src type size Load the input source with the correct type and size media Cancel the current job aintenance Replace the maintenance items and if necessary reset the printer maintenance counter enus Disabled The printer menus are disabled The printer settings cannot be changed from the control panel Note A job can still be canceled Contact a system support person
41. FJ or E3 to scroll through the PRINT TESTS menu and then press FJ to select the desired input source Single or Continuous is displayed on the screen A Single test feeds one sheet of media from the selected input and prints a test page on it No buttons are active during the Single test The Continuous test feeds media from the selected input and prints test pages until is pressed The printer always generates a simplexed version of the Print Test page in its default resolution While the Single or Continuous tests print Printing will display After the Single test prints or the Continuous test is canceled the display returns to the PRINT TESTS menu screen Note The type of media installed in the selected input source will affect the contents of the page Print Quality Pages Prt Quality Pgs This setting reports the values of a broad range of printer settings and tests the printer s ability to generate acceptable printed output Press M to print the report Printing Quality Test Pages will display Once started the printing cannot be canceled and no buttons are active until the printing completes 3 8 Service Manual 4513 630 63W 6EW Hardware Tests This setting contains the following tests e Panel Test e Button Test e DRAM Test e CACHE Test Press fj or 7 to scroll through the Hardware Tests menu and then press FJ to select the desired test Panel Test Once the Panel Test setting is selected the printer au
42. I RE EE SE T 3 8 IMDUUSGUICES coca it miri a dai du 3 8 Print Quality Pages Pit Quality PQS i22 arae a RA ERES penis TRAE AA E AR es 3 8 Hardware Tests iis sits ox A RAR ERROR CC RC RR COR CR RO AO 3 9 Panel T6St iccccccacerseegetee ree merit AAA REPRE REPRE e 3 9 Button TOS soci AA Pa Egeria site o 3 9 DRAM Testaczie kcu o beSVRRSEA RISEPPREEPRATR A Rep uAE PPP QUE EE SEES 3 9 DUDIBX TESIS coa orar carta NE i PERE EE DGE ies 3 10 QUEK TOS cera T 3 10 TOG MAO os ded re rbd ades ed 3 10 Ed rene ve pc 3 10 SHIISOI TOS pericia e io linen aps Dod a dopo ae 3 10 D plax Feed T uas casae rada cided ii IEA aeq E VIE EE 3 11 Input Tray TESSA rer prairies Edid qq a da aded Edi durus eral od E 3 11 laco TES step ET Lande bea tack bee basOeadee evacd R 3 11 Sensa TESE ooseieserkretebedeRRE Re REG edd ee eoraeteormedeegsers decheseeeiaoaes 3 11 iV Service Manual 4513 630 63W 6EW Output bin Tests sai a AR CAUCA AR ORES eee A 3 12 FeBu Tests 22 229 4e d O4 AA da 3 12 SOHSOF LOS rra hase eee A S o Rn S Hb UAR Mole Ets A 3 12 Base Sensor Test B Sensor Test 22 00 0000000 e x Rr n rx Rx ees 3 12 Printer Sell oie dE add Dd dE Rd RR AR AURA dE MS d di Eb ei Dc RR OR ede 3 13 Dells u s iiio ode EIAS este Veoh Dei Bane ak Wurde didi ace ACE IRE DIT 3 13 Printed Page Count Page Count secans sese a b Rb RHET ERREUR RR RR ES 3 13 Permanent Page Count Perm Page Count oooccccccccccc eh 3 13 Seral Number i422 392444 ERI REY ERE REA R
43. I Ai 4 5 Controller board removal 50 00000 A ea aa aa IA BR AR A A 4 6 Over open SEIS ax bs isa bandas baii a Us 4 8 Door MOURLTEMOVEl aucune ich oboe REOR AAA ARANA 4 9 Flea el 43 523 dd m Ep ve iia eee dot eee ee ey AEN a RENT Ue RU TA are 4 11 Duplex main motor gear drive interface removal 00 0 e eee eee eee 4 13 Ig Eli spain 225 345 272525 Tee ee ee Tc eee ONE TAS Co 4 16 Frontaccess door remoVal em aa acea ir AAA IA ee UP ean odd 4 17 Fuserremoval aimara ex RACER A A A A N RR ana 4 21 Left side cover removal cla A a a tee 4 24 Lower front cover removal xx iad canes RR CR OC CULO RR CC eel da aa ama 4 26 LVPS HVPSTOmoVal icc dade i ker ai a Rata Fra E Kd DEANTE hd b ao hae ahs ee 4 28 Main motor gear drive removal masia 0 00 a RA RR KORG CRGO RR CRT RR 4 31 Manual feed clutch removal 122222222622 E ak E ee he UE UAR RR EROR DR EORR RH RR RR Rn 4 33 Manual feed solenoid removal 44 ia ni rane d kk ace x ERE REOR ER UR OR EG dod wa 4 35 Media ACM ASM feeder removal 24 34 xri Rc eR XR X HORE DES rai ACERO is 4 37 Media feed clutch with cable removal o ooococcnccnca n nnn nnn 4 40 Media manual input sensOFr wicks sce rd A AA RR OUR RR OCA RR UN RR A 4 42 Multipurpose feeder MPF removal eseseeeeeee RII IIIA 4 45 Multipurpose feeder MPF feed clutch removal 2 2 2 42 2 2 4 48 Nameplate removal cisiesisiment mit A A au EE 4 50 Operator panel removal 4
44. It may also be a result of overly dry or moist environments With the printer off check to make sure that the laser beam is not blocked Inspect the toner cartridge and paper feed components especially the drive coupler and drive gears for debris binds or damage Toner on back of page FRU Action Photoconductor kit not Print a menu page found under Utilities and check settings for media type a FRU Inspect the overall paper path for signs of spilled toner Gently clean the contaminated areas with a soft cloth Fuser Inspect the fuser for signs of contamination Replace the fuser as necessary Transfer roll A transfer roll contaminated with toner can cause toner to transfer to the back of pages Inspect the transfer roll for contamination and its cable for continuity HVPS or controller board Loss of the proper high voltages can cause excessive toner to contaminate the transfer roller None of these voltages can be measured but the contacts and continuities can be checked To check the lower voltage see J502 on the wiring diagram Replace the LVPS HVPS or controller board as necessary 2 32 Service Manual 4513 630 63W 6EW Solving print quality problems Note Refer to the print defects guide at the end of the manual for repeating defects Print quality problems Problem Cause action Light or blurred Light print characters See Light print on page 2 32 The toner
45. RARERRRTERROR RARE RE RS Ed 3 14 Service Tag only on Some PEINTES eame His horam ed A AS 3 14 Engine Setting J ABFOUDBIA di ei 3 14 MoJe Name ascos boats variedad A qued 3 14 CONNIQUIBIONID escocia AA AAA 3 14 o iid mire dt aa dcl en Boe Da Ie hm Prades dite deb ER gud 3 14 Par S Strobe Adj parallel strobe adjustment eee eee 3 14 EPISODE wR ea eee RUP E ae A AA A 3 15 EPOS AUS ea ains 3 15 Fuser Temperature Fuser Temp ev srcorrosiorrararirr rre 3 15 Were o a 3 15 Pint COontast pesos recrear 3 15 Charge ROl stats ys de 3 15 Gan AGUST auseua liar AAA dur doa eeers 3 15 Automatic Darkness Adjustment Auto Dark Adj LL ua La 3 16 ICQ Se ses ado see rita eee er eT 115 150 72 1225252755 a be Gea ED DOS 3 16 EVENTION a opi RE TTL ILI LO AAA e 3 16 Display LOQ es ada ee H n aa 3 16 Pur LOQ A 3 17 GIBBr o o PEI E 93d 0d dene etd IEA ib bbc EUR Ed PA odia 3 17 Exit Diagnostics cici iaia dd a a cana er siae Sed onsen eed d xa dus vades ahh aga 3 17 Printhead assembly electronic adjustment oocooccccnco nn nnn 3 18 Printhead assembly mechanical adjustment coo ccccoccnc nnn 3 19 o AAA to Rope bb E EEEE Id Fa EQ ET 4 1 Handling ESD sensilive Paris conse eina Da Ead RR is RUN e cR UR RU 4 1 Removal epe stp o ar T a id Ai 4 2 ACM pick tire roller removal manen mena nana ae ead OR E A ee aa aa 4 3 Bezel removal cia a esr e aai A A
46. V dc Tray 2 2 24 V dc 6 Ground J501 1 5 V dc Toner patch density sensor 3 1 V de 0 V dc 4 Ground 5 5 V dc OV dc J502 1 3 5 7 11 5V dc LVPS HVPS 13 15 4 5V dc 6 24 V dc 17 19 24 V dc Other OV de Locations and connections 5 5 4513 630 63W 6EW 5 6 Service Manual 4513 630 63W 6EW 6 Preventive maintenance This chapter describes procedures for printer preventive maintenance Follow these recommendations to help prevent problems and maintain optimum performance Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist then find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication specifications FRUs are typically lubricated as needed from the factory If not then lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack parts Use P N 99A0394 Nyogel 744 to lubricate appropriate areas Lubricate gears that were lubricated in th
47. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 1 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 7 milliwatt met een golflengte van 655 675 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 Lasermeddelelse viii Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 60825 1 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 7 milliwatt galliumarsenid laser som arbejder p belgelaengdeomr det 655 675 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Service Manual 4513 630 63W 6EW Laserilmoitus Tama tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J standardin mukaiseksi luokan 1 lasertuotteeksi ja muualla IEC 60825 1 standardin mukaiseksi luokan lasertuotteeksi Luokan lasertuotteita ei pidet haitallisina Tulostimen sis ll on luokan IIIb 3b laser jok
48. a on nimellisteholtaan 7 mW n galliumarsenidilaser ja toimii 655 675 nanometrin aallonpituuksilla Laserj rjestelm ja tulostin ovat rakenteeltaan sellaisia ett kayttaja ei joudu alttiiksi luokkaa 1 suuremmalle s teilylle normaalin k yt n yll pidon tai huollon aikana Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 1 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan IIIb 3b 7 milliwatin galliumarsenidilaser joka toimii aaltoalueella 655 675 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 l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra l nder uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 60825 1 Laserprodukter i Klass anses ej h lsov dliga Skrivaren har
49. ace the operator panel and the controller board at the same time Each card contains the printer settings When either of these cards is new it obtains its settings from the other card Critical factory settings are lost when both cards are new and are replaced at the same time 1 Remove the right side cover See Right side cover assembly removal on page 3 58 2 Remove the three screws A from the USB port Note The E460dw printer has a wireless antenna and does not have a parallel port Ldi For ent purposes or S 4513 630 63W 6EW 3 Disconnect all of the cables from the controller board Note A drip guard B has been added below the controller board The drip guard may need to be removed to access to the controller board 4 Remove the five screws C from the controller board 5 Lift the controller board and remove Note When installing the controller board place the USB port and parallel port screws first and then place the controller board screws Repair information 4 7 4513 630 63W 6EW Cover open sensor 1 Remove the right side cover See Right side cover assembly removal on page 3 58 2 Disconnect the cable A from the controller board 3 Use a 1 Phillips screwdriver to remove the screw B holding the sensor 4 Remove the cover open sensor 4513 630 63W 6EW Door mount removal Open the front cover Remove the lower front cover See Lower front cover
50. ark Adj EP Defaults Restores all EP settings to factory default values Selections are Restore and Do Not Restore Fuser Temperature Fuser Temp Changing this setting can reduce media curl or melting of some letterhead images Selections are Normal default Lower and Lowest Transfer The transfer can be adjusted to Low Medium or High The default setting is Medium Print Contrast The print contrast can be adjusted to Low Medium or High The default setting is Medium Charge Roll The charge roll can be adjusted to Low Medium or High The default setting is Medium Gap Adjust Adjusts the minimum gap between sheets during printing This setting reduces speed pages per minute but can be used to reduce curl of printed media and improve stacking in the output bin The range is O default to 255 Adjusting by one results in 9 mm of increased gap Diagnostic aids 3 15 4513 630 63W 6EW Automatic Darkness Adjustment Auto Dark Adj This setting attempts to optimize the amount of toner used when printing with a specific operating point Each time this setting executes the printer performs the following Calibrates its toner density sensor Measures the reflectivity of its bare drum Prints patches on the drum and measures the drum s reflectivity through the patches Cleans the transfer roll Calculates reflectivity ratios and operating points in order to attain each operating point s darkness target e Modifies the EP
51. aser beam which may be partially blocked With the printer off clear the path or clean the lens The toner cartridge or fuser may be E N defective Try a different toner cartridge Inspect the fuser at its entry for debris BC B E Horizontal streaks The toner cartridge or the fuser may be the cause due to excessive page count or defect B E Replace as needed If the lines are parallel and match the two intended ghost images then the Form Type may be incorrectly set Check those settings The PC cleaner sump may be full Replace the photoconductor kit Diagnostics information 2 33 4513 630 63W 6EW Print quality problems Continued Problem Cause action Toner smears or rubs off the page Toner is not being fused to the paper Replace the fuser Change the media texture setting in the driver If special media is being used such as card stock or labels then be sure to select the correct media type Try a different kind of paper Paper designed for copiers gives the best quality fusing The print is getting light but the printer has not indicated it is low on toner Toner is becoming low in the cartridge The Toner Low message does not display if the 1 500 page toner cartridge is installed Remove the toner cartridge and gently shake it from side to side to redistribute the toner Replace the toner cartridge The Toner Low message displays Remove the toner cartridge and gent
52. at J23 Input sensor Voltages on pins 1 and 4 at J27 pin 1 at J23 should change as the flags intersect with the sensor f correct then replace the input paper feed sensor f these voltages are not correct then replace the controller board Check the pick tires Clean or replace as necessary 2 26 Service Manual 4513 630 63W 6EW Media never picks FRU Action Paper feed pick tires tray 1 Paper feed pick tires tray 2 Media drive ASM Media feed clutch ASM Manual feed clutch ASM Open the left cover and verify that the solenoids and clutches are functioning when an attempt is made to feed the media Make sure the rubber tires on the ACM are installed and clean Replace the tires ACM drive clutch assemblies solenoids or drive shaft as P U and manual feed solenoid necessary ACM drive shaft Media occasionally mispicks or picks multiple sheets at once FRU Action Tray 1 Tray 2 option Check tray for media catch points If the sheet being fed stops momentarily then the ACM applies additional vertical force causing additional sheets to feed Do not mix media types in one tray Paper pick tires Tray 1 or tray 2 Check the tires in the ACM assembly for signs of wear or damage Replace the tires as necessary ACM clutch Manual feed clutch Media feed clutch ASM tray 1 only Manual feed clutch solenoid Open left cover and observe the
53. atalog 7 1 4513 630 63W 6EW Assembly 1 Covers 7 2 Service Manual Assembly 1 Covers 4513 630 63W 6EW Asm Part Units Units Description Index number mach FRU 1 1 40X5373 1 1 Top cover assembly 2 40X5377 1 1 Rear upper and lower cover assembly 3 40X5375 1 1 Right side cover 4 40X5398 1 1 Optional 250 sheet tray 4 40X5399 1 1 Optional 550 sheet tray 5 40X5394 1 1 250 sheet Tray 2 assembly 5 40X5395 1 1 550 sheet Tray 2 assembly 6 40X2855 1 4 Tray 2 wear strips 550 sheet tray only 7 40X5382 1 6 Wear strips 250 sheet trays optional and primary 8 40X5381 1 1 Primary tray 9 40X5379 1 1 Front door cover 10 40X5359 1 1 Nameplate cover 11 40X5378 1 1 Front access door assembly 12 40X5374 1 1 Left side cover 13 40X5357 1 1 LCD bezel cover E460dn 13 40X5391 1 1 LCD bezel cover E460dw Parts Catalog 7 3 4513 630 63W 6EW Assembly 2 Electronics 7 4 Service Manual Assembly 2 Electronics 4513 630 63W 6EW Asm Part Units Units Description Index number mach FRU 2 1 40X5356 1 LCD operator panel assembly E460dn E460dw 2 40X5344 1 Fuser assembly 115 V 2 40X5345 1 Fuser assembly 230 V 2 40X5346 1 Fuser assembly 100 V 3 40X5365 1 1 Duplex and media sensor assembly 4 40X5360 1 1 Access door open sensor assembly 5 40X5392 1 1 Cooling fan screws included 6 40X5385 1 1 Toner low sensor 7 40X5036 1 1 Wireless card
54. d printing v v PCL 5e and PCL 6 v v PostScript 3 v v PPDS migration tool v v PDF v1 6 v v XPS v v HTML including DBCS v v Direct image v v Compatibility Windows Macintosh Linux Windows Macintosh Linux Standard local connections Parallel v x USB v v Standard network connections Ethernet 10 100 Base Tx v v Wireless ethernet 802 11b g n x v Optional local connections Optional network connections v v external print server support All models are USB 2 0 Certified devices supporting Hi Speed data transfer 1 Includes the HD photo image format 2 Includes support for the following graphics formats TIFF TIF JPG GIF PNG BMP PCX AND DCX 1 4 Service Manual Media trays and supply capacity 4513 630 63W 6EW tem oa 51398 Lexmark E460dw Available input trays Integrated 250 sheet tray v v 50 sheet MP feeder v v 1 sheet manual feed slot x x Optional input sources 250 sheet drawer v v 550 sheet drawer v v Maximum input sheet capacity 850 850 excluding envelopes excluding envelopes Manual integrated print duplex Integrated Integrated Envelope conditioning x x Available output trays Standard 150 sheet sensing bin v v Toner and photoconductor Toner cartridge 1 500 standard pages SWE 3 500 standard pages SWE 7 000 standard pages SWE High toner cartridge 9 000 standard pages 9 000 standard pag
55. device 32 XX Unsupported cartridge errors 32 01 MC CC Mismatch Incorrect cartridge installed in printer or printer settings are incorrect based on cartridge capacity 32 02 Down level device installed on cartridge 32 03 Down level device installed on cartridge 32 04 Unknown toner type indicated by the device 32 05 OEM Mismatch Incorrect cartridge installed in printer or printer settings are incorrect based on cartridge OEM identification 32 06 Printer already married to a SWE cartridge Must purchase after market cartridge 32 07 SWE cartridge already married to a printer 2 8 Service Manual 4513 630 63W 6EW Paper jam error codes 200 series Note The Event log See Event log on page 3 16 will list any of these errors that have occurred Repeating jams or jam messages can be caused by any of the following Faulty contaminated pick solenoids or worn cams of the solenoids Faulty contaminated flags or springs Debris in the paper path Media not of the specified length Paper jam error codes 200 series Error Description 200 00 Paper jam around input sensor 200 01 Classic input jam The media is too long over the input sensor Possible causes include multi sheet feed tray size sensing problem and media slippage 200 02 The main input sensor never became uncovered from the sheet ahead 200 0
56. dge paper jam option port and so on If a user error message displays then go to User attendance messages on page 2 5 and Paper jam error codes 200 series on page 2 9 Power On Self Test POST sequence The following is an example of the events that occur during the POR sequence when the printer is turned on 1 Diamonds are displayed on the operator panel 2 While code is being loaded into DRAM dots scroll across the operator panel 3 Ascreen is displayed with the memory and processor speed A typical example of this message is 64MB Performing Self Test is displayed Busy is displayed Close Door will be displayed if the cover is open Any cartridge errors such as Defective Cartridge are displayed Applicable maintenance messages are displayed Applicable toner low messages are displayed The printer displays Ready SO SIDO a b Diagnostics information 2 1 4513 630 63W 6EW Overview of the operator panel and menus The operator panel on your printer is a 4 line back lit grayscale display that can show both graphics and text The Back Menu and Stop buttons are located to the left of the display the navigation buttons are located below the display and the numeric pad is located to the right of the display Menu Back LCD Select Keypad button button display button Menu Back OE O CIE B ODO oog Indicator Stop Navigation light button buttons The use of the
57. dpi to prevent a 38 Memory Full error Res Reduced remains on the display while the job prints Restoring Factory Defaults Wait for the message to clear Note When factory default settings are restored All downloaded resources fonts macros symbol sets in the printer memory are deleted All menu settings return to the factory default except The Display Language setting in the Setup Menu All settings in the Parallel Menu Network Menu and USB Menu Std Bin Full The standard bin is full Toner Low e Replace the toner cartridge e Press EJ to clear the message and continue printing Tray x Missing Insert the tray into the printer USB The printer is processing data through the specified USB port Waiting The printer has received a page of data to print but is waiting for an End of Job command a Form Feed command or additional data e Press E to print the contents of the buffer Cancel the current job Diagnostics information 2 7 4513 630 63W 6EW Cartridge error messages Error Description 30 XX Cartridge errors 30 01 No bucket transition out of the top bucket If the cartridge has not been refilled then it usually is a mechanical problem with the cartridge During development it could also have the wrong chip installed 30 02 No bucket transition out of the middle buckets If the cartridge has not been refilled then i
58. e CR dE AA 2 5 User attendance messages 20 cece cece cece ee ehh hh nh hh 2 5 Carmidge error messages eoa siae aded PERE ree do OE A da 2 8 Paper jam error codes 200 series 000s cece eee RI III 2 9 Service BITOT COURS parri bas s eS Roo Fa CX BA veges Le BRI ens d QR A OR CRGA EC a 2 13 Symptom tables sos ha eee deed Gea i AA Mead UR dU Mula d FR RR d oe arai i 2 19 POST symptom table nig sux scias a A AA RC CORE ACCORD RC AC RD ARR AAA 2 19 Printer symptom fable 2142 a3 oa Po A da Ka a d eed 2 20 Service checks iua xac oco oo REX CR CR RURAL CR RU dic UR RU DR OCCUR A UR Dc Ea 2 21 Controller board service Check 6 6 cee ence cee eee mak tuashresshranad sas 2 21 Cooling fan service Check as sx io ko ice dox x seaweed ORC CROCO CR RO RC ROG CR CON 8 2 22 Cover interlock switch service check 0 ccc cece c eee e eee eee eee nnne 2 22 Dead Machine service CHECK a acea wage El PG RE CE DE A AN e 2 23 FOser service Check cao CBE rabia DDD ERO RE DA E A EE Noa a adi ea 2 24 LVPS HVPS Service Cheek avis mapa ives Gomme as os CER e e 2 24 Main molor service CHECK aia A AAA A e 2 25 Operator panel Service Check ix ici e a ia A e 2 26 Paper feed service checks sx 00000000000 RR RAR RARE A 2 26 Paper jam error indication during POST 226 0 ies as beseeresa Re ra 2 26 Media picks but stops halfway through the printer llle 2 26 Media never PICKS sisse erecta sindbis ii a Ee RE 2 27 Table of conte
59. e left holder is unlatched 4 With a hand at each end lift the transfer roll out Note Do not try removing the spring on the left it is not removeable but can be dislodged The spring included with the FRU is to be used only if the old right side spring is damaged or lost Both springs must be positioned on posts that cannot be seen If the old springs are moved then feel the base of the springs to assure that they are on the posts The top of the springs must be captured in the bearings of the transfer roll Repair information 4 63 4513 630 63W 6EW Upper front guide assembly removal 1 Open the front access door 2 Remove the four screws A from the upper front guide 3 Remove the upper front guide 4 64 4513 630 63W 6EW Wear strip tray 1 and 250 sheet tray 2 removal 1 Hold the tray with the bottom up 2 Use a spring hook to disconnect the strip from the top of the tray 3 Remove the strip from inside the tray Repair information 4 65 4513 630 63W 6EW Wear strip 550 sheet tray 2 removal 1 Use a spring hook to disconnect the strip from the top of the tray 2 Life the strip and remove Note When replacing the strip for all trays e Carefully insert the strip from the top of the tray and push it down through the opening until it snaps into place Turn the tray over to view the bottom of the strip Using the spring hook check to make sure that the end of the strip is
60. e original part Maintenance kits Maintenance kits include Fuser P N 40X5344 40X5345 or 40X5346 Exit guide P N 40X5372 Tray 1 ACM feed tires P N 40X5451 Transfer roll P N 40X5364 Maintenance kits Description Part number Low voltage 110 V maintenance kit 40X5400 High voltage 220 V maintenance kit 40X5401 100 V maintenance kit 40X5402 Preventive maintenance 6 1 4513 630 63W 6EW 6 2 Service Manual 7 Parts Catalog How to use this parts catalog 4513 630 63W 6EW The following legend is used in the parts catalog Asm Part Index number Units mach Units FRU Description Asm index identifies the assembly and the item in the diagram For example 3 1 indicates assembly 3 and the item number 1 Units FRU refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not PP Parts Packet in the parts description column indicates the part is contained in a parts Part number identifies the unique number that identifies this FRU e Units mach refers to the number of units actually used in the machine or product e e pictured in the illustration e packet Model information used in the parts catalog Machine type aun and model Description 4513 630 Lexmark E460dn 4513 63W Lexmark E460dw 4513 6EW Parts C
61. e printer on 4 Verify 24 V dc on positions 6 17 and 19 of the cable connector LVPS HVPS 5 f voltage is correct then check the continuity in the other conductors of the cable If the cable is good then turn the printer off and check the connectors to the controller board 6 Verify that pins 10 12 14 16 and 18 on both the cable and the card connector are grounded 7 f grounds are not correct on the cable but the cable passes continuity otherwise then check the LVPS HVPS 8 If the grounds are not correct on the controller board then replace the controller board Check with one probe on the connector pin and the other on the card s ground plane found at each screw head Controller board voltage outputs Turn the printer off and plug the LVPS HVPS cable into J502 of the controller board See the wiring diagram at the end of the manual which identifies the output voltages and grounds for a good controller board Turn the printer off before plugging or unplugging any connectors Diagnostics information 2 21 4513 630 63W 6EW Controller board service check Continued FRU Action LVPS HVPS Verify main power to controller board With the printer off unplug the LPS HVPS cable at J502 on the controller board Verify grounds on pins 10 12 14 16 and 18 for both the cable and the controller board If any of these grounds are incorrect then check the cable for continuity If the cab
62. e risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when the machine is not being worked on and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair information 4 1 4513 630 63W 6EW Removal procedures Note Remove the toner cartridge and media tray before removing other printer parts The toner cartridge should be protected from light while out of the printer We recommend disconnecting all external cables from the printer to prevent damage during service Unless otherwise stated reinstall the parts in reverse order of removal When reinstalling a part held with several screws start all screws before final tightening Remove the paper tray and print cartridge before proceeding with a removal 4513 630 63W 6EW ACM pick tire roller removal 1 Place the printer on its side Note Be careful to not mar the finish of the printer 2 Open the duplex jam door just far enough to pull out the ACM pick tires Warning Open the duplex door only far enough to remove the ACM pick tires If
63. ee eer eee eee eee 7 7 Manual feed clutch CBM ee emet eee T Manual feed solenoid 2 rr rIrIlIlISllle 7 5 Media feed ACM clutch rrr eee nee eee eens 7 5 MPF feed clutch VV Ve VV ee ee eee eee eee eee eee ee eee ee eee eee eee 7 5 Media exit guide assembly redrive me 7 7 Top cover assembly 7 3 Left side cover 2 2 2 eee ee een nee ee ee ee 3 3 Right side cover n 73 Rear upper and lower cover assembly me ee 7 3 Front access door assembly ee ee 7 3 Front door cover mm ne eee eee eee 7 3 Complete duplex assembly 2 0 2 errr eee eee ee eee eee 27 Primary tray ee ee ee 73 Wear strips 250 sheet trays optional and primary 73 Upper front frame assembly nn eee 7 7 Toner low sensor 7 5 LSU E460dn E460dw printhead nn 7 5 Part number index l 3 4513 630 63W 6EW 40X5391 40X5392 40X5394 40X5395 40X5396 40X5397 40X5398 40X5399 40X5400 40X5400 40X5401 40X5401 40X5402 40X5440 40X5451 40X5453 40X5704 40X5937 40X5938 40X5939 40X5940 40X5951 40X5952 40X5969 40X5970 40X5971 40X5972 7470094 LLCD bezel cover E460dw VV Ve ee ee me ee 7 3 Cooling fan screws included ee eee 7 5 Tray 2 assembly 7 3 550
64. ee motion Controller board None should be ground except for 4 contact from the front Unplug the printer and check the cable continuity between the LVPS HVPS connector marked OPC at CN202 and the corresponding wire form spring found about 14 mm above and to the right of the transfer roll gear e If there is not continuity then call the next level of service Try a different toner cartridge and PC kit If those fail then replace the LVPS HVPS controller board or the printhead in that order Diagnostics information 2 29 4513 630 63W 6EW Black page Note Incorrect laser exposure or incorrect charging of the photoconductor causes an all black page Always verify the same results from a different print cartridge assembly and developer before proceeding FRU Action Toner electrodes not a FRU Check the three rearward electrodes below the toner cartridge assembly for contamination damage or a short to ground Correct as necessary Check continuity between the cable DEV TAR and doctor blade connection PCN3 and on the contact tips below the toner cartridge assembly If continuity fails then call the next level of service A LVPS HVPS board Controller board Miscellaneous cables With the printer off disconnect the LVPS HVPS cable from J502 on the controller board Turn the printer on and verify 24 V dc on pins 17 and 19 of the cable Verify 5 V dc on pins 1 3 5 13 a
65. eguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les questions de seguretat si s utilitzen peces de recanvi no autoritzades e Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e 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 profess les mesures convenients ional ha d estar ne assabentat i prendre PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar tag e EASKE Peds 38 178459 Ht 492 PAE 97 BIASE RUH Wer rM lee be al FUE 419419141 9t Of WE AGS XX Sey Cee let TL eee del ME ee ARM El WO Se H MATL A Qs A A ALC 10 L A NL LE IC og T KH e ENES WVU SA 89 7 I7 58 ENTS sus UH te Al s 4 e ope uw AS Se s ps ea SASS El dE a AA aia van FIE ae eA el mo ze fe e AREA VE DA ARA AE m BR TA E RAM E BE fl TRAZA RARA fld OST ES TEA Ut o E DUDEN VOIR AS A RR EAN ST Af H SERRA HEIN ARA REH NERER MA EW IBA A posce AE T
66. ents CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface gt Pb gt Bb CAUTION This type of caution indicates a tipping hazard Service Manual 4513 630 63W 6EW 1 General information The Lexmark E460dn and E460dw are monochrome laser printers designed for single users or small workgroups This book contains information on E460dn and E460dw For more information on E260d and E260dn see the 4513 220 230 service manual For information on E360d and 360dn see the 4513 420 430 service manual Maintenance approach The diagnostic information in this manual leads to the correct field replaceable unit FRU or part Use the error code charts symptom index and service checks to determine the symptom and repair the failure See Diagnostics information on page 2 1 for more information See Repair information on page 4 1 to help identify parts After completing the repair perform tests as needed to verify the repair General information 1 1 4513 630 63W 6EW Overview of the operator panel The control panel consists
67. es 15 000 standard pages Photoconductor kit Up to 30 000 2 Up to 30 000 2 1 Declared value in accordance with ISO IEC 19752 2 Up to 30 000 pages based on an average of 3 pages per job and approximately 5 coverage per page Yields may vary based on customer usage General information 1 5 4513 630 63W 6EW Types of print media Note Ensure trays are properly loaded Never mix media types within a tray preprinted colored paper light paper heavy paper custom type x Source Sizes Types Weight Input capacity sheets Input tray 1 A4 A5 A6 JIS B5 Plain paper 60 90 g m e 250 paper letter legal executive recycled labels e 50 labels 250 sheet tray oficio Mexico folio bond letterhead 16 24 Ib statement preprinted colored paper light paper heavy paper rough cotton custom type x 2nd Drawer option A4 A5 JIS1 B5 letter Plain paper 60 90 g m e 250 paper legal executive oficio recycled labels e 550 paper UU PARI Mexico folio bond letterhead 16 24 Ib 50 ae rawer statement preprinted colored paper light paper heavy paper rough cotton custom type x Multipurpose A4 A5 A6 JIS B5 Plain paper 60 163 g m e 50 paper feeder letter legal executive transparency 16 43 lb e 15 lables oficio Mexico folio recycled labels e 10 transparencies statement bond letterhead P preprinted col
68. f the installed input sources All pages used during this test drop into the default output bin For each installed input source press FJ to select Single or press El and FJ to select Continuous The Single test feeds one sheet of media to the default output bin The Continuous test feeds media to the default output bin until is pressed The operator panel displays Select Input Tray Feeding while either of these tests perform Sensor Test The Sensor Test verifies that the Tray 1 Tray 2 and MP Feeder if installed sensors are working correctly Press FJ to select this test from the INPUT TRAY TESTS menu Select Input Tray Tray Present will display on the operator panel Diagnostic aids 3 11 4513 630 63W 6EW Output bin tests The Output bin tests setting is used to test the printer s output bins and its sensors Feed Tests This test verifies that the media from the printer s default input source feeds to the specific output bin Press EJ to select Single or press El and FJ to select Continuous The Single test feeds one sheet of media to the default output bin No buttons are active during this test The Continuous test feeds media to the default output bin until is pressed The indicator light blinks green and the operator panel displays Select Output Bin Feeding while either of these tests perform Sensor Test This test verifies that the selected output bin s sensors are working correctly The following sensors
69. fa alo HZA 770 795 LE Ol E S TFHA SScte Class ill 3b ajo xj amp Hol Aa SUC E alo AAMT BREE AA Ae SOL FAL EF BLE PAE MAA lol A 7 2 Class PEY al o Eo Ao ECH 3428 913 So 9 uc Notices and safety information XI 4513 630 63W 6EW Xii Service Manual 4513 630 63W 6EW Lithium warning CAUTION This product contains a lithium battery THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE Discard used batteries according to the battery manufacturer s instructions and local regulations Safety information The safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized 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 CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit Norme di La s curit de ce produit repose su
70. fastened tightly e Be sure that the drafted edge of the strip is installed toward the bottom of the tray 4 66 4513 630 63W 6EW 5 Locations and connections Locations Front view Front door y release Operator j panel y NN Paper SS stop lt gt Front Ta gt door S DO Standard output Multi purpose bin feeder door System board door Standard 250 sheet tray Tray 1 Rear view Locking device USB Printer power port cord socket Power switch Locations and connections 5 1 4513 630 63W 6EW Lexmark E460dn controller board 200000 200000 J14 EXIT 1 J11 NRW 20420341 goooooo0o000000000 Qoooooo0oo0o0o000oo0o 1 J10 DPSOL 1 J9 FAN OOO0000000000000000000000000 OOOOO00000000000000000000o000 DOLOMO ID ODVODI e m J100 DRV HSYN 1 J27 IN DPX J2 WRLSS J5 OP PANEL J26 J4 CART FED J24 fe MPF Le J23 MPFS gt J13 TNR h J501 TPS J17 MTR 000000000 1
71. fault value for the settings listed below Device Setting U S value Non U S value Paper sizes Letter A4 Envelope size 10 DL Envelope PCL Symbol Set PC 8 PC 850 PPDS Code Page 437 850 Universal Units of Measure Inches Millimeters If the value of a setting is changed then Submitting Changes displays Press E to exit the Defaults setting and return to the Printer Setup menu Printed Page Count Page Count The value of this setting gauges the amount of usage on the printer The Page Count setting s value will equal the values of the Picked Sides meter After all print tests have been completed the value will reset to 0 Note The value of this setting cannot be changed manually Press Ej to exit the Page Count setting and return to the Printer Setup menu Permanent Page Count Perm Page Count The value of this setting indicates the total number of pages that have been printed After all print tests have been completed the value will reset to 0 Note The Permanent Page Count s value cannot be reset Press E to exit the Permanent Page Count and return to the Printer Setup menu Diagnostic aids 3 13 4513 630 63W 6EW Serial Number The serial number can only be viewed and cannot be changed To view the serial number 1 Select Serial number from PRINTER SETUP 2 Press Return to return to PRINTER SETUP Service Tag only on some printers The service tag number ca
72. ge behind to signal that this page supervisor no longer needs to stay alive so he can figure his gap 902 57 Invalid paper path location 902 58 Hsync counter lt O 902 59 Page never picked from duplex 2 14 Service Manual Service error codes 9xx Continued 4513 630 63W 6EW Error Description 902 60 Transfer voltage requested is greater than HVPS limit 902 61 TBD 902 62 TBD 902 63 Invalid System Clock 902 64 TBD 902 65 TBD 902 66 TBD 902 67 ASIC register overflow during Mookie sequence 902 68 Tried to call but the line was busy 902 69 Performed the compression set sequence from an invalid engine manager state 902 70 Page ahead never let go of control of the transfer system 902 71 ASIC problem detected 902 72 Manufacturing Smart Chip NPA function out of range 902 73 Page ID associated with finishing request not found 902 74 Watchdog counter is near tripped value 902 75 Fan control error from fan supervisor 902 76 Fuser ADC error 902 77 Step PP control still running when attempted to load 902 78 Invalid leading edge step PP control state 902 79 Invalid trailing edge step PP control state 902 80 Step PP control didn t finish task in allotted time 902 81 Heartbeat bandwidth problem 902 98 TDS Error DC pick motor errors 914 00 DC pick motor er
73. ge power supply high voltage power supply board should be performed with the printer positioned on its back side Note When making voltage readings always use frame ground unless another ground is specified See the wiring diagram in the back of the book for more information Controller board service check Controller board servic e check FRU Action Controller board assembly Warning Do not replace the operator panel and controller board at the same time Each card contains the printer settings When either of these cards is new it obtains some of the settings from the other card Settings are lost when both are new and replaced at the same time POST Power On Self Test Note The printer should complete POST in approximately 30 seconds If the printer fails to display lights or activate the drive motor fuser or fan then check the following order 1 Power to the LVPS HVPS 2 Power from the LVPS HVPS to the controller board 3 Cables are plugged in correctly especially for the operator panel The printer will not power up without a functioning operator panel 4 The controller board assembly The LED adjacent to J12 will be illuminated if the card is powered and good 5 The operator panel See Operator panel service check on page 2 26 Verify 24 V dc input from the LVPS HVPS 1 Turn the printer off 2 Disconnect the LVPS HVPS cable from the controller board at J502 3 Turn th
74. hanging the setting s value press E Top Margin This setting moves the black plane s top margin up or down Increasing the margin value moves text down the page and increases the amount of space between the page s top edge and the top margin Decreasing the margin value moves text up the page and narrows the amount of space between the page s top edge and the top margin The default margin is 1 6 inch Note Modifying the top margin moves the entire image either up or down on the physical page In order to preserve the bottom margin changing the top margin does not compress or expand the image Bottom Margin This setting moves the black plane s bottom margin up or down Increasing the margin value moves text down the page and narrows the amount of space between the bottom edge of the page and the bottom margin Decreasing the margin value moves text up the page and widens the amount of space between the bottom edge of the page and the bottom margin The default margin is 1 6 inch Note Modifying the bottom margin affects the rate of the stepper motor and may cause the page image to be compressed or expanded Left Margin This setting moves the position of the black plane to the right or left Increasing the margin value moves the plane to the right Decreasing the margin value moves the plane to the left The default margin is 1 4 inch Note The left margin adjustment is used to center the image from left to right The image will re
75. he door Keep the spring in place Remove the two screws E and lift off the cable cover Connect the operator panel to the cable and pull the cable through the front access door until the operator panel can be held lightly with the four screws F Note Do not over pull the cable o7 9 o0co Repair information 4 19 4513 630 63W 6EW 4 20 Reinstall the cable cover and latch assuring that the tab G is in place Pull all the excess cable through the frame opening at the hinge and into the controller board area Connect the cable to the controller board and loop it so that the closing and opening of the front access door does not cause bending Finish tightening the screws F and reinstall the remaining parts 4513 630 63W 6EW Fuser removal 1 Remove the rear exit guide See Rear exit guide assembly with sensor and reversing solenoid removal on page 3 56 2 Remove the two screws A 4 Push in on the cable connector cover B and remove Repair information 4 21 4513 630 63W 6EW 5 Disconnect the AC cable C C B 6 Disconnect the thermistor cable D 4 22 4513 630 63W 6EW 7 Disconnect the exit sensor cable E from the controller board 8 Remove the fuser Note Be careful to not damage the gears during the fuser installation Be sure to reinstall the AC cable during the fuser installation Repair information 4 23 4513 630 63W 6EW Left s
76. hen the paper tray will become lodged and the printer will need to be replaced 4 44 4513 630 63W 6EW Multipurpose feeder MPF removal 1 Open the front access door 2 Remove the four screws A from the upper front guide 3 Remove the upper front guide 4 Remove the two screws B Repair information 4 45 4513 630 63W 6EW 5 Close the front access door and pull up on the MPF by the steel shaft until the MPF lifts from its hinges 6 Disconnect the MPF from the lower front cover 4 46 4513 630 63W 6EW 7T Open the front access door and remove the lower paper guide Repair information 4 47 4513 630 63W 6EW Multipurpose feeder MPF feed clutch removal 1 Remove the left side cover See Left side cover removal on page 3 24 2 Remove the duplex See Duplex removal on page 3 11 3 Disconnect the cable A from the controller board 4 Place the printer on its right side Note Be careful to not damage any cables or mar the finish of the printer 4 48 4513 630 63W 6EW 5 Remove the three screws B from the left side of the printer S T FE B 6 Disconnect the left hinge C from the feed clutch and remove the e clip D D C 7 Lift and remove the multipurpose feeder MPF feed clutch Repair information 4 49 4513 630 63W 6EW Nameplate removal 1 Open the front access door 2 Remove the three screws A Note The p
77. his menu group are used to configure a printer for operation See Configuration menu CONFIG MENU on page 3 2 for more information Diagnostics Mode 1 Turn off the printer 2 Press and hold EJ and 3 Turn on the printer 4 Release the buttons when the clock displays The Diagnostics Mode group contains the settings and operations used while manufacturing and servicing the printer See Diagnostics menu on page 3 6 for more information To run the printer diagnostic tests described in this chapter the printer must be in Diagnostic Mode Diagnostic aids 3 1 4513 630 63W 6EW Configuration menu CONFIG MENU Entering Configuration Menu Turn off the printer Press and hold FJ and Turn on the printer pomo Available menus Release the buttons when the clock displays The menus display on the operator panel in the order shown Maintenance Count Value See Maintenance Count Value Maint Cnt Value on page 3 3 Reset Maintenance Count See Reset Maintenance Count Value Reset Maint Cnt on page 3 3 Count Reset Photoconductor Maintenance See Reset Photoconductor Maintenance Counter Reset PC Cnt on page 3 3 Print Quality Pages See Print Quality Pages on page 3 3 Reports See Reports on page 3 4 Panel Menus See Panel Menus on page 3 4 PPDS Emulation See PPDS Emulation on page 3 4 Demo Mode See Dem
78. ic bushing F 4 14 4513 630 63W 6EW 8 Use a screwdriver to pop the retainer clip G loose from the gear b Repair information 4 15 4513 630 63W 6EW Fan removal 1 Remove the right side cover See Right side cover assembly removal on page 3 58 2 Disconnect the cable A from the controller board and remove the two screws B holding the fan to the right side frame 3 Remove the fan 4513 630 63W 6EW Front access door removal NE mpl Remove the operator panel See Operator panel removal on page 3 51 Remove the left side cover See Left side cover removal on page 3 24 Remove the upper front guide assembly See Upper front guide assembly removal on page 3 64 steps 1 3 Close the front access door While closing the MPF cover pull up on the MPF by the steel shaft until the MPF lifts from its hinges Repair information 4 17 4513 630 63W 6EW 6 Disconnect the MPF from the lower front cover d 7 Disconnect the fuser link A from the front access door 4513 630 63W 6EW 8 Disconnect the front access door cable B and pull it through the opening to clear the side frame Installation note Install a new front access door at its hinges Push the cable C through the side frame and into the controller board area Connect the fuser link Remove the two screws D Slide the latch to the left to free it and then rest it on t
79. icado de mantenimiento e 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 PRECAUCI N este s mbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a e A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas e As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e 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 e CUIDADO Quando vir este s mbolo existe a poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria Xiv Service Manual Informaci de Seguretat 4513 630 63W 6EW e La s
80. icture below shows the E260d E260dn printer The nameplate removal is the same for all models 3 Remove the nameplate 4 50 4513 630 63W 6EW Operator panel removal 1 Remove the nameplate See Nameplate removal on page 3 50 2 Remove the bezel See Bezel removal on page 3 5 3 Remove the four screws A from the display plate A 4 Lift the operator panel cover and disconnect the operator panel cable B 5 Remove the operator panel Repair information 4 51 4513 630 63W 6EW Paper input and duplex sensor assembly removal 1 Remove the right side cover See Right side cover assembly removal on page 3 58 2 Remove the duplex See Duplex removal on page 3 11 3 Remove the two screws A from the sensors 5 Remove the paper input and duplex sensor assembly 4 52 4513 630 63W 6EW Printhead removal 1 Remove the top cover See Top cover assembly removal on page 3 61 2 Remove the right side cover See Right side cover assembly removal on page 4 58 3 Disconnect the two cables A and unroute them back through the frame toward the printhead 4 Remove the three screws B Note Use a pencil to mark the screw locations of the printhead on the metal frame Align the new printhead relative to the location of the old printhead See Printhead assembly mechanical adjustment on page 3 19 5 Remove the printhead Repair information 4 53 4513 630
81. ide cover removal Note Leave the front door closed when removing the left side cover Make sure that the fuser cables are out of the way when removing the left side cover Remove the paper tray Remove the screw A from the rear left side of the printer Peso A 3 Remove the screw B and press the two latches C on the bottom of the left side cover 4 24 4513 630 63W 6EW 4 Swing the cover open and remove the left side cover Repair information 4 25 4513 630 63W 6EW Lower front cover removal 1 Open the lower front cover 2 Disconnect the MPF pins A from the right and left sides of the lower front cover Note The picture below shows the E260d E260dn printer The lower front cover removal is the same for all models Pa A 3 Flex the lower front cover and disconnect it first from its right hinge and then from its left hinge Note An alternative to step 3 is to remove the front access door and remove the three screws from the right door mount See Front access door removal on page 3 17 and Door mount removal on page 3 9 4 26 4513 630 63W 6EW Installation note Use a flathead screw driver to press in on the door mount B while pulling on the front access door to connect the cover to the hinge C Repair information 4 27 4513 630 63W 6EW LVPS HVPS removal 2 Remove the left side cover See Left side cover removal on page 3 24
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83. ines per Page Lines per Inch Page Format Character Set Best Fit Tray 1 Renumber Auto CR after LF Auto LF after CR 2 4 Service Manual Finishing Menu Duplex Duplex Bind Copies Blank Pages Collation Separator Sheets Separator Source Multipage Print Multipage Order Multipage View Multipage Border PCL Emul Menu Font Source Font Name Point Size Pitch Symbol Set Orientation Lines per Page A4 Width Tray Renumber Auto CR after LF Auto LF after CR Parallel Menu Std Parallel Utilities Menu Print Menus Print Stats Print Net Setup Print Fonts Print Directory Factory Defaults Format Flash Defragment Flash Hex Trace Setup Menu Eco Mode Quiet Mode Printer Language Power Saver Resource Save Print Timeout Wait Timeout Auto Continue Jam Recovery Page Protect Display Language Toner Alarm Network Menu Standard Network Job Menu Reset Printer Quality Menu Print Resolution Toner Darkness Small Font Enh USB Menu Standard USB Messages and error codes User attendance messages 4513 630 63W 6EW The printer control panel displays messages describing the current state of the printer and indicates possible printer problems that must be resolved This topic provides a list of all printer messages explains what they mean and tells how to clear the messages The following table lists the messages in alphanumerical order A message can also be located using the index User a
84. ith the door closed 3 Verify discontinuity between cable pins 2 and 3 whether the door is open or closed f any fail then replace the cover interlock switch f both pass continuity then turn the printer on and measure 5 V dc on pin 2 at J7 on the controller board Verify pin 3 at J7 is ground f voltage or ground is not present then see Controller board service check on page 2 21 for more information 2 22 Service Manual Dead machine service check A 4513 630 63W 6EW CAUTION Check the AC line voltage The voltage should be within the following limits 100 V ac volts alternating current 127 V ac for the 110 V printer e 200 V ac 240 V ac for the 220 V printer FRU Action A LVPS HVPS then unplug the card check on page 2 21 Unplug the printer Remove the LVPS HVPS and check the fuses for continuity If open then replace the LVPS HVPS f not open then check the switch continuity across its conductors with the switch on Turn the switch off Plug the AC line into the LVPS HVPS and switch unit on Note Voltages may be exposed at several places on the board Do these verifications and Pins Voltage CN201 6 17 24 V dc 19 CN201 10 12 Ground 14 16 18 CN201 1 3 5 5 V dc 11 13 15 f voltages are not correct then replace the LVPS HVPS f voltages are correct then check the controller board See
85. le fails continuity then call the next level of support Turn the printer on with the cable still unplugged and verify the following on the cable controller board will not be powered Pins Voltage 6 17 19 24 V dc 1 3 5 11 13 45V dc 15 If any of the voltages are incorrect then replace the LVPS HVPS See Dead machine service check on page 2 23 Cooling fan service check FRU Action Cooling fan Make sure the fan cable plug is properly seated at J9 controller board Turn the printer on Within a few seconds the controller board assembly should apply 24 V dc to pin 2 f voltage is not present then check or replace the controller board See Controller board removal on page 4 6 If voltage is present then check pin 1 for 24 V dc as well If itis close to 24 V dc while the fan is still idle then replace the fan See Fan removal on page 4 16 Cover interlock switch service check Note Make sure open switch lever a print cartridge assembly is installed and the cover closes all the way engaging the cover FRU Action Cover interlock switch Disconnect the cover interlock cable from the controller board at J7 With the printer turned off 1 Verify continuity between cable pin 1 and pin 2 with the door closed and discontinuity with the door open 2 Verify continuity between cable pin 1 and pin 3 with the door open and discontinuity w
86. ller board Squeeze the lower tabs B of the toner level sensor and push it from its holder ee B A 5 Remove the toner level sensor through the inside of the printer Note The toner level sensor must be installed properly or the printer will not function 4 60 4513 630 63W 6EW Top cover assembly removal Open the front access door Remove the left side cover See Left side cover removal on page 3 24 Remove the right side cover See Right side cover assembly removal on page 3 58 Remove the rear door and rear cover See Rear door and rear cover removal on page 3 54 Remove the two screws A from the left side of the printer Pel gt F 6 Remove the two screws B from the right side of the printer Repair information 4 61 4513 630 63W 6EW 7 Lift the top cover and remove Note e Be sure to lift the top cover assembly from the front to remove During reinstallation be sure the exit guide and the paper bin align correctly A mismatch can cause paper jams 4 62 4513 630 63W 6EW Transfer roll removal Note A flashlight may be required to remove the transfer roll 1 Open the front access door 2 Atthe right side of the transfer roll squeeze the holder arms A with the left hand while lifting Stop when the holder is unlatched 3 Atthe left side of the transfer roll squeeze the holder arms with the right hand while lifting with the left hand Stop when th
87. ly shake it from side to side to redistribute the toner Replace the toner cartridge Solid black areas on transparencies There is a mismatch in the transparency and what the software is expecting Choose a different fill pattern in the software program Remove the toner cartridge and gently shake it from side to side to redistribute the toner Try a different type of transparency Replace the toner cartridge Faint images or repetitive spots appear on the page Select a different media type or form type setting from the printer driver Try a different type of paper Media designed for copiers gives the best quality Replace the toner cartridge Pages are blank The print cartridge may be out of toner or defective Replace the cartridge There may be a software error Re initialize the printer by turning it off and back on With the printer off check the printhead beam path If clear then check for a printhead error on POR See Printhead service check on page 2 36 Also see Blank page on page 2 29 2 34 Service Manual 4513 630 63W 6EW Print quality problems Continued Problem Cause action The printer is on and indicates ready but nothing prints Make sure the parallel or USB cable is not damaged and is firmly plugged into the connector on the back of the printer Make sure the toner cartridge assembly is installed properly Print the menu page found under
88. main the same width Right Margin This setting is used to adjust the printhead but only after determining that it is out of adjustment by observing the Quick Test Page Note The right margin setting is not a margin adjustment and should not be used unless a new printhead is installed To adjust a new printhead see Printhead assembly electronic adjustment on page 3 18 or Printhead assembly mechanical adjustment on page 3 19 Diagnostic aids 3 7 4513 630 63W 6EW Quick Test page Print a Quick Test page to verify that the REGISTRATION margin values are set appropriately The Quick Test page consists of the following Alignment diamonds Horizontal lines used for skew adjustment General device information current page count installed memory etc The printer s serial number code levels and print registration settings While the Quick Test page prints Printing will display No buttons are active while the Quick Test page prints When the Quick Test page is finished printing the display returns to the initial REGISTRATION menu Screen Note Print the Quick Test page on Letter or A4 sized media Print Tests This setting tests the printer s ability to generate printed output from each of its installed input sources and to test the printer s current print quality Input sources PRINT TESTS contains the following installed input sources Tray1 Tray 2 Multi Purpose Feeder Print Quality Pages Press
89. mechanism as necessary to adjust toner darkness No messages are displayed on the operator panel to give any indication that this test is running When deactivated the printer disables Reports This setting prints the Diagnostic menu settings page Press M to print the menu settings page Event log Display Log Selecting EVENT LOG provides a history of printer errors The most recent error displays in position 1 and the oldest error displays in position 10 if 10 errors have occurred If an error occurs after the log is full then the oldest error is discarded Identical errors in consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the event log as well as the photoconductor kit and maintenance counter resets and NVRAM resets initiated by the Factory Defaults setting in the UTILITIES menu To view the display log 1 Select Display Log from the EVENT LOG menu The error log is displayed one error per display screen For example Event 1 6 936 Svc Error This error is the first of six errors it is also the latest error This error was a 936 service error To see the second service error press 3 Pressing EJ will display the sixth error as shown Event 6 6 202 01 Paper Jam 2 Press Back once to exit the Display log or press twice to exit the EVENT LOG 3 16 Service Manual 4513 630 63W 6EW Print Log Additional diagnostic information is available when you print
90. media or missing signal HIGH END 201 25 Exit sensor never made by leading edge of media when feeding out the media that was detected during warm up 201 26 Page at fuser nip before fuser started ramping toward desired temperature Indicates code may be receiving more hall interrupts than intended 201 27 Page at fuser nip before fuser reached acceptable operating temperature Page arrived at fuser earlier than expected so it was probably staged 202 00 Paper jam around exit sensor 202 01 Exit sensor never broke on the trailing edge of the sheet at the exit sensor 202 02 Exit sensor never broke from sheet ahead of page heading toward the exit sensor 202 06 Exit sensor bounced 202 13 Exit sensor covered media not expected media not in machine during warm up 202 25 Exit sensor never broke from the sheet ahead of the page heading toward the exit sensor when feeding out the media detected during warm up 202 26 Trailing edge never cleared exit sensor when feeding out media that was detected during warm up 202 32 Long media or shingled multi feed stopped before sending to duplex 231 00 Duplex jam while reversing into the device 231 01 Duplex sensor never made by leading edge reversing into the duplex 231 02 Bouncy duplex sensor never made 232 00 Duplex jam while staging in the device 232 01 Duplex sensor never broke by the sheet ahead after reversing into the duplex 232 02 Page in duplex ahead of
91. n check the controller board See Controller board service check on page 2 21 for more information f voltages are correct then replace the printhead comes with cables Transfer roll service check FRU Action A Transfer roll Note Do not touch the transfer roll except at its ends Place a sheet of paper over the roll to prevent damage from finger oils or hand lotion Check the springs in the left and right transfer roll bearings Do not try to move the left spring The bearing assemblies should support the transfer roll applying evenly distributed forces to the PC drum Replace the transfer roll assembly if the springs or bearings show signs of damage or fatigue Inspect the transfer roll for signs of wear damage or contamination Replace as necessary 2 36 Service Manual 3 Diagnostic aids 4513 630 63W 6EW This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer Configuration Menu 1 Turn off the printer 2 Press and hold M and Q 3 Turn on the printer 4 Release the buttons when the clock displays The Configuration Menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in t
92. n lookup table 922 04 Hot roll timed out in trying to reach the final lamp detection temperature 922 05 Did not roll over to a steady state control in time after the hot roll lamp detection 922 06 Hot roll did not reach the operating temperature in time new enhanced control 922 07 Media reached fuser nip and fuser is under temperature 922 08 Fuser warm up failure motor start condition 922 09 Fuser warm up failure compression set 922 20 Belt fuser failed to reach the preheat temperature for the motor to start during warm up 922 21 Belt fuser was under temperature when the media reached the fuser nip 923 00 Fuser is over temperature 923 01 Fuser is over temperature This applies to the fuser and belt fusers 924 00 Open thermistor check 924 01 Open thermistor check failure This applies to the fuser and belt fusers 924 02 Open thermistor check failure The ADC failed to converge Possible noisy thermistor signal This applies to the fuser and belt fusers 925 00 Wrong fuser lamp installed 925 01 Lamp detection performed and found error 925 02 Too hot to do lamp detection and NVRAM bit indicates previous wrong lamp detected Fan service errors 927 00 Service fan error 927 03 Main fan took too long to ramp up 2 16 Service Manual 4513 630 63W 6EW Service error codes 9xx Continued Error Description 927 04 Main fan is under
93. n only be viewed and cannot be changed 1 Select Service Tag from the PRINTER SETUP menu 2 Press Back to return to PRINTER SETUP Engine Setting 1 through 4 Warning Do not change these settings unless requested to do so by your next level of support Model Name The serial number can only be viewed and cannot be changed Configuration ID The configuration ID is used to communicate characteristics of certain areas of the printer that cannot be determined by hardware sensors The configuration ID was originally set when the printer was manufactured and is located on the printer label Edge to Edge When Edge to Edge is set to On text and graphics are printed with all margins set to the physical edges of the page This feature does not work in PPDS emulation Par S Strobe Adj parallel strobe adjustment This setting adjusts the factory setting for the amount of time the strobe is sampled to determine that valid data is available on the parallel port Incrementing this value by one means the strobe is sampled 50 nanoseconds longer The range of values are between 4 and 6 in increments of one A value of zero indicates no change is made from the factory setting 3 14 Service Manual 4513 630 63W 6EW EP Setup EP Setup displays the following selections EP Defaults Fuser Temperature Fuser Temp Fuser Page Count Warm up Time Transfer Print Contrast Charge Roll Gap Adjust Automatic Darkness Adjustment Auto D
94. n values Controller board 2 30 Service Manual 4513 630 63W 6EW Partial blank image white spots no repeating pattern FRU Action Toner cartridge not a Remove the toner cartridge assembly and gently shake the assembly to evenly distribute FRU the toner Check to make sure that the laser light path is not blocked If toner cartridge is low then try a new one Paper not a FRU Make sure recommended media is being used Check the media settings in the printer driver A heavier media may require higher heat to properly fuse Variation in image density horizontally across page FRU Action Photoconductor kit not The charge roll may have an unbalanced force against the PC photoconductor drum a FRU Try a new photoconductor kit Transfer roll Note Do not touch the transfer roll except at its ends Place a sheet of paper over the roll to prevent damage from finger oils or hand lotion Check the springs in the left and right transfer roll bearings The bearing assemblies should support the transfer roll applying evenly distributed forces to the PC drum Replace the transfer roll assembly if the springs or bearings show signs of damage or fatigue Inspect the transfer roll for signs of wear damage or contamination Replace as necessary Poor fusing of image FRU Action Fuser The fuser may not be operating at the proper temperature to fuse the toner to
95. nd 15 Verify ground on pins 10 12 14 16 and 18 If any of the values are incorrect then replace LVPS HVPS board e f the grounds are incorrect then check ground paths Check continuity in the cable If the cable is bad then call the next level of support duel are correct and the toner electrodes are good then replace the controller oard See the LVPS HVPS service check on page 2 24 and the Controller board service check on page 2 21 if necessary Heavy background Poor development or poorly charged toner particles cause excessive background This is more noticeable as the toner cartridge nears end of life FRU Action Toner cartridge not a Check the toner darkness setting in the driver Try a lower setting FRU i Make sure the toner cartridge and photoconductor kit are correctly installed and the high E FRU ductor kit not voltage contacts are clean If the toner cartridge and photoconductor kit are installed correctly then try a new photoconductor kit first and then toner cartridge Check the contacts for correct installation and contamination where contact is made between the print cartridge assembly and spring contacts which connect to the LVPS HVPS board at CN203 Clean as necessary If this does not correct the problem then replace the following FRUs one at a time in the order shown LVPS HVPS Controller board e VPS HVPS board See Black page on page 2 30 for pi
96. nect the cable D from J25 on the controller board Installation note Install the two screws holding the new solenoid in place and route the cable D behind the MPF clutch E e After disconnecting the old solenoid cable connect the new solenoid cable to J25 on the controller board 4 36 4513 630 63W 6EW Media ACM ASM feeder removal Remove the left side cover See Left side cover removal on page 3 24 Remove the LVPS HVPS See LVPS HVPS removal on page 3 28 Remove the duplex See Duplex removal on page 3 11 Remove the main motor gear drive See Main motor gear drive removal on page 3 31 Remove the media feed clutch See Media feed clutch with cable removal on page 3 40 Use a screwdriver to pop the shaft retainer tab A loose from the ACM feed shaft SAP A 7 Use a small pair of pliers to remove the shaft retainer tab Repair information 4 37 4513 630 63W 6EW 8 Use a screwdriver to pop the inner shaft lock B loose 4 38 4513 630 63W 6EW 10 Pull out the auto compensator shaft and remove the spring D 11 Remove the auto compensator shaft 12 Disconnect the spring E from the cylinder a 4 Le 4 13 Remove the media ACM ASM feeder Repair information 4 39 4513 630 63W 6EW Media feed clutch with cable removal 1 Remove the main motor gear drive See Main motor gear drive removal on page 3 31 2 Remove the duplex See D
97. ng Fan Duplex Solenoid Exit Sensor Narrow Sensor ASC Ave Ave AO LL TIL j c a Dole Ts Pe fs I D Pob s LE SS TEE EST AT EE E J8 J9 J10 Jti J12 Network With printer off unplug this cable and turn printer back on Check Plug values on the cable pins A USB Port El i Tray 2 Connector OPTION CARD OPTION CARD Parallel port E460dn only Legend Input I Output O Plugged voltage if different All voltages are DC unless otherwise noted Print Defects guide Print defects guide Identifying the cause of repeating defects Match a set of repeating defects on a print job to the marks on one of the vertical lines shown in the following table The line that best matches the defects on the print job indicates which particular part is causing the defect The toner cartridge and the photoconductor kit are customer replaceable items If the transfer roller or fuser needs replacement contact Customer Support Replace the Replace the Replace the photoconductor kit transfer roller Replace the fuser
98. nnn 3 2 Available MENUS xxx aai ax OR RACK ARR RAR RA RA RA OR RC ea RR RC C a 3 2 Maintenance Count Value Maint Cnt Value seeeeeeee III 3 3 Reset Maintenance Count Value Reset Maint Cnt llle 3 3 Reset Photoconductor Maintenance Counter Reset PC Cnt 3 3 Pint QUAN Pages ias vir ea Ver di ea E a Tb di ACE Dd eR ERE Ba vs bd kia bs dk 3 3 HNOS sus scada ES NE E tI ToC EU RUE Ea EO Ra ao d d pde Ra e S ici aro 3 4 Menu Senno Page asias rra Sire auti dnd 3 4 EVENT LOQ ierastas desbado in eepES POR cia cec sota RAE TSSeeRaPeRGicpr ve 3 4 Patel Menus ooo bd paw caras RJ p ibi qol and A 3 4 PPDS Emulation 2x5 sisi meca Rod OCA nada nas EE RE Ra EE a RR OR 3 4 Demo Mod A rM 3 4 Factory Defaulis coo o ada d RR AURA aa BR RE EE ED RR RA a RR ACCRUE CR CC Ca 3 4 Action FOr PEFOmpIS oae RIDE eek REUS E IUE RH d VER ER Hd RUE E deeds dee nd ae Rd 3 5 Energy ConServe 000000000 sack RE ROCA RC RC RC RR AR AA RR NE RC COD LR 3 5 Font Sharpening ocaso tae ca bae cd Ere CERA X Ku FEET bale stele anes Pda Rod 3 5 Exit Configuration Menu Exit Config Menu seseeee RII 3 5 ENANOS IES MEN oesisbacaka ana ot bd rad bg ORES Liew UD RO pd b d den RU eae ads 3 6 Entering Diagnostics MENU Lauer bor ii AA AAA AA 3 6 Wi scr iaa ia eee EUER o OR d a 3 7 A ecu d So PISCE GR y dh E REC S MEO Sache wg hub PUE qb E AU pau e die arat 3 7 SLE mr 3 8 Prnt TESIS osa dores ucba i ap Dee o OR eod AAA EO
99. ns a mixture of graphics and text pages 2 and 3 contain only graphics and page 4 is a blank page If Duplex is turned on then the pages are duplexed otherwise they are simplexed Wait for the message to clear Prog Engine Code DO NOT POWER OFF The printer is programming new engine code Wait for the message to clear and the printer to reset Warning Do not turn the printer off while this message is displayed Program Flash DO NOT POWER OFF The printer is storing resources such as fonts or macros in flash memory Wait for the message to clear Warning Do not turn the printer off while this message is displayed 2 6 Service Manual 4513 630 63W 6EW User attendance messages Continued Message Action Prog System Code DO NOT POWER OFF The printer is programming new system code Wait for the message to clear and the printer to reset Warning Do not turn the printer off while this message is displayed Ready Send a job to print Remove Paper Standard Bin The standard output bin is full Resetting Maint Cnt Valu The printer is resetting the counter that tracks wear on the fuser Resetting PC Cnt Value The printer is resetting the counter that tracks wear on the photoconductor Resetting the Printer Wait for the message to clear Res Reduced The printer is reducing the resolution of a page in the current job from 600 dots per inch dpi to 300
100. ntries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right 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 Lexmark Lexmark with diamond design and MarkVision are trademarks of Lexmark International Inc registered in the United States and or other countries PCLO is a registered trademark of the Hewlett Packard Company All other trademarks are the property of their respective owners O 2008 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G9813 4513 630 63W 6EW Table of contents Table Cl CODIORIB ME E AAA iii Notices and safety information oooooccconnccca ennnen vii Laser DO GB eet eet EU aba eee ba d dedi dde d E GO CE d dic d Ud eee d RU RUE QUU are ree ae a vii Lithium warning kg ach Ropa d EVER ud EHE A A e Io RS xiii Safety inlormallOlt esae sd daria Reb ERU obe eb RR o do ASA e e xiii PIBISEB aua dh cir RARA RRE AAA ICRA
101. nts iii 4513 630 63W 6EW Media occasionally mispicks or picks multiple sheets at once 2 27 Mois SKOWS cas lide edv oA eb dass EGRE IA 2 27 Media trees wrinkles stacks poorly Or CUMS u e ua eee eee eee 2 28 Parallel or USB port service check xoxo a ee RA ae 2 28 Print quality service CHECKS cima ciate aha ena d IRR DAN Ead RUN RR ewe RO 2 29 Blank page 4 0955 ied Edo dita thie bad ena d Saad te pees mucius Benet ed ecd 2 29 Black PEGS MM PU U u 2 30 Heavy background iuis iari id 2 30 Partial blank image white spots no repeating pattern 0 cece eee 2 31 Variation in image density horizontally across page 2 cece eee eee pii 2 31 Poor SING CHMAGS saciar e 2 31 Eight pill da AE hehe Oe Nu Ee MOREE GEC EEES diae 2 32 Whiter blacklinias OF Dada i ciudactereccesiadesteeereegbecesdet arses a peng anes 2 32 TONSTOMDACCONDADS amada aria gam eaae bene Renee wae aec Baas 2 32 Solving pnt Quality PIODIOMS 2s casas vassemtarat essa mi tea ges eames erhi aTe E se 2 33 Printhead service CDecK fic ii e nce a Rd iR RUM dea Ru OR die Rell mie da 2 36 Transfer roll service Check siria ARO A AA eR A ORC an 2 36 a AAA O MITTERE 3 1 Accessing service MENUS bibi eii adi aa Ceo he RR a eA 3 1 Configuration menu CONFIG MENU s sm xxr RR cme EXE XO see ROS ROR OR ame eee 3 2 Entering Configuration Menu seseeeeeeer ee eh hh hh hh
102. o Mode on page 3 4 Factory Defaults See Factory Defaults on page 3 4 Action for Prompts See Action For Prompts on page 3 5 Energy Conserve See Energy Conserve on page 3 5 Font Sharpening See Font Sharpening on page 3 5 Exit Config Menu See Exit Configuration Menu Exit Config Menu on page 3 5 Note Menus may vary depending on the features and options of the printer 3 2 Service Manual 4513 630 63W 6EW Maintenance Count Value Maint Cnt Value The Maintenance Count Value displays the current value of the Maintenance Kit counter which provides a rough gauge of the printer s usage A simplex print job increases the counter by one and a duplex print job increases the counter by two Press M to enter this setting The following displays El Maintenance Count Value Value Press 5 to return to the Configuration Menu Note When the Maintenance Count Value is equal to the Maintenance Kit s rated life the operator panel displays the 80 Scheduled Maintenance message Perform the required maintenance and then reset the Maintenance Kit counter to 0 Reset Maintenance Count Value Reset Maint Cnt This setting resets the maintenance count value to 0 1 Press EJ to enter the Reset Maintenance Count Value setting The following displays El Reset Cnt v Reset 2 Select Reset 3 Resetting Maintenance Counter displays
103. o decrease the value 3 Press EJ to save the desired margin value Left Margin 1 Select Left Margin from the DUPLEX TESTS menu 2 To change the margin value press El to decrease the value or to increase the value 3 Press 7 to save the desired margin value Sensor Test This test is used to determine if the input sensor is operating correctly e If the sensor is operating correctly then OP Open will appear on the display Sensor Test Input 0P e Press to return to the DUPLEX TESTS menu 3 10 Service Manual 4513 630 63W 6EW Duplex Feed 1 1 Select Duplex Feed 1 from the DUPLEX TESTS menu The following will appear on the display Duplex Feed 1 Feeding 2 Ablank page will feed through the printer The following will appear on the display Duplex Feed 1 Clear Paper 3 Remove the blank page from the printer and press E to return to the DUPLEX TESTS menu Input Tray Tests The INPUT TRAY TESTS setting is used to test the printer s installed input trays and their sensors Feed Tests The Feed Test observes the paper path of media as it passes through the printer This setting contains the following tests Tray 1 e Tray 2 e MP Feeder if installed To observe the paper path open the upper rear door during the feed test Note The upper front door cannot be opened during the feed test The feed test can be performed by using media from any o
104. om for more information about which media provides optimum results for the current printing environment The removal and adjustment procedures require the following tools and equipment Spring hook Needle nose pliers Volt ohmmeter 1 and 2 Phillips screwdriver Slotted screwdriver 1 8 Service Manual Acronyms ACM ADC ASIC CBM DEV DIMM ENA FRU HBP HVPS LCD LED LSU LVPS NVRAM PC PCL POR POST PPDS PRC TAR SDR SWE USB Vac V dc Autocompensator Mechanism or paper feed Analog to digital Converter Application Specific Integrated Circuit Complete Bill Of Material Development Roll of print cartridge photoconductor System Dual In Line Memory Module External Network Adapter Field Replaceable Unit Host Based Printing High Voltage Power Supply Liquid Crystal Diode Light Emitting Diode Laser Scanning Unit Low Voltage Power Supply Nonvolatile Random Access Memory Photoconductor Printer Control Language Power On Reset Power On Self Test Personal Printer Data Stream People s Republic of China Toner Add Roll Synchronous Dynamic RAM Shipped With Equipment Universal Serial Bus Volts alternating current Volts direct current 4513 630 63W 6EW General information 1 9 4513 630 63W 6EW 1 10 Service Manual 4513 630 63W 6EW 2 Diagnostics information Start CAUTION Unplug power from the printer before connecting or disconnecting any cable assembly or electronic card Thi
105. om the operator panel 2 2 Service Manual 4513 630 63W 6EW Operator panel Continued Button Function Keypad Use the keypad to enter numbers or symbols on the display OO OO Ol Cc CJ Indicator light The indicator light indicates printer status e If the light is off then the printer power is off If the light is blinking green then the printer is warming up processing data or printing e If the light is solid green then the printer is on but idle If the light is blinking red then operator panel intervention is needed Display panel The display shows messages describing the current state of the printer and indicating possible printer problems that must be resolved The top line of the display is the header line It will display the current status and the Supplies Warnings status This is where printer status supplies messages and show me screens are viewed Diagnostics information 2 3 4513 630 63W 6EW Diagram of the printer menus The diagram shows the menu index on the operator panel and the menus and items available under each menu Not all menus or selections will be available in all situations These are accessed through the driver Paper Menu Paper Source Paper Size Paper Type Custom Types Universal Setup Substitute Size Paper Texture Paper Weight Paper Loading PostScript Menu Print PS Error Font Priority PPDS Menu Orientation L
106. ondition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen Landern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 60825 1 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse Illb 3b bei dem es sich um einen Galliumarsenlaser mit 7 Milliwatt handelt der Wellen der L nge 655 675 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 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 60825 1 relatives aux produits laser de Classe l Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe lllb 3b ars niure de gallium d une puissance nominale de 7 milliwatts mettant sur des longueurs d onde comprises entre 655 et 675 nanom tre
107. ontain debug information or secondary codes for 900 service errors However the event log printed from DIAGNOSTICS mode does include this information Panel Menus The settings are On and Off The default is On PPDS Emulation This menu item activates or deactivates the PPDS emulation data stream The selections are Deactivate default and Activate When PPDS emulation is activated the following settings are also changed e SmartSwitch settings for each port are turned off The printer language is changed to PPDS Emulation Users can still switch languages on the operator panel and through the PJL data stream Demo Mode This setting contains a built in demonstration mode The settings allow you to turn the Demo Mode Off default or On While Demo Mode is set the printer will start in Demo Mode until you change the setting Note While Demo Mode is set to On only demonstration files can print Files received across the network or from the host computer are ignored Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings The selections are Do not restore default and Restore now Network does not appear unless you have a network printer The following settings are not changed Display language Settings in the NETWORK PORTS MENU group 3 4 Service Manual Action For Prompts 4513 630 63W 6EW This setting determines which input source receives paper
108. onverge 935 18 Printhead sweep error enable amp Ki state 935 19 Printhead sweep error amp Ki failed to converge 935 20 Printhead sweep error enable offset controller state 935 21 Printhead sweep error load scan regs state 935 22 Printhead sweep error fwd and rev capture times differ by too much 935 23 Printhead sweep error check sweep accuracy state Diagnostics information 2 17 4513 630 63W 6EW Service error codes 9xx Continued Error Description 935 24 Printhead sweep error reserved 935 25 Printhead sweep error detected resonant frequency out of expected range 935 26 Printhead sweep error timed out waiting for end of sweep Transport motor service errors 936 01 No lock detected at normal motor start 936 02 No lock detected at motor start for motor ID 936 03 No halls detected at motor start 936 04 Failed to stop within timeout 936 05 Stall detected during speed control 937 00 Main transport motor lost lock 937 01 Main transport motor lost lock detected by engine control 937 02 Overspeed detected during position control 937 03 Overspeed detected during speed control Power supply service errors 940 00 LVPS service error 940 01 Line frequency outside allowed range of 45Hz 64Hz 940 02 Line frequency below 43Hz 940 03 No zero cross detected on belt fuser model 2 18 Service Manual
109. ored paper light paper heavy paper rough cotton custom type x Card stock e 120 163 g m 20 16 43 Ib Index Bristol e 75 163 g m 46 100 Ib Tag 7 34 9 10 DL C5 B5 Envelopes 75 g m 20 Ib 7 other Rough envelopes Duplex M letter legal oficio Plain paper 60 90 g m Mexico folio recycled bond letterhead 16 24 Ib cycled Japanese Industry Standard Capacity for 20 Ib print media unless otherwise noted Use for occasional printing only Grain short is recommended Use rear exit for best results 2 If a source supports size sensing and is activated then neither the oficio value nor the folio value appears in that source s list of supported media sizes These values only appear in a source s list of supported media sizes either when the source is non size sensing or when the source s size sensing hardware is deactivated and then the device is power 1 6 Service Manual 4513 630 63W 6EW Tips on preventing jams Paper path A Paper path A B 125 3 B Manual feed sensor B C 9 0 C Upper end feed rolls C D 59 8 D Input sensor D E 44 9 E Transfer roll E F 112 7 F Fuser F G 21 4 G Fuser exit rolls G H 114 8 H Fuser exit sensor H I 7 5 l Exit rolls l J 17 0 J Exit sensor narrow media sensor I K 211 7 K Duplex unit K L 93 4 L Duplex sensor L M 8 4 M Auto compensator M B 177 2 General information 1 7 4513 630 63W 6EW Most paper jams can be avoided by cor
110. play on the operator panel in the order shown Registration See Registration on page 3 7 Print tests See Print Tests on page 3 8 Hardware tests See Hardware Tests on page 3 9 Duplex tests See Duplex Tests on page 3 10 Input Tray Tests See Input Tray Tests on page 3 11 Output Bin Tests See Output bin tests on page 3 12 Base Sensor Test See Base Sensor Test B Sensor Test on page 3 12 Printer setup See Printer Setup on page 3 13 EP Setup See EP Setup on page 3 15 Reports See Reports on page 3 16 Event Log See Reports on page 3 16 Exit Diagnostics See Exit Diagnostics on page 3 17 Note Menus may vary depending on the features and options of the printer 3 6 Service Manual 4513 630 63W 6EW Registration The Registration menu settings adjust the black plane s margins To set print registration select REGISTRATION from the Diagnostics menu The following will display EJ REGISTRATION Top Margin la Bottom Margin Left Margin Right Margin QuicR Test E Press rj or FJ to move to the desired setting and then press M Margins To change the value of any margin setting press Eq or r3 to increase or decrease the margin setting value and then press FJ to save The panel displays Submitting changes and returns to the initial REGISTRATION menu screen To exit the margin setting menu without c
111. r continuity Remove the left side cover to access the connector on the motor f continuity exists on each wire then replace the main motor gear drive which includes the motor f continuity does not exist on one or more of the wires then call the next level of support f these voltages are not correct then see Lexmark E460dn E460dw controller board connector pin values on page 5 4 or replace the controller board See Controller board removal on page 4 6 Diagnostics information 2 25 4513 630 63W 6EW Operator panel service check Inspect the operator panel cable for damage Make sure the cable is plugged in securely Run POST and check each light for proper operation See Power On Self Test POST sequence on page 2 1 LCD Operator panel service check FRU Action Operator panel LCD Controller board Warning Do not replace the operator panel and controller board at the same time Each card contains the printer settings When either of these cards is new it obtains the settings from the other card Settings are lost when both are new and replaced at the same time Lights If the LCD does not come on then open the controller board cage and locate the operator panel connector at J3 Make sure the cable is properly connected to the controller board and the controller board has input voltage to it With the printer on verify the following without disconnecting the
112. r des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es 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 ATTENTION Ce symbole indique la pr sence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension sicurezza La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici II produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti 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 ATTENZIONE Questo simbolo indica la presenza di tensione pericolosa nell area del prodotto
113. r shorted Note Resistance measures approximately 400K ohms when cool and 1K ohms hot LVPS HVPS service check FRU Action LVPS portion of board Fuses that open typically indicate a faulty LVPS HVPS Disconnect the power cable and open the LVPS HVPS enough to test the switch The switch will show continuity across the conductors with a meter when the switch is on If the switch is good then see Dead machine service check on page 2 23 for more LVPS HVPS diagnostics HVPS portion of board Problems with the HVPS are exhibited in the print quality See Print quality service checks on page 2 29 for more information 2 24 Service Manual Main motor service check 4513 630 63W 6EW FRU Action A Main motor gear drive Main motor cable LVPS HVPS Controller board Warning Do not replace the operator panel and controller board at the same time Each card contains the printer settings When either of these cards is new it obtains the settings from the other card Settings are lost when both are new and replaced at the same time Turn off the printer and unplug the main motor cable at J17 Turn on the printer and check for the following voltages at J17 J17 pins Voltages Pins 1 4 6 Approx 5 V dc Pins 7 9 18 V dc 24 V dc Verify ground at pin 5 for both the card and cable f these voltages are correct then check the main motor cable fo
114. ramp up transport motor 200 18 Manual feeder sensor never became uncovered from the sheet ahead 200 19 The media never reached the input sensor but was detected at manual feeder sensor 200 20 The media is too long over the manual feeder sensor Possible causes include multi sheet feed media size length problem pre staged media in the tray 200 22 FAILED SMALL GAP OR NO GAP JAM RECOVERY Engine detected small gap or no gap at the manual feeder sensor opened the gap by stopping the feed rolls but never saw the leading edge of the second page at the input sensor 200 23 Laser Servo never started due to potential conflict with the transfer servo Possible causes slow or missing transport motor positional feedback or the media is transferred too quickly to the input sensor Diagnostics information 2 9 4513 630 63W 6EW Paper jam error codes 200 series Continued Error Description 200 24 The measured gap at the input sensor is too small to meet the video delivery requirements There is not enough time since prior image finished to start new image 200 26 The trailing edge never cleared the input sensor when feeding out the media that was detected during warm up 200 27 Printhead Driver Mirror motor fell out of lock condition after the media at the input sensor more time elapsed since the printhead than the expected
115. rature which leads to more of these problems except stacking in plain paper Change settings using the printer driver Use the local printer setup utility included on the CD to change the NVRAM settings Try a different ream of paper Moist media has a higher tendency to crease treeing and curl Parallel or USB port service check 1 RON Perform a print test to make sure the printer prints correctly Verify that the indicator light is on then print the menu settings by selecting Print Menu under Utilities Be sure the printer parallel cable is designed for bidirectional printing Be sure the user s application is set up correctly If the internal print test page prints correctly then the user s application printer driver is set up correctly and the correct bidirectional parallel cable is installed but the printer still fails to print on command from the host computer replace the controller board Check the USB cable for continuity 2 28 Service Manual 4513 630 63W 6EW Print quality service checks Note Ensure the cover closes tightly A gap in the opening may allow light to expose the photoconductor resulting in a dirty print Extreme environmental conditions temperatures and humidity will affect the print quality Using print quality test pages To help isolate print quality problems like streaking print test pages using the print quality test pages To print the print quality test pages
116. rectly loading paper and specialty media in the printer The following hints can help prevent paper jams Use only the recommended print media Do not overload the print media sources Make sure the stack height does not exceed the maximum height indicated by the stack line on the labels in the sources Do not load wrinkled creased damp or curled print media Flex fan and straighten print media before loading it If jams do occur with the print media then try feeding one sheet at a time through the manual feeder Do not mix print media sizes weights or types in the same print media source Push all trays in firmly after loading them Note Make sure the media stack is below the maximum media fill indicators on the 250 sheet tray before pushing the tray into the printer Tools Make sure paper guides are positioned before loading the paper or specialty media Do not remove trays while a job is printing Before loading transparencies fan the stack to prevent sheets from sticking together Do not use envelopes that Have excessive curl Are stuck together Are damaged in any way Contain windows holes perforations cutouts or embossments Have metal clasps string ties or metal folding bars Have postage stamps attached Have any exposed adhesive when the flap is in the sealed position Use only recommended media Refer to the Card Stock amp Label Guide available on the Lexmark Web site at www lexmark c
117. related or envelope related change prompts when they occur Press M to enter Action For Prompts from the Configuration Menu The following displays El Action For Prompts v Prompt user Continue Use Current Press M to select a prompt Submittin Configuration Menu Press Ey to exit the Env Prompts setting at anytime Energy Conserve g Selection displays The screen automatically returns to the This menu controls what values appear on the Power Saver menu If Off is selected in the Energy Conserve menu then the Power Saver can be turned off If On default is set in Energy Conserve then the Power Saver feature cannot be turned off Font Sharpening This menu allows a user to set a text point size value below which the high frequency screens will be used when printing font data For example if this setting s value is 24 then all fonts sized 24 points or less will use the high frequency screens To increase this setting s value by 1 press press Exit Configuration Menu Exit Config Menu 5 To decrease this setting s value by 1 Press M to exit the Configuration menu The printer performs a POR and restarts in normal mode Diagnostic aids 3 5 4513 630 63W 6EW Diagnostics menu Entering Diagnostics menu pomo Turn off the printer Press and hold E and Turn on the printer Release the buttons when the clock displays Available tests The tests dis
118. relative to the location of the old printhead Note Skew is caused by a sheet being fed through the printer while misaligned The entire image is rotated relative to the sheet edges However a mechanically misaligned printhead causes the horizontal lines to appear skewed while the vertical lines remain parallel to the vertical edges There are no adjustments for skew Check the pick roll paper pick assembly for wear the paper path for obstructions the fuser for proper setting and the tray paper guides for fit to the media Paper feed Printhead skew misalignment To adjust the printhead Enter the Diagnostics Menu See Entering Diagnostics menu on page 3 6 Select PRINT TESTS Select Tray 1 Select Single Fold the printed test page on the left side so that a few millimeters of grid lines wrap around the outside of the fold See photo below Fold a second vertical fold near the center so that the left side top edge aligns with the right side top edge o ao Diagnostic aids 3 19 4513 630 63W 6EW 7 If the grid lines of the right flap align below the corresponding lines on the left flap then adjust the printhead clockwise relative to the printer and recheck See the left side of the figure below If the grid lines of the left flap align below the corresponding lines of the right side then adjust the printhead counterclockwise See the right side of the figure below 8
119. removal on page 3 26 Remove the left side cover See Left side cover removal on page 3 24 Remove the right side cover See Right side cover assembly removal on page 3 58 Disconnect the operator panel cable A mpm 6 Remove the cable through the opening 7 Remove the three screws B from the right side of the printer Repair information 4 9 4513 630 63W 6EW 8 Disconnect the fuser link C 9 Remove the three screws D from the left side of the printer D 10 Remove the door mounts 4 10 4513 630 63W 6EW Duplex removal 1 Remove the right side cover See Right side cover assembly removal on page 3 58 2 Remove the LVPS HVPS See LVPS HVPS removal on page 3 28 3 Remove the three screws A from the shield Repair information 4 11 4513 630 63W 6EW 5 Lift the duplex slightly push to the left and tilt to clear the right side of the printer 6 Remove the duplex 4513 630 63W 6EW Duplex main motor gear drive interface removal Remove the LVPS HVPS See LVPS HVPS removal on page 3 28 Remove the duplex See Duplex removal on page 3 11 Remove the main motor gear drive See Main motor gear drive removal on page 3 31 Remove the e clip A from the gear Poh gt A 5 Remove the gear B and gear shaft C Repair information 4 13 4513 630 63W 6EW 6 Remove the screw D from the gear E D E 7 Remove the plast
120. roductos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 7 milivatios en una longitud de onda de 655 a 675 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 Declarac 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 a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe I em conformidade com os requisitos da norma IEC 60825 1 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe IIIb 3b designado laser de arseneto de pot ssio de 7 milliwatts operando numa faixa de comprimento de onda entre 655 e 675 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um nivel de Classe durante a operac o normal a manutenc 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
121. ror 914 01 Lost encoder feedback Transfer service errors 917 00 Transfer service error 917 01 Transfer servo result too low 917 02 Immediate transfer servo indicates that the HVPS requires erase lamps Fuser service errors 920 00 Under temperature during steady state control Diagnostics information 2 15 4513 630 63W 6EW Service error codes 9xx Continued Error Description 920 01 Fuser took too long to heat up after transitioning to new enhanced mode 920 02 Fuser fell too far below desired temperature while printing 920 03 Fuser too cool while checking for slope change 920 04 Fuser too cool when heating to desired temperature after slope change 920 05 Fuser under temperature while printing 920 06 Fuser under temperature while printing 920 20 Belt fuser under temperature during steady state control This can occur in printing or standby modes 921 00 Under temperature during standby control 921 01 Fuser temperature did not reach standby temperature after two attempts 922 00 Fuser failed to ramp to target temperature 922 01 Fuser did not reach standby temperature in time standby control 922 02 Hot roll took too long to reach the beginning lamp detection temperature 922 03 Hot roll reached final lamp detection temperature but took longer than largest time i
122. s L imprimante et son syst me laser sont concus 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 60825 1 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 7mW che opera sulla lunghezza d onda compresa tra 655 e 675 nanometri 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 Notices and safety information vii 4513 630 63W 6EW 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 establecidos 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 60825 1 para productos l ser de Clase I 1 Los p
123. s is a precaution for personal safety and to prevent damage to the printer Use the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer They will lead you to solutions or service checks including use of various tests Symptom tables If your machine completes the Povver On Self Test POST sequence on page 2 1 without an error and you have a symptom then go to Messages and error codes on page 2 5 Locate your symptom and take the appropriate action Service errors 9xx xx s If a service error code appears while you are working on the machine then go to Messages and error codes on page 2 5 and take the indicated action for that error Service error codes are indicated by a three digit error code followed by a period and additional numbers in the format XXX YY In most cases five digits are shown User status and attendance messages User status messages provide the user with information on the current status of the printer Ready displays on the first line of the display unless invoked and then Power Saver displays If a user status message is displayed then go to Messages and error codes on page 2 5 User attendance messages are indicated by a two or three digit error code that provides the user with information that explains a problem with a print cartri
124. s the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F dHHHHE represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 999 999 2 Once the maximum pass count or fail count is reached the test stops the power indicator is turned on solid and the final results display If the test fails then the message DRAM Error displays for approximately three seconds and the failure count increases by 1 3 To stop the test before it completes turn off the printer The test does not terminate Diagnostic aids 3 9 4513 630 63W 6EW Duplex Tests The following tests are used to determine if the duplex is working correctly Quick Test Top Margin Left Margin Sensor Test Duplex Feed 1 Quick Test The Quick Test contains the following information on a duplexed page Print registration settings Alignment diamonds at the top and bottom Horizontal lines to check for skew General printer information including current page count installed memory serial number and code level To print the duplexed Quick Test page 1 Select Quick Test from the DUPLEX TESTS menu 2 Select Single or Continuous by pressing EJ or D 3 Press M to print the page Top Margin 1 Select Top Margin from the DUPLEX TESTS menu 2 To change the margin value press El to increase the value or 5 t
125. se font card assembly 22 2 ame mem ee 7 8 Traditional Chinese font card assembly eee eee eee eee eee 7 8 Japanese font card assembly nn 7 8 Field relocation package assembly eee eee eee 7 7 l 4 Service Manual l Toner Cartridge Smart Chip E460d E460dn Wiring Diagram Dr Blade TAR Developer Toner Patch Sensor OV 5V Main Motor Drive 24V Lea E 5v 5V 7 AAA 5V 5V 5V 5V 20V 5V EE D gt CN203 CN202 CN201 o Le Le de Le Es Le EESSSSSESSSEECEREEEEGESES Photoconductor Rit O Photoconductor El s 3 5 5 e 1s s e ESL E PT Toner Level Sensor TT ES 1213 J501 Operator Panel HB HB J17 1 J502 se With printer off unplug this cable and turn printer back on Check values on the cable pins J26 Ave MPF Sensor MPF Clutch Manual Clutch Solenoid Paper Feed Clutch CEELEN Q J4 J5 Paper In Sensor Duplex Sensor Battery Cover Open Switch CCE EG ES J100 J7 I E a lt Cooli
126. sheet Tray 2 assembly 7 3 Screws miscellaneous eee eee eee ee eee ee ee eee eee eee 7 7 Front mounts tt eee eee 7 7 Optional 250 sheet tray ee eee 7 3 Optional 550 sheet tray c rllll eee eee eee 73 110 V maintenance kit T7 Low voltage 110 V maintenance kit 6 1 220 V maintenance kit 2 2 eee eee eee eee 7 7 High voltage 220 V maintenance kit 6 1 100 V maintenance kit eee eee eee ee eee eee eee ee 6 1 7 7 Tray 2 paper feed tires ee eee 7 7 Paper feed ACM tires TT Media ACM drive assembly TT 256MB flash nina ie de e le ia o o e mI se sie a ds ad cee 7 8 128MB DIMM 222 7 8 256MB DIMM 2 ee eee 7 8 512MB DIMM I llllllllllllllllllllllllllllllllllll 7 8 Bar code and forms 2 25 255 22 Se ss ie se ee ee ee re eee 7 8 Korean KS KSSMIKSP ee ee me ea ee aa ee eee eer err re ee ee eee eee 7 8 Print cryption card assembly 22 2 eee ee eee ee eee eee ee eee 7 8 Korean font card assembly me ee 7 8 Simplified Chine
127. solenoid and clutch actions at the ACM and manual feed shafts as a print job is attempted Replace the faulty part Controller board P U and manual feed solenoid ASM Disconnect the solenoid cable at J26 on the controller board and measure the resistance across cable pins 1 and 2 The resistance should be approximately 70 ohms e f itis not then replace the solenoid f the resistance is approximately 70 ohms then check the controller board Pin 1 at J26 should be 24 V dc See Controller board service check on page 2 21 for more information Replace controller board as necessary Media skews FRU Action Paper feed pick tires tray 1 Paper feed pick tires tray 2 Tray 1 Tray 2 option Check tires for debris If tires are new then try reversing each on its hub Check side guides on Tray 1 and Tray 2 Guides set for a full stack of media may be too wide when the stack is short Diagnostics information 2 27 4513 630 63W 6EW Media trees wrinkles stacks poorly or curls FRU Action Fuser This problem is most likely due to a worn backup roll It causes the printer to run hotter than required for the media being printed Excessive heat can cause media treeing problems poor stacking or curl Print the menu sheet found under Utilities Look at the media settings Some such as card stock or rough texture may require a higher fuser tempe
128. speed or stalled during speed adjustment state 927 05 Main fan overspeed during speed adjustment state 927 06 Main fan capture data is invalid and speed control is at maximum in fan control idle state 927 07 Main fan capture data is invalid and speed control is at maximum in fan control adjustment state Toner sensor errors 929 00 Toner Sensor Error 929 01 No Home Window Usually a mechanical problem with the cartridge 929 02 Up Secor Transition closed Cartridge mechanical problem Sensor unplugged Bad toner sensor Dirty toner 929 03 No Sensor Transition open Cartridge mechanical problem Sensor unplugged Bad toner sensor Printhead service errors 931 00 No first hsync 931 01 No first hsync 932 00 Lost hsyncs 932 01 Lost hsyncs 934 00 Mirror motor lost lock 934 01 Mirror motor lost lock 935 00 No initial mirror motor lock 935 01 Timed out waiting for mirror motor lock 935 10 Printhead sweep error swept through Hz range without finding the resonant frequency 935 11 Printhead sweep error autosweep hw state 935 12 Printhead sweep error coarse sweep state 935 13 Printhead sweep error init fine sweep state 935 14 Printhead sweep error fine sweep state 935 15 Printhead sweep error check prelim amp state 935 16 Printhead sweep error enable amp Kp state 935 17 Printhead sweep error amp Kp failed to c
129. ssembly is installed properly Diagnostics information 2 35 4513 630 63W 6EW Print quality problems Continued Problem Cause action Unexpected characters print or characters are missing Ensure correct printer driver is being used Select hex trace mode to determine what the problem is Restore factory defaults Make sure the parallel cable or USB cable is firmly plugged in at the back of the printer Jobs are not printing and an error message is displayed The printer is waiting for an appropriate command Make sure the print cartridge assembly is installed properly Make sure the printer front cover is closed While in PostScript 3 emulation the printer is flushing data an error message is displayed Ensure the correct PostScript driver is being used The printer doesn t have enough memory to print the job Install more memory Printhead service check FRU Action Turn the printer off Disconnect the printhead cables from J8 and J100 on the controller board A Turn the printer on vvith the front door closed On the controller board verify 5 V dc on pin 10 at J8 and 5 V dc on pins 1 2 and 3 at Printhead J100 Note New printhead must be aligned See Printhead assembly electronic adjustment on page 3 18 Verify grounds on pins 2 4 and 7 at J8 and on pin 4 at J100 If voltages or grounds are incorrect the
130. t side Note Be careful to not mar the finish of the printer 4 Remove the four screws B from the main motor gear drive 5 Rotate the main motor gear drive enough to access the manual feed solenoid Repair information 4 33 4513 630 63W 6EW 6 Use a screwdriver to remove the e clip C from the manual feed clutch Note The picture below shows the E260d E260dn printer The manual feed clutch removal is the same for all models C 7 Remove the manual feed clutch D 4 34 4513 630 63W 6EW Manual feed solenoid removal 1 Remove the left side cover See Left side cover removal on page 3 24 2 Remove the duplex See Duplex removal on page 3 11 3 Open the front access door and place the printer on its right side Note Be careful to not mar the finish of the printer 4 Remove the two screws A Note The picture below shows the E260d E260dn printer The manual feed solenoid removal is the same for E E E all models o ae gt Vo va A 5 Remove the three screws B from the left door mount gt un SS K 1 t a A t A m Repair information 4 35 4513 630 63W 6EW 6 Lift and remove the left door mount C away from the side frame and unroute the cable D with a spring hook 7 Reinstall the left door mount and place the printer on it s top Note Be careful to not mar the finish of the printer 8 Discon
131. t usually is a mechanical problem with the cartridge During development it could also have the wrong chip installed 30 03 No bucket transition out of the lowest bucket If the cartridge has not been refilled then it usually is a mechanical problem with the cartridge During development it could also have the wrong chip installed 30 04 Excessive bucket jump If the cartridge has not been refilled then it usually is a mechanical problem with the cartridge 30 05 Cartridge has been ran way past it s life such that the cartridge has to been totally void of printable toner During development it could also have the wrong chip installed 31 XX Defective cartridge errors 31 01 Cartridge missing Smartchip installed backwards or missing Cable loose on controller board Bad dirty or broken contacts Bad chip Wrong cartridge installed 31 02 Authentication Failure Failed to authenticate the device possible cartridge is from another family or the chip is defective 31 03 ECC Failure Clone or defective device 31 04 Read Failure Intermittent contact with the device cable on system card not seated well gross electrical noise defective device 31 05 Write Failure Intermittent contact with the device cable on system card not seated well gross electrical noise defective device 31 06 SRL Clone device 31 07 Penalty Too many POR CC events have occurred 31 08 Unsupported SC Firmware Clone or defective
132. the Quick test page Quick Test page sample only use actual sheet Lexmark Hd Quick Test Device Information Printer Margin Settings FA 4 In the Registration menu select the right margin setting 5 To determine the margin setting choose the value that is closest to the darkest bar on the center graph of the margin page Add that value to the current right margin setting printed on the left hand side of the margin page The right margin setting will also appear on the operator panel display For example if the right margin setting on the page is 2 and the number that is closest to the darkest line on the graph is 3 2 3 then the right margin setting will be equal to 1 6 Press FJ or E to the desired setting and press FJ 7 Print the Quick Test page again and check that the darkest line in the center graph is equal to zero If it is then check to see if the left top and bottom margins are detected If it is not then repeat step 5 Note The alignment of the left margin positions the black plane to the right or left The alignment of the right margin does not alter the margins and should only be used to adjust the printhead 3 18 Service Manual 4513 630 63W 6EW Printhead assembly mechanical adjustment A printhead needs to be correctly positioned after it has been removed Use a pencil to mark the screw locations of the old printhead on the metal frame Align the new printhead
133. the error log Some of the additional information includes Detailed printer information including model and serial number Time and date stamps Page counts for each error The printed error log can be faxed to Lexmark or your next level of support for verification or diagnosis This report can also be printed from the Configuration Menu Because you can clear error logs the contents of this log may not match the contents when you view the error log To print the error log 1 Press 7 to enter Print Log from the EVENT LOG menu 2 Press Back to exit the EVENT LOG menu Clear Log 1 Select Clear Log from the Error Log menu Clear Log Yes 2 Select No to exit without clearing the log Press Yes to confirm The log is immediately erased and the display indicates No Events Logged 3 Press Return to exit the Clear Log menu after clearing the log Exit Diagnostics Selecting EXIT DIAGNOSTICS exits the Diagnostics menu and Resetting the Printer displays The printer performs a POR and the printer returns to normal mode Diagnostic aids 3 17 4513 630 63W 6EW Printhead assembly electronic adjustment Note Before aligning the printhead electronically first align the printhead mechanically if needed See Printhead assembly mechanical adjustment on page 3 19 1 Enter the Diagnostics menu See Entering Diagnostics menu on page 3 6 2 Press M to enter the Registration menu 3 Press 7 to print
134. tomatically performs the operator panel test This test toggles each pixel in the operator panel through every contrast level beginning with the darkest and ending with the lightest Once the pixels are toggled the backlight of the operator panel comes on and then goes off Non functioning pixels will appear as blank spaces during the test s darker stages Press anytime to cancel the LCD Test Once the test is canceled the display returns to the initial Hardware Tests screen Button Test The Button Test verifies the operation of each button on the operator panel Press FJ to select the Button Test from the HARDDWARE TESTS menu All of the buttons and the backlight illuminate and PANEL TEST Press Count 0 displays Press EJ M or to increase the value of the Press count field by one If the final Press count does not match the total number of buttons that are pressed then one or more buttons are malfunctioning Press to return to the HARDWARE TESTS menu screen DRAM Test The purpose of this test is to check the validity of DRAM both standard and optional The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly To run the SDRAM Memory Test 1 Select DRAM Test from the menu The power indicator blinks indicating the test is in progress DRAM Test XxxMb P BHBHHE F HHHHHE XxxMB represents the amount of installed DRAM memory in MB P HEHEHE represents the number of time
135. ttendance messages Message Action Activating Demo Mode Wait for the message to clear Activating Menu Changes Wait for the message to clear Activating Deactivating PPDS Wait for the message to clear Busy Wait for the message to clear or cancel the print job Cancelling Job Wait for the message to clear Change Cartridge Invalid Refill The printer has detected an unsupported refilled cartridge Remove the indicated print cartridge and install a new one Close door Close the specified door to clear the message Deactivating Demo Mode Wait for the message to clear Defragmenting Flash DO NOT POWER OFF Warning Do not turn the printer off while this message is displayed Wait for the message to clear Disabling Menus Wait for the message to clear Note The printer settings cannot be changed from the control panel while the menus are disabled Enabling Menus Wait for the message to clear Flushing Buffer Wait for the message to clear Formatting Flash DO NOT POWER OFF Warning Do not turn the printer off while this message is displayed Wait for the message to clear Invalid Engine Code Download valid engine code to the printer Invalid Standard Network Code The code in an internal print server is not valid The printer cannot receive and process jobs until valid code is programmed into the internal print server
136. unicating with host See Parallel or USB port service check on page 2 28 Front access door will not close See Cover interlock switch service check on page 2 22 Operator panel button not responding See Operator panel service check on page 2 26 Operator panel lights are off or very dim See Operator panel service check on page 2 26 Blank page See Blank page on page 2 29 Black page See Black page on page 2 30 Heavy background See Heavy background on page 2 30 Light print See Light print on page 2 32 White or black lines or bands See White or black lines or bands on page 2 32 Toner on back of page See Toner on back of page on page 2 32 Media never picks See Media never picks on page 2 27 Media feeds continuously See Media occasionally mispicks or picks multiple sheets at once on page 2 27 Media wrinkled or bent See Media trees wrinkles stacks poorly or curls on page 2 28 Dead machine no power See Dead machine service check on page 2 23 Print quality problems Light print Blurred characters Toner on both sides of media Toner not fused Streaks Blank pages See Solving print quality problems on page 2 33 2 20 Service Manual 4513 630 63W 6EW Service checks A Service checks which involve measuring voltages on the LVPS HVPS low volta
137. uplex removal on page 3 11 3 Disconnect the media feed clutch cable A from the controller board 4 40 4513 630 63W 6EW 5 Remove the e clip B B 6 Remove the media feed clutch with cable C Repair information 4 41 4513 630 63W 6EW Media manual input sensor 1 Remove the right side cover See Right side cover assembly removal on page 3 58 2 Place the machine on its top Note Be careful to not mar the finish of the printer 3 Disconnect the sensor cable A from J23 MPFS on the controller board 5 Free the cable from its retainers and pull it through the opening toward the sensor mount 4 42 4513 630 63W 6EW Re installation note e Prop open the duplex door and insert the hook end of the spring hook through the frame opening C from the controller board side Extend the hook until the sensor connector can be hooked e Hook the spring hook D to the connector E and pull it through the opening C D E Place the sensor into position and reconnect the cable on the controller board Using the spring hook be sure to reroute the cable through the three retainers F between the sensor and side frame F Note If the cable is not properly installed in its retainers then the loose cable will obstruct the paper path Repair information 4 43 4513 630 63W 6EW Warning Check to make sure the duplex paper jam door is in its proper position If it is not t
138. xvi CONVENTIONS ssec nobel do bd lbs ROG PR pd d ibat ERU ee ib RUD ed eut OS OR ee ba ea end dir xvi General information ui a EEXEARTAATERAEASEIE LO PAS TU PREDA AA 1 1 Maipnt nanpe AO Poch Sus REIS iara d e ti QU bdo or ae OD d do bo db EL 1 1 Overview of the operator panel ma cect ce a ee casa mea Pa RR ERR RUN OR eR RR pan RU D iR 1 2 SpPeCiicCalgns caca RED Rie CER ARA AAA Roo od RE et doa 1 3 ee ooa pa iba vd qa bdo inedia dol SO EA d ree SS aaa 1 3 Print quality se aings risas Ved be eres reas as aaa qp d RR 1 3 Connectivity and compatibility ii iuis kx Rad kA sar REX A oa ds le m aa 1 4 M dia trays and supply capacity ee maia aa dr De 828401808 a AR Ae 1 5 TRES OLA media nasa Teer eT id ded ca Edd rack Qus iaa 1 6 Tips on preventing AMS 21a dora peer Sor ER EG Pelea PER eee de Ka S ad e d Dri ode 1 7 Paper path io REA ACA RE uU ACE UR KE RR ARA RR OD COD CR GE RO 1 7 Do err 1 8 Lupin Er A hee A A a dae A A a A eed 1 9 Diagnostics information 00 0 cece teen iaia veies 2 1 Dai ere SR RE PRE CS DE EG a AR Moma A EE ak 2 1 Symp om Tables usan had 2 1 Service emors SKIES o Leg eT v io edi 2 1 User status and attendance messages ea ele 2 1 Overview of the operator panel and MenuUS oooocccoccc eens 2 2 Diagram of the printer MENUS s vsibx aaa rp x Ea ad RE ERA RR d RR amat 2 4 Messages and error COBeS iux bxesbbsi EX Rag EA Eau ER EA AUD Ka SUUS Fac URN Ed

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