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4049-XXX (Optra) Service Manual

1. Repair Information 4 32 4049 XXX Paper Size Switch Removal oP mw c Remove the paper tray Remove the front cover Unplug the cable B from the switch connector C Remove the two screws A Rotate the switch about 90 and pull it out of the printer 4 33 4049 XXX Printhead Removal IMPORTANT The printhead is ESD sensitive It is not serviceable and should be replaced as a unit Turn the printer off Remove the print cartridge Remove the right and top covers Remove the exit redrive and its belt Remove the air plenum Remove the screws A and the pointer Cut and discard the printhead cable clamp Disconnect the connectors Remove the printhead and the printhead shroud Pry off the grip rings holding the printhead to the shroud SONO a Ao Note After you replace the printhead perform the Printhead Skew Adjustment on page 4 9 Repair Information 4 34 4049 XXX RIP Board and Inner EMC Shield Removal 1 2 3 al Turn the printer off Remove the right cover Disconnect all the external connectors from the RIP board or INAs Remove the INA cards or Hard Disk option Remove the four nuts the standoff and the screw Remove the inner EMC shield by pulling straight out from the printer Remove the four nuts and the standoff to separate the RIP board and the inner EMC sh
2. 4 1 AQUSTIMENTS cases tens eme RE ame 4 2 Envelope Restraint Spring On The Envelope Feeder Adjustment 4 2 Paper Restraint Spring On The 100 Sheet Auxiliary Feeder Adjustment 4 2 Envelope Feeder Magnet 100 Sheet Auxiliary Feeder Magnet Adjustment 4 3 Dual Rear Feeder Gear Alignment Adjustment 4 4 Fuser Drive Gear Backlash Adjustment 4 5 Fuser Solenoid 4 7 Paper Feed Magnet Adjustment 4 8 Printhead Skew Adjustment 4 9 Removal 4 10 E AR ia ET E eege 4 10 Right Cover Removal 27 d A pes dede 4 10 Front Cover w22iscteder geiiceeondeceed 4 10 Left Cover Removal 4 12 Cover Removal espessa poor EG e 4 12 14 in 200 Sheet Paper Tray Top Cover 4 14 14 in 500 Sheet Paper Tray Top Cover 4 14 D roll Assembly Removal 4 14 Drive Motor Removal coin 4 14 Engine Board Removal ssa pass Rer RR RR nn 4 15 Exit Sensor Board Removal 4 16 Fan Redrive Removal 4 17 Fuser Removal EE bid 4 18 Fuser Input Guide Removal 4 19 Fuser Lamp Removal dos e dep 4 20 Fuser Sensor Cable Hemoval 4 21
3. mee dee Units Description 14 1 1381643 1 LV Power Supply 110 V 1 1381644 1 LV Power Supply 220 V NS 1328463 1 Fuse LVPS SB 12A 110 V NS 1328464 d Fuse LVPS 6 3A 220 V 3 1342514 1 Power Cord Set U S Canada Mexico Central and South America Saudi Arabia LV 3 1342530 1 Power Cord Set Germany France Spain Norway Finland the Netherlands Austria Belgium Brazil Greece Luxembourg Por tugal Sweden Turkey Indonesia Saudi Arabia HV 3 1342532 1 Power Cord Set S Africa 3 1342533 1 Power Cord Set Switzerland 3 1342534 1 Power Cord Set Chile ltaly 3 1342535 1 Power Cord Set Denmark 3 1342536 1 Power Cord Set New Zealand Australia Argentina Paraguay 3 1342537 1 Power Cord Set Israel 3 1342543 1 Power Cord Set UK Malaysia Singapore 4 1408274 1 Rod on off 4A 1408277 1 Support Rod on off 4B 1408198 1 Actuator On Off 4 1408275 1 Plate Actuator 4D 1408276 1 Lever Pivot 4E 1408272 1 Latch On Off 4F 1 Spring PP 1381666 5 1381645 1 HV Power Supply with Cable 5A 1381653 1 Cable HVPS 6 1381853 1 RIP Board Lx Rx Lx 6 1381854 1 RIP Board R Rt L R Rt NS 69G3072 1 Jumper Engine Board Rt J16 NS 1408063 1 Cable Erase Lamps Input Sensor Parts Catalog 7 33 4049 XXX Assembly 14 Electronics Continued 7 34 4049 XXX oM Ger Units Description 14 7 1381792 1 Engine Board R L Rt 7 1381796 1 Engine Board Lx Rx R Rt
4. Rear View Paper Restraint Spring On The 100 Sheet Auxiliary Feeder Adjustment 1 Loosen the mounting screw A 2 Position the spring B so it clears the separator roller by 1 0 0 2 mm 0 040 0 008 in 3 Tighten the mounting screw A 1 0 0 2mm 0 040 0 008in Rear View Repair Information 4 2 4049 XXX Envelope Feeder Magnet And 100 Sheet Auxiliary Feeder Magnet Adjustment 1 Hold the armature A in the closed coil active position 2 Loosen the mounting screw B and rotate the magnet assem bly so the armature clears the clutch gear by 0 30 0 20 mm 0 012 0 008 in 3 Tighten the screw 4 Check the adjustment on both sides of the gear 4 3 4049 XXX Dual Rear Feeder Gear Alignment Adjustment Remove the right side cover of the feeder The gear timing marks should be centered in the windows of the gear plate If the timing mark is too far clockwise the gears will chatter during a POR If the mark is too far counterclockwise extra sheets may feed at random times or paper may feed continuously after the first page is fed To adjust Remove the mounting screw at the front of the torquer Loosen the mounting screw at the rear of the torquer Pivot the torquer up to disengage it from the gear Turn the torquer to its detented position Position the gear so the timing mark A is centered in the
5. 4049 XXX Removal Procedures When there is artwork to support a procedure it follows the text Covers Right Cover Removal Es eu rm Turn the printer off Remove all external trays Open the top cover Depress the latch and open the right cover Remove the E clip from the rear pivot pin and lift the cover off the rear pivot pin Front Cover Removal ON o Unplug the power cord Remove the paper tray Open the top cover Open the right cover Release the latches B You can reach the lower latches through the paper tray opening Lift the right side of the cover to disengage the latch D Slide the cover to the right to disengage the bracket from the posts Pull the front cover forward and disconnect the ground strap from the frame on the left side Repair Information 4 10 4049 XXX 4 11 4049 XXX Left Cover Removal Unplug the power cord Open the top cover and remove the print cartridge Remove the front cover Locate the latch E and lift the end to release it Push the top of the cover to the left Remove the cover by sliding it to the rear of the machine PELA rs Top Cover Removal L Lx and Lx Remove stacker plate by pulling upward Remove the top cover screws C Lift the rear of the cover first then the front and lift the cover off Rest the cover on the machine and disconnect the operator panel cable Rom Repair In
6. Medium Plastic 4X Nut with Standoff Captive Star Washer gt 5X Nut with ES Captive Star Washer Male Female Standoff without Groove Female Female Standoff with Groove Mirror Motor Fan Cable Mirror Motor Fan Cable Connections Motor Fan J2 1 1 J2 2 J2 3 J2 5 2 3 J2 4 4 5 6 J2 6 J2 7 2 J2 8 1 Connector Locations 5 7 4049 XXX Operator Panel Output Bin Sensor Cable Op Panel Cable Connector Pin 1 5 8 4049 XXX Operator Panel Output Bin Sensor Cable Connectors Pin Op Panel Sensor L Lx Lx J1 1 1 J1 2 2 J1 3 3 J1 4 4 1 5 5 J1 6 1 J1 7 2 J1 8 3 J1 9 No connection The same cable is sometimes used on the Optra R R and Rx but the output bin sensor leads are not used Connector Locations 5 9 4049 XXX Printhead Connector Locations Pin 1 7 Print Head a Cable Mirror Motor Cable Mirror Motor Connector Duplex Autoconnect Cable Duplex Autoconnect Cable Connectors Engine Board Autoconnect J3 1 No connection J3 2 1 right most pin J3 3 2 J3 4 3 J3 5 4 J3 6 5 J3 7 6 5 10 4049 XXX Printer Ground Straps Operator Panel to Upper Frame Load Box Shaft to Upper Frame Outer Deflector to Lower Frame HVPS to Frame Static Brush to
7. Abbreviations ASIC CSU DRAM EEPROM EP ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR VDC Application Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Electrically Erasable Programmable Read Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Local Area Network Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power On Reset Power On Self Test Print Quality Enhancement Technology Raster Image Processor Read Only Storage Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current General Information 1 4 4049 XXX 2 Diagnostic Information Start Remove power from the printer before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Two digit codes are messages for the user but if they recur fre quently or at inappropriate times they may be symptomatic of a ser vice problem Use the service error code symptom table service checks and diagnostic aids to determine the corrective action necessary to repair a malfunctioning printer 2 1 4049
8. 1 Paper Feed Motor DC 15 1326113 1 Switch Asm Cover Open 16 1381570 1 Switch Asm Front Exit 17 1408969 1 Cover Corner Trim 18 1408942 1 Cover Auto connect Plug 19 1326064 1 Belt Paper Drive 20 1381803 1 Tray Asm 300 w Top Cover L Lx 20 1364882 1 Tray Asm 130 w Top Cover R Rx Rt 21 1408888 1 Paper Stop 300 Tray 21 1408880 1 Paper Stop 130 Tray 22 1381560 1 Top Cover Paper Tray 23 1038708 1 Belt Paper Tray 24 1408883 1 Down Stop 130 Tray 24 1408887 1 Down Stop 300 Tray 25 1408879 1 Guide Edge 130 Tray NS 1381561 1 Gear Parts Pack NS 1381048 1 Flag Parts Pack Parts Catalog 7 39 4049 XXX Assembly 17 Envelope and 100 Sheet Auxiliary Feeder 4049 XXX s geben Units Description 17 1408893 1 Envelope Feeder 1364895 1 100 Sheet Auxiliary Feeder 1 1408862 1 Weight Assembly 2 1622529 1 Screw 3 1039615 1 Spring 4 1383944 1 Magnet Assembly 5 1622303 1 Washer 6 1622536 1 Screw Mtg 7 1408869 1 Cover Right 8 1408868 1 Guide Large 8A 1408861 1 Latch Guide 9 1408863 1 Guide Small 10 1183273 1 Spring Override Lever 100 Sheet Auxil iary Feeder Only NS 1383934 1 Roller Pack Envelope Feeder Only NS 1383935 1 On Pack 100 Sheet Auxiliary Feeder Parts Catalog 7 41 4049 XXX Dual Rear Feeder Assembly 18 7 42 4049 XXX dE Units Description 18 1381799 1 D
9. Service Manual Lexmark is a trademark of Lexmark International Inc registered in the United States and or other countries 4049 XXX Third Edition November 1996 The following paragraph does not apply to the United Kingdom or 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 of the publication Improvements or changes in the products or the programs described in this publication may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase Comments may be addressed to Lexmark International Inc D22A 035 3 740 New Circle Road NW Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you Lexmark is a trademark of Lexmark International Inc registered in th
10. Description 6 1 1427307 1 Bellcrank Metering E 1 o Shaft 1 o Bellcrank 1 o Roll 1 o Thrust Washer 2 1381145 1 Kit Prealigner and Auxiliary Rollers 3 1039278 1 Gear Idler Prealigner 4 1 Spring Prealigner and Metering Bellcranks Parts Packet 1381666 5 1328384 1 Bellcrank Prealigner 1 o Shaft 1 o Roll S 1 o Bellcrank S 1 o Thrust washer N S 1383580 1 Anchor Repair Kit Metering N S 1383908 1 Anchor Repair Kit Prealigner Parts Catalog 7 15 4049 XXX Assembly 7 Paper Feed Drive 7 16 4049 XXX ae RE Units Description Note Machine may have either torquer motor items 9 10 and 11 or paper pick solenoid items 12 13 14 and 15 7 1 6995480 1 D Roller Asm 2 1328279 1 Washer Thrust 3 1 Clip D roll Parts Packet 1381663 4 1408703 1 Rail Assembly Right w o gears 4 1381801 1 Rail Asm Right with Gears and Paper Pick Solenoid 5 1328313 1 Shield D Roll 6 1328454 1 Shaft D Roll with Gear 11 Solenoid 6 1381726 1 Shaft D Roll with Gear 11 Torquer Motor 8 1381886 1 Gear Kit 9 1381306 1 Torquer Motor 10 1408243 1 Adapter Torquer Motor 11 1 Screw Parts Packet 1381663 12 1 Spring Gear Advance Parts Packet 1383316 13 1383433 1 Solenoid Paper Pick 14 1 Spring Magnet Arm Parts Packet 1383316 15 1 Screw amp washer Parts Packet 1383314 16 1381881 1 Gear 9 Solenoid 22 1039170 1 Machine Pad Parts Catalog 7 17 4049
11. High Capacity Feeder Paper Feed Rollers 4 45 High Capacity Feeder 4 47 Connector Locations 5 1 Major Assembly Locations 5 1 ical cic aue dae d acia 5 2 ek ci cepi ae Mid Ede 5 3 Transfer Roller HOUSING 5 3 Engine Board Connectors 5 4 RIP BOs prata pias oka EE Ud 5 6 Board Installation 5 7 Mirror Motor Fan Cable 5 7 Operator Panel Output Bin Sensor Cable 5 8 Printhead Connector Locations 5 10 Duplex Autoconnect Cable 5 10 Printer Ground Sapo ius a deco dre dc pancada 5 11 High Capacity Feeder Board Connectors 5 12 vii 4049 XXX Preventive Maintenance 6 1 Safety Inspection 6 1 Lubrication Specifications casas ns aem kac md 6 1 Scheduled Mechanical Maintenance 6 3 Printhead Window Cleaning Procedure 6 4 Cleaning The Transfer 6 4 Parts Catalog saciar b dada dd pare dera 7 1 How To Use This Parts Catalog 7 1 son cirios id mid 7 2 Lower oid dore PEG e IRE eA PR Edd 7 4 UPS LECH 7 6 alio sagas M sa ee dn eon 7 8 eege EE 7 10 Paper Feed Alignment Ge
12. J13 5 to J13 4 24 VDC J13 6 to J13 4 24 VDC Run the Print Test with the RIP Board removed Make the following voltage checks while printing and again while idling If the voltages are not correct replace the engine board Voltage while Voltage while Connector Printing Idling J13 1 to J13 4 4 5 VDC 0 VDC J13 2 to J13 4 4 VDC 0 VDC If no other trouble is found replace the HVPS Blank Page Inspect the printhead shutter for proper operation and make sure the actuator on top of the cartridge is present and extends into the print head shroud when the printer top cover is closed A failed printhead will cause a 931 Service error rather than blank output Check the continuity of the HVPS cable The HVPS and transfer roll contacts should be clean and spring back when pressed Make sure the transfer roll contact under the left bearing is making contact with the HVPS Diagnostic Information 2 14 4049 XXX Run the Print Test with the RIP Board removed Make the following voltage checks Connector Voltage while Voltage while Printing Idling J13 1 to J13 4 Less than 5 0 VDC VDC J13 2 to J13 4 Less than 5 0 VDC VDC J13 3 to J13 4 Fluctuates 0 VDC between pages 1 5 VDC J13 8 to J13 4 Less than 1 6 VDC VDC If the voltages are not correct replace the engine board Blurred or Fuzzy Print This can be caused by a damaged gear train or by paper slippage in the feed roll or t
13. Loosen screw A 2 Remove the rubber washer 3 Rotate shaft eccentric to obtain 4 2 mm 0 2 mm 0 165 in 0 008 in air gap 4 Tighten screw A Replace the rubber washer e Screw A E eg o 4 7 4049 XXX Paper Feed Magnet Adjustment 1 2 oos Remove the system board The magnet is accessed through the holes in the right frame With the armature latched on the cam step check for 0 60 mm 0 07 mm 0 024 in 0 003 in between the foam pad and the magnet pole piece If adjustment is required continue Keep the armature latched and loosen the magnet mounting screw A Insert the feeler gauge Rotate the magnet against the feeler gauge Tighten the mounting screw The gauge should pass between the foam pad and the magnet pole piece with moderate resistance Repair Information 4 8 4049 XXX Printhead Skew Adjustment 4 9 1 ao R Rt and Rx Remove the plug in the top cover L Lx and Lx Open the paper exit stop Unlatch and remove the spring loaded exit stacker Loosen the screws A Run Print Test 1 or the Quick Test on the Diagnostics Menu Move the pointer B to eliminate the skew Moving the pointer toward the left raises the left adjustment point on the printout Each mark is equivalent to one dot of the skew adjustment points Tighten the screws and verify the adjustment Skew Adjustment Points
14. damping 1 oz 3 9900692 1 Grease IBM 23 1280443 1 Oil IBM 10 4 oz 1381561 1 Duplex Gears parts packet 1381048 1 Duplex Flags parts packet 1381669 1 Jumpers Flags parts packet 1381664 1 Standoffs parts packet 1381661 1 Indicator parts packet 200 sheet tray 1383314 1 Thumbscrew parallel cable Parts Catalog 7 47 4049 XXX Index Numerics 100 sheet auxiliary feeder magnet adjustment 4 3 paper feed problem 2 26 2 27 paper restraint spring adjustment 4 2 paris assembly 7 40 7 42 200 sheet paper tray top cover removal 4 14 500 sheet paper drawer parts assembly 7 24 7 26 500 sheet paper tray parts assembly 7 20 top cover removal 4 14 500 sheet second tray paper feed problem 2 23 A abbreviations 1 4 Adjustment 4 4 adjustment 4 2 100 sheet auxiliary feeder magnet 4 3 envelope restraint spring 4 2 Envelope Feeder magnet 4 3 fuser drive gear backlash 4 5 fuser solenoid 4 7 paper restraint spring 4 2 printhead skew 4 9 auto clean 3 3 auto clean delay 3 4 auto clean frequency 3 3 X 1 Service Manual B background 2 12 banding 2 12 black page 2 13 blank page 2 14 blurred or fuzzy print 2 15 button test 3 4 charge roll 3 4 connector locations 5 1 connectors duplex option autoconnect cable 5 10 engine board 5 4 geartrain 5 2 high capacity feeder board 5 12 HVPS 5 3 mirror motor fan cable 5 7 operator panel output bin sensor cable 5 8 printer ground str
15. screen is displayed when you POR the printer with the duplex unit installed This means the duplex unit and the printer are communicating and thus the printer engine board duplex unit sys tem board and the cables between them are all good If the duplex unit does not home immediately but homes after 5 or 6 seconds the duplex unit is receiving 34 VDC from the printer but is not communicating with the printer The duplex unit homes on its own as a signal that it is functional If the duplex unit does not home at all it is either damaged or is not receiving 34 VDC from the printer To check the connection from the printer engine board to the duplex system board remove the printer RIP Board Remove the duplex top cover and table cover and reinstall the duplex unit Engine board J3 2 should have continuity with the duplex system board J5 1 J3 3 with J5 2 and so on With power on you should have the following voltages Connector Voltage to Ground Engine Board J3 3 34 VDC J3 5 5 VDC J3 7 5 VDC Duplex System J5 2 34 VDC Board J5 4 5 VDC J5 6 45 VDC Diagnostic Information 2 16 4049 XXX If you do not find a cable or voltage problem replace the duplex sys tem board If this does not fix the problem replace the printer engine board A 993 error indicates that communication between the printer and duplex unit had been established but has been lost Check the cable as above if the error persists replace
16. 1 Enter Diagnostics mode Select PRINT TESTS Select Print Test 1 Select Single or Continuous Select CANCEL to stop continuous print Press Return to return to the Diagnostics mode main menu E ON Print Test 2 Print Test 2 generates two printouts a page similar to the test page and a fine dot pattern which can be used to evaluate banding or other print quality problems Print Test 2 will duplex if the duplex option is installed This test prints from the user selected default paper source if the default source is a tray or from Tray 1 if the default source is a feeder You can change the default source by selecting Paper Source in the Paper Menu After running the test reset the default source to the customer s selection To run Print Test 2 Enter Diagnostics mode Select PRINT TESTS Select Print Test 2 Select Single or Continuous Select Cancel to stop continuous print Press Return to return to the Diagnostic mode main menu 3 13 4049 XXX Print Test 3 This test generates 2 printouts a solid black page and a dot pattern that can be used to evaluate print quality Print Test 3 will not duplex This test prints from the user selected default paper source if the default source is a tray or from Tray 1 if the default source is a feeder You can change the default source by selecting Paper Source in the Paper Menu After running the
17. 4049 XXX LVPS Cover Removal Form tabs D away from the power supply to create clearance for tabs A to move downward 2 Release the top latches A 3 Release the side latches 1 4 Release the bottom latches Repair Information 4 30 4049 XXX Operator Panel Removal 1 2 3 Remove the top cover Disconnect the operator panel cable Remove the operator panel mounting screws from the inside of the top cover Paper Feed Rollers Removal Note Replace all paper feed drive rollers at the same time 4 31 Remove the lower frame Disconnect the cable from the input sensor Remove the screws A and the outer deflector Remove the screws B and the toner shield E Separate the side frames Pull the guides C out of the side frames Use a flat blade tool to snap the gears and rollers D off the shaft 00 Right Front View 4049 XXX Paper Feed Magnet Assembly Removal Remove the print cartridge Remove the right cover Remove the RIP board and engine board Remove the LVPS Locate the paper feed magnet mounting screw B visible through the right side frame A Remove the mounting screw B Remove the paper feed magnet assembly from the rear slip the connector under the right frame OO P Go N O After you replace the magnet make the Paper Feed Magnet Adjust ment on page 4 8
18. Laser Notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and else where is certified as a Class laser product conforming to the requirements of IEC 825 Class laser products are not considered to be hazardous The printer contains internally a Class 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition INVISIBLE LASER RADIATION WHEN OPEN AVOID EXPOSURE TO BEAM RADIATION LASER INVISIBLE EVITER L EXPOSITION AU RAYON LORS DE L OUVERTURE UNSICHTBARE LASERSTRAHLUNG WENN ABDECKUNG GEOFFNET NICHT DEM STRAHL AUSSETZEN VOORZICHTIG ONZICHTBARE LASERSTRALING BIJ GEOPENDE KAP VERMIJD BLOOTSTELLING AAN STRAAL ATTENZIONE RADIAZIONI LASER INVISIBILI EVITARE L ESPOSIZIONE DIRETTA QUANDO SI APRE LA STAMPANTE AVISO RADIACION LASER INVISIBLE CUANDO ESTE ABIERTA EVITE LA EXPOSICION A LA RADIACION CUIDADO RADIA O LASER INVIS VEL QUANDO ABRIR EVITE EXPOSI O AOS RAIOS VARO AVATTAESSA OLET ALTTIINA LASERSATEILYLLE ALA KATSO S TEESEEN VARNING OSYNLIG LASERSTRALNING NAR DENNA DEL AR OPPNAD STRALEN AR FARLIG ADVARSEL USYNLIG LASERSTRALING DEKSEL PNES U
19. Lx 9 1364877 1 DRAM SIMM 4MB Rx L Lx 9 1364921 1 DRAM SIMM 2MB R Rt 9 1364876 1 DRAM SIMM 8MB Lxi 11 1381651 1 Inner EMC Shield R Rt L Lx Rx 11 1381848 1 Inner EMC Shield R Rt Lx NS 1381664 1 Standoff Kit Board Mounting 13 1408106 1 Guide Font Card NS 2 Screw HVPS Mtg Parts Packet 1381663 18 2 Screw LVPS Mtg Parts Packet 1381663 19 1383513 1 Switch On Off 20 1039456 1 Switch Pivot 21 1381840 1 ROM SIMM R Rt L Lx Rx 21 1381872 1 ROM SIMM Lx R Rt Parts Catalog 7 35 4049 XXX Assembly 15 Transfer Roll 7 36 4049 XXX NE a Units Description 15 1381922 1 Transfer Roll Asm complete 15 1 1381008 1 Roll Asm Transfer With Right Bearing 2 1381652 1 Housing Transfer 1 o Rear Lens Asm Erase 1 o Contact Transfer Roll 1 o Lamp Asm Erase 3 1328356 1 Cover Clip Bearing NS 1381923 1 Erase Lamp Asm w lens Parts Catalog 7 37 4049 XXX Assembly 16 Duplex Option 7 38 4049 XXX s Ger Units Description 16 1 1381551 1 Top Cover Asm 2 1381552 1 Duplex System Card 3 1381554 1 Bottom Cover 4 1408940 1 Exit Sensor Cover 5 1381555 1 Exit Sensor Asm 6 1381602 1 Bellcrank Kit 7 1408905 1 Table Cover Floor 8 1408949 1 Paper Stop Slide 9 1381558 1 Gear Block Frame Asm 10 1381559 1 Input Sensor Card 12 1326042 1 Cable Stepper Motor 13 1408918 1 Cable Sensor and Autoconnect 14 1381025
20. Ohms If the magnet is good reconnect the cable and monitor the voltage between the two pins of the connector while running the Envelope Feed test if the voltage does not increase momentarily as the magnet is picked replace the engine board Check the adjustment of the feeder magnet If paper is being bent or double fed check the adjustment of the feeder restraint spring Paper Feed Problem 200 Sheet Second Drawer Rt Run the Paper Feed Test and select Tray 2 If Tray 2 is not on the Paper Feed Test menu make sure the jumper at J16 on the engine board is in place and that Tray 2 is properly connected at J17 on the engine board If paper is not being picked check for 34 VDC at J17 1 and J17 2 on the engine board Test the torquer by shorting J17 1 to J17 4 the Diagnostic Information 2 26 4049 XXX torquer moves slightly and makes a noise With the power off there should be 88 ohms between J17 1 and J17 2 and neither should have continuity to ground Remove the module and inspect the tray the D roll and the gear train Make sure the gear train is meshing with the drive gear at the bottom of the printer Check all mechanical areas and electrical con nections The Print Test with the RIP Board Removed can be run from the sec ond tray by disconnecting J14 and shorting J14 2 to J17 1 Paper Feed Problem Dual Rear Feeder Run the diagnostics Paper Feed for Feeder 1 and Feeder 2 Machine Level Information Early level p
21. XXX Assembly 8 Standard Paper Tray 200 Sheet 7 18 4049 XXX a LN Units Description 8 1364894 1 Paper Tray Assembly 11 in 200 sheet 1364893 1 Paper Tray Assembly 14 in 200 sheet gt 1364892 1 Paper Tray Assembly for Labels 11 in 200 sheet 1364890 1 Paper Tray Assembly for Labels 14 in 200 sheet E 1364891 1 Paper Tray Assembly A5 1 1408170 1 Cover 14 in 2 1408725 1 Paper Stop 3 1381577 1 Corner Buckler 4 1408732 1 Liner 11 in 4 1408733 1 Liner 14 in 5 1408724 1 Adjustable Guide 6 1058486 1 Universal Paper Tray 6A 1058488 1 Guide Universal Paper Tray 7 1381661 1 Kit Paper Level Indicator Parts Catalog 7 19 4049 XXX Assembly 9 Paper Tray 500 Sheet 7 20 4049 XXX E T o Units Description 9 1381813 1 E Tray Assembly Std 450g Spring in 1381814 1 Paper Tray Assembly Std 450g Spring 14 in 1381816 1 Paper Tray Assembly Light Weight Labels 550g spring 11 in S 1381815 1 Paper Tray Assembly Light Weight Labels 5500 spring 14 in s 1381807 1 Paper Tray Assembly Heavy Weight Labels 650g spring 11 in 1381808 1 Paper Tray Assembly Heavy Weight Labels 650g spring 14 in 1381809 1 Paper Tray Assembly Super Heavy Weight Labels 7509 spring 11 in 1 1408361 1 Bottom Cover 11 in 1 1408362 1 Bottom Cover 14 in 2 1381660 1 Cover Front Trim 11 in 2 1408369 1 Cover Front Trim 14
22. XXX Refer to the diagnostics Error log for the last six machine errors Error Code Explanation 20 Paper Jam The input sensor was not unmade in time 21 Paper Jam The exit sensor was not made in time after the input sensor was made 22 Paper Jam The exit sensor was not unmade in time 23 Paper Jam Jam at the duplex unit Paper is either not leaving the duplex entry sensor in time or not making or unmaking the duplex exit sensor in time See Duplex on page 2 16 24 Short Paper The defined paper size is too short to print data as formatted 25 Incorrect Manual Feed Input sensor made at wrong time May be due to the paper feeding manually while motors running and previous page in path 26 Duplex Tray Missing Duplex unit is installed but paper tray is not sensed 27 Change Envelope Paper Envelopes paper loaded are wrong size 28 Load Envelope Paper Input sensor not made after pick attempt Tray is empty or not installed paper jam in entry throat or printer is requesting a manual feed 29 Output Bin Full The output bin sensor has not been unmade See Output Bin Sensor on page 2 22 Diagnostic Information 2 2 4049 XXX Error Code Explanation 30 Top Cover Open or Print Cartridge Missing Make sure the spring mounted pin on the printhead shroud is installed properly and that itis detected by the ramp on the print cartridge as the cover closes The
23. adapter box J5 8 and J5 10 are 34 VDC J5 1 is O VDC and J10 1 and J10 2 are 34 VDC For all machines if the J5 10 and J10 1 voltages are incorrect replace the engine board If the other voltages are wrong continue with this service check To test the torquers short J5 1 Feeder 1 or the J5 8 test point Feeder 2 to ground the torquer rotates slightly and makes a noise Turn the power off and disconnect the feeder connector There should be 88 10 ohms between pins 1 and 10 and between pins 8 and 10 Reconnect the feeder and make sure neither J5 1 nor the J5 8 test point nor the J5 10 test point has continuity to ground Skews or Jams Check for worn dirty or damaged rolls gears or envelope bucklers obstructions in the paper path correct paper envelopes properly installed edge guides and flip doors properly positioned and paper load shafts installed parallel to the frame Gear chatter or continuous paper feed Remove the right cover and verify that the gear alignment marks are centered in the win dows of the gear plate when the torquer is in its detent position Refer to Dual Rear Feeder Gear Alignment Adjustment on page 4 4 Continuous feed may also be caused by a short to ground of J5 1 Feeder 1 or J5 8 Feeder 2 Diagnostic Information 2 28 4049 XXX Paper Feed Problem High Capacity Feeder The paper feed rollers should be replaced every 200 000 prints or whenever feeding becomes unreliable Clean rol
24. 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 825 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i b lgelengdeomr det 770 795 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 xiv Service Manual 4049 XXX Av s sobre el Laser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits dIEC 825 Els productes l ser de classe no es consideren perillosos Aquesta impressora cont un laser de classe 1110 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de m
25. ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the 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 you are not work ing on the machine and do not put unprotected ESD sensitive parts on a table f possible keep all ESD sensitive parts in a grounded metal cabinet case Beextra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity 4049 XXX Adjustments Envelope Restraint Spring On The Envelope Feeder Adjustment 1 Loosen the mounting screw A 2 Position the spring B so it clears the separator roller by 1 9 0 2 mm 0 075 0 008 in 3 Tighten the mounting screw B A 1 9 0 2mm 0 075 0 008in
26. is displayed Otherwise Closed is displayed Press Return to return to the Diagnostics mode main menu Top Margin and Duplex Quick Tests The Top Margin and Duplex Quick Test are used together to adjust the duplex front to back registration Make sure the non duplex page registration is correct before adjusting the duplex top margin 5 1 Enter Diagnostics mode 2 Select DUPLEX TESTS 3 4 Select or to raise or lower the back image 0 01 inches per Select Top Margin increment Press Return to return to the Diagnostics mode main menu The Duplex Quick Test is used to verify the Duplex Top Margin 1 Enter Diagnostics mode 2 3 Select Duplex Quick Test 4 Select DUPLEX TESTS Press Return to return to the Diagnostics mode main menu There is some variation in the image position from sheet to sheet Print three or four test pages at each setting 3 15 4049 XXX Transfer This setting varies the transfer voltage offset slightly In normal envi ronments it does not result in a visible difference in the printout In extreme environments with unusual papers this setting may be helpful Do not change this setting unless replacing the transfer roll assembly did not correct the problem Enter Diagnostics mode Select PRINTER SETUP Select Transfer Select Low Medium or High Press Return to return to the Diagnostics mode main menu CONN Wrap Tests The Wrap T
27. lift up Release latch D and lift the table cover out of the front assem bly 4049 XXX Duplex Option Exit Card And Cover Removal Pry up on tabs A After the tabs are released lift up on the 1 cover rotate the cover out and slide it to the right to completely remove it 2 Disconnect the exit sensor card cables 3 Press the exit sensor flag actuator B and lift out the exit sensor card Repair Information 4 40 4049 XXX Duplex Option Bottom Cover And Entry Sensor Card Removal 1 Remove the duplex unit top cover 2 Remove the exit card cover and exit card 3 4 Pry up on the blind connector to remove it from the bottom Pry off the cover for the blind connector cover Release the two latches A on the frame assembly and lift it out of the bottom cover Pry up the entry sensor card at B so it will clear the mounting stud and pull it out of the frame assembly Note When re installing the sensor lift up the flags so they will clear the sensor and not be damaged 4 41 4049 XXX Duplex Option System Card And Motor Removal Disconnect all cables Release latches A and lift the system board out Remove the two motor mounting screws Lift the motor out of the frame assembly Note Reinstall the motor so the belt is not tight but will not jump teeth on the timing pulley Note The remaining FRU is the Gearblock Assembly When yo
28. no slippage in the paper path Make sure the paper tray top cover is not damaged Cold paper curl can also cause jams here see Fuser Temperature And Warm Up Time on page 3 8 2 25 4049 XXX If paper is jamming at the front exit of the printer inspect the duplex exit selector switch and the linkage to the printer exit deflector Check the switch by removing the duplex top cover and table cover and reinstalling the duplex unit in the printer Check for 5 VDC at duplex system board J15 10 The voltage will change from O VDC to 5 VDC as the selector lever is moved Also see 23 Paper Jams on page 2 17 Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Check for the following paper or envelope jammed in the feed path missing hold down weight adjustable guide out of position feeder cable loose disconnected or plugged in the wrong connector feeder incorrectly installed worn or damaged rollers or gears warped or damaged envelopes used envelopes improperly installed envelope flaps must rest against the paper edge guide envelopes other than 20 or 24 pound used in the Envelope Feeder paper other than 20 or 24 pound used in the 100 sheet auxiliary feeder envelopes interleaved with paper Run the diagnostics Envelope Feed test and make sure the feed magnet is being energized If not check the resistance of the mag net at J10 1 to J10 2 on the feeder cable the resistance should be from 105 Ohms to 155
29. no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients SUL Lexmark FFARR Di kr dert ALE EY LET BE A BES T XI EA RE RSE EH Lexmark BEA fasi Acre d EH LARS A REHA SEAT ARE He ARP in ERR ROI TEAS Ha SEIT fs Er lt A BIRKS A RMX AAA Pr T fi FRU HUT UM Notices and Safety Information xxi 4049 XXX re ASE SS Lexmark 74 24 10 AA St 25H ES BPRS SA BA E Seus Sp OHMS SHA Suc Lexmarko CHE wal FEL ALgol St HAS XA geit ALSO TA EF ASME Me 7 8XHgOz EME dons ol Neste APRES REC E MES HAS Bula AS Mae sag BAL AMS elg 1910 AS MBA EXE o AMS Salta ESB ad TAB ASE SIMA xxii Service Manual 4049 XXX Preface This manual is divided into the following chapters General Information contains a general description of the printer available options and the maintenance approach used to repair it Special tools and test equipment are listed in this chapter Diagnostic Information contains error code table symptom table and service checks used to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to l
30. not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemi cally attack polycarbonate parts Use IBM no 10 oil p n 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Reno lin MR30 to lubricate the areas of contact between Gear no 2 and its stud on the side plate Gear no 3 and its stud on the motor bracket Gear no 4 and its thrust washer Gear no 4 and its stud on the motor bracket Gear no 5 and its stud on the motor bracket Preventive Maintenance 6 1 4049 XXX Gear no 6 and its stud on the motor bracket Gear no 6 and its thrust washer Gear no 7 and its stud on the rail Gear no 7 and its thrust washer Gear no 8 and its stud on the rail Gear no 8 and its thrust washer Gear no 9 and its stud on the rail The metering roller shaft and its bushings on the rail assembly The main metering backup roller and its stud and thrust washer The D roller shaft and its bushings on the rail assembly The auxiliary metering roller and its stud on the rail including the snap in groove and the snap ridges in the roller hole Gear no 14 and its stud on the rail Gear no 13 and its stud on the rail The auxiliary paper feed idler and its stud on the rail The prealigner drive idler and its stud on the rail The prealigner drive roller and its stud on the rail The prealigner backup roller and its shaft and thrust washer The fix
31. that the motors sensors printhead and electrophotographic process are working correctly In this mode the operator panel has minimal func tion service codes are not displayed and most error handling is dis abled during normal operation these functions are handled by the RIP board Remove the RIP board and the inner EMC shield together and power on the printer The operator panel has one button active which starts and stops the print test The test consists of horizontal lines spaced about an inch apart down the page This is a continuous print test to print a single page press the start button twice Diagnostic Aids 3 18 4049 XXX 4 Repair Information This chapter explains how to make adjustments to the printer and how to remove defective FRUS Handling ESD Sensitive Parts 4 1 Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive paris follow the instructions below in addition to all the usual pre cautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Putthe ESD wrist strap on your wrist Connect the wrist band to the system
32. the ventilation slots and through the sheet of paper fed in under the slot 8 Open the cover and remove the sheet of paper 9 Measure the distance from the mark on the paper to the trailing edge of the paper If the mark or hole is more than 85 mm from the trailing edge there is a paper slipping problem with the duplex unit paper feed Duplex Feed 2 Test This test verifies that paper feeds through the duplex unit properly and tests the stop point of the page as it feeds back over the top of the duplex paper tray Enter Diagnostics mode Select DUPLEX TESTS Select Duplex Feed 2 Select Tray 1 or Tray 2 te Note Paper feeds all the way into the duplex unit and then feeds out and stops on top of the paper tray 5 The message Clear Paper appears on the display Open the printer top cover 7 lfyou are doing the test with legal size paper open the top cover of the duplex unit D Diagnostic Aids 3 6 4049 XXX 8 9 10 11 12 18 Carefully remove the duplex unit from the printer without dis turbing the position of the paper on the top of the duplex tray Without changing the position of the page hold it to the top of the paper tray and remove the paper tray Measure from the leading edge of the page to the leading edge of the paper stack in the tray This measurement should be 75 mm or less If it is larger than 75 mm there is a drive prob lem in the duplex unit or in the tray
33. the HVPS replace the transfer roll if the continuity is correct If there is no continuity make sure the HVPS contact returns to its upward limit when depressed and make sure the left bearing of the transfer roll is making proper con tact 2 5 4049 XXX Error Code Explanation 920 Fuser Error Fuser is below temperature while printing See Fuser 920 921 or 922 Error on page 2 19 921 Fuser Error Fuser is below standby temperature when idle See Fuser 920 921 or 922 Error on page 2 19 922 Fuser Error Fuser failed to reach standby tem perature See Fuser 920 921 or 922 Error on page 2 19 923 Fuser Error Fuser is too hot while printing or when idle See Fuser 923 or 924 Error on page 2 20 924 Fuser Error Open detected in thermistor circuit See Fuser 923 or 924 Error on page 2 20 927 Fan Stalled See Fan 927 Error on page 2 18 928 Erase Lamps Erase lamp assembly missing or dis connected 931 Printhead Error No first hsync See Printhead on page 2 30 932 Printhead Error Lost hsync See Printhead on page 2 30 934 Printhead Error Lost lock condition See Printhead on page 2 30 935 Printhead Error Mirror motor unable to reach operat ing speed See Printhead on page 2 30 941 ROM SIMM ROM SIMM failed CRC code data or font data Run the diagnostic Mem ory Test for ROM Replace the SIMM if the
34. the duplex system board 23 Paper Jams Examine the paper path in the duplex unit and in the fuser exit area for paper or other obstructions Make sure the duplex unit is positioned correctly on the printer and that the gear at the bottom of the duplex unit meshes with the gear on the top of the paper tray Check that the paper is fed with no skew or binds from the duplexer into the metal channel at the right edge of the tray cover The tray roller should move the paper forward when the tray gear is turned but allow the paper to be pulled by the D roll when it picks Make sure the belt to the duplex DC motor is in place Make sure the duplex table cover floor is correctly snapped in place at its front and rear and that the gear block assembly is correctly snapped into the bottom cover Run duplex diagnostics tests 1 and 2 to make sure there is no slippage in the paper path Make sure the flags of the duplex unit input and exit sensors move freely While the 23 is displayed press and hold the Return button while pressing the second button from the top and note the 7th and 8th digits from the left If they are 01 or 03 there is a problem with the duplex input sensor signal Remove the duplex top cover and table cover and reinstall the duplex unit on the printer Measure the volt age on J5 12 of the duplex system board it should fluctuate from O to 5 VDC as you toggle the sensor Check the sensor cable conti nuity If the sensor and the ca
35. the lamp on and off to maintain the proper hot roll tempera ture Inside the fuser shroud there is a thermal fuse which is in series with the lamp if the TRIAC fails and leaves the lamp on con tinuously the fuse melts and shuts off power to the lamp The thermistor output voltage is proportional to the fuser tempera ture and is on engine board J8 4 The voltage cycles from approxi mately 2 0 to 2 3 VDC as the lamp goes on and off during idle and will be around 2 7 VDC during continuous printing when the Fuser Temperature is set to Normal In Power Saver mode the lamp is left off until a job is printed The engine board signal to the LVPS TRIAC is on J4 16 The voltage is 0 VDC when the lamp is to be on and 5 VDC when the lamp is to be off The lamp can be tested by briefly connecting this pin to ground Fuser 920 921 or 922 Error A 922 error during a POR caused by low line voltage can usually be cleared by doing another POR If the fuser lamp is lighting very dimly check for a 220 V lamp installed in a 110 V machine Check all the connectors to the exit sensor card and the lamp power connections at the left end of the fuser Make sure the thermistor is making contact with the hot roll Check the continuity of the lamp the thermal fuse and the fuser power cable Check the thermistor resis tance at engine board J8 3 to J8 4 it should be from 100K Ohms to 260K Ohms when cold it may be as low as 2 3K Ohms when hot but incr
36. tis DE DEST ad xviii IC Ce xxiii General Information 1 1 Power CONSUMO EE 1 2 ses cia done repe Anes Ed 1 2 Maintenance 1 3 Tools Required For Service 1 3 Allee ei caia o dp od da 1 4 4049 XXX Diagnostic Information 2 1 Site o A oe du E EE ere duds 2 1 Power On Self Test POS D 2 10 Symptom Table a d sete ais 2 11 passes EE 2 12 isie se Tie a ae 2 12 PAGO RT 2 13 Blank uec sco ia RR da EE 2 14 Biumed or FUZZY PIM priest ewes wate 2 15 BeadMaelllie ori 2 15 o cos doa e E a ae doa b eade ditte abd ole 2 16 Fan 927 sf amas ati m rettet dr dr dra 2 18 USER sud spas so ba do oe atr ttn dae ure Sa 2 19 Fuser 920 921 0 922 EMOT estara EE 2 19 FUSER 923 ar 924 EITOF rasas Ee di sand vs 2 20 elef eng euo tardar ras ode ae RE UR 2 20 Horizontal Void or 2 20 LAN Problems prados bs dees 2 21 E RO roce Meise alo a a 2 21 Network Card 977 2 21 Network Wrap REECH 2 22 Q tp t Bm E EE 2 22 Operator Panel Problem 2 22 Paper Feed Problem
37. 049 XXX Auto Clean Delay This can be set from 1 to 60 seconds with a default of 1 Enter Diagnostics mode Select PRINTER SETUP Select Auto Clean Delay Select or to display the delay desired Select Save Press Return to return to the Diagnostics mode main menu Na Button Test To test the operator panel buttons Enter Diagnostics mode Select HARDWARE TESTS Select Button Test Press each button Closed is displayed until the button is released Then Open is displayed 5 Press Return to return to the Diagnostics mode main menu Charge Roll me This setting varies the charge roll bias It is used to reduce back ground on the output In general if there is background and the envi ronment is hot and humid change the setting to low if the environment is cool and dry change the setting to high If the back ground is not reduced try changing the setting the other way Enter Diagnostics mode Select PRINTER SETUP Select Charge Roll Select High Medium or Low Press Return to return to the Diagnostics mode main menu Diagnostic Aids 3 4 4049 XXX Defaults Allows setting the following defaults to U S or Non U S values U s NON U S Letter size paper A4 paper 10 envelopes DL envelopes Symbol Set Roman 8 Symbol Set PC 850 q ERON Enter Diagnostics mode Select PRINTER SETUP Select De
38. 0BASE2 Attach a 50 Ohm BNC terminator cap to each end of the T connector The customer may be able to provide this cap There is no wrap test for Token Ring with Unshielded Twisted Pair cable or for Ethernet 10Base T POR the printer If the printer completes POR successfully the printer network card and the port to the LAN are working correctly If the customer still has a problem printing see LAN Problems on page 2 21 Output Bin Sensor Examine the bin area for obstructions or damage Run the diagnos tic sensor test Make sure the plastic bails and guide are in good condition and that they guide the sensor flag out of and into the sensor as paper passes into the bin On the sensor the voltage from pin 2 to pin 3 pin 1 is the bottom pin should change from 0 to 5 VDC as the sen sor is blocked and unblocked Pin 1 should always measure 5 VDC Replace the sensor the sensor card or the operator panel bin sen sor cable as necessary Operator Panel Problem Note If the printer is in Menus Disabled mode you can activate the menus by powering on the printer with the Return button and the top button pressed Repeat the POR procedure to disable the menus again after service Diagnostic Information 2 22 4049 XXX Possible causes failed LCD or operator panel card cable or con nector problem or engine board problem Replace the operator panel if POR stops with half rows of pels dis played Run the diagn
39. 1 977 Network Card 2 Network card 2 is installed but is not communicating with the RIP Board See Network Card 977 Errors on page 2 21 978 Network Card 1 General network 1 card hardware error Replace network card 1 Diagnostic Information 2 8 4049 XXX Error Code Explanation 978 Network Card 2 979 Network Card 1 979 Network Card 2 General network 2 card hardware error Replace network card 2 General network 1 card software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a software or microcode incompat ibility problem Do Not replace the card Contact your next level of sup port General network 2 card software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a software or microcode incompat ibility problem Do Not replace the card Contact your next level of sup port 990 Duplex Option Duplex error See Duplex on page 2 16 991 Duplex System Card Fail ure Duplex system board failure Replace the duplex system board 993 Duplex Comm Failure Communications between the duplex unit and the printer have failed See Duplex on page 2 16 2 9 4049 XXX Power On Self Test POST When you turn the printer on it performs a Power On Self Test Check for correct POST functioning by observ
40. 1 Parts Packet Parts Catalog 7 45 4049 XXX Assembly 20 Options Ns Units Description 20 2 1364923 1 1MB Flash SIMM 3 1364922 1 2MB Flash SIMM 4 1364879 1 4MB Flash SIMM 5 1364921 1 2MB DRAM SIMM 6 1364877 1 4MB DRAM SIMM 7 1364876 1 8MB DRAM SIMM 8 1364875 1 16MB DRAM SIMM 9 1364874 1 32MB DRAM SIMM 10 13A0339 1 4MB DIMM 11 13A0340 1 8MB DIMM 12 13A0349 1 DE SIMM for IPDS 13 1 Option Cards 1381050 1 o INA LocalTalk 1446702 1 o INA Ethernet 10BASE2 1402217 1 o INA Token Ring 1402218 1 o INA Ethernet 10BASE T 1446702 1 o INA Ethernet Combined 10BASEZ 10BASE T 13A0294 1 o INA SCS 13A0295 1 o INA IPDS 13A0296 1 o 9 pin to Twinax cable SCS or IPDS 13A0297 1 o 9 pin to BNC cable SCS or IPDS 13A0298 1 o 9 pin to 9 pin set up cable 1328563 1 o Thumbscrew INA 11 1364915 1 Font Card Adapter 12 1381856 1 Hard Disk 100MB 40MB Drive No Longer Available Use 100MB Drive 13 1381730 1 Stat Alert Light 13A 1381728 1 Lens Bulb Kit Stat Alert Light 7 46 4049 XXX Assembly 21 Miscellaneous FM Units Description S 1319128 1 Parallel Wrap Plug 1329048 1 Serial Wrap Plug 1381663 1 Fasteners parts packet 1381666 1 Springs parts packet 1381665 1 Gears 7 14 parts packet 1381145 1 Metering and Prealigner rolls parts packet 1329301 1 Grease 20 1384076 1 Grease conductive 1 oz E 1383586 1 Grease
41. 14 Aux Feeder Redrive Gear gt Gear 10 Gear 9 Gear 6 on shaft on motor bracket Redrive Idler si IER Ep x AR Gear 11 Gear 1 Molded on Fuser Gear D roll shaft Gear 13 Optional Tray Drive Gear 4 Gear 12 Mounted on Motor Pinion sideframe Right Rail 5 2 4049 XXX HVPS Print Cartridge Contacts Cover Interlock Transfer Roll Contacts Transfer Roller Housing Erase Lamp Window Transfer Roll Connector Locations 5 3 4049 XXX Engine Board Connectors 5 J17 J16 Q x J1 e J3 de E Li EEA E J8 y ro o 3 J9 J11 5 4 nnnnnnnn o 14 4049 XXX Engine Board Connectors Connector Name Ji Operator Panel Output Bin Sensor J2 Printhead Mirror Motor Fan J3 Duplex J4 LVPS 5 Dual Rear Feeder J6 Paper Drive Motor J7 Board to Board Connecto
42. 1408062 1 Cable Non Rt NS 1381861 1 Mounting Plate Connector Non Rt NS 1 Screw Parts Packet 1381663 Parts Catalog 7 25 4049 XXX Assembly 12 Optional Paper Drawer 500 Sheet 7 26 4049 XXX vele RE Units Description 12 1 1408161 1 Base Assembly 2 1328630 1 Deflector 3 1039170 4 Feet 4 1039596 1 Bellcrank Assembly NS 1 Spring Bellcrank Parts Packet 1381666 6 1039603 1 Drive Roller 7 1039540 1 D Roller Tire 8 1381306 1 Torquer Motor 11 1 Spring Parts Packet 1381666 12 1381638 1 Drive Assembly NS 1381920 1 o Drive Asm Gear Kit 14 1039558 1 Roller 15 1183299 1 Switch Assembly 16 1 Screws Parts Packet 1381663 17 1381887 1 Cable Paper Drawer Parts Catalog 7 27 4049 XXX Assembly 13 Fuser 7 28 4049 XXX Asm Part 2 duda ide Number Units Description 13 1 1381639 1 Fuser and Lamp 110 V R L Rt 1 1381641 1 Fuser and Lamp 220 V R L Rt 1 1381640 1 Fuser and Lamp 110 V Rx Lx R Rt Lx 1 1381642 1 Fuser and Lamp 220 V Rx Lx R Rt Lx 2 4 Screw Fuser Mounting Parts Packet 1381663 3 1382287 1 Fuser Wiper Assembly supply item 4 1328132 1 Fuser Cover 6 1 Spring Redrive Exit Parts Packet 1381666 7 2 Screw Paris Packet 1381663 8 1381528 1 Fuser Lamp 110 V R L Rt Install lamp with color coded end away from gear 8 1381524 1 Fuser Lamp 220 V R L Rt Install lamp with color coded end awa
43. 49 XXX Error Code Explanation 81 Engine Code CRC Microcode to be programmed into the engine board during a machine upgrade has failed a CRC check The microcode data will be dis carded and must be retransmitted from the host computer 88 Toner Low 90X Software Error Toner sensor detects low toner Unrecoverable software error If one of these errors appeared during POST or while the printer was idle not printing or receiving data or while trying to print one of the inter nal test pages replace the RIP Board If the error appeared while sending a job from the host com puter to the printer turn the printer off then turn it on and try again If the error appears again call the next level service support for assistance 917 Transfer Roll Error 918 Transfer Roll Error Cannot start servo operation Verify correct cable connections from the engine board to the HVPS Make sure there is continuity between the transfer roller and its contact on the HVPS replace the transfer roll if the continuity is correct If there is no continuity make sure the HVPS con tact returns to its upward limit when depressed and make sure the left bearing of the transfer roll is making proper contact If the error persists replace the HVPS and cable Servo Failure Verify correct cable connections from the Engine board to the HVPS Make sure there is continuity between the transfer roller and its contact on
44. 500 Sheet Option or 200 Sheet Second Drawer Non Abando 2 23 Paper Feed Base 2 23 Paper Feed Duplex Unit 1 2 25 Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder 2 26 Paper Feed Problem 200 Sheet Second Drawer Rt 2 26 Paper Feed Problem Dual Rear Feeder 2 27 Machine Level Information 2 27 Paper Feed Problem High Capacity Feeder 2 29 Pin dae 2 30 Paper Size Sensing Problem 2 31 Regularly Spaced lt 2 32 Residual magos cem ce es bee ne es eer ages LADA 2 32 Random MAKS 55 pesa sa 2 32 TIR er 2 33 Skew top and bottom only 2 33 Stalled diamonds on 2 34 Vertical Void or Streak oo 2 34 iv Service Manual 4049 XXX Diagnostic Aide 2 2 nk RR nnn 3 1 Diagnostics Mode ssa sas ao Rer rr So de RO 3 1 Diagnostics Mode Menu 5 3 1 Diagnostics Mode 3 3 AUO Gled aoa nois etna d a A i 3 3 Auto Clean Frequency 3 3 Auto Glean Delay en baias dead d os 3 4 BUON TOS seres ier eb gre Ree e 3 4 Chage Pull ee cane buds 3 4 xd dude bb Teen deba oq Ec d pend 3 5 Disk TEWE ps sad doce trish Ego eque dore godes erg a
45. 81915 1 Shaft L Lx 21 1381926 2 Roller backup L Lx 22 1328321 1 Spring backup L Lx 23 2 Jumper Ground Parts Packet 1381669 24 1381015 1 Sensor Asm Paper Size 25 1183244 1 Arm Tray Frame 26 4 Screw Deflector Mtg PP 1381663 Parts Catalog 7 11 4049 XXX Assembly 5 Paper Feed Continued 7 12 4049 XXX RE NE GL Units Description 5 28 1402325 1 Bearing NS 1328450 1 Spring Shaft Grd L Lx NS 1427418 1 Spring Shaft Grd R Rx Rt 29 1408717 1 Outer Redrive Shield R Rx Rt 29 1328381 1 Outer Redrive Shield L Lx NS 2 Screw Backup Spring Mtg Parts Packet 1381663 30 1 Spring Arm Tray Bias Parts Packet 1381666 31 2 Screw Redrive Mtg Parts Packet 1381663 33 1038186 1 Guide Fuser Input 34 1381895 1 Redrive Assembly L Lx 34 1381899 1 Redrive Assembly R Rx Rt 35 6 Screw Frame to Paper Feed Parts Packet 1381663 NS 1328345 1 Spring Bias Transfer Housing 36 1381298 1 Output Bin Sensor L Lx 37 1408064 1 Cable Output Bin Op Panel Output Bin lead has no connection on R Rx Rt 38 1381567 1 Guide Bail and Minibail Kit R Rx Rt uses Minibail only 39 1408061 1 Cable Tray 2 Tray 3 for Rt Blind Mate 40 1408792 1 Cover Tray 2 Cable Opening 41 1408892 1 Cable Duplex Autoconnect Parts Catalog 7 13 4049 XXX Assembly 6 Paper Feed Alignment Gears 7 14 4049 XXX ec goen Units
46. AAMT BREE AA SOIL FA EF 5 Ez HAE MEA HERAA 7 9 Class TES alo x Bch rs YAHA xvi Service Manual 4049 XXX Trademarks Optra and Lexmark are trademarks of Lexmark International Inc registered in the United States and or other countries Apple Talk and LocalTalk are trademarks of Apple Computer Inc registered in the United States and other countries PCL is a registered trademark of the Hewlett Packard Company PCL 5 is Hewlett Packard Company s designation of a set of printer Commande language and functions included in its printer products This printer is designed and manufactured by Lexmark International Inc to be compatible with the PCL 5 language This means the printer recognizes PCL 5 commands used in various applications programs and that the printer emulates the functions corresponding to the commands Details relating to compatibility are included in the 4049 Technical Reference manual Other trademarks are the property of their respective owners Notices and Safety Information xvii 4049 XXX Safety Information This product is designed tested and approved to meet strict global safety standards with the use of specific Lexmark components The safety features of some parts may not always be obvious Lexmark is not responsible for the use of other replacement paris The maintenance information for this product has been prepared for use by a professional
47. Enter Diagnostics mode Select HARDWARE TESTS Select Memory Test Select either DRAM or ROM Select Single or Continuous The display will indicate PASSED or FAILED Select CANCEL to stop continuous memory test Press Return to return to Diagnostics mode main menu Page Count To view or set the page count Rom c 5 Enter Diagnostics mode Select PAGE COUNTS Select Page Count Choose any number between 0000000 and 9999999 by Select ing Next to move the cursor under each digit Select or to select the number you want in each digit Select SAVE to save the page count displayed Paper Feed Tests This test allows you to observe the drive gear train and feed paper through the printer to check for broken gear teeth watch the paper path or check the erase lamps You may want to remove the gear cover before starting this test so you can observe the motor gears Diagnostic Aids 3 10 4049 XXX 4 5 6 Note Feeder refers to the Envelope or 100 Sheet Auxiliary feeder Feeder 1 and Feeder 2 refer to the front and rear bins of the Dual Rear Feeder Enter Diagnostics mode Select PAPER FEED TESTS Select Tray 1 Tray 2 Tray 3 Feeder Feeder 1 Feeder 2 or Manual Select Single or Continuous Select CANCEL to stop continuous Press Return to return to the Diagnostics mode main menu Parallel Confidence This test requires spe
48. Feed Problem 500 Sheet Option or 200 Sheet Second Drawer Non Rt Paper Feed Problem Enve lope Feeder 100 Sheet Auxil iary Feeder Paper Feed Duplex Unit on page 2 25 Paper Feed Problem 500 Sheet Option or 200 Sheet Second Drawer Non Rt on page 2 23 or Paper Feed Problem 200 Sheet Second Drawer on page 2 26 Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder on page 2 26 Paper Feed Problem Dual Rear Feeder Paper Feed Problem Dual Rear Feeder on page 2 27 Paper Feed Problem 200 Sheet Second Tray Rt Paper Feed Problem 200 Sheet Second Drawer Rt on page 2 26 Paper Feed Problem High Capacity Feeder Paper Feed Problem High Capacity Feeder on page 2 29 Automatic Paper Size Sensing Problem Automatic Paper Size Sensing Prob lem Service Check LAN Problems LAN Problems on page 2 21 Blank Page Blank Page on page 2 14 Black Page Black Page on page 2 13 Random Marks Random Marks on page 2 32 2 11 4049 XXX Symptom Go To Regularly Spaced Marks Skew all edges Regularly Spaced Marks on page 2 32 Skew all edges on page 2 33 Skew top and bottom only Skew top and bottom only on page 2 33 Light Print Light Print on page 2 21 Blurred or Fuzzy Print Blurred or Fuzzy Print on page 2 15 Residual I
49. Fuser Solenoid oo 4 22 Fuser Shroud Assembly Removal 4 23 HYPS Removal casada re oo sd 4 24 INA or Hard Disk Removal 4 26 Input Sensor Board Removal 4 26 Lower Frame Assembly 4 28 vi Service Manual 4049 XXX Removal Procedures continued LVPS Removal a2 DER 4 29 LVFS Cover REMOVAL ie 4 30 Operator Panel Removal 4 31 Paper Feed Rollers Removal 4 31 Paper Feed Magnet Assembly Removal 4 32 Paper Size Switch Hemoval 4 33 Printhead Removal 4 34 RIP Board Inner EMC Shield Removal 4 35 Toner Sensor Removal 4 35 Torquer Motor 4 35 Transfer Roll Removal as samp mnm tm ms 4 36 Transfer Roll Housing Removal sus 4 37 Upper Frame Removal 4 38 Duplex Option Top Cover And Table Cover Removal 4 39 Duplex Option Exit Card And Cover Removal 4 40 Duplex Option Bottom Cover And Entry Sensor Card Removal iss 4 41 Duplex Option System Card And Motor Removal 4 42 Dual Rear Feeder Edge Guide Asm 4 43 Dual Rear Feeder Gear Plate Asm 4 43 Dual Rear Feeder Right Cover 4 43 200 Sheet Second Drawer 4 44
50. NNGA EKSPONERING FOR STR LEN ADVARSEL USYNLIG LASERSTRALING VED ABNING UNDGA UDS ETTELSE FOR STRALING E gt MRR ET TS ZOV FIKR NAOT LES CTS MEM O Salat PE BORZ allolat ol LESA YES BHO Notices and Safety Information ix 4049 XXX Laser Der Drucker erf llt gem B 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 L ndern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 825 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse Illb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der L nge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daf im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem Ber Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 825 relatives aux p
51. Roll 53 1 mm Fuser Hot Roll 78 9 79 2 mm Fuser Backup Roll 69 1 mm Charge Roll part of print car 37 1 37 7 mm tridge Developer Roll part of print car 40 0mm tridge Prealigner Feed Roller 68 5 mm Auxiliary Feed Roller 68 5 mm Spacings other than the ones listed could be caused by damage or a bind in the gear train Residual Image Residual image the walking of a leftover image down the page is probably the result of failed erase lamps not discharging the photo conductor or of a failed cleaner inside the print cartridge It can also be caused by a failed fuser hot roll retaining toner and redepositing it on the page Check that the erase lamp voltage at engine board J9 1 is 24 VDC and that the cable has continuity To test the erase lamps jumper engine board J9 2 to ground Random Marks Random marks are nearly always due to a mechanical problem or due to foreign matter loose in the printer or in the print cartridge Diagnostic Information 2 32 4049 XXX Inspect and clean the inside of the printer carefully and correct any problems found Skew all edges If the test print frame is parallel to all edges of the page but the mar gins are not all the same width Print Registration on page 3 12 If the test print frame is not parallel to the left and right edges of the paper the paper has skewed in the paper path Check the paper path for obstructions Make sure the paper in the tray is unda
52. Toner Shield to Lower Frame Lower Frame Load Box Shaft to Upper Frame Toner Shield to Lower Frame Connector Locations 5 11 4049 XXX High Capacity Feeder Board Connectors High Capacity Feeder Board Connectors Connector Name J2 Elevator Motor J3 Paper Feed Motor J4 Lower Limit Switch J5 Door Switch J6 Paper Out Switch J7 R L Selector Switch J8 Upper Limit Switch J9 Power Supply J10 Feeder Ready Switch 5 12 4049 XXX 6 Preventive Maintenance This chapter describes procedures for printer preventive mainte nance Following these recommendations can help prevent prob lems and maintain optimum performance Safety Inspection Guide The purpose of this inspection guide is to aid you in identifying unsafe conditions Use good judgment to identify possible safety conditions not covered by this inspection guide Refer to the safety reminders for a general checklist If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items e 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 Lubricate only when parts are replaced or as needed
53. a does not fit on the page or the paper size cannot be changed from the operator panel Make sure the paper tray and its stops are undamaged Make sure the cable to the paper size switch is connected correctly With the paper tray removed the resistance of the paper size switch should be infinite With the tray installed the resistance of the switch varies with the paper size For Tray 1 remove the front cover disconnect the cable from the sensor and measure the resistance between the two pins on the sensor board For 500 Sheet Option or 200 Sheet Second Drawer Non Rt remove the RIP Board disconnect J15 from the engine board and measure between J15 3 and J15 4 on the cable For 200 Sheet Tray 2 Rt remove the RIP board disconnect J17 from the engine board and measure between J17 3 and J17 4 on the cable If the readings do not match the following within 5 replace the paper size sensor Tray installed and set to A5 1 4K Ohms B5 2 0K Ohms 10 5 3 0K Ohms 11 4 7K Ohms A4 8 0K Ohms 13 or 14 17 8K Ohms legal tray 2 31 4049 XXX Regularly Spaced Marks This is caused by a defect on one of the rolls or gears in the print process The damaged part can be determined by the spacing of the marks according to the following table Find and replace the dam aged part Component Print Defect Spacing on Page PC Drum part of print cartridge 125 7 mm Transfer
54. anera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Japanese Laser Notice 500 ZOZVyLZ57 ii WKBCIADHHS 21 CFR9Z7 Tv 722 J 07241 1 OBRA MALA LP 5 5 ATOT EKKBVACALIEC 825011737 RIOOL 22 1 oncoz co PyYL S RkISADDO 30 OV V 4AARELTIESF CO LE HENTTO T9YStSA FY OMACT BH 5 UTDybhOAVUITAMILDERHTSL P GF COL VAFPhEPYVI HE OH A PDA VAT ES 417 ABERNZSAIDLNLULOL Notices and Safety Information xv 4049 XXX Chinese Laser Notice M E r3 4 LE dT EL ae Se A EA DHHS 21 CFR Subchapter I 4 28 I 1 826 77 Mt mE H Hb TEC 825 ES pn SET BOT Bh TIED OLA ah amp A 27 NI 3b MH seh URS E BO HKEE 770 795 nm Z E VE fH HEIDE ERE AMABILE AR HE E SERES REN V Korean Laser Notice S ll iso 4041 ASSO CHSt DHHS 21 CFR Subchapter 3 TAS Uee Dol 215990 192 jejo IEC 825 TAS 158 404 ME 952 isa alo ASSE Chast ACOH HES 5 MASE otedjLtoj alo 770 795 LE n E 9 oo A Esot Class 3b Lol zh Veit
55. aps 5 11 printhead 5 10 RIP board 5 6 covers front cover removal 4 10 left cover removal 4 12 paris assembly 7 2 right cover removal 4 10 top cover removal 4 12 4049 XXX D dead machine 2 15 default settings 3 5 developed image test 3 17 diagnostics mode 3 1 diagnostics mode menus device tests 3 2 duplex tests 3 2 hardware tests 3 1 page counttests 3 2 paper feed tests 3 2 print registration tests 3 1 print tests 3 1 printer setup tests 3 2 diamonds on display 2 34 disk test clean 3 5 drive motor removal 4 14 D roll assembly removal 4 14 duplex 23 paper jam 2 17 933 error 2 17 diagnosis 2 16 paper feed problem 2 25 duplex feed 1 test 3 6 duplex feed 2 test 3 6 duplex option autoconnect cable connectors 5 10 bottom cover removal 4 41 entry sensor card removal 4 41 exit card and cover removal 4 40 parts assembly 7 38 system card and motor removal 4 42 top cover and table cover removal 4 39 duplex quick test 3 15 E electronics parts assembly 7 32 7 34 engine board connectors 5 4 removal 4 15 envelope enhance 3 7 envelope print test 3 7 Envelope Feeder envelope restraint spring adjustment 4 2 magnet adjustment 4 3 paper feed problem 2 26 2 27 parts assembly 7 40 7 42 error codes 2 2 ESD sensitive parts 4 1 exit sensor board removal 4 16 F fan 927 error 2 18 fan redrive removal 4 17 features 1 1 flash test 3 8 frame lower frame assembly removal 4 28 lower frame parts assembly 7 4 uppe
56. ard Release latch B and pull the board down and forward to get it out of its mounting Disconnect the toner sensor cable from the board Remove the sensor board Repair Information 4 26 4049 XXX 4 27 4049 XXX Lower Frame Assembly Removal 10 11 12 13 Remove the right front and left covers Remove the LVPS and the rod for the on off switch Remove gear cover and the fuser input guide A Remove the transfer roll housing Disconnect the cable from the HVPS Remove the RIP board and the inner EMC shield together Remove the engine board Disengage the upper frame cables from the guide in the paper feed side frame Remove the screws Remove the fuser cover Unplug the fuser wires C and push them below the HVPS Unplug the paper size switch cable Lift the lower frame assembly straight up to separate it from the paper feed assembly Repair Information 4 28 4049 XXX LVPS Removal OO P Go N O 4 29 Disconnect the power cord Remove all external feed trays Remove the left and right side covers Remove the RIP board and the inner EMC shield together Remove the left and right LVPS mounting screws and the screw for the cable tie Disconnect the LVPS cable from the engine board Disconnect the fuser connector A Liftthe supply up and then toward the right side frame to discon nect the On Off switch linkage
57. ars 7 14 Paper Toad DEVO uc sapo bate sas sat 7 16 Standard Paper Tray 200 Sheet n n anaanaaa 7 18 Paper Tray 500 7 20 Base for Paper Drawer 500 Sheet 7 22 Second Paper Drawer 200 Sheet 7 24 Optional Paper Drawer 500 Sheet 7 26 FUSER ots ouai Cic Sd d dE deb oth ac NE ca 7 28 EICCKONIS asas SAD SAS PAGO ER ed Y dd RE ES 7 32 co UNE 7 36 Duplex ODUOD EE EE 7 38 Envelope and 100 Sheet Auxiliary Feeder 7 40 Dual Rear Feeder 7 42 High Capacity 7 44 Oi MD PPP rr 7 46 Miscellaneous spas aspas ars DOS 7 47 el E dr re X1 viii Service Manual 4049 XXX Notices and Safety Information References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product pro gram or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property rights may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility
58. ble are good replace the duplex sys tem board If the 7th and 8th digits are 04 there is an exit sensor problem Remove the duplex top cover and table cover and reinstall the duplex unit on the printer Remove the paper tray so you can reach the sensor Measure the voltage on J5 8 of the duplex board it should fluctuate from O to 5 VDC as you toggle the sensor Check the sensor cable continuity If the sensor and the cable are good replace the duplex system board 2 17 4049 XXX Fan 927 Error The fan should run continuously when the printer is powered up unless the printer is in Power Saver mode Check that the fan rotates freely when spun manually and that the cable connections to the fan are OK The voltage at engine board J2 7 should be approximately 24 VDC when the top cover is up Short J2 7 to ground J2 6 to test the fan if the fan does not run check the continuity of the fan cable before replacing the fan A bad fan can pull down the 24 V line even if it runs check that J2 8 has between 21 and 26 VDC when the fan is running If the voltage is under 21 VDC replace the fan if the voltage is correct and there is still a 927 error replace the engine board Diagnostic Information 2 18 4049 XXX Fuser Theory The fuser lamp operates off line voltage from the LVPS The ther mistor is in contact with the fuser hot roll The system board reads the thermistor resistance and toggles a TRIAC in the LVPS which cycles
59. cific PC software and is to be implemented with the assistance of Lexmark Technical Support It can be used to diagnose parallel port interface problems Permanent Page Count The permanent page count can be displayed only It cannot be mod ified or reset by the customer or servicer 1 2 3 4 Enter Diagnostics mode Select PAGE COUNTS Select Permanent Page Count Press Return to return to the Diagnostics mode main menu Print Contrast This setting varies the developer bias to vary the print darkness If the Print Darkness setting on the customer menu does not allow the darkness to be set correctly this setting can increase or decrease the entire darkness range OO P Go 3 11 Enter Diagnostics mode Select PRINTER SETUP Select Print Contrast Select Low Medium or High Press Return to return to the Diagnostics mode main menu 4049 XXX Print Registration Use Print Test 1 or the Quick Test to evaluate print registration Adjust the registration so the tips of the diamonds are at the top and bottom edges of the page and the printout is centered left to right Verify that the top margin is correct before adjusting the bottom mar gin 1 Enter Diagnostics mode 2 Select PRINT REGISTRATION 3 Select one of the following Left Margin Top Margin Bottom Margin 4 The value of the margin you selected is shown 5 Margins Left Margin can be set between 23 a
60. conductor is good inspect the fuser rolls and transfer roll Make sure the left transfer roll bearing is contacting the contact from the HVPS Make sure the HVPS contacts are clean and spring back when pressed Diagnostic Information 2 34 4049 XXX 3 Diagnostic Aids Diagnostics Mode To run the remainder of the printer diagnostic tests described in this chapter you must put the printer in Diagnostics mode To enter Diagnostics mode 1 Turn the printer off 2 Press and hold the Ready and Return buttons Then turn the printer on The printer performs the Power On Self Test 3 Release the buttons when Performing Self Test is displayed 4 You can exit Diagnostics mode without a POR by selecting Reset Printer Diagnostics Mode Menu Structure The following is the Diagnostics mode menu structure The indented items are submenus available under the main menu items which are in capital letters on the operator panel Menu items referring to options will only be present ifthose options are installed Menus with more than four items will use MORE on the fourth operator panel button to access the next screen of selections PRINT TESTS Print Test 1 Print Test 2 Print Test 3 Envelope Print Test PRINT REGISTRATION Left Margin Top Margin Bottom Margin Quick Test HARDWARE TESTS LCD Test Sensor Tests Toner Low 3 1 4049 XXX Output Bin Input Exit Cover Open Button Test Parallel Confidence Wrap Tests Para
61. d Data has been sent to a port which has been disabled in the Setup Menu The port can be reactivated by entering the customer setup menu and selecting Serial Setup or Parallel Setup Serial Buffer or Paral lel Buffer and changing the setting from Disabled to Auto 57 Check Duplex Connection The duplex unit has been electrically disconnected from the printer but the printer top cover is not open Check the auto connect plugs on the duplex unit and the printer 58 Duplex Not Attached 59 Duplex Cover Open 62 Disk Full Duplex is no longer connected and printer top cover is closed Top cover of duplex unit is sensed open Not enough disk space for data that has been requested to be written to disk 63 Unformatted Disk Format the disk 64 Defective Disk The printer will ignore a disk it senses as defective Run the Quick Disk Test If the test fails the disk is defective or the data on track 1 is bad If the Quick Disk Test passes but the disk does not work run the Disk Test Clean 2 hour test Replace the disk if instructed by the operator panel 7X Network Card Codes These user codes are documented in various network card user manu als See Network Wrap Tests on page 2 22 80 Scheduled Maintenance Printer has reached 200 000 prints without maintenance count reset Refer to Scheduled Mechanical Maintenance on page 6 3 Diagnostic Information 2 4 40
62. d end away from the gear Z 2 REE Repair Information 4 20 4049 XXX Fuser Sensor Cable Removal 4 21 oo A WIN Turn the printer off Remove the RIP board and the inner EMC shield together Disconnect the cable from the exit sensor board Remove the front cover Disconnect the cable from the paper sensor assembly Remove the cable through the right frame 4049 XXX Fuser Solenoid Removal Remove the fuser 1 2 Remove the two mounting screws A holding the solenoid housing to the fuser housing 3 Disengage the solenoid bracket from the plunger Note When a new solenoid assembly is installed the fuser sole noid must be adjusted Y d S Repair Information 4 22 4049 XXX Fuser Shroud Assembly Removal Note Replacing only the thermistor or thermal fuse is not recom mended Replace the complete shroud assembly 1 2 3 4 23 Unplug the printer Remove the fuser wiper and fuser cover Pry the thermal fuse connectors off the terminals at each end of the fuser Disconnect the thermistor cable from the fuser exit board and free the cable from the cable guides Release the metal shroud from the fuser by prying up on the slotted tab at each end then rotating the shroud toward the rear Remove the shroud assembly by bending the left frame of the fuser slightly to the left 4049 XXX HVPS Remo
63. e 3 Through the opening for the paper output flip the metal ESD shield up out of the way and disconnect the exit sensor cable from the fuser Remove the fuser cover Disconnect the power wires A from the left side of the fuser Remove the fuser input guide Completely loosen the four fuser mounting screws Lift the fuser out of the machine on o o P Repair Information 4 18 4049 XXX Fuser Input Guide Removal 1 Remove the fuser input guide B by lifting the rear end of the guide and unsnapping both sides from the fuser 2 Lift the fuser input guide upward at both sides near the fuser and slide the guide toward the rear of the machine to release 3 Lift the guide out of the machine 4 Clean the fuser input guide before installing it an SASS 4 19 4049 XXX Fuser Lamp Removal CAUTION THE TEMPERATURE OF THE HOT ROLLER IS 150 230 302 446 USE EXTREME CAUTION WHEN REMOV ING THIS UNIT BEFORE YOU SERVICE THIS UNIT ALLOW THE MACHINE TO COOL FOR 5 MINUTES Note The fuser lamp is a glass heater Do not touch the lamp with your hands skin oils and acids can reduce the life of the heater lamp Use a soft cloth to handle the heater lamp at all times if the lamp is to be reinserted 1 Remove the fuser 2 Remove the right lamp bracket A 3 Carefully pull the lamp B out to the right using a soft cloth if the lamp is to be reinserted Install the new lamp with the color code
64. e 3 5 Duplex Feed 1 Test eene mte 3 6 Duplex 2 MOST sues ccr se xev m A 3 0 Envelope ENNARCO cidad dra ia 3 7 Envelope Print 3 7 LOM ER 3 8 Flash 3 8 Fuser Temperature Warm Up Time 3 8 Fuser Ke TEE 3 9 Fuser Warm Up Time 3 9 LEDTE E a aid O 3 9 Maintenance Kit 3 10 Eer 3 10 ere EE 3 10 Paper Feed Teste e Asa dba Deed 3 10 Parallel Confidence 3 11 Permanent Page Count 3 11 Print Contrast iu aac Sade ei DRT shane EE 3 11 Print Registrat ii Pas Bea 3 12 SU Dad erario 3 13 PHA T8512 ciue Ss aud deed 3 13 TOS duds peso qid sabes btc IE dn IU qu 3 14 Quick DISK Test ves sick piscina ass Ee 3 14 QUICK 3 14 Sensor e E der phi E pes 3 15 Top Margin and Duplex Quick Tests 3 15 EE 3 16 Wian DESSE as n C dd a 3 16 4049 XXX Ger TESS SERRE SSD 3 17 Developed Image Test 3 17 LAN 1 3 53 54 904 ads ESG as 3 17 Print l est Pages eomm cn dra aa da 3 18 Print Test with RIP Board Removed 3 18 Repair 4 1 Handling ESD Sensitive
65. e United States and or other countries OCopyright Lexmark International Inc 1995 1996 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 4049 XXX Table of Contents Notices and Safety ix Lasar ENEE ix PAS sad SOUS E X Avis relatif l utilisation de laser X Avvertenze sui prodotti xi Avisos sobre el laser asse ais did pus EE E do dad d xi Declara o sobre Laser xii Lasarnntorffialle cip papa si CELA CEPR RERES 3 xii Lasermeddelelse xiii Huomautus laserlaitteesta xiii CLASS MONS E dE PROS da OO E xiv Laser melders rere a xiv Avis sobre el ai Xv Japanese Laser Chinese Laser xvi Korean Laser a DES xvi ee er xvii Safety Information ssie rasas
66. e los requisitos para los productos l ser de Clase 1 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 825 para productos l ser de Clase I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase Illb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n disefiados 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 Notices and Safety Information xi 4049 XXX Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcap tulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe em conformidade com os requisitos da norma IEC 825 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe 1116 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 795 nan metros O sistema e a impressora laser
67. e page are covered by faint 6 mm circles This print defect is usually caused by the print cartridge If it is not the problem verify that the tab on the transfer roll housing is touch ing the contact on the HVPS the transfer roll housing should have continuity to ground Make sure the HVPS ground lead to the side frame is in place and making good contact Horizontal Void or Streak This is usually due to the cartridge not being installed correctly Check the printhead area for obstructions and check the mechani cal workings of the print cartridge and printhead shutter If nothing is found see Blank Page on page 2 14 and follow those instructions Diagnostic Information 2 20 4049 XXX LAN Problems You cannot find a printer or network problem but jobs still do not print If the network card checks out successfully the problem may be with the hardware or software outside of the network card Below are some suggestions to the customer for checking hardware and soft ware for possible problems Refer the customer to the LaserPrinter Network Printer Utility Guide to find the problem Make sure the network protocol you want is enabled from the printer operator panel e Verify proper print queue and printer driver configuration e Verify the adapter port has been associated Verify correct installation of the software utility e Single route broadcast not supported across network bridge if bridge is used Server p
68. eases quickly as the fuser cools There should be no connection from either pin to ground If the thermal fuse is open the fuser and the fuser wiper may be damaged Before replacing the fuser and the fuser wiper check the voltage at engine board J4 16 as you POR again It should stay at O until the 922 Error is displayed and then go to 5 VDC if it does not replace the engine board the fuser and the fuser wiper Next mea 2 19 4049 XXX sure the voltage to the fuser lamp during a POR it should be line voltage until the 922 Error is displayed if it does not replace the LVPS the fuser and the fuser wiper If the voltage to the fuser lamp is the not the same as the line volt age replace the LVPS If the lamp fuser power cable thermal fuse thermistor and lamp voltage are OK check J4 16 to see if the engine board is sending the correct signal to the TRIAC At POR this signal should go to 5 VDC and then immediately drop to O VDC until the fuser is warm if it does not replace the engine board If the signal is OK replace the LVPS Fuser 923 or 924 Error Check the connection and continuity of the cable from the fuser exit sensor board to engine board J8 Check the thermistor condition and connection Check the thermistor resistance at engine board J8 3 to J8 4 It should be from 100K Ohms to 260K Ohms when cold it may be as low as 2 3K Ohms when hot but increase quickly as the fuser cools Honeycomb Areas of th
69. ed center idler gear in the 500 sheet base and its shaft The idler gear in the 500 sheet base and its shaft Use IBM no 23 grease Approved equivalent Shell Darina 1 to lubri cate Front pivot latch studs Gear no 8 teeth at gear no 7 contact points Gear no 9 teeth at gear no 11 contact points Gear no 9 teeth at gear no 8 and gear no 10 contact points Cover Hinge Spring tips Cartridge ramps at top center of both sides frames Latch handle tips Area of contact between fuser release bail and roll All release arms areas of contact of fuser solenoid lever Use grease 1329301 to lubricate gear nos 2 3 4 5 6 and 12 Use all the grease in the packet Apply part of the grease rotate the gears and apply the rest The teeth of gears 3 4 and 5 should be completely coated 6 2 4049 XXX Use grease p n 1384076 to lubricate A areas of contact between the two shafts and the grounding spring Use grease p n 1383586 to lubricate B on the duplex unit Scheduled Mechanical Maintenance On some models the operator panel will display the message 80 Scheduled Maintenance at each 200K page count interval lt is nec essary to replace the fuser assembly transfer roller D roll and lower redrive shaft assembly at this interval to maintain the print quality and reliability of the printer These items are available as individual FRUs They are also available as a maintenance kit through the dealer options
70. ests check the circuits used to communicate with the host computer Note The Parallel wrap test does not test all signals used for bi directional communication Contact Lexmark Technical Support for instructions on running the Parallel Confidence Test To run the Wrap Test 1 Turn the printer off 2 Disconnect the interface cable 3 Install the wrap plug in one of the interface cable connectors Note Install the parallel wrap plug part no 1319128 for the parallel test or install the 25 pin serial wrap plug part no 1329048 for the serial test Enter Diagnostics mode Select HARDWARE TESTS Select Wrap Test Select Parallel for the parallel port or Serial for the 25 pin serial port Select Single or Continuous 9 Select CANCEL to stop continuous SOD OU Diagnostic Aids 3 16 4049 XXX A Passed message indicates the printer connection to the printer cable connector is good A Failed message indicates a defective RIP board Note Ignore the number displayed after a failure is displayed 10 Press Return to return to the Diagnostics mode main menu 11 Turn the printer off and remove the wrap plug from the interface connector Other Tests Developed Image Test Use the Developed Image Test to isolate print quality problems You might have to practice this procedure several times to get the timing correct To run the Developed Image Test 1 Open the front exit tray 2 Pri
71. faults Select U S or NON U S Press Return to return to the Diagnostics mode main menu Disk Test Clean This is a two hour test three hours for 100MB drives that should be performed only on a disk that contains bad data and is therefore unusable This test destroys all data on the disk by doing a multi pass write read on every block of the disk Bad blocks are flagged and removed from use If over 2000 bad blocks are found the test stops and the display indicates the disk must be replaced A message describing test progress is displayed during the test 3 5 1 Enter Diagnostics mode 2 Select DEVICE TESTS 3 4 Select CONTINUE to start the test or CANCEL to return to Select Disk Test Clean Diagnostics mode main menu Select CANCEL to interrupt the test Press Return to return to the Diagnostics mode main menu 4049 XXX Duplex Feed 1 Test This test checks for slipping paper problems It verifies that the paper is entering the duplex unit far enough for the trailing edge to clear the selector fingers before the paper reverses direction Enter Diagnostics mode Select DUPLEX TESTS Select Duplex Feed 1 Select Tray 1 or Tray 2 GER es Note Paper feeds all the way into the duplex unit and stops 5 The message Clear Paper appears on the display 6 Slide the tray extension all the way out until it stops 7 Push a small screwdriver through the lower end of one of
72. ff Remove the RIP board and the inner EMC shield together Disconnect the engine board cable connections Remove the nut and the three threaded standoffs Unsnap the board from the plastic standoff 4049 XXX Exit Sensor Board Removal Remove the front cover 1 2 Disconnect the fuser sensor cable 3 Disconnect the thermistor cable 4 Disconnect the fuser solenoid cable 5 Release the latches A 6 Pull the sensor board down to remove it Repair Information 4 16 4049 XXX Fan Redrive Removal 4 17 OD 1 Open the top cover 2 Remove the print cartridge 3 4 Remove the lower redrive shaft by disengaging the right end to Remove the top cover the rear of the machine Disconnect the long redrive belt A and slip it off the lower shaft L Lx and Lx Disconnect the output bin sensor cable Remove the redrive assembly screws D Remove the plenum assembly and screws B Unplug the fan cable The fan C can now be removed from the plenum assembly 4049 XXX Fuser Removal Note The heater lamp is fragile and may be damaged if you are not careful when you remove or replace the fuser unit CAUTION THE TEMPERATURE OF THE HOT ROLLER IS 150 230 302 446 F USE EXTREME CAUTION WHEN REMOV ING THIS UNIT BEFORE YOU SERVICE THIS UNIT ALLOW THE MACHINE TO COOL FOR 5 MINUTES 1 Unplug the power cord 2 Remove the printer cartridg
73. foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um n vel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 825 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse IIIb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 xii Service Manual 4049 XXX Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 825 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p belgelaengdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse l niveau ved normal drift brugervedligeholdelse eller obligato
74. formation 4 12 4049 XXX 4 13 4049 XXX 14 in 3 D roll eom de o NL 200 Sheet Paper Tray Top Cover Push the tab where the left corner of the tray cover pivots Move the left tray cover pivot pin forward and then upward Remove the cover from the tray 500 Sheet Paper Tray Top Cover Remove the two screws which secure the front trim panel Slide the trim panel to the rear to expose the tray cover pivot pins Lift the cover from the tray Assembly Removal Unplug the power cord Remove the paper tray Remove the print cartridge Remove the fuser input guide Remove the transfer roll housing assembly Pull the D roll firmly to the left to remove it Note The D roll is designed to be installed only once if it is removed for any reason it should be replaced with a new one It may take considerable force to install the new D roll Drive ONAARWN SH Motor Removal Unplug the power cord Remove the RIP board and inner EMC shield together Remove the engine board Remove the fuser input guide Remove the transfer housing assembly Remove the gear cover by releasing the rear latch and lifting up Remove the motor mounting nuts B and screws D Work the motor out of the machine Repair Information 4 14 4049 XXX Engine Board Removal 4 15 1 nook Check the page count and write it down so you can set the count on the new engine board Turn the printer o
75. he D roll or gear 11 is damaged and should be replaced e The D roll will turn continuously a Torquer There is a possible short to ground of the lead between the torquer gear and engine board J14 2 or the timing marks on the torquer gear and the D roll gear are mis aligned Examine the condition of the torquer leads and replace the torquer motor if necessary The timing marks are visible when the engine board is removed If no problem is found replace the engine board b Solenoid There is a possible short to ground of the lead between the solenoid and engine board J14 2 or the sole noid is out of adjustment Examine the condition of the sole noid leads Adjust the solenoid air gap see Paper Feed Magnet Adjustment on page 4 8 or replace the solenoid if necessary If no problem is found replace the engine board The D roll will not move at all Either the engine board signal is Diagnostic Information 2 24 4049 XXX incorrect or the torquer motor or solenoid is defective Adjust the solenoid air gap see Paper Feed Magnet Adjustment on page 4 8 On torquer machines make sure the torquer gear is not slipping on the shaft Engine board J14 1 should always be 34 VDC J14 2 should be 34 VDC when the torquer or solenoid is not picking Short engine board pin J14 2 to ground and listen carefully for the torquer or solenoid it will move slightly and make a noise If it does replace the engine board The D roll wi
76. he same for all machines NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration INDENTURE The indenture is marked by a series of dots located before the parts description The indenture indicates the relationship of a part to the next higher assembly For example INDENTURE RELATIONSHIP OF PARTS No dot MAIN ASSEMBLY One dot o Detail parts of a main assembly One dot o Subassembly of the main assembly Two dot o o Detail part of a one dot subassembly Two dot o o Subassembly of a one dot subassembly Parts Catalog 7 1 4049 XXX Assembly 1 Covers 7 2 4049 XXX ie Aer Units Description 1 1 1408175 1 Top Cover R 1 1427491 1 Top Cover Rx 1 1408173 1 Top Cover L 1 1425483 1 Top Cover Lx Lxi 1 6993152 1 Cover Rt 1 1381852 1 Top Cover R 1 1381851 1 Top Cover 1 1381850 1 Top Cover Lx Lxi 1A 1381631 1 Operator Panel Asm NS 4 Screw Operator Panel Parts Packet 1381663 NS 1408172 1 Plug Printhead Adjustment R Rx Rt 2 1381656 1 Tray Asm Stacker L Lx NS 1 Spring Stacker Parts Packet 1381666 3 1408176 1 Right Cover Asm 4 1381865 1 Plastic Latch Right Cover 4 1381862 1 Metal Latch Right Cover NS 1408233 1 Spring Right Cover Latch 5 1408184 1 Front Cover Asm R Rx Rt plastic latch 5 1408384 1 Front Cover Asm L Lx plastic latch 5 69G9481 1 Front Cover Asm R Rx Rt metal
77. hroud Assembly 3 1408033 1 Cable Fan Mirror Motor 4 1408034 1 Cable hsync NS 1038199 1 Cable Tie 5 1425284 1 Cable Laser Install with marked end to Printhead 6 1 Pin Parts Packet 1381666 7 1 Spring Parts Packet 1381666 8 2 Screw Printhead Mtg Parts Packet 1381663 8A 1 Screw Hex Headed Parts Packet 1381663 8B 1 Pointer Parts Packet 1381663 8C 1 Clip Hex Screw Ground Parts Packet 1381663 9 2 Retainer Parts Packet 1381663 Parts Catalog 7 9 4049 XXX Assembly 5 Paper Feed 7 10 4049 XXX RIS Ser Units Description 5 1 1039101 1 Outer Deflector 2 1183597 1 Upper Deflector 3 1381670 1 Inner Deflector with Roller NS 1381919 1 o Roller Asm 4 1381636 1 Input Sensor Board 5 1408859 1 Lower Deflector 6 1 Flag Input Sensor Parts Packet 1381669 7 1408703 1 Rt Rail Asm without Gears 7 1381801 1 Rt Rail Asm w Gears 8 Paper Solenoid 8 1039170 4 Machine Pad 9 1408690 1 Toner Shield 10 1328317 1 Left Frame 11 1039175 1 Tray Frame Spring 12 1042211 1 Belt Redrive R Rx Rt 12 1328192 1 Belt Redrive L Lx 13 1328193 1 Belt Auxiliary L Lx 14 1381912 1 Shaft Asm Lower Redrive 15 1408249 1 Extension Asm Right Rail 16 1381908 1 Shaft Asm Upper Redrive 17 1381914 1 Shaft Asm Auxiliary Shaft L Lx 18 1381910 1 Shaft Asm Middle Redrive R Rx Rt 18 1328173 1 Shaft Asm Middle Redrive L Lx 19 1381073 1 Toner Sensor 20 13
78. ield Note If the RIP board is being replaced remove the ROM SIMM and all options for installation on the new board Toner Sensor Removal E O Na Remove the fuser input guide Remove the transfer roll housing Lift the input sensor board far enough to disconnect the cable Remove the end of the bellcrank spring Lift the sensor to unsnap it Work the cable out of the frame and remove the sensor Torquer Motor Removal 1 2 3 4 5 Remove the lower frame assembly from the base Remove the D roll Remove gear 11 and the D roll shaft Do not lose the plastic bearings Remove the two screws that hold the torquer motor to the base and remove the torquer motor Unsnap the mounting adapter from the torquer motor Note When reinstalling the torquer motor align the timing marks on the torquer motor gear and the D roll gear 4 35 4049 XXX Transfer Roll Removal 1 2 3 Unplug the power cord Remove the print cartridge Remove the bearing cover from the left side of the transfer roll Note Do not touch the transfer roll surface Support the left bearing cover from the front with your left hand Use a small screwdriver to push the rear latch forward and release the bearing cover This exposes the bearing on the end of the transfer roll Grasp the bearing on the end of the transfer roll Lift slightly and move it to the left until the right end of the transfer roll shaf
79. ilable 1 2 parts assembly 7 46 output bin sensor 2 22 page count 3 10 paper drawer base parts assembly 7 22 paper feed alignment gears parts assembly 7 14 magnet adjustments 4 8 magnet assembly removal 4 32 parts assembly 7 10 7 12 rollers removal 4 31 paper feed drive parts assembly 7 16 paper feed problem 100 sheet auxiliary feeder 2 26 2 27 500 sheet second tray 2 23 base printer 2 23 duplex unit 2 25 Envelope Feeder 2 26 2 27 high capacity feeder 2 29 paper feed tests 3 10 paper size sensing problem 2 31 paper size switch removal 4 33 parts catalog how to use 7 1 permanent page count 3 11 power consumption 1 2 power on selftest POST 2 10 preventive maintenance 6 1 print contrast 3 11 print registration 3 12 bottom margin 3 12 left margin 3 12 top margin 3 12 printtest 1 3 13 print test 2 3 13 print test3 3 14 print test page 3 18 print test with RIP board re moved 3 18 printer ground straps connectors 5 11 printhead 934 and 935 errors 2 30 connectors 5 10 parts assembly 7 8 problem 2 30 removal 4 34 skew adjustment 4 9 printhead window cleaning 6 4 Q quick disk test 3 14 quick test 3 14 R random marks 2 32 regularly spaced marks 2 32 removals 4 10 residual image 2 32 RIP board connectors 5 6 removal 4 35 Index X 4 4049 XXX 5 safety inspection guide 6 1 scheduled mechanical mainte nance 6 3 sensor test 3 15 skew all edges 2 33 top and bottom only 2 33 stalled printe
80. in 3 1408708 1 Paper Guide 4 1408387 1 Slide 11 in 4 1408388 1 Slide 14 in 5 6989056 1 Paper Stop 1408710 1 Slider Paper Stop 6 1408170 1 Cover 14 in 7 1195835 1 Pivot Plate with label 8 2 Retainer Parts Packet 1381663 10 1424558 d Spring Assembly 4509 11 1 Setscrew Parts Packet 1381663 12 1039594 1 Thumb Wheel Gear 13 1408707 1 Wheel 14 1039597 1 Detent Spring 15 2 Screw Parts Packet 1381663 16 1408389 1 Indicator Paper Level Parts Catalog 7 21 4049 XXX Assembly 10 Base for Paper Drawer 500 Sheet 7 22 4049 XXX NI Let Units Description 10 1 1408289 1 Housing 2 1039558 1 Roll 3 1409146 1 Plate Assembly Gear 4 1039170 4 Pad Machine NS 1328674 1 Clip Ground NS 4 Screw PP 1381663 Parts Catalog 7 23 4049 XXX Assembly 11 Second Paper Drawer 200 Sheet 7 24 4049 XXX RIS NE di Units Description 11 1 1381836 1 Base Asm Second Drawer Rt 1 1381860 1 Base Asm Second Drawer Non Rt 2 1381837 1 Detent Roller 3 1381838 4 Foot 4 1383922 1 Switch Asm 5 1381839 1 Tray Guide Right 6 1381841 1 Tray Guide Left 7 1381831 1 Drive Asm NS 1381918 1 o Drive Asm Gear Kit 8 1381842 1 D Roller Tire 9 1381843 1 Drive Roller 10 1381306 1 Torquer Motor 11 1381844 1 Bellcrank Asm 12 1381845 1 Deflector 13 1381846 1 Ground Clip 14 1381847 1 Cable Engine Board Rt 14
81. ing the following 1 2 3 One and one half rows of pels appear on the display and then clear Diamonds fill the display and then clear The fuser lamp and the fan turn on Performing Self Test appears on the display Note The printer may be idle for up to 60 seconds as the fuser warms to operating temperature Printer idle time is shorter if the fuser is already warm Note If the duplex unit is installed the duplex drive motor turns on for about five seconds just before the Ready screen appears The ready screen appears on the display Note Diagnostics menu appears if you are in diagnostic mode The drive motor and the mirror motor start The fan starts to run at high speed The drive motor runs for approximately ten seconds The fan runs at high speed then switches to low speed If the printer completes all these steps and no error messages are displayed the printer has successfully completed the POST Diagnostic Information 2 10 4049 XXX Symptom Table Symptom Go To Dead Machine Dead Machine on page 2 15 Machine Hangs Displaying Diamonds Machine Hangs Displaying Dia monds Service Check Repeats a pattern of 5 beeps and a pause Operator Panel Problem on page 2 22 Operator Panel Operator Panel Problem on page 2 22 Paper Feed Base Printer Paper Feed Base Printer on page 2 23 Paper Feed Duplex Unit Paper
82. latch 5 69G9482 1 Front Cover Asm L Lx metal latch 1381858 1 Bracket Front Cover Retaining plastic latch 1381864 1 Bracket Front Cover Retaining metal latch 7 1329070 1 Output Deflector 8 69G9483 1 Output Deflector Lever W spring 12 1408188 1 Left Cover 14 1381657 1 Paper Stop Asm R Rx Rt 14 1381658 1 Paper Stop Asm L Lx 15 1381875 1 Cover Asm Front Exit Tray 17 1408394 1 Manual Feed Tray with guide Parts Catalog 7 3 4049 XXX Assembly 2 Lower Frame 7 4 4049 XXX Asm Part index Number Units Description 2 1 1381667 1 Lower Frame Assembly 2 1381632 1 Motor Brkt and Gear Asm R L Rt 2 1381633 1 GH Brkt and Gear Asm Lx Rx R Rt X 3 1408572 1 Plate Asm Gear Box Mtg NS 1408779 1 Clip Ground Motor Mtg NS 2 Mtg Screw Motor Asm Parts Packet 1381663 NS 4 Mtg Nut Gear Asm Parts Packet 1381663 6 1328243 1 Gear No 2 7 1039391 2 Detent Box 8 1329013 1 Right Cartridge Latch 9 1 Spring Parts Packet 1381666 11 1039271 1 Shaft Gear 2 12 1 Nut Gear 2 Parts Packet 1381663 13 1 Lockwasher Gear 2 Parts Packet 1381663 14 1329144 1 Left Cartridge Latch 15 1408645 1 Gear Train Cover 18 1328428 1 LH Bracket Duplex 19 1328427 1 RH Bracket Duplex NS 1 Screw Duplex Bracket Parts Packet 1381663 20 1039476 1 Grommet Printhead Cable 22 1408623 2 Cable Clamp NS 1408721 1 Guide Cable NS 4 Scre
83. lers with alcohol or water at every service call The feeder receives a pick signal from the printer and will not do a test feed without the printer installed Paper can be manually picked by rotating the paper feed rollers by hand or by removing the upper paper feed motor screw pivoting the motor downward and rotating the gear For all paper feed problems Verify that the printer designator switch on the rear of the high capacity feeder is set to the correct printer model being used Make sure the paper is undamaged shin gled correctly properly installed in the tray and is the correct weight 16 to 24 Ib and size letter or A4 Letter paper size and A4 paper size model feeders are available Paper sizes are not interchange able between the two models Make sure that all paper in the tray is the same type and has not been run through the printer before Envelopes and transparencies are not supported in the high capac ity feeder Jams Make sure the printer is installed correcily on the feeder Check for obstructions in the printer throat Make sure the paper in the tray does not have excessive curl Look between the printer and feeder to make sure the paper is entering the printer correctly Failure to feed Check the printer Paper Source menu for a Tray 2 indication to be sure the printer detects the high capacity feeder Check the condition of the feed rollers and clean with alcohol or water replace if necessary Make su
84. ll move slightly but will not complete an entire revo lution This indicates a bind or defect in the gear train or a mis alignment of the torquer motor gear timing marks If paper is jamming clean the paper path of obstructions or repair any damaged parts Very thin or thick paper labels transparencies or card stock has a higher jam rate than regular xerographic paper Check the condition of the paper in the tray and verify that the tray is installed correctly If the paper feeds but stops undamaged in the paper path run the input and exit sensor test Check for 5 VDC at the input sensor engine board J9 6 and exit sensor engine board J8 6 with paper present Check continuity on the cable before replacing a sensor If paper is curling badly enough to cause a problem feeding or stack ing see Fuser Temperature And Warm Up Time on page 3 8 Paper Feed Duplex Unit Check that all gears and belts are working correctly both in the duplex unit and on the tray top cover and that the gear on the tray top cover correctly engages the gear on the duplex unit If paper is jamming in the table cover area make sure the table cover is properly installed Run diagnostics Duplex Test 1 to make sure the paper is feeding far enough into the duplex unit before reversing Examine the condition of all rollers If paper is stopping or jamming as it is fed back across the top of the paper tray run diagnostics Duplex Test 2 to make sure there is
85. llel Serial Memory Tests DRAM ROM PAGE COUNTS Page Count Permanent Page Count Maintenance Count PAPER FEED TESTS Tray 1 Tray 2 Tray 3 Feeder Feeder 1 Feeder 2 Manual DUPLEX TESTS Top Margin Duplex Quick Test Duplex Feed 1 Duplex Feed 2 DEVICE TESTS Disk Test Clean Quick Disk Test Flash Test PRINTER SETUP Fuser Temperature Warm Up Time Diagnostic Aids 3 2 4049 XXX Envelope Enhance Auto Clean Auto Clean Frequency Auto Clean Delay Transfer Print Contrast Charge Roll Defaults ERROR LOG RESET PRINTER Diagnostics Mode Tests Auto Clean Auto Clean needs to be turned on if there is an unacceptable amount of toner being deposited on the back of the page When Auto Clean is on after printing the number of pages specified in Auto Clean Frequency the printer will pause the number of seconds specified in Auto Clean Delay This pause minimizes the toner accu mulating on the fuser cleaner ON Enter Diagnostics mode Select PRINTER SETUP Select Auto Clean Select On or Off Press Return to return to the Diagnostics mode main menu Auto Clean Frequency 3 3 This can be set from 10 to 255 pages with a default of 50 ON Enter Diagnostics mode Select PRINTER SETUP Select Auto Clean Frequency Select or to display the frequency desired Select Save Press Return to return to the Diagnostics mode main menu 4
86. mage Residual Image on page 2 32 Honeycomb Honeycomb on page 2 20 Background Background on page 2 12 Horizontal Void or Streak Horizontal Void or Streak on page 2 20 Vertical Void or Streak Vertical Void or Streak on page 2 34 Banding Banding on page 2 12 Banding Banding appears as light and dark horizontal lines on a page that is supposed to be uniformly gray It is due to variation in the speed of the paper as it moves from roll to roll during development or transfer It is undetectable when printing text and is most noticeable on fine dot or horizontal line patterns such as the second page of Print Test 2 or Print Test 3 Inspect the gear train and the paper feed roll ers for wear damage dirt or binds Background Areas that are supposed to stay blank are getting small amounts of toner deposited on them Clean the erase lamps and the printhead window Verify that all the erase lamps are working by powering on or off with the top cover open Verify that there is 24VDC on engine board Diagnostic Information 2 12 4049 XXX J9 1 and between 15 and 20VDC on engine board J9 2 Shorting engine board J9 2 to ground should turn on all the erase lamps Check the erase lamp cable continuity Replace the transfer roll housing if the voltage and the cable are good Inspect the contacts on the HVPS make sure each spring loaded contact retu
87. maged and loaded properly and the tray side restraint is properly adjusted Check the prealigner drive and auxiliary rollers springs and backup rollers for dirt wear or damage refer to the parts catalog for repair kits for broken bellcrank spring attachment hooks on the side frame Make sure all the bellcrank assemblies pivot freely Check the gear train for damage or binds Skew top and bottom only If the test print frame is parallel to the left and right edges of the paper but not parallel to the top and bottom the printhead skew needs to be adjusted See Printhead Skew Adjustment on page 4 9 2 33 4049 XXX Stalled diamonds on display Check the continuity of the cable from J1 on the engine board to the operator panel Next reseat the ROM and memory SIMMs and POR This condition can also occur if the RIP and engine board are not seated or their connectors are damaged If the problem is still present replace one at a time the 1 ROM SIMM 2 Engine board 3 RIP Board Vertical Void or Streak Do a developed image test to determine if the defect is occurring before or after the transfer process If you see the defect on the photoconductor check the operation of the printhead shutter and clean the printhead window with a lint free cloth folded over a cotton swab do not use a bare swab and do not use any cleaning fluids or water on the printhead window Inspect the HVPS contacts If the image on the photo
88. nal from the feeder ready switch is not reaching the printer Dead unit Check the printer Paper Source menu for a Tray 2 indi cation to be sure the printer detects the high capacity feeder Check feeder power supply input and output voltages If the output is cor rect pin 1 24 VDC pin 2 GND pin 3 5 VDC pin 4 GND replace the circuit board When replacing the circuit board check the A4 U S jumper to verify that the correct paper size is selected Be sure to plug each cable into the correct board connector Plug ging a cable into the wrong board connector can damage the new board or other components Printhead Note The printhead is a sealed unit It contains no internal parts that can be replaced or adjusted Verify the presence of the following voltages 24 VDC at engine board J2 1 5 VDC at engine board J11 4 and 5 VDC at engine board J12 8 If these voltages are not correct replace the engine board Verify the continuity of the fan mirror motor cable the hsync cable and the laser cable 934 and 935 errors Check engine board J2 5 during a POR the voltage should be between 2 VDC and 4 VDC for about seven seconds after the main motor turns on If the voltage is incorrect replace the engine board If the voltage is correct check the continu Diagnostic Information 2 30 4049 XXX ity of the fan mirror motor cable Replace the printhead if the cable is good Paper Size Sensing Problem The printed are
89. nd 23 Changing the number by one moves the margin 1 75 inch Moving the number in a positive direction moves the margin toward the right and negative moves the margin to the left Top Margin can be set between 20 and 20 Changing the number by one moves the margin by 1 75 inch Moving the number in a positive direction moves the margin down the page and widens the top margin Moving the number in a negative direction moves the text up the page and narrows the top margin Bottom Margin can be set between 20 and 20 Moving the number in a positive direction moves the margin down and narrows the bottom margin Moving the number in a negative direction moves the text up the page and leaves a wider bottom margin 6 Select to move the number in a positive direction or select to move the number in a negative direction Select SAVE to save your settings when they are correct 7 Select Quick Test to check your settings 8 Press Return to return to the Diagnostics mode main menu Diagnostic Aids 3 12 4049 XXX Print Test 1 Print Test 1 generates one printout similar to the test page and will not duplex This test prints from the user selected default paper source if the default source is a tray or from Tray 1 if the default source is a feeder You can change the default source by selecting Paper Source in the Paper Menu After running the test reset the default Source to the customer s selection To run Print Test
90. nt the test page 3 As soon as the leading edge of the paper is visible coming out the front exit slot turn off the printer 4 Remove the print cartridge and look at the image on the photo conductor LAN Information The printer may be connected to one of the following LAN types Token Ring Ethernet 10BASE T Ethernet 10BASE2 LocalTalk The printer test page indicates to which type of LAN the printer is connected The Network external connectors are shown below 3 17 4049 XXX 0 A 0000 Token Ring Ethernet 10Base2 Ethernet 10BaseT LocalTalk Print Test Page You can run the Print Test even if the printer is not attached to a computer Use this test to check print and graphics quality and the version numbers of printer microcode This test prints from the user selected default paper tray To run the Print Test Turn the printer on Select MENUS Select TESTS MENU Select Print Test Page Select either Single for one page or Continuous for continu ous test pages 6 Select Stop when you want the continuous test to end Hi Ze co TO c Print Test with RIP Board Removed Most meter measurements required during printer service will be on the engine board connectors which are inaccessible with the RIP board in place The printer has a service mode which allows you to test the printer without the RIP board installed This verifies
91. o e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona elevato personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen Notices and Safety Information xix 4049 XXX Pautas de Seguridad Este producto se ha dise ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio La informaci n sobre el mantenimiento de este producto est dirigida exclusivamen
92. ocate 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 major components and test points on the printer Preventive Maintenance contains safety inspection guidelines lubrication specifications and maintenance information to prevent problems and maintain optimum performance Parts Catalog contains illustrations and part numbers for individual FRUs Preface xxiii 4049 XXX 1 1 1 General Information The Optra Laser Printers are designed to attach to IBM compati ble PC s and to most computer networks There are multiple models all with standard PostScript Level 2 emulation and PCL 5 emulation From a service standpoint models Lxi and Lxn are the same as Lx model Lxi is the same as Lx and model Rn is the same as R Models Lxi Lxn Lxi and Rn are not mentioned elsewhere in this manual The plus models have a different ROM SIMM RIP board and top cover and all have a maximum speed of 16 ppm There are no other hardware differences Processing speed and efficiency have been improved and scheduled maintenance has been eliminated 4049 XXX Power Consumption R L RUR Rt Rx Lx Lx Power Saver Mode 21W 20W Printing average 260W 310W Max AC draw 110V 6 8A 9 8A Max AC draw 220V 3 4A 5 0A Options The following options are a
93. or log Press Return to return to the Diagnostics mode main menu PONS Flash Test This test writes to and reads from the flash memory It destroys all data stored in the flash SIMM 1 Enter Diagnostics mode 2 Select DEVICE TESTS 3 Select Flash Test The operator panel will display Passed or Failed 4 Press Return to return to the Diagnostics mode main menu Fuser Temperature And Warm Up Time These settings allow adjustment of the fuser to correct problems with paper curl or melting letterheads Paper curl in which the top and bottom of the page curl away from the printed side hot paper curl can be corrected by reducing the fuser temperature Reduce the setting from Normal to No Boost if necessary reduce the setting further to Low Temperature Verify that the toner is being adequately fused to the paper at the new tempera ture setting Paper curl in which the edges of the paper curl toward the printed side cold paper curl can be corrected by increasing the fuser warm up time Use the lowest setting that corrects the problem Setting 0 is the factory default and is the shortest warm up time Diagnostic Aids 3 8 4049 XXX Setting 5 increases warm up time by 90 seconds lower settings increase the time proportionately less Settings other than 0 may reduce throughput Use the or key to change the number and then select SAVE Melting letterheads may be prevented by reducing the fu
94. ordering channel After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message Preventive Maintenance 6 3 4049 XXX Printhead Window Cleaning Procedure Do not use cleaning fluids on the printhead window Do not use a bare cotton swab The swab deposits lint on the window Note The printhead window is a coated glass Do not push too hard and scratch or break the glass 1 Remove the print cartridge 2 Fold a lint free cloth over a cotton swab Swab Lint Free Cloth 3 Open the shutter 4 Insert the swab and cloth combination in the printhead window slot then slide it left to right several times Move the swab to a clean spot on the cloth and repeat the cleaning procedure Do this procedure several times to make sure the window is clean Cleaning The Transfer Roller Power off the printer Power on and let it complete POST Do this two to three times 6 4 4049 XXX 7 Parts Catalog How To Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are broken down on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description PP Parts Packet in the parts description column indicates the part is contained in a parts packet AR As Required in the Units column indicates that the quan tity is not t
95. ork card 2 processor failure Replace network card 2 Network card 1 RAM failure Replace network card 1 2 7 4049 XXX Error Code Explanation 971 Network Card 2 972 Network Card 1 972 Network Card 2 973 Network Card 1 Network card 2 RAM failure Replace network card 2 Network card 1 ROS FLASH failure Replace network card 1 Network card 2 ROS FLASH failure Replace network card 2 Network card 1 EEPROM NVRAM failure Replace network card 1 973 Network Card 2 Network card 2 EEPROM NVRAM failure Replace network card 2 974 Network Card 1 Network card 1 Network interface error Replace network card 1 974 Network Card 2 Network card 2 Network interface error Replace network card 2 976 Network Card 1 Network card 1 software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a soft ware or microcode incompatibility problem Do not replace the card Contact your next level of support 976 Network Card 2 Network card 2 software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a soft ware or microcode incompatibility problem Do not replace the card Contact your next level of support 977 Network Card 1 Network card 1 is installed but is not communicating with the RIP Board See Network Card 977 Errors on page 2 2
96. ostic tests for the LCD and for the buttons If only some buttons or pels work replace the operator panel If the printer beeps 5 times at POR or if the operator panel is blank check for 5 VDC at pin 4 of the cable connector at the operator panel and also at engine board J1 4 Replace the operator panel or the cable if they are the problem If the voltage at the engine system board is incorrect check that the LVPS is providing 5 VDC at J4 7 J4 9 and J4 11 and replace the LVPS if its output voltages are wrong Paper Feed Problem 500 Sheet Option or 200 Sheet Second Drawer Non Rt Remove the module and inspect the tray the module D roll and the gear train Make sure the gear train is meshing with the drive gear at the bottom of the printer Look for other mechanical problems or damage Make sure the printer and module auto connectors mate properly when the module is installed Check for 34 VDC at engine board J15 2 You can test the torquer motor by shorting engine board J15 1 to ground J15 3 Paper Feed Base Printer Note The printer paper pick mechanism may have either a torquer motor or a solenoid Run the print test or the diagnostic paper feed test and carefully examine the area of the problem If paper is not feeding make sure the paper is in the tray correctly and is not damaged or stuck together With 500 sheet trays make sure the tension wheel is set high enough to give good contact between the D roll and the
97. paper stack If paper is not feeding make sure the gear train is rotating The main motor should be on during most of POR and during any attempt to 2 23 4049 XXX feed paper Remove the RIP board and run Print Test with RIP Board Removed During the test check for 19 2 Vdc on the engine board J6 1 J6 2 J6 3 and J6 4 If the voltage is wrong replace the engine board Remove the motor and gear assembly from the printer and recon nect it to the engine board Reconnect all the other engine board connectors and reinstall at least one engine board mounting nut to make sure the engine board is grounded POR the printer If the motor does not run during POR replace the motor If the motor is OK look for a bind elsewhere in the gear train Intermittent problems may be caused by a thermal problem in the motor Run an extended print test if the gear train stops suddenly replace the motor If paper is not feeding or is feeding continuously with no gaps between pages remove the paper tray and the RIP board Press switches 1 and 3 on the paper size switch assembly Watch the D roll as you run the Print Test with RIP Board Removed One of the following will occur The D roll will make one complete revolution and stop with the flat side down This indicates that the mechanism is working correctly If the flat side is not facing down or if the printer had error code 20 or 28 turn the D roll if it rotates easily more than 10 either t
98. pin should enter the tower on the HVPS and depress the cover switch 32 Wrong Print Cartridge installed The installed print cartridge is not supported by the Optra printer 37 Insufficient Collation Mem ory Memory is too full to collate the print job 38 Memory Full Memory used to store pages is full To verify that the printer recognizes all the installed memory go to the user menus and print the Print Menus test page Make sure the memory shown on the printout matches the installed memory 39 Complex Page Page too complex to print To verify that the printer recognizes all the installed memory go to the user menus and print the Print Menus test page Make sure the memory shown on the printout matches the installed memory 43 Font Card Not Supported Font card format not supported by printer 44 Defective Font Card Defective font card installed in font slot 47 Font Card Removed While Printing Printer needs data on removed card 51 Defective Flash 52 Flash Full The printer detects a defective Flash SIMM If the error recurs replace the Flash SIMM Not enough flash memory for data requested to be stored 53 Unformatted Flash Flash problem at POR or while attempting to write 2 3 4049 XXX Error Code Explanation 54 Serial Error Framing or parity error on serial 56 Serial Port Disabled or Par allel Port Disable
99. r J8 Exit Paper Size Sensor Fuser Solenoid J9 Input Toner Sensor Board Erase Lamps J10 Envelope Feeder Magnet J11 Printhead Hsync J12 Printhead Laser J13 HVPS J14 Torquer Motor or Paperfeed Magnet Tray 1 J15 500 Sheet Option or 200 Sheet Second Drawer Non Rt J16 Jumper Tray 2 Rt J17 Torquer Motor Paper Size Sensor Tray2 Rt J18 Reserved JF1 Reserved Connector Locations 5 5 4049 XXX RIP Board J11 J6 J3 Jonanao Lo RIP Board Connectors Connector Name J1 Font Card on back of board J2 J3 Parallel Port J4 Board to Board J5 J6 INA Disk 1 J7 ROMM SIMM flash memory option J8 ROMM SIMM printer microcode J9 DRAM SIMM J10 DRAM SIMM J11 Serial Port J12 INA Disk 2 5 6 4049 XXX Board Installation Hardware Female Female T Standoff without Groove Short Plastic Standoff Engine Board Male Female Standoff with Groove Tall Plastic Standoff RIP
100. r 2 34 streaks 2 34 symptom table 2 11 T toner sensor removal 4 35 tools used 1 3 top margin and duplex quick test 3 15 top margin test 3 15 torquer motor removal 4 35 transfer roller cleaning 6 4 paris assembly 7 36 removal 4 36 transfer roller housing connectors 5 3 removal 4 37 transfer test 3 16 V vertical void 2 34 W wrap tests 3 16 X 5 Service Manual
101. r frame parts assembly 7 6 upper frame removal 4 38 Index X 2 4049 XXX fuser 920 921 or 922 error 2 19 923 or 924 error 2 20 input guide removal 4 19 lamp removal 4 20 paris assembly 7 28 7 30 removal 4 18 solenoid adjustment 4 7 solenoid removal 4 22 temperature and warm up time 3 8 theory 2 19 fuser drive gear backlash 4 5 fuser temperature test 3 9 fuser warm up time test 3 9 fuser sensor cable removal 4 21 G gear train connectors 5 2 H hard disk removal 4 26 high capacity feeder cover removal 4 47 paper feed rollers removal 4 45 honeycomb 2 20 horizontal void or streak 2 20 HVPS connectors 5 3 removal 4 24 INA removal 4 26 inner EMC shield removal 4 35 input sensor board removal 4 26 X 3 Service Manual L LAN information 3 17 problems 2 21 LCD test 3 9 light print 2 21 lubrication specifications 6 1 LVPS cover removal 4 30 removal 4 29 maintenance approach 1 3 maintenance kit count 3 10 marks random 2 32 regularly spaced 2 32 vertical void or streak 2 34 memory tests 3 10 menu structure diagnostics mode 3 1 mirror motor fan cable connectors 5 7 models available 1 1 network card 977 errors 2 21 network connectors 3 17 network wrap tests 2 22 Ethernet 10Base 2 2 22 Token Ring 2 22 4049 XXX O operator panel problems 2 22 removal 4 31 operator panel output bin sen sor cable connectors 5 8 optional paper drawer 500 sheet parts assembly 7 24 7 26 options ava
102. ransfer roll Also see Banding Inspect the HVPS contacts make sure each spring loaded contact returns when pressed and released Inspect the transfer roll housing contacts for damage or contamination Check the gear train for dam age binds or wear When using the 100 sheet auxiliary feeder some blurring may occur at the point where the feeder s friction rollers release the paper Dead Machine Possible causes no voltage reaching the printer LVPS failure blown LVPS fuse failure of the On Off switch or switch linkage or a shorted electrical component Check for the indicated voltages at the LVPS connection to the engine board If no voltages are present remove the LVPS cover and check fuse F1 and the power switch before replacing the LVPS If some voltages are present but all are not correct disconnect all cables except the LVPS from the engine board POR and verify that 2 15 4049 XXX the LVPS voltages are correct Turn the power back off and one at a time reconnect the engine board cables powering on in between each connection and checking the voltages The connection which causes the voltages to be wrong indicates which component is bad Repair or replace the failing component or cable as necessary Duplex The duplex unit should home the front shafts should turn and the input deflector should move immediately when you install the duplex unit with the printer already powered on or just before the Ready
103. re the feed motor is connected and functioning The motor winding resistance is 36 ohms 2 ohms for the following pins 1 4 1 6 2 3 and 2 5 No pin should have con tinuity to the motor case and no pin should have a short to any other pin Multiple feeds This is often due to environmental factors or the customer s choice of papers Make sure the paper is undamaged and that the corner bucklers are in good condition and free to move up and down with the paper stack Tray does not raise lower properly Elevator motion can be tested by opening and closing the door with or without the printer installed 2 29 4049 XXX The elevator mechanism and switches can be inspected by remov ing the cover positioning it near the feeder reconnecting the power supply and door switch cables and reconnecting the line cord Check the tray height and door switches and all cable connections If the tray does not move at all check the elevator motor and the upper and lower limit switches Inspect the gears belts and shafts for mechanical damage or blockage The motor winding resistance is 36 ohms 2 ohms for the following pins 1 4 1 6 2 3 and 2 5 No pin should have continuity to the motor case and no pin should have a short to any other pin If the elevator raises normally but immediately reverses when the upper limit switch is made the paper out switch is not working If the elevator behaves normally but the printer does not become Ready the sig
104. reeing the cover 4 43 4049 XXX 200 Sheet Second Drawer Rt Remove the print cartridge Remove all paper trays and any duplex or dual rear feeder options Remove the right cover Remove the RIP board and inner EMC shield together Remove the cable cover near the right cover pivot pin Disconnect J15 and J17 from the engine board and push the cables down through the hole into the base Carefully turn the machine onto its left side 8 Remove the four screws holding the second drawer to the printer avoiding damage to the two cables and remove the drawer m Op Repair Information 4 44 4049 XXX High Capacity Feeder Paper Feed Rollers 1 2 4 45 Open the feeder door so the tray lowers Turn the printer power off and remove the line cord from the electrical outlet Remove all paper trays and auxiliary rear feeders from the printer Remove the printer from the feeder Remove the two roller retainers from the feedroll shaft Roller Slide the roller shaft to one side to disengage it then lift and slide the other way to free both ends from the arms Lift the shaft keeping the drive chain engaged Slide the rollers off each end 4049 XXX Note Rollers must be installed in the correct orientation The new right feed roller has words on the metal bearing on the flange side the left roller does not d Right 9 Install the new feed rollers with the flange
105. rinters do not support the Dual Rear Feeder without an upgrade If the feeder is not being recognized by the printer print the Print Menus test page and make sure the Base code level is at least 32 00 and the Engine code level is at least 43 42 On the early machines engine board connector J5 is wired differ ently These machines require the J5 J10 external adapter box in order to support the Dual Rear Feeder On the Print Menus test page machines which require the adapter have an Engine Card of 12 or 16 machines not requiring the adapter have 12 A or 16 A Upgrade kits containing code upgrades and the adapter box are available through normal marketing channels No paper feed If the Dual Rear Feeder is recognized by the printer Feeder 1 front tray and Feeder 2 rear tray will be shown on the Paper Source menu and on the diagnostics Paper Feed Test menu If itis not check the printer code levels see Note above and test the torquer J5 8 and J5 10 are inaccessible J5 8 may be measured on test point RXD and J5 10 may be measured on test point TXD 2 27 4049 XXX Es J1 J2 a E RXD TXD fe O J5 1 carries the pick signal for Feeder 1 J5 8 carries the pick signal for Feeder 2 and J5 10 is 34 VDC When the feeder is connected all three pins have 34 VDC For early level machines using the external J5 J10
106. riske servicebetingelser Huomautus laserlaitteesta kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 825 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia kayttajalle Kirjoittimessa on sis inen luokan IIIb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometria Laserj rjestelm ja kirjoitin on suunniteltu siten etta kayttaja ei altistu luokan maarityksia voimakkaammalle s teilylle kirjoittimen normaalin toiminnan kayttajan tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina lasers teilylle Al katso sateeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Notices and Safety Information xiii 4049 XXX Laser notis Denna skrivare ar i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 l nder uppfyller skrivaren kraven laserprodukter av Klass enligt kraven i IEC 825 Laserprodukter i Klass anses h lsov dliga Skrivaren har en inbyggd laser av Klass Illb 3b som best r av en laserenhet av gallium arsenid p 5 milliwatt som arbetar 1 v gl ngdsomr det 770 795 nanometer Lasersystemet och skrivaren r utformade s
107. rns when pressed and released Rough Paper mode can cause background on some papers if Rough Paper mode is on turn it off and run the print test again Printing on coated paper or using refilled print cartridges can also cause background Run the Print Test with the RIP Board removed and check the follow ing voltages then stop the test and check the voltages again Connector Voltage while Voltage while Idling Printing J13 1 Less than 5 VDC 0 VDC J13 2 Less than 5 VDC 0 VDC J13 3 Fluctuates 0 VDC between pages 1 5 VDC J13 8 Less than 1 VDC 6 VDC If any voltages are not correct replace the engine board If no problem is found enter the diagnostics mode and change the Charge Roll setting Users who run large jobs with very dense graphics in high humidity environments may get some print quality improvement from increas ing the Transfer setting users with more normal jobs will see no dif ference Make sure the HVPS contacts to the transfer roll housing are in good condition Black Page Black output is usually caused by an incorrect high voltage in the printing process resulting in toner development on the entire photo 2 13 4049 XXX conductor drum Check the condition of each HVPS contact and make sure they spring back when pressed Check the continuity of the HVPS cable Make sure the following voltages are correct if they are not replace the engine board Connector Voltage
108. roblem check print server installation and configuration using the appropriate system guide to operations Light Print Light print is frequently caused by a worn out print cartridge Clean the transfer roll by powering on and off two or three times leaving the printer on for about two minutes each time Other causes are the same as for Blank Page See Blank Page on page 2 14 Make sure Print Darkness on the customer menu is set to Normal or Dark Increasing the diagnostics mode Print Contrast setting will darken print further PostScript emulation output may appear lighter than PCL emulation output or a test print this is not a defect Verify on the Print Test that the print is too light before performing service Network Card 977 Errors All network card errors are recorded as 977 in the error log If there are 977 errors in the log POR several times and take the appropri ate action for the displayed error code 2 21 4049 XXX If the displayed error is 977 verify that the network card is installed and grounded correctly Remove the network card and check for 5 VDC at pin B24 of RIP board J6 or J12 whichever the network card was connected to If the voltage is incorrect replace the engine board if there is 5 VDC replace the network card Network Wrap Tests Token Ring with Shielded Twisted Pair Cable Disconnect the LAN cable from the electrical outlet leaving it connected to the printer network card Ethernet 1
109. roduits laser de Classe Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe x Service Manual 4049 XXX Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe 1116 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Avisos sobre el l ser Se certifica que en los EE UU esta impresora cumpl
110. s facing inward toward the drive chain 10 Reinstall the roller shaft making sure the drive chain is still engaged 11 Reinstall the roller retainers 12 Reinstall the printer reconnect power and test Left Repair Information 4 46 4049 XXX High Capacity Feeder Cover 1 2 4 47 Remove all paper from the feeder Turn the printer power off and remove the line cord from the electrical outlet and the feeder power jumper cable from the printer Remove all paper trays and auxiliary rear feeders from the printer Remove the printer from the feeder Remove the four screws in the top of the feeder Carefully place the feeder on its left side and remove the eight screws holding the cover to the bottom plate The feeder mech anism is attached to the bottom plate Slide the feeder and bottom plate partially out of the cover Dis connect the power supply cable and the door switch cable from the circuit board before removing the feeder from the cover 4049 XXX 5 Connector Locations This chapter shows the locations of major printer assemblies gears connectors and ground straps Major Assembly Locations Operator Panel Upper Frame Print Cartridge Transfer Roll Low Voltage High Voltage Power Supply Power Supply Fuser Lower Frame Output Sensor Paper Tray Toner Sensor Inout Sensor Paper Feed Connector Locations 5 1 4049 XXX Gear Train Gear 8 Gear
111. ser temperature as described above for paper curl Fuser Temperature OO P Go Enter Diagnostics mode Select PRINTER SETUP Select Fuser Temperature Select Normal No Boost Or Low Temperature Press Return to return to the Diagnostics mode main menu Fuser Warm Up Time 1 2 3 4 5 Enter Diagnostics mode Select PRINTER SETUP Select Warm Up Time Select a setting of 0 through 5 Use the or key to change the number O is the shortest fuser warm up factory setting 5 is the longest fuser warm up Press Return to return to the Diagnostics mode main menu LCD Test 3 9 To test the operator panel display OO P Go o Enter Diagnostics mode Select HARDWARE TESTS Select LCD Test Select Single or Continuous The display goes through a continuous sequence of turning pels on and off Press Return to stop continuous LCD test Press Return to return to the Diagnostics mode main menu 4049 XXX Maintenance Kit Count This non displayed counter must be reset after the maintenance kit is replaced to prevent the 80 Scheduled Maintenance message from displaying when the machine is turned on OT Pore Enter Diagnostics mode Select PAGE COUNTS Select Maintenance Count Select Reset to set the count back to 0 Press Return to return to the Diagnostics mode main menu Memory Tests SE O gr Acc n
112. service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t con u test et approuv pour respecter les normes strictes de s curit globale lors de I utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de I utilisation d autres pieces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires xviii Service Manual 4049 XXX Norme di sicurezza Il prodotto stato progettato testato e approvato in conformit a severi standard di sicurezza e per Putilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non responsabile per Putilizzo di parti di ricambio di altri produttori Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggi
113. t slides out of the right side bearing Remove the transfer roll Lift the right bearing straight up and out of the machine Repair Information 4 36 4049 XXX Transfer Roll Housing Removal 1 2 3 4 37 Remove the print cartridge Remove the fuser input guide Grasp the housing and pull toward the front of the machine to disconnect the housing from the mounting studs visible through openings B in the inner deflector Lift the transfer roll housing far enough to disconnect the erase lamp cable Lift the transfer roll housing out of the machine 4049 XXX Upper Frame Removal JO 10 11 12 Unplug the power cord Remove the print cartridge Remove the right left and top covers Remove the RIP board and the inner EMC shield together Remove the engine board Remove the load box latches A Release the latches B Pivot the upper frame to the rear to release the spring tension Unsnap the plastic insert D holding the upper frame cables in the right side frame Remove the screws C Remove the upper frame cables through the side frame Lift the upper frame off the machine Repair Information 4 38 4049 XXX Duplex Option Top Cover And Table Cover Removal 4 39 1 Open the top cover by pulling up at A and pivoting 90 2 Pry the top cover from the bottom cover at 3 4 Release latches C on the table cover and
114. te al personal cualificado de mantenimiento 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 Informa es de Seguran a Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem n o ser sempre bvias A Lexmark n o respons vel pela utiliza o de outros componentes de substitui o 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 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 xx Service Manual 4049 XXX Informaci de Seguretat RE Aquest producte esta dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components especifics de Lexmark Les caracteristiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i
115. test reset the default Source to the customer s selection Enter Diagnostics mode Select PRINT TESTS Select Print Test 3 Select Single or Continuous Select Cancel to stop continuous print Press Return to return to the Diagnostics mode main menu Quick Disk Test OU de o mor This is a one minute test which performs a non destructive write read on one block per track on the disk It tests the printer to disk communications and the disk hardware and circuitry but does only incidental testing of the disk surface itself The Quick Disk Test does not destroy data on the disk existing data is read and stored prior to the testing of each track and then rewrit ten after the track is tested Enter Diagnostics mode Select DEVICE TESTS Select Quick Disk Test The display will indicate Test Passed or Test Failed Press Return to return to the Diagnostics mode main menu Sr eoe ce Quick Test The Quick Test is activated by pressing Ready from any screen while in Diagnostics mode as well as being an entry under PRINT REGISTRATION It provides a simple page alignment pattern that prints faster than the other print tests Diagnostic Aids 3 14 4049 XXX Sensor Test 6 1 Enter Diagnostics mode 2 Select HARDWARE TESTS 3 4 Select one of the following sensor tests Toner Low Output Bin Select Sensor Test Input Exit or Cover Open When the sensor is blocked Open
116. test fails or the problem recurs after POR replace the RIP Board if the SIMM does not fix the problem 944 RIP Board RIP processor failure Replace the RIP Board Diagnostic Information 2 6 4049 XXX Error Code Explanation 945 RIP Board 946 RIP Board 947 Engine Board ASIC 1 failure Replace the RIP Board ASIC 2 failure Replace the RIP Board Engine ASIC RAM failure Replace the engine board 948 Engine Board Engine ASIC electronics failure Replace the engine board 950 RIP Board SRAM failure Replace the RIP Board 951 Engine Board PQET SRAM failed verification test Replace the engine board 952 Engine Board Unable to zero PQET SRAM Replace the engine board 953 Engine Board 954 Engine Board 960 Memory Error NVRAM failure Replace the engine board Printhead crystal not functioning cor rectly Replace the engine board Bad or missing DRAM in the base DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM POR the printer If the test fails or the problem recurs replace the DRAM SIMM 961 Memory Error 970 Network Card 1 970 Network Card 2 971 Network Card 1 Bad DRAM in the optional DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM POR the printer If the test fails or the problem recurs replace the DRAM SIMM Network card 1 processor failure Replace network card 1 Netw
117. top cover Select CONTINUE Perform the test several times to verify that the measurement is accurate Press Return to return to the Diagnostics mode main menu Envelope Enhance Use this procedure to set the fuser solenoid power level to low medium or high Increase the level to reduce envelope wrinkling or decrease the level to reduce solenoid noise ON Enter Diagnostics mode Select PRINTER SETUP Select Envelope Enhance Select Low Medium or High Press Return to return to the Diagnostics mode main menu Envelope Print Test 3 7 Use Envelope Print Test to test the Envelope or Auxiliary feeder Envelope Print Test generates one printout a page of ripple print Printing will occur only on the first page or envelope O Enter Diagnostics mode Select PRINT TESTS Select Envelope Print Test Select Single or Continuous Select CANCEL to stop continuous print Press Return to return to the Diagnostic mode main menu 4049 XXX Error Log The error log records the last six 2X Paper Jam or 9XX Service errors In a full log position 6 is the oldest error If more than six errors are received the oldest error is discarded If the same error occurs consecutively it is recorded only once All 97X Network Card errors are logged as 977 Enter Diagnostics mode Select ERROR LOG Select CLEAR and then CONTINUE to clear the err
118. u replace this FRU see Lubrication Specifications on page 6 1 Repair Information 4 42 4049 XXX Dual Rear Feeder Edge Guide Asm 1 Remove the left frame by removing the eight mounting screws 2 To remove the front edge guide assembly remove the left end of the door from the pick roll shaft 3 Slide the edge guide assembly paper shaft pick rollers and buckler assemblies out to the left leaving the pick roll shaft in place Dual Rear Feeder Gear Plate Asm 1 Remove the right cover 2 Remove the three screws and remove the gear plate assembly and the torquers To reinstall The 42 tooth gear that mounts to the back center of the gear plate assembly must be installed such that there is a gap between the gear face and the plate To reinstall the plate with the torquer gears in the correct positions see Dual Rear Feeder Gear Alignment Adjustment on page 4 4 Dual Rear Feeder Right Cover There are five snaps holding the right cover to the frame 1 Free the cable from the cover by pulling the grommet down ward 2 Pull the lower front of the cover to the right to release the two snaps along the bottom of the cover 3 Pry the front upper portion slightly away from the frame so you can see the snap Insert a screwdriver between the frame and the cover Press the front of the snap with the screwdriver to release it 4 Repeat step 3 on the rear upper portion 5 The rear snap releases easily f
119. ual Rear Feeder 1 1381832 1 Cover Right 2 1381798 1 Dual Torquer Asm 3 4 Screw Torquer PP 1367169 4 1381793 1 Gear Kit 5 1381794 1 Roller Kit 6 1367019 1 Envelope Buckler Kit 7 1367463 2 Pick Roll Hub Kit 8 1381833 2 Extender 9 1381795 2 Edge Guides amp Width Adjust Strip Kit 10 1381834 1 Slider 11 1381797 1 Door 12 3 Screw Frame PP 1367169 13 1381835 2 Paper Load Shaft 14 4 Clip PP 1367169 Parts Catalog 7 43 4049 XXX Assembly 19 High Capacity Feeder 7 44 4049 XXX vele M Units Description 19 1 1381928 1 Cover with A C inlet amp cable and printer designator switch amp cable 2 1381930 1 Bottom Plate 3 1381931 1 Door Assembly 4 1381929 1 Rear Paper Path Deflector 5 1381945 1 Power Supply 6 1381932 1 Cable harness with circuit board power supply and printer connectors 7 1381934 1 Door Switch Cable Assembly 8 1381942 1 Feeder Subassembly U S 8 1381943 1 Feeder Subassembly A4 9 1381941 1 Paper feed roller kit with retainers 10 1381933 1 Circuit Board check A4 U S jumper position 11 1381935 1 Elevator Motor with pinion 12 1381936 1 Paper feed motor with pinion 13 1381937 1 Microswitch upper limit with cable 14 1381938 1 Microswitch lower limit with cable 15 1381939 1 Microswitch paper out with cable 16 1381940 1 Microswitch feeder ready with cable 17 1381953 1 Power Jumper Cable NS 1381944
120. vailable Some options are not available in every country Contact your point of purchase for options available in your country Memory upgrade options of 2MB 4MB 8MB 16MB and 32MB Flash memory options of 1MB 2MB and 4MB Integrated network options Token Ring Ethernet AppleTalk SCS IPDS 200 and 500 sheet paper trays of A5 letter and legal size 500 sheet second drawer with letter size paper tray Envelope feeder 100 sheet auxiliary feeder Duplex option Font cards bitmapped or scalable fonts 100MB Hard Disk Dual Rear Feeder Stat Alert Light High Capacity Feeder 1500 sheets General Information 1 2 4049 XXX Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the error code charis symptom index service checks and diagnostic aids to determine the symptom and repair the failure Begin with Start on page 2 1 This printer can be serviced without being connected to a host com puter After you complete the repair perform tests as needed to verify the repair Tools Required For Service 1 3 Flat blade screwdriver 1 Phillips screwdriver 2 Phillips screwdriver 5 5 mm nut driver 8 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 4049 XXX
121. val D Joo bk Unplug the power cord Remove the left cover Remove the fuser input guide Remove the transfer roll housing Remove the fuser cover Disconnect the cable from the HVPS connector Remove the power switch rod Remove the ground screw B Remove the mounting screws C Pull the ground strap through the hole D The power supply is held in place by two latches on the left side To release the latches Push one latch E in and raise one of the studs F to release the latch Push the other latch E in and raise the other stud F to release the latch Lift the power supply until the studs F align with the large openings then move the power supply to the right to release it from the frame Move the front of the power supply to the right to clear the fuser power wires Tilt the front of the power supply up and lift it out of the machine Repair Information 4 24 4049 XXX 4 25 4049 XXX INA or Hard Disk Removal Ics Open the top cover Open the right cover Remove mounting screws as required Pop the card off the plastic standoffs Input Sensor Board Removal Remove the fuser input guide Remove the transfer roll housing Remove the D roll Disconnect the input sensor cable from the input sensor board Note Use care the flag can be damaged while removing the bo
122. w Cable Clamp Parts Packet 1381663 Parts Catalog 7 5 4049 XXX Assembly 3 Upper Frame 7 6 4049 XXX mee ONE Units Description 3 1 1325196 1 Cover Hinge Asm R Rx Rt does not include the load box 1 1381045 1 Cover Hinge Asm L Lx does not include the load box 1A 1 Screw Cover Hinge Parts Packet 1381663 2 1325103 1 Upper Plate Asm R Rx Rt 2 1328218 1 Upper Plate Asm L Lx 3 1427306 1 Cartridge Load Box 4 1 Right Cam Button Parts Packet 1381663 5 1039693 1 Right Bellcrank 6 1 Left Cam Button Parts Packet 1381663 7 1 Spring Bellcrank Parts Packet 1381666 8 1039692 1 Left Bellcrank 9 1383998 1 Fan Asm NS 1424481 1 Pad Acoustic Fan 10 1328222 1 Plenum Asm 11 1 Retainer Parts Packet 1381663 12 1 Spring Parts Packet 1381666 16 2 Screw Plenum Mtg Parts Packet 1381663 18 1408616 1 Handle Latch with Grip R Rx Rt 18 1408216 1 Handle Latch with Grip L Lx 19 1328308 2 Sleeve 20 1 Spring Handle Parts Packet 1381666 21 2 Ground Strap Parts Packet 1381669 23 1 Retainer E Clip Parts Packet 1381663 24 1 Pivot Handle Parts Packet 1381663 27 1 Washer Parts Packet 1381663 28 2 Screw Shaft Mtg Parts Packet 1381663 30 1328467 1 Spring Plenum Parts Catalog 7 7 4049 XXX Assembly 4 Printhead 7 8 4049 XXX IS NE e Units Description 4 1 1381635 1 Printhead 2 1328431 1 Printhead S
123. win dow 6 Pivot the torquer down install the front screw and tighten the rear screw keeping the timing centered in the window DF ah Repair Information 4 4 4049 XXX Fuser Drive Gear Backlash Adjustment 4 5 Fuser drive gear backlash is adjusted so that when gear 2 is held still there is a slight amount of backlash in the fuser gear Print qual ity can be affected if the gears are too tight 1 2 3 Remove the fuser cover Locate gear 2 It is the white adjustable gear mounted to the side frame below the fuser gear Rotate the adjustable gear in one direction to check for back lash To adjust backlash Loosen the nut on the idler stud Move the idler stud downward in its slot Insert a 0 95 mm 037 in feeler gage between the gear shoul ders from the front of the machine You may need to use an angled or very small feeler gauge With the nut snug but not tight tap the idler upward until the gage is snug between the gear shoulders Tighten the locking nut Check the clearance again tightening may have altered the adjustment Be sure the fuser gear can be rotated slightly when gear 2 is held still 4049 XXX Fuser Gear Right Sideplate 0 95 0 15 037 006 Stud Idler Gear Repair Information 4 6 4049 XXX Fuser Solenoid Adjustment Note The fuser solenoid must be mounted on the fuser for this adjustment and should be at room temperature 1
124. y from gear 8 1381011 1 Fuser Lamp 110 V Rx Lx R Rt Lx Install lamp with color coded end away from gear 8 1381037 1 Fuser Lamp 220 V Rx Lx R Rt Lx Install lamp with color coded end away from gear 8A 1381146 1 Hot Roll Assembly With Bearings NS 1329928 1 Backup Roll 10 1328458 1 Redrive Idle Arm Asm 11 1381687 1 Paper Exit Bd Asm 12 1 Flag Parts Packet 1381669 13 1039481 1 Fuser Power Cable 14 1381662 1 Cable Fuser Paper Size Sensor Parts Catalog 7 29 4049 XXX Assembly 13 Fuser Continued 7 30 4049 XXX SC Units Description 13 15 1328134 3 Clips Thermal Fuse 16 1381888 1 Bail Handle 17 1381018 1 Fuser Solenoid Asm 18 2 Screw Solenoid Mtg Parts Packet 1381663 19 1328124 1 Gear No 1 Hot Roll 20 1 Gear 18T Redrive Parts Packet 1381665 21 1 Spring Redrive Idler Parts Packet 1381666 22 1328437 1 Contact Asm Right Lamp 23 1328438 1 Contact Asm Left Lamp 24 2 Screw Mtg Parts Packet 1381663 25 1039316 5 Detack Fingers 26 1039317 5 Detack Finger Springs 27 1427473 1 Detack Housing W Fingers and Springs 28 1375937 1 Lower Exit Guide 29 1381786 1 Shroud W Thermal Fuse Thermistor and Clips R L Rt 29 1381788 1 Shroud W Thermal Fuse Thermistor and Clips Rx Lx R Rt Lx NS 1381826 1 Thermistor high temperature Parts Catalog 7 31 4049 XXX Assembly 14 Electronics 7 32 4049 XXX

4049-XXX (Optra) Service Manual

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