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OptraTM Series

4049-XXX

· Table of Contents · Start Diagnostics · Safety and Notices · Trademarks · Index · Main Menu

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 the United States and/or other countries.

©Copyright 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 Information . . . . . . . . . . . . . . . . . . . . . . . . . . .ix Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Laser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x Avis relatif à l'utilisation de laser. . . . . . . . . . . . . . . . . . . . . . . . . x Avvertenze sui prodotti laser . . . . . . . . . . . . . . . . . . . . . . . . . . xi Avisos sobre el láser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Declaração sobre Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Laserinformatie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Lasermeddelelse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Huomautus laserlaitteesta . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii Laser-notis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Laser-melding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Avís sobre el Làser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Japanese Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Chinese Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi Korean Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xviii Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxiii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

iii

4049-XXX Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Black Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Blank Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Blurred or Fuzzy Print . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Dead Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Fan (927 Error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Fuser Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Fuser: 920, 921, or 922 Error . . . . . . . . . . . . . . . . . . . . 2-19 Fuser: 923 or 924 Error . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Horizontal Void or Streak. . . . . . . . . . . . . . . . . . . . . . . . 2-20 LAN Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Network Card 977 Errors. . . . . . . . . . . . . . . . . . . . . . . . 2-21 Network Wrap Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Output Bin Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Operator Panel Problem . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Paper Feed Problem, 500-Sheet Option or 200-Sheet Second Drawer, Non-Rt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Paper Feed, Base Printer . . . . . . . . . . . . . . . . . . . . . . . 2-23 Paper Feed, Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . 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 Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Paper Size Sensing Problem. . . . . . . . . . . . . . . . . . . . . 2-31 Regularly Spaced Marks . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Random Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Skew, all edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Skew, top and bottom only . . . . . . . . . . . . . . . . . . . . . . 2-33 Stalled (diamonds on display) . . . . . . . . . . . . . . . . . . . . 2-34 Vertical Void or Streak. . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

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4049-XXX Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . 3-1 Diagnostics Mode Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Auto Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Auto Clean Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Auto Clean Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Envelope Enhance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Envelope Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Flash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Fuser Temperature And Warm-Up Time . . . . . . . . . . . . . 3-8 Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Fuser Warm-Up Time . . . . . . . . . . . . . . . . . . . . . . . . .3-9 LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Maintenance Kit Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Memory Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Paper Feed Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Parallel Confidence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Print Test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Print Test 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Print Test 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Top Margin and Duplex Quick Tests . . . . . . . . . . . . . . . 3-15 Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Wrap Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

v

4049-XXX Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Developed Image Test . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 LAN Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Print Test Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Print Test with RIP Board Removed . . . . . . . . . . . . . . . 3-18 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 And 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 Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-7 Paper Feed Magnet Adjustment . . . . . . . . . . . . . . . . . . . 4-8 Printhead Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-9 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Left Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Top Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Engine Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Exit Sensor Board Removal . . . . . . . . . . . . . . . . . . . . . 4-16 Fan/Redrive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Fuser Input Guide Removal. . . . . . . . . . . . . . . . . . . . . . 4-19 Fuser Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Fuser/Sensor Cable Removal . . . . . . . . . . . . . . . . . . . . 4-21 Fuser Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Fuser Shroud Assembly Removal . . . . . . . . . . . . . . . . . 4-23 HVPS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 INA or Hard Disk Removal . . . . . . . . . . . . . . . . . . . . . . 4-26 Input Sensor Board Removal . . . . . . . . . . . . . . . . . . . . 4-26 Lower Frame Assembly Removal . . . . . . . . . . . . . . . . . 4-28

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Service Manual

4049-XXX Removal Procedures (continued) LVPS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29 LVPS Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Paper Feed Rollers Removal . . . . . . . . . . . . . . . . . . . . . 4-31 Paper Feed Magnet Assembly Removal . . . . . . . . . . . . 4-32 Paper Size Switch Removal . . . . . . . . . . . . . . . . . . . . . . 4-33 Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 RIP Board and Inner EMC Shield Removal . . . . . . . . . . 4-35 Toner Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Torquer Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 Transfer Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Transfer Roll Housing Removal . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . 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, Rt . . . . . . . . . . . . . . . . . . . . 4-44 High Capacity Feeder Paper Feed Rollers. . . . . . . . . . . 4-45 High Capacity Feeder Cover . . . . . . . . . . . . . . . . . . . . . 4-47 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Major Assembly Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Transfer Roller Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Engine Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . 5-4 RIP Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Board Installation Hardware . . . . . . . . . . . . . . . . . . . . . . . 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 Straps . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 High Capacity Feeder Board Connectors. . . . . . . . . . . . 5-12

vii

4049-XXX Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Scheduled Mechanical Maintenance . . . . . . . . . . . . . . . . . . . 6-3 Printhead Window Cleaning Procedure . . . . . . . . . . . . . . . . . 6-4 Cleaning The Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . 7-1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Lower Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Paper Feed Alignment Gears . . . . . . . . . . . . . . . . . . . . . 7-14 Paper Feed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Standard Paper Tray (200-Sheet) . . . . . . . . . . . . . . . . . . 7-18 Paper Tray (500-Sheet). . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 Duplex Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Envelope+ and 100-Sheet Auxiliary Feeder . . . . . . . . . . 7-40 Dual Rear Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X1

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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, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property rights may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user's responsibility.

Laser Notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 825. Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (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 I level during normal operation, user maintenance, or prescribed service condition.

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Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 825 gemäß amtlicher Bestätigung erfüllt. Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l'utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 825 relatives aux produits laser de Classe I. Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d'un laser de Classe IIIb (3b) (arséniure de gallium d'une puissance nominale de 5 milliwatts) émettant sur des longueurs d'onde comprises entre 770 et 795 nanomètres. L'imprimante et son système laser sont conçus pour impossible, dans des conditions normales d'utilisation, d'entretien par l'utilisateur ou de révision, l'exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

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Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825. I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all'arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d'onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1..

Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 825 para productos láser de Clase I (1). Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

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Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 825. Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 825. Laserprodukten van klasse I 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.

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Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 825 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä. VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

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Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 825. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 825. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

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Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d'IEC 825. Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d'arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d'ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d'un nivell de classe I durant una operació normal, durant les tasques de manteniment d'usuari ni durant els serveis que satisfacin les condicions prescrites.

Japanese Laser Notice

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Chinese Laser Notice

Korean Laser Notice

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Trademarks
Optra and Lexmark are trademarks of Lexmark International, Inc.,
registered in the United States and/or other countries.

AppleTalk 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 commands (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.

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Safety Information ·
This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

· ·

Consignes de Sécurité ·
Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

· ·

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Norme di sicurezza ·
Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l'utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l'utilizzo 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 smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

· ·

Sicherheitshinweise ·
Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. 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 für dieses Produkt übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

· ·

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Pautas de Seguridad ·
Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

· ·

Informações de Segurança ·
Este produto foi concebido, testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

· ·

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Informació de Seguretat ·
Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informació pel manteniment d'aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d'aquest producte. El personal professional ha d'estar-ne assabentat i prendre les mesures convenients.

· ·

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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 locate or repeat symptoms of printer problems. "Repair Information" provides instructions for making printer adjustments and removing and installing FRUs. "Connector Locations" uses illustrations to identify the 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.

· · · · · ·

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1. General Information
The OptraTM Laser Printers are designed to attach to IBM-compatible 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.

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Power Consumption
R/L/Rt/R+/Rt+ Rx/Lx/Lx+

Power Saver Mode Printing (average) Max. AC draw 110V Max. AC draw 220V

21W 260W 6.8A 3.4A

20W 310W 9.8A 5.0A

Options
The following options are available. 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)

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Maintenance Approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, 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 computer. After you complete the repair, perform tests as needed to verify the repair.

Tools Required For Service
Flat-blade screwdriver #1 Phillips screwdriver #2 Phillips screwdriver 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

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Abbreviations
ASIC CSU DRAM EEPROM EP ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR VAC VDC Application-Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Electrically Erasable Programmable ReadOnly 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

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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 frequently or at inappropriate times they may be symptomatic of a service problem. Use the service error code, symptom table, service checks, and diagnostic aids to determine the corrective action necessary to repair a malfunctioning printer.

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4049-XXX Refer to the diagnostics Error log for the last six machine errors.
Error Code 20 Paper Jam 21 Paper Jam Explanation The input sensor was not unmade in time. The exit sensor was not made in time after the input sensor was made. The exit sensor was not unmade in time. 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 The defined paper size is too short to print data as formatted. Input sensor made at wrong time. May be due to the paper feeding manually while motors running and previous page in path. Duplex unit is installed but paper tray is not sensed. Envelopes/paper loaded are wrong size. 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. The output bin sensor has not been unmade.See "Output Bin Sensor" on page 2-22.

22 Paper Jam 23 Paper Jam

24 Short Paper 25 Incorrect Manual Feed

26 Duplex Tray Missing 27 Change Envelope/Paper 28 Load Envelope/Paper

29 Output Bin Full

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Error Code 30 Top Cover Open or Print Cartridge Missing Explanation Make sure the spring-mounted pin on the printhead shroud is installed properly and that it is detected by the ramp on the print cartridge as the cover closes. The pin should enter the tower on the HVPS and depress the cover switch. The installed print cartridge is not supported by the Optra printer. Memory is too full to collate the print job. 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. 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. Font card format not supported by printer. Defective font card installed in font slot. Printer needs data on removed card. 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. Flash problem at POR or while attempting to write.

32 Wrong Print Cartridge installed 37 Insufficient Collation Memory 38 Memory Full

39 Complex Page

43 Font Card Not Supported 44 Defective Font Card 47 Font Card Removed While Printing 51 Defective Flash

52 Flash Full 53 Unformatted Flash

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Error Code 54 Serial Error 56 Serial Port Disabled or, Parallel Port Disabled Explanation Framing or parity error on serial. 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 Parallel Buffer, and changing the setting from Disabled to Auto. 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. 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. Format the 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. These user codes are documented in various network card user manuals. See "Network Wrap Tests" on page 2-22 Printer has reached 200,000 prints without maintenance count reset. Refer to "Scheduled Mechanical Maintenance" on page 6-3.

57 Check Duplex Connection

58 Duplex Not Attached 59 Duplex Cover Open 62 Disk Full

63 Unformatted Disk 64 Defective Disk

7X Network Card Codes

80 Scheduled Maintenance

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Error Code 81 Engine Code CRC Explanation Microcode to be programmed into the engine board during a machine upgrade has failed a CRC check. The microcode data will be discarded and must be retransmitted from the host computer. 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 internal test pages, replace the RIP Board. If the error appeared while sending a job from the host computer 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. 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 contact 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 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 contact.

88 Toner Low 90X Software Error

917 Transfer Roll Error

918 Transfer Roll Error

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Error Code 920 Fuser Error Explanation Fuser is below temperature while printing. See "Fuser: 920, 921, or 922 Error" on page 2-19. Fuser is below standby temperature when idle. See "Fuser: 920, 921, or 922 Error" on page 2-19. Fuser failed to reach standby temperature. See "Fuser: 920, 921, or 922 Error" on page 2-19. Fuser is too hot while printing or when idle. See "Fuser: 923 or 924 Error" on page 2-20. Open detected in thermistor circuit. See "Fuser: 923 or 924 Error" on page 2-20. See "Fan (927 Error)" on page 2-18. Erase lamp assembly missing or disconnected. No first hsync. See "Printhead" on page 2-30. Lost hsync. See "Printhead" on page 2-30. Lost lock condition. See "Printhead" on page 2-30. Mirror motor unable to reach operating speed. See "Printhead" on page 2-30. ROM SIMM failed CRC; code data or font data. Run the diagnostic Memory Test for ROM. Replace the SIMM if the test fails or the problem recurs after POR; replace the RIP Board if the SIMM does not fix the problem. RIP processor failure. Replace the RIP Board.

921 Fuser Error

922 Fuser Error

923 Fuser Error

924 Fuser Error

927 Fan Stalled 928 Erase Lamps 931 Printhead Error 932 Printhead Error 934 Printhead Error 935 Printhead Error

941 ROM SIMM

944 RIP Board

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Error Code 945 RIP Board 946 RIP Board 947 Engine Board 948 Engine Board 950 RIP Board 951 Engine Board 952 Engine Board 953 Engine Board 954 Engine Board 960 Memory Error Explanation ASIC 1 failure. Replace the RIP Board. ASIC 2 failure. Replace the RIP Board. Engine ASIC RAM failure. Replace the engine board. Engine ASIC electronics failure. Replace the engine board. SRAM failure. Replace the RIP Board. PQET SRAM failed verification test. Replace the engine board. Unable to zero PQET SRAM. Replace the engine board. NVRAM failure. Replace the engine board. Printhead crystal not functioning correctly. 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. 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. Network card 2 processor failure. Replace network card 2. Network card 1 RAM failure. Replace network card 1.

961 Memory Error

970 Network Card 1 970 Network Card 2 971 Network Card 1

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Error Code 971 Network Card 2 972 Network Card 1 972 Network Card 2 973 Network Card 1 973 Network Card 2 974 Network Card 1 974 Network Card 2 976 Network Card 1 Explanation 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. Network card 2 EEPROM/NVRAM failure. Replace network card 2. Network card 1/ Network interface error. Replace network card 1. Network card 2/Network interface error. Replace network card 2. 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 software or microcode incompatibility problem. Do not replace the card. Contact your next level of support. 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 software or microcode incompatibility problem. Do not replace the card. Contact your next level of support. Network card 1 is installed but is not communicating with the RIP Board. See "Network Card 977 Errors" on page 2-21. Network card 2 is installed but is not communicating with the RIP Board. See "Network Card 977 Errors" on page 2-21. General network 1 card hardware error. Replace network card 1.

976 Network Card 2

977 Network Card 1

977 Network Card 2

978 Network Card 1

Diagnostic Information 2-8

4049-XXX
Error Code 978 Network Card 2 979 Network Card 1 Explanation 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 incompatibility problem. Do Not replace the card. Contact your next level of support. 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 incompatibility problem. Do Not replace the card. Contact your next level of support. Duplex error. See "Duplex" on page 2-16. Duplex system board failure. Replace the duplex system board. Communications between the duplex unit and the printer have failed. See "Duplex" on page 2-16.

979 Network Card 2

990 Duplex Option 991 Duplex System Card Failure 993 Duplex Comm. Failure

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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 observing the following: 1. One and one half rows of pels appear on the display and then clear. 2. Diamonds fill the display and then clear. 3. 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. 4. The ready screen appears on the display. Note: Diagnostics menu appears if you are in diagnostic mode. 5. The drive motor and the mirror motor start. The fan starts to run at high speed. 6. 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 Dead Machine Machine Hangs Displaying Diamonds Repeats a pattern of 5 beeps and a pause. Operator Panel Paper Feed, Base Printer Paper Feed, Duplex Unit Paper Feed Problem, 500Sheet Option or 200-Sheet Second Drawer, Non-Rt Go To "Dead Machine" on page 2-15. Machine Hangs Displaying Diamonds Service Check. "Operator Panel Problem" on page 2-22. "Operator Panel Problem" on page 2-22. "Paper Feed, Base Printer" on page 2-23. "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, Rt" on page 2-26. "Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Auxiliary Feeder" on page 2-26. "Paper Feed Problem, Dual Rear Feeder" on page 2-27. "Paper Feed Problem, 200-Sheet Second Drawer, Rt" on page 2-26. "Paper Feed Problem, High Capacity Feeder" on page 2-29 Automatic Paper Size Sensing Problem Service Check. "LAN Problems" on page 2-21. "Blank Page" on page 2-14. "Black Page" on page 2-13. "Random Marks" on page 2-32.

Paper Feed Problem, Envelope+ Feeder/100-Sheet Auxiliary Feeder Paper Feed Problem, Dual Rear Feeder Paper Feed Problem, 200Sheet Second Tray, Rt Paper Feed Problem, High Capacity Feeder Automatic Paper Size Sensing Problem LAN Problems Blank Page Black Page Random Marks

2-11

4049-XXX
Symptom Regularly Spaced Marks Skew, all edges Skew, top and bottom only Light Print Blurred or Fuzzy Print Residual Image Honeycomb Background Horizontal Void or Streak Vertical Void or Streak Banding Go To "Regularly Spaced Marks" on page 2-32. "Skew, all edges" on page 2-33. "Skew, top and bottom only" on page 2-33. "Light Print" on page 2-21. "Blurred or Fuzzy Print" on page 2-15. "Residual Image" on page 2-32. "Honeycomb" on page 2-20. "Background" on page 2-12. "Horizontal Void or Streak" on page 2-20. "Vertical Void or Streak" on page 2-34. "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 rollers 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 returns 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 following voltages; then stop the test and check the voltages again:
Connector Voltage while Printing Voltage while Idling

J13-1 J13-2 J13-3

J13-8

Less than 5 VDC Less than 5 VDC (Fluctuates between pages) +1.5 VDC Less than 1 VDC

0 VDC 0 VDC 0 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 increasing the Transfer setting; users with more normal jobs will see no difference. 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

J13-5 to J13-4 J13-6 to J13-4

+24 VDC +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.
Connector Voltage while Printing Voltage while Idling

J13-1 to J13-4 J13-2 to J13-4

+4.5 VDC +4 VDC

0 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 printhead 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 Printing Voltage while Idling

J13-1 to J13-4 J13-2 to J13-4 J13-3 to J13-4

J13-8 to J13-4

Less than 5 VDC Less than 5 VDC (Fluctuates between pages) +1.5 VDC Less than 1 VDC

0 VDC 0 VDC 0 VDC

+6 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 transfer 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 damage, 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] 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 system 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 J32 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

Duplex System Board

J3-3 J3-5 J3-7 J5-2 J5-4 J5-6

+34 VDC +5 VDC +5 VDC +34 VDC +5 VDC +5 VDC

Diagnostic Information 2-16

4049-XXX If you do not find a cable or voltage problem replace the duplex system 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 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 voltage on J5-12 of the duplex system board; it should fluctuate from 0 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. 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 0 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 thermistor is in contact with the fuser hot roll. The system board reads the thermistor resistance and toggles a TRIAC in the LVPS which cycles the lamp on and off to maintain the proper hot roll temperature. 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 continuously, the fuse melts and shuts off power to the lamp. The thermistor output voltage is proportional to the fuser temperature and is on engine board J8-4. The voltage cycles from approximately 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 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 increases 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 0 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, mea2-19

4049-XXX sure the voltage to the fuser lamp during a POR; it should be line