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OptraTM E 4026-0XX
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Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
4026-0XX
Third Edition (April 1997)
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 and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 1995, 1997 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.
4026-0XX
Contents
1
Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . .vi Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi Ozone Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Service Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 User Error Message Table . . . . . . . . . . . . . . . . . . . . . . . . 2-6 User Secondary Error Message Table . . . . . . . . . . . . . . . 2-8 Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . 2-10 POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Charge Brush Service Check . . . . . . . . . . . . . . . . . . . . . 2-15 Cover Interlock Service Check . . . . . . . . . . . . . . . . . . . . 2-16 D-Roll Assembly Service Check. . . . . . . . . . . . . . . . . . . 2-16 Exit Sensor Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-17 Fan Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Cold Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-18 Hot Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Input Sensor Service Check. . . . . . . . . . . . . . . . . . . . . . 2-20 Low Voltage Power Supply Service Check . . . . . . . . . . 2-22 Main Drive Motor Service Check . . . . . . . . . . . . . . . . . . 2-25 Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . 2-27 Optional Paper Tray Two Service Check . . . . . . . . . . . . 2-28 Paper Take-Up Solenoid Service Check . . . . . . . . . . . . 2-32 Parallel Port Service Check . . . . . . . . . . . . . . . . . . . . . . 2-34 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-34 Paper Feed Frame Assembly Service Check . . . . . . . . 2-37 Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . 2-38 Registration Service Check . . . . . . . . . . . . . . . . . . . . . . 2-44 Transfer Assembly Service Check . . . . . . . . . . . . . . . . . 2-44 Transfer Corona Service Check . . . . . . . . . . . . . . . . . . . 2-45 ROM SIMM Service Check . . . . . . . . . . . . . . . . . . . . . . 2-45 iii
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Power-On Self Test (Post) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Printer Diagnostic Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Service Diagnostic Test Page . . . . . . . . . . . . . . . . . . . . . 3-4 User Mode Print Test Page . . . . . . . . . . . . . . . . . . . . . . . 3-6 Paper Feed Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Fuser Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Configuration Mode Operator Panel Overlay . . . . . . . . 3-10 Operator Panel Configuration Mode Button Definition . 3-11 Hex Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Restoring Factory Defaults . . . . . . . . . . . . . . . . . . . . . . 3-13 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Print Registration Adjustment . . . . . . . . . . . . . . . . . . . . . 4-2 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Board Cage Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Cover Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Controller Board Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-5 D-Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Engine Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Exit Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Exit Sensor Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Exit Paper Feed Roller Assembly Removal. . . . . . . . . . . 4-7 Fan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Fuser Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Fuser Lower Frame Assembly Removal . . . . . . . . . . . . . 4-8 Fuser Upper Frame Assembly Removal . . . . . . . . . . . . . 4-8 Fuser Paper Separator Removal. . . . . . . . . . . . . . . . . . . 4-8 HVPS Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 HVPS Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Left Side Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 LVPS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Main Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . 4-10 Main Drive/Paper Feed Gears Removal . . . . . . . . . . . . 4-10 Manual Paper Feed Guide Plate Removal . . . . . . . . . . 4-10 Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Paper Entry Sensor Removal . . . . . . . . . . . . . . . . . . . . 4-11 Paper Entry Sensor Flag Removal . . . . . . . . . . . . . . . . 4-11 Paper Feed Frame Assembly Removal. . . . . . . . . . . . . 4-12 iv
4026-0XX Removal Procedures (continued) Paper Feed Solenoid Removal . . . . . . . . . . . . . . . . . . . 4-12 Paper Feed Input Tray Assembly Removal . . . . . . . . . . 4-12 Paper Lift Plate Assembly Removal . . . . . . . . . . . . . . . . 4-12 Paper Separator Removal . . . . . . . . . . . . . . . . . . . . . . . 4-13 Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Print Media Selection Lever Removal (06C/06F/071) . . 4-13 Second Paper Tray Option Connector Removal . . . . . . 4-13 Thermal Fuse Removal (06A/06B/06D/06J/070) . . . . . . 4-14 Thermostat Removal (06C/06F/071) . . . . . . . . . . . . . . . 4-14 Thermistor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Transfer Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . 5-1 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . 5-2 Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Second Paper Tray Sensor Board (Option) . . . . . . . . . . . 5-7 Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Paper Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Paper Entry Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Paper Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . 6-1 Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Assembly 2: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Assembly 3: Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Assembly 4: Paper Feed Input Tray. . . . . . . . . . . . . . . . 6-14 Assembly 5: Paper Feed Frame. . . . . . . . . . . . . . . . . . . 6-16 Assembly 6: Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Assembly 7: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . 6-22 Assembly 8: Transfer Assembly. . . . . . . . . . . . . . . . . . . 6-26 Assembly 9: Option - Second Paper Drawer . . . . . . . . . 6-28 Assembly 10: Options . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34 Assembly 11: Miscellaneous . . . . . . . . . . . . . . . . . . . . . 6-35 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
v
4026-0XX
Notices and Safety Information
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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4026-0XX Laser product labels are located on the back of the printer and on the printhead.
CLASS 1 LASER PRODUCT LASER KLASSE1 NACH IEC825 LUOKAN 1 LASERLAITE APPAREIL A LASER DE CLASSE1 TO IEC 825
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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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4026-0XX
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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4026-0XX
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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4026-0XX
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.
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4026-0XX
Japanese Laser Notice
Chinese Laser Notice
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4026-0XX
Korean Laser Notice
Safety Information
· ·
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. The safety features of some parts may not always be obvious. Therefore, replacement parts must have the identical or equivalent characteristics as the original parts.
·
Sicherheitshinweise
·
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
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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. Ersatzteile müssen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen, da nicht immer offensichtlich ist, welche Teile des Geräts Sicherheitsmerkmale aufweisen.
Consignes de Sécurité
· · ·
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. Les normes de sécurité de certaines pièces n'étant pas toujours explicites, les pièces de rechange doivent être identiques ou conformes aux caractéristiques des pièces d'origine.
Norme di sicurezza
· ·
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. Poiché non tutti i pezzi di ricambio garantiscono la stessa sicurezza, questi devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali.
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Pautas de Seguridad
· ·
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
Notices and Safety Information xvii
4026-0XX personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias. Los dispositivos de seguridad de algunas piezas no siempre pueden reconocerse a simple vista. Por lo tanto, los recambios deben poseer características idénticas o equivalentes a las de las piezas originales.
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Informações de Segurança
· ·
As informações de segurança relativas a este produto destinamse 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. Os dispositivos de segurança de algumas peças poderão não ser sempre suficientemente evidentes. Assim, as peças sobressalentes devem possuir características idênticas ou equivalentes às peças originais.
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Informació de Seguretat
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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. Les característiques de seguretat d'algunes de les peces poden no ser òbvies. Per tant, les característiques dels recanvis hauran de ser idèntiques o equivalents a les de les peces originals.
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xviii Service Manual
4026-0XX
Chinese Safety Information
Korean Safety Information
Ozone Information
This product does not produce measurable amounts of ozone gas.
Notices and Safety Information
xix
4026-0XX
Preface
This manual is divided into the following chapters:
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· · · · ·
"General Information" contains a general description of the printer, options, and the maintenance approach used to repair it. General environmental and safety instructions as well as 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. "Parts Catalog" contains illustrations and part numbers for individual FRUs.
xx Service Manual
4026-0XX
1. General Information
This printer is a letter-quality page printer designed to attach to an IBM Personal Computer or other computers compatible with the IBM Personal Computer (with 386 processor or higher). The printer is available in models 4026-06A, 06C, 06D, and 06J without Flash memory and models 4026-06B and 06F with Flash memory. Model upgrade is not available. The printer can print in various pitches and has bit image graphics capability, allowing the user to print advanced graphics. Model 4026-06D has PostScript Level 2 emulation. The model 4026-070 printer includes a manual input guide, additional memory and font selections. The 4026-071 is a label printing model which also includes a manual input guide, additional memory and font selections.
Options
Memory upgrade options are 1MB, 2MB, and 4MB. The paper tray option is a 250 sheet secondary paper tray. Contact your point of purchase for options available in your country.
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. After you complete the repair, perform tests as needed to verify the repair.
Tools Required For Service
Magnetic Phillips Screwdriver
General Information 1-1
4026-0XX
Acronyms
CSU DRAM EP EPROM ESD FRU HVPS LASER LCD LED LVPS MROM NVRAM OEM PC POST ROM SIMM SRAM UPR V ac V dc Customer Setup Dynamic Random Access Memory Electrophotographic Process Erasable, Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low Voltage Power Supply Masked Read Only Memory Nonvolatile Random Access Memory Original Equipment Manufacturer Photoconductor Power-On Self Test Read Only Memory Single In-Line Memory Module Static Random Access Memory Used Parts Return Volts alternating current Volts direct current
1-2
4026-0XX
2. Diagnostic Information Start
CAUTION: NEVER manually actuate or disable the top cover interlock switch and the printhead shutter actuator at the same time. To perform some of the service checks and tests, such as troubleshooting paper feed problems, you need to actuate the top cover interlock switch with the covers opened or removed and power applied to the machine. It is important for personal safety that you DO NOT, FOR ANY REASON, disable the printhead shutter actuator when power is on. 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. Use the service error code, user error message, symptom table, service checks, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. The lights on the operator panel can indicate either a user error message or service error message. When a service error occurs the printer stops printing and all operator panel LEDs blink in a continuous pattern, indicating a service error, until the printer is powered off. If all operator panel LEDs are blinking, go to the "Service Error Codes" on page 2-2. When a user error message occurs, one or two operator panel LEDs are on solid or blinking. Go to the "User Error Message Table" on page 2-6. If your machine does not have a service error code and does not complete POST, go to the "POST Symptom Table" on page 2-12. If your machine completes POST without an error, and you have a symptom, go to the "Symptom Table" on page 2-13. Locate your symptom and take the appropriate action. If a service error code appears while you are working on the machine, go to the "Service Error Codes" on page 2-2 and take the indicated action for that error.
Diagnostic Information 2-1
4026-0XX
Service Error Codes
When a service error occurs the printer stops printing and all operator panel LEDs blink in a continuous pattern, indicating a service error, until the printer is powered off. Press and release the operator panel button to display the service error code. Locate the blinking LEDs in the following table and take the indicated action.
Blinking Operator Panel LED Software Service Error Code Action Run the Printer Diagnostic Test to diagnose between the ROM SIMM and the controller board. If no other error code displays after the test completes, replace the controller board.
Fuser Failure Error
Go to the "Cold Fuser Service Check" on page 2-18.
Mirror Motor Error
The Polygon Mirror Motor is not rotating during printing. Replace the engine board. If this does not correct the problem, replace the printhead assembly.
Laser Diode Failure
Replace the printhead assembly. If this does not correct the problem, replace the engine board.
2-2
4026-0XX
Blinking Operator Panel LED Controller Card Failure
Action Replace Controller board
Optional Memory Error
Replace the optional memory SIMM. If this does not correct the problem, replace the controller board.
Fan Failure Error
Go to the "Fan Service Check" on page 2-17.
ROM Checksum Error
Replace the ROM SIMM. If this does not correct the problem, replace the controller board.
Base Memory Error
Replace Controller board
Diagnostic Information 2-3
4026-0XX
Blinking Operator Panel LED NVRAM Failure Error
Action Replace Controller board
ASIC Register Failure Error
Replace Controller board
ASIC SRAM Failure Error
Replace Controller board
Flash Memory Failure Error
Replace the ROM SIMM w/Flash. If this does not correct the problem, replace the controller board.
Font Checksum Failure Error
Replace the ROM SIMM. If this does not correct the problem, replace the controller board.
2-4
4026-0XX
Blinking Operator Panel LED Engine Board Communications Failure Error
Action Replace the engine board. If this does not correct the problem, replace the controller board.
Controller SRAM Failure Error
Replace Controller board
Diagnostic Information 2-5
4026-0XX
User Error Message Table
When a user error message occurs the printer stops printing and one or two operator panel LEDs are on solid or blinking until the printer is powered off. Locate the printer's LED Status in the following table and take the indicated action.
User Error Message Paper Jam LED Status Paper Jam on solid Action Open cover and clear any paper jams. Close the top cover. If the error message is still present, go to the "Paper Feed Service Check" on page 2-34. Load media into the manual slot and push the operator panel button to resume printing or do a front panel reset by pressing and holding the operator panel button for more than three seconds. Load media in the appropriate paper tray and push the operator panel button to resume printing or do a front panel reset by pressing and holding the operator panel button for more than three seconds. Close the top cover. If the error LED remains on solid and POST does not continue, go to the "Cover Interlock Service Check" on page 2-16
Load Manual Paper/ Envelope
Load Paper blinks and Press Button on solid
Load Paper/Load Envelope
Load Paper on solid and Press Button on solid
Top Cover Open
Error on solid
2-6
4026-0XX
User Error Message Memory Full/Complex Page/Resolution Reduction Warning/ Data Transmission Error
LED Status Error on solid and Press Button on solid
Action The printer memory is full or the page is too complex to print. The printer is forced to reduce the resolution of a formatted page to 300 dpi before printing, or the printer is unable to maintain the required data transfer rate. Go to the "User Secondary Error Message Table" on page 2-8. This condition only occurs when the Flash SIMM is installed. (4026-06B or 4026-06F) Go to the "User Secondary Error Message Table" on page 2-8.
Flash Memory Full
Error blinks and Press Button on solid
Diagnostic Information 2-7
4026-0XX
User Secondary Error Message Table
Press and release the operator panel button two times to display the user secondary error LED status. Each press and release action must be performed within a half second. Locate the printer's LED status in the following table and take the indicated action.
User Error Message Complex Page LED Status Ready, Error, and Press Button on solid Action Switch the printing mode to a different printing mode using the Lexmark driver for Windows, or push the operator panel button to resume printing, or do a front panel reset by pressing and holding the operator panel button for more than three seconds. Change the printing mode to Quick Print Plus or reduce the complexity of the job or the resolution, or push the operator panel button to resume printing, or do a front panel reset by pressing and holding the operator panel button for more than three seconds.
Memory Full
Ready, Data, Error, and Press Button on solid
2-8
4026-0XX
User Error Message Resolution Reduction
LED Status Ready, Data blinking and the Error, Press Button on solid
Action Switch from the GL/2 or raster mode to Quick Print Plus mode using the Lexmark driver for Windows, or press the operator panel button to resume printing, or do a front panel reset by pressing and holding the operator button for more than three seconds. Switch to Print Accelerator using the Lexmark driver for Windows if 2MB of memory or more is installed, or switch to the GL/2 printing mode using the Lexmark driver for Windows, or push the operator panel button to resume printing, or do a front panel reset by pressing and holding the operator panel button for more than three seconds. This condition only occurs when the Flash memory is full.
Data Transmission Error
Data, Error, and Press Button on solid
Flash Memory Full
Error blinking and Press Button on solid
Diagnostic Information 2-9
4026-0XX
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. 2. 3. 4. 5. 6. 7. 8. 9. All LEDs come on solid. The fan turns on for 2 seconds. All the LEDs turn off. The engine board checks the status of the cover interlock switch. The LEDs begin to turn on then off sequentially. The fan turns off. The engine board checks the status of the paper exit sensor. The engine board checks the status of the thermistor. The fuser lamp turns on. Note: The printer may be idle for up to 40 seconds as the fuser warms to operating temperature. Printer idle time is shorter if the fuser is already warm. 10. 11. 12. 13. 14. The polygon motor (printhead motor) turns on. The main motor turns on. The paper feed gears turn. The print cartridge drive gear engages. The paper feed take-up shaft and D-roll assembly rotates to home position. (The paper feed lift plate assembly is in the down position). All the LEDs turn off. Models 4026-06A, 06C, 06D and 06J, 070 and 071 - The Ready LED turns on solid and the Data LED blinks. Go to Step 17. Models 4026-06B and 06F - The Ready LED turns on solid and the Data LED blinks. The controller board checks flash ROM installation. The controller board verifies that flash is formatted. The controller board attempts to format flash if unformatted. The Data LED blinks during format. The printer continues POST after format is complete. If format fails, a "Flash Memory Failure" error displays. The main drive motor turns off.
15. 16.
· · · · · ·
17.
2-10
4026-0XX 18. The polygon motor (printhead motor) turns off. 19. The Data LED turns off. 20. The Ready LED stays on solid. If your printer did not successfully complete POST, locate the symptom in the "POST Symptom Table" on page 2-12 and take the appropriate action. If the printer completes all these steps and no error indications are displayed, the printer has successfully completed the POST. If the printer has completed POST without an error and a symptom exists, go to the "Symptom Table" on page 2-13.
Diagnostic Information 2-11
4026-0XX
POST Symptom Table
Symptom POST completes except one or more LEDs do not come on. None of the LEDs come on. The printer is dead (No LEDs come on, no motor turns) The fan does not come on. The fuser lamp does not come on. The polygon motor does not come on. The main drive motor does not come on. The paper feed gears do not turn. The paper feed solenoid picks and tries to feed paper. The toner/print cartridge gears do not turn. Action Go to the "Operator Panel Service Check" on page 2-27. Go to the "Operator Panel Service Check" on page 2-27. Go to the "Low Voltage Power Supply Service Check" on page 2-22. Go to the "Fan Service Check" on page 2-17 Go to the "Cold Fuser Service Check" on page 2-18. Replace the printhead assembly. If this does not fix the problem, replace the engine board. Go to the "Main Drive Motor Service Check" on page 2-25. Go to the "Paper Feed Service Check" on page 2-34. Go to the "Paper Feed Service Check" on page 2-34. Go to the "Main Drive Motor Service Check" on page 2-25.
2-12
4026-0XX
Symptom Table
Locate your symptom in the following table and take the appropriate action
Symptom Dead printer Fan not working Fan noisy Fuser parts melted Fuser Lamp doesn't light Toner not fused to the paper Blank page Black page High or heavy background Offset print (image around characters) Poor image (characters washed out) Paper jams Main Drive Motor noisy Main Drive Motor does not move Main Drive Motor runs backward Action Go to the "Low Voltage Power Supply Service Check" on page 2-22. Go to the "Fan Service Check" on page 2-17. Go to the "Fan Service Check" on page 2-17 Go to the "Cold Fuser Service Check" on page 2-18. Go to the "Cold Fuser Service Check" on page 2-18. Go to the "Cold Fuser Service Check" on page 2-18. Go to the "Print Quality Service Check" on page 2-38. Go to the "Print Quality Service Check" on page 2-38. Go to the "Print Quality Service Check" on page 2-38. Go to the "Print Quality Service Check" on page 2-38. Go to the "Print Quality Service Check" on page 2-38. Go to the "Paper Feed Service Check" on page 2-34. Go to the "Main Drive Motor Service Check" on page 2-25. Go to the "Main Drive Motor Service Check" on page 2-25. Replace the Engine board.
Diagnostic Information 2-13
4026-0XX
Symptom Paper is not picked or never leaves the primary tray Paper is not picked or never leaves the optional paper tray (Tray 2) Paper feeds continuously Paper fails to exit printer or stack in output bin Paper skew Toner on the back of the page Poor print quality Incorrect characters print Printer not communicating with host White or black lines or bands Paper wrinkled or bent Top cover will not close Light print
Action Go to the "Paper Feed Frame Assembly Service Check" on page 2-37. Go to the "Optional Paper Tray Two Service Check" on page 2-28. Go to the "Paper Feed Service Check" on page 2-34. Go to the "Paper Feed Service Check" on page 2-34. Go to the "Paper Feed Service Check" on page 2-34. Go to the "Transfer Assembly Service Check" on page 2-44. Go to the "Print Quality Service Check" on page 2-38. Go to the "Print Quality Service Check" on page 2-38. Go to the "Parallel Port Service Check" on page 2-34. Go to the "Print Quality Service Check" on page 2-38. Go to the "Paper Feed Service Check" on page 2-34. Go to the "Cover Interlock Service Check" on page 2-16. Go to the "Print Quality Service Check" on page 2-38
2-14
4026-0XX
Service Checks
Charge Brush Service Check
Note: The charge brush charges the photoconductor and is located inside the photoconductor unit.
FRU 1 Action
Photoconductor Unit
Spots and marks can be caused by a defective charge brush inside the photoconductor unit. If there are any spots or marks, especially ones that appear in the same spot on the printed page, replace the photoconductor unit. Check the photoconductor unit for a damaged charge brush contact.
2
Main Drive Motor Gears Charge Brush Bias Contact (right side frame)
Be sure the main drive motor and gears are operating correctly and turning the charge brush. Check the charge brush bias contact located on the right side frame for damage, corrosion, wear or pitting. Intermittent failure of the charge brush contact can cause an all black page, horizontal black bars or lines. If any of these are found, replace the charge brush bias contact. Check the photoconductor unit ground contact on the right side frame for damage. Intermittent failure of the photoconductor unit ground contact can cause print quality problems such as an all black page, horizontal black bars or lines. If any of these are found, replace the photoconductor unit ground contact. Unplug the machine and check the HVPS for correct mounting, pitted or discolored contacts. If the HVPS is damaged, replace as necessary. If no problems are found replace the photoconductor unit assembly.
3
4
Photoconductor Unit Ground Contact
5
HVPS board
Diagnostic Information 2-15
4026-0XX
Cover Interlock Service Check
FRU 1 Action
Right Hand Transfer Bracket
Check the right hand transfer bracket actuator arm to be sure it contacts the interlock switch actuator mounted in the LVPS. Replace the bracket if the arm is damaged or broken.
2
Top Cover Interlock Switch LVPS
If the interlock switch is being actuated correctly, check the continuity of the switch between CN7A-1 and CN7A-2 on the cable as you activate the switch. If incorrect, replace the LVPS. Be sure the voltage at CN7-1 measures +24 V dc. If incorrect, turn the printer power off and disconnect the LVPS cable from the engine board. Turn the printer power on. The voltage on the LVPS cable pin 1 should measure approximately +24 V dc. If incorrect, replace the LVPS. If correct, go to the "Low Voltage Power Supply Service Check" on page 2-22.
3
D-Roll Assembly Service Check
FRU 1 Action
D-Roll D-Roll Clutch Assembly Solenoid
Check the D-roll for wear, broken, or worn parts. Replace as necessary. Be sure the clutch assembly operates correctly. Replace as necessary. Be sure the paper feed solenoid operates correctly. If the solenoid fails to pick, go to the "Paper Take-Up Solenoid Service Check" on page 2-32. Be sure the main drive/paper feed gears operate correctly. Check for broken teeth or damaged gears. Replace as necessary.
2
3
4
Paper Feed Drive Gears
2-16
4026-0XX
Exit Sensor Service Check
FRU 1 Action
Engine Board
Disconnect the exit sensor cable from the engine board. Check for +4.5 V dc to +5.5 V dc at CN8-1. If incorrect, replace the engine board. Be sure the exit sensor is snapped in place and the cable is firmly connected. Check the flag for damage and free movement and replace as necessary. Be sure the exit sensor spring is properly installed and not disconnected, damaged, or missing. Reconnect the exit sensor cable and check the voltage at CN8-3 on the engine board as you press the exit sensor flag. The voltage should change as the flag is moved in and out of the sensor. If incorrect, replace the exit sensor.
2
Exit Sensor Exit Sensor Flag
3
4
Exit Sensor Cable
Check the continuity of the cable. If incorrect, replace the exit sensor cable.
Fan Service Check
FRU 1 Action
Engine Board
Turn the printer power off. Disconnect CN11 on the engine board. Turn the printer on and measure the voltage between CN11-1 and CN11-2. The voltage should read approximately +24 V dc. If incorrect, replace the engine board. If correct, turn the printer off and connect CN11. Monitor the voltage between ground and CN11-1 (FAN*) immediately as you power on the printer. The voltage should go from +24 V dc with the fan motor off to approximately 0 V dc when the motor turns on. If incorrect, replace the fan motor and cable assembly.
2
Fan Motor/ Cable
Be sure the fan is properly installed if the fan is noisy. If correct, replace the fan motor assembly.
Diagnostic Information 2-17
4026-0XX
Cold Fuser Service Check
If all the Cold Fuser Service Check items are correct, go to the "Hot Fuser Service Check" on page 2-20 Note: Toner buildup on the fuser input guide, paper separator, hot roll and backup roll causes paper jams. When toner is partially fused to the paper it is usually caused by low fuser temperature. Avoid handling the lamp as much as possible as it is easily broken. Be careful not to touch the glass housing with bare hands as the skin contains acids that can weaken the glass. When making checks and handling the fuser lamp make sure you allow enough time for the fuser lamp and associated parts to cool.
FRU 1 Action
Line Voltage
The voltage to the printer must be within the following limits. 100 V ac (90 V ac - 110 V ac) Japan 120 V ac (108 V ac - 132 V ac) U.S. 220/230 V ac (207 Vac - 253 V ac) W.T.
2
Fuser Lamp
Turn off the printer and wait a few minutes for the fuser lamp to cool. Turn the machine on and observe the lamp turning on during POST. You can see the lamp through the left rear vents of the top cover. If the lamp lights, be sure the correct voltage lamp is installed. The voltage rating is stamped on one of the ceramic end pieces.
2-18
4026-0XX
FRU 3
Action
Thermistor
If the fuser lamp comes on and a fuser failure LED error code displays, be sure the thermistor is contacting the hot roll and the thermistor cable is firmly seated in connector CN2 on the engine board. Check for excessive toner buildup on the surface of the thermistor. Clean or replace as necessary. Turn the printer power off and disconnect the thermistor cable from CN2 on the engine board. Measure the resistance of the thermistor between CN2-1 and CN2-2. The resistance should measure 250K ohms or less. If incorrect, replace the thermistor and cable assembly. If correct, replace the engine board. Note: The thermistor assembly is fragile. Use care when handling to avoid damage.
4
Fuser Lamp Cable
If the fuser lamp does not come on and a fuser failure LED error code displays, unplug the printer power cord and check the continuity between the fuser cable contacts in the lower fuser cover. If incorrect, check the continuity of the fuser lamp, thermal fuse and terminals. Repair or replace as necessary. If correct, check the continuity of the fuser lamp cable. If incorrect, replace the cable. If correct, replace the following FRUs one at a time in the order shown: Engine Board LVPS If the lamp does not come on and the Error LED is on solid, go to the "Fan Service Check" on page 2-17
5
Fuser Thermostat (402606C and 06F)
Check the fuser thermostat if the fuser lamp does not come on or if it comes on and does not go off. Unplug the printer power cord and check the thermostat to be sure that it opens and closes properly. Replace as necessary.
Diagnostic Information 2-19
4026-0XX
Hot Fuser Service Check
Note: If you replace the fuser assembly for overheating, also replace the engine board. CAUTION: FUSER PARTS MAY BE HOT.
FRU 1 Action
Fuser Assembly
Check for melted or damaged hot roll bearings, drive gear, paper separators, thermistor, hot roll, backup roll or frame parts. If the fuser assembly shows evidence of overheating or thermal damage, repair as necessary. Note: If the lower fuser frame is damaged, replace the complete assembly.
2
Engine Board
Replace the engine board if the fuser continues to operate erratic or overheats.
Input Sensor Service Check
If the paper never leaves the tray or fails to be picked from the tray, go to the "Paper Feed Service Check" on page 2-34.
FRU 1 Action
Paper
Check the paper for rough edges, creases, tears, or folds. Be sure the paper leaves the paper tray as soon as it is picked by the D-Roll. If it does not, go to the "Paper Feed Service Check" on page 2-34.
2
Envelopes (if being used)
Be sure no more than 10 envelopes are stacked in the input paper tray. They may not pick or may jam at the input sensor or paper separator.
Note: Coated papers, synthetic papers, multi-sheet forms, thermal papers, envelopes with windows, holes, cutouts, perforations, string-ties, metal fasteners, exposed flap adhesive, excessive curl, bent corners and some labels cause problems.
2-20
4026-0XX
FRU 3
Action
Input Sensor Flag Input Sensor
Check the flag for damage, especially at the front edge, Be sure the flag moves freely. Replace the flag as necessary. Be sure the input sensor is correctly installed and the sensor/solenoid cable is properly connected. Disconnect the input sensor cable from the CN3 connector on the engine board. The voltage at CN3-1 measures between +4.5 V dc and +5.5 V dc. If incorrect, replace the engine board. If correct, reconnect the input sensor cable at CN3. Monitor the voltage at CN3-3 while moving the sensor flag in and out. The voltage changes from +2 V dc to 0 V dc. If incorrect, check the input sensor/solenoid cable continuity. If cable continuity is incorrect, replace the paper feed frame assembly. If cable continuity is correct, replace the following FRUs one at a time in the order shown: Input Sensor Engine Board
4
Diagnostic Information 2-21
4026-0XX
Low Voltage Power Supply Service Check
Note: The controller board, HVPS and printhead assembly receive power from the LVPS through the engine board. If the machine is dead, be sure the controller board is correctly seated in the engine board connector. Check and reseat all cables. Dead Printer
FRU 1 Action
Line Voltage
Check the AC line voltage. The voltages should be within the following limits: 100 V ac (90 V ac - 110 V ac) Japan 120 V ac (108 V ac - 132 V ac) U.S. 220/230 V ac (207 V ac - 253 V ac) W.T.
2
LVPS
The voltage measures approximately +5 V dc between CN7-4 and ground on the engine board. If incorrect, disconnect CN7 on the engine board and measure the voltage between CN7-4 (+5 V dc) and CN7-3 (+5 V ground). The reading should measure approximately +5 V dc. If +5 V dc is not present, unplug the printer line cord and check fuse F1. If the fuse is open, replace the fuse. If the fuse is not open, replace the LVPS.
3
Engine Board
If +5 V dc is present when CN7 is disconnected then disconnect CN2, CN4, CN5, CN9 and CN10 from the engine board. Also disconnect the controller board and remove the ROM SIMM and any optional memory SIMMs. Reconnect CN7 and check for +5 V dc. If incorrect, replace the engine board. Reinstall the controller board. Check for +5 V dc at CN7-4. If incorrect, replace the controller board.
4
Controller Board
2-22
4026-0XX
FRU 5
Action
ROM SIMM and Optional Memory SIMM
Reinstall the ROM SIMM. Check for +5 V dc at CN7-4. If incorrect, replace the ROM SIMM. Reinstall the optional memory SIMM if one was installed. Check for +5 V dc at CN7-4. If incorrect, replace the optional memory SIMM. Reconnect CN4 and check for +5 V dc at CN74. If incorrect, replace the HVPS. Reconnect CN5 and CN10. Check for +5 V dc at CN7-4. If incorrect, replace the printhead assembly. Reconnect CN2 and check for +5 V dc at CN74. If incorrect, replace the thermistor/cable assembly.
6
HVPS Printhead Assembly Thermistor
7
8
Post Incomplete - ERROR LED remains on solid Note: Be sure the top cover is closed when doing the following checks.
FRU 1 Action
LVPS
Disconnect the LVPS cable from the engine board. The voltage measures approximately +24 V dc between pin 1 (+24 V dc) and pin 2 (+24 V dc ground). If incorrect, replace the LVPS. Reconnect the LVPS cable and measure the voltage on CN7-1. The reading should measure approximately +24 V dc. If incorrect, disconnect CN3, CN4, CN6, CN9, CN10 and CN11 from the engine board. The voltage on CN7-1 measures +24 V dc. If incorrect, replace the engine board. If correct, reconnect one cable at a time checking the voltage at CN7-1 until the FRU causing the problem is found. Replace the failing FRU. If the CN3 or CN9 are causing the problem, it is necessary to disconnect each solenoid and check the voltage at CN7-1. Replace the failing FRU.
2
Engine Board
Diagnostic Information 2-23
4026-0XX Fuse F1 continues to open after being replaced
FRU 1 Action
Fuse F1
If fuse F1 continues to open after being replaced, disconnect CN7 from the engine board and turn the printer power on. If F1 opens, replace the LVPS. If F1 does not open with CN7 disconnected, check the following: Turn the printer power off and disconnect all the cables connected to the engine board and remove the controller board. Reconnect each cable and the controller board one at a time until the FRU causing F1 to open is found. Replace the failing FRU.
2-24
4026-0XX
Main Drive Motor Service Check
FRU
1
Action Disconnect CN6 from the engine board. Check the motor for shorts between each pin on CN2 and the motor case. If continuity is indicated, replace the motor. Check the resistance between the following pins on the cable connector. If incorrect, replace the motor. If correct, replace the engine board. CN2-1 to CN2-2, 8 - 10 ohms CN2-1 to CN2-1, 8 - 10 ohms CN2-1 to CN2-4, 8 - 10 ohms CN2-2 to CN2-3, 8 - 10 ohms CN2-2 to CN2-4, 8 - 10 ohms CN2-3 to CN2-4, 8 - 10 ohms CN2-1 to CN2-5, 3 - 5 ohms CN2-2 to CN2-5, 3 - 5 ohms CN2-3 to CN2-5, 3 - 5 ohms CN2-4 to CN2-5, 3 - 5 ohms
Main Drive Motor
2
Left Side Frame Gears
Remove the toner cartridge and print cartridge. Manually rotate the paper feed gears on the left side frame assembly and check for smooth movement with no binds. If there are binds or the gears do not turn, repair as necessary. Be sure the paper feed frame assembly is correctly installed and the drive gear is engaging correctly. Check the fuser gears, print cartridge, transfer roll gear and photoconductor unit gears to make sure they turn freely. Repair as necessary.
3
Paper Feed Frame Assembly Associated Gears
4
Diagnostic Information 2-25
4026-0XX
FRU
5
Action Check the motor for proper mounting, tight mounting screws, and gear mesh. If incorrect, repair as necessary. If correct, replace the main drive motor. If the motor continues to make noise after the motor is replaced, replace the engine board.
Motor Noise
2-26
4026-0XX
Operator Panel Service Check
FRU 1 Action
Operator Panel Assembly
LEDs Be sure the operator panel cable is properly seated in J5 on the controller board. Run POST and check each LED for proper operation. If more than one LED does not light or an individual LED stays on solid during POST, replace the following FRUs one at a time in the order shown: Controller board Operator panel If all LEDs are very dim and operate erratically during POST or all LEDs come on and stay on solid during POST replace the following FRUs one at a time in the order shown: Operator panel assembly Controller board If none of the LEDs are on, be sure +5 V dc is present at J1-2 on the controller board. If correct, replace the operator panel assembly. If incorrect, replace the controller board. If all the LEDs come on and remain on, replace the following FRUs one at a time in the order shown: Operator Panel Assembly Controller Board Button Inoperative Disconnect the operator panel cable at J5 on the controller board. Check the continuity between J5-5 and J5-6 on the cable as you press the button. The meter should read from approximately 10K ohms to approximately zero ohms when the button is pressed. If the continuity is incorrect, replace the operator panel assembly. If correct, replace the following FRUs one at a time in the order shown: Operator Panel Assembly Controller Board
Diagnostic Information 2-27
4026-0XX
Optional Paper Tray Two Service Check
Check the following before servicing tray two:
· Be sure tray one is working correctly. · Be sure the second paper tray is correctly installed and the sec· · · ·
ond paper tray connector on the base printer properly contacts the second paper tray connector in the second paper tray. Be sure the second paper tray is selected in the user's application and no other application is on the selected port. Be sure the base printer and tray two connectors are not damaged. Be sure the second paper tray drive gear in the base printer operates correctly. Check the paper feed frame assembly for any obstruction or damage in the area of the second paper tray feed slot that can cause the paper to catch or jam.
Note: Only paper can feed from tray two. Envelopes, label sheets, and transparencies must feed from tray one or manual feed. Wrinkled or damaged paper
FRU 1 Action
Paper
Check the paper supply for wrinkled, damaged or out of specification paper. Correct as necessary. Check the paper feed lift plate assembly, paper empty flag, paper separators, paper feed rollers or anything in the paper path that might catch the paper or cause the paper to wrinkle.
2
Paper Path
Paper fails to leave Paper Tray Two - Solenoid never picks
FRU 1 Action
Paper
Check the paper supply for any paper that may cause a problem.
2-28
4026-0XX
FRU 2
Action
Paper Lift Plate Assembly
Check the lift plate assembly, release button, button spring, release arm and all related hardware for proper operation. Be sure the lift plate D-roll pad mounted on the top of the lift plate is not worn, contaminated or missing. Repair as necessary. Check the paper sensor flag for damage and proper operation. Repair or replace as necessary. Be sure the voltage at CN9-4 on the engine board is between +4.5 V dc and +5.5 V dc. If incorrect, replace the engine board. If correct, check the voltage at CN9-6. The voltage changes from approximately +2.00 V dc to 0 V dc as you manually move the sensor flag in and out of the sensor. If incorrect, be sure tray two cable measures continuity. If incorrect, replace the cable. If correct, replace the tray two sensor board. Be sure the solenoid cable is connected to the paper sensor board cable and the cable is properly connected to the sensor board. Disconnect CN9 at the engine board. The voltage measures approximately +24 V dc at CN9-1. If incorrect, replace the engine board. If correct, reconnect CN9 and measure the voltage again at CN9-1. If the voltage continues to be incorrect, check the resistance of the solenoid at the solenoid cable connector which measures from 60 to 90 ohms. If incorrect, replace the tray two solenoid. If correct, be sure the solenoid to sensor board cable measures continuity. If incorrect, replace the sensor board and cable assembly. If correct, be sure the tray two to engine board cable measures continuity. If incorrect, replace the cable. If correct, replace the tray two sensor board.
3
Paper Empty Sensor Flag Paper Empty Sensor
4
5
Second Paper Tray Solenoid/ Engine Board/Solenoid Cable/ Tray Two Cable
Diagnostic Information 2-29
4026-0XX Paper Tray Two feeds paper. - Paper does not reach the input sensor in the base printer.
FRU 1 Action
Second Paper Tray Gear Assembly Second Paper Tray D-Roll Second Paper Tray D-Roll Clutch Assembly Paper Feed Shaft, Gear and Roller Paper Feed Roller, Holder and Spring Assembly Base Printer Paper Feed Frame Assembly
Be sure the second paper tray drive assembly operates properly by manually feeding paper through the second paper tray. Repair as necessary. Be sure the D-roll assembly operates properly. Repair as necessary. Be sure the D-roll clutch assembly operates properly. Repair as necessary.
2
3
4
Be sure the paper feed gear, shaft and roller operate properly. Repair as necessary. Be sure the paper feed roller, holder and spring that is mounted on the tray two base frame operates properly. Repair as necessary.
5
6
Be sure there is no obstruction or damage at the tray two feed slot in the bottom of the paper feed frame. Repair as necessary. Note: If the problem appears to be with the base printer paper feed frame, go to the "Paper Feed Frame Assembly Service Check" on page 2-37
2-30
4026-0XX Paper Tray Two selected in the application. Paper does not feed from Tray Two but instead feeds from Tray One. Tray Two reset to Tray One in printer utility.
FRU 1 Action
Engine Board
Be sure the voltage at CN9-8 on the engine board measures approximately 0 V dc. If incorrect, turn the printer power off and measure the resistance between ground and CN9-8. Be sure the resistance measures 0 ohms. If incorrect, be sure the tray two cable measures continuity. If incorrect, replace the cable. If correct, replace the following FRUs one at a time in the order shown: Engine Board Tray Two Sensor Board
Diagnostic Information 2-31
4026-0XX
Paper Take-Up Solenoid Service Check
FRU 1 Action
Solenoid
Be sure the solenoid/engine board cable is firmly seated in connector CN3 on the engine board. Be sure the solenoid cable is firmly seated in the solenoid/engine board cable connector at the solenoid. Check the solenoid for proper mechanical operation and that the solenoid spring is not broken, loose, or stretched. Replace parts as neccessary. Be sure the solenoid to paper lift plate ground strap is installed correctly. Disconnect the solenoid cable from CN3 on the engine board. Check the resistance of the solenoid between CN3-5 and CN3-6 on the cable. The resistance should measure between 60 to 90 ohms. Check the continuity of the solenoid/engine board cable. If the cable continuity is correct, replace the solenoid. If the cable continuity is incorrect, replace the paper feed frame assembly. Disconnect the solenoid from the solenoid/ engine board cable at the solenoid and check the resistance between each pin on the solenoid connector and the solenoid frame. If continuity is indicated, replace the solenoid assembly.
2-32
4026-0XX
FRU 2
Action
Engine Board
Disconnect the solenoid/input sensor cable from CN3 on the engine board. Check the voltage at CN3-5. The voltage should measure approximately +24 V dc. If incorrect, replace the engine board. If the voltage reads approximately +24 V dc, check the voltage at CN3-6 while running a test page. The voltage should measure 0 V dc and read approximately 1 V dc at the time the solenoid should pick. If incorrect, replace the engine board.
Diagnostic Information 2-33
4026-0XX
Parallel Port Service Check
1. Do a print test to be sure the printer prints correctly. 2. Be sure the printer parallel cable is designed for bi-directional printing. 3. Be sure the user application is set up correctly. Improper set up can prevent establishing a communication link with the printer. 4. Be sure controller board jumper J3 is located on pins two and three. J3 in this position causes the parallel port pull-up resistors to be disabled. Some computers have open collector outputs which require enabling the parallel port pull-up resistors. Do the following to enable the pull-up resistors: Turn the printer power off. Place J3 between pins one and two. Turn the printer power on and run POST. Run a print test page from the host. 5. If the printer still does not print, return J3 to the original position. 6. If the internal print test page prints correctly, the user application and printer driver is set up correctly and the correct printer parallel bi-directional cable is installed. If the printer fails to print on command from the host, replace the controller board.
Paper Feed Service Check
CAUTION: To check the paper feed it may be necessary to run the machine with the covers removed and the top cover interlock disabled. If this is necessary, NEVER disable both the top cover interlock and the printhead shutter actuator at the same time. If it is necessary to run the machine to check for paper feed problems, open the top cover and disable t