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Lexmark Optra E 4026-0 Series Reference Handbook

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First Edition (March, 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
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OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
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This publication could include technical inaccuracies or typographical errors. Changes are
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A form for reader's comments is provided at the back of this publication. If the form has
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Lexmark, MarkNet, MarkVision, Optra and WinWriter are trademarks of Lexmark
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© Copyright Lexmark International, Inc. 1996. All Rights Reserved.
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Summary of Contents for Lexmark Optra E 4026-0 Series

  • Page 1 A form for reader’s comments is provided at the back of this publication. If the form has been removed, comments may be addressed to Lexmark International, Inc., Department F95/035-3, 740 New Circle Road, Lexington, Kentucky 40511, 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.

  • Page 2: Table Of Contents

    Contents 4026-0XX ..........1-1 Diagnostics .
  • Page 3 4037 / 4047-05E ........4-1 Diagnostics .
  • Page 4 Adjustments ........5-22 Envelope Restraint Spring .
  • Page 5 4047-05W ..........7-1 Diagnostics .
  • Page 6 LCD Test ........8-22 Maintenance Kit Count .
  • Page 7 5045 ..........9-1 Diagnostic/Maintenance Approach .

  • Page 8: 4026-0Xx

    4026-0XX Optra E 4026-0XX...
  • Page 9 Notes: Laser Printer Reference Handbook...

  • Page 10: Diagnostics

    4026-0XX Diagnostics 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.

  • Page 11: Power-On Self Test (Post)

    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 1-12. Power-On Self Test (Post) The printer performs the following Power-On Self Test when powered 1.

  • Page 12: Service Error Codes

    17. The main drive motor turns off. 18. The polygon motor (printhead motor) turns off. 19. The Data LED turns off. 20. The Ready LED stays on solid. If the printer completes all these steps and no error indications are displayed, the printer has successfully completed the POST.
  • Page 13 Blinking Operator Panel LED Action Laser Diode Failure Replace the printhead assembly. If this does not correct the problem, replace the engine board. Controller Card Failure Replace Controller board Optional Memory Error Replace the optional memory SIMM. If this does not correct the problem, replace the controller board.
  • Page 14 Blinking Operator Panel LED Action Base Memory Error Replace Controller board NVRAM Failure Error 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.
  • Page 15 Blinking Operator Panel LED Action Font Checksum Failure Error Replace the ROM SIMM. If this does not correct the problem, replace the controller board. Engine Board Communications Replace the engine board. If this Failure Error does not correct the problem, replace the controller board.
  • Page 16 User Error LED Status Action Message Load Manual Load Paper blinks Load media into the manual Paper/Envelope and Press Button slot and push the operator on solid panel button to resume printing or do a front panel reset by pressing and holding the operator panel button for more than three seconds.
  • Page 17 Ready, Error, and Switch the printing mode to Press Button on a different printing mode solid 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.
  • Page 18 Message Data Transmission Data, Error, and Switch to Print Accelerator Error Press Button on using the Lexmark driver for solid 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...
  • Page 19 Symptom Action The paper feed gears do not turn. Refer to the Paper Feed Service Check in the Service Manual. The paper feed solenoid picks Refer tot he Paper Feed Service and tries to feed paper. Check in the Service Manual. The toner/print cartridge gears do Refer to the Main Drive Motor Service not turn.
  • Page 20 Symptom Action Poor image (characters washed Refer to the Print Quality Service out) Check in the Service Manual. Paper jams Refer to the Paper Feed Service Check in the Service Manual. Main Drive Motor noisy Refer to the Main Drive Motor Service Check in the Service Manual.
  • Page 21 Symptom Action Top cover will not close Refer to the Cover Interlock Service Check in the Service Manual. Light print Refer to the Print Quality Service Check in the Service Manual. 1-14 Laser Printer Reference Handbook...

  • Page 22: Diagnostics Aids

    Diagnostics Aids Printer Diagnostic Test The following tests run sequentially when performing this test: Standard Memory Test Optional Memory Test Microcode Check LED Test Read/Write ASIC Register Test Read/Write ASIC SRAM Test Read/Write controller board SRAM Test Perform the following steps to run the Printer Diagnostic Test: 1.

  • Page 23: Service Diagnostic Test Page

    Service Diagnostic Test Page The service diagnostic test page includes registration marks to aid in adjusting print registration and also includes the installed printer base code level. The service test page displays the user default values for the following: Top Margin Offset Left Margin Offset Printer Page Count Permanent Page Count...
  • Page 24 1-17 4026-0XX...

  • Page 25: User Mode Print Test Page

    User Mode Print Test Page The User Mode Print Test Page displays the user default values, installed options, printer features, various typefaces, and the installed printer base code level. 1. Be sure the Ready LED is on solid (printer is in the ready state). 2.

  • Page 26: Configuration Mode

    Configuration Mode The configuration mode gives the ability to set the following printer functions through the operator panel: Hex Trace NPA Mode (Parallel) Parallel Protocol Advanced Status PPDA Activated Auto CRLF/LFCR Perform the following steps to enter the configuration mode: 1.
  • Page 27 Operator Panel Configuration Mode Button Definition Term Description Result Brief Button Press Press the operator This action moves panel button no longer through the than three seconds. configuration mode value list. Long Button Press Press and hold the This action selects operator panel button and saves the value for more than three...

  • Page 28: Hex Trace

    Hex Trace Use Hex Trace to isolate the cause of print problems. When a job is printed, the printer operator panel displays the Hex Trace indication, (Ready LED blinking), showing that the printer remains in the Hex Trace mode. Turn the printer power off or do a front panel reset (long button press) to exit the Hex Trace mode.

  • Page 29: Restoring Factory Defaults

    Restoring Factory Defaults Restoring factory defaults returns the printer settings to the original factory settings. Perform the following steps to invoke factory defaults: 1. Turn the printer power off. 2. Open the top cover. 3. Turn the printer power on. The printer starts POST. 4.

  • Page 30: Connectors

    Connectors Low Voltage Power Supply Connector Pin No. Signal CN1 Engine Board +24 V dc +5 V dc FUSER LAMP* CN2 Fuser Lamp/ HEAT N Thermal Fuse NO CONNECTION HEAT L High Voltage Power Supply Connector Pin No. Signal CN1 Engine Board HV C HV T* HV SEL 2*...
  • Page 31 Engine Board CN1A Controller Board Pin No. Signal Pin No. Signal NO CONNECTION CMD* NO CONNECTION CTBSY* NO CONNECTION PRINT* NO CONNECTION SRCLK* RESET* VIDEO* +5 V dc HSYND* +5 V dc EPRDY* PRRDY* +5 V dc TDD* CPRDY* ETBSY* +5 V dc STS* TEST*...
  • Page 32 Connector Signal CN4A HVPS HV C HV T* HV SEL2* HV SEL1* HV B BIAS MON +24 V dc CN5A Laser Diode S SCAN Drive Board LD APC2 (LDVR2) LD APC1 (LDVR1) L DATA* +5 V dc CN6A Main Motor PHASE A PHASE A* PHASE B...
  • Page 33 Connector Signal CN9A 2nd Paper Tray +24 V dc (Option) FEED 2* NO CONNECTION +5 V dc P EMP2 PSIZED 2NDBIN* MM/INCH CHECK0* CHECK1* CHECK2* CN10A Polygon NO CONNECTION Motor +24 V dc +5 V dc POLYGON CONTROL CN11A Fan Motor FAN* +24 V dc 1-26...
  • Page 34 Second Paper Tray Sensor Board (Option) Connector Pin No. Signal CN1A Engine Board CHECK2* CHECK1* CHECK0* MM/INCH 2NDBIN* PSIZEO P EMP 2 +5 V dc NO CONNECTION FEED2* +24 V dc CN3A Paper Take-up +24 V dc Solenoid - 2nd Paper Tray (Option) FEED2* Controller Board...
  • Page 35 J4 Engine Board Pin No. Signal Pin No. Signal NO CONNECTION NO CONNECTION CTBSY NO CONNECTION PRINT NO CONNECTION SRCLK RESET* R VIDEO* +5 V dc RHSYNC* +5 V dc EPRDY* PRRDY* +5 V dc TOD* CPRDY ETBSY* +5 V dc STS* NO CONNECTION Connector...
  • Page 36 J2 Parallel Port (Continued) Pin No. Signal Pin No. Signal RACK* RBUSY RPERROR RSELOUT RINIT* RAUTOFD* RFAULT* RSELECTIN* Paper Exit Sensor Connector Pin No. Signal CN3S Engine Board ANODE (PC3) PC3* Paper Entry Sensor Connector Pin No. Signal CN1S Engine Board PC1* ANODE (PC1) Paper Feed Solenoid...

  • Page 37: Parts Catalog

    Parts Catalog Covers Description 69G8341 Left Side Cover 69G9969 Cover, Cable 69G8301 Top Cover 69G8306 Fan Cover 69G8305 69G9990 Label, S/N Blank 69G8340 Exit Paper Tray 69G8303 Cover Release Assembly 69G8302 Printhead Interlock Actuator 69G8396 Operator Panel Assembly inc. English Overlay 69G9981 Operator Panel Assembly inc.
  • Page 38 Frame (Continued) Part Description Number 69G8357 Spring, Rt Side Frame, Cartridge Latching 69G8359 Terminal, Rt Side Ground HVPS to Bd Cage 69G9982 Terminal, Ground 11A7424 Terminal, Left Side Plate to LVPS 11A7425 Terminal, Left Side Plate to Lift Plate 69G8377 Clutch Cam Assembly 69G8379 Bushing...
  • Page 39 Paper Feed Frame Part Description Number 69G8368 Paper Feed Frame Assembly 69G8369 Gear, 16T Paper Feed 69G8371 Sensor, Paper Entry 11A7409 Cable, Input Sensor/Solenoid to Engine Board 69G8372 Flag, Paper Entry Sensor 69G8373 Separator, Paper 11A7442 Paper Feed Pressure Roller Assembly 69G8374 Terminal, Solenoid Ground 69G8370...
  • Page 40 Fuser (Continued) Part Description Number 69G8326 Terminal, Fuser Lamp Left side 69G8318 Upper Fuser Assembly 69G9697 Lever, Fuser Drive 69G8323 Spring, Inside 69G9698 Arm, Fuser Drive 69G8324 Spring, Outside 69G9699 Holder, Fuser Drive 11A7431 Transfer Corona cleaning tool Electronics Part Description Number 69G8380...
  • Page 41 Transfer Assembly Part Description Number 69G8307 Transfer Assembly 69G8310 Right Transfer Frame Guide 69G8311 Spring, Right Transfer Guide 69G9968 Transfer Corona Assembly 69G9967 Spring, Left Transfer Guide 69G8308 Left Transfer Frame Guide 69G8309 Gear, 18/21T Option - Second Paper Drawer Part Description Number...
  • Page 42 Option - Second Paper Drawer (Continued) Part Description Number 69G9955 Shaft, D-Roll 69G9991 Pin, D-Roll Shaft 69G9957 Bushing, D-Roll Shaft 69G9956 D-Roll 69G9953 Gear, 14T 69G9952 Bushing, Paper Feed Shaft, Outside 69G9950 Paper Feed Shaft W/Roller 69G9951 Bushing, Paper Feed Shaft, Inside 69G9959 Holder, Sensor Flag 69G9960...
  • Page 43 1-36 Laser Printer Reference Handbook...

  • Page 44: 4027-04W

    4027-04W Winwriter 200 4027-04W...
  • Page 45 Notes: Laser Printer Reference Handbook...

  • Page 46: Diagnostics

    4027-04W Diagnostics Start Caution: NEVER manually actuate or defeat the top cover interlock switch and the print head shutter actuator at the same time. To perform some of the service checks and tests, such as troubleshooting paper feed problems, you will need to actuate the top cover interlock switch with the covers opened or removed and power applied to the machine.
  • Page 47 Error Message Table Error Code/ Action Message [Error 920 Fuser Refer to the Cold Fuser Service Check in the Temp] Service Manual. [Error 930] Mirror The Polygon motor is not rotating during printing. Motor] Replace the engine board. If this does not fix the problem, replace the print head assembly.
  • Page 48 Printer Status Light Table Status Action Add XXX Paper Printer is out of paper. Add paper, then if the error remains, refer to the Paper Feed Take-Up Shaft (Audible: Add Service Check in the Service Manual. paper to printer) Clear Paper Jam Refer to the Paper Feed Service Check in the Service Manual.

  • Page 49: Power-On Self Test (Post)

    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. The status LED comes on solid. 2. The fan turns on for 2 seconds. 3.
  • Page 50 POST Symptom Table Symptom Action Fuser Lamp does Refer to the Cold Fuser Service Check in the not light Service Manual. Main motor not Refer to the Main Motor Service Check in the working Service Manual. Polygon motor not Replace the engine board. If you still have the working problem, replace the print head assembly.
  • Page 51 Symptom Table Symptom Action Dead machine Refer to the Low Voltage Power Supply Service Check in the Service Manual. Fan not working Refer to the Fan Service Check in the Service Manual. Fan noisy Refer to the Fan Service Check in the Service Manual.
  • Page 52 Symptom Table Symptom Action Toner on the back Refer to the Transfer Service Check in the Service of the page Manual. Poor print quality Refer to the Print Quality Service Check in the Service Manual. Incorrect Refer to the Print Quality Service Check in the characters print Service Manual.

  • Page 53: Diagnostic Aids

    Diagnostic Aids Customer Test Page (From WPS) Use this test to check print and graphics quality. Running the print test resets temporary settings to the printer default settings and deletes all macros and downloaded fonts. To run the Print Test: 1.

  • Page 54: Wps.ini File

    WPS.INI File This file can be used to check for the last error code, date and time of the last error sent from the printer to WPS. 1. Select File Manager from the Microsoft Windows Main Menu (double click with mouse). 2.

  • Page 55: Connectors

    Connectors Low Voltage Power Supply Signal CN1 Fan otor +12VDC CN2 Main Motor otor otor otor Motor SW12VDC CN3 Engine Board GND +5.1VDC +5.1VDC GND +12VDC SW12VDC Fuser Lamp Fan Motor Main Motor Main Motor Main Motor Main Motor CN4 Cover SW +12VDC SW12VDC 2-12...
  • Page 56 High Voltage Power Supply Signal CN1 PF Solenoid SOL ON +12VDC CN2 Engine Board GND1 +5.1VDC +12VDC GND2 SOL ON Engine Board Signal CN1 LVPS GND1 +5.1VDC GND2 +12VDC Fuser Lamp Fan On Main Motor Main Motor Main Motor Main Motor CN2 Thermistor Thermistor +5.1VDC...
  • Page 57 Signal CN4 HVPS GND1 Input Sensor +5.1VDC +12VDC GND2 Drum Chg On Ter Roll On DOC Blade PF SOL ON CN5 Printhead POL LOCK P/H Select POLY MTR CLK POLY MTR ON GND2 +12VDC +5.1VDC LDATA 9‘ GND1 LDVR1 LDVR2 LDLVL SSCAN CN6 Controller Board...
  • Page 58 CN6 Controller Board (Continued) Signal Signal GND1 +5.1VDC GND1 GND1 RHYSNC +5.1VDC EPRDY GND1 PRRDY +5.1VDC CPRDY ETBSY +5.1VDC Signal CN9 Op Panel GND1 LED1 Controller Board Signal J1 Optional SIMM J2 Parallel Port Signal Signal RSTROBE 2-15 4027-04W...
  • Page 59 J2 Parallel Port (Continued) Signal Signal RACK RBUSY RPERROR RSELOUT RINIT RAUTOFD RFAULT RSELECTIN Signal J3 Pullup +5.1VDC 5V Jumper 2-16 Laser Printer Reference Handbook...
  • Page 60 J4 Engine Board Signal Signal LED1 CTBSY PRINT SRCLK Reset Video +5.1VDC RHSYNC +5.1VDC EPRDY PRRDY +5.1VDC CPRDY ETBSY +5.1VDC 2-17 4027-04W...

  • Page 61: Parts Catalog

    Parts Catalog Parts Packet Description 1427269 Screw Parts Packet Covers Description 1427161 Top Cover Asm 1427162 Anti Static Brush 1427163 Paper Tray, Exit 1427164 Left Side Cover 1427165 Right Side Cover 1427166 Front Cover 1427267 Cover, Op Panel, with LED 1427167 Paper Tray, FNT Left Side Frame...
  • Page 62 Print Head Description 1427178 Print Head, with PWB-O 1427179 Print Head Bracket Paper Feed Lift Plate Description 1427180 Paper Feed Lift Plate Asm 1427181 Pressure Spring Paper Feed/Transfer Description 1427182 Paper Feed Asm 100/220/240V 1427183 Paper Feed Asm 120V 1427186 Actuator Sensor 1427187 Paper Take-up Shaft Asm...
  • Page 63 Fuser Description 1427189 Fuse Asm, 120V 1427190 Fuser Asm, 220/240V 1427197 Frame/Thermal Fuse Asm 1427191 Fuser Lamp, 120V 1427192 Fuse Lamp, 220/240V 1427193 Thermistor 1427194 Sensor, Photo 1427195 Actuator, Sensor Flag 1427196 Torsion Spring Electronics Description 1427198 Power Supply, 120V 1427199 Power Supply, 220/240V 1427251...
  • Page 64 4033 4033...
  • Page 65 Notes: Laser Printer Reference Handbook...

  • Page 66: Diagnostics

    4033 Diagnostics Start If the adapter is replaced, the customer must delete all associations after removing the adapter from the LAN. When the replacement adapter is connected to the LAN, the customer must perform the configuration steps and establish new associations. Power Test The power LED should always be on when there is power to the adapter.

  • Page 67: Symptoms After Reset

    • Models 20X and 30X: The following LED sequence occurs during a normal reset. A successful reset results in the Power and Status LEDs on and the Test and Data LEDs off. Status Test Data If an error is detected the LEDs will hang in their current state. Reset again and replace the adapter if the error recurs.

  • Page 68: Diagnostic Aids

    Diagnostic Aids Sample Print Test (Models 20X and 30X) Press and release the Test button to send a single-page file to all ports. If the test is successful, go to “LAN Connection Check” on page 3-6. If the print test fails, go to “Wrap Test for Adapter Ports” on page 3-5. Wrap Test for Adapter Ports To test any port: 1.

  • Page 69: Lan Connection Check

    LAN Connection Check 1. For Token-Ring using shielded twisted-pair cable (Models 001, 011, 201, or 301): Disconnect the LAN cable from the network, leaving it connected to the adapter. For Ethernet 10BASE2 (Models 003, 013, 202, or 302): Make sure the switch is set to position 2 for Models 003 and 013, or position 16/2 for Models 202 and 302.

  • Page 70: Printer Checks

    If the adapter checks out successfully, the problem may be with other hardware or software on the network. The following are suggestions to the customer for checking hardware and software for possible problems. Printer checks • Make sure the printer is operating correctly by running printer diagnostics and the printer wrap test.

  • Page 71: Parts Catalog

    Parts Catalog Description 1381605 4033- 201 Token-Ring network adapter 1381603 4033- 202 Ethernet network adapter 1381606 4033- 301 Token-Ring network adapter with serial port 1381604 4033- 302 Ethernet network adapter with serial port 1418613 Cover, switch 1418601 Cord set, jumper power 2182994 T-connector, Ethernet 9900769...
  • Page 72 Description 1339518 Line Cord, New Zealand/Australia, Argentina, Uruguay 1339521 Line Cord, Israel 1339519 Line Cord, UK 1339523 Line Cord, Pakistan 1339519 Line Cord, Hong Kong, Malaysia, Singapore, Burma, Brunei, India 1339523 Line Cord, Bangladesh, Sri Lanka 1339517 Line Cord, Laos, Thailand 1339518 Line Cord, China (PRC) 1339524...
  • Page 73 3-10 Laser Printer Reference Handbook...
  • Page 74 4037 / 4047-05E 4037 / 4047-05E...
  • Page 75 Notes: Laser Printer Reference Handbook...

  • Page 76: 4037 / 4047-05E

    4037 / 4047-05E Diagnostics Start Use the error message table, symptom table, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. If an error message is displayed on your machine, locate it in the Error Message Table below and take the appropriate action.
  • Page 77 Error Message Table (Continued) Error Code/Message Action [Error 943 System NVRAM is bad and the system board must be Board] replaced. This Error Code can be overridden to allow the operator to use the machine temporarily. Refer to the section on Storage in your Service Manual.

  • Page 78: Power-On Self Test (Post)

    Error Message Table (Continued) Error Code/Message Action [Tray1 Missing] Install the Paper Tray. If the error remains, refer to the Tray 1 Service Check in the Service Manual. [Tray2 Missing] Install the Paper Tray. If the error remains, refer to the Tray 2 Service Check in the Service Manual.
  • Page 79 If your printer did not complete POST, locate your symptom in the “POST Symptom Table” on page 4-6, and take the appropriate action. Note: If the machine is in button lockout mode, POST will complete, but the right half of the display will be blank and the buttons will not operate. Turning the machine off will not exit the button lockout mode.
  • Page 80 Symptom Table (Continued) Symptom Action Fuser Lamp doesn’t Refer to the Cold Fuser Service Check in the light Service Manual. Toner not fused to the Refer to the Cold Fuser Service Check in the paper Service Manual. Blank Page Refer to the Print Quality Service Check in the Service Manual.
  • Page 81 Symptom Table (Continued) Symptom Action Printer prints: Replace the Serial Adapter. (Hardware error, have protocol converter serviced) Printer not Refer to the Parallel Port Service Check in the communicating with Service Manual. host Charge Roll noisy or Refer to the Charge Roll Service Check in the binding Service Manual.

  • Page 82: Diagnostic Aids

    Diagnostic Aids Print Test (Main Menu) You can run the print test even if the printer is not attached to a computer. Use this test to check print and graphics quality. Running the print test resets temporary settings to the printer default settings and deletes all macros and down-loaded fonts.

  • Page 83: Diagnostics Print Test 1

    Diagnostics Print Test 1 This test generates a one-page printout. To run the Diagnostics Print Test: 1. Enter Diagnostics mode. 2. Select [PRINT TEST 1]. 3. Select [SINGLE] for one page, or [CONTINUOUS] for continuous print. In continuous print mode, the word [CANCEL] will appear next to button.

  • Page 84: Wrap Test

    Wrap Test The Wrap Test checks the circuits used to communicate with the host computer. To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the parallel cable. 3. Install the parallel wrap plug (part no. 1319128). 4. Turn the printer on. 5.

  • Page 85: Button Lockout Mode (4047 Only)

    Button Lockout Mode (4047 Only) To test the Button Lockout Mode: 1. Depress and hold the top button and the RETURN button, then turn the machine on. 2. When the Button Lockout Menu is displayed, select [YES]. The Lockout Mode is now enabled. Power off the machine to exit this menu.

  • Page 86: Error Log

    Error Log 1. Enter Diagnostics mode. 2. Select [ERROR LOG]. 3. The last 6 errors will be displayed, 1 being the latest. 4. To clear the error log: • Press the RESET button. The second menu appears. • Select [YES] to clear the log. •...

  • Page 87: Adjustments

    Adjustments Print Head Calibration This procedure calibrates the Print Head to the Printer and is required after the print head or system board is replaced. 1. Enter Diagnostics 2. Select [PRINT HEAD]. 3. There are 17 digits in the bar code number. Locate the 15th and 16th digits of the Bar Code number (the 2nd and 3rd digit from the right).

  • Page 88: Advanced Setup Menu (Early 4037 Models Only)

    Bottom Margin This margin can be set between -7 and +7. Moving the number in a positive direction moves the margin down and narrower bottom margin. Moving the number in a negative direction moves the text up the page and leaves a wider bottom margin. Changing the bottom margin does not affect the top margin 5.

  • Page 89: Fastbytes

    Fastbytes This procedure enables turning off the Fastbytes protocol. Fastbytes is an enhance parallel protocol which, when turned on, allows the printer to receive data faster than in standard protocol. It can cause problems with some systems which may require turning Fast Byte off. Note: For 4047, enter this mode from the main menu.

  • Page 90: Connectors

    Connectors This chapter shows the locations of major printer assemblies, connectors, and ground straps. System Board Connectors Connector Connector Name Print Head Signal Print Head Power Operator Panel (4037 only) Flash Option (4047 only) Flash Option (4037 only) DRAM Option (4047 Flash) Parallel Port (4047 DRAM) Parallel Port (4047 only) Operator Panel (4047 only)

  • Page 91: Parts Catalog

    Parts Catalog Description 1381309 E-Ring, O-Ring, G Clip (Left Side Cover), Washer, Standoff 1381310 Spring, Guide, Corner Buckler Bellcrank 1381311 Screw, Lock washer Description 1363437 Bezel Operator Panel Assembly 1363503 Button Pad, Operator Panel 1381286 Card, Operator Panel 1363202 Cable, Operator Panel Description 1381287 Side Bracket, Left...
  • Page 92 Description 1381333 Cover, Top Inner 1381289 Print Head Assembly 1381290 Card, LED Circuit 1363135 Belt Description 1364481 Paper Tray, Standard 1363457 Restraint, Side Description 1381261 Fuser Assembly, 110V, with lamp Note: This fuser will work on all machines. Early 4037 printers had a feature that opened the fuser rollers when the top cover was opened.
  • Page 93 Description 1363797 D-Roll Asm, 250 Option 1363208 Cable, Tray Sensor 1381306 Motor, Torquer 1381305 Board, Tray Sense 1363830 Lever, Switch Description 1364483 11” Tray Assembly - 250 Sheet 1364484 14” Tray Assembly - 250 Sheet 4-20 Laser Printer Reference Handbook...
  • Page 94 4039-1XX 4039-1XX...
  • Page 95 Notes: Laser Printer Reference Handbook...

  • Page 96: 4039-1Xx

    4039-1XX Diagnostics Failures With Error Codes Two-digit codes are messages for the 4039 user, but if they recur frequently or at inappropriate times they may be symptomatic of a service problem. On “plus” models, refer to the diagnostics error log for the last six errors or paper jam codes.
  • Page 97 Error Message Table (Continued) Error/Code Action 37 Insufficient Not enough memory for function requested. To Memory verify that the printer recognizes all the installed memory, go to “Print Tests” on page 5-18 and print the test page. Make sure the memory shown on the printout matches the installed memory.
  • Page 98 Error Message Table (Continued) Error/Code Action 7X Network Card These user codes are documented in various Codes network card user manuals. Refer to “Network Wrap Test Service Check” in your Service Manual. 80 Scheduled Printer has reached 200,000 prints (12C reached Maintenance 100,000 prints) without maintenance count reset.
  • Page 99 Error Message Table (Continued) Error/Code Action 923 Fuser Error Fuser is too hot while printing or when idle. Refer to Fuser 923 Error Service Check in your Service Manual. 927 Fan Stalled Refer to Fan Service Check in your Service Manual. 931 Printhead Error No first hsync.
  • Page 100 Error Message Table (Continued) Error/Code Action 971 Network Card Network card RAM failure. Replace the Network Card. 972 Network Card Network card ROS/FLASH failure. Replace the Network Card. 973 Network Card Network card EEPROM/NVRAM failure. Replace the Network Card. 974 Network Card Network card/Network interface error.

  • Page 101: Power-On Self Test (Post)

    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. 1½ rows of pels appear on the display and then clear. 2. Diamonds fill the display and then clear. 3.

  • Page 102: Diagnostic Aids

    Diagnostic Aids Diagnostics Mode To run some of the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics mode. To enter Diagnostics mode: 1. Turn the printer off. 2. Press and hold the Ready and RETURN buttons. Then turn the printer on.
  • Page 103 Auto Clean Frequency This can be set from 10 to 255 pages with a default of 50. Auto Clean Delay does not appear on the menu unless Auto Clean is on. 1. Enter Diagnostics mode. 2. Select [Auto Clean Frequency]. 3.
  • Page 104 Disk Test/Clean This is a two hour test that should be performed only on a disk that contains bad data and is therefore unusable. This test destroys all data on the disk by doing a multi-pass write/read on every block of the disk. Bad blocks are flagged and removed from use.
  • Page 105 Duplex Feed 2 Test This test verifies that paper feeds through the duplex unit properly and tests the stop point of the page as it feeds back over the top of the duplex paper tray. 1. Enter Diagnostics mode. 2. Select [Duplex Tests]. 3.
  • Page 106 Envelope Print Test Printing will only occur on the first envelope. The envelope will feed from the automatic envelope feeder if present. If there is no automatic feeder present, the printer will use manual envelope. 1. Enter Diagnostics mode. 2. Select [Envelope Print]. 3.
  • Page 107 Fuser Temperature 1. Enter Diagnostics mode. 2. Select [Fuser Temperature]. 3. Select [Normal], [No Boost], Or [Low Temperature]. 4. Press RETURN to return to the Diagnostics mode main menu. Warm-Up Time 1. Enter Diagnostics mode. 2. Select [Warm Up Time]. 3.

  • Page 108: Operator Panel Tests

    Operator Panel Tests The following tests check for proper functioning of the operator panel buttons and display (LCD). Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [Button Test]. 3. Press each button. [Closed] will be displayed until the button is released.
  • Page 109 Paper Feed Test This test allows you to observe the drive gear train and feed paper through the printer to check for broken gear teeth, watch the paper path, or check the erase lamps. Note: You may want to remove the gear cover before starting this test so you can observe the motor gears.
  • Page 110 Print Registration Adjustment Use Print Test 1 or the Quick Test to evaluate print registration. Adjust the registration so the tips of the diamonds are at the top and bottom edges of the page and the printout is centered left to right. Verify that the Top Margin is correct before adjusting the Bottom Margin.

  • Page 111: Print Tests

    Print Test Page You can run the Print Test even if the printer is not attached to a computer. Use this test to check print and graphics quality and the version numbers of printer microcode. The first page of this test feeds from Tray 1.
  • Page 112 Print Test 3 This test generates two printouts: a solid black page and a dot pattern. These can be used to evaluate print quality. 1. Enter Diagnostics mode. 2. Select [Print Test 3]. 3. Select [Single] or [Continuous]. 4. Select [CANCEL] to stop continuous print. 5.

  • Page 113: Network Connections And Checks

    Sensor Test To run the Senor Test: 1. Enter Diagnostics mode. 2. Select [Sensor Test]. 3. Select one of the following sensor tests: • Toner Low • Output Bin • Input • Exit • Cover Open Note: The Output Bin sensor can have up to a 15 second delay in changing to open.

  • Page 114: Lan Information

    9. Press RETURN to return to the Diagnostics mode main menu. 10. Turn the printer off, then remove the wrap plug from the interface connector. LAN Information The printer may be connected to one of the following LAN types: • Token-Ring •...

  • Page 115: Adjustments

    Adjustments Envelope Restraint Spring 1. Loosen the mounting screw [A]. 2. Position the spring [B] so it clears the separator roller by 1.9 ±0.2 mm (0.075 ±0.008 in.). 3. Tighten the mounting screw. Paper Restraint Spring 1. Loosen the mounting screw [A]. 2.

  • Page 116: Printhead Skew - Level 2

    Printhead Skew - Level 1 1. Loosen the mounting screws [A]. 2. Pivot the printhead around the shoulder screw [B] until the skew marks on the printout are parallel to the top edge of the paper. Use Print Test 1 or Quick Test to check this. Rotating the printhead clockwise will lower the left skew adjustment point on the test print.

  • Page 117: Printhead Skew - Level 2

    Printhead Skew - Level 2 1. Remove the top cover. 2. Loosen the screws [A]. 3. Run Print Test 1 or the Quick Test on the Diagnostics Menu. 4. Move the pointer [B] to eliminate the skew. Moving the pointer toward the left raises the left adjustment point on the printout.

  • Page 118: Connectors

    Connectors System Board Connectors 10R/12R/12C/12L Connector Name DRAM SIMM DRAM SIMM ROM SIMM (flash memory option) ROM SIMM (printer microcode) Printhead Mirror Motor(Printhead)/ Fan Laser (Printhead)/ Hsync Operator Panel/Output Bin Sensor DC to DC Convertor DC to DC Convertor INA Power Card LVPS Envelope Feeder Magnet INA Card...
  • Page 119 System Board Connectors, 16L Connector Name DRAM SIMM DRAM SIMM Mirror Motor(Printhead)/ Fan Laser (Printhead)/ Hsync Operator Panel/Output Bin Sensor Duplex Font Card Hard Disk Option Envelope Feeder Magnet ROM SIMM (Printer microcode) ROM SIMM (flash memory option) INA Card Parallel and Serial Port 500 Sheet Option Paper Drive Motor...
  • Page 120 System Board Connectors, 10P (Continued) Connector Name LVPS Envelope Feeder Magnet INA/Hard Disk HVPS Parallel Port Second Paper Tray Option Duplex Exit &Paper Size Sensor/Fuser Solenoid Input & Toner Sensor Board/Erase Lamps Drive Motor Torquer Motor (Tray 1 pick) 5-27 4039-1XX...

  • Page 121: Parts Catalog

    Parts Catalog Parts Packets Description 1381035 Duplex Gears 1381048 Duplex Flags 1381145 Metering and Prealigner Rolls 1383313 Cables/Jumpers 1383316 Springs 1383314 Fasteners 1383315 Clips 1383317 Gears 1-6 1383318 Gears 7-14 1383385 Paper Tray 1383390 Paper Tray Covers Description 1381017 Operator Panel Asm Lower Frame Description 1381046...
  • Page 122 Upper Frame Description 1383998 Fan Asm 1381004 Output Bin Sensor Assembly (handle mounted) 12L/16L 1381099 Cable, Output Bin/Operator Panel 12L(handle mounted sensor) 1381134 Cable, Output Bin/Operator Panel 16L(handle mounted sensor) 1381095 Cable, Operator Panel 12C/12R/10R/10P 1383314 Washer, Parts Packet Printhead Description 1381624 Printhead 10P...
  • Page 123 Paper Feed Alignment Gears Description 1328383 Bellcrank, Metering 10P/10R/12R/12L/16L 1409238 Bellcrank, Metering 12C 1381145 Kit, Prealigner and Metering Rollers 1039278 Gear, Idler, Prealigner 1328384 Bellcrank, Prealigner 10P/10R/12R/12L/16L 1402336 Bellcrank, Prealigner 12C Paper Feed Drive Description 1381549 D-Roller Asm 10R/12R/12L/16L 1408705 D-Roller Asm, 10P/12C 1328454 Shaft, D-Roll with Gear 11, 10R/12R/12C/12L/16L...
  • Page 124 Optional Paper Drawer (500-Sheet) Description 1183342 Base Assembly 1039540 D-Roller Tire 1383925 Paper Feed Magnet 1381622 Drive Assembly 1183299 Switch Assembly Fuser Description 1381082 Fuser and Lamp 110V 10R 1381083 Fuser and Lamp 110V 12R/12L 1381521 Fuser and Lamp 110V 12C 1381084 Fuser and Lamp 220V 10R 1381085...
  • Page 125 Fuser (Continued) Description 1039305 Backup Roll 10R/12R/12L/16L 1329928 Backup Roll, 10P 1328458 Redrive Idle Arm Asm, 12R,12L,12C,16L 1376367 Redrive Idle Arm Asm, 10R/10P 1381687 Paper Exit Bd Asm 1039481 Fuser Power Cable 1381537 Cable, Fuser/Front Cover Exit Sensor 1039328 Clips, Thermal Fuse 10R/10P 1328134 Clips, Thermal Fuse 12R/12L/16L/12C 1381018...
  • Page 126 Electronics (Continued) Description 1328291 Cable, HVPS/Input Sensor Board 10R/12R/12C/12L/16L 1321882 DRAM SIMM 4 MB 12R/12L/12C/16L 1328589 DRAM SIMM 2 MB 10R 1383513 Switch On/Off 1381513 ROM SIMM 10R 1381484 ROM SIMM 12R/12L/12C 1381509 ROM SIMM 16L 1381696 ROM SIMM 10P 1376388 ROM SIMM, 10R, 4039 plus 1376389...
  • Page 127 Envelope and 100-Sheet Auxiliary Feeder Description 1183151 Envelope+ Feeder 1183966 100-Sheet Auxiliary Feeder 1183226 Weight Assembly 1383944 Magnet Assembly Options Description 1364923 1 MB Flash SIMM 1364922 2 MB Flash SIMM 1364879 4 MB Flash SIMM 1364876 8 MB DRAM SIMM 1381050 INA-LocalTalk 1446702...
  • Page 128 4040 Optra N 4040...
  • Page 129 Notes: Laser Printer Reference Handbook...

  • Page 130: Maintenance Approach

    4040 The Optra N, model 4040 is a 600 dpi laser printer designed to attach to IBM-compatible PC’s and to most types of computer networks. The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country.

  • Page 131: Diagnostic Information

    Diagnostic Information Diagnostic Approach This printer can be serviced without being connected to a host computer. This printer displays both operator correctable errors and service errors on the front (operator) panel. In addition, there are two tests available from the base machine and the optional 2,000 sheet paper deck that allow you to bypass the controller card.

  • Page 132: Troubleshooting

    Print Paper Checks • Be sure the recommended paper for this printer is being used. • Check the paper for dampness. Make a trial print with paper from a newly opened package, and check the result. EP Cartridges If blank spots appear on an output image, there is a chance that the toner is not even.

  • Page 133: Error Code/Message Tables

    Error Code/Message Tables Service Error Codes Error Symptom or Message Action Unrecoverable Software Refer to the operator manual Error Fuser Error, Fuser lamps do Refer to the “Fuser (Temperature not come on during POR, or Low) Service Check (920/922)” in fuser lamps come on but do the Service Manual.
  • Page 134 Service Error Codes (Continued) Error Symptom or Message Action System Board Error Be sure all cables are securely installed then POR the machine. If you still have a failure, replace the system board. Incorrect CHECKSUM Replace the EPROM controller (EPROM) card (J8).

  • Page 135: Operator Codes

    Service Error Codes (Continued) Error Symptom or Message Action Device Error, Lifter Be sure J214 is securely installed malfunction in the to the system board. Be sure the multipurpose tray. connectors on the multipurpose tray board are installed correctly. If necessary, replace the lifting plate solenoid SL2.
  • Page 136 Operator Codes (Continued) Code Message or Symptom Action Change Paper, Possible Be sure the correct paper size is locations: installed. 27 Tray 1 Refer to the “Paper Jam 27, Paper 27 Tray 2 Size/Change Paper Service Check” in the Service Manual. Refer to the “Paper Deck Lifting Change Paper, Possible location:...

  • Page 137: Diagnostic Information

    Operator Codes (Continued) Code Message or Symptom Action Check Tray 3 Be sure the following are correct: • Tray 3, Paper drawer closed • Power cord plugged in • Option controller is installed • Option controller signal cable is completely installed. •...

  • Page 138: Symptom Tables

    If you think your symptom is caused by a paper feed failure, go to the “Paper Feed Symptom Table” on page 6-12. If you think your problem is caused by a malfunction in the paper deck refer to “Paper Deck Service Checks” in the Service Manual. If you think your symptom is caused by a paper feed problem in the paper deck refer to “Paper Deck Paper Feed Service Checks”...
  • Page 139 Print Quality Symptom Table (Continued) Symptom Action Vertical Streaks/Lines Refer to “Vertical Streaks/Lines Service Check” in the Service Manual. White Horizontal Lines Refer to “White Horizontal Lines Service Check” in the Service Manual. White Vertical Lines Refer to “White Vertical Lines Service Check”...
  • Page 140 Other Malfunction Symptom Table Symptom Action Printhead Malfunction Refer to “Printhead Service Check” in the Service Manual. Electrical Assembly Fan (FM3) Refer to “Electrical Assembly Fan Failure (FM3) Service Check” in the Service Manual. Faulty Main Motor Refer to “Main Motor Service Check” in the Service Manual.
  • Page 141 Other Malfunction Symptom Table (Continued) Symptom Action No Paper Pick-Up from Envelope Refer to “Paper Pick-Up from Feeder Envelope Feeder Service Check” in the Service Manual. Poor Output from High-Voltage Refer to “High-Voltage Power Supply Power Supply Output Service Check” in the Service Manual.
  • Page 142 Paper Deck Symptom Table Symptom Action No power Refer to “Paper Deck Power Input Service Check” in the Service Manual. Wrinkled paper Refer to “Paper Deck Wrinkled Paper Service Check” in the Service Manual. Bent leading paper edge Refer to “Paper Deck Bent Leading Edge Service Check”...

  • Page 143: Diagnostic Aids

    Diagnostic Aids This printer has three different methods of running diagnostics. The printer can run internal diagnostics tests. These tests are in the same format as the other Optra models and are described in this chapter. The printer may be tested without the controller card. The basic engine test will isolate any a failure to either the engine or the controller card.
  • Page 144 5. Press the Engine Test Print switch through the 1/4 inch hole and verify a machine paper pick-up from tray 2 and output on top exit with vertical lines running down the page. POR the machine to continue using the operator panel. Menu Disable To disable or lockout the menu press the Return key and top soft button as you turn the printer off and on.
  • Page 145 important that care is taken while operating the test mode to only load one sheet of print paper at a time in the tray. If multiple sheets of paper are loaded in the tray, the paper deck will continuously feed paper into the printer until running out causing a paper jam in the printer.
  • Page 146 HARDWARE TESTS LCD Test Button Test Parallel Confidence Test Wrap Tests Parallel Serial Memory Tests DRAM PAGE COUNTS Page Count Permanent Page Count PAPER FEED TESTS Tray 1 Tray 2 Tray 3 (if installed) Multipurpose Feeder (if installed) DUPLEX Duplex Quick Test DEVICE TESTS (If Installed) Disk Test/Clean Quick Disk Test...

  • Page 147: Diagnostics Mode Tests

    Diagnostics Mode Tests Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Button Test]. 4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed. 5. Press Return to return to the Diagnostics mode main menu. Defaults Allows setting the following defaults to U.S.
  • Page 148 Duplex Quick Test Print on both sides with machine specification information on one side. Error Log The list of the six most recent errors is displayed. The newest error is displayed in position one. In a full log, position six is the oldest error. If more than six errors are received, the oldest error is discarded.
  • Page 149 LCD Test To test the operator panel display: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [LCD Test]. 4. Select [Single] or [Continuous]. 5. The display goes through a continuous sequence of turning pels on and off. 6. Press Return to stop continuous LCD test. 7.
  • Page 150 Permanent Page Count The permanent page count can be only displayed. It cannot be modified or reset by the customer or servicer. 1. Enter Diagnostics mode. 2. Select [PAGE COUNTS]. 3. Select [Permanent Page Count]. 4. Press Return to return to the Diagnostics mode main menu. Print Test 1 Print Test 1 generates one printout similar to the test page.
  • Page 151 Print Test 3 This test generates two printouts: a solid black page, the second page is a gray scale page. The gray scale can be used to spot developer band problems. 1. Enter Diagnostics mode. 2. Select [PRINT TESTS]. 3. Select [Print Test 3]. 4.
  • Page 152 Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer. To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the interface cable. 3. Install the wrap plug in one of the interface cable connectors. 4.

  • Page 153: Adjustments

    Adjustments Envelope Feeder Separation Guide and Lower Separation Roller Gap Adjustment Under normal conditions, remove the separation guide along with the upper cover. If you removed just the separation guide or replaced a bent separation guide, adjust the gap as follows: Insert the separation guide 1.5 mm from the lower separation roller.

  • Page 154: Paper Drawer Cassette Side Registration Adjustment

    Paper Drawer Cassette Side Registration Adjustment Make this adjustment when the side registration of the cassette is not aligned. The side adjustment registration levers in the upper and lower cassettes are adjusted in the factory. If either the upper or lower cassette needs replacing in the field, re-adjustment of the margins on the left side is necessary.

  • Page 155: Connectors

    Connectors System Board Connector Signals System Board Connector J201 Signal Signal Name /FPCS Front Panel Controller Chip Select Signal Reserved Vsync Request Signal /VSREQ Vsync Request Signal /VSYNC Vertical Sync Signal /STS Status Signal /CMD Command Signal Reserved /SPCHG Speed Change Signal Reserved /FPO Front Panel Serial Output Signal...
  • Page 156 System Board Connector J201 (Continued) Signal Signal Name Video Signal /FPI Front Panel Serial Input Signal FPCK Front Panel Serial Clock Signal /PPRDY Printer Power Ready Signal /PRNT Print Signal /PCLK Printer Clock Signal /CCLK Controller Clock Signal Reserved Paper Delivery Signa /PDLV Reserved Beam Detection Signa...
  • Page 157 System Board Connector J203 Signal Signal Name Front Panel Serial Output Signa /FPO /FPI Front Panel Serial Input Signal /FPCS Front Panel Controller Chip Select Signal Front Panel Serial Clock Signa FPCK System Board Connector J204 Signal Signal Name +24VA System Board Connector J205 Signal Signal Name...
  • Page 158 System Board Connector J206 Signal Signal Name /BDI Beam Detection Input Signal System Board Connector J207 Signal Signal Name /SCNRDY Scanner Motor Ready Signal /SCND Scanner Motor Drive Signal SCNCLK Scanner Motor Control Clock Signal +24VA System Board Connector J208 Signal Signal Name FAN1D...
  • Page 159 System Board Connector J212 Signal Signal Name FSRTH Flying Roller Temperature Sense Signal SVIN Service Status Signal SVOUT Service Command Signal +24VA System Board Connector J213 Signal Signal Name +24VA +24VA /DUPIDS Duplexing Unit Sense Signal /DUPSTS Duplexing Unit Status Signal DUPCMD Duplexing Unit Command Signal /DUPCLK...
  • Page 160 System Board Connector J215 Signal Signal Name LSIZE4 Lower Cassette Paper Size Sense Signal LSIZE3 Lower Cassette Paper Size Sense Signal LSIZE2 Lower Cassette Paper Size Sense Signal LSIZE1 Lower Cassette Paper Size Sense Signal USIZE4 Upper Cassette Paper Size Sense Signal USIZE3 Upper Cassette Paper Size Sense Signal USIZE2...
  • Page 161 System Board Connector J218 Signal Signal Name /MMRDY Main Motor Ready Signal /MMOTD Main Motor Drive Signal +24VB +24VB System Board Connector J219 Signal Signal Name FEDAND Pick-up Motor Control Signal FEDAD Pick-up Motor Control Signal FEDBND Pick-up Motor Control Signal FEDBD Pick-up Motor Control Signal /UDECKS...
  • Page 162 System Board Connector J220 Signal Signal Name HVTS Transfer Bias Monitor Signal /HVTRVSD Transfer Negative Bias Drive Signal TONRS Toner Level Signal DENADJ Image Density Adjustment Signal /DBACD Developing ac Bias Drive Signal /DBFRQ Developing Bias Frequency Output Signal +24VB HVNLTD Transfer Bias Drive Signal /HVTRVSD...
  • Page 163 System Board Connector J222 Signal Signal Name FSRTYP1 Fuser Main Heater Type Sense Signal FSRTP1R FSRTP2R FSRTYP2 Fuser Sub Heater Type Sense Signal FSRTH Fuser Roller Temperature Sense Signal System Board Connector J223 Signal Signal Name TONRS Toner Level Signal System Board Connector J225 Signal Signal Name...

  • Page 164: Paper Deck Switches, Sensors, Clutches, Solenoid, Motors

    Paper Deck Switches, Sensors, Clutches, Solenoid, Motors Name Function Name Function SW31 Lift Abnormal Position PS35 Door Sensor Sensing Switch SW601 Paper-level Sensing Sw. CL31 Lifter Clutch SW602 Paper-level Sensing Sw. CL32 Registration Clutch SW701 Paper-size Sensing Sw. CL33 Feed Clutch SW702 Paper-size Sensing Sw.
  • Page 165 Paper Deck Driver Board Connector J201 (Continued) Signal Signal Name STRBO Strobe Signal PWRON-IN Power On Signal +24V Paper Deck Driver Board Connector J202 Signal Signal Name Serial Out Signal Serial In Signal CONTI Communication Ready Signal +24V Synchronous Clock Signal +24V STRBO Strobe Signal...
  • Page 166 Paper Deck Driver Board Connector J204 Signal Signal Name DCMOT-RDY Deck Motor Ready Signal DCMOT-ON Deck Motor Drive Signal +24V +24V Paper Deck Driver Board Connector J205 Signal Signal Name FEDBND Pick-up Motor Control Signal FEDBD Pick-up Motor Control Signal FEDAND Pick-up Motor Control Signal Pick-up Motor Control Signa...
  • Page 167 Paper Deck Driver Board Connector J208 Signal Signal Name +24V PICKUPSL Pick-up Solenoid Drive Signal PAP-EXIST Tray Paper-out Sense Signal LIFT Paper Surface Sense Signal DOOR Door Open Sense Signal Paper Deck Driver Board Connector J209 Signal Signal Name PAP-SIZE4 Paper Size Sense Signal 4 PAP-SIZE3 Paper Size Sense Signal 3...

  • Page 168: Option Controller Interface Connectors

    Option Controller Interface Connectors Option Controller Interface Connector Signal Signal Name RESET Reset Signal (unused) /PRINT Print Signal (unused) /SPCHG Speed Change Signal (unused) /PDLV Paper Delivery Signal /undetermined 1 For expansion N.C. /CKEN Communication Ready Signal Send Data Line N.C.
  • Page 169 Optional I/O Device Interface Signal Signal Name Send Data Line Receive Data Line /TERMINATE Communication Ready Signal +24V /CLOCK Synchronized Clock Signal GND (KEY) Mis-insertion prevention +24V /STROBE Strobe Signal PWRON Power On Signal +24V 6-42 Laser Printer Reference Handbook...

  • Page 170: Parts Catalog

    Parts Catalog Covers and Panels Description 11A8012 • Stopper, Open/close 11A8013 • Lever, Door Right Cover 11A8002 Hinge, Stopper 11A8001 , Delivery Cover 11A8019 Tray, Face-down Paper Internal Paper Mechanism Description 11A8033 Motor, Main (Mt1) 11A8034 B/M Stopper, Pawl 11A8028 Bracket, Front Sock Damper 11A8029 Bracket, Rear Sock Damper...
  • Page 171 Power Supply/Fuser Cables (Continued) Description 11A8088 Fuse, 120 V 11A8089 Fuse, 250 V Face-Up Solenoid Description 11A8101 Face-up Solenoid Asm. High Voltage Power Supply Description 11A8102 High Voltage Power Supply Printer Driver Description 11A8104 Printer Driver Gear B/M 11A8103 Fuser Transfer Gear B/M Lower Drawer Description 11A8118...
  • Page 172 Upper Drawer (Continued) Description 11A8110 Spring, Paper Empty 11A8106 Handle, Drawer Open B/M 11A8107 Drawer Paper Size Indicator 11A8116 Roller, Left Rear 11A8117 Gear, Paper Adjust Paper Pick-up Description 11A8152 Clutch, Electromagnet 11A8151 Pickup Roller Drive Gear B/M 11A8160 Guide, Open/close 11A8155 Paper Roller/Separation/Pickup 11A8158...
  • Page 173 Multipurpose Tray Pick-Up Description 11A8180 Pick-up Gear B/M, MPT 11A8176 Clutch, Electromagnet 11A8179 Solenoid Asm. Met Pick-Up, B/M 11A8183 Flag, Sensor 11A8185 Separation Pad B/M 11A8186 Arm, Stop 11A8184 Pick-up Roller/ Separation Pad B/M 11A8188 Arm, Sensor, Paper Present 11A8189 Multipurpose Tray Board Multipurpose Tray Description...
  • Page 174 Fuser Description 11A8233 Fuser Asm. (110/115) 11A8234 Fuser Asm. (220/240) 11A8245 Fuser Lamp 110V B/M 11A8248 Fuser Lamp 240V B/M 11A8250 Thermoswitch 11A8251 Bracket, Thermostat Mounting 11A8236 Compression Guide, B/M 11A8243 Label, (110/115V) 11A8244 Label, (220/240) 11A8351 Hot Roll, Upper, Fuser 11A8352 Hot Roll, Lower, Fuser 11A8246...
  • Page 175 Envelope Feeder Drive 1 Description 11A8318 Envelope Feeder Board 11A8320 Roller, Pickup #2 11A8321 Roller, Lower Separation 11A8323 Roller, Feed #2 11A8324 Roller 11A8322 Roller, Feed #1 11A8325 Motor, Envelope Feeder Envelope Feeder Drive Separation/Registration Description 11A8338 Lever, Sensor 11A8347 Torque Limiter 11A8346 Roller, Upper...
  • Page 176 Duplex Drive (Continued) Description 11A8407 Roller, Reverse 11A8418 Motor, SM21 Paper Deck, Main Body Description 11A8465 Paper Sensor Board 11A8471 Paper Size Sensing Board 11A8476 Fuse 11A8475 Power Supply, DC 11A8461 Paper Deck Driver Board 11A8366 Abnormal Position Switch Paper Deck, Paper Drawer Description 11A8527 Paper Sensing B/M...
  • Page 177 Paper Deck, Paper Feed Description 11A8628 Gear B/m, Feed Assembly 11A8624 Clutch Magnet, CL33, CL32 11A8634 Roller, Register 11A8638 Roller, Feed 11A8643 Jam Sensor B/M, PS32 11A8642 Registration Sensor B/M, PS31 11A8641 Roller, Feed Option Controller Card Description 11A8361 Board, Option Controller Options Description 1381856...
  • Page 178 4047-05W 4047-05W...
  • Page 179 Notes: Laser Printer Reference Handbook...
  • Page 180 4047-05W Diagnostics Start Use the error code message table, symptom tables, and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer. If an error code, alert, or service message appears on the host display, and the printer status light is not flashing continuously, locate the error condition in the table below.
  • Page 181 Error Code Message Table (Continued) Error Code/Message Action Print Job Lost Either communication between the printer and the computer was lost while a job was printing, or the data sent to the printer was not able to be printed. Short Paper Error The paper fed into the printer is shorter than the paper size chosen in the Windows Printing System setup dialog box.

  • Page 182: 4047-05W

    Error Code Message Table (Continued) Error Code/Message Action [Error 980] Replace EPROMs, or MROM if installed. If this does not fix the problem, replace the system board. [Paper Jam] Refer to the Paper Jam Service Check in the Service Manual. [Load Manual] Refer to the Manual Feed Service Check in the Service Manual.

  • Page 183: Power-On Self Test (Post)

    Printer Status Light Table Status Action CLEAR PAPER Refer to the Paper Jam Service Check in the Service Manual. ADD ‘XXX’ PAPER Make sure the correct paper is loaded in the tray specified in the setup box. If correct, go to the appropriate paper tray service check in the Service Manual.
  • Page 184 If the printer completes all these steps and no error messages are displayed, the printer has successfully completed the POST. If your printer has completed POST, go to the “Symptom Table” on page 7-8. If your printer did not complete POST, locate your symptom in the POST Symptom Table on the following page, and take the appropriate action.
  • Page 185 Symptom Table Symptom Action Dead printer Refer to the Power Supply Service Check in the Service Manual. Fan not working Refer to the Fan Service Check in the Service Manual. Fan noisy Refer to the Fan Service Check in the Service Manual.
  • Page 186 Symptom Table (Continued) Symptom Action Toner on the back of Refer to the Transfer Roll Service Check in the page the Service Manual. Poor print quality Refer to the Print Quality Service Check in the Service Manual. Incorrect characters Refer to the Print Quality Service Check in the print Service Manual.

  • Page 187: Diagnostic Aids

    Diagnostic Aids Customer Test Page (From WPS) Use this test to check print and graphics quality. Running the print test resets temporary settings to the printer default settings and deletes all macros and downloaded fonts. To run the Print Test: 1.

  • Page 188: Developed Image Test

    Developed Image Test This test allows you to examine the image on the photoconductor and may be used to diagnose print quality problems. You may need to do this procedure several times to get the timing correct. To run the Developed Image Test: 1.

  • Page 189: Diagnostics Test Page

    Diagnostics Test Page This test generates a one-page printout. 1. Use either the service diskette or the internal WPS Diagnostic Toolkit, if installed. 2. Select Setup from the menu. 3. Select Print Diagnostics Test Page from the Commands Description List. 4.

  • Page 190: Hex Trace

    Hex Trace Hex trace allows you to get a hexadecimal printout of the data stream sent to the printer. You can use either the service diskette or the internal WPS Diagnostic Toolkit, if installed. 1. Select Setup from the menu. 2.

  • Page 191: Wrap Test

    Wrap Test The Wrap Test checks the circuits used to communicate with the host computer. To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the parallel cable. 3. Install the parallel wrap plug (P/N 1319128). 4. Open the top cover. 5.

  • Page 192: Printhead Calibration

    3. Select Print Diagnostics Test Page from the Commands Description List. 4. Select Send to Printer. 5. Select OK. 6. Stored error codes will print under Error Log in the Information block on the Diagnostic Test Page. To clear the error log of all stored codes: 1.

  • Page 193: Print Registration Adjustment

    Print Registration Adjustment Use the Diagnostics Test Page to decide if any changes need to be made to the print registration adjustment. The values for each margin are printed in the diagnostic information block on the test page. You can use either the diagnostic service diskette or the internal WPS Diagnostic Toolkit, if installed.

  • Page 194: Fuser Temperature

    Bottom Margin This margin can be set between -26 and +7. Moving the number in a positive direction moves the margin down and narrows the bottom margin. Moving the number in a negative direction moves the text up the page and leaves a wider bottom margin. Changing the bottom margin does not affect the top margin.

  • Page 195: Connectors

    Connectors System Board Connectors Connector Connector Name Printhead Signal Printhead Power LED/Cover Interlock Not used Not used DRAM Option Parallel Port Tray 1 Torquer Input Sensor Tray 2 Torquer Motor Exit Sensor Tray 1 Sensor Power Supply ROM Select 7-18 Laser Printer Reference Handbook...

  • Page 196: Parts Catalog

    Parts Catalog Parts Packet Description 1381309 E-Ring, O-Ring, Washer, Clip (Left Side Cover) 1381310 Spring 1381311 Screw, Lockwasher Covers Description 1412161 LED, Cover Interlock Switch/Cable Left Side Frame Description 1381287 Side Bracket, Left, without D-Roll 1381306 Motor, Torquer, w/Cable 1381298 Sensor, Input 1363757 Flag, Input Sensor...
  • Page 197 Top Cover Description 1381333 Cover, Top Inner 1381290 Card, LED Circuit 1381288 Roll CBM, Charge 1381289 Printhead Assembly 1363135 Belt Standard Paper Tray Description 1364481 Paper Tray, Standard 1363457 Restraint, Side Fuser Description 1381621 Fuser Assembly, 110V, w/Lamp 1383311 Lamp, 110v 1381294 Hot Roll Assembly, w/Bearings (Also Replace Thermistor Asm.)

  • Page 198: 4049-Xxx

    4049-XXX Optra 4049-XXX...
  • Page 199 Notes: Laser Printer Reference Handbook...

  • Page 200: Diagnostics

    4049-XXX Diagnostics 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.Refer to the diagnostics Error log for the last six machine errors. Error Code Message Table Error Code Explanation 20 Paper Jam...
  • Page 201 Error Code Message Table (Continued) Error Code Explanation 32 Wrong Print Cartridge The installed print cartridge is not installed supported by the Optra printer. 37 Insufficient Collation Memory Memory is too full to collate the print job. 38 Memory Full Memory used to store pages is full.
  • Page 202 Error Code Message Table (Continued) Error Code Explanation 58 Duplex Not Attached Duplex is no longer connected, and printer top cover is closed. 59 Duplex Cover Open Top cover of duplex unit is sensed open. 62 Disk Full Not enough disk space for data that has been requested to be written to disk.
  • Page 203 Error Code Message Table (Continued) Error Code Explanation 917 Transfer Roll Error Cannot start servo operation. Verify correct cable connections from the engine board to the HVPS. Make sure there is continuity between the transfer roller and its contact on the HVPS; replace the transfer roll if the continuity is correct.
  • Page 204 Error Code Message Table (Continued) Error Code Explanation 928 Erase Lamps Erase lamp assembly missing or disconnected. 931 Printhead Error No first hsync. Refer to the Printhead section in the Service Manual. 932 Printhead Error Lost hsync. Refer to the Printhead section in the Service Manual.
  • Page 205 Error Code Message Table (Continued) Error Code Explanation 961 Memory Error 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.
  • Page 206 Error Code Message Table (Continued) Error Code Explanation 977 Network Card 1 Network card 1 is installed but is not communicating with the RIP Board. Refer to the Network Card 977 Errors section in the Service Manual. 977 Network Card 2 Network card 2 is installed but is not communicating with the RIP Board.

  • Page 207: Power-On Self Test (Post)

    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.
  • Page 208 Symptom Table (Continued) Symptom Go To Paper Feed Problem, 500-Sheet Refer to the Paper Feed Problem, 500- Option or 200-Sheet Second Sheet Option or 200-Sheet Second Drawer, Non-Rt Drawer, Non-Rt or Paper Feed Problem, 200-Sheet Second Drawer, Rt section in the Service Manual.
  • Page 209 Symptom Table (Continued) Symptom Go To Residual Image Refer to the Residual Image section in the Service Manual. Honeycomb Refer to the Honeycomb section in the Service Manual. Background Refer to the Background section in the Service Manual. Horizontal Void or Streak Refer to the Horizontal Void or Streak section in the Service Manual.

  • Page 210: Diagnostic Aids

    Diagnostic Aids Diagnostics Mode To run the printer diagnostic tests described in this section, you must put the printer in Diagnostics mode. To enter Diagnostics mode: 1. Turn the printer off. 2. Press and hold the Ready and Return buttons. Then turn the printer on.
  • Page 211 HARDWARE TESTS LCD Test Sensor Tests Toner Low Output Bin Input Exit Cover Open Button Test Parallel Confidence Wrap Tests Parallel Serial Memory Tests DRAM PAGE COUNTS Page Count Permanent Page Count Maintenance Count PAPER FEED TESTS Tray 1 Tray 2 Tray 3 Feeder Feeder 1...
  • Page 212 PRINTER SETUP Fuser Temperature Warm-Up Time Envelope Enhance Auto Clean Auto Clean Frequency Auto Clean Delay Transfer Print Contrast Charge Roll Defaults ERROR LOG RESET PRINTER 8-15 4049-XXX...

  • Page 213: Diagnostics Mode Tests

    Diagnostics Mode Tests Auto Clean Auto Clean needs to be turned on if there is an unacceptable amount of toner being deposited on the back of the page. When Auto Clean is on, after printing the number of pages specified in Auto Clean Frequency, the printer will pause the number of seconds specified in Auto Clean Delay.

  • Page 214: Button Test

    Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Button Test]. 4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed. 5. Press Return to return to the Diagnostics mode main menu. Charge Roll This setting varies the charge roll bias.

  • Page 215: Disk Test/Clean

    Disk Test/Clean This is a two hour test (three hours for 100MB drives) that should be performed only on a disk that contains bad data and is therefore unusable. This test destroys all data on the disk by doing a multi-pass write/read on every block of the disk.

  • Page 216: Duplex Feed 2 Test

    Duplex Feed 2 Test This test verifies that paper feeds through the duplex unit properly and tests the stop point of the page as it feeds back over the top of the duplex paper tray. 1. Enter Diagnostics mode. 2. Select [DUPLEX TESTS]. 3.

  • Page 217: Envelope Print Test

    Envelope Print Test Use Envelope Print Test to test the Envelope+ or Auxiliary feeder. Envelope Print Test generates one printout: a page of ripple print. Printing will occur only on the first page or envelope. 1. Enter Diagnostics mode. 2. Select [PRINT TESTS]. 3.

  • Page 218: Fuser Temperature And Warm-Up Time

    Fuser Temperature And Warm-Up Time These settings allow adjustment of the fuser to correct problems with paper curl or melting letterheads. Paper curl in which the top and bottom of the page curl toward the printed side (hot paper curl) can be corrected by reducing the fuser temperature.

  • Page 219: Laser Printer Reference Handbook

    LCD Test To test the operator panel display: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [LCD Test]. 4. Select [Single] or [Continuous]. 5. The display goes through a continuous sequence of turning pels on and off. 6. Press Return to stop continuous LCD test. 7.

  • Page 220: Page Count

    6. Press Return to return to the Diagnostics mode main menu. Parallel Confidence This test requires specific PC software and is to be implemented with the assistance of Lexmark Technical Support. It can be used to diagnose parallel port interface problems. 8-23...

  • Page 221: Permanent Page Count

    Permanent Page Count The permanent page count can be displayed only. It cannot be modified or reset by the customer or servicer. 1. Enter Diagnostics mode. 2. Select [PAGE COUNTS]. 3. Select [Permanent Page Count]. 4. Press Return to return to the Diagnostics mode main menu. Print Contrast This setting varies the developer bias to vary the print darkness.

  • Page 222: Print Test 1

    • Top Margin can be set between -20 and +20. Changing the number by one moves the margin by 1/75 inch. Moving the number in a positive direction moves the margin down the page and widens the top margin. Moving the number in a negative direction moves the text up the page and narrows the top margin.

  • Page 223: Print Test 2

    Print Test 2 Print Test 2 generates two printouts: a page similar to the test page, and a fine dot pattern which can be used to evaluate banding or other print quality problems. Print Test 2 will duplex if the duplex option is installed. This test prints from the user-selected default paper source if the default source is a tray, or from Tray 1 if the default source is a feeder.

  • Page 224: Quick Disk Test

    Quick Disk Test This is a one minute test which performs a non-destructive write/read on one block per track on the disk. It tests the printer-to-disk communications, and the disk hardware and circuitry, but does only incidental testing of the disk surface itself. The Quick Disk Test does not destroy data on the disk;...

  • Page 225: Top Margin And Duplex Quick Tests

    The Wrap Tests check the circuits used to communicate with the host computer. Note: The Parallel wrap test does not test all signals used for bidirec- tional communication. Contact Lexmark Technical Support for instruc- tions on running the Parallel Confidence Test. 8-28...

  • Page 226: Developed Image Test

    To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the interface cable. 3. Install the wrap plug in one of the interface cable connectors. Note: Install the parallel wrap plug part no. 1319128 for the parallel test or install the 25-pin serial wrap plug part no. 1329048 for the serial test.

  • Page 227: Lan Information

    LAN Information The printer may be connected to one of the following LAN types: Token-Ring Ethernet 10BASE-T Ethernet 10BASE2 LocalTalk The printer test page indicates to which type of LAN the printer is connected.The Network external connectors are shown below. Token Ring Ethernet 10Base2 Ethernet 10BaseT...

  • Page 228: Print Test With Rip Board Removed

    Print Test with RIP Board Removed Most meter measurements required during printer service will be on the engine board connectors, which are inaccessible with the RIP board in place. The printer has a service mode which allows you to test the printer without the RIP board installed.

  • Page 229: Parts Catalog

    Parts Catalog Description 1381048 Duplex Flags 1381145 Metering and Prealigner Rolls 1381561 Duplex Gears 1381663 Screw, Nut, Lockwasher, Right and Left Cam Buttons, Retainer, Pivot, Washer, Pointer, Clip, Setscrew, Fasteners 1381664 Standoffs 1381665 Gear 18T Redrive, Gears 7-14 1381666 Spring, Pin 1381669 Ground Strap, Flag, Jumper Covers...
  • Page 230 Printhead (Continued) Description 1038199 Cable, Tie 1425284 Cable, Laser (Install with marked end to printhead) Paper Feed Description 1381636 Input Sensor Board 1408703 Right Rail Asm (Without Gears) 1042211 Belt, Redrive R/Rx/Rt 1328192 Belt, Redrive, L/Lx 1381073 Toner Sensor 1381015 Sensor Asm, Paper Size 1381895 Redrive Assembly L/Lx...
  • Page 231 Standard Paper Tray (200 Sheet) Description 1364894 Paper Tray Assembly, 11 in. (200-sheet) 1364893 Paper Tray Assembly, 14 in. (200-sheet) 1408725 Paper Stop 1408567 Corner Buckler 1408724 Adjustable Guide Paper Tray (500 Sheet) Description 1381813 Paper Tray Assembly, 11 in. 1381814 Paper Tray Assembly, 14 in.
  • Page 232 Fuser Description 1381639 Fuser and Lamp 110V R/L/Rt 1381641 Fuser and Lamp 220V R/L/Rt 1381640 Fuser and Lamp 110V Lx/Rx/ R / Rt / Lx 1381642 Fuser and Lamp 220V Lx/Rx/ R / Rt / Lx 1382287 Fuser Wiper Assembly (supply item) 1328132 Fuser Cover 1381523...
  • Page 233 Electronics (Continued) Description 1364921 DRAM SIMM 2MB, R/Rt 1383513 Switch On/Off 1381840 ROM SIMM R/ Rt/ L/ Lx/ Rx 1381872 ROM SIMM R / Rx Transfer Roll Description 1381008 Roll Asm, Transfer 1381652 Housing, Transfer Duplex Option Description 1381552 Duplex System Card 1408940 Exit Sensor Cover 1381555...
  • Page 234 High Capacity Feeder Description 1381933 Circuit Board 1381935 Elevator Motor 1381936 Paper Feed Motor 1381941 Paper Feed Roller Kit Dual Rear Feeder Description 1381799 Dual Rear Feeder 1381832 Right Side Cover 1381798 Torquer Asm 1367019 Buckler Kit, L and R Envelope 1367463 Pick Roll Hub Asm 1381795...
  • Page 235 Miscellaneous Description 1319128 Parallel Wrap Plug 1329048 Serial Wrap Plug 1381663 Fasteners parts packet 1381666 Springs parts packet 1381665 Gears (7-14) parts packet 1381145 Metering and Prealigner rolls parts packet 8-38 Laser Printer Reference Handbook...
  • Page 236 5045 Optra C 5045...
  • Page 237 Notes: Laser Printer Reference Handbook...

  • Page 238: Diagnostic/Maintenance Approach

    5045 Refer to the Service Manual for information on removal procedures and part numbers. Diagnostic/Maintenance Approach This printer can be serviced without being connected to a host computer. This printer will display both operator correctable errors and service errors on the front (operator) panel. In addition, there are tests available from the Density Adjustment Panel on the back of the machine that bypass the video controller card.

  • Page 239: Start

    Start Use the error message table, symptom table, service checks in the Service Manual and the Diagnostic Aids below, to determine the corrective action to repair a printer. If the operator panel is blank, black or appears unusual, unplug the video controller board and run the engine print tests using the Density Adjustment Panel.
  • Page 240 7. The Transfer Drum Drive Motor is energized, the Transfer Drum Engagement and Cleaning Brush Engagement solenoids pick within 10 seconds, and 5 seconds later, the Cleaning Brush Motor is energized. 8. The Display reads “Busy”. 9. Each Cartridge in turn is pressed into the development position, stirred and checked for low toner.

  • Page 241: Diagnostic Aids

    Diagnostic Aids Diagnostics Mode To run the printer diagnostic tests, you must put the printer in Diagnostics mode. The Video Controller card must be plugged into the connector card (normal state). Note: Entering the Diagnostic mode clears NVRAM. To enter Diagnostics mode: 1.

  • Page 242: Diagnostics Mode Menu Structure

    Diagnostics Mode Menu Structure The following is the Diagnostics mode menu structure, The indented items are sub-menus available under the main menu items, which are in capital letters on the operator panel. Menu items referring to options will only be present if those options are installed. Menus with more than four items will use [MORE] on the fourth operator panel button to access the next screen of selections.

  • Page 243: Diagnostics Mode Tests

    Diagnostics Mode Tests Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Button Test]. 4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed. 5. Press Return to return to the Diagnostics mode main menu. Compressor This Test allows one time or continuous testing of Compress/Decompress portion of the video controller board.

  • Page 244: Disk Test/Clean

    Disk Test/Clean This is a 90 minute test that should be performed only on a disk that contains bad data and is therefore unusable. This test destroys all data on the disk by doing a multi-pass write/read on every block of the disk. Bad blocks are flagged and removed from use.

  • Page 245: Flash Test

    Flash Test This test causes the file system to write and read data on the flash to test the flash device. This test destroys all data on the flash. The flash is formatted at the end of the test. To test the flash: 1.

  • Page 246: Page Count

    Page Count To view or set the page count: 1. Enter Diagnostics mode. 2. Select [PAGE COUNTS]. 3. Select [Page Count]. 4. Choose any number between 0000000 and 9999999 by selecting [Next] to move the cursor under each digit. Select [+] or [-] to select the number you want in each digit.

  • Page 247: Print Test 2

    Print Test 2 Print Test 2 generates ten printouts: Four pages of each color at high density, four pages of each color at medium density and two pages of multi color that fade away. All of these can be used to evaluate banding or other print quality problems.

  • Page 248: Wrap Tests

    To run the Quick Disk Test: 1. Enter Diagnostics mode. 2. Select [DEVICE TESTS]. 3. Select [Quick Disk Test]. 4. The display will indicate [Test Passed] or [Test Failed]. 5. Press Return to return to Diagnostics mode main menu. Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer.

  • Page 249: Lan Information

    LAN Information The printer may be connected to one of the following LAN types: • Token-Ring • Ethernet 10BASE-T • Ethernet 10BASE2 • LocalTalk The Network external connectors are shown below. The printer test page also indicates to which type of LAN the printer is connected. 9-14 Laser Printer Reference Handbook...

  • Page 250: Attendance/Error Messages

    Attendance/Error Messages Message Action 20 Paper Jam Tray The printer has detected a paper jam in the tray or or Feeder feeder area. The display will also show the access door (Feeder Door, Tray 1, Tray 2). The entire paper path must be cleared of paper.
  • Page 251 Message Action 28 Load Paper The printer is requesting paper from a source it detects is empty. The display shows the following information: The source where it expects to find the paper. The size of the paper it expects to find. If Tray 1+2 is displayed, you must load the requested size paper in both tray 1 and tray 2.
  • Page 252 Message Action 39 Complex Page The amount of text, graphics and print information on the page requires more time to print. You can either select RESET or CONTINUE. Try the following: • If Page Protect is Off, set it On and try again. •...
  • Page 253 Message Action 53 Unformatted The printer detected an unformatted flash memory Flash card. If you select CONTINUE, the flash memory is ignored and normal operation will continues. To correct the error condition and use the flash memory: Format the flash memory card. (Select MENUS, TESTS MENU, MORE, Format Flash and CONTINUE.) Send the data again.
  • Page 254 Message Action 63 Unformatted The printer detected an unformatted disk when the Disk printer was turned on. If you continue, the disk will be ignored and normal operation will continue. To correct the error condition and use the Disk Option: Format the disk.
  • Page 255 Message Action 88 Black Toner The Toner Low Alarm is active and the printer has detected that this cartridge is low on toner. Select CONTINUE, or replace the appropriate color toner and select CONTINUE. 148 Developer See “46 Toner Cartridge Not Correctly Installed” on Unit Revolution page 9-17 Failure...

  • Page 256: Service Tips

    (This is the same as turning the machine off, and then on again.) Ordering Parts • Always refer to the part number from the Lexmark Parts Catalog when ordering FRUs. • The fuser in the 5045 is an expensive, complicated part. Replace...

  • Page 257: Handling The Printer

    Handling The Printer • ALWAYS use two people to lift printer. Handholds are located on the left and right sides of the printer. One person should grab the front left and right handholds, while the other person grabs the rear two handholds. Do not attempt to pick up the machine with one person on the right side and one on the left.

  • Page 258: Temperature/Humidity Sensor

    Temperature/Humidity Sensor This sensor is a small PCB located on the bottom, rear of the Toner Cartridge Eject Assembly. It monitors the environment of the printer and adjusts various engine parameters accordingly. It does this at: Power On, after a cartridge eject, after a certain number of copies, and a specific time interim.
  • Page 259 9-24 Laser Printer Reference Handbook...

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