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Lexmark 11A4006 - Optra K 1220 B/W Laser Printer Service Manual

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TM
Lexmark Optra
K
4046
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
Lexmark and Optra are trademarks of
Lexmark International, Inc., registered
in the United States and/or other
countries.

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Summary of Contents for Lexmark 11A4006 - Optra K 1220 B/W Laser Printer

  • Page 1 Lexmark Optra 4046 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 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.

  • Page 3: Table Of Contents

    Contents Notices and Safety Information ......vii Laser Notice ........vii Laser Advisory Label .
  • Page 4 Standard Bin Full Sensor Service Check ... 2-27 Toner Sensor Service Check..... 2-29 Transfer Corona Service Check .
  • Page 5 Removal Procedures ....... 4-4 Control Board Removal ......4-4 Cover Removal.
  • Page 6 Input Paper Feed....... 6-14 Printhead and Paper Feed Redrive ....6-16 Exit Paper Feed Frame .

  • Page 7: Notices And Safety Information

    Notices and Safety Information References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, pro- gram, or service may be used.

  • Page 8: Laser Advisory Label

    Laser Advisory Label Label is inside printerl Class 1 Laser Statement Label Label is on back of printer. viii Service Manual...
  • Page 9 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...
  • Page 10 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...
  • Page 11 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.
  • Page 12 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.
  • Page 13 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...
  • Page 14 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.
  • Page 15 Chinese Laser Notice Korean Laser Notice Notices and Safety Information xv...

  • Page 16: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 17 Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. •...
  • Page 18 Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. • As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser...
  • Page 19 Notices and Safety Information xix...
  • Page 20 xx Service Manual...

  • Page 21: General Information

    1. General Information 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, and service checks to determine the symptom and repair the failure. After you complete the repair, perform tests as needed to verify the repair.

  • Page 22: Abbreviations

    Abbreviations ASIC Application-Specific Integrated Circuit Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read- Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply Local Area Network LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode...

  • Page 23: Mechanical Operation

    Mechanical Operation This printer uses three motors to feed paper. The pick-up motor drives the pick-up roller in the printer or in the multi-function feeder. The rotating direction of the motor determines which roller will be selected. The paper feed motor drives the paper feed roller. The main motor drives the fuser, the paper exit roller, and the redrive roller.

  • Page 24: System Diagram

    System Diagram The central processing unit (CPU) in the main controller controls the entire printer and the data received from the interconnect.

  • Page 25: Printer Operation

    Printer Operation 1. When the printer receives a printing command, the main motor starts to rotate to initialize the print unit (including the photocon- ductive drum, developer, cleaning roller, and toner agitator) and to warm up the fuser. The motor in the printhead also starts to rotate to initialize the printhead.
  • Page 26 is transmitted to the paper feed roller.

  • Page 27: Process Drive Mechanism

    Process Drive Mechanism The power of the main motor is distributed to the print unit, the fuser, and the paper eject roller. The power of the motor is transmitted to the print unit through gears A, B, C, and D, and to the hot roll of the fuser through gears A,B,C,E, and F.

  • Page 28: Fuser

    Gear A receives power from the process drive assembly, transmitting the power to the photoconductive drum gear, the magnet roll (gear B), the toner agitator (gear C), the recycle screw, and gear D. Fuser The fuser consists of the hot roll assembly, and the backup roller. The hot roll has a halogen lamp, hot roll, temperature sensor, ther- mal fuse, and supporting parts.
  • Page 29 to the upper exit bin. Roller gears receive power from the hot roll gear. General Information 1-9...
  • Page 30 1-10...

  • Page 31: Diagnostic Information

    2. Diagnostic Information The diagnostic information in this chapter leads you to the failing part. Before you replace an entire assembly, determine if just the defective part is available in the parts catalog. Some diagnostic pro- cedures indicate the parts catalog location of the part to be checked by including the assembly number and reference number in paren- thesis.

  • Page 32: Start

    Start Initial Check Before you start troubleshooting, check the following: Installation Environment • The power supply line voltage is plus or minus 10% of the rated line voltage. • The machine is securely installed on a level surface in a well- ventilated place.

  • Page 33: Service Error Code Table

    Service Error Code Table Error Code Action 900 RIP Software Replace the controller board. 920 Fuser Error Indicates the fuser is not operating at the correct temperature. Go to the “Fuser Ser- vice Check” on page 2-13. 935 Printhead Error The mirror motor is not operating correctly.
  • Page 34 Error Code Action 954 NVRAM Failure Indicates the NVRAM chip on the engine board has experienced a CRC failure. Replace the engine board. 960 RAM Memory Error Replace the controller board. 961 RAM Memory Error Indicates a problem with the expanded memory.

  • Page 35: User Error Messages

    User Error Messages User Error Message Explanation 200 Paper Jam Paper is jammed at the printer Input Sensor. Remove Cartridge Open the printer’s upper front door and remove the print cartridge to access the paper jam area. 201 Paper Jam Paper is jammed between the printer’s input and Remove Cartridge exit sensors.
  • Page 36 User Error Message Explanation 34 Short Paper The printer determines the paper length is too short to print the formatted data. This occurs when the printer does not know the actual paper size loaded in the tray. For auto-size sensing trays, this error occurs if the paper stop is in the incorrect position.
  • Page 37 User Error Message Explanation 53 Unformatted Flash This message is displayed when the printer detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted.

  • Page 38: Symptom Table

    User Error Message Explanation 63 Unformatted Disk This error code displays when the printer detects an unformatted disk at power on. Press Go to clear the message. The disk is marked as bad and normal operation continues. Disk operations are not allowed until the disk is formatted. 88 Toner Low This error displays when toner low occurs and the toner low alarm is activated.

  • Page 39: Service Checks

    Symptom Action Image Banding Go to “Image Quality Service Check” on page 2-13. Background Go to “Image Quality Service Check” on page 2-13. Toner on Backside of Paper Go to “Image Quality Service Check” on page 2-13. Random Vertical Streaks Go to “Image Quality Service Check”...

  • Page 40: Dead Machine Service Check

    • Intercon- Replace these FRUs in the following order: nect Board • Engine 1. Interconnect Board Board 2. Engine Board Dead Machine Service Check Action Line Voltage Check the ac voltage. If the line voltage is incorrect, inform the customer. AC Line Cord Inspect the cord for damage.

  • Page 41: Engine Fan Service Check

    • LVPS Check engine board connector CNMC for the fol- • Engine lowing voltages: Board • Intercon- CNMC-A1 = +5 V dc nect Board CNMC-B16 = +5 V dc If the voltages are correct, check the operator panel cable condition and connection. If the voltages are incorrect, disconnect all cables from the engine board but leave the engine board connected to the interconnect board.

  • Page 42: Exit Sensor Service Check

    Exit Sensor Service Check Error Code 202 Paper Jam Open Rear Door may display if the exit sensor flag is stuck down or defective. The printer will not power up if the exit sensor flag is not in the sen- sor.

  • Page 43: Fuser Service Check

    Fuser Service Check Action 920 Fuser Check the connection of the lamp cable at the Error, Lamp LVPS and at the thermal fuse. Be sure the lamp is does not come not burned out or broken. Check the thermal fuse for conductivity. If the ther- mal fuse conducts no current, replace the fuser.
  • Page 44 An incorrect printer driver for the installed software can cause prob- lems. Incorrect characters could print and the copy may not fit the page properly. Measure all voltages from the connector to printer ground. Be sure to turn the printer off before you make any checks on the transfer corona.
  • Page 45 Print Quality - Blank Page Action Printhead Generally a 935 Printhead Error is posted if the Cable printhead assembly fails. Check the connection of the printhead. Transfer Check the transfer corona for correct installation or Corona signs of damage. Clean the transfer wire with the cleaning tool provided with the printer.
  • Page 46 Print Quality - Light Print Action Transfer Check the transfer corona for dirt or damage. Corona Check the contact and contact spring for pitting or contamination. Clean or replace as necessary. Also see the “Transfer Corona Service Check” on page 2-29.
  • Page 47 Print Quality - Residual Image Install a new print unit if one is available, before you begin this check. Residual image can be caused by the photoconductor, cleaning mechanism, and other parts inside the print unit. Action Erase LED Check the erase LED for signs of paper dust, toner Assembly build-up or other contamination.
  • Page 48 Light that enters the machine while some covers are removed may cause background. Action Erase LED See the “Erase LED Service Check” on page 2-11. Printhead The printhead is a sealed unit and cannot be cleaned. Try a replacement printhead only if all other attempts to correct a background problem fail.
  • Page 49 Print Quality - Toner on the Back Side of a Printed Page Action Fuser Toner is being carried out on the back side of the media. The problem is generally caused by a toner buildup on the fuser hot roll or backup roll. Check these rolls for any noticeable buildup of toner.

  • Page 50: Main Motor Service Check

    Distance Between Lines or Marks Cause and Action 49mm (1.9 inches) This can be caused by the feed roller or gear that turns the feed roller. Inspect for damage and replace as necessary. 24mm (0.9 inch) This can be caused by a gear in the print unit.

  • Page 51: Input Sensor Service Check

    Input Sensor Service Check Error Code 200 Paper Jam Remove Print Unit may display if the input sensor flag is stuck down or defective. Error Code 240 Paper Jam Tray or Feeder may display if the input sensor flag is broken or stuck in the upward position. Paper jam error codes may be caused by a faulty or worn pick roller.

  • Page 52: Operator Panel Buttons Service Check

    Operator Panel Buttons Service Check Before you continue, perform the “Button Test” on page 3-6. Action Operator Panel If any of the buttons failed the Button Test, replace the operator panel. Engine Board Disconnect the operator panel cable from the (No buttons engine board.

  • Page 53: Options Service Check

    Options Service Check Flash Memory Option Run a copy of the test page to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Be sure the memory SIMM is installed correctly and is not broken or damaged.

  • Page 54: Paper Feed Service Check

    Network Card Option Error code 975 indicates the printer cannot recognize the network card. Error code 976 indicates an unrecoverable software error in the network card. Verify the network card is installed correctly and is properly grounded. If you find no problem, replace the network card. If the problem remains, replace the controller board.
  • Page 55 Pick Roller If the motor is operating correctly, check the pick Gear roller gear train. The pick roller gear contains a clutch that allows rotation in only one direction. If it is installed backwards, the pick roller cannot pick the paper. If the pick roller gear is properly installed but not working correctly, replace the gear.

  • Page 56: Parallel Port Service Check

    Failures Occur at or Near the Bottom of the Stack of Paper The paper tray lift plate may not be lifting the paper with enough force for the pick roller to move the paper. Check the paper tray lift plate spring for proper operation. Also check the pick roller for wear, scratches, or rough spots.

  • Page 57: Process Fan Service Check

    Action Engine Board Disconnect the printhead cable and check the volt- age on the engine board at the following locations: OPT-1 = +24 V dc OPT-2 = +24 V dc OPT-9 = Ground OPT-13 = Ground OPT-16 = +5 V dc OPT-19 = +5 V dc OPT-20 = Ground Process Fan Service Check...
  • Page 58 “Remove Paper Standard Bin” message never appears: Action • Standard Check the flag for damage or improper operation. If Bin Full incorrect, replace the sensor. Sensor • Sensor Disconnect the sensor cable from the engine board Cable and check the cable for continuity. •...

  • Page 59: Toner Sensor Service Check

    Toner Sensor Service Check An “Insert Print Unit or Toner” or “88 Toner Empty” message may appear if the toner sensor cable is not seated correctly or if the cable is defective. Action Toner Sensor Be sure the toner sensor cable is seated properly. Check the voltage at CNTN-1 on the engine board.
  • Page 60 2-30...

  • Page 61: Diagnostic Aids

    3. Diagnostic Aids This chapter explains the tests and procedures to identify printer fail- ures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostic Mode To enter the Diagnostic Mode: 1.

  • Page 62: Power-On Self Test (Post)

    Power-On Self Test (POST) When you turn the machine on the following POST sequence takes place: 1. The Power LED turns on. 2. Diamonds scroll across the display, then clear. 3. “Performing Self Test” appears on the display. 4. The printhead mirror motor turns on. 5.

  • Page 63: Disk Test/Clean

    Disk Test/Clean WARNING: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approxi- mately 1 1/2 hours depending on the disk size. To run the Disk Test/Clean Test: 1.

  • Page 64: Disabling Download Emulations

    • “Flash Test/Test Passed” message displays if the test passes and the busy indicator turns on solid. • “Flash Test/Test Failed” message displays if the test fails and the busy indicator turns on solid. 2. Press Go or Return or Stop to return to the Device Tests menu. Disabling Download Emulations Error Code 964: Download Emulation CRC Failure.

  • Page 65: Clearing The Error Log

    discarded. Identical errors in consecutive positions in the log are entered. All 2xx and 9xx error messages are stored in the error log. To view the Error Log: 1. Select Display Log from the Error Log menu. The Error log dis- plays on 3 screens as only 4 entries display at a time.

  • Page 66: Button Test

    Button Test To run the Button Test: 1. Select Button Test from the Diagnostic menu. With no buttons pressed several OP (Open) appear on the display. 2. Press each button one at a time and a CL (Closed) displays in place of an OP.

  • Page 67: Parallel Wrap Test

    same numbers for DRAM. The busy indicator flashes indicating the test is in process. The test runs continuously. 2. Press Return or Stop to exit the test. Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following messages displays for approximately 3 seconds: ROM Checksum Error...

  • Page 68: Serial Wrap Test

    RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error False Init Fall Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum count is reached the test stops.
  • Page 69 3. This test runs continuously unless canceled by pressing Return or Stop. Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following failure messages displays for approximately 3 seconds and the Fail Count increases by 1: Receive Status Interrupt Error Status Error...

  • Page 70: Input Tray Tests

    Input Tray Tests Input Tray Feed Test This test lets the servicer observe the paper path as media is feed- ing through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the multipurpose feeder.

  • Page 71: Base Sensor Test

    4. Press Return or Stop to exit the test. The multipurpose tray does not have a paper low sensor. Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly. The following sensors can be checked: Standard Bin Full Upper Front Door Open Rear Door Open (paper guide)

  • Page 72: Printer Setup

    When the value you want is displayed, press Select to save the value. 5. To exit the Registration menu, press Return. To verify the margin values are correct you must print the “Quick Test Page” from the registration screen. Press Go to print the test page. While printing the Quick Test Page the “Quick Test Printing”...

  • Page 73: Viewing The Permanent Page Count

    Viewing the Permanent Page Count The Permanent Page Count can only be viewed and cannot be changed. To view the Permanent Page Count: 1. Select Permanent Page Count from the menu. 2. Press Return to exit the diagnostic menu. Setting Configuration ID The configuration ID is used to communicate information about cer- tain areas of the printer that cannot be determined using hardware sensors.

  • Page 74: Print Tests

    Print Tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. Each of the installed options is listed in the following order in the menu: Tray 1 Tray 2 (if installed) Multipurpose Feeder (if installed)

  • Page 75: Printing Menu Settings Page

    1. Turn the printer off. 2. Press and hold Select and Return. 3. Turn on the printer. 4. Release the buttons once Performing the Self Test displays. 5. The printer performs its normal POR cycle then print one copy of the Print Quality Test pages. If you want more than one copy, perform these steps again.

  • Page 76: Paper Jams - Base Printer

    Paper Jams - Base Printer Error Message 200 - Paper Jam - Remove Print Unit This message indicates that paper is jammed at the printer input sensor. This condition can be caused by the paper jamming prior to activating the input sensor flag, the sensor not detecting paper over the sensor or paper arriving at the sensor too late.

  • Page 77: Repair Information

    4. Repair Information Precautions for Disassembly and Cleaning Observe the following precautions whenever you service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer, reverse the order of disassembly unless otherwise specified.

  • Page 78: Precautions For Handling The Drum Cartridge

    During Replacement: • Before you unplug connectors from the circuit boards, be sure the power cord has been unplugged from the power outlet. • When you remove a board from its conductive bag or case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the board.

  • Page 79: Precautions For Handling The Laser Equipment

    Precautions for Handling the Laser Equipment • When a service job needs to be performed in the laser beam path, such as when working around the printhead and the drum cartridge, be sure to turn the printer off first. • A highly reflective tool can be dangerous if it is brought into the laser beam path.

  • Page 80: Removal Procedures

    Removal Procedures Do not disassemble the following parts: • Printhead • Toner Bottle • Fuser • Transfer Corona Assembly Control Board Removal 1. Remove the right side cover. 2. Remove the outer shield. 3. Disconnect the controller board cable from J4. 4.

  • Page 81: Cover Removal

    Cover Removal 1. Open the upper door. 2. Remove the three screws from the upper cover. 3. Remove the rear cover (1 screw). Repair Information 4-5...
  • Page 82 4. Remove the left and right side covers. 5. Use a screwdriver to release the latches on the left side of the upper cover as you lift the cover upward. As you lift the cover, disconnect the print density cable and operator panel cable from the operator panel.

  • Page 83: Cover-Open Switch Removal

    Cover-Open Switch Removal 1. Remove the interconnect board and the high voltage power sup- ply. 2. Disconnect the cover-open switch connector. 3. Disengage the two latches of the left guide and pull the left guide upward to remove it. 4. Remove the cover-open switch. Installation Note: When you install the new switch, place the switch in the left guide then carefully slide the guide along the metal frame into position.

  • Page 84: Engine Board Removal

    Engine Board Removal 1. Remove the right side cover. 2. Open the controller board door assembly. 3. Disconnect all connectors from the engine board, except for the lower control board cable (connectors CNCA and CNCB). 4. Remove the two screws and disengage the hook on the left side of the card.

  • Page 85: Engine Fan Removal

    Engine Fan Removal 1. Remove the right side and the upper cover. 2. Open the controller card door assembly. 3. Remove the fan shield plate. 4. Disconnect the engine fan and pull the cable through the toroid. 5. To remove the fan, lift it at an angle as you press the lower mounting plate down with a screwdriver.

  • Page 86: Exit Paper Feed Roller Assembly Removal

    Exit Paper Feed Roller Assembly Removal 1. Remove the right side cover. 2. Open the controller board cage door assembly and disconnect the process fan from the engine board. 3. Remove the fuser and power supply board assembly. 4. Remove the paper feed guide assembly. 5.

  • Page 87: Fuser Removal

    Fuser Removal 1. Remove the right side cover. 2. Open the controller card door assembly and remove the fan shield plate. 3. Disconnect the process fan from the engine card and pull it through the toroid. 4. Remove the rear cover. 5.

  • Page 88: High Voltage Power Supply Board And Interconnect Board Removal

    High Voltage Power Supply Board and Interconnect Board Removal 1. Remove the paper tray. 2. Remove the right side cover and the control board cage door. 3. Remove the engine board. 4. Remove the four screws from the bottom of the printer to remove the interconnect board/HVPS assembly.
  • Page 89 5. Remove five screws to remove the interconnect board. 6. Remove three screws to remove the high voltage power supply board. Installation Notes: 1. When you install the interconnect board, observe the order of fastening screws as shown above. 2. When you install the high voltage power supply/interconnect board assembly, be careful the cable does not overlap the four spring electrodes on the bottom left of the printer mechanism.

  • Page 90: Main Motor Removal

    Main Motor Removal 1. Remove the right side and upper cover. 2. Open the controller board cage door assembly. 3. Remove the fan shield plate. 4. Remove the engine cooling fan. 5. Remove the engine board. 6. Remove the main motor assembly (4 screws). 4-14...
  • Page 91 7. Remove four screws and disconnect the cable to remove the main motor. Repair Information 4-15...

  • Page 92: Multi-Function Feeder Board Removal

    Multi-Function Feeder Board Removal 1. Remove the right side cover. 2. Disconnect the cable from the MFF board. 3. Remove the board (1 screw). 4-16...

  • Page 93: Paper Feed Motor Removal

    Paper Feed Motor Removal 1. Remove the right side cover. 2. Open the controller board cage door assembly. 3. Disconnect the controller board cable and remove the controller board door assembly. 4. Remove the engine board. 5. Remove the fan shield plate. 6.

  • Page 94: Paper Feed Roller Removal

    Paper Feed Roller Removal 1. Remove the upper cover and the left and right side covers. 2. Remove three screws, disengage three hooks, and disconnect the toner sensor connector to remove the upper front cover assembly. 3. Remove the right and left springs and lift the upper feed roll from the paper feed frame.
  • Page 95 remove the lower feed roll. 6. Use diagonal cutting pliers to cut the hook off the gear at the right end of the lower feed roll. 7. Move the lower feed roll to the left and pull out the roller from the left end.
  • Page 96 Installation Note: 1. When you install the lower feed roll: a. Insert the right end D-cut of the lower feed roll into the hole of the right bearing, then the hole of a new gear until the gear is caught by the hook. b.
  • Page 97 Repair Information 4-21...

  • Page 98: Pick-Up Motor Removal

    Pick-up Motor Removal 1. Remove the paper tray. 2. Remove the left side cover. 3. Remove the left paper tray guide assembly. 4. Remove the interconnect board and high voltage power supply assembly. 5. Remove the pick-up motor, (2 screws). 4-22...

  • Page 99: Pick-Up Roller Removal

    Pick-up Roller Removal 1. Remove the paper tray. 2. Remove the left side cover. 3. Remove the screw from the pick-up roller shaft ground plate and remove the ground plate. 4. Use a screwdriver to remove the bearing. 5. Pull the pick-up roller shaft out approximately 50 mm to remove the pick-up roller.
  • Page 100 Installation Note: When you put the pick-up roller on the shaft, face the tapered rib of the roller toward the pick-up motor. 4-24...

  • Page 101: Power Supply Board Removal

    Power Supply Board Removal 1. Remove the right side cover and the shield plate. 2. Open the controller card door assembly and disconnect the pro- cess fan. 3. Remove the fuser and power supply board assembly. 4. Turn the assembly upside down. 5.

  • Page 102: Print Density Board Removal

    Print Density Board Removal 1. Remove the control board. 2. Remove the fan shield plate. Remove the print density board from the bottom of the frame (1 screw). 4-26...

  • Page 103: Printhead Removal

    Printhead Removal 1. Remove the upper cover. 2. Disconnect the connector from the printhead assembly. 3. Remove the printhead cover and the printhead assembly (3 screws). Printhead Erase LED Assembly Removal 1. Remove the upper cover. 2. Remove the printhead. 3.

  • Page 104: Process Fan Removal

    Process Fan Removal 1. Remove the fuser and power supply assembly. 2. Remove the fan from the side of the assembly (2 screws). 4-28...
  • Page 105 Installation Note: Install the fan so the air flow arrow is to the outside. Repair Information 4-29...

  • Page 106: Separator Assembly Removal

    Separator Assembly Removal 1. Remove the paper tray. 2. Place the paper tray upside down, push in the two separator assembly latches, and remove the separator assembly. Be care- ful not lose the spring. Installation Note: Be sure to install the separator so the rubber sur- face is toward the front of the drawer.

  • Page 107: Stacker Full Sensor Board Removal

    Stacker Full Sensor Board Removal 1. Remove the upper cover. 2. Remove the cable from the stacker-full sensor. 3. Remove the board (1 screw). Repair Information 4-31...

  • Page 108: Transfer Corona Removal

    Transfer Corona Removal Be careful, the parts could be hot. 1. Open the upper door. 2. Remove the print assembly. 3. Use a screwdriver to remove the transfer corona holding block at the left side of the transfer corona. 4. Open the latch on the left side of the base frame and use a screwdriver to lift the left side of the transfer corona then pull it toward the left side.

  • Page 109: Locations

    5. Locations Front and Right Side of Printer Locations 5-1...

  • Page 110: Rear And Left Side Of Printer

    Rear and Left Side of Printer...

  • Page 111: Interior Of Printer With Upper Door Open

    Interior of Printer with Upper Door Open Locations 5-3...

  • Page 112: Optional Multi-Function Feeder And Paper Feeder

    Optional Multi-Function Feeder and Paper Feeder Locations 5-4...

  • Page 113: Sensors

    Sensors Locations 5-5...

  • Page 114: Ep Diagram

    EP Diagram...

  • Page 115: Engine Board

    Engine Board Locations 5-7...

  • Page 116: Control Board

    Control Board Locations 5-8...

  • Page 117: Power Supply Board

    Power Supply Board Locations 5-9...

  • Page 118: Interconnect Board

    Interconnect Board 5-10...

  • Page 119: Parts Catalog

    6. Parts Catalog How to Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 120: Upper Cover

    Assembly 1: Upper Cover...
  • Page 121 Part Units Description Number 11A4200 Cover Assembly, Top 11A4202 Door, Top Cover 11A4203 Hinge, Door, Outer Left 11A4204 Hinge, Door, Inner 11A4205 Hinge, Door, Outer Right Screw, PP 12A4039 11A4208 Control Panel with English Overlay 11A4209 Control Panel Overlay, W.T. Kit 11A4210 Cable, Operator Panel 11A4211...

  • Page 122: Covers

    Assembly 2: Covers...
  • Page 123 Part Units Description Number 11A4207 Filter, Ozone, Top Cover 11A4212 Cover, Left 11A4213 Cover, Right 11A4214 Cover, Rear, Center Screw, PP 12A4039 11A4215 Stacker, Rear 11A4216 Guide, Rear Stacker 11A4218 Cover, Lower Front Parts Catalog 6-5...

  • Page 124: Electronics

    Assembly 3: Electronics...
  • Page 125 Part Units Description Number 11A4305 Plate, Ground 11A4316 Board, High Voltage Screw, PP 12A4039 Screw, PP 12A4039 11A4324 Board, Interconnect Screw, PP 12A4039 11A4294 Cover, Board Access 11A4307 Lever, Paper Present Sensor 11A4312 Guide, High Voltage Cover 1339526 Power Cord, U.S, Canada, A.P. (LV), Bolivia, Columbia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Nicaragua, Panama, Peru, Venezuela, Brazil (LV/HV), Mexico...
  • Page 126 Assembly 3: Electronics (cont)
  • Page 127 Part Units Description Number 11A4335 Sensor Assembly, Stacker Full Screw, PP 12A4039 11A4340 Cable, SFS 12A4043 Baffle, Cooling Fan Screw, PP 12A4039 11A4304 Clamp 11A4283 Toroid 11A4333 Cable, Printhead 11A4349 Plate, Fan Shield Screw, PP 12A4039 11A4332 Board, Engine 11A4347 Bracket, Fixed Hinge 11A4330 Shield Assembly (Inner), With Insulators...

  • Page 128: Frame, Left Side

    Assembly 4: Frame, Left Side 6-10...
  • Page 129 Part Units Description Number 12A4047 Motor, Pick Gear Pick Motor, PP 12A4036 Gear Assembly, MFF, A, PP 12A4036 11A4345 Clip Screw, PP 12A4039 Screw, PP 12A4039 Gear, MFF, B, PP 12A4036 Gear, MFF, C, PP 12A4036 Gear, MFF, D, PP 12A4036 Gear, MFF, E, PP 12A4036 Screw, PP 12A4039 11A4348...

  • Page 130: Frame, Right Side

    Assembly 5: Frame, Right Side 6-12...
  • Page 131 Part Units Description Number 11A4402 Gear Box Assembly, Main Motor Screw, PP 12A4039 11A4235 Guide Assembly, Paper Tray, Right 11A4348 Foot, Rubber 11A4405 Board, Paper Size Sensor 11A4406 Cable, Paper Size Sensor Screw, PP 12A4039 11A4407 Lever, Paper Tray Lock 11A4408 Spring 11A4410...

  • Page 132: Input Paper Feed

    Assembly 6: Input Paper Feed 6-14...
  • Page 133 Part Units Description Number 11A4268 Frame, Paper Feed 11A4271 Bearing, Feed Roll 11A4269 Feed Roll, Lower • Gear, Feed Roll, PP 12A4038 11A4272 • Strip, Mylar, Left Guide 11A4273 • Strip, Mylar, Right Guide 11A4274 Terminal, Left Paper Feed Ground 11A4276 Feed Roll, Upper 11A4277...

  • Page 134: Printhead And Paper Feed Redrive

    Assembly 7: Printhead and Paper Feed Redrive 6-16...
  • Page 135 Part Units Description Number 11A4225 LED, Printhead Erase 11A4228 Printhead 11A4229 Cover Screw, PP 12A4039 11A4231 Label, Caution 11A4311 Paper Feed Redrive Exit Assembly 11A4314 Roller, Redrive 11A4315 Holder, Roller 11A4317 Guide, Roller 11A4300 Roller Assembly Gear, #6 (Lower), PP 12A4038 Gear, #7 (upper), PP 12A4038 11A4319 Belt, Timing...

  • Page 136: Exit Paper Feed Frame

    Assembly 8: Exit Paper Feed Frame 6-18...
  • Page 137 Part Units Description Number 11A4234 Board, Power Supply, 100-120 V 11A4236 Board, Power Supply, 220-240 V Screw, PP 12A4039 Screw, PP 12A4039 11A4253 Cover, Power Supply Switch 11A4254 Lever, Exit Sensor 11A4298 Frame, Center 11A4299 Sensor, Exit Paper Feed 11A4300 Roller Assembly, Exit Paper Feed 11A4301 Frame, Right Side...

  • Page 138: Fuser

    Assembly 9: Fuser 6-20...
  • Page 139 Part Units Description Number 11A4321 Fuser Assembly, 100-120 V 11A4322 Fuser Assembly, 220-240 V Parts Catalog 6-21...

  • Page 140: Paper Tray, 250 Sheet

    Assembly 10: Paper Tray, 250 Sheet 6-22...
  • Page 141 Part Units Description Number 10-1 12A4028 Tray Assembly 12A4001 Holder, Paper Lift Plate, Left 12A4002 Holder, Paper Lift Plate, Right Spring, Lift Plate Holder, PP 12A4037 12A4003 Plate, Paper Lift Spring, Paper Tray Lift Plate, PP 12A4037 12A4004 Separator, Paper Spring, PP 12A4037 12A4005 Guide, Paper, Left...

  • Page 142: Optional 450 Sheet Second Paper Tray

    Assembly 11: Optional 450 Sheet Second Paper Tray 6-24...
  • Page 143 Part Units Description Number 11-1 12A4029 Tray Assembly, 450 Sheet 12A4011 Holder, Plate, Left 12A4012 Holder, Plate, Right Spring, PP 12A4037 Spring, PP 12A4037 12A4014 Separator, Paper Spring, PP 12A4037 12A4015 Guide, Paper, Left 12A4016 Guide, Paper, Right 12A4017 Guide, Paper, End 12A4019 Lever, Paper Size 12A4031...

  • Page 144: Optional 450 Sheet Second Paper Drawer (2)

    Assembly 12: Optional 450 Sheet Second Paper Drawer (2) 6-26...
  • Page 145 Part Units Description Number 12-1 12A4025 Drawer, 450 Sheet Feeder, without Tray 12A4026 Frame, Front 12A4027 Roller, Redrive Backup 11A4323 Bushing, Redrive, Backup Roller 11A4329 Spring Screw, PP 12A4039 11A4221 Bracket, Pick Roller 11A4331 Shaft, Pick Roller 11A4224 Gear, Pick Roller 11A4287 Roller, Pick 11A4404...

  • Page 146: Optional 450 Sheet Second Paper Drawer (2)

    Assembly 13: Optional 450 Sheet Second Paper Drawer (2) 6-28...
  • Page 147 Part Units Description Number 13 -1 11A4421 Roller, Redrive 11A4404 Bearing, Roller Screw, PP 12A4039 12A4424 Spring 12A4000 Lever, Lock 12A4009 Gear, Redrive 12A4010 Gear, Idler 12A4013 Bracket, Motor Mounting Screw, PP 12A4039 12A4018 Motor, Pick Screw, PP 12A4039 12A4020 Lever, Multi-switch 11A4223 Board, Paper Size Sensor...

  • Page 148: Optional Multi-Function Feeder

    Assembly 14: Optional Multi-Function Feeder 6-30...
  • Page 149 Part Units Description Number 14 -1 12A4024 Feeder, Multi-Function Parts Catalog 6-31...
  • Page 150 Assembly 15: Options Part Units Description Number 12A4024 Feeder, Multi-Function 12A4025 Drawer, 450 Sheet Feeder, without Tray 99A0420 Card Assembly, INA, Token Ring 99A0421 Card Assembly, INA, Ethernet 10/100 Base-T 99A0560 Card Assembly, Tri-Port 99A0515 Disk Drive, Hard, without Control Card 99A0517 Memory, 4MB, DRAM 99A0518...
  • Page 151 Assembly 16: Miscellaneous Part Units Description Number 12A4036 Parts Packet, Left/Right Frame Gears 12A4037 Parts Packet, Paper Tray Springs 12A4038 Parts Packet, Paper Feed Gears 12A4039 Parts Packet, Screws 99A0426 Parts Packet, Parallel Connector Mounting Screws 7350166 Packaging, Printer 12A4040 Tool, Wire Cleaning Parts Catalog 6-33...
  • Page 152 6-34...

  • Page 153: Index

    4046 6-10 Index frame assembly, left side 6-12 frame assembly, right side front and right side of printer 6-20 fuser assembly 4-11 fuser removal abbreviations 2-13 fuser service check 3-11 base sensor test hardware tests button test high voltage power supply board and interconnect board removal 4-12 control board...
  • Page 154 4-28 paper feeder process fan removal 2-27 optional multi-function feeder process fan service check 6-30 assembly optional 450 sheet second paper 6-26, 6-28 drawer assembly quick disk test optional 450 sheet second paper 6-24 tray assembly 6-32 options rear and left side of printer 2-23 options service check removal procedures...
  • Page 155 PN 11A4080 10/98 Form You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.
  • Page 156 UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 2659 LEXINGTON, KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035-3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511-9954 | | | | | |...

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Optra k 4046

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