Lexmark 4049LMO - Optra Lx+ B/W Laser Printer Service Manual
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Lexmark 4049LMO - Optra Lx+ B/W Laser Printer Service Manual

Lexmark 4049LMO - Optra Lx+ B/W Laser Printer Service Manual

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TM
Optra
Series
4049-XXX
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Main Menu
Lexmark is a trademark of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark 4049LMO - Optra Lx+ B/W Laser Printer

  • Page 1 Optra Series 4049-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Main Menu Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Comments may be addressed to Lexmark International, Inc., D22A/035-3, 740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 3: Table Of Contents

    4049-XXX Table of Contents Notices and Safety Information ......ix Laser Notice ........ix Laser.
  • Page 4 4049-XXX Diagnostic Information ....... . 2-1 Start ..........2-1 Power-On Self Test (POST) .
  • Page 5 4049-XXX Diagnostic Aids ........3-1 Diagnostics Mode .
  • Page 6 4049-XXX Other Tests ........3-17 Developed Image Test .
  • Page 7 4049-XXX Removal Procedures (continued) LVPS Removal ....... . 4-29 LVPS Cover Removal ......4-30 Operator Panel Removal .
  • Page 8 4049-XXX Preventive Maintenance ....... 6-1 Safety Inspection Guide ......6-1 Lubrication Specifications .

  • Page 9: Notices And Safety Information

    4049-XXX Notices and Safety Information References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, pro- gram, or service may be used.

  • Page 10: Laser

    4049-XXX 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 11: Avvertenze Sui Prodotti Laser

    4049-XXX Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825.

  • Page 12: Declaração Sobre Laser

    4049-XXX Declaração sobre Laser A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 825.

  • Page 13: Lasermeddelelse

    4049-XXX 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 14: Laser-Notis

    4049-XXX 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 15: Avís Sobre El Làser

    4049-XXX 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.

  • Page 16: Chinese Laser Notice

    4049-XXX Chinese Laser Notice Korean Laser Notice xvi Service Manual...

  • Page 17: Trademarks

    4049-XXX Trademarks Optra and Lexmark are trademarks of Lexmark International, Inc. registered in the United States and/or other countries. AppleTalk and LocalTalk are trademarks of Apple Computer, Inc., registered in the United States and other countries. PCL is a registered trademark of the Hewlett-Packard Company.

  • Page 18: 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 19 Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.
  • Page 20 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
  • Page 21 Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d’aquest producte està...
  • Page 22 4049-XXX xxii Service Manual...

  • Page 23: Preface

    4049-XXX Preface This manual is divided into the following chapters: • “General Information” contains a general description of the printer, available options, and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter. •...

  • Page 24: General Information

    4049-XXX 1. General Information The Optra™ Laser Printers are designed to attach to IBM-compati- ble PC’s and to most computer networks. There are multiple models, all with standard PostScript Level 2 emulation and PCL 5 emulation. From a service standpoint models Lxi and Lxn are the same as , model Lxi is the same as Lx, and model Rn...

  • Page 25: Power Consumption

    4049-XXX Power Consumption R/L/Rt/R Rx/Lx/Lx Power Saver Mode Printing (average) 260W 310W Max. AC draw 110V 6.8A 9.8A Max. AC draw 220V 3.4A 5.0A Options The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country.

  • Page 26: Maintenance Approach

    4049-XXX Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. Begin with “Start”...

  • Page 27: Abbreviations

    4049-XXX 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 28: Diagnostic Information

    4049-XXX 2. Diagnostic Information Start Remove power from the printer before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Two-digit codes are messages for the user, but if they recur fre- quently or at inappropriate times they may be symptomatic of a ser- vice problem.
  • Page 29 4049-XXX Refer to the diagnostics Error log for the last six machine errors. Error Code Explanation 20 Paper Jam The input sensor was not unmade in time. 21 Paper Jam The exit sensor was not made in time after the input sensor was made.
  • Page 30 4049-XXX Error Code Explanation 30 Top Cover Open or Print Make sure the spring-mounted pin Cartridge Missing on the printhead shroud is installed properly and that it is detected by the ramp on the print cartridge as the cover closes. The pin should enter the tower on the HVPS and depress the cover switch.
  • Page 31 4049-XXX Error Code Explanation 54 Serial Error Framing or parity error on serial. 56 Serial Port Disabled or, Par- Data has been sent to a port which allel Port Disabled has been disabled in the Setup Menu. The port can be reactivated by entering the customer setup menu and selecting Serial Setup or Parallel Setup, Serial Buffer or Paral-...
  • Page 32 4049-XXX Error Code Explanation 81 Engine Code CRC Microcode to be programmed into the engine board during a machine upgrade has failed a CRC check. The microcode data will be dis- carded and must be retransmitted from the host computer. 88 Toner Low Toner sensor detects low toner.
  • Page 33 4049-XXX Error Code Explanation 920 Fuser Error Fuser is below temperature while printing. See “Fuser: 920, 921, or 922 Error” on page 2-19. 921 Fuser Error Fuser is below standby temperature when idle. See “Fuser: 920, 921, or 922 Error” on page 2-19.
  • Page 34 4049-XXX Error Code Explanation 945 RIP Board ASIC 1 failure. Replace the RIP Board. 946 RIP Board ASIC 2 failure. Replace the RIP Board. 947 Engine Board Engine ASIC RAM failure. Replace the engine board. 948 Engine Board Engine ASIC electronics failure. Replace the engine board.
  • Page 35 4049-XXX Error Code Explanation 971 Network Card 2 Network card 2 RAM failure. Replace network card 2. 972 Network Card 1 Network card 1 ROS/FLASH failure. Replace network card 1. 972 Network Card 2 Network card 2 ROS/FLASH failure. Replace network card 2. 973 Network Card 1 Network card 1 EEPROM/NVRAM failure.
  • Page 36 4049-XXX Error Code Explanation 978 Network Card 2 General network 2 card hardware error. Replace network card 2. 979 Network Card 1 General network 1 card software error. Verify that the network card is installed and grounded correctly. If this error returns after a POR, there is a software or microcode incompat- ibility problem.

  • Page 37: Power-On Self Test (Post)

    4049-XXX Power-On Self Test (POST) When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning by observing the following: 1. One and one half rows of pels appear on the display and then clear.

  • Page 38: Symptom Table

    4049-XXX Symptom Table Symptom Go To Dead Machine “Dead Machine” on page 2-15. Machine Hangs Displaying Machine Hangs Displaying Dia- Diamonds monds Service Check. Repeats a pattern of 5 beeps “Operator Panel Problem” on page and a pause. 2-22. Operator Panel “Operator Panel Problem”...

  • Page 39: Banding

    4049-XXX Symptom Go To Regularly Spaced Marks “Regularly Spaced Marks” on page 2-32. Skew, all edges “Skew, all edges” on page 2-33. Skew, top and bottom only “Skew, top and bottom only” on page 2-33. Light Print “Light Print” on page 2-21.

  • Page 40: Black Page

    4049-XXX J9-1 and between +15 and +20VDC on engine board J9-2. Shorting engine board J9-2 to ground should turn on all the erase lamps. Check the erase lamp cable continuity. Replace the transfer roll housing if the voltage and the cable are good. Inspect the contacts on the HVPS;...

  • Page 41: Blank Page

    4049-XXX conductor drum. Check the condition of each HVPS contact and make sure they spring back when pressed. Check the continuity of the HVPS cable. Make sure the following voltages are correct; if they are not, replace the engine board. Connector Voltage J13-5 to J13-4...

  • Page 42: Blurred Or Fuzzy Print

    4049-XXX Run the Print Test with the RIP Board removed. Make the following voltage checks: Voltage while Voltage while Connector Printing Idling J13-1 to J13-4 Less than 5 0 VDC J13-2 to J13-4 Less than 5 0 VDC J13-3 to J13-4 (Fluctuates 0 VDC between...

  • Page 43: Duplex

    4049-XXX the LVPS voltages are correct. Turn the power back off and, one at a time, reconnect the engine board cables, powering on in between each connection and checking the voltages. The connection which causes the voltages to be wrong indicates which component is bad. Repair or replace the failing component or cable as necessary.
  • Page 44 4049-XXX If you do not find a cable or voltage problem replace the duplex sys- tem board. If this does not fix the problem, replace the printer engine board. A 993 error indicates that communication between the printer and duplex unit had been established but has been lost. Check the cable as above;...

  • Page 45: Fan (927 Error)

    4049-XXX Fan (927 Error) The fan should run continuously when the printer is powered up, unless the printer is in Power Saver mode. Check that the fan rotates freely when spun manually and that the cable connections to the fan are OK.

  • Page 46: Fuser Theory

    4049-XXX Fuser Theory The fuser lamp operates off line voltage from the LVPS. The ther- mistor is in contact with the fuser hot roll. The system board reads the thermistor resistance and toggles a TRIAC in the LVPS which cycles the lamp on and off to maintain the proper hot roll tempera- ture.

  • Page 47: Fuser: 923 Or 924 Error

    4049-XXX sure the voltage to the fuser lamp during a POR; it should be line voltage until the 922 Error is displayed, if it does not, replace the LVPS, the fuser, and the fuser wiper. If the voltage to the fuser lamp is the not the same as the line volt- age, replace the LVPS.

  • Page 48: Lan Problems

    4049-XXX LAN Problems You cannot find a printer or network problem, but jobs still do not print. If the network card checks out successfully, the problem may be with the hardware or software outside of the network card. Below are some suggestions to the customer for checking hardware and soft- ware for possible problems.

  • Page 49: Network Wrap Tests

    4049-XXX If the displayed error is 977, verify that the network card is installed and grounded correctly. Remove the network card and check for +5 VDC at pin B24 of RIP board J6 or J12 (whichever the network card was connected to). If the voltage is incorrect replace the engine board;...

  • Page 50: Paper Feed Problem, 500-Sheet Option Or 200-Sheet Second Drawer, Non-Rt

    4049-XXX Possible causes: failed LCD or operator panel card, cable or con- nector problem, or engine board problem. Replace the operator panel if POR stops with half rows of pels dis- played. Run the diagnostic tests for the LCD and for the buttons. If only some buttons or pels work, replace the operator panel.
  • Page 51 4049-XXX feed paper. Remove the RIP board and run Print Test with RIP Board Removed. During the test check for 19±2 Vdc on the engine board J6-1, J6-2, J6-3, and J6-4. If the voltage is wrong, replace the engine board. Remove the motor and gear assembly from the printer and recon- nect it to the engine board.

  • Page 52: Paper Feed, Duplex Unit

    4049-XXX incorrect or the torquer motor or solenoid is defective. Adjust the solenoid air gap (see “Paper Feed Magnet Adjustment” on page 4-8). On torquer machines, make sure the torquer gear is not slipping on the shaft. Engine board J14-1 should always be +34 VDC;...

  • Page 53: Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Auxiliary Feeder

    4049-XXX If paper is jamming at the front exit of the printer, inspect the duplex exit selector switch and the linkage to the printer exit deflector. Check the switch by removing the duplex top cover and table cover and reinstalling the duplex unit in the printer. Check for +5 VDC at duplex system board J15-10.

  • Page 54: Paper Feed Problem, Dual Rear Feeder

    4049-XXX torquer moves slightly and makes a noise. With the power off there should be 88 ohms between J17-1 and J17-2, and neither should have continuity to ground. Remove the module and inspect the tray, the D-roll and the gear train.
  • Page 55 4049-XXX J5-1 carries the pick signal for Feeder 1, J5-8 carries the pick signal for Feeder 2, and J5-10 is +34 VDC. When the feeder is connected, all three pins have +34 VDC. For early level machines using the external J5/J10 adapter box, J5-8 and J5-10 are +34 VDC, J5-1 is 0 VDC, and J10-1 and J10-2 are +34 VDC.

  • Page 56: Paper Feed Problem, High Capacity Feeder

    4049-XXX Paper Feed Problem, High Capacity Feeder The paper feed rollers should be replaced every 200,000 prints or whenever feeding becomes unreliable. Clean rollers with alcohol or water at every service call. The feeder receives a pick signal from the printer, and will not do a test feed without the printer installed.

  • Page 57: Printhead

    4049-XXX The elevator mechanism and switches can be inspected by remov- ing the cover, positioning it near the feeder, reconnecting the power supply and door switch cables, and reconnecting the line cord. Check the tray height and door switches, and all cable connections. If the tray does not move at all check the elevator motor and the upper and lower limit switches.

  • Page 58: Paper Size Sensing Problem

    4049-XXX ity of the fan/mirror motor cable. Replace the printhead if the cable is good. Paper Size Sensing Problem (The printed area does not fit on the page, or the paper size cannot be changed from the operator panel.) Make sure the paper tray and its stops are undamaged. Make sure the cable to the paper size switch is connected correctly.

  • Page 59: Regularly Spaced Marks

    4049-XXX Regularly Spaced Marks This is caused by a defect on one of the rolls or gears in the print process. The damaged part can be determined by the spacing of the marks according to the following table. Find and replace the dam- aged part.

  • Page 60: Skew, All Edges

    4049-XXX Inspect and clean the inside of the printer carefully and correct any problems found. Skew, all edges If the test print frame is parallel to all edges of the page but the mar- gins are not all the same width. “Print Registration”...

  • Page 61: Stalled (Diamonds On Display)

    4049-XXX Stalled (diamonds on display) Check the continuity of the cable from J1 on the engine board to the operator panel. Next reseat the ROM and memory SIMMs and POR. This condition can also occur if the RIP and engine board are not seated or their connectors are damaged.

  • Page 62: Diagnostic Aids

    4049-XXX 3. Diagnostic Aids Diagnostics Mode To run the remainder of the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics mode. To enter Diagnostics mode: 1. Turn the printer off. 2. Press and hold the Ready and Return buttons. Then turn the printer on.
  • Page 63 4049-XXX 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 Feeder 2 Manual DUPLEX TESTS Top Margin...

  • Page 64: Diagnostics Mode Tests

    4049-XXX Envelope Enhance Auto Clean Auto Clean Frequency Auto Clean Delay Transfer Print Contrast Charge Roll Defaults ERROR LOG RESET PRINTER Diagnostics Mode Tests Auto Clean Auto Clean needs to be turned on if there is an unacceptable amount of toner being deposited on the back of the page. When Auto Clean is on, after printing the number of pages specified in Auto Clean Frequency, the printer will pause the number of seconds specified in Auto Clean Delay.

  • Page 65: Auto Clean Delay

    4049-XXX Auto Clean Delay This can be set from 1 to 60 seconds with a default of 1. 1. Enter Diagnostics mode. 2. Select [PRINTER SETUP]. 3. Select [Auto Clean Delay]. 4. Select [+] or [-] to display the delay desired. 5.

  • Page 66: Defaults

    4049-XXX Defaults Allows setting the following defaults to U.S. or Non-U.S. values. U.S. NON-U.S. Letter size paper A4 paper # 10 envelopes DL envelopes Symbol Set Roman-8 Symbol Set PC-850 1. Enter Diagnostics mode. 2. Select [PRINTER SETUP]. 3. Select [Defaults]. 4.

  • Page 67: Duplex Feed 1 Test

    4049-XXX Duplex Feed 1 Test This test checks for slipping paper problems. It verifies that the paper is entering the duplex unit far enough for the trailing edge to clear the selector fingers before the paper reverses direction. 1. Enter Diagnostics mode. 2.

  • Page 68: Envelope Enhance

    4049-XXX 8. Carefully remove the duplex unit from the printer without dis- turbing the position of the paper on the top of the duplex tray. 9. Without changing the position of the page, hold it to the top of the paper tray and remove the paper tray. 10.

  • Page 69: Error Log

    4049-XXX Error Log The error log records the last six “2X Paper Jam” or “9XX Service” errors. In a full log, position 6 is the oldest error. If more than six errors are received, the oldest error is discarded. If the same error occurs consecutively it is recorded only once.

  • Page 70: Fuser Temperature

    4049-XXX Setting “5” increases warm-up time by 90 seconds; lower settings increase the time proportionately less. Settings other than “0” may reduce throughput. Use the [+] or [-] key to change the number and then select [SAVE]. Melting letterheads may be prevented by reducing the fuser temperature as described above for paper curl.

  • Page 71: Maintenance Kit Count

    4049-XXX Maintenance Kit Count This non-displayed counter must be reset after the maintenance kit is replaced to prevent the [80 Scheduled Maintenance] message from displaying when the machine is turned on. 1. Enter Diagnostics mode. 2. Select [PAGE COUNTS]. 3. Select [Maintenance Count]. 4.

  • Page 72: Parallel Confidence

    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. Permanent Page Count The permanent page count can be displayed only.

  • Page 73: Print Registration

    4049-XXX Print Registration Use Print Test 1 or the Quick Test to evaluate print registration. Adjust the registration so the tips of the diamonds are at the top and bottom edges of the page and the printout is centered left to right. Verify that the top margin is correct before adjusting the bottom mar- gin.

  • Page 74: Print Test 1

    4049-XXX Print Test 1 Print Test 1 generates one printout similar to the test page and will not duplex. This test prints from the user-selected default paper source if the default source is a tray, or from Tray 1 if the default source is a feeder.

  • Page 75: Print Test 3

    4049-XXX Print Test 3 This test generates 2 printouts: a solid black page, and a dot pattern that can be used to evaluate print quality. Print Test 3 will not duplex. This test prints from the user-selected default paper source if the default source is a tray, or from Tray 1 if the default source is a feeder.

  • Page 76: Sensor Test

    4049-XXX Sensor Test 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Sensor Test]. 4. Select one of the following sensor tests: Toner Low, Output Bin, Input, Exit, or Cover Open. 5. When the sensor is blocked, [Open] is displayed. Otherwise, [Closed]is displayed.

  • Page 77: Transfer

    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 bi- directional communication. Contact Lexmark Technical Support for instructions on running the Parallel Confidence Test. To run the Wrap Test: 1.

  • Page 78: Other Tests

    4049-XXX A [Passed] message indicates the printer connection to the printer cable connector is good. A [Failed] message indicates a defective RIP board. Note: Ignore the number displayed after a failure is displayed. 10. Press Return to return to the Diagnostics mode main menu. 11.

  • Page 79: Print Test Page

    4049-XXX Token Ring Ethernet 10Base2 Ethernet 10BaseT LocalTalk Print Test Page You can run the Print Test even if the printer is not attached to a computer. Use this test to check print and graphics quality and the version numbers of printer microcode. This test prints from the user- selected default paper tray.

  • Page 80: Repair Information

    4049-XXX 4. Repair Information This chapter explains how to make adjustments to the printer and how to remove defective FRUs. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual pre- cautions, such as turning off power before removing logic boards: •...

  • Page 81: Adjustments

    4049-XXX Adjustments Envelope Restraint Spring On The Envelope+ Feeder Adjustment 1. Loosen the mounting screw [A]. 2. Position the spring [B] so it clears the separator roller by 1.9 ± 0.2 mm (0.075 ± 0.008 in.). 3. Tighten the mounting screw. Paper Restraint Spring On The 100-Sheet Auxiliary Feeder Adjustment 1.

  • Page 82: Envelope+ Feeder Magnet And 100-Sheet Auxiliary Feeder Magnet Adjustment

    4049-XXX Envelope+ Feeder Magnet And 100-Sheet Auxiliary Feeder Magnet Adjustment 1. Hold the armature [A] in the closed (coil active) position. 2. Loosen the mounting screw [B], and rotate the magnet assem- bly so the armature clears the clutch gear by 0.30 ± 0.20 mm (0.012 ±...

  • Page 83: Dual Rear Feeder Gear Alignment Adjustment

    4049-XXX Dual Rear Feeder Gear Alignment Adjustment Remove the right side cover of the feeder. The gear timing marks should be centered in the windows of the gear plate. If the timing mark is too far clockwise the gears will chatter during a POR. If the mark is too far counterclockwise, extra sheets may feed at random times, or paper may feed continuously after the first page is fed.

  • Page 84: Fuser Drive Gear Backlash Adjustment

    4049-XXX Fuser Drive Gear Backlash Adjustment Fuser drive gear backlash is adjusted so that when gear #2 is held still, there is a slight amount of backlash in the fuser gear. Print qual- ity can be affected if the gears are too tight. 1.
  • Page 85 4049-XXX Fuser Gear Right Sideplate Stud Idler Gear Repair Information 4-6...

  • Page 86: Fuser Solenoid Adjustment

    4049-XXX Fuser Solenoid Adjustment Note: The fuser solenoid must be mounted on the fuser for this adjustment and should be at room temperature. 1. Loosen screw [A]. 2. Remove the rubber washer. 3. Rotate shaft [B] (eccentric) to obtain 4.2 mm ± 0.2 mm (0.165 in.

  • Page 87: Paper Feed Magnet Adjustment

    4049-XXX Paper Feed Magnet Adjustment 1. Remove the system board. The magnet is accessed through the holes in the right frame. 2. With the armature latched on the cam step check for 0.60 mm ± 0.07 mm (0.024 in. ± 0.003 in.) between the foam pad and the magnet pole piece.

  • Page 88: Printhead Skew Adjustment

    4049-XXX Printhead Skew Adjustment 1. R, R , Rt, Rt , and Rx : Remove the plug in the top cover. : Open the paper exit stop. Unlatch and remove L, Lx, and Lx the spring-loaded exit stacker. 2. Loosen the screws [A]. 3.

  • Page 89: Removal Procedures

    4049-XXX Removal Procedures When there is artwork to support a procedure, it follows the text. Covers Right Cover Removal 1. Turn the printer off. 2. Remove all external trays. 3. Open the top cover. 4. Depress the latch and open the right cover. 5.
  • Page 90 4049-XXX 4-11...

  • Page 91: Left Cover Removal

    4049-XXX Left Cover Removal 1. Unplug the power cord. 2. Open the top cover and remove the print cartridge. 3. Remove the front cover. 4. Locate the latch [ E ] and lift the end to release it. 5. Push the top of the cover to the left. 6.
  • Page 92 4049-XXX 4-13...

  • Page 93: 14 In. 200-Sheet Paper Tray Top Cover

    4049-XXX 14 in. 200-Sheet Paper Tray Top Cover 1. Push the tab where the left corner of the tray cover pivots. 2. Move the left tray cover pivot pin forward and then upward. 3. Remove the cover from the tray. 14 in.

  • Page 94: Engine Board Removal

    4049-XXX Engine Board Removal 1. Check the page count and write it down so you can set the count on the new engine board. 2. Turn the printer off. 3. Remove the RIP board and the inner EMC shield together. 4.

  • Page 95: Exit Sensor Board Removal

    4049-XXX Exit Sensor Board Removal 1. Remove the front cover. 2. Disconnect the fuser/sensor cable. 3. Disconnect the thermistor cable. 4. Disconnect the fuser solenoid cable. 5. Release the latches [A]. 6. Pull the sensor board down to remove it. Repair Information 4-16...

  • Page 96: Fan/Redrive Removal

    4049-XXX Fan/Redrive Removal 1. Open the top cover. 2. Remove the print cartridge. 3. Remove the top cover. 4. Remove the lower redrive shaft by disengaging the right end to the rear of the machine. 5. Disconnect the long redrive belt [A] and slip it off the lower shaft.

  • Page 97: Fuser Removal

    4049-XXX Fuser Removal Note: The heater lamp is fragile and may be damaged if you are not careful when you remove or replace the fuser unit. CAUTION: THE TEMPERATURE OF THE HOT ROLLER IS 150 °- 230 ° C (302 °- 446 ° F). USE EXTREME CAUTION WHEN REMOV- ING THIS UNIT.

  • Page 98: Fuser Input Guide Removal

    4049-XXX Fuser Input Guide Removal 1. Remove the fuser input guide [ B ] by lifting the rear end of the guide and unsnapping both sides from the fuser. 2. Lift the fuser input guide upward at both sides near the fuser and slide the guide toward the rear of the machine to release.

  • Page 99: Fuser Lamp Removal

    4049-XXX Fuser Lamp Removal CAUTION: THE TEMPERATURE OF THE HOT ROLLER IS 150- 230 ° C (302-446 ° F). USE EXTREME CAUTION WHEN REMOV- ING THIS UNIT. BEFORE YOU SERVICE THIS UNIT, ALLOW THE MACHINE TO COOL FOR 5 MINUTES. Note: The fuser lamp is a glass heater.

  • Page 100: Fuser/Sensor Cable Removal

    4049-XXX Fuser/Sensor Cable Removal 1. Turn the printer off. 2. Remove the RIP board and the inner EMC shield together. 3. Disconnect the cable from the exit sensor board. 4. Remove the front cover. 5. Disconnect the cable from the paper sensor assembly. 6.

  • Page 101: Fuser Solenoid Removal

    4049-XXX Fuser Solenoid Removal 1. Remove the fuser. 2. Remove the two mounting screws [ A ] holding the solenoid housing to the fuser housing. 3. Disengage the solenoid bracket from the plunger. Note: When a new solenoid assembly is installed, the fuser sole- noid must be adjusted.

  • Page 102: Fuser Shroud Assembly Removal

    4049-XXX Fuser Shroud Assembly Removal Note: Replacing only the thermistor or thermal fuse is not recom- mended. Replace the complete shroud assembly. 1. Unplug the printer. 2. Remove the fuser wiper and fuser cover. 3. Pry the thermal fuse connectors off the terminals at each end of the fuser.

  • Page 103: Hvps Removal

    4049-XXX HVPS Removal 1. Unplug the power cord. 2. Remove the left cover. 3. Remove the fuser input guide. 4. Remove the transfer roll housing. 5. Remove the fuser cover. 6. Disconnect the cable from the HVPS connector. 7. Remove the power switch rod. 8.
  • Page 104 4049-XXX 4-25...

  • Page 105: Ina Or Hard Disk Removal

    4049-XXX INA or Hard Disk Removal 1. Open the top cover. 2. Open the right cover. 3. Remove mounting screws as required. 4. Pop the card off the plastic standoffs. Input Sensor Board Removal 1. Remove the fuser input guide. 2.
  • Page 106 4049-XXX 4-27...

  • Page 107: Lower Frame Assembly Removal

    4049-XXX Lower Frame Assembly Removal 1. Remove the right, front, and left covers. 2. Remove the LVPS and the rod for the on/off switch. 3. Remove gear cover and the fuser input guide [ A ]. 4. Remove the transfer roll housing. 5.

  • Page 108: Lvps Removal

    4049-XXX LVPS Removal 1. Disconnect the power cord. 2. Remove all external feed trays. 3. Remove the left and right side covers. 4. Remove the RIP board and the inner EMC shield together. 5. Remove the left and right LVPS mounting screws and the screw for the cable tie.

  • Page 109: Lvps Cover Removal

    4049-XXX LVPS Cover Removal 1. Form tabs [ D ] away from the power supply to create clearance for tabs [ A ] to move downward. 2. Release the top latches [ A ]. 3. Release the side latches [ B ]. 4.

  • Page 110: Operator Panel Removal

    4049-XXX Operator Panel Removal 1. Remove the top cover. 2. Disconnect the operator panel cable. 3. Remove the operator panel mounting screws from the inside of the top cover. Paper Feed Rollers Removal Note: Replace all paper feed drive rollers at the same time. 1.

  • Page 111: Paper Feed Magnet Assembly Removal

    4049-XXX Paper Feed Magnet Assembly Removal 1. Remove the print cartridge. 2. Remove the right cover. 3. Remove the RIP board and engine board. 4. Remove the LVPS. 5. Locate the paper feed magnet mounting screw [ B ] (visible through the right side frame [ A ]).

  • Page 112: Paper Size Switch Removal

    4049-XXX Paper Size Switch Removal 1. Remove the paper tray. 2. Remove the front cover. 3. Unplug the cable [B] from the switch connector [C]. 4. Remove the two screws [A]. 5. Rotate the switch about 90 ° and pull it out of the printer. 4-33...

  • Page 113: Printhead Removal

    4049-XXX Printhead Removal IMPORTANT: The printhead is ESD-sensitive. It is not serviceable and should be replaced as a unit. 1. Turn the printer off. 2. Remove the print cartridge. 3. Remove the right and top covers. 4. Remove the exit redrive and its belt. 5.

  • Page 114: Rip Board And Inner Emc Shield Removal

    4049-XXX RIP Board and Inner EMC Shield Removal 1. Turn the printer off. 2. Remove the right cover. 3. Disconnect all the external connectors from the RIP board or INAs. 4. Remove the INA cards or Hard Disk option. 5. Remove the four nuts, the standoff, and the screw. 6.

  • Page 115: Transfer Roll Removal

    4049-XXX Transfer Roll Removal 1. Unplug the power cord. 2. Remove the print cartridge. 3. Remove the bearing cover from the left side of the transfer roll: Note: Do not touch the transfer roll surface. • Support the left bearing cover from the front with your left hand.

  • Page 116: Transfer Roll Housing Removal

    4049-XXX Transfer Roll Housing Removal 1. Remove the print cartridge. 2. Remove the fuser input guide. 3. Grasp the housing and pull toward the front of the machine to disconnect the housing from the mounting studs, visible through openings [ B ] in the inner deflector. 4.

  • Page 117: Upper Frame Removal

    4049-XXX Upper Frame Removal 1. Unplug the power cord. 2. Remove the print cartridge. 3. Remove the right, left, and top covers. 4. Remove the RIP board and the inner EMC shield together. 5. Remove the engine board. 6. Remove the load box latches [ A ]. 7.

  • Page 118: Duplex Option Top Cover And Table Cover Removal

    4049-XXX Duplex Option Top Cover And Table Cover Removal 1. Open the top cover by pulling up at [ A ] and pivoting 90 °. 2. Pry the top cover from the bottom cover at [ B ]. 3. Release latches [ C ] on the table cover and lift up. 4.

  • Page 119: Duplex Option Exit Card And Cover Removal

    4049-XXX Duplex Option Exit Card And Cover Removal 1. Pry up on tabs [ A ]. After the tabs are released, lift up on the cover, rotate the cover out, and slide it to the right to completely remove it. 2.

  • Page 120: Duplex Option Bottom Cover And Entry Sensor Card Removal

    4049-XXX Duplex Option Bottom Cover And Entry Sensor Card Removal 1. Remove the duplex unit top cover. 2. Remove the exit card cover and exit card. 3. Pry off the cover for the blind connector. 4. Pry up on the blind connector to remove it from the bottom cover.

  • Page 121: Duplex Option System Card And Motor Removal

    4049-XXX Duplex Option System Card And Motor Removal 1. Disconnect all cables. 2. Release latches [ A ] and lift the system board out. 3. Remove the two motor mounting screws [ B ]. 4. Lift the motor out of the frame assembly. Note: Reinstall the motor so the belt is not tight but will not jump teeth on the timing pulley.

  • Page 122: Dual Rear Feeder - Edge Guide Asm

    4049-XXX Dual Rear Feeder - Edge Guide Asm. 1. Remove the left frame by removing the eight mounting screws. 2. To remove the front edge guide assembly, remove the left end of the door from the pick roll shaft. 3. Slide the edge guide assembly, paper shaft, pick rollers, and buckler assemblies out to the left, leaving the pick roll shaft in place.

  • Page 123: 200-Sheet Second Drawer, Rt

    4049-XXX 200-Sheet Second Drawer, Rt 1. Remove the print cartridge. 2. Remove all paper trays and any duplex or dual rear feeder options. 3. Remove the right cover. 4. Remove the RIP board and inner EMC shield together. 5. Remove the cable cover near the right cover pivot pin. 6.

  • Page 124: High Capacity Feeder Paper Feed Rollers

    4049-XXX High Capacity Feeder Paper Feed Rollers 1. Open the feeder door so the tray lowers. 2. Turn the printer power off and remove the line cord from the electrical outlet. 3. Remove all paper trays and auxiliary rear feeders from the printer.
  • Page 125 4049-XXX Note: Rollers must be installed in the correct orientation. The new right feed roller has words on the metal bearing on the flange side; the left roller does not. 9. Install the new feed rollers with the flanges facing inward toward the drive chain.

  • Page 126: High Capacity Feeder Cover

    4049-XXX High Capacity Feeder Cover 1. Remove all paper from the feeder. 2. Turn the printer power off and remove the line cord from the electrical outlet and the feeder power jumper cable from the printer. 3. Remove all paper trays and auxiliary rear feeders from the printer.

  • Page 127: Connector Locations

    4049-XXX 5. Connector Locations This chapter shows the locations of major printer assemblies, gears, connectors, and ground straps. Major Assembly Locations Operator Panel Upper Frame Print Cartridge Exit Redrive Transfer Roll Print Head Low Voltage High Voltage Power Supply Power Supply Fuser Engine Board Lower Frame...

  • Page 128: Gear Train

    4049-XXX Gear Train...

  • Page 129: Hvps

    4049-XXX HVPS Print Cartridge Contacts Cover Interlock Transfer Roll Contacts Transfer Roller Housing Erase Lamp Window Transfer Roll Connector Locations 5-3...

  • Page 130: Engine Board Connectors

    4049-XXX Engine Board Connectors...
  • Page 131 4049-XXX Engine Board Connectors Connector Name Operator Panel/Output Bin Sensor Printhead Mirror Motor/Fan Duplex LVPS Dual Rear Feeder Paper Drive Motor Board-to-Board Connector Exit/Paper Size Sensor/Fuser Solenoid Input/Toner Sensor Board/Erase Lamps Envelope Feeder Magnet Printhead Hsync Printhead Laser HVPS Torquer Motor or Paperfeed Magnet (Tray 1) 500 Sheet Option or 200-Sheet Second Drawer, Non-Rt Jumper, Tray 2, Rt...

  • Page 132: Rip Board

    4049-XXX RIP Board RIP Board Connectors Connector Name Font Card (on back of board) Parallel Port Board-to-Board INA/Disk 1 ROMM SIMM (flash memory option) ROMM SIMM (printer microcode) DRAM SIMM DRAM SIMM Serial Port INA/Disk 2...

  • Page 133: Board Installation Hardware

    4049-XXX Board Installation Hardware Female/Female Standoff Short Plastic without Groove Standoff Engine Board Male/Female Standoff with Groove Tall Plastic Standoff Medium Board Plastic (4X) Nut with Standoff Captive Star Washer (5X) Nut with Captive Star Washer Male/Female Standoff Female/Female Standoff without Groove with Groove Mirror Motor/Fan Cable...

  • Page 134: Operator Panel/Output Bin Sensor Cable

    4049-XXX Operator Panel/Output Bin Sensor Cable Op Panel Cable Connector Pin 1 Pin 1...
  • Page 135 4049-XXX Operator Panel/Output Bin Sensor Cable Connectors Op Panel Sensor L, Lx, Lx J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J1-8 J1-9 No connection * The same cable is sometimes used on the Optra R, R and Rx, but the output bin sensor leads are not used.

  • Page 136: Printhead Connector Locations

    4049-XXX Printhead Connector Locations Pin 1 Print Head Cable H-sync Connector Fan Connector Mirror Motor Cable Pin 1 Laser Connector Pin 1 Mirror Motor Connector Pin 1 Duplex Autoconnect Cable Duplex Autoconnect Cable Connectors Engine Board Autoconnect J3-1 No connection J3-2 1 (right most pin) J3-3...

  • Page 137: Printer Ground Straps

    4049-XXX Printer Ground Straps Operator Panel Load Box to Upper Frame Shaft to Upper Frame Outer Deflector to Lower Frame HVPS to Frame Static Brush to Toner Shield to Lower Frame Lower Frame Load Box Shaft to Upper Frame Toner Shield to Lower Frame Connector Locations 5-11...

  • Page 138: High Capacity Feeder Board Connectors

    4049-XXX High Capacity Feeder Board Connectors High Capacity Feeder Board Connectors Connector Name Elevator Motor Paper Feed Motor Lower Limit Switch Door Switch Paper Out Switch R/L Selector Switch Upper Limit Switch Power Supply Feeder Ready Switch 5-12...

  • Page 139: Preventive Maintenance

    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis.
  • Page 140 4049-XXX • Gear no. 6 and its stud on the motor bracket • Gear no. 6 and its thrust washer • Gear no. 7 and its stud on the rail • Gear no. 7 and its thrust washer • Gear no. 8 and its stud on the rail •...

  • Page 141: Scheduled Mechanical Maintenance

    4049-XXX Use grease, p/n 1384076 to lubricate [ A ] areas of contact between the two shafts and the grounding spring. Use grease, p/n 1383586 to lubricate [ B ] on the duplex unit. Scheduled Mechanical Maintenance On some models the operator panel will display the message “80 Scheduled Maintenance”...

  • Page 142: Printhead Window Cleaning Procedure

    4049-XXX Printhead Window Cleaning Procedure Do not use cleaning fluids on the printhead window. Do not use a bare cotton swab. The swab deposits lint on the window. Note: The printhead window is a coated glass. Do not push too hard and scratch or break the glass.

  • Page 143: Parts Catalog

    4049-XXX 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 144: Covers

    4049-XXX Assembly 1: Covers...
  • Page 145 4049-XXX Asm- Part Units Description Index Number 1408175 Top Cover, R 1427491 Top Cover, Rx 1408173 Top Cover, L 1425483 Top Cover, Lx/Lxi 69G3152 Top Cover, Rt 1381852 Top Cover, R 1381851 Top Cover, Rt 1381850 Top Cover, Lx /Lxi 1381631 Operator Panel Asm Screw, Operator Panel-Parts Packet...

  • Page 146: Lower Frame

    4049-XXX Assembly 2: Lower Frame...
  • Page 147 4049-XXX Asm- Part Units Description Index Number 1381667 Lower Frame Assembly 1381632 Motor, Brkt. and Gear Asm, R/L/Rt 1381633 Motor, Brkt. and Gear Asm, Lx/Rx/R 1408572 Plate Asm. Gear Box Mtg. 1408779 Clip, Ground, Motor Mtg. Mtg. Screw, Motor Asm-Parts Packet 1381663 Mtg.

  • Page 148: Upper Frame

    4049-XXX Assembly 3: Upper Frame...
  • Page 149 4049-XXX Asm- Part Units Description Index Number 1325196 Cover Hinge Asm R/Rx/Rt (does not include the load box) 1381045 Cover Hinge Asm L/Lx (does not include the load box) Screw, Cover Hinge Parts Packet 1381663 1325103 Upper Plate Asm R/Rx/Rt 1328218 Upper Plate Asm L/Lx 1427306...

  • Page 150: Printhead

    4049-XXX Assembly 4: Printhead...
  • Page 151 4049-XXX Asm- Part Units Description Index Number 1381635 Printhead 1328431 Printhead Shroud Assembly 1408033 Cable, Fan/Mirror Motor 1408034 Cable, hsync 1038199 Cable, Tie 1425284 Cable, Laser (Install with marked end to Printhead) Pin, Parts Packet 1381666 Spring, Parts Packet 1381666 Screw, Printhead Mtg., Parts Packet 1381663 Screw, Hex Headed Parts Packet...

  • Page 152: Paper Feed

    4049-XXX Assembly 5: Paper Feed 7-10...
  • Page 153 4049-XXX Asm- Part Units Description Index Number 1039101 Outer Deflector 1183597 Upper Deflector 1381670 Inner Deflector with Roller 1381919 o Roller Asm 1381636 Input Sensor Board 1408859 Lower Deflector Flag, Input Sensor, Parts Packet 1381669 1408703 Rt Rail Asm (without Gears) 1381801 Rt Rail Asm w/Gears &...
  • Page 154 4049-XXX Assembly 5: Paper Feed (Continued) 7-12...
  • Page 155 4049-XXX Asm- Part Units Description Index Number 5-28 1402325 Bearing 1328450 Spring, Shaft Grd. L/Lx 1427418 Spring, Shaft Grd. R/Rx/Rt 1408717 Outer Redrive Shield, R/Rx/Rt 1328381 Outer Redrive Shield L/Lx Screw Backup Spring Mtg., Parts Packet 1381663 Spring, Arm Tray Bias, Parts Packet 1381666 Screw, Redrive Mtg., Parts Packet 1381663...

  • Page 156: Paper Feed Alignment Gears

    4049-XXX Assembly 6: Paper Feed Alignment Gears 7-14...
  • Page 157 4049-XXX Asm- Part Units Description Index Number 1427307 Bellcrank, Metering o Shaft o Bellcrank o Roll o Thrust Washer 1381145 Kit, Prealigner and Auxiliary Rollers 1039278 Gear, Idler, Prealigner Spring, Prealigner and Metering Bellcranks, Parts Packet 1381666 1328384 Bellcrank, Prealigner o Shaft o Roll o Bellcrank...

  • Page 158: Paper Feed Drive

    4049-XXX Assembly 7: Paper Feed Drive 7-16...
  • Page 159 4049-XXX Asm- Part Units Description Index Number Note: Machine may have either torquer motor (items 9, 10, and 11) or paper pick solenoid (items 12, 13, 14, and 15). 69G5480 D-Roller Asm 1328279 Washer, Thrust Clip, D-roll, Parts Packet 1381663 1408703 Rail Assembly, Right (w/o gears) 1381801...

  • Page 160: Standard Paper Tray (200-Sheet)

    4049-XXX Assembly 8: Standard Paper Tray (200-Sheet) 7-18...
  • Page 161 4049-XXX Asm- Part Units Description Index Number 1364894 Paper Tray Assembly, 11 in. (200-sheet) 1364893 Paper Tray Assembly, 14 in. (200-sheet) 1364892 Paper Tray Assembly for Labels, 11 in. (200-sheet) 1364890 Paper Tray Assembly for Labels, 14 in. (200-sheet) 1364891 Paper Tray Assembly, A5 1408170 Cover, 14 in.

  • Page 162: Paper Tray (500-Sheet)

    4049-XXX Assembly 9: Paper Tray (500-Sheet) 7-20...
  • Page 163 4049-XXX Asm- Part Units Description Index Number 1381813 Paper Tray Assembly, Std. (450g Spring) 11 in. 1381814 Paper Tray Assembly, Std. (450g Spring) 14 in. 1381816 Paper Tray Assembly, Light Weight Labels (550g spring), 11 in. 1381815 Paper Tray Assembly, Light Weight Labels (550g spring), 14 in.

  • Page 164: Base For Paper Drawer (500-Sheet)

    4049-XXX Assembly 10: Base for Paper Drawer (500-Sheet) 7-22...
  • Page 165 4049-XXX Asm- Part Units Description Index Number 10-1 1408289 Housing 1039558 Roll 1409146 Plate Assembly, Gear 1039170 Pad, Machine 1328674 Clip, Ground Screw, PP 1381663 Parts Catalog 7-23...

  • Page 166: Second Paper Drawer, (200-Sheet)

    4049-XXX Assembly 11: Second Paper Drawer, (200-Sheet) 7-24...
  • Page 167 4049-XXX Asm- Part Units Description Index Number 11-1 1381836 Base Asm, Second Drawer, Rt 1381860 Base Asm, Second Drawer, Non-Rt 1381837 Detent Roller 1381838 Foot 1383922 Switch Asm 1381839 Tray Guide, Right 1381841 Tray Guide, Left 1381831 Drive Asm 1381918 o Drive Asm Gear Kit 1381842 D-Roller Tire...

  • Page 168: Optional Paper Drawer (500-Sheet)

    4049-XXX Assembly 12: Optional Paper Drawer (500-Sheet) 7-26...
  • Page 169 4049-XXX Asm- Part Units Description Index Number 12-1 1408161 Base Assembly 1328630 Deflector 1039170 Feet 1039596 Bellcrank Assembly Spring, Bellcrank--Parts Packet 1381666 1039603 Drive Roller 1039540 D-Roller Tire 1381306 Torquer Motor Spring--Parts Packet 1381666 1381638 Drive Assembly 1381920 o Drive Asm Gear Kit 1039558 Roller 1183299...

  • Page 170: Fuser

    4049-XXX Assembly 13: Fuser 7-28...
  • Page 171 4049-XXX Asm- Part Units Description Index Number 13-1 1381639 Fuser and Lamp 110 V R/L/Rt 1381641 Fuser and Lamp 220 V R/L/Rt 1381640 Fuser and Lamp 110 V Rx/Lx/R 1381642 Fuser and Lamp 220 V Rx/Lx/R Screw, Fuser Mounting, Parts Packet 1381663 1382287 Fuser Wiper Assembly (supply item)
  • Page 172 4049-XXX Assembly 13: Fuser (Continued) 7-30...
  • Page 173 4049-XXX Asm- Part Units Description Index Number 13-15 1328134 Clips, Thermal Fuse 1381888 Bail Handle 1381018 Fuser Solenoid Asm Screw, Solenoid Mtg., Parts Packet 1381663 1328124 Gear No. 1, Hot Roll Gear 18T Redrive, Parts Packet 1381665 Spring, Redrive Idler Parts Packet 1381666 1328437 Contact Asm, Right Lamp...

  • Page 174: Electronics

    4049-XXX Assembly 14: Electronics 7-32...
  • Page 175 4049-XXX Asm- Part Units Description Index Number 14-1 1381643 LV Power Supply 110 V 1381644 LV Power Supply 220 V 1328463 Fuse, LVPS SB 12A 110 V 1328464 Fuse, LVPS 6.3A 220 V 1342514 Power Cord Set, U.S./Canada/Mexico/ Central and South America/Saudi Arabia (LV) 1342530 Power Cord Set, Germany/France/Spain/...
  • Page 176 4049-XXX Assembly 14: Electronics (Continued) 7-34...
  • Page 177 4049-XXX Asm- Part Units Description Index Number 14-7 1381792 Engine Board, R/L/Rt 1381796 Engine Board, Lx/Rx/R 1364877 DRAM SIMM 4MB, Rx/L/Lx 1364921 DRAM SIMM 2MB, R/Rt 1364876 DRAM SIMM 8MB, Lxi 1381651 Inner EMC Shield, R/Rt/L/Lx/Rx 1381848 Inner EMC Shield, R 1381664 Standoff Kit, Board Mounting 1408106...

  • Page 178: Transfer Roll

    4049-XXX Assembly 15: Transfer Roll 7-36...
  • Page 179 4049-XXX Asm- Part Units Description Index Number 1381922 Transfer Roll Asm, complete 15-1 1381008 Roll Asm, Transfer, With Right Bearing 1381652 Housing, Transfer o Rear Lens Asm, Erase o Contact, Transfer Roll o Lamp Asm, Erase 1328356 Cover, Clip Bearing 1381923 Erase Lamp Asm w/lens Parts Catalog 7-37...

  • Page 180: Duplex Option

    4049-XXX Assembly 16: Duplex Option 7-38...
  • Page 181 4049-XXX Asm- Part Units Description Index Number 16-1 1381551 Top Cover Asm 1381552 Duplex System Card 1381554 Bottom Cover 1408940 Exit Sensor Cover 1381555 Exit Sensor Asm 1381602 Bellcrank Kit 1408905 Table Cover (Floor) 1408949 Paper Stop/Slide 1381558 Gear Block Frame Asm 1381559 Input Sensor Card 1326042...

  • Page 182: Envelope+ And 100-Sheet Auxiliary Feeder

    4049-XXX Assembly 17: Envelope+ and 100-Sheet Auxiliary Feeder 7-40...
  • Page 183 4049-XXX Asm- Part Units Description Index Number 1408893 Envelope+ Feeder 1364895 100-Sheet Auxiliary Feeder 1408862 Weight Assembly 1622529 Screw 1039615 Spring 1383944 Magnet Assembly 1622303 Washer 1622536 Screw, Mtg 1408869 Cover, Right 1408868 Guide, Large 1408861 Latch, Guide 1408863 Guide, Small 1183273 Spring, Override Lever (100-Sheet Auxil- iary Feeder Only)

  • Page 184: Dual Rear Feeder

    4049-XXX Assembly 18: Dual Rear Feeder 7-42...
  • Page 185 4049-XXX Asm- Part Units Description Index Number 1381799 Dual Rear Feeder 1381832 Cover, Right 1381798 Dual Torquer Asm Screw, Torquer, PP 1367169 1381793 Gear Kit 1381794 Roller Kit 1367019 Envelope Buckler Kit 1367463 Pick Roll Hub Kit 1381833 Extender 1381795 Edge Guides &...

  • Page 186: High Capacity Feeder

    4049-XXX Assembly 19: High Capacity Feeder 7-44...
  • Page 187 4049-XXX Asm- Part Units Description Index Number 19-1 1381928 Cover with A.C. inlet & cable and printer designator switch & cable 1381930 Bottom Plate 1381931 Door Assembly 1381929 Rear Paper Path Deflector 1381945 Power Supply 1381932 Cable harness with circuit board, power supply and printer connectors 1381934 Door Switch Cable Assembly...

  • Page 188: Options

    4049-XXX Assembly 20: Options Asm- Part Units Description Index Number 20-2 1364923 1MB Flash SIMM 1364922 2MB Flash SIMM 1364879 4MB Flash SIMM 1364921 2MB DRAM SIMM 1364877 4MB DRAM SIMM 1364876 8MB DRAM SIMM 1364875 16MB DRAM SIMM 1364874 32MB DRAM SIMM 13A0339 4MB DIMM...

  • Page 189: Miscellaneous

    4049-XXX Assembly 21: Miscellaneous Asm- Part Units Description Index Number 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 1329301 Grease, 2g 1384076 Grease, conductive 1 oz.
  • Page 190 4049-XXX Index background 2-12 banding 2-12 Numerics black page 2-13 100-sheet auxiliary feeder blank page 2-14 magnet adjustment 4-3 blurred or fuzzy print 2-15 paper feed problem 2-26, button test 3-4 2-27 paper restraint spring adjustment 4-2 charge roll 3-4 parts assembly 7-40, 7-42...
  • Page 191 4049-XXX dead machine 2-15 electronics default settings 3-5 parts assembly 7-32, 7-34 developed image test 3-17 engine board diagnostics mode 3-1 connectors 5-4 diagnostics mode menus removal 4-15 device tests 3-2 envelope enhance 3-7 duplex tests 3-2 envelope print test 3-7 hardware tests 3-1 Envelope+ Feeder page count tests 3-2...
  • Page 192 4049-XXX fuser 920, 921, or 922 error 2-19 923 or 924 error 2-20 information 3-17 input guide removal 4-19 problems 2-21 lamp removal 4-20 LCD test 3-9 parts assembly 7-28, 7-30 light print 2-21 removal 4-18 lubrication specifications 6-1 solenoid adjustment 4-7 LVPS solenoid removal 4-22 cover removal 4-30...
  • Page 193 4049-XXX parts catalog how to use 7-1 operator panel permanent page count 3-11 problems 2-22 power consumption 1-2 removal 4-31 power-on self test (POST) 2-10 operator panel//output bin sen- preventive maintenance 6-1 sor cable print contrast 3-11 connectors 5-8 print registration 3-12 optional paper drawer (500- bottom margin 3-12 sheet)
  • Page 194 4049-XXX safety inspection guide 6-1 scheduled mechanical mainte- nance 6-3 sensor test 3-15 skew all edges 2-33 top and bottom only 2-33 stalled printer 2-34 streaks 2-34 symptom table 2-11 toner sensor removal 4-35 tools used 1-3 top margin and duplex quick test 3-15 top margin test 3-15 torquer motor removal 4-35...

This manual is also suitable for:

Optra color 4511a7530 - optra e+ b/w laser printerOptra seriesOptra 4049 series

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