Lexmark T420 Service Manual
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Lexmark T420 Service Manual

Lexmark T420 Service Manual

Service manual
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See also: Reference Manual , User Reference
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Safety and Notices
• Trademarks
• Index
Lexmark™ T420(n) Laser
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
4048–00x

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Summary of Contents for Lexmark T420

  • Page 1 4048–00x • Table of Contents • Start Diagnostics • Safety and Notices • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 1-800-553-9727. In other countries, contact your point of purchase. Lexmark, Lexmark with diamond design, MarkNet, MarkVision, Optra, and Prebate are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Optra Forms and PictureGrade are trademarks of Lexmark International, Inc.

  • Page 3: Table Of Contents

    4048-00x Table of Contents Laser Notices......... . . vii Safety Information.
  • Page 4 4048-00x Service Checks ........2-29 Cooling Fan Service Check .
  • Page 5 4048-00x Right Guide Removal ......4-28 Left Guide Removal ....... 4-28 Smart Button Sensor Removal .
  • Page 6 4048-00x Service Manual...

  • Page 7: Laser Notices

    4048-00x Laser Notices The following laser notice labels may be affixed to this printer as shown: Laser advisory label Laser Notices...

  • Page 8: Laser Notice

    4048-00x Laser Notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 9 4048-00x Avis relatif à l’utilisation de laser Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.
  • Page 10 4048-00x Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 11 4048-00x Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt.
  • Page 12 4048-00x Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
  • Page 13 4048-00x Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
  • Page 14 4048-00x Japanese Laser Notice Chinese Laser Notice Service Manual...
  • Page 15 4048-00x Korean Laser Notice Laser Notices...
  • Page 16 4048-00x Service Manual...

  • Page 17: Safety Information

    4048-00x Safety Information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 18 4048-00x Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
  • Page 19 4048-00x Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
  • Page 20 4048-00x Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 21 4048-00x Safety Information...

  • Page 22: Preface

    4048-00x Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

  • Page 23: General Information

    T420 models. Note: Unless otherwise noted, all references to the Lexmark T420(n) laser printer are intended to refer equally to both the T420 Base and the T420 Network models. Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part.

  • Page 24: Serial Number

    4048–00x Serial Number Look for the serial number label on the inside front cover of the printer. Printer Identification Flap Duct cover Asm Front cover Flags Cover MPF Asm (MPF door) Service Manual...

  • Page 25: Printer Features

    4048–00x Printer Features Memory and User Flash Memory Each model has a standard amount of memory (RAM) soldered on the system card, and a certain number of 100-pin DIMM slots available for installing additional memory or user flash memory options. Memory Base Model Network Model...

  • Page 26: Resolution And Print Quality

    4048–00x Resolution and Print Quality Note: • IET, PQET, PictureGrade™, print resolution, print darkness, and toner saver can all be set independently of each other through the data stream. • Control panel menus allow a user to independently set PQET, PictureGrade, and print resolution.

  • Page 27: Print Area

    4048–00x Print Area The following print area settings are available. Print Area Option Base Model Network Model ✓ ✓ Normal ✓ ✓ Fit to page ✓ ✓ Edge to edge General Information...

  • Page 28: Print Media

    4048–00x Print Media The following table shows the supported media, media weights and media textures which together are used to select a technology operating point to provide optimal print quality across a variety of media. Media Base Model Network Model Media Operating Points ✓...

  • Page 29: Printer Data Streams

    • 4048–00x supports version 3010 of the Adobe definition of PostScript 3, and the interpreter is backward compatible with the Optra T 610/612/614/616 and other members of Lexmark’s Optra family of laser printers. • PPDS is backward compatible with Optra T 610/612/614/616 and Lexmark’s Optra family of laser printers.

  • Page 30: Fonts

    4048–00x Fonts Fonts / Options Base Model Network Model PCL bitmapped PCL scalable PS scalable PPDS bitmapped PPDS scalable Paper Handling Paper Handling Base Model Network Model Standard Standard input sources: • Integrated 250–sheet tray The 250 sheet drawer supports the following sizes: A4, A5, JIS B5, folio, letter, legal,...
  • Page 31 4048–00x Paper Handling Base Model Network Model ✓ ✓ Universal paper size • Minimum bitmap width 64800 64800 and length • Maximum bitmap width 183600 183600 • Maximum bitmap 306000 306000 length Options Maximum # of optional drawers Optional drawers: ✓...

  • Page 32: Connectivity

    4048–00x Connectivity Attachments Base Model Network Model ✓ ✓ Standard parallel interface Parallel interface connector is a 1284–B connector. ✓ ✓ Parallel mode 2 ✓ ✓ Standard USB interface ✗ ✓ Standard Ethernet 10/ 100 Base–TX Note: ✓ Indicates attachment is part of the model factory shipped configuration.

  • Page 33: Printer Speed

    4048–00x Printer Speed Speed Base Model Network Model Pages/minute in 300 dpi Pages/minute in 600 dpi Pages/minute in 1200 Image Quality Time to first print 10 seconds 10 seconds Automatic power saver RIP Card Specifications Feature Base Model Network Model Processor 922T 922T...

  • Page 34: Supplies

    4048–00x Supplies Approximate Print Cartridge Average Yield Coverage Prebate™ print 5,000 cartridges 10,000 Regular cartridges 5,000 (without Prebate terms and conditions) 10,000 Operator Panel The 4048–00x operator panel consists of six light’s and two buttons. The operator panel is used to indicate status as well as an input to modify some printer settings.

  • Page 35: Options

    4048–00x Options “Options” on page 7-22 for a list of options available for the T420(n) printer. 1-13 General Information...

  • Page 36: Acronyms

    4048–00x Acronyms Charge Roll Counterclockwise Clockwise Direct Current Developer Roll DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Field Replaceable Unit Ground HVPS High Voltage Power Supply Integrated Development Environment Image Enhancement Technology Internal Network Adapter Kilobyte Light–Emitting Diode Laser Scanning Unit LVPS Low Voltage Power Supply...

  • Page 37: Diagnostic Information

    4048–00x 2. Diagnostic Information Start CAUTION: Unplug power from the printer before connecting or disconnecting any cable, assembly, or electronic card. This is a precaution for personal safety and to prevent damage to the printer. This chapter contains the codes and diagnostic tools to aid in providing corrective action for a malfunctioning printer.

  • Page 38: Operator Panel

    4048–00x Operator Panel The 4048–00x operator panel consists of six indicator lights and two buttons. Ready/Data Toner Low Load/Remove Paper Paper Jam Error Press Continue Continue Cancel Note: Traditional printer settings such as paper source, paper size, and orientation may not be selected or modified using the operator panel.

  • Page 39: Light Patterns

    4048–00x Light Patterns The following symbols are used in the status, attendance, and service information tables. ❍ Light is off. ● Light is on solid. ✳ Light is blinking. ✕ Light is blinking slowly. Status Information Light Patterns Status ● ❍...
  • Page 40 4048–00x Status ● ● ● ● ● ● Canceling Job/Resetting Printer/Activating Changes All lights cycling Restarting Printer ❍ ❍ ● ● ❍ ❍ Diagnostics–Memory Test ● ● ● ❍ ❍ ❍ Programming System Code– DO NOT POWER OFF Note: The Error and Press Continue lights cycle through four different patterns to indicate...

  • Page 41: Attendance Information Light Patterns

    4048–00x Invalid Code Secondary Light Patterns Status ● ❍ ● ❍ ● ❍ Invalid Engine Code ● ❍ ✳ ❍ ● ❍ Invalid Network Code Attendance Information Light Patterns Attendance Condition ❍ ❍ ● ❍ ❍ ● Load Paper–Tray 1, Tray 2 or ❍...
  • Page 42 4048–00x Attendance Condition ❍ ● ❍ ❍ ❍ ● Toner Low Intervention ❍ ❍ ❍ ❍ ❍ ● Offline ❍ ❍ ❍ ● ❍ ● Paper Jam Note: A double press of Continue causes a secondary light pattern which indicates further information on the type of paper jam.
  • Page 43 4048–00x Paper Jam Secondary Light Patterns Attendance Condition ● ❍ ❍ ● ❍ ● Paper Jam–Input Sensor ❍ ● ❍ ● ❍ ● Paper Jam–Exit Sensor ❍ ✳ ❍ ● ❍ ● Paper Jam–Duplex Sensor ❍ ❍ ● ● ❍ ●...
  • Page 44 4048–00x Printer Error Secondary Light Patterns To obtain the secondary light pattern, quickly press Continue twice. Attendance Condition ● ❍ ❍ ❍ ● ● Complex Page ❍ ● ❍ ❍ ● ● Insufficient Collation Area ❍ ❍ ● ❍ ● ●...

  • Page 45: Service Information Light Patterns

    4048–00x Service Information Light Patterns Service Condition ✳ ✳ ✳ ✳ ✳ ✳ Service Error Note: A double press of Continue causes a secondary light pattern which indicates further information on the type of printer error. See “Service Error Codes” on page 2-11 for more information.
  • Page 46 4048–00x Service Error Secondary Light Patterns Quickly press and release Continue twice to obtain the secondary light pattern. Service Condition ✳ ❍ ❍ ❍ ❍ ❍ Software Error (90x) ✳ ❍ ❍ ❍ ❍ ✳ Transfer Roll Error (91x) ✳ ❍...

  • Page 47: Obtaining Information About Printer Service Error Codes

    POR the printer to temporarily recover from the error condition. RIP Software Error / Illegal Trap Contact the next level of support or call Lexmark 1–800–539–6275 for assistance. (900) Note: The alarm is not actuated for this error.
  • Page 48 4048–00x Engine Flash or Engine Software Error The first error message below (901) indicates the flash into which the engine code is programmed is bad. Either the flash cannot be erased or the program failed when programming was attempted. The remaining errors, 902–906, indicate an unrecoverable engine software error.
  • Page 49 4048–00x Transfer Roll Error Indicates a problem in the transfer roll area. Check the cable from the HVPS (CN1) to the controller card (J3). Also check the voltage at pin #4 of J3. (917) Note: If the alarm control is turned on, the alarm does sound when this error occurs.

  • Page 50: Fuser Error

    4048–00x Fuser Error Indicates a problem with the fuser. See the “Fuser Service Check” on page 2-34 for more information. Incorrect fuser lamp installed (925). Open circuit in thermistor path (924). Fuser too hot during printing or idle (923). Fuser failed to reach standby temperature (922). Fuser below standby temperature at idle (921).

  • Page 51: Toner Sensor Error

    4048–00x Fan Stalled This error indicates a printer fan stall. Primary Code Secondary Code Tertiary Codes Ready/Data Ready/Data Ready/Data Toner Low Toner Low Toner Low Load/ Load/ Load/ Remove Paper Remove Paper Remove Paper Paper Jam Paper Jam Paper Jam Error Error Error...

  • Page 52: Printhead Error

    4048–00x Printhead Error Indicates a problem with the printhead. Check cables to the printhead. Replace the printhead as necessary. See “Printhead Assembly Adjustment” on page 4-2 for realignment procedures. Mirror motor not at operating speed (935). (Verify +24 V dc on pin #5 of J7.) Mirror motor lost lock (934).
  • Page 53 4048–00x Transport Motor Error Indicates a problem with the main drive motor system. The problem could be the motor, the RIP card, the cabling or the drive assembly. Check the cable connectors. The tertiary code below, with four flashing lights indicates a problem in the drive assembly. Transport motor lost lock (937).
  • Page 54 4048–00x RIP to Engine Communication Failure (Controller Card) This error indicates that the RIP processor cannot communicate with the engine processor. Primary Code Secondary Code Tertiary Codes Ready/Data Ready/Data Ready/Data Toner Low Toner Low Toner Low Load/ Load/ Load/ Remove Paper Remove Paper Remove Paper Paper Jam...
  • Page 55 4048–00x Engine Circuitry Failure (Controller Card) This error indicates a failure in the engine circuitry portion of the controller card. Primary Code Secondary Code Ready/Data Ready/Data Toner Low Toner Low Load/ Load/ Remove Paper Remove Paper Paper Jam Paper Jam Error Error Press Continue...

  • Page 56: Nvram Failure

    4048–00x NVRAM Failure This lighting sequence indicates a problem in the NVRAM. Replace the RIP card assembly. Primary Code Secondary Code Tertiary Codes Ready/Data Ready/Data Ready/Data Toner Low Toner Low Toner Low Load/ Load/ Load/ Remove Paper Remove Paper Remove Paper Paper Jam Paper Jam Paper Jam...
  • Page 57 4048–00x RIP Card Error (ROM / NAND) Indicates a failed RIP card assembly. Replace the RIP card. SRAM failure (959). NAND failure (958). ASIC failure (957). Processor failure (956). Code ROM or NAND failed Cyclic Redundancy Check (CRC) (955). Note: –...
  • Page 58 4048–00x RAM Memory Error This error indicates RAM failure. Remove DIMM(s) and re–POR the printer. If the error persists, replace the card. If the error subsides, check each DIMM independently. Replace faulty DIMM. RAM in slot 3 is bad (963). RAM in slot 2 is bad (962).

  • Page 59: Network Error

    4048–00x Network Error Indicates an error in the network circuitry. Replace the RIP card assembly. Primary Code Secondary Code Ready/Data Ready/Data Toner Low Toner Low Load/ Load/ Remove Paper Remove Paper Paper Jam Paper Jam Error Error Press Continue Press Continue Tertiary Codes Ready/Data Toner Low...
  • Page 60 4048–00x Paper Port Communication Failure Indicates an error communicating with tray 2, if installed. Remove tray 2 and recheck. If the error doesn’t recur, replace tray 2. If the error recurs replace the RIP card assembly. Invalid command parameter received by specified device (984).

  • Page 61: Power-On Operations

    4048–00x Power–On Operations To access the printer operations for the 4048: 1. Turn off the printer. 2. Press and hold the buttons in the following table for the operation needed. 3. Turn on the printer. Hold the buttons until the lights cycle on the operator panel.

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

    4048–00x Power–On Self Test (POST) When you turn the printer on, it performs a Power–On Self Test. Check for correct POST functioning of the base printer by observing the following symptoms: Symptom Tables POST Symptom Table Symptom Action The main motor, cooling fan and See the “Cover Interlock Switch fuser do not come on.

  • Page 63: Printer Symptom Table

    4048–00x Printer Symptom Table Symptom Action Dead machine (no power) “Dead Machine Service Check” on page 2-33. Fan noisy or not working “Cooling Fan Service Check” on page 2-29. Fuser parts melted “Hot Fuser Service Check” on page 2-37. Fuser lamp doesn’t light “Cold Fuser Service Check”...
  • Page 64 4048–00x Symptom Action Printer not communicating with “Parallel Port Service Check” host on page 2-47. Paper wrinkled or bent “Paper “Trees,” Wrinkles, Stacks Poorly Or Curls” on page 2-46. Top cover will not close “Cover Interlock Switch Service Check” on page 2-30.

  • Page 65: Service Checks

    4048–00x Service Checks Service checks involve measuring voltages of the LVPS, HVPS, and RIP card assembly. Continuity and resistance verifications are done on cables and components as required. Note: When looking at the printed side of a PCB, connectors are designated with “J”...

  • Page 66: Cover Interlock Switch Service Check

    4048–00x Cover Interlock Switch Service Check Note: Make sure a toner cartridge is installed and the cover closes all the way, engaging the cover open switch lever. Action Cover Interlock Switch Disconnect the cover interlock cable from the interlock switch. Push the cover interlock switch to the closed position and verify continuity between the bottom and...

  • Page 67: Rip Card Service Check

    4048–00x RIP Card Service Check Action RIP Card Assembly Check for +24 V dc from the LVPS card to the RIP card assembly. • Turn the printer off. • Disconnect the LVPS cable from the RIP card at J20. • Turn the printer on. Verify +24 V dc from the cable, pins #1 and #2.
  • Page 68 4048–00x Action RIP Card Assembly (continued) Note: With all cables connected, the printer should complete POST within approximately 12–15 seconds in the following sequence: 1. All operator panel lights on solid momentarily. 2. Lights then flash on and off sequentially. After lights quit flashing, the Ready/Data light turns on solid.

  • Page 69: Dead Machine Service Check

    4048–00x Dead Machine Service Check Note: Check the AC line voltage. The voltage should be within the following limits: • 100 V ac–127 V ac for the nominal–110 V model printer • 200 V ac–240 V ac for the nominal–220 V model printer Low Voltage Power Supply (LVPS) Service Check Action Low Voltage Power Supply Card...

  • Page 70: Fuser Service Check

    4048–00x Fuser Service Check When toner is partially fused to the paper, it is usually caused by low fuser temperature. Warning: Avoid handling the lamp as much as possible as it is easily broken. Be careful not to touch the glass housing with bare hands, as skin contains acids that can weaken the glass.

  • Page 71: Cold Fuser Service Check

    4048–00x Cold Fuser Service Check Action Fuser Lamp Unplug the printer and disconnect the fuser lamp cable from the LVPS card Lamp Cable connector (CN3). See “Power Supply LVPS (LVPS)” on page 5-11 for more information. Check for continuity across the fuser lamp.
  • Page 72 4048–00x Make sure the correct voltage lamp is installed. The voltage rating is stamped on one of the lamp contacts. Action Fuser assembly If the fuser lamp comes on and a fuser failure error code displays, be sure the thermistor is contacting the hot roll and the thermistor cable is firmly seated in connector J22 on the RIP card assembly.

  • Page 73: Main Motor Service Check

    4048–00x Hot Fuser Service Check Make sure the correct voltage lamp is installed. The voltage rating is stamped on one of the lamp contacts. Action Fuser assembly Unplug the printer and measure the resistance of the thermistor. The resistance measures approximately 245K ohms when cool (approximately 40°C) and 2K–3K ohms hot.

  • Page 74: Operator Panel Service Check

    4048–00x Operator Panel Service Check Inspect the operator panel cable for damage. Make sure the cable is plugged in securely. Run POST and check each light for proper operation. Action Front Cover If more than one light does not turn on or an individual light stays on solid during POST, check the operator panel cable for continuity.
  • Page 75 4048–00x Action Front Cover If all lights are dim and operate Operator Panel Cable erratically during POST or come on RIP Card Assembly and stay on solid during POST, replace the following FRUs one at a time in the order shown: •...

  • Page 76: Transfer Roll Service Check

    4048–00x Transfer Roll Service Check Action Transfer Assembly Roll Check the springs in the left and Transfer Bearing right transfer roll bearings. The bearing assemblies should support the transfer roll, applying even pressure to the PC drum. The roll should rotate evenly and smoothly. Replace both the transfer roll bearing assemblies if the springs or bearings indicate damage or lack of...

  • Page 77: Paper Feed Service Checks

    4048–00x Paper Feed Service Checks Paper Picks and Advances Approximately 4 Inches Action Plate Assembly (reference edge) Turn printer off and remove the print Paper Feed Gear cartridge and left side cover. Drive Assembly With a left finger, rotate the main motor counterclockwise while using a right finger to resist gear movement in the plate assembly...
  • Page 78 4048–00x Paper Jam Error Indication During POST Action Stack Control Flags If the exit sensor flag is not resting Photo Sensor within the paper exit sensor during POST, the printer indicates Load/ Remove Paper. Make sure the flag is operating freely and correctly. Replace the photo sensor and/or the stack control flag as necessary.
  • Page 79 4048–00x Paper Picks During POST and/or Continuously Action Paper Feed Assembly Check the pick roller clutch for wear. Paper Feed Solenoid The solenoid interacts with the clutch controlling motion of the pick roller. If the cam surface of the pick roller clutch assembly is worn, the solenoid may not stop the D–roll (pick roll) from rotating.
  • Page 80 4048–00x Paper Picks but Stops Half Way Through the Printer Action Input Paper Feed Sensor Make sure the input paper feed RIP Card Assembly sensor is working properly. Check for a broken or stuck flag on the input paper feed sensor. Make sure the cable is seated on the RIP card assembly (J23).
  • Page 81 4048–00x Paper Never Picks Action Paper Tray Make sure the paper tray and paper are correctly positioned. Check the input tray for missing or broken parts. Replace the tray as necessary. Paper Feed Solenoid Make sure solenoid is installed RIP Card Assembly correctly and its cable is plugged into the RIP card assembly.
  • Page 82 4048–00x Paper Occasionally Picks or Picks Multiple Sheets at Once Action Paper Feed Roll Check the paper feed roll (D–roll/pick D–Roll at Tray 1 Spring roll) for wear. Replace as necessary. Paper Feed Assembly Verify that the extension spring is working properly.
  • Page 83 4048–00x 2-47 Diagnostic Information...

  • Page 84: Print Quality Service Checks

    4048–00x Print Quality Service Checks Blank Page Action Toner Cartridge Remove the toner cartridge and gently shake the assembly to evenly distribute the toner. Ensure clean electrical contacts on the right side. 2-48 Service Manual...
  • Page 85 4048–00x Action Printhead Blank pages can be caused by a Printhead Cable defective printhead assembly, high HVPS voltage power supply, or RIP card RIP Card Assembly assembly. See “RIP Card Service Cartridge Contacts Assembly Check” on page 2-31 and verify the required voltages and proper ground at connectors J1 and J3.
  • Page 86 4048–00x Black Page Note: Incorrect laser exposure or incorrect charging of the photoconductor by the charge roll causes an all black page. Action HVPS Contacts Check the contacts for contamination and correct installation. Replace as necessary. RIP Card Assembly Ensure the HVPS to RIP card and Controller Card charge roll cables are correctly HVPS Cable...
  • Page 87 4048–00x Heavy Background Poor development or poorly charged toner particles cause excessive background. This is more noticeable as the toner cartridge nears end of life. Action Toner Cartridge (not a FRU) Make sure the toner cartridge is correctly installed and the high voltage contacts are clean.
  • Page 88 4048–00x Partial Blank Image/White Spots (no periodic pattern) Action Toner Cartridge (not a FRU) Remove the toner cartridge and gently shake the assembly to evenly distribute the toner. If the toner cartridge is low, try a new one. Fuser Backup Roll Springs Check springs at each end of the (not a FRU) backup roller springs and backup...
  • Page 89 4048–00x Poor Fusing of Image Action Fuser Lamp The fuser may not be operating at the proper temperature to fuse the toner to the paper. See “Cold Fuser Service Check” on page 2-35. Make sure recommended paper is being used. Light Print Action Toner Cartridge...
  • Page 90 4048–00x White or Black Lines or Bands Action Toner Cartridge Banding appears as light or dark Paper Feed Drive Gears horizontal lines on a uniformly gray page or on a page with a large area of graphics. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer especially in the developer and...

  • Page 91: Solving Print Quality Problems

    4048–00x Solving Print Quality Problems Note: To run the print quality test pages: • Turn the printer off and open the door. • Turn the printer on while pressing Continue. • Continue to press and hold Continue until lights finish cycling.
  • Page 92 • Change the media texture setting. You can download the latest driver from the Lexmark Web site, www.lexmark.com. 2-56 Service Manual...
  • Page 93 4048–00x Problem Action The print is getting light but the • The Toner Low light does not Toner Low light is not on. come on if the standard 5,000 page print cartridge is installed. • Remove the print cartridge and gently shake it from side to side to redistribute the toner.
  • Page 94 4048–00x Problem Action Pages are blank. • The print cartridge may be out of toner or defective. Replace the cartridge. • You may have a software error. Try turning the printer off and back on. • Check the photoconductor circuit for continuity.
  • Page 95 4048–00x Problem Action The media skews or buckles. • Don’t overfill tray 1 or the optional tray 2 (see media capacities in the media types and sizes table in the User’s Guide). • Make sure the paper guides are flush against the edges of the media.
  • Page 96 4048–00x Problem Action The paper fails to feed from the • Make sure the optional tray 2 is optional tray 2. selected from the printer driver. • Remove the paper from the optional tray 2 and fan the paper. • Make sure the tray is pushed all the way in.
  • Page 97 4048–00x Problem Action The Load Paper light is on even • Make sure the tray is pushed all though there is paper loaded in the way in. the optional tray 2. • Press Continue. The printer does not print after a •...

  • Page 98: Restoring Factory Defaults

    4048–00x Restoring Factory Defaults Sometimes resetting the printer to the original factory default settings solves formatting problems. 1. Enter the configuration mode. See “Configuration Menu Group or Diagnostic Menu Group” on page 3-2 for more information. 2. Press and release Cancel. The Ready/Data light is on.

  • Page 99: Diagnostic Aids

    4048–00x 3. Diagnostic Aids Operator Panel Menu Definition The operator panel settings and operations are divided in two menu groups. Configuration Menu Group The Configuration Menu group contains a set of menus, settings, and operations which are infrequently required by a user. Generally, the options made available in this menu group are used to configure a printer for operation.

  • Page 100: Configuration Menu Group Or Diagnostic Menu Group

    4048–00x Configuration Menu Group or Diagnostic Menu Group Correct entry of either mode is indicated with the four top lights on. Press and hold Continue (about 4 seconds) for the printer to produce a page similar to the ones on page 3-4 page 3-5,...
  • Page 101 4048–00x Changing Settings or Printing Graphical Aids Select the desired item by pressing and releasing Cancel. If the item has values, press and release Continue to select the desired value. • Press and hold Continue to: – Activate printing. Three pages are in the Print Quality Pages. Instructions for either the Configuration or Diagnostics mode occupy one page.
  • Page 102 4048–00x Printer Settings Configuration Service Manual...
  • Page 103 4048–00x Printer Diagnostics Diagnostic Aids...

  • Page 104: Printer Diagnostics Mode

    4048–00x Printer Diagnostics Mode The Printer Diagnostics mode is for service use only. Its manipulation is the same as the Configuration mode. The following functions can be performed in the Diagnostics mode. See “Configuration Menu Group or Diagnostic Menu Group” on page 3-2 for more information.
  • Page 105 4048–00x 6. Print history: pressing Continue prints the service error history report. 7. Defaults allows the printer to be set for U.S. or non–U.S. after the RIP card has been replaced. 8. Configuration ID allows the printer to have the ID set to match the label after the RIP card has been replaced.

  • Page 106: Continuity Check On Hvps/Cartridge

    4048–00x Continuity Check on HVPS/Cartridge Continuity between the HVPS and the charge roll, Dr. B (blade), TAR (toner adder roll), the developer roll, and the photoconductor (DC) can be checked as follows: 1. Turn printer off. 2. Remove the right side cover. See “Right Side Cover Removal”...

  • Page 107: Repair Information

    4048–00x 4. Repair Information Warning: Read the following before handling electronic parts. 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 precautions, such as turning off power before removing logic cards: •...

  • Page 108: Adjustments

    Only a horizontal line adjustment can be made; margins cannot be adjusted. Contact the next support level or call Lexmark 1–800–539– 6275 for assistance. To perform the registration check and adjustment: 1.

  • Page 109: Adjusting Paper Feed Alignment

    4048–00x 11. Adjust the printhead as necessary. If a horizontal line is clockwise on the paper, adjust the printhead counterclockwise. 12. After obtaining a properly adjusted image on the paper, tighten all four screws. Note: Printhead misalignment results in skewed horizontal lines but a consistent margin top to bottom of page.
  • Page 110 4048–00x P/N 56P0633 P/N 56P0637 Service Manual...

  • Page 111: Re-Assembly

    4048–00x P/N 56P0635 P/N 56P0636 Re–assembly Ensure all cables are re–connected when re–assembling the printer. The printer may not detect a disconnected sensor in some areas without extensive running. For example, the “tray full” sensor has a connector in the left cover and has to be disconnected to remove the rear cover.

  • Page 112: Removal Procedures

    4048–00x Removal Procedures Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed. Be sure to remove the print cartridge before you perform removal procedures. Cover Removals Lower Front Cover (Multipurpose Feeder Cover) Removal 1.
  • Page 113 4048–00x Front Cover Removal 1. Open the front cover. 2. Disconnect the cable from the display panel [A]. 3. Remove the four screws [B]. 4. Remove the front cover. Repair Information...
  • Page 114 4048–00x Top Cover Assembly Removal 1. Remove the toner cartridge. 2. Remove the two (2) screws in front [A]. 3. Open the rear exit door. 4. Remove the two screws in the rear [A]. Service Manual...
  • Page 115 4048–00x 5. Remove the duct assembly in the top cover. Repair Information...
  • Page 116 4048–00x 6. Carefully, lift the rear edge of the top cover to clear the exit flags and rotate the front cover hinge until the cover is in a vertical position. 4-10 Service Manual...
  • Page 117 4048–00x To completely remove the top cover: 7. Open the front cover. 8. Remove the E–clips from both hinges that connect the charge roller and top cover [B]. 9. Remove the stud hinges. 10. Disconnect the cable [A]. 11. Remove the top. The front cover remains attached to the top cover.
  • Page 118 4048–00x Right Side Cover Removal 1. Remove the paper tray. 2. Remove the front right screw and same side rear screw from the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. Note: If you do not have an appropriate screwdriver to access the front right screw, remove the two screws holding the right side of the front cover to the hinge.
  • Page 119 4048–00x Note: The MPF door may need to be lifted slightly for the side cover to clear. 6. Release the top rear latch, if necessary. Swing the cover out and lift it from the base. Right Side Cover Removal There may be an occasion where you have to completely remove the top cover instead of just lifting it to access the screw and latches.
  • Page 120 4048–00x Left Side Cover Removal 1. Open the front cover and the MPF cover. 2. Disengage the two latches (located in the front and top) [A]. 3. Swing the left side cover away from the printer. 4-14 Service Manual...
  • Page 121 4048–00x Note: With only the left side cover and inner cover removed, the following items can also now be removed and replaced: • MPF gear–see “Multipurpose Feeder (MPF)” on page 7-4 more information. • Toner level sensor–see “Electronics and Cables” on page 7-8 for more information.
  • Page 122 4048–00x Rear Cover Removal 1. Remove the paper tray. 2. Remove the right side cover. See “Right Side Cover Removal” on page 4-12 for more information. 3. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information.
  • Page 123 4048–00x 8. Remove the six screws [A]. 9. Lift the top cover slightly with one hand while pulling out on the rear cover. Note: When reinstalling the rear cover, be sure to position the fuser exit guide fingers such that they are not bound by the rear cover.

  • Page 124: Rear Exit Door Removal

    4048–00x Rear Exit Door Removal 1. Open the rear exit door. 2. Use your index finger or screwdriver to disengage the left (facing back of printer) hinge from the rear cover [A]. With your opposite hand, apply force to remove the door away from the printer.

  • Page 125: Duplex Tray Assembly Removal

    4048–00x Duplex Tray Assembly Removal 1. Remove the paper tray. 2. Disconnect all cables on the back of the printer. 3. Tilt the printer on its back. 4. Remove the five screws [A]. 5. Work the right side loose first, disconnect the paper input sensor cable.

  • Page 126: Fuser Assembly, Fuser Paper Exit Guide, Fuser Exit Sensor, And Fuser Lamp Removal

    4048–00x Fuser Assembly, Fuser Paper Exit Guide, Fuser Exit Sensor, and Fuser Lamp Removal 1. Unplug the printer. 2. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. 3. Remove the rear cover. See “Rear Cover Removal”...
  • Page 127 4048–00x 8. Unplug the fuser lamp, exit sensor, and thermistor cables [B]. Note: It may be easier to unplug the fuser lamp once the fuser is loosened. 9. Remove the four screws [A]. Note: Removing the lower left screw requires a long screwdriver (approximately a 6–inch shank).

  • Page 128: Terminal Assembly Removal

    4048–00x Terminal Assembly Removal 1. Remove the HVPS. See “HVPS Card Removal” on page 4-56 for more information. 2. Remove the terminal assemblies [A]. Note: The lower right terminal (to the transfer roll) is gold in color. 4-22 Service Manual...

  • Page 129: Tray Damper And Spring Removal

    4048–00x Tray Damper and Spring Removal 1. Remove the right side cover. See “Right Side Cover Removal” on page 4-12 for more information. 2. Remove the tray damper spring from the printer frame post [A]. 3. Rotate the lever counterclockwise as far as possible and lift out. 4-23 Repair Information...

  • Page 130: Door Latches Removal

    4048–00x Door Latches Removal 1. Remove the right side cover. See “Right Side Cover Removal” on page 4-12 for more information. 2. Remove the two screws [A] and replace the latches. 3. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information.

  • Page 131: Bracket, Opener Shutter Removal

    4048–00x Bracket, Opener Shutter Removal 1. Remove the HVPS. See “HVPS Card Removal” on page 4-56 for more information. 2. Remove the toner cartridge. 3. Unsnap the latches from the frame. 4. Remove the opener shutter bracket. Note: The bracket can be removed (with possible latch breakage) by wedging a screwdriver or similar tool between the bracket and the frame.

  • Page 132: Paper Guide Roller Removal

    4048–00x Paper Guide Roller Removal 1. Remove the HVPS. See “HVPS Card Removal” on page 4-56 for more information. 2. Remove the toner cartridge. 3. Remove the upper body MPF assembly. See “Upper (MPF) Housing Assembly (with Paper Flag) Removal” on page 4-49 for more information.

  • Page 133: Charge Roll Removal

    4048–00x Charge Roll Removal 1. Open the front cover and remove the toner cartridge. 2. Grasp the charge roll on the left end, and push the bearing and roll away from each other. Warning: Handle the charge roll with clean dry hands and only at the ends.

  • Page 134: Right Guide Removal

    4048–00x Right Guide Removal 1. Remove the toner cartridge. 2. Remove the top cover. See “To completely remove the top cover:” on page 4-11 for more information. 3. Remove the HVPS. See “HVPS Card Removal” on page 4-56 for more information. 4.
  • Page 135 4048–00x 5. Remove the three screws [A and B], one holding the link guide bracket arm to the left guide. 6. Remove the left stud hinge on the top cover. See step 6 on page 4-11 for more information. 7. Remove the HVPS. See “HVPS Card Removal”...
  • Page 136 4048–00x 8. Disconnect the single conductor wire (spade connector) [D]. Note: Removal of the LSU (printhead) is not necessary but gives better visibility and access. Illustrations are with the LSU removed. See “Printhead Removal” on page 4-39 for more information. 9.

  • Page 137: Smart Button Sensor Removal

    4048–00x Smart Button Sensor Removal 1. Remove the toner cartridge. 2. Remove the gear train assembly. See “Main Drive Assembly Removal” on page 4-44 for more information. 3. Remove the two screws and the bracket coupling assembly. 4. For additional clearance, remove the charge roll. See “Charge Roll Removal”...

  • Page 138: Entrance Guide Removal

    4048–00x Entrance Guide Removal 1. Remove the LSU (printhead). See “Printhead Removal” on page 4-39 for more information. 2. Remove the two screws [A] holding the entrance guide. 3. Remove the duplex unit. See “Duplex Tray Assembly Removal” on page 4-19 for more information.

  • Page 139: Transfer Roll Assembly And Left Transfer Support Bearing Removal

    4048–00x Transfer Roll Assembly and Left Transfer Support Bearing Removal Note: Do not touch the transfer roll except on the ends. 1. Remove the toner cartridge. 2. Unlatch and lift the left side support bearing. 3. Unlatch and lift the right transfer support bearing. 4.

  • Page 140: Bracket, Paper Detect (Input Sensor) Removal

    4048–00x Bracket, Paper Detect (Input Sensor) Removal 1. Remove the print cartridge to expose latches in the bracket. Leave the door open. 2. Remove the duplex tray assembly. See “Duplex Tray Assembly Removal” on page 4-19 for more information. 3. Disconnect the cable to the sensor or remove the sensor and cable together.

  • Page 141: D-Roll Tray 1 Feed Removal

    4048–00x D–Roll Tray 1 Feed Removal 1. Remove the left cover and inner cover for the MPF gearing. See “Left Side Cover Removal” on page 4-14 for more information. 2. Remove the duplex tray. See “Duplex Tray Assembly Removal” on page 4-19 for more information.

  • Page 142: D-Roll (Tray 1) Shaft Assembly Removal

    4048–00x D–Roll (Tray 1) Shaft Assembly Removal 1. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information. 2. Remove the inner cover. 3. Remove the MPF gear. 4. Remove the gear train assembly. See “Main Drive Assembly Removal”...
  • Page 143 4048–00x 5. Remove the solenoid [B]. 6. With the printer on its back, remove the D–roll. See “D–Roll Tray 1 Feed Removal” on page 4-35 for more information. Note: Slowly extract the shaft while facing the D–roll end. Capture the small washer and the bearing. (The bearing must be removed and reinserted through the opening adjacent to its operating location [A].

  • Page 144: 3-Pin And 2-Pin Connectors Removal

    4048–00x 3–Pin and 2–Pin Connectors Removal 1. Remove the RIP card cage. See “RIP Card Cage (with card in place) Removal” on page 4-40 for more information. 2. Remove the rear cover. See “Rear Cover Removal” on page 4-16 for more information. 3.

  • Page 145: Printhead Removal

    4048–00x Printhead Removal 1. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8. 2. Disconnect the printhead cable. Note: Mark alignment of the printhead at the screw areas with the printhead to keep the same alignment upon reinstallation.

  • Page 146: Rip Card Cage (With Card In Place) Removal

    4048–00x RIP Card Cage (with card in place) Removal 1. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information. 2. Loosen the six screws in the controller cage cover and slide the cover off. 3.
  • Page 147 4048–00x RIP Card Assembly Removal 1. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information. 2. Loosen the six screws in the controller cage cover and slide the cover off. 3. Remove the inner cover. 4.

  • Page 148: Main Drive Motor Assembly Removal

    4048–00x Main Drive Motor Assembly Removal 1. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information. 2. Disconnect the cable to the PWB. 3. Remove the four screws holding the metal base plate to the gear train assembly.

  • Page 149: Motor Assembly (Stepper) Removal

    4048–00x Motor Assembly (Stepper) Removal 1. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. 2. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information. 3. Remove the RIP card cage. See “RIP Card Cage (with card in place) Removal”...

  • Page 150: Main Drive Assembly Removal

    4048–00x Main Drive Assembly Removal 1. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. 2. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information. 3. Remove the RIP card cage. See “RIP Card Cage (with card in place) Removal”...
  • Page 151 4048–00x 4-45 Repair Information...

  • Page 152: Reference Plate Assembly Removal

    4048–00x Reference Plate Assembly Removal 1. Remove the print cartridge. 2. Remove the gear train assembly. See “Main Drive Assembly Removal” on page 4-44 for more information. 3. Remove the three screws. Located between the main gear drive and the assembly plate. 4.
  • Page 153 4048–00x – When a reference plate (reference edge) assembly is removed, reinstallation requires alignment. Use a long shank (6–inches) Phillips screwdriver to adjust the rear screw holding the assembly in place. It is accessed through the hole in the main drive assembly between the RIP card cage and the main motor PCB.

  • Page 154: Cartridge Coupling Assembly Removal

    4048–00x Cartridge Coupling Assembly Removal 1. Remove the toner cartridge. 2. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. 3. Remove the left cover. See “Left Side Cover Removal” on page 4-14 for more information. 4.

  • Page 155: Upper (Mpf) Housing Assembly (With Paper Flag) Removal

    4048–00x Upper (MPF) Housing Assembly (with Paper Flag) Removal 1. Open the front cover. 2. Remove two screws holding the assembly. 3. Carefully, lift the assembly out. Note: A sensor flag is attached below. 4-49 Repair Information...

  • Page 156: Lower (Mpf) Housing Assembly - Paper Sensor Removal

    4048–00x Lower (MPF) Housing Assembly - Paper Sensor Removal 1. Remove the lower front (MPF) door. See “Lower Front Cover (Multipurpose Feeder Cover) Removal” on page 4-6 for more information. 2. Remove the feed–roll cover, one screw. 3. At the lower–right assembly hinge, separate the metal plate from the plastic housing.
  • Page 157 4048–00x 4. Support the left side with the left hand while separating the left hinge. Note: In the next step, note a loaded compression spring [A] on the left side and under the metal plate. 5. Rotate the metal plate until the sensor can be accessed. 6.

  • Page 158: Lower (Mpf) Housing Assembly Removal

    4048–00x Lower (MPF) Housing Assembly Removal 1. Remove the lower front MPF door. See “Lower Front Cover (Multipurpose Feeder Cover) Removal” on page 4-6 for more information. 2. Remove the left side cover. See “Left Side Cover Removal” on page 4-14 for more information.

  • Page 159: Mpf Roller Assembly Removal

    4048–00x MPF Roller Assembly Removal 1. Remove the upper body MPF assembly. See “Upper (MPF) Housing Assembly (with Paper Flag) Removal” on page 4-49 for more information. 2. Remove the MPF cover. See “Lower Front Cover (Multipurpose Feeder Cover) Removal” on page 4-6 for more information.
  • Page 160 4048–00x 6. Remove the MPF gear using your thumbnail to release the latch and slide the gear from the shaft. 4-54 Service Manual...
  • Page 161 4048–00x 7. Remove two screws [A] holding the roller assembly and one screw facing the front of the printer. 8. Remove the roller assembly. 4-55 Repair Information...

  • Page 162: Hvps Card Removal

    4048–00x HVPS Card Removal 1. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. 2. Remove the right side cover. See “Right Side Cover Removal” on page 4-13 for more information. 3. Disconnect the HVPS cable. 4.

  • Page 163: Lvps Card Removal

    4048–00x LVPS Card Removal 1. Unplug the printer. 2. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. 3. Remove the right side cover. See “Right Side Cover Removal” on page 4-13 for more information. 4.

  • Page 164: Cooling Fan Removal

    4048–00x Cooling Fan Removal 1. Remove the top cover. See “Top Cover Assembly Removal” on page 4-8 for more information. 2. Remove the right side cover. See “Right Side Cover Removal” on page 4-13 for more information. 3. Disconnect the fan cable. 4.

  • Page 165: Locations

    4048–00x 5. Locations Flap Duct cover Asm Front cover Flags Cover MPF Asm (MPF door) Locations...

  • Page 166: Cables

    4048–00x Cables Service Manual...
  • Page 167 4048–00x Reference Description Cable Assembly, Cover Switch Display and cable included with P/N’s 56P0601 and 56P0602 (front cover) Switch, Interlock Cover 4 and 5 Sensor and Cable Included with P/N 56P0611 6 and 7 Solenoid, Paper Feed Sensor, Toner Level Cable Assembly, Drawer Card Assembly, RIP Card Assembly, Network RIP...

  • Page 168: Cables (Continued)

    4048–00x Cables (continued) Service Manual...
  • Page 169 4048–00x Reference Description Power Supply, 110 V Power Supply, 220 V 2, 7, 8, 9 Cable Assembly, Main Harness Locations: 2. HVPS 7. Fan 8. LVPS Power 9. LVPS Control NS Paper–In, Duplex Fuser PS, High Volt Guide Assembly, Left Cable Assembly, LVPS to Fuser Fan, Cooling Card Assembly, RIP...

  • Page 170: Sensors

    4048–00x Sensors Service Manual...
  • Page 171 4048–00x Reference Description Paper Path Exit Flag Paper Path below Cartridge Paper Path Duplex Paper Path MPF Paper Path below Cartridge Sensor, Toner Level Sensor, Smart Button Sensor, Fuser Exit Locations...

  • Page 172: Rip Card Assembly

    4048–00x RIP Card Assembly Note: Pin number 1 is designated on the printed circuit card by either a white triangle, a number 1, or both. The pin numbers follow chronologically to the opposite end of the connector. J10 J8 Service Manual...
  • Page 173 4048–00x Function Name on Card # of Pins Pin # Signal Name Mirror J1–MMTR Gnd. motor +24 V Cover J2–CO +5 V Gnd. J3–LSU 1, 5 Gnd. +5 V Gnd. SDRAM J4–DIMM 2 6, 21, 31, +3.3 V 42, 50 71, 81, 92, +3.3 V 1, 12, 26,...
  • Page 174 4048–00x Function Name on Card # of Pins Pin # Signal Name LVPS J15–LVPS Gnd. control Paper feed J16–FD 1–2 +24 V during solenoid tray 1 pick 2nd drawer J17–TRAY2 Gnd. interface +24 V Fuser exit J19–P EXIT +5 V tray full Gnd.

  • Page 175: Power Supply (Lvps)

    4048–00x Power Supply (LVPS) CAUTION - 110/220 V ac Function Name on Card # of Pins Pin # Signal Name 110 / 220 +5 V dc Volts 1, 2, 5, 6 Gnd. 3, 4 +5 V dc 7, 8 +24 V dc Heater 1–2 110 / 220 V ac...

  • Page 176: High Voltage Power Supply (Hvps)

    4048–00x High Voltage Power Supply (HVPS) Function Name on Card # of Pins Pin # Signal Name To RIP J16–CN1 Gnd. +24 V dc +5 V dc Charge Terminal roll 5-12 Service Manual...

  • Page 177: 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 178 4048–00x Service Manual...

  • Page 179: Parts Catalog

    4048–00x 7. Parts Catalog How to Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown 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 180 4048–00x Assembly 1: Covers Service Manual...
  • Page 181 4048–00x Assembly 1: Covers Asm- Part Units Description Index Numbers 1–1 56P0608 Cover Assembly, Rear 1–2 56P0607 Door Assembly, Rear Exit 1–3 56P0680 Flap, Paper Holder 1–4 56P0603 Cover Assembly, Duct 1–5 56P0604 Cover Assembly, Top 1–6 56P0605 Cover Assembly, Right 1–7 56P0601 Cover Assembly, Front, with Display...
  • Page 182 4048–00x Assembly 2: Multipurpose Feeder (MPF) Service Manual...

  • Page 183: Index

    4048–00x Multipurpose Assembly 2: Feeder (MPF) Asm- Part Units Description Index Numbers 2–1 56P0612 Housing Assembly, Upper (MPF) 2–2 56P0611 Housing Assembly, Lower (MPF) 2–3 56P0615 Cap, MPF Paper Feed Cover 2–4 56P0613 Assembly, Roller (MPF) 2–5 56P0614 Gear, MPF Paper Pick Parts Catalog...
  • Page 184 4048–00x Assembly 3: Charging Service Manual...
  • Page 185 4048–00x Assembly 3: Charging Asm- Part Units Description Index Numbers 3–1 56P0640 Roll, Charge 3–2 56P0668 Parts Pack, (Screws and E–Rings) 3–3 56P0669 Hinge, Pivot (quantity 2) 3–4 56P0642 Guide Assembly, Right 3–5 56P0643 Assembly, Transfer Roll 3–6 56P0644 Bearings, Transfer Roll 3–7 56P0641 Guide Assembly, Left...
  • Page 186 4048–00x Assembly 4: Electronics and Cables Service Manual...
  • Page 187 4048–00x Assembly 4: Electronics and Cables Asm- Part Units Description Index Numbers 4–1 56P0626 Power Supply, 110 V 4–1 56P0627 Power Supply, 220 V 4–2, 7, 8, 56P0663 Cable Assembly, Main Harness Locations: 2. HVPS 7. Fan 8. LVPS Power 9.
  • Page 188 4048–00x Assembly 4 (cont.): Electronics and Cables 7-10 Service Manual...
  • Page 189 4048–00x Assembly 4 (cont.): Electronics and Cables Asm- Part Units Description Index Numbers 4–1 56P0624 Cable Assembly, Cover Switch 4–2 56P0621 Cable Assembly, Operator Panel 4–3 56P0625 Switch, Interlock Cover 4–4 and 5 Sensor and Cable Included with P/N 56P0611 (lower MPF housing) 4–6 and 8 56P0616 Solenoid, Paper Feed...
  • Page 190 4048–00x Assembly 4 (cont.): Electronics and Cables This page left intentionally blank. 7-12 Service Manual...
  • Page 191 4048–00x Assembly 4 (cont.): Electronics and Cables Asm- Part Units Description Index Numbers 70G0478 Power Cord, Bolivia, Canada, Caribbean Countries, Columbia, Costa Rica, Dominican Republic, Equador, El Salvador, Guatemala, Honduras, Japan, Mexico, Nicaragua, Peru, Panama, Puerto Rico, Saudi Arabia, Taiwan, The Virgin Islands, Venezuela, US, AP–LV 1339528...
  • Page 192 4048–00x Assembly 5: Paper Feed 7-14 Service Manual...
  • Page 193 4048–00x Assembly 5: Paper Feed Asm- Part Units Description Index Numbers 5–1 56P0677 Flags, Stack Control 5–2 56P0651 Assembly, Duplex 5–3 56P0645 Sensor, Photo 5–4 56P0618 Spring, D–Roll 5–5 56P0656 Roll, Paper Feed 5–6 56P0655 Bracket, Paper Sensor 5–7 56P0657 Assembly, Paper Feed 5–8 56P0654...
  • Page 194 4048–00x Assembly 6: Frame 7-16 Service Manual...
  • Page 195 4048–00x Assembly 6: Frame Asm- Part Units Description Index Numbers 6–1 56P0606 Duct, Air 6–2 56P0623 Assembly, Printhead 6–3 56P0629 Assembly, Cartridge Contacts (quantity 5) 6–4 56P0662 Feet, Base 6–5 56P0661 Damper, Tray 6–6 56P0668 Parts Pack, (Screws and E–Rings) 6–7 56P0609 Assembly, Tray 1...
  • Page 196 4048–00x Assembly 7: Fuser 7-18 Service Manual...
  • Page 197 4048–00x Assembly 7: Fuser Asm- Part Units Description Index Numbers 7–1 56P0648 Assembly, Fuser (110 V) 7–1 56P0671 Assembly, Fuser (220 V) 7–2 56P0673 Fuser Assembly, Paper Guide 7–3 56P0676 Spring, Fuser Exit 7–4 56P0646 Lamp, Fuser (110 V) 7–4 56P0647 Lamp, Fuser (220 V) 7-19...
  • Page 198 4048–00x Assembly 8: Sensors 7-20 Service Manual...
  • Page 199 4048–00x Assembly 8: Sensors and Locations Asm- Part Units Description Index Numbers 8– 1–5, 8 56P0645 Sensor, Photo Locations: 1. Paper Path Exit Flag 2. Paper Path below Cartridge 3. Paper Path Duplex 4. Paper Path MPF 5. Paper Path below Cartridge 8.
  • Page 200 4048–00x Assembly 9: Options 7-22 Service Manual...
  • Page 201 4048–00x Assembly 9: Options Asm- Part Units Description Index Numbers 9–1 56P0674 Drawer Assembly, 250–Sheet 9–2 56P0609 Tray, 250–Sheet 9–3 56P0675 Drawer Assembly, 500–Sheet 9–4 56P0678 Tray, 500–Sheet 56P0694 DIMM, 4MB SDRAM 56P0695 DIMM, 8MB SDRAM 56P0696 DIMM 16MB SDRAM 56P0697 DIMM, 32MB SDRAM 56P0698...
  • Page 202 4048–00x Assembly 9: Options Asm- Part Units Description Index Numbers 1038693 Cable, Serial (50 ft) 56P0670 Kit, Repack 7-24 Service Manual...
  • Page 203 4048–00x Index D-Roll (Tray 1) Shaft Assembly Removal 4-36 Acronyms 1-14 Duplex Tray Assembly Removal 4-19 Adjusting Paper Feed Alignment Adjustments paper feed alignment Entrance Guide Removal 4-32 printhead assembly ESD-Sensitive Parts Attendance Information Lights Factory Defaults Bracket, Opener Shutter Removal restoring 2-62 4-25...
  • Page 204 4048–00x Print Media operating points Main Drive Assembly Removal 4-44 textures Main Drive Motor Assembly Removal weights 4-42 Print Quality Maintenance Approach solving problems 2-55 Memory using test pages 2-62 flash memory Printer Diagnostics Mode Motor Assembly (Stepper) Removal Printer Error Secondary Lights 4-43 Printer Features MPF Roller Assembly Removal...
  • Page 205 4048–00x cartridge coupling assembly 4-48 transfer roll assembly charge roll 4-27 left transfer bearing 4-33 connectors tray damper 4-23 2-pin 4-38 spring 4-23 3-pin 4-38 upper MPF assembly 4-49 cooling fan 4-58 Resolution cover Right Guide Removal 4-28 front Right Side Cover Removal 4-12 4-13 left side...
  • Page 206 4048–00x Service Error Codes 2-11 engine circuitry error 2-19 engine flash error 2-12 engine software error 2-12 fan stalled error 2-15 fuser error 2-14 network error 2-23 NVRAM failure 2-20 paper communication failure 2-24 printhead error 2-16 RAM memory error 2-22 RIP card error 2-21...
  • Page 207 4048–00x Part Numbers 56P0627 56P0628 1038693 7-24 56P0629 7-17 11D0330 7-13 56P0630 12A2405 7-23 56P0631 7-11 12G9830 7-23 56P0632 7-15 12G9831 7-23 56P0633 7-15 12G9832 7-23 56P0634 7-15 12G9833 7-23 56P0635 7-15 1329605 7-23 56P0636 7-15 1339520 7-13 56P0637 7-15 1339528 7-13 56P0638...
  • Page 208 4048–00x 56P0674 7-23 56P0675 7-23 56P0676 7-19 56P0677 7-15 56P0678 7-23 56P0679 56P0680 56P0682 7-11 56P0693 7-15 56P0694 7-23 56P0695 7-23 56P0696 7-23 56P0697 7-23 56P0698 7-23 56P0699 7-23 56P1248 7-23 56P1250 7-23 56P1251 7-23 70G0478 7-13 99A0545 7-23 99A1683 7-23 99A1684 7-23...

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