4045-XXXLexmark OptraTM M410/M412

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

Index

Safety and Notices

Trademarks

Start Diagnostics

Table of Contents

Edition: May 2000The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. A form for readers comments is provided at the back of this publication. If the form has been removed, comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, 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. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase.Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Color Jetprinter is a trademark of Lexmark International, Inc.Other trademarks are the property of their respective owners. Copyright Lexmark International, Inc. 2000.All rights reserved.UNITED STATES GOVERNMENT RESTRICTED RIGHTSThis software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

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Table of Contents

Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiLaser Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiSafety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvGeneral Information Options . . . . . . . . . . . Printer Specifications Diagnostic InformatioStart . . . . . . . . . . . . .

Service Error CodeUser Status MessagUser Error MessagePower-On Self TestSymptom Tables . Charge Roll ServiceCover Open SwitchDead Machine ServErase Lamp ServiceFan Service CheckFuser Service ChecInput Sensor ServicInput Tray(s) OptionMain Drive Service Operator Panel SerOptions Service ChPaper Feed ServiceParallel Port ServicPrinthead Service CPrint Quality ServicSerial Port Service Transfer Roll Servic

Diagnostic Aids . . . Configuration Mode .

Print Quality Test PPanel Menus . . . . PPDS Emulation . Discard Buffered JoDownload Emulatioiii

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2es . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 (POST). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

/Cable Service Check . . . . . . . . . . . . . . . . . 2-19ice Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23k . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23e Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Service Check . . . . . . . . . . . . . . . . . . . . . . 2-26Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29vice Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-30eck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

e Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35heck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36

e Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47e Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1ages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3bs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Restore Factory Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4Narrow Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Exiting the Configuration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Exiting the Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Print Registration . .Print Tests . . . . . . .Hardware Tests . . .Input Tray Tests . .Base Sensor Test .Printer Setup . . . . .Error Log . . . . . . . .Device Tests . . . . .

Hardware Test Mode .Operator Panel TesMain Motor Test . .Solenoid Test . . . .Tray 2 Motor Test .Mirror Motor Test . .Sensor Monitor TesCooling Fan / FuserErase Lamp Test . .Reset Test Mode . .Engine Firmware . .

Printer Operation . . . .Electrophotographic PrPaper Feeding, TransfPaper Path/Sensor LocCable Locations . . . . .Repair Information . .Handling ESD-SensitivAdjustment Procedures

Printhead AssemblyPaper Alignment . .

Removal Procedures .Covers . . . . . . . . . .Charge Roller . . . .Controller Board . .Cooling Fan . . . . . .Developer Drive AsEngine Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24 Control Test . . . . . . . . . . . . . . . . . . . . . . . .3-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27ocess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27erring and Fusing . . . . . . . . . . . . . . . . . . . . .3-27ations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1e Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11sembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

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Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Inner Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18Left Side Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Multipurpose Tray Paper Alignment AsPick Roll . . . . . . . . Printhead . . . . . . . Redrive Assembly Right Side Frame . Transfer Roller . . .

Connector LocationsLow Voltage PowerHigh Voltage PoweEngine Board . . . . Interconnect BoardOption Tray Board

Parts Catalog . . . . . Assembly 1: CoversAssembly 2: FrameAssembly 3: PrintheAssembly 4: Paper Assembly 5: Paper Assembly 6: Paper Assembly 7: Main DAssembly 8: DeveloAssembly 9: FuserAssembly 10: TransAssembly 11: ChargAssembly 12: ElectAssembly 13: 250-SAssembly 14: 500-SAssembly 15: Optio

Index. . . . . . . . . . . . . v

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24sembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1r Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6ad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Feed - Multipurpose Unit. . . . . . . . . . . . . . . 6-10Feed - Alignment. . . . . . . . . . . . . . . . . . . . . 6-12Feed - Output . . . . . . . . . . . . . . . . . . . . . . . 6-14rive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16per Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20fer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

ronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28heet Tray . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34heet Tray . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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Notices and Safety Information

Laser Notices

The following laser shown:

Laser AdvisoryNotices and Safety Information vii

notice labels may be affixed to this printer as

Label

viii Service Manual

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Class 1 Laser Statement Label

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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

Class I laser producprinter contains intemilliwatt gallium ars770-795 nanometerthere is never any hlevel during normal service condition.

Laser

Der Drucker erfllt gAnforderungen der Human Services) 2In anderen Lndernder die AnforderungCommission) 825 gLaserprodukte der KDruckers befindet ssich um einen Galliuder Lnge 770-795 Drucker sind so kondurch den BenutzerKundendienst LaseMenschen keinesfa

Avis relatif luPour les Etats-Unisprovisions DHHS 21Classe I (1). Pour lenormes IEC 825 relNotices and Safety Information ix

825.

ts are not considered to be hazardous. The rnally a Class IIIb (3b) laser that is nominally a 5 enide laser operating in the wavelength region of s. The laser system and printer are designed so uman access to laser radiation above a Class I operation, user maintenance, or prescribed

em amtlicher Besttigung der USA die Bestimmung DHHS (Department of Health and 1 CFR Teil J fr Laserprodukte der Klasse I (1). gilt der Drucker als Laserprodukt der Klasse I, en der IEC (International Electrotechnical em amtlicher Besttigung erfllt.

lasse I gelten als unschdlich. Im Inneren des ich ein Laser der Klasse IIIb (3b), bei dem es marsenlaser mit 5 Milliwatt handelt, der Wellen

Nanometer ausstrahlt. Das Lasersystem und der zipiert, da im Normalbetrieb, bei der Wartung oder bei ordnungsgemer Wartung durch den rbestrahlung, die die Klasse I bersteigen wrde, lls erreicht.

tilisation de laser: cette imprimante est certifie conforme aux CFR alina J concernant les produits laser de s autres pays : cette imprimante rpond aux atives aux produits laser de Classe I.

x Service Manual

4045-XXX

Les produits laser de Classe I sont considrs comme des produits non dangereux. Cette imprimante est quipe dun laser de Classe IIIb (3b) (arsniure de gallium dune puissance nominale de 5 milliwatts) mettant sur des longueurs donde comprises entre 770 et 795 nanomtres. Limprimante et son systme laser sont conus pour impossible, dans des conditions normales dutilisation, dentretien par lutilirayonnements laser

Avvertenze sui

Questa stampante ai requisiti del DHHclasse 1 ed certificlasse 1 conforme a

I prodotti laser di clastampante contieneallarseniuro di gallilunghezza donda claser e la stampantepersone a contatto funzionamento, le otecnica, non ricevan1.

Avisos sobre eSe certifica que, enrequisitos para los psubcaptulo J de la Sanidad y Servicioscondiciones expuesClase I (1).Los productos lserimpresora contienearseniuro de galio dlongitud de onda deimpresora estn disverse afectada por nsateur ou de rvision, lexposition des suprieurs des rayonnements de Classe I .

prodotti laser certificata negli Stati Uniti per essere conforme

S 21 CFR Sottocapitolo J per i prodotti laser di cata negli altri Paesi come prodotto laser di i requisiti della norma CEI 825.

sse non sono considerati pericolosi. La al suo interno un laser di classe IIIb (3b) o della potenza di 5mW che opera sulla ompresa tra 770 e 795 nanometri. Il sistema sono stati progettati in modo tale che le

con la stampante, durante il normale perazioni di servizio o quelle di assistenza o radiazioni laser superiori al livello della classe

l lser los EE.UU., esta impresora cumple los roductos lser de Clase I (1) establecidos en el

norma CFR 21 del DHHS (Departamento de ) y, en los dems pases, rene todas las tas en la norma IEC 825 para productos lser de

de Clase I no se consideran peligrosos. La en su interior un lser de Clase IIIb (3b) de e funcionamiento nominal a 5 milivatios en una 770 a 795 nanmetros. El sistema lser y la eados de forma que ninguna persona pueda ingn tipo de radiacin lser superior al nivel de

4045-XXX

la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situacin de servicio tcnico.

Declarao sobre Laser A impressora est crequisitos da regulaClasse I (1) de prodcomo um produto larequisitos da norma

Os produtos laser dInternamente, a imp(3b), designado las,operando numa fainanmetros. O sisteforma a nunca existradiao laser supenormal, a manutenassistncia prescrit

Laserinformatie

De printer voldoet alaserprodukt van klavastgelegd in DHHSIEC 825.

Laserprodukten vanaangemerkt. De pri(3b), dat wil zeggeneen golflengte van 7printer zijn zo ontworeparatie conform daan laserstraling boklasse 1.Notices and Safety Information xi

ertificada nos E.U.A. em conformidade com os mentao DHHS 21 CFR Subcaptulo J para a utos laser. Em outros locais, est certificada ser da Classe I, em conformidade com os IEC 825.

a Classe I no so considerados perigosos. ressora contm um produto laser da Classe IIIb

er de arseneto de potssio, de 5 milliwatts xa de comprimento de onda entre 770 e 795 ma e a impressora laser foram concebidos de ir qualquer possiblidade de acesso humano a rior a um nvel de Classe I durante a operao o feita pelo utilizador ou condies de

as.

an de eisen die gesteld worden aan een sse I. Voor de Verenigde Staten zijn deze eisen 21 CFR Subchapter J, voor andere landen in

klasse I worden niet als ongevaarlijk nter is voorzien van een laser van klasse IIIb een gallium arsenide-laser van 5 milliwatt met 70-795 nanometer. Het lasergedeelte en de rpen dat bij normaal gebruik, bij onderhoud of e voorschriften, nooit blootstelling mogelijk is ven een niveau zoals voorgeschreven is voor

xii Service Manual

4045-XXX

LasermeddelelsePrinteren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 825.

Klasse I-laserproduindeholder internt emilliwatt galliumarse770-795 nanometersledes, at mennesKlasse I-niveau vedobligatoriske servic

Huomautus las

Tm kirjoitin on Yh21 CFR Subchaptelaserlaitteiden IEC 8

Luokan I laserlaitteiKirjoittimessa on sisgalliumarsenidilaseLaserjrjestelm ja altistu luokan I mnormaalin toiminnanhuoltotoimien yhtey

VARO! Avattaessankymttmlle las

VARNING! Osynligsprren r urkoppla

Laser-notis

Denna skrivare r i CFR, underparagralnder uppfyller skrikraven i IEC 825.kter betragtes ikke som farlige. Printeren n Klasse IIIB (3b)-laser, der nominelt er en 5 nid laser, som arbejder p blgelngdeomrdet . Lasersystemet og printeren er udformet ker aldrig udsttes for en laserstrling over normal drift, brugervedligeholdelse eller ebetingelser.

erlaitteesta

dysvalloissa luokan I (1) laserlaitteiden DHHS r J -mrityksen mukainen ja muualla luokan I 25 -mrityksen mukainen.

den ei katsota olevan vaarallisia kyttjlle. inen luokan IIIb (3b) 5 milliwatin

r, joka toimii aaltoalueella 770 - 795 nanometri. kirjoitin on suunniteltu siten, ett kyttj ei rityksi voimakkaammalle steilylle kirjoittimen , kyttjn tekemien huoltotoimien tai muiden

dess.

ja suojalukitus ohitettaessa olet alttiina ersteilylle. l katso steeseen. laserstrlning nr denna del r ppnad och d. Betrakta ej strlen.

USA certifierad att motsvara kraven i DHHS 21 f J fr laserprodukter av Klass I (1). I andra varen kraven fr laserprodukter av Klass I enligt

4045-XXX

Laserprodukter i Klass I anses ej hlsovdliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som bestr av en laserenhet av gallium-arsenid p 5 milliwatt som arbetar i vglngdsomrdet 770-795 nanometer. Lasersystemet och skrivaren r utformade s att det aldrig finns risk fr att ngon person utstts fr laserstrlning ver Klass I-niv vid normal anvndning, underhll som utfrs av anvndaren eller an

Laser-meldingSkriveren er godkjeunderkapittel J, for kgodkjent som et Kla825.

Klasse I-laserproduinneholder internt egallium-arsenlasere770-795 nanometerpersoner aldri utsetvanlig bruk, vedlikehserviceoperasjoner.

Avs sobre el LSegons ha estat cecompleix els requislser de classe I (1)producte lser de c

Els productes lser impressora cont unominalment de 5 mde 770-795 nanmeconcebuts de maneper sobre dun nivelles tasques de mansatisfacin les condicNotices and Safety Information xiii

nan freskriven servicetgrd.

nt i USA etter kravene i DHHS 21 CFR, lasse I (1) laserprodukter, og er i andre land sse I-laserprodukt i samsvar med kravene i IEC

kter er ikke betrakte som farlige. Skriveren n klasse IIIb (3b)-laser, som bestr av en nhet som avgir strling i blgelengdeomrdet . Lasersystemet og skriveren er utformet slik at tes for laserstrling ut over klasse I-niv under old som utfres av brukeren, eller foreskrevne

serrtificat als Estats Units, aquesta impressora its de DHHS 21 CFR, apartat J, pels productes , i segons ha estat certificat en altres llocs, s un lasse I que compleix els requisits dIEC 825.

de classe I no es consideren perillosos. Aquesta n lser de classe IIIb (3b) darsenir de gal.li,

il.liwats, i funciona a la regi de longitud dona tres. El sistema lser i la impressora han sigut ra que mai hi hagi exposici a la radiaci lser l de classe I durant una operaci normal, durant teniment dusuari ni durant els serveis que ions prescrites.

xiv Service Manual

4045-XXX

Japanese Laser Notice

Chinese Laser Notice

4045-XXX

Korean Laser Notice

Safety Informat This product is

global safety stcomponents. Tbe obvious. Lexreplacement pa

The maintenanprepared for usintended to be

There may be ainjury during diProfessional senecessary prec

Consignes de S Ce produit a t

normes strictescomposants LeNotices and Safety Information xv

ion

designed, tested and approved to meet strict andards with the use of specific Lexmark he safety features of some parts may not always mark is not responsible for the use of other rts. ce information for this product has been e by a professional service person and is not used by others.n increased risk of electric shock and personal

sassembly and servicing of this product. rvice personnel should understand this and take autions.

curit conu, test et approuv pour respecter les de scurit globale lors de l'utilisation de xmark spcifiques. Les caractristiques de

xvi Service Manual

4045-XXX

scurit de certains lments ne sont pas toujours videntes. Lexmark ne peut tre tenu responsable de l'utilisation d'autres pices de rechange.

Les consignes d'entretien et de rparation de ce produit s'adressent uniquement un personnel de maintenance qualifi.

Le dmontage certains risquedevra prendre t

Norme di sicure Il prodotto sta

severi standardLexmark specifnon sempre soresponsabile p

Le informazionsono indirizzate

Durante lo smorischio di subireelevato. Il persoadottare le prec

Sicherheitshinw Dieses Produk

entworfen und SicherheitsanfoFunktionen deroffensichtlich. SLexmark sind, wHaftung fr die

Die Wartungsinausschlielich Wartungsfachm

Whrend des AGerts bestehtSchlags und ket l'entretien de ce produit pouvant prsenter s lectriques, le personnel d'entretien qualifi outes les prcautions ncessaires.

zza

to progettato, testato e approvato in conformit a di sicurezza e per lutilizzo con componenti ici. Le caratteristiche di sicurezza di alcune parti no di immediata comprensione. Lexmark non er lutilizzo di parti di ricambio di altri produttori.i riguardanti la manutenzione di questo prodotto soltanto al personale di assistenza autorizzato.ntaggio e la manutenzione di questo prodotto, il scosse elettriche e danni alla persona pi nale di assistenza autorizzato, deve, quindi, auzioni necessarie.

eise

t und die zugehrigen Komponenten wurden getestet, um beim Einsatz die weltweit gltigen rderungen zu erfllen. Die sicherheitsrelevanten Bauteile und Optionen sind nicht immer ofern Teile eingesetzt werden, die nicht von ird von Lexmark keinerlei Verantwortung oder

ses Produkt bernommen.formationen fr dieses Produkt sind

fr die Verwendung durch einen ann bestimmt.useinandernehmens und der Wartung des

ein zustzliches Risiko eines elektrischen rperlicher Verletzung. Das zustndige

4045-XXX

Fachpersonal sollte entsprechende Vorsichtsmanahmen treffen.

Pautas de Seguridad Este producto s

cumplir los msusando los comlas caractersticsiempre evidenotras piezas de

La informacindirigida exclusimantenimiento

Existe mayor ripersonales durmquina. El pepeligro y tomar

Informaes de Este produto fo

os padres globespecficos da dos componenno responssubstituio.

As informaesdestinam-se a utilizadas por o

Risco de choqudesmontagem destes servioscuidados necesNotices and Safety Information xvii

e ha diseado, verificado y aprobado para estrictos estndares de seguridad global ponentes especficos de Lexmark. Puede que as de seguridad de algunas piezas no sean tes. Lexmark no se hace responsable del uso de recambio. sobre el mantenimiento de este producto est vamente al personal cualificado de .

esgo de descarga elctrica y de daos ante el desmontaje y la reparacin de la rsonal cualificado debe ser consciente de este las precauciones necesarias.

Segurana i concebido, testado e aprovado para satisfazer ais de segurana na utilizao de componentes

Lexmark. As funes de segurana de alguns tes podem no ser sempre bvias. A Lexmark vel pela utilizao de outros componentes de

de segurana relativas a este produto profissionais destes servios e no devem ser utras pessoas.es elctricos e ferimentos graves durante a e manuteno deste produto. Os profissionais devem estar avisados deste facto e tomar os srios.

xviii Service Manual

4045-XXX

Informaci de Seguretat Aquest producte est dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes normes de seguretat globals amb la utililitzaci de components especfics de Lexmark. Les caracterstiquesempre siguin d'altres peces d

La informaci porientada excluning que no h

El risc de xoc edurant el procEl personal promesures conves de seguretat d'algunes peces pot ser que no bvies. Lexmark no es responsabilitza de l'us e recanvi.el manteniment daquest producte est sivament a professionals i no est destinada a o sigui.lctric i de danys personals pot augmentar s de desmuntatge i de servei daquest producte. fessional ha destar-ne assabentat i prendre les nients.

4045-XXX

Chinese Safety Information

Korean Safety INotices and Safety Information xix

nformation

xx Service Manual

4045-XXX

4045-XXX

1. General Information

The Lexmark OptraTM M410 and M412 laser printers are letter-quality laser page printers designed to attach to an IBM compatible Personal Computer and to most computer networks.

The M410 printer isminute. The M412 iminute. Both model1200 x 1200 dpi Imprinter comes with 4using both SDRAM up to 16MB.General Information 1-1

capable of printing at speeds of 12 pages per s capable of printing at speeds of 17 pages per s print with a true 600 x 600 dpi resolution or age Quality resolution. Each model of the base MB of memory and is expandable to 132MB DIMM slots. User flash memory is also available

1-2 Service Manual

4045-XXX

OptionsThe following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country.

500-Sheet DrawSDRAM MemoFlash Memory Internal Networ

Token RingEthernet 1010Base2/TTri-Port Car

Hard Disk - 2.1Coax/Twinax AExternal Netwocompatibleer

ry DIMMs: 4MB, 8MB, 16MB, 32MB and 64MBDIMMs: 2MB, 4MB, 8MB and 16MBk Options

/100BaseTX

dGBdapter for SCSrk Adapter: Marknet Pro 1 and 3 series

4045-XXX

Printer Specifications

Acoustics Operating:

1-4 Service Manual

4045-XXX

Maintenance ApproachThe diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to dfailure. After you coverify the repair.

Tools RequiredFlat-blade scre#1 Phillips scre#2 Phillips screNeedlenose pliDiagonal pliersSpring hookAnalog or digitaParallel wrap pSerial wrap pluTwinax/serial dCoax/serial debetermine the printer problem and repair the mplete the repair, perform tests as needed to

For Servicewdriverwdriverwdriverers

l multimeterlug 1319128g 1329048ebug cable 1381963ug cable 1381964

4045-XXX

Acronyms

CSU Customer SetupDIMM Dual In-Line Memory ModuleDRAM Dynamic Random Access MemoryEDO EnhaEP ElectEPROM Erasa

MemESD ElectFRU Field GB GigabHVPS High LASER Light

of RaLCD LiquidLED Light-LVPS Low VMROM MaskNVRAM NonvOEM OriginPC PhotoPOR PowePOST PoweRIP RasteROM ReadSIMM SinglSRAM StaticUPR UsedV ac Volts V dc Volts General Information 1-5

nced Data Outrophotographic Processble, Programmable Read-Only

oryrostatic DischargeReplaceable Unityte

Voltage Power SupplyAmplification by Stimulated Emission diation Crystal DisplayEmitting Diodeoltage Power Supply

ed Read Only Memoryolatile Random Access Memoryal Equipment Manufacturerconductorr-On Resetr-On Self Testr Imaging Processor Only Memorye In-Line Memory Module Random Access Memory Parts Returnalternating currentdirect current

1-6 Service Manual

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4045-XXX

2. Diagnostic Information

StartCAUTION: Removdisconnect any cabsafety and to preventhe side of the printprinter when you lift

Use the service erromessage, symptomchapter to determinmalfunctioning print

Service error codesservice error code ipage 2-2.

User status messagcurrent status of thedisplay unless Powedisplayed. If a user Status Messages o

User error messagethat provides the usprint cartridge, papemessage is displaye

If your machine comsymptom, go to thesymptom and take t

If a service error comachine, go to the indicated action for Diagnostic Information 2-1

e power from the printer before you connect or le or electronic board or assembly for personal t damage to the printer. Use the handholds on

er. Make sure your fingers are not under the or set the printer down.

r code, user status message, user error table, service checks, and diagnostic aids in this e the corrective action necessary to repair a er.

are indicated by a three-digit error code. If a s displayed, go to the Service Error Codes on

es provide the user with information on the printer. Ready is displayed on the first line of the r Saver is invoked, and then Power Saver is

status message is displayed, go to the User n page 2-5.

s are indicated by a two or three-digit error code er with information that explains a problem with a r jam, option, port, and so on. If a user error d, go to the User Error Messages on page 2-9.

pletes the without an error, and you have a Symptom Tables on page 2-15. Locate your he appropriate action.

de appears while you are working on the Service Error Codes on page 2-2 and take the that error.

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4045-XXX

Service Error CodesService Error Codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition.

Error Code Act

900 RIP Software Rep

902Engine Software

IndRep

920 Fuser Error Indprinpag

921 Fuser Error IndwheChe

922 Fuser Error FusCo

923 Fuser Error Fusto t

924 Fuser Error An Theon

931-935 Printhead Error

Theto t

931 - Printhead: no first Hsync

932 - Printhead: Lost Hsyncs

935 - Mirror Motor unable to reach operating speed.

936Transport Motor

IndMaion

lace the controller board.

icates an unrecoverable engine software error. lace the engine board.

icates that the fuser is below temperature when ting. Go to the Cold Fuser Service Check on e 2-23.

icates that the fuser is below standby temperature n the printer is idle. Go to the Cold Fuser Service ck on page 2-23.

er failed to reach standby temperature. Go to the ld Fuser Service Check on page 2-23.

er is too hot during printing or when printer is idle. Go he Hot Fuser Service Check on page 2-25.

open circuit has been detected in the Fuser rmistor Circuit. Go to the Hot Fuser Service Check

page 2-25.

se errors represent a problem with the printhead. Go he Printhead Service Check on page 2-36.

icates a problem with the main drive motor. Go to the in Drive Service Check on page 2-29.

4045-XXX

939 Controller -EngineCommunications Error

The controller board and the engine board cannot communicate with one another. The controller board, engine board or interconnect board is defective. Check each board for correct installation and secure ground. If no ord

con

eng

inte

Nocod

941 Controller Code CRC

Rep

941 Controller Font CRC

Rep

943 Controller Font Version

Indinco

944 Controller Board Failure

Rep

945 Controller Board Failure - ASIC Failure

Rep

946 Controller Board Failure - SRAM Failure

Rep

947 Engine Board

Rep

953 NVRAM Failure

Indfaile

954 NVRAM Failure

IndRep

960 RAM Memory Error

IndRep

Error Code ActionDiagnostic Information 2-3

problem is found, replace the FRUs in the following er:

troller board

ine board

rconnect board

te: The controller software also can cause a 939 error e. Contact your next level for software support.

lace the controller board.

lace the controller board.

icates that the controller code and FONT ROM are mpatible.

lace the controller board.

lace the controller board.

lace the controller board.

lace the engine board.

icates the NVRAM chip on the engine board has d. Replace the engine board.

icates the NVRAM experienced a CRC failure. lace the engine board.

icates a DRAM Memory Error on the controller board. lace the controller board.

2-4 Service Manual

4045-XXX

961 RAM in Slot 1 is Bad.

Replace the SIMM in Slot 1. If this does not fix the problem, replace the controller board.

962 RAM in Slot 2 is Bad.

Replace the SIMM in Slot 2. If this does not fix the pro

964 Emulation Error

Indis perro964Fai965Emto

965 Emulation Error

975 - 979 Network Card

ThecarNet976978Rep979Car

Error Code Actionblem, replace the controller board.

icates a failure within the Download Emulation which rogrammed into the code overlay SIMM. The specific r is as follows: - Download Emulation CRC Failure. Checksum

lure. - Download Emulation Outdated, The Download ulation and the controller code are incompatible. Go Download Emulation on page 3-3.

following errors indicate a failure with the network d. 975 - Unrecognizable Network Card. Replace work Card. - Unrecoverable software error in Network Card. - Bad checksum while programming Network Card. lace Network Card. - Flash parts failed while programming Network d.

4045-XXX

User Status Messages

User Status Message Status Action

Ready or Power Saver The printer is ready to receive and process

Press Menu> or or until Reset Printer is on the second line of the display. Press Select to Reset the printer.

The printer is busy receiving or processing data, or printing data.

Note: The printer indicator light blinks while the printer is processing data.

Press Stop to take the printer out of Busy. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready.

The printer is flushing corrupted print data and the current print job is being discarded.

No button actions are possible while this message is displayed.

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Printing Menu Settings The printer is processing or printing a list of current settings menus because Print Menu

Press Stop to take the printer out of Ready. The Not Ready message is displayed.

Printing Directory List

User Status Message Status ActionSettings is selected from the menu.

No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready after the page prints. Press Menu> or until Reset Printer is on the second line of the display. Press Select to reset the printer.

A directory of the flash and disk contents is processing or printing because Print Directory is selected from the menu.

Press Stop to take the printer out of Ready. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the paper path. Press Go to return to Ready after the page prints. Press Menu> or until Reset Printer is on the second line of the display. Press Select to reset the printer.

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Restoring Factory Defaults

The printer is restoring factory defaults.

No button actions are possible while this message is displayed.

Performing Self Tests

Not Ready (Press Go)

Resetting Printer

Formatting Flash (Do Not Power Off)

Program Flash (Do Not Power Off)

Formatting Disk

User Status Message Status ActionDiagnostic Information 2-7

The printer is running the normal series of start-up tests after it is powered On. When the tests are complete, the printer returns to Ready.

No button actions are possible while this message is displayed.

The printer is in the Not Ready state, which means it is not ready to receive or process data. This message displays when Menu> or or until Reset Printer is on the second line of the display. Press Select to reset the printer.

The printer is deleting any print jobs in process and restoring all settings to user defaults.

No button actions are possible while this message is displayed.

The flash memory is being formatted.

No button actions are possible while this message is displayed.

The flash memory is being programmed, which means fonts or macros are being written to flash memory.

Do not perform any button actions while this message is displayed.

The disk is being formatted.

No button actions are possible while this message is displayed.

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Programming Disk (Do Not Power Off)

The disk is being programmed, which means fonts or macros are being written to disk.

No button actions are possible while this message is displayed.

Menus Disabled

Activating Menu Changes

User Status Message Status ActionNote: If information is written to flash memory and to disk at the same time, the Program Flash message is displayed.

The printer menus have been disabled. This occurs when Menu> or

4045-XXX

User Error Messages

User Error Message Explanation

200 Paper Jam Remove Cartridge

Paper is jammed at the printer Input Sensor. Open the printers upper front door and remove

201 Paper Jam Remove Cartridge

202 Paper Jam Open Rear Door

203 Paper JamShort Paper

250 Paper Jam Check MP Feeder

Insert Cartridge or CloseDoor

34 Short Paper

35 Res Save OffDeficient Memory

37 Insufficient Collation Memory

38 Memory FullDiagnostic Information 2-9

the print cartridge to access the paper jam area.Paper is jammed between the printers input and exit sensors. Open the printers upper front door and remove the print cartridge to access the jam area.

Paper is jammed at the printer exit sensor. Open the printer rear door to access the jam area.Paper stops behind the rear door when feeding to the top output bin. Paper or envelopes that are shorter than 6.2 inches (157.5 mm) in length must exit through the rear exit.

Paper is jammed in the multipurpose feeder.

This message displays when the printers front door is open or the print cartridge is missing. If this message cannot be cleared go to Cover Open Switch/Cable Service Check on page 2-19.

The printer determines the paper length is too short to print the formatted data. This occurs when the printer does not know the actual paper size loaded in the tray. For auto-size sensing trays, this error occurs if the paper stop is in the incorrect position. Make sure the Paper Size setting is correct for the size paper that is being used.

This message displays when the printer has insufficient memory to enable Resource Save. Modification of user settings that use memory can cause this error.

This message is displayed when the printer memory used to store pages is too full to collate the print job.This message is displayed when the printer memory used to store pages is full.

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4045-XXX

39 Complex Page This message is displayed when the page is too complex to print.

51 Defective Flash This message is displayed when the printer

52 Flash Full

53 Unformatted Flash

54 Network Software Error

56 Parallel Port Disable

61 Defective Disk

User Error Message Explanationdetects a defective flash. This error may occur at power on, or during flash format and write operations. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the problem is resolved.

This message is displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash.

This message is displayed when the printer detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted.

This error is displayed when the connection to the network port is lost during power on. Press Go to clear the message. The printer clears the setting, but no communication can exist with the network until the network software is reloaded.

d This error is displayed when data is sent to the printer across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset.

This error code is displayed when the printer detects a defective disk. This error may occur at power on or during disk format and write operations. The following actions may be taken while this message is displayed: Press Go to clear the message. The disk is marked defective and normal printer operations continue. Disk operations are not allowed with a defective disk. The Format Disk menu is not shown.

4045-XXX

User Line 2 Messages

If none of the condiline 2 is blank. If anfollowing actions ca

Press Menu> or

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User Line 2 Link Messages

If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, no messages display. The link messages are listed in the following table.

User Message

Check Configuration ID

Parallel

Serial

Network

LocalTalk

Infrared

USB

FaxExplanation

The printer configuration ID is not set or is invalid. This condition can only be cleared when a valid configuration ID is set. Go to Setting Configuration ID on page 3-15.

This is the host interface from which the printer is currently drawing data.

4045-XXX

Check Device Connection Messages

The messages in the following table display when the printer looses communications with one of the following devices.

User Status Message Explanation

Check Tray 2 ConnectionDiagnostic Information 2-13

This message can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure.

If the device is temporarily removed or not connected properly, then reattach it. When the option is recognized, the printer automatically clears the error and continues.

If the option is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, turn the printer off, remove the option and call for service.

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4045-XXX

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:

1. The LED come2. The operator p3. The operator p

and then clears4. Performing Se5. Ready appea6. The fuser lamp

from a cold sta7. The cooling fan8. The main drive9. The developer

toner cartridge.10. The exit rollers11. The printhead m12. The cooling fan13. The main drive14. The exit rollers15. The printhead m16. The LED stays

Ready.s on.

anel displays one row of pels, and then clears.anel displays one and a half rows of diamonds, .

lf Test appears on the display.rs on the display. turns on. The fuser takes longer to warm up rt than a warm start. turns on and runs full speed. motor turns on.drive assembly drives the developer shaft in the

turn.irror motor turns on.

turns on and runs slowly. motor turns off. stop turning.

irror motor turns off. on solid and the operator panel displays

4045-XXX

Symptom Tables

Symptom Action

Dead Machine Go to the Dead Machine Service Check on page 2-20.

Operator Panel - One obuttons do not work.

Operator Panel - DisplaPrinter sounds 5 beeps

Operator Panel - DisplaPrinter does not emit 5

Operator Panel continudisplays all diamonds, sbeeps and does not comPOST.

Paper feed problems - Bprinter or Integrated 25Tray

Paper jams at exit of ReAssembly.

Print quality - Black pag

Print quality - Blank pag

Print quality - Light prin

Print quality - Backgrou

Print quality - Residual

Print quality - Skew

Print quality - Banding

Print quality - Random Diagnostic Information 2-15

r more Go to the Operator Panel Buttons Service Check on page 2-30.

y is blank. .

Go to the Operator Panel Service Check on page 2-30.

y is blank. beeps.

Replace the operator panel assembly.

ously ounds five

plete

Go to the Operator Panel Service Check on page 2-30.

ase 0 Paper

Go to the Paper Feed Service Check on page 2-33.

drive Go to the Paper Feed Service Check on page 2-33.

e Go to Print Quality - All Black Page on page 2-38.

e Go to Print Quality - Blank Page on page 2-38.

t Go to Print Quality - Light Print on page 2-46.

nd Go to Print Quality - Background on page 2-42.

image Go to Print Quality - Residual Image on page 2-45.

Go to the Paper Feed Service Check on page 2-33.

Go to Print Quality - Banding on page 2-44.

marks Go to Print Quality - Random Marks on page 2-39.

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4045-XXX

Print quality - Toner on backside of printed page.

Go to Print Quality - Toner on backside of printed page on page 2-47.

Print quality - Vertical blon edge of copy.

Paper feed problem witsheet paper tray option

Symptom Actionack bands Go to Print Quality - Black bands on outer edges of the page on page 2-44.

h 500 .

Go to Input Tray(s) Option Service Check on page 2-26.

4045-XXX

Service Checks

Note: Anytime the engine board is replaced, the Configuration ID must be reset in NVRAM on the new engine board.

Review the followingchecks.

Paper feed Prothe Error Log oindications of rea particular are

Paper feed ProMessages on

Print Quality Prpage 3-2 and pbefore changin

Use the residenproblem beforeoptions.

Charge Roll ServiService Tip: Close aapart or spots on thcontaminated charg

FRU

1 Charge Roll Assem

2 Left Side Charge Rand BushingDiagnostic Information 2-17

information before performing any service

blems (especially paper jams): Go to Viewing n page 3-17 and check the printer error log for petitive entries that help to isolate a problem to

a of the printer or option.blems with error message: Use the User Error page 2-9 to help diagnose the problem.oblems: Go to Print Quality Test Pages on rint a test page to help diagnose problems g any settings or working on the printer.t diagnostics test provided to help isolate a

taking the machine apart or removing any

ce Checknd evenly spaced repetitive marks 47.5 mm

e page can be caused by a damaged or e roll.

Action

bly Check the charge roll for correct installation, toner buildup, marks, cuts or other signs of contamination or damage. Replace as necessary.

oll Arm Check the left side charge roll arm and bushing for correct assembly operation. Check for damage to the arm or bearing assembly.

2-18 Service Manual

4045-XXX

3 Right Side Charge Roll Arm and Bushing

Check the right side charge roll arm and bushing for correct assembly operation. Check the right charge roll bushing for signs of wear or

FRU Actioncontamination. Excessive contamination could cause intermittent charging of the charge roll. If incorrect, replace the bushing. Check for continuity from the bushing to the charge roll high voltage contact on the right side frame. If incorrect, replace the right charge roller arm.

Note: The screw that attaches the charge roll lead to the contact must be secure.

4045-XXX

Cover Open Switch/Cable Service Check

FRU Action

1 Toner Cartridge Check the toner cartridge to make sure it is correctly installed and that

2 Cover Open SwitchAssemblyDiagnostic Information 2-19

the right and left cartridge tracks are not loose or broken. Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover open switch spring.

/Cable Check the cover open switch for proper mechanical operation. If incorrect, repair as necessary. Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4-6. It measures approximately +5 V dc. If the voltage is incorrect, replace the engine board. If the voltage is correct, check for ground at J4-8. If incorrect, replace the engine board. If the ground is correct, check the continuity between J4-6 and J4-7 on the cable. If no change in continuity occurs as the switch is activated, replace the cover open switch/cable assembly. If the continuity changes as the switch is activated, replace the engine board.

Note: It is easier to check the voltages on J4 with the controller board removed.

2-20 Service Manual

4045-XXX

Dead Machine Service CheckNote: Remove any paper handling options before servicing the printer for a dead machine condition. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemblies.

Service Tip: The LVwith another connecSome force may beconnector.

FRU

1 Line Voltage

2 AC Line Cord

3 +24 V dc at Tray 2 Connector

4 Controller Board

5 Engine Board Test

6 LVPS Fuse F1PS uses a self-docking connector that mates tor mounted on the left side frame assembly.

required to pull the LVPS loose from the

Action

Check the AC line voltage. If the line voltage is incorrect, inform the customer.

Check the line cord for any signs of damage. If correct, check the continuity of the line cord and replace if necessary.

Check for +24 V dc at pin 7 of the tray 2 connector located under the printer. If +24 V dc is present at the connector, go to step 9. If +24 V dc is not present, go to step 4.

Remove the controller board. Turn on the printer. If the printer powers on in the Hardware Test Mode, replace the controller board. If the printer does not power on, go to step 5.

Points Check for +5 V dc at the TP5 test point and +24 V dc at the TP6 test point on the engine board. If correct, replace the engine board. If incorrect, go to step 6.

Remove the LVPS from the printer and check fuse F1. Replace the fuse if the fuse is blown.

4045-XXX

7 LVPS Fuse F1 - Continues to blow after LVPS installed in the printer.

Replace fuse F1 if necessary. Turn the LVPS on/off switch Off and connect the AC line cord and turn the LVPS On.

8 LVPS

9 Engine Board

FRU ActionDiagnostic Information 2-21

CAUTION: Before checking fuse F1 turn the LVPS Off and disconnect the AC line cord. Check fuse F1. If the fuse is blown, replace the LVPS.

Remove the LVPS from the machine. CAUTION: Before making any measurements on the LVPS output connector, observe all necessary safety precautions before applying AC power. Measure the voltages on LVPS output connector CN1. If any voltages are incorrect, replace the LVPS.

Turn the printer off and disconnect all the cables from the engine board. Check for +5 V dc at TP5 test point and +24 V dc at test point TP6 on the engine board. If incorrect, replace the FRUs in the following order:

engine board

interconnect board

If correct, turn the printer off and reconnect one cable at a time until you find the defective assembly.

Service Tip: A short or low resistance load that is attached to the engine board can cause the LVPS to overcurrent and shut the +5 V dc supply down to 0 V dc.

2-22 Service Manual

4045-XXX

Erase Lamp Service CheckError code 928 may be displayed when the printer detects that the erase lamp assembly, cable or engine board is defective.

Note: If the erase lamp assembly is defective, both the erase lamp and lens are replac

Make the following

FRU

1 Cable, Front Harne

2 Engine Boarded as a kit.

checks when a 928 service error displays.

Action

ss Check the connection of the front harness to connector J10 on the engine board for correct installation. If incorrect, repair as necessary. Check the front harness to erase lamp assembly for correct installation. If incorrect, repair as necessary.

Remove the controller board and toner cartridge from the machine. Perform the Erase Lamp Test in the Hardware Test Mode. The erase lamps turn on. The lamps can be observed through the front of the machine with the cover open and print cartridge removed. If the lamps do not turn on, measure the voltage on J12-1. The voltage reads approximately +24 V dc. If incorrect, replace the engine board. If correct, check the voltage at J12-2. The voltage reads between 0.6 V dc to 0.8 V dc. If incorrect, check the continuity of the erase lamp cable. If incorrect, replace the cable. If correct, replace the erase lamp assembly.

4045-XXX

Fan Service CheckCheck the cable connections at J13 on the engine board and at the main fan assembly. The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode.

Fuser Service Che

Cold Fuser Service C

Error codes 920, 92920 error caused byturning the machine

Service Tip: Set thethis service check.

FRU

1 Fan

2 Engine BoardDiagnostic Information 2-23

ck

heck

1, and 922 may display for a cold fuser failure. A low line voltage can sometimes be cleared by off and then on again.

Fuser Temperature to NORMAL before starting

Action

Manually spin the fan and check that it rotates freely. Check the cable connection to the engine board, J13 for correct installation.

Check the continuity of the cable. If incorrect, replace the cable. Perform the Cooling Fan Test in the Hardware Test Mode. Turn the cooling fan on to slow or fast. Disconnect the fan connector at J13 and measure the voltage. The voltage measures+24 V dc. If correct, replace the fan. If incorrect, replace the engine board.

2-24 Service Manual

4045-XXX

FRU Action

1 Fuser Lamp Remove the controller board and run the Cooling Fan Test in the

2 LVPS

3 ThermistorHardware Test Mode. Observe the lamp through the left side frame. If the lamp doesnt come on, unplug the printer and check the continuity between the two pins on the fuser lamp cable going to the fuser assembly. If you do not measure continuity, remove the fuser assembly and check the continuity of the lamp. If incorrect, replace the lamp. If correct, replace the contact in the fuser cover.

Turn the printer off. Disconnect the fuser lamp connectors at the fuser assembly. Turn the printer on and check across the cable for line voltage. If incorrect, remove the LVPS and check both F1 and F2 fuses. Remove the LVPS from the printer. Replace any open fuses and attach the power cord. If the fuses open, replace the LVPS. If the fuses open after the lamp cables are connected to the fuser, the fuser lamp circuit is shorted. Inspect the fuser lamp contacts in the fuser cover. Replace the contacts as necessary.

Disconnect the thermistor cable from the engine board. The resistance is as follows:

HOT - 1K ohms

COLD = 150K ohms to 475K ohms

4045-XXX

Hot Fuser Service Check

Error codes 923 and 924 may display for a hot fuser failure.

CAUTION: The fuser may be hot, use caution before removing or servicing.

Input Sensor ServService Tip: Run thproper operation. Tsensor flag is manu

FRU

1 Fuser Thermistor

2 Engine Board

3 Fuser Hot RollBackup Roll BearinDiagnostic Information 2-25

ice Checke Base Sensor Test. Check the input sensor for he display changes from open to closed as the ally moved in and out of the sensor.

Action

Check for damage to the thermistor assembly. Check the resistance of the themistor:

HOT - 1K ohms

COLD =150K ohms to 475K ohms

With the cable connected, check the continuity from J8-6 and J8-7 to ground. If there is continuity, replace the fuser thermistor.

Error code 924 indicates the engine board detects an open circuit in the thermistor circuit for the fuser assembly. The voltage on J8-6 on the engine board measures approximately +5 V dc. If incorrect, replace the engine board.

gsExamine the fuser assembly for signs of overheating or damage. Check the hot roll and backup roll for signs of excessive toner, label glue, labels or other contaminants. If any are found, repair as necessary or replace the fuser assembly.

2-26 Service Manual

4045-XXX

Service Tip: Run the Sensor Monitor Test in the Hardware Test Mode with the controller board removed.

Input Tray(s) Optio500-Sheet Input Tray

Service Tip: Try all are properly feedingHardware Test Modcomponents are wotray 2 solenoid from

FRU Action

1 Input Sensor Flag Check the input sensor flag for

2 Engine Board

3 Input Sensor Cablen Service CheckOption

the other input paper sources to make sure they paper. Run the Tray 2 Motor Test in the e to verify motor and related paper feed rking properly. With the motor on, actuate the the Solenoid Test to feed paper.

damage and proper operation. If a problem is found, repair as necessary.

Check for approximately +5 V dc at J2-3 on the engine board. If incorrect, replace the engine board.

Check the continuity of the input sensor cable. If incorrect, replace the cable. If correct, replace the input sensor assembly.

4045-XXX

Printer does not recognize Tray 2 is installed

Printer displays messTray 2

200 Paper Jam messainput sensor OR Traypaper in the tray.

FRU Action

1 Tray 2 Interconnect Cable Make sure the printer is positioned correctly on top of tray 2. The tray 2

FRU

1 Tray 1 Inserted Sen

FRU

1 Paper Path/Guides

2 Pick Roll

3 SolenoidDiagnostic Information 2-27

age Insert Tray 1 when trying to print from

ge displays, paper is jammed before the 2 Empty message displays when tray 2 has

interconnect cable contacts must engage the tray 2 cable on the base printer. Replace the cable if the contacts are defective.

Action

sor Check the tray 2 option for correct installation with the base printer. Run the Sensor Test in the Hardware Test Mode to verify the printer detects the tray 1 present sensor. If the sensor is not detected, check the sensor for correct installation and connection at the tray 2 board. If the installation is correct, replace the sensor.

Action

/Tray 2 Check the paper path for any foreign objects. Make sure tray 2 is fully installed and the lift plate raises when the tray is inserted.

Check the pick roll for signs of wear and correct installation. Replace as necessary.

Check the solenoid for correct operation. Use the Solenoid Test to check for correct operation. Replace as necessary.

2-28 Service Manual

4045-XXX

4 Tray 2 Motor Use the Tray 2 Motor Test to check the tray 2 motor. Replace as necessary.

FRU Action

4045-XXX

Main Drive Service CheckService Tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or engine board.

Service Tip: If there are equally spaced horizontal lines across the page, go to Print Qon page 2-41.

WARNING: Whenemachine it must be gears to come in coavoid gear damage.staples or other maassembly.

FRU

1 Main Drive Assemb(Excessive noise ovibration)

2 Main Drive Motor CDiagnostic Information 2-29

uality - Evenly spaced horizontal lines or marks

ver the gearbox assembly is removed from the handled very carefully. Do not allow any of the ntact with any metal or other hard surface to It is also very important not to let any dirt, paper, terial come intact with the grease in the gearbox

Action

ly r

Remove the controller board and run the Main Motor Test in the Hardware Test Mode. If the noise goes away with the toner cartridge removed, inform the customer to replace the toner cartridge. Determine if the noise is in the main drive assembly, fuser, developer drive assembly or alignment assembly. Look for any loose, worn or binding parts in all assemblies. Repair as necessary.

If a service error code 936 - Transport Motor message displays, check the voltage at J3-6 and J3-8 on the engine board. The voltages measure approximately +5 V dc when the motor is not running and go to 0 V dc when the motor is running. If incorrect, replace the engine board.

able Check the continuity of the main drive motor cable. If incorrect, replace the cable.

2-30 Service Manual

4045-XXX

Operator Panel Se

Operator Panel Butto

Note: Before continon page 3-9 and O

3 Motor does not turn, no gear error code 936 or User message 201 Paper Jam displays.

Check the voltages at J3 on the engine board with the main motor cable connected.

FRU

1 Operator Panel As

2 Engine Board (No buttons work)

FRU Actionrvice Check

ns Service Check

uing with this service check do the Button Test perator Panel Test on page 3-21.

J3-1 - +24 V dcJ3-2 - +24 V dcJ3-3 - GroundJ3-4 - GroundJ3-5 - +2.5 V dcJ3-7 - +5 V dcJ3-9 - +5 V dc

If any voltage is incorrect, replace the FRUs in the following order:

main drive motor assembly

engine board

Action

sembly If any button fails the Button Test, replace the operator panel assembly.

Check the voltage at J1-2. The voltage measures approximately +5 V dc with the controller board removed. If incorrect, replace the engine board. If correct, check the continuity of the operator panel cable. If incorrect, replace the cable. If correct, replace the operator panel assembly.

4045-XXX

Operator Panel Display Service Check

SERVICE TIP: The printer has detected a problem with the engine board, operator panel cable or operator panel assembly if POST does not complete and the printer emits 5 beeps and stops in a continuous pattern until the printer is turned off. The operator panel cable is an individuacable assembly with

Note: If the operatoa few PELS missingthe hardware tests bcheck.

FRU

1 Operator Panel Ca

2 Operator Panel Disblank, 5 beeps, LE

3 Operator Panel Disblank, 5 beeps, LE

4 Operator Panel all diamonds, No Bee

5 Operator Panel all diamonds, 5 BeepsDiagnostic Information 2-31

l cable on some printers and a combination the cover switch cable on later models.

r panel is operating properly except for a PEL or or broken, run the LCD Test on page 3-8 from efore continuing with this diagnostic service

Action

ble Check for proper installation of the cable at the engine board (J1) and at the operator panel. Check the continuity of the operator panel cable. If incorrect, replace the cable.

play D Off

Check the voltage at J1-2 on the engine board. It measures approximately +5 V dc. If incorrect, replace the engine board. If correct, replace the operator panel assembly.

play D On

Check for ground between J1-4 and ground. If correct, replace the operator panel assembly. If incorrect, replace the engine board.

psCheck to make sure a DIMM is not plugged in backward. This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps.

Check the voltage at Pins J1-1, J1-3 and J1-5. The voltage measures approximately +5 V dc. If incorrect, replace the FRUs in the following order:

operator panel assembly

engine board

2-32 Service Manual

4045-XXX

Options Service CheckFlash Memory Option(s)

Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the optioMemory DIMM is inthe Memory DIMM irun the Flash TestFLASH DIMM. If theboard.

DRAM Memory Optio

This service check check with the follow

Run the DRAM MeDRAM Memory DIMdamaged. If the tescontinues, replace t

Hard Disk Option

Check to make surecorrectly installed. RDevice Test on the Deither with the hard

Note: The Quick DPass or Fail. If the texists, replace the h

The Disk Test/Cleathe disk contains bacleaning and a verif

WARNING: This casize. This test leavemust reformat the dis a destructive typeshould not be perfon is not listed. Check to make sure that the stalled correctly and is not broken or damaged. If s correctly installed not broken or damaged then on page 3-19. If the test fails, replace the problem continues, replace the controller

n(s)is the same as the flash memory option service

ing exception:

mory Test on page 3-9 from the menu if the M is correctly installed and not broken or

t fails, replace the DRAM DIMM. If the problem he controller board.

the fixed disk and the fixed disk board are un the Quick Disk Test on page 3-17 from the iagnostic Menu when a problem is suspected

disk system board or with the hard disk.

isk Test is a non-destructive test and indicates est fails, replace the hard disk. If a problem still ard disk board.

n on page 3-18 is used to help restore the disk if d data and is unusable. This test is divided into a ying or testing section.

n be a very lengthy test depending on the disk s the hard disk unformatted. The servicer or user isk using the Format Disk Menu operation. This of test. All the data on the disk is destroyed and rmed on a known good disk.

4045-XXX

Network Card Option

Error Code 976 - Network Card

A 976 error code indicates an unrecoverable software error in the network card. Verify that the network card is correctly installed in the socket on the intercfind no problem, cothe network card.

Error Code 54 - Netwo

A 54 error displays card is installed in sestablish communic

Paper Feed ServicIf you have a 936 Tron page 3-22.

FRU

1 Alignment Assemb

2 Inner DeflectorDiagnostic Information 2-33

onnect board and is properly grounded. If you ntact your next level of support before replacing

rk Card

when the RIP software detects that a network lot 1 on the interconnect board but cannot ations with the network card.

e Checkansport Motor Error go to the Main Motor Test

Action

ly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight. Check the alignment assembly for any signs of worn rollers, contaminated rollers or binds. Replace the alignment assembly if any problem is found.

Check the inner paper deflector for correct installation. If the deflector is bowed or not fitting correctly, replace the deflector.

2-34 Service Manual

4045-XXX

Pick roll fails to feed paper.

Printer continually fe

Paper feed failures oc

The most common paper from tray x anReinstall the paper may be necessary tthe paper appears t

Failures occur mainly

Check the paper traplate spring can caustack.

FRU Action

1 Pick Roll Check the pick roll for signs of wear and correct installation. Replace as

2 Pick Roll Solenoid

FRU

1 Pick Roll Solenoid

2 Pick Roll Shaft Asseds paper.

cur only near the top of the stack of paper.

cause of this problem is paper curl. Remove the d check for the natural curvature in the paper.

in the correct manner. If the problem persists, it o reduce the stack height. Replace the pick roll if o be flat in the tray but there is still a problem.

near the bottom of the stack of paper.

y lift plate for proper operation. A fatigued lift se paper feed problems near the bottom of the

necessary.

Check the solenoid for correct operation and installation. Use the Solenoid Test in the Hardware Test Mode to check operation. Replace as necessary.

Action

Check the solenoid for correct operation and installation. Use the Solenoid Test in the Hardware Test Mode to check operation. Replace as necessary.

embly Inspect the cam surface of the pick roller shaft assembly to make sure the solenoid actuator correctly interlocks with the cam. Replace the pick roll shaft assembly if the cam is worn.

4045-XXX

Double Feeding Paper

Note: If double feeding paper occurs mostly from the bottom of the stack, check for missing or damaged restraint pads in the tray.

Multipurpose Tray

Paper fails to feed fro

The pick roll shouldflat side down. If theroll for signs of weaslick spots. If you finCheck to ensure themultipurpose tray aspecifications.

Parallel Port Servi

Run the Parallel W

Note: The Parallel hardware by using aParallel Diagnostic parallel cable and hdisplay for approximproblem is detected

FRU Action

1 PaperDiagnostic Information 2-35

m the multipurpose tray.

make one complete revolution and stop with the pick roll turns but does not pick paper, check the r, oil or grease on the surface of the pick roll or d a problem, replace the pick roll assembly. media that is being fed through the

ssembly meets recommended paper

ce Check

rap Test on page 3-10.

Wrap Test is designed to check the parallel port wrap plug (P/N 1319128) and invoking the

Test. This test helps isolate the printer from the ost. The test provides failure information on the ately three seconds. If the test indicates that a , replace the controller board.

Paper is usually the primary cause of a double feeding paper problem. Flex the paper before placing the paper in the tray. Edge-welded paper is the most common cause of double feeding. Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding.

2-36 Service Manual

4045-XXX

Printhead Service CheckThe printhead assembly does not contain any service replaceable parts or components.

Service Error Code Explanation

1 Error Code 931No first HYSNC SiError Code 932 Lost HYSNC

2 Error Code 935Mirror Motor unablreach operating spgnal These errors usually indicate a failure in the HYSNC signal to the printhead. Check the continuity of the cable connected to J5 on the engine board. If incorrect, replace the defective cable. The voltage at J5-6 measures approximately +5 V dc. If incorrect, replace the engine board. If correct, replace the printhead assembly.

e to eed

These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the engine board cable or engine board assembly. Check the continuity of the mirror motor cable connected to J8 on the engine board. If incorrect, replace the cable. The voltage at J8-5 measures approximately+24 V dc. If incorrect, replace the engine board. If correct, replace the FRUs in the following order:

printhead assembly

engine board

4045-XXX

Print Quality Service CheckService Tip: Before troubleshooting any print quality problems do the following:

Install another print cartridge if available before proceeding with the service che

Use Tray 1 to te

Select the followingthe original settingscustomer printer se

Print Resolutiobe checked at d

Print Darkness Toner Saver: S PQET: Set to O

An incorrect printer problems. Incorrectthe page correctly.

Measure all voltagevoltages measured controller board remDiagnostic Information 2-37

cks.st for print quality of the base printer.

menu settings as indicated. Be sure and note so you can return the printer to the original tup.

n: Set to 300 dpi (print quality problems should ifferent resolution settings).

: Set to NORMAL.et to OFF.FF.

driver for the installed software can cause characters could print and the copy may not fit

s from the connector to printer ground. All during the print cycle are measured with the oved while running the print test.

2-38 Service Manual

4045-XXX

Print Quality - All Black Page

Service Tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.

Print Quality - Blank P

FRU

1 High Voltage Conta

2 Engine Board

3 HVPS Cable/HVPS

FRU

1 Print Cartridge

2 Developer Drive anCouplerage

Action

cts Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted, contaminated or damaged. If incorrect, replace the contact.

Check the voltages on J9-1 through J9-9. If incorrect, replace the HVPS.

Check the continuity of the HVPS cable. If incorrect, replace the cable assembly. If correct, replace the HVPS.

Action

Check the print cartridge for any signs of damage, especially the PC drum contact on the cartridge.

d Make sure the developer drive is working properly and the coupler is correctly installed between the main drive and the developer drive.

4045-XXX

Print Quality - Rando

Service Tip: The prmaterial moving arophotoconductor, cha

3 High Voltage Contact Check the contacts on the right side frame for damage, cartridge contact wear or contamination. If the contacts are bent or damaged,

4 HVPS/HVPS CableEngine Board

5 Printhead Assemb

Symptom

1 Random Marks

FRU ActionDiagnostic Information 2-39

m Marks

imary cause of random marks is due to loose und inside the printer and attaching to the rge roll or transfer roll.

replace the contacts.

Note: Inspect the HVPS contacts on the board for any signs of damage or contamination.

/ If the voltages at J9 are incorrect, replace the engine board. If the voltages are correct, check the HVPS cable for continuity. If you measure continuity, replace the HVPS.

ly Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom.

The printhead used in the printer does not have a mechanical shutter as previous laser printers. The printer is interlocked through the front top cover switch.

Action

Check the print cartridge for any signs of loose or foreign material that might be on the photoconductor. Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls.

2-40 Service Manual

4045-XXX

Print Quality - Blurred or Fuzzy Print

Blurred or fuzzy print is usually caused by a problem in the main drive gearbox assembly, alignment assembly, any feed roller or in the transfer roll bearings or transfer roll. Check the gearbox assembly for correct operation. Check the transfer roll for binds or a contaminated shaft or bearings.

Blurred print can alsinput paper sources

Check the high voltacorroded or damageo be caused by incorrect feeding from one of the .

ge contacts to ensure they are not bent, d. Replace as necessary.

4045-XXX

Print Quality - Evenly spaced horizontal lines or marks

FRU Action

1 Lines spaced 2.2 mm (.08 inch) apart

This can be caused by the motor pinion gear on the main drive motor.

2 Lines spaced 21(8.33 inches) apLines spaced 14inches) apart

3 Lines spaced 15(0.61 inch) apart

4 Lines spaced 47(1.85 inch) apart

5 Lines spaced 38(1.50 inches) apLines spaced 46(1.83 inches) ap

6 Lines spaced 80(3.14 inches) ap

7 Lines spaced 77(3.03 inches) ap

8 Lines spaced 52(2.06 inches) apDiagnostic Information 2-41

Replace the main drive assembly.

1.5 mm art

1 mm (5.56

This can be caused by a defective gear in the main drive assembly. Replace the main drive gearbox assembly.

.6 mm Replace the FRUs in the following order:

developer drive assembly

main drive assembly

mm Replace the FRUs in the following order:

toner cartridge

charge roll

main drive assembly

.0 mmart

.5 mmart

This can be caused by a defective gear in the developer drive assembly. Replace the developer drive assembly.

.0 mm art

Replace the hot roll.

mmart

Replace the backup roll

mmart

Replace the transfer roll.

2-42 Service Manual

4045-XXX

Print Quality - Backgr

Service Tip: Some bpapers or non-Lexmon, turn it off and ru

Some slick or coateproblems occur withhumid environment.quality by increasing

9 Lines spaced 112.8 mm (4.45 inches) apart

Replace the FRUs in the following order:

alignment assembly

10 Lines spaced 94(3.7 inches) apa

11 Lines spaced 45(1.78 inches) apLines spaced 52(2.07 inches) apLines spaced 75(2.96 inches) ap

FRU Actionound

ackground problems can be caused by rough ark toner cartridges. If the rough paper mode is n the print test.

d papers may also cause background. Some printers that run a large amount of graphics in a The customer may try to improve the print the transfer setting.

main drive assembly

mmrt

Replace the FRUs in the following order:

toner cartridge

main drive assembly

.1 mm art

.6 mmart

.2 mmart

Replace the alignment assembly.

4045-XXX

FRU Action

1 Erase Lamp/Lens Assembly

Check the erase lamp lens for any signs of toner, paper dust or other

2 Printhead

3 Transfer Roll Assem

4 High Voltage ContaDiagnostic Information 2-43

types of contamination. Clean the lens with a soft dry cloth if necessary. If unable to clean the contamination off the lens, replace the lens and lamp assembly. Check the erase lamp assembly. Use the same procedure as outlined in the Erase Lamp Test on page 3-26.

The printhead on the Optra M410 printers cannot be cleaned. Try another printhead if all other attempts fail to correct a background problem.

bly Check the high voltage contact from the HVPS to the transfer roll. Check the transfer arm assembly right side bearing for any signs of contamination, pitting or a loose cable to the bearing. If any problems are found, replace the defective part. Check the transfer roll shaft for any signs of contamination, wear or pitting on the ends of the shaft that go into the bearings. If a problem is found, clean the ends of the shaft or replace the transfer roll assembly.

cts Check the high voltage contacts on the right side frame to ensure they are clean and not bent, deformed, or pitted. If incorrect, replace the contact.

2-44 Service Manual

4045-XXX

Print Quality - Banding

Service Tip: Banding is difficult to detect except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds through the printer, especially in the development and transfer process. Inspect theall other paper feeddamage, especiallyhorizontal lines on a

Print Quality - Black b

This print quality proboth sides of the co

FRU

1 Charge Roll LinkagSprings

2 Charge Roll AssemCharge Roll Link A alignment assembly, main drive assembly and components for signs of wear, dirt, binds, or the drive gears. Banding appears as light or dark uniformly gray page.

ands on outer edges of the page

blem appears as vertical black bands on one or py and can be wide, narrow, light or dark.

Action

e If the problem is just on one side of the page, check the charge roll linkage spring on that side. You can check to see if enough force is being applied to the charge roll by applying a slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample. See if the problem changes or goes away. If this fixes or changes the problem, then check the springs and charge roll link arm assemblies for binds or defective parts. Replace as necessary.

bly rm

Check the charge roll for any signs of toner buildup or other contamination on the outer edges that correspond to the bands on the page. Check the charge links and arms for proper operation, binds or incorrectly mounted counterbalance springs. Repair or replace as necessary.

4045-XXX

Print Quality - Residu

Service Tip: Install aservice check. Resiphotoconductor, clecartridge.

3 HVPS Check the following voltages atJ9-7 on the engine board:

Printer Idle

FRU ActionDiagnostic Information 2-45

al Image

new print cartridge if available before doing this dual image can be caused by the aning blade and other parts inside the print

J9-7 measures 0 V dc

Printer Printing Test PageJ9-7 voltage changes from 0 V dc to +4 V dc

If the voltage does not vary, check the continuity of line J9-7 in the front cable harness. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If this does not correct the problem, replace the engine board.

Turn the printer Off and check the resistance between J9-9 and printer ground. The resistance measures approximately 0 ohms. If incorrect, make sure the engine board is mounted correctly and securely grounded. If correct, replace the engine board.

2-46 Service Manual

4045-XXX

Print Quality - Light P

FRU Action

1 Erase Lamp Assembly Check the erase lamp lens assembly for any signs of paper dust, toner

2 Fuser Assembly

FRU

1 Transfer Roll

2 Right Side TransfeArm Assemblyrint

buildup or any other contamination. Clean with a soft cloth or replace the lens and lamp assembly which are provided together in a kit. If the lens is clean then check the erase lamp assembly for failed erase lamps. If defective, replace the erase lamp assembly.

Check the fuser assembly for signs of toner contamination. The hot roll especially might cause toner to be retained and deposited on the page.

Action

Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll.

r Roll Check the right side transfer roll arm assembly bearing for any signs of wear or contamination. Also check to ensure the transfer cable is firmly attached to the bearing. If incorrect, reposition the bearing to make contact with the wire. Replace the bearing as necessary. Check the connection of the transfer roll assembly cable to the transformer on the HVPS board. Check the continuity of the cable from the bearing to the spade terminal on the cable. If incorrect, replace the right side transfer arm assembly. If correct, replace the HVPS.

4045-XXX

Print Quality - Toner on backside of printed page

Service Tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper.

Serial Port Servic

Run the Serial Wra

Note: The Serial Whardware by using aSerial Post Diagnosthe serial cable anddisplay for approximproblem, replace th

FRU

1 Fuser Assembly

2 Transfer RollDiagnostic Information 2-47

e Check

p Test on page 3-11.

rap Test is designed to check the serial port wrap plug (P/N 1329048) and invoking the tic Test. The test helps isolate the printer from host. The test provides failure information on the ately three seconds. If the test indicates a

e controller board.

Action

Toner is being carried out on the backside of the media. This problem is generally caused by a toner buildup on the fuser hotroll or backup roll. Check the fuser hotroll and backup roll for any noticeable buildup of toner. Repair as necessary.

Check the transfer roll for any signs of toner buildup or loose toner. Clean the area and run another copy. If the problem continues, replace the FRUs in the following order:

HVPS

engine board

2-48 Service Manual

4045-XXX

Transfer Roll Service CheckService Tip: The circumference of the transfer roll is 52 mm. Any print quality problems such as lines that are spaced 52 mm apart indicate you should check the transfer roll for damage, toner or foreign ma