Lexmark OptraTM - Manuals

Notices and Safety Information vii 4026-0XX Laser product labels are located on the back of the printer and onthe printhead. CLASS 1 LASER PRODUCTLASER KLASSE1 NACH IEC825LUOKAN 1 LASERLAITEAPPAREIL A LASER DE CLASSE1TO IEC 825

Notices and Safety Information ix 4026-0XX Laser Der Drucker erfüllt gemäß amtlicher Bestätigung der USA dieAnforderungen der Bestimmung DHHS (Department of Health andHuman Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,de...

x Service Manual 4026-0XX Avvertenze sui prodotti laser Questa stampante è certificata negli Stati Uniti per essere conformeai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser diclasse 1 ed è certificata negli altri Paesi come prodotto laser diclasse 1 conforme ai requisiti della norma...

Notices and Safety Information xi 4026-0XX Declaração sobre Laser A impressora está certificada nos E.U.A. em conformidade com osrequisitos da regulamentação DHHS 21 CFR Subcapítulo J para aClasse I (1) de produtos laser. Em outros locais, está certificadacomo um produto laser da Classe I, em confor...

xii Service Manual 4026-0XX Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, ioverenstemmelse med kravene i IEC 825. Klasse I-laserprodukter betragtes ikke som farlige. Printerenindeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5milliwatt galliumarsenid laser, som a...

Notices and Safety Information xiii 4026-0XX Laser-notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21CFR, underparagraf J för laserprodukter av Klass I (1). I andraländer uppfyller skrivaren kraven för laserprodukter av Klass I enligtkraven i IEC 825. Laserprodukter i Klass I an...

xiv Service Manual 4026-0XX Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressoracompleix els requisits de DHHS 21 CFR, apartat J, pels producteslàser de classe I (1), i segons ha estat certificat en altres llocs, és unproducte làser de classe I que compleix els requisi...

Notices and Safety Information xv 4026-0XX Japanese Laser Notice Chinese Laser Notice

xvi Service Manual 4026-0XX Korean Laser Notice Safety Information • The maintenance information for this product has been preparedfor use by a professional service person and is not intended tobe used by others. • There may be an increased risk of electric shock and personalinjury during disassembl...

Notices and Safety Information xvii 4026-0XX • Während des Auseinandernehmens und der Wartung desGeräts besteht ein zusätzliches Risiko eines elektrischenSchlags und körperlicher Verletzung. Das zuständigeFachpersonal sollte entsprechende Vorsichtsmaßnahmentreffen. • Ersatzteile müssen gleiche oder ...

xviii Service Manual 4026-0XX personales durante el desmontaje y la reparación de lamáquina. El personal cualificado debe ser consciente de estepeligro y tomar las precauciones necesarias. • Los dispositivos de seguridad de algunas piezas no siemprepueden reconocerse a simple vista. Por lo tanto, lo...

Notices and Safety Information xix 4026-0XX Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of ozone gas.

xx Service Manual 4026-0XX Preface This manual is divided into the following chapters: • “General Information” contains a general description of theprinter, options, and the maintenance approach used to repair it.General environmental and safety instructions as well as specialtools and test equipmen...

4026-0XX General Information 1-1 1. General Information This printer is a letter-quality page printer designed to attach to anIBM Personal Computer or other computers compatible with the IBMPersonal Computer (with 386 processor or higher). The printer is available in models 4026-06A, 06C, 06D, and 0...

4026-0XX 1-2 Acronyms CSU Customer Setup DRAM Dynamic Random Access Memory EP Electrophotographic Process EPROM Erasable, Programmable Read-OnlyMemory ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emissionof Radiation LC...

4026-0XX Diagnostic Information 2-1 2. Diagnostic Information Start CAUTION: NEVER manually actuate or disable the top cover interlock switch and the printhead shutter actuator at the sametime. To perform some of the service checks and tests, such astroubleshooting paper feed problems, you need to a...

4026-0XX 2-2 Service Error Codes When a service error occurs the printer stops printing and alloperator panel LEDs blink in a continuous pattern, indicating aservice error, until the printer is powered off. Press and release the operator panel button to display the serviceerror code. Locate the blin...

4026-0XX Diagnostic Information 2-3 Controller Card Failure Replace Controller board Optional Memory Error Replace the optional memory SIMM.If this does not correct the problem,replace the controller board. Fan Failure Error Go to the “Fan Service Check” on page 2-17 . ROM Checksum Error Replace the...

4026-0XX Diagnostic Information 2-5 Engine Board CommunicationsFailure Error Replace the engine board. If thisdoes not correct the problem,replace the controller board. Controller SRAM Failure Error Replace Controller board Blinking Operator Panel LED Action

4026-0XX 2-6 User Error Message Table When a user error message occurs the printer stops printing andone or two operator panel LEDs are on solid or blinking until theprinter is powered off. Locate the printer’s LED Status in thefollowing table and take the indicated action. User Error Message LED St...

4026-0XX Diagnostic Information 2-7 Memory Full/Com-plex Page/ResolutionReduction Warning/Data TransmissionError Error on solid andPress Button on solid The printer memory isfull or the page is toocomplex to print. Theprinter is forced toreduce the resolutionof a formatted page to300 dpi before prin...

4026-0XX 2-8 User Secondary Error Message Table Press and release the operator panel button two times to display theuser secondary error LED status. Each press and release actionmust be performed within a half second. Locate the printer’s LEDstatus in the following table and take the indicated actio...

4026-0XX Diagnostic Information 2-9 Resolution Reduction Ready, Data blinkingand the Error, PressButton on solid Switch from the GL/2or raster mode toQuick Print Plus modeusing the Lexmarkdriver for Windows, orpress the operatorpanel button toresume printing, or doa front panel reset bypressing and ...

4026-0XX Diagnostic Information 2-11 18. The polygon motor (printhead motor) turns off. 19. The Data LED turns off. 20. The Ready LED stays on solid. If your printer did not successfully complete POST, locate thesymptom in the “POST Symptom Table” on page 2-12 and take the appropriate action. If the...

4026-0XX 2-12 POST Symptom Table Symptom Action POST completes except one ormore LEDs do not come on. Go to the “Operator Panel ServiceCheck” on page 2-27. None of the LEDs come on. Go to the “Operator Panel ServiceCheck” on page 2-27. The printer is dead (No LEDscome on, no motor turns) Go to the “...

4026-0XX Diagnostic Information 2-13 Symptom Table Locate your symptom in the following table and take the appropriateaction Symptom Action Dead printer Go to the “Low Voltage Power Sup- ply Service Check” on page 2-22 . Fan not working Go to the “Fan Service Check” on page 2-17 . Fan noisy Go to th...

4026-0XX Diagnostic Information 2-15 Service Checks Charge Brush Service Check Note: The charge brush charges the photoconductor and is locatedinside the photoconductor unit. FRU Action 1 Photoconduc-tor Unit Spots and marks can be caused by a defectivecharge brush inside the photoconductor unit . I...

4026-0XX Diagnostic Information 2-17 Exit Sensor Service Check Fan Service Check FRU Action 1 Engine Board Disconnect the exit sensor cable from theengine board. Check for +4.5 V dc to +5.5 V dcat CN8-1. If incorrect, replace the engine board. 2 Exit Sensor Be sure the exit sensor is snapped in plac...

4026-0XX 2-18 Cold Fuser Service Check If all the Cold Fuser Service Check items are correct, go to the “Hot Fuser Service Check” on page 2-20 Note: Toner buildup on the fuser input guide, paper separator, hotroll and backup roll causes paper jams. When toner is partially fused to the paper it is us...

4026-0XX Diagnostic Information 2-19 3 Thermistor If the fuser lamp comes on and a fuser failureLED error code displays, be sure the thermistoris contacting the hot roll and the thermistorcable is firmly seated in connector CN2 on theengine board. Check for excessive toner buildup on the surfaceof t...

4026-0XX 2-20 Hot Fuser Service Check Note: If you replace the fuser assembly for overheating, alsoreplace the engine board. CAUTION: FUSER PARTS MAY BE HOT. Input Sensor Service Check If the paper never leaves the tray or fails to be picked from the tray,go to the “Paper Feed Service Check” on page...

4026-0XX Diagnostic Information 2-21 3 Input SensorFlag Check the flag for damage, especially at thefront edge, Be sure the flag moves freely.Replace the flag as necessary. 4 Input Sensor Be sure the input sensor is correctly installedand the sensor/solenoid cable is properly con-nected. Disconnect ...

4026-0XX 2-22 Low Voltage Power Supply Service Check Note: The controller board, HVPS and printhead assembly receivepower from the LVPS through the engine board. If the machine is dead, be sure the controller board is correctlyseated in the engine board connector. Check and reseat all cables. Dead P...

4026-0XX 2-24 Fuse F1 continues to open after being replaced FRU Action 1 Fuse F1 If fuse F1 continues to open after beingreplaced, disconnect CN7 from the engineboard and turn the printer power on. If F1 opens,replace the LVPS. If F1 does not open with CN7 disconnected,check the following: Turn the...

4026-0XX Diagnostic Information 2-25 Main Drive Motor Service Check FRU Action 1 Main DriveMotor Disconnect CN6 from the engine board. Checkthe motor for shorts between each pin on CN2and the motor case. If continuity is indicated,replace the motor. Check the resistance between the following pinson ...

4026-0XX Diagnostic Information 2-27 Operator Panel Service Check FRU Action 1 OperatorPanel Assem-bly LEDsBe sure the operator panel cable is properlyseated in J5 on the controller board. Run POST and check each LED for properoperation. If more than one LED does not light or an indi-vidual LED stay...

4026-0XX 2-28 Optional Paper Tray Two Service Check Check the following before servicing tray two: • Be sure tray one is working correctly. • Be sure the second paper tray is correctly installed and the sec-ond paper tray connector on the base printer properly contactsthe second paper tray connector...

4026-0XX Diagnostic Information 2-29 2 Paper LiftPlate Assem-bly Check the lift plate assembly, release button,button spring, release arm and all related hard-ware for proper operation. Be sure the lift plateD-roll pad mounted on the top of the lift plate isnot worn, contaminated or missing. Repair ...

4026-0XX Diagnostic Information 2-31 Paper Tray Two selected in the application. Paper does not feedfrom Tray Two but instead feeds from Tray One. Tray Two reset toTray One in printer utility. FRU Action 1 Engine Board Be sure the voltage at CN9-8 on the engineboard measures approximately 0 V dc. If...

4026-0XX 2-32 Paper Take-Up Solenoid Service Check FRU Action 1 Solenoid Be sure the solenoid/engine board cable isfirmly seated in connector CN3 on the engineboard. Be sure the solenoid cable is firmly seated in thesolenoid/engine board cable connector at thesolenoid. Check the solenoid for proper ...

4026-0XX Diagnostic Information 2-33 2 Engine Board Disconnect the solenoid/input sensor cable fromCN3 on the engine board. Check the voltage atCN3-5. The voltage should measure approxi-mately +24 V dc. If incorrect, replace the engineboard. If the voltage reads approximately +24 V dc,check the volt...

4026-0XX Diagnostic Information 2-37 Paper Feed Frame Assembly Service Check 3 Paper FeedExit Shaft/RollerAssembly Check the paper feed exit shaft, rollers, andgear for proper operation. Repair as necessary. 4 Paper FeedExit ShaftGround Ter-minal Be sure the paper feed exit shaft ground termi-nal is...

4026-0XX 2-38 Print Quality Service Check Before you perform the Print Quality Service Check, do thefollowing: • The toner cartridge can cause a variety of print quality prob-lems. Be sure the toner cartridge is in good condition, workscorrectly, and is not low on toner. If in doubt, install a new t...

4026-0XX 2-40 White or Black Lines or Bands Note: Poor image development, incorrect charging of the photocon-ductor, incorrect laser exposure, poor image transfer, or poor fusingcauses white/black bands or lines. 2 Cables/Con-nectors Be sure the printhead cables to the engineboard are properly seate...

4026-0XX 2-44 Registration Service Check Note: Use the Service Test Page to check the registration. Transfer Assembly Service Check Note: The transfer assembly left and right transfer bracket springsbias the transfer assembly toward the photoconductor unit. Be surethe transfer assembly is free to mo...

4026-0XX Diagnostic Information 2-45 Transfer Corona Service Check ROM SIMM Service Check FRU Action 1 TransferCorona Be sure the transfer corona is clean. Clean withthe transfer cleaning tool located on the upperfuser cover. Check the high voltage contacts for pitting, con-tamination, or damage. Be...

4026-0XX 3-3 Diagnostic Tests Printer Diagnostic Test The following tests run sequentially when performing this test: Standard Memory Test Optional Memory Test Microcode Check LED Test Read/Write ASIC Register Test Read/Write ASIC SRAM Test Read/Write controller board SRAM Test Perform the following...

4026-0XX Diagnostic Aids 3-4 Service Diagnostic Test Page The service diagnostic test page includes registration marks to aid inadjusting print registration and also includes the installed printerbase code level. The service test page displays the user defaultvalues for the following: Top Margin Off...

4026-0XX Diagnostic Aids 3-6 User Mode Print Test Page The User Mode Print Test Page displays the user default values,installed options, printer features, various typefaces, and theinstalled printer base code level. 1. Be sure the Ready LED is on solid (printer is in the ready state). 2. Press and r...

4026-0XX Diagnostic Aids 3-8 Paper Feed Timing The following describes the timing of paper flow through the printerto aid in diagnosing paper jam problems. Detection of paper in theprinter paper feed path is accomplished by the low or high statuscondition of the paper entry and paper exit sensors. T...

4026-0XX 3-9 Fuser Operation Fuser Control The thermistor detects the hot roll temperature and sends acorresponding analog signal to the engine board. The engine boardturns the lamp on or off depending on the analog signal from thethermistor. If the thermistor detects a high temperature failure but ...

4026-0XX Diagnostic Aids 3-10 Configuration Mode The configuration mode gives the ability to set the following printerfunctions through the operator panel: Hex Trace NPA Mode (Parallel) Parallel Protocol Advanced Status PPDA Activated Auto CRLF/LFCR Perform the following steps to enter the configura...

4026-0XX 3-11 Operator Panel Configuration Mode Button Definition Term Description Result Brief Button Press Press the operatorpanel button no longerthan three seconds. This action movesthrough the configura-tion mode value list. Long Button Press Press and hold theoperator panel buttonfor more than...

4026-0XX Diagnostic Aids 3-12 Hex Trace Use Hex Trace to isolate the cause of print problems. When a job isprinted, the printer operator panel displays the Hex Trace indication,(Ready LED blinking), showing that the printer remains in the HexTrace mode. Turn the printer power off or do a front panel...

4026-0XX 3-13 Restoring Factory Defaults Restoring factory defaults returns the printer settings to the originalfactory settings. Perform the following steps to invoke factory defaults: 1. Turn the printer power off. 2. Open the top cover. 3. Turn the printer power on. The printer starts POST. 4. Th...

4026-0XX Repair Information 4-1 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 toelectrostatic discharge (ESD). To prevent damage to ESD-sensitiveparts, follow the inst...

4026-0XX 4-2 Adjustment Procedures CAUTION: Be sure to unplug the power cord whenever you areworking on the printer with one of the covers removed. Print Registration Adjustment Print the service diagnostic test page after you replace the engineboard. Check the position of the bottom left and right ...

4026-0XX Repair Information 4-3 Removal Procedures CAUTION: Be sure to unplug the power cord whenever you areworking on the printer with one of the covers removed. Use caution when the photoconductor unit is out of the machine. Donot expose it to light for more than 15 - 20 minutes. Screw Identifica...

4026-0XX 4-4 Board Cage Removal 1. Remove the controller board. 2. Remove the engine board. 3. Remove the two remaining screws that hold the board cage to the mainframe. 4. Note the way the cables are routed to the engine board before removing the board cage. 5. Remove the board cage. Cover Removals...

4026-0XX Repair Information 4-5 Top Cover 1. Unplug the power cord from the machine. 2. Remove the toner cartridge and P.C. drum. 3. Remove the left, right, and front covers. 4. Disconnect CN7, CN11, CN2, and CN8 from the engine board. 5. Remove the fuser lamp cable cover. 6. Remove the cable cover ...

4026-0XX Repair Information 4-7 Exit Paper Feed Roller Assembly Removal 1. Remove the transfer assembly. 2. Remove the fuser upper and lower frame assemblies. 3. Note the orientation of the notches in the left and right bushings. Reinstall with the notches facing away from the top cover. 4. Be sure ...

4026-0XX Repair Information 4-9 HVPS Board Removal 1. Unplug the power cord from the machine. 2. Remove the HVPS cover. 3. Disconnect CN1 from the HVPS board. 4. Disconnect the transfer assembly high voltage connector from T1 on the HVPS board. 5. Disconnect the red transfer assembly wire at TRET on...

4026-0XX Repair Information 4-11 Operator Panel Removal 1. Unplug the power cord from the machine. 2. Remove the toner cartridge and P.C. drum. 3. Disconnect the operator panel cable from the controller board. 4. Loosen the front operator panel mounting screw from the board cage. 5. Remove the rear ...

4026-0XX Repair Information 4-13 Paper Separator Removal 1. Remove the paper feed input tray assembly. 2. Remove the lift plate assembly. 3. Remove the manual feed guide plate. 4. Remove the engine board. 5. Remove the controller board. 6. Remove the paper feed frame assembly. 7. Use a screwdriver t...

4026-0XX Repair Information 4-15 Models 4026-06C, 06F and 071 1. Open the top cover. 2. Remove the transfer cable cover screw and transfer cable cover. 3. Remove the two screws that hold the transfer unit to the rear of the top cover. 4. Unplug the wire to the transfer roll assembly. Pay attention t...

4026-0XX Connector Locations 5-1 5. Connector Locations Low Voltage Power Supply Connector Pin No. Signal CN1 Engine Board 1 +24 V dc 2 GND 3 GND 4 +5 V dc 5 FUSER LAMP* CN2 Fuser Lamp/Thermal Fuse 1 HEAT N 2 NO CONNECTION 3 HEAT L

4026-0XX Connector Locations 5-2 High Voltage Power Supply Connector Pin No. Signal CN1 Engine Board 1 HV C 2 HV T* 3 HV SEL 2* 4 HV SEL 1* 5 HV B 6 BIAS MON 7 GND 8 +24 V dc T T HV to TRANSFERCORONA CHARGE TRET TRET HV to TRANSFERCORONA HOUSING

4026-0XX Connector Locations 5-4 CN4A HVPS 1 HV C 2 HV T* 3 HV SEL2* 4 HV SEL1* 5 HV B 6 BIAS MON 7 GND 8 +24 V dc CN5A Laser DiodeDrive Board 1 S SCAN 2 CO 3 LD APC2 (LDVR2) 4 LD APC1 (LDVR1) 5 GND 6 L DATA* 7 +5 V dc CN6A Main Motor 1 PHASE A 2 PHASE A* 3 PHASE B 4 PHASE B* CN7A LVPS 1 +24 V dc 2 ...

4026-0XX 5-7 Second Paper Tray Sensor Board (Option) Controller Board Connector Pin No. Signal CN1A Engine Board 1 CHECK2* 2 CHECK1* 3 CHECK0* 4 MM/INCH 5 2NDBIN* 6 PSIZEO 7 P EMP 2 8 GND 9 +5 V dc 10 NO CONNECTION 11 FEED2* 12 +24 V dc CN3A Paper Take-upSolenoid - 2nd PaperTray (Option) 1 +24 V dc ...

4026-0XX Connector Locations 5-8 J4 Engine Board Pin No. Signal Pin No. Signal 1 NO CONNECTION 16 CMD 2 NO CONNECTION 17 CTBSY 3 NO CONNECTION 18 PRINT 4 NO CONNECTION 19 SRCLK 5 GND 20 GND 6 RESET* 21 GND 7 GND 22 R VIDEO* 8 GND 23 +5 V dc 9 GND 24 GND 10 RHSYNC* 25 +5 V dc 11 EPRDY* 26 GND 12 PRRD...

4026-0XX Parts Catalog 6-1 6. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority ofidentical parts, they are broken down on the same list. Commonparts are shown by one index number. Parts peculiar to one orthe other of the assemblies are listed sep...

4026-0XX Parts Catalog 6-35 Assembly 11: Miscellaneous Asm-Index PartNumber Units Description 11 69G9986 1 Parts Packet, C-Clips for printer and SecondPaper Drawer 11 69G9987 1 Parts Packet, Springs 11 69G9988 1 Parts Packet, Fuser Gears 11 69G9989 1 Parts Packet, Paper Feed Gears 11 69G9974 1 Parts...

X-1 4026-0XX Index A Acronyms 1-2 Adjustment Procedure 4-2 Print Registration 4-2 C Configuration Mode 3-10 Connector Locations Controller Board 5-7 Engine Board 5-3 High Voltage Power Supply 5-2 Low Voltage Power Supply 5-1 Paper Entry Sensor 5-11 Paper Exit Sensor 5-11 Paper Feed Solenoid 5-11 Sec...