LEXMARK SERVICE TIPS ARCHIVE - ALL MODELS

Transcription

485
Service Tips and Information
Quick Index to
Service Tips
Service Tips are listed by machine type in the pages following. Use this quick
Index and the Inkjet and Laser Index Tables to quickly find the tips you need.
Click on Page Number, Subject, or Product below
Page Number
Online Technical Service Bulletins
499
Inkjet Printer Service Tips
486
Laser Printer Service Tips
488
Dot Matrix Printer Service Tips
498
Service Support Guide
10.02
486
Inkjet Service Tips
Machine Type /
Model
Description
Date
Page
4077-20X (Lexmark
2050 Color
Jetprinter)
Paper Guide Field Change NoticeRevised
1/12/99,
1/20/98
565
4077-20X (Lexmark
2050 Color
Jetprinter)
4077 Paper Guide Problem
6/9/97
568
4077-20X and 4090
Paper Guide Change to Prevent
Occasional Paper Buckling at Bottom of
Page — Revised
12/27/96
570
4085-001
(Lexmark J110)
J110 Field Update Procedure
Revised
9/9/02
571
4085-001
(Lexmark J110)
Print Quality Correction Procedures
7/25/01
579
4085-001
(Lexmark J110)
938 Service Thermal System Error
Revised
9/9/02
589
4085-001
(Lexmark J110)
Print quality/deprime of mono head
5/28/02
593
4092 (7000 Series
Color Jetprinter)
Correction and Additional Part Number
for System Board
11/16/98
594
4092 (7000 Series
Color Jetprinter)
Lock Washer Installation
10/10/97
594
10.02
487
Machine Type /
Model
Description
Date
Page
4093 (5700 Color
Jetprinter) and 4094
(5000 Color
Jetprinter)
ASF Right Mounting Screw Rubbing On
The Printhead Carrier
03/19/99
595
4093 (5700 Color
Jetprinter and 4094
(5000 Color
Jetprinter)
Printer Feet Parts Packet
12/02/98
596
4093 (5700 Color
Jetprinter and 4094
(5000 Color
Jetprinter)
Conversion Kits for 0.5mm to 1mm
Carrier and System Board
12/10/98
595
4093 (5700 Color
(5000 Color
Jetprinter)
Cable Popping After Installing Cuff and
Pad
6/26/98
596
4093 (5700 Color
(5000 Color
Jetprinter)
Carrier Stall in 5700 and 5000 Color
Jetprinters
5/11/98
596
4093 (5700 Color
(5000 Color
Jetprinter)
Replacing the 0.5mm Carrier Assembly
and System Board
5/7/98
597
10.02
488
Laser Printer
Service Tips
Machine Type /
Model
Description
Date
Page
4096 (Color
Jetprinter 1100)
Field Replacement Packing Material Now
Available
11/2/98
598
4099-001 (Z31 Color
Jetprinter)
New Power Supply Part Numbers
8/6/99
599
4100-S001 (Z11
Color Jetprinter)
Smoking Printer
11/29/99
600
Machine Type /
Model
Description
Date
Page
Most Laser Printers
Approved Lubricants for Lexmark Laser
printers
6/3/98
508
Most Laser Printers
OPTION ADDED and/or SERVICE
IDENTIFICATION label
4/24/98
508
Most Laser Printers
Thermal Fuse Replacement Part
Numbers
9/95,
revised
11/00
510
4059, 4059-345,
4069 (Optra S, Optra
Se, and Optra T)
Alternative Solution for Backside
Contamination
11/18/99
512
10.02
489
Machine Type /
Model
Description
Date
Page
4019 (IBM Laser
4019)
Change to the Envelope Feeder Cover
05/03/99
515
4023-001 (Optra
W810)
New part numbers for Engine Card,
Power Supply, and Resistor for some
Optra W810 printers
1/31/01
516
4023-001 (Optra
W810)
File to Change Fuser Life
12/10/99
518
4023-001 (Optra
W810)
Optra W810 Service Manual Corrections
11/11/99
519
4026 (Optra E)
Right Transfer Frame Guide
5/19/97
520
4026 (Optra E)
“Cat’s Eye” Problem
1/9/97
522
4026 (Optra E)
Label printing
4027-04W
Transfer Roll FRU
2/5/97
524
4039 10P
Operator Panel Changes
1/31/97
525
4039 10P
Covers Available For All Models
11/12/96
526
4039 10P
ESD Strap on Output Deflector and Paper
Jams
7/30/96
526
4039 (Early Models)
New Flash Memory SIMMS in Older Style
4039 Laser Printers
5/3/96
527
4039 10P
Heavy Card Stock - Fuse Grade
9/95
528
4039 10P
Front Exit Deflector Micro Switch
9/95
529
10.02
523
490
Machine Type /
Model
Description
Date
Page
4039 10P
Paper Feed Part Numbers
3/95
530
4039 10P
New Operator Panel
4/10/96
531
4040 (Optra N) All
Models
New FRU for Paper Deck (Green) Limit
Latches
10/28/99
532
4040 (Optra N)
Part Numbers for the Connector cable
(Optra N, 240, 245)
9/17/96
532
4040 (Optra N)
939 Error on the Optra N
8/21/96
533
4040 (Optra N)
Optra N maintenance Kit Contents
6/5/96
533
4044-001
(Optra E310)
Removing the Print Cartridge Fuse
Contact Assembly
5/2/00
534
4045 (Optra M410/
Optra M412)
Thermal Fuse (TCO) Replacement
4/3/01
535
4045 (Optra M410)
Service Manual Correction
11/11/99
539
4045 (Optra M410)
Part Number Correction
9/21/99
540
4046-001 (Optra K
1220)
10/14/99
541
4046-001 (Optra K
1220)
Corrected Guide Roller Part Number
6/15/98
542
4046-001 (Optra K
1220)
Paperfeed Motor P/N
6/15/98
542
10.02
491
Machine Type /
Model
Description
Date
Page
4046-001 (Optra K
1220)
920 Fuser Error Service Check
6/15/98
543
4049 (Optra) and
4039 10P
Fuser Lamp
11/11/96
544
4049 (Optra) and
4039 10P
Fuser FRUs
5/3/96
544
4049 (Optra) and
4039 10P
Maintenance Kits for Network Laser
Printers
4/10/96
545
4049 (Optra) and
4039 10P
Push-On Clip Terminal Removed from the
LVPS Grounding Wires
4/16/96
546
4049 (Optra) or 4039
10P
Printhead Shroud Repair when the Toner
Cartridge Interlock Spring Mounting Post
is Removed
6/5/96
547
4049 (Optra) or
Other Laser
Printers
Design Change in Gear 9 of the Paperfeed
Gear Train
4/22
548
4049 (Optra) and
4039 10P
939 Service Error
2/19/96
549
4049 (Optra) and
4039 10P
Tray for Non-Standard Size Papers
4/17/97
549
4049 (Optra)
Top Cover Part Numbers
10/11/96
550
4049 (Optra)
Toner Cartridge and Fuser Wiper Use in
Optra Printers
7/4/96
551
10.02
492
Machine Type /
Model
Description
Date
Page
4049 (Optra)
ST MICR machine unique models
5/12/95
552
4059 (Optra S)
Series
Replacing the Deflector Assembly
(Redrive) to prevent paper jams.
03/23/99
555
4059 (Optra S)
Series
Printer Causes Circuit Breaker to Trip
and/or Printer Becomes Electrically ‘Hot’
11/25/98
557
4059 (Optra S)
Series
Power Takeoff ‘Bevel’ Drive Gear
Available Separately
11/23/98
559
4059 (Optra S)
Series
RPQ Label Stacker Output Trays
10/18/98
560
4059 (Optra S)
Series
Special Media Tray (250 Sheet) for
Optra S
10/18/98
560
4059 (Optra S)
Series
Shipping Cartridges for an Optra S
10/18/98
561
4059 (Optra S
Series)
Change to Right Side Covers — the
Molded Bosses Above the Hand-Hold
Cutout
4/24/98
562
4059 (Optra S
Series)
Kiosk Solution for the Optra S Laser
Printer Family
12/11/97
563
4403-001
(Lexmark X83)
LCD replacement on the X83 machine.
9/10/01
604
4402-001, 4403-001
(Lexmark X73,
Lexmark X83)
Service tip matrix for Lexmark X73 and
X83 models
9/12/01
606
10.02
493
Machine Type /
Model
Description
Date
Page
4520-xxx
(Lexmark T52x)
Internal Tray Card (ITC) Assembly Part
Number
8/28/02
610
4520-xxx
(Lexmark T52x)
Maintenance kit part number correction
7/18/01
610
5016-XXX
Lexmark C710
Busy Hangs
10/26/01
611
5016-XXX
(Lexmark C710)
Main Drive Gear is available separately
from the OPC Coupling Drive Block
Assembly
8/27/01
612
5024-XXX
(Lexmark C720)
Error messages: 82/995 while coming out
of Power Saver or receiving intermittent
82/995 error
Revised
9/9/02
613
5024-XXX
(Lexmark C720)
Error messages: 82 PC Photo Developer
Cartridge Missing ERROR and/or related
995, PC belt timing error
8/27/01
614
5024-XXX
(Lexmark C720)
32 Unsupported Cartridge
5/28/02
616
5024-XXX
(Lexmark C720)
82 Photo Developer Missing
5/28/02
617
5024-XXX
(Lexmark C720)
Residual image or smeared images
5/28/02
618
5024-XXX
(Lexmark C720)
Vertical voids (white streaks)
5/28/02
619
10.02
494
Machine Type /
Model
Description
Date
Page
5040 (Optra SC)
New FRU for 24 Tooth Rack Drive Gears
10/28/99
620
5040 (Optra SC
1275)
Rack Adjustment Tool to Alleviate Printer
“Moaning”
10/19/98
620
5040 (Optra SC)
Removing stray toner from the inside of
the printer
4/24/98
623
5040 (Optra SC) and
5045 (Optra C)
Packaging Kits for Optra SC and Optra C
12/1/97
624
5045 (Optra C)
Paper Feed Springs and Transfer Drum
Springs
6/12/98
625
5045 (Optra C)
Checking the Optical Photoconductors
(OPC)
8/22/96
625
5045 (Optra C)
25 Paper Jam When There is No Paper in
Printer
7/23/96
628
5045 (Optra C)
Testing the Optra C Without the Video
Controller Card Installed
5/7/96
630
5045 (Optra C)
Sheen or Gloss Variation on Optra C
5/7/96
631
5045 (Optra C)
Horizontal White Lines That Repeat Every
Four or Five Inches
5/2/96
631
5045 (Optra C)
Turning off the Corona Wire on the
Optra C
5/2/96
632
5045 (Optra C)
Resetting the NVRAM on the Optra C
2/27/96
632
5045 (Optra C)
117 Fuser Pump Failure
2/23/96
633
10.02
495
Machine Type /
Model
Description
Date
Page
5045 (Optra C)
Vertical Lines Changing Color on Grid
Printout
1/19/96
633
5050 (Optra Color
1200) All Models
Complete Tray Assembly Available as
FRU
10/28/99
634
5050 (Optra Color
1200) All Models
Explanation of Toner Status Gauge
10/28/99
634
5050 (Optra Color
1200) All Models
Transparencies Paper Jam from Tray 1
10/28/99
638
5050 (Optra Color
1200)
11G0604 RIP Card Short
05/03/99
639
5050 (Optra Color
1200)
Service Call Notes
05/03/99
640
5050 (Optra Color
1200)
Additional Test after 923 Error (High
Voltage (220V) Machine)
05/03/99
641
5050 (Optra Color
1200)
Dark Line on OHP (Transparencies)
05/03/99
643
5050 (Optra Color
1200)
How Do You Maintain Optimum Color
Fidelity and Photoconductor Timing?
11/13/98
644
5050 (Optra Color
1200)
Solid Lines Across One Plane
11/8/98
647
5055
(Lexmark C910)
Paper skewing
9/9/02
648
10.02
496
Machine Type /
Model
Description
Date
Page
5055
(Lexmark C910)
FU/FD Deflector not moving or not being
seen with 980 message
5/28/02
649
5055
(Lexmark C910)
The ITU is stuck halfway out of the printer
5/28/02
653
5055
(Lexmark C910)
Op Panel is blank and the green LED on
the front of the printer is still on at power
on
Revised
9/9/02
656
5055
(Lexmark C910)
Cyan dots or streaks appear
Revised
9/9/02
(previous
version
5/28/02)
657
5055
(Lexmark C910)
88 Toner Empty message stays on after
toner cartridge has been replaced.
Revised
9/9/02
660
5060
(Lexmark C750)
Color registration and alignment
10/8/02
661
5060
(Lexmark C750)
Replacing the Autocompensator
10/8/02
665
5060
(Lexmark C750)
100 ITU Belt Tracking diagnostic
9/9/02
669
5060
(Lexmark C750)
100 ITU Error - Detecting the belt home
sensor
Revised
9/9/02
(original
1/2/02)
673
10.02
497
Machine Type /
Model
Description
Date
Page
5060
(Lexmark C750)
PSD (180-195) error is displayed during
print jobs or calibration due to
malfunction PSD Sensor assembly
5/28/02
680
5060
(Lexmark C750)
990 Service Tray X errors in printers with
500 Option trays
5/28/02
682
5060
(Lexmark C750)
When the engine and/or RIP cards are
replaced, the NVRAM settings may be
lost or replaced with an invalid set of
values
5/28/02
684
5060
(Lexmark C750)
Printhead PSD use discontinued with
852.054 Rip/9_00-R00 Engine Code
5/28/02
685
10.02
498
Dot Matrix Service
Tips
Dot Matrix Printer Service Tips
Machine Type /
Model
Description
Date
Page
Forms Printer
4227
Auto Gap Adjustment
1/12/99,
1/20/98
601
2380-S02,
2380-SP2 and
2380-S03
Passbook
Printers
Service Bulletin
1/9/97
500
23XX Forms
Printers
Serial Adapters
1/9/97
502
23XX Forms
Printers
Setting Top of Form
1/9/97
505
10.02
499
Online Technical
Service Bulletins
Technical Service Bulletins (Service Tips) are available online. You can view
bulletins by:
• Bulletin Number
• Date Modified
• Description
Once you open a Technical Service Bulletin, you’ll see an information table
similar to the one below, along with Description of Problem and Problem
Solution. When Code Updates are required, you can download directly from the
tip.
Bulletin #
Error Code:
Machine Type/Model
Date Created
Last Updated
Safety Issue?
Code Update?
Engineering Change?
New Parts?
Old parts status:
Voltage: 120/240
Serial No. Range
C750-105
18x thru 195 Error
Lexmark C750, all Models
4/12/02
6/6/02
No
Yes
No
No
N/A
All
All
The tips can be accessed at XXXXXXXXXXXXXXXXXXXXX. Use
your LOCID as your password.
Note: LSSG Tips will eventually move to the internet site. New tips will be
published in both locations for a short period and then all tips will be posted only
to the internet.
10.02
500
2380-S02,
2380-SP2 and
2380-S03
Passbook Printers
Service Bulletin
For service purposes, the 2380-S02 Passbook Printer is generally the same as
the 2380-002. Similarly, the 2380-SP2 and 2380-S03 Passbook Printers are
generally the same as the 2380-003. The few differences are described in this
bulletin.
Mechanical differences
The 2380-S02, 2380-SP2, 2380-S03 automatically set the printhead gap
thickness required for each inserted passbook. The forms thickness
adjustment is fixed to its largest setting by adding a cap to the top cover where
the lever passes through. A spring has been added to the carrier assembly to
keep the printhead against the passbook.
To insure adequate document drive force, stronger springs are used at the ends
of the lower pinch roller shaft.
The left cut sheet guide is replaced with a lockable guide. The extra center
guide serves as the right guide for passbooks and is ignored when feeding cut
sheets.
The 2380-S02, 2380-SP2, and 2380-S03 do not have the head gap sensor
which on the 2380-002 and 2380-003 slows the print speed for thick forms.
Since passbooks are always thick, the 2380-S02, 2380-SP2, and 2380-S03
have as a fixed print speed the slowest 2380-002 or 2380-003 print speed.
10.02
501
Removal Procedures and Adjustments
All procedures are performed the same as the 2380-002 and 2380-003, except
when reinstalling the Top Cover. The Forms Thickness Lever must be in
position 7 (maximum forms thickness).
Parts Catalog
The following service parts are unique to the 2380-S02, 2380-SP2, and
2380-S03:
P/N
Description
Contents
1368325
Spring Kit
Two Lower Pinch Roller Springs and one Carrier Assembly
Spring
1368326
Paper Guides
Left and Center Paper Guides
1368327
Logo/Cover Cap
Log and Cap to prevent use of the Forms Thickness Lever
1368328
Carrier Assembly
Unique to the 2380-S02 and 2380-SP2 due to additional
spring.
11A3316
Eprom Kit
Microcode is unique to the 2380-S03. Changes include:
• Reverse Form Feed
• 5LPI command
• Page Presentation Media command which allows the
user to set the TOF to 3.9mm and 6.1mm
• Message command which allows the user to use the
macro LEDs to indicate which user’s job is printing.
Date:
10.02
1/9/97
502
23XX Forms
Printers
Serial Adapters
Feature Numbers
79F4758
1363110
1368162
1368700
1368705 *
FRU P/N
79F4758
1364927
1368190
1368701
1368706
Buffer
2K
192 Bytes
192 Bytes
2K
2K
Zero Buffer
N/A
V2.0 - N/A
V3.0 - Switch 8
V3.2 - Switch 8
V2.0 - N/A
V3.0 - Switch 8
V3.2 - Switch 8
Switch 8
Switch 8
RCA Jack/Plug
Standard
N/A
Standard
Standard
Standard
Power LED
N/A
Yes
Yes
Yes
Yes
Robust XON/ XOFF
N/A
V2.0 - N/A
V3.0 - Standard
V3.2 - Standard
V2.0 - N/A
V3.0 - Standard
V3.2 - Standard
ON/OFF;
Switch 4 and
Switch 9
ON/OFF;
Switch 4 and
Switch 9
XON/ XOFF and
DTR
N/A
N/A
N/A
ON/OFF; Switch 4
and Switch 9
ON/OFF; Switch 4
and Switch 9
Feature number 1368700 (FRU number 1368701) is the current level of the
serial interface adapter for the 23XX series of printers and is a substitute for all
prior levels of the serial interface adapter.
Feature number 1368705 (FRU number 1368706 is a new adapter that works
on the 23XX-002 and 23XX-003 machines but is primarily used for the laser
printers that require a serial interface adapter (Optra E, 4037, 4039, etc.) This
adapter will replace 1363110 (FRU number 1364927) for the laser printers.
10.02
503
Both adapters support:
•
•
•
•
•
•
•
RS-232E up to 19200bps
RS-422A up to 38400bps
Hardware handshaking (DTR)
Software handshaking (XON/XOFF)
Test page mode
“minimum buffer mode”
Data bits and parity configurations
The key differences between 136870X and 1363110/13668162 are:
• Larger Buffer
The 1368700 SIAs include a 2K byte buffer. The 1368162/1363110 series
had a 192 byte buffer. The larger buffer prevents data overruns when the
host computer is unable to respond immediately to a SIA handshaking
signal.
• POR (Power-On Reset)
The 1368700 has a more robust POR circuit which is not susceptible to
brown out conditions where the AC line voltage to the printer is dropped
substantially for several cycles.
• Robust XON/XOFF modified
10.02
504
The robust XOFF routine was modified to send a maximum of 4 XOFFs to
the host computer, rather than 1 XOFF for each character after the initial
XOFF is sent. Some host systems were unable to handle the multiple
XOFFs sent when the host system overran the buffer by more than a few
characters.
• AutoFDXT Select pins (Affecting laser printers only)
The 1363110 SIA ties two signals together (pins 13 and 14 on the
Centronics Interface) in order that the firmware in the Lexmark 4037 printer
can identify the presence of a SIA on the 4037 test page. These two pins
are no longer connected on 1368705 (FRU 1358706). This change has the
benefit of preventing lockups with bidirectional capable printers that have
an error condition. On the Optra E printer, the printer would signal an error
on pins 13 and 14.
• The color of the SIA has been changed from Brown to Black.
• Added DTR + XON/XOFF mode
This combines DTR-hardware handshaking with XON/XOFF-software
handshaking.
• 150 bps is no longer a selection.
Date:
1/9/97
10.02
505
23XX Forms
Printers
Setting Top of Form
Top of Form with Continuous Paper
1
Begin with no paper in the printer.
2
Place paper in the tractor feeds. Align the left margin with the “[A”.
3
Press FormFeed to load the paper. The READY light blinks when the
paper is loaded.
4
Adjust the TOF using MICRO UP/DN.
5
When the desired position is set, press START/STOP to save this setting
and bring the printer on-line. The READY light comes on solid.
6
The paper advances to Tearoff.
7
Adjust the Tearoff position using MICRO UP/DN.
8
When the desired Tearoff position is set, press START/STOP twice. The
printer beeps twice, resets itself and is ready to print.
10.02
506
Top of Form With Cut Sheets
1
Insert a piece of cut sheet paper into the manual feed door on the front on
the printer. The printer grabs the paper and pulls it in.
2
At this point, one of two things happens:
•
READY light comes on solid
If this happens, use MICRO UP/DN to move the paper to the desired
TOF and press ALT + SET TOF. The position is saved.
•
READY light flashes
If this happens, use the MICRO UP/DN keys to move the paper to the
desired TOF and press START/STOP. The position is saved.
TOP OF FORM Using Macros
MACROS are turned ON in the Setup Menu by selecting Forms Macros
Options/Set Default Macro/then choose a Macro as your default.
Continuous Forms
1
Turn the print On. Paper should be placed into the push tractor feed pins
and the doors closed and the paper select lever on the right hand side of
the printer should be in the down position.
2
If the READY light is solid, press START/STOP to turn it off.
3
Press MACRO until the light corresponding to the macro you want to select
is lit.
4
Press START/STOP. The paper moves back and forth and the READY
light is solid.
10.02
507
5
Press START/STOP to turn the READY light off.
6
Press ALT + FORMFEED. The paper should back out of the printer and
the PAPER OUT light flashes.
7
Follow steps 2 through 8 in Top of Form with Continuous Paper above.
8
If you need to set the top of form in any other macros, return to step 2 in
this section.
Cut Sheet Forms
1
Turn the printer ON. The PAPER OUT light flashes.
2
Press MACRO until the macro you want to adjust top of form is lit.
3
Perform the Top of Form With Cut Sheets procedure.
4
If you need to set the TOP on another macro, follow the procedures again.
Date:
10.02
1/9/97
508
Most Laser
Printers
Approved Lubricants for Lexmark Laser printers
Approved lubricants for all models of 4039 (4039-10P), 4049 (Optra) and 4059
(Optra S) are listed below. The Lubricants are environmentally packaged and
include the appropriate MSDS sheet, meeting Lexmark Health and
Environmental Safety standards.
Description
Part Number
744 Nyogel Grease
99A0394
Shell Darina (otherwise known as IBM #23) Grease
99A0462
These are available through the Lexmark Parts Center.
Date:
Most Laser
Printers
6/3/98
OPTION ADDED and/or SERVICE IDENTIFICATION label
Affects the following printers: 5045 (Optra C), 5040 (Optra SC), 4040 (Optra N),
4059 (Optra S), 4049 (Optra) and 4039-10P.
Both the Option Added or Service Identification label placed near the
Machine type and Model number or on a specific part indicates the presence
of (non-standard) customer-unique hardware, generally the result of an RPQ
(Request for Price Quote).
The specific hardware is NOT listed in the parts catalog of the Lexmark service
manuals or Lexmark Service Parts Identification Catalog CD. The “customerunique” FRU P/N is placed on the appropriate hardware during manufacturing,
10.02
509
packaging, or assembly to simplify the process of reordering service parts
(FRUs). The Option Added labels are shipped with RPQ features (includes
application instructions) allowing field configuration personnel to add the labels.
The Service Identification label provides a space for entering the Part number
of the feature installed. The Service Identification. label is generally
associated with mechanical hardware while the Option Added label is
generally associated with firmware (ROMs, SIMMs, etc.).
The Option Added and/or Service Identification label designation in
conjunction with the TLI number will allow the LexExpress repair depot to
determine the original factory configuration when cross shipping machines.
Date:
10.02
4/24/98
510
Most Laser
Printers
Thermal Fuse Replacement Part Numbers
Machines affected: 4019-All, 4029-All, 4035-All, 4037-All, 4047-All, 4039-10X,
12X, 16X and 4049-12X, 16X.
As of 09/15/95 the thermal fuse P/N1381546 is no longer available. Orders for
this part will be cancelled in the parts system. The thermal fuse has been
redesigned to comply with new requirements that require two fuses be mounted
into the fuser shroud. For this change to work properly in existing printers, the
fuser shroud must also be replaced.
This FRU Bill of Materials contains a new fuser shroud with a new thermal fuse
and thermister installed in the shroud. Use the installation instructions included
with the FRU to replace the shroud assembly.
All new machines and new and rebuilt fusers have this change incorporated
into the design.
10.02
511
Select the proper part number based on the machine type, and model code
from the list below.
Machine Type(s) and Model(s)
Fru Part Number
4019-ALL, 4029-ALL
1381784
4039-10X, 4035-ALL
1381785
4039-12X, 4049-12X
1381786
4037-ALL, 4047-ALL
1381787
4039-16X, 4049-16X
1381788
Date:
10.02
9/95, revised 11/00
512
4059, 4059-345,
4069 (Optra S,
Optra Se, and
Optra T)
Alternative Solution for Backside Contamination
Background
Product Engineering has developed a fix for “backside contamination”, also
known as “fuser wiper dumps”. For those not familiar with this problem, it is
unwanted toner that appears on the backside of a simplex page. (Note: On
duplexed pages, the contamination will occur on the front side because of the
sequence in which the sides are printed.) It typically shows up on the backside
of the first page printed after a long continuous run of high coverage pages. It
is caused by toner that did not get completely fused to the page ending up on
things that contact the hot roll, such as the felt wiper, detack fingers and the
thermistor. After the printer pauses, this build up of toner is released when the
machine starts back up. The toner is transferred to the backup roll and then,
when paper comes through the fuser, it is transferred to the back of the sheet
of paper.
10.02
513
Solution
We have released “special” fusers to help address this problem. In concept, the
solution to this problem was fairly straightforward: remove all the components
in the paper path that contact the hot roll. We have done this as follows: (1) the
felt wiper is replaced with the Optra T fuser insert (plastic piece that fits into the
wiper slot), (2) the thermistor has been moved to the edge of the paper path
and (3) all but the outer two detack fingers have been removed; these are fixed
in position, 0.5mm away from the hot roll. The last item presents the only known
shortcoming of this solution and keeps us from implementing it across all
machines. This solutions relies on the media to detach itself from the hot roll.
In all the applications we've seen so far, this has not been a limitation. Large
jobs have been printed on letter, legal, or A4 size media using various grades
of 20#, 80 gsm or heavier papers.
Special Considerations and Limitations:
This fuser is only intended to be put in applications where the following media
or conditions do not exist:
1
Use of transparencies.
2
Use of short grain papers.
3
Use of paper weights less than 20# or 80 gsm.
10.02
514
4
Media narrower than A4 (approximately 210mm or 8.3 in.).
5
Printing solid graphics closer than 12mm or 0.5 in. from the top edge of the
media.
Doing any of the above will significantly increase paper jams in the fuser that
may require a service call.
Order Information
The current plans are to only have these fusers available through Field Service
or as a recommendation from our Customer Support Center (CSC). The
following FRU Part Nos. have been released:
Optra S (24ppm/110 V.)
P/N 99A1071
P/N 99A1072
P/N 99A1073
P/N 99A1074
Optra T (25ppm&35ppm/110 V.)
P/N 99A1815
Optra T (25ppm&35ppm/220 V.)
P/N 99A1816
We have not released Fusers FRUs for the 12, 16, 18 or 20 ppm models since
there have been no reported problems with these speed machines. The
inference is that most users don't run the type of jobs on these models that
exhibit the problem. High volume customers typically buy the faster machines.
Date:
10.02
11/18/99
515
4019 (IBM Laser
4019)
Change to the Envelope Feeder Cover
For all 4019 printers:
A change has been made to the Envelope Feeder Cover for IBMTM 4019. The
stainless steel guide deflector was eliminated from the Envelope Feeder Cover
(FRU 99A0379), leaving an exposed screw hole in the molded plastic. The old
and new level covers function interchangeably with the envelope feeders.
Customers who previously were aware of the stainless steel deflector may
question its absence or the screw holes purpose.
Date:
10.02
05/03/99
516
4023-001 (Optra
W810)
New part numbers for Engine Card, Power Supply, and Resistor for
some Optra W810 printers
There are three new part numbers for the Engine Card, Power Supply and
resistor for the Optra W810 that apply to some machines. If the serial number
is greater than S/N 1W856776, please use the new part numbers below.
Description
Existing P/N for
S/N < 1W856776
(with/“Niveau 14” label)
New Part Numbers for S/N
> 1W856776
(with/“Niveau 14” label)
220V Engine Card
12G2374
12G3458
220V Power Supply
12G2366
12G3457
220V Power Supply Resistor
10.02
12G3456
517
Note: There may be some machines below
S/N 1W856776 that have been reworked
with the new parts. These machines also
need to use the new parts. In order to tell if a
printer has a new Engine Card and new
Power Supply already installed, a label with
“Niveau: 14,” is attached underneath the
manufacturing label on the back of the
printer. If a 220V printer below S/N
1W856776 needs an Engine Card or Power
Supply and does not have the “Niveau: 14”
label attached, use the existing part numbers
listed in the table above.
NOTES:
• This change is due to a Flickers Harmonics Compliance with machines
built after 01/01/01. Machines with serial numbers below 1W856776 and
do not have the “Niveau 14” sticker attached below the manufacturing label
do not need to be upgraded with new parts.
• You cannot mix old parts with new parts. For example, a machine with a
serial number below 1W856776 that needs an engine board replaced
would use 12G2374 and cannot use 12G3458. The same goes for the
power supplies. The new resistor is a new part (12G3456) is unique to
machines with serial numbers greater than S/N 1W856776 and does not
exist on earlier level machines.
Date:
1/31/01
10.02
518y
4023-001 (Optra
W810)
File to Change Fuser Life
The fuser life on the Optra W810 has been recently increased from 150,000
pages to 250,000 pages. Lexmark has developed a file that can be downloaded
to the printer to change this setting. It can be found at:
ftp://ftp.lexmark.com/pub/driver/laser_dos/fuser250.exe.
The filename to be downloaded is named: fuser250,exe. This is a selfextracting file and when run, you will receive the following files:
Filename
Purpose
FUSER250.NPA
Command to update Fuser Maximum Life for the Optra
W810.
README.1ST
Readme file explaining installation from diskette
To change the fuser life, follow the instructions contained in the README.1ST
file. After these procedures are performed, the printer will issue the “Replace
Fuser” warning after 250,000 letter sized pages have been printed instead of
150,000. The Fuser gauge on the Menu Settings page will also reflect the new
maximum life of 250,000 letter sized pages.
Date:
10.02
12/10/99
519
4023-001 (Optra
W810)
Optra W810 Service Manual Corrections
The following are corrections to the Optra W810 Service Manual. These
changes will be included in the next revision.
Page 4-56, “1st Cassette (Tray 1) Paper Width Detecting Sensor Removal”
should be disregarded.
Part Number Corrections:
Assembly
Ref
Change
Assembly 1: Printer Housing
1-23
Operator Control Panel part number
should read 12G3520.
Assembly 17: Printer Controller
Card
17-2
Controller Card SIMM Code part number
should read 11G3523.
Assembly 44: Optional Features
N/A
Printer Field-Return Packaging should
read 12G3522
Date:
10.02
11/11/99
520
4026 (Optra E)
Right Transfer Frame Guide
For all models of Optra E.
The Right Transfer Frame Guide, P/N 69G8310, has been redesigned to
prevent breakage of the PC Drum Cartridge when the PC drum cartridge is
incorrectly installed. The P/N shown in the service manual (P/N 11A7626,
revised 5/97) is incorrect.
Note: While this part prevents PC Drum Cartridge damage, it does not prevent
the incorrect installation of the PC Drum Cartridge or the effects. An incorrectly
installed cartridge may cause the printing of blank pages, grinding sounds,
paper jams or the inability to close the top cover.
10.02
521
To install the Right Transfer Frame Guide:
CAUTION: Be sure to unplug the power cord and disconnect the interface cable
from the printer.
1
Open the top cover.
2
Remove the toner and PC Drum Cartridges.
3
Remove the Right Transfer Frame Guide mounting screw [3]
4
Carefully lift up and remove the Right Transfer Frame Guide [2]. Be sure to
note the mounting and orientation of the Right Transfer Assembly Tension
Spring [4] and make sure you correctly install this part on the new Right
Transfer Frame Guide.
5
Install the new style Right Transfer Guide. Align tension spring in groove
underneath the Transfer Corona Assembly [1].
10.02
522
6
Reinstall the Right Transfer Frame Guide mounting screw to secure in
place.
7
Reinstall the Toner and PC Drum Cartridges
8
Close the Top Cover.
9
To ensure proper operation, print test page by momentarily depressing the
blue button located on the Operator Panel.
Date:
4026 (Optra E)
5/19/97
“Cat’s Eye” Problem
The “cat’s eye” is usually caused by a build up of adhesives on the PC drum.
The source of the adhesive is the end of the paper ream. The newer Optra E
DC’s (with the yellow dot) have the wiper blade to remove the adhesive residue.
A second cause of a “cat’s eye” has been identified. The mechanism that
causes it is handling the DC. Charge builds up on the rear shutter of the DC and
when the cartridge is removed the shutter can be squeezed close enough to
the DC to cause an arc. The arc destroys a small amount of the DC coating and
creates a hole. After printing for a while, toner accumulates in the hold and
causes a “cat’s eye”. The wiper blade will not fix this, so it should be easy to
identify.
Date:
10.02
1/9/97
523
4026 (Optra E)
Label printing
The Optra E Laser Printer Family supports occasional printing on paper labels.
Occasional usage is defined as less than 3% of the total number of pages
printed. Of the remaining usage, a minimum of 88% is intended for Xerographic
or Office Papers with up to 9% of the remaining usage distributed among
envelopes, heavy papers, transparencies or additional office papers.
When printing on paper labels refer to the following guidelines to avoid damage
to the printer:
• The labels should be able to withstand a temperature of 190 Centigrade
(374 Fahrenheit) and force of 25psi for one second, without sheet
separation, discoloring, melting, offsetting or releasing hazardous
emissions.
• Labels with an acrylic-based adhesives are preferred.
• Adhesives must not extend to within 1mm (0.040in.) of the edge of the
label, between die-cuts of the label, or come in contact with any part of the
printer.
• Use full label sheets. Partial sheets (with exposed areas due to missing
labels) may result in jams or damage to the printer.
• Print no more than 10 labels at one time.
• After printing labels, sufficient amounts of xerographic or bond paper
should be feed to maintain the intended occasional usage percentage.
• Do not use label sheets with slick backing material.
• Do not print within 1mm of the die-cut.
10.02
524
4027-04W
Transfer Roll FRU
The Transfer Roll FRU (P/N 11A7479) is now available for the 4027-04W.
Instructions for removing and reinstalling the transfer roll are not included in the
service manual, but are included in the FRU itself.
Date:
10.02
2/5/97
525
4039 10P
Operator Panel Changes
There are two new operator panels for the 4039 which are the same color as
the printer covers, and are similar to the Optra operator panel. There are no
functional differences between the older style panel and the newer ones.
FRU P/N 1381017 (dark gray, square styled) will be replaced with (subbed to)
P/N 1381976, which is dimensionally equivalent. Some customers may have
space limitations because they use desk niches and kiosks. Most 4039 10P
printers manufactured beginning third quarter, 1996 use operator panel FRU
1381857 (resembles the Optra printer), however, this operator panel is
approximately 17mm longer front to rear.
In summary:
• P/N 1381017 becomes obsolete, replaced with 1381976 (similar to the
Optra panel, with trim bezel).
• P/N 1381857 (similar to Optra panel, without trim bezel) is approximately
17mm longer front to rear.
Initial reasons for the panel change were to make the 4039 10P compatible with
the 4049 (Optra) electronics and reduce inventory costs. Engineering changes
included a minor cable change. All FRU part numbers listed above are
functionally equivalent.
Date:
10.02
1/31/97
526
4039 10P
Covers Available For All Models
A complete set of covers is available for both the short and tall versions of all
models of the 4039 LaserPrinter. The tall cover set contains both versions of
the Right Cover Door. Servicers who have numerous broken cover parts and/or
customers with unique cover colors (which may no longer be available) may
order these entire cover sets.
Logos are not included, however, “Pop-in” logos are available separately.
Date:
4039 10P
11/12/96
ESD Strap on Output Deflector and Paper Jams
The ESD strap can interfere with the output deflector rotation, causing a paper
jam. An ESD strap is riveted on the left side of the output deflector. During
factory assembly this terminal is positioned approximately 30 degrees to the
horizontal. During service, it is possible for the terminal to become rotated to a
completely horizontal position (to the left), causing a potential interference with
the mounting bracket on the cover. This prevents the output defector from fully
rotating to the “front” output detent position. This can cause paper jams.
Servicers should take care to position the ESD cable to prevent this condition
and to make sure the output deflector can rotate freely.
Date:
10.02
7/30/96
527
4039 (Early
Models)
New Flash Memory SIMMS in Older Style 4039 Laser Printers
Flash Memory SIMMs were redesigned in late 1995, and older style SIMMs
and the newer style SIMMs were available under the same part number
(1328585). The newer style Flash memory SIMMs are designed for the 4049
(Optra) Laser Printers and the 4039 Plus Laser Printers. Older models of the
4039 Laser Printer (base code less than 20.09) may display the following
symptoms:
• Printer may hang while formatting Flash
• Format Flash item does not appear in the Test Menu
• Directory of flash contents reveals zero bytes on a SIMM known to have
saved files.
The best solution in most cases is to have the customer order the older style of
2M SIMM (P/N 1364922). However, if the customer switches the flash SIMM
between Optra or 4039 plus models and any older models, have the customer
upgrade the code of the older models to plus level (base code greater or equal
to 20.09).
Note: Older (base code less than 20.09) 4039 printers can only address 2M of
Flash memory.
Date:
10.02
5/3/96
528
4039 10P
Heavy Card Stock - Fuse Grade
Symptom
Due to thickness of heavy card stock the fuse grade on this type application
media might be degraded to the point of being unacceptable to the customer.
The print appears light and will most likely have voids in the characters.
Problem Isolation Aids
Follow all normal diagnostic procedures. Check all operator panel settings to
assure the printer is properly setup to print on card stock media. This may
require changing some settings to another paper type, such as using the
‘Labels’ setting instead of ‘Normal’ setting.
Be sure the card stock meets the recommendations for usage in the
LaserPrinter by consulting the Lexmark Card Stock and Label Guide for
LaserPrinters (P/N 1043935).
Fix
Install fuser High Temperature Thermister (P/N1381826) FRU. This will allow
the fuser to reach a higher temperature and in turn produce a higher fuse grade
for the heavy card stock.
Note: Use of this High Temp Thermister should only be made as a last resort
attempt to make the fuse grade/print quality on heavy card stock acceptable to
the user.
10.02
529
This thermister should not be used on those machines where only occasional
use of such media is required. Due to the increased running temperature of the
fuser, other problems with paper curl, letterhead melting and etc. may occur.
Date:
4039 10P
9/95
Front Exit Deflector Micro Switch
The front exit deflector micro switch that mounts to the inside front cover is
hardwired to the Fuser/Sensor cable FRU 1328401 located in the 4039 parts
catalog Fuser Assembly Index 14. The micro switch is opened or closed by
moving the output deflector lever up or down. The switch is installed on all 4039
models with the exception of the 4039 12C but is only required if a duplex unit
is attached.
Order P/N 1381537 which includes the micro switch, a cable tie, cable
assembly and instructions.
Date:
10.02
9/95
530
4039 10P
Paper Feed Part Numbers
4039 Model 10P printers can contain either a paper pick torquer motor or paper
pick magnet assembly. 4039 10P printers with a paper pick magnet assembly
can be identified by a information label located on the inside right cover. 403910P printers with a paper pick magnet assembly installed use the following
parts as listed for models 10R/12R/12C/12L and 16L in the 4039 Service
Manual (SA40-0837-00).
Description
Part Number
Paper Pick Magnet Assembly
1383433
D-roll shaft with gear
1328454
Gear advance leaf spring
1383316
IMPORTANT: It is NOT recommended to interchange a paper pick torquer
motor with a paper pick magnet assembly on 4039 10P printers.
Date:
10.02
3/95
531
4039 10P
New Operator Panel
New 4039-10P operator panels retain all the functions of the older style, but
have a new look (similar to the Optra Laser Printer). The new style replacement
operator panel part number is P/N 1381857. The older style operation panel,
P/N 1381017, continues to be available until existing inventories are depleted,
at which time the newer style will be substituted. The two operator panels are
interchangeable.
Note: See “Operator Panel Changes” on page 421 for additional information
relating to 4039 10P operator panel FRUs.
Date:
10.02
4/10/96
532
4040 (Optra N) All
Models
New FRU for Paper Deck (Green) Limit Latches
New FRU available for Optra N, Paper Deck (4040). The limit latch (green
plastic) has been removed from parts packet 11A8646 and is being made
available separately. A quantity of 3 is used on the paper deck drawer, often lost
or broken during service.
New FRU P/N11B4288 - Limit Latches
Date:
4040 (Optra N)
10/28/99
Part Numbers for the Connector cable (Optra N, 240, 245)
The field replacement (FRU) part number is 11D0305. This is the short
connecting cable from the 2,000 sheet paper deck option to the base printer
available through Lexmark Parts Center.
Date:
10.02
9/17/96
533
4040 (Optra N)
939 Error on the Optra N
The “riser” which plugs into J5 on the Controller Card (assembly 19, item 2 of
the service manual dated 3/96) to connect the options could be reversed. The
J5 may be loose or poorly seated. If a 939 error appears or the riser has been
installed incorrectly, try turning the riser around 180 degrees or upside down.
This riser has a rectangular keyway on the side (on top). When viewed from
above, it should look exactly like the riser soldered into the adjacent position J6.
Unfortunately, there is no keyway on the bottom to prevent this missconnection.
Troubleshooting a 939 error message with the 3/96 service manual incorrectly
lead a technician to the system board (assembly 4, item 9). This should be
corrected in subsequent Optra N Service Manuals.
Date:
4040 (Optra N)
8/21/96
Optra N maintenance Kit Contents
Fuser, transfer roll, and 6 paper feed rollers (2 for tray 1, 2 for tray 2, and 2 for
optional paper deck).
Date:
10.02
6/5/96
534
4044-001
(Optra E310)
Removing the Print Cartridge Fuse Contact Assembly
Early-level Optra E310 printers had a Print Cartridge Fuse Contact Assembly,
P/N 12G0055 (FRU P/N was referenced in Optra E310 Service Manual,
P/N12A2195, 03/99). This contact assembly was unused in these early
machines and later level machines had the contact assembly removed as well
as the connector CN404 on the interconnect board. When the interconnect
board is replaced on early machines, a servicer needs to remove and discard
the contact assembly as well, but leave the plastic contact cover mount in place.
The FRU P/N and referenced picture have been removed in later revisions of
the service manual.
Date:
10.02
5/2/00
535
4045 (Optra M410/
Optra M412)
Thermal Fuse Replacement Field Change
Affected Machines and Conditions
Affected Machines
Affected Serial Number Range
OptraTM M410 (LV)
Below 2543448
Optra M410 (HV)
Below 4557346
Optra M412 (LV)
Below 3035249
Optra M412 (HV)
Below 5028801
General Information
Optra M410 and M412 printers within the designated serial range may
experience a shutdown and service error code 921, Fuser Error, caused by a
blown Thermal Fuse.
Corrective Action
Manufacturing: All printers shipped since approximately March, 2001 contain
an improved Thermal Fuse which is not subject to failure. All new Fuser
Assembly or Thermal Fuse FRUs shipped later than March 2001 are not
subject to failure.
Field Failures: Order and install a new Thermal Fuse (FRU PN 12G3980). For
further information, see “Thermal Fuse (TCO) Replacement” on page 537
(4/03/01).
10.02
536
Administrative Notes, Other Information
Lexmark will extend warranty coverage through a Special Program for failures
of the Thermal Fuse only on machines within the designated serial number
range until December 31, 2002. Customers should not be charged for Thermal
Fuse replacement on machines which meet the eligibility requirements in this
Service Bulletin.
Warranty claims from Lexmark Authorized Servicers will be honored for repairs
of this defect on eligible machines through December 31, 2002. The labor
reimbursement rate for this Special Program is $66.00 per incident. The Parts
Exchange/ Warranty Reimbursement Form (PE/ WRF) must be properly
completed and submitted following the existing Lexmark warranty claims
reimbursement process. The PE/ WRF must include the following information
in addition to that required for normal Lexmark call activity reporting
procedures.
PE/WRF Field
Information Required
Warranty Transaction Code
OF (Special Programs)
Special Instructions/Comments
FCN010601
Vendor Part Number
12G3980 (Thermal Fuse FRU Part Number)
10.02
537
4045 (Optra M410/
Optra M412)
Thermal Fuse (TCO) Replacement
There is a possibility of the Thermal Fuse on an Optra M410/M412 printer
opening prematurely, causing a 921 fuser error. In the event that a printer
requires service, the technician may need to replace the thermal fuse, P/N
12G3980. Conditions for replacement (all three must be present at the same
time):
• If the serial number is below, AND:
M410 110V (LV)
2543448
M410 220V (HV)
4557346
M412 110V (LV)
3035249
M412 220V (HV)
5028801
• Repair action does not involve fuser replacement (see new part numbers
below) AND,
• The fuser is not marked with an “F” on the temperature label (see circled
on label below).
Some machines may also be marked with the Product Name and voltage.
10.02
538
Fuser Assembly Part Numbers
M410 Fuser Asm. 115V
12G3982
12G3983
12G3984
12G3985
To replace the Thermal Fuse:
1
Remove Fuser Assembly and place with metal brackets toward operator.
2
Push gear-side bracket slightly outward and remove paper guides by
pulling to opposite side and out.
3
Rotate fuser with red roller pointed upward. Remove two Thermal Fuse
Screws and Fuse.
WARNING: Do not handle the hot roll. If scratched, it will need replaced.)
4
Install new Thermal Fuse using the two screws contained in the new
thermal fuse FRU.
5
Re-insert paper guides and re-install fuser assembly.
6
IMPORTANT!: After replacing the thermal fuse, mark the fuser with an “F”
on the yellow temperature label (see example above).
Date:
10.02
4/3/01
539
4045
(Optra M410)
In the Optra M410 Service Manual, an incorrect part number is listed within the
parts catalog section. Part number 12G0273 on page 6-31 (Asm-index: 12-25)
should be 12G0442. The 12G0273 part number should not be used.
This will be changed in the next revision of the service manual.
Date:
10.02
11/11/99
540
4045
(Optra M410)
Part Number Correction
The Optra M410 Service Manual lists the part numbers 99A1780 through
99A1784 in the Parts Catalog, Assembly 15: Options section.
The part numbers are incorrect for the descriptions. Below are the correct part
numbers with their corresponding descriptions.
Note: The 99A178x numbers are being used in the Optra T series printers but
as different parts.
Incorrect P/N
Correct P/N
Description
99A1780
99A1683
Optra Forms 2MB Flash SIMM
99A1781
99A1684
99A1782
99A1685
99A1783
99A1686
99A1784
99A1774
16MB Flash
Date:
10.02
9/21/99
541
4046-001 (Optra K
1220)
The part drawn on page 6-14 of the service manual that has no reference
number (pictured below and highlighted in blue) should be labeled as
Reference 6-14 “Front Paper Guide”, P/N 12A4048.
The part number that appears in the service manual as Reference 6-14 on
page 6-15,”11A4282 - Guide, Paper, Front” is incorrect and should not be used.
Note: This is an update to the service manual only and not a modification to the
part itself. The existing part has not changed.
Date:
10.02
10/14/99
542
4046-001 (Optra K
1220)
Corrected Guide Roller Part Number
The part number listed in the Optra K 1220 Service Manual for the Guide Roller
is incorrect. The part number for the Guide Roller should read 11A4314, but is
listed as 11A4307 (page 6-19). 11A4307 is the part number for the Paper
Present Sensor Lever (page 6-7).
Date:
4046-001 (Optra K
1220)
6/15/98
Paperfeed Motor P/N
An incorrect part number and description was listed in the Optra K 1220
Service Manual for the Reference Item 6-16 in Assembly 6: “Input Paper Feed”
in the Parts Catalog of the Optra K 1220 Service Manual. The incorrect part
number and description listed is 11A4343 and “Motor, Pick”. The correct part
number and description is 12A4047 and “Motor, Paperfeed”.
Part Number 11A4343 is the correct part number for the Motor, Pick in
Assembly 4: “Frame, Left Side”.
Date:
10.02
6/15/98
543
4046-001 (Optra K
1220)
920 Fuser Error Service Check
A 920 Fuser Error code for the Optra K 1220 may be a result of a defective or
disconnected Process Cooling Fan. In the case of a 920 Fuser Error code, it is
recommended that the servicer also check the Process Fan as outlined in the
Process Fan Service Check.
Date:
10.02
6/15/98
544
4049 (Optra) and
4039 10P
Fuser Lamp
Orienting the colored end of the Fuser Lamp away from the gear end places the
filament in a more centered position in the paper path. Otherwise, the filament
is not symmetric to the paper path and may cause an imbalance of heat
distribution on the Hot Roll and possibly lead to a shorter Fuser life.
Date:
4049 (Optra) and
4039 10P
11/11/96
Fuser FRUs
Fuser FRUs now include a package of multi-colored molded bail handles.
Certain machines have uniquely colored levers and handles and the servicer
may select the desired colored handle at the time of installation.
Date:
10.02
5/3/96
545
4049 (Optra) and
4039 10P
Maintenance Kits for Network Laser Printers
Product
Maintenance Kit Part Number
Optra Rx Lx Lxi
69G5249
Optra R / L
69G5257
4039-12R / 12L / 12R+ / 12L+
1325531
4039-16L / 16L+
1329140
4039-12C
1325949
There are no maintenance kits available for the following products:
IBM 4019/4019E
IBM 4029 5E / 6A / 6P / 10 / 10A / 10L / 10P
Lexmark WinWriter 400 (4047-05W)
Lexmark WinWriter 600 (4035-05W)
Lexmark ValueWriter 200 (4037 05E / S01)
Lexmark ValueWriter 600 (4047-05E)
IBM 4039-10R / 10D / 10R+
Lexmark 4039-10P
Optra plus models
Maintenance kits include the Fuser Assembly, Transfer Roller, D-Roller, and
Lower Redrive Shaft.
Date:
10.02
4/10/96
546
Authorized Servicer Use Only
4049 (Optra) and
4039 10P
Push-On Clip Terminal Removed from the LVPS Grounding Wires
The star ring terminal on the LVPS end of the grounding wire replaces the old
push-on clip terminal (similar to the terminal of the frame end). Normal tool
wear in the production of the push-on clip “teeth” occasionally resulted in
reduced terminal holding and grounding capability for the previous push-on clip
connector.
Install the braided cable points in the 2 o’clock position using the lower outer
defector mounting screw. Part numbers 1381669 and 1383313 contain
installation instructions for this grounding strap.
Date:
10.02
4/16/96
547
4049 (Optra) or
4039 10P
Printhead Shroud Repair when the Toner Cartridge Interlock Spring
Mounting Post is Removed
A repair kit P/N 1381951 is available which allows servicers to repair the
printhead shroud without requiring removal of the printhead. The kit consists of
the interlock pin, spring shoulder screw, washer, lock washer, nut and
installation instructions.
When the plastic mounting post is broken, a core pin hole remains. The
shoulder screw is inserted through this hole from the bottom (providing the
replacement mounting post). The shoulder screw is retained through the
shroud by first placing the backup washer over the threaded shaft, then
installing the lock washer and securing with the nut. The interlock sprint and pin
attache to the shoulder screw’s mounting post as before.
P/N 1381951 is available as a warranty part. Removal and replacement of the
entire printhead shroud (P/N 1382431) may be eliminated and, therefore, no
readjustment for printhead skew should be required and service time reduced.
Date:
10.02
6/5/96
548
4049 (Optra) or
Other Laser
Printers
Design Change in Gear 9 of the Paperfeed Gear Train
Gear 9 of the Paperfeed Gear Train has been changed to avoid breakage when
excessive forces are encountered. Field orders for previous part numbers
automatically are substituted to the new part numbers.
Products
Part Name
Part Number
Replaces Old Part
Number
4049, 4039, 4029, 4019
Gear #9
1381881
New
4039-10P
Gear #9
1381881
1408259
4039, 4029, 4019
Parts Packet
1381884
1383318
4049
Gear Kit
1381886
1381665
4039 (All with Magnet)
Rail Assembly
1381950
1328385
Installation instructions are included.
Date:
10.02
4/22
549
4049 (Optra) and
4039 10P
939 Service Error
The 939 error on 4049-XXX is a Rip to Engine bus failure. The 29K processor
cannot communicate with the engine processor. This error could be a bad
connection between the two boards. Replace the RIP board before replacing
the engine board.
On a 4039-1XX, the 939 error signals the same failure, but the single engine
board should be replaced.
939 - 959 error codes are reserved for system board errors. These error codes
are not listed in the service manuals.
Date:
4049 (Optra)
2/19/96
Tray for Non-Standard Size Papers
A 200-sheet (500 gram spring heavy duty) paper tray is available for all Optra
Series printers which support 200-sheet trays. The tray is equipped with
adjustable width and length micro-ratchet paper guide detents (1mm
increments) allowing users to customize the paper tray settings to feed unique
size papers ranging from 8.5 inch by 11 inch (standard U.S.) to 3 inch by 6 inch
(minimum) paper size.
Type
Description
Part Number
Feature
200-sheet Paper Tray for Unique paper sizes
13A0369
FRU
FRU for 200-sheet Paper Tray for Unique paper sizes
1381979
10.02
550
The Tray and FRU are ONLY available as completed assemblies. Supported
paper types and weights must continue to be used.
Date:
4049 (Optra)
4/17/97
Top Cover Part Numbers
A short and tall Top Cover is available for Optra Laser Printers (4049). Both
covers come with the “Lexmark Laser Printer, Ready & Return” graphics printed
on them, including a set of “burnish on” logo decals (with servicer installation
instructions) for all models of the short and tall machines. This eliminates the
need to stock multiple top covers having factory printed logos. A set of logo
decals is also available.
Fru P/N
Description
1381974
4049 Optra Top Cover, short, including logo decals
1381975
4049 Optra Top Cover, tall, including logo decals
1381978
4949 Optra logo decals, tall and short top covers
Date:
10.02
10/11/96
551
4049 (Optra)
Toner Cartridge and Fuser Wiper Use in Optra Printers
If customers are using Optra Laser Printers (at code level 43.74 or higher)
dedicated to label use, they are encouraged to use the 4039 print cartridge.
Print Cartridge Name
Capacity
Number of Wipers
Included
Part Number
Long Life 4039
7K @ 5% usage
1
1380850
Marathon Performance 4039
12.8K @ 5% usage
2
1380950
The fuser wipers included with the 4039 cartridges should be used. If additional
fuser wipers are needed, order part number 1380785. This particular fuser
wiper has oil in the pad which lubricates the fuser and prolongs fuser assembly
life when used with the 4039 print cartridges. This wiper also reduces toner
buildup on some labels and therefore produces improved print quality.
Lexmark does not recommend using the 4039 fuser wipers with the Optra print
cartridges (Diamond Fine toner) when duplexing. The 4039 print cartridges are
not recommended for general use in Optra Printers since they cannot produce
the 1200 dpi quality needed for graphics and gray scaling, but they do provide
darker print. When 1200 dpi is called for or the Optra printer is being used for
more than one media (for example, 20# paper), then the Optra (Diamond Fine)
toner cartridge with the dry wiper is appropriate.
Date:
10.02
7/4/96
552
4049 (Optra)
ST MICR machine unique models
Unique model numbers have been released for Source Technologies
Incorporated (ST) machines employing MICR (magnetic ink character
recognition) technology.
Standard Machine
(after 4/29/96)
ST MICR Machine
ST MICR machine
(after 4/29/96)
4049-LMO
4049-LSO
4049-LSO *
4049-LM1 (LFO *)
4049-LS1
4049-LS2 *
4049-RA0 (RB1 *)
4049-RS0
4049-RS2 *
4049-RB0 (RB1 *)
4049-RS1
4049-RS3 *
4049-
(RN0 *)
4049-RS4 *
* The new model number(s) in the 4/29/96 announcement indicate these machines were
included in the upgrade from 2M to 4M memory as standard equipment. Model LS0 remained
unchanged. Model RN0 is new.
10.02
553
These machines display both the Lexmark and Source Technologies (ST) logos
and unique ST parts will have the following service information label attached:
Unique Part
Identification Label
SIMM Card
Part # ST-M SIMM contains code developed by Source
Technologies (STI). For replacement part, warranty and
service contact STI (800) 922-8501
Engine Card
Part # ST-M ENGINE contains code developed by Source
Technologies (STI). For replacement part, warranty and
service contact STI (800) 922-8510.
Toner Sensor
Part # ST-1632 Toner is supplied by Source Technologies
(STI). For replacement part, warranty and service contact STI
(800) 922-8510.
EMC Shield
NOTICE TO SERVICER
The parts listed below are provided or modified by Source
Technologies (STI):
ST-M SIMM
MICR SIMM card
ST-M ENGINE
MICR Engine card
ST-1632 Toner
MICR toner sensor
ST-400039/49
MICR toner cartridge
For replacement parts, warranty and service contact STI
(800) 922-8510.
10.02
554
A limited number of 4039 and 4049 STI MICR machines were manufactured
which DO NOT have the unique model number(s) or service information labels
shown above. These are identified by having the dual logos (as described
above) and utilize the same unique parts (as described above).
Date:
10.02
5/12/95
555
4059 (Optra S)
Series
Replacing the Deflector Assembly (Redrive) to prevent paper jams.
Note: This failure should only be found on Optra S 12/16/18ppm machines that
have a duplexer.
The retaining ring (see photo below) located on the redrive actuator arm may
work loose. This has resulted in paper jam failures in “short machines”. In order
to ensure that the retaining ring stays in place, you must replace the Deflector
Assembly (Redrive), INNER 250, P/N 99A0091.
Product Engineering found the lower molded post on the redrives in question
was undersized. This was determined to be a process problem and has since
been fixed at the vendor. The serial number ranges for each control code listed
below are suspect:
10.02
556
Minimum SN
Maximum SN
ControlCode
11DKP15
11DYR12
1A
11DBX26
11DZM52
1B
11DPB43
11DXM02
1C
11DCC44
11DVA02
1D
Date:
10.02
03/23/99
557
4059 (Optra S)
Series
Printer Causes Circuit Breaker to Trip and/or Printer Becomes
Electrically ‘Hot’
Due to a change in the manufacturing process, some fuser hot rolls (Asm-Index
11-7, all models) produced between approximately September 28 - November
13, 1998 may contain small quantities of debris (metal shavings) inside the
core. Lexmark has attempted to capture all suspect components. Should this
debris become trapped between the fuser lamp base, lamp socket and the
fuser frame, line voltage could be applied to the fuser frame and machine. This
could result in tripping the customers machine power circuit breaker and/or
other machine malfunctions.
As long as the machine is operated with all internal grounding in place and the
3-wire power cord is connected to a properly grounded electrical outlet, there
should be no risk of customer exposure. Servicers, however, should always
follow recommended safety practices when working in the area of the fuser or
other areas of the machine potentially exposed to line voltage.
• Machine power switch should be turned OFF and the power cord
UNPLUGGED from the power source PRIOR to working in these areas.
• All machine grounds must be properly connected before reapplying power
to the machine.
• The 3-wire power cord must be intact and the power receptacle must be
properly grounded to ensure complete protection.
10.02
558
Corrective Action
Actions have been taken to correct the manufacturing process, to inspect fuser
hot rolls (both new build and FRUs) and to capture all affected FRUs for this
condition. When replacing the hot roll or lamp, servicers should inspect the hot
roll and carefully remove any evidence of debris. Avoid damaging the black
coating on the inside of the roll. Check to make sure that no debris is pushed
out when inserting the lamp into the housing. Always follow recommended
safety practices when working in the area of the fuser or other areas of the
machine potentially exposed to line voltage.
Date:
10.02
11/25/98
559
4059 (Optra S)
Series
Power Takeoff ‘Bevel’ Drive Gear Available Separately
Engineering has released the ‘bevel’ drive gear, formerly only available as part
of the gearbox assembly for Optra S, 4059. This bevel drive gear fits onto the
Power Takeoff Shaft.
It may be removed from the assembly by pushing up on the bevel gear itself,
and “popping” it out of its bearing journals. The gearbox need not be removed
from the printer and the replacement gear is installed in the reverse manner.
Engineering cautions servicers that even a scratch or small dent damaging the
bevel gear teeth may result, causing a “ticking or clicking” sound when the
machine is operated, although this should have no effect on print quality.
Should a repetitive print quality defect be found on the printed page, it is
recommended the entire gearbox be replaced.
Name/Description
Gear, Bevel Drive (for Power Takeoff Shaft)
Date:
10.02
11/23/98
FRU P/N
99A0954
560
4059 (Optra S)
Series
RPQ Label Stacker Output Trays
Listed below are the FRU equivalents for RPQ Label output tray features:
RPQ Feature P/N
FRU P/N
Name/Description
43H5694
99A0863
Hopper Integrated Label Letter
43H5695
99A0864
Hopper Letter/Legal Label Stacker
43H5695
99A0865
Hopper Legal Label Stacker
Date:
4059 (Optra S)
Series
10/18/98
Special Media Tray (250 Sheet) for Optra S
A Special Media Tray (Feature, 250 sheet) is available for Optra S. Feature P/N
43H5410 provides a special media tray and diskette containing a machine code
level upgrade to 56.76 code, which includes double pick (if required). This FRU
for the RPQ, Special Media Tray has additional paper pick “dams” instead of the
standard 3.
Feature P/N
FRU P/N
Name/Description
43H5410
99A0911
Special Media Tray (RPQ)
Date:
10.02
10/18/98
561
4059 (Optra S)
Series
Shipping Cartridges for an Optra S
Two FRUs have been created which provide one (1) and (2) shipping
cartridges. The shipping cartridge (which is devoid of toner, OPC and other
parts) may be installed in the printer during shipping or extensive
transportation, if the normal print cartridge has been removed. The shipping
cartridge helps protect the printer during shipment. It is recommended for use
by self servicers (large companies, etc.) which may be operating their own
repair depots. Lexmark printers sold without a tone cartridge are shipped from
the factory with a shipping cartridge installed.
Name/Description
FRU P/N
Shipping cartridge (content: 1)
99A0909
Shipping cartridges (contents: 2)
99A0910
Date:
10.02
10/18/98
562
4059 (Optra S
Series)
Change to Right Side Covers — the Molded Bosses Above the
Hand-Hold Cutout
In 4th quarter, 1997 the right side covers (and right side frame) of the Optra S
printer were changed. Cover engagement bosses were added above the
bottom hand-hold cutout. These bosses engage a hole in the right side frame,
providing improved cover mounting.
Early production printers do not have the hole in the side frame to receive these
bosses, and, therefore, the bosses may simply be cut off (flush) and removed
to eliminate interference. Cover mounting is adequate without them. The cover
FRUs affected are P/N 99A0011 (1250, 1650) and P/N 99A0012 (2450).
Date:
10.02
4/24/98
563
4059 (Optra S
Series)
Kiosk Solution for the Optra S Laser Printer Family
Lexmark International, Inc. has announced a Kiosk Adapter Solution for the
Optra S family of laser printers. This option expands the application versatility
of Optra S printers to facilitate unattended kiosk printing. Please review the
Lexmark Product announcement for the Optra S Kiosk Adapter dated
December 1, 1997 for marketing and other general information regarding this
product.
Brief Product Overview
Features of the Optra S Kiosk Adapter include:
•
•
•
•
Quickly installs on any Optra S printer
No cabling or external power requirement
No physical change to standard Optra S printer
Easy access to printer consumables
Warranty and Service
Warranty
The Optra S Kiosk Adapter carries the same warranty coverage as the Optra S
printer to which it is attached. For full warranty information on the Optra S
printers, refer to the Warranty Section of the Optra S User's Guide.
10.02
564
Service
Service parts information for the Kiosk Adapter was included within the revision
of the Optra S Service Manual in the Parts Catalog section, Assembly 22. This
manual is available from the Lexmark Parts Center (1-800-553-9727), P/N
43H1798, dated 11/97 or later.
Date:
10.02
12/11/97
565
4077-20X (Lexmark
2050 Color
Jetprinter)
Paper Guide Field Change Notice-Revised
Field Change Notice # 971201
Affected Machine Types/Models
Affected Machine Models
Machine Types
Affected Serial Number
Ranges (Approximate)
Lexmark 2050 Color Jetprinter
4077-201
11C0000 thru 11CR000
4077-202
11C0000 thru 11W9999
1115851 thru 1121500
4077-203
11X0000 thru 11CR000
4077-204
1120500 thru 1121500
General Information
The Paper Guide (Paper Feed - Reference 1) in CJP2050 printers produced
between October 1996 and January 1997 within the designated serial range
may experience breakage of the plastic tabs which mount the Torsion Springs.
Failure of the Paper Guide may result in paper jam errors, damage to the
encoder strip or both.
10.02
566
Corrective Action
Manufacturing: All product shipped since approximately March, 1997 contains
an improved paper guide which is not subject to breakage. All Paper Guide
Field Replacement Units (FRU PN 69G4074 without Small Feed Roll Shaft
support boss and FRU PN 70G3039 with the Small Feed Roll support boss)
include paper guides manufactured to the new specifications.
Field Failures: Order and install the “Field Fix” B/M (P/N 1425547) which
includes three Pins, three Metal Clips, three Torsion Springs and instructions.
This B/M can be used to repair a broken Paper Guide in approximately 15
minutes. Replacement of the paper guide assembly is not necessary. Insertion
Tool FRU P/N 1425546 is required to install the clips. It is not included in the
“Field Fix” B/M and must be ordered separately.
Description
Part Number
“Field Fix” B/M (requires Insertion Tool, order separately)
1425547
Insertion Tool
1425546
Additional References
Lexmark Service Support Guide (this document), Inkjet Printer Service Tips,
4077 Paper Guide Problem (6/97).
10.02
567
Administrative Notes, Other Information
Lexmark will extend warranty coverage through a Special Program for failures
of the Paper Guide only on machines within the designated serial number
range until June 30, 1999. Customers should not be charged for repair of a
broken paper guide on machines which meet the eligibility requirements in this
Service Bulletin.
Warranty claims from Lexmark Authorized Servicers will be honored for repairs
of this defect on eligible machines through June 30, 1999. The labor
reimbursement rate for this Special Program is $25.00 per incident.
The Parts Exchange/Warranty Reimbursement Form (PE/WRF) must be
properly completed and submitted following the existing Lexmark warranty
claims reimbursement process. The PE/WRF must include the following
information in addition to that required for normal Lexmark call activity reporting
procedures.
PE/WRF Field
Information Required
Warranty Transaction Code
0F (Special Programs)
Special Instructions/Comments
FCN971201
Vendor Part #
PN 1425547 (Field Fix B/M)
Date:
10.02
1/12/99, 1/20/98
568
4077-20X (Lexmark
2050 Color
Jetprinter)
4077 Paper Guide Problem
Lexmark has identified a potential problem with some 4077 Paper Guides. You
may experience breakage of the plastic tabs which mount the Torsion Springs.
The following actions have been taken:
• The Paper Guide B/M’s for the 4077-20X have been redefined to include a
“Known Good” Paper Guide, EOF Flag, EOF Flag Spring, Installation
Instructions, and three Torsion Springs (P/N 69G4074 without Small Feed
Roll Shaft Support Boss and P/N 70G3039 with Feed Roll Support tab).
• A new “Field Fix” B/M has been created and includes three Pins, three
Metal Clips, Installation Instructions, and three Torsion Springs (P/N
1425547). This B/M can be used to repair a broken Paper Guide. The use
of the Field Fix B/M will greatly reduce the amount of parts required, and
the time to repair the problem because minimal disassembly of the printer
is required to install the repair clips.
• A new tool (P/N 1425546) has been made available which should be used
to install the clips included in the “Field Fix” B/M. The tools must be ordered
separately. It is not included in the “Field Fix” B/M.
The part numbers of the existing B/M’s will be sub’ed to the new numbers.
69G4128 will be sub’ed by 69G4074. 13A1192 will be sub’ed by 70G3039. All
stock of the old part numbers should be scrapped.
10.02
569
In summary, the Part Numbers of the B/M’s are as follows:
Description
New P/N
Old - Scrap
4077 Paper Guide B/M without Feed Roll Support tab
69G4074
69G4128
4077 Paper Guide B/M with Feed Roll Support tab
70G3039
13A1192
Paper Guide Field Fix B/M
1425547
Clip insertion Tool, not included and must be ordered
separately
1425546
Note: Some printers that have the defective Paper Guide may also exhibit
damage to the encoder strip. Be sure to check the Encoder Strip when installing
the “Field Fix” B/M or replacing any defective Paper Guide
Date:
10.02
6/9/97
570
4077-20X and 4090
Paper Guide Change to Prevent Occasional Paper Buckling at
Bottom of Page — Revised
Applies to the following models: 4077-201 (Lexmark 2050 Color Jetprinter), and
4090-001 (Lexmark 2050 Color Jetprinter).
Install the new style paper guide and matching small feed roll assembly. The
new small feed roll FRU contains a cut-out in the paper flap to allow the boss
feature on the paper guide to contact the small feed roll shaft.
Small Feed Roll and Paper Flap
P/N
Notes
Old P/N
70G2557
Only works with old Paper Guide Asm.
New P/N
13A1280
Works with old or new Paper Guide Asm.
Paper Guide Asm.
P/N
Notes
Old P/N
69G4074
Works with old or new Small Feed Roll
New P/N
70G3039
Only works with new Small Feed Roll
The new Small Feed Roll and Paper Guide can be installed on the WinWriter
150c (4077-001). If the Paper Guide is installed, the new Small Roll must be
used. The new Small Feed Roll can be replaced by itself.
Date:
10.02
12/27/96
571
4085-001
(Lexmark J110)
J110 Field Update Procedure
This procedure has been written to assist those in the field who want to replace
J110 printheads or update printers with the highest level of confidence.
Overview:
This procedure has been divided into three sections.
• Verify purge station operation
• Flash in new Engine Code
• Install new printheads
The Purge Station Troubleshooting Instructions (see page 576) will assist in
diagnosing any problems encountered during purge station verification. This is
arranged in two sections:
• Quick repair
• Further troubleshooting tips
10.02
572
Procedures
Verify purge station operation
This operation is very simple and will verify proper maintenance for the
new printheads.
1
Turn the printer on and open the top cover. The carrier will move out to the
left side of the printer.
2
Visually inspect the condition of the purge cap station before the purge
test. Especially be aware of the amount of ink in the cap at this time (a
flashlight may help). If needed, manually move the purge cap station
towards the front of the printer by gently pulling the printhead capping
station.
3
Check that the printheads are correctly installed (or re-install them at this
time). You should use the old printheads, if possible, for this procedure (it
will run even if a PH error is displayed). Now turn the printer off.
4
Press and hold GO and SELECT while turning on the printer to enter CE
mode. Continue to press these two buttons until “INPUT TRAY TESTS” is
displayed on the OP Panel.
10.02
573
5
Press MENU > and then SELECT to run the Purge test. Visually inspect
the purge cap after running the purge test. There should be ink in the cap.
If there is no ink then the purge station is not properly working.
If the purge station is not working, then go to the “Purge Station
Troubleshooting Instructions” at the end of this document.
Figure 1: Maintenance Station Overview
10.02
574
Flash in new Engine Code
1
To obtain the CPJE1704.pjl file:
With your browser, go to http://support.lexmark.com/printerfirmware/
and enter J110engn as your authorization keycode.
2
Copy the Engine Code file into a drive and directory that you can
remember in your computer. Also be sure to start your computer with the
parallel cable already attached to the parallel port on the computer.
3
Power the printer down.
4
Press and hold MENU >, SELECT, and Return while turning the computer
on.
Hold these three buttons until “Invalid Engine Code” appears on the OP
Panel.
5
Make sure the parallel cable on your computer is connected to the printer.
6
From the DOS prompt in the correct drive and directory of the Engine Code
File in your computer, type
COPY /B CPJE1701.pjl LPT1:
and press Enter.
10.02
575
The printer will display the status of the reflash (the display is the
percentage completed).
WARNING: It is very important not to turn the printer off while this reflash
is occurring to prevent damage to the printer.
After the printer has finished the reflash procedure it continues to power up to
the ready mode. Allow the printer to complete this process. This power up
procedure takes an extra (one-time only) 40 seconds if the current set of
printheads in the machine are OK. If there is a problem with these printheads,
an error message displays on the OP Panel.
Install New Printheads
1
Remove the old printheads from the printer.
2
Remove the new printheads from the packaging materials and install them
in the printer according to the printhead installation procedures.
One thing that you will notice is an initial purge cycle with the new
printheads. This is a one-time process that only occurs with a new
printhead or ink tank and takes an additional 40 seconds.
3
When the printer displays the “Ready” prompt, this process is complete
and you can continue with any other set-up activity required for this printer
10.02
576
Purge Station Troubleshooting Instructions
Quick Repair
1
Lubricate the purge cap cam.
a
b
2
Obtain a small amount of nyogel lubricant. If some is not readily
available you will usually find some excess lubricant on two silver
carrier shafts in the printer.
Place a small amount of this lubricant on the purge cap cam. This cam
is the L-shaped projection on the left side of the purge cap.
Lubricate the purge cap lip.
Place your finger on one of the wet-wipe foam pads (see figure 1 on
page 573). Obtain some wet-wipe fluid on your finger and rub around the
inside and outside of the top of the purge cap lip.
3
Verify the purge station operation again.
10.02
577
Further troubleshooting tips (SE)
If the purge station still does not operate correctly after verification, then more
in-depth troubleshooting is required. Here are some tips on some more things
to look for:
1
Remove the printheads, fill the purge cap half full with water and run the
purge test. If the water is sucked out of the cap then the pump is working
correctly but the cap is not correctly engaging with the PH (go to step 2 of
this section). If the water is not sucked out, go to step 3.
2
Make sure that the purge cap is moving freely up and down and is not tilted
to one side. Work the cap up and down in the engaged position. Add
additional lubricant as needed. Other things to check here are gear train,
purge cap assemblies and linkages. Also inspect the purge cap lip for tears
or defects. Verify purge station operation.
3
Check to be sure that the tubing is all routed and attached correctly7. Make
sure there is no dried ink in the tubes.
4
If the pump still does not pull a vacuum, remove the rear cover:
•
•
Check all tubing for correct connection without crimping, twisting, or
blocking.
Remove pump, make sure flappers are installed correctly, tubing in
pump is correctly installed, and pump rollers are engaging correctly.
Go back to step 1 of this section.
10.02
578
These steps should be sufficient to diagnose most problems. If the pump still
does not pull a vacuum, then the vacuum pump, tubing, and/or the purge cap
station may need replacement to ensure correct purge operation.
Date:
10.02
Revised 9/9/02
579
4085-001
(Lexmark J110)
Print Quality Correction Procedures
Troubleshooting Matrix for Printing Problems
Solutions (See the procedures below)
Problem/ Error
Message
Reseat
Printhead
Wipe
Contacts
Reseat
Printhead
933 Service
Printhead
Step 1
Step 2
Step 3
934 Service
Printhead
Step 1
Step 2
Step 3
938 Thermal
System
Step 1
Step 2
Step 3
931 Service
Printhead
Step 1
Step 2
Step 3
31 Missing Tank
Step 1
Step 2
Step 3
Poor Print Quality
Step 1
Step 2
Step 3
10.02
Short
Clean
Long
Clean
Long
Clean
Clean
Nozzles
Step 4
Step 5
Step 6
Step 7
580
Reseat
Printheads
1
Open the cover and move the carrier to the center of the printer (Make sure
that the printer is powered on before the carrier is moved. Otherwise, the
carrier will pull across the maintenance caps.)
2
Lift the carrier handle, then re-latch.
Ink Tanks
1
Open the cover and move the carrier to the center of the printer. (Make
sure that the printer is powered on before cover is opened. Otherwise, the
carrier will pull across the maintenance caps.) Lift the carrier handle.
2
Remove the ink tank from the printhead that is displayed as missing on the
Op Panel.
3
Re-insert the ink tank into the printhead.
10.02
581
Wipe
Tab Circuit Contacts
1
Open the cover and slide carrier to the center of the printer.
Make sure the printer is powered on before the cover is opened.
Otherwise, the carrier will pull across the maintenance caps. Always pull
the carrier from the left side of the printer - the ink tank install position only.
2
Lift the carrier handle.
3
Remove the printhead that is showing an error on the Op Panel.
If it is unclear which printhead is the problem, remove both printheads.
4
For 933, 934, and 938 errors, or poor print quality, wipe the tab circuit of
the printhead with a damp, lint-free cloth (see Figure 1).
5
Allow the tab circuit to dry and re-insert the printhead(s).
10.02
582
Ink Tank Memory Module
Printhead Memory Module
Tab Circuit
Tab Circuit
Printhead Nozzles
Figure 1: Location of Tab Circuit, Printhead Memory Module,
Ink Tank Memory Module, and Printhead Nozzles.
10.02
583
Printhead memory module contacts
1
Open the cover and slide carrier to the center of the printer.
Make sure the printer is powered on before the cover is opened.
the carrier from the left side of the printer - the ink tank install position only.
2
Lift the carrier handle
3
Remove the printhead that is showing an error on the Op Panel.
4
For 931, 932, and 31 Missing Printhead errors, wipe the memory module
of the printhead with a damp, lint-free cloth (see Figure 1).
Be careful not to dislodge or damage the memory module by catching the
corners or edges with the cloth.
5
Allow the memory module to dry before reinserting the printhead.
Ink Tank Memory Module Contacts
1
Open the cover. The carrier should go to the left side of the printer — the
ink tank install position.
2
Remove the ink tank that is displayed as missing or defective on the Op
Panel.
3
Wipe the memory module with a damp, lint-free cloth (see figure 1).
10.02
584
Note: Only wipe the ink tank memory module with the tank out of the
printhead to avoid contaminating the printhead contacts with memory
module grease.
4
Allow the memory module to dry then re-insert into the printhead.
Short Clean
1
Press MENU> until you see the Utilities Menu.
2
Press SELECT.
3
Press MENU> until you see “Clean Printheads” on the second line of the
display.
4
Press SELECT.
“Short Clean” appears on the second line of the display.
5
Press SELECT.
6
Once the test page has finished printing the four color bars, press GO to
exit to “Ready.”
Long Clean
1
Press MENU> until you see the Utilities Menu.
2
Press SELECT.
10.02
585
3
Press MENU> until you see “Clean Printheads” on the second line of the
display.
4
Press SELECT.
5
Press MENU> until “Long Clean” appears on the second line of the display.
6
Press SELECT.
7
Once the test page has finished printing the four color bars, a “Clean
[1]?=Go/Stop” message appears on the op panel display for each bar. For
each color bar press the STOP button if the quality is satisfactory or the GO
button if the quality is not improved.
A “Long Clean” will be repeated if the GO button is pressed for any colors.
8
Press RETURN to go back to “Ready” or press STOP for all four colors.
Clean Nozzles
1
Open the top cover to move the carrier to the center of the printer.
Make sure that the printer is powered on before the cover is opened.
from the left side of the printer — the ink tank install position — only!
2
Lift the carrier handle and remove the printhead.
3
Lay a damp, lint-free cloth on a hard surface.
10.02
586
4
Hold the printhead nozzles facing down on the damp cloth for about three
seconds.
5
Slowly pull the printhead towards you across the cloth (wiping the nozzles
along the long axis). There should be a trail of ink on the cloth.
Figure 2: Cleaning Printhead Nozzles
6
Reinsert the printhead and close the top cover.
Date:
10.02
7/25/01
587
4085-001
(Lexmark J110)
938 Service Thermal System Error
Bad contact with the carrier or a failed printhead.
An update to the engine code (engine code level 17.04 and later) should reduce
the incidence of 938 errors. It is necessary to flash code whenever possible to
bring a printer up to this level. Running an earlier level of code greatly increases
the risk for 938 failures. The necessary code and flash instructions can be
acquired from the following directory:
http://support.lexmark.com/printerfirmware/ and enter the
authorization keycode J110engn.
938 Errors on the J110 can be caused by missing contacts between the carrier
and the printheads. The first thing to try when one of these errors occurs is to
reseat the printheads.
Reseating the printheads
Also, see “Print Quality Correction Procedures” on page 579.
1
Open the top cover.
2
Raise the carrier handle.
3
Remove and firmly reseat the printheads in the carrier.
4
Firmly close the carrier handle.
5
Close the top cover.
10.02
588
Cleaning the contacts
If this does not clear the error, the user should then attempt to clean the
contacts on the printhead and the pogo pins on the carrier. It is possible for ink
or dust to get on the contacts and prevent a good electrical connection.
Also, see “Print Quality Correction Procedures” on page 579.
1
Open the top cover.
2
Raise the carrier handle.
3
Remove the printheads from the printer.
4
Wipe the tab circuit on each printhead with a damp, lint-free cloth.
5
Inspect the contact pins in the carrier for bits of paper or dirt. If debris is
detected, wipe the pins with a small nylon brush, such as a toothbrush. You
can also use your index finger if it is clean and dry. Do not touch the
lubricated pogo pins.
6
Reinsert the printheads into the carrier.
7
Close the carrier handle.
8
Close the top cover.
10.02
589
Replace the printhead
If cleaning the contacts does not clear the error, it will be necessary to replace
the appropriate printhead. To determine which head it is necessary to enter
debug mode while the error is displayed.
1
With the error on the op panel, hold down the select and return buttons.
2
The display should now be in the following format:
EN aa bb cc dd 1
EN nn oo pp qq 2
where dd should be one of 01, 02, 03 or 04.
A code of 01 indicates that the black head has failed. The other three codes
indicate that one of the color heads has failed.
3
Restart the printer to get out of debug mode.
Replace the carrier
If after replacing the printhead the error still does not clear, next replace the
carrier 12G6034.
If the failure returns after some period of time, start the process again with
reseating the printheads. There is a good chance the new printheads have
failed.
Date:
10.02
Revised 9/9/02
590
4085-001
(Lexmark J110)
Print quality/deprime of mono head
Missing nozzles/apparent deprime on a brand new mono printhead. This failure
will show itself immediately upon installation and printing, even with the
extended purge that has been added in the engine code to help with deprimes.
This failure varies in severity from a few missing nozzles to an apparent
deprime.
Note: The method of recovery outlined below applies only for startup of new
mono printheads.
To Recover a new Printhead from Streaky Print
Method 1 - Time is available
1
Turn the printer on.
If this is the first time they’ve installed the head, there will be a purge that
lasts about 10 seconds, during which time, the customer will hear clicking
and moving of the carrier and maintenance station inside the printer.
2
Load media in the printer.
3
Print the desired document.
4
If print quality is not acceptable, allow the printhead to sit in the printer for
at least 12 hours.
Note: The printer can be off or on, but if it is turned off, it must be allowed
to go through its power off cycle so that the printheads will be capped
properly.
10.02
591
5
After 12 hours, print the file again.
Usually, 12 hours is sufficient. If print quality is still not acceptable, leaving
the printhead in the printer longer will gradually improve print quality. If time
is not available, proceed to the next set of recovery steps.
Note: If some time is available but not a full 12 hours, the customer should
be encouraged to allow the head to sit capped in the printer for as long as
possible before trying to print normally again. This should recover at least
some of the nozzles, possibly making print quality acceptable. Also, a small
amount of printing (<10 pages every couple of hours) during the 12 hours
should not hinder the recovery.
Method 2 - Limited time is available
1
If print quality is not acceptable, and there is no time to allow the printhead
to sit in the printer, remove the printhead from the printer.
2
Place a clean cloth (lint-free) on a hard surface, like a tabletop.
3
Add a generous amount of water, but the water should be allowed to soak
into the cloth. (Deionized water is best, if available.)
4
Place the printhead, nozzles facing down and parallel to the ground, on the
wet cloth and apply downward pressure from the top of the ink tank and
hold the nozzles against the cloth for 3-5 seconds.
10.02
592
5
Continuing to apply pressure, slowly pull the head across the cloth. Repeat
this wiping motion until there is a trail of ink on the cloth.
Note: Doing this several times will help recover the printheads.
6
After a solid trail of ink is visible on the cloth, reinsert the printhead in the
printer.
7
At the Ready prompt, send the desired file again. If print quality is still not
acceptable, repeat the wiping procedure.
8
If print quality is still not recovered, proceed to the next set of recovery
steps.
Note: Wet-wiping the printheads with non-deionized water is not desirable and
should only be done if the customer cannot allow the printhead to sit in the
printer for any length of time in order to allow slow recovery.
Method 3 - Last resort
This method should only be used if all other methods have failed and there is
an immediate requirement for the printer. This procedure has the potential to
introduce other errors if not done carefully and properly. Wetting the print
nozzles removes dried ink on the print cartridge nozzles or contacts. Wetting
the nozzles also helps to disperse dried ink and clogs within the cartridge.
1
Remove the print cartridge from the printer.
2
Turn the cartridge upside-down, such that the nozzles are visible.
10.02
593
3
Thoroughly dampen a clean, lint-free cloth with water (deionized water is
preferable, if available).
4
Gently squeeze two or three drops of water from the cloth onto the nozzles
such that all nozzles are covered with water.
5
Wait ten seconds, and then wipe the water from the nozzles with the clean
cloth.
6
If the copper-colored area around the contacts is wet, allow it to dry.
7
Reinstall the printhead.
8
Print the desired file again, and see if print quality is improved.
Note: The use of non-deionized water is not desirable and should only be used
in this manner as a last resort.
WARNING: If the contacts get wet during this process, they must be
dried before being installed into the printer. Do NOT, however, wipe the
nozzles and the contacts with the same section of cloth because ink could
smear on the contacts. Electrical damage to the printer could occur if
the contacts are contaminated with ink or if they are wet.
Date:
10.02
5/28/02
594
4092 (7000 Series
Color Jetprinter)
Correction and Additional Part Number for System Board
The description for the System Board for the 4092 inkjet printer (P/N 17B0160),
should read “W/O Code Module”. The Code Module for 4092-005 is (P/N
17B0186), this part number is not listed in the Service Manual.
System Board W/O Code Module
17B0160
Code Module for 4092-005
17B0186
Date:
4092 (7000 Series
Color Jetprinter)
11/16/98
Lock Washer Installation
Some 4092 (7000 Color Jetprinter) printers have been received for service with
loose screws on each end of the carrier guide rod. This could cause print quality
problems. To correct this problem, P/N 17B0168, a bag of 50 lock washers
(enough to repair 25 machines) have been released to the field. Effective
immediately, any 4092 printer that is received for service should have one lock
washer installed on the screw at each end of the carrier guide rod.
Date:
10.02
10/10/97
595
4093 (5700 Color
Jetprinter) and
4094 (5000 Color
Jetprinter)
ASF Right Mounting Screw Rubbing On The Printhead Carrier
A very limited number of 5000/5700 ink jet machines have experienced a
problem with the ASF right mounting screw rubbing on the printhead carrier.
This condition can be detected by hearing a clicking noise as the carrier moves
across the print area. Other symptoms may be blurred print on the right side of
the print area or in a rare case a carrier stall.
On machines experiencing this problem, a washer can be installed under the
ASF right mounting screw. A packet containing 10 washers and installation
instructions can be ordered using Lexmark P/N 12G0249.
Date:
4093 (5700 Color
Jetprinter and
4094 (5000 Color
Jetprinter)
03/19/99
Conversion Kits for 0.5mm to 1mm Carrier and System Board
To make conversion of the.5mm Carrier and System Board on the 4093/4094
easier, conversion kits containing one 1mm Carrier and one 1mm System
Board have been created.
Model
Description
Kit P/N
4093
0.5mm to 1mm Conversion Kit (1mm Carrier and 1mm System Board
13A4494
4094
0.5mm to 1mm Conversion Kit (1mm Carrier and 1mm System Board
13A4497
The individual 1mm Carrier and System Board parts are still available.
Date:
10.02
12/10/98
596
4093 (5700 Color
Jetprinter and
4094 (5000 Color
Jetprinter)
Printer Feet Parts Packet
To avoid replacing the complete bottom cover assembly on the 4093/4094
inkjet printers to replace missing rubber feet, a packet of 20 rubber feet is now
available. The part number of the packet is 12G0149.
Date:
4093 (5700 Color
Jetprinter) and
4094 (5000 Color
Jetprinter)
Cable Popping After Installing Cuff and Pad
A new field fix kit is available for the early level 4093/4094 inkjet printers that
experience the cable popping problem after having the Cuff and Pad installed.
The Printhead Cable Guide Strip, P/N 17A0493, allows the servicer to repair 5
machines and contains 5 Clips, 5 Mylar Strips and instruction sheet.
Date:
4093 (5700 Color
Jetprinter) and
4094 (5000 Color
Jetprinter)
12/02/98
6/26/98
Carrier Stall in 5700 and 5000 Color Jetprinters
Some 4093/4094 printers have experienced a “Carrier Stall: related to the
carrier cable sliding along the frame. In some cases the cable can move the
encoder strip resulting in a carrier stall to the left side of the machine.
A Field Fix Kit to repair five machines has been released for this problem. The
Belt Cuff and Cable Pad FRU (P/N 17A0748) contains 5 Belt Tensioner Cuffs,
5 Cable Friction Pads, and an Instruction Sheet in English.
Date:
10.02
5/11/98
597
4093 (5700 Color
Jetprinter) and
4094 (5000 Color
Jetprinter)
Replacing the 0.5mm Carrier Assembly and System Board
There were a limited number of 4093 and 4094 inkjet printers manufactured
with a .5mm Carrier Assembly and .5mm System Board installed. When
replacing either the .5mm Carrier Assembly or .5mm System Board on the
4093 or 4094 inkjet printer you should order both the 1mm Carrier and the 1mm
System Board and replace both. There are no .5mm Carrier Assemblies
or .5mm System Boards available.
Date:
10.02
5/7/98
598
4096 (Color
Jetprinter 1100)
Field Replacement Packing Material Now Available
In case you need replacement packing material for moving or shipping a
machine for service, a new part number has been released for the Field
Replacement packing B/M for the Color Jetprinter 1100, 4096 Models 003 and
004. That new part number is 7350132.
Date:
10.02
11/2/98
599
4099-001
(Z31 Color
Jetprinter)
New Power Supply Part Numbers
The power supply part numbers have changed. No change was made to the
part itself.
Description
Old FRU P/N
New FRU P/N
P/S External (LV) 100V — Japan
12G1812
12G1825
P/S External (LV) 120V
12G1813
12G1826
P/S External (HV) 220V
12G1814
12G1827
Date:
10.02
8/6/99
600
4100-S001 (Z11
Color Jetprinter)
Smoking Printer
Some reports have been received from the field of Lexmark Z11 printers
smoking. This problem can be caused by connecting a non Lexmark power
supply to the printer. When a non Lexmark power supply is used the printer may
not work and damage may be done to the Logic Card. The card may, or may
not, smoke when connected with the wrong adapter. As a result, even if the
correct Lexmark power supply is connected to the printer, the printer will be
inoperable. The printer may or may not smoke at this time depending on if it
smoked during the initial connection of the non Lexmark power supply.
The problem can also be caused by a defective printhead with a burr on the foil
tab circuit that creates a short across multiple contacts on the printhead cable.
Customers who experience this symptom should contact the Lexmark
Customer Support Center for assistance. Support Center personnel will
diagnose the failure and provide the user with an effective warranty solution.
Date:
10.02
11/29/99
601
Forms Printer 4227
Auto Gap Adjustment
When customers experience light or no print, using either single or multi-part
forms, the servicer should follow the instructions in the service manual to
determine if there is a hardware problem. In addition to the information in the
service manual, they would need to follow the below instructions, “Assembly
Instructions For Auto Gap Adjustment”. The problem is that the bracket may be
out of alignment, causing the gears to slip on the Auto Gap Motor, creating a
false sense of printhead gap clearance. This false sense of the printhead gap
clearance results in either light or no print.
They will need to order FRU P/N 11A6234, Auto Gap Motor Bracket. The Auto
Gap Motor Bracket FRU contains a new bracket, the Auto Gap Motor
Adjustment Tool, and the below instructions.
10.02
602
To Remove the Auto Gap Assembly and Adjust the Auto Gap Bracket:
1
Remove the Top Cover. (See “Top Cover Removal” in the 4227-100
Service Manual on page 4-37).
2
Remove the Sub Logic Board. (See “Sub Logic Board Removal” on page
4-36).
3
Remove the Ribbon Drive Motor Assembly. (See “Ribbon Drive Motor
Assembly Removal” on page 4-33.)
4
Remove the Carrier Motor Assembly. (See “Carrier Motor Assembly
Removal” on page 4-13.)
5
Remove the C Clip and Gear A.
6
Remove the 3 Screws (A) holding the Auto Gap Motor Bracket.
7
Remove the Auto Gap Motor Bracket. Remove the Auto Gap Motor.
10.02
603
8
Install the new Auto Gap Motor Bracket using the 3 Screws (A) into the
respective holes as shown but don’t tighten the screws.
9
Rest Gap Adjustment Tool (with the groove underneath) onto Auto Gap
Stud and slide the Gap Adjustment Tool toward the bracket until the end of
the tool fits into the hole on the bracket.
Using the screwdriver, lift the Auto Gap Motor Bracket until the Gap
Adjustment Tool slides into the hole.
10 Using the screwdriver to hold the position of the bracket tighten the 3
Screws (A) with another screwdriver. Finally, secure Screw (B) to the
Bottom Cover. Recheck the Gap Adjustment Tool to confirm concentricity
between the stud and bracket hole again after tightening the screws.
Remove the Gap Adjustment Tool.
11 Reassemble.
Date:
10.02
1/20/98
604
4403-001
(Lexmark X83)
LCD replacement on the X83 machine.
On the X83, we started North America production with a 7 language LCD. The
only place that received the 7 language LCD's is US, Canada, and LAD. EMEA
should not have machines with the 5.74 LCD's. This 7 language LCD used a
FW level of 5.74. We eventually switched production to a 10 language LCD.
This 10 language LCD uses FW 5.75Z or FW5.76C. We used the 10 language
LCD on the following serial number ranges.
S/N Range
06230056386 ~ 06240078585
06240078586 ~ 06290165517
06290166058 ~ 06330241023
06330250800 ~ 06330253799
06340253809 ~ 06340272242
06350282168 ~ 06350283065
06360292837 ~ EOL
Eventually there will be no 7 language LCD's available for repair. So, if we have
to replace an OP panel from a 5.74 machine with a 10 language LCD, the
Firmware will have to be upgraded.
10.02
605
Firmware Download Instructions
1
Software must be installed before firmware can be installed. The two files
you need are lxasflash.exe and fw576c.bin.
a
b
c
d
With your browser, go to
https://secure.lexmark.com/reseller/formscenter/lasp.html.
Put in your LOCID as a password.
Click on LSSG Service Tip File Download.
Click on LXASFLASH.ZIP and FW576c.BIN.
2
Be sure X83 is connected to the PC and powered on.
3
Detach the .bin file to your desktop
4
Detach lxasflash.exe to your desktop
5
Drag and drop the .bin file onto the lxasflash.exe icon.
6
A DOS window should open and display several status messages
Wait about 30-40 seconds and the MFP should reboot and display the new
firmware version on the LCD screen when it is powering on.
Date:
10.02
9/10/01
606
4402-001, 4403-001
(Lexmark X73,
Lexmark X83)
Service tip matrix for Lexmark X73 and X83 models
Product
Problem description
Verification/Action
Root Cause
S/N range
X83/X73
“Wavy” gray image during
copy or scan.
Perform a copy using the OP panel
buttons. If image is the same,
replace machine.
Voltage regulator
X73 - SOP to
06210054713
X83 - SOP to
05210007401
X83
During power up, 3 LED's
stay on and LCD screen
goes blank. The machine
will not power off using
power button.
Un-plug power, wait 10 seconds
then replug. Wait for POR to
complete. If problem still remains
after 3 attempts, replace machine.
To avoid this problem in the future,
customer should use power button
to turn off machine. If the problem
remains, replace the machine.
Hurricane reset
problem
X83 - Currently
evaluating fix
X73/X83
During power on, the
scanner makes a loud
“clicking” noise and the
LCD displays “Unlock
Scanner”.
Verify the customer has removed the
scanner lock. If the problem
remains, turn product on its left side
and replug the power. Repeat this
twice, if the problem remains,
replace the machine. Advise the
customer this is shipping related and
should not repeat.
Scanner unit
interference with the
middle frame.
X73 06320245845
10.02
X83-SOP to
06320229213
607
Product
Problem description
Verification/Action
Root Cause
S/N range
X83
LCD displays “Unlock
Scanner”, immediately
after plugging machine.
Replug machine, ensure the
customer does not hear any
“clicking” noise. If no clicking noise is
heard, replace machine.
Scanner cable failure
(Bad connector is
white in color)
X73 - SOP to
06340263666
X83 - SOP to
06340269112,
06340269242 to
06340269533,
06340283179 to
06340283656
X73/X83
Black screen when
copying or scanning
Print a color copy from the machine.
If problem remains, replace
machine.
Same as above
X73/X83
Purple, teal or yellow tint
on Copied or Scanned
image
If problem remains, replace
machine.
Same as above
X73/X83
Teal light and dark bands
across Copied or
Scanned image
If problem remains, replace machine
Same as above
X73
Scanned or copied
images appear
“stretched”. The scanner
shakes while scanning.
Draw a diagonal line from corner to
corner on a plain piece of paper.
Copy the page. This problem will
cause the diagonal lines to be
skewed.
Firmware problem.
This FW is downloaded by the driver.
This problem was
fixed in the Gold 12A
version of the driver.
See “Firmware
Download
Instructions” on
page 605.
10.02
608
Product
Problem description
Verification/Action
Root Cause
S/N range
X83
Scanner lamp is
“flickering” and copy/scan
quality is poor
Power machine off and on. The
problem should disappear. Advise
customer, that this can happen with
prolonged use. It will recover every
time after removing power.
Bad production run of
scanner lamps
X83
06310212824 ~
06310212877
X73
The X73 units will print a
couple of lines and the
printer hangs. The unit will
operate normally if a scan
is performed.
Unplug and replug the X73. Print the
test page on the driver control panel.
See if the X73 hangs after printing 23 lines during the print.q
Currently, we
implemented a new
USB hub chip on
08/23. The machine
EC level is 07.
Machines with EC
08 and below.
This EC level is
the first 2 digits in
the SN.
07260397847 to
297936,
07340263750 to
291099,
07350291307 to
294145,
07350298909 to
and later.
10.02
609
Product
Problem description
Verification/Action
Root Cause
S/N range
X83
Standalone copy color
reproduction of red and
yellow
The verification is if the customer
complains about the red and yellow
color reproduction and has FW
5.74Z on their machine.
The new FW was
implemented on 09/20
and the machine EC
level has been
changed to 08. When
powering up the
machine, the LCD
screen will display
“V5.76C”. We will only
address customer
complaints on a
limited basis.
All machines with
EC 08 and above
have the 5.76C
FW. Machine SN
is from
08380328193
and later. FW
upgrade is on a
limited basis only.
Date:
10.02
9/12/01
610
4520-xxx
(Lexmark T52x)
Internal Tray Card (ITC) Assembly Part Number
The P/N for the ITC Assembly for the Lexmark T52x is 56P1139. It is specific
to this machine.
Do not use the same ITC Assembly used in Models of Optra S through Lexmark
T62 (99A0128).
Date:
4520-xxx
(Lexmark T52x)
8/28/02
Maintenance kit part number correction
In the Scheduled Maintenance section of the Lexmark T52x service manual,
the part numbers for the 110V and 220V Maintenance Kits are reversed. The
correct numbers are below.
Description
Part Number
Maintenance Kit (115V)
99A2420
Maintenance Kit (220V)
99A2421
Date:
10.02
7/18/01
611
5016-XXX
Lexmark C710
Busy Hangs
A busy hang may occur on the C710 in several instances:
• When printing from Claris Works in the Mac OS environment.
• Because of Fuser Drive Clutch failure.
• Due to Engine Card failure (this should go to a 900 error after 10-20
minutes).
An update to the newest base code.will resolve the Mac OS environment issue.
To obtain the Optra C710.bin.hqx file:
1
With your browser, go to
https://secure.lexmark.com/reseller/formscenter/lasp.html.
2
Put in your LOCID as a password.
3
Click on LSSG Service Tip File Download.
4
Click on OPTRAC710.SIT.
Engine Card failure as described above is resolvable only through replacement
of the Engine Card P/N 12G1562. All other busy hang issues consistently
appearing on boot or when printing with the machine disconnected from any
network connection should be treated as the Fuser Drive Clutch issue
resolvable only by Fuser Drive Assembly replacement P/N 12G1348.
Date:
10.02
10/26/01
612
5016-XXX
(Lexmark C710)
Main Drive Gear is available separately from the OPC Coupling
Drive Block Assembly
The Main Drive Gear (PN 12G1711) is now available separately for OPC
Coupling Drive Block Assembly. Previously this gear was unavailable and if
damaged, the OPC Coupling Drive Block Assembly was required to repair the
printer. The gear is now available individually.
Description
FRU P/N
Gear, OPC Coupling Drive Block
12G1711
Date:
10.02
8/27/01
613
5024-XXX
(Lexmark C720)
Error messages: 82/995 while coming out of Power Saver or
receiving intermittent 82/995 error
When a C720 comes out of Power Saver mode after some variable period of
time it may report a false 82/995 error. These errors may also occur
intermittently. This issue is resolved withan available code update Go to:
http://support.lexmark.com/printerfirmware/ and enter IFa160p as your
authorization keycode.
This file should be saves to an available location on your harddrive and copied
to the printer either over the network or with a parallel attachment. Nonintermittent errors (such as would appear on POR) would still fall under the
previous service tip regarding 82/995 errors. See “Error messages: 82 PC
Photo Developer Cartridge Missing ERROR and/or related 995, PC belt
timing error” on page 614.
Date:
10.02
Revised 9/9/02
614
5024-XXX
(Lexmark C720)
Error messages: 82 PC Photo Developer Cartridge Missing ERROR
and/or related 995, PC belt timing error
The Belt Sensor (PBS) (FRU PN 12G7079) performs two functions:
• Reflective sensing of the presence of the Photoconductor cartridge and
• Detection/timing of two timing marks located on the side of the
Photoconductor Belt, itself.
The following conditions can cause or contribute to machine malfunction and
result in the 82 PC Photo Dev Cart Missing ERROR:
• Photoconductor
– Improper or incomplete installation
– Gear missing, broken, improper gear alignment, or white snap-ring on
gear retaining bushing weak or missing.
– Another PC cartridge (if available) may be installed to rule out
machine hardware deficiency.
• Sensor
– Sensor blocked by toner or paper dust, debris
– Broken, defective, weak Belt Sensor (PN 12G7079)
– Incorrectly installed, not properly ‘snapped’ or angled position,
incorrectly plugged, or failing to make wiring contact
10.02
615
• Additional machine hardware
– Failure of IOD1 P.W.B. Card (PN 12G7064)
– Failure of Main Engine MCTL P.W.B. Card (PN 12G7030)
– Failure of Main Motor Drive (PN 12G7052) or associated cabling - can
yield same error code - 82 PC MISSING and/or 995 Belt timing error.
Date:
8/27/01
10.02
616
5024-XXX
(Lexmark C720)
32 Unsupported Cartridge
If the printer thinks that a non-Lexmark cartridge is being used, the Operator
Panel will post a “32 Unsupported Cartridge” error. This occurs when the toner
key sensor is not tripped by the cartridge key.A number of other things can
cause this error. Try the following sequence:
1
Re-install the toner cartridges and be sure that they are Lexmark keyed.
2
Bend the tabs on the left side of the cartridge out slightly.
3
Check the left side of the front door for proper seating, if bent too far out
the cams will not push the cartridges into the sensor.
4
Check the toner key sensor 12G7062 connection to the IOD1 connector
DCN15. Reseat the connector and replace sensor if necessary.
5
If all else checks OK, replace the toner key sensor. A common failure is the
metal hinge will be bent (beyond 90° angle).
Only If the previous options did not fix the problem, then replace the IOD1 board
and the MCTL card as necessary.
Date:
10.02
5/28/02
617
5024-XXX
(Lexmark C720)
82 Photo Developer Missing
The service Manual is incorrect for the diagnosis of this error. If the printer fails
to sense the Photo Developer, the Operator Panel displays “82 Photo
Developer Missing”. This occurs when the belt sensor does not recognize the
photo developer. A number of things can cause this error. The sequence for
fixing this should be the following:
1
Re-install the photo developer to clear the message and continue printing.
2
Check for toner spilled on the belt sensor. Carefully clean with a vacuum.
3
Check the belt sensor 12G7079 connection to the IOD1 connector DCN14.
Reseat the connector and replace sensor, if necessary.
4
Check the Waste Toner Feeder Upper Unit (plate which the sensor snaps
into) be sure to have the bracket positioned parallel with the OPC. Be sure
that the sensor is snapped into position in the center of the hole.
Only if the previous steps do not fix the problem, replace the IOD1 board and
the MCTL card as necessary.
Date:
10.02
5/28/02
618
5024-XXX
(Lexmark C720)
Residual image or smeared images
If transfer drum cleaner roller is not seated properly, residual images appears
on each page following the first print. Sometimes the image appears smeared,
other times it will be a clean image on the following page. Oil from the fuser
spills onto the transfer drum of the C720. The transfer drum cleaner roller may
become unseated during shipping. If the cleaner roller is loosely seated, it may
come loose during usage.
Reseat transfer drum cleaner roller.
1
Take printer off line.
2
Open printer top cover.
3
Move the two photoconducter green hinges forward.
4
Remove white shielding by pressing tabs back, rotating shielding back,
and lifting.
5
Press drum cleaner down with even force at the two ridged areas.
When seated properly, it should rotate freely and the each shaft end should
be below the end of the leaf spring as illustrated below.
6
Reassemble printer.
7
Print test page to verify fix, it may take several pages for cleaning to be
complete.
Date:
10.02
5/28/02
619
5024-XXX
(Lexmark C720)
Vertical voids (white streaks)
Debris on the printhead lens or plastic housing may cause vertical voids (thin
white streaks) on all planes of printed images. This defect will be noticeable as
a white void or lower color intensity in the same location (right to left) of the
printed page and will go from top to bottom of the page. It will be most
noticeable on halftone printing. To remove the voids or streaks, clean the
printhead lens and plastic housing of all foreign contaminants and debris.
1
Take printer off line.
2
Open printer top cover.
3
Remove Optical Photoconducter. Cover green foil with clean sheet of
paper to prevent light exposure.
4
Open front door.
5
Remove print cartridges.
6
Grasp the printhead lens tabs and pull up to remove the printhead lens.
7
Wipe the printhead lens with a clean lint free cloth and remove all
contaminants.
8
Clean plastic housing area.
9
Reassemble printer.
10 Print test page.
Date:
10.02
5/28/02
620
5040 (Optra SC)
New FRU for 24 Tooth Rack Drive Gears
The correct FRU part number for the 24 tooth Rack Drive Gear for Optra SC
(5040) is 18A0434. When this FRU is ordered, 4 (four) gears are provided
within the FRU (4 gears are used per machine). Previously the FRU (12C0543)
only contained one gear. Servicers ordering the old part number will
automatically receive the new FRU 18A0434 (all four gears should be
replaced).
Date:
5040 (Optra SC
1275)
10/28/99
Rack Adjustment Tool to Alleviate Printer “Moaning”
A Rack Adjustment Tool is available for Optra 1275. In the U.S. the tool is
available as a warranty item. It must be returned within the standard 30 day
period, or the dealer/servicer will be charged for the part. Outside of the
warranty period the tool may be obtained using the exchange price (only being
charged a minimal amount for shipping, handling and CSP processing),
allowing servicers to return the tool (within 30 days) after use to install the Rack,
P/N12C0820. Servicer may purchase the tool, if desired.
The following associated FRUs are available.
FRU P/N
Name/Description
12C0837
Tool, Rack Adjustment
12C0820
Rack
12C0836
Guide Plates, Rack
10.02
621
Background
“Moaning” (3rd speed moan) is a hardware condition caused by the black
cartridge being too far from the photoconductor. The moan is the result of
added strain on the rack mechanism and the electrical charge of the black
cartridge and photoconductor, due, in part, to the excessive gap between the
two parts. To correct the problem first verify that the photoconductor and the
black cartridge are installed properly, according to the manual. The following
procedure may be used to perform the adjustment:
Optra SC Toner Cartridge Gauge Instructions
Moaning Noise countermeasure
Note: This adjustment should be checked whenever the Rack or the individual
(green) toner cartridge holder plates are removed and / or replaced. Read this
entire procedure first, so it will be understood.
1
Turn the printer off
2
Open the front door, if necessary, rotate the rack to place the black toner
cartridge in the removal/installation position. Remove the cartridge.
3
Remove the Waste Toner Bottle.
4
Prepare the gauge for installation by positioning the brass portions that are
marked “L” and “R” with the marks up. The gauge snaps into the printer
body using the same slots as the studs on either side of the OPC. Snap the
shaft portion of the gauge into the OPC slots.
10.02
622
5
The locating pin on the brass portions of the gauge should just fit into the
green cartridge plates. Slide the pin in from the side. Check both sides.
6
If the pin will not enter the plate or there is excessive clearance, loosen the
plate retaining screw(s) and readjust the plate until the pin just fits into the
plate.
If the plate has insufficient travel, do the following:
a
b
c
d
7
Place a piece of paper under the plate to catch the retaining screw,
should you drop it.
Remove the screw(s) and the plate(s).
The washers may be stuck to the plate. remove them.
Remove as much glue as possible from the plate, washers and screw.
When tightening the screw, it may be necessary to trap the plate (use a flattip screwdriver) so it does not return to it’s original position.
Notes:
• It is recommended that the black toner cartridge lot number ends in ‘5’.
This lot number is located on the back of the cartridge, directly below the
handle.
• In general, moving the cartridge plate out from the rack, decreases the
amount of ‘moan’ during the ‘run in - run out’ portion of printing.
• If the plate(s) are out too far, the output may develop streaks.
• The cartridge plates are pinned so they will only move in and out, not up
and down.
Date:
10/19/98
10.02
623
5040 (Optra SC)
Removing stray toner from the inside of the printer
A Cleaning Kit, P/N 12C0850 is available to remove stray toner from inside the
Optra SC printer. The following instructions increase the effectiveness of the
cleaning procedure and increase the duration between cleaning.
Please read each step completely before attempting any action.
1
Open the front cover of the printer.
Do NOT remove any of the supplies.
2
Locate the ITM (Image Transfer Belt Mechanism).
With the front cover open, the ITM is the most inward unit in the front door
assembly. It is directly behind the OPC Drum (the unit with the green
handle). On top of the ITM, locate the bracket with the silver extension
spring. Near the ends of the ITM, this bracket has a black tab on each end,
on the rear side of the ITM.
3
Grasp the right and left tabs and GENTLY pull back against the spring
tension (approximately 1/4”) and let it snap back into position. This
releases any excess or stray toner allowing the cleaning kit to remove it.
4
Repeat several times.
5
Install the cleaning kit P/N 12C0850.
10.02
624
6
Run ‘Clean Engine’ procedure found on page 81 of the User’s Guide.
7
Run a ‘Menus’ page to ensure the output is clean.
Note: usually several pages need to be run after cleaning the printer to pick up
any residual toner.
Date:
5040 (Optra SC)
and 5045 (Optra C)
4/24/98
Packaging Kits for Optra SC and Optra C
Packaging Bills of Materials are available for both Optra SC 1275 and 1275n,
and/or the Optra C.
Description
Machine Type
FRU P/N
Warranty Status
Relocation Packing Kit
5040-001 (Optra SC)
7349408
Non-Warranty
Package BM
5045-001 (Optra C)
7347621
Non-Warranty
Both kits include all packing materials and/or additional equipment required to
read and package the machines for proper transport or shipment, including
pallets. The kits may be purchased from the Lexmark Parts Center as a service
part. This P/N is not valid for warranty claims.
Date:
10.02
12/1/97
625
5045 (Optra C)
Paper Feed Springs and Transfer Drum Springs
Paper Feed Springs and Transfer Drum Springs are available for Optra C, 5045.
Each packet listed below (11A2407 and 11A2408) contains two (2) springs:
Description
FRU P/N
Canon P/N
Paper Feed Springs (two, 250 gram
springs)
11A2406
RS5-2316-020
Transfer Drum Springs (two)
11A2405
RS5-2302
Date:
5045 (Optra C)
6/12/98
Checking the Optical Photoconductors (OPC)
When diagnosing print quality, do NOT swap Photoconductors (OPCs) as a
diagnostic tool. The 5045’s high voltage power supply read the capacitive
characteristics of the OPC during Poser On Self Test (POST), after a cartridge
change etc. If a new OPC is installed as a test, the printer will electronically zero
a counter on the DC Controller board. Unfortunately, the counter will not reset
itself when the old OPC is reinstalled. The printer only recognizes the change
from old to new OPCs.
If the OPC is suspect and a new OPC is installed, the counter is reset. If the
problem is determined to be in a different area, such as the cartridge, when the
old OPC is installed, the printer will not prompt the customer to replace the OPC
10.02
626
when it reaches the predetermined expected life count. The customer
continues to use an OPC which is not legitimately beyond end of life without
being prompted to replace it.
Checking the OPC
As outlined in the Service Manual, there is a simple method to check the OPC,
and the cartridges with one test page. This does require access to the Density
Adjustment Panel (DAP) on the back of the printer. This panel has some LEDs
and buttons, and is located directly above the ozone and air filters on the rear
of the printer.
Note: Perform the following steps quickly, otherwise the printer will reset itself.
The following test will only print from Tray 1.
1
While holding the “Color Select” button, press Enter eight (8) times. All four
color LEDs will now flash.
2
Press the “+” button two (2) times. The Center LED will move two places
to the right and flash.
3
Press Enter. This will select the proper internal test pattern.
4
Press “Test Print”
The engine will produce a test pattern with four (4) vertical columns which get
progressively darker down the page. Since the colors are not mixed, it is ideal
for checking on the life of the cartridges and OPC. Vertical streaking within an
10.02
627
individual color indicates that cartridge needs replacement. Customers using
low percentage of color coverage may exceed the life of the cartridge before it
runs out of toner.
Wear Patterns
When checking the OPC, wear usually manifests itself as small black spots on
the output. These spots become more numerous and eventually will be
connected with a very thin vertical line. These spots are easy to recognize
because they repeat every 129 mm and appear at the same place on each
page.
Date:
10.02
8/22/96
628
5045 (Optra C)
25 Paper Jam When There is No Paper in Printer
The printer senses a paper jam if the top output sensor is faulty, oil-soaked, or
the flag is not working properly. Check to verify the flag is working properly and
if you diagnose that the sensor is at fault, follow the instructions below for
replacement.
25 Paper Jam Sensor Removal
1
Remove fuser.
a
b
c
d
e
f
2
Lower fuser bay door.
Remove support strap.
Lower paper feed door
Lower fuser bay door far enough to align keyway and slide door off to
the left.
Use screwdriver to loosen captive screws two (2) at the base of the
fuser.
Remove oil bottle and use the black round knobs to pull fuser out of
bay and lift out.
Fuser disassembly.
a
b
c
Remove three (3) gold screws that hold the black plastic cover over
the fuser connector on the right side of the fuser. Remove the screw
in the center of the right pull out knob.
Remove black plastic covers and the knob from the fuser.
Remove the two (2) gold screws that hold the fuser connector in place.
10.02
629
d
e
f
g
h
i
Remove the three (3) silver screws that hold the corner plate of the
fuser.
Remove the two (2) silver screws that hold the mounting bracket for
the fuser connector. Remove the bracket.
Remove the three (3) silver screws that hold the corner plate of the
fuser.
Remove the plate by slipping the fuser lamp and sensor wires out of
their groves in the plate.
Remove the C-clip that holds the sensor flag in place, then remove the
spring from the flag and slide it off it’s peg.
Use a flat screw driver and carefully pop the sensor out of the frame.
Note: Any pressure at will break the tabs.
j
k
3
Disconnect the white connector from the sensor and remove sensor.
Clean or replace sensor part number 11A2117.
Reassemble fuser.
Date:
10.02
7/23/96
630
5045 (Optra C)
Testing the Optra C Without the Video Controller Card Installed
Below are the test procedures on the Optra C for testing the printer engine
without the Video Controller card installed.
1
Turn the printer off.
2
Slide the Video Controller out at least one inch.
3
Remove pin access cover on the left side of the printer.
4
Jumper between pins 8 and 3.
5
Turn on printer and see if it completes Power-On Self Test (POST). The
printer should do the Cartridge Check and perform basic POST.
Date:
10.02
5/7/96
631
5045 (Optra C)
Sheen or Gloss Variation on Optra C
A difference in gloss or sheen may be noticed when printing on the Optra C.
Check the paper weight to make certain that the paper is within specifications.
As paper mass increases, the paper acts as a heat sink that drops the fuser
temperature of the pressure feed rollers. This drop in temperature causes the
difference in sheen. When selecting the high gloss or low gloss mode on the
printer, the fuser temperature is changed accordingly. The higher the
temperature the glossier the output. A general rule is, the higher the weight of
paper, the greater the effect on the output. The lighter the weight of the paper,
the less effect on the gloss.
Date:
5045 (Optra C)
5/7/96
Horizontal White Lines That Repeat Every Four or Five Inches
If the horizontal lines appear on the page in the same places, about five (5)
inches apart, then there is a scratch on the Optical Photoconductor (OPC).
Raise the top cover of the printer and watch the paper as it passes over the
Transfer Drum and see if the lines appear. This will eliminate the fuser as a
possible source of the problem. Replace the OPC.
Date:
10.02
5/2/96
632
5045 (Optra C)
Turning off the Corona Wire on the Optra C
At the back panel, push and hold in the color select button. While holding the
color select button, push the Enter button three (3) times. The “Y” and “Bk” color
select LEDs flash to indicate that the separation voltage control designation
mode has been entered. To turn off the Corona wire, press the “+” button once
and press the Enter button. This procedure can be found on page 3-13 of the
Optra C Service Manual.
Date:
5045 (Optra C)
5/2/96
Resetting the NVRAM on the Optra C
With the printer off, hold in the top (Menu) and two bottom buttons (Ready and
Return) at the same time while turning on the machine.
Date:
10.02
2/27/96
633
5045 (Optra C)
117 Fuser Pump Failure
On the Optra C one may experience a 117 Fuser Pump Failure. This may be
caused by oil on the oil level sensor. It may also be caused by the printer not
installed on a level surface. This is the more common failure. If the printer is
tilted to a small degree so that the rear of the printer is lower than the front of
the printer, then the error can occur. Remove the oil from the printer. Raise the
rear of the printer about one half of an inch (1 to 2 cm). Pump the oil from the
fuser into the reservoir using the green pump handle located on the fuser. In
the case oil is on the sensor, the sensor can be cleaned and then replaced if
the error is not corrected.
Date:
5045 (Optra C)
2/23/96
Vertical Lines Changing Color on Grid Printout
The customer is creating a grid and some of the vertical lines are changing
colors when printed on the Optra C.
There is a problem with the Optra C in contone mode with very thin vertical
lines. If the line is less than 2 pells in width, then there may be some fading of
the color. For example, if you have a certain shade of blue that has cyan and
magenta, then you may only see cyan on some lines.
This only shows up with print code lower than 60.70. Upgrade the customer to
at least 60.70 code. Contact the Customer Support Center for assistance.
Date:
10.02
1/19/96
634
5050 (Optra Color
1200)
All Models
Complete Tray Assembly Available as FRU
Correction of FRUs. P/N 11G0377 is a complete Tray assembly.
P/N
Incorrect
Description
Correct Description
Comments
11G0376
Lower Base
Plate, Tray Base
(which includes metal
plate and cork inlay)
11G0377
Plate, Lower plate
CAS
Tray, Complete
Assembly
(Includes entire Cassette
Tray assembly)
Date:
5050 (Optra Color
1200)
All Models
10/28/99
Explanation of Toner Status Gauge
Two components in this system function interactively. The first component is the
actual hardware sensor that is located in each cartridge block on the right hand
side of the machine. It is a typical send/receive infrared sensor. The second
component is the software algorithm that decrements the 'gas gauge' from
100% to 0%.
The hardware portion of this system only knows 2 states: Low and Empty. This
is very important!!!
When the Optra Color 1200 leaves Lexington, the algorithm is fed a value of
100% by the line operator since obviously the user will install the new cartridges
that come with the machine.
10.02
635
As the printer prints over the next few thousand pages, the logical algorithm
based on average usage/coverage will decrement the 'gas gauge.' It is one of
the 'better' performing algorithms to date, but some usage methods could still
'confuse' it.
It is important to remember that the hardware portion of the system cannot
gauge the toner depletion, and that the 'gas gauge' movement is totally based
upon the algorithm's ability to decrement it properly. Still, the hardware sensor
is constantly 'looking' inside the cartridge and waiting for movement of the toner
paddle inside. Once the toner nears empty, the toner paddle will be able to turn
freely (as there is no toner mass to hold it still) and the infrared sensor will
gauge this increasing movement. At this point the hardware system will report
a “Toner Low” message to the engine.
If the algorithm had properly guessed the toner usage, this “Toner Low”
message should occur at 5% on the gas gauge. Once the “Toner Low”
message has been sent to the engine, the printer will Post a “Toner Low”
message on the OP panel. The user now has approx. 250 pages before the
machine will shut down. During this period the hardware system will be looking
for a 'new' cartridge. It knows a new cartridge, because it will be full of toner,
and the toner paddle will not be able to move. In other words, the infrared
sensor will have been reporting constant sign wave movement from the old
cartridge, but as soon as the top door is opened and the cartridge is replaced
with a new one, it will suddenly report NO activity. This will cause the engine to
reset the 'gas gauge' back to 100% for that color and the process starts over.
10.02
636
Here is what can happen:
1
The algorithm does not properly guess the toner consumption because the
user is using an unusually high coverage. This means that there is actually
less toner in the cartridge than what the 'gas gauge' is reporting. Let's say
the 'gas gauge' is showing 20%, but the toner cartridge is almost empty.
The user prints out a menu's page and sees that they have 20%, so they
start their job. After a few pages the hardware sensor sees enough activity
to report a 'toner low' to the engine, so the engine will automatically send
the 'gas gauge' to 5%. The user prints out the menu page again, but now
it says 5%, but they have only printed 3 pages! The user is generally
concerned about the 'jumping' around of the gas gauge.
2
The algorithm decrements the 'gas gauge' too quickly. This means that the
'gas gauge' will most likely set at 5% for an unlimited amount of time, until
the hardware sensor actually reports a 'toner low' message.
3
Toner gauge does not reset after installation of new cartridge (This is the
most common complaint). In this example, the user replaces the toner
cartridge before the printer reports the “Toner Low” message. This means
that the engine is now looking for the sudden decrease in sensor activity
so it does not recognize the cartridge as new. The result is that the gas
gauge algorithm will take it to 5% and wait there until the cartridge runs out
of toner (which means it could set a 5% for several thousand pages. The
user must wait for the “Toner Low” message on the OP panel before
installing the new cartridge. If this occurs the printer can be forced to go
back 100% by sending the appropriate NPA command.
10.02
637
4
Very rarely, the hardware sensor may fail so that it is not reporting toner
activity properly. This means that the gauge may reset back to 100% with
the NPA command, but it will immediately go back to 5% (because the
sensor is constantly reporting a toner low condition). NOTE: This can also
happen if the user uses the NPA commands to force the gauge back to
100% if the cartridge is truly low.
Date:
10.02
10/28/99
638
5050 (Optra Color
1200)
All Models
Transparencies Paper Jam from Tray 1
Potential failure that may occur on the Optra Color 1200.
Symptom: 241 paper jams when printing transparencies from tray 1. The
symptom occurs only when tray 1 is loaded with approximately 50
transparencies.
Root Cause: Some paper trays may have lift springs too weak to push a stack
of 50 transparencies firmly against the pick rollers.
Fix: Send the customer a new paper tray, FRU # 11G0377. Do not send a
service technician. The customer can replace tray 1 with the FRU. The FRUs
have been inspected for this failure. The inspected FRUs either:
1
Have a date code of 0499 (April 1999) or newer or
2
Are labeled with blue dots.
Date code location: A small white label on the bottom of the tray in the rear
corner. Blue dots are in both of these locations:
1
On the box next to the FRU label and
2
In the paper tray between the front cover and the paper pass-through slot.
Date:
10.02
10/28/99
639
5050 (Optra Color
1200)
11G0604 RIP Card Short
A low probability exists for a 24V-to-ground short on the 11G0604 RIP Card.
The short occurs between the RIP card and the RIP Card housing for service
parts produced before 3/22/99. Cards manufactured after 3/22/99 include a
protective washer that safeguards against the problem. Cards currently
installed in the printers pose no risk of shorting. Cards replaced, re-installed or
exchanged should be inspected for an adhesive washer. A NON functioning fan
may be indicative of the scenario.
Electrical tape may be used to cover the two contact holes. Both holes may be
covered with a small piece of tape if positioned correctly. To cover the contact
holes with tape, do the following:
Hold the RIP Card with the back (noncomponent populated) facing you. The
cable connector should be at the top and the edge connector should be facing
left. Cover the contacts located in the upper right corner (just to the right of but
slightly below the 2-pin fan connector) by placing electrical tape over the two
small contact holes directly beneath the screw hole on the back of the card.
Date:
10.02
05/03/99
640
5050 (Optra Color
1200)
Service Call Notes
WARNING: The potential of excess heat applied to a Fuser Oil Coating
Roller (OCR) may result in a damaged OCR. As a precaution and to
prevent users from being unable to print due to a damaged OCR, it is
recommended that the OCR be replaced during the following conditions.
920 Fuser Error Service Call
IF the following parts are replaced due to a 920 Fuser error:
a) Fuser Heater
11G0348 (115V)
b) Fuser Heater
11G0549 (230V)
c) Fuser Thermostat
11G0353
d) Fuser
11G0375 (115V)
e) Fuser
11G0542 (230V)
ALSO replace:
Fuser Oil Coating Roller
10.02
11G0603
641
923 Fuser Error Service Call
IF the following parts are replaced due to a 923 Fuser error):
a) Fuser
11G0375 (115V)
b) Fuser
11G0542 (230V)
c) Thermistor
11G0353
ALSO replace:
Fuser Oil Coating Roller
Date:
5050 (Optra Color
1200)
11G0603
05/03/99
Additional Test after 923 Error (High Voltage (220V) Machine)
If service is required in the field for a High Voltage (220V) Optra Color 1200 that
has a 923 error, run the following additional test after replacing the defective
parts:
1
Replace parts as required by the service manual.
2
Run normal tests to insure fix.
3
In addition to normal printing, allow the printer to go into Power Saver mode
and monitor for 5 minutes for another 923 error.
10.02
642
The Power Saver mode can be accessed quickly by reducing the time-out value
to 1 minute through the Operator Panel:
Hit the <menu> button until SETUP Menu is displayed and press <select>.
Press <menu> until POWER SAVER is displayed and press <select>. The
Power Saver setting is normally set to 20 minutes. Press <menu> until 1 is
displayed and press <select>. This will set the Power Saver value to 1 minute.
Allow the printer to enter Power Saver mode and continue to monitor the
Operator Panel for 5 minutes. If the 923 error occurs, turn off the power
immediately. If no error occurs, the printer is operating correctly. Please reset
Power Saver to 20 minute default.
On some High Voltage (220V) Optra Color 1200's, there is a potential for a
shorted solder joint on the Low Voltage Power Supply (P/N 11G0541). If pin #9
and pin # 10 on connector CN604 are shorted together, the potential of a 923
error and fuser damage occurs when the printer enters the Power Saver mode.
If a 923 error occurs within 5 minutes of entering Power Saver mode,
inspect/replace the Low Voltage Power Supply (P/N 11G0541).
Note: During this test, be sure to monitor the printer at all times to prevent fuser
damage. If this problem exists, the 923 error should occur within 1 minute of
entering Power Saver mode. If an error occurs, the fusers thermal cutoff will be
damaged after 2 minutes in the 923 error condition.
Date:
10.02
05/03/99
643
5050 (Optra Color
1200)
Dark Line on OHP (Transparencies)
For printers that experience a dark line on OHP (transparencies) due to the
fuser thermistor, the following procedure may be performed by the customer
(which may eliminate the need to replace the entire fuser unit):
1
Take a standard piece of 20-24lb paper and fold it twice to get a 4X
thickness.
2
Open the rear exit assembly cover.
3
Remove the Fuser Oil Coating Roller. (Be careful, because the fuser can
be hot.)
4
Gently slide the folded paper between the Thermistor and the fuser hot roll
5-10 times. (This location is on the right side of the fuser and towards the
front of the printer. When looking into the fuser, you will identify the
thermistor as a thin piece of mylar that is in contact with the fuser hot roll.)
5
Reinstall the Fuser Oil Coating Roller and re-run the test page.
To correctly fuse the toner on the Optra Color 1200, the fuser requires a slight
layer of oil on the fuser hot roll. This oil is applied by the Fuser Oil Coating
Roller. The thermistor is a sensor that lightly touches the Fuser hot roll to
monitor the fuser temperature. If the thermistor touches the hot roll too heavily
or has debris behind it, the thermistor can remove the oil that is necessary for
proper fuse grade. This can effect OHP (transparency) as well as cause a
streak on paper.
10.02
644
The above cleaning process serves 3 functions to eliminate/reduce this
problem:
• Removes any debris between the hot roll and the thermistor.
• Re-distributes the oil across the area that is oil depleted.
• Relieves excess pressure from the thermistor.
Date:
05/03/99
5050 (Optra Color
1200)
How Do You Maintain Optimum Color Fidelity and Photoconductor
Timing?
The Optra Color 1200 utilizes four print units, each consisting of a toner
cartridge and a photoconductor. (Black, Magenta, Cyan and Yellow). During
manufacture, the ‘color’ photoconductors are measured for roundness. (All
photoconductors are slightly non-concentric). The photoconductors are then
characterized and set at a certain point. This point can be physically seen by
looking at the set of round holes at the right side of the photoconductor (See
“INSTRUCTIONS” below). If the cartridges are not timed in this manner, the
potential exists of having color planes out of phase at a certain point on the
page.
10.02
645
Service Precautions
The following scenarios could cause the “color planes out of phase” problem
described above:
• Photoconductors should NOT be swapped between machines!
For example, you have a printer that has a print quality defect that looks
like it is a cyan Print unit problem. If there is another Optra Color 1200 that
is working correctly (in close proximity), it might seem logical to swap the
cyan Print unit to diagnose the failure, however, this would be incorrect.
The timing would now be disrupted on both sets of photoconductors; the
original printer with the questionable supply as well as the “good” printer
from which the Print unit (used for the test) was removed.
• All Print Units should be reinstalled before the cover is closed.
For example, a paper jam in the printer may necessitate the removal of the
Print units to clear the paper. If one of the Print units is left out (usually
magenta) and the cover re-closed, the photoconductors that are in the
printer will be turned, causing a timing problem.
• If one color photoconductor requires replacement, all three must be
replaced as a set (and are only available as a “matched” set).
It is recommended that all three color toner cartridges are replaced, even
if only one is exhausted. The color toner cartridges also come as a set of
three, Cyan, Yellow, and Magenta. Black is available separately.
10.02
646
Instructions for Visual Inspection and Manual Retiming of
Photoconductors
The black photoconductor does not have to be re-timed because it is
automatically controlled by the printer.
1
Remove the Print unit from the printer that will be re-timed.
2
Remove the photoconductor from the Print unit (toner cartridge).
For the example below, the yellow timing is being described. Looking at the
right side of the photoconductor unit, notice the set of 3 round holes. Each
hole is marked with a letter. The hole that corresponds with the “Y” for
yellow will be used to dial in the proper position of the yellow
photoconductor.
3
Using the Drum gear, manually rotate the photoconductor unit until the
alignment hole is split in half by a black semi-circle on the left-hand side
and a silver semi-circle on the right-hand side.
The drum can be rotated in either direction to accomplish this.
4
Adjust the two other color photoconductors using the hole denoted with
either the “M” for Magenta or “C” for Cyan.
5
Reinstall the correctly adjusted photoconductor into the toner cartridge
and install the entire Print unit into the printer for each of the three
photoconductor units.
Date:
10.02
11/13/98
647
5050 (Optra Color
1200)
Solid Lines Across One Plane
A scratch on any OPC of the Optra Color 1200 could result in a solid area of
100% coverage. This print defect could start as just a scratch or repeating mark
every 94.2mm (OPC Frequency). This would normally require an OPC
replacement. On the Optra Color 1200 with engine code level less than
GE614006, it is possible for transfer voltages on the transfer belt to short to this
scratch, and cause a shorted area on the OPC. The result could be a black line
up to 5mm or 6mm wide that repeats at 94.2mm. This would require
replacement of the OPC or color OPC set if a color OPC is defective.
Date:
10.02
11/8/98
648
5055
(Lexmark C910)
Paper skewing
Several causes may induce skew on the C910. They are:
•
•
•
•
Tray guides may have skipped teeth when shut with excessive force.
The roll at the front edge of the transport belt may be misseated.
The duplex may not be installed all of the way into the machine.
The paper may not be under the corner bucklers or the tray may be
overloaded with paper causing the paper to come out from under the
corner bucklers when the tray is closed.
Problem Solution
1
Take the tray out of the machine and turn it over (this does not apply to the
multi-purpose feeder). The tray guides are connected in the center of the
tray by a toothed gear that ensures they move in unison. Remove the screw
at the center of the gear and use a sheet of paper in the tray as a template
to retime the guides.
2
Reseat the roll at the leading edge of the transport belt.
3
Reinstall the duplex firmly.
4
Make sure the correct amount of paper is in the tray and that it is under the
corner bucklers.
The paper lift tray must be pushed down to the lock position every time
before the drawer is closed.
Date:
10.02
9/9/02
649
5055
(Lexmark C910)
FU/FD Deflector not moving or not being seen with 980 message
980 - Face Up/Down Switching Error can occur because of the Face Up/Down
Deflector not moving or not being detected by the sensor.
1
Locate the Face Up/Down Deflector.
2
Verify the tab on the deflector is in the slot in the assembly. On the far end
there is a tab that connects into the Face Up/Down Assembly.
If it’s not in the slot reposition the tab in the slot.
3
Press on the deflector near the tab and release.
The deflector should click into place in the other orientation. Press again.
Does the deflector return to the first position and click in place?
–
–
4
If deflector doesn’t move, replace Face Up Exit Assembly (FRU#
56P9557)
If the deflector moves correctly, close the printer and continue.
POR the printer and ensure the deflector moves on POR.
–
If deflector moves, replace the sensor (FRU# 11G0243 Photo
Interrupter).
– If deflector doesn’t move, replace Face Up Exit Assembly (FRU#
56P9557).
Date:
5/28/02
10.02
650
5055
(Lexmark C910)
The ITU is stuck halfway out of the printer
The belt was not lowered using the supplies menu before removal and is now
stuck.
1
Make sure the printer is turned off.
2
Remove the two thumb screws on the waste toner bottle.
3
Remove the waste toner bottle. Be careful not to spill the toner.
WARNING: Do not turn the white handle; this can damage the Belt Up
Down Clutch.
4
Look behind the handle; you will be able to see one of the cams that raises
the belt. Locate where the cam follower has fallen off the cam.
5
With a screw driver push up on the follower and gently slip it back on the
ITU frame.
6
Seat the ITU back in the printer.
7
Re-install the waste toner bottle in the printer.
8
Close the printer and POR the printer.
9
Now go through the proper removal of the belt by using the Supplies Menu.
10.02
651
Using the Supply Menu to lower the Transfer Belt
1
Open the Supplies Menu on the operator panel.
2
Select Replace Supplies.
3
Select Belt, and select Replace Now.
If the 80 Transfer Belt Life Warning or Exhausted message appears,
press Select when the Select = Replace message appears.
The message Preparing for Maintenance appears, followed by Printer
Ready for Maintenance, then Power Off to Replace Items.
Removing the Transfer Belt
WARNING: Do not turn the printer off until the Power Off to Replace
Items message appears.
1
Turn the printer off along with any optional devices connected to the printer.
2
Open the front cover and top unit.
WARNING: Do not touch, drop or place anything on the transfer belt.
Touching the surface of the transfer belt or placing items on the belt may
cause damage.
3
Loosen the thumbscrews.
10.02
652
4
Lift and remove the transfer belt cover.
If the operator panel is inoperable or if you have an unrecoverable error
code, perform steps 1 through 4 and then:
a
b
c
d
e
Override the front cover interlock switch.
Look for the belt to lower during power on sequence.
Turn the printer off when the belt lowers.
Turn the printer off and proceed with step 5, Removing the Transfer
Belt.
5
Loosen the thumbscrews.
6
Pull the transfer belt out.
7
After replacing the transfer belt and removing the four shipping spacers,
tighten the transfer belt thumbscrews and reinstall the transfer belt cover.
8
Close the top unit and rotate the locking lever to the right, close the front
cover.
10.02
653
9
Note: If the message Did you Replace Belt? appears, wait for the
message Select = yes Stop = no and press Select.
If you replaced the belt before the Life Warning or Exhausted message
appeared, open the Supplies Menu on the operator panel and select
Replace Supplies, then select Belt, and select Replaced. The message
Printing Alignment Page appears and the printer prints the alignment
page.
Follow the instructions on the display to set the alignment values for the
new transfer belt.
Date:
10.02
5/28/02
654
5055
(Lexmark C910)
Op Panel is blank and the green LED on the front of the printer is
still on at power on
The code on the printer has become corrupt and the printer does not power up
normally. This shuts the op panel down on the printer since the code was not
able to load fully.
Replace the RIP Card; 56P9904 for Network or 56P9897 for Parallel. Once the
new card is installed in the printer it is very important that the printer be updated
to at least EC2 Code (702.054 Rip Code and 033D Engine Code). The code is
available from the following directory:
http://support.lexmark.com/printerfirmware/ and use for the
authorization keycode either 703007n for network code or 703007b for the
base printer code.
Update instructions
To update your C910 by parallel attach:
1
Download the latest code update from the site above.
2
At a printer READY state. copy the file to the LPT port with the /b switch.
Example: “copy filename.pjl lpt1 /b”
(assumes you are in the same directory as filename.pjl)
10.02
655
Do not power off the printer while updating code.
To update your C910 by network attach:
1
2
At a printer READY state, ftp to the IP address if you are using a network
printer:
a
Using an FTP Client connect to the printer.
Example “ftp: 111.111.111.11”.
b
c
Type “bin” (puts ftp session in binary mode)
Type “put c:\filename.pjl” (assumes the file is in your root directory).
WARNING: Do not power off printer while updating code.
To update your C910 by USB attach:
1
Download the latest code update from the links above.
2
At a printer READY state.
3
Download the USBFlash program (Copyright 2001 Lexmark International,
Inc.) from:
http://support.lexmark.com/printerfirmware/ and use USBFlash as the
authorization keycode.
4
Connect the printer to the computer through USB.
10.02
656
5
In the USBFlash program, select the code to flash to the printer from the
File Open Icon.
6
Select the printer in pull down menu.
7
Click Start.
Date:
10.02
Revised 9/9/02
657
5055
(Lexmark C910)
Cyan dots or streaks appear
The Customer is getting cyan dots and/or streaks in area of like cyan coverage.
Customer is getting cyan dots and/or streaks on white background or in areas
when there should be no cyan. Possible causes
• This problem is seen mostly when the customer is using the printer on the
low end or outside the environmental spec for the printer.
• This can also happen from printing consistent low coverage of cyan in low
humidity.
• This can also occur from printing a lot of mono print job with printer in ‘max
speed’ setting, when in low humidity.
This issue is resolved with the following code update:
Go to http://support.lexmark.com/printerfirmware/ and enter the
authorization keycode for either network (703007n) or for the base model
(703007b) to download latest code.
Date:
10.02
Revised 9/9/02 (previous version 5/28/02)
658
5055
(Lexmark C910)
88 Toner Empty message stays on after toner cartridge has been
replaced.
Update the Engine and RIP code to at least EC2.
1
Go to:http://support.lexmark.com/printerfirmware/ and enter the
authorization keycode as either 703007n for network or 703007b for base
printer code.
2
Put the printer in the “Invalid Engine Code” state by holding down Right
Menu, Select and Return while powering on.
3
Flash the Engine code first, followed by the appropriate network or base
printer RIP code.
Update instructions
1
2
At a printer “Invalid Engine Code” state, copy the file to the LPT port with
the /b switch.
10.02
659
1
2
At a printer “Invalid Engine Code” state, ftp to the IP address:
a
Using an FTP Client, connect to the printer.
Example “ftp: 111.111.111.11”.
b
c
1
2
Use the USBFlash program (Copyright 2001 Lexmark International, Inc.)
to download by USB:
a
Download the USBFlash program from:
http://support.lexmark.com/printerfirmware/ and use USBFlash
as the authorization keycode.
b
c
Put the printer in the “Invalid Engine Code” state by holding down
Right Menu, Select and Return while powering on.
In the USBFlash program, select the code to flash to the printer from
the File Open Icon.
d
10.02
660
e
f
Click Start.
WARNING: Do not power off the printer while updating code.
Date:
10.02
Revised 9/9/02
661
5060
(Lexmark C750)
Color registration and alignment
When dealing with the Lexmark C750, the K Plane is misregistered to the
printed page and/or the CMY Planes are misaligned to the K Plane.
This could happen for a variety of reasons but should not happen frequently on
an individual machine.
Follow registration and alignment instructions below to resolve the issue.
Color Printer Registration and Alignment
To perform the registration and alignment through the Diagnostics Menu:
1
Power off the printer and power back on while pressing Go and Return
until display reads Performing Self Test.
2
When Registration appears on the display press Select. Four margin offset
settings will be presented on the display.
3
Press Go to print the registration quick test page.
4
Examine the registration marks on the top, bottom, left, and right sides on
the page. If the registration is set correctly, the broad lines at the tip of
triangles should be at the edge of the page.
10.02
662
5
Adjust the margin settings so that the broad lines are on the edge of the
page. The top margin should be adjusted before bottom margin, and the
right adjusted before the left. Menu keys change the values and Select
saves the new value chosen, and moves to the next margin setting.
T= Top
Adding to the current value moves the color plane down the page.
L= Left
Adding to the current value moves the color plane to the left.
R= Right
Adding tot he current value moves the color plane to the left.
B=Bottom
Adding tot he current value moves the color plane down the page.
Go prints the quick test page. Print the quick test page after making and
saving a change.
6
After completing the registration, press Return to exit the registration
function.
7
Press Menu until Alignment appears; press Select.
8
Press Select to run an Alignment Test Page from the options in the
Alignment Menu. Three sheets print.
Whichever color is superimposed over the black target at the top of the
page is the color to use that particular page to align (for example, if you see
cyan over black, select to align cyan from the Alignment menu; black is
never aligned to black).
Note: Use only the top row when aligning the printer.
10.02
663
9
Press Menu until Cyan displayed and press Select. Four alignment
settings will be presented on the display
T= Top
L= Left
R= Right
Z= Theta
10 Press Go to print the cyan alignment quick test page. Only use the top row
when making adjustments. Menu, Select, and Go perform the same
functions. Remember to press Go after making and saving a change to see
how it effected the registration.
Menu change the values. Select saves the new value chosen and moves
to the next margin setting. Go prints the quick test page.
Print the quick test page after making and saving a change.
11 After aligning cyan, press Return.
12 Repeat steps 9 and 10 for magenta and yellow.
13 After aligning the magenta and yellow, press Return until you reach the
main Diagnostic Menu (the top line will be blank and bottom line will display
Alignment).
14 Press Menu until Print Tests displays and press Select.
15 Select Print Line Length Calibration. .
16 Examine each of the six alignment groups, A through F. A color band will
be visible through the black bars.
10.02
664
17 Locate the center of the band and determine the value.
18 If the center is located not between -2 and +2, calculate the appropriate
alignment adjustment for that color.
Alignment group
Adjustment calculation(s)
A
dT-(A+B+B-C+D)/3
B or C
dT-(A+B+B-C+D)/3
D
dT-(A+B+B-C+D)/3
E
dL=(E-F)*6
F
dL=(E-F)*6
dZ=(B-C)*2
dR=F*6
19 After completing calculations for the colors that are out of spec, return to
Alignment menu. (See Steps 6 and 9).
20 Select the appropriate color.
21 Change value of the respective setting by the amount specified by the
calculation.
For example, if T= -5 and dT= 2, the new T value will be (T+dT= -5 + 2)-3.
22 Once all values requiring update are changed, return to the Print Tests
menu and select Print Line Length Calibration.
10.02
665
23 Verify that the values are within the -2 and +2. Repeat if necessary.
Note: The Line Length Calibration must printed after making any changes
to color alignment.
24 Exit diagnostics.
Date:
5060
(Lexmark C750)
10/8/02
Replacing the Autocompensator
Autocompensator replacement is often necessitated by the incorrect removal
of a paper(cardstock) jam from the tray (for example, not using the paper jam
door on the side of the printer).
Problem Description
The Autocompensator is hard to remove from the printer. The process
described below is the least time consuming method.
Problem Solution
1
Remove all the Cartridges.
2
Remove the ITU.
3
Remove the Primary Tray.
4
Remove the transfer roll.
5
Remove the transfer plate.
10.02
666
6
Remove black mylar piece by removing the two screws.
7
Remove the lower left front cover and the jam access door cover.
8
Remove the pin that holds in the MPF swing arm assembly and remove the
MPF swing arm assembly.
9
Remove paper level sensor.
a
Remove both of the screws located under the back VTB bekt and a
third that is located at the pivot point for the transfer plate. This allows
the paper level assembly to drop into the cavity that the tray is inserted
into.
b Disconnect the wire from the paper level sensor and remove the paper
level assembly.
10 Disconnect the two connectors that are located where the black mylar
piece was.
11 Remove four screws that hold in the Pick Assembly.
12 Push the bellcrank in to allow the pick arm to fall to the bottom of the tray.
(The bellcrank lifts and lowers the pick arm.)
13 Disconnect the spring clip from the pick arm. Be sure not to let the spring
come off of the lower frame. Also identify which clips the spring clip is
sitting on.
14 Leaving the pick arm down, lift up on the pick assembly and slide it toward
the back of the machine. Drop it through the holes located next to the
brackets.
15 Once the pick assembly is removed you can see the transparency assy.
10.02
667
Note how the parts are assembled together before you remove the e-clip
and slide the transparency sensor assy off the shaft. When you are ready
replace the existing transparency sensor assembly with the new one and
reinstall a new e-clip. If you do not have a new e-clip use the same e-clip
you took off.
16 Reassemble into the lower frame.
Make sure both the pick motor and transparency connectors are placed
through the holes before you insert the brackets.
17 Reinsert the pick assembly into the lower frame.
Make sure the boss on the pick arm is on top of the bellcrank so it can raise
and lower the arm. Once the pick assembly brackets are through their
openings slide the assembly toward the front of the machine until the half
moon on the bracket is against the locator pin.
18 Once the pick assembly is in place, start with the first screw and bias the
pick assembly toward the front of the machine. Continue with the three
remaining screws.
19 Reconnect the connectors and reattach the paper level sensor.
20 When you place the mylar strip into position make sure you place it back
under the metal bar under the inner deflector.
21 Reattach the spring clip to the pick arm. Make sure the pick arm and
transparency assembly rotates freely from top to bottom in the machine.
22 The pick assembly is now in place and you can finish reassembling.
Date:
10.02
10/8/02
668
10.02
669
5060
(Lexmark C750)
100 ITU Belt Tracking diagnostic
Problem description
This diagnostic procedure determines whether a machine has an out of
nominal specification frame that forces the ITU Belt to track to the front or back
of the machine and produces a 100 ITU Error that can be resolved with the
application of a shim.
Solution
Perform the following diagnostic procedure:
1
Enter Diagnostic mode by pressing Go and Return during POR.
a
b
2
Scroll to Misc Tests and press Select.
Scroll to Belt Tracking and press Select.
– If Belt Tracking is available, skip to Step 3.
– If Belt Tracking is not available, the RIP and Engine code must be
updated to continue.
With the old ITU in the machine, update the machine code to at least
Engine code of 7.11-R00 and RIP code of 852.054 go to
http://support.lexmark.com/printerfirmware/ and enter the
authorization keycode as either 853007n for the network code or 853007b
for the base code.
10.02
670
•
•
•
3
To flash over USB use the utility and an installed Lexmark
International, Inc. driver configured to print though USB, go to
http://support.lexmark.com/printerfirmware/ and enter USBFlash
as the authorization keycode.
To prevent machine from calibrating between code flashes, remove
one cartridge and power up machine in Invalid Engine Code mode
(Right Arrow, Select and Return).
After each flash, machine tries to come up to Ready, but finds a
cartridge missing. Power off and bring back up in Invalid Engine Code
for next flash.
When the code update is complete, power off machine and insert the new
ITU. Note location of belt on tension roll. This is the roll on the opposite side
from the handle. It would be best to measure the belt position from inside
face of the front ITU sideplate to the front edge of the belt.
Note: Do not reinstall cartridges or close the front door.
4
Start machine in Diagnostics (CE) mode (hold Go and Return buttons as
you turn on the printer).
5
Select Misc. Tests. Select Belt Tracking.
The diagnostic runs 100 belt revolutions. This takes 10-15 minutes at most.
•
If the diagnostic displays “Test Complete,” the machine is within
specification. The old ITU was defective and was the cause of the
previous 100 ITU. Record the Code displayed under Test Complete
10.02
671
•
6
and pass on to Engineering. Check the belt position to verify that it is
centered. It may have tracked some while adjusting to the machine,
but it should not have tracked off excessively to one side.
If the diagnostic displays “Test Failed,” the machine is outside of
specification. The old ITU was within specification, but was damaged
due to being tracked off by the out of specification machine.
– Record the Code displayed and pass it onto Engineering.
– Remove the ITU and check the belt position to determine which
way the belt tracked. If the belt tracked to the rear, place the shim
in the rear. If the belt tracked to the front, place the shim in the
front.
– The plastic shim must be placed on the shaft on the right side of
the machine while the ITU is out of the machine. It can be
snapped in place and then slide to the rear or front depending on
where it is needed. The ITU hold down must be lifted to slide it
completely into position.
Put the ITU back in the machine and rerun the diagnostic.
•
The diagnostic should report “Test Complete.” This indicates that the
shim fixed the machine. Record the code displayed and report it to
Engineering.
– If the diagnostic reports “Test Failed,” and the belt has continued
to track to the same side, make sure that the shim was placed in
the right position.
– If the shim is correctly installed, the machine is too far out of
alignment for the shim to compensate and must be replaced.
10.02
672
7
Check the belt position to see if it has returned to the center of the
machine.
8
Power off the machine. Install the cartridges and power the machine back
up. Printer should calibrate.
9
Enter Diagnostics (CE) mode (Go and Return) and run the Line Length
Page.
a Select Print Menus.
b Select Prt Line Len Page.
10 Exit Diagnostics. Press Return twice and right arrow to display Exit
Diagnostics and press Select.
11 Print Menu Settings, Demo Page under regular menu. Print Quality Pages
in Config Menu (Select and Return). Check that color alignment and print
quality is satisfactory.
Date:
10.02
9/9/02
673
5060
(Lexmark C750)
100 ITU Error - Detecting the belt home sensor
When dealing with the Lexmark C750 the 100 ITU Error indicates that the
printer did not detect the belt home sensor, which is located inside of the ITU
Assembly. This bulletin provides a diagnostic procedure to determine the cause
of the problem. Follow the diagnostic procedure given below and then refer to
the Service Manual for the proper procedure to replace the faulty part.
To address an out of box failure:
If the printer displays the 100 ITU Error during the first power up, or during the
first “Printer Calibrating” cycle, it is possible that the printer was damaged
during shipment to the customer. If the printer has additional symptoms of
shipping damage, the printer should be replaced through the point of purchase
without a service call. Additional symptoms could include one or more of the
following:
• The printer carton was not 4 way banded to its original pallet when it
arrived at the customer’s site.
• The Tip N Tells indicate that the printer carton has been tipped when it
arrived at the customer’s site.
• Broken parts are apparent, such as Covers, Operator Panel, Redrive Door
Hinge.
• Waste Toner is apparent inside or outside of the printer.
• The ITU Hold Down Bellcranks are out of position on the right hand end of
the ITU frame.
10.02
674
Additional diagnostic steps
If the printer shows no other signs of shipping damage, but displays the 100 ITU
Error out of the box, follow the procedure as described below.
1
Ensure that the ITU Detensioner has been removed.
The ITU Detensioner is packing material located underneath the Toner
Cartridges, and is removed by pulling upward on the RED Handle on the
Right Hand side of the ITU. All cartridges must be removed to access the
Detensioner packing material.
2
Check that the ITU Cleaner Gear is turning at POR.To determine if the ITU
Cleaner Gear is turning:
a
b
Open the small paper jam access door above Tray 1.
Observe the white ITU Cleaner Gear on the left side of the opening
during POR.
This gear should rotate slowly, but smoothly for a few seconds before
the printer declares the 100 ITU Error.
–
–
10.02
If the Cleaner Gear is NOT TURNING, continue with Step 3.
If it turns smoothly, go to Step 6.
675
3
Check that the ITU Drive Roll Gear is turning during POR. To determine if
the ITU Drive Roll Gear is turning:
a
b
4
Check that the ITU Drive Motor is turning during POR. To determine if the
ITU Drive Motor is turning:
a
b
5
Open the MPF door to its horizontal position
Observe the gear on the left end of the ITU Drive Roll during POR.
– If the ITU Drive Roll Gear TURNS for a few seconds before the
printer declares the 100 ITU Error, then either the ITU Assembly
is faulty or the Second Transfer Roll may be out of position (See
“Removal of Second Transfer Roll” in the Service Manual).
– If the ITU Drive Roll Gear does NOT TURN, then go on to Step 4.
Remove the Back Covers from the printer as described in the Service
Manual,.
Observe the motor during POR.
– If the ITU Drive Motor TURNS for a few seconds before the printer
declares the 100 ITU Error, the ITU Drive Assembly is faulty.
– If the motor does NOT TURN, then go on to Step 5, or refer to the
Service Manual regarding a 154 Motor Error.
Check the cable and connector between the ITU Drive Motor and the
Engine Card.
If the cable checks OK and the connector is fully seated on the Motor Card
and the Engine Card, then either the Drive Motor or the Engine Card is
faulty.
10.02
676
6
Reseat the ITU Release Lever to ensure that there is a good electrical
connection between the printer and the ITU Assembly. The ITU Release
Lever can be located by opening the MPF door to its horizontal position.
The ITU Release Lever is a blue lever that rotates to a 6 o’clock position
when it is locked, and to a 3 o’clock position it is released. First release,
then lock this lever, applying a firm pressure to lock the lever in the
6 o’clock position. If the 100 ITU Error persists after POR, continue to
Step 7.
7
Check Sensor Connectors on front end of the ITU Handle. The ITU
Assembly must be removed from the printer to check that the sensor
connectors are fully seated.
•
•
8
If the connectors are not fully seated, reinstall the ITU Assembly and
POR the printer to check for the 100 ITU Error after fully seating the
connectors.
If the connectors are fully seated upon inspection or if the error
persists, continue to Step 8.
Check the position of the Front Contamination Seal. With the ITU
Assembly removed from the printer, check that the thin black plastic film
which is attached to the front plate of the ITU Frame, is laying on top of the
ITU belt. (Both the front and the rear Seals should lay on top of the belt.) If
this Seal is underneath the belt, it can block the belt home sensor from the
reflective tape.
If the Seal is on top of the belt, continue to Step 9.
10.02
677
9
Check Belt Position on ITU Assembly. While the ITU Assembly is removed
from the printer, examine the position of the ITU belt relative to the ITU
Frame Front Plate.
•
If the belt position is between 3 mm and 8 mm from the ITU Frame
Front Plate, the belt position is OK, go on to Step 11.
• If the position of the belt is significantly shifted to the front or the rear
of the ITU Assembly, “100 ITU Belt Tracking diagnostic” on page
669 for information on the repair procedure.
10 Check the cables and connectors between the ITU Assembly and the
Engine Card. Replace the cable assembly if defective.
If cables and connectors check OK, go on to Step 11.
11 If the 100 ITU Error persists to this point, the problem is either in the ITU
Assembly or the Engine Card. Try a new ITU Assembly first, then replace
the Engine Card.
Date:
10.02
Revised 9/9/02 (original 1/2/02)
678
5060
(Lexmark C750)
PSD (180-195) error is displayed during print jobs or calibration due
to malfunction PSD Sensor assembly
The error could be displayed on the op panel of any printer with code prior to
EC2 (EC2 CODE: RIP-852.054, Engine-9.00-R00). The solution is to update
the printer with EC2 code (Engine and RIP Code/Option Code) from the
following source https://support.lexmark.com/printerfirmware and enter:
• For Network code (C750n) - use 850ncode as the keycode.
• For Base code (C750) - use 850code as the keycode.
Save the code to an easily accessible location on your harddrive
Update instructions
1
2
At a printer READY state, copy the file to the LPT port with the /b switch.
WARNING: DO NOT POWER OFF MACHINE WHILE UPDATING CODE.
10.02
679
1
2
At a printer READY state, ftp to the IP address if you are using a network
printer:
a
Using an FTP Client, connect to the printer.
Example “ftp: 111.111.111.11”.
b
c
1
2
At a printer READY state, download the USBFlash program (Copyright
2001, Lexmark International, Inc.) from
support.lexmark.com/printerfirmware/. You will need to call TSC at 1-888LEXMARK for the keycode to enable the download, or use the instructions
for updating through parallel or network.
3
4
In the USBFlash program, select the code to flash to the printer from the
File Open Icon.
5
10.02
680
6
Click Start.
For other Printer Code updates or clarifications, contact the Lexmark Technical
Support Center at 1-888-LEXMARK.
Date:
5060
(Lexmark C750)
5/28/02
990 Service Tray X errors in printers with 500 Option trays
This problem occurs when the 500 option tray is at the downlevel build code
(03.20-R01) with a production level printer. The tray works fine until the printer
goes into power saver mode and a print job is sent to the printer. Once the
printer tries to come out of power saver mode, the 500 option/printer code
interaction results in a 990 service tray X message. The option tray needs new
code loaded only if the current code on the option is lower than 05.25-R00. If
code is updated and error message still appears, refer to the C750 service
manual for 990 Service Error Displays (2-65).
Flash the option tray with the latest level of approved option code. Print out
menu page. If the code version for the tray with the error is 03.20-R00 or earlier,
it needs to be updated to the current approved version (download directory link
below). If the 500 option tray is already at this level and the message still
appears, refer to the C750 service manual for 990 Service Error Displays.
10.02
681
Flash Instructions:
WARNING: When flashing any type of code, it is always important not to
power off the machine once the flash process has begun. If the machine is
powered off during the option tray code update, the option card cannot be
reprogrammed and needs replacing before current level code can be
installed.
1
Download the file from
ftp://ftp.lexmark.com/laser_printers/Lexmark_C750/Trays/
2
At the ready state, copy the option code file over to the printer.
•
For an option tray under a Base Model C750, you may copy the file to
the LPT port with the /b switch.
Example: “copy TrayX_05.25-R00.flm lpt1 /b” (assumes you are in the
same directory as TrayX_05.25-R00.flm) 2)
•
For an option tray under a Network Model C750, you may ftp to the IP
address.
Example ftp: 111.111.111.11, type bin (puts ftp session in binary
mode), type “put c:\TrayX_05.25-R00.flm” (assumes the file is in your
root directory).
•
If you are using a Marknet Pro, you will have to put the file to the
correct port.
Example ftp: 111.111.111.11, type bin, type “put c:\TrayX_05.25R00.flm /prt0” (This would send the file to the printer on parallel port
1; “/prt1” would send it to port 2).
10.02
682
3
After the machine is loaded with code and reboots, print out menu page
and see if the code version for the 500 option in question has been updated
to current approved level. If the 500 option tray is at the current production
release code of 05.25-R00 and the message still appears, refer to the
C750 service manual for 990 Service Error Displays.
Date:
5060
(Lexmark C750)
5/28/02
When the engine and/or RIP cards are replaced, the NVRAM
settings may be lost or replaced with an invalid set of values
Each card carries a mirror of the NVRAM settings. If only one card is replaced,
then the NVRAM settings can be transferred to the new card. If both cards are
replaced at the same time, then the proper NVRAM settings are lost. This
requires the motors to be detected, trays calibrated, and black registration and
color alignments redone. It is very important that one card be replaced at a time
to ensure NVRAM settings are maintained.
Replacing both cards
If both the Engine card and the RIP card must be replaced, replace one at a
time, power on the machine between each card replacement and check for
proper NVRAM transfer. Begin with the Engine card first.
1
If the Engine card must be replaced, refer to the Service Manual for the
physical replacement instructions.
2
When the Engine card replacement is completed, power on the machine.
10.02
683
•
•
If the new Engine card NVRAM settings are blank or invalid, the
machine will automatically copy the NVRAM from the RIP to the new
Engine card.
If the new Engine card does have valid NVRAM settings, the machine
displays “RIP to Engine.” Press GO (Green Button). This will take the
machine’s NVRAM settings and copy it from the current RIP card to
the new Engine card.
Replacing the RIP card
Note: Always replace the Engine card first.
1
If the RIP card must be replaced, power off the machine and refer to the
Service Manual for the physical replacement instructions.
2
When the RIP card replacement is completed, power on the machine.
•
•
3
If the new RIP card NVRAM settings are blank or invalid, the machine
will automatically copy the NVRAM from the Engine to the new RIP.
If the new RIP card does have valid NVRAM settings, the machine will
display “RIP to Engine.” Press STOP (Red Button). The machine will
display “Engine to RIP.” Press GO (Green Button). This will take the
machine’s NVRAM settings and copy it from the Engine card to the
new RIP card.
Run Print Menus and verify the Engine and RIP cards for the proper levels
of code.
10.02
684
Updating code
Update any down level code from the following link:
http://support.lexmark.com/printerfirmware and enter keycode 850ncode
for Network code (C750n) or keycode 850code for base model (C750). Save
the resulting downloaded file to an easily accessible location on your harddrive.
Run some test pages to ensure that Black Registration and Color Alignment
was maintained.
Date:
5060
(Lexmark C750)
5/28/02
Printhead PSD use discontinued with 852.054 Rip/9_00-R00 Engine
Code
With the code level mentioned above the PSD sensors have been disabled.
When machines with PSD’s are updated to EC2 code, the main PSD function
is discontinued and a thermistor onboard the PSD card will be used instead. If
this thermistor ever has problems, it is best to leave the PSD in place so as not
to disturb the printerhead and install a new thermistor card.
1
Enter the CE menu (Go and Return), enter the Alignment Menu, select
Drift Sensors. The following information will be displayed.
Com = XXX M = XX C = XX Y= XX K = XX
•
Where XXX is one of the following
– Err - RIP cannot communicate with AtoD - RIP card failure
– Good - No communications problems.
10.02
685
•
Where XX is one of the following codes based on the last reading from
the AtoD part.
– OP - Open Detected
– SH - Short Detected
– RA - Range Check Error Detected
– Err - No reading on this sensor
– # - Last temp reading in degrees C if system is functional. This
should be close to room temperature, 22 - 25 C
2
If the sensors are good, go to Print Tests and print the Print Line Len page.
This will set TD1 to E for Enabled instead of A for enabled with assumed
data. Restart machine, and run Print Menus page. Check TD1 information
on settings page.
3
If any errors appear, still run Print Line Len page and run Print Menus
page. Check TD1 information on settings page. Use attached Diagnostics
slide below for repair instructions.
Date:
10.02
5/28/02

LEXMARK SERVICE TIPS ARCHIVE - ALL MODELS

Transcription

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