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Lexmark 4049LMO Service Manual - Page 26

Maintenance Approach, Tools Required For Service, Spring hook - drivers

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4049-XXX Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. Begin with "Start" on page 2-1. This printer can be serviced without being connected to a host computer. After you complete the repair, perform tests as needed to verify the repair. Tools Required For Service Flat-blade screwdriver #1 Phillips screwdriver #2 Phillips screwdriver 5.5 mm nut driver 8 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964 1-3

Section	Page
Table of Contents	3
Notices and Safety Information	9
Laser Notice	9
Laser	10
Avis relatif à l’utilisation de laser	10
Avvertenze sui prodotti laser	11
Avisos sobre el láser	11
Declaração sobre Laser	12
Laserinformatie	12
Lasermeddelelse	13
Huomautus laserlaitteesta	13
Laser-notis	14
Laser-melding	14
Avís sobre el Làser	15
Japanese Laser Notice	15
Chinese Laser Notice	16
Korean Laser Notice	16
Trademarks	17
Safety Information	18
Consignes de Sécurité	18
Norme di sicurezza	19
Sicherheitshinweise	19
Pautas de Seguridad	20
Informações de Segurança	20
Informació de Seguretat	21
Preface	23
1. General Information	24
Power Consumption	25
Options	25
Maintenance Approach	26
Tools Required For Service	26
Abbreviations	27
2. Diagnostic Information	28
Start	28
Power-On Self Test (POST)	37
Symptom Table	38
Banding	39
Background	39
Black Page	40
Blank Page	41
Blurred or Fuzzy Print	42
Dead Machine	42
Duplex	43
Fan (927 Error)	45
Fuser Theory	46
Fuser: 920, 921, or 922 Error	46
Fuser: 923 or 924 Error	47
Honeycomb	47
Horizontal Void or Streak	47
LAN Problems	48
Light Print	48
Network Card 977 Errors	48
Network Wrap Tests	49
Output Bin Sensor	49
Operator Panel Problem	49
Paper Feed Problem, 500-Sheet Option or 200-Sheet ...	50
Paper Feed, Base Printer	50
Paper Feed, Duplex Unit	52
Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Au...	53
Paper Feed Problem, 200-Sheet Second Drawer, Rt	53
Paper Feed Problem, Dual Rear Feeder	54
Paper Feed Problem, High Capacity Feeder	56
Printhead	57
Paper Size Sensing Problem	58
Regularly Spaced Marks	59
Residual Image	59
Random Marks	59
Skew, all edges	60
Skew, top and bottom only	60
Stalled (diamonds on display)	61
Vertical Void or Streak	61
3. Diagnostic Aids	62
Diagnostics Mode	62
Diagnostics Mode Menu Structure	62
Diagnostics Mode Tests	64
Auto Clean	64
Auto Clean Frequency	64
Auto Clean Delay	65
Button Test	65
Charge Roll	65
Defaults	66
Disk Test/Clean	66
Duplex Feed 1 Test	67
Duplex Feed 2 Test	67
Envelope Enhance	68
Envelope Print Test	68
Error Log	69
Flash Test	69
Fuser Temperature And Warm-Up Time	69
LCD Test	70
Maintenance Kit Count	71
Memory Tests	71
Page Count	71
Paper Feed Tests	71
Parallel Confidence	72
Permanent Page Count	72
Print Contrast	72
Print Registration	73
Print Test 1	74
Print Test 2	74
Print Test 3	75
Quick Disk Test	75
Quick Test	75
Sensor Test	76
Top Margin and Duplex Quick Tests	76
Transfer	77
Wrap Tests	77
Other Tests	78
Developed Image Test	78
LAN Information	78
Print Test Page	79
Print Test with RIP Board Removed	79
4. Repair Information	80
Handling ESD-Sensitive Parts	80
Adjustments	81
Envelope Restraint Spring On The Envelope+ Feeder ...	81
Paper Restraint Spring On The 100-Sheet Auxiliary ...	81
Envelope+ Feeder Magnet And 100-Sheet Auxiliary Fe...	82
Dual Rear Feeder Gear Alignment Adjustment	83
Fuser Drive Gear Backlash Adjustment	84
Fuser Solenoid Adjustment	86
Paper Feed Magnet Adjustment	87
Printhead Skew Adjustment	88
Removal Procedures	89
Covers	89
Right Cover Removal	89
Front Cover Removal	89
Left Cover Removal	91
Top Cover Removal	91
14 in. 200-Sheet Paper Tray Top Cover	93
14 in. 500-Sheet Paper Tray Top Cover	93
D-roll Assembly Removal	93
Drive Motor Removal	93
Engine Board Removal	94
Exit Sensor Board Removal	95
Fan/Redrive Removal	96
Fuser Removal	97
Fuser Input Guide Removal	98
Fuser Lamp Removal	99
Fuser/Sensor Cable Removal	100
Fuser Solenoid Removal	101
Fuser Shroud Assembly Removal	102
HVPS Removal	103
INA or Hard Disk Removal	105
Input Sensor Board Removal	105
Lower Frame Assembly Removal	107
LVPS Removal	108
LVPS Cover Removal	109
Operator Panel Removal	110
Paper Feed Rollers Removal	110
Paper Feed Magnet Assembly Removal	111
Paper Size Switch Removal	112
Printhead Removal	113
RIP Board and Inner EMC Shield Removal	114
Toner Sensor Removal	114
Torquer Motor Removal	114
Transfer Roll Removal	115
Transfer Roll Housing Removal	116
Upper Frame Removal	117
Duplex Option Top Cover And Table Cover Removal	118
Duplex Option Exit Card And Cover Removal	119
Duplex Option Bottom Cover And Entry Sensor Card R...	120
Duplex Option System Card And Motor Removal	121
Dual Rear Feeder - Edge Guide Asm.	122
Dual Rear Feeder - Gear Plate Asm.	122
Dual Rear Feeder - Right Cover	122
200-Sheet Second Drawer, Rt	123
High Capacity Feeder Paper Feed Rollers	124
High Capacity Feeder Cover	126
5. Connector Locations	127
Major Assembly Locations	127
Gear Train	128
HVPS	129
Transfer Roller Housing	129
Engine Board Connectors	130
RIP Board	132
Board Installation Hardware	133
Mirror Motor/Fan Cable	133
Operator Panel/Output Bin Sensor Cable	134
Printhead Connector Locations	136
Duplex Autoconnect Cable	136
Printer Ground Straps	137
High Capacity Feeder Board Connectors	138
6. Preventive Maintenance	139
Safety Inspection Guide	139
Lubrication Specifications	139
Scheduled Mechanical Maintenance	141
Printhead Window Cleaning Procedure	142
Cleaning The Transfer Roller	142
7. Parts Catalog	143
How To Use This Parts Catalog	143