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Model 4040 - 600dpi laser printer -
Service Manual
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Lexmark OptraTM N
4040
· Table of Contents · Start Diagnostics · Safety and Notices · Trademarks · Index · Manuals Menu
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
4040
Third Edition (March, 1999)
The following paragraph does not apply to the united kingdom or any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION "AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions of the publication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase. Comments may be addressed to Lexmark International, Inc., Department D22/ 035-3, 740 New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. LocalTalk is a trademark of Apple, Inc., registered in the United States and other countries. Other trademarks are the property of their respective owners. ©Copyright Lexmark International, Inc. 1996, 1999. All Rights Reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.
4040
Contents
Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . xii Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xx Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxv General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Diagnostic Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Initial Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Error Code/Message Tables. . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Service Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Operator Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Symptom Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Print Quality Symptom Table . . . . . . . . . . . . . . . . . . . . . 2-11 Paper Feed Symptom Table . . . . . . . . . . . . . . . . . . . . . 2-12 Other Malfunction Symptom Table. . . . . . . . . . . . . . . . . 2-13 Paper Deck Symptom Table . . . . . . . . . . . . . . . . . . . . . 2-15 Base Machine Service Checks . . . . . . . . . . . . . . . . . . . . . . . 2-16 AC Power Input Service Check . . . . . . . . . . . . . . . . . . . 2-16 DC Power Input Service Check . . . . . . . . . . . . . . . . . . . 2-17 Duplex Horizontal Registration Guide Service Check . . 2-18 Fan Motor Service Check (927) . . . . . . . . . . . . . . . . . . . 2-19 Power Supply Fan (FM1) Check . . . . . . . . . . . . . . . .2-20 Fuser/Printhead Fan (FM2) Check . . . . . . . . . . . . . .2-20 Electrical Assembly Fan (FM3) Check . . . . . . . . . . .2-21 Fuser Fan (FM4) Check . . . . . . . . . . . . . . . . . . . . . .2-21 Fuser (Abnormal Temperature) Service Check (923) . . 2-22 Fuser (Temperature Low) Service Check (920/922) . . . 2-23 Fuser (Wrong Type) Service Check (924) . . . . . . . . . . . 2-24 High-Voltage Power Supply Output Service Check . . . . 2-24 Lifting Plate (Multipurpose Tray) Service Check . . . . . . 2-25 Main Motor Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-25 Paper Pick-Up from Envelope Feeder Service Check . . 2-26 Paper Pick-Up from Cassettes Service Check. . . . . . . . 2-26 Contents iii
4040 Base Machine Service Checks (Continued) Paper Pick-Up from Multipurpose Tray Service Check . 2-27 Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Printhead/Laser Service Check . . . . . . . . . . . . . . . . . . . 2-28 Printhead/Scanner Motor Service Check . . . . . . . . . . . 2-29 Registration Roller Service Check. . . . . . . . . . . . . . . . . 2-29 Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Black Page Service Check: . . . . . . . . . . . . . . . . . . . . . . 2-30 Blank Spots Service Check . . . . . . . . . . . . . . . . . . . . . . 2-30 Blank Page Service Check . . . . . . . . . . . . . . . . . . . . . . 2-31 Dark Image Service Check . . . . . . . . . . . . . . . . . . . . . . 2-32 Dirt on Back of Paper Service Check . . . . . . . . . . . . . . 2-32 Dirty Image Service Check . . . . . . . . . . . . . . . . . . . . . . 2-33 Distorted Print Service Check . . . . . . . . . . . . . . . . . . . . 2-33 Light Image Service Check . . . . . . . . . . . . . . . . . . . . . . 2-34 Poor Fusing Service Check . . . . . . . . . . . . . . . . . . . . . . 2-35 Sharp Black Horizontal Lines Service Check . . . . . . . . 2-35 Smudged Horizontal Bands Service Check. . . . . . . . . . 2-36 Vertical Dots in a Line Service Check . . . . . . . . . . . . . . 2-36 Vertical Streaks/Lines Service Check . . . . . . . . . . . . . . 2-37 White Horizontal Lines Service Check . . . . . . . . . . . . . 2-37 White Vertical Lines Service Check. . . . . . . . . . . . . . . . 2-38 Paper Feed Service Checks . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Bent Leading Edge of Paper Service Check . . . . . . . . . 2-40 Duplexing Assembly Paper Jams Service Check . . . . . 2-41 Envelope Feeder Paper Jams Service Check. . . . . . . . 2-42 Fuser and Delivery, Paper Jams Service Check . . . . . . 2-43 Multiple Paper Feed Service Check . . . . . . . . . . . . . . . 2-44 Paper Jam Sensor Service Check. . . . . . . . . . . . . . . . . 2-45 Paper Jam 20, Paper Deck Tray or Feeder . . . . . . . 2-47 Paper Jam 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 Paper Jam 21, Input . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Paper Jam 22, Fuser . . . . . . . . . . . . . . . . . . . . . . . . 2-48 Paper Jam 23, Top Output/Delivery . . . . . . . . . . . . . 2-49 Paper Jam 25, Duplex . . . . . . . . . . . . . . . . . . . . . . . 2-49 Paper Jam 27, Paper Size/Change Paper . . . . . . . . 2-49 Paper Skew Service Check . . . . . . . . . . . . . . . . . . . . . . 2-50 Pick-Up Assembly Paper Jams Service Check . . . . . . . 2-51 Wrinkled Paper Service Check . . . . . . . . . . . . . . . . . . . 2-52
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4040 Paper Deck Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Paper Deck Feed Roller Service Check. . . . . . . . . . . . . 2-53 Paper Deck Lifting Plate Service Check. . . . . . . . . . . . . 2-53 Paper Deck Motor Service Check . . . . . . . . . . . . . . . . . 2-55 Paper Deck Paper Pick-Up Service Check . . . . . . . . . . 2-55 Paper Deck Power Input Service Check . . . . . . . . . . . . 2-57 Paper Deck Registration Roller Service Check . . . . . . . 2-58 Paper Deck Paper Feed Service Checks . . . . . . . . . . . . . . . 2-58 Paper Deck Bent Leading Edge Service Check. . . . . . . 2-58 Paper Deck Left Edge Registration Service Check . . . . 2-59 Paper Deck Multiple Paper Feed Service Check . . . . . . 2-59 Paper Deck Paper Jam Service Check . . . . . . . . . . . . . 2-59 Paper Deck Paper Skew Service Check . . . . . . . . . . . . 2-60 Paper Deck Wrinkled Paper Service Check. . . . . . . . . . 2-60 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Interlock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Basic Engine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Menu Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Option-2000 Sheet Paper Deck (Tray 3) Self Test. . . . . . 3-2 Diagnostics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . 3-4 Diagnostics Mode Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Flash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Memory Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Print Test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Print Test 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Print Test 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Left Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Top Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Wrap Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
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4040 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Envelope Feeder Separation Guide and Lower Separation Roller Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Paper Drawer Cassette Side Registration Adjustment . . 4-4 Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . 4-5 External Parts Removal Procedures . . . . . . . . . . . . . . . . . . . 4-6 Cover Removal Procedures . . . . . . . . . . . . . . . . . . . . . . 4-6 Face-Down Tray Removal . . . . . . . . . . . . . . . . . . . . . 4-7 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Upper Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Delivery Cover Removal . . . . . . . . . . . . . . . . . . . . . 4-12 MultiPurpose Tray Removal . . . . . . . . . . . . . . . . . . . 4-12 Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Left Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . 4-14 Fan Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . 4-15 Power Supply Fan (FM1) Removal . . . . . . . . . . . . . 4-16 Fuser/Scanner Fan (FM2) Removal . . . . . . . . . . . . . 4-17 Electrical Fan (FM3) Removal . . . . . . . . . . . . . . . . . 4-19 Fuser Fan (FM4) Removal . . . . . . . . . . . . . . . . . . . . 4-20 Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Drive System Removal Procedures . . . . . . . . . . . . . . . . . . . 4-22 Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Main Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Paper Transport System Removal Procedures . . . . . . . . . . 4-25 Pick-Up Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Pick-Up Motor Removal . . . . . . . . . . . . . . . . . . . . . . 4-28 Feed Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Cassette Pick-Up Solenoid Removal . . . . . . . . . . . . 4-29 Delivery Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Registration Roller Removal . . . . . . . . . . . . . . . . . . . . . 4-31 Registration Clutch Removal . . . . . . . . . . . . . . . . . . 4-32 Registration Lower Roller Removal . . . . . . . . . . . . . 4-32 Manual Feed Pick-Up Removal. . . . . . . . . . . . . . . . . . . 4-34 Manual Feed Pick-Up Clutch Removal . . . . . . . . . . 4-36 Lifting Plate Solenoid Removal . . . . . . . . . . . . . . . . 4-36 Manual Feeding Pick-Up Roller Removal . . . . . . . . . . . 4-38 Separation Pad Removal. . . . . . . . . . . . . . . . . . . . . . . . 4-39 Pick-Up/Feed/Separation Rollers Removal . . . . . . . . . . 4-40
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4040 Exposure System Removal Procedures . . . . . . . . . . . . . . . . 4-41 Printhead Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Electrostatic Imaging/Developing/Cleaning System Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 EP Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Drum Protective Shutter . . . . . . . . . . . . . . . . . . . . . .4-44 Photosensitive Drum . . . . . . . . . . . . . . . . . . . . . . . . .4-44 Transfer Charging Roller Removal. . . . . . . . . . . . . . . . . 4-45 Fuser Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Fuser Roller Heater Removal. . . . . . . . . . . . . . . . . . . . . 4-48 Thermoswitch Removal . . . . . . . . . . . . . . . . . . . . . .4-49 Thermistor Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-50 Fuser Upper Roller Removal . . . . . . . . . . . . . . . . . .4-51 Fuser Lower Roller Removal . . . . . . . . . . . . . . . . . .4-56 Electronic Components Removal Procedures . . . . . . . . . . . 4-58 Controller Card Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-58 System Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 Pick-Up Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 Multipurpose Tray Board Removal. . . . . . . . . . . . . . . . . 4-60 Switch/Sensor Board Removal. . . . . . . . . . . . . . . . . . . . 4-61 High Voltage Power Supply Board . . . . . . . . . . . . . . . . . 4-63 Cassette-Size Sensing Boards Removal . . . . . . . . . . . . 4-64 Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-65 Envelope Feeder Removal Procedures . . . . . . . . . . . . . . . . 4-67 Envelope Feeder Cover Removals . . . . . . . . . . . . . . . . 4-67 Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . .4-67 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . .4-67 Lower Cover Removal . . . . . . . . . . . . . . . . . . . . . . .4-68 Upper Cover Removal . . . . . . . . . . . . . . . . . . . . . . .4-69 Envelope Side Guide Removal . . . . . . . . . . . . . . . . . . . 4-70 Envelope Feeder Pick-Up Motor Removal . . . . . . . . . . . 4-71 Envelope Feeder Driver Board Removal . . . . . . . . . . . . 4-73 Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74 Envelope Feeder Pick-Up Roller Removal. . . . . . . . . . . 4-75 Separation Rollers and Torque Limiter Removal . . . . . . 4-75
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4040 Duplex Assembly Removal Procedures. . . . . . . . . . . . . . . . 4-77 Upper Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77 Lower Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78 Switchback Roller Release Solenoid Removal . . . . . . . 4-80 Duplex Deflector Drive Solenoid Removal . . . . . . . . . . 4-81 Switchback Motor Removal . . . . . . . . . . . . . . . . . . . . . . 4-84 Side Registration Motor Removal . . . . . . . . . . . . . . . . . 4-85 Duplex Feed Clutch Removal . . . . . . . . . . . . . . . . . . . . 4-86 Duplex Driver Board Removal . . . . . . . . . . . . . . . . . . . . 4-87 Paper Deck Removal Procedures . . . . . . . . . . . . . . . . . . . . 4-89 External Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-89 Left Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-89 Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-90 Feed Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-91 Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-91 Paper Deck Drive System Removal Procedures . . . . . . . . . 4-92 Drive Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 4-92 Lifter Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-93 Deck Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-93 Limit Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94 Paper Transport System Removal Procedures . . . . . . . . . . 4-95 Pick-Up Assembly Removal . . . . . . . . . . . . . . . . . . . . . 4-95 Pick-Up Solenoid Removal . . . . . . . . . . . . . . . . . . . 4-97 Pick-Up Motor Removal . . . . . . . . . . . . . . . . . . . . . . 4-98 Feed Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . 4-99 Feed Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . 4-100 Registration Clutch Removal . . . . . . . . . . . . . . . . . 4-101 Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . . . 4-102 Registration Roller Removal . . . . . . . . . . . . . . . . . 4-103 Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104 Lifter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105 Electronic Component Removal Procedures . . . . . . . . . . . 4-113 Paper Deck Driver Board Removal . . . . . . . . . . . . . . . 4-113 Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-113 Paper-size Sensing Switch Board Removal . . . . . . . . 4-114 Paper-level Sensing Switch Board Removal . . . . . . . . 4-115 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Parts of the Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Duplexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Cross Section View of Printer and Duplexer . . . . . . . . . . 5-4
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4040 Locations (Continued) Cross Section View of Envelope Feeder . . . . . . . . . . . . . 5-5 Base Machine Sensor and Switch Operation. . . . . . . . . . 5-6 Base Machine Motor and Clutch Operation . . . . . . . . . . . 5-8 Paper Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Duplex Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Paper Deck Sensor and Switch Operation. . . . . . . . . . . 5-12 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Clutches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Motor, Fans, and Heaters. . . . . . . . . . . . . . . . . . . . . . . . 5-19 Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 System Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 System Board Connector Signals . . . . . . . . . . . . . . . . . 5-28 System Board Connector J201 . . . . . . . . . . . . . . . . .5-28 System Board Connector J201 . . . . . . . . . . . . . . . . .5-30 System Board Connector J202 . . . . . . . . . . . . . . . . .5-30 System Board Connector J203 . . . . . . . . . . . . . . . . .5-30 System Board Connector J204 . . . . . . . . . . . . . . . . .5-30 System Board Connector J205 . . . . . . . . . . . . . . . . .5-32 System Board Connector J206 . . . . . . . . . . . . . . . . .5-32 System Board Connector J207 . . . . . . . . . . . . . . . . .5-32 System Board Connector J208 . . . . . . . . . . . . . . . . .5-32 System Board Connector J209 . . . . . . . . . . . . . . . . .5-33 System Board Connector J210 . . . . . . . . . . . . . . . . .5-33 System Board Connector J212 . . . . . . . . . . . . . . . . .5-33 System Board Connector J213 . . . . . . . . . . . . . . . . .5-33 System Board Connector J214 . . . . . . . . . . . . . . . . .5-35 System Board Connector J215 . . . . . . . . . . . . . . . . .5-35 System Board Connector J216 . . . . . . . . . . . . . . . . .5-35 System Board Connector J217 . . . . . . . . . . . . . . . . .5-36 System Board Connector J218 . . . . . . . . . . . . . . . . .5-36 System Board Connector J219 . . . . . . . . . . . . . . . . .5-36 System Board Connector J220 . . . . . . . . . . . . . . . . .5-38 System Board Connector J221 . . . . . . . . . . . . . . . . .5-38 System Board Connector J222 . . . . . . . . . . . . . . . . .5-38 System Board Connector J223 . . . . . . . . . . . . . . . . .5-40 System Board Connector J225 . . . . . . . . . . . . . . . . .5-40 Switch/Sensor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 Cassette Size Sensing Switch Board . . . . . . . . . . . . . . . 5-40 High Voltage Power Supply Board . . . . . . . . . . . . . . . . . 5-41
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4040 Locations (Continued) Envelope Feeder Driver Board . . . . . . . . . . . . . . . . . . . 5-41 Paper Deck Switches, Sensors, Clutches, Solenoid, Motors . 5-42 Paper Deck Printed Circuit Boards . . . . . . . . . . . . . . . . 5-43 Paper Deck Connectors . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Paper Deck Driver Board. . . . . . . . . . . . . . . . . . . . . . . . 5-45 Paper Deck Driver Board Connectors . . . . . . . . . . . . . . 5-45 Paper Deck Driver Board Connector J201 . . . . . . . . 5-45 Paper Deck Driver Board Connector J202 . . . . . . . . 5-47 Paper Deck Driver Board Connector J203 . . . . . . . . 5-47 Paper Deck Driver Board Connector J204 . . . . . . . . 5-47 Paper Deck Driver Board Connector J205 . . . . . . . . 5-49 Paper Deck Driver Board Connector J206 . . . . . . . . 5-49 Paper Deck Driver Board Connector J207 . . . . . . . . 5-49 Paper Deck Driver Board Connector J208 . . . . . . . . 5-49 Paper Deck Driver Board Connector J209 . . . . . . . . 5-51 Paper Deck Driver Board Connector J210 . . . . . . . . 5-51 Paper-level Sensing Switch Board . . . . . . . . . . . . . . . . 5-51 Paper-size Sensing Switch Board . . . . . . . . . . . . . . . . . 5-51 Option Controller Interface Connector Locations . . . . . 5-52 Option Controller Interface Connector. . . . . . . . . . . . . . 5-53 Optional I/O Device Interface . . . . . . . . . . . . . . . . . . . . 5-55 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Expected Life of Consumable Parts . . . . . . . . . . . . . . . . 6-1 Maintenance, Customer Checks . . . . . . . . . . . . . . . . . . . 6-2 Service Checkpoints - Printer . . . . . . . . . . . . . . . . . . . . . 6-2 Cartridge - Photosensitive Drum . . . . . . . . . . . . . . . . 6-2 Manual Feeding Pick-Up Roller, Cassette Pick-Up Roller, Separation Roller, and Feed Roller . . . . . . . . . . . . . . 6-2 Separation Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Registration Roller Unit . . . . . . . . . . . . . . . . . . . . . . . 6-2 Transfer Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Transfer Charging Roller . . . . . . . . . . . . . . . . . . . . . . 6-3 Static Charge Eliminator . . . . . . . . . . . . . . . . . . . . . . 6-3 Feed Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Service Checkpoints - Paper Deck . . . . . . . . . . . . . . . . . 6-3 Pick-Up Roller, Separation Roller, Feed Roller . . . . . 6-3 Lubricants and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
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4040 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . 7-1 Covers and Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Internal Paper Mechanism . . . . . . . . . . . . . . . . . . . . . . . . .7-6 Internal Paper Drawer/Print Cartridge Mtg. . . . . . . . . . . . .7-8 Printhead/System Board . . . . . . . . . . . . . . . . . . . . . . . . .7-12 Power Supply/Fuser Cables. . . . . . . . . . . . . . . . . . . . . . .7-14 Face-Up Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18 High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . .7-20 Printer Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22 Lower Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-24 Upper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28 Paper Pick-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 Registration Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44 Multipurpose Tray Pick-Up . . . . . . . . . . . . . . . . . . . . . . . .7-46 Multipurpose Tray. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50 Paper Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-52 Paper Delivery Frame . . . . . . . . . . . . . . . . . . . . . . . . . . .7-54 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-56 Controller Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-60 Envelope Feeder Covers . . . . . . . . . . . . . . . . . . . . . . . . .7-62 Envelope Feeder Drive 1 . . . . . . . . . . . . . . . . . . . . . . . . .7-64 Duplex Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-68 Paper Deck, Covers and Frame. . . . . . . . . . . . . . . . . . . .7-76 Paper Deck, Main Body . . . . . . . . . . . . . . . . . . . . . . . . . .7-78 Paper Deck, Paper Drawer . . . . . . . . . . . . . . . . . . . . . . .7-80 Paper Deck Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-86 Paper Deck, Paper Pick-Up . . . . . . . . . . . . . . . . . . . . . . .7-88 Paper Deck, Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . .7-92 Option Controller Card . . . . . . . . . . . . . . . . . . . . . . . . . . .7-96 Options (No Illustration). . . . . . . . . . . . . . . . . . . . . . . . . .7-98 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
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Notices and Safety Information
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property rights may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user's responsibility.
Laser Notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 825. Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.
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Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 825 gemäß amtlicher Bestätigung erfüllt. Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.
Avis relatif à l'utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 825 relatives aux produits laser de Classe I. Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d'un laser de Classe IIIb (3b) (arséniure de gallium d'une puissance nominale de 5 Notices and Safety Information xiii
4040 milliwatts) émettant sur des longueurs d'onde comprises entre 770 et 795 nanomètres. L'imprimante et son système laser sont conçus pour impossible, dans des conditions normales d'utilisation, d'entretien par l'utilisateur ou de révision, l'exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .
Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825. I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all'arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d'onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1..
Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 825 para productos láser de Clase I (1). Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.
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Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 825. Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.
Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 825. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.
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Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 825 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä. VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen. VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.
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Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 825. Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 825. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.
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Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d'IEC 825. Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d'arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d'ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d'un nivell de classe I durant una operació normal, durant les tasques de manteniment d'usuari ni durant els serveis que satisfacin les condicions prescrites.
Japanese Laser Notice
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Chinese Laser Notice
Korean Laser Notice
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Safety Information ·
This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.
· ·
Consignes de Sécurité ·
Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.
· ·
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Norme di sicurezza ·
Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l'utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l'utilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.
· ·
Sicherheitshinweise ·
Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.
· ·
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Pautas de Seguridad ·
Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.
· ·
Informações de Segurança ·
Este produto foi concebido, testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
· ·
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Informació de Seguretat ·
Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informació pel manteniment d'aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d'aquest producte. El personal professional ha d'estar-ne assabentat i prendre les mesures convenients.
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Preface
This manual is divided into the following chapters:
· "General Information" contains a general description of the · · · · · ·
printer and the maintenance approach used to repair it. Special tools, test equipment, and options are listed. "Diagnostic Information" contains error code table, symptom table, and service checks used to isolate failing field replaceable units (FRUs). "Diagnostic Aids" contains tests and checks used to locate or repeat symptoms of printer problems. "Repair Information" provides instructions for making printer adjustments and removing and installing FRUs. "Locations" uses illustrations to identify the major components and test points on the printer. "Preventive Maintenance" contains safety inspection guidelines, lubrication specifications, and maintenance information to prevent problems and maintain optimum performance. "Parts Catalog" contains illustrations and part numbers for individual FRUs.
Preface
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1. General Information
The OptraTM N, model 4040 is a 600 dpi laser printer designed to attach to IBM-compatible PC's and to most types of computer networks.
Options
The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country. 2000-Sheet Paper Deck Duplexer Envelope Feeder Memory upgrade options of 2MB, 4MB, 8MB, 16MB and 32MB. Flash memory options of 1MB, 2MB and 4MB Integrated network options Token-Ring Ethernet Internal disk option LocalTalk
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. 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.
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Tools
The removal and adjustment procedures described in this manual require the following tools and equipment:
· · · · · · · · ·
Magnetic tip Phillips screwdrivers large and small Flat-blade screwdriver Analog volt ohmmeter (a digital volt ohmmeter may also be used). Oiler Grease Cleaning tissue Magnifier Gloves Ruler
Refer to the parts catalog for part numbers of special tools. When taking voltage readings, always use frame ground unless another ground is specified.
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Abbreviations
ASIC CSU DRAM EEPROM EP ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR VAC VDC Application-Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Electrically Erasable Programmable ReadOnly Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Local Area Network Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power-On Reset Power-On Self Test Print Quality Enhancement Technology Raster Image Processor Read-Only Storage Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current
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2. Diagnostic Information Diagnostic Approach
This printer can be serviced without being connected to a host computer. This printer displays both operator correctable errors and service errors on the front (operator) panel. In addition, there are two tests available from the base machine and the optional 2000 sheet paper deck that allow you to bypass the controller card. You can use these basic engine function tests to eliminate potential software problems. See "Diagnostic Aids" on page 3-1. The diagnostic information in this chapter should lead you to the failing part. Before you replace an entire assembly, determine if just the defective part is available in the parts catalog. Some diagnostic procedures indicate the parts catalog location of the part to be replaced by including the assembly number and reference number in parenthesis. Use the error code tables, symptom table, service checks and the diagnostic aids chapter to determine the symptom and repair the failure. After you complete the repair, perform the appropriate tests to verify the repair.
Start
Initial Check
Before you start troubleshooting, check the following: Installation Environment
· ·
The power supply line voltage is plus or minus 10% of the rated line voltage. The printer is securely installed on a level surface in a well-ventilated place.
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· · · · ·
The room temperature is between 10 and 32.5 ° C, and the relative humidity between 20 and 80%. Avoid sites generating ammonia gas, high temperature or high humidity (near water faucets, kettles, humidifiers), cold spaces, near open flames, and dusty areas. Avoid sites exposed to direct sunlight.
Print Paper Checks Be sure the recommended paper for this printer is being used. Check the paper for dampness. Make a trial print with paper from a newly opened package, and check the result.
EP Cartridges If blank spots appear on an output image, there is a chance that the toner is not evenly mixed. Rock the toner cartridge and then make a print to see if the toner has evenly mixed. Other If a packaged EP cartridge is opened soon after being moved from a cold room to a warm room, condensation will appear inside the cartridge; this can cause various image defects. In such cases, be sure to instruct the customer that it is necessary to leave the cartridge sealed for one to two hours at room temperature to allow it to acclimatize.
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Troubleshooting
Use the error message tables, symptom table, and service checks, in this chapter and the diagnostic aids in Chapter 3 to diagnose a failure. If the operator panel is blank, black, has diamonds across the display, or appears unusual, unplug the controller card and run "Basic Engine Test" on page 3-2. Go to Chapter 3 "Diagnostic Aids" to diagnose this problem because the operator panel or controller card may have a defect. If your machine makes it through POST without an error but you have a symptom, go to the appropriate symptom table, locate your symptom and take the appropriate action. If an error is displayed, locate it in the following "Error Message Tables" and take the appropriate action. If an error message appears while you are working on the printer, go to the error message table and take the indicated action.
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Error Code/Message Tables
Service Error Codes
Error 900 920 922 Symptom or Message Unrecoverable Software Error Fuser Error, Fuser lamps do not come on during POR, or fuser lamps come on but do not reach operating temperature after 180 seconds. Fuser Error, Fuser is too hot or warming up abnormally. Fuser Error, Wrong voltage Action Refer to the operator manual Go to the "Fuser (Temperature Low) Service Check (920/922)" on page 2-23.
923
Go to the "Fuser (Abnormal Temperature) Service Check (923)" on page 2-22. Go to the "Fuser (Wrong Type) Service Check (924)" on page 2-24. Go to the "Fan Motor Service Check (927)" on page 2-19. Check the printhead connectors. Replace the printhead if necessary. If you still have a failure, replace the system board (4-9). If the main motor (MT1) (2-7) runs during POR, replace the printhead (4-32). If the motor does not run during POR, check the connectors to the motor. If necessary, replace the motor and POR the machine. If you still have a failure, replace the system board (4-9).
924
927 931 932 933 934 935
Fan stalled Printhead Errors
Printhead Error
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Error 938 Symptom or Message Paper Deck Option Card, No response Action Check all connectors on the paper deck board and be sure all doors are securely closed. POR the machine. If you still have a failure, replace the paper deck option controller card (29-1). If you still have a failure, replace the paper deck driver board (23-41). Be sure all cables, SIMM, and option controller riser card are correctly installed, then POR the machine. If you still have a failure, replace the system board (4-9). Replace the EPROM controller card (J8) (19-3). Replace the controller card (19-2). Be sure to move the controller SIMM, memory SIMMS, and option cards from the old board to the new one. Replace memory SIMM J3 (1910) on the controller card. Replace optional memory SIMM J2 on the controller card. Be sure the controller riser card and the INA are properly installed. Replace the INA. If you still have a failure, replace the system board (4-9).
939
System Board Error
941 944 945 946 947 950 953 960 961 97X
Incorrect CHECKSUM (EPROM) Controller Card Failure
Memory Error, Base DRAM (J3) Memory Error, Option DRAM (J2) INA Failure
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Error 977 Symptom or Message Network Card Error Action The system processor has detected an INA card is installed but cannot communicate with it. The X after the card indicates which one has the problem. Network card 1 will always refer to the INA in the bottom slot and Network card 2 will always refer to the INA card in the top slot. Be sure the controller card riser card is properly installed. 980 Device Error, 2000- sheet paper deck motor. Device Error, Lifter malfunction in the multipurpose tray. Be sure the motor is securely installed. If necessary, replace motor MT31 (26-3). Be sure J214 is securely installed to the system board. Be sure the connectors on the multipurpose tray board are installed correctly. If necessary, replace the lifting plate solenoid SL2 (14-6). If you still have a failure, replace the multipurpose tray board (14-20). 983 Device Error, Lifter malfunction, 200-sheet paper deck. Be sure the lifter plate clutch (CL31) connector (J206) on the paper deck driver board is securely installed. Check for broken parts. If necessary replace the paper deck lifter clutch (26-5). Be sure the duplex registration motor cable is installed correctly. Check for broken registration parts. If necessary, replace the duplex registration motor SMT22 (22-22).
982
990
Service Duplex Option
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Operator Codes
The following code numbers are operator instructions and messages. In some cases, no action is required; others are operator-correctable; others may require service. An error code may require up to two minutes to appear. Some symptoms may not generate an error code. Locate your code in the table and take the appropriate action.
Code 20 21 22 23 25 Message or Symptom Paper Jam, Clear All Paper Possible error locations: 20 Tray 1 20 Tray 2 20 Tray 3 21 Input 21 Input Feeder (envelope) 21 Input Multipurpose Tray 22 Fuser 23 Top Output 25 Duplex Change Envelope Change Paper, Possible locations: 27 Tray 1 27 Tray 2 27 Change Paper, Possible location: 27 Tray 3 28 Load Envelope Feeder Be sure the correct envelope size and weight is installed. Replace PS931 paper sensor (21-7) on the envelope driver board. Action Clear all paper jams and POR the machine. If the error remains, go to the "Paper Jam Sensor Service Check" on page 2-45. If the paper sensors are good go to the "Paper Feed Symptom Table" on page 2-12 or the "Paper Deck Symptom Table" on page 2-15 and check for mechanical problems. No service required, refer to operator manual. Be sure the correct paper size is installed. Go to the "Paper Jam 27, Paper Size/Change Paper" on page 2-49. Go to the "Paper Deck Lifting Plate Service Check" on page 2-53.
27 27
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Code 29 Message or Symptom Output Bin Full, top bin only Action Remove the paper from the output face-down bin. Check and replace if necessary: · Paper Full Lever (16-4) · Switch Sensor Board (4-18) 32 Print Cartridge Missing Be sure the print cartridge is properly installed. Clean or replace the high voltage power supply contacts (7-2). No service required, refer to operator manual. No service required, refer to operator manual. No service required, refer to operator manual. Go to Diagnostic Aids and run the device tests. Replace Flash SIMM J-7, on the controller card, if necessary. No service required, refer to operator manual. No service required, refer to operator manual. No service required, refer to operator manual. Be sure the following are correct: · · · · Tray 3, Paper drawer closed Power cord plugged in Option controller is installed Option controller signal cable is completely installed. · If you still have no power to the paper deck, go to the "Paper Deck Power Input Service Check" on page 2-57.
37 38 39 51
Insufficient Memory Memory Full Complex Page Defective Flash
52 54 56 57
Flash Full Serial Port Disabled Parallel Port Disabled Check Tray 3
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Code 58 Message or Symptom Duplex not attached Action Be sure the duplexer is securely latched into the printer. POR to reset the printer. 59 63 Print Job on Disk Unformatted Disk No service required, refer to operator manual. Format the disk. Go to "Diagnostic Aids" on page 3-1 and run the device tests. Replace the defective disk. Go to "Diagnostic Aids" on page 3-1 to format the new disk . No service required, refer to operator manual. The Maintenance Kit must be ordered and installed by the customer. Part numbers can be found in the User's Guide. This message appears each time the printer is turned on.
64
Defective Disk
80
Scheduled Maintenance
Diagnostic Information
The diagnostic information in this chapter is divided as follows:
· · · · ·
Base Machine Service Checks Print Quality Service Checks Paper Feed Service Checks Paper Deck Service Checks Paper Deck Paper Feed Service Checks
If you think your symptom is caused by a print quality failure go to the "Print Quality Symptom Table" on page 2-11. If you think your symptom is caused by a paper feed failure, go to the "Paper Feed Symptom Table" on page 2-12. If you think your problem is caused by a malfunction in the paper deck go to "Paper Deck Service Checks" on page 2-53. Diagnostic Information 2-9
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Symptom Tables
Print Quality Symptom Table
Symptom Black Page Blank Spots Blank Page Dark Image Dirt on back of paper Dirty Image Distortion Light Image Poor Fusing Sharp Black Horizontal Lines Action Go to "Black Page Service Check:" on page 2-30. Go to "Blank Spots Service Check" on page 2-30. Go to "Blank Page Service Check" on page 2-31. Go to "Dark Image Service Check" on page 2-32. Go to the "Dirt on Back of Paper Service Check" on page 2-32. Go to the "Dirty Image Service Check" on page 2-33. Go to "Distorted Print Service Check" on page 2-33. Go to "Light Image Service Check" on page 2-34. Go to "Poor Fusing Service Check" on page 2-35. Go to "Sharp Black Horizontal Lines Service Check" on page 2-35. Go to "Smudged Horizontal Bands Service Check" on page 2-36. Go to "Light Image Service Check" on page 2-34. Go to "Vertical Streaks/Lines Service Check" on page 2-37. Go to "White Horizontal Lines Service Check" on page 2-37.
Smudged Horizontal Bands Vertically Dots in a Line Vertical Streaks/Lines White Horizontal Lines
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Symptom White Vertical Lines Action Go to "White Vertical Lines Service Check" on page 2-38.
Paper Feed Symptom Table
Symptom Paper Jam in Pick-up Assembly Action Go to "Pick-Up Assembly Paper Jams Service Check" on page 2-51. Go to "Fuser and Delivery, Paper Jams Service Check" on page 2-43. Go to "Paper Jam 25, Duplex" on page 2-49. Go to "Envelope Feeder Paper Jams Service Check" on page 2-42. Go to "Multiple Paper Feed Service Check" on page 2-44. Go to "Wrinkled Paper Service Check" on page 2-52. Go to "Bent Leading Edge of Paper Service Check" on page 2-40. Go to "Paper Skew Service Check" on page 2-50.
Paper Jam in Fuser and Delivery Assembly Paper Jam in Duplexing Assembly Paper Jam in Envelope Feeder
Multiple Paper Feed Wrinkled Paper Bent Leading Edge of Paper Skewed Paper
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Other Malfunction Symptom Table
Symptom Action Go to the "Printhead Service Check" on page 2-28. Go to "Electrical Assembly Fan (FM3) Check" on page 2-21. Go to "Main Motor Service Check" on page 2-25. Go to "Fuser (Abnormal Temperature) Service Check (923)" on page 2-22. Go to "Fuser (Temperature Low) Service Check (920/922)" on page 2-23. Go to "Fuser (Wrong Type) Service Check (924)" on page 2-24. Go to "Fuser Fan (FM4) Check" on page 2-21. Go to the "Fuser/Printhead Fan (FM2) Check" on page 2-20. Go to "Duplex Horizontal Registration Guide Service Check" on page 2-18. Go to the "Printhead/Laser Service Check" on page 2-28. Go to the "Lifting Plate (Multipurpose Tray) Service Check" on page 2-25. Go to "AC Power Input Service Check" on page 2-16. Go to "DC Power Input Service Check" on page 2-17. Go to "Paper Pick-Up from Multipurpose Tray Service Check" on page 2-27.
Printhead Malfunction Electrical Assembly Fan (FM3) Failure Faulty Main Motor Fuser Failure (Abnormal Temperature) Fuser Failure (Abnormal Warmup/Temperature Low) Fuser Failure (Wrong Type) Fuser Fan (FM4) Failure Fuser/Printhead Fan (FM2) Failure Horizontal Registration Guide Failure (Duplexing Installed) Printhead/Laser Malfunction Lifting Plate Failure (Multi-purpose Tray) No AC Power Input (Dead Machine) No DC Power Input (Dead Machine) No Paper Pick-Up (From Multipurpose Tray)
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Symptom Action Go to "Paper Pick-Up from Cassettes Service Check" on page 2-26. Go to "Paper Pick-Up from Envelope Feeder Service Check" on page 2-26. Go to "High-Voltage Power Supply Output Service Check" on page 2-24. Go to "Fan Motor Service Check (927)" on page 2-19. Go to "Registration Roller Service Check" on page 2-29. "Printhead/Scanner Motor Service Check" on page 2-29. Go to the Diagnostic Aids Chapter and run the LCD and Button tests. If the tests fail, replace the operator panel. If the display has diamonds on it or is blank, run the basic engine test. If the test completes and the panel remains blank, replace the operator panel (1-22). If diamonds remain, check the SIMM (19-3) for proper installation. If you still have a problem, replace the controller card (19-2). If your machine beeps 5 times and the screen is blank or all diamonds, replace the operator panel. No Side Output Bin Operation Check and replace the face-up solenoid assembly parts (asm. 6). Replace the face-up solenoid if necessary.
No Paper Pick-Up from Upper or Lower Cassette No Paper Pick-Up from Envelope Feeder Poor Output from High-Voltage Power Supply Power Supply Fan (FM1) Failure Registration Roller Does Not Rotate Printhead/Scanner Motor Malfunction
Operator Panel Does Not Operate Properly
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Paper Deck Symptom Table
Symptom No power Wrinkled paper Bent leading paper edge Paper skew Left edge registration failure Action Go to the "Paper Deck Power Input Service Check" on page 2-57. Go to the "Paper Deck Wrinkled Paper Service Check" on page 2-60. Go to the "Paper Deck Bent Leading Edge Service Check" on page 2-58. Go to the "Paper Deck Paper Skew Service Check" on page 2-60. Go to the "Paper Deck Left Edge Registration Service Check" on page 2-59. Go to the "Paper Deck Paper PickUp Service Check" on page 2-55. Go to the "Paper Deck Registration Roller Service Check" on page 2-58. Go to the "Paper Deck Feed Roller Service Check" on page 2-53. Go to the "Paper Deck Multiple Paper Feed Service Check" on page 2-59. Go to the "Paper Deck Lifting Plate Service Check" on page 2-53. Go to the "Paper Deck Lifting Plate Service Check" on page 2-53. Go to the "Paper Deck Motor Service Check" on page 2-55.
Paper doesn't pick-up from the paper deck Paper doesn't exit paper registration roller. Paper doesn't exit paper deck , jam in feed roller. Multiple sheets of paper feeding.
Paper deck doesn't lift properly Paper deck does not sense paper size, paper full, or surface obstruction. Faulty paper deck drive motor
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Base Machine Service Checks
AC Power Input Service Check
FRU 1 Action
Voltage
The correct voltage may not be present at the outlet. Inform the customer that the correct line voltage is not available at the outlet. The power cord may not be firmly plugged into the printer, the paper deck and the outlet. Push the power plugs in firmly. The circuit breaker may be off. Remove the power supply. Press the circuit breaker button to set the circuit breaker on.
The power switch may be defective. Remove the power supply. Measure the resistance between the two terminals of the power switch by applying the tester probes to the terminals. The resistance must be zero when the power is turned on, and infinity when the switch is turned off. If it is not, replace the power supply.
2
Power Cord
3
Circuit Breaker
4
Power Switch
5
Low Voltage Power Supply
The ac power line in the low voltage power supply may be defective. Replace the power supply.
If ac power is present and the machine is dead go to the "DC Power Input Service Check" on page 2-17.
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DC Power Input Service Check
FRU 1 Action
AC Power Overcurrent/ Overvoltage Detection Circuit
If the ac power is not present, go to "AC Power Input Service Check" on page 2-16. The overcurrent/overvoltage detection circuit may be active. If the problem does not disappear when the power switch is turned off and on again, find the cause of activation of the overcurrent/over voltage detection circuit of the power supply. Turn the power switch off for 2 minutes then turn it on again. Th