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Lexmark Optra N 4040

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Lexmark Optra N 4040 Manuel de service

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Description

Lexmark Optra N 4040 Service Manual
Third Edition (March, 1999)

Notices and Safety Information xii
Laser Notice . xii
Safety Information. xx
Preface xxv
General Information .1-1
Options 1-1
Maintenance Approach1-1
Tools1-2
Abbreviations . 1-3
Diagnostic Information . .2-1
Diagnostic Approach2-1
Start 2-1
Troubleshooting . 2-3
Error Code/Message Tables2-4
Service Error Codes. 2-4
Operator Codes 2-7
Diagnostic Information . 2-9
Symptom Tables2-11
Print Quality SymptomTable . 2-11
Paper Feed Symptom Table . 2-12
OtherMalfunction 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 Check2-26
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 Check2-35
Sharp Black Horizontal Lines Service Check 2-35
Smudged Horizontal Bands Service Check2-36
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 Check2-38
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 Check2-42
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 Jam20 2-47
Paper Jam 21, Input . 2-48
Paper Jam22, Fuser 2-48
Paper Jam23, Top Output/Delivery . 2-49
Paper Jam25, 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
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 Check2-60
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 Test3-2
Diagnostics Mode. 3-4
Diagnostics Mode Menu Structure 3-4
Diagnostics Mode Tests . 3-6
Button Test3-6
Defaults 3-6
Disk Test/Clean 3-6
Error Log . 3-7
Flash Test. 3-8
LCD Test . 3-8
Memory Tests3-8
Page Count . 3-9
Permanent Page Count 3-9
Print Test 13-9
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
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 SystemRemoval 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 Removal4-39
Pick-Up/Feed/Separation Rollers Removal 4-40
Exposure System Removal Procedures4-41
Printhead Removal. 4-42
Electrostatic Imaging/Developing/Cleaning System Removal
Procedures 4-43
EP Cartridge4-43
Drum Protective Shutter . .4-44
Photosensitive Drum .4-44
Transfer Charging Roller Removal. 4-45
Fuser Removal Procedures . 4-46
Fuser Removal4-47
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 Removal4-61
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
Duplex Assembly Removal Procedures4-77
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 Removal4-99
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 Printer5-1
Duplexer . 5-3
Envelope Feeder . 5-3
Cross Section View of Printer and Duplexer 5-4
Locations (Continued)
Cross Section View of Envelope Feeder . 5-5
Base Machine Sensor and Switch Operation5-6
Base Machine Motor and Clutch Operation . 5-8
Paper Feed5-9
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 Heaters5-19
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
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 Board5-45
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 Connector5-53
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
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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