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Lexmark Optra W840 4024

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Lexmark Optra W840 4024 Manuel de service

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Description

Lexmark Optra W840 4024-XXX Service Manual
Edition: November 15, 2007

Notices . ix
Laser notice ix
Safety information. xiii
Preface xvi
Definitions . xvi
General information 1-1
About this manual . 1-1
Printer overview . .1-1
Basic model . .1-1
Configured model . 1-2
Tools required for service .  . 1-2
Acronyms . 1-3
Diagnostic information . .2-1
Start . 2-1
Using service checks 2-1
Confirm the installation status .  . 2-2
POR sequence .  2-2
Printer operator panel .2-3
Error code messages 2-4
Service checks . .  2-22
200.00 Sensor (registration) off jam (too long) . 2-22
200.01 Sensor (registration) static on jam . 2-23
201.00 Sensor (fuser exit) on jam 2-24
202.00 Sensor (fuser exit) off jam 2-25
202.01 Sensor (fuser exit) off (too short) jam 2-26
202.02 Sensor (fuser exit) static jam 2-27
203.00 Sensor (exit 2) on jam 2-28
203.01 Sensor (exit 2) off jam .2-30
241.00 Sensor (pre-feed) on jam (tray 1 feed) . 2-31
241.01 Sensor (registration) on jam (tray 1 feed) 2-32
242.00 Sensor (pre-feed) on jam (tray 2 feed) . 2-33
242.01 Sensor (tray 2 feed-out) on jam (tray 2 feed) 2-35
242.02 Sensor (registration) on jam (tray 2 feed) 2-36
242.03 Sensor (tray 2 feed-out) static jam 2-38
250.00 Sensor (registration) on jam (MPF pick) . 2-38
900.XX RIP card assembly software failure . 2-40
903.00 RAM read/write check failure . 2-40
904.00 NVM data failure 2-41
905.00 NVM read/write cannot be executed failure . 2-41
906.00 CPU power to access NVM failure . 2-42
907.00 RFID ASIC failure 2-42
908.00 PPM data failure . 2-43
910.00 Transport motor stop failure 2-43
911.00 Transport motor failure 2-44
912.00 PC cartridge unit motor failure . 2-44
913.00 Printhead assembly failure 2-45
914.00 Toner add motor assembly failure 2-45
915.00 Fuser cooling fan failure 2-46
916.00 PC cartridge cooling fan failure 2-47
918.00 Sensor (exit 1 media shift HP) failure 2-48
920.00 Fuser unit assembly on time failure . 2-49
921.00 Over heat temperature failure . .2-49
922.00 Center thermistor failure . .2-50
923.00 Rear thermistor failure . .2-50
924.00 Pressure roll thermistor failure .2-50
925.00 Fuser operating temperature failure . .2-51
927.00 PC cartridge RFID data write failure .2-51
928.00 PC cartridge RFID communication failure .2-52
929.00 Sensor (ATC) failure . .2-52
930.00 Laser power failure .2-53
932.00 Toner cartridge RFID data write failure .2-53
933.00 Toner cartridge RFID communication failure . .2-54
939.00 RIP card assembly communication failure . .2-55
941.00 Media tray 1 lift up / no media tray failure . .2-55
942.00 Media tray 2 lift up / no media tray failure .2-56
950.00 through 950.29 EPROM mismatch failure .2-58
950.30 through 950.60 EPROM mismatch failure .2-59
951.XX RIP card assembly NVRAM failure . .2-59
952.XX Interconnect card assembly NVRAM CRC failure . .2-60
953.XX Operator panel assembly NVRAM failure .2-60
954.XX Interconnect card assembly NVRAM failure .2-61
955.XX RIP card assembly NAND CRC failure .2-62
956.00 RIP card assembly processor failure .2-62
956.01 RIP card assembly processor over temperature failure .2-63
956.02 RIP card assembly cooling fan failure . .2-63
980.03 Exit interface card assembly communication failure .2-64
Media size mismatch in width . .2-64
No media in the select media tray .2-65
Paper is installed (short edge) in the media paper tray . .2-66
PC cartridge end of life . .2-66
PC cartridge end of life . .2-66
PC cartridge RFID failure . .2-67
PC cartridge set failure . .2-67
Printer front door open . .2-68
Printer left door open .2-69
Printer left lower door open . .2-69
Scheduled maintenance required . .2-70
Standard bin 1 full .2-70
Standard bin 2 full . .2-71
Toner cartridge empty .2-72
Toner cartridge near empty . .2-73
Toner cartridge failure . .2-74
Toner cartridge RFID failure .2-74
Toner cartridge set failure . .2-75
Tray 1 media size failure . .2-75
Tray 2 media size failure .2-76
Tray 1 media size mismatch in length .2-77
Tray 2 media size mismatch in length .2-78
Image quality trouble . .  .2-81
Troubleshooting . .2-81
Image Quality . .2-82
Diagnostic aids .  . 3-1
Accessing service menus . ..3-1
Diagnostics mode .  .3-2
Entering Diagnostics mode: .3-2
Available tests ..3-2
Exiting Diagnostics mode .3-4
MOTOR TESTS . .3-5
PRINT TESTS . .3-5
HARDWARE TESTS . .3-6
DUPLEX TESTS . 3-9
INPUT TRAY TESTS 3-10
OUTPUT BIN TESTS .  3-11
FINISHER TESTS 3-12
BASE SENSOR TEST . .3-14
DEVICE TESTS . 3-15
PRINTER SETUP . .3-16
EVENT LOG . .3-18
EXIT DIAGNOSTICS . 3-19
Configuration menu (CONFIG MENU) 3-20
Entering Configuration Menu . 3-20
Available menus . 3-20
Maintenance page count (Maint Cnt Value) . 3-21
Maintenance page counter reset (Reset Maint Cnt) . 3-21
REGISTRATION . .3-22
Print quality pages (Prt Quality Pgs) . 3-23
SIZE SENSING 3-24
Panel Menus . .  3-24
PPDS Emulation .  3-25
Demo Mode . .3-25
Factory Defaults . .3-25
Energy Conserve .3-25
EVENT LOG 3-25
Paper Prompts .3-25
Env Prompts .3-26
Jobs On Disk . 3-26
Disk Encryption . .3-26
Font Sharpening . 3-26
Short Edge Printing .3-26
Tray Low Message . 3-26
Exit Config Menu . 3-26
Analyzing the Print Test .  3-27
Driving force transmission path . 3-28
Media transport 3-29
Functions of main components . 3-31
Media tray assembly 3-32
Multi-purpose feeder (MPF) 3-34
Detecting media size .3-35
Transfer roll assembly 3-36
Printhead assembly . .3-36
Fuser . 3-38
Exit .3-40
Drive . .3-41
Electrical components and controller 3-42
Control 3-44
Media size control 3-44
Printhead control 3-45
Fuser control . 3-45
Xerographic Process During a Print Cycle 3-46
Safety system diagram .3-53
Repeating defects . .  . 3-55
Repair information.  . 4-1
Handling ESD-sensitive parts . 4-1
Removal procedures .  . 4-2
Before starting service work 4-2
Printer front left cover removal 4-3
Top rear cover removal . 4-4
Switch (printer front door interlock) removal . .4-5
Operator panel assembly removal . .4-6
Top cover assembly removal . .  .4-8
Printer front door assembly removal . .4-9
Front door support strap and front door magnetic catch removal .4-10
Front inner cover removal . .4-11
Right upper cover removal .4-12
Right lower cover removal . .4-13
Cable hookup door removal . .4-14
Rear motor cover removal .4-15
Rear lower cover removal . .4-16
Option hookup cover removal .4-17
Switch (media size) removal . .4-18
Media feed unit assembly 1 removal . .4-19
Media feed unit assembly 2 removal . .4-22
Media tray side guides removal . .4-25
Media tray end guide removal .4-28
Media tray lift gear group removal .4-30
Media feed lift motor removal .4-31
Tray lift coupling assembly removal . .4-32
Tray lift one way clutch / gear assembly removal .4-33
Media feed unit drive gear - 13 tooth removal . .4-35
Media out actuator removal .4-36
Sensor (media level) removal .4-37
Sensor (media out) removal . .4-38
Sensor (pre-feed) removal .4-39
Media feed unit drive gear - 28 / 21 tooth removal .4-40
Media feed unit drive gear - 29 tooth removal . .4-41
Feed roll removal .4-43
Feed roll one way clutch removal . .4-44
Feed roll one way gear 22 tooth removal . .4-45
Separation roll one way friction clutch removal . .4-46
Separation roll removal . .4-47
Pick roll idler gear 33 tooth removal . .4-48
Pick roll removal .4-49
Pick roll drive gear 25 tooth removal .4-50
Feed unit drive gear 27 tooth removal . .4-51
MPF feed unit assembly removal . .4-52
MPF media out actuator and upper frame removal . .4-53
Sensor (MPF media out) removal . .4-54
MPF transport pinch roll assembly removal .4-55
MPF rear cover removal .4-56
MPF feed drive gear group removal . .4-57
MPF pressure pad removal .4-58
MPF transport roll assembly removal .4-59
MPF pick solenoid / pick lever removal .4-60
MPF feed shaft assembly removal .4-61
MPF pick roll removal .4-62
MPF fold down tray assembly removal . .4-63
Vertical drive gear assembly . .4-65
Switch (left lower door interlock) . .4-66
Media transport roll assembly / gear removal . .4-67
Printer left lower door assembly removal .4-68
Printer left lower pinch roll assembly removal .4-69
Left lower door handle assembly removal .4-70
Transfer roll assembly removal . .4-71
Printer left door support strap removal .4-72
Printer left door assembly removal .4-73
Switch (printer left door interlock) removal . .4-74
Transfer roll guide assembly removal 4-75
Printer left door assembly handle removal 4-76
Registration roll assembly removal 4-77
Registration clutch assembly removal . 4-78
Sensor (registration) removal . 4-79
Transport clutch assembly removal . 4-80
Sensor (tray 2 feed-out) removal 4-82
Switch (PC cartridge interlock) removal 4-83
Sensor (humidity and temperature) removal 4-89
Sensor (RFID PC cartridge) and sensor (RFID toner cartridge) removal 4-94
Toner cartridge guide assembly removal . 4-95
Toner add motor assembly removal . 4-97
Fuser cooling fan removal . 4-98
Printhead assembly removal . 4-99
PC cartridge cooling fan duct removal 4-101
PC cartridge cooling fan removal 4-103
Sensor (fuser exit) removal . 4-104
Fuser unit assembly removal 4-105
Exit 1 media shift assembly removal 4-106
Media shift motor removal 4-108
Sensor (exit 1 media shift) removal . 4-109
Sensor (exit 1 bin full) removal 4-110
Exit 1 media shift gear removal 4-111
Standard exit 1 top cover removal 4-114
Exit 1 drive belt removal 4-114
Dual drive motor assembly removal 4-116
High voltage power supply (HVPS) card removal . 4-117
Switch (main power) removal 4-118
Exit interface card assembly removal . 4-119
Printer engine card assembly removal 4-120
Low voltage power supply (LVPS) card assembly removal . 4-122
AC power input socket assembly removal . 4-124
AC power input socket removal 4-125
Finisher AC output removal . 4-126
Rear RIP card cover removal 4-127
RIP card assembly removal . 4-127
Interconnect card assembly removal . 4-128
Component locations. 5-1
Locations .  5-1
Printer boards 5-1
HVPS .5-1
LVPS . 5-1
Printer motors and sensors . 5-2
Printer switches 5-7
Cables . .5-8
Preventive maintenance6-1
Safety inspection guide . 6-1
Lubrication specifications . .  6-2
Scheduled maintenance . 6-2
Parts catalog . .7-1
How to use this parts catalog 7-1
Assembly 1: Covers and operator panel (1 of 2) . 7-2
Assembly 2: Covers . 7-4
Assembly 3: Media feed unit 7-5
Assembly 4: Media feed unit exploded (tray 1 and tray 2) . 7-6
Assembly 5: Media tray .  . 7-8
Assembly 6: MPF unit 7-10
Assembly 7: MPF unit feed . 7-12
Assembly 8: Left lower door and transport 7-14
Assembly 9: Left door and transfer roll .7-16
Assembly 10: Printer left door 7-18
Assembly 11: Registration . 7-20
Assembly 12: Printhead, cartridge guides, and fans .  7-22
Assembly 13: Fuser . 7-24
Assembly 14: Dual unit drive motor .7-27
Assembly 15: Electrical . .  7-29
Assembly 16: Electrical cables 7-31
Assembly 17: Electrical cables . 7-32
Assembly 18: Electrical cables. 7-33
Assembly 19: Electrical cables7-34
Assembly 20: Electrical cable. .7-35
Assembly 21: Power cords 7-36
Assembly 22: Miscellaneous . 7-37
Index.I-1
Part number index. .I-5






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