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Lexmark Optra W840 Options 4024

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Lexmark Optra W840 Options 4024 Manuel de service

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Description

Lexmark Optra W840 Options 4024-XXX Service Manual P/N 12G9603
Edition: January 30, 2007

Safety information. .xiii
Preface xvi
Definitions . xvi
General information .  1-1
Options and features . .  1-1
Tray 2 1-1
Driving force transmission path 1-2
Media transport . 1-3
Media transport path 1-3
Layout of media transport path 1-4
Main components associated with the media transport . 1-4
Functions of main components 1-4
Media tray assembly . 1-5
Front media tray guide and rear media tray guide . 1-5
Media tray end guide 1-5
Bottom plate 1-5
Media feed unit assembly 1-5
Media feed lift motor 1-5
Switch (media size) . 1-5
Sensor (media out) . 1-5
Sensor (media level) 1-5
Sensor (pre-feed) 1-6
Main components . 1-7
Switch (2TM/TTM left door interlock) . 1-7
Sensor (tray 3 feed-out) . 1-7
Sensor (tray 4 feed-out) . 1-7
2TM/TTM Transport roll assembly . 1-7
2TM/TTM controller card assembly . 1-7
Switch (media size) . 1-8
Tandem tray 1-9
Driving force transmission path . 1-10
2 tray / tandem tray drive motor assembly 1-10
Media transport 1-11
Media transport path . 1-11
Media transport path . 1-12
Functions of main components . 1-12
Media tray assembly 1-13
Media feed unit assembly . 1-13
Front media guide / rear media guide 1-13
Bottom plate . 1-13
Media feed unit assembly . 1-14
Media feed lift motor . 1-14
Switch (TTM media size) 1-14
Sensor (media out) 1-14
Sensor (media level) . 1-15
Sensor (pre-feed) . 1-15
Main components 1-16
Switch (2TM/TTM left door interlock) 1-16
Sensor (tray 3 feed-out) 1-16
Sensor (tray 4 feed-out) 1-16
2TM/TTM media transport roll assembly 1-16
2TM/TTM controller card assembly 1-16
Switch (tandem tray media size) 1-17
High capacity feeder 1-18
Media feeding . .1-19
Outline . .1-19
HCF media feed unit assembly .1-19
HCF media transport roll assembly . .1-19
HCF media feed unit assembly operation .1-21
HCF media transport roll assembly operation . .1-22
HCF media feed unit assembly sensor/motor functions . .1-23
Status monitoring ..1-24
Static media jam detection .1-24
Interlock detection .1-24
Tray insertion detection .1-25
Functions of sensors used for status monitoring . .1-25
Media size detection . .1-26
Sensor for media size detection .1-26
Size sensors . .1-26
Tray lifting . .1-26
Media out detection . .1-27
Sensor (media out) .1-28
Remaining media volume detection . .1-28
Sensor (media level) .1-28
Duplex .1-30
Duplex drive motor . ..1-30
Media transport . ..1-31
Media transport path .1-31
Layout of media transport path . .1-32
Functions of main components .1-32
Switch (duplex left door interlock) .1-32
Sensor (duplex wait) . .1-32
Duplex media transport roll assembly . .1-33
Duplex controller card assembly . .1-33
Duplex drive motor .1-33
Exit 2 .  .1-34
Exit 2 drive motor .1-34
Media transport ..1-35
Media transport path .1-35
Layout of media transport path . .1-36
Functions of Main Components .1-36
Drive motor .1-36
Media shift motor . .1-37
Exit interface card assembly (located in the printer) .1-37
Exit 2 left door assembly . .1-37
Sensor (exit 2) . .1-37
Sensor (Standard bin full exit 2) .1-37
Sensor (exit 2 media shift HP) . .1-37
Exit 2 transport roll assembly and media exit roll assembly . .1-37
Tools required for service .  .1-39
Acronyms .1-39
Diagnostic information2-1
Start . .2-1
Using service checks . ..2-1
Confirm the installation status .  . .2-2
POR (Power-On Reset) sequence .2-2
Error code messages - 2X 500-sheet drawer (2TM) . .2-3
Service checks - 2X 500-sheet drawer (2TM) . .2-5
243.00 Sensor (pre-feed) on jam (tray 3 media feed) . .2-5
243.01 Sensor (tray 3 feed-out) on jam (tray 3 media feed) . .2-6
243.02 Sensor (tray 2 feed-out) on jam (tray 3 media feed) . .2-8
243.03 Sensor (registration) on jam (tray 3 media feed) . .2-10
243.04 Sensor (tray 3 feed-out) static jam 2-12
244.00 Sensor (tray 4 feed-out) on jam (tray 4 media feed) . 2-13
244.01 Sensor (tray 3 feed-out) on jam (tray 4 media feed) . 2-14
244.02 Sensor (tray 2 feed-out) on jam (tray 4 media feed) . 2-16
244.03 Sensor (registration) on jam (tray 4 media feed) . 2-18
244.04 Sensor (pre-feed) on jam (tray 4 media feed) 2-20
244.05 Sensor (tray 4 feed-out) static jam 2-22
943.00 Tray 3 lift up / no tray failure 2-23
944.00 Tray 4 lift up / no tray failure 2-24
980.00 2TM/TTM controller card assembly communication failure 2-26
Tray 3 media size failure .2-26
Tray 4 media size failure . 2-27
2TM/TTM left door assembly open . 2-28
No media in the select media tray . 2-29
Media size mismatch in width 2-30
Tray 3 media size mismatch in length 2-31
Tray 4 media size mismatch in length 2-33
Error code messages - 2000-sheet dual input (TTM) .  2-36
Service checks - 2000-sheet dual input (TTM) . .  . 2-38
243.00 Sensor (pre-feed) on jam (tray 3 media feed) 2-38
243.01 Sensor (tray 3 feed-out) on jam (tray 3 media feed) . 2-39
243.02 Sensor (tray 2 feed-out) on jam (tray 3 media feed) . 2-41
243.03 Sensor (registration) on jam (tray 3 media feed) . 2-43
243.04 Sensor (tray 3 feed-out) static jam 2-44
244.00 Sensor (tray 4 feed-out) on jam (tray 4 media feed) . 2-45
244.01 Sensor (tray 3 feed-out) on jam (tray 4 media feed) . 2-48
244.02 Sensor (tray 2 feed-out) on jam (tray 4 media feed) 2-50
244.03 Sensor (registration) on jam (tray 4 media feed) . 2-51
244.04 Sensor (pre-feed) on jam (tray 4 media feed) 2-53
244.05 Sensor (tray 4 feed-out) static jam 2-55
943.00 Tray 3 lift up / no tray failure 2-56
944.00 Tray 4 lift up / no tray failure 2-57
980.00 2TM/TTM controller card assembly communication failure 2-59
Tray 3 media size failure . 2-59
Tray 4 media size failure 2-60
2TM/TTM left door assembly open . 2-61
No media in the select media tray . 2-62
Media size mismatch in width 2-63
Tray 3 media size mismatch in length 2-64
Tray 4 media size mismatch in length 2-66
Error code messages - HCF . 2-69
Service checks - HCF . .2-70
245.00 Sensor (tray 5 feed-out) on jam . 2-70
245.01 Sensor (tray 2 feed-out) on jam . 2-72
245.02 Sensor (registration) on jam 2-73
245.03 Sensor (tray 5 feed-out) static jam . 2-75
945.00 HCF unit media tray lift failure 2-77
945.01 HCF unit NVM R/W failure . 2-78
980.01 Tray 5 HCF communication failure 2-78
HCF top door assembly open .2-79
HCF unit docking failure or tray 5 set failure 2-80
No media in the select media tray . 2-81
Error code messages - DUP . 2-83
Service checks - DUP . .  2-84
230.00 Sensor (duplex wait) on jam 2-84
230.01 Sensor (duplex wait) static jam . 2-85
231.00 Sensor (registration) on jam (duplex paper feed) . 2-86
231.01 Sensor (registration) on jam (duplex paper feed) . 2-87
980.04 Duplex controller card assembly communication failure 2-89
997.00 Duplex controller card assembly type failure . .2-90
Duplex left door assembly open .2-90
Error code messages - EX2 .2-92
Service checks - EX2 .2-93
203.00 Sensor (exit 2) on jam .2-93
203.01 Sensor (exit 2) off jam .2-94
203.02 Sensor (exit 2) on jam in standard bin or finisher .2-96
203.03 Sensor (exit 2) static jam .2-97
230.00 Sensor (duplex wait) on jam . .2-98
919.00 Sensor (exit 2 media shift HP) failure .2-99
919.01 Exit 2 unit assembly connection failure . .2-100
Exit 2 left door assembly open .2-101
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
Input source tests .3-5
Print quality pages (Prt Quality Pgs) . .3-6
HARDWARE TESTS . .3-6
Panel Test . .3-6
Button Test . .3-6
DRAM Test . .3-7
CACHE Test .3-7
Parallel Wrap tests . .3-8
Serial Wrap tests .3-8
DUPLEX TESTS .3-9
Quick Test (duplex) .3-9
Sensor Test (duplex) . .3-9
INPUT TRAY TESTS . .3-10
Feed Tests (input tray) . .3-10
Sensor Test (input tray) .3-10
OUTPUT BIN TESTS .3-11
Feed Tests (output bins) . .3-11
Feed To All Bins .3-11
Sensor Test (output bin) .3-11
FINISHER TESTS .3-12
Staple Test .3-12
Hole Punch Test .3-12
Feed Tests .3-12
Sensor Test (finisher) .3-13
BASE SENSOR TEST .3-14
DEVICE TESTS . .3-15
Quick Disk Test .3-15
Disk Test/Clean .3-15
Flash Test . .3-16
PRINTER SETUP .3-16
Defaults .3-16
Page Count . .3-16
Perm Page Count (permanent page count) . .3-16
Serial Number . .3-17
Engine Setting 1 through 4 .3-17
Model Name . .3-17
Configuration ID .3-17
Edge to Edge .3-17
Parallel strobe adjustment (Par x Strobe Adj) 3-18
EVENT LOG . 3-18
Display Log 3-18
Print Log 3-18
Clear Log 3-19
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
Top Margin 3-22
Tray 1—5 Left Margin . 3-22
Quick Test . 3-23
Print quality pages (Prt Quality Pgs) . 3-23
SIZE SENSING .3-24
Statement/A5 3-24
Executive/B5 . 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
Using print test to locate a feed or media transport problem 3-27
Using print test to analyze a print quality problem 3-27
Driving force transmission path . 3-28
Transport motor . 3-28
PC cartridge motor 3-28
Media transport 3-29
Media transport path . 3-29
Media transport path layout 3-30
Functions of main components . 3-31
Media tray assembly . 3-31
Front media tray guide assembly and rear media guide 3-31
Media tray end guide . 3-31
Bottom plate . 3-31
Media tray assembly 3-32
Detection of media size . 3-32
Media feed unit assembly . 3-32
Media feed lift motor . 3-32
Switch (media size) 3-32
Sensor (media out) 3-32
Sensor (media level) . 3-33
Sensor (pre-feed) . 3-33
Multi-Function Peripheral (MPF) 3-34
MPF pick roll . 3-34
MPF pick roll . 3-34
MPF pick solenoid . 3-34
Sensor (MPF media out) . .3-34
Sensor (MPF media width) .3-34
Detecting media size . .3-35
Transfer roll assembly .3-36
Printhead assembly .3-36
Fuser .3-38
Heat roll .3-38
Pressure roll . .3-38
Heater lamp . .3-38
Thermostat .3-38
Center thermistor . .3-38
Rear thermistor . .3-38
Pressure roll thermistor .3-38
Fuser exit sensor . .3-39
Exit . .3-40
Dual drive motor assembly .3-40
Exit 1 media exit roll assembly . .3-40
Sensor (standard bin full exit 1) .3-40
Media diverter gate .3-40
Drive . .  .3-41
Media transport motor . .3-41
PC cartridge motor .3-41
Electrical components and controller .3-42
Switch (main power) . .3-42
Finisher AC output .3-42
Switch (printer front door interlock) and switch (printer left door interlock) . .3-42
Switch (PC Cartridge interlock) .3-42
Switch (printer left lower door interlock) .3-42
Fuser cooling fan . .3-42
LVPS card assembly .3-42
HVPS card assembly .3-42
Printer engine card assembly .3-42
RIP card assembly .3-42
Transport roll assembly .3-42
Registration roll assembly .3-43
Control .3-44
Media size control . .3-44
Printhead control .3-45
Rotation of printhead motor . .3-45
Determination of printhead ready . .3-45
Printhead reference value .3-45
Fuser control . .3-45
Fuser control method .3-45
Main/sub heater lamps on/off control .3-45
Fuser warm-up . .3-45
Xerographic Process During a Print Cycle .3-46
Charge . .3-47
Exposure . .3-48
Development .3-49
Transfer .3-51
Cleaning .3-52
Discharge . .3-52
Safety system diagram . .3-53
‘Repair information. .  . 4-1
Handling ESD-sensitive parts .4-1
Removal procedures .  .4-2
Before starting service work .4-2
2X 500-sheet drawer (2TM) removals .4-3
2X 500-sheet drawer (2TM)–top cover removal . 4-3
2X 500-sheet drawer (2TM)–foot cover removal 4-4
2X 500-sheet drawer (2TM)–right cover removal . 4-4
2X 500-sheet drawer (2TM)–left cover removal . 4-5
2X 500-sheet drawer (2TM)–rear cover removal 4-5
2X 500-sheet drawer (2TM)–2TM/TTM left door assembly removal . 4-6
2X 500-sheet drawer (2TM)–caster removal . 4-7
2X 500-sheet drawer (2TM)–switch (media size) assembly removal 4-8
2X 500-sheet drawer (2TM)–media feed unit assembly removal (tray 3) 4-9
2X 500-sheet drawer (2TM)–media feed unit assembly removal (tray 4) . 4-11
2X 500-sheet drawer (2TM)–media tray guides removal 4-12
2X 500-sheet drawer (2TM)–media tray end guide removal 4-14
2X 500-sheet drawer (2TM)–tray lift gear group removal 4-16
2X 500-sheet drawer (2TM)–media feed lift motor removal 4-17
2X 500-sheet drawer (2TM)–lift coupling assembly removal . 4-18
2X 500-sheet drawer (2TM)–tray lift one-way gear clutch assembly removal . 4-19
2X 500-sheet drawer (2TM)–media feed unit drive gear - 13 tooth removal . 4-21
2X 500-sheet drawer (2TM)–media out actuator removal 4-22
2X 500-sheet drawer (2TM)–sensor (media level) removal 4-23
2X 500-sheet drawer (2TM)–sensor (media out) removal 4-24
2X 500-sheet drawer (2TM)–sensor (pre-feed) removal . 4-25
2X 500-sheet drawer (2TM)–media feed unit drive gear - 28 / 21 tooth removal . 4-26
2X 500-sheet drawer (2TM)–media feed unit drive gear - 29 tooth removal . 4-27
2X 500-sheet drawer (2TM)–feed roll removal . 4-28
2X 500-sheet drawer (2TM)–feed roll one-way clutch removal . 4-29
2X 500-sheet drawer (2TM)–feed roll one-way gear 22 tooth removal . 4-30
2X 500-sheet drawer (2TM)–separation roll one-way friction clutch removal . 4-31
2X 500-sheet drawer (2TM)–separation roll removal . 4-32
2X 500-sheet drawer (2TM)–pick roll idler gear - 33 tooth removal 4-33
2X 500-sheet drawer (2TM)–pick roll removal . 4-34
2X 500-sheet drawer (2TM)–pick roll drive gear 25 tooth removal 4-35
2X 500-sheet drawer (2TM)–feed unit drive gear - 27 tooth removal . 4-36
2X 500-sheet drawer (2TM)–sensor (tray 3 feed-out) removal 4-37
2X 500-sheet drawer (2TM)–sensor (tray 4 feed-out) removal 4-38
2X 500-sheet drawer (2TM)–upper media transport roll removal . 4-39
2X 500-sheet drawer (2TM)–lower media transport roll assembly removal . 4-40
2X 500-sheet drawer (2TM)–left door pinch roll assembly removal . 4-41
2X 500-sheet drawer (2TM)–switch (2TM/TTM left door interlock) removal . 4-42
2X 500-sheet drawer (2TM)–2TM/TTM controller card assembly removal 4-43
2X 500-sheet drawer (2TM)–transport clutch removal 4-44
2X 500-sheet drawer (2TM)–drive motor assembly removal . 4-45
2000-sheet dual input (TTM) removals . .  4-46
2000-sheet dual input (TTM)–top cover removal . 4-47
2000-sheet dual input (TTM)–foot cover removal 4-48
2000-sheet dual input (TTM)–right cover removal . 4-49
2000-sheet dual input (TTM)–left cover removal . 4-50
2000-sheet dual input (TTM)–rear cover removal 4-51
2000-sheet dual input (TTM)–caster removal . 4-52
2000-sheet dual input (TTM)–tray support roll removal . 4-53
2000-sheet dual input (TTM)–tray 4 assembly removal . 4-55
2000-sheet dual input (TTM)–tray 3 assembly removal . 4-56
2000-sheet dual input (TTM)–tray 3 front cover removal 4-57
2000-sheet dual input (TTM)–tray 3 rear cable assembly removal 4-58
2000-sheet dual input (TTM)–tray 3 front cable assembly removal . 4-61
2000-sheet dual input (TTM)–media guide rack and pinion removal 4-62
2000-sheet dual input (TTM)–tray 3 media guide lock assembly removal 4-65
2000-sheet dual input (TTM)–tray 3 mylar actuator removal . 4-66
2000-sheet dual input (TTM)–tray 4 front cover removal 4-68
2000-sheet dual input (TTM)–tray 4 media transport assembly removal . 4-69
2000-sheet dual input (TTM)–tray 4 rear cables removal . .4-70
2000-sheet dual input (TTM)–tray 4 front cables removal . .4-73
2000-sheet dual input (TTM)–tray 4 media guide rack and pinion removal . .4-75
2000-sheet dual input (TTM)–tray 4 media guide lock assembly removal .4-77
2000-sheet dual input (TTM)–tray 4 mylar actuator removal . .4-78
2000-sheet dual input (TTM)–media feed unit assembly removal (tray 4) .4-80
2000-sheet dual input (TTM)–sensor (tray 4 feed-out) removal .4-83
2000-sheet dual input (TTM)–switch (TTM media size) removal .4-84
2000-sheet dual input (TTM)–media feed unit assembly removal (tray 3) .4-85
2000-sheet dual input (TTM)–2TM/TTM media transport roll assembly removal .4-88
2000-sheet dual input (TTM)–sensor (tray 3 feed-out) removal .4-89
2000-sheet dual input (TTM)–media feed lift motor removal . .4-90
2000-sheet dual input (TTM)–lift coupling assembly removal . .4-91
2000-sheet dual input (TTM)–one-way clutch / gear assembly removal . .4-92
2000-sheet dual input (TTM)–media feed unit drive gear 13 tooth removal .4-94
2000-sheet dual input (TTM)–media out actuator removal .4-95
2000-sheet dual input (TTM)–sensor (media level) removal . .4-96
2000-sheet dual input (TTM)–sensor (media out) removal .4-97
2000-sheet dual input (TTM)–sensor (pre-feed) removal .4-98
2000-sheet dual input (TTM)–media feed unit drive gear 28 / 21 tooth removal . .4-99
2000-sheet dual input (TTM)–media feed unit drive gear 29 tooth removal . .4-100
2000-sheet dual input (TTM)–feed roll removal .4-101
2000-sheet dual input (TTM)–feed roll one-way clutch removal . .4-102
2000-sheet dual input (TTM)–one-way 22 tooth removal . .4-103
2000-sheet dual input (TTM)–separation roll one-way friction clutch removal . .4-104
2000-sheet dual input (TTM)–separation roll removal . .4-105
2000-sheet dual input (TTM)–pick roll idler gear 33 tooth removal .4-107
2000-sheet dual input (TTM)–pick roll removal .4-108
2000-sheet dual input (TTM)–pick roll drive gear 25 tooth removal .4-109
2000-sheet dual input (TTM)–feed unit drive gear 27 tooth removal . .4-110
2000-sheet dual input (TTM)–2TM/TTM left door assembly removal . .4-111
2000-sheet dual input (TTM)–switch (2TM/TTM left door interlock) removal .4-112
2000-sheet dual input (TTM)–tray 3 lift gear assembly removal . .4-113
2000-sheet dual input (TTM)–tray 4 lift gear assembly removal . .4-114
2000-sheet dual input (TTM)–drive motor assembly removal . .4-115
2000-sheet dual input (TTM)–2TM/TTM controller card assembly removal .4-116
2000-sheet dual input (TTM)–clutch removal .4-118
High capacity feeder (HCF) removals .4-119
HCF top cover removal .4-119
HCF right cover removal . .4-120
HCF sensor (HCF media tray set) removal .4-121
HCF sensor (HCF media size) removal .4-122
HCF caster removal . .4-123
HCF left cover removal .4-124
HCF rear cover removal . .4-124
HCF media tray front cover removal .4-125
HCF media long edge guide assembly removal .4-126
HCF media tray assembly removal . .4-127
HCF lift cables removal .4-128
HCF tray lift gear bracket removal . .4-131
HCF media feed unit assembly removal . .4-132
HCF feed lift motor removal .4-132
HCF feed lift gear bracket removal . .4-133
HCF separation gear group removal .4-134
HCF media tray lift coupling assembly removal .4-135
HCF pick solenoid assembly removal .4-136
HCF sensor (pre-feed) removal . .4-137
HCF media out actuator removal . .4-138
HCF sensor (media level) removal . .4-139
HCF sensor (media out) removal . 4-140
HCF pick roll shaft assembly removal . 4-141
HCF pick roll assembly removal . 4-142
HCF feed roll assembly removal . 4-143
HCF separation roll shaft assembly removal . 4-144
HCF separation roll assembly removal 4-145
HCF top door assembly removal . 4-146
HCF switch (top door interlock) removal 4-147
HCF sensor (tray 5 feed-out) removal . 4-148
HCF media transport roll assembly removal . 4-149
HCF media transport motor assembly removal . 4-150
HCF switch (unit docking interlock) removal . 4-151
HCF controller card assembly removal 4-152
Duplex unit removals . 4-153
Duplex unit assembly removal . 4-154
Duplex docking locks removal . 4-156
Duplex support strap



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