Lexmark N 4040 Service Manual
Lexmark Optra™ N
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
4040
• Index
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, THEIMPLIEDWARRANTIESOF 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
NoticesandSafetyInformation..........................xii
LaserNotice....................................... xii
SafetyInformation................................... xx
Preface ............................................xxv
GeneralInformation...................................1-1
Options.......................................... 1-1
Maintenance Approach.............................. 1-1
Tools............................................ 1-2
Abbreviations..................................... 1-3
DiagnosticInformation ................................2-1
Diagnostic Approach................................ 2-1
Start............................................ 2-1
InitialCheck................................... 2-1
Troubleshooting ................................... 2-3
Error Code/Message Tables.......................... 2-4
ServiceErrorCodes............................. 2-4
OperatorCodes................................ 2-7
Diagnostic Information . .......................... 2-9
SymptomTables.................................. 2-11
PrintQualitySymptomTable..................... 2-11
Paper Feed Symptom Table ..................... 2-12
OtherMalfunctionSymptomTable................. 2-13
Paper Deck Symptom Table ..................... 2-15
BaseMachineServiceChecks....................... 2-16
AC Power Input Service Check . . . ................ 2-16
DC Power Input Service Check . . . ................ 2-17
Duplex Horizontal Registration Guide Service Check . . 2-18
FanMotorServiceCheck(927)................... 2-19
Power Supply Fan (FM1) Check ................2-20
Fuser/Printhead Fan (FM2) Check ..............2-20
ElectricalAssemblyFan(FM3)Check ...........2-21
FuserFan(FM4)Check ......................2-21
Fuser (Abnormal Temperature) Service Check (923) . . 2-22
Fuser (Temperature Low) Service Check (920/922) . . . 2-23
Fuser(WrongType)ServiceCheck(924)........... 2-24
High-Voltage Power Supply Output Service Check .... 2-24
LiftingPlate(MultipurposeTray)ServiceCheck...... 2-25
MainMotorServiceCheck....................... 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
RegistrationRollerServiceCheck................. 2-29
PrintQualityServiceChecks........................ 2-30
BlackPageServiceCheck:...................... 2-30
BlankSpotsServiceCheck...................... 2-30
BlankPageServiceCheck...................... 2-31
DarkImageServiceCheck...................... 2-32
DirtonBackofPaperServiceCheck.............. 2-32
DirtyImageServiceCheck...................... 2-33
DistortedPrintServiceCheck.................... 2-33
LightImageServiceCheck...................... 2-34
PoorFusingServiceCheck...................... 2-35
SharpBlackHorizontalLinesServiceCheck........ 2-35
Smudged Horizontal Bands Service Check.......... 2-36
VerticalDotsinaLineServiceCheck.............. 2-36
VerticalStreaks/LinesServiceCheck.............. 2-37
WhiteHorizontalLinesServiceCheck ............. 2-37
WhiteVerticalLinesServiceCheck................ 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
PaperJam20..............................2-47
Paper Jam 21, Input . ........................2-48
PaperJam22,Fuser ........................2-48
PaperJam23,TopOutput/Delivery.............2-49
PaperJam25,Duplex .......................2-49
Paper Jam 27, Paper Size/Change Paper . . ......2-49
Paper Skew Service Check...................... 2-50
Pick-UpAssemblyPaperJamsServiceCheck....... 2-51
Wrinkled Paper Service Check ................... 2-52
iv Service M anual
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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
DiagnosticAids ......................................3-1
InterlockOverride............................... 3-1
BasicEngineTest .............................. 3-2
MenuDisable.................................. 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
ButtonTest.................................... 3-6
Defaults...................................... 3-6
DiskTest/Clean................................ 3-6
ErrorLog ..................................... 3-7
FlashTest..................................... 3-8
LCDTest..................................... 3-8
MemoryTests.................................. 3-8
PageCount ................................... 3-9
Permanent Page Count .......................... 3-9
PrintTest1.................................... 3-9
PrintTest2................................... 3-10
PrintTest3................................... 3-10
PrintRegistration.............................. 3-11
LeftMargin ................................3-11
TopMargin ................................3-11
QuickTest.................................3-11
QuickDiskTest............................... 3-12
WrapTests................................... 3-12
Contents v
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RepairInformation....................................4-1
Handling ESD-Sensitive Parts ........................ 4-2
Adjustments...................................... 4-3
Envelope Feeder Separation Guide and Lower Separation
RollerGapAdjustment .......................... 4-3
Paper Drawer Cassette Side Registration Adjustment . . 4-4
ServiceInformation................................ 4-5
ReleasingPlasticLatches........................ 4-5
ExternalPartsRemovalProcedures................... 4-6
CoverRemovalProcedures ...................... 4-6
Face-DownTrayRemoval.....................4-7
FrontCoverRemoval.........................4-8
Upper Cover Removal ........................4-9
RearCoverRemoval ........................4-11
DeliveryCoverRemoval .....................4-12
MultiPurposeTrayRemoval...................4-12
RightCoverRemoval........................4-13
LeftRearCoverRemoval.....................4-14
FanRemovalProcedures....................... 4-15
Power Supply Fan (FM1) Removal .............4-16
Fuser/ScannerFan(FM2)Removal.............4-17
ElectricalFan(FM3)Removal .................4-19
FuserFan(FM4)Removal....................4-20
Operator Panel Removal. ....................... 4-21
DriveSystemRemovalProcedures................... 4-22
DriveUnitRemoval............................ 4-22
MainMotorRemoval........................... 4-24
Paper Transport System Removal Procedures .......... 4-25
Pick-UpUnitRemoval.......................... 4-25
Pick-UpMotorRemoval......................4-28
FeedClutchRemoval........................4-28
Cassette Pick-Up Solenoid Removal ............4-29
DeliveryUnitRemoval.......................... 4-30
RegistrationRollerRemoval..................... 4-31
RegistrationClutchRemoval ..................4-32
RegistrationLowerRollerRemoval .............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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ExposureSystemRemovalProcedures................ 4-41
Printhead Removal............................. 4-42
Electrostatic Imaging/Developing/Cleaning System Removal
Procedures ...................................... 4-43
EPCartridge.................................. 4-43
DrumProtectiveShutter ......................4-44
PhotosensitiveDrum.........................4-44
TransferChargingRollerRemoval................. 4-45
Fuser Removal Procedures ......................... 4-46
FuserRemoval................................ 4-47
FuserRollerHeaterRemoval..................... 4-48
ThermoswitchRemoval ......................4-49
ThermistorRemoval .........................4-50
FuserUpperRollerRemoval ..................4-51
FuserLowerRollerRemoval ..................4-56
Electronic Components Removal Procedures ........... 4-58
ControllerCardRemoval........................ 4-58
SystemBoardRemoval......................... 4-59
Pick-UpBoardRemoval......................... 4-60
MultipurposeTrayBoardRemoval................. 4-60
Switch/SensorBoardRemoval.................... 4-61
High Voltage Power Supply Board. ................ 4-63
Cassette-SizeSensingBoardsRemoval............ 4-64
Power Supply Removal ......................... 4-65
Envelope Feeder Removal Procedures ................ 4-67
Envelope Feeder Cover Removals ................ 4-67
RearCoverRemoval ........................4-67
FrontCoverRemoval ........................4-67
LowerCoverRemoval .......................4-68
Upper Cover Removal .......................4-69
EnvelopeSideGuideRemoval ................... 4-70
Envelope Feeder Pick-Up Motor Removal........... 4-71
Envelope Feeder Driver Board Removal ............ 4-73
DriveUnitRemoval ............................ 4-74
Envelope Feeder Pick-Up Roller Removal........... 4-75
Separation Rollers and Torque Limiter Removal ...... 4-75
Contents vii
4040
Duplex Assembly Removal Procedures. . .............. 4-77
UpperGuideRemoval.......................... 4-77
LowerGuideRemoval.......................... 4-78
Switchback Roller Release Solenoid Removal . . ..... 4-80
DuplexDeflectorDriveSolenoidRemoval .......... 4-81
SwitchbackMotorRemoval...................... 4-84
SideRegistrationMotorRemoval................. 4-85
DuplexFeedClutchRemoval.................... 4-86
DuplexDriverBoardRemoval.................... 4-87
Paper Deck Removal Procedures .................... 4-89
ExternalCovers............................... 4-89
FrontCoverRemoval........................4-89
LeftCoverRemoval .........................4-89
RightCoverRemoval........................4-90
FeedCoverRemoval........................4-91
RearCoverRemoval ........................4-91
Paper Deck Drive System Removal Procedures ......... 4-92
DriveAssemblyRemoval ....................... 4-92
LifterClutchRemoval........................4-93
DeckMotorRemoval ........................4-93
LimitSwitchRemoval.......................... 4-94
Paper Transport System Removal Procedures .......... 4-95
Pick-UpAssemblyRemoval..................... 4-95
Pick-UpSolenoidRemoval ...................4-97
Pick-UpMotorRemoval......................4-98
FeedAssemblyRemoval........................ 4-99
FeedClutchRemoval.......................4-100
RegistrationClutchRemoval .................4-101
FeedRollerRemoval.......................4-102
RegistrationRollerRemoval .................4-103
TrayRemoval............................... 4-104
LifterRemoval............................... 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
PartsofthePrinter.............................. 5-1
Duplexer..................................... 5-3
Envelope Feeder ............................... 5-3
CrossSectionViewofPrinterandDuplexer.......... 5-4
viii Service Manual
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Locations (Continued)
Cross Section View of Envelope Feeder ............. 5-5
BaseMachineSensorandSwitchOperation.......... 5-6
BaseMachineMotorandClutchOperation........... 5-8
Paper Feed. ................................... 5-9
DuplexOperation.............................. 5-10
Paper Deck Sensor and Switch Operation........... 5-12
Switches..................................... 5-14
Sensors..................................... 5-15
Clutches and Solenoids ......................... 5-17
Motor,Fans,andHeaters........................ 5-19
PrintedCircuitBoards .......................... 5-21
Connector Locations . . ......................... 5-23
SystemBoard................................. 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/SensorBoard........................... 5-40
CassetteSizeSensingSwitchBoard............... 5-40
High Voltage Power Supply Board. ................ 5-41
Contents ix
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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
SafetyInspectionGuide ......................... 6-1
ExpectedLifeofConsumableParts................ 6-1
Maintenance, Customer Checks ................... 6-2
ServiceCheckpoints-Printer..................... 6-2
Cartridge-PhotosensitiveDrum ................6-2
Manual Feeding Pick-Up Roller, Cassette Pick-Up Roller,
SeparationRoller,andFeedRoller ..............6-2
SeparationPad .............................6-2
RegistrationRollerUnit .......................6-2
TransferGuide..............................6-3
TransferChargingRoller ......................6-3
StaticChargeEliminator ......................6-3
FeedGuide ................................6-3
Fuser .....................................6-3
ServiceCheckpoints-PaperDeck................. 6-3
Pick-Up Roller, Separation Roller, Feed Roller .....6-3
Lubricants and Cleaners . ........................ 6-4
x Service Manual
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PartsCatalog ........................................7-1
HowToUseThisPartsCatalog....................... 7-1
Covers and Panels...............................7-2
Internal Paper Mechanism .........................7-6
InternalPaperDrawer/PrintCartridgeMtg.............7-8
Printhead/System Board .........................7-12
Power Supply/Fuser Cables.......................7-14
Face-Up Solenoid...............................7-18
High Voltage Power Supply .......................7-20
PrinterDriver ..................................7-22
LowerDrawer..................................7-24
Upper Drawer..................................7-28
Paper Pick-up..................................7-32
RegistrationRoller..............................7-42
Feeder.......................................7-44
MultipurposeTrayPick-Up........................7-46
MultipurposeTray...............................7-50
Paper Delivery .................................7-52
Paper Delivery Frame . ..........................7-54
Fuser ........................................7-56
ControllerCard.................................7-60
Envelope Feeder Covers .........................7-62
Envelope Feeder Drive 1 .........................7-64
DuplexOption..................................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
OptionControllerCard...........................7-96
Options (NoIllustration)..........................7-98
WiringDiagram.......................................8-1
Index............................................... X-1
Contents xi
4040
Notices and Safety Information
References in this publication to products, programs, or services do
not imply that the manufacturerintends to make these availablein 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) l aser 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 wavelengthregion 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.
xii Service Manual
4040
The Class 1 laser label is attached to the back of the printer.
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
KundendienstLaserbestrahlung, 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 expuestasen 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 afectadapor 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.
xiv Service Manual
4040
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.
Notices and Safety Information xv
4040
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! Avattaessaja 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.
Notices and Safety Information xvii
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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
xviii Service Manual
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Chinese Laser Notice
Korean Laser Notice
Notices and Safety Information xix
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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.
xx Service Manual
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Norme di sicurezza
•
Il prodotto è stato progettato, testato e approvato in conformità a
severi standard di s icurezza e per l’utilizzo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune par ti
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.
Notices and Safety Information xxi
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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.
xxii Service Manual
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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.
Pautas de Seguridad xxiii
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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 xxv
4040
1. General Information
The OptraTMN, 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 foroptions 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.
General Information 1-2
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Abbreviations
ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable Read-
Only Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Network
LASER Light Amplification by Stimulated Emission
of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PICS Problem Isolation Charts
PIXEL Picture Element
POR Power-On Reset
POST Power-On Self Test
PQET Print Quality Enhancement Technology
RIP Raster Image Processor
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
VAC Volts alternating current
VDC 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 star t 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-ven-
tilated place.
Diagnostic Information 2-1
4040
• The room temperature is between 10 and 32.5 ° C, and the rela-
tive 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 tr ial 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 movedfrom 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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