Lexmark 4038-001 Service Manual Download Page 3

Page: 3 / 202

iii

4038-001

Table of contents

Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii

Definitions

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii

General information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Machine features

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Print materials

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Cleaning the machine

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Cleaning the outside of the machine

. . . . . . . . . . . . . . . . . . . . 1-5

Cleaning the inside of the machine

. . . . . . . . . . . . . . . . . . . . . 1-6

Cleaning the scan unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Cleaning the photoconductor drum

. . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance approach

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Tools

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Abbreviations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Diagnostic information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Error message table

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Symptom table

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Paper feed problems

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Printing and copying problems

. . . . . . . . . . . . . . . . . . . . . . . 2-13

Scanning problems

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Faxing problems

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Print quality checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Service checks

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Diagnostic aids

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Configuration modes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Clear All Memory mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Clear Count mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Dial mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Error Rate mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Modem Speed mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Park CCD module mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Print Properties mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Send Level mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

System Settings Report mode

. . . . . . . . . . . . . . . . . . . . . . . . 3-8

Summary of Contents for 4038-001

Page 1: ...215 MFP Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks...

Page 2: ...or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 4...

Page 3: ...9 Maintenance approach 1 9 Tools 1 9 Abbreviations 1 10 Diagnostic information 2 1 Start 2 1 Error message table 2 2 Symptom table 2 10 Paper feed problems 2 11 Printing and copying problems 2 13 Scan...

Page 4: ...nt feed ADF removals 4 17 CCD module assembly removal 4 19 Fan removal 4 31 Fuser removal 4 32 HVPS contact removal 4 33 LVPS HVPS card removal 4 34 Main drive assembly removal 4 37 Main paper feed ro...

Page 5: ...or panel 5 4 HVPS LVPS card 5 6 Modem card 5 8 Operator panel card 5 9 Scanner card 5 10 System board 5 12 ADF paper path 5 14 Printer engine paper path paper jams 5 15 Preventive maintenance 6 1 Part...

Page 6: ...vi Service Manual 4038 001...

Page 7: ...ii 4038 001 Laser notices The following laser notice labels may be affixed to this printer as shown Laser advisory label With the middle cover removed the laser advisory label is affixed to the top of...

Page 8: ...viii Service Manual 4038 001 Class 1 Laser Statement label The Class 1 laser label is located on the rear of the machine Example...

Page 9: ...service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse...

Page 10: ...n par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe I Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere c...

Page 11: ...al nivel de la Clase I durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em c...

Page 12: ...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 Lasermedd...

Page 13: ...ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis...

Page 14: ...r foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe I 1 i...

Page 15: ...Laser notices xv 4038 001 Japanese Laser Notice Chinese Laser Notice...

Page 16: ...xvi Service Manual 4038 001 Korean Laser Notice...

Page 17: ...nplug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit La s curit de ce produit repose sur des tests et des agr ations po...

Page 18: ...to deve essere alimentato per eseguire l intervento Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendu...

Page 19: ...fe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O...

Page 20: ...ucte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aque...

Page 21: ...Safety information xxi 4038 001...

Page 22: ...ovides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preven...

Page 23: ...d faxing Machine features Print speeds up to 17 ppm Print resolution up to 600 x 600 dpi Paper tray capacity up to 250 sheets Front output bin 150 sheet capacity Manual bypass paper feeder one page at...

Page 24: ...io 215 9 x 330 2 8 5 x 13 Legal 215 9 x 355 6 8 5 x 14 Executive 184 2 x 266 7 7 25 x 10 5 B5 182 x 257 7 2 x 10 Yes 250 Yes 1 A5 148 x 210 5 83 x 8 27 A6 105 x 148 4 13 x 5 88 No 0 Yes 1 Envelopes No...

Page 25: ...ions that could cause it to wrinkle or curl During storage you should use moisture proof wrap such as a plastic container or bag to prevent dust and moisture from contaminating your paper Always use p...

Page 26: ...and 86o F 15o C to 30o C The relative humidity should be between 10 and 70 The laser printing process heats paper to high temperatures of 180 C 356 F Use only paper able to withstand these temperature...

Page 27: ...mmonia based cleaners or volatile solvents such as thinner on the printer While cleaning the inside of the machine be careful not to touch the transfer roller located under the toner cartridge Oil fro...

Page 28: ...s buildup can cause print quality problems such as toner specks or smearing 1 Turn the machine off unplug the power cord and then wait for the machine to cool down 2 Open the front cover and remove th...

Page 29: ...area and the toner cartridge cavity Warning To prevent damage to the toner cartridge do not expose it to light for more than a few minutes Cover it with a piece of paper if necessary Do not touch the...

Page 30: ...ssible copies 1 Slightly dampen a soft lint free cloth or paper towel with water 2 Open the document cover 3 Wipe the surfaces of the document glass and ADF until they are clean and dry 4 Wipe the und...

Page 31: ...uctor surface are affixed to the paper If the problem persists repeat these steps If the photoconductor drum has been cleaned several times and the problem is still unresolved install a new toner cart...

Page 32: ...ry EP Electrophotographic process ESD Electrostatic discharge FRU Field replaceable unit HSYNC HVPS High voltage power supply Kbps Kilobits per second LCD Liquid crystal display LED Light emitting dio...

Page 33: ...he printhead shutter actuator when power is on Remove power from the printer before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the...

Page 34: ...e manual bypass Make sure the main paper feed toner cartridge present sensor actuator is not broken improperly installed or stuck with paper debris Perform the Sensor test on page 3 17 to check proper...

Page 35: ...ccess cover until it locks If the message does not clear perform the Sensor test on page 3 17 to check proper operation of the switch If the switch works properly the problem is likely associated with...

Page 36: ...rror A problem in the LSU laser scanning unit Make sure all cables are properly connected to the printhead If correct replace the printhead Memory Full Collated copy is too large for memory Reduce the...

Page 37: ...printer senses that the thermistor isn t connected or faulty Make sure the thermistor is properly connected to CN7 on the HVPS LVPS If the problem persists replace the fuser Overheat The fuser unit ha...

Page 38: ...er paper debris Make sure the manual bypass sensor actuator is not broken improperly installed or stuck with paper debris Perform the Sensor test on page 3 17 to check proper operation of the sensor I...

Page 39: ...occur Remove any obstructions and other paper debris Perform the Sensor test on page 3 17 to check proper operation of the sensor If the sensor works properly the problem is likely associated with th...

Page 40: ...sor test on page 3 17 to check proper operation of the sensor If the sensor works properly the problem is likely associated with the system board Make sure the fuser exit sensor actuator is not broken...

Page 41: ...Press the asterisk to select AM or PM and then press Select Note If the machine is unplugged for longer than 15 minutes or turned off for longer than an hour when the power is turned back on the mach...

Page 42: ...opying problems on page 2 13 Scanning problems See Scanning problems on page 2 18 Faxing problems See Faxing problems on page 2 19 Print quality problems See Print quality checks on page 2 21 Dead mac...

Page 43: ...s may cause some paper to stick together Multiple sheets do not feed Different types of paper may be stacked in the paper tray Load paper of only one type size and weight When loading paper do not for...

Page 44: ...special materials use the manual bypass An incorrect type of paper is being used Use only paper that meets specifications See Selecting print materials on page 1 2 for more information There may be d...

Page 45: ...s Paper jam Clear the paper jam No paper loaded Load paper Toner cartridge is not installed Install the toner cartridge Connection cable between the computer and the machine is not connected properly...

Page 46: ...ect the spool setting you want Half the page is blank Page orientation setting may be incorrect Change the page orientation in your program Paper size and the paper size settings do not match Ensure t...

Page 47: ...rs may experience poor USB communication Change the USB mode to SLOW 1 Press Menu 2 Press the scroll button until MACHINE SETUP appears on the top line of the display and then press Select 3 Press the...

Page 48: ...al clean the document glass and underside of the document cover Copy image is skewed Original document not positioned correctly Ensure the original is positioned correctly on document glass or that AD...

Page 49: ...d paper is recommended Check for paper or pieces of paper remaining in the machine after a jam is cleared Fewer copies from the toner cartridge than expected Originals contain pictures solids or heavy...

Page 50: ...f necessary replace the cable If using a parallel cable ensure that it is compliant with the IEEE 1284 standard Make sure that the scanner job is sent to the correct port for example LPT1 or USB Scans...

Page 51: ...ure that the numbers are stored in the memory correctly Print a phonebook list Document does not feed Make sure that the document is not wrinkled and you are putting it in correctly Check that the doc...

Page 52: ...t Check your scan glass for marks and clean it Machine dials a number but fails to make a connection with another fax machine The other fax machine may be turned off out of paper or cannot answer inco...

Page 53: ...t Toner cartridge failure Note If dense paper is used or processing a lot of graphics the cartridge may need changing more often Paper may not meet specifications too moist or too rough See Paper and...

Page 54: ...print materials on page 1 2 for more information Toner cartridge failure Fuser failure Dark or blurry black spots occur periodically White spots occur periodically Paper may not meet specifications to...

Page 55: ...be too slick causing characters to be improperly formed and producing hollow images See Selecting print materials on page 1 2 for more information Scanner unit may be defective causing characters to...

Page 56: ...terials on page 1 2 for more information Turn over the stack of paper and rotate 180 in the tray Back of printout is dirty Clean transfer roller See Cleaning the machine on page 1 5 for more informati...

Page 57: ...heck that correct media type is selected Fuser failure Character voids White areas within the parts of characters that should be solid black If transparencies are used try another type of transparency...

Page 58: ...ions can increase background shading Dirty transfer roll Transfer roll failure or improperly installed HVPS failure Residual image occurs at 75 mm intervals Toner cartridge failure Bad or dirty high v...

Page 59: ...ure Bad or dirty high voltage contacts Residual image occurs at 64 mm intervals Fuser temperature maintained too high Check for toner buildup on hot roller and thermistor surface Clean or replace fuse...

Page 60: ...t have blank pages Bad or dirty high voltage contacts inspect and clean contacts Replace the LVPS HVPS Replace the system board Blank page prints One or several blank pages print When printer is power...

Page 61: ...black spots voids Toner cartridge 2 37 7 mm Charge roller Black spots Toner cartridge 3 37 0 mm Supply roller Horizontal shock lines Toner cartridge 4 35 2 mm Developer roller Horizontalshock lines T...

Page 62: ...o see if the fan turns on If the fan turns on the problem is likely associated with the system board If the fan does not turn on make sure the cooling fan cable is properly seated in CN3 on the LVPS H...

Page 63: ...faulty system board If the motor does not work at all during this test make sure the motor cable is properly connected If connections are correct and the problem persists replace the main drive assemb...

Page 64: ...tem board cable Ensure the cable connecting the LVPS HVPS to the system board is properly seated LVPS HVPS Check the following voltages on CN2 of the LVPS HVPS pin 3 5 V dc pin 4 5 V dc pin 5 Ground p...

Page 65: ...ration of the LCD screen LED s and key buttons If the operator panel does not work at all check the following on the scanner card CN2 1 Ground CN2 2 5 V dc If the voltage is not present replace the sc...

Page 66: ...2 34 Service Manual 4038 001...

Page 67: ...te Page counts are not reset when Clear All Memory is performed To adjust Clear All Memory 1 Press Menu 1 9 3 4 The LCD displays TECH 2 Press Menu and then Select 3 Select Data Setup 4 Select Clear Al...

Page 68: ...hen Select 6 The following choices are available and can be reset 7 Press Return to go back to TECH screen 8 Press Menu 1 9 3 4 to exit TECH mode Total Page CNT The page count printed on the current f...

Page 69: ...Press Menu 1 9 3 4 to exit TECH mode Error Rate mode The Error Rate setting is a level used to automatically lower the modem speed when errors occur Whenever the error rate exceeds this setting the ba...

Page 70: ...4 8 9 6 12 0 14 4 28 8 33 6 Kbps To adjust the Modem Speed 1 Press Menu 1 9 3 4 The LCD displays TECH 2 Press Menu and then Select 3 Select Data Setup 4 Select Modem Speed 5 Select the desired modem s...

Page 71: ...module 1 Press Menu 1 9 3 4 The LCD screen displays TECH 2 Press Menu and then Select 3 Select Machine Test 4 Select Move CCD The CCD module parks in the shipping position 5 At this point the printer...

Page 72: ...Watermark text printed over an existing document Overlay specific text or images printed on multiple documents such as the text or images that make up a letterhead Odd Even pages and Manual feed used...

Page 73: ...ide Source select the paper input source front input tray or manual bypass The Manual Feed source is used when printing specialty media Load one sheet at a time into the manual bypass If the paper sou...

Page 74: ...and then Select 3 Select Data Setup 4 Select Send Level 5 Key in desired send level 9 15 and press Select 6 Press Return to go back to TECH screen 7 Press Menu 1 9 3 4 to exit TECH mode System Setting...

Page 75: ...ss Menu 1 9 3 4 The LCD screen displays TECH 2 Press Menu and then Select 3 Select Machine Test 4 Select DRAM Test The test runs automatically If the test passes the LCD screen displays OK If the test...

Page 76: ...est 4 Select Report 5 Select Protocol A Modem Protocol log page prints 6 Press Menu 1 9 3 4 to exit TECH mode Modem test The Modem test causes the modem to send various transmit signals on the telepho...

Page 77: ...iagnostic 3 Press Select for Mtr Fan Sol Each component is listed one at a time The first component is the main drive motor 4 To test the component press 1 5 To turn off the component test and proceed...

Page 78: ...Button test 1 Press Menu 1 9 3 4 The LCD screen displays TECH 2 Press Menu and then Select 3 Select Machine Test 4 Select Switch Test 5 Press the desired key button s one at a time to perform the test...

Page 79: ...ED test The light contrast LED turns off By continuing to press any key each LED turns off When the last LED is turned off the Key Button test begins 6 Press each key button prompted by the LCD screen...

Page 80: ...isted one at a time The first component is the printhead LSU motor 5 To test the component press 1 The LCD screen displays Ready once the component passes the test 6 To turn off the component test and...

Page 81: ...CD screen displays TECH 2 Press Menu and then Select 3 Select Machine Test 4 Select Pattern Test 5 Select the pattern to print or select All to print all test patterns Select the number of pages to be...

Page 82: ...Menu 1 9 3 4 The LCD screen displays TECH 2 Press Menu and then Select 3 Select Machine Test 4 Select ROM Test The test runs automatically If the test passes the flash and engine code levels are disp...

Page 83: ...moothly or not at all check that the belt is properly installed between the motor pulley and CCD module Ensure the CCD module is installed correctly If the CCD module strikes the left side of the scan...

Page 84: ...move to the next sensor to be tested The test can be exited at any time by pressing Return Note If a component was activated when Return is pressed that component remains activated while another test...

Page 85: ...tent The content setting is used to improve copy quality Choose from the following settings Text use for documents containing mostly text Mixed use for documents with mixed text and graphics Photo use...

Page 86: ...d typed or printed documents Dark works well with light print or faint pencil markings To adjust the darkness press Darkness repeatedly Each time you press the button the LED labeled with the selected...

Page 87: ...fined copy size 1 Press Scale The default setting appears on the bottom line of the display 2 Press a scroll button repeatedly until the copy size is displayed 3 Press Select To customize the copy siz...

Page 88: ...e page The advanced settings available when a document is loaded in the scanner bed include Off turns off the advanced copy features Auto Fit automatically reduces or enlarges the original image so th...

Page 89: ...is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Re...

Page 90: ...4 2 Service Manual 4038 001 3 Press in on one side of the access cover to release it 4 Release the other side of the access cover and remove...

Page 91: ...e the scanner and scanner card assembly See Scanner assembly removal on page 4 64 and Scanner card assembly removal on page 4 68 for more information 2 Slip the cables out of the middle cover A scanne...

Page 92: ...4 4 Service Manual 4038 001 4 From the front of the printer pull both the middle cover legs away from the printer to release tabs 5 Lift up to remove the middle cover...

Page 93: ...Repair information 4 5 4038 001 Rear cover removal 1 Remove four screws A...

Page 94: ...4 6 Service Manual 4038 001 2 Pull the rear cover to remove...

Page 95: ...ment cover removal 1 Remove the left side cover See Left side on page 4 12 for more information 2 Remove the ground screw on the drive assembly See Scanner assembly removal on page 4 64 for more infor...

Page 96: ...4 8 Service Manual 4038 001 4 Un thread the cable A from the scanner document cover...

Page 97: ...Repair information 4 9 4038 001 5 Open the document cover...

Page 98: ...4 10 Service Manual 4038 001 6 Lift the document cover until the hinges catch A...

Page 99: ...Repair information 4 11 4038 001 7 Tilt back and lift off the scanner document cover...

Page 100: ...4 12 Service Manual 4038 001 Side cover removals Left side 1 Remove the rear cover See Rear cover removal on page 4 5 for more information 2 Disconnect the speaker cable A A...

Page 101: ...Repair information 4 13 4038 001 3 Slide the cover toward the rear of the printer to release...

Page 102: ...4 14 Service Manual 4038 001 4 Tilt away from printer 5 Lift to remove the left side cover...

Page 103: ...Repair information 4 15 4038 001 Right side 1 Remove the rear cover See Rear cover removal on page 4 5 for more information 2 Slide the cover toward the rear of the printer to release...

Page 104: ...4 16 Service Manual 4038 001 3 Tilt away from printer 4 Lift to remove the right side cover...

Page 105: ...Repair information 4 17 4038 001 Automatic document feed ADF removals ADF Pick roller 1 Open ADF access cover 2 Rotate the pick roller bearing A to release from the ADF housing...

Page 106: ...ce Manual 4038 001 3 Lift the pick roller and slide out ADF Pad 1 Remove the ADF pick roller See Automatic document feed ADF removals on page 4 17 for more information 2 Grab both sides of the ADF pad...

Page 107: ...l 1 Remove the scanner assembly and operator panel See Scanner assembly removal on page 4 64 and Operator panel removal on page 4 50 for more information 2 Remove four screws A 3 Slip a flat blade scr...

Page 108: ...4 20 Service Manual 4038 001 4 Lift off glass housing to remove...

Page 109: ...Repair information 4 21 4038 001 5 Use a flat blade screwdriver to gently pry open the CCD module assembly housing to release the belt...

Page 110: ...4 22 Service Manual 4038 001 6 Pry the shaft loose on both ends and slide out...

Page 111: ...Repair information 4 23 4038 001 7 Release the ribbon cable from slots A...

Page 112: ...4 24 Service Manual 4038 001 8 Disconnect the ribbon cable A from the CCD 9 Remove the CCD assembly...

Page 113: ...1 Remove the left right and rear covers See Left side on page 4 12 Right side on page 4 15 and Rear cover removal on page 4 5 for more information 2 Remove two screws A at the rear of the printer 3 P...

Page 114: ...4 26 Service Manual 4038 001 4 Remove 10 screws A in card cage...

Page 115: ...Repair information 4 27 4038 001 Note Hold the card cage as you remove the last screw as the cage can fall...

Page 116: ...4 28 Service Manual 4038 001 5 Lift the card cage to remove...

Page 117: ...Repair information 4 29 4038 001 6 Disconnect all cables on the system board See reinstallation note...

Page 118: ...4038 001 Reinstallation note Make note of the cable locations A for the cartridge fuse CN4 and main paper feed cable CN6 as these pin connectors can be interchanged This reversal could cause the prin...

Page 119: ...ir information 4 31 4038 001 Fan removal 1 Remove the right side cover See Right side on page 4 15 for more information 2 Disconnect the fan cable from the LVPS HVPS 3 Pull the fan straight out to rem...

Page 120: ...4 32 Service Manual 4038 001 Fuser removal 1 Remove the card cage See Card cage removal on page 4 25 for more information 2 Remove four screws A 3 Pull the fuser straight out to remove...

Page 121: ...001 HVPS contact removal 1 Remove the right side cover See Right side on page 4 15 for more information 2 Remove the screw in the cover to the HVPS contacts 3 Remove the cover 4 Using needle nose plie...

Page 122: ...4 34 Service Manual 4038 001 LVPS HVPS card removal 1 Remove the card cage See Card cage removal on page 4 25 for more information 2 Disconnect the cable CN2 on the LVPS HVPS card...

Page 123: ...Repair information 4 35 4038 001 3 Remove seven screws A Note The bracket securing the LVPS HVPS card must be removed to reveal the last screw holding the LVPS HVPS card...

Page 124: ...4 36 Service Manual 4038 001 4 Remove the LVPS HVPS card...

Page 125: ...formation 4 37 4038 001 Main drive assembly removal 1 With the left side cover removed See Left side on page 4 12 for more information 2 Remove six screws A across the top and bottom of the main drive...

Page 126: ...4 38 Service Manual 4038 001 3 Pull the main drive assembly out a little and disconnect the drive motor cable A 4 Lift out the main drive assembly to remove...

Page 127: ...r feed roller removal 1 Remove the middle cover and main drive assemblies See Middle cover removal on page 4 3 and Main drive assembly removal on page 4 37 for information 2 Remove the three screws A...

Page 128: ...4 40 Service Manual 4038 001 4 Remove the two screws A 5 Lift the metal plate and remove...

Page 129: ...6 Lift the metal shaft registration roller with both bearings attached Reinstallation note When installing the four gears make sure the arms of the solenoids are in the correct position 7 Pry up the m...

Page 130: ...038 001 Main feed roller solenoid removal 1 With the card cage and main drive assembly removed See Card cage removal on page 4 25 and Main drive assembly removal on page 4 37 for more information 2 Re...

Page 131: ...Repair information 4 43 4038 001 3 Remove the pick roller gear 4 Remove one screw...

Page 132: ...4 44 Service Manual 4038 001 5 Remove the main feed roller solenoid...

Page 133: ...38 001 Manual paper feed sensor actuator removal 1 With the paper tray feed roller removed See Paper tray feed roller removal on page 4 56 for more information 2 Flex the tab with your thumb and pry u...

Page 134: ...46 Service Manual 4038 001 3 Lift and remove from the printer Note Ensure the spring remains on the actuator Reinstallation note Verify the spring is in the correct orientation and flexes the actuato...

Page 135: ...Repair information 4 47 4038 001 Modem card removal 1 With the card cage removed See Card cage removal on page 4 25 for more information 2 Disconnect the modem ribbon cable CN3...

Page 136: ...4 48 Service Manual 4038 001 3 Remove two screws A 4 Using needle nose pliers squeeze the standoff to release the modem card...

Page 137: ...Repair information 4 49 4038 001 5 Remove the modem card...

Page 138: ...4 50 Service Manual 4038 001 Operator panel removal 1 Remove three screws A on the underside of the operator panel 2 Rotate the top portion of the operator panel up...

Page 139: ...Repair information 4 51 4038 001 3 Disconnect the operator panel cables CN1 and CN2 4 Remove the operator panel...

Page 140: ...4 52 Service Manual 4038 001 Paper empty sensor actuator removal 1 Remove the card cage See Card cage removal on page 4 25 for more information 2 Deflect the tab to the side of the actuator to release...

Page 141: ...Repair information 4 53 4038 001 3 Remove the paper empty sensor actuator...

Page 142: ...l 1 Remove the paper tray pick roller assembly and paper empty sensor actuator See Paper tray pick roller assembly removal on page 4 57 and Paper empty sensor actuator removal on page 4 52 for more in...

Page 143: ...Repair information 4 55 4038 001 3 Lift and remove the paper feed sensor actuator...

Page 144: ...001 Paper tray feed roller removal 1 Remove the paper tray pick roller See Paper tray pick roller assembly removal on page 4 57 for more information 2 Pull down to release from bushings A 3 Remove th...

Page 145: ...aper tray pick roller assembly removal 1 Remove the main drive assembly See Main drive assembly removal on page 4 37 for more information 2 Remove the paper tray 3 Remove the three screws A securing t...

Page 146: ...4 58 Service Manual 4038 001 4 Remove the pick roller gear 5 With the card cage removed See Card cage removal on page 4 25 for more information...

Page 147: ...Repair information 4 59 4038 001 6 With a flat blade screwdriver lift the tab A on the right bushing...

Page 148: ...4 60 Service Manual 4038 001 7 While holding the tab up push the pick roller to the right until the shaft A is released on the left side 8 Remove the pick roller...

Page 149: ...4038 001 Paper tray solenoid removal 1 Remove the card cage and main drive assembly See Card cage removal on page 4 25 and Main drive assembly removal on page 4 37 for more information 2 Remove the s...

Page 150: ...4 62 Service Manual 4038 001 3 Remove the paper tray solenoid...

Page 151: ...4038 001 Printhead removal 1 Remove the middle cover See Middle cover removal on page 4 3 for more information 2 Remove four screws A from the printhead 3 Lift the printhead 4 Disconnect two connector...

Page 152: ...Remove the left right and rear covers See Left side on page 4 12 Right side on page 4 15 and Rear cover removal on page 4 5 for more information 2 Remove the ground screw from the main drive assembly...

Page 153: ...Repair information 4 65 4038 001 cable A CN3 cable A with toroid CN6...

Page 154: ...4 66 Service Manual 4038 001 cable A CN2...

Page 155: ...Repair information 4 67 4038 001 ribbon cable A CN1 4 Remove two screws in rear of printer...

Page 156: ...ervice Manual 4038 001 5 Remove the scanner assembly Scanner card assembly removal 1 Remove the left side cover See Left side on page 4 12 for more information 2 Disconnect all cables from the scanner...

Page 157: ...Repair information 4 69 4038 001 3 Remove two screws A from the card...

Page 158: ...4 70 Service Manual 4038 001 4 Lift out the scanner card to remove...

Page 159: ...Repair information 4 71 4038 001 Scanner assembly cushion removal Pull the scanner cushion away to release from adhesive...

Page 160: ...removal 1 With the scanner document cover removed See Scanner assembly document cover removal on page 4 7 for more information 2 Lay the scanner document cover upside down 3 Remove three screws A from...

Page 161: ...information 4 73 4038 001 System board removal 1 Remove the modem card See Modem card removal on page 4 47 for more information 2 Disconnect the LVPS HVPS cable CN14 3 Remove the modem card ribbon cab...

Page 162: ...4 74 Service Manual 4038 001 Note See reinstallation note 4 Remove five screws A...

Page 163: ...ir information 4 75 4038 001 5 Remove the system board 6 Remove the modem card standoff from the system board Reinstallation note Reinstall the modem card standoff and ribbon cable on the new system b...

Page 164: ...access cover 2 Remove the toner cartridge Note Place toner cartridge on a flat surface and cover with paper to prevent light getting to the developer Prolonged exposure of light to the green PC drum...

Page 165: ...pair of needle nose pliers grab the right end of the shaft and move to the right Note Touching the roller may cause print quality problems 5 Once the left side of the transfer roll is released still h...

Page 166: ...4 78 Service Manual 4038 001...

Page 167: ...Front view ADF release knob Scanning bed Document output tray Document cover Paper output extension Document guide Automatic Document feeder ADF Document input tray Operator panel Front output tray Fr...

Page 168: ...5 2 Service Manual 4038 001 Rear view Telephone line connector USB connector Parallel connector Rear cover Power switch AC power cord connector...

Page 169: ...Locations 5 3 4038 001 EP rollers 1 OPC drum 2 Charge roller 3 Supply roller 4 Developing roller 5 Transfer roller 6 Heat roller 7 Pressure roller Toner Cartridge Fuser 1 2 3 4 5 6 7...

Page 170: ...anual 4038 001 Operator panel 1 2 3 4 5 6 7 8 9 0 Return Menu Select Copy Fax Number Resolution Phonebook Redial Pause Light Text Scale Advanced Mixed Photo Dark Normal Fax Copy Darkness Content 1 2 3...

Page 171: ...ls the most recently used fax number Also used to enter programmed delays when entering shortcuts Telephone icon Starts a dial tone used to send a fax manually 1 2 3 4 5 6 7 8 9 Display Displays the c...

Page 172: ...5 6 Service Manual 4038 001 HVPS LVPS card CN2 1 OP104 OP103 OP101 OP102 CN3 CN1 C O Switch 1...

Page 173: ...2 110 220 240 V ac Neutral System board CN2 26 3 4 7 12 5 6 8 9 10 11 5 V dc 12 V dc 24 V dc Ground Cooling fan CN3 3 1 24 V dc Cover open switch C O Switch Manual bypass sensor OP101 Main paper feed...

Page 174: ...5 8 Service Manual 4038 001 Modem card Function name Name on card of pins Pin Signal System board CN3 14 10 2 12 5 V dc Ground 1 CN3 CN1...

Page 175: ...Locations 5 9 4038 001 Operator panel card Function name Name on card of pins Pin Signal Document cover sensor CN1 3 1 3 5 V dc Ground Scanner card CN2 6 2 1 5 V dc Ground CN2 1 CN1 CN3 1 1...

Page 176: ...5 10 Service Manual 4038 001 Scanner card 1 CN2 1 CN6 1 CN1 CN4 1 CN5 CN3 1 1...

Page 177: ...22 1 3 5 7 12 20 24 5 V dc 24 V dc Ground Operator panel CN2 6 2 1 5 V dc Ground ADF CN3 16 3 2 4 1 11 13 15 5 V dc 24 V dc Ground System board CN4 26 1 2 3 8 9 10 18 19 20 22 24 26 5 V dc Ground Sys...

Page 178: ...5 12 Service Manual 4038 001 System board CN13 1 CN20 C156 CN10 CN8 CN9 CN7 1 1 1 1 CN14 1 CN4 CN12 CN6 CN5 CN2 CN1 1 1 1 1 CN3 1 1 1...

Page 179: ...4 V dc Pre transfer LED CN3 2 1 3 3 V dc Toner cartridge fuse CN4 2 Main drive motor CN5 4 Main paper feed bypass solenoid CN6 2 1 24 V dc Fuser thermistor CN7 2 Scanner card CN8 26 1 2 3 4 5 10 15 16...

Page 180: ...ath Not used CN13 Modem card CN14 14 10 2 12 5 V dc Ground Function name Name on card of pins Pin Signal CCD Module Exit roller Document sensor Pickup roller ADF roller ADF Idle roller Scan sensor Reg...

Page 181: ...ter engine paper path paper jams PTL PIC K R CR DR SR TR FR OPC Bypass jam BR Fuser Printhead Paper jam 0 Paper jam 2 Paper jam 1 Main paper feed toner cartridge present sensor Manual bypass sensor Em...

Page 182: ...5 16 Service Manual 4038 001...

Page 183: ...Preventive maintenance 6 1 4038 001 6 Preventive maintenance The Lexmark X215 MFP does not require preventive maintenance...

Page 184: ...6 2 Service Manual 4038 001...

Page 185: ...he same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NS Not Shown in the Asm Index column in...

Page 186: ...7 2 Service Manual 4038 001 Assembly 1 Scanner assembly 1 2 3 4 5 6 7 8 9 10 11...

Page 187: ...ess 2 56P1923 1 Kit asm ADF pick roll pad 3 56P1922 1 Roller ADF idler 4 56P1983 1 Scanner complete 5 56P1936 1 Overlay main 6 56P1935 1 Overlay menu select return 7 56P1934 1 Panel asm operator 8 56P...

Page 188: ...7 4 Service Manual 4038 001 Assembly 2 Main assembly 1 2 4 5 12 15 14 6 7 9 13 18 16 17 19 21 8 10 11 20 3...

Page 189: ...S 240 V 7 56P1906 1 Cable system to power supply 8 56P1918 1 Card asm modem Americas 8 56P1986 1 Card asm modem West Europe 8 56P1987 1 Card asm modem S Africa 8 56P1988 1 Card asm modem Asia 8 56P198...

Page 190: ...7 6 Service Manual 4038 001 Assembly 3 Frame assembly 1 3 4 5 6 8 9 10 11 14 15 16 17 18 19 20 22 21 23 24 25 26 27 28 30 31 32 2 12 7 29 33 9 10 28 11 24 24 13...

Page 191: ...cartridge latch 12 56P1948 4 Contact high voltage 13 56P1949 1 Cover HV contact 14 56P1950 1 Latch paper tray 15 56P1951 1 Actuator cover open 16 56P1947 2 Foot rubber 17 56P1952 1 Latch right cartrid...

Page 192: ...7 8 Service Manual 4038 001 Assembly 3 cont Frame assembly 1 3 4 5 6 8 9 10 11 14 15 16 17 18 19 20 22 21 23 24 25 26 27 28 30 31 32 2 12 7 29 33 9 10 28 11 24 24 13...

Page 193: ...ong Kong Malaysia Singapore Ireland UK NS 1339529 1 Line cord Austria Belgium Czech Slav Finland France Germany Greece Hungary Iceland Italy Luxembourg Netherlands Holland Norway Poland Portugal Russi...

Page 194: ...7 10 Service Manual 4038 001...

Page 195: ...kness 3 20 number 3 20 scale 3 21 D dial mode 3 3 DRAM memory test 3 9 drum clean 1 9 E envelopes 1 2 error message 2 2 bypass jam 2 2 door open 2 3 fuser error 2 4 jam 2 3 load bypass 2 4 LSU error 2...

Page 196: ...16 copies too light 2 16 copy image skewed 2 16 envelopes skew 2 12 frequent jams 2 17 half of page is blank 2 14 illustrations print incorrectly 2 15 image rubs off easily 2 16 LCD does not turn on 2...

Page 197: ...ht side 4 15 covers scanner assembly 4 7 fan 4 31 fuser 4 32 HVPS contact 4 33 LVPS HVPS card 4 34 main drive assembly 4 37 main feed roller solenoid 4 42 main paper feed roller 4 39 manual paper feed...

Page 198: ...Index 4 Service Manual 4038 001...

Page 199: ...asm LVPS HVPS 110 V 7 5 56P1905 Card asm LVPS HVPS 220 V 7 5 56P1906 Cable system to power supply 7 5 56P1908 Cover asm middle 7 5 56P1909 Extender output bin 7 5 56P1910 Cover asm cartridge access 7...

Page 200: ...feed 7 7 56P1958 Contact transfer roll 7 7 56P1959 Roller main paper feed 7 7 56P1960 Bearing feed roller 7 7 56P1961 Roller paper tray feed 7 7 56P1962 Roller asm paper tray pick 7 7 56P1963 LED pre...

Page 201: ...round 7 5 56P1986 Card asm modem West Europe 7 5 56P1987 Card asm modem S Africa 7 5 56P1988 Card asm modem Asia 7 5 56P1989 Card asm modem Australia 7 5 56P1990 Fuser complete 240 V 7 7 56P2028 Card...

Page 202: ...Part number index 8 Service 4038 001...

Search results

Summary of Contents for 4038-001

Reviews:

Related manuals for 4038-001

Brands by name

Popular brands

Lexmark 4038-001, Service Manual

Search results

Summary of Contents for 4038-001

Reviews:

Related manuals for 4038-001

Brands by name

Popular brands