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Lexmark Optra N model 240, Service Manual

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Lexmark Optra N model 240 Service Manual Download Page 51

Repair Information 3-20

4040 Finisher

6. Remove the spring hook (1), then the spring (2).

7. Remove the C-clip (3), the bushing (4), then the reversing roller

(5).

Electrical Components Removal Procedures

Driver Board Removal

1. Remove the rear cover.

2. Disconnect the 13 connectors (1).

3. Remove the 4 screws (2), then the finisher driver board (3).

Summary of Contents for Optra N model 240

Page 1: ...tion 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 St...

Page 2: ...ion 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 Internationa...

Page 3: ...istance Detecting Sensor Service Check 2 10 Paper Delivery Motor Service Check 2 11 Paper Delivery Service Check 2 11 Paper Feed Motor Service Check 2 12 Paper Jam 41 Paper Input Service Check 2 12 Pa...

Page 4: ...moval 3 10 Staple Tray Alignment Plate Shift Motor Removal 3 11 Staple Tray Delivery Roller 1 Removal 3 11 Face up Solenoid Removal 3 13 Staple Assembly Removal 3 14 Tray Assembly Drive Removal 3 16 P...

Page 5: ...Cont 5 4 Stapler Main Body 5 6 Stapler Main Body 5 10 Stapler Tray Main Body 5 14 Stapler Tray Main Body Cont 5 16 Swing Guide Assembly 5 20 Stapler Tray 5 22 Tray Drive 5 24 Upper Feeder 5 26 Center...

Page 6: ...h other products programs or services except those expressly designated by the manufacturer are the user s responsibility Safety Information This product is designed tested and approved to meet strict...

Page 7: ...s le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Norme di sicurezza Il prodotto stato progettato testato e approvato in conformit a severi standard di sicurezza e pe...

Page 8: ...ht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende Vorsichtsma nahmen treffen Pautas de Seguridad Este producto se ha di...

Page 9: ...oduto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Informaci de Seguretat Aquest producte est dissenyat comprovat i aprovat per tal d acomplir les...

Page 10: ...x Service Manual 4040 Finisher...

Page 11: ...ice checks to determine the symptom and repair the failure After you complete the repair perform tests as needed to verify the repair Stapler Test The stapler test must be run after a new staple cartr...

Page 12: ...several staples along one edge of the page This primes the stapler for future jobs and improves stapling reliability Tools The removal and adjustment procedures described in this manual require the f...

Page 13: ...l 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 OE...

Page 14: ...if just the defective part is available in the parts catalog Some diagnostic pro cedures indicate the parts catalog location of the part to be checked by including the assembly number and reference nu...

Page 15: ...s securely installed on a level surface in a well ventilated place The room temperature is between 10 and 32 C 50 and 90 F and the relative humidity between 20 and 80 Avoid sites generating ammonia ga...

Page 16: ...error does not clear check the door switches and replace if necessary 31 Finisher Interlock Open PI 15 Be sure the finisher is positioned snugly against the printer and the latches on either side of t...

Page 17: ...Sensor Service Check on page 2 13 If there is still a problem after that go to the Symptom Table on page 2 7 45 Staple Jam The printer has detected a staple jam in the finisher See the User s Guide 4...

Page 18: ...appear If Auto Continue is On when the printer detects this error the printer waits 30 seconds for the condition to be corrected and then continues normal operation Select CONTINUE to resume printing...

Page 19: ...erly installed and tested PORA the machine if the stapler is not in the home position If there is still a problem go to the Stapler Motor Service Check on page 2 16 954 The adjusting plate requires se...

Page 20: ...en you have com pleted the repair Symptom Action Dead finisher Finisher Output Option Missing displays on the printer operator panel when you enter the paper menu selection Check the power cords and i...

Page 21: ...f it is not in the safety range POR stops 4 The swing guide closes 5 The shutter closes 6 The tray assembly returns to the home position 7 The shutter opens 8 The swing guide opens 9 The alignment pla...

Page 22: ...point at the corner 23 The stapler returns to the home position 24 The staple motor rotates in reverse to return to the stapling operation home position 25 The staple motor rotates until the stapling...

Page 23: ...ely 16 Ohms replace the alignment plate shift motor PN 11D0162 3 Finisher Driver Board 13 1 If there is still a problem replace the finisher driver board PN 11D0294 FRU Action 1 Connector J6 Be sure t...

Page 24: ...1 and Delivery Roller 2 6 25 6 44 Check delivery rollers 1 and 2 for wear or damage Replace as necessary PN 11D0188 11D0194 3 Delivery Roller 1 Drive Belts 6 26 Check the delivery roller 1 drive belts...

Page 25: ...between J10 1 and J10 4 6 and between J10 2 and J10 3 5 on the motor side If it does not read 4 3 Ohms replace the paper feed motor PN 11D0118 3 Finisher Driver Board 13 1 If there is still a problem...

Page 26: ...0121 for the reversing paper sensor PI 2 2 Reversing Paper Sensor PI 2 3 10 Check the voltage of J12 3 on the finisher driver board There should be 5 V when the sensor is activated PN 11D0071 3 Finish...

Page 27: ...inisher board If it does not measure approximately 5 V replace the option controller board PN 11D0326 If this does not fix the problem replace the printer controller board 3 Fuse Remove the power supp...

Page 28: ...eck driver board PN 11A8461 6 Option Controller Board If there is still a problem replace the option controller board PN 11D0326 7 Printer Controller Board If there is still a problem replace the prin...

Page 29: ...lace the stapler motor assembly PN 11D0344 3 Finisher Driver Board 13 1 If there is still a problem replace the finisher driver board PN 11D0294 1 Connector Be sure J8 is properly connected to the fin...

Page 30: ...s not 0 Ohms with the swing guide down or infinity with the swing guide up replace the swing guide close sensing switch PN 11D0139 4 Swing Guide Open Sensor PI 18 5 1 Measure the voltage between J13 5...

Page 31: ...071 3 Tray Upper Limit Detection Switch MS 5 3 33 Unplug J5 from the finisher driver board Measure the resistance between J5 7 and J5 8 on the switch side If it is not 0 Ohms replace the tray upper li...

Page 32: ...the voltage of the Lithium battery on the finisher driver board is over 2 7 V 2 Set the DIP switch SW1 on the finisher driver board to 1 OFF 2 OFF 3 OFF 4 ON 3 Load a sheet of blank paper in Bins 1 2...

Page 33: ...Repair Information 3 2 4040 Finisher Cover Removal Procedures External Covers 1 Trays 2 Top Door 3 Top Cover 4 Rear Cover 5 Right Cover 6 Front Cover 7 Front Door...

Page 34: ...inisher Front Door Removal 1 Open the front door 1 2 Remove the screw 2 and bracket 3 then the front door Rear Cover Removal 1 Open the top door 1 2 Remove the 3 screws 2 and lift the rear cover 3 to...

Page 35: ...Repair Information 3 4 4040 Finisher Top Door Removal 1 Open the top door 1 2 Remove the 2 latches 2 then the top door Right Cover Removal 1 Open the right cover 1 2 Remove the hinge 2...

Page 36: ...3 5 4040 Finisher 3 Pull out the right cover 1 Top Cover Removal 1 Open the top cover 2 Remove the rear cover 3 Open the right cover 4 Remove the 2 latches 1 and lift the top cover 2 to remove it...

Page 37: ...Repair Information 3 6 4040 Finisher Front Cover Removal 1 Remove the 3 screws 1 from the front cover 2 2 Remove the 3 latches 1 then the front cover 2...

Page 38: ...ray Removal 1 Remove the slide guide 1 2 Remove the 2 stoppers 2 3 Lift the tray 3 to remove it Top Guide Removal 1 Remove the slide guide 1 2 Remove the 5 screws 2 3 Remove the screw 3 then remove th...

Page 39: ...ove the 3 screws 2 and pull the bottom guide 3 4 Remove the cable 2 from the cable guide 1 5 Disconnect the 2 connectors 3 and remove the bottom guide 4 When you replace the bottom guide be sure it is...

Page 40: ...per Transport Removal Procedures Staple Tray Removal 1 Remove the rear cover 2 Remove the top and bottom guides 3 Disconnect the 2 connectors 1 4 Remove the cable 2 from the cable guides 1 5 Disconnec...

Page 41: ...Information 3 10 4040 Finisher 6 Remove the 3 screws 1 then the staple tray 2 Staple Tray Delivery Motor Removal 1 Remove the screw 1 then the motor cover 2 2 Remove the 2 screws 3 then the delivery m...

Page 42: ...Motor Removal 1 Disconnect the connector 1 2 Remove the 2 screws 2 then the alignment plate shift motor 3 Staple Tray Delivery Roller 1 Removal 1 Remove the latch 1 then the arm 2 2 Remove the 2 rolle...

Page 43: ...ion 3 12 4040 Finisher 4 Remove the C clip 1 then the bushing 2 5 Slide the delivery rollers 3 to the left to remove them 6 Remove the C clip 2 from the delivery roller 1 then the cam 3 gear 4 pin and...

Page 44: ...2 from the delivery roller 1 then the pin 3 and the gear 4 Face up Solenoid Removal 1 Remove the rear cover and the top cover 2 Remove the finisher driver board 3 Remove the power supply 4 Disconnect...

Page 45: ...Information 3 14 4040 Finisher 6 Remove the 2 screws from inside the main unit then the face up flapper solenoid 2 Staple Assembly Removal 1 Remove the rear cover 2 Remove the screw 1 then the board c...

Page 46: ...isher 3 Disconnect the 2 connectors 1 from the staple tray motor card 2 4 Remove the staple assembly 5 Release the cable guide 1 and remove the cable band 2 then disconnect the connector 3 6 Remove th...

Page 47: ...tion 3 16 4040 Finisher 7 Remove the 2 screws 1 then the staple assembly 2 Tray Assembly Drive Removal 1 Remove the staple assembly 2 Remove the C clip 1 then the bushing 2 3 Remove the 2 screws 3 the...

Page 48: ...3 17 4040 Finisher 4 Disconnect the 2 connectors 2 5 Release the cable guide 1 6 Disconnect the 2 connectors 2...

Page 49: ...the 3 screws 1 then the tray assembly drive 2 Paper Feed Motor Removal 1 Remove the power supply with the finisher driver board on it 2 Remove the C clip 1 then the gear 2 3 Remove the 2 screws 3 and...

Page 50: ...oval 1 Remove the power supply with the finisher driver board on it 2 Remove the screw 1 then the reversing solenoid 2 3 Remove the spring 3 4 Remove the C clip 4 then the 2 gears 5 5 Remove the bushi...

Page 51: ...k 1 then the spring 2 7 Remove the C clip 3 the bushing 4 then the reversing roller 5 Electrical Components Removal Procedures Driver Board Removal 1 Remove the rear cover 2 Disconnect the 13 connecto...

Page 52: ...isher Power Supply Removal 1 Remove the finisher driver board 2 Remove the screw 1 the 3 screws 2 then the power supply assembly 3 3 Release the cable guide 1 on the power supply 3 and discon nect the...

Page 53: ...3 22 4040 Finisher 4 Remove the 3 screws 2 on the power supply 1 then remove the cover 3 Interface Board Removal 1 Remove the rear cover 2 Disconnect the connector 1 3 Remove the 4 screws 3 then the...

Page 54: ...3 23 4040 Finisher Test Staple Switch Board Removal 1 Remove the front cover 2 Disconnect the connector 1 3 Remove the screw 2 then the test staple switch board 3...

Page 55: ...Locations 4 1 4040 Finisher 4 Locations Parts of the Finisher 1 Top Door 2 Tray Assembly 3 Interface Connector 4 Power Receptacle...

Page 56: ...4 2 4040 Finisher 5 Top Guide labeled 1 6 Bottom Guide labeled 2 7 Staple Test Switch 8 Right Cover 9 Guide Rail 10 Staple Assembly and Serial Number Label 11 Front Door...

Page 57: ...Locations 4 3 4040 Finisher Cross Sectional View 1 Tray Assembly 2 Shutter 3 Swing Guide 4 Distance Sensor 5 Paddle 6 Reversing Roller 7 Staple Assembly 8 Tray Assembly Elevation Motor...

Page 58: ...r Open Close Detection Switch MS 2 Swing Guide Close Detecting Switch MS 3 Safety Range Sensing Switch MS 4 Shutter Close Sensing Switch MS 5 Tray Upper Limit Sensing Switch MS 6 Swing Guide Close Sen...

Page 59: ...r Sensor PI 5 Shutter Open Sensor PI 6 Alignment Plate Home Position Sensor PI 7 Stapler Home Position Sensor PI 8 Tray Assembly Home Position Sensor PI 9 Tray Assembly Elevation Motor Clock Sensor PI...

Page 60: ...le Drive Solenoid SL6 Standard Plate Withdrawal Solenoid SL7 Reversing Roller Drive Solenoid SL8 Face up Flapper Solenoid M1 Paper Feed Motor M2 Paper Delivery Motor M3 Alignment Plate Shift Motor M4...

Page 61: ...st Staple Switch Board For test staple switch 3 Staple Relay Board 2 Relays signals between sensors and the finisher driver board 4 Staple Relay Board 1 Relays signals between sensors and the finisher...

Page 62: ...4 8 4040 Finisher Driver Board...

Page 63: ...Locations 4 9 4040 Finisher Connectors...

Page 64: ...4 10 4040 Finisher...

Page 65: ...Locations 4 11 4040 Finisher Finisher Driver Board Inputs and Outputs...

Page 66: ...4 12 4040 Finisher...

Page 67: ...Locations 4 13 4040 Finisher...

Page 68: ...d for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Asm Index column...

Page 69: ...Parts Catalog 5 2 4040 Finisher Assembly 1 External Covers...

Page 70: ...0301 13 1 Flag Sensor PP 11D0302 14 1 Hinge PP 11D0302 15 11D0032 1 Spring Torsion 16 11D0303 1 Roller A 17 1 Spring Torsion PP 11D0301 18 11D0027 1 Latch Right Guide 19 11D0030 1 Spring Torsion 20 11...

Page 71: ...Parts Catalog 5 4 4040 Finisher Assembly 2 External Covers Cont...

Page 72: ...ew PP 11D0300 9 11D0044 1 Guide Hurdle Top 10 6 Screw PP11D0300 11 11D0047 2 Plate Hurdle 1 12 11D0046 1 Plate Hurdle 2 13 11D0048 1 Guide Hurdle Lower 14 11D0050 1 Shutter Hurdle 15 11D0051 1 Spring...

Page 73: ...Parts Catalog 5 6 4040 Finisher Assembly 3 Stapler Main Body...

Page 74: ...uide Paper Feed 15 11D0092 1 Deflector 16 1 Screw PP 11D0300 17 11D0094 1 Spring Leaf 18 11D0095 1 Microswitch MS1 MS7 19 11D0096 1 Cover Switch 20 11D0307 1 Cable Switch 21 11D0308 1 Cable Power Supp...

Page 75: ...Parts Catalog 5 8 4040 Finisher Assembly 3 Stapler Main Body Cont...

Page 76: ...5 9 4040 Finisher Ref Part Number Units Description 36 11D0068 1 Microswitch Rail Tray Lift MS3 37 11D0069 1 Holder NS 11D0343 1 Fuse Power Supply...

Page 77: ...Parts Catalog 5 10 4040 Finisher Assembly 4 Stapler Main Body...

Page 78: ...1D0105 1 Gear 16T 24T 16 1 Spring Tension PP 11D0301 17 1 Collar Spring PP 11D0302 18 11D0110 1 Gear 45T 55T 19 1 Screw PP 11D0302 20 11D0114 1 Solenoid Reversing SL7 21 11D0106 1 Gear 17T 46T 22 11D0...

Page 79: ...Parts Catalog 5 12 4040 Finisher Assembly 4 Stapler Main Body Cont...

Page 80: ...Description 37 11D0127 1 Cover Spring 38 11D0126 1 Guide Reverse 39 11D0128 1 Guide Center 40 2 Screw PP 11D0300 41 11D0134 1 Caster 42 11D0135 1 Mount Rail 43 11D0118 1 Motor Paper Feed M1 44 1 Pin P...

Page 81: ...Parts Catalog 5 14 4040 Finisher Assembly 5 Stapler Tray Main Body...

Page 82: ...ide Strip 12 11D0146 1 Roller Staple Tray 13 11D0151 1 Photo Interrupter PI 3 14 11D0150 1 Mount Sensor 15 11D0148 1 Flag Sensor 16 1 Spring Torsion PP 11D0301 17 11D0299 1 Gear 15T 32T 18 1 Washer PP...

Page 83: ...Parts Catalog 5 16 4040 Finisher Assembly 6 Stapler Tray Main Body Cont...

Page 84: ...D0166 1 Bushing 16 1 Pin Parallel PP 11D0302 17 11D0180 1 Gear 18T 18 11D0181 1 Cam Shutter 19 1 C Clip PP 11D0302 20 2 C Clip PP 11D0302 21 11D0184 1 Link Shutter B 22 1 Screw PP 11D0300 23 11D0186 1...

Page 85: ...Parts Catalog 5 18 4040 Finisher Assembly 6 Stapler Tray Main Body Cont...

Page 86: ...204 1 Lever Stop Front 39 11D0205 1 Spring Torsion 40 11D0206 1 Plate Support Front 41 11D0207 1 Stop Front 42 11D0193 1 Bearing 43 11D0191 1 Bearing 44 11D0194 1 Shaft Delivery Roller 2 45 11D0318 1...

Page 87: ...Parts Catalog 5 20 4040 Finisher Assembly 7 Swing Guide Assembly...

Page 88: ...1D0213 1 Arm Stop Front 10 11D0217 1 Lever Swing 11 1 Spring Tension PP 11D0301 12 11D0219 1 Guide Swing 13 11D0220 1 Static Eliminator 14 11D0221 2 Static Eliminator 15 11D0222 1 Static Eliminator 16...

Page 89: ...Parts Catalog 5 22 4040 Finisher Assembly 8 Stapler Tray...

Page 90: ...ray 2 3 Screw PP 11D0300 3 11D0238 1 Plate Guide 4 11D0233 1 Roller Stapler Tray Frame 5 4 C Clip PP 11D0302 6 11D0234 1 Guide Slide Top 7 11D0235 1 Guide Slide Bottom 8 11D0240 1 Roller Bottom Staple...

Page 91: ...Parts Catalog 5 24 4040 Finisher Assembly 9 Tray Drive...

Page 92: ...in PP 11D0302 5 11D0245 1 Gear 48T 6 11D0243 1 Bracket Drive Small 7 11D0246 1 Bushing 8 11D0247 1 Cam 9 1 C Clip PP 11D0302 10 11D0249 1 Gear 22T 11 1 Washer PP 11D0302 12 11D0251 1 Spring Compressio...

Page 93: ...Parts Catalog 5 26 4040 Finisher Assembly 10 Upper Feeder...

Page 94: ...4040 Finisher Ref Part Number Units Description 1 11D0255 1 Guide Upper labeled 1 2 11D0259 1 Spring Torsion 3 11D0303 4 Roller A 4 11D0257 1 Spring Roller Holder 5 11D0256 1 Roller B 6 11D0258 1 Roll...

Page 95: ...Parts Catalog 5 28 4040 Finisher Assembly 11 Center Guide...

Page 96: ...t Number Units Description 1 11D0260 1 Shaft Stapler Roller 2 11D0259 4 Spring Torsion 3 11D0303 4 Roller A 4 2 C Clip PP 11D0302 5 11D0191 1 Bushing 6 11D0261 1 Gear 20T 7 11D0262 1 Gear 16T 8 11D026...

Page 97: ...Parts Catalog 5 30 4040 Finisher Assembly 12 Stapler...

Page 98: ...16T 14 11D0278 1 Flange Pulley 15 1 C Clip PP 11D0302 16 11D0281 1 Roller 17 11D0282 1 Gear 16T Pulley 40T 18 11D0283 1 Belt Timing 19 11D0284 1 Plate Rack 20 5 Screw PP 11D0302 21 11D0286 1 Plate Gui...

Page 99: ...Parts Catalog 5 32 4040 Finisher Assembly 13 Electronic Boards and Power Cords...

Page 100: ...r Cord Germany 4 11D0335 1 Power Cord Italy 4 11D0334 1 Power Cord Spain 4 11D0336 1 Power Cord Swiss French 4 11D0336 1 Power Cord Swiss German 4 11D0336 1 Power Cord Swiss Italian 4 11D0337 1 Power...

Page 101: ...Parts Catalog 5 34 4040 Finisher Assembly 14 Attachment Parts...

Page 102: ...t Number Units Description 1 11D0229 3 Tray Face up 2 11D0231 2 Screw Tray 3 11D0305 1 Cable Interface 4 11D0322 1 Rail 5 11D0325 1 Screw Stepped 6 11D0327 2 Screw 7 11D0323 1 Holder Interface Cable 8...

Page 103: ...4040 Finisher Option Wiring Diagram Optra N 4040 Finisher Service Manual 11 96...

Page 104: ...nformation 1 1 N notices vi O operator error message table 2 3 P paper delivery motor service check 2 11 paper delivery service check 2 11 paper feed motor removal 3 18 paper feed motor service check...

Page 105: ...est 1 1 start 2 2 swing guide service check 2 17 switches 4 4 symptom table 2 7 T test staple switch board removal 3 23 testing the finisher 2 7 tools 1 2 top cover removal 3 5 top door removal 3 4 to...

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