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Lexmark E238 Service Manual - Page 2

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4511-xxx Edition: September 13, 2005 The following paragraph does not apply to 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, THE IMPLIED WARRANTIES OF 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. Improvements 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 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in 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 right 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. Lexmark, Lexmark with diamond design, MarkNet, and MarkVision are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Optra Forms and PictureGrade are trademarks of Lexmark International, Inc. PCL® is a registered trademark of the Hewlett-Packard Company. PostScript® is a registered trademark of Adobe Systems Incorporated. Other trademarks are the property of their respective owners. © 2005 Lexmark International, Inc. All rights reserved. UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense. U.S.A. P/N 12G9615

Section	Page
Laser notices	7
Safety information	17
Preface	22
Definitions	22
1. General information	23
Models	23
Maintenance approach	23
Overview of the operator panels	24
Models E238, 240, and 240n	24
Models E340 and E342n	25
Overview of the operator panel	25
Specifications	26
Memory	26
Print speed	26
Connectivity and compatibility	27
Media trays and supply capacity	28
Types of print media	29
Tips on preventing jams	30
Tools	30
Acronyms	31
2. Diagnostic information	33
Start	33
Diagnostics-E238, E240, and E240n	34
Power-On Self Test (POST) sequence	34
Light patterns and error messages	35
Common primary light patterns	36
Common secondary light patterns	40
Secondary errors-paper jams	44
Additional information-primary codes	45
Ready / Power Saver	45
Busy	46
Hex Trace Ready	47
Waiting	47
Flushing / Resolution reduced	48
Not ready	48
Close door / Insert cartridge	49
Load media	49
Load manual feeder	50
Print side two of duplex job	50
Toner low	51
Replace photoconductor kit (an early warning)	51
Replace photoconductor kit (printer hard stop)	52
Print cartridge error / Print cartridge is not installed	52
Invalid engine code / Invalid network code	53
Programming engine code / Programming system code	53
Cancel job / Reset printer	54
Service error	54
Printer error	55
Additional information-secondary error codes	56
Paper jam at the input sensor (200 error)	56
Paper jams between input sensor and exit sensor (201 error)	57
Paper jams as a printed job exits the printer (202 error)	57
Paper jams as it exits tray 2 into the printer (241 error)	58
Paper Jams as it exits tray 2 (242 error)	58
Paper jam in the manual feeder (251 error)	59
Complex page	59
Print cartridge errors	60
Insufficient printer memory	61
Insufficient collation area	62
Font error	62
Defective flash	63
Insufficient defrag memory	63
Network interface errors	64
Network or ENA connection lost	64
Memory full	65
Short paper	65
Flash full	66
Unformatted flash	66
Invalid engine code	67
Invalid network code	67
Service codes	68
Service primary code	69
Service secondary error codes	70
Service tertiary error codes	72
Controller software	72
Transfer roll or tray 2	73
Fuser, fan, or toner sensor error	74
Printhead, transport motor or RIP/engine communication error	76
NVRAM failure	78
RAM memory error	80
Network error	81
Diagnostics-E340 and E342n	82
Power-On Self Test (POST) sequence	82
Overview of the operator panel and menus	83
Indicator light	83
Buttons	84
Diagram of the printer menus	86
Messages and error codes	87
User attendance messages	87
Paper jam messages	96
Service error codes	97
Sub error codes	100
Displayed error codes	101
Printed error codes	101
Values	101
Diagnostics-all models	111
Symptom tables	111
POST symptom table	111
Printer symptom table	111
Service checks	113
Cooling fan service check	113
Controller card service check	114
Cover interlock switch service check	117
Dead machine service check	118
Fuser service check	119
Cold fuser service check	121
Hot fuser service check	121
LVPS/HVPS service check	122
Main motor service check	123
Operator panel service check (models E238, E240, and E240n)	124
Operator panel service check (models E340 and E342n)	125
Paper feed service checks	126
Paper jam error indication during POST	126
Paper picks during POST and/or continuously	126
Paper picks but stops halfway through the printer	127
Paper never picks	127
Paper occasionally mispicks or picks multiple sheets at once	128
Paper “trees,” wrinkles, stacks poorly, or curls	128
Parallel port service check (models E238, E240, and E240n)	129
Parallel port service check (models E340 and E342)	129
Print quality service checks	130
Blank page	131
Black page	132
Heavy background	133
Partial blank image/white spots (no repeating pattern)	133
Variation in image density horizontally across page	134
Poor fusing of image	134
Light print	135
White or black lines or bands	135
Toner on back of page	136
Solving print quality problems	137
Printhead service check	143
Transfer roll service check	143
3. Diagnostic aids	145
Diagnostic aids-E238, E240, and E240n	146
Accessing service menus	146
Printing menus	146
Configuration Menu printout sample	147
Diagnostics mode printout sample	148
Moving around the menu	149
Configuration menu selections	150
Utilities	150
Setup	151
Parallel	152
USB	153
Network	154
Diagnostics mode selections	155
Development	155
Parallel	156
Network	157
Diagnostic aids-E340 and E342n	158
Accessing service menus	158
Printing menus	158
Configuration menu (CONFIG MENU)	159
Entering Configuration Menu	159
Available menus	159
Reset PC Cnt	160
Print quality pages (Prt Quality Pgs)	160
Panel Menus	160
PPDS Emulation	160
Download Emuls	161
Demo Mode	161
Factory Defaults	161
Energy Conserve	161
Error log	162
Print Log	162
Paper Prompts	162
Env Prompts	162
Exit Config Menu	162
Diagnostics mode	163
Available tests	163
Registration	165
Quick Test	166
Print tests	166
Input source tests	166
Print quality pages (Prt Quality Pgs)	167
Hardware tests	167
LCD Test	167
Button Test	167
DRAM Test	168
Parallel Wrap	169
Input tray tests	170
Feed Tests (input tray)	170
Sensor Test (input tray)	171
Base sensor test	172
Device tests	172
Flash Test	172
Printer setup	173
Defaults	173
Page Count	173
Perm Page Count (permanent page count)	173
Serial Number	174
Engine Setting 1 through 4	174
Model Name	174
Configuration ID	174
Edge to Edge	174
Parallel strobe adjustment (Par S Strobe Adj)	174
EP setup	175
EP Defaults	175
Fuser Temperature (Fuser Temp)	175
Transfer	175
Print Contrast	175
Charge Roll	175
Gap Adjust	175
Error log	176
Display Log	176
Print Log	177
Clear Log	177
Exit Diagnostics mode	177
4. Repair information	179
Handling ESD-sensitive parts	179
Removal procedures	180
Covers	180
Extender cover removal	180
Front access cover removal (E238, E240, and E240n)	180
Front access cover removal (E340 and E342n)	183
Left side cover removal	187
Rear cover removal	188
Right side cover removal	190
Top cover removal	192
Controller card removal	193
Cover open sensor removal	196
Developer drive coupling assembly removal	198
Door latch assembly removal	199
Exit sensor removal (on the fuser)	200
Fan removal	204
Front access cover logo removal (E238, E240, and E240n)	205
Fuser removal	206
Fuser idle gear links removal	208
Fuser power cable removal	210
Input roller clutch and lever removal (autocompensator clutch)	212
Input sensor #1 removal	213
Input sensor #2 (manual feed) removal	214
LCD bezel removal	215
LCD operator panel removal	217
LED operator panel removal (E238, E240, and E240n)	218
LVPS/HVPS card assembly removal	219
LVPS/HVPS-to-controller card cable removal	221
Manual feed clutch assembly removal	222
Paper exit guide assembly removal	224
Paper feed rollers (autocompensator tires) removal	225
Printhead removal	226
Toner level sensor cable removal (E340 and E342n)	227
Toner level sensor removal (E340 and E342n)	227
Transfer roll removal	228
Transport motor cable removal	229
5. Locations and connections	231
Locations	231
Front view	231
Rear view	232
Connectors	233
Controller card	233
Controller card connector pin values	234
6. Preventive maintenance	237
7. Parts catalog	239
How to use this parts catalog	239
Assembly 1: Covers	240
Assembly 2: Electronics	242
Assembly 3: Frame	244
Assembly 4: Options	246
Assembly 5: Miscellaneous	247
Index	249
Numerics	249
A	249
B	249
C	249
D	250
E	250
F	251
G	251
H	251
I	251
L	251
M	251
N	252
O	252
P	252
Q	253
R	253
S	253
T	254
U	254
Part number index	255

Match case Limit results 1 per page

Edition: September

, 2005

The following paragraph does not apply to 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, THE IMPLIED WARRANTIES OF

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. Improvements 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 40550, U.S.A or e-mail at

[email protected]. Lexmark may use or distribute any of the

information you supply in any way it believes appropriate without incurring any obligation

to you. You can purchase additional copies of publications related to this product by

calling 1-800-553-9727. In other countries, contact your point of purchase.

References in this publication to products, programs, or services do not imply that the

manufacturer intends to make these available in 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 right 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.

Lexmark, Lexmark with diamond design, MarkNet, and MarkVision are trademarks of

Lexmark International, Inc., registered in the United States and/or other countries.

Optra Forms and PictureGrade are trademarks of Lexmark International, Inc.

PCL

is a registered trademark of the Hewlett-Packard Company.

PostScript

is a registered trademark of Adobe Systems Incorporated.

Other trademarks are the property of their respective owners.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are

commercial computer software and documentation developed exclusively at private

expense.

U.S.A. P/N

12G9615

4511-xxx