Lexmark Optra N 4040-FIN User manual

4040-FIN
Optra™ N Finisher Option
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
• Start Diagnostics
• Manuals Menu

Second Edition (November 1997)
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, 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 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 D22A/035-3,
740 New Circle Road NW, 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.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 1996, 1997. 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 Finisher

Contents iii
4040 Finisher
Contents
Notices................................................vi
SafetyInformation.................................... vi
GeneralInformation ....................................1-1
Maintenance Approach............................... 1-1
StaplerTest.................................... 1-1
Tools............................................. 1-2
Abbreviations...................................... 1-3
DiagnosticInformation .................................2-1
Start ............................................. 2-2
InitialCheck.................................... 2-2
OperatorErrorMessageTable...................... 2-3
ServiceErrorMessageTable....................... 2-6
SymptomTable................................. 2-7
TestingtheFinisher.............................. 2-7
Power On Reset (POR) Sequence. .................. 2-8
ServiceChecks.................................... 2-10
AlignmentPlateShiftMotorServiceCheck........... 2-10
DistanceDetectingSensorServiceCheck............ 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
Paper Jam, 42, Reversing Paper Sensor Service Check. 2-13
Paper Jam, 43, Delivery Paper Sensor Service Check . . 2-13
Paper Jam, 44, Staple Tray Paper Sensor Service Check 2-14
PowerServiceCheck............................ 2-14
ReversingRollerServiceCheck.................... 2-16
ShutterServiceCheck........................... 2-16
StaplerMotorServiceCheck...................... 2-17
StaplerShiftMotorServiceCheck.................. 2-17
SwingGuideServiceCheck....................... 2-18
TrayElevationMotorServiceCheck................ 2-18
TrayHeightServiceCheck........................ 2-19

iv Service Manual
4040 Finisher
RepairInformation.....................................3-1
Adjustments....................................... 3-1
DistanceSensorAdjustment....................... 3-1
Cover Removal Procedures. . ......................... 3-2
ExternalCovers................................. 3-2
FrontDoorRemoval............................. 3-3
RearCoverRemoval............................. 3-3
TopDoorRemoval .............................. 3-4
RightCoverRemoval ............................ 3-4
TopCoverRemoval.............................. 3-5
FrontCoverRemoval ............................ 3-6
TrayRemoval.................................. 3-7
TopGuideRemoval.............................. 3-7
BottomGuideRemoval........................... 3-8
Paper Transport Removal Procedures . . ................ 3-9
StapleTrayRemoval............................. 3-9
StapleTrayDeliveryMotorRemoval................ 3-10
StapleTrayAlignmentPlateShiftMotorRemoval ..... 3-11
StapleTrayDeliveryRoller1Removal.............. 3-11
Face-upSolenoidRemoval....................... 3-13
StapleAssemblyRemoval........................ 3-14
TrayAssemblyDriveRemoval .................... 3-16
Paper Feed Motor Removal ...................... 3-18
ReversingRollerRemoval........................ 3-19
Electrical Components Removal Procedures............. 3-20
DriverBoardRemoval........................... 3-20
Power Supply Removal. . ........................ 3-21
InterfaceBoardRemoval......................... 3-22
TestStapleSwitchBoardRemoval................. 3-23
Locations ............................................4-1
PartsoftheFinisher................................. 4-1
Cross Sectional View............................. 4-3
Switches...................................... 4-4
Sensors....................................... 4-5
SolenoidsandMotors............................ 4-6
PrintedCircuitBoards............................ 4-7
DriverBoard ................................... 4-8
Connectors . . .................................. 4-9
Finisher Driver Board Inputs and Outputs............ 4-11

Contents v
4040 Finisher
PartsCatalog .........................................5-1
HowtoUseThisPartsCatalog......................... 5-1
ExternalCovers..................................5-2
ExternalCovers(Cont).............................5-4
Stapler,MainBody................................5-6
Stapler,MainBody...............................5-10
StaplerTray,MainBody...........................5-14
StaplerTray,MainBody(Cont).....................5-16
SwingGuideAssembly ...........................5-20
StaplerTray....................................5-22
TrayDrive......................................5-24
Upper Feeder...................................5-26
CenterGuide...................................5-28
Stapler........................................5-30
ElectronicBoardsandPowerCords .................5-32
AttachmentParts................................5-34
WiringDiagram........................................6-1
Index................................................X-1

vi Service Manual
4040 Finisher
Notices
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 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.
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.

Notices vii
4040 Finisher
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.
Norme di sicurezza
•Il prodotto è stato progettato, testato e approvato in conformità a
severi standard di sicurezza e per l’utilizzo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune parti
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.

viii Service Manual
4040 Finisher
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.
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.

Notices ix
4040 Finisher
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.
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.

x Service Manual
4040 Finisher

General Information 1-1
4040 Finisher
1. General Information
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, and service 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 cartridge has been
installed.
1. Be sure Side is selected from the output bin menu so jobs are
directed to the finisher, and Staple is set to Staple 1 or Staple 2.
2. Use the tip of a ballpoint pen or similar object to press the test
button.

1-2
4040 Finisher
3. Close the stapler access door. Press Continue to Perform Sta-
ple Test appears on the operator panel display.
4. Select CONTINUE from the printer operator panel. Performing
Staple Test appears on the display. When the test page is deliv-
ered to the finisher, the finisher puts 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 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
•Ruler
When you make voltage readings, always use frame ground unless
another ground is specified.

General Information 1-3
4040 Finisher
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

2-1
4040 Finisher
2. Diagnostic Information
Use the serial number from the indicated label to identify the
machine for reporting service related activity.
The diagnostic information in this chapter leads 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 pro-
cedures indicate the parts catalog location of the part to be checked
by including the assembly number and reference number in paren-
thesis. Some part numbers are also included. Use the error code
tables, symptom table, service checks and the diagnostic aids chap-
ter to determine the symptom and repair the failure. After you com-
plete the repair, perform the appropriate tests to verify the repair.

Diagnostic Information 2-2
4040 Finisher
If an error is displayed, locate it in the following Operator Error Mes-
sage Table, or the Service Error Message Table and take the appro-
priate action.
If an error message appears while you are working on the finisher,
go to the error message table and take the indicated action.
If you are in doubt whether the problem is with the printer or the fin-
isher, unplug the finisher and see if the printer performs normally.
Start
Initial Check
Before you start troubleshooting, check the following:
Installation Environment
•The power supply line voltage is plus or minus 10% of the rated
line voltage.
•The machine is 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 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 trial print with paper
from a newly opened package, and check the result.
Other
If you move the finisher into a warm room from a cold location such
as a warehouse, various problems can occur due to condensation if
it is immediately unpacked. If condensation should appear, either
wipe the relevant parts with a dry cloth, or leave the finisher power
onfor10to20minutes.

2-3
4040 Finisher
Operator Error Message Table
If you have a paper jam, be sure to clear all paper from the finisher,
paper deck, and printer. If you are unable to clear an operator error
code for a paper jam; note the location of the paper jam and check
the paper sensor for that station. See “Switches” on page 4-4 or
“Sensors” on page 4-5. If the sensors are working properly, see the
“Service Checks” on page 2-10 for other mechanical failures. If no
paper is present you must open a finisher cover to clear the error
code.
Message Action
30 Finisher Door Open (MS1,
MS7) Be sure the finisher top cover, right access door, and stapler access
door are completely closed. If the
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 the finisher
are snapped in place. If the error
does not clear, check the interlock
sensor. Replace if necessary.
41 Paper Jam (PI-1) There is a paper jam in the input
area, right access door. If the error
code does not reset after you clear
the paper jam, go to the “Paper Jam,
41, Paper Input Service Check” on
page 2-12. If there is still a problem
after that, go to the “Symptom Table”
on page 2-7.
42 Paper Jam (PI-2) There is a paper jam at the right
access door. If the error code does
not clear after you clear the paper
jam, go to the “Paper Jam, 42,
Reversing Paper Sensor Service
Check” on page 2-13.Ifthereisstill
a problem after that, go to the
“Symptom Table” on page 2-7.

Diagnostic Information 2-4
4040 Finisher
43 Paper Jam (PI-3) There is a paper jam at the top
cover. If the error code does not
clear after you clear the paper jam,
go to the “Paper Jam, 43, Delivery
Paper Sensor Service Check” on
page 2-13. If there is still a problem
after that, go to the “Symptom Table”
on page 2-7.
44 Paper Jam (PI-4) There is a paper jam at the staple
tray or output bins1, 2, or 3. If the
error code does not clear after you
clear the paper jam, go to the “Paper
Jam, 44, Staple Tray Paper Sensor
ServiceCheck”onpage2-13.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.
47 Finisher Bin X Full Empty the output bin identified in the
message and select CONTINUE.
48 Top Output Bin Full Empty the top output bin and select
CONTINUE. If this doesn’t correct
theproblem,gototheOptraN
Service Manual.
49 Output Bins Full All three output bins are full. Empty
all three bins as well as the top
output bin, if Top Bin Linking is set
on. Then select CONTINUE.
If this doesn’t correct the problem,
go to the “Distance Detecting Sensor
ServiceCheck”onpage2-10.
Message Action

2-5
4040 Finisher
89 Staples Low The finisher has 10 or fewer staples
remaininginthestaplecartridge.
The Staple Alarm must be set to
Single or Continuous for this
message to appear. If Auto Continue
is On when the printer detects this
error, the printer waits 30 seconds
fortheconditiontobecorrectedand
then continues normal operation.
Select CONTINUE to resume
printing.
90 Staples Empty The finisher is out of staples. The
Staple Alarm must be set to Single
or Continuous for this message to
appear. Select CONTINUE to
resume printing.
Message Action

Diagnostic Information 2-6
4040 Finisher
ServiceErrorMessageTable
Error Symptom or Message Action
938 Finisher Option Controller
Card, No response Be sure the power cord and interface cable are securely
plugged in. POR the printer. If
there is still a failure, replace the
finisher option controller card (PN
11D00326) located on the printer
controller board.
If there is still a problem, replace
thefinisherdriverboard(PN
11D0294).
951 The delivery motor requires
service. Go to the “Paper Delivery Motor Service Check” on page 2-11.
952 The stapler assembly
requires service. Be sure the stapler is clear of jams and the staple cartridge is
properly 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
service. Go to the “Stapler Shift Motor Service Check” on page 2-16.
955 The finisher output bin
assembly has had a vertical
movement failure.
Go to the “Tray Height Service
Check” on page 2-18.
956 The shutter requires service. Go to the “Shutter Service Check”
on page 2-15.
957 The swing guide requires
service. Go to the “Swing Guide Service Check” on page 2-17.
958 The paper full sensor
requires service. Go to the “Distance Detecting Sensor Service Check” on page
2-10.
959 The stapler motor requires
service. Go to the “Stapler Motor Service Check” on page 2-16.
962 The shift motor requires
service. Go to the “Stapler Shift Motor Service Check” on page 2-16.

2-7
4040 Finisher
Symptom Table
Testing the Finisher
To run paper through the finisher from the printer:
1. Select MENUS.
2. Select PAPER MENU.
3. Scroll until you have the option you want and be sure it is on and
saved.
4. Return to Ready.
5. Select MORE.
6. Select TEST MENU.
7. Select Print Fonts, or Print Test Page.
8. Do not use Continuous for staple or offset because there is no
end of job.
9. Be sure to reset the customer settings when 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
interface cables. Go to the
“Power Service Check” on page
2-14.
Paper fails to enter finisher and the
paper feed motor does not run. Go to the “Paper Feed Motor ServiceCheck”onpage2-12.
The paper feed motor runs but the paper
fails to complete reversing or face down
delivery.
Go to the “Reversing Roller
ServiceCheck”onpage2-15.
Paper fails to exit swing guide or stapler
tray. Go to the “Paper Delivery ServiceCheck”onpage2-11.