Service Manual - Printer Parts Exchange

Lexmark™ E238, E240,
E240n, E340, and E342n
4511-000
4511-100
4511-410
4511-600
4511-610
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
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
ServiceInfoAndTraining@Lexmark.com. 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
4511-xxx
Table of contents
Laser notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vi
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xvi
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxi
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of the operator panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models E238, 240, and 240n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models E340 and E342n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of the operator panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connectivity and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media trays and supply capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Types of print media. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tips on preventing jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-1
1-2
1-2
1-3
1-3
1-4
1-4
1-4
1-5
1-6
1-7
1-8
1-8
1-9
Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Diagnostics—E238, E240, and E240n 2 . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power-On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Light patterns and error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Common primary light patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Common secondary light patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Secondary errors—paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Additional information—primary codes . . . . . . . . . . . . . . . . . . . . . . 2-13
Additional information—secondary error codes . . . . . . . . . . . . . . . . 2-24
Service codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Diagnostics—E340 and E342n 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Power–On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Overview of the operator panel and menus . . . . . . . . . . . . . . . . . . . . . 2-51
Indicator light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Diagram of the printer menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Messages and error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Paper jam messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
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Service error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65
Sub error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
Diagnostics—all models 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
POST symptom table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-79
Printer symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Cooling fan service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
Controller card service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
Cover interlock switch service check . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Dead machine service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-86
Fuser service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
Cold fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-89
Hot fuser service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
LVPS/HVPS service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Main motor service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Operator panel service check (models E238, E240, and E240n) . . . 2-92
Operator panel service check (models E340 and E342n) . . . . . . . . .2-93
Paper feed service checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
Parallel port service check (models E238, E240, and E240n). . . . . . 2-97
Parallel port service check (models E340 and E342) . . . . . . . . . . . . 2-97
Print quality service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Printhead service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Transfer roll service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Diagnostic aids—E238, E240, and E240n 2 . . . . . . . . . . . . . . . . . . . . .3-2
Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Printing menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Moving around the menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Configuration menu selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Diagnostics mode selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Diagnostic aids—E340 and E342n 14 . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Printing menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Reset PC Cnt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
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Print quality pages (Prt Quality Pgs) . . . . . . . . . . . . . . . . . . . . . . . .
Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Download Emuls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Demo Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Paper Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Env Prompts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exit Config Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input tray tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base sensor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Device tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EP setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exit Diagnostics mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16
3-16
3-16
3-17
3-17
3-17
3-17
3-18
3-18
3-18
3-18
3-19
3-19
3-21
3-22
3-23
3-26
3-28
3-28
3-29
3-31
3-32
3-33
Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Controller card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Cover open sensor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Developer drive coupling assembly removal . . . . . . . . . . . . . . . . . . 4-20
Door latch assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Exit sensor removal (on the fuser) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Front access cover logo removal (E238, E240, and E240n) . . . . . . 4-27
Fuser removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Fuser idle gear links removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Fuser power cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Input roller clutch and lever removal (autocompensator clutch). . . . 4-34
Input sensor #1 removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Input sensor #2 (manual feed) removal . . . . . . . . . . . . . . . . . . . . . . 4-36
LCD bezel removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
LCD operator panel removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
LED operator panel removal (E238, E240, and E240n). . . . . . . . . . 4-40
LVPS/HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . 4-41
LVPS/HVPS–to–controller card cable removal . . . . . . . . . . . . . . . . 4-43
Manual feed clutch assembly removal . . . . . . . . . . . . . . . . . . . . . . . 4-44
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Paper exit guide assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-46
Paper feed rollers (autocompensator tires) removal . . . . . . . . . . . . . 4-47
Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Toner level sensor cable removal (E340 and E342n) . . . . . . . . . . . . 4-49
Toner level sensor removal (E340 and E342n) . . . . . . . . . . . . . . . . . 4-49
Transfer roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Transport motor cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Locations and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Rear view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Controller card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Controller card connector pin values . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Assembly 2: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4
Assembly 3: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
Assembly 4: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Assembly 5: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7
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4511-xxx
Laser notices
The following laser notice labels may be affixed to this MFP as shown:
Laser advisory label
Laser notices
vi
4511-xxx
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS
21 CFR Subchapter J for Class I (1) laser products, and elsewhere is
certified as a Class I laser product conforming to the requirements of IEC
60825-1.
Class I laser products are not considered to be hazardous. The printer
contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt
gallium arsenide laser operating in the wavelength region of 770-795
nanometers. The laser system and printer are designed so there is never
any human access to laser radiation above a Class I level during normal
operation, user maintenance, or prescribed service condition.
Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die
Anforderungen der Bestimmung DHHS (Department of Health and Human
Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die
Anforderungen der IEC (International Electrotechnical Commission) 608251 gemäß amtlicher Bestätigung erfüllt.
Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers
befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen
Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert,
daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei
ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die
die Klasse I übersteigen würde, Menschen keinesfalls erreicht.
vii Service Manual
4511-xxx
Avis relatif à l’utilisation de laser
Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions
DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour
les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives
aux produits laser de Classe I.
Les produits laser de Classe I sont considérés comme des produits non
dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b)
(arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant
sur des longueurs d’onde comprises entre 770 et 795 nanomètres.
L’imprimante et son système laser sont conçus pour impossible, dans des
conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision,
l’exposition à des rayonnements laser supérieurs à des rayonnements
de Classe I .
Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai
requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed
è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti della norma CEI 60825-1.
I prodotti laser di classe non sono considerati pericolosi. La stampante
contiene al suo interno un laser di classe IIIb (3b) all’arseniuro di gallio della
potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale
che le persone a contatto con la stampante, durante il normale
funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della
classe 1.
Laser notices
viii
4511-xxx
Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para
los productos láser de Clase I (1) establecidos en el subcapítulo J de la
norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los
demás países, reúne todas las condiciones expuestas en la norma IEC
60825-1 para productos láser de Clase I (1).
Los productos láser de Clase I no se consideran peligrosos. La impresora
contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de
funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795
nanómetros. El sistema láser y la impresora están diseñados de forma que
ninguna persona pueda verse afectada por ningún tipo de radiación láser
superior al nivel de la Clase I durante su uso normal, el mantenimiento
realizado por el usuario o cualquier otra situación de servicio técnico.
Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os
requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I
(1) de produtos laser. Em outros locais, está certificada como um produto
laser da Classe I, em conformidade com os requisitos da norma IEC 608251.
Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um produto laser da Classe IIIb (3b),
designado laser de arseneto de potássio, de 5 milliwatts ,operando numa
faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a
impressora laser foram concebidos de forma a nunca existir qualquer
possiblidade de acesso humano a radiação laser superior a um nível de
Classe I durante a operação normal, a manutenção feita pelo utilizador ou
condições de assistência prescritas.
ix Service Manual
4511-xxx
Laserinformatie
De printer voldoet aan de eisen die gesteld worden aan een laserprodukt
van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS
21 CFR Subchapter J, voor andere landen in IEC 60825-1.
Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De
printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een
gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij
normaal gebruik, bij onderhoud of reparatie conform de voorschriften, nooit
blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.
Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med
kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder
internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid
laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig
udsættes for en laserstråling over Klasse I-niveau ved normal drift,
brugervedligeholdelse eller obligatoriske servicebetingelser.
Laser notices
x
4511-xxx
Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR
Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC
60825-1 -määrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.
Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser,
joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin
on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä
voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän
tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle
lasersäteilylle. Älä katso säteeseen.
VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är
urkopplad.
Betrakta ej strålen.
Laser-notis
Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR,
underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller
skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825-1.
Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd
laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5
milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att
någon person utsätts för laserstrålning över Klass I-nivå vid normal
användning, underhåll som utförs av användaren eller annan föreskriven
serviceåtgärd.
xi Service Manual
4511-xxx
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J,
for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse Ilaserprodukt i samsvar med kravene i IEC 60825-1.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder
internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet
som avgir stråling i bølgelengdeområdet 770-795 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for
laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres
av brukeren, eller foreskrevne serviceoperasjoner.
Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els
requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i
segons ha estat certificat en altres llocs, és un producte làser de classe I
que compleix els requisits d’IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. Aquesta
impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,
nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770795 nanòmetres. El sistema làser i la impressora han sigut concebuts de
manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de
classe I durant una operació normal, durant les tasques de manteniment
d’usuari ni durant els serveis que satisfacin les condicions prescrites.
Laser notices
xii
4511-xxx
Japanese Laser Notice
Chinese Laser Notice
xiii Service Manual
4511-xxx
Korean Laser Notice
Laser notices
xiv
4511-xxx
xv Service Manual
4511-xxx
Safety information
• The safety of this product is based on testing and approvals of the
original design and specific components. The manufacturer is not
responsible for safety in the event of use of unauthorized 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.
•
CAUTION: When you see this symbol, there 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.
Consignes de sécurité
• La sécurité de ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des composants
particuliers. Le fabricant n'assume aucune responsabilité concernant
la sécurité en cas d'utilisation de pièces de rechange non agréées.
• 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.
•
ATTENTION : Ce symbole indique la présence
d'une tension dangereuse dans la partie du produit sur
laquelle vous travaillez. Débranchez le produit avant de
commencer ou faites preuve de vigilance si l'exécution de
la tâche exige que le produit reste sous tension.
Safety information
xvi
4511-xxx
Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione del
progetto originale e dei componenti specifici. Il produttore non è
responsabile per la sicurezza in caso di sostituzione non autorizzata
delle parti.
• 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.
•
ATTENZIONE: Questo simbolo indica la presenza
di tensione pericolosa nell'area del prodotto. Scollegare il
prodotto prima di iniziare o usare cautela se il prodotto deve
essere alimentato per eseguire l'intervento.
Sicherheitshinweise
• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des
ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung
nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung
oder Haftung für die Sicherheit 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.
•
ACHTUNG: Dieses Symbol weist auf eine gefährliche
elektrische Spannung hin, die in diesem Bereich des
Produkts auftreten kann. Ziehen Sie vor den Arbeiten am
Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit
großer Vorsicht, wenn das Produkt für die Ausführung der
Arbeiten an den Strom angeschlossen sein muß.
xvii Service Manual
4511-xxx
Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y aprobaciones del
diseño original y componentes específicos. El fabricante no es
responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.
• 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.
•
PRECAUCIÓN: este símbolo indica que el voltaje de la
parte del equipo con la que está trabajando es peligroso.
Antes de empezar, desenchufe el equipo o tenga cuidado
si, para trabajar con él, debe conectarlo.
Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações do
modelo original e de componentes específicos. O fabricante não é
responsável pela segunrança, no caso de uso de peças de
substituição não autorizadas.
• 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.
•
CUIDADO: Quando vir este símbolo, existe a possível
presença de uma potencial tensão perigosa na zona do
produto em que está a trabalhar. Antes de começar,
desligue o produto da tomada eléctrica ou seja cuidadoso
caso o produto tenha de estar ligado à corrente eléctrica
para realizar a tarefa necessária.
Safety information
xviii
4511-xxx
Informació de Seguretat
• La seguretat d'aquest producte es basa en l'avaluació i aprovació del
disseny original i els components específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
• 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.
•
PRECAUCIÓ: aquest símbol indica que el voltatge de la
part de l'equip amb la qual esteu treballant és perillós.
Abans de començar, desendolleu l'equip o extremeu les
precaucions si, per treballar amb l'equip, l'heu de
connectar.
xix Service Manual
4511-xxx
Safety information
xx
4511-xxx
Preface
This manual contains maintenance procedures for service personnel. It is
divided into the following chapters:
1. General information contains a general description of the MFP and
the maintenance approach used to repair it. Special tools and test
equipment are listed, as well as general environmental and safety
instructions.
2. Diagnostic information contains an error indicator table, symptom
tables, and service checks used to isolate failing field replaceable units
(FRUs).
3. Diagnostic aids contains tests and checks used to locate or repeat
symptoms of MFP problems.
4. Repair information provides instructions for making MFP adjustments
and removing and installing FRUs.
5. Connector locations uses illustrations to identify the connector
locations and test points on the printer.
6. Preventive maintenance contains the lubrication specifications and
recommendations to prevent problems.
7. Parts catalog contains illustrations and part numbers for individual
FRUs.
Definitions
Note: A note provides additional information.
Warning: A warning identifies something that might damage the product
hardware or software.
CAUTION: A caution identifies something that might cause a servicer
harm.
CAUTION: When you see this symbol, there 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.
xxi Service Manual
4511-xxx
1. General information
The Lexmark™ E238, E240, E240n, E340, and E342n printers are
monochrome laser printers designed for single users or small workgroups.
Models
There are five models:
• E238—16MB memory standard, a USB (universal serial bus) port, a
•
•
•
•
parallel port, and prints 25 pages per minute on letter-size paper
(24 ppm on A4).
Note: The optional 550-sheet tray is not supported.
E240—16MB of memory standard, a parallel port, a USB port, and
prints 27 ppm on letter-size paper (26 ppm on A4).
E240n—32MB of memory standard, an integrated Ethernet adapter, a
parallel port, a USB port, and prints 27 pm on letter-size paper (26 ppm
on A4).
E340, 32MB of memory standard, a parallel port, a USB port, and
prints 30 ppm on letter-size paper (28 ppm on A4).
E342n, 32MB of memory standard, an integrated Ethernet adapter, a
parallel port, a USB port, and prints 30 ppm on letter-size paper
(28 ppm on A4).
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. See
“Diagnostic information” on page 2-1 for more information. See “Repair
information” on page 4-1 to help identify parts. After completing the repair,
perform tests as needed to verify the repair.
General information
1-1
4511-xxx
Overview of the operator panels
There are two available operator panels.
Models E238, 240, and 240n
These models have six lights and two buttons. See “Diagnostics—E238,
E240, and E240n” on page 2-2 for more information.
Continue
(also a light)
Cancel
Ready
Toner Low /
Replace PC Kit
Load Paper
Paper Jam
Error
• Press and hold
until lights flash to print the setting sheet.
• Press and release
to resume printing.
• Press and release
twice quickly to display a secondary error code
following an error.
• Press and release
• Press and hold
1-2 Service Manual
to cancel the job currently printing.
until all of the lights come on to reset the printer.
4511-xxx
Models E340 and E342n
These models have LCD operator panel. See page “Diagnostics—E340
and E342n” on page 2-50.
Overview of the operator panel
• Press Go to resume printing.
• Press Menu to move forward and backward through the menu
•
•
•
•
selections.
Press Return to go one level back in the menu.
Press Select to indicate the menu or selection you choose.
Press Stop to cancel the job currently printing.
Light indicates Busy (flashing) or Ready (on steadily).
General information
1-3
4511-xxx
Specifications
Memory
4511-000
Lexmark
E238
4511-100
Lexmark
E240
4511-410
Lexmark
E240n
4511-600
Lexmark
E340
4511-610
Lexmark
E342n
Base
memory
16MB
16MB
32MB
32MB
32MB
Maximum
memory
80MB
80MB
160MB
160MB
160MB
Item
Flash support
✔
✔
Print speed
4511-000
Lexmark
E238
4511-100
Lexmark
E240
4511-410
Lexmark
E240n
4511-600
Lexmark
E340
4511-610
Lexmark
E342n
Letter—8.5 x
11 in.
25 ppm
27 ppm
27 ppm
30 ppm
30 ppm
A4—210 x
297 mm
24 ppm
26 ppm
26 ppm
28 ppm
28 ppm
Media Size
Speed measured on media from tray 1, simplex, and at 600 x 600 dpi.
1-4 Service Manual
4511-xxx
Connectivity and compatibility
Item
4511-100
Lexmark
E240
4511-410
Lexmark
E240n
4511-600
Lexmark
E340
4511-610
Lexmark
E342n
✔
✔
✔
✔
✔
Mac OS
only
Mac OS
only
✔
✔
✔
✔
✔
4511-000
Lexmark
E238
Data stream emulations
PCL 6
PostScript 3
PPDS
Compatibility
Windows/Macintosh/Linux*
Connectivity
USBa
✔
✔
✔
✔
✔
Parallelb
✔
✔
✔
✔
✔
Ethernetc
ENA option
✔
✔
✔
✔
✔
✔
✔
* Linux support for E238/E240/E240n models utilizing the PCL data stream.
Wirelessd
✔
✔
✔
✔
✔
a
These products are USB 2.0 Certified and support full-speed (12MB/sec)
data transfer. They are also compatible with Hi-Speed USB systems,
peripherals, and cables.
b
IEEE 1284 Bi-directional.
c
10/100 BaseTx Ethernet.
d
802.11g wireless print adapter.
General information
1-5
4511-xxx
Media trays and supply capacity
Item
4511-000
Lexmark
E238
4511-100
Lexmark
E240
4511-410
Lexmark
E240n
4511-600
Lexmark
E340
4511-610
Lexmark
E342n
Available input trays
250-sheet
tray
✔
✔
✔
✔
✔
Single-sheet
manual
feeder
✔
✔
✔
✔
✔
✔
✔
✔
✔
550-sheet
option drawer
Toner and photoconductor
Toner
cartridge
yield
1,500 pages* (starter toner cartridge)
PC kit yield
30,000 pages*
2,500
pages
*Photoconductor yield based on approximately 5% coverage of pages.
1-6 Service Manual
4511-xxx
Types of print media
Ensure trays are properly loaded. Never mix media types within a tray.
Input
capacity
(sheets)
Source
Sizes
Types
Weight
Tray 1
A4, A5,
JIS B5,
letter, legal,
executive,
folio,
statement,
Universala
Plain paper,
transparencies,
paper labelsb
60–90 g/m2
(16–24 lb)
250 paper,
50 labelsb,
50 transparencies
A4, A5,
JIS B5,
letter, legal,
executive,
folio,
statement,
Universala
Plain paper,
transparencies,
paper labelsb
60–163 g/m2
(16–43 lb)
550 paper,
50 labelsb,
50 transparencies,
card stockc
A4, A5,
JIS B5,
letter, legal,
executive,
folio,
statement,
Universala
Plain paper,
transparencies,
paper labelsb,
card stockc
60–163 g/m2
(16–43 lb)
1 sheet
7¾, 9, 10,
DL, C5, B5,
otherd
Envelopes
(250-sheet
tray)
Tray 2
(550-sheet
— E240(n)/
E340/
E340n only)
Manual
feeder
a
Universal size range: 76–216 x 127–356 mm (3.0–8.5 x 5.0–14.0 in.)
(includes 3 x 5 in. cards).
b
Dual web, integrated, or vinyl labels are not supported.
c
Card stock up to 90# Index. Grain short is recommended.
d
Maximum and minimum sizes for other envelopes are 98.4 x 162 mm to
176 x 250 mm (3.87 x 6.38 in. to 6.93 x 9.84 in.
General information
1-7
4511-xxx
Tips on preventing jams
You can avoid most paper jams by correctly loading paper and specialty
media.
The following hints can help you avoid paper jams:
•
•
•
•
•
•
•
•
•
•
Do not load wrinkled, creased, or damp paper.
Never mix media types within a tray.
Flex, fan, and straighten paper before you load it.
Do not exceed the maximum stack height.
Push all trays firmly into the printer after loading them.
Make sure the guides in the trays are positioned snugly against the
paper or specialty media.
Do not remove paper trays while a job is printing. Wait for a Load
Paper or Ready light sequence or message before you remove the
tray.
Before loading transparencies, fan the stack to prevent sheets from
sticking together.
Do not use envelopes that:
– Have excessive curl
– Are stuck together
– Are damaged in any way
– Contain windows, holes, perforations, cutouts, or embossing
– Have metal clasps, string ties, or metal folding bars
– Have postage stamps attached
– Have any exposed adhesive when the flap is in the sealed position
Use only recommended paper. Refer to the Card Stock & Label Guide
available on the Lexmark Web site at www.lexmark.com for more
information about which paper provides optimum results for the current
printing environment.
Tools
The removal and adjustment procedures require the following tools and
equipment:
• Magnetic tip Phillips screwdrivers, large and small
• Volt-ohmmeter
1-8 Service Manual
4511-xxx
Acronyms
ACM
ASIC
CBM
CRC
DEV
DIMM
ECC
EEPROM
ENA
FRU
HBP
HVPS
LCD
LED
LVPS
NVRAM
PC
PCL
POR
POST
PPDS
PRC
PSO
RIP
TAR
SDR
USB
V ac
V dc
Autocompensator Mechanism (or paper feed)
Application Specific Integrated Circuit
Complete Bill Of Material
Cyclic Redundancy Check
Development Roll (of print cartridge/photoconductor
system)
Dual In-Line Memory Module
Error Correction Code
Erasable Electrically Programmable Read-Only
Memory
External Network Adapter
Field Replaceable Unit
Host Based Printing
High Voltage Power Supply
Liquid Crystal Diode
Light Emitting Diode
Low Voltage Power Supply
Nonvolatile Random Access Memory
Photoconductor
Printer Control Language
Power-On Reset
Power-On Self Test
Personal Printer Data Stream
Peoples' Republic of China
Participating Standards Organization
Raster Image Processor
Toner Add Roll
Synchronous Dynamic RAM
Universal Serial Bus
Volts alternating current
Volts direct current
General information
1-9
4511-xxx
1-10 Service Manual
4511-xxx
2. Diagnostic information
Start
CAUTION: Unplug power from the printer before connecting or
disconnecting any cable, assembly, or electronic card. This is a
precaution for personal safety and to prevent damage to the
printer.
This chapter contains the codes and diagnostic tools to aid in providing
corrective action for a malfunctioning printer. To determine the corrective
action to repair a printer, look for the following information:
• A description of a problem, see “Symptom tables” on page 2-79.
• Information from the operator panel of the printer.
– Models E238, E240, and E240n have an operator panel containing
lights and buttons. For diagnostic information specific to these
modes, see “Diagnostics—E238, E240, and E240n” on
page 2-2.
– Models E340 and E342n have an operator panel with messages.
For diagnostic information specific to these models, see
“Diagnostics—E340 and E342n” on page 2-50.
Diagnostic information
2-1
4511-xxx
Diagnostics—E238, E240, and E240n
2
Power-On Self Test (POST) sequence
When you turn the printer on, it performs a POST. Check for correct POST
functioning of the base printer by observing the following process:
1. All operator panel lights on momentarily
2. Lights then flash on and off sequentially.
3. After the lights quit flashing, the
light flashes until the fuser comes
up to temperature (5–20 additional seconds, depending on the initial
temperature of the fuser) and then stays on.
4. If there is a problem in the printer such as a paper jam, the panel lights
indicate the problem. See “Common primary light patterns” on
page 2-4 for more information.
5. The printer cycles down into standby mode, and
2-2 Service Manual
lights solid.
4511-xxx
Light patterns and error messages
User attendance messages, paper jam errors, and service errors display a
light pattern. This may be all the information you need. However, if you
double-click
on the panel, a second pattern may appear with more
detailed information. If you double-click
a third time, you usually return to
the first pattern. Not all initial level light patterns have secondary patterns;
when you double-click, the pattern does not change.
All service errors are indicated by all lights flashing as the primary
notification or code. The secondary code indicates an area or function which
has the error. Additional tertiary codes used for service (see “Service
tertiary error codes” on page 2-40) indicate specific errors. See “Service
codes” on page 2-36.
'RXEOH
&OLFN
3ULPDU\
&RGHV
6HFRQGDU\
&RGHV
Note: If you send data to the printer and all lights flash immediately, and
double-clicking does not change the display, there may be a code
problem. Contact the next level of support.
Diagnostics—E238, E240, and E240n
2-3
4511-xxx
Common primary light patterns
See “Overview of the operator panels” on page 1-2 for icon information.
z
Light on
Light off
✷
Light blinking
x
Light blinking slowly
z
Flushing / Resolution
reduced
(See page 2-16)
Waiting
(See page 2-15)
Hex Trace Ready
(See page 2-15)
2xx Paper Jam (see
secondary errors
on page 2-24
Busy
(See page 2-14)
Lights
Ready/Power Saver
(See page 2-13)
Primary light patterns
z
Continue
z
✷
x
z
✷
Ready
Toner Low/
Replace PC
Kit
Load Paper
z
Paper Jam
✷
Error
2-4 Service Manual
Lights
z
z
z
z
✷
Toner low
(See page 2-19)
Print side two
of duplex job
(See page 2-18)
Load manual feeder
(See page 2-18)
Load media
(See page 2-17)
Close door / Insert
cartridge
(See page 2-17)
Not ready
(printer offline)
(See page 2-16)
4511-xxx
Primary light patterns (continued)
✷
Continue
Ready
z
Toner Low/
Replace PC
Kit
z
Load Paper
Paper Jam
z
Error
Diagnostics—E238, E240, and E240n
2-5
Lights
z
✷
Error
2-6 Service Manual
✷
✷
z
z
z
z
z
Cancel job /
Reset printer
(See page 2-22)
Programming engine
code / Programming
system code
(See page 2-21)
Invalid engine code /
Invalid network code
(See page 2-21)
Cartridge errors
(See page 2-28)
Replace
photoconductor kit
(printer hard stop)
(See page 2-20)
Replace
photoconductor kit
(See page 2-19)
4511-xxx
Primary light patterns (continued)
z
Continue
Ready
Toner Low/
Replace PC
Kit
z
z
z
z
z
z
Load Paper
z
Paper Jam
z
4511-xxx
✷
Service error (see
Service secondary
codes on page 2-38
or Service tertiary
codes on
page 2-40.)
Lights
Printer error (see
“Secondary error
codes” on page 2-24.)
Primary light patterns (continued)
✷
Continue
✷
Ready
✷
Toner Low/
Replace PC
Kit
✷
Load Paper
✷
Paper Jam
z
✷
Error
Diagnostics—E238, E240, and E240n
2-7
4511-xxx
Common secondary light patterns
When the
and
lights are both on, a secondary error has occurred.
Press and release
twice quickly to display the secondary error code
light pattern. The following table shows what these light patterns mean.
Secondary error codes
z
z
z
z
Insufficient printer
memory
(See page 2-29)
Complex page
(See page 2-27)
Too many options
attached
Primary
code
Unsupported
flash in slot
Lights
Standard network
software error
manual feeder
(See page 2-32)
Secondary error codes
z
z
z
✷
z
z
Continue
Ready
z
z
z
z
Toner Low/
Replace PC
Kit
Load Paper
z
z
z
z
Paper Jam
z
Error
2-8 Service Manual
z
Lights
z
Continue
Ready
z
z
z
✷
z
z
Toner Low/
Replace PC
Kit
z
z
z
✷
z
ENA connection
lost
(See page 2-32)
Network interface
errors
(See page 2-32)
Insufficient defrag
memory
(See page 2-31)
Defective flash
(See page 2-31)
PPDS font error
(See page 2-30)
Insufficient
collation area
(See page 2-30)
4511-xxx
Secondary errors (continued)
Secondary codes
Load Paper
Paper Jam
z
z
z
✷
z
z
Error
Diagnostics—E238, E240, and E240n
2-9
Lights
z
Error
2-10 Service Manual
Continue
z
z
z
z
z
z
z
z
z
Paper Jam
z
z
z
z
Invalid network
code
(See page 2-35)
Invalid engine code
(See page 2-35)
Flash full
(See page 2-34)
Unformatted flash
(See page 2-34)
Short paper
(See page 2-33)
Memory full
(See page 2-33)
4511-xxx
Secondary errors (continued)
Secondary error codes
z
Ready
z
Toner Low/
Replace PC
Kit
Load Paper
z
z
z
✷
z
z
Lights
z
Continue
z
z
z
z
z
z
z
Unsupported
print cartridge
(See page 2-29)
Missing or defective
print cartridge
(See page 2-28)
Print cartridge has
invalid refill
(See page 2-28)
Print cartridge
mismatch
(See page 2-28)
4511-xxx
Secondary errors (continued)
Secondary error codes
z
z
Ready
z
Toner Low/
Replace PC
Kit
z
Load Paper
Paper Jam
z
z
z
z
Error
Diagnostics—E238, E240, and E240n
2-11
Lights
z
z
Paper Jam
Error
2-12 Service Manual
z
z
z
z
z
z
Load Paper
z
z
z
z
z
z
251 Paper jam
manual feeder
(See page 2-27)
242 Paper Jam
Tray 2 jam
(See page 2-26)
241 Paper jam
Tray 1 jam
(See page 2-26)
202 Paper jam exit
sensor
(See page 2-25)
201 Paper jam
between input and
exit sensors
(See page 2-25)
200 Paper jam input
sensor
(See page 2-24)
4511-xxx
Secondary errors—paper jams
Secondary errors—paper jams
Secondary error codes
Continue
z
z
z
✷
Ready
z
Toner Low/
Replace PC
Kit
z
4511-xxx
Additional information—primary codes
The following tables explain the primary light patterns, or codes, and
secondary error codes, what they mean and how to clear them. User
attendance and status information is included. For service information, see
“Service codes” on page 2-36.
Ready / Power Saver
Light pattern
Meaning
Action
• Printer ready to
receive and process
data.
• Printer is in Power
Saver mode.
• Send a print job.
• Press
to print the
menu settings pages for a
list of current printer
settings.
• Press and hold
to
reset the printer.
Note: To change the Power
Saver setting, use the Local
Printer Setup Utility. See the
User’s Reference for more
information.
Diagnostics—E238, E240, and E240n
2-13
4511-xxx
Busy
Light pattern
Meaning
Action
• Printer is busy
receiving and
processing data or
printing.
• Printer is
defragmenting the
flash memory to
reclaim storage
space occupied by
deleted resources.
• Printer is formatting
the flash memory.
• Printer is storing
resources, such as
fonts or macros, in
flash memory.
• Printer is printing a
directory, font list,
menu settings pages,
or Print Quality Test
Pages.
• Busy:
– Wait for message to
clear.
– Press and release
to cancel print job.
– Press and hold
to
reset printer.
• Defragmenting flash,
formatting flash, or
programming flash:
– Wait for message to
clear.
– Warning: Do not turn
the printer off while this
message is displayed.
• Printing a directory, a font
list, menu settings pages,
or Print Quality Test Pages:
– Wait for the pages to
print. The Busy
message is displayed as
the pages print. The
light is on when
printing stops.
– Press and release
to cancel printing.
– Press and hold
to
reset printer.
• Receiving/processing data
from a host interface:
– Wait for message to
clear.
– Press and release
to stop processing.
– Press and hold
to
reset printer.
2-14 Service Manual
4511-xxx
Hex Trace Ready
Light pattern
Meaning
Action
Printer is in the Ready
mode and Hex Trace is
active.
• Hex Trace helps
troubleshoot printing
problems. After resolving
the problem, turn off the
printer to exit Hex Trace.
• Or, press and hold
to
reset the printer.
Waiting
Light pattern
Meaning
Action
Printer is waiting until a
print timeout occurs, or
until it receives
additional data.
• Press and release
to
print contents of the print
buffer.
• Press and release
to
cancel the print job.
• Press and hold
to
reset the printer.
Diagnostics—E238, E240, and E240n
2-15
4511-xxx
Flushing / Resolution reduced
Light pattern
Meaning
Action
• Printer is flushing
corrupted print data.
• Printer is processing
data or printing
pages, but the
resolution of a page
in the current print job
is reduced from
600 dots per inch
(dpi) to 300 dpi to
prevent a memory full
error.
• Wait until
is on to print
other jobs.
• Press and release
to
cancel print job.
• Press and hold
to
reset printer.
Meaning
Action
Printer is not ready to
receive or process data,
or the printer ports are
offline.
• Press
to return to
Ready or Busy state.
• Press and release
to
cancel print job.
• Press and hold
to
reset printer.
Not ready
Light pattern
2-16 Service Manual
4511-xxx
Close door / Insert cartridge
Light pattern
Meaning
Action
The printer door is
open.
Close the door.
Meaning
Action
Load media
Light pattern
The printer is out of
media, or the media did
not feed properly,
thereby not making the
input sensor in the
allotted time.
• Load media into tray 1 or
the optional
550-sheet tray, and press
to resume printing.
• Check that the media is
loaded correctly in tray 1 or
the optional 550-sheet tray.
• Press
to cancel the
print job.
Diagnostics—E238, E240, and E240n
2-17
4511-xxx
Load manual feeder
Light pattern
Meaning
Action
Printer prompts to load
a single sheet of media
in the manual feeder.
• Load media in the manual
feeder with the side to be
printed facing up.
• Press
to resume
printing.
• Press and hold
to
reset printer.
Print side two of duplex job
Light pattern
Meaning
Action
Print the other side of
duplex print job.
• Reinsert print job in tray 1
using the instructions in
the driver pop-up menu to
orient the pages correctly
(printed side up, loading
edge to front of the
printer).
• Press
to resume
printing.
• Press and hold
to
reset printer.
2-18 Service Manual
4511-xxx
Toner low
Light pattern
Meaning
Action
The toner in the print
cartridge is getting low.
• Send a print job.
• Press
to print the
menu settings page for a
list of current settings.
• Remove the print
cartridge, and shake it to
extend the life of the
cartridge.
• Replace the print
cartridge.
• Press and hold
to
reset printer.
Note: The
light may
not come on if the starter
print cartridge is installed in a
base model.
Replace photoconductor kit (an early warning)
Light pattern
Meaning
Action
The photoconductor kit
drum is full and needs
replacing.
• Press
to resume
printing.
• Replace the
photoconductor kit.
Diagnostics—E238, E240, and E240n
2-19
4511-xxx
Replace photoconductor kit (printer hard stop)
Light pattern
Meaning
Action
The photoconductor kit
drum is full and needs
replacing. No pages
print until the
photoconductor kit is
replaced.
Replace the photoconductor
kit.
Print cartridge error / Print cartridge is not installed
Light pattern
Meaning
Action
The print cartridge is
not installed, or the
printer detects a print
cartridge error.
• If the print cartridge is not
installed, install it.
• If the print cartridge is
installed, remove it and
install a new print
cartridge.
See secondary codes “Print
cartridge errors” on
page 2-28.
The error is caused by a
defective cartridge, an
unsupported cartridge,
an invalid refill, or a
cartridge meant to be
used in another
geographic region.
2-20 Service Manual
4511-xxx
Invalid engine code / Invalid network code
Light pattern
Meaning
Action
The code in an internal
print server has not
been programmed, or
the programmed code is
not valid.
• Download valid network
code to the internal print
server.
• Press
twice quickly to
see the secondary error
code.
Programming engine code / Programming system code
Light pattern
Meaning
Action
New code is being
loaded into the engine
or firmware code flash.
Wait for the message to clear.
When the printer has finished
loading the code, it performs
a soft reset.
Diagnostics—E238, E240, and E240n
2-21
4511-xxx
Cancel job / Reset printer
Light pattern
Meaning
Action
• The current print job
is canceled.
• The printer is
resetting to the user
default settings.
– Any active print
jobs are canceled.
– A user default
setting remains in
effect until changed
or until restored to
factory default
settings.
Wait for the message to clear.
Meaning
Action
The printer has a
service error, and
printing has stopped.
Turn the printer off and back
on.
Service error
Light pattern
If the lights are still blinking,
contact the place where
printer was purchased.
Press and release
twice
quickly to view the secondary
message. See page
“Service primary code” on
page 2-37.
2-22 Service Manual
4511-xxx
Printer error
Light pattern
Meaning
Action
The printer has one of
the following errors:
• Memory is full,
insufficient to save
what is in the buffer,
or insufficient to
defragment flash
memory.
• A page is too
complex to print or is
shorter than the set
page margins.
• Resolution of a
formatted page is
reduced to 300 dpi.
• A font error occurred.
• Communication with
the host computer is
lost.
• Press
twice quickly to
see the secondary error
code. See “Additional
information—secondary
error codes” on
page 2-24 for more
information.
• Press
to clear the
secondary message.
Diagnostics—E238, E240, and E240n
2-23
4511-xxx
Additional information—secondary error codes
• When the
light is flashing and
error has occurred.
• When the
and
error has occurred.
• When the
light is on, a secondary printer
lights are both on, a paper jam secondary
and the
lights are both on, a print cartridge error
has occurred.
Press and release
pattern.
twice to display the secondary error code light
The following tables show what these light patterns mean and what to do.
Paper jam at the input sensor (200 error)
Light pattern
Meaning
Action
Media has stopped over
the input sensor.
Remove the print cartridge to
access the area. Check for
obstructions and remove
them.
2-24 Service Manual
4511-xxx
Paper jams between input sensor and exit sensor (201 error)
Light pattern
Meaning
Action
Paper has cleared the
input sensor but not
made the exit sensor.
Check the paper path for
obstacles. The fuser should
be inspected.
Paper jams as a printed job exits the printer (202 error)
Light pattern
Meaning
Action
A paper jam has
occurred as the paper is
exiting the printer.
Clear the paper jam.
Diagnostics—E238, E240, and E240n
2-25
4511-xxx
Paper jams as it exits tray 2 into the printer (241 error)
Light pattern
Meaning
Action
A paper jam has
occurred as the paper is
exiting the paper tray
and entering the printer.
Clear the paper jam.
Paper Jams as it exits tray 2 (242 error)
Light pattern
Meaning
Action
Paper jams in Tray 2
between time of picking
and the input sensor.
Clear the paper jam.
2-26 Service Manual
Check the pick tires and for
any obstructions.
4511-xxx
Paper jam in the manual feeder (251 error)
Light pattern
Meaning
Action
A paper jam has
occurred in the manual
feeder.
Clear the paper jam.
Meaning
Action
Complex page
Light pattern
The page may not print
correctly because the
print information on the
page is too complex
(that is, too large for the
printer memory).
• Press
to clear the
message and continue
processing the print job
(some of the print data
may be lost).
• To avoid this error in the
future:
– Reduce the complexity of
the page by reducing the
amount of text or
graphics on the page and
deleting unnecessary
downloaded fonts or
macros.
– Set Page Protect to on
in the Local Printer Setup
Utility.
• Install additional printer
memory.
Diagnostics—E238, E240, and E240n
2-27
4511-xxx
Print cartridge errors
Light pattern
Meaning
Action
31 Error—Print
cartridge is either
missing or defective.
Install the correct cartridge.
32 Error—The print
cartridge is
unsupported.
Replace the cartridge.
33 Error—The print
cartridge has an invalid
refill.
Replace the cartridge.
2-28 Service Manual
4511-xxx
Print cartridge errors (continued)
Light pattern
Meaning
Action
42 Error—The print
cartridge was
manufactured for a
different geographic
region than the printer.
Replace the cartridge with a
cartridge from the same
region as the printer.
Insufficient printer memory
Light pattern
Meaning
Action
The printer does not
have enough memory to
save the data in the
buffer.
• Press
to continue
printing the job.
• Press
to cancel the
print job.
• Press
to cancel the
print job, turn off the printer
and install additional
memory.
Diagnostics—E238, E240, and E240n
2-29
4511-xxx
Insufficient collation area
Light pattern
Meaning
Action
The printer memory
does not have the free
space necessary to
collate the print job. This
may happen due to one
of these errors:
• Press
to clear the
message and continue
printing the job (the job
may not print correctly).
• Press and release
to
cancel the print job.
• Press and hold
to
reset the printer.
• To avoid this error in the
future:
– Simplify the print job.
Reduce the complexity of
the page by reducing the
amount of text or
graphics on the page and
deleting unnecessary
downloaded fonts or
macros.
– Install additional printer
memory.
• Memory is full.
• A page is too
complex to print.
• A page is shorter
than the set page
margins.
• Memory is insufficient
to save what is in the
buffer.
Font error
Light pattern
Meaning
Action
The printer has received
a request for a PPDS
font which is not
installed.
• Press and release
to
cancel the print job.
• Press and hold
to
reset the printer.
• Press and release
to
clear the message and
continue printing.
2-30 Service Manual
4511-xxx
Defective flash
Light pattern
Meaning
Action
The printer detects
defective flash memory.
• Press
to clear the
message and continue
printing.
– Downloaded fonts and
macros not previously
stored in flash memory
are deleted.
– Install flash memory.
Insufficient defrag memory
Light pattern
Meaning
Action
The printer has
insufficient memory to
free unused space in
flash memory.
• Delete fonts, macros, and
other data in RAM.
• Install additional printer
memory.
Diagnostics—E238, E240, and E240n
2-31
4511-xxx
Network interface errors
Light pattern
Meaning
Action
The printer cannot
establish
communication with the
network.
Press
to clear the
message and continue
printing (the job may not print
correctly).
Network or ENA connection lost
Light pattern
Meaning
Action
The printer has lost the
connection to an
external print server
(also called an external
network adapter or
ENA).
• Make sure the cable
connecting the ENA and
the printer is securely
attached.
• Turn the printer off and
then on to reset the printer.
• Press and hold
to
reset the printer.
This light pattern is
displayed if your printer
is connected to the
network, but it cannot
detect the print server
when you turn on the
printer.
2-32 Service Manual
4511-xxx
Memory full
Light pattern
Meaning
Action
The printer is
processing data, but the
memory used to store
pages is full.
• Press
to clear the
message and continue
printing the job (the job
may not print correctly).
• Press and release
to
cancel the print job.
• Press and hold
to
reset the printer.
• To avoid this error in the
future:
– Simplify the print job.
Reduce the complexity
of the page by reducing
the amount of text or
graphics on the page
and deleting
unnecessary
downloaded fonts or
macros.
– Install additional printer
memory.
Short paper
Light pattern
Meaning
Action
The paper length is too
short to print the
formatted data. This
occurs when the printer
does not know the
media size loaded in the
tray, or there is a
problem feeding the
media.
• Make sure the print media
you loaded is large
enough.
• Open the front cover, clear
the paper path, and close
the cover to resume
printing.
• Press
to clear the
message and continue
printing the job.
• Press
to cancel the
print job.
Diagnostics—E238, E240, and E240n
2-33
4511-xxx
Flash full
Light pattern
Meaning
Action
There is not enough
free space in the flash
memory to store the
data you are trying to
download.
• Delete fonts, macros, and
other data stored on the
flash memory to free up
space.
• Press
to clear the
message and continue
printing.
– Downloaded fonts and
macros not previously
stored in flash memory
are deleted.
– Install flash memory
with more storage
capacity.
• Press and release
to
cancel the print job.
• Press and hold
to
reset the printer.
Meaning
Action
The printer detects
unformatted flash
memory.
• Press
to clear the
message and continue
printing. The job may not
print correctly.
• Reformat the flash
memory. Refer to the
Technical Reference on
the Lexmark Web site for
more information.
• If the error message
remains, the flash memory
may be defective and
should be replaced.
Unformatted flash
Light pattern
2-34 Service Manual
4511-xxx
Invalid engine code
Light pattern
Meaning
Action
The code in an internal
print server has not
been programmed, or
the programmed code is
not valid.
Download valid engine code
to the internal print server.
Invalid network code
Light pattern
Meaning
Action
The code in an internal
print server has not
been programmed, or
the programmed code is
not valid.
Download valid network code
to the internal print server.
Diagnostics—E238, E240, and E240n
2-35
4511-xxx
Service codes
All service errors are indicated by all lights flashing as the primary
notification or code. The secondary light pattern indicates an area or
function which has the error. Tertiary codes (shown on the following pages)
indicate specific device errors. When all lights flash, double-click
to see
the secondary code. Double-click
again to see the tertiary code. If you
double-click again, you return to the primary light pattern again.
In the following example:
• The primary light pattern indicates a service error (all flashing). Doubleclick
for more information.
• The secondary light pattern indicates a fuser or toner sensor error.
Double-click
for more information.
• The tertiary light pattern indicates the fan has stalled. If you doubleclick again, the original primary light pattern will appear.
Note: If you send data to the printer and all lights flash simultaneously, and
double-clicking
does not produce a secondary code, you may
have a code problem. Contact the next level of support.
2-36 Service Manual
4511-xxx
Service primary code
✷
Light blinking
When this code appears, double-click
to reveal the secondary codes.
Lights
Primary code for
service errors
See secondary codes
Service primary code
✷
Continue
✷
Ready
✷
Toner Low/
Replace PC
Kit
✷
Load Paper
✷
Paper Jam
✷
Error
Diagnostics—E238, E240, and E240n
2-37
4511-xxx
Service secondary error codes
Service secondary error codes
✷
✷
✷
✷
95x—Controller card
(NVRAM, ROM, or
NAND)
94x—RIP to engine
communications,
engine electronics
93x—Printhead,
drive motor, RIP
to engine
92x—Fuser or toner
sensor
90x—Software
Lights
91x—DC motor or
transfer roll
Service secondary error codes
✷
✷
✷
✷
Continue
Ready
Toner Low/
Replace PC
Kit
Load Paper
✷
✷
Paper Jam
✷
Error
2-38 Service Manual
✷
✷
4511-xxx
Service secondary error codes (continued)
98x—Paper port
communications
97x—Network
Lights
96x—RAM memory
Service secondary error
codes
✷
✷
✷
Continue
Ready
✷
Toner Low/
Replace PC
Kit
✷
✷
✷
✷
Load Paper
Paper Jam
✷
Error
Diagnostics—E238, E240, and E240n
2-39
4511-xxx
Service tertiary error codes
Service error codes are generally non-recoverable except in an intermittent
condition when you can POR (power-on reset) the printer to temporarily
recover from the error.
Note: All service errors are initially communicated by all lights flashing
which is the primary indication or code. For brevity, this indication is
not repeated in the following codes.
Controller software
Controller software error/illegal trap (90x). For the other errors, which
indicate a faulty programming process or faulty component on the controller
card, replace the controller card. See “Controller card removal” on
page 4-15.
Service tertiary error codes—controller software
Lights
905—Interface
violation by
paperport device
Service tertiary
codes
902—General
engine
software error
Service
secondary
codes—
90x
✷
Continue
✷
✷
Ready
Toner Low/
Replace PC
Kit
✷
Load Paper
✷
Paper Jam
✷
Error
2-40 Service Manual
4511-xxx
Transfer roll or tray 2
CAUTION: When you see this symbol, there 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.
Code 914 indicates an error in tray 2 motor. Replace the drawer.
Code 917 indicates a problem in the transfer roll circuitry. Check the
continuity from the cable connection on the HVPS (high voltage power
supply) to the right side of the transfer roll.
Service tertiary error codes—transfer roll
Lights
917—Transfer
roll circuitry
Service tertiary
codes
914—Tray 2
motor
Service
secondary
codes—
91x
✷
Continue
✷
✷
✷
✷
Ready
Toner Low/
Replace PC
Kit
Load Paper
✷
Paper Jam
✷
✷
Error
Diagnostics—E238, E240, and E240n
2-41
4511-xxx
Fuser, fan, or toner sensor error
Codes 920 through 929 indicate a problem in the fuser (see “Fuser service
check” on page 2-87 for more information), a stalled fan motor, or a faulty
toner sensor or toner cartridge.
Service tertiary error codes—fuser, fan, or toner sensor
924—Open circuit
in thermistor path
923—Fuser too
hot during printing
or idle
922—Fuser failed
to reach standby
temperature
921—Fuser below
standby
temperature at idle
Lights
Service teriary codes—fuser, fan, or toner
sensor
920—Fuser
below temperature
when printing
Service
secondary
codes—
92x
✷
Continue
✷
✷
✷
✷
✷
Ready
Toner Low/
Replace PC
Kit
✷
Load Paper
✷
✷
✷
Paper Jam
✷
Error
2-42 Service Manual
✷
4511-xxx
Service tertiary error codes—fuser, fan, or toner sensor (continued)
929—Toner
sensor or toner
cartridge
927—Fan stalled
926—Fuser
thermistor open
circuit
Lights
925—Incorrect
fuser lamp
installed
Service teriary codes—fuser, fan, or
toner sensor
Continue
✷
✷
✷
✷
Ready
✷
Toner Low/
Replace PC
Kit
✷
✷
✷
✷
✷
Load Paper
Paper Jam
✷
✷
✷
Error
Diagnostics—E238, E240, and E240n
2-43
4511-xxx
Printhead, transport motor or RIP/engine communication error
Codes 930 through 935 indicate a problem with the printhead. Check cables
to the printhead. Replace the printhead as necessary.
Codes 936 and 937 indicate a problem in the drive system.
Code 939 indicates a communication failure between the RIP and engine
processors.
Service tertiary error codes—printhead, transport motor, or RIP engine
communication error
934—Mirror motor
lost
lock
933—Mirror motor
locked
Lights
931—No first
HYSNC. Verify
interlock switch
at J13.
932—Printhead
lost HYSNC
Service tertiary codes—printhead, transport
motor, or RIP engine communication
930—Wrong
printhead
Service
secondary
codes—
93x
✷
Continue
✷
✷
✷
✷
✷
Ready
Toner Low/
Replace PC
Kit
✷
Load Paper
✷
✷
✷
Paper Jam
✷
Error
2-44 Service Manual
✷
✷
4511-xxx
Service tertiary error codes—printhead, transport motor, or RIP/engine
communication error (continued)
939—RIP/engine
communication
error
937—Transport
motor lost lock
Lights
935—Mirror motor
not at opening
speed. Verify
+24 V dc at J11-5
936—Transport
motor initial lock
failure
Service teriary error codes
Continue
✷
✷
✷
✷
Ready
✷
Toner Low/
Replace PC
Kit
✷
✷
✷
✷
✷
Load Paper
Paper Jam
✷
✷
✷
Error
Diagnostics—E238, E240, and E240n
2-45
4511-xxx
NVRAM failure
Error codes 950–954 indicate a problem in the NVRAM (nonvolatile random
access memory). Replace the operator panel assembly. Codes 955–959
indicate a failed controller card assembly. Replace the controller card.
Service tertiary error codes—NVRAM failure
955—Code ROM or
NAND failed CRC
954—NVRAM
chip failure
952—NVRAM CRC
failure
Lights
Service teriary codes—NVRAM failure
950—Secure
EEPROM data
does not match
NVRAM
951—Secure
EEPROM failure
Service
secondary
codes—
95x
✷
Continue
✷
✷
✷
✷
✷
✷
✷
Ready
Toner Low/
Replace PC
Kit
✷
Load Paper
✷
Paper Jam
✷
✷
✷
Error
Note: NVRAM is on the operator panel printed circuit board while secure
NVRAM is on the controller card. Check margin alignments after
replacing the operator panel assembly. See “Printhead service
check” on page 2-111 for more information. If margin errors are
unacceptable, corrections can only be made through software.
Contact the next level of support.
2-46 Service Manual
4511-xxx
Service tertiary error codes—NVRAM failure (continued)
959—SRAM
failure
958—NAND failure
957—ASIC failure
Lights
956—Processor
failure
Service tertiary codes—NVRAM
failure
Continue
✷
✷
✷
✷
✷
✷
Ready
Toner Low/
Replace PC
Kit
✷
✷
✷
✷
Load Paper
Paper Jam
✷
✷
Error
Diagnostics—E238, E240, and E240n
2-47
4511-xxx
RAM memory error
This error indicates RAM failure. Remove DIMM(s), and POR the printer. If
the error persists, replace the card. If the error subsides, check the DIMM.
Replace faulty DIMM.
Service tertiary error codes—RAM memory error
961—RAM in
slot 1 is bad
Lights
Service teriary
codes—RAM
960—RAM
soldered on the
board is bad
Service
secondary
codes—
96x
✷
Continue
✷
✷
Ready
Toner Low/
Replace PC
Kit
✷
Load Paper
✷
Paper Jam
✷
Error
2-48 Service Manual
4511-xxx
Network error
Indicates an error in the network circuitry. Replace the controller card
assembly.
Service tertiary error codes—network error
979—Flash parts
failed while
programming port
978—Bad checksum
while programming
port
976—Unrecoverable
software error in
network port
Lights
Service teriary codes - network
975—Unrecognizable
network port
Service
secondary
codes—
97x
✷
Continue
✷
✷
✷
✷
✷
✷
Ready
Toner Low/
Replace PC
Kit
✷
✷
✷
Load Paper
✷
✷
Paper Jam
✷
✷
✷
Error
Diagnostics—E238, E240, and E240n
2-49
4511-xxx
Diagnostics—E340 and E342n
2
Power–On Self Test (POST) sequence
The following is an example of the events that occur during the POR
sequence when the printer is turned on.
1. Diamonds are displayed on the operator panel.
2. While code is being loaded into DRAM, dots scroll across the operator
panel.
3. A screen is displayed with the memory and processor speed. A typical
example of this message is:
*
32 Mb
366 Mhz
4. Performing Self Test is displayed.
5. Busy is displayed.
6. Close Door will be displayed if the cover is open.
7. Any cartridge errors, such as Defective Cartridge, are displayed.
8. Applicable maintenance messages are displayed.
9. Applicable toner low messages are displayed.
10. The printer displays Ready.
2-50 Service Manual
4511-xxx
Overview of the operator panel and menus
Indicator light
The indicator light gives information about the status of your printer.
If the light is
The printer is
Off
Off
On
On, but idle
Blinking
On and busy
Diagnostics—E340 and E342n
2-51
4511-xxx
Buttons
Use the five operator panel buttons to open a menu, scroll through a list of
values, change printer settings, and respond to printer messages.
Note: Buttons act on the information displayed on the second line of the
operator panel.
The following information describes the functions of each button.
Button
Function
Go
Press Go to:
• Return to the Ready state if the printer is offline (the
Ready message does not appear on the display).
• Exit printer menus and return to the Ready state.
• Clear some operator panel messages.
• Resume printing after loading media and clearing paper
jams.
• Exit Power Saver.
If you have changed printer settings from the operator panel
menus, press Go before sending a job to print. The printer
must display Ready for jobs to print.
Menu
Each end of the button has a function. Press Menu>:
• When Ready is displayed, to take the printer offline (out of
the Ready state) and enter the menus.
• When Busy is displayed, to take the printer to the Job
Menu.
• When the printer is offline, to scroll through the menus.
Press <Menu to go to the previous item in the menus.
However, menus are circular, and using either side of the
button will eventually get to the same point.
For menu items with numeric values, such as Copies, press
and hold Menu> to scroll quickly through the values. Release
the button when the number you want appears.
2-52 Service Manual
4511-xxx
Button
Function
Select
Press Select to:
• Open the menu shown on the second line of the operator
panel. Depending on the type of menu, this action:
– Opens the menu and displays the first item in the menu.
– Opens the menu item and displays the default setting.
• Save the displayed menu item as the new user default
setting. The printer displays the Saved message and
returns to the menu item.
• Clear certain messages from the operator panel.
Return
Press Return to return to the previous menu level or menu
item.
Stop
Press Stop at the Ready, Busy, or Waiting message to
temporarily take the printer offline. The message changes to
Not Ready. No data is lost.
Press Go to return the printer to the Ready, Busy, or
Waiting state.
Diagnostics—E340 and E342n
2-53
4511-xxx
Diagram of the printer menus
Not all menus or selections will be available on all models or in all situations.
Paper Menu
Paper Source
Paper Size
Paper Type
Custom Types
Universal Setup
Substitute Size
Paper Texture
Paper Weight
PostScript
Menu
Print PS Error
Font Priority
PPDS Menu
Orientation
Lines per Page
Lines per Inch
Page Format
Character Set
Best Fit
Tray 1 Renumber
Auto CR after LF
Auto LF after CR
Finishing Menu
Copies
Blank Pages
Collation
Separator Sheets
Separator Source
Multipage Print
Multipage Order
Multipage View
Multipage Border
PCL Emul Menu
Font Source
Font Name
Point Size
Pitch
Symbol Set
Orientation
Lines per Page
A4 Width
Tray Renumber
Auto CR after LF
Auto LF after CR
Parallel Menu
PCL SmartSwitch
PS SmartSwitch
NPA Mode
Parallel Buffer
Advanced Status
Protocol
Honor Init
Parallel Mode 2
MAC Binary PS
2-54 Service Manual
Utilities Menu
Quick Demo
Print Menus
Print Net Setup
Print Fonts
Print Directory
Print Demo
Factory Defaults
Hex Trace
Setup Menu
Printer Language
Power Saver
Resource Save
Download Target
Print Timeout
Wait Timeout
Auto Continue
Jam Recovery
Page Protect
Print Area
Display Language
Toner Alarm
Network Menu
PCL SmartSwitch
PS SmartSwitch
NPA Mode
Network Buffer
Mac Binary PS
Std Net Setup
Job Menu
Cancel Job
Reset Printer
Print Buffer
Quality Menu
Print Resolution
Toner Darkness
PictureGrade™
USB Menu
PCL SmartSwitch
PS SmartSwitch
NPA Mode
USB Buffer
Mac Binary PS
4511-xxx
Messages and error codes
User attendance messages
User attendance messages
Message
Explanation
Change Cartridge
Invalid Refill
Remove the print cartridge, and install a new
cartridge.
Change <input source>
<custom type name>
This message displays when the user should
change the media installed in one of the input
options.
• <input source>=Tray 1, Tray 2, Tray 3, or
Manual feeder.
• <Custom Type name>=Custom 1 through
Custom 6 using the MarkVision™ utility.
When the printer is prompting for one of the
custom types which has been named by the
user, then only the custom type name is
displayed on line 2. The name may be
truncated to fit the display.
Change <input source>
<custom string>
This message displays when the user should
change the media installed in one of the input
options.
• <input source>=Tray 1, Tray 2,Tray 3, or
Manual feeder.
• <custom string>= a user-definable name.
Change <input source>
<size>
This message displays when the user should
change the media installed in one of the input
options:
• <input source>=Tray 1, Tray 2, Tray 3, or
Manual feeder.
• <size>=letter, legal, B5, A4, Executive,
Universal, A5, Folio, or Statement. For
envelopes, <size>=7¾ Envelope, 9
Envelope, 10 Envelope, DL Envelope, C5
Envelope, B5 Envelope, or other Envelope.
Diagnostics—E340 and E342n
2-55
4511-xxx
User attendance messages (continued)
Message
Explanation
Change <input source>
<type><size>
This message displays when the user should
change the media installed in one of the input
options.
• <input source>=Tray 1, Tray 2, Tray 3, or
Manual feeder.
• <type>=Bond, Card stock, Colored,
Envelope, Labels, Ltrhead, Plain, Preprint,
or Transparency.
• <size>=letter, legal, B5, A4, Executive,
Universal, A5, Folio, or Statement. For
envelopes, <size>=7¾ Envelope, 9
Envelope, 10 Envelope, DL Envelope, C5
Envelope, B5 Envelope, or other Envelope.
Close Door
Close the front access door.
Delete All Jobs
Go/Stop?
When the user has selected Print and Hold
Delete All Jobs, this message is displayed.
The following actions may be taken:
• Press Go to confirm the selection. All jobs
are deleted.
• Press Return or Stop to cancel the delete
operation.
2-56 Service Manual
4511-xxx
User attendance messages (continued)
Message
Explanation
Insert <tray>
Tray=Tray 1 or Tray 2.
The printer does not detect the presence or
absence of a tray, but that paper was not
picked. Replace the tray, and press Go.
Note: This situation usually occurs when the
tray is refilled during a job. To refill a tray
during a printing session, press Stop, and
wait for pages to reach the output bin before
refilling the tray.
The following actions may be taken:
• Insert the requested tray.
• Press Menu until Job Menu displays. The
following selections are available:
– Cancel Job
– Reset Printer
If the message cannot be cleared, verify
whether the paper is being picked. If so, and
the paper advances to activate the input
sensor, this message would indicate a sensor
problem. Otherwise, check the pick tires and
pick mechanism.
Install Tray x
or Cancel Job
Tray x=Tray 2 or Tray 3.
This message is displayed when a paper
handling option has been hot unplugged. The
printer requires the reinstallation of the option
to print a page which has been formatted by
the interpreter before the option was removed.
The following actions may be taken:
• Install the option.
• Press Menu until Job Menu displays.
Select one of the following:
– Cancel Job
– Reset Printer
If the message cannot be cleared, check
connections and then POR the printer with the
option attached. If the message persists,
check the cables, starting at the controller
card.
Diagnostics—E340 and E342n
2-57
4511-xxx
User attendance messages (continued)
Message
Explanation
Load <input source>
<custom type name>
Input source=Tray 1, Tray 2, or Manual Feeder.
Custom type name is a user defined media
type.
The following actions may be taken:
• Load media in the indicated source.
• Press Menu until Job Menu displays.
Select one of the following:
– Cancel Job
– Reset Printer
If the message cannot be cleared, go to “Input
tray(s) service check” on page 2-64.
Load <input source>
<size>
Input source=Tray 1, Tray 2, or Manual Feeder.
Size=Letter, Legal, B5, A4, A5, Exec, Univ.,
Folio, or Stmt.
The following actions may be taken:
• Load media in the indicated source.
• Press Menu until Job Menu displays.
Select one of the following:
– Cancel Job
– Reset Printer
If the message cannot be cleared, go to “Input
tray(s) service check” on page 2-64.
31 Missing or
Defective Cart.
The cartridge may be missing and the front
access door closed. Return the cartridge. The
cartridge may also be defective. Replace the
cartridge.
32 Unsupported
Print Cartridge
Error 32 displays when the top cover is closed
and an unsupported print cartridge is
detected. It may take the printer 10–20
seconds to determine if the print cartridge is
supported. Depending on the setting of the
Machine Class ID, the printer may be allowed
to print pages during this 10–20 second
interval. If pages are allowed to print, then
they are not reprinted once a good print
cartridge is inserted. Replace the cartridge.
33 Change Cartridge
The toner cartridge has an invalid refill.
2-58 Service Manual
4511-xxx
User attendance messages (continued)
Message
Explanation
35 Res Save Off
Deficient Memory
The printer lacks sufficient memory to enable
Resource Save. The following actions may be
taken:
• Press Go to clear the message. The printer
disables Resource Save.
• Install additional memory.
• Set link buffers to Auto, return to Ready,
enable Resource Save, and reset the link
buffers.
37 Insufficient
Defrag Memory
This message displays prior to the actual start
of the defragmentation process. If there is not
enough free memory available to complete the
process, the process will not proceed, and no
data already in memory will be lost.
While this message is displayed, the following
actions may be taken:
• Press Go to clear the message. To perform
defragmentation operation, you can:
– Delete fonts, macros, and other data from
RAM.
– Install additional printer memory.
• Press Menu until Job Menu appears. The
following functions may be available:
– Cancel Job
– Reset Printer
37 Insufficient
Memory
Held Jobs may be
lost
This message displays when there is not
enough memory available to continue
processing a job, and Print and Hold feature is
in use. The printer frees memory by deleting
the oldest Reserve Print and Verify Print jobs.
It deletes only the amount needed to continue
the incoming job. Some or all of the jobs may
not be restored. If, while printing the current
job, it runs out of memory again, another
message is not posted.
• Press Go to clear the message. Some of
the Print and Hold jobs on the disk will not
be restored. They remain on the disk, but
cannot be accessed.
• Press Menu until Job Menu appears. The
function, Reset Printer, may be available.
Diagnostics—E340 and E342n
2-59
4511-xxx
User attendance messages (continued)
Message
Explanation
38 Memory Full
This message displays when the printer is
processing an incoming job, and there is
insufficient memory available to continue
processing the job. The following actions may
be taken:
• Press Go to clear the message. Perform the
defragment operation:
– Simplify the print job.
– Delete fonts, macros, and other data in
RAM.
– Install additional memory.
• Press Menu to display Job Menu. The
following functions may be available:
– Cancel Job
– Reset Printer
39 Complex Page
This message displays when the page is too
complex to print. The following actions may be
taken:
• Press Go to clear the message and
continue the job. Some data loss may
occur. Simplify the print job and reprint, if
necessary.
• Press Menu until Job Menu appears. The
following selections are possible:
– Cancel Job
– Reset Printer
42 Cartridge Region
Mismatch
2-60 Service Manual
Toner cartridges are manufactured for specific
geographic regions. This message indicates
this cartridge does not match the region for
the printer. Change the cartridge.
4511-xxx
User attendance messages (continued)
Message
Explanation
50 PPDS
Font Error
This message displays when the PPDS
interpreter has encountered a font error.
Note: This error may only occur when the
PPDS compiler requests a font which is not
present or is not installed.
The following actions may be taken:
• Press Go to clear the message and
continue processing the job.
• Press Menu until Job Menu appears. The
following are available:
– Cancel Job
– Reset Printer
51 Defective
Flash
This message displays when the printer
detects a defective flash. This error may occur
at power on, or during flash format and write
operations. Press Go to clear the message.
The flash is marked as bad, and normal
operation continues. Flash operations are not
allowed until the problem is resolved.
52 Flash Full
This message displays when there is not
enough free space in the flash memory to hold
the resources that have been requested to be
written to flash.
The following actions may be taken:
• Press Go to clear the message and
continue processing the job.
• Press Menu until Job Menu appears. The
following are available:
– Cancel Job
– Reset Printer
53 Unformatted
Flash
This message displays when the printer
detects an unformatted flash at power on.
Press Go to clear the message. The flash is
marked as bad, and normal operation
continues. Flash operations are not allowed
until the flash is formatted.
Diagnostics—E340 and E342n
2-61
4511-xxx
User attendance messages (continued)
Message
Explanation
54 Std Network
Software Error
This error displays when a network port is
detected, but the printer cannot establish
communications with it.
Press Go to clear the message. The printer
disables all communications to the network
interface.
55 Unsupported
Flash
An unsupported flash option is installed in the
DIMM slot. Turn off the printer, and remove the
unsupported flash option in the specified slot.
56 Std Parallel
Port Disabled
This error is displayed when data is sent to the
printer across the parallel port, but the parallel
port has been disabled. Once this message is
displayed, reporting of further errors is
suppressed until the menus are entered, or
the printer is reset. The following actions may
be taken:
• Press Go to clear the message. The printer
discards any data received on the parallel
port.
• Press Menu until Job Menu appears, and
select Reset Printer.
56 Standard USB
Port Disabled
Displayed when status is requested over the
USB port, but the port has been disabled.
Once the error has been displayed for the first
time, reporting of further errors is suppressed
until the menus are entered or the printer is
reset.
The following actions may be taken:
• Press Go to clear the message. The printer
discards any data received on the USB
port.
• Press Menu until Job Menu appears, and
select Reset Printer.
58 Too Many
Trays Attached
2-62 Service Manual
This error displays when too many input trays
are attached to the printer.
4511-xxx
User attendance messages (continued)
Message
Explanation
58 Too Many
Flash Options
This error displays when too many flash
options are installed in the printer.
The following options may be taken:
• Turn off the printer, and remove the extra
flash options.
• Press Go to clear the message. The extra
flash options are ignored.
84 Photoconductor
Life Warning
This message displays when the
photoconductor unit is near end of life. Press
Go to clear the message.
84 Replace
Photoconductor
This message displays when the
photoconductor is exhausted. The printer is
disabled until the photoconductor is replaced.
Replace the photoconductor:
1. Turn the printer off, and replace the
photoconductor unit.
2. Reset the page count.
• Press and hold Select and Return while
turning the printer on.
• Release the button when Performing
Self Test displays.
• Select Reset Maint Cnt, and press
Select.
The counter is reset to zero.
88 Toner Low
This message displays when toner low occurs
and the toner low alarm is activated. Press Go
to clear this message.
Diagnostics—E340 and E342n
2-63
4511-xxx
Paper jam messages
Repeating jams or jam messages can be caused by any of the following:
•
•
•
•
•
•
Faulty pick solenoids or worn cams of the solenoids.
Faulty flags or springs.
Worn backup rollers at the reference guide.
Improperly adjusted reference guide.
Debris in the paper path.
Paper not of the specified length.
Paper jam messages
Message
Explanation
200 Paper Jam
Remove Cartridge
The input sensor under print cartridge is
covered too long, is covered during POR, or is
covered when Go is pressed after clearing a
different jam or problem. The exit sensor could
also be covered. Remove the print cartridge and
open the rear door to remove the media.
201 Paper Jam
Remove Cartridge
Paper is jammed between the printer input and
exit sensor. Remove the print cartridge to clear
the paper path.
202 Paper Jam
Open Rear Door
The exit sensor is either covered during POR or
covered too long. Open the rear door to access
the jam area.
241 Paper Jam
Check Tray 1
Paper is jammed between Tray 1 and the input
sensor.
242 Paper Jam
Check Tray 2
Tray 2 pass thru sensor is covered during
warm-up.
Try opening Tray 2. If the tray is difficult to
remove, then you may have to remove the tray
above.
251 Paper Jam
Check Manual Feeder
2-64 Service Manual
Sensor at the manual feeder indicates paper is
stuck in the path. Remove the paper, and check
the flag/sensor.
4511-xxx
Service error codes
Service error codes are generally non-recoverable except in an intermittent
condition when you can POR the printer to temporarily recover from the
error condition.
Service error codes (9xx)
Error
Description
Action
900
Service
RIP software
Server firmware problem. Contact the
next level of support.
902
General engine
software failure
An unrecoverable engine software error.
Reset the printer (POR). If the problem
continues, replace the controller card.
905
Interface violation by
the Paperport device
917
Transfer roll
The likely cause is a faulty HVPS. It may
also indicate a problem in the transfer roll
area. Go to “Transfer roll service
check” on page 2-111.
920
Fuser error
Go to “Fuser service check” on
page 2-87.
Indicates that the fuser
is below temperature
when printing.
921
Fuser error
Indicates that the fuser
is below proper
temperature during
standby or idle time.
922
Fuser error
Fuser failed to reach
standby temperature.
Go to “Fuser service check” on
page 2-87.
Verify line voltage to the fuser. Go to
“Fuser service check” on page 2-87.
923
Fuser is too hot during
printing or when printer
is idle.
Go to “Fuser service check” on
page 2-87.
924
An open circuit has
been detected in the
fuser thermistor circuit.
Check cabling and connectors. Go to
“Fuser service check” on page 2-87 for
the thermistor.
Diagnostics—E340 and E342n
2-65
4511-xxx
Service error codes (9xx) (continued)
Error
Description
Action
925
Fuser Error
Replace fuser with correct one. See
“Fuser removal” on page 4-28.
(Incorrect fuser lamp.)
927
Fan Error
Fan is stalling.
Replace the fan. See “Fan removal” on
page 4-26.
929
Toner sensor
The toner sensor is not operating
properly, the developer drive assembly is
not operating properly, or the print
cartridge is defective. Go to “Sensor Test
(input tray)” on page 3-27.
931
Printhead—no first
HSYNC
Check for unplugged printhead, faulty
cabling, or faulty printhead.
932
Printhead—lost
HSYNC
Replace the printhead.
934
Mirror motor lost lock
Replace the printhead.
935
Mirror motor unable to
reach operating speed.
Faulty printhead, cabling or connector.
936
Transport motor initial
lock failure
Indicates a problem with the main drive
motor or a jam occurred during the motor
ramp-up to speed.
937
Transport motor lost
lock
Faulty motor or a jam occurred after
motor ramp-up to speed. Possible
problem with the main drive or motor
cable.
950
Controller card
There is a mismatch between the
variables in the EPROM on the operator
panel card and those in the secure
NVRAM on the controller card. This can
only occur after a replacement of one of
the two parts, and the replaced part is
faulty. Replace the controller card or the
operator panel.
Warning: Always replace only one at a
time with a POR between.
951
Controller card
2-66 Service Manual
The secure NVRAM was not detected on
the controller card. Replace the controller
card.
4511-xxx
Service error codes (9xx) (continued)
Error
Description
Action
952
NV failure:n
Recoverable error. Reset (POR) the
printer. Where n=offset where error
occurred.
954
NVRAM CRC failure
Indicates the NVRAM experienced a CRC
failure. Replace the controller card.
955
Code CRC <loc>
Replace the controller card. Where
<loc> = CRC Failure or ECC Failure on
the controller card.
956
Controller card
Perform a power on reset (POR). If this
does not fix the problem, replace the
controller card.
957
ASIC failure
Perform a power on reset (POR). If this
does not fix the problem, replace the
controller card.
958
NAND failure
Before proceeding, perform a power on
reset (POR) to see if the ECC (error
correction code) can reflash NAND.
If this does not fix the problem, replace
the controller card.
959
SRAM failure
Perform a power on reset (POR). If this
does not fix the problem, replace the
controller card.
960
RAM soldered on the
card is bad
Indicates a DRAM Memory Error on the
controller card. Replace the controller
card.
961
RAM in slot 1 is bad
If another SDRAM memory DIMM is
available, turn the power off, and switch
the DIMM. If the memory card now works
correctly, replace the failing DIMM. If this
does not fix the problem, replace the
controller card. If another DIMM is not
available, replace the memory option first
and then the controller card if necessary.
Diagnostics—E340 and E342n
2-67
4511-xxx
Service error codes (9xx) (continued)
Error
Description
Action
975
Unrecognizable
network port
A failure with the network port.
976
Software error in
network port
978
Bad checksum while
programming network
port.
979
Flash parts failed while
programming network
port.
If the printer is a network model, replace
the controller card. See “Controller card
removal” on page 4-15.
Sub error codes
The sub error codes are helpful troubleshooting a paper path problem. Each
status byte has a different level of troubleshooting value for each area of the
printer. The following table displays up to 8 status bytes of data. Some or all
of these bytes may be used to help diagnose a printer problem. These
status bytes are designed to help isolate paper jams and paper feed
problems in the base printer.
DU
xx
xx
xx
xx
DU
xx
xx
xx
xx
To identify the bytes:
Byte 1
Byte 2
Byte 3
Byte 4
DU
xx
xx
xx
xx
DU
xx
xx
xx
xx
Byte 5
Byte 6
Byte 7
Byte 8
2-68 Service Manual
4511-xxx
Displayed error codes
When a 9xx or 2xx error displays:
1. Press and hold Return, and press Select to view sub error codes.
The first screen of information displays. Write down the information.
2. Continue pressing Return and Select until each screen of information
is obtained.
When the last screen displays, the original message displays.
Printed error codes
Additional information is available by printing the error log. See “Print Log”
on page 3-33.
Values
In the table below, the values for common variables are listed below:
• media source
10=Manual feeder
11=Tray 1
12=Tray 2
• media size
1=Letter
2=Legal
3=B5
4=A4
5=Executive
6=A5
7=Custom size
9=7¾ in. envelope
A=#9 Envelope
B=#10 Envelope
C=8.661 in. Envelope
D=C5 Envelope
E=B5 Envelope
F=Legal envelope
Diagnostics—E340 and E342n
2-69
4511-xxx
Sub error codes
First 6 bytes sub
error code data
(xx can be any
value)
Explanation
Possible
error
message
84 00 22 x1
x2 00
Indicates the media reached the image
point before EP leading edge state
machine was ready.
(x1=leading edge of media state,
x2=trailing edge of media state)
200
84 01 22 x1
x2 00
Media reached the image point before EP
trailing edge state printer was ready.
(x1=EP leading edge state, x2=EP trailing
edge state.)
200
84 x1 30 x2
x3 x4
Motor head transport motor error.
(x1=motore type, x2=error code,
x3=TimWatchingHallCount,
x4=TimeWatchingHallPeriod.)
84 1x 2D x2
x3 x4
Misidentified no gap jam. Engine detected
no gap at the manual feeder sensor,
attempted to open the gap by stopping
the feed rolls, trailing edge was seen at
the input sensor, manual feeder sensor is
no longer covered.
(x1+x2=page ahead’s expected length,
x3+x4=Page ahead’s measured length)
84 xx 00 x1
x2 x3
This code indicates that the input sensor
is still actuated from the first sheet, and
the second sheet is ready to arrive at the
sensor.
(x1=FsyncFall flag for Page Ahead,
x2=media source, x3=last measured gap
at input sensor).)
• Check the printer input sensor and flag
for correct operation. The flag should
operate freely.
• Check for debris in the area of the input
sensor.
• Check the area of the transfer roll and
input to the fuser for anything that might
cause the paper to remain over the
input sensor.
2-70 Service Manual
200
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
Possible
error
message
Explanation
84 xx 01 x1
x2 00
The video signal did not start within two
inches after actuating the input sensor.
Check input sensor and flag.
(x1=media size, x2=irqcnt)
200
84 xx 02 x1
x2 x3
Paper is over the input sensor too long.
(x1=media size, x2=source,
x3=LastDetectedSize.)
200
Possible causes are:
• Multi sheet feeding.
• Paper size is not the same as
expected.
• The media feeding from the source is
slipping or media is slipping before
exiting the input sensor.
84 xx 03 x1
00 00
The measured gap between sheets of
media at the input sensor is too small to
meet video requirements.
x1=time by which the gap was too small.
84 xx 04 x1
x2 x3
The input sensor was covered when not
expected (media in paper path during
warmup.)
(x1+x2=fuser heating time, x3=fuser
wattage detection result)
200
• Clear the media or debris from the
printer.
• Run the base sensor test (input sensor)
from the diagnostic tests menu to test
the input sensor and flag for correct
operation.
Diagnostics—E340 and E342n
2-71
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
84 xx 05 x1
x2 00
Explanation
There was media at the input sensor too
early. There was not enough time
between printhead start and the printhead
mirror motor to lock.
(x1=input sensor state, x2=0 is normal
printhead lock expectation; 1 is lock
assumption that proved to be wrong.)
Possible
error
message
200
Possible causes for this error are:
• Paper might be pre-staged in the paper
source tray.
• Paper is picking too fast due to faulty
paper feed assembly.
• A defective input sensor.
84 xx 20 x1
x2 00
The imaged page is not the expected
page.
(x1=media size, x2=media source)
200
Check the pass thru sensor to make sure
it is operating properly. If no problem is
found, it may still be necessary to try a
new pass thru sensor.
84 xx 23 x1
x2 x3
Transfer servo never started.
(x1=media size, x2=EP leading edge
state, x3=EP trailing edge state.)
200
Possible causes include:
• Slow or missing transport motor
positional feedback.
• Media too fast to input sensor.
• Gap too small on interpage servo.
84 xx 26 x1
x2 x3
2-72 Service Manual
The media has activated the input sensor;
however, the printhead fell out of lock
condition or expected a stable lock too
soon. The media may have also reached
the input sensor early.
(x1=HSYNC state, x2=0 is normal PH
lock expectation;1 is lock assumption that
proved to be wrong.)
200
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
Possible
error
message
Explanation
84 xx 27 x1
x2 x3
Manual feeder sensor never became
uncovered from the sheet ahead.
(x1=media size, x2=media source,
x3=last measured gap at input sensor
(gap ahead of PageAhead.))
84 xx 28 x1
Media never reached the input sensor, but
was detected at manual feeder sensor.
(x1=last measured gap at input sensor
(gap ahead of PageAhead.))
84 xx 29 x1
x2 x3
Media too long over manual feeder
sensor.
x1=media size, x2=source,
x3=LastDetectedSize
Possible causes include:
• Multiple sheet feed.
• Media too long.
• Media was prestaged.
84 xx 2A 00
00 00
Media detected in manual feeder sensor
when not expected.
Possible causes include:
• Insertion of paper when motor is
running.
• Prestaged media in tray.
84 xx 2B 00
00 00
Could not detect the end of a sheet at the
manual feeder sensor.
Possible causes include:
• Very small interpage gap.
• Excessive bounce of manual feeder
sensor.
Diagnostics—E340 and E342n
2-73
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
Explanation
84 xx 2C x1
x2 x3
Unrecoverable no gap jam. Engine
detected no gap at the manual feeder
sensor, attempted to open the gap by
stopping the feed rolls, but no trailing
edge was ever seen at the input sensor.
(x1=media size, x2=media source,
x3=LastdetectedSize)
84 xx 2D x1
x2 x3
Misidentified no gap jam. Engine detected
no gap at the manual feeder sensor,
attempted to open the gap by stopping
the feed rolls, trailing edge was seen at
the input sensor, manual feeder sensor is
no longer covered.
(x1=media size, x2=source,
x3=LastDectedSize)
84 xx 2E x1
x2 00
Failed no gap jam recovery. Engine
detected no gap at the manual feeder
sensor, opened the gap by stopping the
feed rolls, but never saw the leading edge
of the second page at the input sensor.
(x1=RecoveryStatus, x2-source)
84 xx 2F x1
x2 x3
Laser servo never started due to potential
conflict with the transfer servo.
(x1=bit 0: transfer servo started,
bit 1: transport started; x2+x3=transfer
servo count value.)
Possible causes are:
• Slow or missing transport motor
positional feedback.
• Media arrives too early at the input
sensor.
2-74 Service Manual
Possible
error
message
200
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
84 xx 30 00
00 00
Possible
error
message
Explanation
Input sensor never became uncovered
from page ahead while trying to feed
media out of path during warm-up. Paper
originally detected at option tray pass thru
sensor.
200
• Clear the media or debris from the
printer.
• Enter Diagnostics, and perform the
Base Sensor test to verify the proper
function of the input sensor. See
“Accessing service menus” on
page 3-2 for models E238, E240, or
E240n or “Accessing service
menus” on page 3-14 for models
E340 or E342n. See “Base sensor
test” on page 3-28.
84 xx 3B x1
x2 x3
Media picked from the manual source
failed to reach the input sensor.
251
89 00 01 00
00 00
The exit sensor at the fuser is activated by
a piece of media indicating there is a
piece of media in the paper path during
warmup.
202
Check for media in the exit of the fuser
assembly or redrive assembly. Feed a
sheet of paper, and if the same error
occurs after clearing the fuser, or the
same error occurs when no media is
present, check the exit sensor assembly.
Turn the printer off, enter the diagnostic
tests menu, and select the base sensor
test. Select output sensor, and check the
sensor for correct operation.
Diagnostics—E340 and E342n
2-75
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
89 xx 03 x1
x2 x3
Explanation
The exit sensor did not detect the trailing
edge of the media.
(x1=bit7:filtered exit sensor state;
bits 6–0:H1(time exit sensor covered),
x2=suspect gap measurement at input
sensor, x3=Low(time exit sensor
covered).)
Possible
error
message
202
• This failure can be caused by a broken
fuser exit sensor flag.
• This may also be caused by erratic
operation of exit sensor flag or exit
sensor or a defective piece of media.
89 xx 04 x1
x2 00
The exit sensor never actuated from the
sheet going through the fuser before the
next page entering the sensor.
(x1=media size, x2=GeneralFlags1.)
202
89 xx 0D 00
x2 x3
The fuser exit sensor bounced.
(x2 + x3=paper path location.)
202
Check the exit sensor for correct
operation. Check the sensor cable to J16
on the controller card. Also, the controller
card may be failing.
8A 39 x1 x2
x3 x4
2-76 Service Manual
Printhead driver IR: LE at image point
based on lock assumption that proved to
be wrong.
(x1=printead type, x2=1 if lock,
x3, x4=time since printhead start.)
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
8D 00 00 00
00 00
Possible
error
message
Explanation
The fuser exit sensor was never activated
by the leading edge of the media fed
through the printer.
201
• This error can be displayed after a 201
paper jam.
• This can be caused by a defective fuser
exit sensor assembly.
Note: Enter the diagnostic tests menu,
select Base Sensor Tests, select
Output Sensor Test and check the
fuser exit sensor for correct operation.
If the test fails, check the cable
connection to J17 on the controller
card.
8D 00 01 00
00 00
User pressed Go or Continue after an
8D xx 00 jam, but never opened the
front access cover. Need to open cover
and clear any media under cartridge
before continuing.
8E xx 00 x1
x2 x3
Sheet being duplexed never made it to the
input sensor.
(x1=source, x2+x3=time since pick)
8E xx 08 00
00 00
Page in output hopper flushed; page
ahead of it in the paper path never made it
out of the tray.
8E xx 09 x1
The second pick from Tray 1 failed when
other sheets were committed to the paper
path.
201
250
(x1=media source)
8E x1 10 x2
x3 x4
Received lots of dc feed interrupts before
losing them. Tray 2 motor stall.
(x1=DCFeedMSCounter,
x2=IntegralPWM,
x3+x4=DCFeedRQCount.)
Diagnostics—E340 and E342n
2-77
4511-xxx
Sub error codes (continued)
First 6 bytes sub
error code data
(xx can be any
value)
8E x1 11 x2
x3 x4
2-78 Service Manual
Explanation
Took too long to ramp up Tray 2 motor.
(x1=DCFeedMSCounter,
x2=Low(DCFeedIRQCount),
x3=RampTableLengthCache,
x4=DCFeedClosedLoopState.)
Possible
error
message
4511-xxx
Diagnostics—all models
2
Symptom tables
POST symptom table
Symptom
Action
The main motor, cooling fan,
and fuser do not come on.
See “Cover interlock switch service
check” on page 2-85.
POST completes, except one or
more lights do not come on.
See “Operator panel service check
(models E238, E240, and E240n)” on
page 2-92.
None of the lights come on.
See “Operator panel service check
(models E238, E240, and E240n)” on
page 2-92.
Main motor does not come on.
See “Main motor service check” on
page 2-91.
Fan does not come on.
See “Cooling fan service check” on
page 2-81.
Fuser lamp does not come on.
See “Cooling fan service check” on
page 2-81.
Fuser lamp never turns off.
See “Hot fuser service check” on
page 2-89.
The paper feed picks and tries
to feed paper.
See “Paper feed service checks” on
page 2-94.
Printer symptom table
Symptom
Action
Dead machine (no power).
See “Dead machine service check”
on page 2-86.
Fan noisy or not working.
See “Cooling fan service check” on
page 2-81.
Diagnostics—all models
2-79
4511-xxx
Symptom
Action
Fuser parts melted.
See “Hot fuser service check” on
page 2-89.
Fuser lamp does not light.
See “Cooling fan service check” on
page 2-81.
Toner not fused to the paper.
See“Cooling fan service check” on
page 2-81.
Paper jams.
See “Paper feed service checks” on
page 2-94.
Main motor noisy or not
moving.
See “Main motor service check” on
page 2-91.
Paper skew.
See “Paper feed service checks” on
page 2-94.
Printer not communicating with
host.
See “Parallel port service check
(models E238, E240, and E240n)” on
page 2-97.
Front access cover will not
close.
See “Cover interlock switch service
check” on page 2-85.
Operator panel button not
responding.
See “Operator panel service check
(models E238, E240, and E240n)” on
page 2-92, “Operator panel service
check (models E340 and E342n)” on
page 2-93, or “Controller card
service check” on page 2-82.
Operator panel lights are off or
very dim.
See “Controller card service check”
on page 2-82.
Blank page.
See “Blank page” on page 2-99.
Black page.
See “Black page” on page 2-100.
Heavy background.
See “Heavy background” on
page 2-101.
Light print.
See “Light print” on page 2-103.
White or black lines or bands.
See “White or black lines or bands”
on page 2-103.
Toner on back of page.
See “Toner on back of page” on
page 2-104.
2-80 Service Manual
4511-xxx
Symptom
Action
Paper never picks.
See “Paper never picks” on
page 2-95.
Paper feeds continuously.
See “Paper picks during POST and/
or continuously” on page 2-94.
Paper wrinkled or bent.
See “Paper “trees,” wrinkles, stacks
poorly, or curls” on page 2-96.
Service checks
Service checks which involve measuring voltages on the
LVPS/HVPS (low voltage power supply/high voltage power
supply board) should be performed with the printer positioned
on its back side.
Note: When you make voltage readings, always use frame ground unless
another ground is specified. See the wiring diagram in the back of the
book for more information.
Cooling fan service check
FRU
Action
Cooling fan
Make sure the fan cable plug is properly seated
at J18 (controller card).
Turn the printer off, and disconnect the cooling
fan cable from the controller card.
Turn the printer on. Within a few seconds, the
controller card assembly should apply between
+24 V dc to pin 2.
• If voltage is present and the fan is not turning,
replace the cooling fan. If the fan still doesn’t
function, replace the controller card.
Note: The fan speed is controlled by a
module on the printed circuit board. Between
+8 V and +24 V dc are constantly supplied at
pin 2 (J18). Pin 1 is ground while pin 3
receives feedback from the fan motor.
• If voltage is not present, check the cables and
all connections.
Diagnostics—all models
2-81
4511-xxx
Controller card service check
Controller card service check
FRU
Action
Controller card
assembly
POST (Power-On Self Test)
Note: With all cables connected, the printer
should complete POST within approximately 30
seconds in the following sequence:
• For models E238, E240, and E240n, see
“Power-On Self Test (POST) sequence” on
page 2-2. If some lights are on or flashing see
“Common primary light patterns” on
page 2-4 to determine action required.
• For models E340 and E342n, see “Power–
On Self Test (POST) sequence” on
page 2-50. If error messages are posted, see
“Messages and error codes” on page 2-55.
If the printer fails to complete POST without
displaying an error message, replace the
controller card assembly.
Note: Settings for U.S. versus
non–U.S. and the printer configuration ID can be
changed. For models E238, E240, and E240n,
see “Defaults” on page 3-12 and
“Configuration ID” on page 3-12. For models
E340 and E342n see “Defaults” on page 3-29
and “Configuration ID” on page 3-30.
2-82 Service Manual
4511-xxx
Controller card service check (continued)
FRU
Action
Controller card
assembly (continued)
Verify +24 V dc input from the
LVPS/HVPS.
• Turn the printer off.
• Disconnect the LVPS/HVPS cable from the
controller card at J4.
• Turn the printer on.
• Verify +24 V dc from the cable connector of
J4, pins 8 and 9.
If voltage is correct, check the continuity in the
cable. If the cable is good, check the
connectors to the controller board.
Verify that pins 7 and 14 on both the cable and
the card connector are ground.
• If grounds are not correct on the cable, first
check it for continuity and then the LVPS/
HVPS.
• If the grounds are not correct on the controller
card, replace the controller card. (Check with
one probe on the connector pin and the other
on the card’s ground plane found at each
screw head.)
Diagnostics—all models
2-83
4511-xxx
Controller card service check (continued)
FRU
Action
LVPS/HVPS
Verify main power to controller card
With the printer off, unplug the LPS/HVPS cable
at J4 on the controller card. Verify grounds on
pins 7, 12, and 14 for both the cable and the
controller card. If any of these grounds are
incorrect, check the cable for continuity. Replace
the cable or the respective card as necessary.
Turn the printer on with the cable still unplugged,
and verify the following on the cable (controller
card will not be powered):
Pins
Voltage
J4-1
+5 V dc
J4-2
+5 V dc
J4-3
+5 V dc
J4-4
+5 V dc
J4-8
+24 V dc
J4-9
+24 V dc
J4-13
+5 V dc
If any of the voltages are incorrect, check or
replace the LVPS/HVPS. See “Dead machine
service check” on page 2-86.
Controller card
assembly
Controller card voltage outputs
Turn the printer off, and plug the LVPS/HVPS
cable into J4 of the controller card. See the
table, “Controller card connector pin values”
on page 5-4, which identifies the voltages and
grounds for a good controller card.
Note: Turn the printer off before pugging or
unplugging any connectors.
2-84 Service Manual
4511-xxx
Cover interlock switch service check
Note: Make sure a print cartridge assembly is installed and the cover
closes all the way, engaging the cover open switch lever.
FRU
Action
Cover interlock switch
Disconnect the cover interlock cable from the
controller card at J15.
With the printer turned off, verify continuity
between cable pin 1 and pin 2 with the door
closed and discontinuity with the door open.
Verify continuity between cable pin 1 and pin 3
with the door open and discontinuity with the
door closed.
Verify discontinuity between cable pins 2 and 3
whether the door is open or closed.
• If either fails, replace the cover interlock
switch.
• If both pass continuity, turn the printer on, and
measure +5 V dc on pin 2 at J15 on the
controller card.
• Verify pins 1 and 3 at J15 are ground.
• If voltage or ground is not present, see
“Controller card service check” on
page 2-82 for more information.
Diagnostics—all models
2-85
4511-xxx
Dead machine service check
CAUTION: Check the AC line voltage. The voltage should be
within the following limits:
• 100 V ac (volts alternating current) – 127 V ac for the 110 V
printer
• 200 V ac – 240 V ac for the 220 V printer
FRU
Action
Unplug the printer and check the fuses on the
LVPS/HVPS board for continuity.
LVPS/HVPS
• If open, replace the LVPS/HVPS board.
If fuse opens again, see “LVPS/HVPS
service check” on page 2-90 for more
information.
• If not open, unplug the cables at CN102 and
CN201 (fuser and controller card
respectively).
Plug LVPS/HVPS board to source and turn
switch on.
Verify 24 V dc on pin 8 at connector CN201 (or
pin 8 at J4 on the controller card).
Verify line voltage (100 V, 110 V, or 220 V ac)
across pins 1 and 2 of CN102.
• If voltages are not correct for the geography,
replace the LVPS/HVPS board.
• If voltages are correct, check the controller
card. See “Controller card” on page 5-3.
Verify grounds. See the wiring diagram at the
end of the book.
2-86 Service Manual
4511-xxx
Fuser service check
When toner is partially fused to the paper, it is usually caused by low fuser
temperature.
Warning: Avoid handling the lamp as much as possible, as it is easily
broken. Be careful not to touch the glass housing with bare hands, because
skin acids can weaken the glass.
Note: The lamp is not a service part.
The line voltage to the printer must be within the following limits:
• 100 V ac–127 V ac for the 110 V model printer
• 200 V ac–240 V ac for the 220 V model printer
Turn the printer off, and wait a few minutes for the fuser lamp to cool. Turn
the printer on, and observe the lamp turning on during POST.
You can see the light from the lamp by opening the left side
cover and observing the upper opening through which the
fuser power cables pass.
Fuser service check
FRU
Action
Unplug the printer, and disconnect the fuser
lamp cable plug from the LVPS/HVPS board
connector at CN102.
Fuser power cable
LVPS/HVPS
Fuser
Check for continuity across the fuser lamp by
checking across the connector pins.
• If there is continuity, go to Step 1: Continuity.
• If there is no continuity, go to Step 2: No
continuity.
Step 1: Continuity
Turn the printer on with only the fuser power
disconnected. Measure the voltage at connector
CN102 on the LVPS/HVPS. It should match the
line voltage. If line voltage is not present, see
“LVPS/HVPS service check” on page 2-90 for
more information.
Make sure the fuser thermistor is correctly
connected to the controller board. If the problem
persists, disconnect the thermistor cable at J16,
and check for less than +5 V dc on pin 1. Pin 2
should be ground. If line voltage is incorrect on
pin 1, see “Controller card service check” on
page 2-82 for more information.
Diagnostics—all models
2-87
4511-xxx
Fuser service check
FRU
Action
Fuser power cable
LVPS/HVPS
Fuser
Step 2: No continuity
Check the lamp cable for continuity.
(continued)
• If correct, replace the fuser.
• If incorrect, replace the lamp cable.
Disconnect the thermistor cable from J16 on the
controller card.
Measure the resistance across the ends of the
thermistor cable.
Fuser
Replace the fuser assembly if the resistance is
lower than 1K ohm or shorted.
Note: Resistance measures approximately
240K ohms when cool and 1K ohms hot.
2-88 Service Manual
4511-xxx
Cold fuser service check
Make sure the correct voltage lamp is installed. The voltage rating is
stamped on one of the lamp contacts.
FRU
Action
If the fuser lamp comes on and a fuser failure
light error code displays, be sure the thermistor
is contacting the hot roll, and the thermistor
cable is firmly seated in connector J6 on the
controller card.
Fuser AC cables
LVPS/HVPS
Fuser
Check for excessive toner buildup on the surface
of the thermistor. Clean as necessary.
With the printer unplugged, disconnect the
thermistor cable from J16 on the controller card.
Measure the resistance of the thermistor. The
resistance measures from approximately 1K
ohms immediately after printing or POR to
approximately 240K ohms when the thermistor
reaches room temperature. (It may take 30
minutes to cool.)
Replace the fuser assembly as necessary.
Hot fuser service check
Note: Ensure correct lamp is installed.
FRU
Fuser AC cables
LVPS/HVPS
Fuser
Action
Measure the resistance of the thermistor. The
resistance measures from approximately 1K
ohms immediately after printing or POR to
approximately 240K ohms when thermistor
reaches room temperature. (It may take 30
minutes to cool.)
Replace the fuser assembly as necessary.
Diagnostics—all models
2-89
4511-xxx
LVPS/HVPS service check
FRU
Action
LVPS portion of board
Fuses that open typically indicate a faulty LVPS/
HVPS.
LVPS/HVPS
Use the voltage meter to verify the appropriate
voltage at the printer end of the power cable.
Remove the LVPS/HVPS assembly from the
printer. Check continuity on the fuses. If either
fuse has opened, replace the card.
Ensure the switch is off, and plug the power cord
into the card. Turn the switch on.
CAUTION: The card has several points where
AC voltage is exposed.
Carefully verify the AC voltage between pins 1
and 2 of CN102 matches the power cable (wall)
voltage. If voltage is incorrect, replace the card
assembly.
Verify +24 V dc from pin 8 at CN201. If voltage
is incorrect, replace the card assembly.
HVPS portion of board
Problems with the HVPS are exhibited in the
print quality. See “Print quality service
checks” on page 2-98 for more information.
2-90 Service Manual
4511-xxx
Main motor service check
FRU
Action
Turn off the printer, and unplug the main motor
cable at J8. Turn on the printer, and check for
the following voltages at J8:
J8 pins
Voltages
Main motor cable
LVPS/HVPS
Controller card
Pins 1–4
Approx. +3.3 V dc
Pin 6
Approx. +5 V dc
Warning: Do not
replace the operator
panel and controller
card at the same time.
Each card contains the
printer settings. When
either of these cards is
new, it obtains the
settings from the other
card. Settings are lost
when both are new
and replaced at the
same time.
Pins 7–9
10 V dc–24 V dc
Verify ground at pin 5 for both the card and
cable.
• If these voltages are correct, check the main
motor cable for continuity.
– Remove rear cover to access connector on
motor.
– If continuity exists on each wire, call next
level of service.
– If continuity does not exist on one or more of
the wires, replace the motor cable.
• If these voltages are not correct, see
“Controller card connector pin values” on
page 5-4, or replace the controller card. See
“Controller card removal” on page 4-15.
Note: The main motor is not a service part.
Diagnostics—all models
2-91
4511-xxx
Operator panel service check (models E238, E240, and
E240n)
Inspect the operator panel cable for damage. Make sure the cable is
plugged in securely.
Run POST, and check each light for proper operation. See “Power-On Self
Test (POST) sequence” on page 2-2.
LED Operator panel service check
FRU
Action
Operator panel (LED)
Buttons
Open controller card cage and locate the
operator panel connector at J19.
Check for continuity between pins 1 and 2 of the
cable as you press the Continue
button.
Similarly, check the continuity between pins 1
and 6 of the cable while pressing Cancel
.
If continuity is not present, replace the operator
panel.
Note: Check margin alignments after replacing
the operator panel assembly. If margin errors
are unacceptable, corrections can only be made
through software. Contact the next level of
support.
2-92 Service Manual
4511-xxx
LED Operator panel service check (continued)
FRU
Action
Operator panel (LED)
Controller card
Lights
Warning: Do not
replace the operator
panel and controller
card at the same time.
Each card contains the
printer settings. When
either of these cards is
new, it obtains the
settings from the other
card. Settings are lost
when both are new
and replaced at the
same time.
If none of the lights come on, make sure the
cable is properly connected to the controller
card and the controller card has input voltage
to it.
Verify +24 V dc on cable pin 8 at J4.
• Check for +5 V dc at J19, pin 5. See
“Controller card service check” on
page 2-82.
• If these voltages are not correct, replace the
controller card.
• If these voltages are correct, replace the
operator panel.
If more than one light does not turn on, or an
individual light stays on solid during POST,
replace the operator panel.
If all lights are dim and operate erratically during
POST, or all lights come on and stay on solid
during POST, replace the FRUs in the following
order one at a time:
• Controller card
• Operator panel
Operator panel service check (models E340 and E342n)
Inspect the operator panel cable for damage. Make sure the cable is
plugged in securely. Run POST, and check for proper operation. See
“Power–On Self Test (POST) sequence” on page 2-50.
LCD operator panel service check
FRU
Action
Operator panel (LCD)
Enter Diagnostics mode (turn off the printer,
restart while holding Return and Go), and press
Menu until HARDWARE TESTS display. The first
two items, LCD Test and Button Test interactively
test the screen and buttons. The LED below the
Menu button is not tested, but can otherwise be
checked during POR. Also, it flashes when the
printer is working and stays on steady at Ready.
Diagnostics—all models
2-93
4511-xxx
Paper feed service checks
Paper jam error indication during POST
FRU
Action
Exit sensor
If the exit sensor flag is not resting within the
paper exit sensor during POST, the printer
displays a paper jam message. Make sure the
flag is operating freely and is correctly installed.
Input sensor #1 (under
print cartridge
assembly) and
Input sensor #2
(manual)
Make sure the input paper feed sensors are
working properly. A stuck or incorrectly installed
sensor causes this error.
Paper picks during POST and/or continuously
FRU
Action
ACM
(autocompensator
mechanism or paper
feed) clutch
Manual feed clutch
Check the ACM clutch for wear. The solenoid
interacts with the clutch to control the motion of
the pick tires.
If the ratchet teeth of the ACM clutch assembly
are worn or broken, the solenoid may not stop
the ACM from rotating. Replace the ACM clutch
assembly if necessary.
Check the manual feed clutch for the same
damage.
2-94 Service Manual
4511-xxx
Paper picks but stops halfway through the printer
FRU
Action
Input sensor #1 (under
print cartridge
assembly) and
Input sensor #2
(manual)
Make sure the input sensors are working
properly.
Check for a broken or stuck flag on the input
sensors.
Make sure the cables are seated on the
controller card at J9 (Tray 1 input) and J20
(manual input).
Check for about +5 V dc on pin 1 at J9 (Input
sensor #1) and pin 1 at J20 (Input sensor #2).
• If correct, replace the input paper feed sensor.
• If these voltages are not correct, replace the
controller card.
Paper never picks
FRU
Action
Paper feed (pick tires)
Open the left cover, and verify the solenoid and
clutch are functioning when an attempt is made
to feed the paper.
Make sure the rubber tires are installed and
clean.
Replace if necessary.
Diagnostics—all models
2-95
4511-xxx
Paper occasionally mispicks or picks multiple sheets at once
FRU
Action
Tray 1
Tray 2 (option)
Check tray for paper catch points.
If the sheet being fed stops momentarily, the
ACM applies additional vertical force, causing
additional sheets to feed.
Do not mix paper types in one tray.
Paper pick tires
Check the tires in the ACM assembly for signs of
wear or damage.
Replace the tires as necessary.
ACM clutch complete
bill of material (CBM)
Manual feed clutch
CBM
Open left cover, and observe the solenoid and
clutch actions at the ACM and manual feed
shafts as a print job is attempted.
Controller card
Disconnect the solenoid cable at J3 on the
controller card.
Replace the faulty part.
Measure the resistance across cable pins 1 and
2 and then pins 3 and 4.
• The resistance should be
180–250 ohms.
• If it is not, call the next level of service.
• If the resistance is 180–250 ohms, check the
controller card. See “Controller card service
check” on page 2-82 for more information.
Replace controller card as necessary.
Paper “trees,” wrinkles, stacks poorly, or curls
FRU
Action
Fuser
This problem is most likely due to a worn backup
roll. It causes the printer to run hotter than
required for the media being printed. Excessive
heat can cause paper treeing problems, poor
stacking, or curl.
2-96 Service Manual
4511-xxx
Parallel port service check (models E238, E240, and
E240n)
1. Perform a print test to make sure the printer prints correctly. Verify
is on, then press
to print menu settings.
2. Be sure the printer cable is designed for bidirectional printing.
3. Be sure the user’s application is set up correctly.
4. If the internal print test page prints correctly, the user’s application/
printer driver is set up correctly, and the correct bidirectional parallel
cable is installed, but the printer still fails to print on command from the
host computer, replace the controller card.
Parallel port service check (models E340 and E342)
1. Perform a print test to make sure the printer prints correctly. See “Print
quality pages (Prt Quality Pgs)” on page 3-23.
2. Be sure the printer cable is designed for bidirectional printing.
3. Be sure the user’s application is set up correctly.
4. Using an extra long parallel cable may require some adjustment in the
Par S strobe. See “Parallel strobe adjustment (Par S Strobe Adj)”
on page 3-30.
5. Some computers assume the printer samples data on the trailing edge
of the strobe. This printer samples data on the leading edge by default.
This process can be switched by turning Parallel Mode 2 off. To change
this setting:
a. Select PARALLEL MENU from the Ready Menu.
b. Select Parallel Mode 2.
Selections are On and Off.
6. If the printer fails to print on command from the host, verify the
following:
a.
b.
c.
d.
Internal print test page prints correctly.
The user application/printer driver is set up correctly.
The host computer has been restarted.
The bidirectional parallel cable is connected correctly and is
functional.
If the printer still fails to print correctly, replace the controller card
assembly.
Note: Always check printhead alignment after replacing the controller
card assembly.
Diagnostics—all models
2-97
4511-xxx
Print quality service checks
Note: Ensure cover closes tightly. A gap in the opening may allow light to
expose the photoconductor resulting in a ‘dirty’ print. Extreme
environmental conditions, temperatures, and humidity will affect the
print quality.
Using print quality test pages
To help isolate print quality problems, like streaking, print test pages using
the print quality test pages.
Models E238, E240, and E240n
To print the print quality test pages:
1. Enter Configuration Menu.
a. Turn off the printer.
b. Open the front access cover.
c. Turn on the printer while pressing and holding
.
d. When
light stays on, close cover.
e. Wait (approximately 10 seconds) until the printer drive activates.
2. Slowly press and release
come on.
3. Press and hold
test pages.
three times until the
and
lights
until all the lights flash to initiate printing the quality
Four pages print to help you evaluate print quality. The first page has
various fonts and a graphic, the second page is gray with graphics, the
third page is black, and the last page is blank. Once the paper exits into
the output bin, the printer returns to the home state (four top lights on).
4. Use the test pages to isolate problems such as light or toner streaks.
See “POST symptom table” on page 2-79 for solutions to these
problems.
To exit print quality test pages, turn the printer off.
Models E340 and E342n
To print the print quality test pages:
1. Enter Configuration Menu.
a. Turn the printer off.
b. Press and hold Select and Return.
c. Turn the printer on.
d. Release the buttons when Performing Self Test displays.
2. Select Prt Quality Pgs.
2-98 Service Manual
4511-xxx
3. Press Go.
Four pages print to help you evaluate print quality. The first page has
various fonts and a graphic, the second page is gray with graphics, the
third page is black, and the last page is blank.
4. Use the test pages to isolate problems such as light or toner streaks.
See “POST symptom table” on page 2-79 for solutions to these
problems.
To exit, press Menu until Exit Config Menu appears, and press Select.
Blank page
FRU
Action
Toner cartridge (not a
FRU)
Remove the toner cartridge, and gently shake it
to evenly distribute the toner.
Check for cartridge damage.
Blank pages can be caused by a defective
printhead assembly,
LVPS/HVPS, or controller card.
Printhead
LVPS/HVPS
Controller card
Toner electrodes
(cable assembly)
• Printhead errors typically result in printer
service errors.
• Blank pages typically are caused by the PC
roll not being properly charged. Try a different
PC kit.
Unplug the printer, and check the cable
continuity between the LVPS/HVPS connector
marked OPC and the corresponding wire form
(spring) found about 14 mm above and to the
right of the transfer roll gear.
• If there is not continuity, call the next level of
service.
Try a different toner cartridge and PC kit.
• If those fail, replace the LVPS/HVPS.
Diagnostics—all models
2-99
4511-xxx
Black page
Note: Incorrect laser exposure or incorrect charging of the photoconductor
causes an all black page. Always verify the same results from a
different print cartridge assembly and developer before proceeding.
FRU
Action
Toner electrodes (not a
FRU)
Check the three rearward electrodes below the
print cartridge assembly for contamination or
damage. Correct as necessary.
Check continuity between the cable (DEV, TAR,
and doctor blade) connection CN203 and on the
contact tips below the print cartridge assembly.
• If continuity fails, call the next level of service.
With the printer off, disconnect the LVPS/HVPS
cable from J4 on the controller card.
Turn the printer on, and verify +24 V dc on pin 8
of the cable.
LVPS/HVPS board
Controller card
2-100 Service Manual
Verify ground on pin 7.
• If the voltage is incorrect, replace LVPS/
HVPS board.
• If voltage is correct and the toner electrodes
are good, replace the controller card.
• See the “LVPS/HVPS service check” on
page 2-90 and the “Controller card service
check” on page 2-82, if necessary.
4511-xxx
Heavy background
Poor development or poorly charged toner particles cause excessive
background. This is more noticeable as the toner cartridge nears end–of–
life.
FRU
Action
Toner cartridge (not a
FRU)
PC Kit (not a FRU)
Make sure the toner cartridge and PC Kit are
correctly installed and the high voltage contacts
are clean.
If the toner cartridge and PC Kit are installed
correctly, try a new PC Kit first and then toner
cartridge.
Check the contacts for correct installation and
contamination where contact is made between
the print cartridge assembly and LVPS/HVPS
board. Clean as necessary.
LVPS/HVPS
Controller card
If this does not correct the problem, replace the
following FRUs one at a time in the order shown:
• LVPS/HVPS board
• Controller card
Partial blank image/white spots (no repeating pattern)
FRU
Action
Toner cartridge (not a
FRU)
Remove the toner cartridge assembly, and
gently shake the assembly to evenly distribute
the toner.
If toner cartridge is low, try a new one.
Paper (not a FRU)
Make sure recommended paper is being used.
Diagnostics—all models
2-101
4511-xxx
Variation in image density horizontally across page
FRU
Action
PC Kit (not a FRU)
The charge roll may have an unbalanced
pressure against the PC (photoconductor) drum.
Try a new PC Kit.
Transfer roll
Check the springs in the left and right transfer
roll bearings. The bearing assemblies should
support the transfer roll, applying even pressure
to the PC drum.
Replace the transfer roll assembly if the springs
or bearing show signs of damage or fatigue.
Inspect the transfer roll for signs of wear,
damage or contamination.
Replace as necessary.
Poor fusing of image
FRU
Action
Fuser
The fuser may not be operating at the proper
temperature to fuse the toner to the paper.
See“Hot fuser service check” on page 2-89
for more information.
Paper (not a FRU)
Make sure recommended paper is being used.
2-102 Service Manual
4511-xxx
Light print
FRU
Action
Toner cartridge (not a
FRU)
Make sure the toner cartridge and PC Kit are
installed correctly and that the toner cartridge is
not low on toner.
If the problem continues, install a new toner
cartridge.
Recheck condition before replacing PC Kit, if
necessary.
Check the transfer roll for signs of toner buildup
and contamination.
Inspect the HVPS contact (transfer roll) for
contamination.
Transfer roll
LVPS/HVPS board
Verify the high voltage cable is plugged into the
LVPS/HVPS.
If all components appear free of contamination,
replace the following FRUs one at a time in the
order shown:
• Transfer roll
• LVPS/HVPS board
White or black lines or bands
FRU
Action
Print cartridge
assembly (not a FRU)
Banding appears as light or dark horizontal lines
on a uniformly gray page or on a page with a
large area of graphics. Banding is primarily due
to a variation in the speed of the paper as it
feeds through the printer, especially in the
developer and transfer process.
Developer drive
coupling assembly
Inspect the toner cartridge and paper feed
components, especially the drive coupler and
drive gears for debris, binds, or damage.
Diagnostics—all models
2-103
4511-xxx
Toner on back of page
FRU
Action
PC Kit (not a FRU)
Inspect the overall paper path for signs of spilled
toner.
Gently clean the contaminated areas with a soft
cloth or compressed air.
Fuser
The fuser hot roll can cause toner deposits on
the back of the paper if toner is building up on
the hot roll. This buildup may transfer to the
backup roll, later transferring to the back of the
paper.
Inspect the hot roll and backup roller for signs of
contamination.
Replace the fuser as necessary.
Transfer roll
A transfer roll contaminated with toner can
cause toner to transfer to the back of printed
pages.
Inspect the transfer roll for contamination, and
replace as necessary.
2-104 Service Manual
4511-xxx
Solving print quality problems
Print quality problems
Problem
Action
Light or blurred
characters.
Light print
The toner cartridge may be getting low on toner:
• Remove the toner cartridge and print
cartridge assembly.
• Shake it from side to side to redistribute the
toner.
• Reinstall it and recheck for condition.
• Make sure you are using recommended print
media (see media types and sizes in the
User’s Reference).
• Use MarkVision to define the custom type
setting for media type, media texture, or
media weight.
• The toner cartridge or PC Kit may be
defective. Replace the PC Kit first and
recheck.
Blurred characters
Blurred images, including characters, are
usually caused by a defective printhead. See
“Light print” on page 2-103.
Toner smudges appear
on the front or back of
the page.
• Make sure the paper is straight and
unwrinkled.
• Replace the PC Kit and recheck before
replacing the toner cartridge. See “Toner on
back of page” on page 2-104 for more
information.
Diagnostics—all models
2-105
4511-xxx
Print quality problems (continued)
Problem
Action
Vertical or horizontal
streaks appear on the
page.
Replace the toner cartridge for vertical black
streaks.
Wipe the glass lens clean with a soft tissue for
vertical “white” streaks.
For horizontal streaks, see “White or black
lines or bands” on page 2-103 for more
information.
Toner smears or rubs
off the page.
• Replace the fuser. The toner is not being
fused. See “Cooling fan service check” on
page 2-81 for more information.
• Try a different kind of paper. Paper designed
for copiers gives the best quality fusing.
• If you are printing on special media, such as
card stock or labels, be sure you select the
correct paper type in the printer driver.
• Change the media texture setting. If the
setting is not in your driver, you can download
the correct Lexmark setup utility from the
Lexmark Web site at www.lexmark.com.
The print is getting
light but the printer has
not indicated it is low
on toner.
• The
light nor Toner Low message do
not display if the standard 1,500 page toner
cartridge is installed.
• Remove the toner cartridge and gently shake
it from side to side to redistribute the toner.
• Replace the toner cartridge.
The
light is on
(E238, E240, and
E240n) or Toner Low
displays (E240 and
E242n).
• Remove the toner cartridge and gently shake
it from side to side to redistribute the toner.
• Replace the toner cartridge.
2-106 Service Manual
4511-xxx
Print quality problems (continued)
Problem
Action
Solid black areas on
transparencies or
white streaks on paper.
• Choose a different fill pattern in your software
program.
• Try a different type of paper. Paper designed
for copiers gives the best quality.
• Remove the toner cartridge, and gently shake
it from side to side to redistribute the toner.
• Replace the toner cartridge.
Faint images or
repetitive spots appear
on the page.
• Select a different media type or form type
setting from your printer driver.
• Try a different type of paper. Paper designed
for copiers gives the best quality.
• Replace the toner cartridge.
Pages are blank.
• The print cartridge may be out of toner or
defective. Replace the cartridge.
• You may have a software error. Try turning the
printer off and back on.
• Check the printhead. See “Paper feed
service checks” on page 2-94 for more
information.
Diagnostics—all models
2-107
4511-xxx
Print quality problems (continued)
Problem
The printer is on, but
nothing prints.
Toner Low light is on
and printing stops.
Action
• Make sure the toner cartridge assembly is
installed properly.
• Make sure the parallel or USB cable is not
damaged and is firmly plugged into the
connector on the back of the printer.
• Press and release
to print a menu
settings page (E238, E240, E240n), or press
Menu to select Utilities Menu, and then select
Print Menus (E340, E342n).
– If you cannot print a menu settings page,
contact the next level of support.
– If you can print a menu settings page, the
problem is one of the following:
• Computer
• Software program
• Cable
• (USB only) failed ASIC or controller card.
Replace card.
Note: Test by unplugging USB and
replugging it with the printer on. If the
computer indicates “unknown device,”
replace the card.
If you are using a 3,000 or 6,000 page toner
cartridge and the Toner Low alarm is set to on,
the printer stops printing until you replace the
toner cartridge.
Download the correct Lexmark setup utility from
the Lexmark Web site at www.lexmark.com to
change the Toner Low alarm.
The Error light is on
(E238, E240, E240n).
Make sure the printer cover is closed.
The Toner Low light is
blinking, and the Error
light is on (E238, E240,
E240n).
• Make sure the toner cartridge is installed
correctly.
• Install a new toner cartridge.
The media skews or
buckles.
• Don’t overfill Tray 1 or the optional Tray 2 (see
media capacities in the media types and sizes
table in the User’s Reference).
• Make sure the paper guides are flush against
the edges of the media.
2-108 Service Manual
4511-xxx
Print quality problems (continued)
Problem
Action
The paper sticks
together, resulting in
the printer feeding
multiple sheets of
paper.
• Remove the paper from Tray 1 or the optional
Tray 2, and fan it.
• Don’t overfill Tray 1 or the optional Tray 2 (see
media capacities in the media types and sizes
chart in the User’s Reference).
The paper fails to feed
from Tray 1.
• Remove the paper from Tray 1, and fan the
paper.
• Make sure Tray 1 is selected from the printer
driver. For E340/E342n, make sure the proper
tray and paper type is selected from the
printer.
• Do not overfill the tray.
• Check the condition of the rubber on the
paper feed rolls.
• Verify clutch for ACM is functioning correctly.
The paper fails to feed
from the optional
Tray 2.
• Make sure the correct tray and paper type are
selected from the driver. For E340/E342n,
make sure the correct tray and paper type is
selected from the printer.
• Make sure the tray is pushed all the way in.
• Remove the paper from the optional Tray 2,
and fan it.
• Check the rubber on the paper feed tires.
• Check the paper path in the tray for burrs or
debris that may hinder paper movement.
• Make sure the paper does not exceed the
stack height indicator.
The Load Paper light is
on even though there
is paper loaded in the
optional Tray 2.
• Make sure the tray is pushed all the way in.
• Press
or Go.
The printer does not
print after a paper jam
has been cleared.
• Clear all jams.
• Press and release
(E238, E240, E240n)
or Go (E340, E342n), or open and close the
printer cover to restart the printer.
• Make sure the print cartridge assembly is
installed properly.
Diagnostics—all models
2-109
4511-xxx
Print quality problems (continued)
Problem
Action
Unexpected characters
print or characters are
missing.
• Ensure correct printer driver is being used.
• Select hex trace mode to determine what the
problem is.
• Restore factory defaults.
• Make sure the parallel cable or USB cable is
firmly plugged in at the back of the printer.
Jobs are not printing,
and the error light is on
solid.
• Make sure the print cartridge assembly is
installed properly.
• Make sure the printer top cover is closed.
While in PostScript 3
emulation, the printer
is flushing data
(Ready/Data and Error
lights are blinking).
• Ensure the correct PostScript driver is being
used.
• The printer doesn’t have enough memory to
print the job. Install more memory.
While using manual
duplex, the printer gets
a paper jam.
A paper jam interrupts the duplex process. As a
result, the information on the page that jammed
is lost.
• Press and release
to cancel the print job
(E238, E240, E240n) or press Menu and
select Cancel (E340, E342n).
• Press and hold
(approximately 3
seconds) to reset the printer.
• Resend the print job.
2-110 Service Manual
4511-xxx
Printhead service check
FRU
Action
Unplug the printer.
Disconnect the printhead cables from J13 and
J14 on the controller card.
Turn the printer on.
Printhead
On the controller card, verify +24 V dc on pin 5
at J13 and +5 V dc on pin 7 at J14.
Verify grounds on pin 4 at J13 and on pins 2, 6,
and 8 at J14.
• If voltages or grounds are incorrect, check the
controller card. See “Controller card service
check” on page 2-82 for more information.
• If voltages are correct, replace the printhead
(comes with cables).
Transfer roll service check
FRU
Action
Check transfer roll area for debris, and clean
area as necessary.
Verify continuity between the spring below the
left side bearing and the transfer roll shaft.
Transfer roll
Verify continuity in the spring and the cable
connection on the LVPS/HVPS.
Inspect the roll for signs of wear or damage and
replace if necessary.
Diagnostics—all models
2-111
4511-xxx
2-112 Service Manual
4511-xxx
3. Diagnostic aids
Since the operator panels differ, you need to determine which model you are
servicing, and begin in the section below:
• Model E240 and E240n—go to “Accessing service menus” on
page 3-2.
• Model E340 and E342n—go to “Accessing service menus” on
page 3-14.
Diagnostic aids
3-1
4511-xxx
Diagnostic aids—E238, E240, and E240n3
Accessing service menus
Diagnostics
mode
1. Turn off the printer.
2. Open the front access
cover.
3. Press and hold
while turning on the
printer.
4. Close cover once the
light is displayed.
1. Turn off the printer.
Enter
Configuration 2. Open the front access
Menu
cover.
3. Turn on the printer while
pressing and holding
.
4. Close cover once the
light is displayed.
Reset
NVRAM and
enter normal
mode
The diagnostic group contains
menu settings and operations
that are useful in the
manufacturing of the printer. It
also features other aids in
diagnosing problems.
See “Diagnostics mode
printout sample” on page 3-4
or “Diagnostics mode
selections” on page 3-11 for
details on the available settings.
The configuration group contains
a set of menus, configuration
settings, and operations which
are not used by an end user.
See “Configuration Menu
printout sample” on page 3-3
or “Configuration menu
selections” on page 3-6 for
details on the available settings.
1. Turn off the printer.
2. Open the front cover.
3. Press and hold both
and
buttons
pressed.
4. Close cover once the
light is displayed.
Printing menus
Print menus by pressing and holding
samples on page 3-3 and page 3-4).
3-2 Service Manual
until the lights flash (see menu
4511-xxx
Configuration Menu printout sample
Diagnostic aids—E238, E240, and E240n
3-3
4511-xxx
Diagnostics mode printout sample
3-4 Service Manual
4511-xxx
Moving around the menu
“Configuration Menu printout sample” on page 3-3 and “Diagnostics
mode printout sample” on page 3-4 are similar to the instructions printed
by following steps 1–6 on page 3-2. These menu items are designated by
the non–indented items listed along the left edge of the page (Bottom as
printed from printer). These items are also un–shaded.
• Press and release
to move sequentially from one menu item to
another.
• Press and hold
to jump to home state (top four lights on).
• Press and release
to move through the menu settings (indicated
by
and
lights).
This action rotates only through the possible settings of the selected
menu item.
Diagnostic aids—E238, E240, and E240n
3-5
4511-xxx
Configuration menu selections
To enter Configuration menu, turn off the printer, open the front access
cover, turn on the printer while pressing and holding
, and close the
cover once the
light displays.
Print menus by pressing and holding
until the lights flash.
Utilities
Use the Utilities menu to troubleshoot printer problems.
Setting
Use setting to
Values
Reset
Factory
Defaults
Return the printer settings to factory default values.
Sometimes resetting the printer to the original settings solves
formatting problems.
All menu items are reset to the factory default values except:
• Display Language.
• All settings in the Parallel menu, Network menu, LocalTalk
menu, and USB menu.
• All downloaded resources (fonts, macros, and symbol
sets) in printer memory (RAM) are deleted.
Resources in flash memory are unaffected.
Hex Trace
Help isolate printing
problems when
unexpected characters
print or characters are
missing.
Hex Trace helps
determine if there is a
problem with the
language interpreter or
the cable by providing
information about what
the printer is receiving.
To exit Hex Trace, turn off
the printer.
3-6 Service Manual
Off (default)
On
4511-xxx
Setting
Use setting to
Values
Print Quality
Test Pages
Help isolate print quality problems, such as streaking. Four
pages print to help evaluate print quality:
• A text page with printer information, cartridge information,
current margin settings, and a graphic.
• One page is gray with graphics, one is black, and one is
blank.
Reset Photoconductor
Counter
Return the photoconductor counter to zero.
The replace photoconductor message should be cleared only
when the photoconductor kit has been replaced.
Setup
Use the Setup menu to configure how the printer formats the end of a line
depending on the computer system being used.
Menu item
Use setting to
Values
Demo Mode
Put printer into demo
mode where internal
sheets print with each
press of
.
Deactivate (default)
Activate
To deactivate, turn the
printer off, and re-enter
configuration group. Set
to deactivate.
Auto CR
After LF
Specify whether the
printer automatically
performs a carriage
return after a line feed
control command.
Off (default)
Auto LF after
CR
Specify whether the
printer automatically
performs a line feed after
a carriage return control
command.
Off (default)
On
On
Diagnostic aids—E238, E240, and E240n
3-7
4511-xxx
Parallel
Use the Parallel menu to change printer settings on jobs sent through a
parallel port.
Menu item
Use setting to
Values
NPA Mode
Send print jobs to the
printer and query printer
status information
simultaneously.
Off
Receive information at a
much higher transmission
rate if your printer is set to
Fastbytes (if your
computer supports
Fastbytes) or receive
information at a normal
transmission rate if your
printer is set to Standard.
Standard
Parallel
Mode 2
Determine whether the
parallel port data is
sampled on the leading
(On) or trailing (Off) edge
of strobe.
Off
MAC Binary
PS
Configure the printer to
process Macintosh binary
PostScript print jobs.
Off—The printer filters
PostScript print jobs using
Standard protocol.
Protocol
On
Auto (default)
Fastbytes (default)
On (default)
On—The printer processes raw
binary PostScript print jobs from
computers using the Macintosh
operating system. This setting
often causes Windows print jobs
to fail.
Auto (default)—The printer
processes print jobs from
computers using either
Windows or Macintosh
operating systems.
3-8 Service Manual
4511-xxx
USB
Use the USB menu to change printer settings on jobs sent through a USB
port.
Menu item
Use setting to
Values
NPA Mode
Send print jobs to the
printer and query printer
status information
simultaneously.
Off
Configure the printer to
process Macintosh binary
PostScript print jobs.
Off—The printer filters
PostScript print jobs using
Standard protocol.
MAC Binary
PS
On
Auto (default)
On—The printer processes raw
binary PostScript print jobs from
computers using the Macintosh
operating system. This setting
often causes Windows print jobs
to fail.
Auto (default)—The printer
processes print jobs from
computers using either
Windows or Macintosh
operating systems.
Diagnostic aids—E238, E240, and E240n
3-9
4511-xxx
Network
Use the network menu to change printer settings on jobs sent through a
network port (either standard network or network opt <x>).
Menu item
Use setting to
Values
NPA Mode
Send print jobs to the
printer and query printer
status information
simultaneously.
Off
Configure the printer to
process Macintosh binary
PostScript print jobs.
Off—The printer filters
PostScript print jobs using
Standard protocol.
MAC Binary
PS
Auto (default)
On—The printer processes raw
binary PostScript print jobs from
computers using the Macintosh
operating system. This setting
often causes Windows print jobs
to fail.
Auto (default)—The printer
processes print jobs from
computers using either
Windows or Macintosh
operating systems.
Set Card
Speed
Automatically detect the
connection speed of your
network.
This setting can be
disabled to set the speed
manually.
Auto (default)—the printer
detects current network speed.
10Mbps, half duplex—forces the
printer to try to connect to the
network only at 10Mbps, half
duplex.
10Mbps, full duplex—forces the
printer to try to connect to the
network only at 10Mbps, full
duplex.
100Mbps, half duplex—forces
the printer to try to connect to
the network only at 100Mbps,
half duplex.
100Mbps, full duple—forces the
printer to try to connect to the
network only at 100Mbps, full
duplex.
3-10 Service Manual
4511-xxx
Diagnostics mode selections
To enter Diagnostics mode, turn off the printer, open the front access cover,
press and hold
while turning on the printer, and close the cover when
the
light displays.
Print menus by pressing and holding
until the lights flash.
Development
Menu item
Use setting to
Value
Edge to
Edge
Allow a shift of all four
margins (top, bottom,
right, and left) to the
physical edge of the page
(printable area of
supported paper).
Off (default)
On
Setting is ignored by
PPDS interpreter.
Print quality
pages
Print test pages by
pressing and holding
until the lights flash.
Help isolate print quality
problems, such as
streaking. Four pages
print:
• A text page with printer
information, cartridge
information, current
margin settings, and a
graphic.
• Three pages all gray,
all black, and the last
one blank.
Note: Cartridge lockout
function is disabled.
Continuous
print—
simplex
Tray 1
Continuously print pages
containing cross lines,
printer information, and
margin settings.
Press and hold
until
the lights flash to begin.
Press
to stop.
Diagnostic aids—E238, E240, and E240n
3-11
4511-xxx
Development (continued)
Menu item
Use setting to
Continuous
print—
simplex
Tray 2
Continuously print pages
containing cross lines,
printer information, and
margin settings.
Value
This menu item does not
appear if Tray 2 is not
installed.
Press and hold
until
the lights flash to begin.
Press
Print History
to stop.
Print history of errors.
Press and hold
until
the lights flash to print.
Defaults
Change sizes and
designations to metric.
U.S. (default)
Allow the printer ID to
match the label ID after
the controller card is
replaced.
000101 (default)
Menu item
Use setting to
Value
Par S Strobe
Adjustment
Adjust for an unusually
long parallel cable.
(Parallel mode 2 only is
supported and can be
turned off in the
configuration group.)
Range from -1 to 3,
0 is default.
Configuration
ID
Non-U.S.
000189
Parallel
3-12 Service Manual
4511-xxx
Network
Menu item
Use setting to
History
Print history of errors.
Value
Press and hold
until
the lights flash to print.
Mark History
History Mode
Dump
NVRAM
Append a tag to the
history report to indicate
the most recent crashes.
Mark
Post the 976 error code to
the user each time it
occurs. The default
(modified) internally
resets the posting but
records it in the crash
history. A substantial
number of consecutive
errors result in posting
976.
Modified (default)
Do not mark (default)
Every time
Print a hex dump if the
network NVRAM partition.
Press and hold
until
the lights flash to initiate
this action.
Reinit
NVRAM
Rest the network NVRAM
to factory defaults.
Press and hold
until
the lights flash to initiate
this action.
Meditech
Mode
Prevent the network card
from accepting more than
one 9100 mode
connection at a time.
Yes
No (default)
Diagnostic aids—E238, E240, and E240n
3-13
4511-xxx
Diagnostic aids—E340 and E342n
3
Accessing service menus
There are different test menus that can be accessed during POR to identify
problems with the printer.
Configuration
Menu
1. Turn off the printer.
2. Press and hold Select and
Return.
3. Turn on the printer.
4. Release the buttons when
Performing Self Test
displays.
The Configuration Menu
group contains a set of
menus, settings, and
operations which are
infrequently required by a
user. Generally, the options
made available in this menu
group are used to configure a
printer for operation.
See “Available menus” on
page 3-15.
Diagnostics
Mode
1. Turn off the printer.
2. Press and hold Go and
Return.
3. Turn on the printer.
4. Release the buttons when
Performing Self Test
displays.
The Diagnostics Mode group
contains the settings and
operations used while
manufacturing and servicing
the printer.
See “Available tests” on
page 3-19.
Printing menus
To print a listing of the menus:
1. At the Ready prompt, press Menu until Utilities appears.
2. Press Select.
3. Press Menu until Print Menus appears.
4. Press Select.
3-14 Service Manual
4511-xxx
Configuration menu (CONFIG MENU)
Entering Configuration Menu
1. Turn off the printer.
2. Press and hold Select and Return.
3. Turn on the printer.
4. Release the buttons when Performing Self Test displays.
The message CONFIG MENU displays on the top line of the operator
panel.
Available menus
Reset PC Cnt
See “Reset PC Cnt” on page 3-16.
Prt Quality Pgs
See “Print quality pages (Prt Quality Pgs)”
on page 3-16.
Panel Menus
See “Panel Menus” on page 3-16.
PPDS Emulation
See “PPDS Emulation” on page 3-16.
Download Emuls
See “Download Emuls” on page 3-17.
Demo Mode
See “Demo Mode” on page 3-17.
Factory Defaults
See “Factory Defaults” on page 3-17.
Energy Conserve
See “Energy Conserve” on page 3-17.
ERROR LOG (print log only) See “Error log” on page 3-18.
Paper Prompts
See “Paper Prompts” on page 3-18.
Env Prompts
See “Env Prompts” on page 3-18.
Exit Config Menu
Some menus are not available, depending on the configuration of the
printer.
Diagnostic aids—E340 and E342n
3-15
4511-xxx
Reset PC Cnt
When you install a new photoconductor, this number should be reset.
To reset the counter:
1. Select Reset PC Cnt from the CONFIG MENU.
2. Press Select to reset the counter to zero.
Note: Permanent page count is not affected by this operation.
Print quality pages (Prt Quality Pgs)
To print the Print Quality Pages:
1. Select Prt Quality Pgs from CONFIG MENU.
2. Press Select.
Four pages print. Additional button presses are ignored until the pages
have printed. If duplex is selected, the pages print front and back.
The first page is a mix of graphics and text. The second two pages are
graphics, and the last page is blank.
The Print Quality Pages can also be printed from the Diagnostics Mode.
Panel Menus
If no password is set, Panel Menus lets you restrict access to the Ready
Menu Group. When a password is set by an administrator, this menu item
does not appear.
1. Select Panel Menus from the Diagnostics Mode.
2. Select Disable to make menus in the Ready Menu Group inaccessible.
To change the setting, select Panel Menus, and select Enable to make the
menus available.
PPDS Emulation
This menu lets you turn on PPDS emulation, if desired.
1. Select PPDS Emulation from CONFIG MENU.
2. Select Activate to enable PPDS emulation and Deactivate to turn it
off.
3-16 Service Manual
4511-xxx
Download Emuls
This menu item only displays if a downloaded emulator is installed.
To disable downloaded emulations:
1. Select Download Emuls from CONFIG MENU.
2. Select Disable.
The printer performs a POR and starts as if the downloaded
emulations were not loaded.
To reactivate downloaded emulations, restart the printer.
Demo Mode
This menu item lets you turn demo mode on or off.
1. Select Demo Mode from CONFIG MENU.
2. Select Activate to turn the demo mode on or Deactivate to turn demo
mode off.
Factory Defaults
This menu lets you restore the printer settings to their factory default values.
1. Select Factory Defaults from the Configuration Menu.
2. Select either Restore Base or Restore Network. Restore Network is
only available if an integrated network adapter is installed.
Energy Conserve
Select On to allow access to the Power Saver menu. If you select Off, an
additional item appears in the Power Saver menu. Disable lets you enable
or disable Power Saver from the customer menu.
Diagnostic aids—E340 and E342n
3-17
4511-xxx
Error log
See “Error log” on page 3-32 for a more detailed description. The error log
printed from the Diagnostics Mode contains additional debug information for
9xx errors than the error log printed from the Configuration Menu. You can
also view or clear the log from the Diagnostics Mode.
Print Log
Additional diagnostic information is available when you print the error log.
This report can also be printed from the Diagnostics Mode. See “Print Log”
on page 3-33. Also, the error log printed from the Diagnostics Mode
contains additional debug information for 9xx errors than the error log
printed from the Configuration Menu. Because you can clear error logs you
can view, the contents of this log may not match the contents when you view
the error log.
To print the error log:
1. Select Print Log from the Error Log menu.
2. Press Return to exit the Error Log menu.
Paper Prompts
Setting Paper Prompts controls which tray a change prompt is directed to
when paper is sensed to be the wrong size. Selections include Auto and
Manual Paper.
Env Prompts
Setting Env Prompts controls which tray a change prompt is directed to
when envelopes are sensed to be the wrong size. Selections include Auto
and Manual Env.
Exit Config Menu
Select Exit Config Menu to exit the Configuration Menu and return to
normal mode.
3-18 Service Manual
4511-xxx
Diagnostics mode
Available tests
The tests display on the operator panel in the order shown:
Diagnostics mode tests
REGISTRATION
See “Registration” on page 3-21.
Bottom Margin
Top Margin
Left Margin
Right Margin
Quick Test
See “Quick Test” on page 3-22.
PRINT TESTS
Tray 1
See “Input source tests” on page 3-22.
Tray 2 (if installed)
Manual Feeder
Prt Quality Pgs
See “Print quality pages (Prt Quality Pgs)”
on page 3-23.
HARDWARE TESTS
LCD Test
See “LCD Test” on page 3-23.
Button Test
See “Button Test” on page 3-23.
DRAM Test
See “DRAM Test” on page 3-24.
Parallel Wrap
See “Parallel Wrap” on page 3-25.
INPUT TRAY TESTS
Feed Tests
See “Feed Tests (input tray)” on page 3-26.
Sensor Test
See “Sensor Test (input tray)” on page 3-27.
BASE SENSOR TEST
See “Base sensor test” on page 3-28.
Front Door
Toner
Input
Output
Standard Bin
DEVICE TESTS
Flash Test (if installed)
See “Flash Test” on page 3-28.
Diagnostic aids—E340 and E342n
3-19
4511-xxx
Diagnostics mode tests (continued)
PRINTER SETUP
Defaults
See “Defaults” on page 3-29.
Page Count
See “Page Count” on page 3-29.
Perm Page Count
See “Perm Page Count (permanent page
count)” on page 3-29.
Serial Number
See “Serial Number” on page 3-30.
Engine Setting 1
through 4
See “Engine Setting 1 through 4” on
page 3-30.
Model Name
See “Model Name” on page 3-30.
Configuration ID
See “Configuration ID” on page 3-30.
Edge to Edge
See “Edge to Edge” on page 3-30.
Par S Strobe Adj
See “Parallel strobe adjustment (Par S
Strobe Adj)” on page 3-30.
EP SETUP
EP Defaults
See “EP Defaults” on page 3-31.
Fuser Temp
See “Fuser Temperature (Fuser Temp)” on
page 3-31.
Transfer
See “Transfer” on page 3-31.
Print Contrast
See “Print Contrast” on page 3-31.
Charge Roll
See “Charge Roll” on page 3-31.
Gap Adjust
See “Gap Adjust” on page 3-31.
ERROR LOG
Display Log
See “Display Log” on page 3-32.
Print Log
See “Print Log” on page 3-33.
Clear Log
See “Clear Log” on page 3-33.
EXIT DIAGNOSTICS
3-20 Service Manual
4511-xxx
Registration
To set print registration:
1. Select REGISTRATION from the Diagnostics menu.
The Top margin sign/value pair blinks. This indicates it is the margin
value being changed.
T=sxx*
L=sxx*
B=sxx*
R=sxx*
2. To select the margin value to be changed, press Select until the margin
value pair you want to change is blinking.
The print registration range is:
Variable
Description
Value
s
sign
blank for positive values, “-” for
negative values
B=
Bottom margin
-20 to +20—Each increment causes
approximately 0.55 mm shift in the
bottom margin.
T=
Top margin
-16 to +16
L=
Left margin
-25 to +25
R=
Right margin
-10 to +10
3. To change the margin value, press Menu. When the value you want
displays, press Select to save the value.
To verify the margin values are correct, you must print the Quick Test
page. Press Go to print the test page. While printing, Quick Test
Printing displays. Once the Quick Test page completes printing, the
registration screen displays again.
4. To exit, press Return.
5. To Test the setting by printing the Quick Test page for all the source,
see “Quick Test” on page 3-22. Select all the available sources.
Print the Quick Test Page on letter or A4 paper.
Diagnostic aids—E340 and E342n
3-21
4511-xxx
Quick Test
The Quick Test contains the following information:
•
•
•
•
Print registration settings
Alignment diamonds at the top and bottom
Horizontal lines to check for skew
General printer information, including current page count, installed
memory, serial number, and code level.
To print the Quick Test page:
Note: Print the Quick Test Page on letter or A4 paper.
1. Select REGISTRATION from DIAGNOSTICS.
2. Press Go.
Once the Quick Test Page completes printing, the Registration screen
displays again.
Print tests
Input source tests
Input source print tests can verify that the printer can print on media from
the installed input sources. Only installed sources appear in the menu.
To run the input source test:
1. Select PRINT TESTS from Diagnostics Mode.
2. Select the input source from the sources displayed on the Feed Test
menu. All installed sources are listed.
Menu selections
Description
Tray 1
Standard tray
Tray 2*
Optional tray
* If installed
3. Select either Single (feeds one sheet of blank media from the selected
source) or Continuous (continues feeding blank media from the
selected source until Return or Stop is pressed).
Press Return or Stop to exit the test.
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Print quality pages (Prt Quality Pgs)
To print the Print Quality pages:
1. Select PRINT TESTS from Diagnostics Mode.
2. Select Prt Quality Pgs.
3. Press Select.
Four pages print. Additional button presses are ignored until the pages
have printed.
The first page is a mix of graphics and text. The second two pages are
graphics, and the last page is blank.
The Print Quality pages can also be printed from the Configuration Menu.
Hardware tests
Select the following selections from HARDWARE TESTS:
•
•
•
•
•
LCD Panel
Buttons
Op Panel
DRAM
Parallel Port
LCD Test
This test continuously executes a pattern.
1. Select LCD Test from Diagnostics Mode. The test continually
executes.
2. Press Return or Stop to cancel the test.
Button Test
1. Select Button Test from Diagnostics Mode.
With no buttons pressed, several occurrences of OP (Open) appear on
the display.
OP
OP
OP
OP
OP
OP
2. To test the proper operation of each button, press each button on the
operator panel one at a time, and a CL (Closed) displays in place of
an OP.
3. Press Return or Stop to cancel the test.
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DRAM Test
The purpose of this test is to check the validity of DRAM, both standard and
optional. The test writes patterns of data to SDRAM to verify that each bit in
memory can be set and read correctly.
To run the SDRAM Memory Test:
1. Select DRAM Test from the menu. The power indicator blinks
indicating the test is in progress.
DRAM Test
P:######
xxxMb
F:#####
xxxMB represents the amount of installed DRAM memory in MB.
P:###### represents the number of times the memory test has
passed and finished successfully. Initially 000000 displays with the
maximum pass count being 999,999.
F:##### represents the number of times the memory test has failed
and finished with errors. Initially 00000 displays with the maximum fail
count being 99,999.
2. Once the maximum pass count or fail count is reached, the test stops,
the power indicator is turned on solid, and the final results display. If the
test fails, the message DRAM Error displays for approximately three
seconds and the failure count increases by 1.
Turn the power off if you want to stop the test before it completes.
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Parallel Wrap
This test is used with a wrap plug to check operation of the parallel port
hardware. Each parallel signal is tested.
To run the Parallel Wrap Test:
1. Disconnect the parallel interface cable, and install the wrap plug (P/N
1319128).
2. Select HARDWARE TESTS from Diagnostics Mode.
3. Select Parallel Wrap.
4. Select Parallel Wrap, Parallel 1 Wrap, Parallel 2 Wrap, or Parallel 3
Wrap.
The power indicator blinks, indicating the test is in progress. The test
runs continuously until canceled.
Parallel Wrap
P:######
F:#####
P:###### represents the number of times the memory test has
passed and finished successfully. Initially 000000 displays with the
maximum pass count being 999,999.
F:##### represents the number of times the memory test has failed
and finished with errors. Initially 00000 displays with the maximum fail
count being 99,999.
5. Each time the test finishes, the screen updates. If the test passes, the
pass count increases by 1, however if the test fails, a message displays
for approximately three seconds. One of the following failure messages
may display:
Sync Busy Error
Byte Interrupt Request Error
Strobe Interrupt Request Error
Init Fail Error
Init Busy Error
Host Busy Error
RAM Data FF Error
RAM Data AA Error
RAM Data 00 Error
RAM Data 55 Error
DMA Count Error
DMA Address Error
DMA Interrupt Error
DMA Memory Error
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DMA Background Error
Clear Init Rise Error
False Init Rise Error
False Init Fail Error
Autofeed Rising Interrupt Error
Clear Autofeed Rise Error
False Autofeed Rise Error
Autofeed Failing Interrupt Error
Clear Autofeed Fail Error
6. Once the maximum count is reached, the test stops. The power
indicator goes on solid, and the final results display.
Press Return or Stop to exit the test.
Input tray tests
Feed Tests (input tray)
These tests are used to determine if the input tray sensors are working
correctly. Observe the paper path as blank media is being fed through the
printer. The front access door cannot be opened during the feed test. To
observe the paper path, open the door cover to access the manual feeder.
Any media that meets the specifications for the printer can be used for this
test.
To run the Input Tray Feed Test:
1. Open the manual feeder door.
Note: Do not open the front cover.
2. Select the Feed Test from the INPUT TRAY TESTS menu.
3. Select the input source. Only installed sources display, but may include
Tray 1, Tray 2, and Manual Feeder.
4. Select Single to feed a single blank sheet or Continuous to feed blank
sheets until you press Return or Stop.
The selected input source appears on the display:
<input source>
Feeding...
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Sensor Test (input tray)
This test is used to determine if the input tray sensors are working correctly.
1. Select the Sensor Test from the Input Tray Test menu.
2. Select the input source. Only installed sources display, but may include
Tray 1, Tray 2, and Manual Feeder.
<input source>
Testing...
3. A list of sensors appears, depending upon the input source selected.
For example, if tray 2 were selected:
Tray 2
TP=OP
P=OP
TP refers to tray present sensor.
P refers to pass thru sensor.
OP indicates the sensor is open.
CL indicates the sensor is closed.
Not all sources have the same set of sensors. The table below
indicates which sources should display which sensors.
Source
Tray present (TP)
Pass thru sensor (P)
Tray 1
No
No
Tray 2
No
No*
Manual feeder
Yes
No
* Only available if tray is a 550-sheet drawer.
4. Press Return or Stop to exit the test.
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Base sensor test
Base sensor test is used to determine if the sensors inside the printer are
working correctly.
To run the Base Sensor Test:
1. Select BASE SENSOR TEST from the Diagnostics Mode.
2. Select the sensor to test. The following sensors may be tested:
Input (input sensor)
Output (exit sensor)
Front Door (front access door sensor)
The selected sensor is displayed with OP for open or CL for closed. You can
actuate the sensors to toggle between open and closed.
Device tests
This menu is only displayed if flash memory is installed.
Flash Test
This test causes the file system to write and read data on the flash to test
the flash.
Warning: This test destroys all data on the flash. The flash will be
unformatted at the end of the test. Format Flash is available from the
Utilities menu.
To run the Flash Test:
1. Select Flash Test from the DEVICE TESTS menu.
The power indicator blinks while the test is running.
Files will be
Lost.
Go/Stop?
2. Select Go to continue. Select Stop or Return to exit.
Flash Test
Testing...
The results are displayed, and the power indicator turns on solid:
Flash Test
Test Passed
Flash Test
Test Failed
3. Press Go, Return, or Stop to return to the DEVICE TESTS menu.
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Printer setup
Defaults
Selections are U.S. or Non-U.S. This selection affects the following defaults:
Printer setting
U.S. value
Non-U.S. value
Default paper size*
Letter
A4
Envelope size*
10 Envelope
DL Envelope
Fax paper size
Letter
A4
PCL Symbol Set
PC-8
PC-850
PPDS code page
437
850
Units of measure
Inches
Millimeters
* Where input sources do not have size sensing capabilities.
Warning: Changing this setting resets the printer to factory defaults and
data may be lost. It cannot be undone.
Page Count
Reset the page count when an engine card is replaced.
To reset the page count:
1. Select Page Count from the PRINTER SETUP menu.
Page Count
=1234567*
2. The leftmost number blinks. Use Menu to increase or decrease the
number, and press Select to move to the next digit to the right.
Continue until the correct number displays. To skip a number without
changing it, press Select.
When Select is pressed after the last digit, the number is saved.
Perm Page Count (permanent page count)
The permanent page count can only be viewed and cannot be changed.
To view the permanent page count:
1. Select Perm Page Count from PRINTER SETUP.
2. Press Return to return to PRINTER SETUP.
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Serial Number
The serial number can only be viewed and cannot be changed.
To view the serial number:
1. Select Serial number from PRINTER SETUP.
2. Press Return to return to PRINTER SETUP.
Engine Setting 1 through 4
Warning: Do not change these settings unless requested to do so by your
next level of support.
Model Name
The serial number can only be viewed and cannot be changed.
Configuration ID
The configuration ID is used to communicate characteristics of certain areas
of the printer that cannot be determined by hardware sensors. The
configuration ID was originally set when the printer was manufactured and is
located on the printer label.
Edge to Edge
When Edge to Edge is set to On, text and graphics are printed with all
margins set to the physical edges of the page. This feature does not work in
PPDS emulation.
Parallel strobe adjustment (Par S Strobe Adj)
This setting adjusts the factory setting for the amount of time the strobe is
sampled to determine that valid data is available on the parallel port.
Incrementing this value by one means the strobe is sampled
50 nanoseconds longer. The range of values are between -4 and +6, in
increments of one. A value of zero indicates no change is made from the
factory setting.
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EP setup
EP Defaults
Restores all EP settings to factory default values. Selections are Restore
and Do Not Restore.
Fuser Temperature (Fuser Temp)
Changing this setting can reduce paper curl or melting of some letterhead
images. Selections are Normal (default), Lower, and Lowest.
Transfer
The transfer can be adjusted to Low, Medium, or High. The default setting
is Medium.
Print Contrast
The print contrast can be adjusted to Low, Medium, or High. The default
setting is Medium.
Charge Roll
The charge roll can be adjusted to Low, Medium, or High. The default
setting is Medium.
Gap Adjust
Adjusts the minimum gap between sheets during printing. This setting
reduces speed (pages per minute), but can be used to reduce curl of printed
media and improve stacking in the output bin.
Range is 0 (default) to 255. Adjusting by one results in 9 mm of increased
gap.
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Error log
Display Log
Selecting ERROR LOG provides a history of printer errors. It contains the 12
most recent errors that have occurred on the printer. The most recent error
displays in position 1 and the oldest error displays in position 12 (if 12 errors
have occurred). If an error occurs after the log is full, the oldest error is
discarded. Identical errors in consecutive positions in the log are entered. All
2xx and 9xx error messages are stored in the error log.
To view the error log:
1. Select Display Log from the Error Log menu.
The error log is displayed on three screens, but only four entries are
shown at a time. To move to the next screen, press Menu. For
example:
1-200
3-928
2-920
4-922
5-250
7-230
6-990
8-230
9-953
11-000
10-000
12-000
In this example, the last error was a 200 error. In positions 10, 11, and
12, no codes were recorded.
2. Press Return to exit the error log.
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Print Log
Additional diagnostic information is available when you print the error log.
Some of the additional information includes:
• Detailed printer information, including model and serial number
• Time and date stamps
• Page counts for each error
The printed error log can be faxed to Lexmark or your next level of support
for verification or diagnosis. This report can also be printed from the
Configuration Menu. Because you can clear error logs, the contents of this
log may not match the contents when you view the error log.
To print the error log:
1. Select Print Log from the Error Log menu.
2. Press Return to exit the Error Log menu.
Clear Log
1. Select Clear Log from the Error Log menu.
Clear Log
=Yes
2. Press Yes to confirm. Select No to exit without clearing the log.
1-000
3-000
2-000
4-000
3. Press Return to exit the Clear Log menu after clearing the log.
Exit Diagnostics mode
Selecting EXIT DIAGNOSTICS exits the Diagnostics mode, and
Resetting the Printer displays. The printer performs a POR, and the
printer returns to normal mode.
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4. Repair information
Warning: Read the following before handling electronic parts.
Handling ESD-sensitive parts
Many electronic products use parts that are known to be sensitive to
electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts,
follow the instructions below in addition to all the usual precautions, such as
turning off power before removing logic cards:
• Keep the ESD-sensitive part in its original shipping container (a special
“ESD bag”) until you are ready to install the part into the printer.
• Make the least-possible movements with your body to prevent an
increase of static electricity from clothing fibers, carpets, and furniture.
• Put the ESD wrist strap on your wrist. Connect the wrist band to the
•
•
•
•
•
•
system ground point. This discharges any static electricity in your body
to the printer.
Hold the ESD-sensitive part by its edge connector shroud (cover); do
not touch its pins. If you are removing a pluggable module, use the
correct tool.
Do not place the ESD-sensitive part on the MFP cover or on a metal
table; if you need to put down the ESD-sensitive part for any reason,
first put it into its special bag.
Machine covers and metal tables are electrical grounds. They increase
the risk of damage because they make a discharge path from your
body through the ESD-sensitive part. (Large metal objects can be
discharge paths without being grounded.)
Prevent ESD-sensitive parts from being accidentally touched by other
personnel. Install machine covers when you are not working on the
machine, and do not put unprotected ESD-sensitive parts on a table.
If possible, keep all ESD-sensitive parts in a grounded metal cabinet
(case).
Be extra careful in working with ESD-sensitive parts when coldweather heating is used because low humidity increases static
electricity.
Repair information
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4511-xxx
Removal procedures
Note:
1. Remove the toner cartridge and paper tray before removing other
printer parts. The toner cartridge should be protected from light while
out of the printer.
2. We recommend disconnecting all external cables from the printer to
prevent damage during service.
3. Unless otherwise stated, reinstall the parts in reverse order of removal.
4. When reinstalling a part held with several screws, start all screws
before final tightening.
Covers
Extender cover removal
1. Locate the latches on the left and right sides of the extender cover.
2. Push the latches, and pull the cover away from the rear of the printer.
Front access cover removal (E238, E240, and E240n)
1. Open the front access cover.
2. Place thumbs on the inside of the respective hinge.
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3. Force the left hinge out of its socket, and relax it above the socket.
4. Force the right hinge out of its socket, and lift it above the socket.
Warning: Do not pull the fuser link out of the printer any farther than
when the door is fully open. Otherwise, the link extension may dislodge
the cartridge coupler.
5. Carefully lift the cover free from the printer frame.
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6. Use your left hand to hold the fuser link at the cover joint while rotating
the right side of the cover slightly away from the printer to disengage
the link.
7. Remove the front access cover.
Reinstallation note: If the front access cover is being replaced, remove the
logo plate, and install it on the new cover. See “Front access cover logo
removal (E238, E240, and E240n)” on page 4-27.
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Front access cover removal (E340 and E342n)
1. Open the front access cover.
2. Remove the screw (A) securing the LCD cable cover.
3. Remove the left and right screws (B) that hold the LCD bezel.
B
A
4. Close the front access cover.
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4-5
4511-xxx
5. Place a piece of tape (C) across the LCD lens and the bezel.
Use about three inches and fold one end under to form a tab to allow
easy removal after reinstallation.
6. Using fingernails, pull the top of the bezel away from the front access
cover. Carefully work the bezel away from the buttons and front access
cover.
Push down on the top edge of the bezel to deflect it away from the
buttons.
C
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7. Remove the screws (D) holding the button card assembly to the front
access cover.
8. Unlatch the LCD display (right and left sides).
D
9. Carefully pull the LCD assembly away from the front access cover.
10. Disconnect the LCD panel and controller card.
11. Open the front access cover, and position the cable outside the cover.
12. Place thumbs on the inside of the respective hinge.
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4-7
4511-xxx
13. Force the left hinge out of its socket, and relax it above the socket.
14. Force the right hinge out of its socket, and lift it above the socket.
Warning: Do not pull the fuser link out of the printer any farther than
when the door is fully open. Otherwise, extending the link may dislodge
the cartridge coupler.
15. Carefully lift the cover free from the printer frame.
16. Use your left hand to hold the fuser link at the cover joint while rotating
the right side of the cover slightly away from the printer to disengage
the link.
17. Remove the front access cover.
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Left side cover removal
1. Open the rear door (output tray).
2. Open the front access cover.
3. Remove the screw (A).
4. Press the two latches (B) to release the left side cover.
5. Swing the cover open.
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6. To remove the cover, position the printer with the left rear corner
hanging over the edge of the table.
7. Lift the top rear of the cover over the pivot point, and drop the cover
away from the printer.
Rear cover removal
1. Remove the right side cover. See “Right side cover removal” on
page 4-12 for more information.
2. Remove the left side cover. See “Left side cover removal” on
page 4-9 for more information.
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3. Remove the two screws (A) holding the cover.
4. Open the rear door (rear exit tray).
5. Lift the rear cover, unhooking it from the frame at the bottom and
remove.
Repair information
4-11
4511-xxx
Right side cover removal
1. Open the front access cover.
2. Open the rear door (output tray).
3. Release the latches (A) while applying opening force with the right
hand.
4. Swing the cover open.
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5. To remove the cover, position the printer with the right rear corner
hanging over the edge of the table.
6. Lift the top rear of the cover over the pivot point, and drop the cover
away from the printer.
Repair information
4-13
4511-xxx
Top cover removal
1. Open the front access cover.
2. Open the left cover.
3. Open the right cover.
4. Open the rear door.
5. Remove two screws (A) at the top rear corners of the top cover.
6. Remove two screws (B) at the front of the top cover just behind the
access door.
7. Release the top cover latch (C) which holds the top cover to the metal
side frame.
C
B
A
8. Lift and remove the top cover.
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4511-xxx
Controller card removal
Warning:
• Always touch a ground before touching the card.
• Handle the card carefully by the edges.
1. Remove the right side cover. “Right side cover removal” on
page 4-12.
2. Remove the screw (A) securing the metal controller card cover.
3. Disconnect all the cables from the controller card.
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4. Remove two screws (B) securing the parallel port and the screw (C)
securing the USB port to the frame at the back of the printer.
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5. Remove five screws (D) holding the card to the metal side frame.
6. Carefully lift the card, and remove.
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Cover open sensor removal
1. Open the right side cover.
2. Disconnect the cover open switch at J15 on the controller card, and
extract the cable.
3. For E340 and E342n models, remove the two screws (A) securing the
inner cover to gain access to the sensor.
A
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4. Use a smaller Phillips screwdriver to remove the screw (B) holding the
sensor.
B
5. Slide the sensor from the positioning post.
Installation note: Be sure to reroute the cable through the cable clip.
Repair information
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Developer drive coupling assembly removal
1. Remove the left side cover. See “Left side cover removal” on
page 4-9.
2. Carefully place the printer on its right side.
Use a clean cloth to protect the cover from marring.
3. Remove four screws (A) in the gear train metal cover.
A
4. Lift the metal cover from the printer.
5. Remove the developer drive coupler (B) and the conical spring (C).
C B
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Door latch assembly removal
1. Open the front access cover.
2. Open the left side cover.
3. Locate the opening on the inside of the button.
The opening is partially covered by the front left edge of the printhead
metal frame.
4. Use a small shank Phillips screwdriver to remove the screw.
5. Restrain the spring as the latch is removed.
Repair information
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Exit sensor removal (on the fuser)
1. Remove the paper exit guide assembly. See “Paper exit guide
assembly removal” on page 4-46 for more information.
2. Unplug the exit sensor at J17 on the controller card.
3. Push the shaft (A) to the right using your right thumb against the inside
gear surface and your left index finger against the opposite end of the
shaft.
A
Warning: There will be some lubricant on the gear and shaft. Be sure
to wipe hands clean with each contact to prevent spreading lubricant to
other areas.
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4. Align the flat portion on the right end of the shaft with the opening of
the bearing support, and lift the right end of the shaft through the
support.
5. Swing the shaft away from the printer to expose the sensor flag.
6. Remove the two screws (B) securing the fuser.
B
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7. Slide the fuser out just enough to access the screw holding the sensor.
8. Unsnap the sensor from the bracket.
9. Observe the orientation of the flag (C) and spring (D) before replacing
units.
C
10. Remove the sensor and its attached cable.
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4511-xxx
11. Loosen the screw (E) that secures the bracket to remove the cable.
E
Repair information
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Fan removal
1. Open the right side cover.
2. Unplug the fan from the controller card at J18.
3. Remove two screws (A) holding the fan to the metal side frame.
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Front access cover logo removal (E238, E240, and
E240n)
1. Open the front access cover.
2. Remove the screw (A) holding the logo cover in place.
3. Remove the logo cover from the front access cover.
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Fuser removal
1. Remove the paper exit guide assembly. See “Paper
exit guide assembly removal” on page 4-46 for more
information.
2. Remove the two screws (A) securing the fuser.
A
3. Disconnect the thermistor at J16 and exit sensor at J17 on the
controller card.
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4. Slide the fuser out far enough to access the power cables on the right
side.
5. To disconnect the fuser power cables, slide the insulation (B) back to
expose the connectors. Press the tang (C) on the connector to
disconnect the cable connector.
B
C
6. Slide the fuser out while carefully directing the thermistor and exit
sensor cables through the frame openings.
Note: Be sure to slide the insulation back in place after reconnecting the
cables.
Repair information
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4511-xxx
Fuser idle gear links removal
1. Remove the front access cover. For models E238, E240, and E240n,
see “Front access cover removal (E238, E240, and E240n)” on
page 4-2.
For models E340 and E342n, first perform steps 1 and 2 of “Front
access cover removal (E340 and E342n)” on page 4-5. Gently pull
enough slack in the cable to remove the cover without disconnecting
the cable, then follow the instructions for E238, E240, and E240n
models.
2. Remove the left side cover. See “Left side cover removal” on
page 4-9.
3. Place printer on its right side. Protect the cover from being marred.
4. Remove the screws (A) securing the metal plate covering the gear
train.
A
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5. Remove the metal cover and unsnap the link (A) from the shaft.
6. Disconnect the coupler from the front link, and remove the links.
A
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Fuser power cable removal
1. Remove the LVPS/HVPS card. See “LVPS/HVPS
card assembly removal” on page 4-41 for more
information.
Note: The cable can be reached and disconnected
without fully removing the card.
2. Remove the rear cover. See “Rear cover removal” on page 4-10 for
more information.
3. Remove the exit guide assembly. See “Paper exit guide assembly
removal” on page 4-46 for more information.
4. Remove the two screws (A) from the lower corners of the fuser.
A
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5. Slide the fuser out far enough to expose and disconnect the AC cable
connections.
You may have to remove the fuser to disconnect the cables. See
“Fuser removal” on page 4-28.
6. To disconnect the fuser power cables, slide the insulation (A) back to
expose the connectors. Press the tang (B) on the connector to
disconnect the cable connector.
B
C
7. Extract the fuser power cable from the LVPS/HVPS side.
Note: Be sure to slide the insulation back in place after reconnecting the
cables.
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Input roller clutch and lever removal (autocompensator
clutch)
1. Remove the left side cover. See “Left side cover removal” on
page 4-9.
2. Place the printer on its right side. Protect the cover from being marred.
3. Remove four screws in the gear train metal cover.
A
4. Remove the screws (B) from the shaft of the input roller clutch
assembly and the lever (pawl).
B
5. Remove the clutch assembly and the lever. If the pieces come apart,
they can be easily reassembled if necessary.
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Input sensor #1 removal
1. Open the right side cover.
2. Disconnect the sensor cable at J9 on the controller card (front, near top
of card).
3. Carefully place the printer on its top.
4. Using a small shank screwdriver, remove the screw (A) behind the
ACM (autocompensator) pivot which holds the paper sensor in place.
A
5. Remove the sensor assembly.
6. Reinstall the sensor so that the flag is spring loaded against the page
as it advances in its path.
7. Verify the cable is captured and out of the paper path.
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Input sensor #2 (manual feed) removal
1. Open the right side cover. See “Right side cover removal” on
page 4-12 for more information.
2. Disconnect the sensor cable at J20 on the controller card.
3. Carefully place the printer on its top, with the front facing you.
4. Remove the screw (A) beside and under the left pick tire.
A
5. Remove the sensor assembly.
6. Reinstall the new sensor in the same orientation as the old. The flag
should be spring loaded against the leading edge of an advancing
sheet.
7. Verify the cable is captured and away from the paper path.
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LCD bezel removal
1. Open the front access cover.
2. Remove the two screws (A) that hold the LCD bezel.
A
3. Close the front access cover.
Repair information
4-37
4511-xxx
4. If the bezel will be reused, stick a piece of tape (B) across the LCD lens
and bezel.
Use about three inches of tape and fold the end under to form a tab to
allow easy removal after reinstallation.
5. Using your fingernail or sharp, non-marring object, pull the top of the
bezel away from the front access cover. Carefully work the bezel away
from the buttons and front access cover.
Note: Push down on the top edge of the bezel to deflect it away from
the buttons. If the bezel does not easily come out, open the front
access cover, remove the three screws holding the shield cover
behind the LCD panel, and release the bezel latch.
B
4-38 Service Manual
4511-xxx
Installation note: The clear lens has a molded-in triangle (C). Install the
lens so the triangle is positioned toward the LCD buttons. Be sure the lens is
free of debris and fingerprints before installing.
C
LCD operator panel removal
1. Remove the LCD bezel. See “LCD bezel removal” on page 4-37.
2. Remove the two screws (A) holding the LCD assembly to the front
access cover.
3. Unlatch the LCD display (left and right side of the LCD).
A
4. Carefully pull the LCD assembly away from the front access cover.
5. Disconnect the LCD cable.
Repair information
4-39
4511-xxx
LED operator panel removal (E238, E240, and E240n)
1. Open the access door.
2. Remove the right side cover. See “Right side cover removal” on
page 4-12.
3. Unplug the operator panel from the controller card at J19.
4. Remove two screws (A) holding the operator panel.
A
5. Remove the operator panel.
4-40 Service Manual
4511-xxx
LVPS/HVPS card assembly removal
1. Remove the cover extender (if installed).
2. Remove the rear cover. See “Rear cover removal”
on page 4-10 for more information.
3. Place the printer onto its top, with the back and bottom in view.
4. Remove two screws (A), one left of the power switch and the other at
the opposite side of the panel.
5. Remove the screws (B) securing the two foot brackets.
B
A
A
B
Repair information
4-41
4511-xxx
6. Remove four screws (C) in the bottom of the metal cover.
C
7. Lift the metal cover so the connecting cables can be unplugged on the
side shown.
4-42 Service Manual
4511-xxx
8. Rotate the assembly, and unplug the remaining cables.
9. Remove the assembly.
LVPS/HVPS–to–controller card cable removal
1. Remove the LVPS/HVPS card. See “LVPS/HVPS card assembly
removal” on page 4-41 for more information.
2. Unplug the cable at J4 on the controller card and at CN201 on the
LVPS/HVPS card, and extract the cable.
Repair information
4-43
4511-xxx
Manual feed clutch assembly removal
1. Remove the left side cover.
2. Place the printer on its right side. Protect the cover from being marred.
3. Remove the four screws (A) in the gear train metal cover.
A
4-44 Service Manual
4511-xxx
4. Remove the clip (B) from the shaft of the pick up clutch assembly.
5. Remove the screw (C) and lever (pawl).
C
B
6. Remove the clutch assembly. If the pieces come apart, they can be
easily reassembled.
Repair information
4-45
4511-xxx
Paper exit guide assembly removal
1. Remove the rear cover. See “Rear cover removal” on page 4-10 for
more information.
2. Remove the two screws (A) and the longer screw (B) holding the exit
guide.
A
B
A
3. Remove the paper exit guide assembly.
Reinstallation note: It may be necessary to rotate the gears to mesh with
the fuser and drive gear.
4-46 Service Manual
4511-xxx
Paper feed rollers (autocompensator tires) removal
1. Be sure you have removed the paper tray and the toner cartridge.
2. Turn the printer onto its back.
Note: Be careful not to mar the finish of the printer.
3. Remove the rubber paper feed rollers.
4. Make sure the new paper feed rollers are captured between the rims of
the plastic hub.
Repair information
4-47
4511-xxx
Printhead removal
1. Remove the top cover. See “Top cover removal” on page 4-14 for
more information.
2. Remove the right side cover. See “Right side cover removal” on
page 4-12.
3. Notice the alignment of the printhead at each screw.
4. Unplug the printhead cables at locations J13 and J14.
5. Remove three screws (A) securing the printhead to the cross brace.
A
6. Remove the printhead.
Install the new printhead in the same position as the old one. Always run the
registration test following replacement, and adjust as needed. See
“Registration” on page 3-21.
Check skew caused by the printhead by printing the Quick Test. For E340
and E342n, see “Quick Test” on page 3-22. For the E238, E240, and
E240n, enter Diagnostic mode (see “Diagnostics mode selections” on
page 3-11), and select Continuous print—simplex Tray 1.
The printed test sheets have horizontal lines and two vertical lines.
Printhead misalignment causes skewed horizontal lines, but not vertical
lines (that is, the vertical lines will be parallel to the vertical edges). If the
ends of the horizontal lines on the right side drop down from the left side to
the right side, adjust the printhead clockwise to the printer. Adjust the
printhead counterclockwise if the horizontal lines rise from left to right.
4-48 Service Manual
4511-xxx
Toner level sensor cable removal (E340 and E342n)
1. Open the right side cover. See “Right side cover removal” on
page 4-12 for more information.
2. Unplug the sensor at J11, and extract the cable.
3. Unplug the cable from the sensor.
Toner level sensor removal (E340 and E342n)
1. Open the right side cover. See “Right side cover removal” on
page 4-12 for more information.
2. Unplug the cable (A) from the sensor.
3. Unsnap the toner level sensor from the frame, and remove it through
the inside of the printer.
A
Repair information
4-49
4511-xxx
Transfer roll removal
Note: Handle or touch the transfer roll as little as possible.
1. Open the front access cover.
2. Place a sheet of clean paper around the transfer roll to protect it.
3. At the right side of the transfer roll, squeeze the holder arms with the
left hand while lifting. Stop when the holder is unlatched.
4. At the left side of the transfer roll, squeeze the holder arms with the
right hand while lifting with the left hand. Stop when the left holder is
unlatched.
5. With a hand at each end, lift the transfer roll out. The springs should
remain in place. Replace the right spring with the transfer roller FRU.
Reinstallation note: Verify the springs are inserted into the bearings when
re–installing.
4-50 Service Manual
4511-xxx
Transport motor cable removal
1. Remove the right cover. See “Right side cover
removal” on page 4-12 for more information.
2. Remove the controller card cover. See “Controller
card removal” on page 4-15 for more information.
3. Unplug the transport motor cable at J8 on the controller card.
4. Remove the LVPS/HVPS card assembly. See “LVPS/HVPS card
assembly removal” on page 4-41 for more information.
5. Extract the cable (A) through the side frame, leaving it free at the
opening above the LVPS/HVPS (B).
A
B
6. Turn the printer over.
7. Remove the fuser. See “Fuser removal” on page 4-28.
8. Extract the cable through the hole and from its retainers behind the
fuser.
9. Unplug the cable at the motor. 30
Repair information
4-51
4511-xxx
4-52 Service Manual
4511-xxx
5. Locations and connections
Locations
Front view
)URQW
SDSHU
VXSSRUW
)URQW
DFFHVV
FRYHU
0DQXDO
IHHGHU
6KHHW
RXWSXWELQ
)URQW
DFFHVV
FRYHU
ORJR
7UD\
2SWLRQDO
VKHHW
GUDZHU
2SHUDWRU
SDQHO
(((Q
2SHUDWRU
SDQHO
((Q
Locations and connections
5-1
4511-xxx
Rear view
3RZHU
EXWWRQ
5HDUGRRU
RXWSXWWUD\
3DUDOOHO
SRUW
(WKHUQHWSRUW
LISUHVHQW
86%
SRUW
5-2 Service Manual
4511-xxx
Connectors
Controller card
J7
1
J5
J6
J12
1
J13
1
J14
1
J1
J15
1
J16
1
J17
1
1
J18
J2
1
1
J19
1
J20
1 J11
J3
J9
J10
1
1
1
1
J8
J4
1
Locations and connections
5-3
4511-xxx
Controller card connector pin values
(Also, see the wiring diagram at back of book.)
These values were measured with all connections made (plugged) or with
only one connector at a time unplugged to expose the pins. Always
disconnect and connect with the printer power off. Otherwise, the values
below may not match.
Connector Pin #
Value
(plugged)
Value
(unplugged) Comments
J2
1, 4
+5 V dc
+5 V dc
2
+24 V dc
+24 V dc
6
Ground
Ground
3, 5
Signal
Signal
1, 3
+24 V dc
+24 V dc
2, 4
+24 V dc
0 V dc
1, 2
0 V dc
3. 4
+5 V dc
5, 6
Signal
Main power
source to
controller
card
7
Ground
8, 9
+24 V dc
10
Signal
11
+5
12, 14
Ground
13
Signal
J3
J4
Without tray 2 attached;
Ready mode
Manual and paper feed
solenoids; Ready mode
LVPS/HVPS; Ready
mode
J5
–
–
–
USB port
J6
–
–
–
Network port (Ethernet)
J7
–
–
–
Parallel port
5-4 Service Manual
4511-xxx
Connector Pin #
J8
Value
(plugged)
Value
(unplugged) Comments
1
–
+3.3 V dc
2
–
+3.3 V dc
3
–
+3.3 V dc
4
–
+3.3 V dc
5
Ground
Ground
6
+5 V dc
+5 V dc
7, 8, 9
+24 V dc
<+24 V dc
1
+1.1 V dc
+5 V dc
2
+5 V dc
+5 V dc
3
Ground
Ground
J10
1, 2
Signal
Signal
Smart chip
J11
1
Signal
Signal
Toner low sensor
2
Ground
Ground
3
Signal
Signal
J9
J13
J14
J15
1
2, 3
+5 V dc
+5 V dc
4
Ground
Ground
5
+24 V dc
+24 V dc
1
–
2
Ground
3
+3.3 V dc
–
4
Signal
–
5
+3.3 V dc
–
6
Ground
Ground
7
+5 V dc
+5 V dc
8
Ground
Ground
9
+5 V dc
–
1
+5 V dc
0 V dc
2
+5 V dc
+5 V dc
3
Ground
Ground
Ready mode, main motor
drive.
Input sensor, Ready
mode
Mirror motor, Ready
mode
LSU, Ready mode
Ground
Door open sensor,
Ready mode (door
closed)
Locations and connections
5-5
4511-xxx
Value
(plugged)
Value
(unplugged) Comments
1
Approx.
+2 V dc
Approx.
+5 V dc
2
Ground
Ground
1
+1.1 V dc
+5 V dc
2
+5 V dc
+5 V dc
3
Ground
Ground
1
Ground
Ground
2
+11–12 V dc
+24 V dc
3
Approx.
+1.5 V dc
+3.2 V dc
1
Ground
Ground
2
+5 V dc
+5 V dc
3
0 V dc
0 V dc
4
+5 V dc
+5 V dc
5
+5 V dc
+5 V dc
6
LED ONLY
+5 V dc
7
+5 V dc
+5 V dc
1
+1.1 V dc
+5 V dc
2
+5 V dc
+5 V dc
3
Ground
Ground
4
–
–
Connector Pin #
J16
J17
J18
J19
J20
5-6 Service Manual
Thermistor
Exit sensor, Ready mode
Fan, Ready mode (fan
running)
Operator panel, Ready
mode. LED and LCD
panels use the same
common connector.
Manual feed sensor
4511-xxx
6. Preventive maintenance
The Lexmark E238, E240, E240n, E340, and E342n do not require
preventive maintenance.
Preventive maintenance
6-1
4511-xxx
6-2 Service Manual
4511-xxx
7. Parts catalog
How to use this parts catalog
The following legend is used in the parts catalog:
AsmIndex
Part
number
Units/
mach
Units/
FRU
Description
• Asm-index: identifies the assembly and the item in the diagram. For
example 3-1 indicates assembly 3 and the item number 1.
• Part number: identifies the unique number that identifies this FRU.
• Units/mach: refers to the number of units actually used in the machine
or product.
• Units/FRU: refers to the number of units packaged together and
identified by the part number.
• NS: (Not shown) in the Asm-Index column indicates that the part is
procurable but is not pictured in the illustration.
• PP: (Parts Packet) in the parts description column indicates the part is
contained in a parts packet.
• Model information used in the parts catalog.
Machine type
and model
Description
4511-000
Lexmark E238
4511-100
Lexmark E240
4511-410
Lexmark E240n (network)
4511-600
Lexmark E340
4511-610
Lexmark E342n (network)
Parts catalog
7-1
4511-xxx
Assembly 1: Covers
7-2 Service Manual
4511-xxx
Assembly 1: Covers
AsmIndex
Part
number
Units/
mach
Units/
FRU
Description
1—1
40X1335
1
Top cover assembly
2
40X1339
1
Rear cover assembly
2
40X1349
1
Rear cover assembly (white)
3
40X1320
1
Right side cover
3
40X1346
1
Right side cover (white)
4
40X1341
1
Optional media drawer assembly
(no tray)
4
40X1350
1
Optional media drawer assembly
(no tray) (white)
5
40X1342
1
Optional tray 2
5
40X1352
1
Optional tray 2 (white)
6
40X1340
1
Main tray
6
40X1351
1
Main tray (white)
7
40X1336
1
Left side cover
7
40X1348
1
8
40X1356
1
15
Language overlays
9
40X1357
1
1
LCD bezel, E340 cover
9
40X1327
1
1
LCD bezel, E342n cover
10
40X1309
1
Front access cover assembly, E340,
E342n
11
40X1310
1
Front access cover assembly, no
logo, E238, E240, E240n
11
40X1343
1
Front access cover assembly
(white), E238, E240, E240n
12
40X1354
1
Springs, ACM and front access door
13
40X1359
1
Logo plate cover, E238
13
40X1311
1
Logo plate cover, E240
13
40X1312
1
Logo plate cover, E240n
13
40X1314
1
Logo plate cover, E240n (white)
13
40X1313
1
Logo plate cover, E240 (white)
Left side cover (white)
Parts catalog
7-3
4511-xxx
Assembly 2: Electronics
7-4 Service Manual
4511-xxx
Assembly 2: Electronics
AsmIndex
Part
number
Units/
mach
Units/
FRU
Description
2–1
40X1303
1
Laser/mirror printhead assembly,
E238/ E240/E240n
1
40X1304
1
Laser/mirror printhead assembly,
E340/E342n
2
40X1300
1
Fuser assembly, 110 V
2
40X1301
1
Fuser assembly, 220 V
2
40X1302
1
Fuser assembly, 100 V
3
40X1325
1
Exit sensor assembly
4
40X1333
1
Miscellaneous cable assemblies
•
•
•
•
Fuser power
Toner sensor
LVPS/HVPS to controller
Main drive motor
5
40X1323
1
Input #1 sensor assembly
6
40X1326
1
Cover open sensor assembly
7
40X1328
1
Cooling fan
8
40X1332
1
Toner level sensor
9
40X1360
1
Controller card, E238
9
40X1305
1
Controller card, E240
9
40X1306
1
Controller card, E240n
9
40X1307
1
Controller card, E340
9
40X1308
1
Controller card, E342n
10
40X1316
1
LED operator panel assembly,
E238/E240/E240n
10
40X1345
11
40X1315
1
LCD operator panel assembly,
E340/E342n
11
40X1358
1
LCD operator panel assembly,
Katakana
12
40X1317
1
LVPS/HVPS card assembly, 110 V
12
40X1318
1
LVPS/HVPS card assembly, 220 V
13
40X1324
1
Input #2 sensor assembly (manual)
LED operator panel assembly,
E238/E240/E240n (white)
Parts catalog
7-5
4511-xxx
Assembly 3: Frame
7-6 Service Manual
4511-xxx
Assembly 3: Frame
AsmIndex
Part
number
Units/
mach
Units/
FRU
Description
3–1
40X1334
1
Paper exit guide assembly
2
40X1322
1
Transfer roll, bearings, gear, spring
3
40X1321
1
Legal-size paper extender cover
3
40X1347
1
Legal-size paper extender cover
(white)
4
40X1353
N/A
Screws, miscellaneous (actual size)
TP2NC-3.0+6P-Ni (2)
M3.0*0.5+6P-Ni,2 Washer (2)
MT3.0*0.5+6PF-Ni (5)
TP2NC-3.0+6PF-Ni (4)
5
40X1319
2
Paper feed, rubber tires
6
40X1354
1
Front access door and ACM springs
7
40X1331
1
ACM clutch CBM
8
40X1338
1
Door-fuser idle gear link CBM
9
40X1330
1
Manual feed clutch CBM
10
40X1355
2
Plastic snap rings
11
40X1329
1
Developer drive coupling assembly
12
40X1337
1
Front access cover latch CBM
Parts catalog
7-7
4511-xxx
Assembly 4: Options
AsmIndex
Part
number
Units/
mach
Units/
FRU
Description
NS
40X1564
1
32MB flash card assembly
NS
40X1513
1
Simplified Chinese font card
assembly
NS
40X1514
1
Traditional Chinese font card
assembly
NS
40X1512
1
Japanese font card assembly
NS
40X1515
1
Korean font card assembly
NS
40X1364
1
32MB SDR DIMM
NS
40X1365
1
64MB SDR DIMM
NS
40X1366
1
128MB SDR DIMM
7-8 Service Manual
4511-xxx
Assembly 5: Miscellaneous
AsmIndex
Part
number
Units/
mach
Units/
FRU
Description
NS
40X1368
1
USB cable, packaged (2 m)
NS
40X1367
1
Parallel cable, packaged (3 m)
NS
7372839
1
Field location package assembly
NS
40X0289
1
Power cord, 1.8M (straight)—USA,
Canada
NS
40X0278
1
Power cord, 6 foot (straight)—
Europe and others
NS
40X0288
1
Power cord, 6 foot (straight)—
Argentina
NS
40X0271
1
Power cord, 6 foot (straight)—
United Kingdom
NS
40X0275
1
Power cord, 6 foot (straight)—Israel
NS
40X0274
1
Power cord, 6 foot (straight)—
Switzerland
NS
40X0276
1
Power cord, 6 foot (straight)—South
Africa
NS
40X0287
1
Power cord, 6 foot (straight)—
Traditional Italy
NS
40X0279
1
Power cord, 6 foot (straight)—
Danish
NS
40X0277
1
Power cord, 6 foot (straight)—Brazil
NS
40X0282
1
Power cord, 1.8M (straight)—PRC
NS
40X0270
1
Power cord, 1.8M (straight)—Japan
NS
40X0280
1
Power cord, 1.8M (straight)—Korea
NS
40X0281
1
Power cord, 1.8M (straight)—
Taiwan
NS
40X0296
1
Power cord, 1.8M (straight)—
Australia
NS
40X0248
1
Coax/Twinax adapter
Parts catalog
7-9
4511-xxx
7-10 Service Manual
4511-xxx
Index
Numerics
3x—9x attendance messages 2-4,
2-58
2xx paper jams 2-24, 2-64
9xx service errors 2-36, 2-65
A
abbreviations 1-9
acronyms 1-9
Auto CR After LF, E238/E240(n) 3-7
Auto LF After CR, E238/E240(n) 3-7
autocompensator clutch
parts catalog 7-7
removal 4-34
autocompensator tires 4-47
B
Button Test, E340/E342n 3-23
buttons
E238/240(n) 1-2
E340/E342n 1-3, 2-52
numeric values 2-52
C
cables
fuser power cable 4-32
LVPS/HVPS to controller card cable
4-43
Charge Roll, diagnostics mode 3-31
compatibility 1-5
configuration ID
E238/E240(n) 3-12
E340/E342n 3-30
configuration menu—E238/E240(n)
accessing 3-2
navigating menu 3-5
Network
Mac Binary PS 3-10
NPA Mode 3-10
Set Card Speed 3-10
Parallel
MAC Binary PS 3-8
NPA Mode 3-8
Parallel Mode 2 3-8
Protocol 3-8
printing menu 3-3
Setup
Auto CR After LF 3-7
Auto LF After CR 3-7
Demo Mode 3-7
table of light patterns 3-3
USB
Mac Binary PS 3-9
NPA Mode 3-9
Utilities
Hex Trace 3-6
Print Quality Pages 3-7
Reset Factory Defaults 3-6
Reset Photoconductor Counter
3-7
configuration menu—E340/E342n
accessing 3-14
Demo Mode 3-17
Download Emuls 3-17
Energy Conserve 3-17
entering 3-15
Env Prompts 3-18
ERROR LOG 3-18
Exit Config Menu 3-18
Factory Defaults 3-17
menus 3-15
Panel Menus 3-16
Paper Prompts 3-18
PPDS Emulation 3-16
Prt Quality Pgs 3-16
Reset PC Cnt 3-16
controller card
removal 4-15
service check 2-82
Index
I-1
4511-xxx
D
Defaults
E238/E240(n) 3-12
E340/E342n
US/Non-US defaults 3-29
Demo Mode
E238/E240(n) 3-7
E340/E342n 3-17
diagnostic information 2-1
diagnostics mode—E238/E240(n)
Development
Configuration ID 3-12
Continuous Print
Simplex Tray 1 3-11
Simplex Tray 2 3-12
Defaults 3-12
Edge to Edge 3-11
Print History 3-12
Print Quality Pages 3-11
entering 3-2
Network
Dump NVRAM 3-13
History 3-13
History Mode 3-13
Mark History 3-13
Reinit NVRAM 3-13
Parallel
Par S Strobe Adjustment 3-12
printout sample 3-4
diagnostics mode—E340/E342n 3-14
available tests 3-19
Base Sensor Test 3-28
Device Tests
Flash Test 3-28
EP Setup
Charge Roll 3-31
EP Defaults 3-31
Fuser Temp 3-31
Gap Adjust 3-31
Print Contrast 3-31
Transfer 3-31
Error Log
Clear Log 3-33
Display Log 3-32
Print Log 3-33
Exit Diagnostics 3-33
I-2 Service Manual
exiting 3-20
Hardware Tests
Button Test 3-23
DRAM Test 3-24
LCD Test 3-23
Parallel Wrap 3-25
Input Tray Tests
Feed Tests 3-26
Sensor Test 3-27
menu list 3-19
Print Tests
input source 3-22
input source tests 3-22
Prt Quality Pgs 3-23
Printer Setup
Configuration ID 3-30
Defaults 3-29
Edge to Edge 3-30
Engine Settings 3-30
Model Name 3-30
Page Count 3-29
Par S Strobe Adj 3-30
Perm Page Count 3-29
Serial Number 3-30
Registration 3-21
Quick Test 3-22
door latch assembly 4-21
Download Emuls, E340/E342n 3-17
DRAM Test, E340/E342n 3-24
dump NVRAM, E238/E240(n) 3-13
E
Edge to Edge
E238/E240(n) 3-11
E340/E342n 3-30
Energy Conserve, E340/E342n 3-17
Env Prompts, E340/E342n 3-18
EP Defaults, E340/E342n 3-31
error log, E238/E240(n)
see History 3-13, 3-18
error log, E340/E342n
clear log (diagnostics mode) 3-33
display log (diagnostics mode) 3-32
Print Log 3-33
print log (configuration menu) 3-18
4511-xxx
error messages
E238/E240(n)
additional information 2-13, 2-24
primary light patterns 2-3
secondary light patterns 2-8
secondary paper jams 2-12
service error codes 2-36
user attendance messages 2-3
E340/E342n
paper jams 2-64
service error codes 2-65
sub error codes 2-68
user attendance messages 2-55
ESD-sensitive parts 4-1
F
Factory Defaults, E340/E342n 3-17
fan
parts catalog 7-5
removal 4-26
service check 2-81
Flash Test, E340/E342n 3-28
frame, parts catalog 7-6
fuser
parts catalog 7-5
removal 4-28
service check 2-87
Fuser Temp, E340/E342n 3-31
G
Gap Adjust, E340/E342n 3-31
H
handling ESD-sensitive parts 4-1
Hex Trace
E238/E240(n) 3-6
E340/E342n 2-54
History
E238/E240(n) 3-13
E340/E342n, see error log 3-33
I
input feed tests, E340/E342n 3-26
input sensor tray tests, E340/E342n
3-27
input source tests 3-22
input source tests, E340/E342n 3-22
L
laser notices iv-vi
LCD operator panel 4-39
LCD Test, E340/E342n 3-23
LED operator panel 4-40
light patterns—E238/E240(n)
additional information 2-13
description 2-3
primary 2-4
secondary 2-8
service codes 2-36
lights 1-2
locations
front views 5-1
rear views 5-2
logo removal 4-27
LVPS/HVPS
cable removal 4-43
parts catalog 7-5
removal 4-41
service check 2-90
M
maintenance approach 1-1
manual feed
clutch assembly 4-44
input sensor #2 4-36
print media types and sizes 1-7
mark history, E238/E240(n) 3-13
menus
E238/E240(n)
accessing service menus 3-2
configuration menu 3-3
diagnostics mode 3-4
printing 3-2
E340/E342n
accessing service menus 3-14
configuration menu 3-15
diagnostic mode 3-19
Index
I-3
4511-xxx
numerical values 2-52
printing 3-14
messages
E238/E240(n)
paper jams 2-24
service error codes 2-36
user attendance messages 2-4
E340/E342n
paper jam 2-64
service error codes 2-65
user attendance messages 2-55
Model Name, E340E342n 3-30
models
comparison 1-1
diagnostic aids 3-1
diagnostics 2-2, 2-50
diagrams 5-1, 5-2
operator panels 1-2, 1-3
service menus 3-2, 3-14
trays available 1-6
paper jams
E238/E240(n) 2-24
paper feed service check 2-94
tips on preventing 1-8
Paper Prompts, E340/E342n 3-18
parallel port service check
E238/E240(n) 2-97
E340/E342n 2-97
parallel wrap test, E340/E342n 3-25
part number index 2-7
parts catalog
covers 7-2
electronics 7-4
frame 7-6
how to use 7-1
options 7-8
permanent page count, E340/E342n
3-29
power-on self test (POST)
E238/E240(n) 2-2
E340/E342n 2-50
N
symptoms 2-79
PPDS emulation, E340/E342n 3-16
NPA Mode, E238/E240(n) 3-8
Print Contrast, E340/E342n 3-31
print history, E238/E240(n)
O
3-12
operator panel
print
media
LCD—E340/E342n
preventing jams 1-8
buttons 1-3
trays by model 1-6
overview 1-3 , 2-51
types and sizes 1-7
removal 4-39
print
quality pages
service check 2-93
E238/E240(n) 3-7, 3-11
LED—E238/E240(n) 4-40
E340/E342n 3-16, 3-23
buttons 1-2
using
2-98
lights 1-2
print
quality
problems
overview 1-2
print media 1-8
primary light patterns 2-13
service check 2-98
removal 4-40
solving
2-105
secondary light patterns 2-8, 2-24
printer
symptom
table 2-79
service check 2-92
operator panel test, E340/E342n 3-23 printhead
parts catalog 7-5
removal 4-48
P
service check 2-111
Page Count, E340/E342n 3-29
Protocol, E238/E240(n) 3-8
Panel Menus, E340/E342n 3-16
paper exit guide, removal 4-46
I-4 Service Manual
4511-xxx
Q
Quick Test
E238/E240(n) 3-11
E340/E342n 3-21, 3-22
R
registration, E340/E342n 3-21
Reinit NVRAM, E238/E240(n) 3-13
removals
autocompensator clutch 4-34
controller card 4-15
cover open sensor 4-18
covers
extender 4-2
front access cover
238/E240(n) 4-2
E340/E342n 4-5
front access cover logo—E238/
E240(n) 4-27
left side cover 4-9
rear cover 4-10
right side cover 4-12
top cover 4-14
developer drive coupling assembly
4-20
door latch assembly 4-21
exit sensor 4-22
fan 4-26
fuser 4-28
fuser idle gear links 4-30
fuser power cable 4-32
input roller clutch and lever 4-34
input sensor #1 4-35
input sensor #2 (manual feed) 4-36
LCD bezel—E340/E342n 4-37
LVPS/HVPS card assembly 4-41
LVPS/HVPS to controller card cable
4-43
manual feed clutch assembly 4-44
operator panel
LCD—E340/E342n 4-39
operator panel—E238/E240(n) 4-40
paper exit guide assembly 4-46
paper feed rollers 4-47
printhead 4-48
procedures 4-2
toner level sensor cable—E340/
E342n 4-49
toner level sensor—E340/E342n
4-49
transfer roll 4-50
transport motor cable 4-51
Reset Factory Defaults
E238/E240(n) 3-6
E340/E342n 3-29
reset maintenance page counter,
E238/E240(n) 3-7
reset NVRAM, E238/E240(n) 3-2
Reset PC Counter
E238/E240(n) 3-7
E340/E342n 3-16
S
safety information xvi
secondary error codes
complex page 2-27
defective flash 2-31
error communicating with the host
computer 2-32
flash full 2-34
font error 2-30
insufficient collation area 2-30
insufficient defrag memory 2-31
insufficient printer memory 2-29
invalid engine code 2-35
invalid network code 2-35
memory full 2-33
network interface errors 2-32
PPDS font error 2-30
short paper 2-33
unformatted flash 2-34
sensors
cover open 4-18
exit 4-22
input sensor #1 4-35
input sensor #2 (manual feed) 4-36
Serial Number, E340/E342n 3-30
service checks 2-81
controller card 2-82
cooling fan 2-81
cover interlock switch 2-85
dead machine 2-86
Index
I-5
4511-xxx
fuser 2-87
cold 2-89
hot 2-89
LVPS/HVPS 2-90
main motor 2-91
operator panel E238/E240(n) 2-92
operator panel E340/E342n 2-93
paper feed 2-94
paper jam during POST 2-94
paper never picks 2-95
paper picks but stops 2-95
paper picks during POST 2-94
paper picks sheets 2-96
paper trees, curls 2-96
parallel port E238/E240(n) 2-97
parallel port E340/E342n 2-97
print quality 2-98
black page 2-100
blank page 2-99
heavy background 2-101
image density 2-102
light print 2-103
partial blank image 2-101
poor fusing of image 2-102
toner on back of page 2-104
white or black lines 2-103
printhead 2-111
transfer roll 2-111
service error codes
E238/E240(n)
accessing 2-36
primary light pattern 2-37
secondary light patterns 2-38
tertiary light patterns 2-40
E340/E342n 2-65
service menus
E238/E240(n) 3-2
E340/E342n 3-14
special tools 1-8
specifications
connectivity 1-5
input trays 1-6
memory 1-4
operating systems 1-5
photoconductor capacity 1-6
print media 1-7
I-6 Service Manual
print speed 1-4
toner capacity 1-6
start 2-1
strobe adjustment, E340/E342n 3-30
sub error codes 2-68
symptom tables 2-79
POST 2-79
printer 2-79
T
test pages
Print Quality Pages 3-7, 3-23
Quick Test 3-11, 3-21
tires, removal 4-47
tools 1-8
Top Margin, E340/E342n 3-21
transfer roll
parts catalog 7-7
removal 4-50
service check 2-111
Transfer, E340/E342n 3-31
transport motor cable, removal 4-51
U
user attendance messages
E238/E240n 2-4
E340/E342n 2-55
4511-xxx
Part number index
P/N
Description
Page
40X0248
40X0270
40X0271
40X0274
40X0275
40X0276
40X0277
40X0278
40X0279
40X0280
40X0281
40X0282
40X0287
40X0288
40X0289
40X0296
40X1300
40X1301
40X1302
40X1303
40X1304
40X1305
40X1306
40X1307
40X1308
40X1309
40X1310
40X1311
40X1312
40X1313
40X1314
40X1315
40X1316
40X1317
40X1318
40X1319
40X1320
40X1321
40X1322
Coax/Twinax adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power cord, 1.77M (straight)—Japan . . . . . . . . . . . . . . . . . . .
Power cord, 6 foot—United Kingdom . . . . . . . . . . . . . . . . . . .
Power cord, 6 foot—Switzerland . . . . . . . . . . . . . . . . . . . . . . .
Power cord, 6 foot (straight)—Israel . . . . . . . . . . . . . . . . . . . .
Power cord, 6 foot—South Africa . . . . . . . . . . . . . . . . . . . . . .
Power cord, 6 foot (straight)—Brazil . . . . . . . . . . . . . . . . . . . .
Power cord, 6 foot (straight)—Europe and others . . . . . . . . .
Power cord, 6 foot (straight)—Danish . . . . . . . . . . . . . . . . . . .
Power cord, 1.77M (straight)—Korea . . . . . . . . . . . . . . . . . . .
Power cord, 1.77M (straight)—Taiwan . . . . . . . . . . . . . . . . . .
Power cord, 1.77M (straight)—PRC . . . . . . . . . . . . . . . . . . . .
Power cord, 6 foot (straight)—Traditional Italy . . . . . . . . . . . .
Power cord, 6 foot—Argentina . . . . . . . . . . . . . . . . . . . . . . . .
Power cord, 1.77M (straight)—USA, Canada . . . . . . . . . . . . .
Power cord, 1.8M (straight)—Australia . . . . . . . . . . . . . . . . . .
Fuser assembly, 110 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser assembly, 220 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuser assembly, 100 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Laser/mirror printhead assembly, E238/ E240/E240n . . . . . .
Laser/mirror printhead assembly, E340/E342n . . . . . . . . . . . .
Controller card, E240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller card, E240n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller card, E340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller card, E342n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front access cover assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Front access cover assembly, no logo . . . . . . . . . . . . . . . . . .
Logo plate cover, E240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logo plate cover, E240n . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logo plate cover, E240 (white) . . . . . . . . . . . . . . . . . . . . . . . .
Logo plate cover, E240n (white) . . . . . . . . . . . . . . . . . . . . . . .
LCD operator panel assembly, E340/E342n . . . . . . . . . . . . . .
LED operator panel assembly, E238/E240/E240n . . . . . . . . .
LVPS/HVPS card assembly, 110 V . . . . . . . . . . . . . . . . . . . .
LVPS/HVPS card assembly, 220 V . . . . . . . . . . . . . . . . . . . .
Paper feed, rubber tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Legal-size paper extender cover . . . . . . . . . . . . . . . . . . . . . . .
Transfer, roll, bearings, gear, spring . . . . . . . . . . . . . . . . . . . .
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-9
7-5
7-5
7-5
7-5
7-5
7-5
7-5
7-5
7-5
7-3
7-3
7-3
7-3
7-3
7-3
7-5
7-5
7-5
7-5
7-7
7-3
7-7
7-7
Part number index
I-7
4511-xxx
40X1323
40X1324
40X1325
40X1326
40X1327
40X1328
40X1329
40X1330
40X1331
40X1332
40X1333
40X1333
40X1333
40X1333
40X1333
40X1334
40X1335
40X1336
40X1337
40X1338
40X1339
40X1340
40X1341
40X1342
40X1343
40X1345
40X1346
40X1347
40X1348
40X1349
40X1350
40X1351
40X1352
40X1353
40X1354
40X1354
40X1355
40X1356
40X1357
40X1358
40X1359
40X1360
40X1364
40X1365
40X1366
Input #1 sensor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input #2 sensor assembly (manual) . . . . . . . . . . . . . . . . . . . .
Exit sensor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover open sensor assembly . . . . . . . . . . . . . . . . . . . . . . . . .
LCD bezel, E342n cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Developer drive coupling assembly . . . . . . . . . . . . . . . . . . . .
Manual feed clutch CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACM clutch CBM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toner level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable assembly, misc - fuser power . . . . . . . . . . . . . . . . . . . .
Cable assembly, misc - main drive motor . . . . . . . . . . . . . . . .
Cable assembly, misc.- toner sensor . . . . . . . . . . . . . . . . . . .
Miscellaneous cable assemblies . . . . . . . . . . . . . . . . . . . . . .
Cable assembly, misc.- LVPS/HVPS to controller . . . . . . . . . . .
Paper exit guide assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left side cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front access cover latch CBM . . . . . . . . . . . . . . . . . . . . . . . .
Door-fuser idle gear link CBM . . . . . . . . . . . . . . . . . . . . . . . .
Rear cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional media drawer assembly (no tray) . . . . . . . . . . . . . . .
Optional tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front access cover assembly (white) . . . . . . . . . . . . . . . . . . .
LED operator panel assembly, E238/E240/E240n (white) . . .
Right side cover (white) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Legal-size paper extender cover (white) . . . . . . . . . . . . . . . .
Left side cover (white) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear cover assembly (white) . . . . . . . . . . . . . . . . . . . . . . . . .
Optional media drawer assembly (no tray) (white) . . . . . . . . .
Main tray (white) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional tray 2 (white) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front access door and ACM springs . . . . . . . . . . . . . . . . . . .
Springs, ACM and front access door . . . . . . . . . . . . . . . . . . .
Plastic snap rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Language overlays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCD bezel, E340 cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCD operator panel assembly, Katakana . . . . . . . . . . . . . . . .
Logo plate cover, E238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller card, E238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32MB SDR DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64MB SDR DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
128MB SDR DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I-8 Service Manual
7-5
7-5
7-5
7-5
7-3
7-5
7-7
7-7
7-7
7-5
7-5
7-5
7-5
7-5
7-5
7-7
7-3
7-3
7-7
7-7
7-3
7-3
7-3
7-3
7-3
7-5
7-3
7-7
7-3
7-3
7-3
7-3
7-3
7-7
7-7
7-3
7-7
7-3
7-3
7-5
7-3
7-5
7-8
7-8
7-8
4511-xxx
40X1367
40X1368
40X1512
40X1513
40X1514
40X1515
40X1564
7372839
Parallel cable, packaged (3 m) . . . . . . . . . . . . . . . . . . . . . . . .
USB cable, packaged (2 m) . . . . . . . . . . . . . . . . . . . . . . . . . .
Japanese font card assembly . . . . . . . . . . . . . . . . . . . . . . . . .
Simplified Chinese font card assembly . . . . . . . . . . . . . . . . . .
Traditional Chinese font card assembly . . . . . . . . . . . . . . . . .
Korean font card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
32MB flash card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field location package assembly . . . . . . . . . . . . . . . . . . . . . .
7-9
7-9
7-8
7-8
7-8
7-8
7-8
7-9
Part number index
I-9
4511-xxx
I-10 Service Manual
Cover
Open
Switch
E238, E240,E34X
1
2
3
Wiring Diagram
Toner
Cartridge
Smart
Chip
Dr. Blade
TAR
Developer
Manual Input
Sensor
5
4
3
2
1
5
4
3
2
1
Printhead
CN202
1 2 3
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CN201
CN203
Main
Motor Drive
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
Hall_U
Hall_V
Hall_W
F_Gnd
Gnd
(5VDC) V_C1_U
(24VDC) V_C1_V
(24VDC) V_C_W
+24V
Gnd
+5v Dc
Gnd
(5VDC) Xero X_C
+24v
+24v
Gnd
(5VDC) TxEnable_C
(5VDC) Tx_C
Dev_C
Charge_C
1 I
2
3 O
1
2
1
2
1
2
3
1 O
2 I
3
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
I
O
J11
VREF
HSYNC_C (5VDC)
Gnd
+5V_LD (5VDC)
Gnd
LDEN_C
Video_C
VDO_ADJ_C (3.3VDC)
Gnd
LPOW_C (H/Hr only)
3 2 1
10 9 8 7 6 5 4 3 2 1
5 4 3 2 1
2 1
I
3 2 1
O I
10 9 8 7 6 5 4 3 2 1
O I
O
OOO
O
5 4 3 2 1
I OO
O
J20
J19
J17
J18
J14
+24V Dc
Gnd
MMLock-C (5VDC)
MMStart-C (5VDC)
MMRef-C
2 1
3 2 1
I O
J16
J15
1
2
3
~2VDC
Gnd
~5VDC Fuser_Th_C
3 2 1
Gnd
+5V Dc
LD (Signal) +5V_
Gnd
5V Paper_Out_C
<5V Dc (1.1VDC)
3 2 1
3 2 1
I O
J13
J10
J9
J7
I
O
O
O
O
J8
Option Card
Network
Plug
(if equipped)
J6
J4
O
O
O
O
J3
J1
J2
1
2
3
4
5
6
(1.1VDC)<5VDC
(5VDC)Paper_In_C
Gnd
7 6 5 4 3 2 1
7 6 5 4 3 2 1
O I O IO O I
1
2
3
4
5
6
3C_Data_C
Gnd
Feedback (~1.5VDC)
+24V Dc (11-12VDC)
Gnd
Input
Sensor
End_C
Gnd
+5v Dc (when active)
4 3 2 1
4 3 2 1
I O
Gnd
MPF_C (+5V)
<5v Dc (~1.1V)
3
2
1
1
2
3
4
Lamp
LVPS
Exit
Sensor
Toner
Level
Sensor
SCL (5VDC)
Button2_C (LED ONLY)
+5V Dc
LED_Data_C (+5VDC)
LED_CLK_C
Button1_C (+5VDC)
Gnd
Thermistor
TCO
1
2
3
4
CN102
Fuser
120 VAc
120 VAc
Charge Roller
Mirror
Motor
LSU
1 2
1 2
HVPS
Photoconductor
Kit
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
Main Fan
Transfer Roll
Spade
Connector
OP
Panel
J5
USB
Tray 2
(Optional)
1
3
5
2
4
6
MPF Paper Feed
Solenoid Solenoid
(5VDC) Tray2__FB
+24V
(5VDC) TR2SOLTray2_DET
Tray2_Pwm
Gnd
FD SOL+(<24V)
FDSOLMPFSOL+ (<24V)
MPFSOL-
Photoconductor
Excl. E238
Legend
Input = I
Output = O
Plugged Voltage = ( )
All voltages are DC
unless otherwise
noted