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Lexmark E238 Service Manual

Service manual
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See also: Reference , Setup & Installation
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark™ E238, E240,
E240n, E340, and E342n
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
4511-000
4511-100
4511-410
4511-600
4511-610

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Summary of Contents for Lexmark E238

  • Page 1 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.
  • Page 2 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.

  • Page 3: Table Of Contents

    Overview of the operator panels ....... 1-2 Models E238, 240, and 240n ....... 1-2 Models E340 and E342n .
  • Page 4 Diagnostic aids ..........3-1 Diagnostic aids—E238, E240, and E240n 2 .....3-2 Accessing service menus .
  • Page 5 LCD operator panel removal ......4-39 LED operator panel removal (E238, E240, and E240n)..4-40 LVPS/HVPS card assembly removal .
  • Page 6 4511-xxx Paper exit guide assembly removal ......4-46 Paper feed rollers (autocompensator tires) removal ... . . 4-47 Printhead removal .

  • Page 7: Laser Notices

    4511-xxx Laser notices The following laser notice labels may be affixed to this MFP as shown: Laser advisory label Laser notices...

  • Page 8: Laser Notice

    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.
  • Page 9 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.
  • Page 10 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).
  • Page 11 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.
  • Page 12 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.
  • Page 13 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 I- laserprodukt 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.
  • Page 14 4511-xxx Japanese Laser Notice Chinese Laser Notice xiii Service Manual...
  • Page 15 4511-xxx Korean Laser Notice Laser notices...
  • Page 16 4511-xxx Service Manual...

  • Page 17: Safety Information

    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.
  • Page 18 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.
  • Page 19 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. •...
  • Page 20 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. •...
  • Page 21 4511-xxx Safety information...

  • Page 22: Preface

    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.

  • Page 23: General Information

    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).

  • Page 24: Overview Of The Operator Panels

    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)

  • Page 25: Models E340 And E342N

    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.

  • Page 26: Specifications

    4511-xxx Specifications Memory 4511-000 4511-100 4511-410 4511-600 4511-610 Item Lexmark Lexmark Lexmark Lexmark Lexmark E238 E240 E240n E340 E342n Base 16MB 16MB 32MB 32MB 32MB memory Maximum 80MB 80MB 160MB 160MB 160MB memory ✔ ✔ Flash support Print speed 4511-000...

  • Page 27: Connectivity And Compatibility

    ✔ Ethernet ✔ ✔ ✔ ✔ ✔ ENA option * Linux support for E238/E240/E240n models utilizing the PCL data stream. ✔ ✔ ✔ ✔ ✔ Wireless 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.

  • Page 28: Media Trays And Supply Capacity

    4511-xxx Media trays and supply capacity 4511-000 4511-100 4511-410 4511-600 4511-610 Item Lexmark Lexmark Lexmark Lexmark Lexmark E238 E240 E240n E340 E342n Available input trays ✔ ✔ ✔ ✔ ✔ 250-sheet tray ✔ ✔ ✔ ✔ ✔ Single-sheet manual feeder ✔...

  • Page 29: Types Of Print Media

    4511-xxx Types of print media Ensure trays are properly loaded. Never mix media types within a tray. Input Source Sizes Types Weight capacity (sheets) Tray 1 A4, A5, Plain paper, 60–90 g/m 250 paper, JIS B5, transparencies, (16–24 lb) 50 labels (250-sheet letter, legal, paper labels...

  • Page 30: Tips On Preventing Jams

    – 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.

  • Page 31: Acronyms

    4511-xxx Acronyms Autocompensator Mechanism (or paper feed) ASIC Application Specific Integrated Circuit Complete Bill Of Material Cyclic Redundancy Check Development Roll (of print cartridge/photoconductor system) DIMM Dual In-Line Memory Module Error Correction Code EEPROM Erasable Electrically Programmable Read-Only Memory External Network Adapter Field Replaceable Unit Host Based Printing HVPS...
  • Page 32 4511-xxx 1-10 Service Manual...

  • Page 33: Diagnostic Information

    “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.

  • Page 34: Diagnostics-E238, E240, And E240N 2

    4511-xxx Diagnostics—E238, E240, and E240n 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.

  • Page 35: Light Patterns And Error Messages

    2-36. 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...

  • Page 36: Common Primary Light Patterns

    4511-xxx Common primary light patterns “Overview of the operator panels” on page 1-2 for icon information. Light on Light off ✷ Light blinking Light blinking slowly Primary light patterns Lights Continue ✷ ✷ Ready Toner Low/ Replace PC Load Paper Paper Jam ✷...
  • Page 37 4511-xxx Primary light patterns (continued) Lights ✷ Continue Ready Toner Low/ Replace PC ✷ Load Paper Paper Jam Error Diagnostics—E238, E240, and E240n...
  • Page 38 4511-xxx Primary light patterns (continued) Lights Continue Ready ✷ ✷ Toner Low/ Replace PC Load Paper Paper Jam ✷ Error Service Manual...
  • Page 39 4511-xxx Primary light patterns (continued) Lights ✷ ✷ Continue ✷ Ready ✷ Toner Low/ Replace PC ✷ Load Paper ✷ Paper Jam ✷ Error Diagnostics—E238, E240, and E240n...

  • Page 40: Common Secondary Light Patterns

    4511-xxx Common secondary light patterns When the 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 Secondary error codes Primary code...
  • Page 41 4511-xxx Secondary errors (continued) Secondary codes Lights Continue Ready ✷ Toner Low/ Replace PC ✷ Load Paper ✷ Paper Jam Error Diagnostics—E238, E240, and E240n...
  • Page 42 4511-xxx Secondary errors (continued) Secondary error codes Lights Continue Ready Toner Low/ Replace PC ✷ Load Paper Paper Jam Error 2-10 Service Manual...
  • Page 43 4511-xxx Secondary errors (continued) Secondary error codes Lights Continue Ready Toner Low/ Replace PC Load Paper Paper Jam Error 2-11 Diagnostics—E238, E240, and E240n...

  • Page 44: Secondary Errors-Paper Jams

    4511-xxx Secondary errors—paper jams Secondary errors—paper jams Secondary error codes Lights Continue ✷ Ready Toner Low/ Replace PC Load Paper Paper Jam Error 2-12 Service Manual...

  • Page 45: Additional Information-Primary Codes

    • Printer is in Power list of current printer Saver mode. settings. • Press and hold reset the printer. Note: To change the Power Saver setting, use the Local Printer Setup Utility. See the User’s Reference for more information. 2-13 Diagnostics—E238, E240, and E240n...
  • Page 46 4511-xxx Busy Light pattern Meaning Action • Busy: • Printer is busy receiving and – Wait for message to processing data or clear. printing. – Press and release • Printer is to cancel print job. defragmenting the – Press and hold flash memory to reset printer.
  • Page 47 Printer is waiting until a • Press and release print timeout occurs, or print contents of the print until it receives buffer. additional data. • Press and release cancel the print job. • Press and hold reset the printer. 2-15 Diagnostics—E238, E240, and E240n...
  • Page 48 4511-xxx Flushing / Resolution reduced Light pattern Meaning Action • Wait until is on to print • Printer is flushing corrupted print data. other jobs. • Printer is processing • Press and release data or printing cancel print job. pages, but the •...
  • Page 49 • Check that the media is allotted time. loaded correctly in tray 1 or the optional 550-sheet tray. • Press to cancel the print job. 2-17 Diagnostics—E238, E240, and E240n...
  • Page 50 4511-xxx Load manual feeder Light pattern Meaning Action Printer prompts to load • Load media in the manual a single sheet of media feeder with the side to be in the manual feeder. printed facing up. • Press to resume printing.
  • Page 51 Replace photoconductor kit (an early warning) Light pattern Meaning Action The photoconductor kit • Press to resume drum is full and needs printing. replacing. • Replace the photoconductor kit. 2-19 Diagnostics—E238, E240, and E240n...
  • Page 52 4511-xxx Replace photoconductor kit (printer hard stop) Light pattern Meaning Action Replace the photoconductor The photoconductor kit drum is full and needs kit. replacing. No pages print until the photoconductor kit is replaced. Print cartridge error / Print cartridge is not installed Light pattern Meaning Action...
  • Page 53 Light pattern Meaning Action New code is being Wait for the message to clear. loaded into the engine When the printer has finished or firmware code flash. loading the code, it performs a soft reset. 2-21 Diagnostics—E238, E240, and E240n...
  • Page 54 4511-xxx Cancel job / Reset printer Light pattern Meaning Action Wait for the message to clear. • The current print job is canceled. • The printer is resetting to the user default settings. – Any active print jobs are canceled. –...
  • Page 55 • Resolution of a formatted page is reduced to 300 dpi. • A font error occurred. • Communication with the host computer is lost. 2-23 Diagnostics—E238, E240, and E240n...

  • Page 56: Additional Information-Secondary Error Codes

    4511-xxx Additional information—secondary error codes • When the light is flashing and light is on, a secondary printer error has occurred. • When the lights are both on, a paper jam secondary error has occurred. • When the and the lights are both on, a print cartridge error has occurred.
  • Page 57 Paper jams as a printed job exits the printer (202 error) Light pattern Meaning Action A paper jam has Clear the paper jam. occurred as the paper is exiting the printer. 2-25 Diagnostics—E238, E240, and E240n...
  • Page 58 4511-xxx Paper jams as it exits tray 2 into the printer (241 error) Light pattern Meaning Action Clear the paper jam. A paper jam has occurred as the paper is exiting the paper tray and entering the printer. Paper Jams as it exits tray 2 (242 error) Light pattern Meaning Action...
  • Page 59 – Set Page Protect to on in the Local Printer Setup Utility. • Install additional printer memory. 2-27 Diagnostics—E238, E240, and E240n...
  • Page 60 4511-xxx Print cartridge errors Light pattern Meaning Action 31 Error—Print Install the correct cartridge. cartridge is either missing or defective. 32 Error—The print Replace the cartridge. cartridge is unsupported. 33 Error—The print Replace the cartridge. cartridge has an invalid refill. 2-28 Service Manual...
  • Page 61 • Press to cancel the buffer. print job. • Press to cancel the print job, turn off the printer and install additional memory. 2-29 Diagnostics—E238, E240, and E240n...
  • Page 62 4511-xxx Insufficient collation area Light pattern Meaning Action • Press to clear the The printer memory does not have the free message and continue space necessary to printing the job (the job collate the print job. This may not print correctly). may happen due to one •...
  • Page 63 – Install flash memory. Insufficient defrag memory Light pattern Meaning Action The printer has • Delete fonts, macros, and insufficient memory to other data in RAM. free unused space in • Install additional printer flash memory. memory. 2-31 Diagnostics—E238, E240, and E240n...
  • Page 64 4511-xxx Network interface errors Light pattern Meaning Action Press to clear the The printer cannot establish message and continue communication with the printing (the job may not print network. correctly). Network or ENA connection lost Light pattern Meaning Action The printer has lost the •...
  • Page 65 • Press to clear the media. message and continue printing the job. • Press to cancel the print job. 2-33 Diagnostics—E238, E240, and E240n...
  • Page 66 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.
  • Page 67 Invalid network code Light pattern Meaning Action The code in an internal Download valid network code print server has not to the internal print server. been programmed, or the programmed code is not valid. 2-35 Diagnostics—E238, E240, and E240n...

  • Page 68: Service Codes

    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.
  • Page 69 Service primary code ✷ Light blinking When this code appears, double-click to reveal the secondary codes. Service primary code Lights ✷ Continue ✷ Ready ✷ Toner Low/ Replace PC ✷ Load Paper ✷ Paper Jam ✷ Error 2-37 Diagnostics—E238, E240, and E240n...
  • Page 70 4511-xxx Service secondary error codes Service secondary error codes Service secondary error codes Lights ✷ ✷ ✷ ✷ ✷ ✷ Continue Ready Toner Low/ Replace PC ✷ ✷ Load Paper ✷ ✷ Paper Jam ✷ ✷ ✷ Error 2-38 Service Manual...
  • Page 71 4511-xxx Service secondary error codes (continued) Service secondary error codes Lights ✷ ✷ ✷ Continue Ready ✷ Toner Low/ Replace PC ✷ ✷ Load Paper ✷ ✷ Paper Jam ✷ Error 2-39 Diagnostics—E238, E240, and E240n...
  • Page 72 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.
  • Page 73 Service tertiary error codes—transfer roll Service Service tertiary secondary codes codes— Lights ✷ Continue ✷ ✷ Ready Toner Low/ Replace PC ✷ ✷ Load Paper ✷ Paper Jam ✷ ✷ Error 2-41 Diagnostics—E238, E240, and E240n...
  • Page 74 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 Service Service teriary codes—fuser, fan, or toner secondary...
  • Page 75 Service tertiary error codes—fuser, fan, or toner sensor (continued) Service teriary codes—fuser, fan, or toner sensor Lights Continue ✷ ✷ ✷ ✷ Ready ✷ Toner Low/ Replace PC ✷ ✷ ✷ Load Paper ✷ ✷ Paper Jam ✷ ✷ ✷ Error 2-43 Diagnostics—E238, E240, and E240n...
  • Page 76 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.
  • Page 77 Service tertiary error codes—printhead, transport motor, or RIP/engine communication error (continued) Service teriary error codes Lights Continue ✷ ✷ ✷ ✷ Ready ✷ Toner Low/ Replace PC ✷ ✷ ✷ Load Paper ✷ ✷ Paper Jam ✷ ✷ ✷ Error 2-45 Diagnostics—E238, E240, and E240n...
  • Page 78 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 Service Service teriary codes—NVRAM failure secondary codes—...
  • Page 79 4511-xxx Service tertiary error codes—NVRAM failure (continued) Service tertiary codes—NVRAM failure Lights Continue ✷ ✷ ✷ ✷ Ready ✷ ✷ Toner Low/ Replace PC ✷ ✷ Load Paper ✷ ✷ Paper Jam ✷ ✷ Error 2-47 Diagnostics—E238, E240, and E240n...
  • Page 80 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 Service Service teriary secondary codes—RAM codes—...
  • Page 81 Service Service teriary codes - network secondary codes— Lights ✷ Continue ✷ ✷ ✷ ✷ Ready ✷ ✷ Toner Low/ Replace PC ✷ ✷ ✷ Load Paper ✷ ✷ Paper Jam ✷ ✷ ✷ Error 2-49 Diagnostics—E238, E240, and E240n...

  • Page 82: Diagnostics-E340 And E342N 50

    4511-xxx Diagnostics—E340 and E342n 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.

  • Page 83: Overview Of The Operator Panel And Menus

    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 On, but idle Blinking On and busy 2-51 Diagnostics—E340 and E342n...

  • Page 84: Buttons

    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.
  • Page 85 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. –...

  • Page 86: Diagram Of The Printer Menus

    4511-xxx Diagram of the printer menus Not all menus or selections will be available on all models or in all situations. Paper Menu Finishing Menu Utilities Menu Job Menu Paper Source Copies Quick Demo Cancel Job Paper Size Blank Pages Print Menus Reset Printer Paper Type...

  • Page 87: Messages And Error Codes

    4511-xxx Messages and error codes User attendance messages User attendance messages Message Explanation Change Cartridge Remove the print cartridge, and install a new Invalid Refill cartridge. Change <input source> This message displays when the user should <custom type name> change the media installed in one of the input options.
  • Page 88 4511-xxx User attendance messages (continued) Message Explanation Change <input source> This message displays when the user should <type><size> 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.
  • Page 89 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.
  • Page 90 4511-xxx User attendance messages (continued) Message Explanation Load <input source> Input source=Tray 1, Tray 2, or Manual Feeder. <custom type name> Custom type name is a user defined media type. The following actions may be taken: • Load media in the indicated source. •...
  • Page 91 4511-xxx User attendance messages (continued) Message Explanation 35 Res Save Off The printer lacks sufficient memory to enable Deficient Memory Resource Save. The following actions may be taken: • Press Go to clear the message. The printer disables Resource Save. •...
  • Page 92 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: –...
  • Page 93 4511-xxx User attendance messages (continued) Message Explanation 50 PPDS This message displays when the PPDS Font Error 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: •...
  • Page 94 4511-xxx User attendance messages (continued) Message Explanation 54 Std Network This error displays when a network port is Software Error detected, but the printer cannot establish communications with it. Press Go to clear the message. The printer disables all communications to the network interface.
  • Page 95 4511-xxx User attendance messages (continued) Message Explanation 58 Too Many This error displays when too many flash Flash Options options are installed in the printer. The following options may be taken: • Turn off the printer, and remove the extra flash options.

  • Page 96: Paper Jam Messages

    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. •...

  • Page 97: Service Error Codes

    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 Service Server firmware problem. Contact the RIP software next level of support.
  • Page 98 4511-xxx Service error codes (9xx) (continued) Error Description Action Fuser Error Replace fuser with correct one. See “Fuser removal” on page 4-28. (Incorrect fuser lamp.) Fan Error Replace the fan. See “Fan removal” on page 4-26. Fan is stalling. Toner sensor The toner sensor is not operating properly, the developer drive assembly is not operating properly, or the print...
  • Page 99 4511-xxx Service error codes (9xx) (continued) Error Description Action NV failure:n Recoverable error. Reset (POR) the printer. Where n=offset where error occurred. NVRAM CRC failure Indicates the NVRAM experienced a CRC failure. Replace the controller card. Code CRC <loc> Replace the controller card. Where <loc>...

  • Page 100: Sub Error Codes

    4511-xxx Service error codes (9xx) (continued) Error Description Action Unrecognizable A failure with the network port. network port If the printer is a network model, replace the controller card. See “Controller card Software error in removal” on page 4-15. network port Bad checksum while programming network port.
  • Page 101 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.
  • Page 102 4511-xxx Sub error codes First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 84 00 22 x1 Indicates the media reached the image x2 00 point before EP leading edge state machine was ready. (x1=leading edge of media state, x2=trailing edge of media state) 84 01 22 x1...
  • Page 103 4511-xxx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 84 xx 01 x1 The video signal did not start within two x2 00 inches after actuating the input sensor. Check input sensor and flag.
  • Page 104 4511-xxx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 84 xx 05 x1 There was media at the input sensor too x2 00 early. There was not enough time between printhead start and the printhead mirror motor to lock.
  • Page 105 4511-xxx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 84 xx 27 x1 Manual feeder sensor never became x2 x3 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...
  • Page 106 4511-xxx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 84 xx 2C x1 Unrecoverable no gap jam. Engine x2 x3 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.
  • Page 107 • 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.
  • Page 108 4511-xxx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 89 xx 03 x1 The exit sensor did not detect the trailing x2 x3 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...
  • Page 109 4511-xxx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 8D 00 00 00 The fuser exit sensor was never activated 00 00 by the leading edge of the media fed through the printer.
  • Page 110 4511-xxx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) 8E x1 11 x2 Took too long to ramp up Tray 2 motor. x3 x4 (x1=DCFeedMSCounter, x2=Low(DCFeedIRQCount), x3=RampTableLengthCache, x4=DCFeedClosedLoopState.) 2-78 Service Manual...

  • Page 111: Symptom Tables

    2-85. POST completes, except one or “Operator panel service check more lights do not come on. (models E238, E240, and E240n)” on page 2-92. None of the lights come on. “Operator panel service check (models E238, E240, and E240n)” on page 2-92.
  • Page 112 Paper skew. “Paper feed service checks” on page 2-94. Printer not communicating with “Parallel port service check host. (models E238, E240, and E240n)” on page 2-97. Front access cover will not “Cover interlock switch service close. check” on page 2-85.

  • Page 113: Service Checks

    4511-xxx Symptom Action Paper never picks. “Paper never picks” on page 2-95. Paper feeds continuously. “Paper picks during POST and/ or continuously” on page 2-94. Paper wrinkled or bent. “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...

  • Page 114: Controller Card Service Check

    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”...
  • Page 115 4511-xxx Controller card service check (continued) Action Controller card Verify +24 V dc input from the assembly (continued) LVPS/HVPS. • Turn the printer off. • Disconnect the LVPS/HVPS cable from the controller card at J4. • Turn the printer on. •...
  • Page 116 4511-xxx Controller card service check (continued) 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.

  • Page 117: Cover Interlock Switch Service Check

    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. 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.

  • Page 118: Dead Machine Service Check

    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 Action Unplug the printer and check the fuses on the LVPS/HVPS board for continuity.

  • Page 119: Fuser Service Check

    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.
  • Page 120 4511-xxx Fuser service check Action Fuser power cable Step 2: No continuity LVPS/HVPS Check the lamp cable for continuity. Fuser • If correct, replace the fuser. (continued) • If incorrect, replace the lamp cable. Disconnect the thermistor cable from J16 on the controller card.

  • Page 121: Cold Fuser Service Check

    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. 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.

  • Page 122: Lvps/Hvps Service Check

    4511-xxx LVPS/HVPS service check Action LVPS portion of board Fuses that open typically indicate a faulty LVPS/ HVPS. Use the voltage meter to verify the appropriate voltage at the printer end of the power cable. LVPS/HVPS Remove the LVPS/HVPS assembly from the printer.

  • Page 123: Main Motor Service Check

    4511-xxx Main motor service check 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 Pins 1–4 Approx. +3.3 V dc Main motor cable LVPS/HVPS Pin 6 Approx.

  • Page 124: Operator Panel Service Check (Models E238, E240, And E240N)

    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.

  • Page 125: Operator Panel Service Check (Models E340 And E342N)

    4511-xxx LED Operator panel service check (continued) Action Lights Operator panel (LED) Controller card If none of the lights come on, make sure the Warning: Do not cable is properly connected to the controller card and the controller card has input voltage replace the operator to it.

  • Page 126: Paper Feed Service Checks

    4511-xxx Paper feed service checks Paper jam error indication during POST 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 Make sure the input paper feed sensors are print cartridge...

  • Page 127: Paper Never Picks

    4511-xxx Paper picks but stops halfway through the printer Action Make sure the input sensors are working Input sensor #1 (under print cartridge properly. assembly) and Check for a broken or stuck flag on the input Input sensor #2 sensors. (manual) Make sure the cables are seated on the controller card at J9 (Tray 1 input) and J20...
  • Page 128 4511-xxx Paper occasionally mispicks or picks multiple sheets at once Action Tray 1 Check tray for paper catch points. Tray 2 (option) 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.

  • Page 129: Parallel Port Service Check (Models E238, E240, And E240N)

    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.

  • Page 130: Print Quality Service Checks

    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.

  • Page 131: Blank Page

    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.

  • Page 132: Black Page

    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. Action Toner electrodes (not a Check the three rearward electrodes below the FRU) print cartridge assembly for contamination or damage.

  • Page 133: Heavy Background

    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. Action Toner cartridge (not a Make sure the toner cartridge and PC Kit are FRU) correctly installed and the high voltage contacts PC Kit (not a FRU) are clean.

  • Page 134: Poor Fusing Of Image

    4511-xxx Variation in image density horizontally across page 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.

  • Page 135: Light Print

    4511-xxx Light print Action Toner cartridge (not a Make sure the toner cartridge and PC Kit are FRU) 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.

  • Page 136: Toner On Back Of Page

    4511-xxx Toner on back of page 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.
  • Page 137 4511-xxx Solving print quality problems Print quality problems Problem Action Light or blurred Light print characters. 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.
  • Page 138 • 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. light nor Toner Low message do The print is getting •...
  • Page 139 4511-xxx Print quality problems (continued) Problem Action Solid black areas on • Choose a different fill pattern in your software transparencies or program. white streaks on paper. • Try a different type of paper. Paper designed for copiers gives the best quality. •...
  • Page 140 • 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.
  • Page 141 The printer does not • Clear all jams. print after a paper jam • Press and release (E238, E240, E240n) has been cleared. or Go (E340, E342n), or open and close the printer cover to restart the printer. • Make sure the print cartridge assembly is installed properly.
  • Page 142 • 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.

  • Page 143: Printhead Service Check

    4511-xxx Printhead service check 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.
  • Page 144 4511-xxx 2-112 Service Manual...

  • Page 145: Diagnostic Aids

    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”...

  • Page 146: Diagnostic Aids-E238, E240, And E240N 2

    4511-xxx Diagnostic aids—E238, E240, and E240n3 Accessing service menus Diagnostics 1. Turn off the printer. The diagnostic group contains mode menu settings and operations 2. Open the front access that are useful in the cover. manufacturing of the printer. It 3.
  • Page 147 4511-xxx Configuration Menu printout sample Diagnostic aids—E238, E240, and E240n...
  • Page 148 4511-xxx Diagnostics mode printout sample Service Manual...

  • Page 149: Moving Around The Menu

    Press and hold to jump to home state (top four lights on). • Press and release to move through the menu settings (indicated lights). This action rotates only through the possible settings of the selected menu item. Diagnostic aids—E238, E240, and E240n...

  • Page 150: Configuration Menu Selections

    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.

  • Page 151: Setup

    Off (default) After LF printer automatically performs a carriage return after a line feed control command. Auto LF after Specify whether the Off (default) printer automatically performs a line feed after a carriage return control command. Diagnostic aids—E238, E240, and E240n...

  • Page 152: Parallel

    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. Auto (default) Protocol Receive information at a Standard much higher transmission...

  • Page 153: Usb

    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...

  • Page 154: Network

    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 Auto (default) status information simultaneously.

  • Page 155: Diagnostics Mode Selections

    Note: Cartridge lockout function is disabled. Continuous Continuously print pages print— containing cross lines, simplex printer information, and Tray 1 margin settings. Press and hold until the lights flash to begin. Press to stop. 3-11 Diagnostic aids—E238, E240, and E240n...

  • Page 156: Parallel

    4511-xxx Development (continued) Menu item Use setting to Value Continuous Continuously print pages print— containing cross lines, simplex printer information, and Tray 2 margin settings. This menu item does not appear if Tray 2 is not installed. Press and hold until the lights flash to begin.

  • Page 157: Network

    NVRAM to factory defaults. Press and hold until the lights flash to initiate this action. Meditech Prevent the network card Mode from accepting more than No (default) one 9100 mode connection at a time. 3-13 Diagnostic aids—E238, E240, and E240n...

  • Page 158: Diagnostic Aids-E340 And E342N 14

    4511-xxx Diagnostic aids—E340 and E342n Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Configuration 1. Turn off the printer. The Configuration Menu group contains a set of Menu 2.

  • Page 159: Configuration Menu (Config Menu)

    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.

  • Page 160: Reset Pc Cnt

    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.

  • Page 161: Download Emuls

    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.

  • Page 162: Error Log

    4511-xxx Error log “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.

  • Page 163: Diagnostics Mode

    4511-xxx Diagnostics mode Available tests The tests display on the operator panel in the order shown: Diagnostics mode tests REGISTRATION “Registration” on page 3-21. Bottom Margin Top Margin Left Margin Right Margin Quick Test “Quick Test” on page 3-22. PRINT TESTS Tray 1 “Input source tests”...
  • Page 164 4511-xxx Diagnostics mode tests (continued) PRINTER SETUP Defaults “Defaults” on page 3-29. Page Count “Page Count” on page 3-29. Perm Page Count “Perm Page Count (permanent page count)” on page 3-29. Serial Number “Serial Number” on page 3-30. Engine Setting 1 “Engine Setting 1 through 4”...

  • Page 165: Registration

    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* B=sxx* L=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.

  • Page 166: Print Tests

    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.

  • Page 167: Hardware Tests

    4511-xxx 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.

  • Page 168: Dram Test

    4511-xxx 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.

  • Page 169: Parallel Wrap

    4511-xxx 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).

  • Page 170: Input Tray Tests

    4511-xxx 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.
  • Page 171 4511-xxx 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.

  • Page 172: Base Sensor Test

    4511-xxx 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)

  • Page 173: Printer Setup

    4511-xxx 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 Envelope size* 10 Envelope DL Envelope Fax paper size Letter PCL Symbol Set PC-8 PC-850 PPDS code page Units of measure Inches...

  • Page 174: Serial Number

    4511-xxx 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.

  • Page 175: Ep Setup

    4511-xxx 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.

  • Page 176: Error Log

    4511-xxx 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).

  • Page 177: Exit Diagnostics Mode

    • 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.
  • Page 178 4511-xxx 3-34 Service Manual...

  • Page 179: Repair Information

    4511-xxx 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: •...

  • Page 180: Removal Procedures

    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.
  • Page 181 4511-xxx 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.
  • Page 182 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. Service Manual...
  • Page 183 4511-xxx 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. 4. Close the front access cover. Repair information...
  • Page 184 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.
  • Page 185 4511-xxx 7. Remove the screws (D) holding the button card assembly to the front access cover. 8. Unlatch the LCD display (right and left sides). 9. Carefully pull the LCD assembly away from the front access cover. 10. Disconnect the LCD panel and controller card. 11.
  • Page 186 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.
  • Page 187 4511-xxx 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. Repair information...
  • Page 188 4511-xxx 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.
  • Page 189 4511-xxx 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. 4-11 Repair information...
  • Page 190 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. 4-12 Service Manual...
  • Page 191 4511-xxx 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. 4-13 Repair information...
  • Page 192 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.

  • Page 193: Controller Card Removal

    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.
  • Page 194 4511-xxx 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. 4-16 Service Manual...
  • Page 195 4511-xxx 5. Remove five screws (D) holding the card to the metal side frame. 6. Carefully lift the card, and remove. 4-17 Repair information...

  • Page 196: Cover Open Sensor Removal

    4511-xxx 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.
  • Page 197 4511-xxx 4. Use a smaller Phillips screwdriver to remove the screw (B) holding the sensor. 5. Slide the sensor from the positioning post. Installation note: Be sure to reroute the cable through the cable clip. 4-19 Repair information...

  • Page 198: Developer Drive Coupling Assembly Removal

    4511-xxx 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. 4.

  • Page 199: Door Latch Assembly Removal

    4511-xxx 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.

  • Page 200: Exit Sensor Removal (On The Fuser)

    4511-xxx 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.
  • Page 201 4511-xxx 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.
  • Page 202 4511-xxx 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. 10. Remove the sensor and its attached cable. 4-24 Service Manual...
  • Page 203 4511-xxx 11. Loosen the screw (E) that secures the bracket to remove the cable. 4-25 Repair information...

  • Page 204: Fan Removal

    4511-xxx 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. 4-26 Service Manual...

  • Page 205: Front Access Cover Logo Removal (E238, E240, And E240N)

    4511-xxx 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. 4-27 Repair information...

  • Page 206: Fuser Removal

    4511-xxx Fuser removal 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. 3. Disconnect the thermistor at J16 and exit sensor at J17 on the controller card.
  • Page 207 4511-xxx 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.

  • Page 208: Fuser Idle Gear Links Removal

    4511-xxx Fuser idle gear links removal 1. Remove the front access cover. For models E238, E240, and E240n, “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...
  • Page 209 4511-xxx 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. 4-31 Repair information...

  • Page 210: Fuser Power Cable Removal

    4511-xxx 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”...
  • Page 211 4511-xxx 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.

  • Page 212: Input Roller Clutch And Lever Removal (Autocompensator Clutch)

    4511-xxx 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. 4.

  • Page 213: Input Sensor #1 Removal

    4511-xxx 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.

  • Page 214: Input Sensor #2 (Manual Feed) Removal

    4511-xxx 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.

  • Page 215: Lcd Bezel Removal

    4511-xxx LCD bezel removal 1. Open the front access cover. 2. Remove the two screws (A) that hold the LCD bezel. 3. Close the front access cover. 4-37 Repair information...
  • Page 216 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.

  • Page 217: Lcd Operator Panel Removal

    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. LCD operator panel removal 1. Remove the LCD bezel. See “LCD bezel removal”...

  • Page 218: Led Operator Panel Removal (E238, E240, And E240N)

    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.

  • Page 219: Lvps/Hvps Card Assembly Removal

    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.
  • Page 220 4511-xxx 6. Remove four screws (C) in the bottom of the metal cover. 7. Lift the metal cover so the connecting cables can be unplugged on the side shown. 4-42 Service Manual...

  • Page 221: Lvps/Hvps-To-Controller Card Cable Removal

    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.

  • Page 222: Manual Feed Clutch Assembly Removal

    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. 4-44 Service Manual...
  • Page 223 4511-xxx 4. Remove the clip (B) from the shaft of the pick up clutch assembly. 5. Remove the screw (C) and lever (pawl). 6. Remove the clutch assembly. If the pieces come apart, they can be easily reassembled. 4-45 Repair information...

  • Page 224: Paper Exit Guide Assembly Removal

    4511-xxx Paper exit guide assembly removal 1. Remove the rear cover. See “Rear cover removal” on page 4-10 more information. 2. Remove the two screws (A) and the longer screw (B) holding the exit guide. 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.

  • Page 225: Paper Feed Rollers (Autocompensator Tires) Removal

    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.

  • Page 226: Printhead Removal

    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.

  • Page 227: Toner Level Sensor Cable Removal (E340 And E342N)

    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.

  • Page 228: Transfer Roll Removal

    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.

  • Page 229: Transport Motor Cable Removal

    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.
  • Page 230 4511-xxx 4-52 Service Manual...

  • Page 231: Locations And Connections

    4511-xxx 5. Locations and connections Locations Front view Locations and connections...

  • Page 232: Rear View

    4511-xxx Rear view Service Manual...

  • Page 233: Connectors

    4511-xxx Connectors Controller card Locations and connections...

  • Page 234: Controller Card Connector Pin Values

    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.
  • Page 235 4511-xxx Value Value Connector Pin # (plugged) (unplugged) Comments – +3.3 V dc Ready mode, main motor drive. – +3.3 V dc – +3.3 V dc – +3.3 V dc Ground Ground +5 V dc +5 V dc 7, 8, 9 +24 V dc <+24 V dc +1.1 V dc...
  • Page 236 4511-xxx Value Value Connector Pin # (plugged) (unplugged) Comments Approx. Approx. Thermistor +2 V dc +5 V dc Ground Ground +1.1 V dc +5 V dc Exit sensor, Ready mode +5 V dc +5 V dc Ground Ground Ground Ground Fan, Ready mode (fan running) +11–12 V dc +24 V dc...

  • Page 237: Preventive Maintenance

    4511-xxx 6. Preventive maintenance The Lexmark E238, E240, E240n, E340, and E342n do not require preventive maintenance. Preventive maintenance...
  • Page 238 4511-xxx Service Manual...

  • Page 239: Parts Catalog

    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 Description and model 4511-000 Lexmark E238 4511-100 Lexmark E240 4511-410 Lexmark E240n (network) 4511-600 Lexmark E340 4511-610...

  • Page 240: Assembly 1: Covers

    4511-xxx Assembly 1: Covers Service Manual...
  • Page 241 40X1327 LCD bezel, E342n cover 40X1309 Front access cover assembly, E340, E342n 40X1310 Front access cover assembly, no logo, E238, E240, E240n 40X1343 Front access cover assembly (white), E238, E240, E240n 40X1354 Springs, ACM and front access door 40X1359 Logo plate cover, E238...

  • Page 242: Assembly 2: Electronics

    4511-xxx Assembly 2: Electronics Service Manual...
  • Page 243 • Main drive motor 40X1323 Input #1 sensor assembly 40X1326 Cover open sensor assembly 40X1328 Cooling fan 40X1332 Toner level sensor 40X1360 Controller card, E238 40X1305 Controller card, E240 40X1306 Controller card, E240n 40X1307 Controller card, E340 40X1308 Controller card, E342n 40X1316...

  • Page 244: Assembly 3: Frame

    4511-xxx Assembly 3: Frame Service Manual...
  • Page 245 4511-xxx Assembly 3: Frame Asm- Part Units/ Units/ Description Index number mach 3–1 40X1334 Paper exit guide assembly 40X1322 Transfer roll, bearings, gear, spring 40X1321 Legal-size paper extender cover 40X1347 Legal-size paper extender cover (white) 40X1353 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)

  • Page 246: Assembly 4: Options

    4511-xxx Assembly 4: Options Asm- Part Units/ Units/ Description Index number mach 40X1564 32MB flash card assembly 40X1513 Simplified Chinese font card assembly 40X1514 Traditional Chinese font card assembly 40X1512 Japanese font card assembly 40X1515 Korean font card assembly 40X1364 32MB SDR DIMM 40X1365 64MB SDR DIMM...

  • Page 247: Assembly 5: Miscellaneous

    4511-xxx Assembly 5: Miscellaneous Asm- Part Units/ Units/ Description Index number mach 40X1368 USB cable, packaged (2 m) 40X1367 Parallel cable, packaged (3 m) 7372839 Field location package assembly 40X0289 Power cord, 1.8M (straight)—USA, Canada 40X0278 Power cord, 6 foot (straight)— Europe and others 40X0288 Power cord, 6 foot (straight)—...
  • Page 248 4511-xxx 7-10 Service Manual...
  • Page 249 2-65 printing menu Setup Auto CR After LF abbreviations Auto LF After CR acronyms Demo Mode Auto CR After LF, E238/E240(n) table of light patterns Auto LF After CR, E238/E240(n) autocompensator clutch Mac Binary PS parts catalog NPA Mode removal...
  • Page 250 4-21 Parallel Download Emuls, E340/E342n 3-17 Par S Strobe Adjustment 3-12 DRAM Test, E340/E342n 3-24 printout sample dump NVRAM, E238/E240(n) 3-13 diagnostics mode—E340/E342n 3-14 available tests 3-19 Base Sensor Test 3-28 Edge to Edge Device Tests E238/E240(n)
  • Page 251 4-44 handling ESD-sensitive parts input sensor #2 4-36 Hex Trace print media types and sizes E238/E240(n) mark history, E238/E240(n) 3-13 E340/E342n 2-54 menus History E238/E240(n) E238/E240(n) 3-13 accessing service menus E340/E342n, see error log...
  • Page 252 3-14 power-on self test (POST) trays available E238/E240(n) E340/E342n 2-50 symptoms 2-79 PPDS emulation, E340/E342n 3-16 NPA Mode, E238/E240(n) Print Contrast, E340/E342n 3-31 print history, E238/E240(n) 3-12 operator panel print media LCD—E340/E342n preventing jams buttons trays by model...
  • Page 253 4-18 Reset PC Counter covers E238/E240(n) extender E340/E342n 3-16 front access cover 238/E240(n) E340/E342n safety information front access cover logo—E238/ secondary error codes E240(n) 4-27 complex page 2-27 left side cover defective flash 2-31 rear cover 4-10 error communicating with the host...
  • Page 254 2-89 toner capacity 2-89 start LVPS/HVPS 2-90 strobe adjustment, E340/E342n 3-30 main motor 2-91 sub error codes 2-68 operator panel E238/E240(n) 2-92 symptom tables 2-79 operator panel E340/E342n 2-93 POST 2-79 paper feed 2-94 printer 2-79 paper jam during POST...

  • Page 255: Part Number Index

    LCD operator panel assembly, E340/E342n ....40X1316 LED operator panel assembly, E238/E240/E240n ..40X1317 LVPS/HVPS card assembly, 110 V ....
  • Page 256 LCD operator panel assembly, Katakana ....40X1359 Logo plate cover, E238 ......40X1360 Controller card, E238 .
  • Page 257 4511-xxx 40X1367 Parallel cable, packaged (3 m) ......40X1368 USB cable, packaged (2 m) ......40X1512 Japanese font card assembly .
  • Page 258 4511-xxx I-10 Service Manual...

  • Page 259: Wiring Diagram

    11 12 13 (if equipped) +24v +24v (5VDC) TxEnable_C (5VDC) Tx_C Dev_C Charge_C Photoconductor Charge Roller Photoconductor Excl. E238 Legend I n p u t = Output = Plugged Voltage = Paper Feed Solenoid Solenoid All voltages are DC unless otherwise noted...

This manual is also suitable for:

E240E240nE340E342n4511-0004511-100 ... Show all

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