Lexmark Optra N 4040 Service Manual
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Lexmark Optra N 4040 Service Manual

Lexmark Optra N 4040 Service Manual

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Optra™ N
4040
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
Lexmark and Optra are trademarks of
Lexmark International, Inc., registered
in the United States and/or other
countries.

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Summary of Contents for Lexmark Optra N 4040

  • Page 1 Optra™ N 4040 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Comments may be addressed to Lexmark International, Inc., Department D22/ 035-3, 740 New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 3: Table Of Contents

    4040 Contents Notices and Safety Information ......xii Laser Notice ........xii Safety Information.
  • Page 4 4040 Base Machine Service Checks (Continued) Paper Pick-Up from Multipurpose Tray Service Check . 2-27 Printhead Service Check ......2-28 Printhead/Laser Service Check .
  • Page 5 4040 Paper Deck Service Checks ......2-53 Paper Deck Feed Roller Service Check... . . 2-53 Paper Deck Lifting Plate Service Check.
  • Page 6 4040 Repair Information ........4-1 Handling ESD-Sensitive Parts .
  • Page 7 4040 Exposure System Removal Procedures ....4-41 Printhead Removal......4-42 Electrostatic Imaging/Developing/Cleaning System Removal Procedures .
  • Page 8 4040 Duplex Assembly Removal Procedures....4-77 Upper Guide Removal ......4-77 Lower Guide Removal .
  • Page 9 4040 Locations (Continued) Cross Section View of Envelope Feeder ... . . 5-5 Base Machine Sensor and Switch Operation..5-6 Base Machine Motor and Clutch Operation ... 5-8 Paper Feed.
  • Page 10 4040 Locations (Continued) Envelope Feeder Driver Board ....5-41 Paper Deck Switches, Sensors, Clutches, Solenoid, Motors . 5-42 Paper Deck Printed Circuit Boards ....5-43 Paper Deck Connectors .
  • Page 11 4040 Parts Catalog ........7-1 How To Use This Parts Catalog .

  • Page 12: Notices And Safety Information

    4040 Notices and Safety Information 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, pro- gram, or service may be used.
  • Page 13 4040 The Class 1 laser label is attached to the back of the printer. 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) 825 gemäß...
  • Page 14 4040 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...
  • Page 15 4040 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 825.
  • Page 16 4040 Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 825. 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.
  • Page 17 4040 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 825. 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...
  • Page 18 4040 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 825.
  • Page 19 4040 Chinese Laser Notice Korean Laser Notice Notices and Safety Information xix...

  • Page 20: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 21 Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.
  • Page 22 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
  • Page 23 Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d’aquest producte està...
  • Page 24 4040 xxiv Service Manual...

  • Page 25: Preface

    4040 Preface This manual is divided into the following chapters: • “General Information” contains a general description of the printer and the maintenance approach used to repair it. Special tools, test equipment, and options are listed. • “Diagnostic Information” contains error code table, symptom table, and service checks used to isolate failing field replaceable units (FRUs).

  • Page 26: General Information

    4040 1. General Information The Optra N, model 4040 is a 600 dpi laser printer designed to attach to IBM-compatible PC’s and to most types of computer net- works. Options The following options are available. Some options are not available in every country.

  • Page 27: Tools

    4040 Tools The removal and adjustment procedures described in this manual require the following tools and equipment: • Magnetic tip Phillips screwdrivers large and small • Flat-blade screwdriver • Analog volt ohmmeter (a digital volt ohmmeter may also be used). •...

  • Page 28: Abbreviations

    4040 Abbreviations ASIC Application-Specific Integrated Circuit Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read- Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply Local Area Network LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode...

  • Page 29: Diagnostic Information

    4040 2. Diagnostic Information Diagnostic Approach This printer can be serviced without being connected to a host com- puter. This printer displays both operator correctable errors and service errors on the front (operator) panel. In addition, there are two tests available from the base machine and the optional 2000 sheet paper deck that allow you to bypass the controller card.
  • Page 30 4040 • The room temperature is between 10 and 32.5 ° C, and the rela- tive humidity between 20 and 80%. • Avoid sites generating ammonia gas, high temperature or high humidity (near water faucets, kettles, humidifiers), cold spaces, near open flames, and dusty areas. •...

  • Page 31: Troubleshooting

    4040 Troubleshooting Use the error message tables, symptom table, and service checks, in this chapter and the diagnostic aids in Chapter 3 to diagnose a failure. If the operator panel is blank, black, has diamonds across the dis- play, or appears unusual, unplug the controller card and run “Basic Engine Test”...

  • Page 32: Error Code/Message Tables

    4040 Error Code/Message Tables Service Error Codes Error Symptom or Message Action Unrecoverable Software Refer to the operator manual Error Fuser Error, Fuser lamps do Go to the “Fuser (Temperature not come on during POR, or Low) Service Check (920/922)” on fuser lamps come on but do page 2-23.
  • Page 33 4040 Error Symptom or Message Action Paper Deck Option Card, No Check all connectors on the paper response deck board and be sure all doors are securely closed. POR the machine. If you still have a failure, replace the paper deck option controller card (29-1).
  • Page 34 4040 Error Symptom or Message Action Network Card Error The system processor has detected an INA card is installed but cannot communicate with it. The X after the card indicates which one has the problem. Net- work card 1 will always refer to the INA in the bottom slot and Net- work card 2 will always refer to the INA card in the top slot.

  • Page 35: Operator Codes

    4040 Operator Codes The following code numbers are operator instructions and mes- sages. In some cases, no action is required; others are operator-cor- rectable; others may require service. An error code may require up to two minutes to appear. Some symptoms may not generate an error code.
  • Page 36 4040 Code Message or Symptom Action Output Bin Full, top bin only Remove the paper from the output face-down bin. Check and replace if necessary: • Paper Full Lever (16-4) • Switch Sensor Board (4-18) Print Cartridge Missing Be sure the print cartridge is prop- erly installed.

  • Page 37: Diagnostic Information

    4040 Code Message or Symptom Action Duplex not attached Be sure the duplexer is securely latched into the printer. POR to reset the printer. Print Job on Disk No service required, refer to oper- ator manual. Unformatted Disk Format the disk. Go to “Diagnostic Aids”...
  • Page 38 4040 If you think your symptom is caused by a paper feed problem in the paper deck go to “Paper Deck Paper Feed Service Checks” on page 2-58. If you think your symptom is caused by any other malfunction, go to “Other Malfunction Symptom Table”...

  • Page 39: Symptom Tables

    4040 Symptom Tables Print Quality Symptom Table Symptom Action Black Page Go to “Black Page Service Check:” on page 2-30. Blank Spots Go to “Blank Spots Service Check” on page 2-30. Blank Page Go to “Blank Page Service Check” on page 2-31.

  • Page 40: Paper Feed Symptom Table

    4040 Symptom Action White Vertical Lines Go to “White Vertical Lines Service Check” on page 2-38. Paper Feed Symptom Table Symptom Action Paper Jam in Pick-up Assembly Go to “Pick-Up Assembly Paper Jams Service Check” on page 2-51. Paper Jam in Fuser and Delivery Go to “Fuser and Delivery, Paper Assembly...

  • Page 41: Other Malfunction Symptom Table

    4040 Other Malfunction Symptom Table Symptom Action Printhead Malfunction Go to the “Printhead Service Check” on page 2-28. Electrical Assembly Fan (FM3) Go to “Electrical Assembly Fan (FM3) Check” on page 2-21. Failure Faulty Main Motor Go to “Main Motor Service Check” on page 2-25.
  • Page 42 4040 Symptom Action No Paper Pick-Up from Upper Go to “Paper Pick-Up from Cas- settes Service Check” on page or Lower Cassette 2-26. No Paper Pick-Up from Enve- Go to “Paper Pick-Up from Enve- lope Feeder Service Check” on lope Feeder page 2-26.

  • Page 43: Paper Deck Symptom Table

    4040 Paper Deck Symptom Table Symptom Action No power Go to the “Paper Deck Power Input Service Check” on page 2-57. Wrinkled paper Go to the “Paper Deck Wrinkled Paper Service Check” on page 2-60. Bent leading paper edge Go to the “Paper Deck Bent Leading Edge Service Check”...

  • Page 44: Base Machine Service Checks

    4040 Base Machine Service Checks AC Power Input Service Check Action Voltage The correct voltage may not be present at the outlet. Inform the customer that the correct line voltage is not available at the outlet. The power cord may not be firmly plugged into Power Cord the printer, the paper deck and the outlet.

  • Page 45: Dc Power Input Service Check

    4040 DC Power Input Service Check Action AC Power If the ac power is not present, go to “AC Power Input Service Check” on page 2-16. Overcurrent/ The overcurrent/overvoltage detection circuit Overvoltage may be active. If the problem does not disap- Detection pear when the power switch is turned off and Circuit...

  • Page 46: Duplex Horizontal Registration Guide Service Check

    4040 Duplex Horizontal Registration Guide Service Check Action Connectors The horizontal registration guide home posi- tion sensor signal line and horizontal registra- tion motor drive signal line connectors may be loose. Reconnect connectors J2005 and J2006 on the duplexing driver board. Gears Gears may be damaged.

  • Page 47: Fan Motor Service Check (927)

    4040 Fan Motor Service Check (927) Be sure the power is on, then check the air flow from each fan to determine which fan is failing. Go to the appropriate fan check below. Diagnostic Information 2-19...

  • Page 48: Power Supply Fan (Fm1) Check

    4040 Power Supply Fan (FM1) Check Action Connector The FM1 drive signal line connector could be loose. Reconnect connector J208 on the sys- tem board. Power Sup- The power supply fan could be defective. Dis- ply Fan connect connector J208 on the system board. Turn the power switch on and measure the voltage between connector J208-1 (FAN1D) and J208-3 (GND) on the system board.

  • Page 49: Electrical Assembly Fan (Fm3) Check

    4040 Electrical Assembly Fan (FM3) Check Action FM3 Drive The FM3 drive signal line connector could be Signal Line loose. Reconnect connector J210 on the sys- tem board and connectors J12 and J13. Connector Electrical The electrical unit fan could be defective. Dis- Unit Fan connect connector J210 on the system board.

  • Page 50: Fuser (Abnormal Temperature) Service Check (923)

    4040 Fuser (Abnormal Temperature) Service Check (923) Action Thermistor The thermistor could be shorted. Turn the power off and remove the fuser assembly. Measure the resistance between the fuser connector J50B-2 (FSRTH) and J50B-3 (GNDTH). The connector J50B is the lower terminal of the left connector.

  • Page 51: Fuser (Temperature Low) Service Check (920/922)

    4040 Fuser (Temperature Low) Service Check (920/922) Action Thermistor The thermistor may be dirty. If the thermistor contact area of the fuser upper roller is dirty, clean it. The thermistor may not be installed correctly. If the thermistor is not evenly contacting the fixing upper roller, re-install the thermistor cor- rectly.

  • Page 52: Fuser (Wrong Type) Service Check (924)

    4040 Fuser (Wrong Type) Service Check (924) Action Fuser The rated voltage of the fuser may not match the power supply voltage. Replace the fuser (18-1). Power Sup- The type detection circuit in the power supply may be defective. Replace the power supply (5-10).

  • Page 53: Lifting Plate (Multipurpose Tray) Service Check

    4040 Lifting Plate (Multipurpose Tray) Service Check Action Lifting Plate The lifting plate drive assembly could be Drive Assem- defective. Replace any damaged parts. Lifting Plate The lifting plate position sensor could be Position Sen- defective. Check the sensor (PS1302) by sor (PS1302) measuring the voltage at J214-3 and J214-6 (+5 V).

  • Page 54: Paper Pick-Up From Envelope Feeder Service Check

    4040 Paper Pick-Up from Envelope Feeder Service Check Action The controller card could be defective. Run Controller paper feed test in Diagnostic Aids to determine Card If the which paper path is causing the problem. envelope is picked up correctly from the enve- lope feeder, replace the controller card (19-2).

  • Page 55: Paper Pick-Up From Multipurpose Tray Service Check

    4040 Action Cassette The cassette pick-up solenoid could be defec- Pick-up Sole- tive. Remove the pick-up unit, and disconnect noid (SL1) cassette pick-up solenoid connector J1203 from the pick-up board. Measure the resis- tance between connectors J1203-1 and J1203-2 on the cable side. If it is not about 155 Ohms, replace the cassette pick-up sole- noid (11-56).

  • Page 56: Printhead Service Check

    4040 Printhead Service Check Condensation could cause this problem. Leave the printer running for 10 to 20 minutes. Action Printhead The printhead signal line connector could be Board Signal loose. Reconnect connector J6 on the print- head board and J206 on the system board. Line Connec- Printhead The printhead assembly could be defective.

  • Page 57: Printhead/Scanner Motor Service Check

    4040 Printhead/Scanner Motor Service Check Action The scanner motor drive line connectors could Connectors be loose. Reconnect connector J1 on the scanner driver board, connector J18, and con- nector J207 on the system board Printhead/ The scanner motor driver could be defective. Scanner Check the connectors on the printhead.

  • Page 58: Print Quality Service Checks

    4040 Print Quality Service Checks Black Page Service Check: Action EP Cartridge The EP cartridge may be defective. Replace the cartridge. High Voltage Be sure all the mounting screws are in place Power Supply and properly tightened. The primary changing roller-bias contact of the high-voltage power supply may not be making a good connection with the cartridge contact (7-2).

  • Page 59: Blank Page Service Check

    4040 Action EP Cartridge If the blank spots on the paper are uniformly spaced approximately 75mm apart, the EP cartridge may be defective. The EP cartridge is a supply item, replaced by the customer. Blank Page Service Check Action EP Cartridge The projection for opening and closing the laser shutter of the EP cartridge may be dam- aged.

  • Page 60: Dark Image Service Check

    4040 Dark Image Service Check Action Image Density The Image density may not be adjusted cor- rectly. Adjust the Image density through the host software. High Voltage The drum grounding contact of the high-volt- Power Supply age power supply may not be making a good connection with the cartridge contact.

  • Page 61: Dirty Image Service Check

    4040 Action • Transfer Check for dirt and clean if necessary. Guide • Feeder Guide • Fuser Entry Guide Dirty Image Service Check Action Paper Make sure the paper is clean. • Pick-up Clean dirty rollers. If they cannot be cleaned, The transfer Roller replace them (11-20, 2-7, 18-20).

  • Page 62: Light Image Service Check

    4040 Light Image Service Check Action Image Density The Image density may not be adjusted cor- rectly. Adjust the Image density by operating the external device. Toner Low toner. Replace the EP cartridge. Toner Image Open the upper cover and remove the EP cartridge while a print is being made.

  • Page 63: Poor Fusing Service Check

    4040 Poor Fusing Service Check Action Envelope The envelope position levers of the fuser are Position raised. Push the levers down (18-6). Lever Fuser Upper If the poorly fused spots are uniformly spaced Roller approximately 126mm apart, the upper fuser roller could be defective.

  • Page 64: Smudged Horizontal Bands Service Check

    4040 Smudged Horizontal Bands Service Check Action EP Cartridge The EP cartridge could be defective. Replace it if necessary. Fuser Upper The fuser upper roller could be dirty, Roller deformed, or worn. Replace the fuser upper roller (18-20). Vertical Dots in a Line Service Check Action Static Charge Check the static charge eliminator (12-8) for dirt.

  • Page 65: Vertical Streaks/Lines Service Check

    4040 Vertical Streaks/Lines Service Check Action Photosensi- The photosensitive drum could be damaged. tive Drum Replace the EP cartridge. Fuser Entry The fuser entry guide could be dirty. Clean the Guide fuser entry guide. Fuser Upper The fuser upper roller could be scratched. Roller Remove the cause of the damage and replace the roller (18-20).

  • Page 66: White Vertical Lines Service Check

    4040 White Vertical Lines Service Check Action Toner Lack of toner. Take out the EP cartridge, rock it to distribute the toner evenly, then reinstall it. If the problem continues, replace the EP car- tridge. Photosensi- The photosensitive drum could be scratched. tive Drum Replace the EP cartridge.

  • Page 67: Paper Feed Service Checks

    4040 Paper Feed Service Checks It is easier to troubleshoot paper feed problems if you override the top cover and delivery door interlock when you run paper feed tests in the diagnostic mode. To do this: 1. Access the paper menu through the operator panel and select submenu Output Bin.

  • Page 68: Bent Leading Edge Of Paper Service Check

    4040 The following information explains troubleshooting for paper jams in each of these assemblies. This section also covers multiple paper feed, wrinkles, bent leading edge, and skewing. Locate your symp- tom in the “Paper Feed Symptom Table” on page 2-12 and take the indicated action.

  • Page 69: Duplexing Assembly Paper Jams Service Check

    4040 Duplexing Assembly Paper Jams Service Check Action Feed Guide Foreign matter may be adhering to the feed guide or it is burred. Remove any foreign mat- ters. If the guide is burred, replace it (22-6). • Switchback The switchback roller, feed roller, or duplex Roller feed roller may be worn or deformed.

  • Page 70: Envelope Feeder Paper Jams Service Check

    4040 Envelope Feeder Paper Jams Service Check Action Envelopes Be sure the recommended envelopes are being used and that there are not too many envelopes in the feeder. Envelope The envelope guide may be pressing against Guide the envelopes. Advise the customer not to set the envelope guide too close to the envelopes.

  • Page 71: Fuser And Delivery, Paper Jams Service Check

    4040 Fuser and Delivery, Paper Jams Service Check Action Fuser Roller The fuser roller does not rotate smoothly. Check for worn or missing gears. Fuser The fuser entrance guide is dirty, damaged, or Entrance clogged with toner. Clean the guide. Guide Fuser Sepa- The fuser separation guide could be dirty,...

  • Page 72: Multiple Paper Feed Service Check

    4040 Multiple Paper Feed Service Check Be sure the recommended paper is being used. If this problem occurs with the multipurpose tray, perform step 3 and subsequent steps. Action The separation roller could be worn or Separation deformed. Run the paper feed test in Diagnostic Roller, Tray 1 Aids to determine which paper path is causing the and 2...

  • Page 73: Paper Jam Sensor Service Check

    4040 Paper Jam Sensor Service Check Paper passes through four major assemblies of the printer: 1. Multipurpose and Envelope Feeder 2. Paper Pick-Up and Registration 3. Duplexer 4. Fuser and Delivery Paper movement is measured in time intervals. A paper jam error code is generated when the moving paper fails to arrive at a specific paper station (PS).
  • Page 74 4040 failure, such as a guide, solenoid, clutch, motor, or gear, and you should go to the appropriate service check. It is important to know which paper path your printer is using when the error code is generated. To check, clear all jammed paper and turn the printer off.

  • Page 75: Paper Jam 20, Paper Deck Tray Or Feeder

    4040 Paper Jam 20, Paper Deck Tray or Feeder Action • Tray 1, 2 Check PS2 pick-up unit paper sensor J219 on the • Pick-Up system board, pin 8 (+5V) to ground. You should Unit Paper see a lower reading when the sensor detects paper. Sensor You can actuate this sensor by sliding a sheet of (PS2)

  • Page 76: Paper Jam 21, Input

    4040 Paper Jam 21, Input Action Registration Check for paper jams in both the envelope feeder Paper Sensor and the multipurpose tray. Remove any paper. (PS1) There are no paper jam sensors in either area. There is a printer input sensor (PS1) in the registra- tion station.

  • Page 77: Paper Jam 23, Top Output/Delivery

    4040 Paper Jam 23, Top Output/Delivery Action Delivery Sen- Remove paper from the rear paper delivery guide. Be sure the delivery sensor actuator operates freely. Switch Sensor Check the delivery paper sensor at J205, pin 9 Board (+5V) to ground for a higher reading when paper is (PS1402) detected.

  • Page 78: Paper Skew Service Check

    4040 Action Guides Be sure the side and end guides are installed in the correct paper size slots. Replace the guides if they are damaged. Front Lock Be sure the front paper size lock is completely locked. Replace the lock if it is damaged. Paper Size Be sure the upper (10-4) and lower (9-4) paper size Sensor Indica-...

  • Page 79: Pick-Up Assembly Paper Jams Service Check

    4040 Pick-Up Assembly Paper Jams Service Check Be sure the recommended paper is being used and that the paper is not curled or wrinkled. If Jams occur in the manual feed pick-up assembly, perform step 3 below and all subsequent steps. If jams occur in the cassette paper pick-up assembly, perform step 6 and all subsequent steps.

  • Page 80: Wrinkled Paper Service Check

    4040 Action The cassette pick-up roller (11-20), separation • Cassette roller (11-20), or feed roller (11-38) could be Pick-Up worn or deformed. Replace if worn or Roller deformed. Run • Separation the paper feed test in Diagnostic Roller Aids to determine which paper path is causing the •...

  • Page 81: Paper Deck Service Checks

    4040 Paper Deck Service Checks Paper Deck Feed Roller Service Check Action Gears Gears could be damaged. Replace any damaged gears (27-11). Feed Clutch The feed clutch could be damaged. Remove (CL33) connector J102. Measure the resistance between connectors J102-9 and J102-10 on the clutch side.
  • Page 82 4040 Action Sensing Remove connector J121 from the lifter abnormal position sensing switch. Measure the resistance Switch between connectors J121-1 and J121-2 on the (SW31) switch side. Replace the switch, (26-43) if the resistance reads infinity when the switch is closed.

  • Page 83: Paper Deck Motor Service Check

    4040 Paper Deck Motor Service Check Action Drive Signal The deck motor drive signal line connector Line Connec- may not be connected properly. Reconnect deck motor connector J118 and connector J204 on the paper deck driver board. Deck Motor The deck motor may be defective. Measure (MT31) the voltage between connectors J204-4 (DCMOT-ON) and J204-2 (GND) on the paper...
  • Page 84 4040 Action Paper Deck The option controller card could be defective (29-1). Option Con- troller Card Controller The controller card could be defective (19-2). Card 2-56...

  • Page 85: Paper Deck Power Input Service Check

    4040 Paper Deck Power Input Service Check Be sure voltage is present at the outlet and the power cords are firmly pugged into the printer and paper deck. Action Connector If the power on signal is not being input, there may be a poor connection at the interface connector.

  • Page 86: Paper Deck Registration Roller Service Check

    4040 Paper Deck Registration Roller Service Check Action Gears could be damaged. Replace any dam- Gears aged gears Registration The registration clutch could be defective. Clutch Remove connector J102. Measure the resis- (CL32) tance between connectors J102-7 and J102-8 on the clutch side. If it is not about 210 Ohms, replace the registration clutch (28-13).

  • Page 87: Paper Deck Left Edge Registration Service Check

    4040 Paper Deck Left Edge Registration Service Check Action Paper Guide The paper guide may not be inserted into the cor- rect paper size position. The upper or lower end of the paper guide may not be inserted into the same paper size position Paper Deck Multiple Paper Feed Service Check Be sure the recommended paper is loaded in the printer.

  • Page 88: Paper Deck Paper Skew Service Check

    4040 Action Paper Deck The paper deck pick-up roller may not be Pick-Up rotating during printing. Go to “Paper Deck Roller Registration Roller Service Check” on page 2-58. Paper Deck Paper Skew Service Check Be sure the recommended paper is correctly loaded in the machine and the paper is not curled, wrinkled or deformed.

  • Page 89: Diagnostic Aids

    4040 3. Diagnostic Aids This printer can run internal diagnostics tests. These tests are in the same format as the other Optra models and are described in this chapter. The printer may be tested without the controller card. The basic engine test will isolate any a failure to either the engine or the con- troller card.

  • Page 90: Basic Engine Test

    4040 Basic Engine Test This test eliminates the controller card as the source of a malfunc- tion. 1. Turn the printer off. 2. Disconnect the controller card by sliding it to the rear 1 inch. The display will not function until the controller card is recon- nected.
  • Page 91 4040 4. Locate JP201 on the paper deck board. Jumper Function Number JP201-1 JP201-2 TEST-1: Jumper to enter the test mode. JP201 -3 TEST-2: reserved JP201-4 JP201-5 PWRON-IN signal 5. Short out TEST-1 and GND, and turn on the printer, to enter test mode.

  • Page 92: Diagnostics Mode

    4040 Diagnostics Mode To run the printer diagnostic tests, you must put the printer in Diagnostics mode. The controller card must be plugged into the system board (normal state). Note: Entering the Diagnostic mode clears NVRAM. To enter Diagnostics mode: 1.
  • Page 93 4040 Button Test Parallel Confidence Test Wrap Tests Parallel Serial Memory Tests DRAM PAGE COUNTS Page Count Permanent Page Count Maintenance Page Count PAPER FEED TESTS Tray 1 Tray 2 Tray 3 (if installed) Multipurpose Feeder (if installed) DUPLEX Duplex Quick Test DEVICE TESTS (If Installed) Disk Test/Clean Quick Disk Test...

  • Page 94: Diagnostics Mode Tests

    4040 Diagnostics Mode Tests Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Button Test]. 4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed. 5.

  • Page 95: Error Log

    4040 1. Enter Diagnostics mode. 2. Select [DEVICE TESTS]. 3. Select [Disk Test/Clean]. 4. Select [CONTINUE] to start the test, or [CANCEL] to return to Diagnostics mode main menu. 5. Select [CANCEL] to interrupt the test. 6. Press Return to return to the Diagnostics mode main menu. Duplex Quick Test Print on both sides with machine specification information on one side.

  • Page 96: Flash Test

    4040 Flash Test This test causes the file system to write and read data on the flash to test the flash device. This test destroys all data on the flash. The flash is formatted at the end of the test. 1.

  • Page 97: Page Count

    4040 Paper Feed Tests Tray 1 Tray 2 Tray 3 Multipurpose Feeder Page Count To view or set the page count: 1. Enter Diagnostics mode. 2. Select [PAGE COUNTS]. 3. Select [Page Count]. 4. Choose any number between 0000000 and 9999999 by selecting [Next] to move the cursor under each digit.

  • Page 98: Print Test 2

    4040 1. Enter Diagnostics mode. 2. Select [PRINT TESTS]. 3. Select [Print Test 1]. 4. Select [Single] or [Continuous]. 5. Select [CANCEL] to stop continuous print. 6. Press Return to return to the main Diagnostics mode main menu. Print Test 2 Print Test 2 generates two printouts: a page similar to the test page, and a fine dot pattern with two black 1 inch squares which can be used to evaluate banding or other print quality problems.

  • Page 99: Print Registration

    4040 Print Registration Use the 3 sub menus of this selection to adjust the left margin, adjust the top margin, and to verify the settings. Left Margin When you select Left Margin, the current value of the left margin is indicated in the display.

  • Page 100: Quick Disk Test

    4040 Quick Disk Test This test performs a non-destructive write/read on one block per track on the disk. The test will read one block on each track, save the data, and proceed to write and read four test patterns to the bytes in the block.
  • Page 101 4040 A [Passed] message indicates the printer connection to the printer cable connector is good. A [Failed] message indicates a defective RIP board. Note: Ignore the number displayed after a failure is displayed. 10. Press Return to return to the Diagnostics mode main menu. 11.

  • Page 102: Repair Information

    4040 4. Repair Information This chapter describes mechanical operation as well as adjustments and removal procedures. Whenever you replace parts, make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed. Note the following precau- tions during disassembly or reassembly.

  • Page 103: Handling Esd-Sensitive Parts

    4040 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 pre- cautions, such as turning off power before removing logic boards: •...

  • Page 104: Adjustments

    4040 Adjustments Envelope Feeder Separation Guide and Lower Separation Roller Gap Adjustment Under normal conditions, remove the separation guide along with the upper cover. If you removed just the separation guide or replaced a bent separation guide, adjust the gap as follows: Insert the separation guide 1.5 mm from the lower separation roller.

  • Page 105: Paper Drawer Cassette Side Registration Adjustment

    4040 Paper Drawer Cassette Side Registration Adjustment Make this adjustment when the side registration of the cassette is not aligned. The side adjustment registration levers in the upper and lower cassettes are adjusted in the factory. There is no need to make adjustments when you install the machine.

  • Page 106: Service Information

    4040 Service Information Releasing Plastic Latches Many of the parts are held in place with plastic latches. To remove such parts, press the hook end of the latch away from the part to which it is latched.

  • Page 107: External Parts Removal Procedures

    4040 External Parts Removal Procedures Cover Removal Procedures 1. Delivery Cover 2. Upper Cover 3. Operator Panel 4. Face-down Tray 5. Upper Cover 6. Rear Cover 7. Multipurpose Tray 8. Pick-Up Door 9. Duplex Door 10. Front Cover Repair Information 4-6...

  • Page 108: Face-Down Tray Removal

    4040 Face-Down Tray Removal 1. Open the upper cover (1). 2. Move the lock lever (2) in the direction of the arrow. 3. Close the upper cover and remove the face-down tray (1).

  • Page 109: Front Cover Removal

    4040 Front Cover Removal 1. Open the upper cover. 2. Open the duplex door (1). 3. Remove the 3 screws (2). 4. Open the delivery cover, and undo the latch (1). Repair Information 4-8...

  • Page 110: Upper Cover Removal

    4040 5. Open the pick-up unit door (1), disconnect the latch (2) and remove the front cover (3). Upper Cover Removal 1. Remove the face-down tray. 2. Remove the front cover. 3. Remove the 2 latches (1), and then the operator panel (2). 4.
  • Page 111 4040 5. Remove the 2 screws (1). 6. Remove the screw (1), and then the upper cover (2). Repair Information 4-10...

  • Page 112: Rear Cover Removal

    4040 Rear Cover Removal 1. Open the upper cover. 2. Open the pick-up door. 3. Remove the 2 screws (1), the latch (2), and the right rear cover (3). 4. Remove the 6 screws (1) and take off the rear cover (2). 4-11...

  • Page 113: Delivery Cover Removal

    4040 Delivery Cover Removal 1. Open the delivery cover (1). 2. Remove the 2 rods (2) holding the delivery cover, pull out the right side first, then the left. MultiPurpose Tray Removal 1. Open the multipurpose tray. 2. Remove the 2 stoppers (1). 3.

  • Page 114: Right Cover Removal

    4040 Right Cover Removal 1. Remove the front cover. 2. Remove the right cover (1). 3. Remove the hinge (2) from the right cover, and then the 4 screws (3). 4. Remove the cassettes. 5. Remove the 2 latches (1), and then the right cover. 4-13...

  • Page 115: Left Rear Cover Removal

    4040 Left Rear Cover Removal 1. Open the delivery cover. 2. Remove the 3 screws (1) and the left rear cover (2). Repair Information 4-14...

  • Page 116: Fan Removal Procedures

    4040 Fan Removal Procedures There are 4 fan motors installed in the printer to circulate air and to prevent the internal temperature from rising. 1. Power supply fan (FM1): Blows air from the power supply. 2. Fuser/Scanner fan (FM2): Blows air from the fuser and the print- head assembly.

  • Page 117: Power Supply Fan (Fm1) Removal

    4040 Power Supply Fan (FM1) Removal 1. Remove the right rear cover and the rear cover. 2. Disconnect the connector (1). 3. Remove the 2 screws (1), and then the power supply fan (2). Repair Information 4-16...

  • Page 118: Fuser/Scanner Fan (Fm2) Removal

    4040 Fuser/Scanner Fan (FM2) Removal 1. Remove the right rear cover and the rear cover. 2. Remove the upper cover. 3. Disconnect the connector (1). 4. Disconnect the connector (1). 5. Remove the cable tie (2), then remove the cable (3) from the cable guide (4).
  • Page 119 4040 6. Remove the cable (1) from the guide (2). 7. Unhook the latch (3), then remove the fan duct (4). 8. Remove the 2 screws (1), and then the fuser/scanner fan (2). Repair Information 4-18...

  • Page 120: Electrical Fan (Fm3) Removal

    4040 Electrical Fan (FM3) Removal 1. Remove the right rear cover and the rear cover. 2. Remove the left rear cover. 3. Undo the connector (1). 4. Pinch the 2 latches (2) holding the electrical fan (3) and pull out the fan.

  • Page 121: Fuser Fan (Fm4) Removal

    4040 Fuser Fan (FM4) Removal 1. Remove the upper cover unit. 2. Open the delivery cover unit. 3. Remove the left rear cover. 4. Undo the connector (1). 5. Remove the screw (2), and then the fan grounding plate (3). Disconnect the 4 latches to remove the fuser fan (4) Repair Information 4-20...

  • Page 122: Operator Panel Removal

    4040 Operator Panel Removal 1. Open the upper cover. 2. Remove the front cover. 3. Unlatch the 2 latches (1) and remove the operator panel (2). 4. Remove the connector and then the operator panel. 4-21...

  • Page 123: Drive System Removal Procedures

    4040 Drive System Removal Procedures Drive Unit Removal 1. Remove the pick-up unit. 2. Remove the screw (1), and then the cassette stay (2). 3. Disconnect the latch (1), and then the clutch cover (2). Repair Information 4-22...
  • Page 124 4040 4. Remove the high voltage power supply unit. 5. Undo the connector, remove the 4 screws and then the main motor. 6. Remove the 2 screws (1) and the drive unit (2) 4-23...

  • Page 125: Main Motor Removal

    4040 Main Motor Removal 1. Remove the right rear cover and the rear cover. 2. Remove the high-voltage power supply. 3. Undo the connector (1), remove the 4 screws (2), and then the main motor (3). Repair Information 4-24...

  • Page 126: Paper Transport System Removal Procedures

    4040 Paper Transport System Removal Procedures Pick-Up Unit Removal 1. Pull out the upper and lower cassettes. 2. Remove the manual feed pick-up unit. 3. Remove the right cover. 4. Undo the connector (1) 4-25...
  • Page 127 4040 5. Remove the pick-up, feed, and separation rollers. 6. Remove the cable (1) from the guide (2). 7. Remove the 4 screws (3), and take out the pick-up unit (4). For Assembly: Remove the pick-up feed and separation rollers dur- ing assembly to prevent grease from getting on them.
  • Page 128 4040 1. 57T Gear 2. Upper Lift-up Cam 3. Pick-up Cam 4. 100T Gear 5. Lower Lift-up Cam 6. 31T/47T Gear 7. 20T/41T Gear 4-27...

  • Page 129: Pick-Up Motor Removal

    4040 Pick-Up Motor Removal 1. Undo the connector (1). 2. Remove the 2 screws (2), and slide the pick-up motor (3) out. Feed Clutch Removal 1. Disconnect the connector (1). 2. Remove the screw (2), and disconnect the 2 latches (3) to remove the pick-up board (4).

  • Page 130: Cassette Pick-Up Solenoid Removal

    4040 3. Undo the latch (1) and remove the clutch fixing plate (2). 4. Remove the E-ring (3), and then the feed clutch (4). Cassette Pick-Up Solenoid Removal 1. Disconnect the connector (1). 2. Remove the screw (2) and take out the cassette pick-up sole- noid (3).

  • Page 131: Delivery Unit Removal

    4040 Delivery Unit Removal 1. Remove the upper cover unit. 2. Remove the front cover. 3. Remove the right rear cover and the rear cover. 4. Open the delivery cover unit. 5. Remove the left rear cover. 6. Disconnect the connector (1) and remove the 3 screws (2). 7.

  • Page 132: Registration Roller Removal

    4040 Registration Roller Removal 1. Open the upper cover. 2. Remove the clutch cover. 3. Open the transfer charging roller guide (1). 4. Undo the connector (1). 5. Remove the 4 screws (2) and take out the registration roller (3). 4-31...

  • Page 133: Registration Clutch Removal

    4040 Registration Clutch Removal 1. Remove the E-ring (1) and the registration clutch (2). Registration Lower Roller Removal 1. Remove the registration clutch. 2. Remove the spring (1), the E-ring (2) and the bushing (3). Repair Information 4-32...
  • Page 134 4040 4-33...

  • Page 135: Manual Feed Pick-Up Removal

    4040 3. Remove the gear (1), the spring (2), the E-ring (3), the bushing (4), and then the registration lower roller (5). Manual Feed Pick-Up Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the multipurpose tray. 4.
  • Page 136 4040 6. Remove the 4 screws (1), and then the manual feed pick-up unit (2). 4-35...

  • Page 137: Manual Feed Pick-Up Clutch Removal

    4040 Manual Feed Pick-Up Clutch Removal 1. Disconnect the connector (1). 2. Remove the E-ring (2) and the bushing (3). 3. Remove the 2 screws (4), the take out the drive side plate (5) and the manual feed pick-up clutch (6). Lifting Plate Solenoid Removal 1.
  • Page 138 4040 3. Disconnect the connector (1). 4. Remove the 2 screws (2), and the manual feed drive unit (3). 5. Remove the 2 screws (1), and then the lifting plate solenoid (2). 4-37...

  • Page 139: Manual Feeding Pick-Up Roller Removal

    4040 Manual Feeding Pick-Up Roller Removal 1. Open the multipurpose tray. 2. Remove the cover (1). 3. Press the lifting plate (1), grasp the manual feeding pick-up roller knob, and pull out the roller (2). Repair Information 4-38...

  • Page 140: Separation Pad Removal

    4040 Separation Pad Removal 1. Open the multipurpose tray. 2. Remove the manual feeding pick-up roller. 3. Use a flat-bladed screwdriver to remove the separation pad (1). 4-39...

  • Page 141: Pick-Up/Feed/Separation Rollers Removal

    4040 Pick-Up/Feed/Separation Rollers Removal 1. Pull out the upper and lower cassettes. 2. Grasp the knobs of each roller; the pick-up roller (1), the sepa- ration roller (2), and the feed roller (3), and pull the rollers out of the printer. 1.

  • Page 142: Exposure System Removal Procedures

    4040 Exposure System Removal Procedures The laser/scanner is the section that sweeps the laser beam across the photosensitive drum. The configuration of the printhead is shown below. 1. Scanner 2. BD Board 3. Laser 4-41...

  • Page 143: Printhead Removal

    4040 Printhead Removal 1. Remove the upper cover. 2. Disconnect the 3 connectors (1) and the cable (2) from the print- head. 3. Remove the 4 screws (1) and the printhead (2). Do not disassemble the printhead as it cannot be adjusted in the field.

  • Page 144: Electrostatic Imaging/Developing/Cleaning System Removal Procedures

    4040 Electrostatic Imaging/Developing/Cleaning System Removal Procedures EP Cartridge The EP cartridge consists of the photosensitive drum, primary charging roller, developing unit, and cleaning unit. As the photosen- sitive drum rotates within the cartridge, a visible image is formed on its surface based on print data as part of the printing process. The EP cartridge cannot be disassembled.

  • Page 145: Drum Protective Shutter

    4040 Drum Protective Shutter Since blank spots and black lines can appear on prints as a result of strong light striking the photosensitive drum, it is covered by a pro- tective shutter. Do not carelessly open the protective shutter. The protective shutter opens automatically when the cartridge is installed in the printer.

  • Page 146: Transfer Charging Roller Removal

    4040 Transfer Charging Roller Removal 1. Open the upper cover. 2. Open the transfer charging roller guide (1). 3. Pinch the gear (2), lift it slightly, and slide it to the left. Remove the transfer charging roller (3). Clean the transfer charging roller only when it is very dirty. Be careful when cleaning not to touch the roller or get solvents or oil on it.

  • Page 147: Fuser Removal Procedures

    4040 Fuser Removal Procedures 1. Fuser Fastening Levers 2. Separation Upper Guide 3. Fuser Upper Roller 4. Thermistor 5. Thermoswitch 6. Fuser Entrance Guide 7. Fuser Heater 8. Fuser Lower Roller 9. Separation Lower Guide 10. Envelope Lever Repair Information 4-46...

  • Page 148: Fuser Removal

    4040 Fuser Removal 1. Open the delivery cover unit. 2. Move the 2 fastened levers (1) of the fuser, slightly lift the fuser (2), and pull it out toward you. When you replace the fuser, be sure to position the fuser envelope lever in the same position it was in when you removed the fuser;...

  • Page 149: Fuser Roller Heater Removal

    4040 Fuser Roller Heater Removal 1. Disconnect the 2 latches (1) that hold the wire cover (2) to the fuser, and then remove the wire cover. 2. Remove the 2 screws (1) and the fuser lead wire (2). 3. Take out the 2 connectors (1). 4.

  • Page 150: Thermoswitch Removal

    4040 Thermoswitch Removal 1. Remove the wire cover. 2. Remove the 4 screws (1) and then the lead wire and ther- moswitch (2). 4-49...

  • Page 151: Thermistor Removal

    4040 Thermistor Removal 1. Remove the wire cover. 2. Disconnect the connector (1) and remove the cable from the fuser left cover. 3. Remove the screw (1) and the thermistor (2). When you install the thermistor, be sure its detection surface is uni- formly contacting the fuser upper roller surface.

  • Page 152: Fuser Upper Roller Removal

    4040 Fuser Upper Roller Removal 1. Hold up the left and right fuser fastening levers (1). 2. Hold up the left and right envelope levers (2). 3. Remove the 2 screws (3) and the separation upper guide (5) as you pull out the separation lower guide (4). 4.
  • Page 153 4040 5. Remove the fuser roller heater. 6. Remove the thermoswitch. 7. Remove the thermistor. 8. Remove the screw (1) and diode holder (2). 9. Remove the screw (3) and the fuser right cover (4). 10. Remove the 3 screws (1) and the fuser left cover (2). 11.
  • Page 154 4040 12. Remove the 2 screws (1), the grounding plate (2), and the ther- moswitch stay (3). 13.Remove the screw (1), undo the 2 latches (2), and take off the fixing roller cover (3). 4-53...
  • Page 155 4040 14.Remove the grounding ring (1). 15.Remove the C-ring (1) from the gear (2). Repair Information 4-54...
  • Page 156 4040 16.Remove the bushing (1). 17.Remove the C-ring (1) from the bushing (2). 18.Remove the bearing (3) from the fuser upper roller (4). 4-55...

  • Page 157: Fuser Lower Roller Removal

    4040 Fuser Lower Roller Removal 1. Remove the fuser upper roller. 2. Disconnect the latch (1) and remove the fuser entrance guide (2). 3. Remove the 2 screws (1) and the 2 separation guides (2). Repair Information 4-56...
  • Page 158 4040 4. Remove the fuser lower roller with its holder. 5. Remove the 2 holders (1) and 2 bushings (2) from the fuser lower roller (3). 4-57...

  • Page 159: Electronic Components Removal Procedures

    4040 Electronic Components Removal Procedures Controller Card Removal 1. Remove the 2 screws (1), then pull out the controller card (2). 2. Remove the 2 screws (1). 3. Remove the 4 screws and the 2 mount retainers, then take out the controller card.

  • Page 160: System Board Removal

    4040 System Board Removal 1. Remove the high-voltage power supply. 2. Disconnect the 17 connectors (1) from the system board. 3. Remove the 4 screws (2) and the mount retainer (3). 4. Press the black clip (5) and remove the system board (4). 4-59...

  • Page 161: Pick-Up Board Removal

    4040 Pick-Up Board Removal 1. Remove the pick-up assembly. 2. Disconnect the 6 connectors (1). 3. Remove the screw (2), disconnect the 2 latches (3), and take out the pick-up board (4). Multipurpose Tray Board Removal 1. Remove the manual feed pick-up assembly. 2.

  • Page 162: Switch/Sensor Board Removal

    4040 Switch/Sensor Board Removal 1. Remove the upper cover unit. 2. Remove the right rear cover and the rear cover. 3. Remove the left rear cover. 4. Remove the 3 screws (1). Remove the 4 screws on the bottom of the shield cover and remove the shield cover (2). 4-61...
  • Page 163 4040 5. Remove the 5 screws (1) and the shield plate (2). 6. Remove the system board. 7. Remove the 3 screws (1) and take out the DC controller mount- ing plate (2). Repair Information 4-62...

  • Page 164: High Voltage Power Supply Board

    4040 Disconnect the connector (1), remove the 2 screws (2), and pull out the board. Disconnect the other connector and remove the switch/sensor board (3). High Voltage Power Supply Board 1. Remove the right rear cover and the rear cover. 2.

  • Page 165: Cassette-Size Sensing Boards Removal

    4040 Cassette-Size Sensing Boards Removal 1. Remove the cassettes. 2. Remove the power supply. 3. Disconnect the connector (1), remove the screw (2), then take off the cassette-size sensing cover (3). 4. Disconnect the connectors (1) from each board, remove the 3 screws (2), then take out the upper cassette-size sensing board (3) and the lower cassette-size sensing board (4).

  • Page 166: Power Supply Removal

    4040 Power Supply Removal 1. Remove the left rear cover and the rear cover. 2. Disconnect the connector (1), remove the 2 screws (2), then take out the fan duct (3). 3. Remove the connector (1). 4. Take out the 5 screws (2). 4-65...
  • Page 167 4040 5. Remove the 4 connectors (1). 6. Remove the 2 screws (1) and the power supply fan (2). 7. Remove the 2 screws (3) and the power supply (4). Repair Information 4-66...

  • Page 168: Envelope Feeder Removal Procedures

    4040 Envelope Feeder Removal Procedures Envelope Feeder Cover Removals Rear Cover Removal Remove the screw (1) and take off the rear cover (2). Before you check on an operation of the envelope feeder, try the envelope feeder with the rear cover off. Be sure to either hold the bottom of the board with your hand or tape it to the frame.

  • Page 169: Lower Cover Removal

    4040 Lower Cover Removal 1. Remove the rear and front covers. 2. Remove the 2 screws (1) and dislodge the lower cover (2). Repair Information 4-68...

  • Page 170: Upper Cover Removal

    4040 Upper Cover Removal 1. Remove the rear and front covers. 2. Take out the screw (1). 3. With a flat blade screwdriver, unfasten the snaps (1) on both sides. Remove the upper cover (2) and spring. 4. Remove the separation guide and upper cover as one unit. 4-69...

  • Page 171: Envelope Side Guide Removal

    4040 Be sure the separation roller pressure spring (1) is correctly installed when you reassemble the covers. Envelope Side Guide Removal Left Front Guide (1) Left Rear Guide (2) Right Rear Guide (3) Right Front Guide (4) Repair Information 4-70...

  • Page 172: Envelope Feeder Pick-Up Motor Removal

    4040 1. Remove the rear, front, lower and upper covers. 2. Remove the 6 screws (1) and take out the guides from under- neath. Envelope Feeder Pick-Up Motor Removal 1. Remove the rear, front, lower, and upper covers. 2. Remove the envelope side guides. 3.
  • Page 173 4040 4. Remove the connector (1). 5. Remove the screw (1) and take out the pick-up motor (2). Reassembly note: After you fasten the guides to the rack, attach the gear by spreading the guides apart. Repair Information 4-72...

  • Page 174: Envelope Feeder Driver Board Removal

    4040 Envelope Feeder Driver Board Removal 1. Remove the rear, front, lower, and upper covers. 2. Remove the envelope guides. 3. Take off the 2 connectors (1) and the screw (2). 4. Remove the sensor lever (1). 5. Remove the envelope feeder driver board (2). 4-73...

  • Page 175: Drive Unit Removal

    4040 Drive Unit Removal 1. Remove the pick-up motor. 2. Take out the screw (1). 3. Remove the drive unit (3) by by removing the E-rings (1) and removing the 3 screws (2). Repair Information 4-74...

  • Page 176: Envelope Feeder Pick-Up Roller Removal

    4040 Envelope Feeder Pick-Up Roller Removal 1. Remove the pick-up motor. 2. Remove the drive motor. 3. Remove the 2 E-rings (1) and 2 bushings (2), then take out the pick-up roller shaft with rollers (3). Separation Rollers and Torque Limiter Removal 1.
  • Page 177 4040 4. Remove the separation lower shaft from the guide (1). 5. Remove the separation upper roller (2) and torque limiter (3) from the shaft. Repair Information 4-76...

  • Page 178: Duplex Assembly Removal Procedures

    4040 Duplex Assembly Removal Procedures Upper Guide Removal Remove the 4 screws (1), then the upper guide (2). When you re-attach the upper guide (1), be sure the guide (2) is on the outside. 4-77...

  • Page 179: Lower Guide Removal

    4040 Lower Guide Removal 1. Remove the upper cover. 2. Remove the connector (1). 3. Remove the 2 screws (2), then the guide (3). 4. Remove the 2 springs (1), then the switch back guide (2). Repair Information 4-78...
  • Page 180 4040 5. Remove the screw (1). 6. Remove the 2 screws (1), then the lower guide (2). 4-79...

  • Page 181: Switchback Roller Release Solenoid Removal

    4040 Switchback Roller Release Solenoid Removal 1. Remove the lower guide. 2. Take out the 2 screws (1), then the board cover (2). 3. Remove the connector (1). Repair Information 4-80...

  • Page 182: Duplex Deflector Drive Solenoid Removal

    4040 4. Remove the cable from the cable guide (1). 5. Remove the 2 screws that hold the switchback roller release solenoid (2) from underneath and take off the solenoid. Duplex Deflector Drive Solenoid Removal 1. Remove the upper guide. 2.
  • Page 183 4040 3. Remove the connector (1). 4. Remove the cable (2) from the guide (3). 5. Remove the 2 screws (1), and take off the motor base plate (2). Repair Information 4-82...
  • Page 184 4040 6. Remove the screw (1) and take off the solenoid cover (2). 7. Remove the 2 screws (1) and take off the duplex deflector drive solenoid (2). 4-83...

  • Page 185: Switchback Motor Removal

    4040 Switchback Motor Removal 1. Remove the upper guide. 2. Take off the board cover and remove the connector (1). 3. Remove the 2 screws (1), and then the motor base plate (2). Repair Information 4-84...

  • Page 186: Side Registration Motor Removal

    4040 4. Take out the 2 screws (1), then slide the switchback motor (2) in the direction of the arrow to remove it. Side Registration Motor Removal 1. Remove the lower guide. 2. Take off the board cover, then remove the connector (1). 4-85...

  • Page 187: Duplex Feed Clutch Removal

    4040 3. Undo the cable guides (1) from the cable (2). 4. Take out the 2 screws (3) and slide the side registration motor (4) in the direction of the arrow to remove it. Duplex Feed Clutch Removal 1. Remove the upper guide. 2.

  • Page 188: Duplex Driver Board Removal

    4040 3. Remove the C-ring (1) and take out the duplex feed clutch (2). Duplex Driver Board Removal 1. Take off the board cover, and remove the 9 connectors (1). 4-87...
  • Page 189 4040 2. Undo the 2 latches (1) holding the board and remove the duplex driver board (2). Repair Information 4-88...

  • Page 190: Paper Deck Removal Procedures

    4040 Paper Deck Removal Procedures External Covers Front Cover Removal 1. Pull out the tray. 2. Remove the paper guide. 3. Remove the 4 screws (1), undo the left and right latches (2), and take off the front cover (3). Left Cover Removal 1.

  • Page 191: Right Cover Removal

    4040 Right Cover Removal 1. Remove the 2 screws (1). 2. Undo the latches (2) and remove the right cover (3). Repair Information 4-90...

  • Page 192: Feed Cover Removal

    4040 Feed Cover Removal 1. Remove the 4 screws (1). 2. Undo the 7 latches (2) and remove the feed cover (3). Rear Cover Removal Remove the 4 screws (1) and take off the rear cover (2). 4-91...

  • Page 193: Paper Deck Drive System Removal Procedures

    4040 Paper Deck Drive System Removal Procedures Drive Assembly Removal 1. Remove the right cover and the rear cover. 2. Pull out the tray. 3. Remove the 2 connectors (1) and 4 screws (2), then take out the drive assembly (3). Repair Information 4-92...

  • Page 194: Lifter Clutch Removal

    4040 Lifter Clutch Removal 1. Remove the screw (1). 2. Remove the clutch cover (2) and bushing (3), then take out the lifter clutch (4). Deck Motor Removal Remove the 4 screws (1) and take out the deck motor (2). 4-93...

  • Page 195: Limit Switch Removal

    4040 Limit Switch Removal 1. Remove the 2 screws (1), then remove the upper cover (2). 2. Pull out the tray. 3. Remove the rear cover. 4. Remove the connector (1). 5. Remove the screw (2) and slide out the stay (3). 6.

  • Page 196: Paper Transport System Removal Procedures

    4040 out of the band (2). 7. Remove the screw (4), then remove the limit switch (5). Paper Transport System Removal Procedures Pick-Up Assembly Removal 1. Remove the feed assembly. 2. Pull out the tray. 3. Remove the right and rear covers. 4.
  • Page 197 4040 5. Remove the 4 screws (1) , then remove the pick-up assembly (2). 6. When you replace the parts of the pick-up assembly, remove the pick-up, feed and separation rollers so you do not get grease on them. Also be careful not to get grease on the paper feed guide.

  • Page 198: Pick-Up Solenoid Removal

    4040 Pick-Up Solenoid Removal 1. Undo the 2 latches (1) and remove the gear cover (2). 2. Remove the connector (3). 3. Remove the 5 screws (1). 4. Remove the gear side plate (2) with the gear (3). 4-97...

  • Page 199: Pick-Up Motor Removal

    4040 5. Remove the screw (1), then remove the pick-up solenoid (2). Pick-Up Motor Removal 1. Remove the gear side plate. 2. Remove the gear (1). 3. Remove the 3 screws (2), then remove the motor base plate (3). Repair Information 4-98...

  • Page 200: Feed Assembly Removal

    4040 4. Remove the 2 screws (1), then remove the pick-up motor (2). Feed Assembly Removal 1. Drop the feed assembly (1) forward. 2. Remove the connector (2). 3. Rotate the feed spacer (3). 4. Remove the 2 screws (4), then remove the feed assembly. 4-99...

  • Page 201: Feed Clutch Removal

    4040 Feed Clutch Removal 1. Remove the feed cover. 2. Remove the cable (2) from the bands (1). 3. Remove the 3 screws (1), then remove the connecting plate (2). 4. Remove the 3 screws (3), then remove the gear side plate (4). Repair Information 4-100...

  • Page 202: Registration Clutch Removal

    4040 5. Remove the connector (2), 2 bushings (3), shaft (4), pin, and gear (5) from the feed clutch (1). Registration Clutch Removal 1. Remove the gear side plate. 2. Remove the connector (1). 3. Remove the E-ring (2) and then remove the registration clutch (3).

  • Page 203: Feed Roller Removal

    4040 Feed Roller Removal 1. Remove the feed clutch. 2. Remove the E-ring (1), gear (2), pin, and bushing (3). 3. Remove the E-ring (1) and bushing (2), then remove the feed roller (3). Repair Information 4-102...

  • Page 204: Registration Roller Removal

    4040 Registration Roller Removal 1. Remove the registration clutch. 2. Remove the 2 E-rings (1) and the bushing (2). 3. Remove the E-ring (1), gear (2), pin, and bushing (3), then remove the registration rollers (4). 4-103...

  • Page 205: Tray Removal

    4040 Tray Removal 1. Remove the front cover. 2. Remove the right and left covers. 3. Remove the screw (1) and the stopper (2). 4. Remove the screw (1) and stopper (2), then remove the tray (3). Repair Information 4-104...

  • Page 206: Lifter Removal

    4040 Lifter Removal 1. Remove the 2 screws (1), the damper (2), then the gear. 2. Remove the E-ring (1), then the 2 pulleys (2). 3. Remove the wires (3) from the pulleys. 4-105...
  • Page 207 4040 4. Remove the 2 screws (1), then the reference plate (2). 5. Remove the screw (1) then the wire cover (2). Repair Information 4-106...
  • Page 208 4040 6. Remove the screw (1), then remove the wire cover (2). 7. Remove the E-ring (1), the rubber ring (2), then the gear (3). 8. Remove the spring (4), pin, and spring stop (5). 4-107...
  • Page 209 4040 9. Remove the E-ring (1) and the 2 pulleys (2). 10. Remove the wires (3) from the pulleys. 11.Remove the 3 screws (1), then the reference plate (2). Repair Information 4-108...
  • Page 210 4040 12.Remove the 2 screws (1), then the wire cover (2). 13.Remove the screw (1) and the wire cover (2), then remove the tray (3). 4-109...
  • Page 211 4040 14.Remove the 2 screws (1) from the tray, then remove either the front wire unit (2), or the rear wire units (2). Repair Information 4-110...
  • Page 212 4040 To assemble the front wire: 1. Insert the pulley alignment pin (2) in the right side (looking from the front) of the shaft (1). 2. Wind the wire (3) one and one-half times around the second groove from the front side of pulley 1 (4) and insert it onto the shaft.
  • Page 213 4040 To assemble the rear wire: 1. Insert the pulley alignment pin (2) in the left side (looking from the front) of the shaft (2). 2. Wind the wire (3) one and one-half times around the second groove from the front side of pulley 2 (4) and insert it onto the shaft.

  • Page 214: Electronic Component Removal Procedures

    4040 Electronic Component Removal Procedures Paper Deck Driver Board Removal 1. Remove the left cover. 2. Remove the rear cover. 3. Take out the 7 connectors (1). 4. After you remove the 2 screws (2) and the 2 board holding pins (3), remove the paper deck driver board (4).

  • Page 215: Paper-Size Sensing Switch Board Removal

    4040 Paper-size Sensing Switch Board Removal 1. Remove the rear cover. 2. Pull out the tray. 3. Remove the screw (1) and the board base plate (2). 4. Undo the 3 latches (3), then remove the paper-size sensing switch board (4) followed by the connector (5). Repair Information 4-114...

  • Page 216: Paper-Level Sensing Switch Board Removal

    4040 Paper-level Sensing Switch Board Removal 1. Remove the rear cover. 2. Pull out the tray. 3. Remove the screw (1) and then the board base plate (2). 4. Undo the 3 latches (3), then remove the paper-level sensing switch board (4) followed by the connector (5). 4-115...

  • Page 217: Locations

    4040 5. Locations Parts of the Printer 1. Operator Panel 2. Face-down tray 3. Upper Cover 4. Delivery Stopper 5. Test Print Switch 6. Multipurpose Tray 7. Duplex Door 8. Upper Cassette 9. Lower Cassette 10. Power Switch Locations 5-1...
  • Page 218 4040 11. Delivery Cover 12. Face-up Tray 13. Video Interface Connector 14. Power Receptacle 15. Cleaning Brush 16. EP-W Cartridge 17. Pick-up Door...

  • Page 219: Duplexer

    4040 uplexer 1. Duplexing Feed Roller 2. Duplexing Assembly Removal Lever Envelope Feeder 1. Envelope Guide 2. Extension Tray 3. Weight Locations 5-3...

  • Page 220: Cross Section View Of Printer And Duplexer

    4040 Cross Section View of Printer and Duplexer 1. Delivery Roller 14.Photosensitive Drum 2. Laser/Scanner Assembly 15. Primary Charging Roller 3. Developing Cylinder 16. Lower Cassette 4. EP-W Cartridge 17. Upper Cassette 5. Manual Feeding Pick-up Roller 18. Duplex Assembly 6.

  • Page 221: Cross Section View Of Envelope Feeder

    4040 Cross Section View of Envelope Feeder 1. Feed Rollers 2. Separation Guide 3. Separation Roller 4. Pick-up Roller Locations 5-5...

  • Page 222: Base Machine Sensor And Switch Operation

    4040 Base Machine Sensor and Switch Operation...
  • Page 223 4040 1. Face-down Tray Delivery Sense signal (FDOUTS) 2. Face-down Tray Paper Full Sense signal (FDFULS) 3. Fixing Unit Delivery Sense signal (/FPOUTS) 4. Upper Cassette Paper Size Sense signal 5. Lower Cassette Paper Size Sense signal 6. Lower Cassette Paper-level Sense signal 1 (LVPS1) 7.

  • Page 224: Base Machine Motor And Clutch Operation

    4040 Base Machine Motor and Clutch Operation...

  • Page 225: Paper Feed

    4040 1. Face-up Solenoid Drive signal (/FUSLD) 2. Registration Clutch Drive signal (/REGCLD) 3. Main Motor Drive signal (MMRDY) 4. Pick-up Motor Drive signal 5. Feed Clutch Drive signal (/FEEDCLD) 6. Cassette Pick-up Solenoid Drive signal (/PUPSLD) 7. Manual Feed Clutch Drive signal (/MPTCLD) 8.

  • Page 226: Duplex Operation

    4040 Duplex Operation 5-10...
  • Page 227 4040 1. Side Registration Motor Drive signal 2. Switchback Roller Release Solenoid Drive signal (/PRRESLD) 3. Duplex Deflector Solenoid Drive signal (/DUPSLD) 4. Switchback Sensor signal (IDUPIDS) 5. Side Registration Guide Home Position Sensor signal (HRHGS) 6. Duplex Feed Roller 1 Home Position Sensor signal (DRHPS) 7.

  • Page 228: Paper Deck Sensor And Switch Operation

    4040 Paper Deck Sensor and Switch Operation 5-12...
  • Page 229 4040 PS31: Registration paper sensor PS32: Paper jam sensor PS33: Tray paper-out sensor PS34: Paper surface sensor SW31: Lifter abnormal position sensing switch SW601: Paper-level sensing switch SW602: Paper-level sensing switch SW701: Paper-size sensing switch SW702: Paper-size sensing switch SW703: Paper-size sensing switch Sw704: Paper-size sensing switch Locations 5-13...

  • Page 230: Switches

    4040 Switches Name Function SW101 Power Switch SW1401 Door Switch SW1601 Lower Cassette-size Sensing Switch SW1602 Lower Cassette-size Sensing Switch SW1603 Lower Cassette-size Sensing Switch SW1604 Lower Cassette-size Sensing Switch SW1601 Upper Cassette-size Sensing Switch SW1602 Upper Cassette-size Sensing Switch SW1603 Upper Cassette-size Sensing Switch SW1604...

  • Page 231: Sensors

    4040 Sensors Name Function Name Function Registration Paper Sensor PS1207 Lower Cassette Paper Out Sensor Pick-up Assembly Paper Sensor PS1208 Upper Cassette Paper Out Sensor Right Door Sensor PS1301 Multipurpose Tray Paper Sensor PS1201 Lower Cassette Sensor PS1302 Lifting Plate Position Sensor PS1202 Upper Cassette Sensor PS1401...
  • Page 232 4040 Sensors (Cont.) Name Function PS21 Duplexer Paper Sensor PS22 Switchback Sensor (Duplexer) PS23 Side Registration Guide Home Position Sensor (Duplexer) PS24 Duplex Feed Roller 1 Home Position Sensor (Duplexer) PS931 Envelope Feeder Paper Sensor (Envelope Feeder) 5-16...

  • Page 233: Clutches And Solenoids

    4040 Clutches and Solenoids Name Function Registration Clutch Feed Clutch Manual Feed Clutch Cassette Pick-up Solenoid Lifting Plate Solenoid Face-up Solenoid Locations 5-17...
  • Page 234 4040 Clutches and Solenoids (Cont.) Name Function CL21 Duplex Feed Clutch SL21 Switchback Roller Release Solenoid (Duplexer) SL22 Duplex Deflector Drive Solenoid 5-18...

  • Page 235: Motor, Fans, And Heaters

    4040 Motor, Fans, and Heaters Name Function Main Motor SMT1 Pick-up Motor FAM1 Power Supply Fan FAM2 Fuser/Scanner Fan FAM3 Electrical Assembly Fan FAM4 Fuser Fan Fuser Main Heater Fuser Sub Heater Locations 5-19...
  • Page 236 4040 Motors, Fans and Heater (Cont.) Name Function SMT11 Envelope Feeder Pick-up Motor SMT21 Switchback Motor (Duplexer) SMT22 Side Registration Motor (Duplexer) 5-20...

  • Page 237: Printed Circuit Boards

    4040 Printed Circuit Boards Name Function 1 System Board Controls Print Sequence High-voltage Power Supply Outputs primary, developing, transfer, Board and separation voltages (bias) accord- ing to the print sequence. Pick-up Board Relays signals between sensors, loads and the system board. Multipurpose Tray Board Relays signals between sensors, loads and the system board.
  • Page 238 4040 Printed Circuit Boards (Cont.) Name Function 7 Duplexing Driver Board Controls loads in the duplexer and sen- sors. 8 Envelope Feeder Driver Board Controls the envelope feeder motor and sensors. 5-22...

  • Page 239: Connector Locations

    4040 Connector Locations Locations 5-23...
  • Page 240 4040 Connector Locations (Cont.) 5-24...
  • Page 241 4040 Connector Locations (Cont.) Locations 5-25...
  • Page 242 4040 Connector Locations (Cont.) 5-26...

  • Page 243: System Board

    4040 System Board Locations 5-27...

  • Page 244: System Board Connector Signals

    4040 System Board Connector Signals System Board Connector J201 Signal Signal Name /FPCS Front Panel Controller Chip Select Signal Reserved Vsync Request Signal /VSREQ Vsync Request Signal /VSYNC Vertical Sync Signal /STS Status Signal /CMD Command Signal Reserved /SPCHG Speed Change Signal Reserved /FPO Front Panel Serial Output Signal...
  • Page 245 4040 Signal Signal Name Video Signal /FPI Front Panel Serial Input Signal FPCK Front Panel Serial Clock Signal /PPRDY Printer Power Ready Signal /PRNT Print Signal /PCLK Printer Clock Signal /CCLK Controller Clock Signal Reserved Paper Delivery Signa /PDLV Reserved Locations 5-29...

  • Page 246: System Board Connector J201

    4040 System Board Connector J201 Signal Signal Name Beam Detection Signa System Board Connector J202 Signal Signal Name LLCONT Laser Output Signal Photo Detection Signal /LENBL Video Data Enable Signal Forced Laser On Signa /LON Video Signal N.C. System Board Connector J203 Signal Signal Name Front Panel Serial Output Signa...
  • Page 247 4040 Signal Signal Name +24VA Locations 5-31...

  • Page 248: System Board Connector J205

    4040 System Board Connector J205 Signal Signal Name +24VA +24VA +24VA UDOORS Upper Door Open Sense Signal FDFULS Face-down Tray Paper Full Sense Signal /FPOUTS Fuser Delivery Sense Signal Face-down Tray Delivery Sense Signa FDOUTS /FUSLD Face-up Solenoid Drive Signal P5VB System Board Connector J206 Signal...

  • Page 249: System Board Connector J209

    4040 System Board Connector J209 Signal Signal Name /REGCLD Registration Clutch Drive Signal +24VA /REGS Registration Paper Sense Signal P5VB3 System Board Connector J210 Signal Signal Name Fan Motor 3 Drive Signa FAN3D /FAN3S Fan Motor 3 Rotating Detection Signal System Board Connector J212 Signal Signal Name...
  • Page 250 4040 Signal Signal Name 5-34...

  • Page 251: System Board Connector J214

    4040 System Board Connector J214 Signal Signal Name +24VA P5VB2 /MPTCLD Manual Feed Clutch Drive Signal /MPTSLD Lifting Plate Solenoid Drive Signal /MPTLS Lifting Plate Sense Signal /MPTPS Multipurpose Tray Paper Sense Signal ENVCMD Envelope Feeder Command Signal ENVSTS Envelope Feeder Status Signal System Board Connector J215 Signal Signal Name...

  • Page 252: System Board Connector J217

    4040 System Board Connector J217 Signal Signal Name FSRTH Fixing Roller Temperature Sense Signal Relay Drive Signal FSRD1E Fuser Main Heater Drive Signal /FSRCT1 Fuser Main Heater Type Sense Signal /FSRD Fuser Main Heater Drive Enable Signal /FSRD1R Fuser Main Heater Drive Enable Signal (200 V Model Only) FSRD2E Fuser Sub Heater Drive Signal...
  • Page 253 4040 Signal Signal Name /UDECKC Upper Cassette Sense Signal /FEEDCLD Feed Clutch Drive Signal /FEEDS Pick-up Unit Paper Sense Signal /PUPSLD Cassette Pick-up Solenoid Drive Signal /LDECKC Lower Cassette Paper-out Sense Signal Lower Cassette Sense Signa /LDECKS LPVS2 Lower Cassette Paper-level Sense Signal 2 LPVS1 Lower Cassette Paper-level Sense Signal 1 UPVS2...

  • Page 254: System Board Connector J220

    4040 System Board Connector J220 Signal Signal Name HVTS Transfer Bias Monitor Signal /HVTRVBD Transfer Negative Bias Drive Signal TONRS Toner Level Signal DENADJ Image Density Adjustment Signal /DBACD Developing ac Bias Drive Signal /DBFRQ Developing Bias Frequency Output Signal +24VB HVTVLTD Transfer Bias Drive Signal...
  • Page 255 4040 Signal Signal Name FSRTYP2 Fuser Sub Heater Type Sense Signal FSRTH Fuser Roller Temperature Sense Signal Locations 5-39...

  • Page 256: System Board Connector J223

    4040 System Board Connector J223 Signal Signal Name TONRS Toner Level Signal System Board Connector J225 Signal Signal Name FAN4D Fan Motor 4 Drive Signal /FAN4S Fan Motor 4 Rotating Detection Signal Switch/Sensor Board Cassette Size Sensing Switch Board 5-40...

  • Page 257: High Voltage Power Supply Board

    4040 High Voltage Power Supply Board Envelope Feeder Driver Board Locations 5-41...

  • Page 258: Paper Deck Switches, Sensors, Clutches, Solenoid, Motors

    4040 Paper Deck Switches, Sensors, Clutches, Solenoid, Motors Name Function Name Function SW31 Lift Abnormal Position PS35 Door Sensor Sensing Switch SW601 Paper-level Sensing Sw. CL31 Lifter Clutch SW602 Paper-level Sensing Sw. CL32 Registration Clutch SW701 Paper-size Sensing Sw. CL33 Feed Clutch SW702 Paper-size Sensing Sw.

  • Page 259: Paper Deck Printed Circuit Boards

    4040 Paper Deck Printed Circuit Boards Name Function Paper Deck Driver Board Controls the various loads and sensors Paper-level Sensing Switch Board Paper level detection Paper-size Sensing Switch Board Paper size detection Locations 5-43...

  • Page 260: Paper Deck Connectors

    4040 Paper Deck Connectors 5-44...

  • Page 261: Paper Deck Driver Board

    4040 Paper Deck Driver Board Paper Deck Driver Board Connectors Paper Deck Driver Board Connector J201 Signal Signal Name Serial In Signal Serial Out Signal CONTO Communication Ready Signal +24V Synchronous Clock Signal +24V STRBI Strobe Signal Locations 5-45...
  • Page 262 4040 Signal Signal Name PWRON-IN Power On Signal +24V 5-46...

  • Page 263: Paper Deck Driver Board Connector J202

    4040 Paper Deck Driver Board Connector J202 Signal Signal Name Serial Out Signal Serial In Signal Communication Ready Signal CONTI +24V Synchronous Clock Signal +24V STRBO Strobe Signal PWRON- Power On Signal +24V Paper Deck Driver Board Connector J203 Signal Signal Name +24V +24V...
  • Page 264 4040 Signal Signal Name +24V +24V 5-48...

  • Page 265: Paper Deck Driver Board Connector J205

    4040 Paper Deck Driver Board Connector J205 Signal Signal Name FEDBND Pick-up Motor Control Signal FEDBD Pick-up Motor Control Signal FEDAND Pick-up Motor Control Signal Pick-up Motor Control Signa FEDAD Paper Deck Driver Board Connector J206 Signal Signal Name +24V LIFTCL Lifter Clutch Drive Signal Paper Deck Driver Board Connector J207...
  • Page 266 4040 Signal Signal Name LIFT Paper Surface Sense Signal DOOR Door Open Sense Signal 5-50...

  • Page 267: Paper Deck Driver Board Connector J209

    4040 Paper Deck Driver Board Connector J209 Signal Signal Name PAP-SIZE4 Paper Size Sense Signal 4 PAP-SIZE3 Paper Size Sense Signal 3 PAP-SIZE2 Paper Size Sense Signal 2 PAP-SIZE1 Paper Size Sense Signal 1 Paper Deck Driver Board Connector J210 Signal Signal Name PAP-VOL1...

  • Page 268: Option Controller Interface Connector Locations

    4040 Option Controller Interface Connector Locations 5-52...

  • Page 269: Option Controller Interface Connector

    4040 Option Controller Interface Connector Signal Signal Name RESET Reset Signal (unused) /PRINT Print Signal (unused) /SPCHG Speed Change Signal (unused) /PDLV Paper Delivery Signal /undeter- For expansion mined 1 N.C. /CKEN Communication Ready Signal Send Data Line N.C. /VSYNC Vertical Synchronized Request Signal /PFED Paper Feed Signal...
  • Page 270 4040 Signal Signal Name undeter- For expansion mined 2 /STROBE Strobe Signal Receive Data Line /CLK Synchronized Clock Signal 5-54...

  • Page 271: Optional I/O Device Interface

    4040 Optional I/O Device Interface Signal Signal Name Send Data Line Receive Data Line /TERMI- Communication Ready Signal NATE +24V /CLOCK Synchronized Clock Signal GND (KEY) Mis-insertion prevention +24V /STROBE Strobe Signal PWRON Power On Signal +24V Locations 5-55...

  • Page 272: Preventive Maintenance

    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Expected Life of Consumable Parts The following parts should be replaced at the indicated intervals.

  • Page 273: Maintenance, Customer Checks

    4040 Maintenance, Customer Checks Maintenance that should be performed by the customer to maintain the printer at the optimum level are listed below. All other mainte- nance procedures are to be performed by a trained service techni- cian. Item Action Toner Cartridge Shake or replace the cartridge.

  • Page 274: Transfer Guide

    4040 Transfer Guide Clean the transfer guide with soft, dry flannel. Transfer Charging Roller Clean the transfer charging roller if it is very dirty. Do not touch the roller or get solvents or oils on it when you clean it. Do not clean the roller with water or solvents.

  • Page 275: Lubricants And Cleaners

    4040 Lubricants and Cleaners Isopropyl Alcohol Clean: Plastic, rub- Follow manufac- ber and external turer’s directions. parts. Clean: Oil and toner Follow manufac- stains. turer’s directions. Lubricating Oil Apply between #10 oil gears and shafts. Lubricating Grease Apply to gears. #23 grease Preventive Maintenance 6-4...

  • Page 276: Parts Catalog

    4040 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 277: Covers And Panels

    4040 Assembly 1: Covers and Panels...
  • Page 278 4040 Part Ref. Number Units Description 11A8005 Cover Asm., Right Top 11A8006 • Stop, Paper Length Delivery 11A8007 • Tray, Delivery • Screw, Paper Feed Stop, PP 11A8258 Screw, Rear Cover Asm, PP 11A8258 11A8023 Cover, Right, Lower Rear Screw, Left Top Cover Asm, PP 11A8258 •...
  • Page 279 4040 Assembly 1: Covers and Panels (Cont)
  • Page 280 4040 Part Ref. Number Units Description 11A8286 Control Panel 11A8804 Tray, Face Up 11A8298 Cable, Operator Panel Parts Catalog 7-5...

  • Page 281: Internal Paper Mechanism

    4040 Assembly 2: Internal Paper Mechanism...
  • Page 282 4040 Part Ref. Number Units Description 11A8259 Bushing, Transfer Roller, PP 11A8259 11A8025 Holder, Transfer Roller Screw, Multipurpose Pickup, PP 11A8258 11A8031 Cover, Paper Feed Clutch Screw, Drive Motor Mtg, PP 11A8258 11A8035 Cable, Motor Drive (Mt1) 11A8033 Motor, Main (Mt1) 11A8034 B/M Stopper, Pawl •...

  • Page 283: Internal Paper Drawer/Print Cartridge Mtg

    4040 Assembly 3: Internal Paper Drawer/Print Cartridge Mtg.
  • Page 284 4040 Part Ref. Number Units Description 11A8050 Cover, Paper Size Sensor 11A8051 Spring, Paper Size Sensor 11A8054 Cassette Size Cable 11A8036 Clip, Right Upper Cover Retainer Clip Wire Saddle, PP 11A8259 11A8049 Cover, Cable, Low V dc 11A8047 Sheet, Rear Frame Insulating 11A8058 Stopper, Rail Spring, Small, Cassette Rail, PP 11A8260...
  • Page 285 4040 Assembly 3: Internal Paper Drawer/Print Cartridge Mtg. (Cont) 7-10...
  • Page 286 4040 Part Ref. Number Units Description 3-30 11A8350 Board Asm, Cassette Size Parts Catalog 7-11...

  • Page 287: Printhead/System Board

    4040 Assembly 4: Printhead/System Board 7-12...
  • Page 288 4040 Part Ref. Number Units Description 11A8068 Holder, Laser Scan. Act. Arm Spring, Arm Lock, PP 11A8260 Spring, Shutter Actuator Arm, PP 11A8260 11A8071 Shutter, Laser Scanner Actuator 11A8070 Arm, Actuator Lock Screw, Spring Mtg. Fuser, PP 11A8258 Screws, Engine Mtg, PP 11A8258 Screws, Tension Spring, PP 11A8258 11A8082 Board, System...

  • Page 289: Power Supply/Fuser Cables

    4040 Assembly 5: Power Supply/Fuser Cables 7-14...
  • Page 290 4040 Part Ref. Number Units Description 11A8084 Fuser, 1 Cable Screw, Control Bd. Cage, PP 11A8258 11A8085 Fuser, 2 Cable 11A8083 Cover, Fuser Cable 11A8100 Plate, Shield, Outer Control Grid 11A8095 Cable, Power Supply Fan #3 11A8094 Fan #3, Electrical Assembly 11A8093 Bracket, Upper, Fan #3 Mounting 11A8092...
  • Page 291 4040 Assembly 5: Power Supply/Fuser Cables (Cont) 7-16...
  • Page 292 4040 Part Ref. Number Units Description 11D0334 Power Cord, Belgium 11D0330 Power Cord, Argentina 11D0331 Power Cord, Brazil 11D0332 Power Cord, Chile 11D0329 Power Cord, Peru Parts Catalog 7-17...

  • Page 293: Face-Up Solenoid

    4040 Assembly 6: Face-Up Solenoid 7-18...
  • Page 294 4040 Part Ref. Number Units Description 11A8101 Face-up Solenoid Asm. • Spring, Tension, PP 11A8260 • Cushion, Lever 9.5x11, PP 11A8259 • Spring, Tension, PP 11A8260 Parts Catalog 7-19...

  • Page 295: High Voltage Power Supply

    4040 Assembly 7: High Voltage Power Supply 7-20...
  • Page 296 4040 Part Ref. Number Units Description 11A8102 High Voltage Power Supply • Spring, Compression, PP 11A8260 • Pin, Contact, PP 11A8259 • Spring, Compression, PP 11A8260 Parts Catalog 7-21...

  • Page 297: Printer Driver

    4040 Assembly 8: Printer Driver 7-22...
  • Page 298 4040 Part Ref. Number Units Description 11A8265 Printer Drive Asm. Screw, PP 11A8258 11A8104 Printer Driver Gear B/M • Gear, 42T / 99T • Gear, 17T / 57T • Gear, 41T • Gear, 17T/57T • Gear, 73T • Gear, 27T / 30T •...

  • Page 299: Lower Drawer

    4040 Assembly 9: Lower Drawer 7-24...
  • Page 300 4040 Part Ref. Number Units Description Drawer Asm, Lower 11A8118 Stops, Paper Guide B/M Spring, Leaf Spring, Leaf Plate, Side Front Plate, Side Plate, side Plate, Side Rear Spring, Leaf Clip, PP 11A8259 11A8113 Indicator, Paper Size Sensor, B/M Cam, Size Shaft, Cam Cam, Size Cam, Size...
  • Page 301 4040 Assembly 9: Lower Drawer (Cont) 7-26...
  • Page 302 4040 Part Ref. Number Units Description 9-11 11A8106 Handle, Drawer Open B/M • Spring, PP 11A8260 • Handle, Drawer Open 11A8107 Drawer Paper Size Indicator 11A8116 Roller, Left Rear Screw, PP 11A8258 11A8117 Gear, Paper Adjust 11A8114 Label, Paper Size Separator 11A8115 Paper Size Separator 11A8119...

  • Page 303: Upper Drawer

    4040 Assembly 10: Upper Drawer 7-28...
  • Page 304 4040 Part Ref. Number Units Description 10-1 Drawer Asm, Upper 11A8118 Stops, Paper Guide B/M Spring, Leaf Spring, Leaf Plate, Side Front Plate, Side Plate, side Plate, Side Rear Spring, Leaf Clip, PP 11A8259 11A8264 Indicator, Paper Size Sensor, B/M Cam, Size Shaft, Cam Cam, Size...
  • Page 305 4040 Assembly 10: Upper Drawer (Cont) 7-30...
  • Page 306 4040 Part Ref. Number Units Description 10-11 11A8106 Handle, Drawer Open B/M • Spring, PP 11A8260 • Handle, Drawer Open 11A8107 Drawer Paper Size Indicator 11A8807 Label 11A8116 Roller, Left Rear Screw, PP 11A8258 11A8117 Gear, Paper Adjust 11A8114 Label, Paper Size Separator 11A8115 Paper Size Separator 11A8119...

  • Page 307: Paper Pick-Up

    4040 Assembly 11: Paper Pick-up 7-32...
  • Page 308 4040 Part Ref. Number Units Description 11-1 Paper Pick-up Asm Retaining Ring (E-Type), PP 11A8259 11A8152 Clutch, Electromagnet 11A8153 Shaft, Connecting 11A8151 Pickup Roller Drive Gear B/M Plate, Grounding Gear 31T Gear 38T Gear 20T, 41T Gear 31T Gear 57T Spring, Compression PP 11A8261 Joint, Coupler PP 11A8261 Spring Pin, PP 11A8261...
  • Page 309 4040 Assembly 11: Paper Pick-up (Cont) 7-34...
  • Page 310 4040 Part Ref. Number Units Description 11-22 11A8231 Shaft Spring, Pin, PP 11A8261 11A8157 Holder, Roller 11A8159 Limiter, Torque 11A8266 Paper Feed Roller, Second Pass Spring, Torsion PP 11A8261 11A8154 Guide Assembly 11A8163 Plate, Guide, Upper Parts Catalog 7-35...
  • Page 311 4040 Assembly 11: Paper Pick-up (Cont) 7-36...
  • Page 312 4040 Part Ref. Number Units Description 11-30 Pickup Asm, Misc. Parts, PP 11A8261 • Spring, Tension, PP 11A8261 • Spring, Tension, PP 11A8261 • Spring, Tension, PP 11A8261 • Spring, Tension, PP 11A8261 • Spring, Tension, PP 11A8261 • Spring, Tension, PP 11A8261 11A8150 Paper Pickup Cam/Lever B/M •...
  • Page 313 4040 Assembly 11: Paper Pick-up (Cont) 7-38...
  • Page 314 4040 Part Ref. Number Units Description 11A8142 11-38 Roller B/M, Lower Paper Feed • Roller • Shaft, Roller • Holder, Roller • Block, Support, Upper • Retaining Ring • Bushing • Bushing • Roller, Paper Feed • Gear, 16T • Gear, 17T Spring, Compression, PP 11A8261 11A8145 Spring, Torsion...
  • Page 315 4040 Assembly 11: Paper Pick-up (Cont) 7-40...
  • Page 316 4040 Part Ref. Number Units Description 11-41 11A8128 Paper Pick-up Board Asm. Screw, PP 11A8258 11A8129 Cable, Paper Pick-up 11A8132 Plate Grounding, 1 Screw, PP 11A8258 11A8131 Motor, Paper Pickup 11A8133 Plate Grounding, 2 11A8138 Switch Sensor B/M, Pickup (PS2) •...

  • Page 317: Registration Roller

    4040 Assembly 12: Registration Roller 7-42...
  • Page 318 4040 Part Ref. Number Units Description 12-1 11A8164 Registration Roller Asm. B/M 11A8165 Plate, Guide Grip Ring, PP 11A8259 11A8170 Clutch, Registration Grip Ring, PP 11A8259 11A8169 Lower Roller, Registration 11A8167 Gear, Bearing B/M, Registration Roller • Gear, 28T • Gear, 32T •...

  • Page 319: Feeder

    4040 Assembly 13: Feeder 7-44...
  • Page 320 4040 Part Ref. Number Units Description 13-1 Feeder Asm 11A8172 Frame, Transfer 11A8173 Feeder Asm. B/M • Block, Shaft Holding, Rear Spring, Compression, PP 11A8260 • Plate, Terminal Spring, Compression, PP 11A8260 • Varistor • Block, Shaft Holding, Front Spring, Compression, PP 11A8260 •...

  • Page 321: Multipurpose Tray Pick-Up

    4040 Assembly 14: Multipurpose Tray Pick-Up 7-46...
  • Page 322 4040 Part Ref. Number Units Description 14-1 Multipurpose Tray Pick-up Asm 11A8180 Pick-up Gear B/M, MPT • Spring, Tension, PP 11A8260 • Link, Solenoid, PP 11A8260 • Spring, Tension, PP 11A8260 • Arm, Auxiliary • Cam • Gear, 23T • Gear, 23T •...
  • Page 323 4040 Assembly 14: Multipurpose Tray Pick-Up (Cont) 7-48...
  • Page 324 4040 Part Ref. Number Units Description 14-14 11A8184 Pick-up Roller/ Separation Pad B/M • Roller, MP Tray Pick-up • Separation Pad Retaining Ring (E-Type), PP 11A8259 11A8188 Arm, Sensor, Paper Present Spring, Torsion Screw, Self-tpg, Pan Head, PP 11A8258 11A8189 Multipurpose Tray Board 11A8181 Cable, MPT Board...

  • Page 325: Multipurpose Tray

    4040 Assembly 15: Multipurpose Tray 7-50...
  • Page 326 4040 Part Ref. Number Units Description 15-1 11A8191 Multipurpose Tray Asm. 11A8196 Paper Guide, Right 11A8194 Tray 11A8193 Tray, Sub 11A8192 Cover, Tray Screw, Binding Head, PP 11A8258 11A8197 Gear, 20T 11A8195 Paper Guide, Left Parts Catalog 7-51...

  • Page 327: Paper Delivery

    4040 Assembly 16: Face Down Paper Delivery 7-52...
  • Page 328 4040 Part Ref. Number Units Description 16-1 Delivery Asm 11A8201 Duct, Fan 11A8204 Lever, Paper Sensing 11A8205 Lever, Paper Full 11A8206 Static Eliminator 11A8207 Roller, Delivery 11A8208 Guide, Delivery 11A8209 Large Pressure Roller B/M • Spring, Compression • Roller • Holder, Roller 11A8211 Frame 11A8212...

  • Page 329: Paper Delivery Frame

    4040 Assembly 17: Face Up Paper Delivery Frame 7-54...
  • Page 330 4040 Part Ref. Number Units Description 17-1 Delivery Frame Asm Retaining Ring (E-Type), PP 11A8260 11A8226 Gear, 20T 11A8225 Bushing, Conductive Screw, Binding, PP 11A8258 11A8222 Paper Vane 2 11A8221 Paper Vane 11A8220 Guide, Feeder 11A8218 Pin, Flapper 11A8219 Guide, Delivery Spring, Torsion, PP 11A8259 11A8213 Bushing...
  • Page 331 4040 Assembly 18: Fuser 7-56...
  • Page 332 4040 Part Ref. Number Units Description 18-1 11A8233 Fuser Asm. (110/115) 11A8234 Fuser Asm. (220/240) 11A8245 Fuser Lamp 110V B/M • Heater, Halogen, 120V, Main • Heater, Halogen, 120V, Sub 11A8248 Fuser Lamp 240V B/M • Heater, Halogen, 240V, Main •...

  • Page 333: Fuser

    4040 Assembly 18: Fuser (Cont) 7-58...
  • Page 334 4040 Part Ref. Number Units Description 18-12 11A8247 Holder, Heater 11A8242 Diode Holder Asm. 11A8241 Separation Claw B/M • Claw, Separation • Spring, Tension Screw, PP 11A8258 Screw, Stepper, w/Washer, PP 11A8258 11A8239 Lever, Holding, Right 11A8240 Separation Roller B/M •...

  • Page 335: Controller Card

    4040 Assembly 19: Controller Card 7-60...
  • Page 336 4040 Part Ref. Number Units Description 19-1 11A8253 Controller Card Mtg. Tray 11A8254 Controller Card 11A8255 Controller SIMM 11A8256 Bezel, Control Card Tray • Screws, Control Card Mtg. PP 11A8262 11A8257 Riser Card, FRU, INA Post, Short INA Mtg, PP 11A8262 Screw, Serial Port, PP 11A8262 Screw, Parallel Port, PP 11A8262 1364875...

  • Page 337: Envelope Feeder Covers

    4040 Assembly 20: Envelope Feeder Covers 7-62...
  • Page 338 4040 Part Ref. Number Units Description 20-1 Envelope Feeder 11A8308 Guide, Static Eliminator • Cable, FG • Nut, Plate • Plate Guide 11A8307 Cover, Center 11A8306 Arm Weight Press • Screw, PP 11A8317 11A8305 Weight, Press 11A8301 Cover, Right Side 11A8304 Roller, PP 11A8317 11A8303...
  • Page 339 4040 Assembly 21: Envelope Feeder Drive 1 7-64...
  • Page 340 4040 Part Ref. Number Units Description 21-1 11A8332 Bushing • E-Clip, PP 11A8317 11A8334 Gear, 20T 11A8330 Bushing • E-Clip, PP 11A8317 • Screw, PP 11A8317 11A8318 Envelope Feeder Board 11A8335 Gear, 42T 11A8333 Gear, 22T 11A8319 Roller, Pickup #1 11A8326 Gear, 24T 11A8331...

  • Page 341: Envelope Feeder Drive 1

    4040 Assembly 21: Envelope Feeder Drive 1 (Cont) 7-66...
  • Page 342 4040 Part Ref. Number Units Description 21-28 11A8342 Feeder Cable Screw, PP 11A8317 Ferrite Core, PP 11A8317 Plate, Drive, Right, PP 11A8317 Clamp, PP 11A8317, PP 11A8317 11A8341 Gear, 24T 11A8340 Gear, 36T • Pin, PP 11A8317 11A8339 Gear, 36T 11A8338 Lever, Sensor •...

  • Page 343: Duplex Option

    4040 Assembly 22: Duplex Option 7-68...
  • Page 344 4040 Part Ref. Number Units Description 22-1 Duplex Option, For Sale Only Screw, PP 11A8422 11A8378 Cover, Top 11A8379 Lever, Paper Sensor 11A8401 Guide, Rear Cable 11A8387 Guide, Paper Entry 11A8388 Spring, Leaf 11A8386 Paper Sensor, PS21 11A8385 Roller, Rear Guide •...
  • Page 345 4040 Assembly 22: Duplex Option (Cont) 7-70...
  • Page 346 4040 Part Ref. Number Units Description 22-22 11A8383 Motor, SMT22 Screw, PP 11A8422 11A8403 Holder, Ground Plate 11A8402 Ground Plate 11A8400 Guide, Front Cable 11A8384 Guide, Lower Left • Clip, PP 11A8422 11A8380 Paper Station B/M, PS 22 • Bracket •...
  • Page 347 4040 Assembly 22: Duplex Option (Cont) 7-72...
  • Page 348 4040 Part Ref. Number Units Description 22-35 • Spring, PP 11A8422 • Screw, PP 11A8422 11A8412 Duplex Power Conn. B/M • Holder, Conn. • Cable, Duplex • Shaft • Plate, Connector • Screw, PP 11A8422 11A8419 Solenoid B/M • Lever •...
  • Page 349 4040 Assembly 22: Duplex Option (Cont) 7-74...
  • Page 350 4040 Part Ref. Number Units Description 22-47 • Pin Parallel, PP 11A8422 11A8413 Belt, Timing 11A8415 Bushing B/M • Bushing • Bushing • Bushing 11A8404 Roller #2 11A8405 Roller #1 11A8406 Gudie, Duplex 11A8386 Paper Sensor, PS22, PS23 11A8410 Clutch •...

  • Page 351: Paper Deck, Covers And Frame

    4040 Assembly 23: Paper Deck, Covers and Frame 7-76...
  • Page 352 4040 Part Ref. Number Units Description 23-1 11A8451 Cover, Top Screw, PP 11A8646 11A8455 Cover, Rear 11A8456 Cable, Motor Pickup 11A8457 Cover, RH Screw, PP 11A8646 11A8458 Caster 11A8459 Cover, Door 11A8453 Pin, Locating 11A8454 Cover, LH Parts Catalog 7-77...

  • Page 353: Paper Deck, Main Body

    4040 Assembly 24: Paper Deck, Main Body 7-78...
  • Page 354 4040 Part Ref. Number Units Description 23-11 11A8464 Cable, Paper Volume 11A8465 Paper Sensor Board 11A8460 Cable, Main 11A8468 Spring, Leaf Screw, PP 11A8646 Clamp, Cable, PP 11A8646 11A8487 Mount, Cover 11A8471 Paper Size Sensing Board 11A8472 Spring, Sensor 11A8473 Holder, Size Clamp, Cable PP 11A8646 11A8474...

  • Page 355: Paper Deck, Paper Drawer

    4040 Assembly 25: Paper Deck, Paper Drawer 7-80...
  • Page 356 4040 Part Number Units Description 25-1 Screw, PP 11A8646 11A8495 Plate, Tray 2 • Latch, Limit, PP 11A8646 11A8491 Plate, Paper 11A8492 Plate, Limit 11A8489 Plate, Paper Limit 11A8527 Paper Sensing B/M • Spring, Tension, PP 11A8646 • Cam, Size 5 •...
  • Page 357 4040 Assembly 25: Paper Deck Paper Drawer (Cont) 7-82...
  • Page 358 4040 Part Ref. Number Units Description 25-12 • Screw, PP 11A8646 11A8505 Roller, Rail 11A8504 Spacer, Roller 11A8503 Plate, Support Rail 11A8507 Arm, Sensor 11A8508 Spring, Tension 11A8500 Pulley 11A8502 Holder, Wire, Right, Rear 11A8501 Plate, Support 11A8506 Damper, Tray 11A8520 Rail, Tray •...
  • Page 359 4040 Assembly 25: Paper Deck, Paper Drawer (Cont) 7-84...
  • Page 360 4040 Part Ref. Number Units Description 25-46 11A8519 Latch, Housing, Left 11A8499 Holder, Wire, Left, Front 11A8498 Holder, Wire, Left, Rear 11A8497 Pulley Parts Catalog 7-85...

  • Page 361: Paper Deck Drive

    4040 Assembly 26: Paper Deck Drive 7-86...
  • Page 362 4040 Part Ref. Number Units Description 26-1 Paper Deck Drive Asm • Screw, TP, M3X8, PP 11A8646 11A8551 Motor, MT31 11A8557 Shaft, H 11A8554 Clutch, Magnet, CL31 11A8555 Bushing • Screw, PP 11A8646 11A8552 Mount, Motor 11A8524 Bushing 11A8556 Gear, B/M, Paper Deck Drive Asm. •...

  • Page 363: Paper Deck, Paper Pick-Up

    4040 Assembly 27: Paper Deck, Paper Pick-Up 7-88...
  • Page 364 4040 Part Ref. Number Units Description 27-1 Paper Pick-Up Asm 11A8574 Cover, Gear 11A8575 Plate, Gear • Connector, PP 11A8646 • Clamp, Cable, PP 11A8646 • Screw, TP, M3X6, PP 11A8646 • Clip, Cord, PP 11A8646 11A8573 Bushing • Retaining Ring (E-Type), PP 11A8646 •...
  • Page 365 4040 Assembly 27: Paper Deck, Paper Pick-Up (Cont) 7-90...
  • Page 366 4040 Part Ref. Number Units Description 27-28 11A8583 Gear, 18T 11A8585 Lever, Door Open Sensor 11A8586 Photo Interuptor PS33, PS34 11A8588 Arm, Paper Sensor 11A8587 Arm, Paper Sensor 11A8594 Cover, Cable 11A8593 Shaft, Paper Sensor 11A8589 Arm, Paper Sensor 2 11A8591 Plate, Solenoid 11A8590...

  • Page 367: Paper Deck, Paper Feed

    4040 Assembly 28: Paper Deck, Paper Feed 7-92...
  • Page 368 4040 Part Ref. Number Units Description 28-1 Paper Feeder Asm 11A8645 Bushing B/M • Bushing • Bushing • Pin, Parallel, PP 11A8646 11A8628 Gear B/m, Feed Assembly • Gear, 16T • Gear, 16T • Gear, 36T • Gear, 24T/44T Retaining Ring (E-Type), PP 11A8646 Retaining Ring (E-Type), PP 11A8646 11A8622 Plate, Clutch...
  • Page 369 4040 Assembly 28: Paper Deck Paper Feed (Cont) 7-94...
  • Page 370 4040 Part Ref. Number Units Description 28-26 11A8634 Roller, Register 11A8629 Spring, Torsion 11A8633 Shaft, Hinge 11A8630 Plate, Hinge, Front 11A8637 Shaft, Roller 11A8638 Roller, Feed Pin, Parallel, PP 11A8646 11A8643 Jam Sensor B/M, PS32 • Bushing • Lever, Jam Sensor •...

  • Page 371: Option Controller Card

    4040 Assembly 29: Option Controller Card 7-96...
  • Page 372 4040 Part Ref. Number Units Description 29-1 11A8361 Board, Option Controller 11A8362 Stand Screw, PP 11A8646 Parts Catalog 7-97...

  • Page 373: Options (No Illustration)

    4040 Assembly 30: Options (No Illustration) 7-98...
  • Page 374 4040 Part Number Units Description 1364921 Memory SIMM 2MB 1364877 Memory SIMM 4MB 1364876 Memory SIMM 8MB 1364875 Memory SIMM 16MB 1364874 Memory SIMM 32MB 1364923 Flash Memory 1MB 1364922 Flash Memory 2MB 1364879 Flash Memory 4MB 1381856 Hard Drive 1402217 Token-Ring 1402218...

  • Page 375: Wiring Diagram

    4040 8. Wiring Diagram A wiring diagram for this printer is available as a PostScript file on this CD-ROM disk. Print file 4040.PS in the DIAGRAM directory. Files are available for either letter or A4 paper sizes.

  • Page 376: Index

    4040 Index diagnostics mode diagnostics mode menu structure abbreviations 2-16 ac power input service check diagnostics mode tests adjustments diagram, wiring dirt on back of paper service check 2-32 2-16 base machine service checks 2-33 dirty image service check basic engine test disk test/clean bent leading edge of paper service 2-33...
  • Page 377 4040 4-46 envelope feeder paper jams service fuser removal procedures 2-42 4-48 check fuser roller heater removal 4-51 envelope feeder parts fuser upper roller removal envelope feeder pick-up motor fuser/printhead fan (FM2) check 4-71 2-20 removal envelope feeder pick-up roller fuser/scanner fan (FM2) removal 4-75 4-17...
  • Page 378 4040 4-24 main motor removal page count maintenance approach paper deck bent leading edge 2-58 maintenance, customer checks service check manual feed pick-up clutch removal paper deck component locations 4-36 5-42 4-34 manual feed pick-up removal paper deck connector locations 5-44 manual feeding pick-up roller 4-38...
  • Page 379 4040 paper deck power input service paper pick-up from multipurpose 2-57 2-27 check tray service check 7-32 paper deck power supply removal paper pick-up parts 4-113 paper transport system removal 4-95 paper deck printed circuit board procedures 5-43 locations paper-level sensing switch board 5-51 paper deck rear cover removal 4-91...
  • Page 380 4040 3-12 4-50 quick disk test thermistor removal 4-49 thermoswitch removal tools transfer charging roller removal 4-11 rear cover removal 4-45 4-32, registration clutch removal 4-104 tray removal 4-101 troubleshooting registration lower roller removal 4-32 7-42 registration roller parts 4-31, registration roller removal upper cover removal 4-103...
  • Page 381 4040 Wiring Diagram Optra N 4040 Service Manual (3/96)
  • Page 382 4040 Wiring Diagram Optra N 4040 Service Manual...

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