Lexmark 4060-400 Maintenance Kit Manuals

Manuals and User Guides for Lexmark 4060-400 Maintenance Kit. We have 1 Lexmark 4060-400 Maintenance Kit manual available for free PDF download: Service Manual

Lexmark 4060-400 Service Manual

Lexmark 4060-400 Service Manual (345 pages)

T63 Series & 4060-Series

Brand: Lexmark | Category: Printer | Size: 8 MB

Table of Contents

Table of Contents
3
Laser Notices

9
Safety Information

15
Preface

18
- Definitions
  18
General Information

19
- Maintenance Approach
  19
- Options
  20
- Print Speed and Performance Print Speed
  21
  - Performance
    21
  - Time to First Print
    22
  - Memory Configuration
    22
- Printer Specifications
  23
  - Dimensions
    23
  - Operating Clearances
    24
  - Power and Electrical Specifications
    24
  - Electrical Specifications
    24
  - Acoustics
    25
  - Environment
    25
- Media Specifications
  26
  - Media Size
    27
  - Media Guidelines
    30
    
    Paper
    30
    
    Envelopes
    31
    
    Transparencies
    31
    
    Labels
    31
  - Print Area
    30
- Tools Required
  32
- Acronyms
  33
Diagnostic Information

35
- Start
  35
- Messages and Error Codes
  36
  - Service Error Codes
    36
  - Sub Error Codes
    39
    
    Sub Error Codes for 9Xx and 2Xx Error Codes
    39
    
    Base Printer Sub Error Codes
    40
    
    Base Printer (Fuser) Sub Error Codes
    45
    
    Duplex Option Sub Error Codes
    46
    
    Envelope Feeder Sub Error Codes
    47
  - User Status Displays
    48
  - User Status Messages
    51
  - User Attendance Messages
    53
    
    User Line 2 Link Messages
    66
    
    Check Device Connection Messages
    67
- Power-On Self Test (POST)
  68
- Symptom Tables
  69
  - Base Printer Symptoms
    69
  - High-Capacity Feeder (2000-Sheet) Symptoms
    69
  - Paper Tray Symptoms
    70
  - Duplex Option Symptoms
    70
  - Envelope Feeder Symptoms
    70
  - Output Expander
    70
  - Staplesmart Finisher
    71
- Service Checks
  72
  - 5-Bin Mailbox Service Check
    72
  - 900 Error Code Service Check
    75
  - Charge Roll Service Check
    77
  - Cover Closed Switch/Cable Service Check
    78
  - Dead Machine Service Check
    79
  - Duplex Option Service Check
    81
  - Envelope Feeder Service Check
    83
  - Fuser Service Checks
    86
    
    Cold Fuser Service Check
    86
    
    Hot Fuser Service Check
    88
  - Fuser Solenoid Service Check
    89
  - High-Capacity Feeder Input Tray Service Check
    90
  - High-Capacity Output Stacker Service Check
    96
  - Input Sensor Service Check
    98
  - Input Tray(S) Service Check
    98
  - Internal Tray Card/Paper Size Sensing Service Check
    100
  - Main Drive Service Check
    102
  - Main Fan Service Check
    103
  - Operator Panel Service Check
    104
    
    Operator Panel Buttons Service Check
    104
    
    Operator Panel Display Service Check
    104
  - Options Service Check
    105
    
    Flash Memory Option(S)
    105
    
    DRAM Memory Option(S)
    105
    
    Hard Disk Option
    105
  - Output bin Sensor Standard Tray Service Check
    106
  - Output Expander Service Check
    106
  - Paper Feed Service Check
    110
  - Parallel Port Service Check
    111
  - Printhead Service Check
    112
  - Print Quality Service Check
    112
  - Smart Contact Assembly Service Check
    119
  - Staplesmart Finisher Service Check
    120
  - Toner Sensor Service Check
    127
  - Transfer Roll Service Check
    128
Diagnostic Aids

129
- Diagnostics Mode
  129
  - Entering Diagnostic Mode
    129
  - Available Tests
    129
  - Exiting Diagnostics Mode
    129
- Device Tests
  130
  - Quick Disk Test
    130
  - Disk Test/Clean
    130
  - Flash Test
    131
  - Disabling Download Emulations
    131
- Duplex Tests
  132
  - Duplex Quick Test
    132
  - Duplex Sensor Test
    132
  - Duplex Motor Test
    133
  - Duplex Feed 1 Test
    133
  - Duplex Feed 2 Test
    134
- Error Log
  134
  - Viewing the Error Log
    134
  - Printing the Error Log
    135
  - Clearing the Error Log
    136
- Hardware Tests
  136
  - LCD Test
    136
  - Button Test
    136
  - SDRAM Memory Test
    137
  - ROM Memory Test
    137
  - Parallel Wrap Test
    137
- Input Tray Tests
  138
  - Input Tray Feed Test
    138
  - Input Tray Sensor Test
    138
- Output bin Tests
  139
  - Output bin Test-Standard bin
    139
  - Output bin Feed Test
    139
  - Feed to All Bins Test
    140
  - Output bin Sensor Test
    140
- Finisher Tests for Staplesmart Finisher
  142
  - Finisher Feed Tests
    142
  - Finisher Sensor Tests
    142
    
    Staple Sensor Test
    143
    
    Cover and Door Sensors
    143
    
    Pass and Media Sensors
    143
    
    Bin Level Sensor
    143
- Base Sensor Test
  144
- Print Registration
  144
- Printer Setup
  145
  - Setting the Page Count
    145
  - Viewing the Permanent Page Count
    145
  - Maintenance Page Count
    145
  - Setting Configuration ID
    146
  - Restore EP Factory Defaults
    146
- Print Tests
  147
  - Print Quality Test Pages
    148
  - Printing Menu Settings Page
    148
- Theory
  149
  - Autocompensator Operation
    149
  - Autoconnect System, Paper Tray Options, Envelope Feeder-Electrical
    149
    
    Autoconnect Cabling and Connectors
    149
    
    Duplex Option
    150
    
    Option Microcode
    150
- Paper Feed Jams
  150
  - Paper Jams-Base Printer
    151
  - Paper Jams-Options
    152
    
    Error Message 23X Paper Jam - Check Duplex Option
    152
    
    Error Message 24X (X=Tray 1 through 5) Paper Jam Check Tray X
    153
    
    Error Message 250 Paper Jam - Check MP Feeder
    153
    
    Error Message 260 Paper Jam - Check Envelope Feeder
    153
    
    Error Message 27X Paper Jam - Check bin X
    153
    
    Error Message 28X Paper Jam (X=Staplesmart Finisher)
    153
    
    Error Message 282 - Check Stapler
    154
    
    Error Message 283 - Check Stapler
    154
Repair Information

155
- Handling ESD-Sensitive Parts
  155
- Adjustment Procedures
  156
  - Duplex Motor Drive Belt Adjustment
    156
  - Fuser Solenoid Adjustment
    156
  - Gap Adjustment
    157
  - Printhead Assembly Adjustment
    157
  - Paper Alignment Assembly Adjustment
    158
- Screw Identification Table
  160
- Removal Procedures
  163
  - Covers Removals
    163
    
    Left Door Removal
    163
    
    Right Cover Removal
    164
    
    Upper Front Cover Removal
    166
    
    Laser Cover Removal
    168
  - Bevel Gear Removal
    170
    
    Installation
    171
  - Communications Board Removal
    172
  - Cover Closed Switch/Cable Removal
    173
  - Developer Drive Assembly Removal
    174
  - Frames Removals
    174
    
    EP Frame Assembly
    174
    
    Left Side Frame
    174
    
    Right Side Frame
    176
  - Fuser Assembly Removal
    177
  - Fuser Cover Removal
    179
  - Fuser Exit Sensor or Fuser Narrow Media Sensor Removal
    182
  - Fuser Lamp Removal
    182
  - Fuser Transfer Plate Removal
    184
  - High Voltage Power Supply Removal
    185
  - Inner Paper Deflector Assembly Removal
    187
  - Inner Shield Removal
    188
  - Input Sensor Removal
    188
  - Integrated Tray Autocompensator Assembly Removal
    189
  - Integrated Tray Autocompensator Pick Roll Assembly Removal
    192
  - Interconnect Board Assembly Removal
    194
  - Internal Tray Card (Itc)/Paper Size Sensing Board Removal
    195
  - Low Voltage Power Supply Removal
    196
  - Main Drive Assembly Removal
    198
  - Main Fan Removal
    200
  - Multipurpose Tray/Lower Deflector Assembly Removal
    201
  - Operator Panel Assembly Removal
    202
  - Operator Panel Bezel Removal
    203
  - Operator Panel Cable Removal
    204
  - Optional 250 or 500-Sheet Paper Tray Assembly Removal
    205
    
    Paper Tray Autocompensator Assembly Removal
    205
    
    Paper Tray Frame Assembly Removal
    205
    
    Paper Tray Board Removal
    205
    
    Paper Tray Paper out Sensor Flag Removal
    205
    
    Paper Size Spring Comb Removal
    205
  - Outer Shield Removal
    206
  - Paper Alignment Assembly Removal
    206
  - Paper bin Full Sensor Flag Assembly Removal
    208
  - Pick Roll Removal (MPT)
    209
  - Printhead Removal
    210
  - Redrive Assembly Removal
    211
  - Smart Contact Assembly Removal
    212
  - System Board Removal
    212
  - Toner Sensor Removal
    215
  - Transfer Roll Assembly Removal
    215
  - Upper Front Cover Hinge Assembly Removal
    216
  - Upper Paper Deflector Assembly Removal
    217
Connector Locations

219
- Autoconnect
  219
- Envelope Feeder Board
  220
- Fuser Board
  220
- High-Capacity Output Stacker Board
  221
- High Voltage Power Supply
  222
- Interconnect Board
  223
- Low Voltage Power Supply
  224
- Output Expander Control Board
  225
- Staplesmart Finisher
  226
- System Board-Non-Network
  228
- System Board-Network
  229
Preventive Maintenance

235
- Safety Inspection Guide
  235
- Lubrication Specifications
  235
- Scheduled Maintenance
  235
Parts Catalog

237
- How to Use this Parts Catalog
  237
- Assembly 1: Covers
  238
- Assembly 2: Frame 1
  240
- Assembly 3: Frame 2
  242
- Assembly 4: Printhead 1 (000/010)
  246
- Assembly 5: Printhead 2 (200/210)
  247
- Assembly 6: Printhead 3 (400/410)
  248
- Assembly 7: Paper Feed-Autocompensator
  249
- Assembly 8: Paper Feed-Multipurpose Feeder
  250
- Assembly 9: Paper Feed-Alignment
  252
- Assembly 10: Integrated Paper Tray-250-Sheet
  254
- Assembly 11: Integrated Paper Tray-500-Sheet
  256
- Assembly 12: Drives-Main Drive and Developer Drive
  258
- Assembly 13: Hot Roll Fuser
  260
- Assembly 14: Transfer/Charging
  262
- Assembly 15: Electronics-Power Supplies
  264
- Assembly 16: Electronics-Card Assemblies
  266
- Assembly 17: Electronics-Shields
  268
- Assembly 18: Cabling Diagrams 1
  271
- Assembly 19: Cabling Diagrams 2
  273
- Assembly 20: Cabling Diagrams 3
  275
- Assembly 21: 250-Sheet Paper Tray
  276
- Assembly 22: 500-Sheet Paper Tray
  277
- Assembly 23: Duplex Option
  284
- Assembly 24: Envelope Feeder
  286
- Assembly 25: Output Expander
  288
- Assembly 26: High-Capacity Output Expander
  292
- Assembly 27: 5-Bin Mailbox
  296
- Assembly 28: High-Capacity Feeder 1
  300
- Assembly 29: High-Capacity Feeder 2
  302
- Assembly 30: High-Capacity Feeder 3
  304
- Assembly 31: High-Capacity Feeder 4
  306
- Assembly 32: High-Capacity Feeder 5
  308
- Assembly 33: Kiosk-Vertical Paper Adapter
  310
- Assembly 34: Kiosk-Horizontal Paper Adapter
  312
- Assembly 35: Staplesmart Finisher I
  314
- Assembly 36: Staplesmart Finisher 2
  316
- Assembly 37: Staplesmart Finisher 3
  318
- Assembly 38: Staplesmart Finisher 4
  320
- Assembly 39: Options
  322
- Assembly 40: Miscellaneous
  324
Index

325
Part Number Index

331

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