Lexmark 438 Manuals

Manuals and User Guides for Lexmark 438. We have 1 Lexmark 438 manual available for free PDF download: Service Manual

Lexmark 438 Service Manual

Lexmark 438 Service Manual (970 pages)

Brand: Lexmark | Category: Printer | Size: 89.9 MB

Table of Contents

Product Information

2
Edition Notice

2
- Table of Contents
  3
Notices, Conventions, and Safety Information

21
- Laser Notice
  21
- Conventions
  22
- Safety Information
  23
Change History

27
General Information

31
- Printer Model Configurations
  31
- Paper Support
  32
  - Supported Paper Sizes
    32
  - Supported Paper Types
    35
  - Supported Paper Weights
    37
- Tools Required for Service
  39
Diagnostics and Troubleshooting

41
Service Menus

377
- Understanding the Printer Control Panel
  377
- Diagnostics Menu
  379
  - Entering the Diagnostics Menu
    379
  - Reports
    379
    
    Device Settings
    379
    
    Installed Licenses
    379
  - Advanced Print Quality Samples
    379
  - Event Log
    380
    
    Display Log
    380
    
    Mark Log
    380
    
    Print Log
    380
    
    Print Log Summary
    380
  - Input Tray Quick Print
    381
  - Output bin Quick Feed
    381
  - Printer Setup
    381
    
    Enable Edge-To-Edge (Printing)
    381
    
    Permanent Page Count
    381
    
    Printed Page Count (Mono)
    381
    
    Engine Setting [X]
    382
    
    EP Setup
    382
    
    Model Name
    382
    
    Processor ID
    382
    
    Serial Number
    382
  - Printer Diagnostics and Adjustments
    383
    
    Motor Tests
    383
    
    Sensor Tests
    383
    
    Add-On Cards Tests
    384
    
    Registration Adjust
    384
    
    Margin Offset
    385
    
    Universal Override
    385
  - Additional Input Tray Diagnostics
    385
    
    Sensor Tests
    385
    
    Motor Tests
    386
  - Output Device Diagnostics
    386
    
    Sensor Tests
    386
- Config Menu
  386
- Entering Invalid Engine Mode
  389
- Entering Recovery Mode
  389
- Accessing the Network SE Menu
  389
- Service Engineer Menu
  389
  - Accessing the Service Engineer (SE) Menu
    389
  - Service Engineer (SE) Menu
    389
Parts Removal

391
- Removal Precautions
  391
- Adjustments
  401
- Removal Procedures
  408
- Left Side Removals
  409
  - Left Cover Removal
    409
  - AC Power Socket Removal
    410
  - Main Motor Drive Removal
    410
  - Fuser Drive Gears Removal
    412
  - Main Fan Removal
    412
  - Motor (MPF) Removal
    413
  - LVPS Removal
    414
  - Paper Feeder Removal
    417
  - Motor (Redrive) Removal
    417
  - Sensor (Toner Smart Chip) Removal
    418
- Right Side Removals
  420
  - Right Cover Removal
    420
  - HVPS Removal
    421
  - Cartridge Fan Removal
    423
  - Controller Board Access Door Removal
    423
  - Controller Board Removal
    424
  - Speaker Removal
    427
  - High Voltage Contacts Guide Removal
    427
  - Toner Cartridge Shutter Actuator Removal
    430
  - Sensor (Toner Cartridge Shutter) Removal
    430
- Front Side Removals
  431
  - Front Door Bracket Removal
    431
  - Front Door Removal
    434
  - Duplex/Mpf Tray Removal
    434
  - Inner Left Cover Removal
    435
  - Inner Right Cover Removal
    436
  - Inner Guide Deflector Removal
    438
  - Sensor (Duplex Interlock) Removal
    438
  - Aligner Removal
    439
  - Sensor (Input) Removal
    440
  - MPF Pick Roller Removal
    442
  - Control Panel (4.3-Inch Display) Removal
    442
  - Control Panel (2.4-Inch) Cover Removal
    444
  - Control Panel (2.4-Inch) Board and Display Removal
    444
  - Sensor (Toner Low) Removal
    446
  - Transfer Roller Removal
    447
  - Sensor (Toner Density) Removal
    448
- Rear Side Removals
  449
  - Rear Door Removal
    449
  - Rear Cover Removal
    450
  - Motor (Duplex) Removal
    450
  - Fuser Removal
    452
  - Sensor (Rear Door Interlock) Removal
    452
  - Upper Redrive Removal
    453
  - Transfer Roller Contact Removal
    453
- Top Side Removals
  455
  - Top Cover Removal
    455
  - Printhead Removal
    455
  - Bin Full Sensor Cover Removal
    460
  - Sensor (Standard bin Full) Removal
    460
  - Bin Cover Removal
    461
- Bottom Side Removals
  464
  - Tray Insert Removal
    464
  - Separator Pad Removal
    464
  - Pick Roller Removal
    465
  - Optional Tray Drive Gear Removal
    466
  - Sensor (Duplex Path) with Cover Removal
    466
  - Sensor (Paper Size) Removal
    467
  - Sensor (Tray 1 Pass-Through) Removal
    468
  - Sensor (Tray 1 Pick) Removal
    469
- Optional 2100-Sheet Tray Removals
  470
- Optional 250- and 550-Sheet Tray Removals
  495
- Optional Output Expander Removals
  516
- Optional High Capacity Output Expander Removals
  545
  - Optional High Capacity Output Expander Removal
    545
  - HCOE Top Cover Removal
    545
  - HCOE Rear Door Removal
    546
  - HCOE Sensor Cover Removal
    547
  - HCOE bin Full Flag Removal
    548
  - Sensor (HCOE bin Full) with Flag Removal
    548
  - HCOE Right Cover Removal
    549
  - HCOE Left Cover Removal
    550
  - HCOE Controller Board Removal
    552
  - HCOE Lower Interface Cable Removal
    553
  - HCOE Upper Interface Cable Removal
    554
  - HCOE Latch Removal
    554
  - Motor (HCOE Diverter) Removal
    556
  - Sensor (HCOE Bin) Removal
    556
  - HCOE bin Spring Removal
    557
  - HCOE bin Pinion Removal
    558
  - Sensor (HCOE Rear Door Interlock) Removal
    559
  - HCOE Drive Belt Removal
    561
  - HCOE Belt Tensioner Removal
    563
  - HCOE Diverter Plunger Assembly Removal
    564
  - HCOE Drive Gear Assembly Removal
    566
  - Motor (HCOE Transport) Removal
    568
  - Sensor (HCOE Diverter) Removal
    570
  - HCOE Top Diverter Spring Removal
    572
  - HCOE Top Diverter Removal
    573
  - HCOE bin Shaft Removal
    574
  - HCOE bin Removal
    575
  - Sensor (HCOE Pass-Through) Removal
    578
- Optional Staple Finisher Removals
  581
- Optional 4-Bin Mailbox Removals
  648
  - Optional 4-Bin Mailbox Removal
    648
  - Mailbox Top Cover Removal
    648
  - Mailbox Rear Door Removal
    649
  - Mailbox Right Cover Removal
    651
  - Mailbox Top bin Cover with Bail Removal
    652
  - Mailbox Spring with String Removal
    653
  - Mailbox Left Cover Removal
    654
  - Mailbox Solenoid Removal
    655
  - Mailbox Latch Removal
    657
  - Sensor (Mailbox Rear Door Interlock) Removal
    658
  - Mailbox Diverter Plunger Assembly Removal
    658
  - Mailbox Transport Drive Gear Removal
    663
  - Motor (Mailbox Transport) Removal
    666
  - Mailbox Controller Board Removal
    667
  - Sensor (Mailbox Diverter Plunger) Removal
    668
  - Mailbox Lower Interface Cable Removal
    670
  - Mailbox Upper Interface Cable Removal
    672
  - Motor (Mailbox Diverter) Removal
    672
  - Mailbox bin Full Flag Removal
    674
  - Sensor (Mailbox bin Full) Removal
    675
  - Mailbox Belt Removal
    678
  - Mailbox bin LED Assembly Removal
    680
  - Mailbox Top Diverter Removal
    683
  - Mailbox Middle Diverter Removal
    688
  - Mailbox Top Diverter Spring Removal
    689
  - Sensor (Mailbox Pass-Through) Removal
    693
- Optional Staple, Hole Punch Finisher Removals
  698
Component Locations

739
- Printer Configurations
  739
- Port Locations
  741
- Printer Roller Locations
  742
- Printer Sensor Locations
  743
- Output Expander Locations
  744
- High Capacity Output Expander Locations
  745
- Mailbox Locations
  746
- Staple, Hole Punch Finisher Locations
  748
- Printer Controller Board Connectors
  749
Maintenance

757
- Inspection Guide
  757
- Scheduled Maintenance
  758
  - Fuser Maintenance Kits
    758
  - Maintenance Kits
    760
  - Identifying the Type of Fuser Used in the Printer
    762
- Preventive Maintenance
  762
  - Device-Specific Preventive Maintenance
    762
- Lubrication Specification
  763
- Cleaning the Printer
  763
  - Cleaning the Printhead Glass
    764
  - Emptying the Hole Punch Box
    765
Parts Catalog

766
- Legend
  766
- Assembly 1: Covers
  767
- Assembly 2: Fuser
  769
- Assembly 3: Electronics 1
  773
- Assembly 4: Electronics 2
  775
- Assembly 5: Motors
  777
- Assembly 6: Sensors 1
  779
- Assembly 7: Sensors 2
  781
- Assembly 8: Duplex
  783
- Assembly 9: Frames
  785
- Assembly 10: Control Panel (2.4-Inch Display)
  787
- Assembly 11: Control Panel (4.3-Inch Display)
  789
- Assembly 12: Tray/Feed
  791
- Assembly 13: Miscellaneous
  793
- Assembly 14: Maintenance Kits
  795
- Assembly 15: 250- and 550-Sheet Tray Options 1
  799
- Assembly 16: 250- and 550-Sheet Tray Options 2
  801
- Assembly 17: 2100-Sheet Tray Option 1
  805
- Assembly 18: 2100-Sheet Tray Option 2
  807
- Assembly 19: 2100-Sheet Tray Option 3
  809
- Assembly 20: Optional Bins
  811
- Assembly 21: Output Expander 1
  813
- Assembly 22: Output Expander 2
  815
- Assembly 23: Output Expander 3
  817
- Assembly 24: Output Expander 4
  819
- Assembly 25: High Capacity Output Expander 1
  821
- Assembly 26: High Capacity Output Expander 2
  823
- Assembly 27: High Capacity Output Expander 3
  825
- Assembly 28: High Capacity Output Expander 4
  827
- Assembly 29: Staple Finisher 1
  829
- Assembly 30: Staple Finisher 2
  831
- Assembly 31: Staple Finisher 3
  833
- Assembly 32: Staple Finisher 4
  835
- Assembly 33: Staple Finisher 5
  837
- Assembly 34: Mailbox 1
  839
- Assembly 35: Mailbox 2
  841
- Assembly 36: Mailbox 3
  843
- Assembly 37: Staple, Hole Punch Finisher 1
  845
- Assembly 38: Staple, Hole Punch Finisher 2
  847
- Assembly 39: Staple, Hole Punch Finisher 3
  849
- Assembly 40: Staple, Hole Punch Finisher 4
  851
- Assembly 41: Staple, Hole Punch Finisher 5
  853
Printer Specifications

855
- Power Consumption
  855
  - Product Power Consumption
    855
  - Sleep Mode
    855
  - Hibernate Mode
    856
  - Off Mode
    856
  - Total Energy Usage
    856
- Selecting a Location for the Printer
  856
- Noise Emission Levels
  857
- Temperature Information
  858
- Enabling the Security Reset Jumper
  858
Options and Features

859
- Available Internal Options
  859
- Optional Trays Supported
  859
- Optional Bins Supported
  859
- Options Configurations
  859
Theory of Operation

861
- Print Cycle Operation
  861
  - Flowchart
    861
  - Electrophotographic (EP) Process
    861
  - Fresh Toner Delivery Drive
    867
  - Main Drive
    868
- Printer Operation
  869
  - Printer Sections
    869
  - Printer Paper Path Rollers
    870
  - Printer Paper Path Sensors
    871
  - Tray Pick and Lift Drive
    872
  - MPF Pick Drive
    873
  - Lower Transport Drive
    874
  - Main Drive
    875
  - Fuser Drive
    876
  - Upper Redrive Drive
    879
  - Duplex Transport Drive
    881
- Optional 250- and 550-Sheet Tray Operation
  882
  - 250- and 550-Sheet Tray Paper Path Rollers
    882
  - 250- and 550-Sheet Tray Paper Path Sensors
    883
  - Paper Presence and Size Detection
    884
  - Tray Pick and Lift Drive
    885
  - Transport Drive
    886
- Optional 2100-Sheet Tray Operation
  888
  - 2100-Sheet Tray Elevator Drive
    888
  - 2100-Sheet Tray Pick Drive
    889
  - 2100-Sheet Tray Transport Drive
    890
- Optional Output Expander Operation
  891
  - Output Expander Paper Path
    891
  - Output Expander Diverter Drive
    892
  - Output Expander Transport Drive
    893
- Optional High Capacity Output Expander Operation
  894
  - High Capacity Output Expander Paper Path
    894
  - HCOE Diverter and Transport Drive
    895
- Optional Mailbox Operation
  896
  - Mailbox Paper Path Rollers
    896
  - Mailbox Paper Path Sensors
    897
  - Mailbox Diverter Drive
    898
  - Mailbox Transport and Exit Drive
    899
- Optional Staple, Hole Punch Finisher Operation
  900
  - Staple, Hole Punch Finisher (SHPF) Layout
    900
  - SHPF Paper Path Rollers
    901
  - SHPF Paper Path Sensors
    902
  - SHPF Entrance Drive
    903
  - SHPF HPU Transport Drive
    904
  - SHPF Hole Punch Drive
    905
  - SHPF Exit Drive
    906
  - Paper Stack Edge Alignment Drives
    907
  - Paper Stack Height Detection
    909
  - SHPF Ejector Drive
    910
  - SHPF Elevator Drive
    911
  - SHPF bin Clamp Drive
    912
- Optional Staple Finisher Operation
  913
  - Staple Finisher (SF) Layout
    913
  - SF Paper Path Rollers
    914
  - SF Paper Path Sensors
    915
  - SF Feed Section
    916
  - SF Exit Section
    917
  - SF Paper Stack Edge Alignment Drives
    918
  - SF Paper Stack Height Detection
    920
  - SF Staple Operation
    921
  - SF bin Section
    922
Acronyms

925
Index

927
Part Number Index

935
Part Name Index

949

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