LEXMARK 4069 Service Manual

Lexmark OptraTM T

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4069-XXX

•Index

Lexmark and Optra are trademarks of
Lexmark International, Inc., registered
in the United States and/or other
countries.

4069-XXX

Edition: January 2003

The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore,
this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes
are periodically made to the information herein; these changes will be incorporated in
later editions. Improvements or changes in the products or the programs described may
be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at
[e-mail]. Lexmark may use or distribute any of the
information you supply in any way it believes appropriate without incurring any obligation
to you. You can purchase additional copies of publications related to this product by
calling 1-800-553-9727. In other countries, contact your point of purchase.

Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United
States and/or other countries.

Other trademarks are the property of their respective owners.

© Copyright Lexmark International, Inc. 1999, 2003.
All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

P/N: 12G3794

4069-XXX

Contents

Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . . . ix

Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Tools Required For Service. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Service Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

User Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . 2-24

Symptom Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Charge Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-29

Cover Open Switch/Cable Service Check . . . . . . . . . . . . 2-31

Dead Machine Service Check . . . . . . . . . . . . . . . . . . . . . 2-32

Duplex Option Service Check. . . . . . . . . . . . . . . . . . . . . . 2-35

Envelope Feeder Option Service Check . . . . . . . . . . . . . 2-38

Erase Lamp Service Check (010/212/414/616) . . . . . . . . 2-45

Fan Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Fuser Solenoid Service Check . . . . . . . . . . . . . . . . . . . . . 2-50

Input Sensor Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-51

Input Tray(s) Option Service Check . . . . . . . . . . . . . . . . . 2-51

High Capacity Feeder Input Tray Service Check . . . . . . . 2-55

Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-68

Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . . 2-69

Options Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71

Output Bin Sensor Standard Tray Service Check . . . . . . 2-73

Output Expander Service Check . . . . . . . . . . . . . . . . . . . 2-74

High-Capacity Output Stacker Service Check . . . . . . . . . 2-79

5-Bin Mailbox Service Check . . . . . . . . . . . . . . . . . . . . . . 2-82

Paper Feed Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-88

Parallel Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-90

Contents iii

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Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-91

Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-92

Smart Cartridge Service Check . . . . . . . . . . . . . . . . . . . 2-105

Serial Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-106

Toner Sensor Service Check . . . . . . . . . . . . . . . . . . . . . 2-106

Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . 2-107

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . 3-3

Duplex Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Parallel Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Output Bin Test - Standard Bin . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Feed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Output Bin X Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

5-Bin Mailbox Diverter Test . . . . . . . . . . . . . . . . . . . . . . . 3-18

Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Printer Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Viewing the Permanent Page Count . . . . . . . . . . . . . . . . 3-20

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Maintenance Page Count. . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Setting Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . 3-22

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Print Quality Test Pages. . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Print Test with RIP (Controller Board) Removed . . . . . . . 3-25

Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-26

Autocompensator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Autoconnect System, Paper Tray Options, Envelope Feeder and

Output Expander Operations. . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Fuser Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Paper Feed Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-Sensitive Parts. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex Motor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuser Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printhead Assembly Adjustment. . . . . . . . . . . . . . . . . . . . . 4-4

Paper Alignment Assembly Adjustment . . . . . . . . . . . . . . . 4-5

Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Center Pan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Developer Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Duplex Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Front Cover Door . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

EMC Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Fuser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Fuser Detack Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Fuser Detack Housing Assembly . . . . . . . . . . . . . . . . . . . 4-32

Fuser Transfer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Fuser Envelope Conditioner Solenoid . . . . . . . . . . . . . . . 4-34

Fuser Narrow Media Sensor/Flag Assembly . . . . . . . . . . 4-35

Contents v

4069-XXX

Fuser Exit Sensor Flag Assembly . . . . . . . . . . . . . . . . . . 4-35

Fuser Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Fuser Lower Exit Guide Assembly. . . . . . . . . . . . . . . . . . 4-36

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . 4-37

Integrated Tray Compensator Assembly . . . . . . . . . . . . . 4-38

Integrated Tray Compensator Pick Roll Assembly . . . . . 4-39

Interconnect Board Assembly . . . . . . . . . . . . . . . . . . . . . 4-40

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . 4-42

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Main Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Multipurpose Tray/Lower Deflector Assembly . . . . . . . . . 4-46

Operator Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Operator Panel Cable/Cover Open Switch Assembly . . . 4-49

Optional 250/500 Paper Tray Assembly . . . . . . . . . . . . . 4-50

Paper Alignment Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-51

Paper Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Paper Input Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Paper Size Sensing Board. . . . . . . . . . . . . . . . . . . . . . . . 4-54

Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Redrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Smart Cartridge Contacts . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Transfer Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Upper Paper Deflector Assembly . . . . . . . . . . . . . . . . . . 4-60

Upper Front Cover Hinge Assembly . . . . . . . . . . . . . . . . 4-61

Upper Front Cover Interlock Switch Assembly . . . . . . . . 4-62

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 5-1

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Envelope Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Duplex Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Autoconnect - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Output Expander Control Board . . . . . . . . . . . . . . . . . . . 5-20

High-Capacity Output Stacker Board. . . . . . . . . . . . . . . . 5-22

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . 7-1

Printer Serial Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 2: Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 3: Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 4: Paper Feed (Autocompensator). . . . . . . . . . 7-14

Assembly 5: Paper Feed - Multipurpose Unit . . . . . . . . . . 7-16

Assembly 6: Paper Feed - Alignment . . . . . . . . . . . . . . . . 7-18

Assembly 7: Paper Feed - Output . . . . . . . . . . . . . . . . . . 7-20

Assembly 8: Integrated Paper Tray - 250 Sheet . . . . . . . 7-22

Assembly 9: Integrated Paper Tray - 500 Sheet . . . . . . . 7-24

Assembly 10: Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 11: Developer Drive . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 12: Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 13: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 14: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 15: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 16: 250 Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-52

Assembly 17: 500 Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-58

Assembly 18: Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62

Assembly 19: Output Expander . . . . . . . . . . . . . . . . . . . . 7-68

Assembly 20: Envelope Feeder . . . . . . . . . . . . . . . . . . . . 7-72

Assembly 21: High Capacity Feeder . . . . . . . . . . . . . . . . 7-76

Assembly 22: Kiosk - Vertical Paper Adapter. . . . . . . . . . 7-90

Assembly 23: Kiosk - Horizontal Paper Adapter. . . . . . . . 7-92

Assembly 24: High-Capacity Output Stacker . . . . . . . . . . 7-94

Assembly 25: 5-Bin Mailbox . . . . . . . . . . . . . . . . . . . . . . 7-100

Assembly 26: Options . . . . . . . . . . . . . . . . . . . . . . . . . . 7-104

Assembly 27: Miscellaneous . . . . . . . . . . . . . . . . . . . . . 7-106

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Contents vii

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viii Service Manual

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Notices and Safety Information

Laser Notices

The following laser notice labels may be affixed to this printer as
shown:

Laser Advisory Label

Notices and Safety Information ix

4069-XXX

Class 1 Laser Statement Label

x Service Manual

4069-XXX

Laser Notice

The printer is certified in the U.S. to conform to the requirements of
DHHS 21 CFR Subchapter J for Class I (1) laser products, and
elsewhere is certified as a Class I laser product conforming to the
requirements of IEC 60825.

Class I laser products are not considered to be hazardous. The
printer contains internally a Class IIIb (3b) laser that is nominally a 5
milliwatt gallium arsenide laser operating in the wavelength region of
770-795 nanometers. The laser system and printer are designed so
there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed
service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die
Anforderungen der Bestimmung DHHS (Department of Health and
Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).
In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,
der die Anforderungen der IEC (International Electrotechnical
Commission) 60825 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des
Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es
sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen
der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der
Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung
durch den Benutzer oder bei ordnungsgemäßer Wartung durch den
Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde,
Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux
provisions DHHS 21 CFR alinéa J concernant les produits laser de
Classe I (1). Pour les autres pays : cette imprimante répond aux
normes IEC 60825 relatives aux produits laser de Classe I.

Notices and Safety Information xi

4069-XXX

Les produits laser de Classe I sont considérés comme des produits
non dangereux. Cette imprimante est équipée d’un laser de Classe
IIIb (3b) (arséniure de gallium d’une puissance nominale de 5
milliwatts) émettant sur des longueurs d’onde comprises entre 770
et 795 nanomètres. L’imprimante et son système laser sont conçus
pour impossible, dans des conditions normales d’utilisation,
d’entretien par l’utilisateur ou de révision, l’exposition à des
rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme
ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di
classe 1 ed è certificata negli altri Paesi come prodotto laser di
classe 1 conforme ai requisiti della norma CEI 60825.

I prodotti laser di classe non sono considerati pericolosi. La
stampante contiene al suo interno un laser di classe IIIb (3b)
all’arseniuro di gallio della potenza di 5mW che opera sulla
lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema
laser e la stampante sono stati progettati in modo tale che le
persone a contatto con la stampante, durante il normale
funzionamento, le operazioni di servizio o quelle di assistenza
tecnica, non ricevano radiazioni laser superiori al livello della classe

1.

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los
requisitos para los productos láser de Clase I (1) establecidos en el
subcapítulo J de la norma CFR 21 del DHHS (Departamento de
Sanidad y Servicios) y, en los demás países, reúne todas las
condiciones expuestas en la norma IEC 60825 para productos láser
de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La
impresora contiene en su interior un láser de Clase IIIb (3b) de
arseniuro de galio de funcionamiento nominal a 5 milivatios en una
longitud de onda de 770 a 795 nanómetros. El sistema láser y la
impresora están diseñados de forma que ninguna persona pueda
verse afectada por ningún tipo de radiación láser superior al nivel de

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4069-XXX

la Clase I durante su uso normal, el mantenimiento realizado por el
usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os
requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a
Classe I (1) de produtos laser. Em outros locais, está certificada
como um produto laser da Classe I, em conformidade com os
requisitos da norma IEC 60825.

Os produtos laser da Classe I não são considerados perigosos.
Internamente, a impressora contém um produto laser da Classe IIIb
(3b), designado laser de arseneto de potássio, de 5 milliwatts
,operando numa faixa de comprimento de onda entre 770 e 795
nanómetros. O sistema e a impressora laser foram concebidos de
forma a nunca existir qualquer possiblidade de acesso humano a
radiação laser superior a um nível de Classe I durante a operação
normal, a manutenção feita pelo utilizador ou condições de
assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een
laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen
vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in
IEC 60825.

Laserprodukten van klasse I worden niet als ongevaarlijk
aangemerkt. De printer is voorzien van een laser van klasse IIIb
(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met
een golflengte van 770-795 nanometer. Het lasergedeelte en de
printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of
reparatie conform de voorschriften, nooit blootstelling mogelijk is
aan laserstraling boven een niveau zoals voorgeschreven is voor
klasse 1.

Notices and Safety Information xiii

4069-XXX

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i
overenstemmelse med kravene i IEC 60825.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren
indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5
milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet
770-795 nanometer. Lasersystemet og printeren er udformet
således, at mennesker aldrig udsættes for en laserstråling over
Klasse I-niveau ved normal drift, brugervedligeholdelse eller
obligatoriske servicebetingelser.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS
21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I
laserlaitteiden IEC 60825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.
Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin
galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei
altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen
normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden
huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina
näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och
spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21
CFR, underparagraf J för laserprodukter av Klass I (1). I andra
länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt
kraven i IEC 60825.

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4069-XXX

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en
inbyggd laser av Klass IIIb (3b) som består av en laserenhet av
gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770­795 nanometer. Lasersystemet och skrivaren är utformade så att det
aldrig finns risk för att någon person utsätts för laserstrålning över
Klass I-nivå vid normal användning, underhåll som utförs av
användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,
underkapittel J, for klasse I (1) laserprodukter, og er i andre land
godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC

60825.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren
inneholder internt en klasse IIIb (3b)-laser, som består av en
gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet
770-795 nanometer. Lasersystemet og skriveren er utformet slik at
personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne
serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora
compleix els requisits de DHHS 21 CFR, apartat J, pels productes
làser de classe I (1), i segons ha estat certificat en altres llocs, és un
producte làser de classe I que compleix els requisits d’IEC 60825.

Els productes làser de classe I no es consideren perillosos. Aquesta
impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,
nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona
de 770-795 nanòmetres. El sistema làser i la impressora han sigut
concebuts de manera que mai hi hagi exposició a la radiació làser
per sobre d’un nivell de classe I durant una operació normal, durant
les tasques de manteniment d’usuari ni durant els serveis que
satisfacin les condicions prescrites.

Notices and Safety Information xv

4069-XXX

Japanese Laser Notice

Chinese Laser Notice

xvi Service Manual

4069-XXX

Korean Laser Notice

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.

• The maintenance information for this product has been

prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precautions.

Consignes de Sécurité

Ce produit a été conçu, testé et approuvé pour respecter les

•

normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. Les caractéristiques de

Notices and Safety Information xvii

4069-XXX

sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres
pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

Norme di sicurezza

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.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise

Dieses Produkt und die zugehörigen Komponenten wurden

•

entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder
Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige

xviii Service Manual

4069-XXX

Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

Pautas de Seguridad

Este producto se ha diseñado, verificado y aprobado para

•

cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de 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.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Informações de Segurança

Este produto foi concebido, testado e aprovado para satisfazer

•

os padrões globais de segurança na utilização de componentes
específicos da Lexmark. As funções de segurança de alguns
dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de
substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

Notices and Safety Information xix

4069-XXX

Informació de Seguretat

Aquest producte està dissenyat, comprovat i aprovat per tal

•

d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de 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

orientada exclusivament a professionals i no està destinada a
ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de servei d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre les
mesures convenients.

xx Service Manual

4069-XXX

Chinese Safety Information

Korean Safety Information

Ozone Information

This product does not produce measurable amounts of ozone gas.

Notices and Safety Information xxi

4069-XXX

Preface

This manual is divided into the following chapters:

• “General Information” contains a general description of the

printer, options, and the maintenance approach used to repair it.
General environmental and safety instructions as well as
special tools and test equipment are listed in this chapter.

• “Diagnostic Information” contains a service error code table,

user status message table, user error message table, symptom
table, and service checks used to isolate failing field replaceable
units (FRUs).

• “Diagnostic Aids” contains tests and checks used to locate or

repeat symptoms of printer problems. Printer operation
information is provided to enhance the tests and checks.

• “Repair Information” provides instructions for making printer

adjustments and removing and installing FRUs.

• “Connector Locations” uses illustrations to identify the major

components and test points on the printer.

• “Preventive Maintenance” contains safety inspection guidelines,

lubrication specifications, and maintenance information to
prevent problems and maintain performance.

• “Parts Catalog” contains illustrations and part numbers for

individual FRUs.

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1. General Information

The Optra™ T laser printers are letter quality page printers designed
to attach to IBM-compatible PC’s and to most computer networks.

The Optra T laser printer is available in the following models.

Model Name Type

Optra T 610 4069-010

Optra T 610n 4069-01n

Optra T 612 4069-212

Optra T 612n 4069-21n

Optra T 614 4069-414

Optra T 614 4069-41b

Optra T 614n 4069-41e

Optra T 614nl 4069-41l

Optra T 614n 4069-41n

Optra T 616 4069-616

Optra T 616n 4069-61n

Optra T 23v 4069-23v

Optra T 23e 4069-23e

General Information 1-1

4069-XXX

Look at the printer serial label to identify the printer you are working
on. There are two service levels of Optra T printers. Some printers
are at a service level B as indicated by the B on the label.

1-2 Service Manual

4069-XXX

Options

The following options are available. Some options are not available
in every country. Contact your point of purchase for options available
in your country.

Memory options of 4MB, 8MB, 16MB, 32MB, 64MB and 128MB
SDRAM DIMM

Flash memory options of 2MB, 4MB, 8MB and 16MB DIMM
Integrated network options

Tok en -R in g
Ethernet
Tri-Port Adapter
IR Adapter
IPDS SIMM
Prescribe SIMM
TIFF SIMM
Barcode SIMM
Parallel Interface Card
SCS
USB/Parallel Port

Marknet Print Servers
250 and 500-sheet paper trays of A5, letter, and legal size.
250 Sheet Special Media Tray Assembly
500 Sheet Special Media Tray
2000 Sheet High Capacity Feeder
Envelope feeder
Duplex option - 250 Sheet
Duplex option - 500 Sheet
Hard Disk - 2.1 GB
Forms Hard Disk - 2.1 GB
Vertical Kiosk Presenter
Horizontal Kiosk Presenter
Output Expander
5-Bin Mailbox
High Capacity Output Stacker

General Information 1-3

4069-XXX

Maintenance Approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the service error codes,
user status messages, user error messages, service checks, and
diagnostic aids to determine the printer problem and repair the
failure. After you complete the repair, perform tests as needed to
verify the repair.

Tools Required For Service

Flat-blade screwdriver
#1 Phillips screwdriver
#2 Phillips screwdriver
T10 Torx Screwdriver

7.0 mm nut driver

5.5 mm wrench
Needlenose pliers
Diagonal pliers
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Serial wrap plug 1329048
Twinax/serial debug cable 1381963
Coax/serial debug cable 1381964

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4069-XXX

Acronyms

CSU Customer Setup
DIMM Dual In-Line Memory Module
DRAM Dynamic Random Access Memory
EDO Enhanced Data Out
EP Electrophotographic Process
EPROM Erasable, Programmable Read-Only

Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
GB Gigabyte
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission

of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
MROM Masked Read Only Memory
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PC Photoconductor
POR Power-On Reset
POST Power-On Self Test
RIP Raster Imaging Processor
ROM Read Only Memory
SIMM Single In-Line Memory Module
SDRAM Synchronous Dual Random Access

Memory
SRAM Static Random Access Memory
UPR Used Parts Return
V ac Volts alternating current
V dc Volts direct current

General Information 1-5

4069-XXX

1-6 Service Manual

4069-XXX

2. Diagnostic Information

Start

CAUTION: Remove the power cord from the printer or wall outlet
before you connect or disconnect any cable or electronic board or
assembly for personal safety and to prevent damage to the printer.
Use the handholds on the side of the printer. Make sure your fingers
are not under the printer when you lift or set the printer down.

Use the service error code, user status message, user error
message, symptom table, service checks, and diagnostic aids in this
chapter to determine the corrective action necessary to repair a
malfunctioning printer.

Service error codes are indicated by a three-digit error code. If a
service error code is displayed, go to the

page 2-2

.

User status messages provide the user with information on the
current status of the printer. Ready is displayed on the first line of the
display unless Power Saver is invoked, and then Power Saver is
displayed. If a user status message is displayed, go to the

Status Messages” on page 2-12

.

“Service Error Codes” on

“User

User error messages are indicated by a two or three-digit error code
that provides the user with information that explains a problem with a
print cartridge, paper jam, option, port, and so on. If a user error
message is displayed, go to the

If your machine completes the

page 2-24
“Symptom Tables” on page 2-25. Locate your symptom and take the

without an error, and you have a symptom, go to the

“User Error Messages” on page 2-16.

“Power-On Self Test (POST)” on

appropriate action.

If a service error code appears while you are working on the
machine, go to the

“Service Error Codes” on page 2-2 and take the

indicated action for that error.

Diagnostic Information 2-1

4069-XXX

Service Error Codes

Service Error Codes are generally non-recoverable except in an
intermittent condition when you can POR the printer to temporarily
recover from the error condition.

Error Code Action

900 RIP Software Contact the next support level or call Lexmark.

901 Engine Flash Indicates that the flash which the engine board code is

programmed into is bad. Replace the engine board.

902 General
Engine Software

903 Paperport
Link Driver Error

904 Interface
Violation by the
controller
software

905 Interface
Violation by
Paperport Device

906 Controller­Engine Link
Driver Error

910 DC Pick
Motor DC Pick
Motor Stall

911 DC Pick
Motor Excessive
PWM

912 DC pick
motor below
speed

These errors indicate an unrecoverable engine software
error. Replace the engine board.

Check for correct location of the jumpers on the
interconnect board for the model/type printer you are
servicing. Incorrect jumper settings can cause a 902
service error. If jumpers are set correctly, replace the
engine board.

Error Codes 910,911,912,913 and 914 are indications
that a Tray 1 paper feed problem has been detected. Go
to the “Input Tray(s) Option Service Check” on

page 2-51.

913 DC pick
motor over speed

2-2 Service Manual