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Lexmark Optra™ C
5045-001
•Table of Contents
•Start Diagnostics
•Safety and Notices
•Trademarks
•Index
•Manuals Menu
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
5045-001
Second Edition (March, 1996)
The following paragraph does not apply to the united kingdom or 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 of the publication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase.
Comments may be addressed to Lexmark International, Inc., Department D22A/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.
©Copyright Lexmark International, Inc. 1995, 1996. 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.
5045-001
Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . .xi
Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Diagnostic/Maintenance Approach . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Operator Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . 2-8 Error Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Error (46) Toner Cartridge Not Installed Correctly . . . . . 2-14 Error (111/112) Fuser, Warm-Up/Temperature Low . . . 2-15 Error (113) Fuser Temperature High . . . . . . . . . . . . . . . 2-16 Error (114) Fuser Failure . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Error (115) Fuser Heater Off . . . . . . . . . . . . . . . . . . . . . 2-17 Error (116) Fuser Unit Missing . . . . . . . . . . . . . . . . . . . . 2-17 Error (117) Fuser Pump Failure . . . . . . . . . . . . . . . . . . . 2-18 Error (121/125) Laser Board Failure . . . . . . . . . . . . . . . 2-20 Error (122) Laser Failure . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Error (123/124) Mirror Motor Start-up or Rotation . . . . . 2-21 Error (126/131) Transfer Drum Motor Failure. . . . . . . . . 2-22 Error (130) Service Motor Error . . . . . . . . . . . . . . . . . . . 2-22 Error (132/133) Main Motor (M2) Start-Up or Rotation. . 2-23 Error (134) Controller Fan Motor Failure . . . . . . . . . . . . 2-23 Error (135) Fuser Unit Fan Motor Failure . . . . . . . . . . . . 2-24 Error (136) Electrical Unit Fan Motor Failure . . . . . . . . . 2-24 Error (141) Power Supply Failure (LVPS 110V or 220V) 2-25 Error (142) Engine Board Memory Failure . . . . . . . . . . . 2-25 Error (143) 5 V / 24 V Supply Failure . . . . . . . . . . . . . . . 2-26 Error (144) Temperature/Humidity Sensor Failure . . . . . 2-26 Error (145) Density Sensor Failure. . . . . . . . . . . . . . . . . 2-26
Contents iii
5045-001
Service Checks (continued)
Error (146) Printer Communication Failure . . . . . . . . . . 2-27 Error (147) Engine Board IC Failure . . . . . . . . . . . . . . . 2-27 Error (148) Developer Unit Rotation Failure . . . . . . . . . 2-28 Error (149) Developer Unit Pressure Failure . . . . . . . . . 2-29 Error (152) Tray 2 Power Failure. . . . . . . . . . . . . . . . . . 2-29 No AC Power/Dead Machine. . . . . . . . . . . . . . . . . . . . . 2-30 No DC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 No Pickup (Manual Feed) . . . . . . . . . . . . . . . . . . . . . . . 2-31 No Pickup (Cassette Feed) . . . . . . . . . . . . . . . . . . . . . . 2-32 No Pickup (Optional Paper Feeder Pickup). . . . . . . . . . 2-32 Registration Roller Does Not Rotate . . . . . . . . . . . . . . . 2-33 High-Voltage Power Supply Output. . . . . . . . . . . . . . . . 2-33 Pickup / Feed System Theory . . . . . . . . . . . . . . . . . . . . 2-34
Paper Feed Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 2-38 Pickup Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 Transfer Drum Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Fuser/Delivery Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 Multi-Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Wrinkles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Leading-Edge Fold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Skewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Error Codes - 9XX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Error (900) Software Error . . . . . . . . . . . . . . . . . . . . . . . 2-46 Error (941) Service ROM SIMM . . . . . . . . . . . . . . . . . . 2-46 Error (939, 942, 943, 944) Service RIP Board. . . . . . . . 2-46 Error (945) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-46 Error (946) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47 Error (947) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47 Error (948) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47 Error (949) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-47 Error (950) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-48 Error (953) Service RIP Board. . . . . . . . . . . . . . . . . . . . 2-48 Error (955) Service Video RAM Error . . . . . . . . . . . . . . 2-48 Error (956) Service L2 Cache Error. . . . . . . . . . . . . . . . 2-48 Error (960) Service Memory Error . . . . . . . . . . . . . . . . . 2-48 Error (961) Bad / Missing DRAM . . . . . . . . . . . . . . . . . . 2-49 Error (970/979) INI Failure. . . . . . . . . . . . . . . . . . . . . . . 2-49 Error (977) Service Network Board . . . . . . . . . . . . . . . . 2-49
iv
5045-001
Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 Print Quality Start Of Call . . . . . . . . . . . . . . . . . . . . . . . . 2-50 Horizontal Variation (“Jitter”) Example . . . . . . . . . . . . . . 2-52 Print Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Black Horizontal Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Black Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Blur at Bottom of Page . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Laser Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Low Color Coverage or Usage . . . . . . . . . . . . . . . . . . . . 2-56 Oil Soaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Random Oil Spots on Page . . . . . . . . . . . . . . . . . . . . . . 2-58 Spew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . 2-61 Black Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 Blank Page Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-62 Blank Spots Service Check . . . . . . . . . . . . . . . . . . . . . . 2-63 Color Aberration Service Check . . . . . . . . . . . . . . . . . . . 2-63 Dark Image Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-64 Dirt On Back Of Paper Service Check . . . . . . . . . . . . . . 2-65 Dirty Print Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-66 Distortion Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-67 Horizontal Voids Service Check . . . . . . . . . . . . . . . . . . . 2-67 Light Image Service Check . . . . . . . . . . . . . . . . . . . . . . 2-68 Poor Fusing Service Check . . . . . . . . . . . . . . . . . . . . . . 2-69 Spacing Table Service Check . . . . . . . . . . . . . . . . . . . . 2-69 Streaking Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-70 Toner Scattered Service Check . . . . . . . . . . . . . . . . . . . 2-71 Vertical Lines Service Check . . . . . . . . . . . . . . . . . . . . . 2-72 Vertical Voids Service Check . . . . . . . . . . . . . . . . . . . . . 2-73
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Basic Engine Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Diagnostics Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . . 3-3 Diagnostics Mode Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Flash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Contents v
5045-001
Diagnostics Mode Tests (continued)
LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Memory Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Print Test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Print Test 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Print Test 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Wrap Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Density Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . 3-12
LAN Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Attraction Roller Drive Assembly . . . . . . . . . . . . . . . . . . . 4-3
Cassette Paper Pickup Drive Motor . . . . . . . . . . . . . . . . 4-4
Registration Roller Drive Clutch . . . . . . . . . . . . . . . . . . . 4-4
Cassette Paper Pickup PCB . . . . . . . . . . . . . . . . . . . . . . 4-5
Cassette Paper Pickup Assembly . . . . . . . . . . . . . . . . . . 4-5
Cassette Paper Pickup D-rollers . . . . . . . . . . . . . . . . . . . 4-6
Cassette Paper Pickup Roller Assembly, Front. . . . . . . . 4-6
Cassette Paper Pickup Roller Assembly, Rear . . . . . . . . 4-6
Cassette Paper Pickup Solenoid . . . . . . . . . . . . . . . . . . . 4-7
Corona Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Cover Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
DC Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Density Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . 4-23
Density Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Developing Rotary Assembly . . . . . . . . . . . . . . . . . . . . 4-24
Discharge Roller Drive Assembly . . . . . . . . . . . . . . . . . 4-25
Drive Gear Solenoid Assembly . . . . . . . . . . . . . . . . . . . 4-26
Drum Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Drum Lift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Fuser Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Fuser Oil Bottle Case Assembly . . . . . . . . . . . . . . . . . . 4-30
Fuser Hot Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
vi
5045-001
Removal Procedures (continued)
Fuser Thermo Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Fuser Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Fuser Oil Apply Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-34
Fuser Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Fuser Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Fuser Oil Applying Input Assembly . . . . . . . . . . . . . . . . 4-39
Fuser Delivery Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-39
High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . 4-40
High Voltage Converter . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . 4-41
Main Drive Motor and Board . . . . . . . . . . . . . . . . . . . . . 4-41
Mechanical Controller PCB . . . . . . . . . . . . . . . . . . . . . . 4-42
Multipurpose Feeder Paper Pickup, D-Roller. . . . . . . . . 4-42
Multipurpose Feeder Paper Sensor . . . . . . . . . . . . . . . . 4-42
Multipurpose Feeder U-Turn Roller Assembly . . . . . . . . 4-43
Multipurpose Feeder D-Roller Solenoid . . . . . . . . . . . . . 4-43
Paper Delivery Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Printhead and Printhead Board . . . . . . . . . . . . . . . . . . . 4-45
Printer Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Rotary Manual Feed Assembly . . . . . . . . . . . . . . . . . . . 4-49
Rear Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Rear Cooling Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Transfer Drum Motor and Developer Drive Motor . . . . . 4-50
Transfer Drum and Holder Assembly . . . . . . . . . . . . . . . 4-51
Transfer Drum Separation Claw. . . . . . . . . . . . . . . . . . . 4-52
Transfer Drum Knob Assembly . . . . . . . . . . . . . . . . . . . 4-52
Transfer Drum Attraction Roller . . . . . . . . . . . . . . . . . . . 4-53
Transfer Drum Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Transfer Drum Front and Rear Slide Assemblies. . . . . . 4-55
Transfer Drum Discharge Roller. . . . . . . . . . . . . . . . . . . 4-55
Transfer Drum HV Contact Assembly . . . . . . . . . . . . . . 4-55
Transfer Drum Gripper Assembly. . . . . . . . . . . . . . . . . . 4-56
Transfer Drum Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Transfer Drum Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Transfer Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Transfer Drum Cleaning Drive Assembly . . . . . . . . . . . . 4-61
Toner Cartridge Ejector . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
Upper Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Upper Output Drive Assembly . . . . . . . . . . . . . . . . . . . . 4-63
Video Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
Optional Paper Feeder Removals . . . . . . . . . . . . . . . . . . . . 4-64
Contents vii
5045-001
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Clutches and Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Motors and Fuser Heaters. . . . . . . . . . . . . . . . . . . . . . . . 5-9
PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
DC Controller Board Connector Locations . . . . . . . . . . 5-17
DC Controller Board Connector Locations (Graphic) . . 5-18
Mechanical Controller Board Connector Locations . . . . 5-24
Mechanical Controller Board Connectors (Graphic) . . . 5-25
Paper Pickup Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Optional Paper Feeder (Driver Board). . . . . . . . . . . . . . 5-33
Optional Paper Feeder (Miscellaneous) . . . . . . . . . . . . 5-34
High Voltage Power Supply PCB . . . . . . . . . . . . . . . . . 5-34
Separation HVT PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Ejection Sensing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Cassette Size Sensing PCB . . . . . . . . . . . . . . . . . . . . . 5-35
Paper Feed Driver PCB. . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Fuser Connector (J21). . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Lubricants and Cleaners . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Maintenance, Customer Checks . . . . . . . . . . . . . . . . . . . 6-3
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How To Use This Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . 7-1
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Toner (used) Reservoir/ HV. . . . . . . . . . . . . . . . . . . . . . . . 7-6
Major Assemblies (Top/Bottom) . . . . . . . . . . . . . . . . . . . . 7-8
DC Controller / Video Controller Board . . . . . . . . . . . . . . 7-10
Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Drive, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Density Adjustment Panel . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Door Switch, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Door Switch, Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Ejector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Solenoid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Cleaning Belt Drive Solenoid. . . . . . . . . . . . . . . . . . . . . . 7-28
viii
5045-001
Parts Catalog (continued)
Rotary Manual Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
Printer Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32
Transfer Drum Cleaning Drive . . . . . . . . . . . . . . . . . . . . .7-34
Discharge Roller Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36
Drum Lift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38
Attraction Roller Drive . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40
Paper Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-42
Universal Cassette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44
Paper Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-46
Cassette Paper Pickup Asm. . . . . . . . . . . . . . . . . . . . . . .7-48
Multipurpose Feeder Pickup Asm . . . . . . . . . . . . . . . . . .7-52
Paper, Side Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-54
Developing Rotary Asm . . . . . . . . . . . . . . . . . . . . . . . . . .7-56
Transfer Drum Mounting Asm . . . . . . . . . . . . . . . . . . . . .7-58
Transfer Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-60
Density Sensor Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-64
Transfer Drum Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .7-66
Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-68
Video Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . .7-72
Optional Paper Feeder (Main Body). . . . . . . . . . . . . . . . .7-74
Optional Paper Feeder (Front) . . . . . . . . . . . . . . . . . . . . .7-76
Paper Pickup Asm (Base) . . . . . . . . . . . . . . . . . . . . . . . .7-80
Paper Pickup Asm (Rear). . . . . . . . . . . . . . . . . . . . . . . . .7-82
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-84
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
Contents ix
5045-001
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).
•“Diagnostic Aids” contains tests and checks used to locate or repeat symptoms of printer problems.
•“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 optimum performance.
•“Parts Catalog” contains illustrations and part numbers for individual FRUs.
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5045-001
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, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property rights may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s responsibility.
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 825.
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.
Notices and Safety Information xi
5045-001
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 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 825 relatives aux produits laser de Classe I.
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 .
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5045-001
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 825.
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 825 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 la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.
Notices and Safety Information xiii
5045-001
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.
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 825.
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.
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5045-001
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. 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 825 -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.
Notices and Safety Information xv
5045-001
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 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 825.
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.
xvi
5045-001
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.
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.
Japanese Laser Notice
Notices and Safety Information xvii
5045-001
Chinese Laser Notice
Korean Laser Notice
xviii
5045-001
Trademarks
Optra and Lexmark are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
AppleTalk and LocalTalk are trademarks of Apple Computer, Inc., registered in the United States and other countries.
PCL® is a registered trademark of the Hewlett-Packard Company. PCL 5 is Hewlett-Packard Company’s designation of a set of printer commands (language) and functions included in its printer products. This printer is intended to be compatible with the PCL 5 language. This means the printer recognizes PCL 5 commands used in various applications programs, and that the printer emulates the functions corresponding to the commands.
Details relating to compatibility are included in the Technical Reference manual.
Other trademarks are the property of their respective owners.
Notices and Safety Information xix
5045-001
Other trademarks are the property of their respective owners.
xx
5045-001
Notices and Safety Information xxi
5045-001
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 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.
xxii
5045-001
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 Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.
Notices and Safety Information xxiii
5045-001
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.
xxiv
5045-001
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.
Notices and Safety Information xxv
5045-001
xxvi
5045-001
1. General Information
The Optra™ C is a 600 dpi Color Laser printer designed to attach to IBM-compatible PC’s and to most types of computer networks. The one model is available with standard PostScript Level 2 emulation and PCL 5 emulation:
|
A4 Full Color |
A4 Mono |
A4 Full Color |
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Color |
Fine Mode |
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||
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Print speed in |
3 |
12 |
2.5 |
pages per minute |
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Power Consumption
Max. A/C draw 110 V |
1.1kW |
Max. A/C draw 220 V |
1.0kW |
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 upgrade options of 2MB, 4MB, 8MB, 16MB and 32MB.
Flash memory options of 1MB, 2MB and 4MB
Integrated network options
Token-Ring
Ethernet
Second drawer option (tray 2)
Internal disk option
General Information 1-1
5045-001
Maintenance Approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure.
This printer can be serviced without being connected to a host computer.
After you complete the repair, perform tests as needed to verify the repair.
When the message “80 scheduled maintenance” appears, replace the following parts:
Note: At 60k prints or less, depending on the number of transparencies.
Fuser Assembly (see assembly 32-1)
Air Filter (see assembly 1-24)
Ozone Filter (see assembly 7-30)
Separation Corona (see assembly 30-5)
Drum Cleaning Assembly (see assembly 31-1)
Also, it is recommended the following parts be replaced at the indicated intervals:
100k - Multipurpose Tray Pickup Roller (see assembly 25-3) 100k - Separation Pad (see assembly 25-5)
100k - Rear Feed Roller (see assembly 24-7) 100k - Front Feed Roller (see assembly 24-4) 200k - Cassette Pickup Roller (see assembly 24-2)
1-2
5045-001
Service Checkpoints
Fuser Unit
Point |
Tool/Solvent |
Remarks |
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|
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Delivery Guide |
MEK |
Clean lightly to remove |
|
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toner. |
|
|
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Separation Claw |
MEK |
Clean carefully, the tip |
Unit |
|
breaks easily. |
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|
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Entrance Guide |
MEK |
Clean |
|
|
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Cassette Pickup Unit |
|
|
|
|
|
Point |
Tool/Solvent |
Remarks |
|
|
|
Feed Roller |
Damp towel or |
Clean |
Separation |
alcohol |
|
Roller |
|
|
|
|
|
Transfer Drum Holder Unit |
|
|
|
|
|
Point |
Tool/Solvent |
Remarks |
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|
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Transfer Sheet |
Lint free paper |
Clean, do not use water or |
|
|
solvents and do not |
|
|
contaminate with solvents or |
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|
oil. |
|
|
|
General Information 1-3
5045-001
Drum Cartridge
Point |
Tool/Solvent |
Remarks |
|
|
|
Photoconductor |
Toner |
Clean, do not use water or |
|
|
solvents and do not |
|
|
contaminate with solvents or |
|
|
oil. When removing the |
|
|
drum store it in the drum |
|
|
cover. |
|
|
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Manual Feeding Tray Pickup Unit |
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|
|
|
|
Point |
Tool/Solvent |
Remarks |
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|
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Separation Pad |
Dry towel |
Clean |
|
|
|
Density Sensor Unit |
|
|
|
|
|
Point |
Tool/solvent |
Remarks |
|
|
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Density Sensor |
Specialty |
Clean |
Window |
brush |
|
|
|
|
Separation |
Specialty |
Clean |
Charging Unit |
brush |
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|
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1-4
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