Lexmark Optra 4049 Service manual

Edition: June 24, 2006

Lexmark Optra™ Series

• Table of Contents

• Start Diagnostics

4049-XXX

• Safety and Notices

• Trademarks

•Index

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

Edition: June 24, 2006

he 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.

his 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 ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation

o you.

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 right 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.

Lexmark, Lexmark with diamond design, MarkNet, and MarkVision are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

ll other trademarks are the property of their respective owners.

1995, 1996, 2006 Lexmark International, Inc. ll rights reserved.

UNITED STATES GOVERNMENT RIGHTS

his software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense.

U.S.A. P/N 13A0329

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

Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Laser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Avis relatif à l’utilisation de laser. . . . . . . . . . . . . . . . . . . . . . . . . x

Avvertenze sui prodotti laser . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Avisos sobre el láser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Declaração sobre Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

Laserinformatie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

Lasermeddelelse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

Huomautus laserlaitteesta . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii

Laser-notis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Laser-melding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Avís sobre el Làser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

Japanese Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Chinese Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

Korean Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvi

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

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi

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

Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

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

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Banding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Black Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Blank Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Blurred or Fuzzy Print. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Dead Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Fan (927 Error). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Fuser Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Fuser: 920, 921, or 922 Error. . . . . . . . . . . . . . . . . . . . . 2-19

iii

Fuser: 923 or 924 Error . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Honeycomb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Horizontal Void or Streak. . . . . . . . . . . . . . . . . . . . . . . . 2-20

LAN Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Light Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Network Card 977 Errors. . . . . . . . . . . . . . . . . . . . . . . . 2-21

Network Wrap Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Output Bin Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Operator Panel Problem . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Paper Feed Problem, 500-Sheet Option or 200-Sheet Second

Drawer, Non-Rt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Paper Feed, Base Printer . . . . . . . . . . . . . . . . . . . . . . . 2-23

Paper Feed, Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Paper Feed Problem, Envelope+ Feeder/

100-Sheet Auxiliary Feeder . . . . . . . . . . . . . . . . . . . . . . 2-26

Paper Feed Problem, 200-Sheet Second Drawer, Rt . . 2-26

Paper Feed Problem, Dual Rear Feeder. . . . . . . . . . . . 2-27

Machine Level Information: . . . . . . . . . . . . . . . . . . . 2-27

Paper Feed Problem, High Capacity Feeder. . . . . . . . . 2-29

Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Paper Size Sensing Problem. . . . . . . . . . . . . . . . . . . . . 2-31

Regularly Spaced Marks . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Random Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Skew, all edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Skew, top and bottom only . . . . . . . . . . . . . . . . . . . . . . 2-33

Stalled (diamonds on display) . . . . . . . . . . . . . . . . . . . . 2-34

Vertical Void or Streak. . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

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

Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Diagnostics Mode Menu Structure . . . . . . . . . . . . . . . . . 3-1

Diagnostics Mode Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Auto Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Auto Clean Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Auto Clean Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Envelope Enhance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

iv Service Manual

Envelope Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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

Flash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Fuser Temperature And Warm-Up Time . . . . . . . . . . . . . 3-8

Fuser Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Fuser Warm-Up Time . . . . . . . . . . . . . . . . . . . . . . . . .3-9

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

Maintenance Kit Count. . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Memory Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Paper Feed Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Parallel Confidence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Print Test 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Print Test 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Print Test 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Top Margin and Duplex Quick Tests . . . . . . . . . . . . . . . 3-15

Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Wrap Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Other Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Developed Image Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

LAN Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Print Test Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Print Test with RIP Board Removed. . . . . . . . . . . . . . . . 3-18

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

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

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Envelope Restraint Spring On

The Envelope+ Feeder Adjustment . . . . . . . . . . . . . . . . . 4-2

Paper Restraint Spring On The 100-Sheet

Auxiliary Feeder Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-2

Envelope+ Feeder Magnet And

100-Sheet Auxiliary Feeder Magnet Adjustment . . . . . . . 4-3

Dual Rear Feeder Gear Alignment Adjustment . . . . . . . . 4-4

Fuser Drive Gear Backlash Adjustment . . . . . . . . . . . . . . 4-5

Fuser Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-7

Paper Feed Magnet Adjustment. . . . . . . . . . . . . . . . . . . . 4-8

Printhead Skew Adjustment . . . . . . . . . . . . . . . . . . . . . . 4-9

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Left Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Top Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

14 in. 200-Sheet Paper Tray Top Cover . . . . . . . . . . . . 4-14

14 in. 500-Sheet Paper Tray Top Cover . . . . . . . . . . . . 4-14

D-roll Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 4-14

Drive Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Engine Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Exit Sensor Board Removal . . . . . . . . . . . . . . . . . . . . . 4-16

Fan/Redrive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Fuser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Fuser Input Guide Removal. . . . . . . . . . . . . . . . . . . . . . 4-19

Fuser Lamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Fuser/Sensor Cable Removal . . . . . . . . . . . . . . . . . . . . 4-21

Fuser Solenoid Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Fuser Shroud Assembly Removal . . . . . . . . . . . . . . . . . 4-23

HVPS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

INA or Hard Disk Removal . . . . . . . . . . . . . . . . . . . . . . 4-26

Input Sensor Board Removal . . . . . . . . . . . . . . . . . . . . 4-26

Lower Frame Assembly Removal . . . . . . . . . . . . . . . . . 4-28

LVPS Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

LVPS Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Paper Feed Rollers Removal . . . . . . . . . . . . . . . . . . . . 4-31

Paper Feed Magnet Assembly Removal. . . . . . . . . . . . 4-32

Paper Size Switch Removal . . . . . . . . . . . . . . . . . . . . . 4-33

Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

RIP Board and Inner EMC Shield Removal. . . . . . . . . . 4-35

Toner Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Torquer Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-35

Transfer Roll Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Transfer Roll Housing Removal. . . . . . . . . . . . . . . . . . . 4-37

Upper Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

Duplex Option Top Cover And Table Cover Removal. . 4-39

Duplex Option Exit Card And Cover Removal. . . . . . . . 4-40

Duplex Option Bottom Cover

And Entry Sensor Card Removal . . . . . . . . . . . . . . . . . 4-41

Duplex Option System Card And Motor Removal . . . . . 4-42

vi Service Manual

Dual Rear Feeder - Edge Guide Asm. . . . . . . . . . . . . . . 4-43

Dual Rear Feeder - Gear Plate Asm. . . . . . . . . . . . . . . . 4-43

Dual Rear Feeder - Right Cover. . . . . . . . . . . . . . . . . . . 4-43

200-Sheet Second Drawer, Rt . . . . . . . . . . . . . . . . . . . . 4-44

High Capacity Feeder Paper Feed Rollers. . . . . . . . . . . 4-45

High Capacity Feeder Cover . . . . . . . . . . . . . . . . . . . . . 4-47

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

Major Assembly Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Gear Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Transfer Roller Housing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

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

RIP Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Board Installation Hardware . . . . . . . . . . . . . . . . . . . . . . . 5-7

Mirror Motor/Fan Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Operator Panel/Output Bin Sensor Cable . . . . . . . . . . . . 5-8

Printhead Connector Locations . . . . . . . . . . . . . . . . . . . 5-10

Duplex Autoconnect Cable. . . . . . . . . . . . . . . . . . . . . . . 5-10

Printer Ground Straps . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

High Capacity Feeder Board Connectors. . . . . . . . . . . . 5-12

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

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

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

Scheduled Mechanical Maintenance . . . . . . . . . . . . . . . . . . . 6-3

Printhead Window Cleaning Procedure . . . . . . . . . . . . . . . . . 6-4

Cleaning The Transfer Roller . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

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

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Lower Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Upper Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

Paper Feed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

Paper Feed Alignment Gears. . . . . . . . . . . . . . . . . . . . . .7-14

Paper Feed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Standard Paper Tray (200-Sheet) . . . . . . . . . . . . . . . . . .7-18

Paper Tray (500-Sheet) . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

Base for Paper Drawer (500-Sheet). . . . . . . . . . . . . . . . .7-22

Second Paper Drawer, (200-Sheet) . . . . . . . . . . . . . . . . .7-24

Optional Paper Drawer (500-Sheet). . . . . . . . . . . . . . . . .7-26

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28

Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32

vii

Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Duplex Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Envelope+ and 100-Sheet Auxiliary Feeder . . . . . . . . . . 7-40

Dual Rear Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

High Capacity Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1

viii Service Manual

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 ix

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 .

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.

x Service Manual

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.

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

Notices and Safety Information xi

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.

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.

xii Service Manual

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 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

Notices and Safety Information xiii

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 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.

xiv Service Manual

Japanese Laser Notice

Chinese Laser Notice

Notices and Safety Information xv

Korean Laser Notice

Trademarks

Optra and Lexmark are trademarks of Lexmark International, Inc.

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 designed and manufactured by Lexmark International, Inc., 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 4049 Technical Reference manual.

xvi Service Manual

Safety Information

•

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.

• The safety features of some parts may not always be

obvious. Therefore, replacement parts must have the identical or equivalent characteristics as the original parts.

Sicherheitshinweise

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.

• Ersatzteile müssen gleiche oder gleichwertige Merkmale wie

die Originalteile aufweisen, da nicht immer offensichtlich ist, welche Teile des Geräts Sicherheitsmerkmale aufweisen.

Consignes de Sécurité

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.

• Les normes de sécurité de certaines pièces n'étant pas

toujours explicites, les pièces de rechange doivent être

Notices and Safety Information xvii

identiques ou conformes aux caractéristiques des pièces d'origine.

Norme di sicurezza

•

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.

• Poiché non tutti i pezzi di ricambio garantiscono la stessa

sicurezza, questi devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali.

Pautas de Seguridad

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.

• Los dispositivos de seguridad de algunas piezas no siempre

pueden reconocerse a simple vista. Por lo tanto, los recambios deben poseer características idénticas o equivalentes a las de las piezas originales.

Informações de Segurança

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

xviii Service Manual

destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

• Os dispositivos de segurança de algumas peças poderão

não ser sempre suficientemente evidentes. Assim, as peças sobressalentes devem possuir características idênticas ou equivalentes às peças originais.

Informació de Seguretat

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.

• Les característiques de seguretat d’algunes de les peces

poden no ser òbvies. Per tant, les característiques dels recanvis hauran de ser idèntiques o equivalents a les de les peces originals.

Notices and Safety Information xix

Chinese Safety Information

Korean Safety Information

xx Service Manual

Preface

This manual is divided into the following chapters:

• “General Information” contains a general description of the

printer, available options, and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter.

• “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.

Preface xxi

xxii Service Manual

1. General Information

The Optra Laser Printers are designed to attach to IBM-compatible PC’s and to most computer networks. There are multiple models, all with standard PostScript Level 2 emulation and PCL 5 emulation.

From a service standpoint models Lxi

, model Lxi is the same as Lx, and model Rn+ is the same as R+.

Models Lxi

, Lxn+, Lxi, and Rn+ are not mentioned elsewhere in this

and Lxn+ are the same as

manual. The plus models have a different ROM SIMM, RIP board, and top

cover, a nd all have a maximum speed of 16 ppm. Ther e are no other hardware differences. Processing speed and efficiency have been improved, and scheduled maintenance has been eliminated.

General Information 1-1

Power Consumption

R/L/Rt/R+/Rt

Power Saver Mode 21W 20W Printing (average) 260W 310W Max. AC draw 110V 6.8A 9.8A Max. AC draw 220V 3.4A 5.0A

Rx/Lx/Lx

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 AppleTalk SCS

IPDS 200 and 500-sheet paper trays of A5, letter, and legal size. 500-sheet second drawer (with letter-size paper tray) Envelope+ feeder 100-sheet auxiliary feeder Duplex option Font cards (bitmapped or scalable fonts) 100MB Hard Disk Dual Rear Feeder Stat Alert Light High Capacity Feeder (1500 sheets)

1-2

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. Begin with “Start” on page 2-2.

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.

Tools Required For Service

Flat-blade screwdriver #1 Phillips screwdriver #2 Phillips screwdriver

5.5 mm nut driver 8 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

General Information 1-3

Abbreviations

ASIC Application-Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-

Only Memory EP Electrophotographic Process ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LAN Local Area Network LASER Light Amplification by Stimulated Emission

of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PICS Problem Isolation Charts PIXEL Picture Element POR Power-On Reset POST Power-On Self Test PQET Print Quality Enhancement Technology RIP Raster Image Processor ROS Read-Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement VAC Volts alternating current VDC Volts direct current

1-4

2. Diagnostic Information

Start

Remove power from the printer before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer.

Two-digit codes are messages for the user, but if they recur frequently or at inappropriate times they may be symptomatic of a service problem.

Use the service error code, symptom table, service checks, and diagnostic aids to determine the corrective action necessary to repair a malfunctioning printer.

Diagnostic Information 2-1

Refer to the diagnostics Error log for the last six machine errors.

Error Code Explanation

20 Paper Jam The input sensor was not unmade in

time.

21 Paper Jam The exit sensor was not made in

22 Paper Jam The exit sensor was not unmade in

23 Paper Jam Jam at the duplex unit. Paper is

24 Short Paper The defined paper size is too short

25 Incorrect Manual Feed Input sensor made at wrong time.

26 Duplex Tray Missing Duplex unit is installed but paper tray

27 Change Envelope/Paper Envelopes/paper loaded are wrong

28 Load Envelope/Paper Input sensor not made after pick

time after the input sensor was made.

time.

either not leaving the duplex entry sensor in time or not making or unmaking the duplex exit sensor in time. See “Duplex” on page 2-16

to print data as formatted.

May be due to the paper feeding manually while motors running and previous page in path.

is not sensed.

size.

attempt. Tray is empty or not installed, paper jam in entry throat, or printer is requesting a manual feed.

29 Output Bin Full The output bin sensor has not been

unmade.See “Output Bin Sensor” on page 2-22.

2-2

Error Code Explanation

30 Top Cover Open or Print Cartridge Missing

32 Wrong Print Cartridge installed

37 Insufficient Collation Memory

38 Memory Full Memory used to store pages is full.

39 Complex Page Page too complex to print.To verify

Make sure the spring-mounted pin on the printhead shroud is installed properly and that it is detected by the ramp on the print cartridge as the cover closes. The pin should enter the tower on the HVPS and depress the cover switch.

The installed print cartridge is not supported by the Optra printer.

Memory is too full to collate the print job.

To verify that the printer recognizes all the installed memory, go to the user menus and print the “Print Menus” test page. Make sure the memory shown on the printout matches the installed memory.

that the printer recognizes all the installed memory, go to the user menus and print the “Print Menus” test page. Make sure the memory shown on the printout matches the installed memory.

43 Font Card Not Supported Font card format not supported by

printer.

44 Defective Font Card Defective font card installed in font

47 Font Card Removed While Printing

51 Defective Flash The printer detects a defective Flash

52 Flash Full Not enough flash memory for data

53 Unformatted Flash Flash problem at POR or while

slot.

Printer needs data on removed card.

SIMM. If the error recurs replace the Flash SIMM.

requested to be stored.

attempting to write.

Diagnostic Information 2-3

Error Code Explanation

54 Serial Error Framing or parity error on serial.

56 Serial Port Disabled or, Parallel Port Disabled

57 Check Duplex Connection The duplex unit has been electrically

58 Duplex Not Attached Duplex is no longer connected, and

59 Duplex Cover Open Top cover of duplex unit is sensed

62 Disk Full Not enough disk space for data that

63 Unformatted Disk Format the disk.

64 Defective Disk The printer will ignore a disk it

Data has been sent to a port which has been disabled in the Setup Menu. The port can be reactivated by entering the customer setup menu and selecting Serial Setup or Parallel Setup, Serial Buffer or Parallel Buffer, and changing the setting from Disabled to Auto.

disconnected from the printer but the printer top cover is not open. Check the auto-connect plugs on the duplex unit and the printer.

printer top cover is closed.

open.

has been requested to be written to disk.

senses as defective. Run the Quick Disk Test. If the test fails, the disk is defective or the data on track 1 is bad. If the Quick Disk Test passes but the disk does not work, run the Disk Test/Clean (2 hour test). Replace the disk if instructed by the operator panel.

7X Network Card Codes These user codes are documented

in various network card user manuals. See “Network Wrap Tests” on page 2-22

80 Scheduled Maintenance Printer has reached 200,000 prints

without maintenance count reset. Refer to “Scheduled Mechanical Maintenance” on page 6-3.

2-4

+ 165 hidden pages