Lexmark Optra C Service Manual

Optra C

SERVICE MANUAL

Document Number SA40-0 897 -01

P/N 69G3225

R. Monahan

Information Development

D22A/035-3

740 New Circle Road N.W.

Lexington, Kentucky 40511

[phone]

This is a development draft, it may contain technical inaccu­racies and typographical errors.

1

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.

A form for reader’s comments is provided at the back of this publication. If the
form has been removed, comments may be addressed to Lexmark
International, Inc., Department F95/035-3, 740 New Circle Road, Lexington,
Kentucky 40511, 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., Greenwich, CT 06836.

Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xi

Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . .xiii

Laser Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Error (146) Printer Communication Failure . . . . . . . . . . 2-27

Contents iii

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

Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Print Quality Start Of Call . . . . . . . . . . . . . . . . . . . . . . . 2-50

Horizontal Variation (“Jitter”) Example. . . . . . . . . . . . . . 2-53

Print Quality Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 2-55

iv

Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Black Horizontal Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55

Black Vertical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Blur at Bottom of Page. . . . . . . . . . . . . . . . . . . . . . . . . . 2-56

Laser Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57

Low Color Coverage or Usage. . . . . . . . . . . . . . . . . . . . 2-57

Oil Soaking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58

Random Oil Spots on Page . . . . . . . . . . . . . . . . . . . . . . 2-59

Spew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59

Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Print Quality Service Checks . . . . . . . . . . . . . . . . . . . . . . . . 2-62

Black Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62

Blank Page Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-62

Blank Spots Service Check . . . . . . . . . . . . . . . . . . . . . . 2-63

Color Aberration Service Check. . . . . . . . . . . . . . . . . . . 2-64

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Flash Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Memory Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Contents v

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

Fuser Thermo Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Fuser Cleaner Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-33

Fuser Oil Apply Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-34

Fuser Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

Fuser Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

vi

Fuser Oil Applying Input Assembly . . . . . . . . . . . . . . . . 4-40

Fuser Delivery Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-40

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . 4-41

High Voltage Converter . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

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

Main Drive Motor and Board . . . . . . . . . . . . . . . . . . . . . 4-42

Mechanical Controller PCB . . . . . . . . . . . . . . . . . . . . . . 4-43

Multipurpose Feeder Paper Pickup, D-Roller. . . . . . . . . 4-43

Multipurpose Feeder Paper Sensor . . . . . . . . . . . . . . . . 4-43

Multipurpose Feeder U-Turn Roller Assembly . . . . . . . . 4-44

Multipurpose Feeder D-Roller Solenoid . . . . . . . . . . . . . 4-44

Paper Delivery Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-45

Printhead and Printhead Board . . . . . . . . . . . . . . . . . . . 4-46

Printer Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 4-49

Rotary Manual Feed Assembly . . . . . . . . . . . . . . . . . . . 4-50

Rear Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Rear Cooling Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

Transfer Drum Motor and Developer Drive Motor . . . . . 4-51

Transfer Drum and Holder Assembly. . . . . . . . . . . . . . . 4-52

Transfer Drum Separation Claw. . . . . . . . . . . . . . . . . . . 4-53

Transfer Drum Knob Assembly . . . . . . . . . . . . . . . . . . . 4-53

Transfer Drum Attraction Roller . . . . . . . . . . . . . . . . . . . 4-54

Transfer Drum Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Transfer Drum Front and Rear Slide Assemblies. . . . . . 4-56

Transfer Drum Discharge Roller. . . . . . . . . . . . . . . . . . . 4-56

Transfer Drum HV Contact Assembly . . . . . . . . . . . . . . 4-56

Transfer Drum Gripper Assembly. . . . . . . . . . . . . . . . . . 4-57

Transfer Drum Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Transfer Drum Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Transfer Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Transfer Drum Cleaning Drive Assembly. . . . . . . . . . . . 4-62

Toner Cartridge Ejector . . . . . . . . . . . . . . . . . . . . . . . . . 4-63

Upper Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Upper Output Drive Assembly . . . . . . . . . . . . . . . . . . . . 4-64

Video Controller Board. . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

Optional Paper Feeder Removals . . . . . . . . . . . . . . . . . . . . 4-65

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

Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Clutches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Contents vii

Clutches and Solenoids . . . . . . . . . . . . . . . . . . . . . . . 5-9

Motors and Fuser Heaters. . . . . . . . . . . . . . . . . . . . . . . 5-10

Motors and Fuser Heaters . . . . . . . . . . . . . . . . . . . . 5-11

PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

DC Controller Board Connector Locations . . . . . . . . . . 5-18

DC Controller Board Connector Locations (Graphic) . . 5-19

Mechanical Controller Board Connector Locations . . . . 5-26

Mechanical Controller Board Connectors (Graphic) . . . 5-27

Paper Pickup Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Optional Paper Feeder (Driver Board). . . . . . . . . . . . . . 5-35

Optional Paper Feeder (Miscellaneous) . . . . . . . . . . . . 5-36

High Voltage Power Supply PCB . . . . . . . . . . . . . . . . . 5-36

Separation HVT PCB. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Ejection Sensing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Cassette Size Sensing PCB . . . . . . . . . . . . . . . . . . . . . 5-37

Paper Feed Driver PCB. . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Fuser Connector (J21). . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

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

Rotary Manual Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30

viii

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

Contents ix

x

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 guide-
lines, lubrication specifications, and maintenance information to
prevent problems and maintain optimum performance.

•

“Parts Catalog” contains illustrations and part numbers for indi­vidual FRUs.

Preface xi

xii

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 xiii

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 .

xiv

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 xv

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.

xvi

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 servicebeting els er.

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 xvii

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.

xviii

Avís sobre el Làse r

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.

Notices and Safety Information xix

Japanese Laser Notice

Chinese Laser Notice

xx

Korean Laser Notice

Notices and Safety Information xxi

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 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.

xxii

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.

Notices and Safety Information xxiii

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
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.

xxiv

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
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.

Notices and Safety Information xxv

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.

xxvi

Chinese Safety Information

Korean Safety Information

Notices and Safety Information xxvii

1. General Information

The Optra C is a 600 dpi Color Laserprinter 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:

Print speed in
pages per minute

A4 Full Color

3 12 2.5

A4 Mono
Color

A4 Full Color
Fine Mode

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 ev ery 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

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

Service Checkpoints

Fuser Unit

Point Tool/Solvent Remarks

Delivery Guide MEK Clean lightly to remove

toner.

Separation
Claw Unit

MEK Clean carefully, the tip

breaks easily.

Entrance Guide MEK Clean

Cassette Pickup Unit

Point Tool/Solvent Remarks

Feed Roller
Separation

Damp towel
or alcohol

Clean

Roller

Transfer Drum Holder Unit

Point Tool/Solvent Remarks

Transfer Sheet Lint free paper Clean, do not use water or

solvents and do not
contaminat e with solv ents or
oil.

General Information 1-3