Lexmark Optra S Service Manual
Revised: 11/1/06
• Table of Contents
•Start Diagnostics
Optra™ S
4059-XXX
• Safety and Notices
• Trademarks
•Index
Lexmark and Lexmark with diamond
design are trade ma rks of Lexmark
International, Inc., registered i n the
United States and/or ot her countries.
First Edition: November 1, 2006
The followin g paragraph does not apply to any country where such
provisions are inc o n s istent with local law: LEXMARK INTERNATIONAL,
INC. PRO VIDES THIS PUBL ICATION “AS IS” WITHOUT WARRANTY OF ANY
KIND, EI THER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO,
THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTI CULAR PURPO SE. Some states do not allow disclaimer of express or
implied warr anties in certain transact ions, therefore, this statement may not
apply to you.
This publica tion could include te chnical inaccuracies or typog raphical errors.
Changes are periodi cally made t o the inf ormati on 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. Publications are not stocked at
the address giv en bel ow; request s f or publ icati ons shoul d be made to yo ur p oint
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 Le xmark
International, Inc., D22A/035-3, 740 New Circle Road NW, Lexington, K entucky
40550, U.S.A. Lexmark may use or distribute any of the information you supply
in any way it believ es appropriate without incurring any obligation to you.
Lexmark and Optra are trademarks of Lexmark International, Inc., registered in
the United States and/or other countries.
©Copyright Lexmark International, Inc. 1998, 2006
All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
This software and documentation are provided with RESTRICTED RIGHTS.
Use, duplicat ion or disclosure by the Government is subj ect to restrictions as
set forth in subpar ag raph ( c)(1) (ii) o f the Ri ghts i n Technical Data and Comp uter
Software clause at DFARS 252.227-7013 and in applicable FAR pr ovisions:
Lexmark International, Inc., Lexington, KY 40550.
USA P/N: 12G0139
Contents
Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . 1-ix
Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-ix
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xvii
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xxii
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tools Required For Service. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
User Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . 2-24
Symptom Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Charge Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-29
Cover Open Switch/Cable Service Check . . . . . . . . . . . . 2-31
Dead Machine Service Check . . . . . . . . . . . . . . . . . . . . . 2-32
Duplex Option Service Check. . . . . . . . . . . . . . . . . . . . . . 2-35
Envelope Feeder Option Service Check . . . . . . . . . . . . . 2-39
Erase Lamp Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-46
Fan Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Fuser Envelope Conditioner Solenoid Service Check . . . 2-51
Input Sensor Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-57
Input Tray(s) Option Service Check . . . . . . . . . . . . . . . . . 2-58
High Capacity Feeder Input Tray Service Check . . . . . . . 2-61
Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Operator Panel Service Check . . . . . . . . . . . . . . . . . . . . . 2-74
Options Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Output Bin Sensor Standard Tray Service Check . . . . . . 2-78
Output Expander Service Check . . . . . . . . . . . . . . . . . . . 2-79
Paper Feed Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-86
Parallel Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-89
Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-91
Contents iii
Smart Cartridge Service Check . . . . . . . . . . . . . . . . . . . 2-102
Serial Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-104
Toner Sensor Service Check. . . . . . . . . . . . . . . . . . . . . 2-104
Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . 2-105
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . 3-3
Duplex Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Duplex Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Duplex Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
DRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Parallel Wrap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Output Bin Test - Standard Bin . . . . . . . . . . . . . . . . . . . . 3-15
Output Bin Feed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Output Bin X Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Printer Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Viewing the Permanent Page Count . . . . . . . . . . . . . . . . 3-19
Maintenance Page Count (2420/2450/2455/3455) . . . . . 3-20
Setting Configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . 3-21
iv 4059 Service Manual
Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Print Quality Test Pages. . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-24
Autocompensator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Autoconnect System, Paper Tray Options, Envelope Feeder and
Output Expander Operations. . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Fuser Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Paper Feed Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-Sensitive Parts. . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Duplex Motor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuser Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Printhead Assembly Adjustment. . . . . . . . . . . . . . . . . . . . . 4-4
Paper Alignment Assembly Adjustment . . . . . . . . . . . . . . . 4-5
Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Center Pan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Developer Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Duplex Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Duplex Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . 4-21
Duplex Front Cover Door . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Duplex Front Cover Door Switch . . . . . . . . . . . . . . . . . . . 4-21
Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
EP Frame Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Fuser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Fuser Detack Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Fuser Detack Housing Assembly . . . . . . . . . . . . . . . . . . . 4-29
Fuser Transfer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Fuser Envelope Conditioner Solenoid . . . . . . . . . . . . . . . 4-31
Fuser Exit Flag Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-31
Fuser Exit Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Fuser Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Fuser Lower Exit Guide Assembly . . . . . . . . . . . . . . . . . . 4-33
High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . 4-34
Contents v
Inner EMC Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Inner Paper Deflector Assembly . . . . . . . . . . . . . . . . . . . 4-36
Integrated Tray Compensator Assembly. . . . . . . . . . . . . 4-37
Integrated Tray Compensator Pick Roll Assembly . . . . . 4-38
Interconnect Board Assembly . . . . . . . . . . . . . . . . . . . . . 4-39
Left Side Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . 4-43
Main Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Main Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Multipurpose Tray/Lower Deflector Assembly . . . . . . . . . 4-46
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Operator Panel Cable/Cover Open Switch Assembly . . . 4-49
Optional 250/500 Paper Tray Assembly . . . . . . . . . . . . . 4-50
Outer EMC Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
Paper Alignment Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-52
Paper Input Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Paper Size Sensing Board. . . . . . . . . . . . . . . . . . . . . . . . 4-54
Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Redrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Right Side Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Smart Cartridge Contacts . . . . . . . . . . . . . . . . . . . . . . . . 4-58
Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Transfer Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
Upper Paper Deflector Assembly . . . . . . . . . . . . . . . . . . 4-60
Upper Front Cover Hinge Assembly . . . . . . . . . . . . . . . . 4-61
Upper Front Cover Interlock Switch Assembly . . . . . . . . 4-62
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 5-1
High Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 5-3
Engine Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Fuser Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Envelope Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Duplex Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Autoconnect - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Output Expander Control Board - Level 1 Stepper Motor 5-22
Output Expander Control Board - Level 2 DC Motor . . . . 5-24
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Scheduled Maintenance (2420/2450/2455/3455). . . . . . . . . . 6-2
vi 4059 Service Manual
Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . 7-1
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly 2: Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly 3: Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Assembly 4: Paper Feed (Autocompensator). . . . . . . . . . 7-12
Assembly 5: Paper Feed - Multipurpose Unit . . . . . . . . . . 7-14
Assembly 6: Paper Feed - Alignment. . . . . . . . . . . . . . . . 7-16
Assembly 7: Paper Feed - Output . . . . . . . . . . . . . . . . . . 7-18
Assembly 8: Integrated Paper Tray - 250 Sheet . . . . . . . 7-20
Assembly 9: Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Assembly 10: Developer Drive . . . . . . . . . . . . . . . . . . . . . 7-24
Assembly 11: Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Assembly 12: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Assembly 13: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Assembly 14: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Assembly 15: 250 Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-48
Assembly 16: 500 Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-52
Assembly 17: 500/500 Dual Tray . . . . . . . . . . . . . . . . . . . 7-56
Assembly 18: Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Assembly 19: Output Expander . . . . . . . . . . . . . . . . . . . . 7-66
Assembly 20: Envelope Feeder . . . . . . . . . . . . . . . . . . . . 7-70
Assembly 21: High Capacity Feeder . . . . . . . . . . . . . . . . 7-74
Assembly 22: Kiosk - Vertical Paper Adapter. . . . . . . . . . 7-84
Assembly 23: Kiosk - Horizontal Paper Adapter. . . . . . . . 7-86
Assembly 24: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88
Assembly 25: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . 7-90
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Contents vii
viii 4059 Service Manual
Notices and Safety Information
Laser Notices
The following laser notice labels may be affixed to this printer as
shown:
Laser Advisory Label
Notices and Safety Information ix
Class 1 Laser Statement Label
CLASS 1 LASER PRODUCT
LASER KLASSE 1
LUOKAN 1 LASERLAITE
APPAREIL À LASER DE CLASSE 1
TO IEC 825
x 4059 Service Manual
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.
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.
Notices and Safety Information xi
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.
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
xii 4059 Service Manual
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
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.
Notices and Safety Information xiii
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.
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.
xiv 4059 Service Manual
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.
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.
Notices and Safety Information xv
Japanese Laser Notice
Chinese Laser Notice
xvi 4059 Service Manual
Korean Laser Notice
Safety Information
•
This product is designed, tested and approved to meet strict
global safety standards with the use of specific Lexmark
components. The safety features of some parts may not always
be obvious. Lexmark is not responsible for the use of other
replacement parts.
• The maintenance information for this product has been
prepared for use by a professional service person and is not
intended to be used by others.
• There may be an increased risk of electric shock and personal
injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precautions.
Consignes de Sécurité
Ce produit a été conçu, testé et approuvé pour respecter les
•
normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. Les caractéristiques de
Notices and Safety Information xvii
sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres
pièces de rechange.
• Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement à un personnel de maintenance
qualifié.
• Le démontage et l'entretien de ce produit pouvant présenter
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.
Norme di sicurezza
•
Il prodotto è stato progettato, testato e approvato in conformità a
severi standard di sicurezza e per l’utilizzo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune parti
non sempre sono di immediata comprensione. Lexmark non è
responsabile per l’utilizzo di parti di ricambio di altri produttori.
• Le informazioni riguardanti la manutenzione di questo prodotto
sono indirizzate soltanto al personale di assistenza autorizzato.
• Durante lo smontaggio e la manutenzione di questo prodotto, il
rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.
Sicherheitshinweise
•
Dieses Produkt und die zugehörigen Komponenten wurden
entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder
Haftung für dieses Produkt übernommen.
• Die Wartungsinformationen für dieses Produkt sind
ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
• Während des Auseinandernehmens und der Wartung des
Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
xviii 4059 Service Manual
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.
Pautas de Seguridad
Este producto se ha diseñado, verificado y aprobado para
•
cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede que
las características de seguridad de algunas piezas no sean
siempre evidentes. Lexmark no se hace responsable del uso de
otras piezas de recambio.
• La información sobre el mantenimiento de este producto está
dirigida exclusivamente al personal cualificado de
mantenimiento.
• Existe mayor riesgo de descarga eléctrica y de daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.
Informações de Segurança
Este produto foi concebido, testado e aprovado para satisfazer
•
os padrões globais de segurança na utilização de componentes
específicos da Lexmark. As funções de segurança de alguns
dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de
substituição.
• As informações de segurança relativas a este produto
destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.
• Risco de choques eléctricos e ferimentos graves durante a
desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.
Notices and Safety Information xix
Informació de Seguretat
•
Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de Lexmark. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Lexmark no es responsabilitza de l'us
d'altres peces de recanvi.
• La informació pel manteniment d’aquest producte està
orientada exclusivament a professionals i no està destinada a
ningú que no ho sigui.
• El risc de xoc elèctric i de danys personals pot augmentar
durant el procés de desmuntatge i de servei d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre les
mesures convenients.
xx 4059 Service Manual
Chinese Safety Information
Korean Safety Information
Ozone Information
This product does not produce measurable amounts of ozone gas.
Notices and Safety Information xxi
Preface
This manual is divided into the following chapters:
• “General Information” contains a general description of the
printer, options, and the maintenance approach used to repair it.
General environmental and safety instructions as well as
special tools and test equipment are listed in this chapter.
• “Diagnostic Information” contains a service error code table,
user status message table, user error message table, symptom
table, and service checks used to isolate failing field replaceable
units (FRUs).
• “Diagnostic Aids” contains tests and checks used to locate or
repeat symptoms of printer problems. Printer operation
information is provided to enhance the tests and checks.
• “Repair Information” provides instructions for making printer
adjustments and removing and installing FRUs.
• “Connector Locations” uses illustrations to identify the major
components and test points on the printer.
• “Preventive Maintenance” contains safety inspection guidelines,
lubrication specifications, and maintenance information to
prevent problems and maintain performance.
• “Parts Catalog” contains illustrations and part numbers for
individual FRUs.
xxii 4059 Service Manual
1. General Information
The Optra™ S Laser Printers are letter quality page printers
designed to attach to IBM-compatible PC’s and to most computer
networks.
The printer is available in eleven models.
Optra S Model
1250 (4059-121)
1255 (4059-125)
General Information 1-1
Optra S Models
1620 (4059-162)
1625 (4059-165)
1650 (4059-160)
1855 (4059-185)
1855 (4059-C01)
1-2 4059 Service Manual
Optra S Models
2420 (4059-242)
2450 (4059-240)
2455 (4059-245)
3455 (4059-345)
General Information 1-3
Options
The following options are available. Some options are not available
in every country. Contact your point of purchase for options available
in your country.
Memory options of 4MB, 8MB, 16MB and 32MB
Flash memory options of 4MB and 8MB
Integrated network options
Token-Ring
Ethernet
Tr i - Po r t
IR Adapter
IPDS
SCS
USB/Parallel Port
250 and 500-sheet paper trays of A5, letter, and legal size.
250 Sheet Special Media Tray Assembly
500/500-sheet dual trays (Models 2450, 2455 and 3455)
2000 Sheet High Capacity Feeder
Envelope feeder
Duplex option
Hard Disk - 1.4 GB (Models 1250, 1620, 1650, 2420 and 2450)
Hard Disk - 2.1 GB (Models 1255, 1625, 1855, 2455 and 3455)
Forms Hard Disk - 2.1 GB
Infrared Adapter
Kiosk Adapter
Output Expander (Models 1650, 1855, 2450, 2455 and 3455)
1-4 4059 Service Manual
Maintenance Approach
The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the service error codes,
user status messages, user error messages, service checks, and
diagnostic aids to determine the printer problem and repair the
failure. After you complete the repair, perform tests as needed to
verify the repair.
Tools Required For Service
Flat-blade screwdriver
#1 Phillips screwdriver
#2 Phillips screwdriver
7.0 mm nut driver
5.5 mm wrench
Needlenose pliers
Diagonal pliers
Spring hook
Feeler gauges
Analog or digital multimeter
Parallel wrap plug 1319128
Serial wrap plug 1329048
Twinax/serial debug cable 1381963
Coax/serial debug cable 1381964
General Information 1-5
Acronyms
CSU Customer Setup
DRAM Dynamic Random Access Memory
EDO Enhanced Data Out
EP Electrophotographic Process
EPROM Erasable, Programmable Read-Only
Memory
ESD Electrostatic Discharge
FRU Field Replaceable Unit
GB Giga Byte
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission
of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
MROM Masked Read Only Memory
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PC Photoconductor
POST Power-On Self Test
RIP Raster Imaging Processor
ROM Read Only Memory
SIMM Single In-Line Memory Module
SRAM Static Random Access Memory
UPR Used Parts Return
V ac Volts alternating current
V dc Volts direct current
1-6 4059 Service Manual
2. Diagnostic Information
Start
CAUTION: 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. Use the hand grips on
the side of the printer. Make sure your fingers are not under the
printer when you lift or set the printer down.
Use the service error code, user status message, user error
message, symptom table, service checks, and diagnostic aids in this
chapter to determine the corrective action necessary to repair a
malfunctioning printer.
Service error codes are indicated by a three digit error code. If a
service error code is displayed, go to the “Service Error Codes” on
page 2-2.
User status messages provide the user with information on the
current status of the printer. Ready is displayed on the first line of the
display unless Power Saver is invoked, then Power Saver is
displayed. If a user status message is displayed, go to the “User
Status Messages” on page 2-12.
User error messages are indicated by a two or three digit error code
that provides the user with information that explains a problem with a
print cartridge, paper jam, option, port, and so on. If a user error
message is displayed, go to the “User Error Messages” on
page 2-16.
If your machine completes the “Power-On Self Test (POST)” on
page 2-24 without an error, and you have a symptom, go to the
“Symptom Tables” on page 2-25. Locate your symptom and take the
appropriate action.
If a service error code appears while you are working on the
machine, go to the “Service Error Codes” on page 2-2 and take the
indicated action for that error.
Diagnostic Information 2-1
Service Error Codes
Service Error Codes are generally non-recoverable except in an
intermittent condition when you can POR the printer to temporarily
recover from the error condition.
Error Code Action
900 RIP Software Contact the next support level or call Lexmark..
901 Engine Flash This error indicates that the flash which the engine board
902 General
Engine Software
903 Paperport
Link Driver Error
904 Interface
Violation by the
controller
software
905 Interface
Violation by
Paperport Device
906 ControllerEngine Link
Driver Error
code is programmed into is bad. Replace the engine
board.
These errors indicate an unrecoverable engine software
error. Replace the engine board.
2-2 4059 Service Manual
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