Lexmark Optra Series User manual

4049-XXX
Lexmark Optra™ Series
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
• Index
• Safety and Notices
• Trademarks
• Start Diagnostics
• Table of Contents

iii
4049-XXX
Table of Contents
NoticesandSafetyInformation......... ..........ix
LaserNotice...................... ......... ix
Laser............................ ..........x
Avisrelatifàl’utilisationdelaser....... ..........x
Avvertenzesuiprodottilaser ......... ......... xi
Avisossobreelláser................ ......... xi
DeclaraçãosobreLaser............. ......... xii
Laserinformatie.................... ......... xii
Lasermeddelelse .................. .........xiii
Huomautuslaserlaitteesta........... .........xiii
Laser-notis....................... ........ xiv
Laser-melding..................... ........ xiv
AvíssobreelLàser................. ......... xv
Japanese Laser Notice.............. .........xv
ChineseLaserNotice............................... xvi
KoreanLaserNotice................................ xvi
Trademarks....................................... xvii
SafetyInformation..................................xviii
Preface ............................................xxiii
GeneralInformation...................................1-1
PowerConsumption................................ 1-2
Options.......................................... 1-2
Maintenance Approach.............................. 1-3
Tools Required For Service .......................... 1-3
Abbreviations..................................... 1-4

iv Service Manual
4049-XXX
DiagnosticInformation ................................2-1
Start............................................ 2-1
Power-OnSelfTest(POST) ........................ 2-10
SymptomTable.................................. 2-11
Banding ..................................... 2-12
Background.................................. 2-12
BlackPage .................................. 2-13
BlankPage .................................. 2-14
BlurredorFuzzyPrint.......................... 2-15
DeadMachine................................ 2-15
Duplex...................................... 2-16
Fan(927Error)............................... 2-18
Fuser Theory. ................................ 2-19
Fuser: 920, 921, or 922 Error .................... 2-19
Fuser:923or924Error......................... 2-20
Honeycomb.................................. 2-20
HorizontalVoidorStreak........................ 2-20
LANProblems................................ 2-21
LightPrint ................................... 2-21
NetworkCard977Errors........................ 2-21
NetworkWrapTests........................... 2-22
OutputBinSensor............................. 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
MachineLevelInformation: ...................2-27
Paper Feed Problem, High Capacity Feeder......... 2-29
Printhead.................................... 2-30
Paper Size Sensing Problem..................... 2-31
RegularlySpacedMarks ...... 2-32
...... 2-32
...... 2-32
...... 2-33
Skew,topandbottomonly...................... 2-33
Stalled (diamonds on display) .................... 2-34
VerticalVoidorStreak.......................... 2-34

v
4049-XXX
DiagnosticAids ..................... .........3-1
Diagnostics Mode.................. ........ 3-1
Diagnostics Mode Menu Structure. . ........ 3-1
Diagnostics Mode Tests . . . .......... ........ 3-3
AutoClean.................... ........ 3-3
Auto Clean Frequency . .......... ........ 3-3
AutoCleanDelay............... ........ 3-4
ButtonTest.................... ........ 3-4
ChargeRoll ................... ........ 3-4
Defaults...................... ........ 3-5
DiskTest/Clean................ ........ 3-5
DuplexFeed1Test............. ........ 3-6
DuplexFeed2Test............................. 3-6
Envelope Enhance.............................. 3-7
EnvelopePrintTest............................. 3-7
ErrorLog ..................................... 3-8
FlashTest..................................... 3-8
FuserTemperatureAndWarm-UpTime............. 3-8
FuserTemperature...........................3-9
FuserWarm-UpTime .........................3-9
LCDTest..................................... 3-9
Maintenance Kit Count. ......................... 3-10
MemoryTests................................. 3-10
PageCount .................................. 3-10
Paper Feed Tests.............................. 3-10
Parallel Confidence . . . ......................... 3-11
Permanent Page Count ......................... 3-11
PrintContrast................................. 3-11
PrintRegistration.............................. 3-12
PrintTest1................................... 3-13
PrintTest2................................... 3-13
PrintTest3................................... 3-14
QuickDiskTest............................... 3-14
QuickTest................................... 3-14
SensorTest.................................. 3-15
TopMarginandDuplexQuickTests............... 3-15
Transfer..................................... 3-16
WrapTests................................... 3-16

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4049-XXX
OtherTests ..................................... 3-17
DevelopedImageTest ......................... 3-17
LANInformation............................... 3-17
PrintTestPage............................... 3-18
PrintTestwithRIPBoardRemoved............... 3-18
RepairInformation....................................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 Ad ...... 4-3
Dual Rear Feeder Gear Alignment Adju ...... 4-4
FuserDriveGearBacklashAdjustment ...... 4-5
Fuser Solenoid Adjustment ......... ...... 4-7
Paper Feed Magnet Adjustment ..... ...... 4-8
Printhead Skew Adjustment ........ ...... 4-9
RemovalProcedures................. ..... 4-10
Covers......................... ..... 4-10
RightCoverRemoval ............. ..... 4-10
FrontCoverRemoval ............. ..... 4-10
LeftCoverRemoval............... ..... 4-12
TopCoverRemoval............... ..... 4-12
14 in. 200-Sheet Paper Tray Top Cove ..... 4-14
14 in. 500-Sheet Paper Tray Top Cove ..... 4-14
D-rollAssemblyRemoval.......... ..... 4-14
DriveMotorRemoval.............. ..... 4-14
EngineBoardRemoval............ ..... 4-15
ExitSensorBoardRemoval ........ ..... 4-16
Fan/RedriveRemoval............. ..... 4-17
FuserRemoval .................. ..... 4-18
FuserInputGuideRemoval...................... 4-19
FuserLampRemoval .......................... 4-20
Fuser/SensorCableRemoval ................... 4-21
................... 4-22
val................. 4-23
................... 4-24
INAorHardDiskRemoval ...................... 4-26
Input Sensor Board Removal .................... 4-26
LowerFrameAssemblyRemoval................. 4-28

vii
4049-XXX
Removal Procedures (continued)
LVPSRemoval................................ 4-29
LVPSCoverRemoval .......................... 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
RIPBoardandInnerEMCShieldRemoval.......... 4-35
TonerSensorRemoval ......................... 4-35
Torquer Motor Removal ......................... 4-35
TransferRollRemoval.......................... 4-36
TransferRollHousingRemoval................... 4-37
Upper Frame Removal. ......................... 4-38
Duplex Option Top Cover And Table Cover Removal . . 4-39
DuplexOptionExitCardAndCoverRemoval........ 4-40
Duplex Option Bottom Cover
AndEntrySensorCardRemoval.................. 4-41
DuplexOptionSystemCardAndMotorRemoval..... 4-42
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
ConnectorLocations ..................................5-1
MajorAssemblyLocations........................... 5-1
GearTrain.................................... 5-2
HVPS........................................ 5-3
TransferRollerHousing.......................... 5-3
Engine Board Connectors ........................ 5-4
RIPBoard..................................... 5-6
BoardInstallationHardware....................... 5-7
MirrorMotor/FanCable.......................... 5-7
Operator Panel/Output Bin Sensor Cable ............ 5-8
Printhead Connector Locations . . . ................ 5-10
t Cable....................... 5-10
ps . ......................... 5-11
er Board Connectors............ 5-12

viii Service Manual
4049-XXX
Preventive Maintenance ...............................6-1
SafetyInspectionGuide............................. 6-1
LubricationSpecifications ........................... 6-1
Scheduled Mechanical Maintenance ................... 6-3
Printhead Window Cleaning Procedure. . ............... 6-4
CleaningTheTransferRoller......................... 6-4
PartsCatalog ........................................7-1
HowToUseThisPartsCatalog................... 7-1
Covers........................................7-2
LowerFrame...................................7-4
UpperFrame...................................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
TransferRoll..................................7-36
DuplexOption.................................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 ...............................................X1

7-2
4049-XXX
Assembly 1: Covers