Lexmark Optra Color 40 Service Manual Download Page 1

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4092-010

Lexmark Optra™ Color 40

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

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Summary of Contents for Optra Color 40

Page 1: ...40 Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Sta...

Page 2: ...ii...

Page 3: ...ut Scrfrmam eps 4 15 Graphics Output Selecpts eps 7 8 7 10 Graphics Output Senccrdp eps 5 3 Graphics Output Sfrtcovm eps 4 9 Graphics Output Sidlgear eps 4 10 Graphics Output Slftsdpt eps 4 12 Graphic...

Page 4: ...removed comments may be addressed to Lexmark International Inc Department D22 035 3 740 New Circle Road N W Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you sup...

Page 5: ...e Checks 2 7 Controller Board Service Note 2 7 Envelope Feed Service Check 2 7 First Print Line Service Check 2 7 Maintenance Station Service Check 2 8 Options Service Check 2 9 DRAM Memory Option SIM...

Page 6: ...emoval 4 9 Gutter Pad Removal 4 9 Inside Idler Gears Removal 4 10 Large Feed Roll Removal 4 11 Large Outside Gear Removal 4 12 Left Side Frame Assembly Removal 4 13 Maintenance Station Assembly Remova...

Page 7: ...ns 6 1 Parts Catalog 7 1 How To Use This Parts Catalog 7 1 Assembly 1 Covers 7 2 Assembly 2 Frames 7 4 Assembly 3 Paper Feed 7 6 Assembly 4 Electronics 7 8 Controller Board Service Note 7 9 Assembly 4...

Page 8: ...viii Service Manual 4092 010...

Page 9: ...y and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t con u test et approuv pour respecter les normes...

Page 10: ...onale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die welt...

Page 11: ...reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a Este produto foi concebido testado e aprovado para sati...

Page 12: ...t d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte est orientada exclusivament a profes...

Page 13: ...Safety Information xiii 4092 010...

Page 14: ...xiv 4092 Service Manual 4092 010...

Page 15: ...ds provide color and true black printing without changing printheads The black cartridge has a total of 208 nozzles and installs on the left The color cartridge has a total of 192 nozzles and installs...

Page 16: ...is on On Blinking Printer is busy Blinks S Blinks S Error condition or printer in demo mode Deactivate Activate Demo Mode on page 3 5 Blinks Twice S Blinks Twice S Memory full condition Blinks S Blink...

Page 17: ...ck for a correct ground measure the voltage between the ground and a known good voltage source The voltage measurement must be the same as the source voltage to consider the ground is correct Continui...

Page 18: ...ty to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge After you complete the repair perform tests as needed to verify the repair Abbreviations Unique...

Page 19: ...Indicator Table on page 2 2 and take the indicated action Unplug the printer to clear the error indicator The printer also logs the last error If you think it may have an intermittent error or the err...

Page 20: ...10 81 3 OFF Go to the Transport Service Check on page 2 17 930 92 4 OFF Go to the Print Quality Service Check on page 2 14 931 89 5 OFF Go to the Transport Service Check on page 2 17 939 Nothing 2 or...

Page 21: ...sum failure Replace the Controller Board 943 Nothing 5 ON Controller code and Font ROM are incompatible Replace the Controller Board 945 Nothing 6 ON ASIC failure Replace the Controller Board 947 Noth...

Page 22: ...s off and the power light stays on If your printer completes POST with no errors go to the Symptom Tables on page 2 5 locate the symptom and take the indicated action If your printer does not complete...

Page 23: ...ment Slow carrier movement Carrier stops Carrier slams side frame Go to the Transport Service Check on page 2 17 Symptom Action Printer not communicating with host computer Go to the Parallel Port Ser...

Page 24: ...opes fail to feed Go to the Envelope Feed Service Check on page 2 7 Paper skews Go to the Paper Path Service Check on page 2 11 Symptom Action No power in printer no Power light no motors Go to the Po...

Page 25: ...vailable as a FRU Envelope Feed Service Check First Print Line Service Check FRU Action 1 Envelope Guide Be sure the envelope guides have been turned to the envelope load positions Be sure the envelop...

Page 26: ...movement to the left will uncap the printheads The wipers clean the printhead nozzles as the carrier leaves the maintenance station The wipers clean the printheads only when the carrier is moving to t...

Page 27: ...ntire paper path for obstructions Be sure there is not too much paper in the sheet feeder Be sure the correct type of paper is being used Check for static in the paper Perform the Print Test Page on p...

Page 28: ...s in one direction only replace the engine board Binds in the paper feed motor or gear train can cause intermittent false paper jam errors Remove the paper feed motor and check the shaft for binds Als...

Page 29: ...ng the paper Be sure the correct type of paper is being used Be sure the printer is installed on a flat surface FRU Action 1 Large and Small Feed Rollers Check for wear and binds 2 Small Feed Roller S...

Page 30: ...11 75 V dc Disconnect the power cable to the controller board and check 5 V dc between the pins at the power cable If you do not have correct voltage replace the power supply Be sure to unplug the pr...

Page 31: ...he paper feed motor Plug the power cord into the printer and look for a symptom change If the symptom changed replace the paper feed motor 5 Printhead Cable Thermal Sensor Board Parallel Cable Encoder...

Page 32: ...eck FRU Action 1 Print Cartridge Be sure the printer contains good print cartridges 2 Printhead Carrier Assembly Reseat the printhead cables in the engine board and check the following parts for wear...

Page 33: ...oor contact between the printhead cable and the print cartridge Check the rubber backer for wear Refer to the test page The temperature value in Celsius or the message Thermal Sensor Not Installed is...

Page 34: ...grip Carrier guide rod for wear or dirt Carrier guide rod should have lock washers under the mounting screws Carrier to carrier frame engagement should be lubricated with Nyogel 744 P N 99A0394 grease...

Page 35: ...gh POST 3 Carrier Guide Rod Clean the carrier rod Note Lubricate the rod and the carrier rod bearing surface with Nyogel 744 P N 99A0394 grease or equivalent 4 Transport Belt Idler Pulley Parts Carrie...

Page 36: ...2 18 Service Manual 4092 010...

Page 37: ...ace a sheet of paper in the manual feed far enough to move the EOF flag out of the sensor A two pin jumper is available in the parts packet 13B0239 Be sure to remove the two pin jumper after completin...

Page 38: ...nozzle test pattern cyan magenta yellow Three lines of all cyan magenta and yellow nozzles printing Color nozzle test pattern Test pages print until the power cord is unplugged from the power supply...

Page 39: ...on solid Manually moving the carrier to the right causes the busy light to flash If the test fails unplug the printer and remove the carrier assembly without unplugging the printhead cables Plug the l...

Page 40: ...r Light blinks Hex Trace The Hex Trace test puts the printer in a mode that is used to isolate print job problems While in this mode each byte of information contained in the job is printed in both he...

Page 41: ...ts no print jobs can be sent to the printer and some diagnostic tests will not run To deactivate the demo mode 1 Unplug the printer 2 Press and hold both buttons and plug the power cord into the power...

Page 42: ...3 6 Service Manual 4092 010...

Page 43: ...ossible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the engine grou...

Page 44: ...program to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge Removal Procedures The following procedures are arranged according to the name of the pri...

Page 45: ...y and pull forward and remove the maintenance station assembly 5 Remove the two screws securing the carrier frame to the base cover 6 Slide the printer off the base cover Carrier Belt Removal 1 Remove...

Page 46: ...front cover 2 Remove the rear cover 3 Remove the base assembly 4 Disconnect the paper feed motor and power supply connectors from the engine board 5 Remove the four screws A securing the carrier frame...

Page 47: ...r frame C 3 Be sure the tab from the paper guide does not deflect the small feedroll shaft downward The shaft should be forward of the tab Carrier Transport Motor Removal 1 Remove the front cover 2 Di...

Page 48: ...1 Remove the front cover 2 Remove the rear cover 3 Remove the paper load door and manual insert tray 4 Remove the pick roll hub shaft and envelope bucklers 5 Remove the two screws from the right side...

Page 49: ...engine board 4 Disconnect the other cables from the engine board 5 Gently release the tension on the encoder strip by flexing the encoder strip tensioner and remove the encoder strip from the left si...

Page 50: ...y 8 Pull up the four clips securing the mid frame to the large feed roll and work the mid frame out of both side frames 9 Spread the right side frame apart far enough to allow removal of the exit driv...

Page 51: ...de the cover forward and off the printer To reassemble 1 Slide the cover over the matching pieces on the bottom cover 2 Press in both sides opposite the cover latches until they latch Gutter Pad Remov...

Page 52: ...4092 010 Inside Idler Gears Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the printer from the base assembly 4 Remove the paper feed motor 5 Gently pry the two idler gears A from...

Page 53: ...pry open the slot in the retainer clip and remove it and the compound idler gear from the compound idler stud 5 Remove the large feed roll from the mid frame by pulling it out of the four mounting cl...

Page 54: ...or and manual insert tray 4 Remove the C clip from the feed arm assembly and remove the feed arm assembly 5 Remove the C clip from the left side of the pick roll shaft 6 Pull the pick roll shaft out f...

Page 55: ...ly 4 Remove the paper load door and manual insert tray 5 Using a small screwdriver pry open the slot in the retainer clip A and remove it and the compound idler gear from the compound idler stud 6 Rem...

Page 56: ...t cover 2 Remove the rear cover 3 Remove the paper load door 4 Spread the right side frame away from the manual insert tray until the pins in the insert tray clear the frame 5 Remove the manual insert...

Page 57: ...motor Note the routing of the motor cable Paper Guide and EOF Flag Assembly Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the printhead carrier assembly 4 Remove the carrier frame...

Page 58: ...extensions B are in the grooves of the small feed roll arms 2 Be sure the short extensions of the two paper flap springs are trapped under the carrier frame C 3 Be sure the tab from the paper guide d...

Page 59: ...roll shaft out to the left and remove the pick roll shaft hubs and envelope bucklers Note During reassembly be sure the pick roll hubs are in the slots at the bottom of the paper guides and the rolls...

Page 60: ...rom the encoder card Note the routing of the cable under the retaining clip on the carrier 4 Separate the cradle from the printhead carrier assembly by pushing out the cradle latches A 5 Feed the fold...

Page 61: ...Repair Information 4 19 4092 010 Note Be sure the cable is secured under the three retaining clips B on the back of the carrier...

Page 62: ...the rod while spreading the right side of the carrier frame 5 Remove the carrier assembly by lifting upward taking care to clear the encoder strip before pulling the carrier assembly out Printhead Rub...

Page 63: ...e the cover latches 5 Slide the cover up and off the printer 6 To reassemble place the cover over the tabs in the bottom cover and press down until the cover latches Be sure the parallel connector sna...

Page 64: ...f the parts Small Feed Roll Shaft Rollers Paper Flap Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the carrier frame assembly 4 Spread the left and right side frames apart far enou...

Page 65: ...inthead Cable 1 J2 Printhead Cable 2 J3 Printhead Cable 3 J4 Transport Motor J5 Paper Feed Motor J6 Test Jumper J7 Thermal Sensor J9 Power Supply J10 Controller to Engine Card Interface SW1 Continue S...

Page 66: ...5 2 Service Manual 4092 010 Controller Board Connectors J1 DRAM SIMM J2 Parallel Port J3 Code Flash SIMM J4 Power Supply J6 Controller to Engine Card Interface...

Page 67: ...Connector Locations 5 3 4092 010 Encoder Card Connector...

Page 68: ...5 4 Service Manual 4092 010...

Page 69: ...ons Lubricate only when parts are replaced or as needed not on a scheduled basis Use with Nyogel 744 P N 99A0394 grease or equivalent All gear mounting studs The left and right ends of the large feed...

Page 70: ...6 2 Service Manual 4092 010...

Page 71: ...the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NS Not Shown in the Asm Index column...

Page 72: ...7 2 Service Manual 4092 010 Assembly 1 Covers...

Page 73: ...h 3 12G0001 1 Front Cover Asm Access Cover with Door Latch Buttons LED Lens 4 12G0003 1 Board Cover with EMC Shield 5 12G0002 1 Rear Cover 6 17B0158 1 Gutter Pad 7 17B0150 1 Base Asm includes Feet Gut...

Page 74: ...7 4 Service Manual 4092 010 Assembly 2 Frames...

Page 75: ...Parts Catalog 7 5 4092 010 Asm Index Part Number Units Description 2 1 13B0411 1 Left Side Frame 2 13B0272 1 Mid Frame 3 13A1236 1 Right Side Frame 4 13B0204 1 Carrier Frame...

Page 76: ...7 6 Service Manual 4092 010 Assembly 3 Paper Feed...

Page 77: ...sm 4 13B0275 1 Large Feed Roll Asm includes Small Compound Idler Gear 5 12G0020 1 Paper Feed Motor Motor Gear Toroid and Heat Sink 5A 13B0239 1 Warning Label Motor PP 6 13B0271 1 Gears B M 7 69G4398 1...

Page 78: ...7 8 Service Manual 4092 010 Assembly 4 Electronics...

Page 79: ...4 1 12G0006 1 Power Supply Universal with Cover 2 13B0045 1 Thermal Sensor Board with Cable 3 12G0005 1 Engine Board Use on machines with a torroid on the flex cable Index 9 3 12G0140 1 Engine Board 4...

Page 80: ...7 10 Service Manual 4092 010 Assembly 4 Electronics continued...

Page 81: ...Cord Brazil LV Power Cord Brazil HV Power Cord Canada Power Cord Chile Power Cord Columbia Power Cord Costa Rica Power Cord Denmark Power Cord Ecuador Power Cord Egypt Power Cord El Salvador Power Co...

Page 82: ...7 12 Service Manual 4092 010 Assembly 5 Carrier...

Page 83: ...ier B M 2 13B0222 1 Printhead Cable Folded 3 13B0238 1 Rubber Backer 4 13B0217 1 Carrier Guide Rod 5 69G4156 1 Encoder Card Asm 6 13B0239 1 Screw Encoder Card Mounting PP 7 13B0221 1 Printhead Cartrid...

Page 84: ...7 14 Service Manual 4092 010 Assembly 6 Carrier Transport...

Page 85: ...er Units Description 6 1 13B0219 1 Carrier Transport Motor Pulley 2 13B0215 1 Carrier Belt 3 69G4403 1 Encoder Strip 4 17B0157 1 Idler Pulley Tension Asm 5 13B0239 2 Screw Carrier Transport Motor Moun...

Page 86: ...7 16 Service Manual 4092 010 Assembly 7 Sheet Feeder...

Page 87: ...1 Upper Paper Support 4 13A1229 1 Pick Roll Paper Load Shaft B M 5 12G0012 2 Pick Roll Hub Asm 6 1367019 1 Envelope Buckler B M Left Right 7 12G0009 1 Back Plate 8 13A1226 1 Paper Load Door 9 69G4165...

Page 88: ...7 18 Service Manual 4092 010 Assembly 8 Maintenance Station...

Page 89: ...Parts Catalog 7 19 4092 010 Asm Index Part number Units Description 8 1 13B0160 1 Maintenance Station Asm 2 70G0590 1 Wiper and Cap B M one of each 3 13B0239 2 Screw Maintenance Station Mounting PP...

Page 90: ...7 20 Service Manual 4092 010...

Page 91: ...4 Power Consumption 1 2 Problems Carrier Transport 2 5 Communications 2 5 Maintenance Station 2 5 Operator Panel 2 5 Paper Feed 2 6 Power 2 6 Print Quality 2 6 R Removal Procedures 4 2 Removals Base...

Page 92: ...l Shaft 4 22 Small Feed Rollers 4 22 Star Roller 4 22 S Safety Information ix Service Checks Envelope Feed 2 7 First Print Line 2 7 Maintenance Station 2 8 Paper Feed 2 9 Paper Path 2 11 Parallel Port...

Page 93: ...te and complete Yes No 3 Was the book easy to use Yes No 4 What can we do to improve the book ______________________________________________ ______________________________________________ 5 What is yo...

Page 94: ......

Page 95: ...Along Line POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape BUSINESS...

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