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4-12

Service Manual

4092-010

Large Outside Gear Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the paper load door 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 far enough to remove the large gear.

Note: Gently pull the feed arm guide [A] on the left side frame
forward, then remove the large gear.

Содержание Optra Color 40

Страница 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...

Страница 2: ...ii...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 94: ......

Страница 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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