Lexmark Optra C Service Manual
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- Lexmark Optra C | Service Manual - Page 1
Lexmark Optra™ C 5045-001 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. - Lexmark Optra C | Service Manual - Page 2
(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 - Lexmark Optra C | Service Manual - Page 3
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 - Lexmark Optra C | Service Manual - Page 4
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 - Lexmark Optra C | Service Manual - Page 5
Quality Troubleshooting 2-54 Background 2-54 Black Horizontal Lines 2-54 Black Vertical Lines 2-55 Blur at Bottom of Page 2-55 Laser Failures 2-56 Low Color Coverage or Usage 2-56 Oil Soaking 2-57 Random Oil Spots on Page 2-58 Spew 2-58 Vertical Streaks 2-59 Print Quality Service Checks - Lexmark Optra C | Service Manual - Page 6
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 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 vi - Lexmark Optra C | Service Manual - Page 7
Fuser Thermo Switch 4-32 Fuser Cleaner Assembly 4-33 Fuser Oil Apply Assembly 4-34 Fuser Thermistor 4-35 Fuser Lamps 4-37 Fuser Oil Applying Input Assembly 4-39 Fuser Board 4-45 Printer Drive Assembly 4-48 Rotary Manual Feed Cleaning Drive Assembly 4-61 Toner Cartridge Ejector 4-62 Upper - Lexmark Optra C | Service Manual - Page 8
5-35 Paper Feed Driver PCB 5-36 Fuser Connector (J21 5-37 Preventive Maintenance 6-1 Safety Inspection Guide 6-1 Lubrication Specifications 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, - Lexmark Optra C | Service Manual - Page 9
5045-001 Parts Catalog (continued) Rotary Manual Feed 7-30 Printer Drive 7-32 Transfer Drum Cleaning Drive 7-34 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 - Lexmark Optra C | Service Manual - Page 10
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 - Lexmark Optra C | Service Manual - Page 11
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 - Lexmark Optra C | Service Manual - Page 12
5045-001 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 ( - Lexmark Optra C | Service Manual - Page 13
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 - Lexmark Optra C | Service Manual - Page 14
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 - Lexmark Optra C | Service Manual - Page 15
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 - Lexmark Optra C | Service Manual - Page 16
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 - Lexmark Optra C | Service Manual - Page 17
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. Japanese Laser Notice Notices and Safety Information xvii - Lexmark Optra C | Service Manual - Page 18
5045-001 Chinese Laser Notice Korean Laser Notice xviii - Lexmark Optra C | Service Manual - Page 19
5045-001 Trademarks Optra and Lexmark are trademarks of Lexmark International, Inc., registered in the United States and/ 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 - Lexmark Optra C | Service Manual - Page 20
5045-001 Other trademarks are the property of their respective owners. xx - Lexmark Optra C | Service Manual - Page 21
5045-001 Notices and Safety Information xxi - Lexmark Optra C | Service Manual - Page 22
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 - Lexmark Optra C | Service Manual - Page 23
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 - Lexmark Optra C | Service Manual - Page 24
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 - Lexmark Optra C | Service Manual - Page 25
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 - Lexmark Optra C | Service Manual - Page 26
5045-001 xxvi - Lexmark Optra C | Service Manual - Page 27
Optra™ C is a 600 dpi Color Laser printer 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 A4 Mono Color 12 A4 Full Color - Lexmark Optra C | Service Manual - Page 28
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 - Lexmark Optra C | Service Manual - Page 29
5045-001 Service Checkpoints Fuser Unit Point Delivery Guide Tool/Solvent MEK Separation Claw Unit Entrance Guide MEK MEK Remarks Clean lightly to remove toner. Clean carefully, the tip breaks easily. use water or solvents and do not contaminate with solvents or oil. General Information 1-3 - Lexmark Optra C | Service Manual - Page 30
5045-001 Drum Cartridge Point Photoconductor Tool/Solvent Toner Remarks Clean, do not use water or solvents and do not contaminate with solvents or oil. When removing the drum store it in the drum cover. Manual Feeding Tray Pickup Unit Point Separation Pad Tool/Solvent Dry towel Remarks Clean - Lexmark Optra C | Service Manual - Page 31
The removal and adjustment procedures described in this manual require the following tools and equipment: • Magnetic tip Phillips screwdrivers large and small • Flat-blade screwdriver • Fuse puller • Analog or digital volt ohmmeter • Oil syringe and bottle • Drop cloth • Grease • Cleaning tissue - Lexmark Optra C | Service Manual - Page 32
-001 Abbreviations ASIC CSU DRAM EPROM EP ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power-On Reset Power-On Self Test Print - Lexmark Optra C | Service Manual - Page 33
printer can be serviced without being connected to a host computer. This printer will display both operator correctable errors and service eliminate potential software problems. These tests are covered in Chapter 3, "Diagnostic Aids". Using the diagnostic information in this manual leads you to - Lexmark Optra C | Service Manual - Page 34
(DCCB) controls the printer. When the PRINT in EEPROM concerning drum life, oil out warnings, registration adjustments, and service check. The DC controller board also provides: • Laser/Scanner control • Image stabilization control (environmental, toner quality, photoconductor drum life) • Fuser - Lexmark Optra C | Service Manual - Page 35
the paper feeder driver PCB by way of the serial communication. The mechanical controller board also provides: • Drive for the various motors and fan motors • Control of the toner carousel, fuser transfer drum and peripheral units • Toner stirring, toner low detection and toner cartridge detection - Lexmark Optra C | Service Manual - Page 36
, go to the error message table and take the indicated action. Note: Some of the following service checks require voltage and/or continuity readings. For continuity readings, turn off and unplug the printer or optional sheet feeder. For voltage measurements, close the front door and be sure the door - Lexmark Optra C | Service Manual - Page 37
5045-001 Operator Codes The following code numbers are operator instructions and messages. In some cases, no action is required; others are operator-correctable; and others may require service. An error code may require up to one minute to appear. Some symptoms may not generate an error code. Locate - Lexmark Optra C | Service Manual - Page 38
the life limit of the web allows an arm to drop, which blocks a sensor located on the printer, (not the fuser) near the exit drive mechanism. If the web is exhausted, drain the fuser oil and replace the fuser. If the arm has prematurely dropped, (or if the customer has pushed it down), reset the - Lexmark Optra C | Service Manual - Page 39
Not Correctly Installed If there is a problem with one or more toner cartridges, check the following: 1. The latch at the rear that keeps the cartridge cover locked. 2. The hook at the rear that locks the cartridge into the rotary assembly. 3. The three color-keyed locating pins in the front of - Lexmark Optra C | Service Manual - Page 40
. 3. The Fuser Lamps and Fans turn on and "Performing Self Test" appears on the display. Note: If there is a fault with the printer, the machine Cartridge in turn is pressed into the development position, stirred and checked for low toner. 10. The Laser Scan Motor is energized. 11. Each cartridge - Lexmark Optra C | Service Manual - Page 41
5045-001 13. After the patches are read by the Density Sensor, the Cleaning Brush mechanism is pressed against the drum and the Cleaning Brush Motor is energized. 14. The calibration process is repeated this time starting at MINIMUM density and going to MAXIMUM density. At the end of this cycle the - Lexmark Optra C | Service Manual - Page 42
Laser failure 123 Mirror motor start-up or rotation 124 Mirror motor start-up or rotation 126 Transfer drum motor failure 130 Service motor error 131 Transfer drum motor failure Action See "Error (46) Toner Cartridge Not Installed Correctly" on page 2-14. See "Error (111/112) Fuser - Lexmark Optra C | Service Manual - Page 43
"Error (134) Controller Fan Motor Failure" on page 2-23. See "Error (135) Fuser Unit Fan Motor Failure" on page 2-24. See "Error (136) Electrical Unit Fan Error (145) Density Sensor Failure" on page 2-26. See "Error (146) Printer Communication Failure" on page 2-27. See "Error (147) Engine Board IC - Lexmark Optra C | Service Manual - Page 44
Go to "Background" on page 2-54 Go to "Black Service Check" on page 2-61 Go to "Blank Page Service Check" on page 2-62 Go to "Blank Spots Service Check" on page 2-63 Go to "Color Aberration Service Check" on page 2-63 Go to "Dark Image Service Check" on page 2-64 Go to "No AC Power/Dead - Lexmark Optra C | Service Manual - Page 45
Feeder Paper Pickup Go to "No Pickup (Manual Feed)" on page 2-31 Paper Feed Problems In Pickup Area Go to "Paper Feed Troubleshooting" on page 2-38 Paper Feed Problems In Drum Area Go to "Transfer Drum Unit" on page 2-40 Paper Feed Problems In Fuser and Delivery Area Code 25, Paper Jam - Lexmark Optra C | Service Manual - Page 46
5045-001 Service Checks Error (46) Toner Cartridge Not Installed Correctly FRU Action 1 Cartridge(s) 2 Carousel brake 3 Mechanical controller PCB. Check for broken locating pins. If the cartridge appears OK, try a different one or set. Check the brake clutch (Asm 16, Ref 9) for continuity. - Lexmark Optra C | Service Manual - Page 47
lower roller? 6 Thermistor soiled Is the thermistor surface contacting the fuser roller soiled? Clean it. 7 Power supply unit (low voltage) DC controller PCB/ Mechanical controller PCB Replace the power supply unit. If the problem remains, replace and check as follows: 1. DC controller PCB, see - Lexmark Optra C | Service Manual - Page 48
and check as follows: 1. DC controller PCB, see "DC Controller Board Information" on page 2-2. 2. Mechanical controller PCB. Error (114) Fuser Failure FRU 1 Fuser Action Replace the fuser unit. Note: Error 114 is stored in the DC Controller Board memory. It will not allow the machine to POR for - Lexmark Optra C | Service Manual - Page 49
controller PCB Action Turn the power switch OFF, and remove the fuser unit. Is there continuity between fuser unit connectors J21-1 and J21-2? See "Fuser Connector (J21)" on page 5-37. Check the continuity of both the fuser upper heater and the thermoswitch, and replace defective parts. Is there - Lexmark Optra C | Service Manual - Page 50
starting the diagnostic procedure, do the following: 1. Be sure the printer is level. 2. Turn the printer off and remove the oil bottle. 3. Use the suction tool to remove as much oil as possible from the reservoir. 4. Pump the fuser manual lever 30 or 40 times. 5. Repeat steps 3 and 4 until no - Lexmark Optra C | Service Manual - Page 51
PCB connector J2009. Reconnect them and replace sensor PS10. Is the hose between the oil supply bottle and the gear pump plugged up? Clean or replace the parts. Replace the fuser unit. If the problem remains, replace and check as follows: 1. Mechanical controller PCB. 2. DC controller PCB, see "DC - Lexmark Optra C | Service Manual - Page 52
one time occurrence, POR the printer to see if it resets. • If it has occurred multiple times, replace the laser FRU. FRU 1 Laser/scanner unit DC controller PCB . Go to the "Horizontal Voids Service Check" on page 2-67. Check the connections on the laser driver PCB connectors J401 and J402. Check - Lexmark Optra C | Service Manual - Page 53
V dc is being supplied between DC controller PCB connectors J101-4 (24 V) and J101-3 (GND). If it is not, replace the power supply unit. 3 Laser/scanner unit DC controller PCB Test print a page. Does the voltage between DC controller PCB connectors J102-8 and J102-7 (GND) change from about 5 V dc - Lexmark Optra C | Service Manual - Page 54
top sensor connector J43. Replace and check as follows: 1. Transfer drum top sensor. 2. DC controller PCB, see "DC Controller Board Information" on page 2-2. Error (130) Service Motor Error FRU 1 Mechanical controller PCB Action Replace the mechanical controller PCB. 2-22 - Lexmark Optra C | Service Manual - Page 55
5045-001 Error (132/133) Main Motor (M2) Start-Up or Rotation FRU Action 1 Poor connection Check the connection on the mechanical controller PCB connector J2013. Reconnect it. 2 Door switch Turn the machine off and disconnect the power cord. Disconnect connector J7 from the power supply unit. - Lexmark Optra C | Service Manual - Page 56
the voltage between mechanical controller PCB connectors J2012-3 and J2012-1 (GND) change from OV to about 24 V dc? If yes, replace the fuser unit fan. If no, replace the mechanical controller PCB. Error (136) Electrical Unit Fan Motor Failure FRU Action 1 Poor connection Check the connection - Lexmark Optra C | Service Manual - Page 57
voltage) DC controller PCB Mechanical controller PCB Action Turn the power switch OFF, and remove the fuser unit. Do the power supply rated voltage and fuser unit rated voltage correspond? Replace the fuser unit so that it corresponds to the power supply rated voltage. Is there continuity between - Lexmark Optra C | Service Manual - Page 58
5045-001 Error (143) 5 V / 24 V Supply Failure FRU 1 Power supply unit (low voltage) DC controller PCB Action Check the connections on the DC controller PCB connector J101 and power supply unit connector J4. Replace and check as follows: 1. Power supply unit. 2. DC controller PCB see "DC - Lexmark Optra C | Service Manual - Page 59
5045-001 Error (146) Printer Communication Failure FRU 1 Paper feeder (printer) 2 Mechanical controller DC controller PCB Action Check to ensure the paper feeder is latched in place, and the self docking connector is not damaged. Check - Lexmark Optra C | Service Manual - Page 60
5045-001 Error (148) Developer Unit Rotation Failure FRU Action 1 Poor connection Check the connection on the mechanical controller PCB connector J2016. Reconnect it. 2 Door switch Turn the machine off and disconnect the power cord. Disconnect connector J7 from the power supply unit. When you - Lexmark Optra C | Service Manual - Page 61
Toner cartridge position sensor. 2. Developing rotary position sensor. 3. Mechanical controller PCB. Error (152) Tray 2 Power Failure FRU Action 1 Poor connection Check the connections on the paper feeder driver Paper feeder driver PCB. 2. Mechanical controller PCB. If the problem remains, - Lexmark Optra C | Service Manual - Page 62
. Check voltage at the outlet. Inform the user that rated voltage is not supplied at the outlet. Is the power cord firmly plugged into the printer, the paper feeder and the outlet? Replug it. Is the circuit breaker OFF? Press the button to reset the breaker. If the circuit breaker turns - Lexmark Optra C | Service Manual - Page 63
the DC load. Is the power supply unit fuse blown? Replace the fuse. Replace the power supply unit. No Pickup (Manual Feed) FRU 1 Gear 2 Pickup motor Pickup PCB 3 Pickup PCB Manual feed solenoid Action Is the pickup motor drive properly transmitted by the gears? Check the gears, and replace any - Lexmark Optra C | Service Manual - Page 64
If no, replace the cassette feed solenoid. No Pickup (Optional Paper Feeder Pickup) FRU 1 Gear train 2 Paper feeder motor Paper feeder driver PCB 3 Paper feeder driver PCB Cassette feed solenoid Action Is the paper feeder motor drive properly transmitted by the gears? Check the gears, and replace - Lexmark Optra C | Service Manual - Page 65
Mechanical controller PCB DC controller PCB Action Are the high-voltage contact terminals soiled or burnt? Clean the high-voltage contacts. Does the trouble disappear when you replace the high-voltage power supply PCB? Replace the highvoltage power supply PCB. If not, replace and check as follows - Lexmark Optra C | Service Manual - Page 66
starts printing. After a sheet of paper is picked up by the cassette pickup roller or the manual feeding pickup roller, it is fed by the feed rollers. Any skew of the paper is , the paper passes through the transfer, separation, fuser, and delivery units to the face-down or face-up tray. 2-34 - Lexmark Optra C | Service Manual - Page 67
5045-001 The paper feed route can be divided into 3 sections: 1. Pickup unit, 2. Transfer drum unit, 3. Fusing/delivery unit. Diagnostic Information 2-35 - Lexmark Optra C | Service Manual - Page 68
5045-001 OHP Sheet Detection (transparency) When an OHP sheet is used for this printer, the dedicated one must be used with a white band at its leading edge. The following determinations are made by measuring the time period that light - Lexmark Optra C | Service Manual - Page 69
5045-001 Diagnostic Information 2-37 - Lexmark Optra C | Service Manual - Page 70
5045-001 Paper Feed Troubleshooting Pickup Unit (Codes 20 - 21, Paper Jam) FRU Action 1 Paper OHP sheet, and to set it correctly. 9 Excessive Is more paper in the manual feeding tray than paper in manual prescribed? Advise the user not to put more feeding tray than the suggested amount - Lexmark Optra C | Service Manual - Page 71
5045-001 FRU Action 13 Paper Is the paper folded? Replace the paper. 14 Excessive paper in cassette Is more print paper in the cassette than suggested? Advise the user not to put more than the suggested amount of paper in the cassette. 15 Cassette Is the cassette pickup roller, the - Lexmark Optra C | Service Manual - Page 72
5045-001 Transfer Drum Unit (Codes 22 - 23, Paper Jam) FRU Action 1 Gripper Is the gripper damaged? Replace the gripper. 2 Gripper Does the gripper properly open and hold the paper? Check whether: • The gripper hold-down spring is deformed or disconnected. • The gripper lever is bent. • The - Lexmark Optra C | Service Manual - Page 73
PS9. Use of a spray contact cleaner in most instances will allow normal functioning of the fuser sensors, which have been contaminated with silicone oil. The only cleaner currently approved by Lexmark is CRC brand industrial contact cleaner # 03130. In addition to the cautions on the Material - Lexmark Optra C | Service Manual - Page 74
belt Is the cleaning belt being wound correctly? Check the fuser cleaner unit. 6 Fuser Is the fuser separation guide soiled? Or is separation there a protrusion due to a flaw or toner guide adhesion? Clean the guide. 7 Delivery paper Does the delivery paper sensor lever move sensor - Lexmark Optra C | Service Manual - Page 75
pad Spring (see Chapter 7, Asm 25-5) Is recommended paper being used? Advise the user to use recommended paper. Does it occur in the manual feeding tray? Check step 5. (Cassette, check step 4). Is the print paper placed properly against the cassette claw? Place the paper correctly. Is the - Lexmark Optra C | Service Manual - Page 76
? Check the pickup unit. Is toner or other foreign matter on the paper guide? Clean the guide. Is the fuser entrance guide soiled? Clean the guide. If no, replace the fuser unit. Leading-Edge Fold FRU Action 1 Paper 2 Paper 3 Excessive paper (manual) 4 Paper setting (cassette) 5 Cassette claw - Lexmark Optra C | Service Manual - Page 77
-001 Skewing FRU 1 Paper 2 Cassette 3 Excessive paper (manual) 4 Paper setting (cassette) 5 Paper setting 6 Cassette Set the paper correctly. Is the paper placed against the manual feeding tray abutment? Properly set the paper on the manual feeding tray. Is the cassette claw deformed? Replace the - Lexmark Optra C | Service Manual - Page 78
it back on. After turning the machine off, wait at least 10 seconds before turning back on. Before replacing the video controller board, turn the printer off and firmly reseat the board. Error (941) Service ROM SIMM Description 1 Code/Font Action Replace the ROM SIMM. Error (939, 942, 943, 944 - Lexmark Optra C | Service Manual - Page 79
Description 1 ASIC 3 failure Action Replace the Video Controller Board. Error (948) Service RIP Board Description 1 Compress/ Decompress failure Action Replace the Video Controller Board. Error (949) Service RIP Board Description 1 Decompress failure Action Replace the Video Controller Board - Lexmark Optra C | Service Manual - Page 80
Error Description 1 Video RAM failure Action Replace the Video Controller Board. Error (956) Service L2 Cache Error Description 1 L2 Cache error Action Replace the Video Controller Board. Error (960) Service Memory Error Description Action 1 Bad or missing Replace the base DRAM. DRAM in the - Lexmark Optra C | Service Manual - Page 81
Failure Description 1 INA failure Action Replace INA. Error (977) Service Network Board Description 1 Bad network board Action This error message The X after the Network Board will identify which network board is having a problem. Network Board 1 always refers to the INA board in the bottom slot - Lexmark Optra C | Service Manual - Page 82
is approximately 5500 pages. Depending on color usage, it is possible to exceed this limit and still have a large quantity of toner remaining in the cartridge. This condition will lead to streaking and background, which will be covered elsewhere in this service check. Print Quality Start Of Call - Lexmark Optra C | Service Manual - Page 83
• If voids are present, go to "Horizontal Voids Service Check" on page 2-67. • If severe "jitter" is visible, replace the affected cartridge, (especially if the "jitter" is greater for one color). • If the "jitter" is consistent across all four colors, replace the photoconductor. Note: Some "jitter - Lexmark Optra C | Service Manual - Page 84
5045-001 Horizontal Variation ("Jitter") Example (Color may vary depending upon your monitor or system.) 2-52 - Lexmark Optra C | Service Manual - Page 85
This test indicates which cartridge(s) is/are contributing to background problems. It also shows which of the four cartridges has reached end-of-life. The test produces a solid band of each color, approximately 2 1/4 inches (60 mm) long. Each color should be a uniform color with no vertical streaks - Lexmark Optra C | Service Manual - Page 86
combination of primary colors. Cause: Cool, dry environments or used cartridges nearing end of life. Resolution: Increase environmental temperature and humidity. Replacing all four toner cartridges reduces background, if they are nearing end of life. Call your country support function for assistance - Lexmark Optra C | Service Manual - Page 87
used photoconductor for diagnostic purposes. The printer determines photoconductor life by its electrical life, which may result in customer dissatisfaction or a service call. Blur at Bottom of Page Symptom: A cartridge or the photoconductor. Resolution: Change paper types. Diagnostic Information - Lexmark Optra C | Service Manual - Page 88
color. Vertical print may be wavy (see following example). Cause: Contaminated (toner) beam detect mirror, or beam detect lens in the printhead, causes the laser printing using minimal color coverage. The internal mechanisms in the cartridge wear out before the level of toner is depleted. Resolution - Lexmark Optra C | Service Manual - Page 89
the fuser prior to printing. This is minimized by setting power saver to the maximum (120 minutes) before the printer fuser every 59 minutes, to keep it close to target temperature. This time interval is not adjustable. Early levels of microcode do not have this feature. • Call your country support - Lexmark Optra C | Service Manual - Page 90
Power Saver 2 mode. This turns on the fuser every hour. • Power Saver 2 does not operate unless Power Saver 1 is enabled. • If maximum printer accessibility is an issue, set Power Saver 1 to 120 minutes. Spew See the "Toner Scattered Service Check" on page 2-71, for detailed information regarding - Lexmark Optra C | Service Manual - Page 91
following page). This may occur on a single color, every color, or any combination. Cause: Cartridge(s) nearing end-of-life. This condition can occur regardless of the amount of toner remaining in the cartridge. For additional information, see "Low Color Coverage or Usage" on page 2-56. Resolution - Lexmark Optra C | Service Manual - Page 92
5045-001 Vertical Streaks Example (Color may vary depending upon your monitor or system.) 2-60 - Lexmark Optra C | Service Manual - Page 93
5045-001 Print Quality Service Checks Black Service Check FRU Action 1 Photoconductor Replace the photoconductor. If problem remains, check the primary charging contact spring, the photoconductor contact, the primary charging contact plate and spring. 3 High-voltage cable / resistor Check the - Lexmark Optra C | Service Manual - Page 94
5045-001 Blank Page Service Check FRU 1 Front cover back panel 2 Laser beam shutter, shutter arm 3 High-voltage cable / ohms. Replace highvoltage cable or contact if necessary. Check the toner cartridge contact. If the problem remains, check and replace as necessary the highvoltage power supply PCB - Lexmark Optra C | Service Manual - Page 95
Blank Spots Service Check FRU Action 1 Paper Is recommended paper being used? Print with recommended paper. If the outcome is good, ask the user to use recommended paper. 2 Paper 3 Toner cartridge 4 Transfer sheet Is the paper damp? Replace the paper. Does it appear for a specific color only - Lexmark Optra C | Service Manual - Page 96
5045-001 Dark Image Service Check FRU 1 Density sensor unit 2 High-voltage power supply PCB, Mechanical controller PCB Action Operate the density adjustment panel to adjust the density. Clean the density sensor lens. If the problem remains, replace the density sensor unit. Clean the transfer drum - Lexmark Optra C | Service Manual - Page 97
spring 4 Feed guide Fuser entrance guide 5 Cleaning brush motor Action Paper must be the correct weight, see "Print Quality" on page 2-50. See "Spacing Table Service Check" on page cleaning brush motor runs. If the problem remains, replace the mechanical controller PCB. Diagnostic Information 2-65 - Lexmark Optra C | Service Manual - Page 98
Fuser upper See "Spacing Table Service Check" on page 2-69 to roller aid in diagnosing the dirty or failing FRU. Photoconductor Toner cartridge weight. Check for soiled paper being used. Clean the feed guide or the fuser entrance guide. Check the entire paper path for paper (especially the - Lexmark Optra C | Service Manual - Page 99
1 Photoconductor If a white horizontal line appears in a repeating or pattern, see "Spacing Table Service Check" on page toner cartridge 2-69 and repair or replace the indicated part. 2 Laser / Scanner If a white horizontal line appears randomly, clean the unit small 1/4 inch square (10 - Lexmark Optra C | Service Manual - Page 100
5045-001 Light Image Service Check Be sure the printer is not installed in an unusually hot or cold environment, see the User's Reference. If the problem is with one color, try a new toner cartridge of that color. FRU 1 Density sensor unit 2 High-voltage cable resistors (approximately 9K Ohms) 3 - Lexmark Optra C | Service Manual - Page 101
the operation of the oil applying unit. 4 Print paper Print with recommended paper. If the outcome is good, ask the user to use recommended paper. 5 Fuser unit Fuser nip width cannot be adjusted. Replace the fuser unit. Spacing Table Service Check FRU Fuser, upper roller Fuser, lower roller - Lexmark Optra C | Service Manual - Page 102
This should not be confused with cartridge streaking. FRU 1 Paper Is the paper damp? 2 Separation voltage 3 Separation charging unit Fuser unit 4 Paper Path 5 Cleaning panel? If the problem remains, go to step 3. Replace and check as follows: 1. Separation charging unit 2. Fuser unit Check the - Lexmark Optra C | Service Manual - Page 103
Toner Scattered Service voltage from the density adjustment panel? If the problem remains, go to step 3. If streaking appeared on Fuser unit 1. Separation charging unit. 2. Temperature humidity sensor. 3. Fuser unit. Note: If a halo is observed surrounding blue characters on the page, instruct - Lexmark Optra C | Service Manual - Page 104
-001 Vertical Lines Service Check Note: Also see "Vertical Streaks" on page 2-59. FRU Action 1 Toner cartridge In which colors do the vertical lines appear? Replace the cartridges of the colors affected. Note: This can occur when cartridges are used at very low color coverage percentages, for - Lexmark Optra C | Service Manual - Page 105
-001 Vertical Voids Service Check FRU Action 1 Toner cartridge 2 Separation Corona wire Does a white vertical line appear for all colors? Remove the cartridge of the color for which it appears from the printer. Shake the cartridge and put it back in the printer. Replace the cartridge if the line - Lexmark Optra C | Service Manual - Page 106
Optra models and are described in this chapter. These tests work in conjunction with the "Power-On Self Test (POST)" on page 2-8. The printer (s) and run one of the three diagnostic methods to determine where the problem is located. There are six internal engine tests accessible by the "Density - Lexmark Optra C | Service Manual - Page 107
the Diagnostic mode clears NVRAM. To enter Diagnostics mode: 1. Turn the printer off. 2. Press and hold the Ready and Return buttons while turning the printer on. 3. Release the buttons when [Performing Self Test] is displayed. The printer performs the Power-On Self Test. 4. You can exit Diagnostics - Lexmark Optra C | Service Manual - Page 108
ROM VRAM L 2 Cache Test Compressor Test PAGE COUNTS Page Count Permanent Page Count DEVICE TESTS (If Installed) Disk Test/Clean Quick Disk Test Flash Test PRINTER SETUP Defaults ERROR LOG RESET - Lexmark Optra C | Service Manual - Page 109
5045-001 Diagnostics Mode Tests Button Test To test the operator panel buttons: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [Button Test]. 4. Press each button. [Closed] is displayed until the button is released. Then [Open] is displayed. 5. Press Return to return to the - Lexmark Optra C | Service Manual - Page 110
. U.S. Letter size paper Symbol Set Roman-8 NON U.S. A4 paper Symbol Set PC-850 To set the defaults: 1. Enter Diagnostics mode. 2. Select [PRINTER SETUP]. 3. Select [Defaults]. 4. Select [U.S.] or [NON U.S.]. 5. Press Return to return to the Diagnostics mode main menu. Disk Test/Clean This is - Lexmark Optra C | Service Manual - Page 111
5045-001 Error Log The list of the six most recent errors is displayed. The newest error is displayed in position one. In a full log, position six is the oldest error. If more than six errors are received, the oldest error is discarded. If a position is all zeros, not enough errors have occurred to - Lexmark Optra C | Service Manual - Page 112
5045-001 LCD Test To test the operator panel display: 1. Enter Diagnostics mode. 2. Select [HARDWARE TESTS]. 3. Select [LCD Test]. 4. Select [Single] or [Continuous]. 5. The display goes through a continuous sequence of turning pels on and off. 6. Press Return to stop continuous LCD test. 7. Press - Lexmark Optra C | Service Manual - Page 113
be only displayed. It cannot be modified or reset by the customer or servicer. To view or set the page count: 1. Enter Diagnostics mode. 2. two page test. One page is comprised of thin, repeating horizontal lines of each color. The other page consists of the same type of line in a vertical pattern. - Lexmark Optra C | Service Manual - Page 114
Test 2 generates ten printouts: Four pages of each color at high density, four pages of each color at medium density and two pages of multi color that fade away. All of these can be used to evaluate banding or other print quality problems. To run Print Test 2: 1. Enter Diagnostics mode. 2. Select - Lexmark Optra C | Service Manual - Page 115
5045-001 Quick Disk Test This test performs a non-destructive write/read on one block per track on the disk. The test will read one block on each track, save the data, and proceed to write and read four test patterns to the bytes in the block. If the block is good then the saved data will be written - Lexmark Optra C | Service Manual - Page 116
-001 Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer. To run the Wrap Test: 1. Turn the printer off. 2. Disconnect the interface cable. 3. Install the wrap plug in one of the interface cable connectors. • Install P/N 1319128 for the parallel test. • Install - Lexmark Optra C | Service Manual - Page 117
5045-001 Other Tests Density Adjustment Panel On the rear of the printer, the density adjustment panel is used for density adjustment, test pattern selection, and service technician printer adjustment. Diagnostic Aids 3-12 - Lexmark Optra C | Service Manual - Page 118
when changing the density or selecting a print test pattern. 4. COLOR SELECT key. Press the key to the desired color to change the density. 5. Density gauge Indicates the currently selected color density or test print pattern. 6. M LED (COLOR SELECT indicator). Lights when magenta has been selected - Lexmark Optra C | Service Manual - Page 119
of your choice. The LEDs light indicating the selected color and that density. 2. Select the density by the + key or - key. When the selected density differs from that currently set in the printer, the Density gauge LED flashes. 3. Save the density by the ENTER key. The Density gauge LED lights - Lexmark Optra C | Service Manual - Page 120
the default position, these values will Not be lost when the printer is turned off. They must be manually set back to the default value. Test Pattern Selection 1. Press the ENTER key 8 times while holding down the COLOR SELECT key. All COLOR SELECT LEDs flash to indicate the shift to the test print - Lexmark Optra C | Service Manual - Page 121
-001 2. Decide on a test print pattern by using the + key or - key. When the test print pattern differs from that currently selected in the printer, the Density gauge LED will flash. The correspondence between the Density gauge LEDs and each test print pattern is as follows. 3. Determine the test - Lexmark Optra C | Service Manual - Page 122
times. The "Y" and "Bk" COLOR SELECT LEDs flash to indicate that the Separation voltage control designation mode has been entered. 2. Select the separation voltage control method by the + key or - key. When the chosen method differs from that currently selected in the printer, the Density gauge LED - Lexmark Optra C | Service Manual - Page 123
5045-001 3. Determine the separation voltage control method by the ENTER key. The Density gauge LED lights and the printer changes the separation voltage control method. Diagnostic Aids 3-18 - Lexmark Optra C | Service Manual - Page 124
. At this time, the "Bk" indicator flashes to indicate the service technician adjustment function if the panel is not OFF. 1. Press the while holding down the TEST PRINT key to initialize the service technician adjustment mode. 2. Press the COLOR SELECT key and select an adjustment item. The LEDs - Lexmark Optra C | Service Manual - Page 125
by pressing of the + key or - key. b. For cassette or manual feeding tray edge registration adjustment. The adjustment value changes by 0.425 mm each the printer is turned ON, or the density adjustment panel is not operated for at least 30 seconds, it enters the OFF state. When OFF, the COLOR - Lexmark Optra C | Service Manual - Page 126
5045-001 LAN Information The printer may be connected to one of the following LAN types: Token-Ring Ethernet 10BASE-T Ethernet 10BASE2 LocalTalk The Network external connectors are shown below. The printer test page also indicates to which type of LAN the printer is connected. 3-21 - Lexmark Optra C | Service Manual - Page 127
electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: • Keep the ESD-sensitive part in - Lexmark Optra C | Service Manual - Page 128
There are no mechanical adjustments. Service Information Releasing Plastic Latches Many the part to which it is latched. Screws This printer is screw intensive. All screws are phillips head. assembly requires no mechanical adjustments. Parts are attached by color-coded screws. • When a metal part is - Lexmark Optra C | Service Manual - Page 129
5045-001 Removal Procedures The removals in this section are arranged in alphabetical order. To install parts, reverse the removal procedure, giving attention to any special conditions listed. When reinstalling the drive gear solenoid assembly removed in step 9, rotate the main drive motor (M2) - Lexmark Optra C | Service Manual - Page 130
5045-001 Cassette Paper Pickup Drive Motor See Assembly 24-9. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the cassette assembly. 4. Remove the two screws and the motor drive - Lexmark Optra C | Service Manual - Page 131
5045-001 Cassette Paper Pickup PCB See Assembly 24-13. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the cassette assembly. 4. Tip the cassette back and remove the three bottom - Lexmark Optra C | Service Manual - Page 132
latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the paper pickup assembly. 4. Remove the center screw in the lower guide and remove the roller assembly. 4-6 - Lexmark Optra C | Service Manual - Page 133
5045-001 Cassette Paper Pickup Solenoid See Assembly 24-10. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the cassette out enough to remove the two retaining brackets and remove the cassette assembly. 4. Remove the two screws and the motor drive - Lexmark Optra C | Service Manual - Page 134
5045-001 Cover Removals Remove the power cord before continuing. 1. Open the fuser door and remove the two screws [A] securing the top cover. 4-8 - Lexmark Optra C | Service Manual - Page 135
5045-001 2. Open the front cover and lift the top access cover. Repair Information 4-9 - Lexmark Optra C | Service Manual - Page 136
5045-001 3. With the top access cover raised, unsnap the plastic link [A]. Remove the top cover trim [B]. Remove the top cover by lifting the right side slightly, while moving the top cover to the right. 4-10 - Lexmark Optra C | Service Manual - Page 137
5045-001 4. Remove the two screws [A] and remove the left cover. Repair Information 4-11 - Lexmark Optra C | Service Manual - Page 138
5045-001 5. Release the two latches [A] and remove the rear cover. 4-12 - Lexmark Optra C | Service Manual - Page 139
5045-001 6. Remove the nine screws [A] and remove the EMC shield. Repair Information 4-13 - Lexmark Optra C | Service Manual - Page 140
5045-001 DC Controller PCB Note: Do not replace this board unless directed to do so by an error code 147 Engine Board IC Failure. Other errors may call for the DC controller to be replaced as part of the ordered FRU replacement. 1. Remove the top cover, left cover, rear cover and the rear EMC shield - Lexmark Optra C | Service Manual - Page 141
5045-001 3. Remove the nine screws [A] from the connector board cover (Asm 5-2) and remove the cover. Repair Information 4-15 - Lexmark Optra C | Service Manual - Page 142
5045-001 4. Disconnect the three cables [A] from the connector board. 4-16 - Lexmark Optra C | Service Manual - Page 143
5045-001 5. Remove the seven screws [A] securing the controller housing to the machine and remove the housing. During reassembly, be sure to thread the flat cable through the toroid before mounting the housing. Repair Information 4-17 - Lexmark Optra C | Service Manual - Page 144
5045-001 6. Release the ZIF connector [A] (J2007) on the mechanical controller PCB and remove the cable. 4-18 - Lexmark Optra C | Service Manual - Page 145
5045-001 7. Release the ZIF connectors (J103, J110 and J111) on the DC controller PCB and remove the cables. Do not remove J112. Repair Information 4-19 - Lexmark Optra C | Service Manual - Page 146
5045-001 8. Disconnect the remaining cables going to the board. Do not disconnect J108 or J112 unless you are replacing the PCB. These are not ZIF connectors. 4-20 - Lexmark Optra C | Service Manual - Page 147
5045-001 9. Remove the two screws [A] securing the cable guard and slide the guard slightly toward the center of the machine and remove it. Repair Information 4-21 - Lexmark Optra C | Service Manual - Page 148
5045-001 10. Remove the four board mounting screws [A] and the board. 4-22 - Lexmark Optra C | Service Manual - Page 149
5045-001 Density Adjustment Panel See Assembly 8-27. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Disconnect the wire cable from the density adjustment panel. 4. Remove the screw that retains the fan grill and - Lexmark Optra C | Service Manual - Page 150
the connector from the operator panel and remove the front cover. Be careful not to damage the hook (Asm 15-3). 5. Remove the four toner cartridges. 6. Remove the EMC shield from the rear of the machine. 7. Disconnect (J1004) from the HVPS. 8. Remove the four mechanical controller PCB mounting - Lexmark Optra C | Service Manual - Page 151
with the slots in the front panel before securing the panel. 4. When installing the ducts, be sure the HVPS wires are separated in the wire guides on this lower duct. Discharge Roller Drive Assembly See Assembly 18-1. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover - Lexmark Optra C | Service Manual - Page 152
5045-001 Drive Gear Solenoid Assembly See Assembly 13. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the rear EMC shield. 4. Open the multipurpose paper pickup door. 5. Release the two green cassette latches - Lexmark Optra C | Service Manual - Page 153
5045-001 Drum Cleaner Assembly See Assembly 31-1. 1. Open the multipurpose paper pickup door. 2. Release two green latches and slide the paper feeder out as far as possible. 3. Unsnap and remove the small, black plastic cover located at the right side of the cleaning assembly. 4. Disconnect the two - Lexmark Optra C | Service Manual - Page 154
5045-001 Drum Lift Assembly Note: This assembly lifts the transfer drum into the photoconductor. See Assembly 19-1. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the transfer drum assembly. 2. Remove the top cover. 3. Remove the left side cover and the rear cover. 4. Remove the EMC - Lexmark Optra C | Service Manual - Page 155
changed or moved, the oil must be removed. a. Locate the oil suction kit (a suction tool and oil storage bottle) shipped with the printer. b. Extract the oil from the oil bottle compartment with the suction tool and put it into the oil storage bottle. c. Drain the oil from the fuser oil pan into the - Lexmark Optra C | Service Manual - Page 156
5045-001 Fuser Oil Bottle Case Assembly See Assembly 32-7. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Use the hypodermic syringe tool (11A2440) to withdraw the oil from the bottle case. Also remove the square - Lexmark Optra C | Service Manual - Page 157
Assembly 32-12, 32-13. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Follow the steps in the Fuser Lamps Removal procedure and remove the lamps. 4. Remove the fuser oil apply assembly. 5. Remove the screws from the - Lexmark Optra C | Service Manual - Page 158
Thermo Switch See Assembly 32-14. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the two screws from the input guide located on the lower left side of the fuser. 4. Remove the screw from the thermo switch - Lexmark Optra C | Service Manual - Page 159
and other items must be replaced in order to maintain maximum print quality. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the two screws from the protective cover and remove the cover. 4. Remove the four - Lexmark Optra C | Service Manual - Page 160
Apply Assembly See Assembly 32-5. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the two extension springs from the fuser oil apply housing (one at the front and one at the rear). 4. Remove the four screws - Lexmark Optra C | Service Manual - Page 161
fuser. It contains oil that can spill. 3. Remove the two screws from the protective cover and remove the cover. 4. Remove the screw from the rear knob and remove the knob. 5. Remove the screw from the shield surrounding the knob and remove the shield. 6. Remove the two screws from the delivery guide - Lexmark Optra C | Service Manual - Page 162
the square cap from the oil tray and withdraw the oil from the oil tray. Store the oil withdrawn in the oil storage bottle tool (11A2441). 13. Pinch or stop up the tube between the oil bottle case and the oil tray to prevent oil from leaking out. 14. Place the fuser assembly on a shop towel or - Lexmark Optra C | Service Manual - Page 163
fuser. It contains oil that can spill. 3. Remove the two screws from the protective cover and remove the cover. 4. Remove the screw from the rear knob and remove the knob. 5. Remove the screw from the shield surrounding the knob and remove the shield. 6. Remove the two screws from the delivery guide - Lexmark Optra C | Service Manual - Page 164
the square cap from the oil tray and withdraw the oil from the oil tray. Store the oil withdrawn in the oil storage bottle tool (11A2441). 13. Pinch or stop up the tube between the oil bottle case and the oil tray to prevent oil from leaking out. 14. Place the fuser assembly on a shop towel or - Lexmark Optra C | Service Manual - Page 165
5045-001 Fuser Oil Applying Input Assembly See Assembly 32-4. 1. Remove the fuser assembly. 2. Place the fuser on a flat surface. Note: Do not tilt the fuser. It contains oil that can spill. 3. Remove the spring from the oil applying input assembly. 4. Remove the E-clip from the oil applying input - Lexmark Optra C | Service Manual - Page 166
5045-001 High Voltage Power Supply See Assembly 2-26. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield. 4. Open the multipurpose paper pickup door, release the two green latches and slide the - Lexmark Optra C | Service Manual - Page 167
5045-001 Low Voltage Power Supply See Assembly 7-4. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield from the rear of the machine. 4. Open the multipurpose paper pickup door, release the two - Lexmark Optra C | Service Manual - Page 168
5045-001 Mechanical Controller PCB See Assembly 7-32. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield from the rear of the machine. 4. Disconnect all connectors (19) on the mechanical controller - Lexmark Optra C | Service Manual - Page 169
5045-001 Multipurpose Feeder U-Turn Roller Assembly See Assembly 25-6. 1. Open the multipurpose paper pickup door. 2. Release the two green cassette latches. 3. Slide the tray out as far as possible. 4. Remove the screw and the gear train cover. 5. Remove the gear from the right side of the U-turn - Lexmark Optra C | Service Manual - Page 170
cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover. 2. Open the fuser access door. 3. Remove the connector from the front of the paper delivery assembly. 4. Remove the screw of the paper delivery assembly. The sensor signals the printer it is time for the 60K maintenance. 4-44 - Lexmark Optra C | Service Manual - Page 171
slide the guard slightly toward the center of the machine and remove it. 10. Remove the four board mounting screws and the board. Repair Information 4-45 - Lexmark Optra C | Service Manual - Page 172
5045-001 11. Remove the screws [A] from the two grounding straps. 4-46 - Lexmark Optra C | Service Manual - Page 173
5045-001 12. Remove the four printhead mounting screws [A] and lift the printhead out of the machine. Repair Information 4-47 - Lexmark Optra C | Service Manual - Page 174
the main drive motor and board assembly and remove the assembly. 9. Remove the paper exit drive assembly. 10. Remove the six silver screws from the printer drive assembly. Do not remove the black screw. Note: When reinstalling the drive assembly, make sure it fits flush on the rear frame. Check the - Lexmark Optra C | Service Manual - Page 175
5045-001 Rotary Manual Feed Assembly See Assembly 15-1. For cover removals, see "Cover Removals" on page 4-8. 1. Open the top cover and the front cover. 2. Remove the left side - Lexmark Optra C | Service Manual - Page 176
5045-001 Rear Cooling Duct See Assembly 7-2 and 7-3. For cover removals, see "Cover Removals" on page 4-8. 1. Remove the top cover. 2. Remove the left side cover and the rear cover. 3. Remove the EMC shield form the rear of the machine. 4. Disconnect the lower fan connector from the mechanical - Lexmark Optra C | Service Manual - Page 177
the back of the holder front plate. 7. Disconnect the three connectors in the holder front plate. 8. Remove the two screws from the waste toner cartridge lock bracket located on the transfer drum holder front plate and remove the bracket. 9. Remove the extension spring from the transfer drum holder - Lexmark Optra C | Service Manual - Page 178
5045-001 Transfer Drum Separation Claw See Assembly 29-6. 1. Remove the transfer drum and holder assembly. 2. Remove the spring from the separation claw. 3. Remove the three screws from the separation claw and remove the claw. Note: During reassembly, place the solenoid link in the claw before - Lexmark Optra C | Service Manual - Page 179
. 5. Place a screwdriver blade through the holes in each end of the attraction roller holder and push the attraction roller out of the holder. 6. Remove the guide roller from each end of the attraction roller. CAUTION: Do not touch the attraction roller with your bare hands. Repair Information 4-53 - Lexmark Optra C | Service Manual - Page 180
5045-001 Transfer Drum Sheet See Assembly 28-8. 1. Remove the transfer drum and holder assembly. 2. Remove the two springs from the attraction roller holder. 3. Remove the two springs from the discharge roller holder. 4. Remove the two extension springs holding the one end of the transfer drum sheet - Lexmark Optra C | Service Manual - Page 181
blade through the holes in each end of the discharge roller holder and push the discharge roller out of the holder. 4. Remove the nylon guide roller from each end of the discharge roller. CAUTION: Do not touch the discharge roller with your bare hands. Transfer Drum HV Contact Assembly See - Lexmark Optra C | Service Manual - Page 182
5045-001 Transfer Drum Gripper Assembly See Assembly 29-2. Note: Also order a transfer sheet, since damage to the sheet may occur when removing it from the gripper assembly. 1. Remove the transfer drum and holder assembly. 2. Remove the two springs from the attraction roller holder. 3. Remove the - Lexmark Optra C | Service Manual - Page 183
5045-001 Transfer Drum Solenoid See Assembly 29-5. 1. Remove the transfer drum and holder assembly. 2. Remove the two springs from the attraction roller holder. 3. Remove the two springs from the discharge roller holder. 4. Remove the two extension springs holding the one end of the transfer drum - Lexmark Optra C | Service Manual - Page 184
5045-001 Transfer Drum Sensors See Assembly 29-3. Note: This sensor is used in two places on the transfer drum assembly. One of the sensors is on the inside of the drum and one on the outside of the drum. To remove the sensor on the inside of the drum, follow the removal procedure to remove the - Lexmark Optra C | Service Manual - Page 185
5045-001 Transfer Drum Assembly See Assembly 29-1. 1. Open the front cover. 2. Remove the paper cassette. 3. Remove the waste toner bottle. 4. Remove the photoconductor unit. Note: Use the cover saved during installation to protect the photoconductor from light. 5. Remove the upper front trim panel - Lexmark Optra C | Service Manual - Page 186
5045-001 4-60 - Lexmark Optra C | Service Manual - Page 187
. Remove the three screws from the transfer drum drive assembly and remove the assembly. Note: One of the screws is accessed through a hole in the printer drive assembly. Repair Information 4-61 - Lexmark Optra C | Service Manual - Page 188
Remove the front door. 3. Remove the top cover. 4. Remove the left cover. 5. Remove one of the toner cartridges. 6. Remove the screw and the upper right hand front panel. 7. Remove the four screws and the left , line the handle up with the handle guide before pressing the latches in place. 4-62 - Lexmark Optra C | Service Manual - Page 189
. 2. Remove the screw that mounts the delivery drive assembly and remove the assembly. Video Controller Board Note: Observe ESD precautions. See Assembly 7-32. 1. Turn the printer off. 2. Loosen the 2 board retaining thumbscrews. 3. Slide the board out. Repair Information 4-63 - Lexmark Optra C | Service Manual - Page 190
order to perform the following removals. 1. Disconnect the power cord. 2. Remove the two lock pins. Note: Two persons should be used to lift the printer from the sheet feeder. Cassette Feed Solenoid See Assembly 35-20. 1. Remove the front pickup unit. 2. Remove the screw and the solenoid. Cassette - Lexmark Optra C | Service Manual - Page 191
5045-001 External Covers See Assembly 34. 1. Remove the cassette tray. 2. Open the Open/Close cover. 3. Remove the three screws and the front cover. 4. Remove the two screws and the rear cover. 5. Remove the two screws and the left cover. 6. Remove the one screw and the right cover. 7. Remove the - Lexmark Optra C | Service Manual - Page 192
5045-001 Paper Feeder Circuit Board See Assembly 36-6. 1. Remove the rear cover. 2. Remove the six screws and the gear cover. 3. Disconnect the three connectors under the gear cover. 4. Remove the three mounting screws and carefully slide the board and its mount out enough to disconnect the three - Lexmark Optra C | Service Manual - Page 193
Note: Always replace the rollers as a set. Pickup Sensor See Assembly 35-5. 1. Remove the front pickup unit. 2. Remove the screw securing the guide. 3. Disengage the claw securing the sensor. 4. Disconnect the connector and remove the sensor. Power Supply See Assembly 36-5. 1. Remove the rear cover - Lexmark Optra C | Service Manual - Page 194
5045-001 Separation Roller Unit See Assembly 37-4. 1. Remove the cassette. 2. Open the Open/Close Door. 3. Remove the screw securing the separation roller unit and remove the separation unit. 4. Remove the E-clip and the bushing to remove the separation roller. 4-68 - Lexmark Optra C | Service Manual - Page 195
2 Toner cartridge 3 Laser / scanner unit 4 Photosensitive drum 5 Primary charging roller 6 Drum cartridge 7 Cleaning unit 8 Gripper 9 Separation charging unit 10 Separation claw 11 Oil applying roller 12 Cleaning belt 13 Top exit delivery roller 14 Fuser upper roller 15 Fuser lower roller 16 Fuser - Lexmark Optra C | Service Manual - Page 196
5045-001 Switches 5-2 - Lexmark Optra C | Service Manual - Page 197
(paper feeder) Cassette-size sensing switch l (paper feeder) Cassette-size sensing switch 2 (paper feeder) Cassette-size sensing switch 3 (paper feeder) * Part of a larger FRU, not serviced individually Locations 5-3 - Lexmark Optra C | Service Manual - Page 198
5045-001 Sensors 5-4 - Lexmark Optra C | Service Manual - Page 199
ASM - Index Function 25 - 9 25 - 9 8-8 Manual feeding paper sensor Manual feeding paper size sensor Toner cartridge position sensor 8-7 26 - 3 29 - 3 29 - Paper top sensor Toner sensor 3 - 10 5 - 14 30 - 6 Waste toner sensor Oil sensor Density sensor 32 - 15 Detects the fuser lower roller - Lexmark Optra C | Service Manual - Page 200
5045-001 Name TP1 ASM - Index 32 - 14 TP2 32 - 14 T/H 2 - 22 * Part of PCB Function Detects the fuser upper roller abnormal temperature Detects the fuser lower roller abnormal temperature Temperature / humidity sensor 5-6 - Lexmark Optra C | Service Manual - Page 201
5045-001 Clutches and Solenoids Locations 5-7 - Lexmark Optra C | Service Manual - Page 202
- 3 13 - 3 13 - 4 35 - 20 Function Developing rotary brake clutch Developing unit drive clutch Registration roller clutch Fuser unit drive clutch Cassette feed solenoid Manual feed solenoid Cleaning belt drive solenoid Gripper drive solenoid Separation claw solenoid Attraction roller press solenoid - Lexmark Optra C | Service Manual - Page 203
5045-001 Motors and Fuser Heaters Locations 5-9 - Lexmark Optra C | Service Manual - Page 204
6 31 - 2 35 - 19 7-7 7-8 5 - 24 32 - 2/11 32 - 2/11 Function Pickup motor Main motor Developing unit motor Drum motor Cleaning brush motor Paper feeder motor Fuser unit fan Electrical unit fan Controller fan Fuser upper roller heater (110 V or 220 V) Fuser lower roller heater (110 V or 220 V) 5-10 - Lexmark Optra C | Service Manual - Page 205
5045-001 PCBs Locations 5-11 - Lexmark Optra C | Service Manual - Page 206
- 23 7 Cassette size-sensing PCB 8 Toner-low detect beam PCB 9 Toner-low detect receive PCB 10 Waste-toner sensing PCB 11 Oil-sensing PCB 3-8 16 - 2 6 - 23 3 - 10 5 - 14 Function Controls printer functions (Laser/scanner control, Image stabilization control, fuser unit temperature control, video - Lexmark Optra C | Service Manual - Page 207
-sensing PCB 13 Video controller PCB ASM Index 3-8 33 - 1 14 Paper feeder driver PCB 15 Cassette paper sensor PCB 36 - 6 35 - 17 Function Detects pulling of the ejection lever. Processes input/output data between the printer and the external device. Drives the solenoids and the motors in the - Lexmark Optra C | Service Manual - Page 208
5045-001 Connector Locations 5-14 - Lexmark Optra C | Service Manual - Page 209
5045-001 Connector Locations Locations 5-15 - Lexmark Optra C | Service Manual - Page 210
5045-001 Connector Locations 5-16 - Lexmark Optra C | Service Manual - Page 211
J 114 Function LVPS Laser Beam Detect / Motor Density Sensor Toner Low Detect (receive) Transfer Drum Cleaning Belt Sensor / Oil Sensor Waste Toner Sensing/ Cassette Size Sensing / Ejection Sensing Terminal Board and Display Not Used Laser Driver Board Laser Driver Board Mechanical Controller Not - Lexmark Optra C | Service Manual - Page 212
5045-001 DC Controller Board Connector Locations (Graphic) 5-18 - Lexmark Optra C | Service Manual - Page 213
5045-001 DC Controller Board Connectors (J101, J102, J103) J 101 LVPS 1 GND 2 +5 V 3 GND 4 +24 VB 5 PCONT 6 POFF 7 DOPN J 102 Laser Beam Detect 1 BDCHK 2 GND 3 /BD 4 +5 V Laser Beam Motor 5 GND 6 SCNCLK 7 GND 8 /SCNON 9 /SCNRDY 10 +24 VB 11 +24 VB J 103 Density Sensor 1 +5 V 2 DSNS 3 /DENSEL 4 - Lexmark Optra C | Service Manual - Page 214
5045-001 DC Controller Board Connectors (J104, J105, J106) J 104 Toner Low Detect (receive) 1 TNSNS 2 GND 3 RET (+5 V) J 105 Transfer Drum Top Sensor 13 4 /GRIPON Attraction Sensor 3 ATTSNS 2 GND 1 LEDON J 106 Cleaning Belt Sensor 1 LEDDRV 2 GND 3 WEBSNS Oil Sensor 4 LEDDRV 5 GND 6 OILSNS 5-20 - Lexmark Optra C | Service Manual - Page 215
5045-001 DC Connector Board Connectors (J107, J108, J109) J 107 Waste Tower Sensing 1 LEDON 2 GND 3 HTSNS Cassette Size Sensing / Ejection Sensing 4 GND 5 /C SIZE 1 6 /C SIZE 2 7 /C SIZE 3 J 108 Terminal Board Video Interface 1 through 37 J 109 Not Used Locations 5-21 - Lexmark Optra C | Service Manual - Page 216
5045-001 DC Controller Board Connectors (J110, J111, J112) J 110 J 111 Laser Drive Board Laser Drive Board 1 + 12 V 2 + 12 V 3 + 12 V 4 GND 5 PDIN 6 GND 7 LLCNT 8 GND 9 DV1 (GND) 10 GND 11 DV2 12 GND 13 DV3 14 GND 15 DV4 16 - Lexmark Optra C | Service Manual - Page 217
5045-001 DC Controller Board Connectors (J113, J114) J 113 Not Used J 114 Density Adjustment Panel 1 /TST2 2 /LCK 3 /DSCK 4 /SDO 5 /SDI 6 GND 7 +5 V 8 /DSPEN Locations 5-23 - Lexmark Optra C | Service Manual - Page 218
Position / Cartridge Position Sensor DC Controller Board LVPS Cleaning Belt Drive Solenoid and Fuser Controller Fan Fuser Drive Clutch Fuser Fan Main Drive Motor Solenoid Plate / Cleaning Brush Motor Drum Motor Developer Motor Toner Low - Lexmark Optra C | Service Manual - Page 219
5045-001 Mechanical Controller Board Connectors (Graphic) Locations 5-25 - Lexmark Optra C | Service Manual - Page 220
, J2005, J2006) J2004 High Voltage Power Supply 1 TXD 2 RXD 3 CLK 4 SEL 5 RES 6 +5 V 7 GND 8 +24 V 9 PGND J2005 Temperature / Humidity Sensor 1 GND 2 TMPSNS 3 GND 4 HUMSNS 5 +5 VU J2006 Toner Cartridge Position Sensor 1 +5 VSAVE 2 GND 3 DEVCAM Rotary Position Sensor 4 +5 VSAVE 5 GND 6 DEVHP 5-26 - Lexmark Optra C | Service Manual - Page 221
31 FXSTS J2008 Low Voltage Power Supply 1 FXSTS 2 SFSNS 3 FXTYP 4 THI 5 /FXROF 6 /FXENB 7 /FXLON 8 /FXUON 9 GND J2009 Cleaning Belt Drive Solenoid / Fuser Fuser 1 THI 2 (THIRET) GND 3 /FXSNS 4 GND 5 FXTYP 6 +5 V Drive Solenoid 7 /WEBSL 8 +24 VA Fuser 9 +5 VSAVE 10 GND 11 POUT 12 +5 VSAVE 13 GND 14 - Lexmark Optra C | Service Manual - Page 222
5045-001 Mechanical Controller Bd (J2010, J2011, J2012) J2010 Controller Fan 1 GND 2 /FANLK3 3 FAND3 J2011 Fuser Drive Clutch 1 /FXON 2 +24 VA J2012 Fuser Fan 1 GND 2 FANLK1 3 FAND1 Mechanical Controller Bd (J2013, J2014, J2015) J2013 Main Drive Motor 1 MLOW 2 /MRDY 3 /MON 4 GND 5 GND 6 +24 VA - Lexmark Optra C | Service Manual - Page 223
Low Detect (beam) / Developing Rotary Brake Clutch / Developing Unit Drive Clutch Brake Clutch 1 /DEVBRK 2 +24 VA 3 /DEVON 4 +24 VA Toner Beam 5 TONLED 6 GND 7 NOT USED J2018 Not Used Mechanical Controller Bd (J2019, J2020, J2021) J2019 Electrical Unit Fan 1 GND 2 FANLK2 3 FAND2 J2020 Not Used - Lexmark Optra C | Service Manual - Page 224
5045-001 Paper Pickup Board Name J301 J302 J303 J304 J305 Function Mechanical Controller Board Manual Feed Size Sensor / Manual Feed Paper Sensor / Manual Feed Solenoid / Registration Roller Clutch Cassette Feed Solenoid Pickup Motor Paper Top Sensor 5-30 - Lexmark Optra C | Service Manual - Page 225
(J301, J302, J303) J301 Mechanical Controller Board 1 TXD 2 RXD 3 CLK 4 GND 5 +5 V 6 PGND 7 +24 VC 8 RES J302 Manual Feed Size Sensor / Manual Feed Paper Sensor / Manual Feed Solenoid Sensor / Registration Roller Clutch Size Sensor 1 LEDDRV2 2 GND 3 MPSSNS Paper Sensor 4 LEDDRV2 5 GND 6 MPPSNS - Lexmark Optra C | Service Manual - Page 226
5045-001 Terminal Board Name J801 J802 J803 J804 Function Video Controller Board DC Controller Board Display Panel Power Supply Terminal Board Connectors (J801, J802, J803) J801 Video Controller Board 1 through 96 Video Interface J802 DC Controller 1 through 37 Video Interface J803 Panel - Lexmark Optra C | Service Manual - Page 227
5 +5 V 6 REMOTE 7 SEL 8 RES J352 Paper Sensors 1 +5 V 2 GND 3 OPREGSNS 4 +5 V 5 GND 6 OPSNS J353 Feed Motor 1 CA 2 CB 3 AO 4 /AO 5 BO 6 /BO Optional Paper Feeder Driver Bd (J354, J355) J354 Solenoid 1 /OPFED 2 +24 V J355 Power Supply 1 +24 V-BS 2 +24 V-GND 3 Remote-GND 4 Remote Locations 5-33 - Lexmark Optra C | Service Manual - Page 228
5045-001 Optional Paper Feeder (Miscellaneous) Name J312 PS351 J359 SL351 PS352 J358 Function Size Sensing PCB Cassette Paper Sensor Paper Sensor Connector Cassette Feed Solenoid Pickup Sensor Pickup Sensor Connector High Voltage Power Supply PCB 5-34 - Lexmark Optra C | Service Manual - Page 229
5045-001 Separation HVT PCB Ejection Sensing PCB Cassette Size Sensing PCB Locations 5-35 - Lexmark Optra C | Service Manual - Page 230
5045-001 Paper Feed Driver PCB 5-36 - Lexmark Optra C | Service Manual - Page 231
5045-001 Fuser Connector (J21) Locations 5-37 - Lexmark Optra C | Service Manual - Page 232
for printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance. Safety Inspection Guide The purpose of this inspection guide is top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments 6-1 - Lexmark Optra C | Service Manual - Page 233
lubrication. Use of a spray contact cleaner in most instances will allow normal functioning of the fuser sensors which have been contaminated with silicone oil. The only cleaner currently approved by Lexmark is CRC brand industrial contact cleaner # 03130. In addition to the cautions on the Material - Lexmark Optra C | Service Manual - Page 234
be performed by the customer to maintain the printer at the optimum level are listed below. All other maintenance procedures are to be performed by a trained service technician. Item Toner Cartridge Drum Cartridge Waste Toner Bottle Oil Registration roller unit (cassette pickup unit) Separation - Lexmark Optra C | Service Manual - Page 235
7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down on 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 - Lexmark Optra C | Service Manual - Page 236
Assembly 1: Covers 7-2 - Lexmark Optra C | Service Manual - Page 237
AsmIndex Part Number Units Description 1-1 11A2747 1 Cover, Pick Up, Lower -2 11A2140 1 Cover, Tray -3 11A2319 1 Cover, Bezel -4 11A2320 1 Cover, Rear -5 11A2321 1 Cover, LH Side -6 11A2322 1 Cover, Top -7 11A2323 1 Cover, Multipurpose Door -8 11A2324 1 Cover, Multipurpose - Lexmark Optra C | Service Manual - Page 238
Assembly 2: Major Components 7-4 - Lexmark Optra C | Service Manual - Page 239
AsmIndex Part Number Units Description 2-1 11A2424 1 Knob, Manual -2 1 Bushing, PP 11A2379 -3 1 Bushing, Front, PP 11A2379 -4 1 page 7-24 -32 See "Density Sensor Asm" on page 7-64 -33 See "Rotary Manual Feed" on page 7-30 -34 See "Attraction Roller Drive" on page 7-40 -35 - Lexmark Optra C | Service Manual - Page 240
Assembly 3: Toner (used) Reservoir/ HV 7-6 - Lexmark Optra C | Service Manual - Page 241
PP 11A2340 -2 11A2429 1 Cover, Conn. -3 11A2431 1 Panel, Guide -4 11A2432 1 Hinge Upper, Door -5 11A2433 1 Stopper Spring -6 Ejection Sensor Board -9 11A2033 1 Switch, Main -10 11A2034 1 Sensor, Waste Toner Asm -11 11A2035 1 Button, Switch -12 11A2036 1 Hinge, Lower Door - - Lexmark Optra C | Service Manual - Page 242
Assembly 4: Major Assemblies (Top/Bottom) 7-8 - Lexmark Optra C | Service Manual - Page 243
" on page 7-28 -17 See "Transfer Drum Cleaning" on page 7-66 -18 See "Paper Pickup" on page 7-46 -19 11A2719 1 Shield, Rear -20 11A2720 1 Handle, Oil Bottle -21 11A2737 1 Screw, Pivot -22 11A2746 1 Stud, Pivot Parts Catalog 7-9 - Lexmark Optra C | Service Manual - Page 244
Assembly 5: DC Controller / Video Controller Board 7-10 - Lexmark Optra C | Service Manual - Page 245
Cable 1 Cable 1 Cable 1 Cable 1 Cable, DC Rear 1 Cable, DC Front 1 Cable, Density Adj. Panel 1 Sensor, Oil Asm 2 Guide, Rail 1 Plate, Cover 1 Plate, RH 1 Plate, Fan Duct 1 Crossmember 2 Guide, Rail 1 Duct, Fan 1 Plate, LH 1 Connector PCB 1 Fan, Video Controller Screw, PP 11A2331 1 Bracket, Opt Conn - Lexmark Optra C | Service Manual - Page 246
Assembly 6: Laser 7-12 - Lexmark Optra C | Service Manual - Page 247
1 Rail, PC Cartridge -15 Screw, PP 11A2331 -16 11A2081 1 Plate, Slide -17 11A2082 2 Guide, Fuser -18 11A2083 1 Rod, ON/Off -19 11A2084 2 Rail Asm -20 1 Spring, PP 11A2354 -21 Screw, PP 11A2331 -22 11A2085 1 Sheet, Caution -23 11A2086 1 PCB, Sensor, Toner Empty (Receive - Lexmark Optra C | Service Manual - Page 248
Assembly 7: Drive, Main 7-14 - Lexmark Optra C | Service Manual - Page 249
V -6 11A2092 1 Motor, Main Drive -7 11A2093 1 Fan, Fuser -8 11A2094 1 Fan, DC Controller, Laser -9 11A2095 1 Gear, Cartridge Press -10 1 Connector, Snap Tite, PP 11A2389 -11 1 11A2331 -32 11A2111 1 Board, Mech Controller -33 See "Printer Drive" on page 7-32 Parts Catalog 7-15 - Lexmark Optra C | Service Manual - Page 250
Assembly 8: Density Adjustment Panel 7-16 - Lexmark Optra C | Service Manual - Page 251
-11 11A2119 1 Contact -12 Screw, PP 11A2340 -13 11A2120 1 Foot, Rear -14 11A2121 1 Crossmember -15 11A2122 1 Mount, Positioning -16 11A2123 2 Guide, Drive Mounting -17 Screw, W/Washer, PP 11A2340 -18 1 Conn., 2 Pin, PP 11A2389 -19 1 Clip, PP 11A2389 -20 1 Edge Saddle, PP - Lexmark Optra C | Service Manual - Page 252
Assembly 9: Bottom Plate 7-18 - Lexmark Optra C | Service Manual - Page 253
Out -2 11A2129 4 Guide, Slide -3 11A2130 1 Shield, Conn. -4 11A2131 1 Rail, Cassette Rt -5 11A2132 1 Rail, Cassette Lft -6 11A2133 1 Crossmember Rail -7 11A2134 1 Foot, Front -8 11A2135 1 Grip, Front, Right -9 11A2136 1 Grip, Rear, Right -10 11A2137 1 Support, Rock Pin - Lexmark Optra C | Service Manual - Page 254
Assembly 10: Door Switch, Upper 7-20 - Lexmark Optra C | Service Manual - Page 255
AsmIndex Part Number Units Description 10-1 -2 -3 -4 -5 -6 -7 -8 -9 11A2141 11A2142 11A2143 11A2144 11A2145 1 Arm, Door 1 1 Arm, Door 2 1 Guide, Cable 1 Mount, Switch Upper 1 Cable, Control 1 Spring, PP 11A2354 Screw, PP 11A2331 Screw, PP 11A2331 E-Ring, PP 11A2373 Parts Catalog 7-21 - Lexmark Optra C | Service Manual - Page 256
Assembly 11: Door Switch, Lower 7-22 - Lexmark Optra C | Service Manual - Page 257
AsmIndex Part Number Units Description 11-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 11A2146 11A2147 11A2148 11A2149 11A2150 11A2151 11A2152 11A2153 1 Arm, Rocker 1 Plate, Insulating Switch 1 Mount, Switch Lower 1 Plate, Slide 1 Cable, Switch 1 Switch 1 Spring, PP 11A2354 Screw, PP 11A2340 1 Spring - Lexmark Optra C | Service Manual - Page 258
Assembly 12: Ejector Lever 7-24 - Lexmark Optra C | Service Manual - Page 259
AsmIndex Part Number Units Description 12-1 -2 -3 -4 -5 -6 11A2740 11A2154 11A2155 11A2156 11A2157 1 Ejector Asm 1 • Ejector 1 • Guide 1 • Hook 1 • Oil Damper 1 • Spring, PP 11A2354 Parts Catalog 7-25 - Lexmark Optra C | Service Manual - Page 260
Assembly 13: Solenoid Plate 7-26 - Lexmark Optra C | Service Manual - Page 261
AsmIndex Part Number Units Description 13-1 -2 -3 -4 -5 -6 -7 -8 -9 11A2158 11A2159 11A2160 11A2161 1 Mount, Solenoid 1 Cable 3 Solenoid 1 Solenoid 3 Conn. 2 Pin, PP 11A2389 1 Conn. 3 Pin, PP 11A2389 Clip, PP 11A2389 Clip, PP 11A2389 Screw, PP 11A2331 Parts Catalog 7-27 - Lexmark Optra C | Service Manual - Page 262
Assembly 14: Cleaning Belt Drive Solenoid 7-28 - Lexmark Optra C | Service Manual - Page 263
AsmIndex Part Number Units Description 14-1 -2 -3 -4 -5 -6 11A2162 11A2163 11A2164 1 Lever, Solenoid 1 Mount, Solenoid 1 Solenoid 1 Conn. 2 Pin, PP 11A2389 E-Ring, PP 11A2373 Screw, PP 11A2340 Parts Catalog 7-29 - Lexmark Optra C | Service Manual - Page 264
Assembly 15: Rotary Manual Feed 7-30 - Lexmark Optra C | Service Manual - Page 265
AsmIndex Part Number Units Description 15-1 -2 -3 11A2165 11A2167 11A2166 1 Feeder, Rotary Manual Asm 1 • Shaft 1 • Hook, Lock Parts Catalog 7-31 - Lexmark Optra C | Service Manual - Page 266
Assembly 16: Printer Drive 7-32 - Lexmark Optra C | Service Manual - Page 267
-10 11A2168 11A2169 11A2170 11A2171 11A2172 11A2173 11A2174 11A2175 11A2176 1 Drive Asm complete 1 • Toner Empty Sensor (Beam) 1 • Bearing Asm, Rotary Unit 1 • Bearing Asm, Transfer Drum 1 • Clutch Asm, Fuser Drive 1 • Motor Asm, Transfer Drum 1 • Motor Asm, Rotary Unit 1 • Clutch Asm, Rotary Unit - Lexmark Optra C | Service Manual - Page 268
Assembly 17: Transfer Drum Cleaning Drive 7-34 - Lexmark Optra C | Service Manual - Page 269
AsmIndex Part Number Units Description 17-1 -2 11A2177 11A2178 1 Transfer Drum Clean Drive Asm 1 • Coupler Parts Catalog 7-35 - Lexmark Optra C | Service Manual - Page 270
Assembly 18: Discharge Roller Drive 7-36 - Lexmark Optra C | Service Manual - Page 271
AsmIndex Part Number Units Description 18-1 -2 11A2179 11A2180 1 Discharge Roller Drive Asm 1 • Cam Parts Catalog 7-37 - Lexmark Optra C | Service Manual - Page 272
Assembly 19: Drum Lift 7-38 - Lexmark Optra C | Service Manual - Page 273
AsmIndex Part Number Units Description 19-1 -2 11A2181 11A2182 1 Drum Lift Asm 2 • Cam Parts Catalog 7-39 - Lexmark Optra C | Service Manual - Page 274
Assembly 20: Attraction Roller Drive 7-40 - Lexmark Optra C | Service Manual - Page 275
AsmIndex Part Number Units Description 20-1 -2 11A2183 11A2184 1 Attraction Roller Drive Asm 1 • Cam Parts Catalog 7-41 - Lexmark Optra C | Service Manual - Page 276
Assembly 21: Paper Drive 7-42 - Lexmark Optra C | Service Manual - Page 277
AsmIndex Part Number Units Description 21-1 -2 11A2185 11A2186 1 Delivery Drive Asm 1 • Belt Parts Catalog 7-43 - Lexmark Optra C | Service Manual - Page 278
Assembly 22: Universal Cassette 7-44 - Lexmark Optra C | Service Manual - Page 279
1 Plate, Lift Asm 1 Knob, Size 1 Plate, Size 1 Spring, PP 11A2354 1 Screw, PP 11A2331 1 Screw, PP 11A2340 1 Screw, PP 11A2331 3 Spring, Lever 1 Label, Universal Parts Catalog 7-45 - Lexmark Optra C | Service Manual - Page 280
Assembly 23: Paper Pickup 7-46 - Lexmark Optra C | Service Manual - Page 281
AsmIndex Part Number Units Description 23-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 11A2213 11A2214 11A2215 1 Cover, Motor 1 Mount, Pivot 1 Spring, PP 11A2364 1 Spring, PP 11A2364 1 Spring, PP 11A2364 1 Screw, PP 11A2331 1 Screw, PP 11A2331 1 Cover See "Cassette Paper Pickup Asm" on page 7-48 See " - Lexmark Optra C | Service Manual - Page 282
Assembly 24: Cassette Paper Pickup Asm 7-48 - Lexmark Optra C | Service Manual - Page 283
AsmIndex Part Number Units Description 24-1 -3 -5 -7 -9 -10 -11 -12 11A2216 1 11A2219 1 11A2221 2 11A2223 1 11A2225 1 11A2226 1 11A2227 1 Cassette Paper Pickup Asm • Shaft Asm • Lever, Lock Slide • Roller, Asm Rear • Motor, Paper Pickup Asm • Solenoid • Clutch • Spring, Lever Lock, PP 11A2364 - Lexmark Optra C | Service Manual - Page 284
Assembly 24: Paper Pickup Cassette (cont.) 7-50 - Lexmark Optra C | Service Manual - Page 285
AsmIndex Part Number Units Description 24-1 -2 -4 -6 -8 -13 11A2216 11A2218 11A2220 11A2222 11A2224 11A2228 1 Cassette Paper Pickup Asm 1 • Roller Asm 2 • Roller 1 • Guide Asm 1 • Roller Asm 1 • PCB Paper Pickup Asm Parts Catalog 7-51 - Lexmark Optra C | Service Manual - Page 286
Assembly 25: Multipurpose Feeder Pickup Asm 7-52 - Lexmark Optra C | Service Manual - Page 287
Description 25-1 -2 -3 -4 -5 -6 -7 -8 -9 11A2217 11A2229 11A2230 11A2231 11A2232 11A2233 11A2234 11A2235 11A2117 1 Multipurpose Paper Pickup Asm 1 • Clip, Roller 1 • Roller, Pickup 1 • Guide, Upper Asm 1 • Pad, Main 1 • Roller, U-turn Asm 1 • Base Asm 1 • Solenoid 2 • Sensor Parts Catalog 7-53 - Lexmark Optra C | Service Manual - Page 288
Assembly 26: Paper, Side Exit Asm 7-54 - Lexmark Optra C | Service Manual - Page 289
AsmIndex Part Number Units Description 26-1 -2 -3 11A2236 11A2237 11A2117 1 Delivery Asm 1 • Frame Asm, Without Rollers 1 • Sensor, Cleaning Belt Parts Catalog 7-55 - Lexmark Optra C | Service Manual - Page 290
Assembly 27: Developing Rotary Asm 7-56 - Lexmark Optra C | Service Manual - Page 291
AsmIndex Part Number Units Description 27-1 -2 -3 11A2238 11A2239 11A2240 1 Rotary Asm 1 • Rotary Disc 1 • Rotary Center Asm Parts Catalog 7-57 - Lexmark Optra C | Service Manual - Page 292
Assembly 28: Transfer Drum Mounting Asm 7-58 - Lexmark Optra C | Service Manual - Page 293
Holder Asm • Slide, Front Asm • Contact, HV Asm • Slide, Rear Asm • Knob, Manual Asm • Lever, Operation • "Transfer Drum" on page 7-60 Sheet, Transfer Drum Roller, Attraction Brkt., Used Toner Sensor Arm, Lock, Used Toner Spring, PP 11A2364 Arm, Lock, Cartridge Spring, PP 11A2364 Parts Catalog 7-59 - Lexmark Optra C | Service Manual - Page 294
Assembly 29: Transfer Drum 7-60 - Lexmark Optra C | Service Manual - Page 295
AsmIndex Part Number Units Description 29-1 -3 -4 -6 -7 -8 -9 -10 -11 -14 -15 11A2247 11A2117 11A2700 11A2702 11A2709 11A2711 11A2712 11A2116 11A2454 11A2452 1 Drum, Transfer Asm 1 • Sensor 1 •Solenoid 1 •Claw, Separation 1 •Arm, Sensing •Spring, PP 11A2354 1 • Cover, Sensor 1 • Cover, Sensor - Lexmark Optra C | Service Manual - Page 296
Assembly 29: Transfer Drum (Cont.) 7-62 - Lexmark Optra C | Service Manual - Page 297
AsmIndex Part Number Units Description 29-1 -2 -3 -5 -13 11A2247 11A2248 11A2117 11A2701 11A2453 1 Drum, Transfer Asm 1 • Gripper, Paper Asm 1 • Sensor 1 • Solenoid 2 • Cap, Plastic Parts Catalog 7-63 - Lexmark Optra C | Service Manual - Page 298
Assembly 30: Density Sensor Asm 7-64 - Lexmark Optra C | Service Manual - Page 299
AsmIndex Part Number Units Description 30-1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 11A2249 11A2250 11A2251 11A2252 11A2253 11A2254 11A2255 11A2256 1 Support, Corona 1 Link 1 Plate Sen/Sep 1 Plate, Sensor 1 Corona, Separation Asm 1 Sensor, Density 1 Spring, PP 11A2364 Screw, PP 11A2340 Screw, - Lexmark Optra C | Service Manual - Page 300
Assembly 31: Transfer Drum Cleaning 7-66 - Lexmark Optra C | Service Manual - Page 301
AsmIndex Part Number Units Description 31-1 -2 -3 -4 11A2257 11A2259 11A2258 11A2732 1 Transfer Drum Clean Asm 1 • Motor 1 • Brush 1 • Blade Parts Catalog 7-67 - Lexmark Optra C | Service Manual - Page 302
Assembly 32: Fuser 7-68 - Lexmark Optra C | Service Manual - Page 303
11A2271 11A2261 11A2266 11A2733 11A2117 11A2117 11A2455 11A2456 1 Fuser 110 V Asm 1 • Oil Tray Asm 1 • Fuser Oil Apply Asm 1 • Fuser Cleaner Asm 1 • Fuser Asm 220 V 1 • Thermistor 1 • Cover Asm 1 • Sensor, Exit 1 • Sensor, Oil Full 1 Oil Syringe (Tool) 1 Oil Bottle (Tool) Parts Catalog 7-69 - Lexmark Optra C | Service Manual - Page 304
Assembly 32: Fuser Asm (Cont.) 7-70 - Lexmark Optra C | Service Manual - Page 305
-13 -14 11A2260 11A2268 11A2265 11A2273 11A2274 11A2261 11A2269 11A2262 11A2263 11A2264 1 Fuser Asm 110 V 2 • Lamp 110 V 1 • Oil Applying Input Asm 1 • Fuser Delivery Asm 1 • Oil Bottle Case Asm 1 Fuser 220 V Asm 2 • Lamp 220 V 1 • Roller, Upper 1 • Roller, Lower 1 • Thermo Switch Parts Catalog - Lexmark Optra C | Service Manual - Page 306
Assembly 33: Video Controller Board 7-72 - Lexmark Optra C | Service Manual - Page 307
AsmIndex Part Number Units Description 33-1 -NS -NS -NS -NS -NS -NS -NS -NS -NS -NS 69G3802 69G3790 1342514 1342536 1342543 1342530 1342537 1342533 1342532 1342534 1342535 1 Video Controller Board 1 ROM SIMM 1 Line Cord (US) 1 Line Cord (APG-ARG) 1 Line Cord (UK) 1 Line Cord (Europe) 1 Line - Lexmark Optra C | Service Manual - Page 308
Assembly 34: Optional Paper Feeder (Main Body) 7-74 - Lexmark Optra C | Service Manual - Page 309
AsmIndex Part Number Units Description 34-1 -1A -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 -16 -17 -18 11A2277 11A2286 11A2278 11A2279 11A2280 11A2281 11A2282 11A2283 11A2284 11A2285 11A2287 2 Lock Lever Link 2 Link 1 Left Cover 1 Right Cover 1 Front Cover 1 Rear Cover 1 Cover, Open/Close - Lexmark Optra C | Service Manual - Page 310
Assembly 35: Optional Paper Feeder (Front) 7-76 - Lexmark Optra C | Service Manual - Page 311
1 Spring Collar 1 Plate 1 Crossmember 1 Motor Mount 1 Paper Feed Roller 1 Front Drive Roller Shaft 1 Pickup Roller Shaft 1 Release Roller 2 Upper Paper Guide 1 Sensor Arm 1 Sensor Mount 1 Right Pickup Frame 1 Left Pickup Frame 1 Front Roller Asm 1 Photo Sensor PCB 1 Photo Sensor Cable 1 Motor - Lexmark Optra C | Service Manual - Page 312
Assembly 35: Optional Paper Feeder (Front)(Cont.) 7-78 - Lexmark Optra C | Service Manual - Page 313
Number Units Description 35-23 -24 -25 -26 -27 -28 -29 -30 -31 -32 -33 -34 -35 -36 -37 -38 -39 -41 -42 -43 -44 -45 -46 11A2117 1 Gear, PP 11A2402 1 Gear, PP 11A2402 1 Gear, PP 11A2402 1 Gear, PP 11A2402 1 Gear, PP 11A2402 1 Gear, PP 11A2402 1 Gear, PP 11A2402 1 Gear, PP - Lexmark Optra C | Service Manual - Page 314
Assembly 36: Paper Pickup Asm (Base) 7-80 - Lexmark Optra C | Service Manual - Page 315
AsmIndex Part Number Units Description 36-1 -2 -3 -4 -5 -6 11A2308 11A2309 11A2310 11A2311 11A2312 11A2414 1 Paper Pickup Asm Base 1 • Cassette Size Sensor Asm 1 • Cable 1 • Power Supply Cable 1 • Power Supply PCB 1 • Paper Feed PCB Parts Catalog 7-81 - Lexmark Optra C | Service Manual - Page 316
Assembly 37: Paper Pickup Asm (Rear) 7-82 - Lexmark Optra C | Service Manual - Page 317
AsmIndex Part Number Units Description 37-1 -2 -3 -4 -5 -6 -7 -8 -13 11A2313 11A2314 11A2315 11A2316 11A2317 11A2318 1 Paper Pickup Asm Rear 1 • Lock Lever, Right 1 • Lock Lever, Left 1 • Rear Roller Asm 2 • Roller 2 • Roller Holder 2 • Spring, PP 11A2364 2 • Latch Spring, PP 11A2364 • Screw, - Lexmark Optra C | Service Manual - Page 318
Assembly 38: Options AsmIndex Part Number Units Description 1364921 1364877 1364876 1364875 1364874 1364923 1364922 1364879 1364873 1381856 1402217 1402218 1446702 Memory SIMM 2MB Memory SIMM 4MB Memory SIMM 8MB * Memory SIMM 16MB Memory SIMM 32MB Flash Memory 1MB Flash Memory 2MB Flash Memory - Lexmark Optra C | Service Manual - Page 319
5045-001 Parts Catalog 7-85 - Lexmark Optra C | Service Manual - Page 320
Block Wiring Diagram Attachment to Optra C 5045-001 Service Manual (9/95) - Lexmark Optra C | Service Manual - Page 321
2-15 113 Fuser Temp High 2-16 114 Fuser Failure 2-16 115 Fuser Heater Off 2-17 116 Fuser Unit Missing 2-17 117 Fuser Pump Failure 2-18 121 Laser Board Failure 2-20 122 Laser Failure 2-20 123 Mirror Motor Rotation 2-21 125 Laser Board Failure 2-20 126 Transfer Drum Motor 2-22 130 Service Motor Error - Lexmark Optra C | Service Manual - Page 322
Test 3-6 Front Pickup Unit 4-65 Fuser Assembly 4-29 Fuser Cleaner Asm 4-33 Fuser Delivery Asm 4-39 Fuser Heaters 5-9 Fuser Hot Rollers 4-31 Fuser Lamps 4-37 Fuser Oil Apply Asm 4-34 Fuser Oil Applying Input Asm 4-39 Fuser Oil Bottle Case Asm 4-30 Fuser Thermo Switch 4-32 Fuser/Delivery Unit 2-41 - Lexmark Optra C | Service Manual - Page 323
54 Printer Drive 7-32 Rotary Manual Feed 7-30 Solenoid Plate 7-26 Toner Laser Failures 2-56 Low Color 2-56 Random Oil Spots 2-58 Service Checks 2-61 Solid Color Test 2-53 Solid White Test 2-53 Spew 2-58 Start of Call 2-50 Troubleshooting 2-54 Vertical Streaks 2-59 Print Quality Tests Cartridge - Lexmark Optra C | Service Manual - Page 324
Lift Asm 4-28 Fuser Cleaner Asm 4-33 Delivery Asm 4-39 Fuser Asm 4-29 Hot Rollers 4-31 Lamps 4-37 Oil Apply Asm 4-34 Oil Bottle Case Asm 4-30 Oil Input 4-39 Printer Drive Asm 4-48 Printhead and Board 4-45 Rear Cooling Duct 4-50 Rear Cooling Fan 4-49 Rotary Manual Feed Asm 4-49 Toner Cartridge - Lexmark Optra C | Service Manual - Page 325
001 S Safety Inspection Guide 6-1 Screws 4-2 Sensors 5-4 Service Checks Cartridge Installation 2-14 Communication Failure 15 Unit Missing 2-17 Warm-Up 2-15 Fuser Fan Motor 2-24 Humidity Sensor 2-26 HV Power Supply Output 2-33 Laser Board Failure 2-20 Laser Failure 2-20 Main Motor Rotation 2-23 Start- - Lexmark Optra C | Service Manual - Page 326
Print Test 3 3-9 Quick Disk Test 3-10 Wrap Tests 3-11 Toner Cartridge Ejector 4-62 Toner Scattered 2-71 Tools 1-5 Transfer Drum Assembly 4-59 Cleaning Drive 4- Claw 4-52 Transfer Drum Sheet 4-54 Transfer Drum Unit 2-40 Troubleshooting Paper Feed 2-38 Print Quality 2-54 U Upper Cooling Fan 4-63
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 |
 |
5045-001
Lexmark
Optra™ C
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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