Lexmark Optra S Service Manual
Contents
1. For the complete PDF manual SS CN please visit www LaserPros com Optra S Service Manual 4059 XXX e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index LEXMARK First Edition November 2004 The following paragraph does not apply to 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 IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase A form for reader s comments is provided at the back of this publication If the form has been removed comments may be addressed to Lexmark International Inc D22A 035 3 740 New Circle Road NW Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you supply in any way it believes appropriate without i2. Count lllssllseelssses 3 19 Viewing the Permanent Page Count 3 19 Maintenance Page Count 2420 2450 2455 3455 3 20 Setting Configuration ID uu iem mmm mm 3 20 Restore EP Factory Defaults 3 21 iV 4059 Service Manual EHE TBI AA AA clot oaa de atk os 3 22 Print Quality Test Pages siis suse rmm mpm 3 23 Printing Menu Settings Page 3 24 Autocompensator Operation a 3 25 Autoconnect System Paper Tray Options Envelope Feeder and Output Expander Operations 222055 3 26 Fuser Opefalloli 25d case exe E RR cere dees E ERES 3 27 Paper T esd Jam 2ad62 queas desqdendderobqgdc sad d 3 29 Repair Information lees 4 1 Handling ESD Sensitive Parts 4 4 1 Adjustment Procedures cece eee eee 4 2 Duplex Motor Drive Belts 20 0 000 4 2 Fuser Solenoid Adjustment lusus 4 3 Gap Adjustment narod pA edes teta yc ora eun d 4 3 Printhead Assembly Adjustment 4 4 Paper Alignment Assembly Adjustment 4 5 Screw Identification Table 0 eee eee 4 7 Removal Procedules sua ludex dud ee xS ede 4 12 COVEIS sess rehus Rescue iow arae NG Wege d 4 12 Center Pan Assembly iius d decani Ede Rd acd 4 18 Controller Board iios cac ie ru o Rh RA D ned 4 19 Developer Drive Assembly an 4 20 Duplex Board 70 0a aaa waaa e ma RR 4 21 Dupl
3. EG evens 4 48 Operator Panel Cable Cover Open Switch Assembly 4 49 Optional 250 500 Paper Tray Assembly 4 50 Guter EMG Shield 2 554 5d eode pepe dd 4 51 Paper Alignment Assembly 0 000 4 52 Paper npa SENSO 1 2100 pede oda cna erasa pant 4 53 Paper Size Sensing Board 0 00 4 54 ad AA AA 4 54 Lt AA AA hens 4 55 Rodio Assembly cesso seddesssaereg ea pe dan 4 56 F ght Side FIalTigi 2 paha KPAG KB HERR Y d Y 4 57 Smart Cartridge Contacts 4a 4 58 Toner DENLON 7a nA ABAKA PGKA NENA RE E E Bee 4 59 Transfer Roll Assembly 24 0004 csse nmn 4 60 Upper Paper Deflector Assembly 4 60 Upper Front Cover Hinge Assembly 4 61 Upper Front Cover Interlock Switch Assembly 4 62 Connector Locations ccc kd KKK ANG sed urinii SERES 5 1 Low Voltage Power Supply aa 5 1 High Voltage Power Supply a 5 3 Engine Boards ous a bie ee RD mbes Ra HG 5 4 aa C ET 5 11 Interconnect DGaIO aa ses ru homme sani 5 14 Envelope Option Board nu ma paan eres 5 17 Duplex Option Board sees seems 5 19 Autoconnect TOI 2 besos dare te perdo NAKA ba d d d RE 5 21 Output Expander Control Board Level 1 Stepper Motor 5 22 Output Expander Control Board Level 2 DC Motor 5 24 Preventive Maintenance a 6 1 Safety Inspection Guide 0 20 cee eee eee 6 1 Lubrication Specifications ss ssa m am DAGAN GA 6 1 Scheduled Mai
4. Miscellaneous lesse 7 90 Me T M Pe I 1 For the complete PDF manual please visit www LaserPros com Contents Vii
5. SIE DISK TES uidrasrniciue md ad sad std eed ahead ee 3 2 Disk TestUCIGHfi ose m exe Row 3 2 aenn aeos nEbewdE pun eb cid segunda 3 3 Disabling Download Emulations 3 3 DUDISX Nes Si ga kan KANA RANA NAKADAGAN ABALA Exp d 3 4 Duplex Quick T l is papaka hha me mms 3 4 Duplex Sensor Test iua GG KAL Re ker kiret 3 5 Duplex Motor Test 000 eee eee eens 3 5 Duplex Feed 1 168t cctadccineraaduidaanesadasone 3 7 Duplex F ed 2 Test za maa died GR eoo maid 3 7 Eira Ea o EUN PEN AA wee 3 8 Viewing the Error Log coss trm riests 3 8 Clearing the Error Log ias namana ke d UG RANA eb KG 3 8 Hardware T6919 pa rm eR KGAD ata 3 9 I E KE Sod i det uid edad eed eT EAS Uds 3 9 BUNTON Tol maa KAG a Ged hm ers kr EUR ER gd 3 9 DRAM Memory TSE sudes doped udo nre Ebr 3 10 HOM Memory Test aes sam mR Rar Karna 3 10 Parallel Wrap Test dados disks c ees dur p dde 3 11 Serial Wrap Test iios e Rr RR REPRE 3 12 IAD Way WSIS e x uela dea dide d m E drag eu RR 3 14 Input Tray Feed Test suis sees m Rem 3 14 Input Tray Sensor Test eee eee 3 14 Output Bin Test Standard Bin 3 15 Output Bin Feed Test iioau ceri edo d dg hd di 3 15 Output Bi Sensor TSt cassa mmm emm 3 16 Output Bin X Sensor Test Cass ama dre a 3 16 Base Sensor Test ws ccs ecceae ecadiedad ad Re Rh 3 17 Put Regita i usa dex duae e Eu NADA NAA AGA 3 18 Panter Setup na maagaw anm e a eR ne PR beaks 3 19 Setting the Page
6. ex Front Cover Assembly 55 4 21 Duplex Front Cover Door aaa 4 21 Duplex Front Cover Door Switch 4 21 Duplex MOTOT aaa sedes he Ree ek Shaun d 4 22 EQUINE DOBTO cud Car educta wae tee a Rua 4 23 EP Frame Assembly naa a ricota emm mmn 4 23 Pale cc ane ie ceed PAGA PE HIGA EP asked 4 24 2I NEEDS 4 26 POSEIDON satus aa ded Eng baie pence ieee 4 27 Fuser COVED osse cm soraira KA msn x don 4 28 Fuser Detack Fingers lllsllllslessss 4 29 Fuser Detack Housing Assembly 4 29 Fuser Transfer PIStg a nk aba sda AE ism dace oud 4 30 Fuser Envelope Conditioner Solenoid 4 31 Fuser Exit Flag Assembly 2 0005 4 31 Fuser Exit Roll Assembly 4 32 Bia PAP AA 4 33 Fuser Lower Exit Guide Assembly 4 33 High Voltage Power Supply 20 085 4 34 Contents V Iter EMC Seld atis oe bep doge deba de 4 35 Inner Paper Deflector Assembly 4 36 Integrated Tray Compensator Assembly 4 37 Integrated Tray Compensator Pick Roll Assembly 4 38 Interconnect Board Assembly 0a 4 39 Left Side Frame AA 9g dada 4 41 Low Voltage Power Supply lsulesluusss 4 43 Main Drive Assembly uuu Coad aaa aa Dap abg ak 4 44 Main Drive MOtor suche cen GEN Rr KG AGANG BG 4 45 Multipurpose Tray Lower Deflector Assembly 4 46 Operator Panel x44 sche DERE Lovee RR R
7. ll Service Check 220005 2 29 Cover Open Switch Cable Service Check 2 31 Dead Machine Service Check 2 55 2 32 Duplex Option Service Check 2 35 Envelope Feeder Option Service Check 2 39 Erase Lamp Service Check 0 aaa 2 46 Fan Service Check iiu gadi ABADILLA SL Badi 2 47 Fuser Service Check 0a 2 48 Fuser Envelope Conditioner Solenoid Service Check 2 51 Input Sensor Service Check 0 0a 2 57 Input Tray s Option Service Check 2 58 High Capacity Feeder Input Tray Service Check 2 61 Main Drive Service Check 20 0 cee eee 2 73 Operator Panel Service Check 2 74 Options Service Check ssri ana ha ERR Ro GAWAAN 2 76 Output Bin Sensor Standard Tray Service Check 2 78 Output Expander Service Check 2 79 Paper Feed Service Check 0 00 2 86 Parallel Port Service Check 0 0a 2 89 Printhead Service Check 0 0a 2 89 Print Quality Service Check 0 0a 2 91 Contents iii Smart Cartridge Service Check 2 102 Serial Port Service Check 0 0 2 104 Toner Sensor Service Check 2 104 Transfer Roll Service Check 2 105 Diagnostic AldS a susce emm ome doe HG KHAN 3 1 Diagnostic MOOB AA PK duh 3 1 Device Tests ccn cane due ga dera n aca Rau dd ds 3 2 QUI
8. ncurring any obligation to you Lexmark and Optra are trademarks of Lexmark International Inc registered in the United States and or other countries Copyright Lexmark International Inc 1998 2004 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 Contents Notices and Safety Information 1 ix Laser MOllG S od aded ws mem dope AD pao car Ra Ra eo 1 ix Safety Information iuo case rr eek dh he wee en 1 xvii ij o M 1 xxii General Information cece eee 1 1 a u cippo dart dbdd us dd aoa sad ears puentes 1 4 Maintenance Approach lees 1 5 Tools Required For Service 0 0c eee eee 1 5 MOMONYINS sue ex ed Y Pb ER wx RRO dx LES 1 6 Diagnostic Information 2 1 ci C PTT 2 1 Service EMO DOOR da scope hala bA Res tide ia 2 2 User Status Messages s eese 2 12 User Error ME3349ES socciexasdaddXadedcesid ded 2 16 Power On Self Test POST 2 24 Symptom TADES setae reise Dha DESIGNS 2 25 Service CHECKS irre naa ma hse me ER Ru 3rd 2 28 Charge Ro
9. ntenance 2420 2450 2455 3455 6 2 vi 4059 Service Manual Parts Catalog atre ens be Ea S PER neds PE 7 1 How To Use This Parts Catalog 04 7 1 Assembly 1 COVO ssri exor RE rri erae n C RES 7 2 PSSM 2 Eralngoessqumsdiessq quiedetssxd Fdw 7 6 Assembly 3 Printhead soccer RE ERR RR 7 10 Assembly 4 Paper Feed Autocompensator 7 12 Assembly 5 Paper Feed Multipurpose Unit 7 14 Assembly 6 Paper Feed Alignment 7 16 Assembly 7 Paper Feed Output 7 18 Assembly 8 Integrated Paper Tray 250 Sheet 7 20 Assembly 9 Main Drive an 7 22 Assembly 10 Developer Drive 7 24 Assembly 11 FUSO 225 rsaps re oo ees eee eer eee ees 7 26 Assembly 12 Transfer 0a paa sso err rms 7 32 Assembly 13 Charging 3222204243 Re be e niss 7 34 Assembly 14 Electronies paaa wc pe ad 7 36 Assembly 15 250 Sheet Tray 7 48 Assembly 16 500 Sheet Tray 7 52 Assembly 17 500 500 Dual Tray 7 56 AESEMON 18 DUPER s 43 d sm dese d ao pU doas 7 60 Assembly 19 Output Expander 7 66 Assembly 20 Envelope Feeder 7 70 Assembly 21 High Capacity Feeder 7 74 Assembly 22 Kiosk Vertical Paper Adapter 7 84 Assembly 23 Kiosk Horizontal Paper Adapter 7 86 Assembly 24 Options a 7 88 Assembly 25
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