Lexmark Optra Color 40 Service Manual
Lexmark Optra Color 40 Service Manual

Lexmark Optra Color 40 Service Manual

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Lexmark Optra™ Color 40
4092-010
• 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.

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Summary of Contents for Lexmark Optra Color 40

  • Page 1 Lexmark Optra™ Color 40 4092-010 • 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.
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  • Page 4 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners.
  • Page 5: Table Of Contents

    4092-010 Table of Contents General Information ........1-1 Operator Panel .
  • Page 6 4092-010 Deactivate/Activate Demo Mode ......3-5 Repair Information ........4-1 Handling ESD-Sensitive Parts .
  • Page 7 4092-010 Engine Board Connectors ....... . 5-1 Controller Board Connectors ......5-2 Encoder Card Connector .
  • Page 8 4092-010 viii Service Manual...
  • Page 9: Safety Information

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 10 Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.
  • Page 11 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. •...
  • Page 12 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 producte està...
  • Page 13 4092-010 xiii Safety Information...
  • Page 14 4092-010 4092 Service Manual...
  • Page 15: General Information

    4092-010 1. General Information The Lexmark Optra™ Color 40 (Machine Type 4092-010) printer is a high quality color inkjet printer designed to be attached to a computer network. The print cartridges contain single-unit customer- replaceable supply items. Dual printheads provide color and true black printing without changing printheads.
  • Page 16: Lights

    4092-010 Lights Left = Right = Conditions Power Busy Power is on Blinking Printer is busy Blinks *S Blinks *S Error condition or printer in demo mode “Deactivate/Activate Demo Mode” on page 3-5 Blinks Blinks Memory full condition Twice *S Twice *S Blinks *S Blinks *S...
  • Page 17: Voltage, Ground, And Continuity Readings

    4092-010 Voltage, Ground, and Continuity Readings Voltage Readings All dc voltages must be within +5% through -10% of the values to be considered correct. Unless stated otherwise, all connectors should be connected normally when a voltage measurement is done. When a “Line Voltage” measurement is done, the voltage on United States and Canada machines should be between 100 V ac and 127 V ac.
  • Page 18: Maintenance Approach

    4092-010 Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error indicator table, symptom table, service checks, and diagnostic aids to determine the symptom and repair the failure. Begin with “Start”...
  • Page 19: Diagnostic Information

    4092-010 2. Diagnostic Information Use the error indicator table, symptom tables, service checks, and diagnostic aids to determine the failing part. Start Service error indications show as a series of blinks of the Power light. There is a pause between each series of blinks. If your printer has an error indication, locate the series of blinks in the “Error Indicator Table”...
  • Page 20: Error Indicator Table

    4092-010 Error Indicator Table Error Number of Service Code in Busy Power Light Action Error Engine Light Blinks NVRAM Nothing Continuously Replace the Controller Board. 65, 66, 79 Continuously Replace the Engine or 127 Code Module or the thru 223 Engine Board.
  • Page 21 4092-010 Error Number of Service Code in Busy Power Light Action Error Engine Light Blinks NVRAM Nothing Code ROM failed the CRC Check. Replace the Controller Board. Nothing Font ROM checksum failure. Replace the Controller Board. Nothing Controller code and Font ROM are incompatible.
  • Page 22: Power-On Self Test (Post) Sequence

    4092-010 Power-On Self Test (POST) Sequence When you plug the printer into a power source, it performs a POST. The POST operation goes through the following steps: 1. DRAM and ROM memories are checked. 2. The lines between the Controller Board and the Engine Board are checked.
  • Page 23: Symptom Tables

    4092-010 Symptom Tables Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems Symptom Action “Transport Service • No carrier movement Go to the Check” on page 2-17 • Slow carrier movement • Carrier stops •...
  • Page 24 4092-010 Paper Feed Problems Symptom Action “First Print Line Paper fails to stop at first print line Go to the Service Check” on page 2-7 “Paper Feed Service • Fails to pick paper Go to the Check” on page 2-9 •...
  • Page 25: Service Checks

    4092-010 Service Checks Controller Board Service Note Earlier level printers may have a ROM Code SIMM plugged into the Controller Board. Later level printers will have the Code soldered on the Controller Board in position U11. The Controller Board FRU will contain the later level board with the soldered on code.
  • Page 26: Maintenance Station Service Check

    4092-010 Maintenance Station Service Check The maintenance station has two functions: 1. Cleans the printhead nozzles during the print operation. 2. Seals the printhead when it is not being used to prevent the nozzles from drying. Action Maintenance As the carrier moves to the right over the Station Assembly maintenance station, a slot on the bottom of the carrier engages a tab on the sled of the...
  • Page 27: Options Service Check

    4092-010 Options Service Check DRAM Memory Option SIMM There is DRAM resident on the Controller Board and DRAM on the Memory Option SIMM. Check to see that the Memory Option SIMM is correctly installed and not borken or damaged. Run the “DRAM Test”...
  • Page 28 4092-010 Action Paper Feed Motor A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or short in the motor • An open or short in the motor driver on the engine board •...
  • Page 29: Paper Path Service Check

    4092-010 Paper Path Service Check Examine the printer for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the paper guides are not worn or broken and are positioned against the paper without binding or buckling the paper.
  • Page 30: Parallel Port Service Check

    4092-010 Parallel Port Service Check Action Parallel Port Run a test page to be sure the printer can print. “Parallel Port Wrap Test” on Run the page 3-4 . If the test fails, replace the Controller board. Power Service Check Action Power Cord Check the line voltage.
  • Page 31 4092-010 Action Transport Motor An open or short in the transport motor shows up as a dead machine. Disconnect the transport Paper Feed Motor motor and check for pins shorted to the case. Also check for 8 to 18 ohms between pins 1 and 2 on the motor cable.
  • Page 32: Print Quality Service Check

    4092-010 Print Quality Service Check Action Print Cartridge Be sure the printer contains good print cartridges. Printhead Carrier Reseat the printhead cables in the engine board Assembly and check the following parts for wear or damage: • Print Cartridge Latch •...
  • Page 33 4092-010 Action “Print Test Page” on page 3-2 Engine Board • Perform the Look for a break in the diagonal line of the test Printhead Cable pattern. A broken line indicates one or more print nozzles are not working. Run the test again Rubber Backer to verify the failure.
  • Page 34 4092-010 Action Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: • Correct type of paper is being used. • Paper for curl or wrinkles. • Feed rollers for wear, dirt, or looseness. •...
  • Page 35: Transport Service Check

    4092-010 Transport Service Check Action Transport Motor Check the motor for binds, or loose motor pulley. Disconnect the transport motor (J4) from the engine board. Check for 8 to 18 ohms between pins 1 and 2 on the motor cable. If the reading is incorrect, replace the motor.
  • Page 36 4092-010 2-18 Service Manual...
  • Page 37: Diagnostic Aids

    4092-010 3. Diagnostic Aids Use these diagnostic test procedures to diagnose a problem and verify a repair. Tests are entered by first unplugging the power cord from the printer. While pressing and holding one or both buttons, place a two pin jumper on connector J6 or activate the EOF sensor, then plug the power cord into the printer.
  • Page 38: Print Test Page

    4092-010 Print Test Page This test prints in the following order: • Engine Board code level and date • Thermal sensor current temperature in degree Celsius (may have to print more than one test page to print the temperature) • Manufacturer name and model •...
  • Page 39: Eof Sensor Test

    4092-010 EOF Sensor Test This test is used to check the EOF sensor on the engine board. The Power Light blinks rapidly when the test is entered. Move the EOF flag in and out of the EOF sensor using a sheet of paper placed in the manual feed.
  • Page 40: Parallel Port Wrap Test

    4092-010 Parallel Port Wrap Test This test performs a wrap around test between the printer parallel port and the parallel port test connector. Install the parallel port wrap plug in the parallel port of the controller board. Refer to the beginning of this chapter to enter the test.
  • Page 41: Dram Test

    4092-010 DRAM Test The DRAM Test is used to check the validity of DRAM on the Controller Board and the option DRAM SIMM. The test involves writing patterns of data to DRAM to verify that each bit in memory can be set and read correctly. This test takes longer to run for larger DRAM SIMM.
  • Page 42 4092-010 Service Manual...
  • Page 43: Repair Information

    4092-010 4. Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. Note: Read the following before handling electronic parts. When working on the printer, always unplug the printer from the electrical outlet.
  • Page 44: Adjustments

    4092-010 • If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case). • Be extra careful in working with ESD-sensitive parts when cold weather heating is used because low humidity increases static electricity. Adjustments The user is directed, in the Printer Control program, to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge.
  • Page 45: Base Assembly Removal

    4092-010 Base Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Disconnect the power supply connector at the engine board. 4. Remove the two screws from the maintenance station assembly. Pull up the right side of the mid frame assembly and pull forward and remove the maintenance station assembly.
  • Page 46: Carrier Frame Assembly Removal

    4092-010 Carrier Frame Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the base assembly. 4. Disconnect the paper feed motor and power supply connectors from the engine board. 5. Remove the four screws [A] securing the carrier frame to the left and right side frames and remove the carrier frame assembly.
  • Page 47: Carrier Transport Motor Removal

    4092-010 Note: During reassembly: 1. Be sure the small feed roll spring extensions [B] are in the grooves of the small feed roll arms. 2. Be sure the short extensions of the two paper flap springs are trapped under the carrier frame [C]. 3.
  • Page 48: Controller Board Removal

    4092-010 Controller Board Removal 1. Remove the controller board cover. 2. Disconnect the cables to the board. 3. Remove the four board mounting screws and remove the board. Note: Be sure to move any SIMMs from the old controller board to the new board.
  • Page 49: Encoder Strip Removal

    4092-010 Encoder Strip Removal 1. Remove the front cover. 2. Remove the printhead carrier assembly. 3. Gently release the tension on the encoder strip by flexing the encoder strip tensioner and remove the encoder strip. Note: When reinstalling the encoder strip, make sure the ends of the strip are centered in their mounting notches and the strip does not bind in the encoder card on the carrier.
  • Page 50: Exit Drive Belt Removal

    4092-010 Exit Drive Belt Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the carrier frame assembly. 4. Remove the paper load door and manual insert tray. 5. Remove the small feed roll shaft. 6. Remove the two screws from the star roller assembly and remove the assembly.
  • Page 51: Front Cover Removal

    4092-010 Front Cover Removal 1. Place a screwdriver in slot [A] and release the cover latches. 2. Slide the cover forward and off the printer. To reassemble: 1. Slide the cover over the matching pieces on the bottom cover. 2. Press in both sides opposite the cover latches until they latch. Gutter Pad Removal 1.
  • Page 52: Inside Idler Gears Removal

    4092-010 Inside Idler Gears Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the printer from the base assembly. 4. Remove the paper feed motor. 5. Gently pry the two idler gears [A] from the left side frame. 4-10 Service Manual...
  • Page 53: Large Feed Roll Removal

    4092-010 Large Feed Roll Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the carrier frame assembly. 4. Using a small screwdriver, pry open the slot in the retainer clip and remove it and the compound idler gear from the compound idler stud.
  • Page 54: Large Outside Gear Removal

    4092-010 Large Outside Gear Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the paper load door and manual insert tray. 4. Remove the C-clip from the feed arm assembly and remove the feed arm assembly. 5.
  • Page 55: Left Side Frame Assembly Removal

    4092-010 Left Side Frame Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the carrier frame assembly. 4. Remove the paper load door and manual insert tray. 5. Using a small screwdriver, pry open the slot in the retainer clip [A] and remove it and the compound idler gear from the compound idler stud.
  • Page 56: Maintenance Station Assembly Removal

    4092-010 Maintenance Station Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the two screws from the maintenance station assembly, lift up the right side of the mid frame assembly and slide the maintenance station assembly forward, out of the printer.
  • Page 57: Paper Feed Motor Removal

    4092-010 Paper Feed Motor Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the base assembly. 4. Remove the two screws securing the paper feed motor and remove the motor. Note the routing of the motor cable. Paper Guide and EOF Flag Assembly Removal 1.
  • Page 58 4092-010 Note: During reassembly: 1. Be sure the small feed roll spring extensions [B] are in the grooves of the small feed roll arms. 2. Be sure the short extensions of the two paper flap springs are trapped under the carrier frame [C]. 3.
  • Page 59: Paper Load Door Removal

    4092-010 Paper Load Door Removal Spread the left side frame where it joins the paper load door and remove the door. Pick Roll Shaft, Hub and Envelope Bucklers Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the paper load door and manual insert tray. 4.
  • Page 60: Printhead Cable, Cradle & Paper Deflector Removal

    4092-010 Printhead Cable, Cradle & Paper Deflector Removal 1. Remove the front cover. 2. Remove the printhead carrier assembly. 3. Disconnect the printhead cable from the encoder card. Note the routing of the cable under the retaining clip on the carrier. 4.
  • Page 61 4092-010 Note: Be sure the cable is secured under the three retaining clips [B] on the back of the carrier. 4-19 Repair Information...
  • Page 62: Printhead Carrier Assembly Removal

    4092-010 Printhead Carrier Assembly Removal 1. Remove the front cover. 2. Unlock the three printhead cable connectors and disconnect the printhead cable from the engine board. 3. Remove the screws from the ends of the carrier guide rod and move the carrier to the left. 4.
  • Page 63: Rear Cover Removal

    4092-010 Rear Cover Removal 1. Remove the front cover. 2. Remove the controller board cover. 3. Disconnect the cables from the controller board and remove the board. 4. Place a screwdriver in slot [A] and release the cover latches. 5. Slide the cover up and off the printer. 6.
  • Page 64: Small Feed Roll Shaft, Rollers & Paper Flap Removal

    4092-010 5. Remove the two screws securing the right side frame to the back plate. Slide the right side frame off the back plate. Note the relationship of the parts. Small Feed Roll Shaft, Rollers & Paper Flap Removal 1. Remove the front cover. 2.
  • Page 65: Connector Locations

    4092-010 5. Connector Locations Engine Board Connectors Printhead Cable Printhead Cable Printhead Cable Transport Motor Paper Feed Motor Test Jumper Thermal Sensor Power Supply Controller to Engine Card Interface Continue Switch Reset Switch EOF Sensor Code Module Busy Light Power Light Connector Locations...
  • Page 66: Controller Board Connectors

    4092-010 Controller Board Connectors DRAM SIMM Parallel Port Code/Flash SIMM Power Supply Controller to Engine Card Interface Service Manual...
  • Page 67: Encoder Card Connector

    4092-010 Encoder Card Connector Connector Locations...
  • Page 68 4092-010 Service Manual...
  • Page 69: Preventive Maintenance

    4092-010 6. Preventive Maintenance This chapter contains the lubrication specifications. Follow these recommendations to prevent problems and maintain optimum performance. Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use with Nyogel 744 (P/N 99A0394) grease or equivalent •...
  • Page 70 4092-010 Service Manual...
  • Page 71: Parts Catalog

    4092-010 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown 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 by description.
  • Page 72: Assembly 1: Covers

    4092-010 Assembly 1: Covers Service Manual...
  • Page 73 4092-010 Asm- Part Units Description Index Number 1 -1 13B0203 Lens (LED) and Buttons 17B0154 Front Access Door with Latch 12G0001 Front Cover Asm, Access Cover with Door Latch, Buttons & LED Lens 12G0003 Board Cover with EMC Shield 12G0002 Rear Cover 17B0158 Gutter Pad...
  • Page 74: Assembly 2: Frames

    4092-010 Assembly 2: Frames Service Manual...
  • Page 75 4092-010 Asm- Part Units Description Index Number 2 -1 13B0411 Left Side Frame 13B0272 Mid Frame 13A1236 Right Side Frame 13B0204 Carrier Frame Parts Catalog...
  • Page 76: Assembly 3: Paper Feed

    4092-010 Assembly 3: Paper Feed Service Manual...
  • Page 77 4092-010 Asm- Part Units Description Index Number 3 -1 13B0205 Paper Guide Asm includes EOF Flag & Spring 13A1280 Small Feed Roll Shaft Roll B/M and Paper Flap 13B0212 Star Roller Asm 13B0275 Large Feed Roll Asm (includes Small Compound Idler Gear) 12G0020 Paper Feed Motor, Motor Gear, Toroid and Heat Sink...
  • Page 78: Assembly 4: Electronics

    4092-010 Assembly 4: Electronics Service Manual...
  • Page 79: Controller Board Service Note

    4092-010 Asm- Part Units Description Index Number 4 -1 12G0006 Power Supply (Universal) with Cover 13B0045 Thermal Sensor Board with Cable 12G0005 Engine Board - Use on machines with a torroid on the flex cable (Index 9). 12G0140 Engine Board 12G0010 Code Module (Engine Board) 12G0003...
  • Page 80: Assembly 4: Electronics (Continued)

    4092-010 Assembly 4: Electronics (continued) 7-10 Service Manual...
  • Page 81 4092-010 Asm- Part Units Description Index Number 1339526 Power Cord, U.S. 1342514 Power Cord, Argentina 1339520 Power Cord, Austria 1339520 Power Cord, Belgium 1342514 Power Cord, Bolivia 1342514 Power Cord, Brazil (LV) 1342534 Power Cord, Brazil (HV) 1339526 Power Cord, Canada 1342534 Power Cord, Chile 1342514...
  • Page 82: Assembly 5: Carrier

    4092-010 Assembly 5: Carrier 7-12 Service Manual...
  • Page 83 4092-010 Asm- Part Units Description Index Number 5 -1 13B0237 Printhead Carrier B/M 13B0222 Printhead Cable (Folded) 13B0238 Rubber Backer 13B0217 Carrier Guide Rod 69G4156 Encoder Card Asm 13B0239 Screw, Encoder Card Mounting (PP) 13B0221 Printhead Cartridge Interlock Key B/M 13B0239 Screw, Carrier Guide Rod (PP) 17B0168...
  • Page 84: Assembly 6: Carrier Transport

    4092-010 Assembly 6: Carrier Transport 7-14 Service Manual...
  • Page 85 4092-010 Asm- Part Units Description Index Number 6 -1 13B0219 Carrier Transport Motor & Pulley 13B0215 Carrier Belt 69G4403 Encoder Strip 17B0157 Idler Pulley Tension Asm 13B0239 Screw, Carrier Transport Motor Mounting (PP) 13B0239 Tensioner, Encoder Strip (PP) 7-15 Parts Catalog...
  • Page 86: Assembly 7: Sheet Feeder

    4092-010 Assembly 7: Sheet Feeder 7-16 Service Manual...
  • Page 87 4092-010 Asm- Part Units Description Index Number 7 -1 13A1227 Right Edge Guide & Width Adjust Strip 13A1228 Left Edge Guide 69G4131 Upper Paper Support 13A1229 Pick Roll & Paper Load Shaft B/M 12G0012 Pick Roll Hub Asm 1367019 Envelope Buckler B/M, Left & Right 12G0009 Back Plate 13A1226...
  • Page 88: Assembly 8: Maintenance Station

    4092-010 Assembly 8: Maintenance Station 7-18 Service Manual...
  • Page 89 4092-010 Asm- Part Units Description Index number 8 -1 13B0160 Maintenance Station Asm 70G0590 Wiper and Cap B/M (one of each) 13B0239 Screw, Maintenance Station Mounting (PP) 7-19 Parts Catalog...
  • Page 90 4092-010 7-20 Service Manual...
  • Page 91 4092-010 Index Sequence Symptom Table Abbreviations Power Consumption Adjustments Problems Assemblies Carrier Transport 1 Covers Communications 2 Frames Maintenance Station 3 Paper Feed Operator Panel 4 Electronics Paper Feed 5 Carrier 7-12 Power 6 Carrier Transport 7-14 Print Quality 7 Sheet Feeder 7-16 8 Maintenance Station 7-18...
  • Page 92 4092-010 Paper Flap 4-22 Paper Guide 4-15 Voltage Readings Paper Load Door 4-17 Paper Load Shaft Pick Roll Hub 4-17 Pick Roll Shaft 4-17 Power Supply 4-17 Printhead Cable 4-18 Printhead Carrier 4-20 Printhead Cradle 4-18 Printhead Rubber Backer 4-20 Rear Cover 4-21 Right Side Frame...
  • Page 93 May, 1998 Form You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.
  • Page 95 BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 2659 LEXINGTON, KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 | | | | | |...

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