Lexmark 4092-010 User manual

4092-010

Lexmark Optra™ Color 40

Lexmark and Lexmark with diamond

design are trademarks of Lexmark

International, Inc., registered in the

United States and/or other countries.

• Table of Contents

• Index

• Safety and Notices

• Trademarks

• Start Diagnostics

• Manuals Menu

ii

iii

../../graphics/output/Mancover.eps i

../../Graphics/Output/Sasmcar2.eps 7-12

../../Graphics/Output/Sasmcar3.eps 4-18, 4-20

../../Graphics/Output/Sasmcdtn.eps 7-14

../../Graphics/Output/Sasmcovr.eps 7-2

../../Graphics/Output/Sasmfrae.eps 7-4

../../Graphics/Output/Sautoshd.eps 7-16

../../Graphics/Output/Sbrkawyr.eps 4-11

../../Graphics/Output/Scarrfrm.eps 4-4

../../Graphics/Output/Scrfrmam.eps 4-15

../../Graphics/Output/Selecpts.eps 7-8, 7-10

../../Graphics/Output/Senccrdp.eps 5-3

../../Graphics/Output/Sfrtcovm.eps 4-9

../../Graphics/Output/Sidlgear.eps 4-10

../../Graphics/Output/Slftsdpt.eps 4-12

../../Graphics/Output/Smaintsn.eps 7-18

../../Graphics/Output/Spapfdam.eps 7-6

../../Graphics/Output/Spapfdfm.eps 4-13

../../Graphics/Output/Spqsc.eps 2-15

../../Graphics/Output/Sprhdcar.eps 4-19

../../Graphics/Output/Sprintam.eps 4-21

../../Graphics/Output/Srpl.eps 4-2

../../Graphics/Output/SSol03C.eps 5-2

../../Graphics/Output/SSol04A.eps 5-1

../../Graphics/Output/Sspring.eps 4-5, 4-16

First Edition (May, 1998)

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 impliedwarranties in certain transactions, therefore,this

statement may not apply to you.

This publicationcouldincludetechnicalinaccuracies or typographical errors. Changesare

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.

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., Department

D22/035-3, 740 New Circle Road N.W., Lexington, Kentucky 40550, U.S.A. Lexmark may

use or distribute any of the information you supply in any way it believes appropriate

without incurring any obligation to you. You can purchase additional copies of publications

related to this product by calling 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.

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.

4092-010

v

4092-010

Table of Contents

GeneralInformation....................................1-1

Operator Panel .........................................1-1

Buttons.............................................1-1

Lights ..............................................1-2

Power Consumption .....................................1-2

Voltage, Ground, and Continuity Readings ...................1-3

Maintenance Approach ..................................1-4

Abbreviations ........................................1-4

Unique Tools Required For Service.......................1-4

DiagnosticInformation .................................2-1

Start .................................................2-1

Error Indicator Table ..................................2-2

Power-On Self Test (POST) Sequence ....................2-4

POST Symptom Table.................................2-4

Symptom Tables .....................................2-5

Service Checks ........................................2-7

Controller Board Service Note ...........................2-7

Envelope Feed Service Check...........................2-7

First Print Line Service Check ...........................2-7

Maintenance Station Service Check ......................2-8

Options Service Check.................................2-9

DRAM Memory Option SIMM............................2-9

Paper Feed Service Check .............................2-9

Paper Path Service Check.............................2-11

Parallel Port Service Check ............................2-12

Power Service Check.................................2-12

Print Quality Service Check ............................2-14

Transport Service Check ..............................2-17

DiagnosticAids .......................................3-1

Print Test Page .........................................3-2

Print Engine NVRAM Contents ............................3-2

EOF Sensor Test .......................................3-3

Encoder Sensor Test ....................................3-3

Parallel Port Wrap Test ..................................3-4

Hex Trace .............................................3-4

Clear Error Log .........................................3-4

ROM Test .............................................3-4

DRAM Test ............................................3-5

vi Service Manual

4092-010

Deactivate/Activate Demo Mode ............................3-5

RepairInformation......................................4-1

Handling ESD-Sensitive Parts ..............................4-1

Adjustments ............................................4-2

Removal Procedures .....................................4-2

Releasing Plastic Latches...............................4-2

Base Assembly Removal ...............................4-3

Carrier Belt Removal...................................4-3

Carrier Frame Assembly Removal ........................4-4

Carrier Transport Motor Removal .........................4-5

Controller Board Removal...............................4-6

Engine Board Code Module Removal......................4-6

Edge Guide Asm and Paper Load Shaft Removal ............4-6

Encoder Card Removal.................................4-6

Encoder Strip Removal .................................4-7

Engine Board Removal .................................4-7

Exit Drive Belt Removal.................................4-8

Exit Roller Removal....................................4-8

Feed Arm Assembly Removal............................4-8

Front Cover Removal ..................................4-9

Gutter Pad Removal ...................................4-9

Inside Idler Gears Removal.............................4-10

Large Feed Roll Removal ..............................4-11

Large Outside Gear Removal ...........................4-12

Left Side Frame Assembly Removal......................4-13

Maintenance Station Assembly Removal ..................4-14

Maintenance Wipers and Caps Removal ..................4-14

Manual Insert Tray Removal............................4-14

Mid Frame Assembly Removal ..........................4-14

Paper Feed Motor Removal ............................4-15

Paper Guide and EOF Flag Assembly Removal.............4-15

Paper Load Door Removal .............................4-17

Pick Roll Shaft, Hub and Envelope Bucklers Removal ........4-17

Power Supply Removal................................4-17

Printhead Cable, Cradle & Paper Deflector Removal .........4-18

Printhead Carrier Assembly Removal .....................4-20

Printhead Rubber Backer Removal.......................4-20

Rear Cover Removal..................................4-21

Right Side Frame Assembly Removal.....................4-21

Small Feed Roll Shaft, Rollers & Paper Flap Removal ........4-22

Star Roller Removal ..................................4-22

ConnectorLocations....................................5-1

vii

4092-010

Engine Board Connectors ................................5-1

Controller Board Connectors ..............................5-2

Encoder Card Connector .................................5-3

Preventive Maintenance ................................6-1

Lubrication Specifications .................................6-1

PartsCatalog .........................................7-1

How To Use This Parts Catalog ............................7-1

Assembly 1: Covers .....................................7-2

Assembly 2: Frames .....................................7-4

Assembly 3: Paper Feed .................................7-6

Assembly 4: Electronics ..................................7-8

*Controller Board Service Note ..........................7-9

Assembly 4: Electronics (continued) .......................7-10

Assembly 5: Carrier ....................................7-12

Assembly 6: Carrier Transport ............................7-14

Assembly 7: Sheet Feeder ...............................7-16

Assembly 8: Maintenance Station .........................7-18

viii Service Manual

4092-010

Safety Information ix

4092-010

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.

• 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 be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.

Professional service personnel should understand this and take

necessary precautions.

Consignes de Sécurité

• Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécurité globale lors de l'utilisation de

composants Lexmark spécifiques. Les caractéristiques de

sécurité de certains éléments ne sont pas toujours évidentes.

Lexmark ne peut être tenu responsable de l'utilisation d'autres

pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance

qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié

devra prendre toutes les précautions nécessaires.

x 4092 Service Manual

4092-010

Norme di sicurezza

• Ilprodotto 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.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettriche e danni alla persona è più

elevato. Il personale di assistenza autorizzato, deve, quindi,

adottare le precauzioni necessarie.

Sicherheitshinweise

• Dieses Produkt und die zugehörigen Komponenten wurden

entworfen und getestet, um beim Einsatz die weltweit gültigen

Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten

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 durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen

Schlags und körperlicher Verletzung. Das zuständige

Fachpersonal sollte entsprechende Vorsichtsmaßnahmen

treffen.

Safety Information xi

4092-010

Pautas de Seguridad

• Este producto se ha diseñado, verificado y 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 mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de

mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la

máquina. El personal cualificado debe ser consciente de este

peligro y tomar las precauciones necesarias.

Informações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes

específicos da Lexmark. As funções de segurança de alguns

dos componentes podem não ser sempre óbvias. A Lexmark

não é responsável pela utilização de outros componentes de

substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser

utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais

destes serviços devem estar avisados deste facto e tomar os

cuidados necessários.

xii 4092 Service Manual

4092-010

Informació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir 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 producte està

orientada exclusivament a professionals i no està destinada a

ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de servei d’aquest producte.

El personal professional ha d’estar-ne assabentat i prendre les

mesures convenients.

Safety Information xiii

4092-010

xiv 4092 Service Manual

4092-010

General Information 1-1

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. The black cartridge has

a total of 208 nozzles and installs on the left. The color cartridge has

a total of 192 nozzles and installs on the right. The printer is capable

of printing in two directions from either cartridge.

Operator Panel

Buttons

There is no power button.

Left =

Reset

Right =

Continue

Used to

X Cancel a print job

X Clear the print buffer

X Eject paper from printer

X Continue printing after fixing an error

1-2 Service Manual

4092-010

Lights

Power Consumption

• 11.1 Watts - Power off and power to the printer

• 12 Watts - Idle Mode (power on - not printing)

• 24 Watts - Printing

Left =

Power

Right =

Busy

Conditions

On Off Power is on

On Blinking Printer is busy

Blinks *S Blinks *S Error condition or printer in demo mode

“Deactivate/Activate Demo Mode” on page 3-5

Blinks

Twice * S

Blinks

Twi ce *S

Memory full condition

Blinks *S Blinks *S While continuing to print - No photo cartridge

installed or a resolution reduction has occurred.

Blinks Off Error condition in engine board

Blinks On Error condition in controller board

*S = Simultaneously

General Information 1-3

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. On World Trade machines, the voltage is according to each

country’s specification.

Ground Checks

To check for a correct ground, measure the voltage between the

ground and a known good voltage source. The voltage

measurement must be the same as the source voltage to consider

the ground is correct. Continuity measurements may be used to

check grounds, however, be sure to measure to a known good

ground using the lowest ohms scale and check for zero ohms.

Note: Always unplug the power cord before doing any continuity

measurement.

Continuity Readings

When measuring continuity, be sure no back circuits affect the

measurement. If necessary, unplug connectors to remove any back

circuits. Zero the ohm range on the lowest scale (X1). An open

circuit will read infinity. A circuit with correct continuity will read zero

ohms.

1-4 Service Manual

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” on page 2-1.

This printer can be serviced without being connected to a host

computer. The user is directed, through the MarkVision cartridge

utility, to perform the head to head and bidirectional alignment

adjustments after replacing a print cartridge.

After you complete the repair, perform tests as needed to verify the

repair.

Abbreviations

Unique Tools Required For Service

Parallel Wrap Plug P/N 1319128

CE Customer Engineer

CSU Customer Setup

EOF End of Forms

ESD Electrostatic Discharge

FRU Field Replaceable Unit

HVPS High Voltage Power Supply

LED Light-Emitting Diode

LVPS Low Voltage Power Supply

NVRAM Nonvolatile Random Access Memory

OEM Original Equipment Manufacturer

POST Power-On Self Test

V ac Volts alternating current

V dc Volts direct current

ZIF Zero Insertion Force

Diagnostic Information 2-1

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” on page 2-2 and take the indicated action. Unplug

the printer to clear the error indicator.

The printer also logs the last error. If you think it may have an

intermittent error, or the error indicator lights have been cleared, you

canretrievetheerror:

1. Run the “Print Engine NVRAM Contents” on page 3-2.The

last error appears at the bottom of the page.

2. Run “Clear Error Log” on page 3-4 to clear the error (the error

may not be the result of a current error).

3. Run the “Print Test Page” on page 3-2. If no error appears, go

to “Power-On Self Test (POST) Sequence” on page 2-4.

2-2 Service Manual

4092-010

Error Indicator Table

Service

Error

Code in

Engine

NVRAM

Number of

Power Light

Blinks

Busy

Light

Action

900 Nothing Continuously ON ReplacetheController

Board.

902 65,66,79

or 127

thru 223

Continuously OFF Replace the Engine

Code Module or the

Engine Board.

908 83 2 OFF Replace the Engine

Code Module or the

Engine Board.

910 81 3 OFF Go to the “Transport

Service Check” on

page 2-17

930 92 4 OFF Go to the “Print

Quality Service

Check” on page 2-14

931 89 5 OFF Go to the “Transport

Service Check” on

page 2-17

939 Nothing 2

or

Power Light is

Off and Busy

Light Blinks

ON The Controller Board

and the Engine Board

are not

communicating with

each other.

The Controller Board,

Engine Board or Flex

Cable are defective.

Check the flex cable

connection at both

boards and a secure

ground. If no problem

is found, replace the

FRUs in the following

order:

• Controller Board

• Engine Board

•FlexCable

Page is loading ...

Lexmark 4092-010, Optra Color 40 User manual

Related papers

Other documents