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LexmarkOptra™Color45
4080-001
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• StartDiagnostics
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LexmarkandLexmarkwithdiamond
designaretrademarksofLexmark
International,Inc.,registeredinthe
UnitedStatesand/orothercountries.
4080-001
Edition: October 2000
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.
CommentsmaybeaddressedtoLexmarkInternational,Inc.,DepartmentD22/035-2,
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.
©CopyrightLexmarkInternational,Inc.1998, 2000.
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.
4080-001
Table of Contents
GeneralInformation .................................... 1-1
Power Consumption
..................................... 1-1
Maintenance Approach
.................................. 1-1
Tools Required For Service
............................... 1-1
Abbreviations
.......................................... 1-2
Operator Panel and Menus
............................... 1-3
Using the Operator Panel
............................... 1-3
Printer Indicator Light
.................................. 1-3
Operator Panel Buttons
................................ 1-4
Printer Messages
..................................... 1-5
Operator Panel Menus
................................... 1-6
Printing the Menu Settings Page
......................... 1-7
Changing Printer Settings
.............................. 1-8
Disabling the Operator Panel Menus
...................... 1-9
DiagnosticInformation ................................. 2-1
Start
................................................. 2-1
Error Indicator Table
.................................. 2-2
Power-On Self Test (POST) Sequence
.................... 2-4
Post Symptom Table
.................................. 2-5
Symptom Tables
..................................... 2-6
Service Checks
........................................ 2-9
Controller Board Service Check
.......................... 2-9
Encoder Card / Strip Service Check
...................... 2-9
End of Forms (EOF) Service Check
...................... 2-10
Maintenance Station Service Check
..................... 2-10
Noisy Paper Feed Motor Service Check
.................. 2-11
Operator Panel (Buttons) Service Check
.................. 2-11
Operator Panel (LCD) Display Service Check
.............. 2-12
Options Service Check
................................ 2-13
Paper Feed Service Check
............................ 2-15
Paper Path Service Check
............................. 2-18
Power Service Check
................................. 2-19
Print Quality Service Check
............................ 2-21
Transport Service Check
.............................. 2-24
Transport Service Check II
............................. 2-25
Tray 2 Service Check
................................. 2-25
User Error Messages
................................. 2-27
DiagnosticAids ....................................... 3-1
iii
4080-001
Diagnostic Mode
........................................3-1
Aligning the Cartridges
...................................3-2
Cleaning the Printheads
..................................3-2
Paper Lifters Operation Theory
.............................3-2
Error Log
..............................................3-3
Viewing the Error Log
..................................3-3
Clearing the Error Log
..................................3-3
Hardware Tests
.........................................3-4
LCD Test
............................................3-4
Button Test
..........................................3-4
DRAM Memory Test
...................................3-5
ROM Memory Test
....................................3-6
Parallel Wrap Test
.....................................3-6
Serial Wrap Test
......................................3-7
Device Tests
...........................................3-8
Hex Trace
...........................................3-8
Quick Disk Test
.......................................3-8
Disk Test/Clean
.......................................3-9
Flash Test
..........................................3-10
Printer Setup
..........................................3-11
Setting the Page Count
................................3-11
Viewing the Permanent Page Count
......................3-11
Restore Factory Defaults
...............................3-12
Print Tests
............................................3-12
Print Quality Test Page
................................3-13
Printing Menu Settings Page
............................3-14
Test Page (Quick Test)
..................................3-15
RepairInformation......................................4-1
Handling ESD-Sensitive Parts
..............................4-1
Adjustments
............................................4-2
Removal Procedures
.....................................4-2
Releasing Plastic Latches
...............................4-2
Covers and Doors
.......................................4-3
Base Assembly Removal
...............................4-4
Code SIMM Access Door Removal
........................4-4
Controller Board Access Cover Removal
...................4-5
Controller Board Access Door Removal
....................4-5
Envelope Guide Removal
...............................4-5
Front Access Door Removal
.............................4-6
Front Cover Removal
..................................4-6
Gutter Pad Removal
...................................4-6
Memory (SIMM) Card Cover Removal
.....................4-7
iv
Service Manual
4080-001
Metal / Plastic Controller Board Cover Removal
............. 4-7
Operator Panel Cover Removal
.......................... 4-8
Option Card(s) Cover Removal
.......................... 4-8
Rear Cover Removal
.................................. 4-8
Rear Access Cover Removal
............................ 4-9
Frames
.............................................. 4-10
Carrier Frame Assembly Removal
....................... 4-11
Carrier Rail Removal
................................. 4-11
Idler Pulley Assembly Removal
......................... 4-12
Left Side Frame Assembly Removal
..................... 4-12
Mid Frame Assembly Removal
......................... 4-13
Right Side Frame Assembly Removal
.................... 4-13
Paper Feed
........................................... 4-14
Exit Roller Assembly Removal
.......................... 4-15
Gear Box Assembly Removal
.......................... 4-15
Large Feed Roller Removal
............................ 4-15
Manual Sheet Feeder Removal
......................... 4-16
Paper Feed Motor Removal
............................ 4-16
Paper Lifters Removal
................................ 4-16
Paper Tray Assembly Removal
......................... 4-17
Small Feed Roller Assembly Removal
.................... 4-17
Small Feed Roller Holder Assembly Removal
.............. 4-17
Star Roller Assembly Removal
......................... 4-17
Electronics
........................................... 4-18
Code or Flash SIMM Removal
.......................... 4-19
Controller Board Removal
............................. 4-20
Encoder / Thermistor Card Removal
..................... 4-21
Engine Board Removal
............................... 4-22
Memory (SIMM) Card Removal
......................... 4-22
Operator Panel Removal
.............................. 4-24
Operator Panel Cable Removal
......................... 4-25
Option Card(s) Removal
.............................. 4-25
Power Supply Removal
............................... 4-26
Tray 2 Sensor Removal
............................... 4-26
Carrier
.............................................. 4-27
Carrier Belt Removal
................................. 4-28
Carrier Rail Removal
................................. 4-28
Carrier Transport Motor Assembly Removal
............... 4-29
Encoder Strip / Retainer Removal
....................... 4-29
Printhead Carrier Removal
............................. 4-30
Maintenance Station
.................................... 4-31
Maintenance Station Assembly Removal
.................. 4-32
Wipers and Caps Removal
............................ 4-32
v
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