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Lexmark Optra
TM
W810
Laser Printer
4023-001
• Table of Contents
•
• Safety and Notices
• Trademarks
•Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
4023-001
Edition: March 2001
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.
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
D22/032-2, 740 West New Circle Road, 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, MarkNet, MarkVision, Optra and OptraImage are trademarks of Lexmark
International, Inc., registered in the United States and/or other countries.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 1999, 2000, 2001.
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.
U.S.A. P/N: 12G3978
4023-001
Table of Contents
Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
General Information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance Approach
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tools
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Serial Number
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Abbreviations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Standard Features
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Printer (Main)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Printer/Options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Parts Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Printer Configuration
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
General Description of Each Section
. . . . . . . . . . . . . . . . . . . . . . . . 1-9
Paper Feed Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Printhead Unit (Exposure Section)
. . . . . . . . . . . . . . . . . . . . . . . . 1-9
Imaging Cartridge (Charging, Development Section)
. . . . . . . . . 1-9
Image Transfer Section (Release Section)
. . . . . . . . . . . . . . . . . 1-9
Fusing Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Cleaning Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Paper Exit Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
General Flow for Printing Process
. . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Paper Feed Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Taking Up Paper–Tray 1 (1st Paper Cassette)
. . . . . . . . . . . . . 1-11
Tray 1 Sensors
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1st Cassette Tray 1 Paper Size Detection
. . . . . . . . . . . . . . . . . 1-15
Tray 2 (2nd Paper Cassette)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Taking up Paper–Tray 2 (2nd Paper Cassette)
. . . . . . . . . . . . . 1-16
Tray 2 Sensors
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Edge Guide and Trailing Edge Stop
. . . . . . . . . . . . . . . . . . . . . . 1-20
Paper Lifting Plate
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Cassette-in-Position Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Paper Near Empty Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Paper Empty Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Paper Separating Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Paper Take-Up Roll
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Paper Feed
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Printhead Unit (Exposure section)
. . . . . . . . . . . . . . . . . . . . . . . . . 1-28
iii
4023-001
Imaging Cartridge (Charging/Development Section)
. . . . . . . . . . . .1-28
Development Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
Toner Empty Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32
Image Transfer Section (Release Section)
. . . . . . . . . . . . . . . . . . .1-34
Optical Erase
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
Fusing Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Fusing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
Temperature Control Using The Thermistor
. . . . . . . . . . . . . . . .1-36
Thermostat (TS1) and Heater Lamp Fuse (TF1)
. . . . . . . . . . . . .1-36
Fusing Temperature Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Fusing PPM Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Paper Exit Section
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
Paper Path Through Exit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
Detection of a New Imaging Cartridge
. . . . . . . . . . . . . . . . . . . . . . .1-39
Right Door Interlock Switch (S2)
. . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
Duplex Unit Option
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Parts Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Cross-Sectional View
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
Switchback Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
Transport and Duplex Paper Take-Up Mechanism
. . . . . . . . . . .1-43
Paper Deck 2500-Sheet (LCC) Option
. . . . . . . . . . . . . . . . . . . . . .1-45
Cross-Sectional View
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-45
Vertical Transport Drive Mechanism
. . . . . . . . . . . . . . . . . . . . . .1-45
Paper Take-Up Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-47
Paper Take-Up Retry Control
. . . . . . . . . . . . . . . . . . . . . . . . . . .1-52
Paper Separating Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . .1-53
Paper Pressure Releasing Mechanism
. . . . . . . . . . . . . . . . . . . .1-53
Paper Take-Up Roll Retracting Mechanism
. . . . . . . . . . . . . . . .1-54
Edge Guides and Trailing Edge Stop
. . . . . . . . . . . . . . . . . . . . .1-54
Paper Size Setting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-55
LCC-in-Position Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-56
Lifting Operations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-57
Paper Near Empty Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59
Paper Empty Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-59
Paper Dehumidifying Heaters
. . . . . . . . . . . . . . . . . . . . . . . . . . .1-60
iv
Service Manual
4023-001
Mailbox/Transport Option
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Parts Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61
Paper Path
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
Paper Transport Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63
Paper Entrance Switching Mechanism
. . . . . . . . . . . . . . . . . . . 1-64
Paper Transport Mechanism (Horizontal Transport Unit)
. . . . . 1-64
Paper Empty Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
Paper Full Detection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
Paper Output Modes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-67
Finisher Option
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
Parts Identification
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-68
Paper Transport Path Switching Mechanism
. . . . . . . . . . . . . . . 1-69
Paper Transport Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70
Punch Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71
Finisher Tray
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
CD Aligning Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72
Shifting Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75
Finisher Tray Drive Mechanism
. . . . . . . . . . . . . . . . . . . . . . . . . 1-76
Paper Holding Tray
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
Elevator Tray
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
Stapling Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
Horizontal Transport Unit
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-81
Diagnostic Information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Service Error Codes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator Messages
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Symptom Tables
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Print Quality Symptom Table
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Paper Feed Symptom Table
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Other Printer Malfunction Symptom Table
. . . . . . . . . . . . . . . . . 2-31
LCC 2500-Sheet Tray 4 Symptom Table
. . . . . . . . . . . . . . . . . . 2-32
Mailbox Symptom Table
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Finisher Symptom Table
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Printer Service Checks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
No Power Service Check (923)
. . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Fuser (Abnormal Temperature) Service Check (923)
. . . . . . . . 2-34
Fuser (Temperature Low) Service Check (920/922)
. . . . . . . . . 2-35
Toner Feed Service Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Print Quality Service Checks
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Black Page Service Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
White Spots Service Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Toner Smudges On Backside Service Check
. . . . . . . . . . . . . . 2-37
Low Image Density Service Check
. . . . . . . . . . . . . . . . . . . . . . 2-38
v
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