LEXMARK OPTRA W820 SERVICE MANUAL

This service guide is a maintenance troubleshooting and instruction owner manual reference used for maintaining, disassembly and servicing the Lexmark Optra W820 printer. It provides comprehensive information on identifying Lexmark Optra W820 printer features, components, and spare parts troubleshooting printer problems and performing printer disassembly procedures.

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure. You may find that the removals in the Repair Information chapter will help you identify parts.

Table contents of Lexmark Optra W820 Service Manual

• Notices and Safety Information
  Laser Advisory and Caution Labels ~ Class 1 Laser Statement Label ~ Laser Notices ~ Safety Information
• Preface
• General Information
  Options ~ Maintenance Approach ~ Tools Required For Service ~ Serial Number Locations ~ Symbols Used in this Manual ~ Safety Details [Power Supply and Electrical Components ~ Mechanical Components ~ Laser Components ~ Fuser Components ~ Safety Components ~ Caution Labels] ~ Service Flowchart ~ Printer Overview[Schematic Diagram of Printer Operation] ~ Printer Power[Power Supply Components ~ Electrical Safety Circuits] ~ Printer Control [Control Functions of the Machine Control Unit (MCU)] ~ Mechanical Drive [Mechanical Drive Components ~ Printer Motor Control] ~ Paper Path[Paper Path Components ~ Paper Path Mechanical Drive ~ Paper Path Component Control] ~ Printhead[Printhead Components ~ Printhead Operation ~ Image Resolution ~ Printhead Control ~ Printhead Safeguards] ~ Xerographics[Xerographics Overview ~ Xerographic Components ~ Xerographic Process During a Print Cycle ~ Mechanical Drive for Xerographics ~ Xerographic Control ~ Image Quality Control - The Toner Sensor ~ Fuser Components ~ Mechanical Drive for the Fuser Assembly ~ Fuser Control] ~ General Specifications ~ Image Registration and Reproduction Tolerances ~ Paper Handling Devices[Face Down Tray (standard) ~ Finisher - option ~ Mailbox - option ~ Duplex - option ~ Envelope Feeder - option ~ MP Feeder (standard)] ~ Glossary of Terms, Acronyms, and Abbreviations .
  
• Diagnostic Information
  Start ~ Operator Panel Messages[Status Screens ~ Status Messages ~ Service Messages ~ Attendance Messages ~ Accessing Additional Debug Information for Service Errors] ~ Service Error Code Table ~ Symptom Service Check Table ~ Attendance Message Table ~ Service Checks Flowchart[How to Use the Service Checks Flowchart ~ How to Follow a Service Check ~ General Notes on Using Service Checks] ~ Service Checks[Error Code Service Checks ~ Attendance Messages ~ Symptom Service Checks ~ Print Quality Service Checks] ~ Electrical Interference
• Diagnostic Aids
  Analyzing the Test Print ~ Using Test Print to Locate a Feed or Paper Transport Problem ~ Using Test Print to Analyze a Print Quality Problem ~ Using the Operator Panel Diagnostics Menu[Entering Diagnostic Mode ~ Exiting Diagnostic Mode] ~ Print Tests [Print Quality Pages] ~ Hardware Tests [LCD Hardware Test ~ Button Test ~ DRAM Memory Test ~ DRAM Error ~ ROM Memory Test ~ Parallel Wrap Test ~ Serial Wrap Test] ~ Duplex Tests [Duplex Quick Test ~ Duplex Sensor Test] ~ Input Tray Tests[Input Tray Feed Test ~ Input Tray Sensor Test] ~ Output Bin Tests[Output Bin Feed Test ~ Feed All Bins Test ~ Output Bin Sensor Test] ~ Finisher Tests [Staple Test ~ Finisher Sensor Test] ~ Base Sensor Test ~ Storage Device Tests [Quick Disk Test ~ Disk Test/Clean ~ Flash Test] ~ Printer Setup [Configuration ID ~ Setting the Page Count ~ Viewing the Permanent Page Count ~ Setting Configuration ID] ~ EP Setup [Restoring EP Factory Defaults] ~ Error Log [Viewing the Error Log ~ Clearing the Error Log] ~ Configuration Mode [Viewing and Resetting the Maintenance Page Count] ~ Setting Printer Registration
• Repair Information
  Removal and Replacement Procedures [Fuser Full Cover ~ Top Cover Assembly ~ Front Cover Assembly ~ Front Inner Cover ~ Rear Cover Assembly ~ Right Cover ~ Operator Panel ~ Rear Cover 1TM ~ Tray 1 Lift Motor ~ Tray 1 Feed Clutch ~ Tray 1 Feed Rolls ~ Feeder, Nudger, and Retard Rolls ~ Tray 1 Take Away Roll Assembly ~ Tray 1 Feeder Assembly ~ Support Assembly Spring ~ Tray 1 Retard Assembly ~ Tray 1 & Tray 2 Front Chute Assemblies ~ Tray 1 & 2 Level Sensors ~ Tray 1 & Tray 2 Paper Size Sensors ~ Tray 1 & 2 No Paper Sensors ~ Actuator Assembly ~ Tray 2 Lift Motor ~ Tray 2 Feed Clutch ~ Tray 2 Feeder Assembly ~ Tray 2 Take Away Roll Assembly ~ Tray 2 Retard Assembly ~ MP Feeder Assembly ~ MP Feeder Tray Assembly ~ MP Feeder Support Assembly ~ L/H Low Cover Assembly ~ Left Lower Cover Assembly ~ Left Lower Cover Pinch Roll Assembly ~ Left Lower Cover Interlock Switch ~ Tray 2 Take Away Sensor ~ Registration Clutch ~ Left Upper Cover Assembly ~ Registration Chute ~ Registration Roll Assembly ~ Registration Sensor ~ Printhead Assembly ~ EP Cartridge ~ BTR Assembly ~ Toner Sensor ~ CRU Interlock Switch ~ Fuser Assembly ~ Fuser Drive Assembly ~ Fuser Fan ~ Offset/Exit Assembly ~ Exit Drive Assembly ~ Exit Gate Solenoid ~ Offset Motor ~ Inverter Clutches ~ Full Stack Sensor ~ Face Up Exit Sensor ~ Flywheel Assembly ~ Main Drive Assembly ~ Low Voltage Power Supply (LVPS) Assembly ~ Fan Assembly ~ AC Driver PWB 120/230 VAC ~ High Voltage Power Supply (HVPS) Assembly ~ I/O PWB ~ Left Cover Interlock Switch Assembly ~ Engine Board (MCU PWB) ~ Controller Board (ESS PWB) ~ ESS Cover ~ 220VAC Transformer ~ ESS Assembly]
• Connector Locations
  P/J Location Table ~ P/J Location Maps ~ Printer Wiring Diagrams
  
• Preventative Maintenance
• Parts Catalog
  How to Use This Parts Catalog ~ Assembly 1: Top Cover Assembly ~ Assembly 2: Front Cover ~ Assembly 3: Rear, Left, and Right Covers ~ Assembly 4: Tray Unit - Paper Stack ~ Assembly 5: Tray Interface ~ Assembly 6: Paper Pick Up ~ Assembly 7: Retard and Take Away - Tray 1 ~ Assembly 8: Retard and Take Away - Tray 2 ~ Assembly 9: Feed Drive Transmission ~ Assembly 10: Multi Purpose Feeder and MPF/Duplex Support ~ Assembly 11: Tray 1 Frame and Left Cover ~ Assembly 12: Tray 2 Frame and Left Cover ~ Assembly 13: Registration ~ Assembly 14: Left Upper Cover Assembly ~ Assembly 15: Printhead Assembly ~ Assembly 16: Xerography and Development ~ Assembly 17: Fuser Assembly ~ Assembly 18: Exit Lower Chute ~ Assembly 19: Exit Drive Assembly ~ Assembly 20: Main Drive Assembly ~ Assembly 21: Fuser Drive Assembly ~ Assembly 22: Power Unit ~ Assembly 23: HVPS and I/O PWB ~ Assembly 24: ESS Assembly ~ Assembly 25: Harness ~ Assembly 26: Miscellaneous
• Index

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