Lexmark 4069-61n, 4069-41n, 4069-41l, 4069-41e, 4069-41b Service Manual

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Lexmark OptraTM T

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4069-XXX

•Index

• Manuals Menu

Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

4069-XXX

Edition: May 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 PAR TICULAR 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 D22A/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 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)(i i) 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.

4069-XXX

Contents

Notices and Safety Information

Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii

Preface

General Information

Diagnostic Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxii

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

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

Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Service Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

User Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

User Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . 2-24

Symptom Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Charge Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-29

Cover Open Switch/Cable Service Check . . . . . . . . . . . . 2-31

Dead Machine Service Check . . . . . . . . . . . . . . . . . . . . . 2-32

Duplex Option Service Check. . . . . . . . . . . . . . . . . . . . . . 2-35

Envelope Feeder Option Service Check . . . . . . . . . . . . . 2-38

Erase Lamp Service Check (010/212/414/616/31v). . . . . 2-45

Fan Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47

Fuser Solenoid Service Check. . . . . . . . . . . . . . . . . . . . . 2-51

Input Sensor Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-52

Input Tray(s) Option Service Check . . . . . . . . . . . . . . . . . 2-53

High Capacity Feeder Input Tray Service Check . . . . . . . 2-56

Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-69

Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . . 2-70

Options Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72

Output Bin Sensor Standard Tray Service Check . . . . . . 2-74

Output Expander Service Check . . . . . . . . . . . . . . . . . . . 2-75

High-Capacity Output Stacker Service Check . . . . . . . . . 2-80

5-Bin Mailbox Service Check . . . . . . . . . . . . . . . . . . . . . . 2-83

Paper Feed Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-89

Parallel Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-91

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Printhead Service Check. . . . . . . . . . . . . . . . . . . . . . . . . 2-92

Print Quality Service Check. . . . . . . . . . . . . . . . . . . . . . . 2-93

Smart Cartridge Service Check. . . . . . . . . . . . . . . . . . . 2-106

Serial Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-107

Toner Sensor Service Check. . . . . . . . . . . . . . . . . . . . . 2-107

Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . 2-108

Diagnostic Aids

Diagnostic Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . 3-3

Duplex Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Clearing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Hardware Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Parallel Wrap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Input Tray Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Output Bin Test - Standard Bin . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Feed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Output Bin X Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

5-Bin Mailbox Diverter Test . . . . . . . . . . . . . . . . . . . . . . . 3-18

Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Printer Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Viewing the Permanent Page Count . . . . . . . . . . . . . . . . 3-20

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Maintenance Page Count. . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Setting Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . 3-22

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Print Quality Test Pages. . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-25

Autocompensator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Autoconnect System, Paper Tray Options, Envelope Feeder and

Output Expander Operations. . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Fuser Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Paper Feed Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Repair Information

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex Motor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Fuser Solenoid Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Printhead Assembly Adjustment. . . . . . . . . . . . . . . . . . . . . 4-4

Paper Alignment Assembly Adjustment . . . . . . . . . . . . . . . 4-5

Screw Identification Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Center Pan Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Developer Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-18

Duplex Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Front Cover Door . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

EP Frame Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Fuser Board (Hot Roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Fuser Cover (Hot Roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Fuser Detack Fingers (Hot Roll). . . . . . . . . . . . . . . . . . . . 4-26

Fuser Detack Housing Assembly (Hot Roll). . . . . . . . . . . 4-27

Fuser Transfer Plate (Hot Roll). . . . . . . . . . . . . . . . . . . . . 4-28

Fuser Envelope Conditioner Solenoid (Hot Roll) . . . . . . . 4-29

Fuser Narrow Media Sensor/Flag Assembly (Hot Roll) . . 4-30

Fuser Exit Sensor Flag Assembly . . . . . . . . . . . . . . . . . . 4-30

Fuser Lamp (Hot Roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

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Fuser Lower Exit Guide Assembly (Hot Roll) . . . . . . . . . 4-31

High Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . 4-32

Inner EMC Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Inner Paper Deflector Assembly . . . . . . . . . . . . . . . . . . . 4-34

Integrated Tray Compensator Assembly. . . . . . . . . . . . . 4-35

Integrated Tray Compensator Pick Roll Assembly . . . . . 4-36

Interconnect Board Assembly . . . . . . . . . . . . . . . . . . . . . 4-37

Left Side Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . 4-41

Main Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Main Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Multipurpose Tray/Lower Deflector Assembly. . . . . . . . . 4-45

Operator Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Operator Panel Cable/Cover Open Switch Assembly . . . 4-48

Optional 250/500 Paper Tray Assembly . . . . . . . . . . . . . 4-49

Outer EMC Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

Paper Alignment Assembly . . . . . . . . . . . . . . . . . . . . . . . 4-51

Paper Input Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

Paper Size Sensing Board. . . . . . . . . . . . . . . . . . . . . . . . 4-53

Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Redrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Right Side Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Smart Cartridge Contacts . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Toner Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Transfer Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Upper Paper Deflector Assembly . . . . . . . . . . . . . . . . . . 4-59

Upper Front Cover Hinge Assembly . . . . . . . . . . . . . . . . 4-60

Upper Front Cover Interlock Switch Assembly . . . . . . . . 4-61

Connector Locations

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . . 5-1

High Voltage Power Supply. . . . . . . . . . . . . . . . . . . . . . . . 5-3

Engine Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Fuser Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Envelope Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Duplex Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Autoconnect - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Output Expander Control Board . . . . . . . . . . . . . . . . . . . 5-20

High-Capacity Output Stacker Board. . . . . . . . . . . . . . . . 5-22

Preventive Maintenance

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Parts Catalog

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

Printer Serial Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Assembly 2: Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Assembly 3: Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Assembly 4: Paper Feed (Autocompensator). . . . . . . . . . 7-14

Assembly 5: Paper Feed - Multipurpose Unit. . . . . . . . . . 7-16

Assembly 6: Paper Feed - Alignment. . . . . . . . . . . . . . . . 7-18

Assembly 7: Paper Feed - Output . . . . . . . . . . . . . . . . . . 7-20

Assembly 8: Integrated Paper Tray - 250 Sheet . . . . . . . 7-22

Assembly 9: Integrated Paper Tray - 500 Sheet . . . . . . . 7-24

Assembly 10: Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . 7-26

Assembly 11: Developer Drive. . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 12: Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . 7-30

Assembly 13: Belt Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Assembly 14: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Assembly 15: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

Assembly 16: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Assembly 17: 250 Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-52

Assembly 18: 500 Sheet Tray . . . . . . . . . . . . . . . . . . . . . 7-56

Assembly 19: Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

Assembly 20: Output Expander . . . . . . . . . . . . . . . . . . . . 7-66

Assembly 21: Envelope Feeder . . . . . . . . . . . . . . . . . . . . 7-70

Assembly 22: High Capacity Feeder . . . . . . . . . . . . . . . . 7-74

Assembly 23: Kiosk - Vertical Paper Adapter. . . . . . . . . . 7-88

Assembly 24: Kiosk - Horizontal Paper Adapter. . . . . . . . 7-90

Assembly 25: High-Capacity Output Stacker . . . . . . . . . . 7-92

Assembly 26: 5-Bin Mailbox. . . . . . . . . . . . . . . . . . . . . . . 7-98

Assembly 27: Options . . . . . . . . . . . . . . . . . . . . . . . . . . 7-102

Assembly 28: Miscellaneous . . . . . . . . . . . . . . . . . . . . . 7-104

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Notices and Safety Information

Laser Notices

The following laser notice labels may be affixed to this printer as shown:

Laser Advisory Label

Notices and Safety Information ix

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Class 1 Laser Statement Label

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Laser Notice

The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825.

Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wav elength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 60825 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I übersteigen würde, Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825 relatives aux produits laser de Classe I.

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Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision, l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825.

I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825 para productos láser de Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nivel de

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la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 60825.

Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanómetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825.

Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.

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Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bø lgelængdeområdet 770-795 nanometer. Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J för laserprodukter av Klass I (1). I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825.

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Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770795 nanometer. Lasersystemet och skrivaren är utf ormade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC

60825. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825.

Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona de 770-795 nanòmetres. El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d’un nivell de classe I durant una operació normal, durant les tasques de manteniment d’usuari ni durant els serveis que satisfacin les condicions prescrites.

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Japanese Laser Notice

Chinese Laser Notice

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Korean Laser Notice

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 sécur ité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de

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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.

Norme di sicurezza

Il prodotto è stato progettato, testato e approv ato in conf ormità 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 sicherheitsrelev anten 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

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Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

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. Le xmark 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.

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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.

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Chinese Safety Information

Korean Safety Information

Ozone Information

This product does not produce measurable amounts of ozone gas.

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Preface

This manual is divided into the following chapters:

“General Information” contains a general description of the

•

printer, options, and the maintenance approach used to repair it. General environmental and safety instructions as well as special tools and test equipment are listed in this chapter.

“Diagnostic Information” contains a service error code table,

•

user status message table, user error message table, symptom table, and service checks used to isolate failing field replaceable units (FRUs).

“Diagnostic Aids” contains tests and checks used to locate or

•

repeat symptoms of printer problems. Printer operation information is provided to enhance the tests and checks.

“Repair Information” provides instructions for making printer

•

adjustments and removing and installing FRUs. “Connector Locations” uses illustrations to identify the major

•

components and test points on the printer. “Preventiv e Maintenance” contains saf ety inspection guidelines,

•

lubrication specifications, and maintenance information to prevent problems and maintain performance.

“Parts Catalog” contains illustrations and part numbers for

•

individual FRUs.

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1. General Information

The Optra™ T laser printers are letter quality page printers designed to attach to IBM-compatible PC’s and to most computer networks.

The Optra T laser printer is available in the following models.

Model Name Type

Optra T 610 4069-010 Optra T 610n 4069-01n Optra T 612 4069-212 Optra T 612n 4069-21n Optra T612v 4069-31v Optra T612vn 4069-31e Optra T 614 4069-414 Optra T 614 4069-41b Optra T 614n 4069-41e Optra T 614nl 4069-41l Optra T 614n 4069-41n Optra T 616 4069-616 Optra T 616n 4069-61n

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Look at the printer serial label to identify the printer you are working on. There are two service levels of Optra T printers. Some printers are at a service level B as indicated by the B on the label.

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Options

The following options are available. Some options are not available in every country. Contact your point of purchase f or options a v ailab le in your country.

Memory options of 4MB, 8MB, 16MB, 32MB, 64MB and 128MB SDRAM DIMM

Flash memory options of 2MB, 4MB, 8MB and 16MB DIMM Integrated network options

Token-Ring Ethernet Tri-Port Adapter IR Adapter IPDS SIMM Prescribe SIMM TIFF SIMM Barcode SIMM Parallel Interface Card SCS USB/Parallel Port

Marknet Print Servers 250 and 500-sheet paper trays of A5, letter, and legal size. 250 Sheet Special Media Tray Assembly 500 Sheet Special Media Tray 2000 Sheet High Capacity Feeder Envelope feeder Duplex option - 250 Sheet Duplex option - 500 Sheet Hard Disk - 2.1 GB Forms Hard Disk - 2.1 GB Vertical Kiosk Presenter Horizontal Kiosk Presenter Output Expander 5-Bin Mailbox High Capacity Output Stacker

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Maintenance Approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the printer problem and repair the failure. After you complete the repair, perform tests as needed to verify the repair.

Tools Required For Service

Flat-blade screwdriver #1 Phillips screwdriver #2 Phillips screwdriver T10 Torx Screwdriver

7.0 mm nut driver

5.5 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax/serial debug cable 1381963 Coax/serial debug cable 1381964

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Acronyms

CSU Customer Setup DIMM Dual In-Line Memory Module DRAM Dynamic Random Access Memory EDO Enhanced Data Out EP Electrophotographic Process EPROM Erasable, Programmable Read-Only

Memory ESD Electrostatic Discharge FRU Field Replaceable Unit GB Gigabyte HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission

of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply MROM Masked Read Only Memory NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PC Photoconductor POR Power-On Reset POST Power-On Self Test RIP Raster Imaging Processor ROM Read Only Memory SIMM Single In-Line Memory Module SDRAM Synchronous Dual Random Access

Memory SRAM Static Random Access Memory UPR Used Parts Return V ac Volts alternating current V dc Volts direct current

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2. Diagnostic Information

Start

CAUTION:

Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure y our fingers are not under the printer when you lift or set the printer down.

Use the service error code, user status message, user error message, symptom table, service checks , and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer.

Service error codes are indicated by a three-digit error code. If a service error code is displayed, go to the

page 2-2

“Service Error Codes” on

User status messages provide the user with information on the current status of the printer. Ready is display ed on the first line of the display unless Power Saver is invoked, and then Power Saver is displayed. If a user status message is displayed, go to the

Status Messages” on page 2-12

“User

User error messages are indicated by a two or three-digit error code that provides the user with information that explains a prob lem with a print cartridge, paper jam, option, port, and so on. If a user error message is displayed, go to the

“User Error Messages” on page 2-16

If your machine completes the

page 2-24 “Symptom Tables” on page 2-25

without an error, and you have a symptom, go to the

“Power-On Self Test (POST)” on

. Locate your symptom and take the

appropriate action. If a service error code appears while you are working on the

machine, go to the

“Service Error Codes” on page 2-2

and take the

indicated action for that error.

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Service Error Codes

Service Error Codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition.

Error Code Action

900 RIP Software Contact the next support level or call Lexmark. 901 Engine Flash Indicates that the flash which the engine board code is

902 General Engine Software

903 Paperport Link Driver Error

904 Interface Violation by the controller software

905 Interface Violation by Paperport Device

906 ControllerEngine Link Driver Error

910 DC Pick Motor DC Pick Motor Stall

911 DC Pick Motor Excessive PWM

programmed into is bad. Replace the engine board. These errors indicate an unrecoverable engine software

error. Replace the engine board. Check for correct location of the jumpers on the

interconnect board for the model/type printer you are servicing. Incorrect jumper settings can cause a 902 service error. If jumpers are set correctly, replace the engine board.

Error Codes 910,911,912,913 and 914 are indications that a Tray 1 paper feed problem has been detected. Go to the “Input Tray(s) Option Service Check” on

page 2-53.

912 DC pick motor below speed

913 DC pick motor over speed

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Error Code Action

914 DC pick motor: No encoder feedback

917 Transfer Roll Indicates a problem in the transfer roll area. Go to the

920 Fuser Error Indicates that the fuser is below temperature when

921 Fuser Error Indicates that the fuser is below standby temperature

922 Fuser Error Fuser failed to reach standby temperature. Go to the

923 Fuser Error Fuser is too hot during printing or when printer is idle . Go

924 Fuser Error An open circuit has been detected in the Fuser

Check the integr ated pa per tray (tray 1 ) f or c orrect pape r loading. Reload the paper and POR the printer. If the error continues, go to the “Input Tray(s) Option Service

Check” on page 2-53.

“Transfer Roll Service Check” on page 2-108.

Note: This error also displays if an incorrect level HVPS assembly is insta lled in a printer tha t has the er ase lam p assembly installed. Check to make sure the correct HVPS assem bly is installed.

printing. Go to the “Fuser Service Check” on page 2-47. For models 31v a nd 3 1e go to “Belt Fus er” on page2-50.

when the printer is idle. Go to the “Fuser Service Chec k ”

on page 2-47.

“Fuser Service Check” on page 2-47. For models 31v

and 31e go to “Belt Fuser” on pag e2-50.

to the “Fuser Service Check” on page 2-47. For models 31v and 31e go to “Belt Fuser” on page 2-50.

Thermistor Circuit. Go to the “Fuser Service Check” on

page 2-47. For model s 31v and 31e go to “Belt Fuser” on page 2-50.

925 Fuser Error 010/212/414/616/ 01n/21n/41b/41l/ 41n/61n

927 Fan Stalled Indicates a printer fan stalled. Go to the “Fan Service

Wrong fuser lamp installe d. Check the fuser lamp f or th e correct type of lamp that should be installed.

Check” on page 2-46.

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Error Code Action

928 Erase Lamps Models 010/212/414/616/31v/01n/21n/31e/41n/61n

929 T one r Sensor The toner sensor is not op erating properly, the developer

930 Printhead Error

931-935 Printhead Error

932 - Printhead: Lost Hsync

933 - Mirror Motor Locks/Lost Hsync

Indicates that the engine has detected that either the erase lamp assemb l y is mi ss ing or disco nne cted. Go to the “Erase Lamp Service Check (010/212/414/616/31v/

01n/21n/31e/41n/61n)” on page 2-45.

Models 41b/41e/41l and models 010/212/414/616/31v/ 01n/21n/31e/41n/61n at service level B do not have erase lamps installed. Go to “Printer Serial Label” on

page 7-2 to identify the printer service level. Check to

make sure the correct HVPS is installed if this error displays on these models.

drive assembly is not operating properly or the print cartridge is defective. Go to the “Toner Sensor Service

Check” on page 2-107.

The wrong printhead is installed. Replace with the correct printhead.

These errors represe nt a p rob lem with the p rinthead. G o to the “Printhead Service Check” on page 2-92.

934 - Mirror Motor Lost Lock

935 - Mirror Motor unable to reach operating speed.

936-937 Trans port Motor

936 - Main Drive Motor initial lock failure

937 - Main Drive Motor lost lock

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Indicates a problem with the mai n drive motor. Go to the

“Main Drive Service Check” on page 2-69.

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Error Code Action

939 Controller Engine Communications Error

941 Controller Code CRC

941 Controller Font CRC

943 Controller Font Version

944 Controller Board Failure

The controller board and the engine board cannot communicate with one another. The controller board, engine board or interconnect board is defective. Check each board for correct installation and secure ground. If no problem is found, replace the FRUs in the following order:

controller board engine board interconnect board

The controller software also can cause a 939 error

Note:

code. Contact your next level for software support. A 941 error can be created by a defective code overlay

SIMM, a code upgrade, a defective IPDS or a prescribe SIMM. These should be checked before replacing the controller board.

Replace the controller board.

Indicates that the controller code and FONT ROM are incompatible.

Replace the controller board.

945 Controller Board Failure ASIC Failure

946 Controller Board Failure SRAM Failure

947 Engine Board

953 NVRAM Failure

954 NVRAM Failure

Replace the controller board.

Replace the engine board.

Indicates the NVRAM chip on the engine board has failed. Replace the engine board.

Indicates the NVRAM experienced a CRC failure. Replace the engine board.

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Error Code Action

956 Configuration IDIndicates a problem with the Configuration ID. This error

960 RAM Memory Error

961 RAM in Slot 1 is Bad.

962 RAM in Slot 2 is Bad.

963 RAM in slot 3 is Bad.

964 Emulation Error

965 Emulation Error

occurs because the engine received a configuration ID from the controller software which is not valid for the level of engine code existing in the printer. Setting the configuration ID correctly should fix this error. The ID can be set via the NPA data stream or operator panel.

Note: This error is not generated at POR to allow the servicer a method of resetting the configuration ID. However, setting the configuration ID is the only operation that the servicer can perform. See “Setting

Configuration ID” on page 3-21.

Indicates a DRAM Memory Error on the controller board. Replace the controller board.

Replace the DIMM in Slot 1. If this does not fix the problem, replace the controller board.

Replace the DIMM in Slot 2. If this does not fix the problem, replace the controller board.

Replace the DIMM in slot 3. If this does not fix the problem, replace the controller board.

Indicates a failure within the Download Emulation which is programmed into the code overlay SIMM. The specific error is as follows: 964 - Download Emulation CRC Failure. Checksum Failure. 965 - Download Emulation Outdated, The Download Emulation and the controller code are incompatible. Go to “Disabling Download Emulations” on page 3-3.

975 - 979 Network Card X

2-6 Service Manual

The following errors indicate a failure with the network card in the specified slot. X=any card installed in slots 1,2 or 3. 975 - Unrecognizable Network Card x. Replace Network Card x. 976 - Unrecoverable software error in Network Card x. 977 - Controller software detects that a Network Card is installed in slot x but cannot establish communications with it. 978 - Bad checksum while programming Network Card x. Replace Network Card x. 979 - Flash parts failed while programming Network Card x. If the printer is a network model, replace the controller board.

4069-XXX

Error Code Action

980 <device> Comm

981 <device> The engine protocol violation detected by the specified

982 <device> Comm

983 <device> Invalid command received by the specified device. 984 <device> Invalid command parameter received by the specified

990 <device> Indicates an equipment check condition has occurred in

991 <device> Card

The engine is experiencing unreliable communications to the specified device.

device. Communications error detected by the specified device.

device.

Service Errors 980 thru 984 <device> can be one

Note:

of the following: engine board, duplex, tray x (1,2,3,4 or

5), envelope feeder or output bin x (1,2 or 3).

the specified device, but the device is unable to identify the exact component failure.

<device> can be one of the following: duplex, tray

Note:

x (1,2,3,4 or 5), envelope feeder or output bin x(1,2 or 3). The specified device has detected an equipment check

in its system card.

<device> can be one of the following: duplex, tray

Note:

x(1,2,3,4 or 5), envelope feeder or output bin x (1,2 or 3).

Sub Error Codes For 9XX and 2XX Error Codes

The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit.

When a 9XX or 2XX error displays: Press and hold return and press select to enter for sub error codes.

Diagnostic Information 2-7

4069-XXX

The following is an e xample of ho w the printer displays a duplex unit sub error code.

DU DU

Byte 1 XX XX Byte 5

Byte 2 XX XX Byte 6

Byte 3 XX XX Byte 7

Byte 4 XX XX Byte 8

Base Printer Sub Error Codes

Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays status bytes 1, 2 and 3. This set of status bytes is designed to help isolate paper jams and paper feed problems in the base printer.

Status Bytes 1, 2,3

84 xx 00 The input sensor is still covered by the first sheet of paper

84 xx 01 Video information has not started on the page at the input

84 xx 02 The media takes too long to complete a pass through the

Explanation

through the printer and the second sheet is ready to arrive at the sensor.

sensor within two inches after activating the input sensor flag.

input sensor.

84 xx 04 This can occur when a sheet of paper is in the machine

84 xx 05 This error is generated whenever media is seen at the input

84 xx 06 A paper jam is detected by the tray you are trying to feed

84 xx 07 A paper jam is detected by a smart option and an error

84 xx 08 Paper Tray 5 pass thru sensor is not activated by a sheet of

during POST and the input sensor flag has tripped the input sensor.

sensor before the sensor flag activates the input sensor.

from.

message displays.

paper.

2-8 Service Manual

4069-XXX

Status Bytes 1, 2,3

84 xx 09 Paper Tray 4 pass thru sensor is not activated by a sheet of

84 xx 0A Paper Tray 3 pass thru sensor is not activated by a sheet of

84 xx 0B Paper Tray 2 pass thru sensor is not activated by a sheet of

84 xx 0C Paper Tray 5 pass thru sensor is not activated and never

84 xx 0D Paper Tray 4 pass thru sensor is not activated and never

84 xx 0E Paper Tray 3 pass thru sensor is not activated and never

84 xx 0F Paper Tray 2 pass thru sensor is not activated and never

84 xx 10 The main motor is stalled or the incorrect main motor is

Explanation

paper.

deactivated. A sheet of paper may still be over the sensor or the flag is still activated.

deactivated. A sheet of paper may still be over the sensor.

installed in the printer. 84 xx 11 The paper activated the input sensor too soon. 84 xx 13 The paper activated the input sensor too soon. 84 xx 1D The envelope feeder pass thru sensor is activated and never

deactivated. 84 xx 1E The envelope feeder pass thru sensor is not activated. 84 xx 1F The paper fed too early from Tray 1. 84 xx 21 The smart option did not pick the paper. 84 xx 22 The smart option did not pick the paper. 8E xx 02 The input sensor is not activated even though the paper is

picked from the source.

Diagnostic Information 2-9

4069-XXX

Status Bytes 1, 2,3

8E xx 0B The autocompensator DC motor stalls when attempting to

8E xx 11 The autocompensator DC motor takes too long to ramp up.

Explanation

pick a sheet of paper.

Envelope Feeder Sub Error Codes

Status byte 1 contains the most valuab le information to help isolate a feed problem with the en velope f eeder and is the only byte contained in the following table.

Status Byte 1

00 There was no envelope feeder error reported. 10 Printer failed POST - Homing of Envelope feeder 11 Printer failed POST - Halted Envelope Feeder 21 The envelope feeder failed to feed, envelope jam. 30 The D.C. motor failed to reach operating speed. 32 The motor stalled.

Explanation

36 The motor failed to stop.

Duplex Unit Sub Error Codes

Status byte 4 contains the most valuab le information to help isolate a failing part or assembly in the duplex option and is the only byte contained in the following table.

Status Byte 4

00 No duplex error. No problem was reported to the engine by the

01 The leading edge of the sheet of paper never arrived at the input

Explanation

duplex system card.

sensor.

2-10 Service Manual

4069-XXX

Status Byte 4

02 The duplex option system board never received media notification

03 The trailing edge of the sheet of paper never cleared the input

04 The leading edge of the sheet of paper never arrived at the exit

05 The duplex logic thinks a sheet of paper is feeding to the duplex

06 The exit sensor detected a sheet of paper too early. 07 The sheet of paper’s trailing edge did not clear the exit sensor in

08 The feed motor experienced a complete motor stall. 0E The D.C. motor is under speed. The motor never reached the

13 There is paper left in the duplex option. P aper w as sensed during

Explanation

from the printer.

sensor.

This error is the most common due to the long length of the

Note:

paper path between the input sensor and the exit sensor.

unit due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send a sheet of paper to the duplex unit.

the desired length of time.

correct operating speed.

the homing operation during POST.

15 There is paper left in the duplex option. P aper w as sensed during

the DC motor diagnostic test during POST. 18 The D.C. motor experienced an acceleration error. 3D There is paper left in the duplex option. Paper was sensed during

IR clear during POST.

Diagnostic Information 2-11

4069-XXX

User Status Messages

User Status Message Status Action

Ready The printer is ready to

receive and process data.

Ready/Hex The printer is ready and

Busy The printer is busy

HEX Trace is active, which is known as HEX Trace Ready.

receiving or processing data, or printing data.

The printer

Note:

indicator light blinks while the printer is processing data.

Press Menu> or <Menu to take the printer out of Ready and enter all the Menus except the TESTS MENU (Busy State).

Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy State). Press Select for the values. Press Menu> until Reset Printer is on the second line of the display. Press Select to Reset the printer.

Press Stop to take the printer out of Busy. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready.

Flushing Buffer The printer is flushing

corrupted print data and the current print job is being discarded.

2-12 Service Manual

No button actions are possible while this message is displayed.

4069-XXX

User Status Message Status Action

Printing Menu Settings The printer is processing

or printing a list of current settings menus because Print Menu Settings is selected from the menu.

Printing Directory List A directory of the flash

and disk contents is processing or printing because Print Directory is selected from the menu.

Press Stop to take the printer out of Ready. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready after the page prints. Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy State). Press Select for the values. Press Menu> until Reset Printer is on the second line of the display. Press Select to reset the printer.

Press Stop to take the printer out of Ready. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the paper path. Press Go to return to Ready after the page prints. Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy Stat). Press Select for the values. Press Menu> until Reset Printer is on the second line of the display. Press Select to reset the printer.

Diagnostic Information 2-13

4069-XXX

User Status Message Status Action

Restoring Factory Defaults

Performing Self Tests The printer is running

Not Ready (Press Go)

Resetting Printer The printer is deleting

The printer is restoring factory defaults.

the normal series of start-up tests after it is powered On. When the tests are complete, the printer returns to Ready.

The printer is in the Not Ready state, which means it is not ready to receive or process data. This message displays when Menu> or <Menu is pressed during a print job.

any print jobs in process and restoring all settings to user defaults.

No button actions are possible while this message is displayed.

Press Go to take the printer out of the Not Ready state. Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy state). Press Menu> until Reset Printer is on the second line of the display. Press Select to reset the printer.

No button actions are possible while this message is displayed.

Formatting Flash (Do Not Power Off)

Program Flash (Do Not Power Off)

Formatting Disk The disk is being

The flash memory is being formatted.

The flash memory is being programmed, which means fonts or macros are being written to flash memory.

formatted.

2-14 Service Manual

No button actions are possible while this message is displayed.

Do not perform any button actions while this message is displayed.

No button actions are possible while this message is displayed.

4069-XXX

User Status Message Status Action

Programming Disk (Do Not Power Off)

Menus Disabled The printer menus have

Activating Menu Changes

The disk is being programmed, which means fonts or macros are being written to disk.

been disabled. This occurs when Menu> or <Menu is pressed while the printer is Ready and Menu Lockout is active. The printer display shows this message for one second and then returns to the Ready message.

The printer is reset to activate a printer setting changed in the menus.

No button actions are possible while this message is displayed.

If information is

Note:

written to flash memory and to disk at the same time, the Program Flash message is displayed.

No button actions are possible while this message is displayed.

Diagnostic Information 2-15

4069-XXX

User Error Messages

User Error Message Explanation

200 Paper Jam Remove Cartridge

201 Paper Jam Remove Cartridge

202 Paper Jam Open Rear Door

230 Paper Jam Check Duplex

24X Paper Jam Check Tray X

250 Paper Jam Check MP Feeder

Paper is jammed at the printer Input Sensor. Open the printer’s upper front door and remove the print cartridge to access the paper jam area.

Paper is jammed between the printer’s input and exit sensors. Open the printer’s upper front door and remove the print cartridge to access the jam area.

Paper is jammed at the printer exit sensor. Open the printer rear door to access the jam area.

The paper is most likely jammed in the Duplex Unit. Remove the duple x front cov er to access the jam area. If the paper is jammed in the rear of the duplex, then replace the duplex front cover and open the duplex rear door. If the paper is not jammed in the duplex unit, then it may be jammed in the rear of the printer. Open the printer rear door to access the jam.

Paper is jammed around Tray X (X=tray 1 thru 5). Try opening Tray X. If the tray is difficult to remove, then you may have to remove the tray above or below tray X to remove the jammed pages.

Paper is jammed in the multipurpose feeder.

260 Paper Jam Check Envelope Feeder

27X Paper Jam Check Output Bin X

Insert Cartridge or Close Door

2-16 Service Manual

Paper is jammed in the envelope feeder.

Paper is jammed in output bin X (X=1 thru 3). Open the rear door of Output Bin X to access the jammed pages.

This message displays when the printer’s front door is open or the print cartridge is missing. If this message cannot be cleared go to “Cover

Open Switch/Cable Service Check” on page 2-31.

4069-XXX

User Error Message Explanation

31 Defective Print Cartridge

32 Unsupported Print Cartridge

34 Short Paper The printer determines the paper length is too

Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, they are not reprinted once a good print cartridge is inserted.

: This error indicates the printer was able to

Note

read the cartridge ID, but the ID did not pass the verification test. To pass the verification test, the ID read from the print cartridge must match the ID from the last “good” print cartridge or the same ID must be read from the print cartridge twice. The last “good” print cartridge ID is stored in NVRAM.

Error 32 is displayed when the top cover is closed and an unsupported print cartr idge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, then they are not reprinted once a good print cartridge is inserted. If this does not fix the problem, go to

“Smart Cartridge Service Check” on page 2-106.

short to print the formatted data. This occurs when the printer does not know the actual paper size loaded in the tray. For auto-size sensing trays, this error occurs if the paper stop is in the incorrect position. Make sure the Paper Size setting is correct for the size paper that is being used.

36 Resolution Reduced The resolution of the page has been reduced

from 600 dpi to 300 dpi in order to prevent a Memory Full error. This message can only occur if the Resolution Reduction setting is turned on.

: 1200 dpi pages are not resolution reduced.

Note

If a 1200 dpi job runs out of memory, a Memory Full error is displayed.

Diagnostic Information 2-17

4069-XXX

User Error Message Explanation

37 Insufficient Collation Memory

38 Memory Full This message is displayed when the printer

39 Complex Page This message is displayed when the page is too

51 Defective Flash This message is displayed when the printer

52 Flash Full This message is displayed when there is not

53 Unformatted Flash This message is displayed when the printer

This message is displayed when the printer memory used to store pages is too full to collate the print job.

memory used to store pages is full.

complex to print.

detects a defective flash. This error may occur at power on, or during flash format and write operations. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the problem is resolved.

enough free space in the flash memory to hold the resources that have been requested to be written to flash.

detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted.

54 Standard Serial Error This error is displayed when a serial error

(framing or parity) is detected on the standard serial port. This usually indicates the serial port is not set up correctly.

54 Serial Option X Error This error is displayed when a serial error

56 Standard Serial Disabled

(framing or parity) is detected on the optional serial port. This usually indicates the optional serial port is not set up correctly.

This error is displayed when data is sent to the printer across the standard serial port, but the port has been disabled.

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4069-XXX

User Error Message Explanation

56 Parallel Port Disabled This error is displayed when data is sent to the

58 Too Many Trays Attached

58 Too Many Bins Attached

58 Too Many Disks Installed

61 Defective Disk This error code is displayed when the printer

62 Disk Full This error code is displayed when there is not

printer across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset.

This error code is displayed when too many input trays are attached to the printer.

This error code is displayed when too many optional output bins are attached to the printer.

This error is displayed when too many disks are attached to the printer.

detects a defective disk. This error may occur at power on or during disk format and write operations. The following actions may be taken while this message is displayed: Press Go to clear the message. The disk is marked defective and normal printer operations continue. Disk operations are not allowed with a defective disk. The Format Disk menu is not shown.

enough free space on the disk to hold the resources that have been requested to be written to the disk. This message displays for both resource and PostScript Disk operators when the disk is full.

63 Unformatted Disk This error code displays when the printer detects

80 Scheduled Maintenance

an unformatted disk at power on. Press Go to clear the message. The disk is marked as bad and normal operation continues. Disk operations are not allowed until the disk is formatted.

The operator panel displays this message at each 300K page count interval. It is necessary to replace the fuser assembly, transfer roller, and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit. For more information, go to “Scheduled Maintenance” on

page 6-2.

Diagnostic Information 2-19

4069-XXX

User Error Message Explanation

81 Engine Code CRC Failure

88 Toner Low This message displays when toner low occurs

This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check. Press Go to clear the message. The microcode data is discarded and must be re-transmitted from the host computer.

and the toner low alarm is activated. Press Go to clear this message.

User Line 2 Messages

If none of the conditions exist that are listed in the following table, line 2 is blank. If any of the messages in the table are displayed the following actions can be taken:

Press Menu> or <Menu to take the printer offline and access the Ready Menu group.

Note:

The Menu buttons are not active if Menu Lockout is turned

on. Press Stop to take the printer offline. The Not Ready message is

displayed. No more data is processed from the host computer . Press the Go button to return the printer to the Ready state.

User Message Explanation

Toner Low If the toner cartridge is low, then “Toner Low”

Tray X Missing If any of the input trays are missing, then “Tray X

displays. The Toner Low condition clears whenever the upper front door is opened, and Toner Low displays again if the condition exists after the upper front door is closed.

Missing” displays (where X designates which Tray (1 through 5) is missing. If multiple trays are missing, they are prioritized in this order: Tray 1,

2..., then tray 5. Tray X Missing status clears whenever Tray X is reinserted.

2-20 Service Manual

4069-XXX

User Message Explanation

Tray X Empty If any of the input trays are empty, then “Tray X

Tray X Low If any of the input trays are low, then “Tray X Low”

Empty” displays where X designates which tray (Tray 1 through 5) is empty. If multiple trays are empty, then they are prioritized in this order: Tray 5, Tray 4,...Tray 1.

Tray X Empty status clears whenever Tray

Note:

X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays. Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder.

displays where X designates which tray (1 through 5) displays. If multiple trays are low, they are prioritized in the following order: Tray 5,4,3,2,1.

Tray X Low clears whenever Tray X goes

Note:

empty, or Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays.

The printer cannot detect when the

Note:

envelope feeder or multipurpose feeder are low.

User Line 2 Link Messages

If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, no messages display. The link messages are listed in the following table.

User Message Explanation

Parallel Standard Parallel Port, if available. Serial Standard Serial Port, if available. Serial X Serial Port, where X=1,2,3, is attached to PCI

connector X.

Network X Network card X, X=1,2,3, is attached to PCI

connector X.

Diagnostic Information 2-21

4069-XXX

User Message Explanation

LocalTalk X LocalTalk Card X,X=1,2,3, is attached to PCI

Infrared Standard Infrared port, if available. Infrared X Infrared Port X, X=1,2,3, is attached to PCI

connector X.

Check Device Connection Messages

The messages in the following table display when the printer looses communications with one of the following devices.

User Status Message Explanation

Check Output Bin X Connection

Check Env Feeder Connection

Check Tray X Connection

Check Duplex Connection

Check Output Bin X (X=1,2,or 3).

Check Envelope Feeder Option Connection.

Check Tray X (X=1,2,3,4 or 5).

Check Duplex Option Connection.

2-22 Service Manual

4069-XXX

The messages in the following table can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure.

If the device is temporarily removed or not connected properly,

•

then reattach it. When the option is recognized, the printer automatically clears the error and continues.

If the option is experiencing a hardware problem, turn the printer

•

off and back on. If the error occurs again, turn the printer off, remove the option and call for service.

User Status Message Explanation

Turn Printer OFF to Enable Option

Insert Duplex Front Cover

Close Duplex Rear Door This message displays when the duplex rear door

This message displays when a printer option, Input Tray, Output Bin or Envelope Feeder, has been attached while the printer is powered On. In order to use the option, the printer must first be powered off and back on again. Data loss results if print jobs are active when the printer is power cycled. If a print job is active, then remove the option and finish the job. The printer automatically clears the message once the option is removed. Once the job is complete, turn off the printer and attach the option again.

This message displays when the duplex front access cover is not installed.

is open.

Diagnostic Information 2-23

4069-XXX

Power-On Self Test (POST)

When you turn the printer On, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following:

1. The LED comes on.

2. The operator panel displays one and a half row of pels , and then clears.

3. Diamonds scroll across the display, and then clear.

4. The operator panel displays one and a half row of pels , and then clears.

5. The top line of the operator panel displays one square block of pels that turn on one at a time until all sixteen blocks display and then they all turn off.

6. “Performing Self Test” appears on the display.

– The 2000 sheet high capacity option elevator tray moves to

the uppermost position if installed. – The duplex option is checked if installed. – The output expander option exit rollers turn if installed.

7. “Busy” appears on the display.

8. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start. (All models except the 31v)

9. The main fan turns on.

10.The main drive motor turns on.

11.The developer drive assembly drives the developer shaft in the toner cartridge.

12. The exit rollers turn.

13. The operator panel LED starts blinking.

14. Models 414 and 616 only - The auxiliary fan turns on and continues to run until the printer is powered off.

15. “Ready” appears on the display.

2-24 Service Manual

4069-XXX

Symptom Tables

Symptom Table - Base Printer

Symptom Action

Auxiliary Fan (414/616) fails to run or is noisy.

Dead Machine Go to the “Dead Machine Service

Operator Panel - One or more buttons do not work.

Operator Panel - Display is blank. Printer sounds 5 beeps.

Operator Panel - Display is blank. Printer does not sound 5 beeps.

Operator Panel continuously displays all diamonds, sounds 5 beeps and does not complete POST.

Paperfeed problems - Base printer or Integrated 250 Paper Tray

Paper jams at exit of Redrive Assembly - No Duplex Option installed.

Paper jams at exit of Redrive Assembly - Duplex Option installed

Go to the “Auxiliary Fan Service

Check” on page 2-46.

Check” on page 2-32.

Go to the “Operator Panel Buttons

Service Check” on page 2-70.

Go to the “Operator Panel Service

Check” on page 2-70.

Replace the operator panel assembly.

Go to the “Operator Panel Service

Check” on page 2-70.

Go to the “Paper Feed Service

Check” on page 2-89.

Go to the “Paper Feed Service

Check” on page 2-89.

Go to the “Duplex Option Service

Check” on page 2-35.

Fuser Solenoid fails to operate. (All models except the 31v)

Print quality - Black page Go to “Print Quality - All Black P age”

Print quality - Blank page Go to “Print Quality - Blank Page” on

Print quality - Light print Go to “Print Quality - Light Print” on

Go to the “Fuser Solenoid Service

Check” on page 2-51.

on page 2-94.

page 2-94.

page 2-104.

Diagnostic Information 2-25

4069-XXX

Symptom Action

Print quality - Background Go to “Print Quality - Background”

Print quality - Residual image Go to “Print Quality - Residual

Print quality - Skew Go to the “Paper Feed Service

Print quality - Banding Go to “Print Quality - Banding” on

Print quality - Random marks Go to “Print Quality - Random

Print quality - Toner on backside of printed page

Print quality - Vertical black bands on edge of copy

Unable to clear a “32-Unsupported Print Cartridge” User Error Message

on page 2-98.

Image” on page 2-103.

Check” on page 2-89.

page 2-101.

Marks” on page 2-96.

Go to “Print Quality - Toner on

backside of printed page” on page 2-105.

Go to “Print Quality - Black bands on

outer edges of the page” on page 2-101.

Go to “Smart Cartridge Service

Check” on page 2-106

Symptom Table - High Capacity Feeder Option (2000 Sheet)

Symptom Action

The printer does not recognize the high capacity feeder option installed.

Paper feed problem with the high capacity feeder option.

Go to the “High Capacity Feeder

Input Tray Service Check” on page 2-56.

Go to the“High Capacity Feeder

Input Tray Service Check” on page 2-56.

2-26 Service Manual

4069-XXX Symptom Table: Paper Tray Options

Symptom Action

Paper feed problem with 250 Sheet Paper Tray Option.

Paper feed problem with 500 Sheet Paper Tray Option.

Media fails to pass thru from the lower attached Paper Tray option to the next higher mounted option.

Go to the “Input Tray(s) Option

Service Check” on page 2-53

Go to the “Input Tray(s) Option

Service Check” on page 2-53

Go to the “Input Tray(s) Option

Service Check” on page 2-53

Symptom Table - Duplex

Symptom Action

Paper feed problem with Duplex Go to the “Duplex Option Service

Check” on page 2-35

Paper jams at Paper Removal Tray

Paper skews in the Duplex Option Go to the “Duplex Option Service

Paper fails to pass from lower option thru the Duplex Option.

Go to the “Duplex Option Service

Check” on page 2-35

Go to the “Duplex Option Service

Check” on page 2-35

Symptom Table - Envelope Feeder Option

Symptom Action

Envelopes do not feed from the envelope feeder.

Envelopes do not feed properly into base printer.

Go to the “Envelope Feeder Option

Service Check” on page 2-38.

Go to the “Envelope Feeder Option

Service Check” on page 2-38

Diagnostic Information 2-27

4069-XXX Symptom Table - Output Expander

Symptom Action

Printer does not display Output Bin Full

Paper does not feed all the way into the output tray.

Go to the “Output Bin Sensor

Standard Tray Service Check” on page 2-74

Go to the “Output Expander Service

Check” on page 2-75

Service Checks

Note:

must be reset in NVRAM on the new engine board. Go to

Configuration ID” on page 3-21

Review the following information before performing any service checks.

Anytime the engine board is replaced, the Configuration ID

Paperfeed Problems (especially paper jams): Go to

•

Error Log” on page 3-8

indications of repetitive entries that help to isolate a problem to a particular area of the printer or option.

Paperfeed Problems with error message: Use the

•

Codes For 9XX and 2XX Error Codes” on page 2-7

the problem. Print Quality Problems: Go to

•

page 3-24

before changing any settings or working on the printer. Use the resident diagnostics test provided to help isolate a

•

problem before taking the machine apart or removing any options.

and print a test page to help diagnose problems

and check the printer error log for

“Sub Error

to help diagnose

“Print Quality Test Pages” on

“Setting

“Viewing the

2-28 Service Manual

4069-XXX

Charge Roll Service Check

Service Tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 inch) apart or spots on the page can be caused by a damaged or contaminated charge roll.

Service Tip: Check to make sure the right charge roll arm bushing is correctly installed and operates correctly.

To remove the charge roll:

1. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.

2. Carefully remove the roll b y pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing.

3. Remove the charge roll from the left side charge roll bearing and remove the roll from the printer. Leave the paper wrapped around the charge roll until it is reinstalled.

FRU Action

1 Charge Roll Assembly Check the charge roll for correct

installation, toner buildup, marks, cuts or other signs of contamination or damage. Replace as necessary.

2 Left Side Charge Roll Link Check the left side charge roll link

assembly for correct assembly operation. Check for damage to the arm or bearing assembly.

Diagnostic Information 2-29

4069-XXX

FRU Action

3 Right Side Charge Roll Link

Right Charge Roll Bushing

Check the right side charge roll link assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination. Excessive contamination could cause intermittent charging of the charge roll. If incorrect, replace the link assembly. Check f or continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame. If incorrect, replace the link assembly.

Make sure the charge roll bushing is installed and operating correctly.

The screw that attaches the

Note:

charge roll lead to the contact must be secure.

2-30 Service Manual

4069-XXX

Cover Open Switch/Cable Service Check

FRU Action

1 Toner Cartridge Check the toner cartridge to make

sure it is correctly installed and that the right and left cartridge tracks are not loose or broken. Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover open switch spring.

2 Cover Open Switch/Cable

Assembly

Check the cover open switch for proper mechanical operation. If incorrect, repair as necessary. Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4-3. It measures approximately +5 V dc. If the voltage is incorrect, replace the engine board. If the voltage is correct, check the voltage at J4-1. If the voltage measures greater than +1.0 V dc, replace the engine board. If the voltage is correct, check the continuity between J4-1 and J4-3 on the cable. If no change in continuity occurs as the switch is activated, replace the cover open switch/cable assembly. If the continuity changes as the switch is activated, replace the engine board.

It is easier to check the

Note:

voltages on J4 with the controller board removed.

Diagnostic Information 2-31

4069-XXX

Dead Machine Service Check

Note:

If a high capacity input tray is installed, remov e the option and check the base printer for correct operation. If the base printer operates correctly, go to

Check” on page 2-56

“High Capacity Feeder Input Tray Service

. If the base printer continues to not operate correctly, remove any other attached paper handling options. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemblies.

Service Tip: When removing the LVPS from the printer observe the following:

1. The LVPS uses a self docking connector that mates with another connector mounted on the left side frame assembly. Some force may be required to pull the LVPS loose from the connector.

2. Gently remove the LVPS supply using caution not to damage the printed circuit board. Pull the LVPS out far enough to reach the fuser lamp cable.

3. The fuser lamp cable uses a locking type of connector system. Unlock the fuser lamp cable connector, disconnect the cable and remove the LVPS from the printer.

Note:

If the LVPS is blowing fuses, remove the LVPS from the printer. Check the metal LVPS shield for signs of damage that causes the shield to touch components on the LVPS board assembly.

FRU Action

1 Line Voltage Chec k the AC line voltage. If the line

2 AC Line Cord Check the line cord for any signs of

voltage is incorrect, inform the customer.

damage. If correct, check the continuity of the line cord and replace if necessary.

2-32 Service Manual

4069-XXX

FRU Action

3 +5 V dc at any Option

Connector

4 +5 V dc at the controller

board test point

5 +5 V dc at the engine board

Tes t Point

6 LVPS Fuse F1 Remove the LVPS from the pr inter

7 LVPS Fuse F1 - Continues

to blow after LVPS installed in the printer.

Check for +5 V dc on any of the option connectors. The easiest to access is the envelope feeder connector located behind the lower front door. If +5 V dc is present at any of the connectors, go to step 9. If +5 V dc is not present, go to step 4.

Check for +5 V dc at the +5 V dc test pad located on the controller board. If correct, go to step 9.

Check for +5 V dc at the +5 V dc test point on the engine board. If correct, replace the engine board. If incorrect, go to step 6.

and check fuse F1. Replace the fuse if the fuse is blown.

Replace fuse F1 if necessary. Turn the LVPS on/off switch Off and connect the AC line cord and turn the LVPS On.

CAUTION

turn the LVPS Off and disconnect the AC line cord. Check fuse F1. If the fuse is blown, replace the LVPS.

: Before checking fuse F1

8 L VPS Remove the LVPS from the machine.

CAUTION:

measurements on the LVPS output connector, observe all necessary safety precautions before applying AC power. Measure the voltage on LVPS output connector CN3. The voltage measures +5 V dc. If incorrect, replace the LVPS.

Before making any

Diagnostic Information 2-33

4069-XXX

FRU Action

9 Engine Board Turn the printer off and disconnect

all the cables from the engine board. Check for +5 V dc at the engine board test point. If incorrect, replace the FRUs in the following order:

engine board interconnect board If correct, turn the printer off and

reconnect one cable at a time until you find the defective assembly.

Service Tip: A short or low resistance load that is attached to the engine board can cause the LVPS to overcurrent and shut the +5 V dc supply down to 0 V dc.

Service Tip: Check the engine board for burn marks or other damage, especially R20,R21, R22 and R23 located next to the upper left engine board mounting screw. If this screw is overtightened it might deform the engine board shield and cause it to short out these resistors.

2-34 Service Manual

4069-XXX

Duplex Option Service Check

The printer does not recognize the Duplex Option is attached. The printer does not recognize tray options below the duplex option are installed.

FRU Action

1 Fuse F1 on Duplex Option

System Board

2 Autoconnect Cables/

Connectors

If fuse F1 is blown, replace the fuse. If fuse F1 continues to blow, check the stepper motor for a short between the motor case and pins J3-1 through J3-4. If no problem is found, check the D.C. servo motor pins J1-1 and J1-2 to the motor housing for a short. If a short is found, replace the motor assembly. If no short is found, replace the system board.

Check the autoconnect cables for damage to the cables or the pins in the connectors. If damaged, replace the cable(s). If no damage is found, check to make sure the cables are connected to J9, J10, J11 and J12 on the duplex system board. If no problem is found, replace the duple x system board.

Diagnostic Information 2-35

4069-XXX POST fails, 230 Paper Jam, Check Duplex message displays.

FRU Action

1 Duplex D.C. Servo Drive

Motor

2 Input Sensor, Input Sensor

Flag

3 Paper Exit Sensor and Flag Check the duplex exit sensor for

Check the D.C. servo motor cables for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage. If no problem is found, replace the FRUs in the following order:

D.C. motor assembly duplex option system board

Run the Duplex Sensor Test from the diagnostics menu. If the test fails, check the input sensor cable at J5 on the system board for correct installation. If no problem is found, replace the FRUs in the following order:

input sensor assembly duplex option system board

correct installation and free movement of the sensor flag. Check to make sure the sensor cable is connected to J8 on the system board. If no problem is found, replace the FRUs in the following order:

2-36 Service Manual

exit sensor assembly duplex option system board

4069-XXX 230 Paper Jam - Check Duplex message displays. The page is not

duplexed and only exits half way out of the redrive.

FRU Action

1 Duplex Stepper Motor Check the stepper motor cable for

cuts or pinched wiring. Check the routing of the motor leads along the left side of the bottom tray. Check for correct installation of the motor cable connector at J3 on the system board. Check for any shorts between each pin of the motor cable and the motor housing. If shorts are found, replace the motor. Check the resistance of the stepper motor between J3-1 (Stpmtr A-) to J3-2 (Stpmtr A+). The resistance measures approximately 10 ohms. The resistance between J3-3 (Stpmtr B-) to J3-4 (Stpmtr B+) measures approximately 10 ohms. If the resistance is incorrect, replace the stepper motor. Check for shorts between windings on pins J3-1 to J3-2 and pins J3-3 to J3-4. If a short is found, replace the stepper motor assembly. If no short is found, replace the duplex system board.

Diagnostic Information 2-37

4069-XXX

Envelope Feeder Option Service Check

Service Tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If an y other options are installed mak e sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise go to the Interconnect Card Service Check.

Service Tip: The envelope feeder option receives its +5 V dc operating voltage from the +24 V dc bulk at J1-7. If +24 V dc is not present at J1-7, tray 1 is the only tray option that is recognized.

Note:

the

If a 260 Paper Jam Chec k Env elope message displa ys, chec k

“Sub Error Codes For 9XX and 2XX Error Codes” on page 2-7

Printer does not recognize the envelope feeder as an attached input option.

FRU Action

1 Envelope Feeder Check to make sure the envelope

feeder is correctly installed and mated to the autoconnect at the front of the printer.

2 Front Autoconnect on

Printer

Check the connector for signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Remove the envelope feeder option and check the v oltages at the autoconnect on the front of the printer. If incorrect, check the interconnect board. If correct, reinstall the envelope option and continue with step 3.

2-38 Service Manual

4069-XXX

FRU Action

3 Autoconnect on the

Envelope Option

Check the connector for any signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages:

J1-3 measures +5 V dc J1-5 measures +5 V dc J1-7 measures +24 V dc

If any of the voltages are incorrect, replace the autoconnect cable/connector. If the voltages are correct, replace the envelope system board.

Diagnostic Information 2-39

4069-XXX Operator panel displays 260 Paper Jam immediately when

envelope feed is requested - POST incomplete.

FRU Action

1 Pass through Sensor Check for any debris, pieces of

envelope and so on over the pass thru sensor. Check for correct installation of the pass thru sensor flag. Make sure the sensor cable is attached to the envelope system board. Perform an envelope feeder sensor test to check both the sensor and sensor flag.

It may be necessary to use a

Note:

small tool to actuate the sensor flag because it is located under the front cover. Be careful not to damage the flag.

If the test fails, check the flag for any signs of damage or binds. If incorrect, replace the flag. If the flag is operating correctly, check the voltage at J3-3. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, check the voltage at J3-2. The voltage changes from 0 to +5 V dc when the flag is moved in and out of the sensor. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the envelope system board.

2-40 Service Manual

4069-XXX Operator panel displays 260 Paper Jam after attempted feed but

before envelopes are put in the hopper OR the operator panel continues to display "Load Envelopes" after envelopes are placed in the hopper.

Service Tip: The kick rolls rotate during the attempted feed cycles.

FRU Action

1 Envelope Out Hopper

Sensor Flag

2 Envelope Out Hopper Input

Sensor

Check the envelope out sensor flag for damage, correct installation and operation. If incorrect, repair or replace the flag.

Check the sensor to make sure it is installed correctly and the sensor cable is properly connected to the envelope system board. If correct, perform the Envelope Feed Sensor Test to check both the sensor and flag. If the test fails, remove any envelopes in the hopper, turn the printer off and disconnect J3 from the system board. T urn the printer on and check the voltage at J3-3 on the system board. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, replace the input sensor assembly.

Diagnostic Information 2-41

4069-XXX 990 Service Error, Envelopes fail to feed from the hopper.

FRU Action

1 D.C. Feed Motor Assembly Check the motor and motor cable for

2 Envelope Feeder System

Board

any signs of loose wires or poor connections. Check to make sure the motor cable is connected to the envelope system board.

Check the voltage on J4-1. The voltage measures approximately +24 V dc. If incorrect, replace the envelope system board, if correct, measure the voltage at J4-6. The voltage measures approximately +5 V dc. If incorrect, disconnect J4 and measure the voltage again. If incorrect, replace the envelope feeder system board. If correct, replace the D.C. motor assembly.

260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls ARE NOT rotating.

FRU Action

1 Main Drive Belt Check the belt for correct installation

and for signs of damage. Replace as necessary.

2 Gears Check all the gears for correct

3 Clutch Latch Assembly Check the clutch latch assembly to

4 Master Cam Gear Master/

Kick Gear

installation and for signs of damage. Repair or replace parts as necessary.

make sure it moves freely. Check the master cam gear and

master/kick gear to make sure they rotate together. If not, then the tenons on the master kick gear may be sheared off. If incorrect, replace the master kick gear.

2-42 Service Manual

4069-XXX 260 Paper Jam displays, unable to clear and envelopes fail to feed

from the hopper. Kick rolls ARE rotating.

Check the deflector gap adjustment before continuing this service check.

FRU Action

1 Deflector Gap Adjustment Check the deflector gap adjustment.

2 Weight Assembly Check the weight assembly to make

3 Envelope Edge Guide Check the envelope edge guide to

The adjustment may be too narrow.

sure it moves up and down freely without any binds. Also check to make sure the weight assembly rests on all the rear kick rollers when the hopper is empty. Replace the weight assembly if it is damaged or does not operate properly.

make sure it is not warped or set too close to the envelopes in the hopper . Replace the edge guide if it is damaged or does not operate properly.

Diagnostic Information 2-43

4069-XXX 260 Paper Jam displays, envelope stops in feeder paper path.

FRU Action

1 Kick Rolls/Feed Rolls/Drive

Rolls

2 Deflector Gap Adjustment Check the deflector gap adjustment.

Check all the rolls for any signs of oil, grease or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder option.

The adjustment may be too narrow.

Envelope Feeder multifeeds or may not display a 260 Paper Jam message.

FRU Action

1 Envelopes Check the envelopes being used in

the feeder. Check for signs of the envelopes being stuck together or signs of glue. Check to make sure the flaps are not interleaved.

2 Deflector Check the deflector gap adjustment.

3 Restraint Roll Bias Spring Check for a missing, broken or

The adjustment may be too wide.

incorrectly installed restraint roll bias spring. If incorrect, reinstall or replace the spring.

260 Paper Jam displays. An envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path.

FRU Action

1 Latch Lever Check to make sure the tip of the

latch lever is centered in the opening in the floor of the paper path. The latch lever may not be detented on the latch.

2-44 Service Manual

4069-XXX

Erase Lamp Service Check (010/212/414/616/31v/01n/ 21n/31e/41n/61n)

Error code 928 may be displayed when the printer detects that the erase lamp assembly, cab le or engine board is defective.

Note: If the erase lamp assembly is defective, both the erase lamp and lens are replaced as a kit. Models 41b/41e/41l and any model at service level B do not have erase lamps installed. Go to “Printer

Serial Label” on page 7-2 to identify the printer service level.

Make the following checks when a 928 service error displays.

FRU Action

1 Cable, Front Harness Check the connection of the front

2 Engine Board Remove the controller board and

harness to connector J10 on the engine board for correct installation. If incorrect, repair as necessary. Check the front harness to erase lamp assembly for co rrect installation. If incorrect, repair as necessary.

toner cartridge from the machine. Ground pin J10-15 . The erase l amps turn on. The lamps can be o bse rved through the front of the mach ine with the cover open and print cartridge remove d. If the lamps do not turn on, measure the v oltage on J10-14. The voltage reads approximately +24 V dc. If incorrect, replace the engine board. If correct, chec k the voltage at J10-1 5. The v oltage re ads between +15 V dc to +20 V dc. If incorrect, check the continuity of the erase lamp lines in the main harness. If incorrect, replace the cable harness. If c orrect, repla ce the erase lamp a ssembly.

Diagnostic Information 2-45

4069-XXX

Fan Service Check

Auxiliary Fan Service Check

The auxiliary fan is in models 414/616/41l/61n.

Fan does not run or is noisy.

FRU Action

1 Fan Assembly Check the fan for proper installation

2 Engine Board Check to make sure the auxil iary fan

and for excessive noise. If incorrect, replace the fan and cable assembly.

cable is seated on connector J7 on the engine board. If correct, check for +24 V dc on J7-1 on the engine board. If incorrect, replace the engine board. If correct, replace the fan assembly.

Note: When the printer is in warmup the voltage at J7-1 measures approximately +12 V dc. When the printer is running, the voltage measures approximately +24 V dc.

Main Fan Service Check

Check the cable connections at J1 on the engine board and at the main fan assembly . The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode.

FRU Action

1 Main Fan Manually spin the fan and chec k t hat

2 Main Fan to Engine Board

Cable

it rotates freely. Check the cable connection to the engine board, J1 for correct insta lla tio n.

Check the continuity of the cable. If incorrect, replace the cable.

2-46 Service Manual

4069-XXX

FRU Action

3 Error Code 927 (Fan runs) Check the voltage at J1-1 on the

4 Error Code 927

(Fan not running)

engine board. The voltage measures +5 V dc (static) 0 V dc (fan running). If incorrect, replace the main fan. If this does not fix the problem, replace the engine board.

Check the voltage at J1-3 on the engine board. The voltages are as follows:

+22 V dc to +24 V dc (printer and fan running)

+12 V dc to +15 V dc (printer not running - fan running about half speed).

If incorrect, replace the engine board. If this does not fix the problem, replace the main fan.

Fuser Service Check Hot Roll Fuser

Cold Fuser Service Check

Error codes 920, 921, and 922 may display for a cold fuser failure. A 920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error indicates the wrong fuser lamp is installed in the printer and does not match the one stored in the printer code.

Note:

Make sure the fuser is correctly installed before proceeding with this service check. The fuser must be firmly seated in the two rear connectors. Both the right and left lock down screws must be tight.

Service Tip: Set the Fuser Temperature to NORMAL before starting this service check.

Diagnostic Information 2-47

4069-XXX

FRU Action

1 Fuser Lamp (Incorrect

Lamp/925 Service Error)

2 Fuser Lamp Remove the controller board. Run

3LVPS

LVPS to Fuser Auto Docking Connector Fuser AC Cable

4 Fuser Top Cover Assembly

(Thermal Fuse/Thermistor Assembly)

Install the correct voltage and wattage lamp or fuser assembly.

the Diagnostic Print Test and observe the lamp through the left side frame. If the lamp doesn’t come on, unplug the printer and check the continuity between the two pins on the fuser lamp cable going to the fuser assembly. If you do not measure continuity , remo ve the fuser assembly and check the continuity of the lamp. If incorrect, replace the lamp. If correct, replace the fuser cover assembly.

Turn the printer off. Remove the fuser assembly. Turn the printer power on. Measure across the AC fuser cable pins for line voltage with the cable connected. If incorrect, turn the printer off and disconnect the power cord. Check the continuity of the LVPS to fuser AC cable. If incorrect, replace the cable. If correct, replace the LVPS.

Disconnect the thermistor cable from the fuser board at J2. The resistance is as follows:

2-48 Service Manual

HOT - J2-1 - J2-2 = 2.5K ohms COLD = 150K ohms to 260K ohms

4069-XXX Hot Fuser Service Check

Error codes 923 and 924 may display for a hot fuser failure.

CAUTION:

The fuser may be hot, use caution before removing or

servicing.

FRU Action

1Fuser Cover Assembly

(Assembly includes Thermistor and Thermal Fuses.)

2 Engine Board Error code 924 indicates the engine

Check for damage to the thermistor assembly. Check the resistance of the thermistor:

HOT - J2-1 to J2-2 = 2.5K ohms COLD =150K ohms to 260K ohms Check the continuity from each pin

of J2 to ground. If there is continuity, replace the fuser cover assembly

board detects an open circuit in the thermistor circuit for the fuser assembly. The voltage on J2-6 on the engine board measures approximately +5 V dc. If incorrect, replace the engine board. If correct, check the continuity of the DC fuser cable (fuser board to auto docking connector) in the fuser assembly and the DC fuser cable (engine board to auto docking connector) in the printer. If there is no continuity, replace the cable. If there is continuity, check the voltage on J2-2 on the fuser control board. It measures approximately +5 V dc. If incorrect, replace the fuser control board.

3 Fuser Hot Roll

Backup Roll Bearings

Examine the fuser assembly for signs of overheating or damage. Check the hot roll and backup roll f or signs of excessive toner, label glue, labels or other contaminants. If any are found, repair as necessary or replace the fuser assembly.

Diagnostic Information 2-49

4069-XXX

Belt Fuser

Hot Fuser Service Check

Error codes 923 and 924 may display for a hot fuser failure.

Note:

The belt fuser assembly is a FRU. Do not attempt to

disassemble and repair the belt fuser.

CAUTION:

The fuser may be hot, use caution before removing or

servicing.

FRU Action

1 Engine Board

EP Autoconnect Cable (Engine Board to Fuser)

Error code 924 indicates the engine board detects an open circuit in the thermistor circuit for the fuser assembly. The voltage on J2-6 on the engine board measures approximately +5 V dc. If incorrect, replace the engine board. If correct, check the continuity of the DC fuser cable (engine board to auto docking connector) in the printer. If there is no continuity, replace the cable. If there is continuity, replace the belt fuser assembly.

2-50 Service Manual

4069-XXX

Fuser Solenoid Service Check

The fuser solenoid is in all models except the 31v and 31e. Service Tip: Try changing the envelope enhance level setting. A

different setting may correct the problem. Note: Check the fuser envelope conditioner solenoid adjustment as

described in the adjustment section “Fuser Solenoid Adjustment” on

page 4-3.

FRU Action

1 Fuser Envelope Conditioner

Solenoid

2 Fuser Control Board The solenoid receives power from the

The operation of the fuser solenoid can be observed by removing the redrive assembly. Check for proper mechanical operation of the solenoid and associated hardware, link and so on. If correct, check the resistance of the solenoid between J4-1 and J4-2. The resistance measures between 5 ohms and 10 ohms. If incorrect, replace the solenoid assembly.

engine board. The fuse r co ntrol boa rd receives +42Vdc from the LVPS via the interconnect board. Check for approximately +42 V dc at the +42 V dc test point o n the fuser co ntrol board. If the v oltage is correct , replace the fuser control board.

Diagnostic Information 2-51

4069-XXX

FRU Action

3LVPS

Interconnect Board

4 Fuser DC Cable (Engine

Board to Fuser Board Cable) Engine Board

If the +42 V dc test point does not measure approximately +42 V dc, check the voltage at CN3-18 on the LVPS. The voltage measures approximately +42 V dc. If the voltage is correct, replace the interconnect board assembly. If the voltage is incorrect, replace the LVPS.

Check for continuity of the DC fuser cable that is attached between J2 on the engine board and J1 on the fuser control board. If the cable does not measure continuity, replace the cable. If the cable measures continuity, replace the engine board.

Input Sensor Service Check

Service Tip: Run the Base Sensor Test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor.

Service Tip: Run a Diagnostic Print T est in the continuous mode with the controller board removed. A defective input sensor or circuit causes the first copy to exit only partially through the fuser assembly.

FRU Action

1 Input Sensor Flag Check the input sensor flag for

2 Engine Board Check for approximately +5 V dc at

damage and proper operation. If a problem is found, repair as necessary.

J10-10 on the engine board. If incorrect, replace the engine board.

2-52 Service Manual

4069-XXX

FRU Action

3 Input Sensor Cable Check the continuity of the input

sensor cable section of the front wiring harness. If incorrect, replace the harness. If correct, replace the input sensor assembly.

Input Tray(s) Option Service Check

250 Sheet and 500 Sheet Trays

Service Tip: Try all the other input paper sources to make sure they are properly feeding paper.

For 990 Error Code- Service Tray X, X= displays the number of the tray that has a problem or needs service.

FRU Action

1 T r ay X option System Board

or Compensator Assembly or Autoconnect Cable

Check the autoconect cables and connectors for any signs of damage. Replace if necessary. Check the cables for continuity. If incorrect, replace the compensator assembly cable. If the cables, connectors and connections are good, replace the FRUs in the following order:

autocompensator assembly option system board

Diagnostic Information 2-53

4069-XXX 24X Paper Jam message displays, Paper jammed over the Pass

Thru Sensor. (The printer displays the value of X for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1)

FRU Action

1 Pass Thru Sensor and Flag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller

The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor for correct installation and the flag for proper operation. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, replace the tray x option pass thru sensor assembly.

Check these parts for signs of broken or damaged parts, contamination on the drive rollers or wear plate and wear or damage to the drive shaft bearings. Check the drive roll assembly and skewed backup roller for signs of wear, slick spots, material buildup, and oil or grease on the rollers. Also check for proper operation of the paper aligning assembly. Repair or replace parts as necessary.

2-54 Service Manual

4069-XXX Tray X Low message displays when Tray X is full or has adequate

paper in the tray.

FRU Action

1 Paper Low Sensor

Assembly Paper Low Sensor Flag Tray X Option System Board

Run the Tray X Sensor Test and check the sensor for proper operation. If incorrect, check the following:

Paper low sensor flag for smooth and correct operation.

Paper low sensor for correct installation on the autocompensator housing.

Paper low sensor cable for signs of cuts, pinched wiring or other damage especially at connector J5 on the system board.

If no problem is found, replace the paper low sensor assembly. If this does not correct the problem, replace the option system board.

Tray X Empty message displays when Tray X has paper in the tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for 2 Paper Out Sensor (On

Option System Board)

correct operation and installation. If correct, replace the option system board. (The paper out sensor is mounted on the system board).

Diagnostic Information 2-55

4069-XXX Printer does not recognize Tray X is installed.

FRU Action

1 Autoconect Cables

Tray X System Board

Check the autoconnect from the printer or option above tray x. Check for signs of cuts, pinched wiring or damage to the contacts in the connector. Check the autoconnect cable(s) for correct installation at the tray x system board. If correct, check the continuity of the autoconnect cable(s). If correct, replace the tray x system board. If incorrect, replace the cable.

Paper from Tray X does not reach the Pass Thru Sensor.

Service Tip: Check the media in tray x to make sure it is within specifications. Some types of labels, foil material and slick papers can cause misfeeds and slippage of the rollers.

FRU Action

1 Autocompensator

Assembly

Check the autocompensator pick arm rollers for any sign of glazing, toner or other buildup. Clean or replace as necessary.

High Capacity Feeder Input Tray Service Check

Note:

Voltage measurements in the high capacity feeder input tray service checks must be made with the high capacity feeder attached to the base printer to obtain accurate results.

Service Tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations f or the size of paper installed in the high capacity feeder tray.

Service Tip: Check the other paper sources to be sure they are operating correctly.

2-56 Service Manual

4069-XXX The base printer indicates a dead machine condition when the

high capacity input tray is installed.

FRU Action

1 AC Line Cord

AC Jumper (HCIT to Printer) AC input and Output Receptacles AC Wiring Harness

If the base printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT, check the AC jumper cord. If defective, replace the cord. If not defective, check the AC input and output receptacles and wiring harness in the HCIT. Repair or replace the receptacles or AC wiring harness as required.

Make sure the ground wire is

NOTE:

installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lockwasher are tightened down.

Diagnostic Information 2-57

4069-XXX

The base printer does not recognize that the high capacity input tray is installed.

FRU Action

1 High Capacity Feeder

Autoconne ct Me ch ani cal Check

2 Base Printer or option

mounted above

3 LVPS (2000 Sheet Option)

Option System Board

Check the high capac ity f e eder in put tray to make sure it is mounted correctly and is not pushed down into the frame assembly or damaged. Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly.

Check the option or base printer autoconnect for si gns of damag e . Repair the high capacity option autoconnect as necessary.

Check the voltages at J11-2 and J11-4. The voltage measures +24 V dc, If the voltage is correct, replace the high capacity system board assembly. If the voltage is incorrect, check the continuity of the AC input cable to the LVPS. If correct, replace the LVPS assemb ly. If incorrect, replace the AC cable to the input of the LVPS.

2-58 Service Manual

4069-XXX

FRU Action

4 High Capacity Feeder

Option Control Board

Check the voltage on J8-1 (green). The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized. If the voltage is correct, check the voltages at J11-3(red) and J114(red). The voltages measure +24 V dc. If correct, replace the high capacity feeder option system board. If incorrect, disconnect J8 from the system board and measure the voltages again. If incorrect, check the LVPS cable and the A.C. internal wiring from the input appliance receptacle. If incorrect, replace as necessary. If correct, replace the LVPS. If the voltages are correct, check the stepper motor for shorts from the motor housing to each pin on the motor connector. If you find a short between any pin and the motor housing, replace the motor assembly. If no shorts are found, replace the high capacity feeder option control board.

Check the voltage at J9-1 (light blue). The voltage measures approximately +24 V dc. If incorrect, disconnect the cable at J9 and check the voltage again. If the voltage continues to be incorrect, replace the high capacity feeder option system board. If the voltage measures correctly, check the cable . If the cable is damaged, replace as necessary. If no problem is found with the cable, replace the high capacity feeder option control board.

Diagnostic Information 2-59

4069-XXX 24X Paper Jam message displays, Paper jammed over the Pass

Thru Sensor. (X=The printer displays the value of X for the paper tray where the error occurs. Example: 242 is a Paper Jam Tray 2)

FRU Action

1 Pass Thru Sensor and Flag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller

2-60 Service Manual

4069-XXX Tray X Paper Low Message displays when Tray X is full or has

adequate Paper in the tray.

FRU Action

1 Paper Low Switch

Paper Low Switch Cable High Capacity Feeder Input System Board

Run the sensor diagnostics for tray X (X=the number that represents the high capacity input tray). If the test fails, disconnect the paper low s witch cable from J3 on the high capacity system board. Short pins 1 and 2 together while observing the sensor test on the display. If the display does not change, replace the high capacity feeder system board. If the display changes check the continuity of the switch. If incorrect, replace the switch. If correct, replace the switch cable.

Tray X empty message displays when there is paper in the high capacity feeder input tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for 2 Paper Out Sensor

(On Option System Board)

correct operation and installation. If correct, replace the high capacity feeder system board. (The paper out sensor is mounted on the high capacity feeder system board).

Diagnostic Information 2-61

4069-XXX The elevator tray fails to stop at the correct position and continues

to drive into the bottom frame.

FRU Action

1 Lower Limit Switch

Lower Limit Switch Cable

2 High Capacity Feeder

Control Board

Check continuity of the lower limit switch. If incorrect, replace the switch. If correct, check the switch cable. If incorrect, replace the cable. If correct, replace the high capacity feeder option control board.

Disconnect the lower limit switch cable and check the voltage at J2-1 (orange). The voltage measures approximately +5 V dc. If incorrect, replace the high capacity feeder option control board.

The elevator tray down button does not operate. The tray moves to the upper position.

Service Tip: Open the high capacity feeder option front door and check the black rubber bumper attached to the door switch spring. Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly.

FRU Action

1 Lower Limit Switch

Lower Limit Switch Cable High Capacity Feeder Control Board

2-62 Service Manual

Check the lower limit switch to make sure it is not closed (normally open). If incorrect, replace the switch. Check the lower limit switch cab le f or a short between pins 1 and 2. If incorrect, replace the cable. If correct, replace the high capacity feeder option control board.

4069-XXX Paper from the high capacity feeder input tray does not reach the

pass thru sensor.

Service Tip: Check to be sure the paper in tray is within specifications.

FRU Action

1 Autocompensator

Assembly

2 Wear Strips Check the wear strips for glazing or

Check the autocompensator pick arm rollers for sign of glazing, toner or other buildup. Replace as necessary.

contamination. Replace as required. It is advisable to replace all four wear strips at the same time.

Diagnostic Information 2-63

4069-XXX The elevator tray does not move up or down. The printer

recognizes that the option is installed.

FRU Action

1 DC Drive Motor High

Capacity Feeder Option System Board

Be sure the motor cable is correctly installed at J1 on the board. Check the cables, damaged or loose wires. Disconnect the motor. Check for a short between each pin and the motor housing. If a problem is found, replace the motor assembly. If no problem is found, measure the resistance between the following pins on the motor cable connector:

Pins 1 (brown) and pin 2 (Yellow) The resistance measures between

approximately 7.5 and 10.5 ohms. If incorrect, replace the motor assembly. If correct, replace the high capacity feeder option system board.

2-64 Service Manual

4069-XXX The elevator moves in one direction only.

FRU Action

1 DC Drive Motor

Assembly High Capacity Feeder System Board

Check the voltages at J1 on the high capacity system board. The voltages measure as follows:

Static (Motor Not Running) J1-1 (Brown): approximately 0 V dc J1-2 (yellow): approximately 0V dc

Motor Running Forward J1-1 (Brown): Approximately 0 V dc J1-2 (Yellow): Approximately +24V dc

Motor Running Reverse J1-1 (Brown): Approximately +24 V dc J1-2 (Yellow): Approximately 0 V dc

If any of the voltages are incorrect, disconnect the motor and measure the resistance between J-1 and J-2. The resistance measures between 7.5 and 10.5 ohms. If incorrect replace the motor. If correct, replace the system board.

Diagnostic Information 2-65

4069-XXX Paper size switch not selecting paper size that is selected.

FRU Action

1 Paper Size Switch

High Capacity Feeder Option Control Board

Check for continuity between the common pin (J5-1) and the pin of the paper size selected.

J5-1 (Black): Common Lead J5-2 (Blue)B5 J5-3 (Green) Executive J5-4 (Yellow) A4 J5-5 (Orange) Letter J5-6 (Red) Legal J5-7 (Brown) A5

If any position does not measure continuity when selected, replace the paper size switch assembly. If the switch assembly is operating correctly, replace the high capacity feeder option control board.

24X Paper Jam Check Tray X Message displays when Tray X is empty. No Tray X Message displays.

FRU Action

1 High Capacity Feeder

Option Control Board

Check the voltages on the board at J4-1(red) and J4-3 (blue). The voltages measure approximately +5 V dc. If incorrect, disconnect J4 from the board and measure the voltages again. If incorrect, replace the high capacity feeder option control board.

2 Elevator Top Optical

Sensor Cable Elevator Top Optical Sensor

2-66 Service Manual

Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.

4069-XXX Tray X Empty message displays. Tray does not respond to loading

paper. No response from the front door switch.

FRU Action

1 High Capacity Feeder

Option Control Board

2 Elevator Top Optical

Sensor Cable Elevator Top Optical Sensor

Check the voltage on the board at J4-2 (green). The voltage measures approximately +5 V dc. If incorrect, disconnect the cable at J4 and check the voltage again. If incorrect, replace the high capacity feeder option control board.

Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.

Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate paper in the tray.

FRU Action

1 Paper Low Switch

Paper Low Switch Cable High Capacity Feeder Option Control Board

Run the sensor diagnostics for tray X (X=the number that represents the high capacity input tray). If the test fails, check the voltage at J3-1 (grey). The voltage measures approximately +24 V dc. If incorrect, disconnect the paper low switch cable from J3 and measure the voltage again on J3-1. If incorrect, replace the high capacity feeder option control board. If correct, check the cable for a short between pins 1 and 2 on the cable. If incorrect, replace the cable. If correct, check the switch for a bent or deformed actuator lever or defective s witch. If incorrect, replace the switch.

Diagnostic Information 2-67

4069-XXX Excessive Noise or Vibration

FRU Action

1 DC Motor Assembly Check to make sure all the motor

2 Idler Pulley

DC Motor Assembly

3 Drive Pulley Check the drive pulley for any signs

4 Motor Drive Belt

Tray Drive Belt

plate mounting screws are tight. Check to make sure the idler pulley

is not binding on the pulley shaft. Check the pulley for any signs of wear. Check the idler pulley shaft on the motor mounting plate for any signs of damage or contamination.

of wear, binds or damage to the pulley or pulley shaft. Make sure the pulley turns freely on the pulley shaft.

Check the DC motor drive belt for any signs of damage. Check to make sure the belt is tracking correctly on the drive pulley, idler pulley and motor pulley. Check the tray drive belt for any signs of damage. Check to make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys.

2-68 Service Manual

4069-XXX

Main Drive Service Check

Service Tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or engine board.

Service Tip: If there are equally spaced horizontal lines across the page, go to

page 2-97

“Print Quality - Evenly spaced horizontal lines or marks” on

WARNING:

Whenever the gearbox assembly is removed from the machine it must be handled very carefully. Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage . It is also v ery important not to let any dirt, paper, staples or other material come intact with the grease in the gearbox assembly.

FRU Action

1 Main Drive Assembly

(Excessive noise or vibration)

2 Main Drive Motor Assembly

(Excessive noise, gears ratcheting and so on)

Remove the controller board and run a Diagnostic Print Test in the continuous mode. Check the main drive assembly for any excessive noise or vibration. Determine if the noise is in the main drive, toner cartridge, fuser or main drive gearbox. Look for any loose or worn parts in the developer drive assembly, main drive gearbox or fuser. Repair as necessary.

A service error code 936 - Transport Motor may be displayed. Check the voltage at J12-6 on the engine board. It measures approximately +5 V dc when the motor is not running and goes to 0 V dc when the motor is running. If incorrect, replace the engine board. If this does not fix the problem, replace the main drive motor.

3 Main Drive Motor Cable Check the continuity of the main

drive motor cable. If incorrect, replace the cable.

Diagnostic Information 2-69

4069-XXX

FRU Action

4 Motor does not turn, no

gear error code 936 or User message 201 Paper Jam displays.

Check the voltages at J12 on the engine board.

Pin number and voltage: J12-1 = +24 V dc J12-4 = +5 V dc (static) 0 V dc

(when main drive motor running) J12-5 = + 5 V dc (static) 0 V dc

(when main drive motor running) J12-6 = +5 V dc (static) +2.5 V dc

(when main drive motor running) J12-7 = +5 V dc (static) 0 V dc

(when main drive motor running) J12-8 = +5 V dc (static) +5 V dc

(when main drive motor running) J12-11 = + 5 V dc (static) 0 V dc

(when main drive motor running) If the voltage is incorrect, replace the

FRUs in the following order: main drive motor assembly engine board

Operator Panel Service Check

Operator Panel Buttons Service Check

Note:

on page 3-9

1 Operator Panel Assembly If any button fails the Button Test,

Before continuing with this service check do the

in the diagnostic aids chapter.

FRU Action

replace the operator panel assembly.

2-70 Service Manual

“Button Test”

4069-XXX

FRU Action

2 Engine Board

(No buttons work)

Check the voltage at J11-5. The voltage measures approximately +5 V dc with the controller board removed. If incorrect, replace the engine board. If correct, check the continuity of the operator panel cable. If incorrect, replace the cable. If correct, replace the operator panel assembly.

Operator Panel Display Service Check

SERVICE TIP: The printer has detected a problem with the engine board, operator panel cable or operator panel assembly if POST does not complete and the printer emits 5 beeps and stops in a continuous pattern until the printer is turned off. The operator panel cable is an individual cable on some printers and a combination cable assembly with the cover switch cable on later models.

Note:

a few PELS missing or broken, run the

If the operator panel is operating properly except f or a PEL or

“LCD Test” on page 3-9

the hardware tests before continuing with this diagnostic service check.

FRU Action

from

1 Operator Panel Cable Check for proper installation of the

2 Operator Panel Display

blank, 5 beeps, LED Off

3 Operator Panel Display

blank, 5 beeps, LED On

cable at the engine board (J11) and at the operator panel. Check the continuity of the operator panel cable. If incorrect, replace the cable.

Check the voltage at J11-2 on the engine board. It measures approximately +5 V dc. If incorrect, replace the engine board. If correct, replace the operator panel assembly.

Check for ground between J13-4 and ground. If correct, replace the operator panel assembly . If incorrect, replace the engine board.

Diagnostic Information 2-71

Lexmark 4069-61n, 4069-41n, 4069-41l, 4069-41e, 4069-41b Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual