Lexmark T62X Service manual

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Revised: December 20, 2006

Lexmark™ T62X

4069-5xx/7xx

• Table of Contents

•Start Diagnostics

• Safety and Notices

• Trademarks

•Index

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark International, Inc., registered in the United States and/or ot her countries.

4069-5XX/7XX

Edition: December 20, 2006

he following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTERN ATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND , EITHER EXPRESS OR IMPLIED, INCLUDING , BUT NOT LIMITED TO, THE IMPLIED W A RRANTIES OF MERCHANT ABI LITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclai mer of e x press or implied w arranties in certain transactions; therefore, this statement may not apply to you.

his publication could include technical inaccuracies or typographical errors. Changes are periodically made to the informa tion her ein; these change s will be i ncorporated in late r editions. Improv ements or changes in the products or the prog rams descr ibed may be made at any time.

Comments may be addressed to Lexmark International, Inc., Departme nt D22A/03 2-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes approp riate without incurring any obligation

o you.

Image Q uick, O ptra Forms, Pi ctureGr ade and St apleSmart are trademarks of Lexmark International, Inc.

Lexmark and Lexmark with diamond design, Prebate an d Ma rk N e t are tr ad em arks of Lexmark Intern ational, Inc., registered in the United States and /or othe r countries.

PostScript is a registered trademark of Adobe Systems Incorporated. PCL is a register ed trad emark of the Hewlett-Packard Company. Other trademarks are the property of their r espective own ers.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

his software and documentation are provided with RESTRICTED RIGHTS. Use, duplic ation or disclosure by the Gov ernment is subject to restrict ions as set forth in subparagraph (c)(1 )(ii) of the Rights in Technical Data and Com puter Software cl ause at DFARS 252.227-7013 and in applicable F AR provisions: Lexmark International, Inc., Lexington, KY 40550.

P/N: 12G3959

4069-5XX/7XX

Table of Content

Laser Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-ix

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xix

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xxiv

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Tools Required for Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

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

User Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

User Attendance Messages. . . . . . . . . . . . . . . . . . . . . . . 2-29

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . 2-41

Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Charge Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-47

Cover Open Switch/Cable Service Check . . . . . . . . . . . . 2-49

Dead Machine Service Check . . . . . . . . . . . . . . . . . . . . . 2-50

Duplex Option Service Check . . . . . . . . . . . . . . . . . . . . . 2-53

Envelope Feeder Option Service Check . . . . . . . . . . . . . 2-56

Fan Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63

Cold Fuser Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-65

Hot Fuser Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-67

Fuser Solenoid Service Check. . . . . . . . . . . . . . . . . . . . . 2-68

Input Sensor Service Check . . . . . . . . . . . . . . . . . . . . . . 2-68

Input Tray(s) Option Service Check . . . . . . . . . . . . . . . . . 2-69

High-Capacity Feeder Input Tray Service Check. . . . . . . 2-72

Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-85

Operator Panel Service Check . . . . . . . . . . . . . . . . . . . . 2-86

Options Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88

Output Bin Sensor Standard Tray Service Check . . . . . . 2-90

Output Expander Service Check . . . . . . . . . . . . . . . . . . . 2-91

High-Capacity Output Stacker Service Check . . . . . . . . . 2-96

5-Bin Mailbox Service Check. . . . . . . . . . . . . . . . . . . . . . 2-99

Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-105

Parallel Port Service Check. . . . . . . . . . . . . . . . . . . . . . 2-107

Printhead Service Check. . . . . . . . . . . . . . . . . . . . . . . . 2-108

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Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . .2-109

Smart Cartridge Contact Assembly Service Check. . . . .2-121

Serial Port Service Check. . . . . . . . . . . . . . . . . . . . . . . .2-122

Toner Sensor Service Check . . . . . . . . . . . . . . . . . . . . .2-122

Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . .2-123

StapleSmart Finisher Service Check . . . . . . . . . . . . . . .2-125

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Diagnostic/Configuration Menu. . . . . . . . . . . . . . . . . . . . . .3-1

Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Exiting the Diagnostics Mode . . . . . . . . . . . . . . . . . . . . . . .3-6

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Quick Disk Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Disk Test/Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . .3-8

Duplex Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Duplex Quick Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Duplex Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Duplex Motor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Duplex Feed 1 Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Duplex Feed 2 Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Clearing the Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

LCD Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

SDRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Parallel Wrap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Input Tray Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Input Tray Feed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Input Tray Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Output Bin - Feed to all Bins Test . . . . . . . . . . . . . . . . . . . . . .3-20

Output Bin Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Finisher Tests, StapleSmart Finisher Option . . . . . . . . . . . . . .3-24

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26

StapleSmart Finisher Tests . . . . . . . . . . . . . . . . . . . . . . . .3-26

StapleSmart Finisher Sensor Test . . . . . . . . . . . . . . . . . .3-27

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5-Bin Mailbox Diverter Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -28

Printer Setu p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Viewing the Permanent Page Count . . . . . . . . . . . . . . . . 3-30

Maintenance Page Count . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Setting Configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -33

Print Quality Test Pages . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-36

Auto Compensator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3 -36

Autoconnect System, Paper Tray Options, Envelo pe Feeder and

Output Expander Operations . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Fuser Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Paper Feed Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Paper Jams - Base Printer. . . . . . . . . . . . . . . . . . . . . . . . 3-40

Paper Jams - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Repair Informatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Card Assembly (NAND Flash). . . . . . . . . . . . . . . . . . . . . 4-18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Developer Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . 4-20

Duplex Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Front Cover Assembly. . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Front Cover Door. . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

EMC Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4069-5XX/7XX

Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30

Fuser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Fuser Detack Fingers . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Fuser Detack Housing Asse mbl y . . . . . . . . . . . . . . . . . . .4-32

Fuser Transfer Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33

Fuser Envelope Conditioner Solenoid. . . . . . . . . . . . . . . .4-34

Fuser Narrow Media Sensor/Flag Assembly . . . . . . . . . . .4-35

Fuser Exit Sensor Flag Assembly. . . . . . . . . . . . . . . . . . .4-35

Fuser Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

Fuser Lower Exit Guide Assembly . . . . . . . . . . . . . . . . . .4-36

High Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . .4-37

Integrated Tray Compensator Assembly. . . . . . . . . . . . . .4-37

Integrated Tray Compensator Pick Roll Assembly . . . . . .4-38

Interconnect Board Assembly. . . . . . . . . . . . . . . . . . . . . .4-40

Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . .4-42

Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43

Main Drive Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45

Multipurpose Tray/Lower Deflector Assembly. . . . . . . . . .4-46

Operator Panel Assembly . . . . . . . . . . . . . . . . . . . . . . . . .4-48

Operator Panel Cable/Cover Open Switch Assembly. . . .4-49

Optional 250/500 Paper Tray Assembly . . . . . . . . . . . . . .4-50

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

Paper Deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-53

Paper Input Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Paper Size Sensing Board . . . . . . . . . . . . . . . . . . . . . . . .4-54

Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-54

Printhead (4069-520/52n) . . . . . . . . . . . . . . . . . . . . . . . . .4-55

Printhead (4069-722/72n) . . . . . . . . . . . . . . . . . . . . . . . . .4-56

Redrive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-57

Smart Cartridge Contact Assembly. . . . . . . . . . . . . . . . . .4-58

Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59

Transfer Roll Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . .4-60

Upper Paper Deflector Assembly . . . . . . . . . . . . . . . . . . .4-60

Upper Front Cover Hinge Assembly . . . . . . . . . . . . . . . . .4-61

Upper Front Cover Interlock Switch Assembly . . . . . . . . .4-62

Pick Roller Repla ce me n t. . . . . . . . . . . . . . . . . . . . . . . . . .4-63

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

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

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

Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Envelope Option Board. . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

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Duplex Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Autoconnect - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Output Expander Control Board. . . . . . . . . . . . . . . . . . . . 5-12

High-Capacity Output Stacker Board. . . . . . . . . . . . . . . . 5-14

System Board Connector Locations . . . . . . . . . . . . . . . . 5-16

System Board Connector Locations . . . . . . . . . . . . . . . . 5-20

StapleSmart Finisher Option - Staple Card Assembly. . . 5-27

Cables - Base Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -31

Fuser Cable, DC Internal. . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Autoconnect Cable, (Fuser to LVPS). . . . . . . . . . . . . . . . 5-31

Deflector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Fuser Cable, AC EP Autoconnect to Fuser Top Cover . . 5-32

Integrated Tray Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

HSYNC Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Mirror Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Main Drive Motor Cable. . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Laser Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Front Harness Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Fuser Cable, DC EP Autoconnect to System Board . . . . 5-34

Autoconnect Cable - System Board to

Top/Interconnect Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Autoconnect Cable - System Board to

Front/Bottom/Interconnect Board. . . . . . . . . . . . . . . . . . . 5-35

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

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

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

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

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

How to Use this Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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

Assembly 2: Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Assembly 3: Printhead. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Assembly 4: Paper Feed (Autocompensator) . . . . . . . . . 7-11

Assembly 5: Paper Feed—Multipurpose Unit . . . . . . . . . 7-12

Assembly 6: Paper Feed—Alignment . . . . . . . . . . . . . . . 7-14

Assembly 7: Paper Feed—Output . . . . . . . . . . . . . . . . . . 7-16

Assembly 8: Integrated Paper Tray—500-Sheet . . . . . . . 7-18

Assembly 9: Main Drive. . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Assembly 10: Developer Drive . . . . . . . . . . . . . . . . . . . . 7-22

Assembly 11: Hot Roll Fuser . . . . . . . . . . . . . . . . . . . . . . 7-24

Assembly 12: Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

Assembly 13: Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

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Assembly 14: Electronics . . . . . . . . . . . . . . . . . . . . . . . . .7-30

Assembly 15: 250-Sheet Tray. . . . . . . . . . . . . . . . . . . . . .7-44

Assembly 16: 500-Sheet Tray. . . . . . . . . . . . . . . . . . . . . .7-50

Assembly 17: Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-54

Assembly 18: Output Expander . . . . . . . . . . . . . . . . . . . .7-60

Assembly 19: Envelope Feed er . . . . . . . . . . . . . . . . . . . .7-64

Assembly 20: High-Capacity Feede r. . . . . . . . . . . . . . . . .7-68

Assembly 21: Kiosk—Vertica l Paper Adapter. . . . . . . . . .7-82

Assembly 22: Kiosk–Horizontal Paper Adapter . . . . . . . .7-84

Assembly 23: High-Capacity Output Stacker . . . . . . . . . .7-86

Assembly 24: 5-Bin Mailbox . . . . . . . . . . . . . . . . . . . . . . .7-92

Assembly 25: StapleSmart Finisher . . . . . . . . . . . . . . . . .7-96

Assembly 26: Options . . . . . . . . . . . . . . . . . . . . . . . . . .7-104

Assembly 27: Miscellaneous . . . . . . . . . . . . . . . . . . . . .7-106

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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Laser Notices

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

Laser Advisory Label

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Class 1 Laser Statement Label

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Laser No tice

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 wavelength 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.

Laserprodukt e der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es sich um einen Galliumar senlaser mit 5 Mi lliwat t hande lt, 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.

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Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est cer tifiée 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.

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 nanometr i. 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

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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 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 potá ssio, 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.

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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.

Laserprodukt en 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 m e t een golflengte van 770-795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebrui k, bij onderhoud of reparatie conform de voorschriften , nooit blootste lling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1.

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 bølgelængdeområdet 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 servicebetingelse r.

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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. Kirjoittimess a on sisäi nen luokan I IIb (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 normaa lin toiminnan, käyttä jän 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.

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 utformade 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.

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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-laserproduk t 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 serviceopera sjoner.

Avís sobr e 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’usuar i 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

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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 par ts.

• 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 precaut ions.

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 sécurité de certain s élémen ts ne sont pas toujours évidente s. 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 r isques électr iqu es, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

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Norme di sicurezza

• Il prodotto è stato progettato, te stato e approvato i n 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 sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei V erantwortung oder Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinandernehme ns und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

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Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

cumplir los más estrictos estándares de seguridad globa l usando los componentes específicos de Lexmark. Pu ede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

Informações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

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Inf ormació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes nor me s de seguretat globals amb la utililitzac ió 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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Safe ty In formation xxiii

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Preface

This book is designed for service personnel. It is divided into the following chapters:

1. General Informati on contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

2. D iagnostic Information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs).

3. D iagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems.

4. Repair Information provides instructions for making printer adjustments and removing and installing FRUs.

5. Connector Locations uses illustrations to identify the connector locations and test points on the printer.

6. Preventive Maintenance contains the lubrication specifications and recommendations to prevent problems.

7. Parts Catalog contains illustrations and part numbers for individual FRUs.

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1. Gen e r a l Informat io n

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

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

Model Name T ype

Lexmark T620 4069-520 Lexmark T620n 4069-52n (Network) Lexmark T622 4069-722 Lexmark T622n 4069-72n (Network)

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Options

The following options are available. Some options are not available in every country. Contact y our point of purchase for options available in your country.

Memory options of 4MB, 8MB, 16MB, 32MB, 64MB and 128MB SDRAM Card Assembly Flash memory options of 2MB, 4MB , 8MB and 16M B Card Assembly Integrated network options

Token-Ring Ethernet Tri-Port Adapter IR Adapter IPDS Card Assembly and SCS/TNe PRESCRIBE Card Assembly TIFF Card Assembl y Bar Code Card Assembly Par allel Interface Card SCS USB/Parallel Port MarkNet™ Print Servers

ImageQuick Card Assembly 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 - 5. 0+ GB Optra Forms™ Hard Disk - 5.0+ GB Vertical Kiosk Presenter Horizontal Kiosk Pres enter Output Expander 5-Bin Mailbox High-Capacity Out put Stacker StapleSmart™ Finisher Option

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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 Phillip s scr ewdriver #2 Phillip s scr ewdriver 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 Cr ysta l Display LED Light-Emitting Diode LVP S Low Voltage Power Supply MROM Masked Read Only Memor y NAND NVRAM Nonvolatile Random Access Memory OEM Original Equip men t Manufacturer PC Photoconductor POR Power-On Reset POST Power-On Self Test RIP Raster Imaging Processor ROM Read Only Memory SDRAM Synchronous Dual Random Access

Memory SRAM S t atic Random Ac cess Memo ry UPR Used Parts Return V ac Vol ts alternating current V dc Vol ts 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 your 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 “Service Error Codes” on

page 2-2.

User status messages provide the user with information on the current status of the printer. Ready is displayed 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 “ U ser

Status Screens” on page 2-24.

User error messages are indicated by a two or three-digit error code that provides the user with information that explains a problem with a print cartrid ge, paper jam, option, por t , and so on. If a user error message is displayed, go to the “User Attendance Messages” on

page 2-29.

If your machine completes the “Power-On Self Test (POST)” on

page 2-41 without an error, and you have a symptom, go to the “Symptom Tables” on page 2-42. 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 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 E xcessi ve PWM

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

error. Replace the system boar d. 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 system 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 2-69.

912 DC Pick Motor below speed

913 DC Pick Motor over speed

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Error Code Action

914 DC Pick Moto r: No encoder feedback

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

920 Fuser Error Indicates that the fuser is below temper ature when

921 Fuser Error Indicates that the fuser is below standby temperature

922 Fuser Error Fuser failed to reach standb y temperature . Go to the

923 Fuser Error Fuser is too hot durin g print ing or when printer i s idle. Go

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

Check the integ rat ed paper tr a y (tra y 1) f or cor rect 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 2-69.

“T ransfer Roll Service Check” on page 2-123.

printing. Go to the “Cold Fuser Service Check” on

page 2-65. Use of the “Base Printer (Fuser) Sub Err or Codes” on page 2-17 may help diagnose fuser failure.

when the printer is idle. Go to the “Cold Fuser Service

Check” on page 2-65. Use of the “Base Printer (Fuser) Sub Error Codes” on page 2-17 may help

diagnose fuser failure .

“Cold Fuser Service Ch eck” on page 2-65. Use of the “Base Printer (Fuser) Sub Error Codes” on page 2-17 may help diagnose fuser failure.

to the “Hot Fuse r S ervice Check” on pa ge 2-67. Use of the “Base Printer (Fuser) Sub Error Codes” on

page 2-17 may help diagnose fuser failure.

Thermistor Circuit. Go to the “Hot Fuser Service

Check” on page 2-67. Use of the “Base Printer (Fuser) Sub Error Codes” on page 2-17 may help

diagnose fuser failure .

925 Fuser Error 1. Indicates the wrong fuser lamp is installed. Check the

fuser lamp for the correct type of lamp that should be installed.

2. Check the line voltage to ensure it is not above the maximum rating for the printer.

3. This error may also indicate t he fuser reached standby temperature too quickly.

4. The hot roll may not be correct f or t his fuser. Ensure that the correct hot roll is installed.

927 Fan Stall ed Indicates a printe r f an stalled. Go to the “Fan Service

Check” on page 2-63.

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Error Code Action

929 T one r Sensor The t oner se nsor is not operat ing pr operly, the devel oper

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

Check” on page 2-122.

930 Printhead Error

932-935 Printhead Error

932 Printhead Error

933 Printhead Error

934 Printhead Error

935 Printhead Error

936-937 Transport Motor

936 - Main Drive Motor init ia l lo ck failure

937 - Main Drive Motor los t lo ck

939 RIP-Engine Communications Lost

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

These errors represe nt a prob le m with the printh ead. Go to the “Printhead Service Check” on page 2-108.

Indicates a pr oblem with the main drive motor. Go to the

“Main Drive Service Check” on page 2-85.

The RIP and engine cannot communi cate with one another. The system board or Int erconnect board is defective. Check for correct installation. If no problem is found, replace the FRUs in the following order:

2-4 Service Manual

System Board Interconnect Board Note: If a problem stil l exists, the RIP software can

cause a 939 error code. Contact your ne xt level for software support.

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Error Code Action

940 Service LV Power Supply

947 PQET Error Indicates that the PQET RAM test was incomplete or a

948 PEL Clock Error

949 Delay Line Calibration Failure

953 - 954 NVRAM Failure

The low voltage power supply zero crossover test failed.

• Check the LVPS for correct instal lat ion. Ensure that the connector on the LVPS assembly is firmly seated with the c onnector on the interconnect card connec tor.

• This error can be caus ed by a noisy AC input power source.

• Check to mak e sure the correct LVPS has been installed.

• If all the above are correct, replace the LVPS assembly.

PQET RAM test busy failure occurr ed. Replace the system board.

Indicates the PEL clo ck check failed. Replace the system board.

Indicates a delay line calibration failure. Replace the system board.

System board failures. 953 NVRAM Chip Failure 954 NVRAM CRC Failure Replace system board.

955 Code CRC <loc>

Code ROM and NAND failed CRC check *<loc> = F or a R OM CRC f ai lure , the l ocati on (loc) will be

a failing block or (B n). *<loc> = For a NAND CRC failur e, the location (loc) will

be a failing page or (Pn). Replace System Board.

Diagnostic Information 2-5

4069-5XX/7XX

Error Code Action

956, 957, 959 System Board

958 NAND Failure

960 - 963 RAM Memory Error

Error codes 956 thru 959 are system board failures. Perform a power on reset (POR). If this does not fix the

problem, replace the system board. *956 = Processor Failure

*957 = ASIC Failure *959 = SRAM Failure

Before proc eeding when a 958 NAND failure is displayed, perform a Power On Reset (power the printer Off then On) to see if the ECC (Error Correc ti on Code) can reflash NAND.

If this does not fix the problem, repl ace the system board.

Error codes 960 thru 963 indic ate the follo wing specific RAM error:

*960 - RAM soldered on the syst em board is failing. Replace the system board. *961 - RAM in slot 1 is fai li ng. *962 - RAM in slot 2 is failing *963 - RAM in slot 3 is fai li ng.

For error s 961 thru 963, if a v ail able , swit ch memory from the failing slot with one from a non-f ailing slot to see if it fixes the problem. If it does fix the problem, replace the system board. If this fixes the problem, replace the defecti ve RAM.

964 Emulation Error

2-6 Service Manual

Download Emulation CRC f ailure has occurred.

4069-5XX/7XX

Error Code Action

975 - 979 Network Card X

980 - 984 Service <device> Comm.

The foll owing errors indicate a failure with t he network card in the speci fi ed slot. X=any card installed in slots 1,2 or 3. 975 - Unrecognizab le Network Card x. Replace Network Card x. 976 - Unrecoverable software error in Network Card x. 977 - Controller sof tware detects that a Network Card is installed in slot x but cannot est ablish communi cations with it. 978 - Bad checksum whil e 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 system board.

These error codes indicate the specified device <device> has detected a paper port failure.

Specified device <device> can be one of the following: *System Board

*Duplex *Tray x (x = 1,2,3,4 or 5) *Env elope Feeder *Output Bin x (x = 1,2,3 to 6) **Will be displayed f or single bin outpu t opt ions. *Output Bins x to y (x to y = 1 to 5, 2 to 6, 6 to 10) **Will be displayed for multiple bi n output options.

980 = The engine is experiencing unreliable

communicat ions to the specified device.

981 = Engine pr otocol viol atio n ha s b een det ected b y the

specified device.

982 = Communications error detected b y the specified

device. 983 = Invalid command received by the specified device. 984 = Invalid command paramete r rec eived by the

specified device.

Diagnostic Information 2-7

4069-5XX/7XX

Error Code Action

990 Service <device>

991 Service <device> Card

This error will be displayed when an equipment check condition has occ u rr ed in the specified device (<device>), but the device is unable to identify the exact component failure.

Specified de vice <devi ce> can be one of the follo wing: *System Board

* Duplex *Tray x (x = 1,2,3,4 or 5) *Env elope Feeder *Output Bin x (x = 1,2,3 to 6) **Will be dis p layed for sin gl e bin ou tp u t o ptio n s. *Output Bins x to y (x to y = 1 to 5, 2 to 6, 6 to 10) **Will be dis p layed for multip le b in outp u t op t io n s. *StapleSmart Finisher Option

This message will be displ ayed when the specified device has detected an equipment check in its system card.

Specified de vice <devi ce> can be one of the follo wing: * Duplex

*Tray x (x = 1,2,3,4 or 5) *Env elope Feeder *Output Bin x (x = 1,2,3 to 6) **Will be dis p layed for sin gl e bin ou tp u t o ptio n s. *Output Bins x to y (x to y = 1 to 5, 2 to 6, 6 to 10) **Will be dis p layed for multip le b in outp u t op t io n s. *StapleSmart Finisher Option

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:

1. Press and hold Retur n and press Select to enter for sub error codes.

2. The first screen of information is displayed. Write down the information.

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4069-5XX/7XX

3. Continue pressing Return and Select until each screen of information is obtained.

4. When the last screen displays, the original message displays.

The following is an example of how the printer shows 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

Diagnostic Information 2-9

4069-5XX/7XX

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 up to 8 status bytes of data. Some or all of these bytes may be used to help diagnose a printer problem. These status bytes are designed to help isolate paper jams and paper feed problems in the base printer

Legend for Tray Source: x=10 (MPT), x-11 (Tray 1), x=12, (Tray 2), x=13 (Tray 3), x-14 (Tray 4), x=15 (Tray 5), x=31 (Env Feeder), X=40 (Manual)

Legend for Stacker Destination: x=91 (Stacker 1), x=92 (Stacker 2), x-93 (Stacker 3)

Legend for media size: x=1 (letter), x=2 (legal), x=3 (B5), x=4 (A4), x=5 (Executive), x=6 (A5), x=7 (Custom), x=9 (73/4 Env), A-#9 Env, B-#10 Env, C=8.661” Env, D=C5 Env, E=B5 Env, F=Legal Env.

First 6 Bytes Sub Error Code Data - N o te: xx can be any value.

Explanation

84 xx 00 x1 x2This code indicates that the input sensor in the printer is still

actuated fro m the fi rst she et and the seco nd shee t is ready t o arrive at the sensor. (x1=media size, x2=media source) *Check the pri nter i nput senso r and fl ag fo r cor rect operat ion.

The flag should operate freely. *Check for any signs of debris in the area of the input sensor. *Check the area of the tr ansf e r plate and input t o the fuse r f or

anything that might cause the paper to remain over the input sensor.

84 xx 01 x1 Video never started on the page.

(x-1=media size) *The video signal never started within 2 in ches after

actuating the input sensor. Check input sensor and flag.

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First 6 Bytes Sub Error Code Data - Note : xx can be any value.

84 xx 02 x1 This error is the most common type of paper jam. Possible

Explanation

causes are (x1=media size): *Multi sheet feeding. *A tray size sensing problem. *The media feeding from the paper source is sli pping or

media is slipping in input to the printer.

84 xx 04 The input sensor was covered during POST by a piece of

84 xx 05 There was a media at the input sensor too early. There w as

84 00 06 A paper jam has been declar ed b y a s mart de vice . Immed iate

84 00 07 A paper jam has been declared by a smart device. Homing

84 xx 0B x1 x2 x3

media still in the machine when it was turned on. *Clear the media from the printer. *Run the base sensor test (input sensor) from the diagnostic

tests menu to test the input sensor and flag f or correct operation.

not enough time between printhead start and the printhead mirror motor to lock. Possible causes for this error are: *Paper might be pre-staged in the paper source tray. *Paper is picking too fast. *A defective input sensor.

stop homing not allowed.

was allowed before the stop. The option tra y pass thru sensor was ne ver actuated by a

piece of media. (x-1=media size) (x-2=media source) (x3=paper source where paper jam was detected) *Run the sensor test for the option tray that is displaying the

error code and check the pass thru sensor for t hat tray for correct operation.

*Check for paper picking from the selected paper input

source.

*If the erro r i s being detected from a lower paper source, see

if paper is feeding correctly from a paper source abov e the detected source.

Diagnostic Information 2-11

4069-5XX/7XX

First 6 Bytes Sub Error Code Data - N o te: xx can be any value.

Explanation

84 xx 0f x1 x2 x3

84 00 10 The main motor ID failed to identify either motor after two

84 xx 17 There is an envelope or envelopes in the envelope feeder

84 xx 18 There is media over the Tray 2 pass thru sensor during warm-

84 xx 19 There is media over the Tray 3 pass thru sensor during warm-

The option Tray pass thru sensor was never deactivated. (x-1=media size) (x-2=media source) (x-3=media source where paper jam was detected) *Check the pass thru sensor and flag f or correct operation. *Check to see if paper has cleared the pass thru area of the

option where the pap er j am oc curred.

tries. Possible causes for this error are: *The main drive motor has stalled. *An incorrect main dri ve motor/gearb ox assembly has been

installed.

during warm-up. An envelope may have partially fed from the envelope feeder. *Remove any envelopes from the feeder and check the

envelope feeder for correct operation.

up. Check for media o ver the sensor. If no media is presen t, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 2 and see if Tray 2

is feedi ng paper correctly and al l th e sensors are working

correctly. *Check to mak e sure the paper size setting is correct for the

size paper in the tr ay.

up. Check for media o ver the sensor. If no media is presen t, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 3 and see if Tray 3

is feedi ng paper correctly and al l th e sensors are working

correctly. *Check to mak e sure the paper size setting is correct for the

size paper in the tr ay.

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First 6 Bytes Sub Error Code Data - Note : xx can be any value.

84 xx 1A There is media over t he Tray 4 pass thru sensor during warm-

84 xx 1B There is media over t he Tray 5 pass thru sensor during warm-

Explanation

up. Check for media ov er the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 4 and see if Tray 4

is feeding paper correctly and all the sensors are working correctly.

*Check to mak e sure t he paper size setting is cor rect for the

size paper in the tray.

up. Check for media ov er the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 5 and see if Tray 5

is feeding paper correctly and all the sensors are working correctly.

*Check to mak e sure t he paper size setting is cor rect for the

size paper in the tray.

84 xx 1C There i s media over the Tray 6 pass thru sensor during warm-

84 xx 1D The envel ope f e eder pa ss thru sen sor ne v er deacti vat ed. The

84 xx 1E x1 x2The envelope feeder pass thru sensor was nev er activated.

up. Check for media ov er the sensor. If no media is present, check the pass thru sensor, flag, and cables. *Try running the Input Tray Tests for Tray 6 and see if Tray 6

is feeding paper correctly and all the sensors are working correctly.

*Check to mak e sure t he paper size setting is cor rect for the

size paper in the tray.

display of this code indicates that an envelope nev er crossed over the sensor flag and passed beyond the sensor, or the flag and sensor are not operating properly. Go to the

“Envelope Feeder Option Service Check” on page 2-56.

(x1=Media Size , x2=Media Source) Ensure that envelopes are fe eding over the sensor. If an envelope feeds over the sensor but the sensor does not activate, check the sensor and flag for cor rect operation. If the sensor and flag are operating correctly, go to the

“Envelope Feeder Option Service Check” on page 2-56.

Diagnostic Information 2-13

4069-5XX/7XX

First 6 Bytes Sub Error Code Data - N o te: xx can be any value.

84 xx 20 x1 x2The imaged page is not the e xpected page.

Explanation

(x1=Media Size, x2=Media Source) Check the pass thru sens or to make sure it is operating

properly. If no problem is found, it may be necessary to try a new pass thru sensor.

84 xx 21 x1 x2The smart tray x did not pick a sheet of paper.

84 xx 22 x1 x2This code indi cates that the media activat ed the input sensor

84 xx 23 x1 x2The transfer servo never started.

84 xx 25 This code indicates that the media has activated the input

84 xx 26 This code indicates that media has activated the input

(x1=Media Size, x2=Media Source) Check tray x auto compensato r and tr ay parts for correct

operation. If no problem is found, go to the “Input Tray(s)

Option Service Check” on page 2-69.

before the printer EP was ready. (x1=Leading Edge of Medi a State , x2=Trailing Edge of Media State)

(x1=Media Size, x2=Leading Edge of Media State)

sensor before the printhead has locked. Enough time has elapsed since printhead start to expect a lock. One of the following may be failing: *Printhead Assembly *System Board *Printhead Cables

sensor; howe v er , the print head f el l out o f loc k c ondition o r not enough time elapsed si nce the printhead start to expect a stable loc k. The media may have also reached the input sensor early.

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4069-5XX/7XX

First 6 Bytes Sub Error Code Data - Note : xx can be any value.

89 00 01 The exit sensor in the fuser is activated by a piece of media

89 xx 03 The fuser exit sensor did not detect the trailing edge of the

Explanation

indicating there is a piece of media in the machine during POST. *Check for media in the exit of the fuser assembly or redrive

assembly. Feed a sheet of paper, and if the same error occurs after clearing the fuser or the same error occurs when no media is present, check the exi t sensor assembly, internal fuser assembly cabling, DC fuser cable to the system board, and the cable connection t o J14 on the system board.

TIP: Turn the printer off, enter the diagnostic tests menu, and select the base sensor test. Select output sensor and check the sensor for correct operation.

media going through the fuser assembly. *This failure can be caused by a brok en fuser exit sensor

flag.

*This may also be caused by erratic operation of exit sensor

flag or exit sensor or a defecti ve piece of media.

89 xx 04 x1 The fuser exit sensor never actuated from the sheet going

through the fuser before the next page begins fee ding. (x-1=Media Size)

89 xx 07 The narrow media sensor in t he fuser was cov er ed b y a shee t

of paper when not expec ted or a piece of media is in the machine during POST. *This error can occur when a 202 paper jam has occurred. *Remove any piece of media that is over the narrow media

sensor.

*Try to feed a piece of paper through the printer (coul d run

the print test from the diagnostic test menu). If the media stops over the narrow media sensor again, check the flag and sensor for cor rect operation.

89 xx 0B x1 The fuser exit sensor may be bouncing.

*This error can be cause d by a failing exit sensor or system

board.

Diagnostic Information 2-15

4069-5XX/7XX

First 6 Bytes Sub Error Code Data - N o te: xx can be any value.

89 xx 0D The fuser exit sensor bounced. Check the exit sensor for

Explanation

correct oper ati on. Check the fuser DC cable to J14 on the system board. Also, the sys tem board may be failing.

8D 00 00 The fuser e xit sensor was never activated by the leading

8E xx 02 x1 x2This error can be caused by the input sensor not being

8E xx 06 x1 The second pick failed from a paper source when paper was

8E xx 07 x1 The second pick failed from a paper source when paper was

8E xx 08 The paper in the output bin was flushed. The paper ahead of

edge of the media f ed through the printer. *This error can be displaye d after a 201 paper jam. *This can be caused by a defective fuser exit sensor

assembly. Enter the diagnos ti c tests menu, select base sensor tests,

select output sensor test and check the f user exit sensor for correct operation. If the test fails, check the internal fuser cabling, DC autoconnect on the fuser frame, fuser DC autoconnect to t he system board cable , and the cable connection to J14 on the system board.

activat ed by a page th at w as know n to hav e bee n pick e d by a source other than the duplex option. *Ensure the correct source has been sele cted and the medi a

is feedi ng from that source.

in the source and the only sheet in the paper path.

in the source. Other sheets may have started to fe ed, but none were in the paper path.

it, in the paper path, never made it past the output bin sensor or into the tray.

8E xx 09 x1 The second pick from the MPT, Tray 1 or feeder fail ed when

8E xx 0A x1 The second pick fr om the MPT, Tra y 1 or feeder failed when

paper was in the sour ce. Other sheets ma y be in the paper path. (x1=Media Source)

paper was in the sour ce. Other sheets ma y have started to pick, but none were in the paper path. x1=Media S ource)

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4069-5XX/7XX

First 6 Bytes Sub Error Code Data - Note : xx can be any value.

8E x1 0B The DC auto compensator failed or stalled when trying to

8E xx 11 It took too long for the DC auto compensator motor to come

Explanation

feed a sheet of media.

up to speed.

8E xx 13 x1 x2Late feedin g from a paper source i nt erf ered wi th the next pick

retry. (x-1=Media Size)(x-2=Media Source)

Base Printer (Fuser) Sub Error Codes

The following Sub Error Codes could be a help in diagnosing Fuser Assembly failures:

First 6 Bytes Sub Error Code Data - Note: xx can be any value

920 Service - Fuser Error (Under temperature while printing) EN 08 xx yy

- 1 EN- zz - - 2

Explanation

xx=Actual Fuser Temperature yy=The tempera ture that the fuser wan ts t o reach. When zz=00 The Hot Roll took too long to heat up.

zz=01 The Hot Roll fell too far below the desired

temperature while printing.

zz=02 The Hot Roll was too cool while the system was

doing some checking.

zz=03 The Hot Roll was too cool when heat ing to the

desired temperature.

921 Service - Fuser Error (Fuser under t em perature while at standby)

Diagnostic Information 2-17

4069-5XX/7XX

First 6 Bytes Sub Error Code Data - Note : xx can be any value

Explanation

EN 41 xx yy

-- 1 EN -- zz -- -2

922 Service - Fuser Error (Fuser failed to reach standby temperature) EN 42 xx yy

-- 1 EN z1 z2 -- -

- 2

923 Service - Fuser Error (Fuser over temperature)

xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach. zz=00 The fuser temper atur e did not change enough from the

fuser lamp temper ature at turn on.

01 The fuser t emper atur e rose more than des ired f r om the

fuser temperature at turn on.

xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach. zz=00 The fuser temper atur e did not change enough from the

fuser lamp temper ature at turn on.

01 The fuser t emper atur e rose more than des ired f r om the

fuser temperature at turn on.

z2=00 The Hot Roll did not reac h standb y tempe rature in time

during sta nd by.

01 The Hot Roll took to o long t o reac h t he begin ning l amp

detection t em perature.

02 The Hot Roll reached ‘fina l l amp detection

temperature’ but took longer than expected.

03 The Hot Roll timed out trying to reach the ‘f inal lamp

detection t em perature.’

04 After Hot Roll lamp detection, did not reach steady

state contr ol i n ti m e.

05 The Hot Roll did not reach opera ting temperature in

time.

EN 12 xx yy

-- 1 EN -- -- -- -2

924 Service - Fuser Error (Open Thermistor Failure) EN 18 xx -- -

- 1 EN -- 00 -- -2

This sub error code is di splayed anytime that the Hot Roll has reached a higher t han desired temperatur e. xx=Actual Fuser Temperature yy=The temperature that the fuser wants to reach.

This code is usually generated when an open circ uit check is made of the thermistor circuit in the fuser. xx=Actual Fuser Temperature

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4069-5XX/7XX

First 6 Bytes Sub Error Code Data - Note: xx can be any value

925 Service - Fuser Error (Wrong Fuser Lam p Inst alled) Note: The Sub Error Codes belo w are only for an incorre ct l am p being installed.

Explanation

EN 07 xx yy zz 1 EN -- -- -- 2

This error code is generated anytime an incorrect lamp is detected. xx=00 Lamp detection performed and found an error.

01 It took long to do lamp detection and NVRAM detected a previous wron g lamp detected. yy=Actual Temperature zz=The tempera tur e that the fuser was trying to reac h.

Envelope Feeder Sub Error Codes

First 6 Bytes Sub Error Code Data - Note: xx can be any value

84 xx 17 There is an envelope in the feeder during POST.

Explanation

Diagnostic Information 2-19

4069-5XX/7XX

First 6 Bytes Sub Error Code Data - Note : xx can be any value

84 xx 1D x1 x2The envelope feeder pass thru sensor activated but never

84 xx 1E x1 x2An envelope never activated the envelope feeder pass thru

Explanation

deactivated. (x1=Media Size)(x2=Media Source) This error can be cau sed by an envel ope over the pass thru sensor. Remove the envelope and try to feed an envelope. If the envelope stops ov er the pass thru sensor, try the following: *Select the diagnostic test men u, sel ect input tray sensor

tests, sele ct envelop e feeder sensor test.

*Check the envelope pass thru sensor to ensure it is

operating correctly. If the sensor test fails, go to the

“Envelope Feeder Option Service Check” on page 2-56.

If the test passes, look for anything that might cause the env elope to stop over the sensor.

sensor or the sensor never sensed the presence of an env elope. (x1=Media Siz e)(x2=Media Source) *Check to mak e sure the envelope feeds to the pass thru

sensor.

*Check to see if the envelope actuates the pass thru sensor

flag.

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4069-5XX/7XX

Stacker Sub Error Codes

First 6 Bytes Sub Error Code Data - Note: xx can be any value

Explanation

84 xx 14 There is media in stacker 1 during POST. Usually associated

84 xx 15 There is media in stacker 2 during POST. If present, remove

84 xx 16 There is media in stacker 3 during POST. If present, remove

95 xx 00 x1 x2Stacker sensor x nev er became uncovered.

95 xx 01 x1 x2Stacker sensor x nev er was covered or actuated.

with a 271 Paper Jam Error mess age. Ma y be displ a yed when a finisher opt i on is insta lled in l ow est or fir st pos iti on a bov e t he printer.

If present, remove the media from stacker 1. If the error continues to be displayed or there is no media present in the stacker, check the pass thru sensor and flag of stacker 1 or, if installed, check the option belo w stacker 1.

the media from stac ker 2. If the error conti nues to be displayed, or there is no media present in the stacker, check the pass thru sensor and flag of stacker 2, or check the option below stacker 2.

the media from stac ker 3. If the error conti nues to be displayed, or there is no media present in the stacker, check the pass thru sensor and flag of stacker 3, or check the option below stacker 3.

(x1=sensor’s stacker, x2=stacker destination) Check stack e r x to see i f a piece of paper is ove r the sens or. If not, check to see i f t he sensor and flag are working correctly.

(x1=sensor’s stacker, x2=stacker destination) Check stacker x to see if the sensor and fl ag are operating correctly.

98 xx 02 x1 x2 x3

Stacker x di d not indicate that a page had been recei ved in the output. (x1=stacker destination)

Diagnostic Information 2-21

4069-5XX/7XX

Duplex Unit Sub Error Codes

First 6 Bytes Sub Error Code Data - Note : xx can be any value

89 xx 00 The duplex unit did not send back a device control. 89 xx 02 The duplex unit did not send an Option Ready response. 89 xx 06 The duplex option did not send back a page in output

8E xx 00 x1 A sheet of paper being fed through the duple x er nev e r made it

8E xx 03 The error code is displayed whenever the print er never sent a

Explanation

response.

to the printer input sensor. The sheet was slow or delayed being fed from the duplex opt ion. (x1=media source )

Select Output device control signal to the duple x option. This can happen when a sheet of paper is leaving the duplex option and the duplex option ne ver sent a Select Input device signal to the printer.

8E xx 04 The printer never saw a signal from the duplexer on a page to

be picked from the duplex option when the duplex option was waiting on a page t o pass over the printer input sensor.

StapleSmart Finisher Op tion Sub E rror Codes

First 6 Bytes Sub Error Code Data - Note : xx can be any value

84 xx 07 The Sub Err or c ode indi cates that f inis her opt ion has det ected

Explanation

a paper jam and homing was allowed before the stop. Usual ly associated with 281 Paper Jams in the finisher.

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First 6 Bytes Sub Error Code Data - Note: xx can be any value

8D xx 01 A timeout associat ed wit h the stapling operation timed out

Explanation

while waiting for the last page of a job to be safe in the stapler accumulator.

98 xx 03 x1 x2 x3

Never saw operation comp let e on a staple job. (x1=destination)

Diagnostic Information 2-23

4069-5XX/7XX

User Status Screens

User Status Screens St atus Action

Ready

Ready <Fax Status>

Ready/Hex The printer is ready and

Power Saver

Power Saver <Fax Status>

The printer is ready to receive and process data

The prin te r w ill dis p lay the FAX status.

HEX Trace is ac tive, which is known as HEX Trace Ready.

When in the po wer sa ve r mode, the printer will display this screen instead of the Ready screen. When a job is received, the powe r saver screen remains displayed until the printer exits the power sav er mode and warms up the printer.

The printer has been configured to receive or send FAX. This screen is displayed.

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 t he values. Pr ess M enu> until R ese t P r in te r is on the second line of the display. Press Selec t to Res e t th e printer.

Pre ss Menu > or Menu< to take the printer offline and access the Ready Menu Group.

Press GO to take the printer out of power saver and initiate a printer warm up cycle.

Press Stop to take t he printer offline. The Not Ready message is displayed, no more data is processed. The Go button must be pressed to return the printer to the previous state.

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User Status Screens Status Action

Res Reduced

Res Reduced <Fax Status>

Waiting <I nterpreter> These screens will be

The printer is processi ng data or printing pages and the resolution of a page belonging to the current job has been reduced from 6 00 t o 300 DPI to prevent a Memory Full Error.

Will be displayed whenev er the printer has been configured to receive or send FAX.

displayed until the current job is terminated or until additional data is received on the acti ve link. (PCL1, PS, PJL, PPDS, SIC or HEX may be displayed for inte rpret er if the printer is not configured for FAX).

Press Stop to ta ke the printer offline. Not Ready is displayed, no more data will be processed and the current job in the paper path is processed. Press Go to retur n th e pr in te r to the previous state.

Press Menu> or Menu< to access th e Busy/Wa iting Menu grou p. T h e fol lowing functions may be available via the Busy/ Waiting Menu group: *Cancel Job *Reset Printer *Reset Active Bin *Cancel FAX

Press Go to print the contents of t he pri nter buffer, staple the accumulated sheets or terminate the collation set. Note: Go does not terminate the current print jo b.

Press Menu> or Menu< to access th e Busy/Wa iting Menu grou p. T h e fol lowing functions may be available via the Busy/ Waiting Manu group: *Cancel Job *Reset Printer *Reset Active Bin *Print Buffer

Diagnostic Information 2-25

4069-5XX/7XX

User Status Screens St atus Action

Busy The prin te r is bus y

receiving or processing data, or printing data.

Note: The printer indicator light blinks while the printer is processing data.

Flushing Buffer The printer is flushing

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

Printing Menu Settings The printer is processing

or printing a list of current settings menus because Print Menu Settings i s selected fro m the menu.

Press Stop to take t he printer out of Busy. The Not Ready message is d ispla y ed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to re tu rn to Ready.

No button actions are possible whil e this message is displayed.

Press Stop to take t he printer out of Ready. The Not Ready message is d ispla y ed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to re tu rn 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 t he values. Pr ess M enu> until R ese t P r in te r is on the second line of the display. Press Select to reset the printer.

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4069-5XX/7XX

User Status Screens Status Action

Printing Directory List A directory of the flash

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

Restoring Factory Defaults

Performing Self Tests The printer is running

The printer is restoring factory defaults.

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

Press Stop to ta ke the printer out of Ready. The Not Ready message is displ ay ed . 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 displa y. Press Select to reset the printer.

No button acti ons are possible whi le this message is displayed.

Not Ready (Press Go)

The printer is in the Not Ready state, which means it is not ready to receive or pr ocess data. This message displays when Menu> or <Menu is pressed duri ng a pri nt job.

Diagnostic Information 2-27

Press Go to take the printer out of the Not Ready state. Press Menu> or <Me n u t o take the printer out of Ready and enter the TESTS MENU (Busy state). Press Men u> until Reset Printer is on the second line of the displa y. Press Select to reset the printer.

4069-5XX/7XX

User Status Screens St atus Action

Resetting Printer The printer is deleting

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

Formatting Flash (Do Not Power Off)

Program Flash (Do Not Power Off)

Formatting Disk The disk is being

Programming Disk (Do Not Power Off)

The flash memory is being formatted.

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

formatted.

The disk is being programme d, whi ch means fonts or macros are being written to disk.

No button actions are possible whil e this message is displayed.

Do not perform any button acti ons while this message is displayed.

No button actions are possible whil e this message is displayed.

No button actions are possible whil e this message is d ispla y ed.

Note: If information i s written to flash memory and to disk at the same time, the Program Flash message is displayed.

Menus Disabled The printe r m enus have

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 retur ns to the R e ady message.

Activa t ing Menu Changes

The prin te r is res e t to activat e a prin ter setting changed in the menus.

2-28 Service Manual

No button actions are possible whil e this message is displayed.

4069-5XX/7XX

User Attendance Messages

User Message Primary

200 Paper J am Remove Cartridge

201 Paper J am Remove Cartridge

User Message Secondary

Leav e Job in Finisher

Explanation

Primary: Paper i s jammed at the printer Input Sensor. Open the printer upper front do or and r emov e the print cartridge to access the paper jam area. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the print er will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

Primary: Paper i s jammed between the printer input and exit sensors. Open the printer upper front door and remove the print cartridge to access the jam area. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the print er will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

202 Paper J am Open Rear Door

Leav e Job in Finisher

Primary: Paper i s jammed at the printer exit se nsor . Open the printe r rear door t o access the jam area. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the print er will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

Diagnostic Information 2-29

4069-5XX/7XX

User Message Primary

230 Paper Jam Check Duplex

24X Paper Jam Check Tray X

User Message Secondary

Leave Job in Finisher

Explanation

Primary: The paper is most likely jammed in the Dupl ex Unit. Remove the duplex front cover to access the jam area. If the paper is jam me d in th e 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 ja mmed in the rear of the printer. Open the printer rear door to access the jam. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are remov ed, the portion of the job printed after the j am will not be stapled.

Primary: Paper is jammed arou nd Tray X (X=tray 1 th ru 5). Try opening Tray X. If the tray is difficult to remove, t hen you may have to remove the tray above or below tray X to remove the jammed pages. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are remov ed, the portion of the job printed after the j am will not be stapled.

250 Paper Jam Check MP Feeder

2-30 Service Manual

Leave Job in Finisher

Primary: Paper is jammed in the multipurpose feeder. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are remov ed, the portion of the job printed after the j am will not be stapled.

4069-5XX/7XX

User Message Primary

260 Paper J am Check Env elope Feeder

27X Paper Jam Check Output Bin X

280 Paper J am Check Finisher

User Message Secondary

Leav e Job in Finisher

Explanation

Primary: Paper is jammed in the env elope feeder. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the print er will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

Primary: Paper i s jammed in output bin X (X=1 thru 3). Open the rear door of Output Bin X to access the jammed pages. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the print er will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not be stapled.

Primary: Paper is jammed in the finisher opti on. Open the finisher option side door or top cover to access the jammed pages. Secondary: When this message is displayed,do not remove accumulated sheets during the jam clearance procedure as the print er will not reprint the removed sheets. Also, if the accumulated sheets are removed, the protion of the job printed after the jam will not be stapled.

281 Paper J am Check Finisher

Remove Job From Finisher

Primary: Paper is jammed in the finisher opti on. Open the finisher option side door or top cover to access the jammed pages. Secondary: When this message is displayed, remove the job from the finisher. The printer will not re prin t th e remov ed sheets.

Diagnostic Information 2-31

4069-5XX/7XX

User Message Primary

282 Staple Jam Check Stapler

283 Staple Jam Check Stapler

Insert Cartridge or Close Door

User Message Secondary

Remove Job from Finisher

Explanation

Primary: A stapl e jam has been detected during normal stapl er operation. Secondary: The printer flashes the secondary message to indicate that all accumulated sheets should be removed during the jam clearance.

Primary: A stapl e jam has been detected during the primi ng operation. Secondary: The printer flashes the secondary message to indicate that all accumulated sheets should be removed during the jam clearance.

Note: The foll owing acti ons can be tak en while either of the primary or secondary messages is displayed

1. Press GO to initiate priming and resume printing.

This message displays when the print er front door is open or the print cartridge is missing. If this message cann ot be cleared go to the “Cover Open Sw itch/Cable

Service Check” on page 2-49.

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4069-5XX/7XX

User Message Primary

31 Defective Print Cartridge

32 Unsupported Print Cartridge

User Message Secondary

Explanation

Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected. It ma y take the printer 10-20 seconds to determine if the print cartridge is defective . Depending on the se tting 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 r epri nted once a good print cartridge is inserted.

Note: This error indicates the printer was abl e to read the cartridge ID , but the ID did not pass the v erification test. To pass the verification test, the ID r ead from the print cartridge must ma tch the ID from the las t “good” print cartridge or the same ID m ust be read from the print cartridge twice. The last “good” print cartridge ID is stored in NVRAM.

Error 32 is displayed when the top co v er is closed and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the se tting 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 fi x th e problem, go to the “Smart

Cartridge Contact Assembly Service Check” on page 2-121.

34 Short Paper The printer d etermi nes the paper length

is too short to print the format ted dat a. This occurs when the printer does not know the a ctual p aper siz e load ed in the tray. For auto-si ze sensing trays, this error occurs if the paper stop is in the incorrect position. Make sure the Paper Size setti ng is correct fo r the size paper that is being used.

Diagnostic Information 2-33

4069-5XX/7XX

User Message Primary

36 Resolution Reduced

37 Insufficient Collation Memory

38 Memory Full This message is displayed when the

39 Complex Page This message is displayed when the

51 Defective Flash This message is displayed when the

User Message Secondary

Explanation

The resolution of the page has been reduced from 600 dpi to 300 dpi to prevent a Memory Full error . Thi s message can only occ ur if the Resolution Reduction setting is turned on.

Note: 1200 dpi p ages are not resolution reduced. If a 1200 dpi job runs out of memory, a Memory Full error is displayed.

This message is displayed when the printer memory used to store pages i s too full to colla te t he print job.

printer memory used to store pages i s full.

page is too complex to print.

printer detects a defective flash. This error may occur at power on, or during flash f ormat 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 res olved.

52 Flash Full This messa ge is displ a ye d whe n ther e is

not enough free space in the flash memory to hold the resources that have been requested to be written to flash.

53 Unformatted Flash

This message is displayed when the printer detects an unformatted flash at power on. Press Go to cl ear the message. The flash is marked as bad and normal operation continues. Flash operations are no t a llo wed unt il t he fl ash is formatted.

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4069-5XX/7XX

User Message Primary

54 Standard Serial Error

54 Serial Option X Error

56 Standard Serial Disabled

56 Parallel Port Disabled

58 T oo M any Trays Attached

User Message Secondary

Explanation

This error is dis played when a serial error (fram ing or parity) is detected on the standard serial port. This usually indicates the serial port is not set up correctly.

This error is dis played when a serial error (fram ing or parity) is detected on the optional serial port. This usually indicates the optional serial port is not set up correctly.

This error is di spla y ed when dat a is sent to the printer across the standard serial port, but the port has been disabled.

This error is di spla y ed when dat a is sent to the printer acro ss the paral lel port, but the parallel port has been disabled. Once this messa ge is displayed, reporting of further errors is suppressed until the menu s are entered, or the printe r is res e t.

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

58 Too Many Bins Attached

58 T oo Many Disks Installed

61 Defective Disk This error code is displayed when the

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

This error is dis played when too man y disks are att ached to the printer .

printer detects a defective disk. This error may occur at power on or during disk format and write operations.While this message is di splayed: press Go to clear the message. The disk is marked defective and normal printer operations continue. Disk operations are not allowed wi th a defectiv e disk. The Format Disk menu is not shown.

Diagnostic Information 2-35

4069-5XX/7XX

User Message Primary

62 Disk Full This error code is displayed when th ere

63 Unformatted Disk

80 Scheduled Maintenance

User Message Secondary

Explanation

is not enough free space on the disk to hold the resourc es that have been requested to be written to the disk. This message displa ys f o r both resou rce and Post Scri pt Disk operators when the disk is full.

This error code displays when the printer detects an unformatted disk at power on. Press Go to cl ear 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 cou nt interval. It is necessary to replace the fuser assemb ly, 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 the “Scheduled Maint enance”

on page 6-2.

81 Engine Code CRC Failure

88 Toner Low This message displays when toner low

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-transmi tted from the host computer.

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

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4069-5XX/7XX

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 Go to return the printer to the Ready state.

User Message Explanation

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

displays. The Toner Low condition clears whenev er the upper front door is opened, and Toner Low displays again i f the condition ex ists after the upper front door is closed.

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

Missing” disp la ys ( where X desi gnates whi ch Tray (1 through 5) is missing. If multiple trays are missing, the y are pri ori ti zed in this order: Tray 1,

2..., then Tray 5. Tray X Missing status clears whenev er Tray X is reinserted.

Diagnostic Information 2-37

4069-5XX/7XX

User Message Explanati on

Tray X Empty If any of the input trays ar e em pty, then “Tray X

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, Tra y 4,...Tray 1.

Note: Tray X Empty status clears whenever Tray X is removed. When Tray X is reinserted, it is exami ned and the appropriate status, if any, displays. Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder.

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

displays where X designates which tray (1 through 5) displays. If m ultiple trays are low, they are prioritized in t he following or der: Tray 5,4,3,2,1.

Note: Tra y X Low cl ears whenever Tray X goes empty, or Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displa ys.

Note: The printer cannot detect when the 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. Link messages are listed in the following table.

User Message Explanati on

Par allel Standard Parallel P ort, if available. Serial Standard Serial Port, if av ailable. 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.

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4069-5XX/7XX

User Message Explanation

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

connector X. 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 M essage Explanation

Check Output Bin X Connection

Check Env F eeder Connection

Check Tray X Connection

Check Duplex Connection

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

Check Env elope Feeder Option Connection.

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

Check Duplex Option Connection.

Diagnostic Information 2-39

4069-5XX/7XX

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 prob lem, 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 disp la ys when the duplex rear door

This message displays when a printer option, Input Tray, Output Bin or Envelope F eeder, has been attached whi le the printer is power ed On. To use the option, the pri nter must first be powered off and back on agai n. Data loss results if print jobs are act iv e when the prin ter is po we r cycl ed. If a print job is active, then remove the option and finish th e job. The p r in te r automatica lly cle a r s th e message once the option is removed. Once the job is complet e, turn off the printer and attach the option again.

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

is open.

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4069-5XX/7XX

Power-On Self Test (POST)

When you turn the printer On, it performs a Power-On Self Tes t. 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. Amount of memory displayed.

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

– The 2000 sheet high capacity option elevator tra y moves to

the uppermost position (if installed).

– The duplex option is checked (if installed).

8. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm star t .

9. The main fan turns on.

10. The main drive motor turns on.

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

12. “Ready” appears on the display.

13. StapleSmart Finisher option homes (if installed).

14. The exit rollers turn.

15. The output expander option, 5-bin mailbox, or high capacity output stacker exit rollers turn (if installed).

Diagnostic Information 2-41

4069-5XX/7XX

Symptom Tables

Symptom Table - Base Printer

Symptom Action

Cartridge Fan (722/72n) fails to run or is noisy

Printhead F an fails to run or is noisy (722/72n).

Dead Machine Go to the “Dead Machine Service

Operator Panel - One or more buttons do no t 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.

Paper feed proble ms - Base printer or Integr ated 250 Paper Tray

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

Go to the “Cartridge Fan Servic e

Check” on page 2-64.

Go to “Printhead Fan Service

Check” on page 2-63. If the fan is

noisy, replace the fan assembly.

Check” on page 2-50.

Go to the “Operator Panel Buttons

Service Check” on page 2-86.

Go to the “Operator Panel Service

Check” on page 2-86.

Replace the operator panel assembly.

Go to the “Operator Panel Service

Check” on page 2-86.

Go to the “Paper Feed Service

Check” on page 2-105.

Go to the “Paper Feed Service

Check” on page 2-105.

Paper jams at exit of Redrive Assembly - Duplex Option installed

Fuser Solenoid f ails to operate . Go to the “Fuser Solenoid Service

Print quality - Black page Go to the “Print Quality - All Black

Print quality - Blank page Go to the “Print Qual it y - Blank

Go to the “Duplex Option Servi ce

Check” on page 2-53.

Check” on page 2-68.

Page” on page 2-110.

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4069-5XX/7XX

Symptom Action

Print quality - Light print Go to the “Print Quality - Toner on

backside of printed page” on page 2-120.

Print quality - Background Go to the “Print Quality -

Background” on page 2-114.

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

Image” on page 2-119.

Print quality - Skew Go to the “Paper Feed Service

Check” on page 2-105.

Print quality - Banding Go to t he “Print Qualit y - Bandin g”

on page 2-117.

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

Print quality - Toner on backside of printed page .

Print quality - Vertical bla c k bands on edge of copy.

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

Marks” on page 2-112.

Go to the “Print Quality - Toner on

backside of printed page” on page 2-120.

Go to the “Print Quality - Black

bands on outer edges of the page.” on page 2-117.

Go to the “Smart Cartridge

Contact Assembly Service Check” on page 2-121.

Symptom Table - High-Capacity Feeder Option (2000 Sheet)

Symptom Action

The printer does not recognize the high-capacity feeder opti on installed.

Paper feed problem with the high capacity f e eder option.

Go to the “High-Capacity Feeder

Input Tray Service Check” on page 2-72.

Go to the“High-Capacity Feeder

Input Tray Service Check” on page 2-72.

Diagnostic Information 2-43

4069-5XX/7XX

Symptom Table: Paper Tray Options

Symptom Action

Paper feed problem with 250Sheet Paper Tray Option.

Paper feed problem with 500Sheet Paper Tray Option.

Media fail s to pass thru from the lower atta ched Paper Tray option to the next higher mounted option.

Go to the “Input Tray(s) Option

Service Check” on page 2-69.

Go to the “Input Tray(s) Option

Service Check” on page 2-69.

Go to the “Input Tray(s) Option

Service Check” on page 2-69.

Symptom Table - Duplex Option

Symptom Action

Paper feed problem with Dupl ex Option.

Paper jams at Paper Removal Tray.

Paper sk ews in the Duplex Option.

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

Go to the “Duplex Option Servi ce

Check” on page 2-53.

Go to the “Duplex Option Servi ce

Check” on page 2-53.

Go to the “Duplex Option Servi ce

Check” on page 2-53.

Go to the “Duplex Option Servi ce

Check” on page 2-53.

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 2-56.

Go to the “Envelope Feeder

Option Service Check” on page 2-56.

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4069-5XX/7XX

Symptom Table - Output Expa n der

Symptom Action

Printer does not displ ay Output Bin Full.

Paper does not feed all the way into the output tr ay.

Go to the “Output Bin Sensor

Standard Tray Service Check” on page 2-90.

Go to the “Output Expander

Service Check” on page 2-91.

Symptom Table - StapleSmart Finisher

Symptom Action

Finisher does not staple. Go to the “StapleSmart Finisher

Service Check” on page 2-125.

Printer does not recognize StapleSmart Finisher Option as being installed.

Close Top Cover displayed. Unable to clear or reset message (POST in co m p lete).

Clos e F i n i s her Side C over displa yed. Unab le to clear or reset message (POST incompl ete).

Paper feeds into finisher option output tray. Paper is not stapled and paper does not align with the right side.