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Lexmark 4069-XXX Printer User Manual

1. 2 25 Service CIBOKS oid ca a 2 28 Charge Roll Service Check 2 29 Cover Open Switch Cable Service Check 2 31 Dead Machine Service Check 2 32 Duplex Option Service Check 2 35 Envelope Feeder Option Service Check 2 38 Erase Lamp Service Check 010 212 414 616 2 45 Fan Service EE Eo Vua E ERE ese we 2 46 IS Service Check ua techs ae 2 47 Fuser Solenoid Service 2 50 Input Sensor Service 2 51 Input Tray s Option Service 2 51 High Capacity Feeder Input Tray Service Check 2 55 Main Drive Service Check 2 68 Operator Panel Service 2 69 Options Service CHeck iusso up YS eee ees 2 71 Output Bin Sensor Standard Tray Service Check 2 73 Output Expander Service Check 2 74 High Capacity Output Stacker Service Check 2 79 5 Bin Mailbox Service 2 82 Paper Feed Service Check 2 88 Parallel Port Service 2 90 Contents iii 4069 XXX Printhead Service 2 91 Print Quality Service
2. 4 58 Service Manual 4069 XXX Toner Sensor 1 Remove the right side cover 2 Remove the toner sensor mounting screw A Disconnect the toner sensor cable and remove the toner sensor Repair Information 4 59 4069 XXX Transfer Roll Assembly 1 Open the upper front cover and remove the print cartridge 2 Unsnap the transfer roll assembly from the left pivot arm 3 Lift the transfer roller assembly toward the left and remove the transfer roller assembly from the printer Upper Paper Deflector Assembly 1 Open the multipurpose tray and remove the tray from the two mounting posts 2 Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right 3 Remove the upper deflector assembly 4 60 Service Manual 4069 XXX Upper Front Cover Hinge Assembly 1 2 3 Remove the upper front cover Remove the laser assembly cover Remove the C clips A from the upper front cover hinge assembly left and right hinge pins and remove the pins Note the pin orientation and the C clip location on the inside of each hinge Detach the two springs B from the upper front cover hinges Disconnect the operator panel cable from the operator panel assembly Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket C Lift the left pivot arm from the bracket and move the
3. 4 1 Adjustment 4 2 Duplex Motor Drive Belts 4 2 Fuser Solenoid Adjustment 4 3 AQUSIIEN 4 3 Printhead Assembly Adjustment 4 4 Paper Alignment Assembly Adjustment 4 5 Screw Identification Table 4 7 Removal Procedures 4 12 COVO aded dedu nq di dr 4 12 Center Pan Assembly 4 16 Controller yoe ceras aim 3a panes 4 17 Developer Drive Assembly auausuaanuaaarunanuaanun 4 18 DUNG EE 4 19 Duplex Front Cover Assembly 4 19 Duplex Front Cover 4 19 Duplex ashes 4 20 ENC SnBIOB 4 21 Eeler 295967944 YER PAESE 4 23 ROG ds Amie 4 24 555890 EE EEN 4 26 FUSE 4 29 FUSE BOSIU EE EE 4 30 Fuser COvel y Sm EO de qu 4 31 Fuser Detack Fingers s sess ENEE EE Rr rr 4 31 Fuser Detack Housing Assembly 4 32 Fuser Transfer 4 33 Fuser Envelope Conditioner Solenoid
4. 7 28 Assembly 12 Hot Roll Fuser 7 30 12 ia Lua a Lak adde x denim aea dd 7 34 Assembly 14 Charging 7 36 Assembly 15 Electronics Lua d er tox bm 7 38 Assembly 16 250 Sheet Tray 7 52 Assembly 17 500 Sheet Tray 7 58 Assembly 18 7 62 Assembly 19 Output Expander 7 68 Assembly 20 Envelope 7 72 Assembly 21 High Capacity Feeder 216 Assembly 22 Kiosk Vertical Paper Adapter 7 90 Assembly 23 Kiosk Horizontal Paper Adapter 7 92 Assembly 24 High Capacity Output Stacker 7 94 Assembly 25 5 Bin Mailbox s i wade dE SECH NN dE e 7 100 Assembly 26 Options 7 104 Assembly 27 Miscellaneous 7 106 i erm Li Contents vii 4069 XXX viii Service Manual 4069 XXX Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown Laser Advisory Label CAUTION Invisible laser radiation when open and interlock defeated Avoid exposure to beam ATTENTION Radiation laser invisible si le dispos tif est ouvert et non bloque Evier l exposition au rayon VORSICHT Unsihtbare laserstrahlung wenn drucker offen und sperre gel st Nicht dem strahl aussetzen VO
5. 4069 XXX Symptom Table Output Expander Symptom Action Printer does not display Output Bin Full Go to the Output Bin Sensor Standard Tray Service Check on page 2 73 Paper does not feed all the way into the output tray Go to the Output Expander Service Check on page 2 74 Service Checks Note Anytime the engine board is replaced the Configuration ID must be reset in NVRAM on the new engine board Go to Setting Configuration ID on page 3 21 Review the following information before performing any service checks Paperfeed Problems especially paper jams Go to Viewing the Error Log on page 3 8 and check the printer error log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option Paperfeed Problems with error message Use the Sub Error Codes For 9XX and 2XX Error Codes on page 2 8 to help diagnose the problem Print Quality Problems Go to Print Quality Test Pages on page 3 24 and print a test page to help diagnose problems before changing any settings or working on the printer Use the resident diagnostics test provided to help isolate a problem before taking the machine apart or removing any options 2 28 Service Manual 4069 XXX Charge Roll Service Check Service Tip Close and evenly spaced repetitive marks 47 19 mm 1 86 inch apart or spots on the page can be caused by a da
6. Paper Paper is usually the primary cause of a double feeding paper problem Flex the paper before placing the paper in the tray Edge welded paper is the most common cause of double feeding Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding 2 Autocompensator Make sure the counterbalance spring is not missing loose or broken at the top of the autocompensator arm assembly If you find a problem replace the autocompensator assembly Diagnostic Information 2 89 4069 XXX Multipurpose Tray Paper fails to feed from the multipurpose tray The pick roll should make one complete revolution and stop with the flat side down If the pick roll turns but does not pick paper check the roll for signs of wear oil or grease on the surface of the pick roll or slick spots If you find a problem replace the pick roll assembly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications Parallel Port Service Check Run the Parallel Wrap Test on page 3 11 Note The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug P N 1319128 and invoking the Parallel Diagnostic Test This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately three seconds If
7. Korean Safety Information eH Ape HAZE SS Lexmark TH 259 Ap Sol 90 42 1 AJA ag FEO PES Su ESSI en Qt Ho t ARIA Suck Lexmarkiz wa 529 cst AS Au e E HSS HASH Bula zi MAC SAS WALL AMS eS Aao AUCH A ien o MAS SASH zie et of HES SHAS Ho zm I gt 02 2 fif Ozone Information This product does not produce measurable amounts of ozone gas Notices and Safety Information xxi 4069 XXX Preface This manual is divided into the following chapters General Information contains a general description of the printer options and the maintenance approach used to repair it General environmental and safety instructions as well as special tools and test equipment are listed in this chapter Diagnostic Information contains a service error code table user status message table user error message table symptom table and service checks used to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Printer operation information is provided to enhance the tests and checks Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components and test points on the printer Preventive Maintenance contains safety inspection guidelines
8. High Voltage Power 5 Engine BOAO s saa acidi donde ai dd Fuser EE io oed eraai pde deor QR aH Ek A Interconnect Board sssr garde arma sais Envalope Ontlan Board 2x22 cis Rd EE A Duplex Option BOAId i24 ssa EE A e EEN A Autoconnect TOD ede eee PER GER otia Output Expander Control Board High Capacity Output Stacker Board Preventive Safety Inspection Guide NENNEN oh m Lubrication 5 lt Scheduled MalbiteBalleb euis reb Dee GE Edu vi Service Manual 4069 XXX Parts Catalog 2 oog5 002 540 O88 og ahr ERS ood RES 7 1 How To Use This Parts Catalog 7 1 Printer Serial Label assu se ssa sex ebbe ch bb ra s 7 2 Assembb COVE dou EE 7 4 Assembly 2 Frame sia secs m re m aes care ae 7 8 Assembly 3 Printhead 4 3 Wies IN ies umma beens 7 12 Assembly 4 Paper Feed Autocompensator 7 14 Assembly 5 Paper Feed Multipurpose Unit 7 16 Assembly 6 Paper Feed Alignment 7 18 Assembly 7 Paper Feed Output 7 20 Assembly 8 Integrated Paper Tray 250 Sheet 7 22 Assembly 9 Integrated Paper Tray 500 Sheet 7 24 Assembly 10 Main Drive 7 26 Assembly 11 Developer
9. Check the print cartridge for any signs of loose or foreign material that might be on the photoconductor Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls Print Quality Blurred or Fuzzy Print Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly alignment assembly any feed roller or in the transfer roll bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect feeding from one of the input paper sources paper trays duplex or envelope feeder Check the high voltage contacts to ensure they are not bent corroded or damaged Replace as necessary Diagnostic Information 2 95 4069 XXX Print Quality Evenly spaced horizontal lines or marks FRU Action Lines spaced 3 19 mm 126 inch apart This can be caused by the motor pinion gear on the main drive motor Replace the main drive motor Lines spaced 22 32 mm 882 inch apart Lines spaced 28 7 mm 1 130 inch apart Lines spaced 47 83 mm 1 883 inch apart Lines spaced 63 77 mm 2 511 inch apart This can be caused by a defective gear in the main drive gearbox assembly Replace the main drive gearbox assembly Lines spaced 38 26 mm 1 506 inch apart Lines spaced 44 64 mm 1 757 inch apart This can be caused by de
10. Move the cover door to the left to clear the right door pivot from the mounting and remove the duplex front cover door Repair Information 4 19 4069 XXX Duplex Motor 1 2 3 Remove the duplex front cover door Gently disconnect the cables from the duplex board Use caution to avoid damage to the cables and connectors Remove the four mounting screws from the left and right return guides and remove the guides Remove the four mounting screws on the right side of the duplex frame assembly Position the duplex assembly on its side Gently release the center drive deflector assembly latch from the bottom front left side of the duplex assembly Remove the center drive deflector assembly and the frame assembly from the duplexer Remove the two duplex motor mounting screws and remove the motor Note Pay attention to cable routing to avoid pinching or cutting wires during reassembly Ensure cables are securely placed into the cable retaining tabs Do the adjustment Duplex Motor Drive Belts on page 4 2 whenever you remove or replace the duplex motor 4 20 Service Manual 4069 XXX EMC Shields Inner EMC Shield 1 Remove the left door 2 Remove the outer EMC shield 3 4 5 Remove all option boards from the connector board slots Remove the inner EMC shield mounting screws A Remove the inner EMC shield A 201 A 102 A 201 A 102 Repair Information 4 21 4069
11. High normal force is one of the most significant contributors to double feeding paper The pick arm is counter balanced by an extension spring located on the pick arm to reduce weight in the rest state This spring is factory set to exert no more than ten to fifteen grams on the stack This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has come loose Poor gear efficiency can cause the arm to generate higher normal forces If the pick assembly is noisy replacement may be required The arm must pivot freely through its full range of motion On 500 sheet trays there are wrap springs located on the pivot arbors of the arm These springs aid to prevent the arm from bouncing If the arm appears to be binding or sticky near the bottom of the tray these springs may be the problem Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at bottom until the pick assembly can be replaced However the counterbalance spring is not to be considered an adjustment for feeding problems Autoconnect System Paper Tray Options Envelope Feeder and Output Expander Operations Electrical Autoconnect Cabling and Connectors The printer options make electrical conne
12. S 5 14 Service Manual 4069 XXX Envelope Option Board Connector Pin No Signal J1 1 N A Ground Tx EOC Ground Rx EOC 24 V dc Return o oOo AJ OJN 24 V dc J2 Ground Paper Present m 5 V dc J3 Ground Paper Present N 5 V dc J4 1 Motor Phase B Motor Phase A Motor Phase B SV ow N Motor Phase A Connector Locations 5 15 4069 XXX 5 16 Service Manual 4069 XXX Duplex Option Board Note Duplex connectors J10 and J11 are interchangeable No problem results if the connectors are switched Connector Pin No Signal J1 Motor 1 Motor 2 Motor J2 DC Motor 1 5 V dc Sensor Sensor Encoder Board 2 Tach 3 Ground J3 Stepper Motor 1 STPMOTA 2 STPMOTA 3 STPMOTB 4 STPMOTB J4 Fan 1 24 V dc 2 Fan On J5 Paper Input Sensor 1 5 V dc Sensor 2 Input 3 Ground J6 Rear Cover 1 Top Cover Open Open Switch 2 Ground J7 Jam Removal Tray 1 Front Drawer Open Open Switch 2 Ground J8 Paper Exit Sensor 1 5 V dc Sensor 2 Exit 3 Ground Connector Locations 5 17 4069 XXX Connector Pin No Signal J9 Autoconnect 1 Ground Option Below 2 PrtxDout 3 Ground 4 PrtRxd J10 Autoconnect 1 24 V dc Option Below 2 Ground J11 P
13. sp gt ES d Ze CS P E CH Gi 204 ma ag Osa LEM za gs E e e el db ES ERC SS ad aa TRANSFER TE el 3E m h HE wn Connector Locations 5 3 4069 XXX Engine Board Connector Pin No Signal J1 Main Fan Fan Stall Ground m Main Fan J3 Printhead Mirror Motor 24 V dc Return 24 V dc Return ReFREQ LOCKn Start 24 V dc Return OO oO AJ OJN 24 V dc J4 Cover Closed Switch Cover Closed Ground N 45 V dc J5 Printhead LENA Ground LAOJ Ground LASERPWM 45 V dc Ground Video NI a AJ Goy PY Ground A Ground 5 4 Service Manual 4069 XXX Connector Pin No Signal J6 Output Level Sensor 1 Ground 2 Ground 3 Opt2 4 Ground 5 5 V de J7 Auxiliary Fan 1 Cartfan 414 616 2 Ground J8 Printhead HYSNC 1 Ground 2 HSYNC 3 Ground 4 5 V dc Connector Locations 5 5 4069 XXX Connector Pin No Signal J10 Erase Cartridge Sensor Input Sensor HVPS AT Servo HVPS Servo OutT HVPS TXENABLE HVPS Transfer HVPS 24 V dc HVPS Charge HVPS Ground HVPS Developer HVPS NI oO oa AJ OJN Ground I
14. Diagnostic Information 2 3 4069 XXX Error Code Action 928 Erase Lamps Models 010 212 414 616 Indicates that the engine has detected that either the erase lamp assembly is missing or disconnected Go to the Erase Lamp Service Check 010 212 414 616 on page 2 45 Models 41b 416 41l and models 010 212 414 616 at service level B do not have erase lamps installed Go to Printer Serial Label on page 7 2 to identify the printer service level Check to make sure the correct HVPS is installed if this error displays on these models 929 Toner Sensor The toner sensor is not operating properly the developer drive assembly is not operating properly or the print cartridge is defective Go to the Toner Sensor Service Check on page 2 106 930 Printhead Error The wrong printhead is installed Replace with the correct printhead 931 935 Printhead Error 932 Printhead Lost Hsync 933 Mirror Motor Locks Lost Hsync 934 Mirror Motor Lost Lock 935 Mirror Motor unable to reach operating speed These errors represent a problem with the printhead Go to the Printhead Service Check on page 2 91 936 937 Transport Motor 936 Main Drive Motor initial lock failure 937 Main Drive Motor lost lock Indicates a problem with the main drive motor Go to the Main Drive Service Check on page 2 68 2 4 Service Manual 4069 XXX
15. Diagnostic Information 2 85 4069 XXX Paper does not feed into the bin selected 271 Paper Jam Check Bin 1 displays FRU Action 1 Deflector Check all the bin parts for signs of Deflector Spring missing or loose springs binds in the Deflector Cover deflector or deflector cover broken or Deflector Cover Spring binding shaft assemblies or broken Shaft assemblies gear teeth If incorrect repair as necessary 2 Bin X Solenoid Assembly Check the solenoid for any binds Control Board Make sure the solenoid is contacting the latch correctly If incorrect repair as necessary If the solenoid appears to be operating mechanically check the resistance of the solenoid It measures between 30 and 50 ohms If incorrect replace the failing solenoid assembly If correct replace the control board 3 Mechanical Linkage If the DC motor is functioning properly Motor Assembly check the gears clutch and other linkage parts for correct operation and any signs of wear broken gear teeth or damaged parts If incorrect replace the mechanical linkage assembly DC motor assembly 2 86 Service Manual 4069 XXX 990 Service Error displays FRU Action 1 Mechanical Linkage Check the DC motor cable connector DC Motor Assembly to be sure it is correctly installed at J2 on the control board If correct disconnect J2 from the control board and check the resistance of the motor on the cable connector J2 1 to
16. 4 34 Fuser Narrow Media Sensor Flag Assembly 4 35 Contents v 4069 XXX Fuser Exit Sensor Flag Assembly PUSS ESI ud ar dos dde do a dot op ET in Fuser Lower Exit Guide Assembly High Voltage Power Supply Integrated Tray Compensator Assembly Integrated Tray Compensator Pick Roll Assembly Interconnect Board Assembly Low Voltage Power Supply Main Drive Mam DNE 5 guardada Oe ial ae eee males Multipurpose Tray Lower Deflector Assembly Operator Panel Assembly Operator Panel Cable Cover Open Switch Assembly Optional 250 500 Paper Tray Assembly Paper Alignment Assembly Paper damn eka td ae d dou aic ded Paper Input SENSO eus d hehe ES Er Rd odes Paper Size Sensing Board EE EE Bt der EE Redrive Assembly Smart Cartridge Contacts EEN TONER Sell SO Transfer Roll Assembly Upper Paper Deflector Assembly Upper Front Cover Hinge Assembly Upper Front Cover Interlock Switch Assembly Connector Locations Low Voltage Power Supply
17. Press Stop to take the printer offline The Not Ready message is displayed No more data is processed from the host computer Press the Go button to return the printer to the Ready state User Message Explanation Toner Low If the toner cartridge is low then Toner Low displays The Toner Low condition clears whenever the upper front door is opened and Toner Low displays again if the condition exists after the upper front door is closed Tray X Missing If any of the input trays are missing then Tray X Missing displays where X designates which Tray 1 through 5 is missing If multiple trays are missing they are prioritized in this order Tray 1 2 then tray 5 Tray X Missing status clears whenever Tray X is reinserted 2 20 Service Manual 4069 XXX User Message Explanation Tray X Empty If any of the input trays are empty then Tray X Empty displays where X designates which tray Tray 1 through 5 is empty If multiple trays are empty then they are prioritized in this order Tray 5 Tray 4 Tray 1 Note Tray X Empty status clears whenever Tray X is removed When Tray X is reinserted it is examined and the appropriate status if any displays Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder Tray X Low If any of the input trays are low then Tray X Low displays where X designates which tray 1 through 5 displays If multiple trays are
18. Print Quality All Black Page on page 2 93 Print quality Blank page Go to Print Quality Blank Page on page 2 93 Print quality Light print Go to Print Quality Light Print on page 2 103 Diagnostic Information 2 25 4069 XXX Symptom Action Print quality Background Print quality Residual image Go to Print Quality Background on page 2 97 Go to Print Quality Residual Image on page 2 102 Print quality Skew Go to the Paper Feed Service Check on page 2 88 Print quality Banding Go to Print Quality Banding on page 2 100 Print quality Random marks Go to Print Quality Random Marks on page 2 95 Print quality Toner on backside of printed page Print quality Vertical black bands on edge of copy Go to Print Quality Toner on backside of printed page on page 2 104 Go to Print Quality Black bands on outer edges of the page on page 2 100 Unable to clear a 32 Unsupported Print Cartridge User Error Message Go to Smart Cartridge Service Check on page 2 105 Symptom Table High Capacity Feeder Option 2000 Sheet Symptom Action The printer does not recognize the high capacity feeder option installed Go to the High Capacity Feeder Input Tray Service Check on page 2 55 Paper feed problem with the high capacity feede
19. Service Tip Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or engine board Service Tip If there are equally spaced horizontal lines across the page go to Print Quality Evenly spaced horizontal lines or marks on page 2 96 WARNING Whenever the gearbox assembly is removed from the machine it must be handled very carefully Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come intact with the grease in the gearbox assembly FRU Action 1 Main Drive Assembly Excessive noise or vibration 2 Main Drive Motor Assembly Excessive noise gears ratcheting and so on Remove the controller board and run a Diagnostic Print Test in the continuous mode Check the main drive assembly for any excessive noise or vibration Determine if the noise is in the main drive toner cartridge fuser or main drive gearbox Look for any loose or worn parts in the developer drive assembly main drive gearbox or fuser Repair as necessary A service error code 936 Transport Motor may be displayed Check the voltage at J12 6 on the engine board It measures approximately 5 V dc when the motor is not running and goes to 0 V dc when the motor is running If incorrect replace the engine board If this does not fix the problem replace the main
20. lubrication specifications and maintenance information to prevent problems and maintain performance Parts Catalog contains illustrations and part numbers for individual FRUs xxii Service Manual 4069 XXX 1 General Information The Optra T laser printers are letter quality page printers designed to attach to IBM compatible PC s and to most computer networks The Optra T laser printer is available in the following models Model Name Type Optra T 610 4069 010 Optra T 610n 4069 01n Optra T 612 4069 212 Optra T 612n 4069 21n Optra T 614 4069 414 Optra T 614 4069 41b Optra T 614n 4069 41e Optra T 614nl 4069 411 Optra T 614n 4069 41n Optra T 616 4069 616 Optra T 616n 4069 61n Optra T 23v 4069 23v Optra T 23e 4069 23e General Information 1 1 4069 XXX Look at the printer serial label to identify the printer you are working on There are two service levels of Optra T printers Some printers are at a service level B as indicated by the B on the label P N XXXXXXXX XXXXXX Type 4069 S N XX XXXXX P N XXXXXXXX CNFG XXXXXX Type 4069 XXX S N XX XXXXX 1 2 Service Manual 4069 XXX Options The following options are available Some options are not available in every country Contact your point of purchase for options available in your country Memory options of 4MB 8MB 16MB 32MB 64MB and 128MB SDRAM DIMM Flash m
21. 7 19 7 105 7 29 7 19 ret 7 11 7 69 7 106 7 49 T 7 7 106 7 106 7 53 7 65 7 99 7 104 7 79 7 83 7 81 7 83 re JT J 9 7 79 7 83 7 77 7 79 7 77 7 81 7 81 7 83 4069 XXX 99A0675 99A0676 99A0677 99A0678 99A0679 99A0681 99A0684 99A0685 99A0690 99A0691 99A0692 99A0695 99A0698 99A0702 99A0703 99A0704 99A0705 99A0706 99A0707 99A0710 99A0711 99A0712 99A0714 99A0715 99A0716 99A0717 99A0719 99A0720 99A0725 99A0799 99A0801 99A0803 99A0815 99A0816 99A0833 99A0834 99A0863 99A0864 99A0865 99A0867 99A0889 99A0893 99A0897 99A0899 99A0904 99A0906 99A0907 7 106 7 106 7 106 7 89 753 7 89 TST 7 83 7 83 7 79 7 77 7 89 7 83 7 77 7 106 7 106 7 106 7 106 7 106 7 106 7 106 7 106 7 106 7 81 7 83 TT 7 89 7 81 7 89 7 31 7 105 7 27 7 47 7 9 7 47 7 5 7 49 7 5 7 31 7 5 7 105 7 105 7 105 FE 7 51 7 23 1 7 7 33 feti 7 9 7 93 7 93 99A0909 99A0910 99A0912 99A0913 99A0914 99A0915 99A0919 99A0923 99A0945 99A0952 99A0954 99A1015 99A1017 99A1031 99A1054 99A1055 99A1056 99A1059 99A1084 99A1089 99A1126 99A1130 99A1131 99A1133 99A1134 99A1164 99A1280 99A1290 99A1501 99A1502 99A1503 99A1504 99A1505 99A1506 99A1507 99A1509 99A1510 99A1511 99A1512 99A1514 99A1515 99A1516 99A1517 99A1518 99A1519 99A1520 99A1521 7 105 7 105 TFA 7 71 7 99 1 09 7 97 7 69 7 31 7 104 7 105 7 67 7 35 7 37 7 104 7 53
22. Banding is difficult to detect except on a page with a uniform gray or a large amount of graphics printed on the page Banding is primarily due to a variation in the speed of the paper as it feeds thru the printer especially in the development and transfer process Inspect the alignment assembly main drive assembly and all other paper feed components for signs of wear dirt binds or damage especially the drive gears Banding appears as light or dark horizontal lines on a uniformly gray page Banding can also be caused by a defective charge roll brush contact or HVPS Check the charge roll contact for any signs of damage and for proper connection to the HVPS and print cartridge Print Quality Black bands on outer edges of the page This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide narrow light or dark FRU Action Charge Roll Counterbalance Springs If the problem is just on one side of the page check the charge roll counterbalance spring on that side You can check to see if enough force is being applied to the charge roll by applying a slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample See if the problem changes or goes away If this fixes or changes the problem then check the springs and charge roll link arm assemblies for binds or defective
23. Drive 250 Duplex Shaft Assembly Drive 3 Roll 500 Duplex Shaft Assembly Drive 2 Roll 500 Duplex Shaft Assembly Decurl Screw Tensioner PP 99A0413 Retainer 6 mm Clutch Roll PP 99A0404 Feet Duplex Base Guide Debuckle Bp 2 oa Ra h M M H BA WA b i BA ABB och ese on on in a Parts Catalog 7 67 4069 XXX Assembly 19 Output Expander 7 68 Service Manual 4069 XXX Part dE index N rmbar Units Description 19 1 99A1857 1 Deflector Upper Redrive Also order 99A0104 19 2 99A0104 1 Spring Upper Diverter 19 3 99A0369 1 Shaft Assembly Exit Also order PP 99A0572 19 4 99A0052 1 Shaft Assembly Lower Exit Also order PP 99A0572 19 5 1 Screw PP 99A0263 19 6 99A0915 19 7 99A0571 19 8 99A1817 19 9 99A1666 19 10 99A1689 19 11 99A1688 19 12 99A0482 19 13 99A1784 19 14 99A0914 Board Output Expander DC motor Cover Front Control Board with ESD Brush Tray Output Expander Label Options Spring Clutch Assembly Diverter Arm Spring Output Tray Bracket Attach Output Expander Assembly Mechanical Linkage Cover Left Side Spring Swing Arm pop A oa a oa un ua 19 15 99A0372 19 16 99A0415 19 17 99A0481 19 18 19 19 99A0409 19 20 99A1580 19 21 99A0414 Latch Output Tray Shaft Bearing PP 99A0572 Level Sensor Bracket Flag Output Paper Level a nx po A pp Sensor Dual Bin Full
24. check each one to see if the printer recognizes any single option as being installed If the printer recognizes any of the output expander options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized expander option 2 74 Service Manual 4069 XXX FRU Action 1 Output Expander Option Make sure the output expander option is the only option that is not recognized by the base printer If the output expander is the only option not recognized by the printer continue with step 2 If not check the autoconnects of the options not recognized and the interconnect board and cable connections 2 Output Expander Assembly Check the autoconnects for damage Mechanical Linkage especially the connector pins Remove the left and right side covers Remove the front control board cover Check the cables at J1A J1B J2A and J2B on the control board to make sure they are attached securely and correctly Remove the output expander and check the voltages on the output bin autoconnect located on the top left rear of the printer Go to Autoconnect Top on page 5 19 If the voltages are correct reinstall the output expander unit and check the voltages at J1A and J1B on the connector If correct replace the output expander control board If incorrect replace the output expander assembly mechanical linkage Diagnostic Information 2 75 4069 XXX 202 Paper Jam Open Re
25. drum contact wear or contamination If the contact is bent or damaged replace the contact Note Inspect the HVPS PC drum contact on the board for any signs of damage or contamination 3 HVPS Check the fuse on the HVPS If open replace the HVPS Check the voltages at J10 on the engine board Measure the following voltages from connector J10 to printer ground Printer Idle J10 5 measures 24 V dc Printer Printing J10 5 measures 24 V dc In the voltages at J10 5 are incorrect replace the engine board 4 Front Cable Harness HVPS Section Check the front cable harness at J10 on the engine board and at CN1 on the HVPS to make sure the harness is connected properly If connected properly check the continuity of the cable harness If there is no continuity replace the front cable harness 5 Printhead Assembly Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom The printhead used in the printer does not have a mechanical shutter as previous laser printers The printer is interlocked through the front top cover interlock switch 2 94 Service Manual 4069 XXX Print Quality Random Marks Service Tip The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor charge roll or transfer roll Symptom Action Random Marks
26. 16 99A0144 2 Retainer Backup Roll Bearing 12 17 99A1553 1 Board Assembly Fuser 010 212 414 616 01n 21n 61n 23v 23e 12 17 99A1868 1 Board Assembly Fuser 41b 416 411 12 18 99A1649 2 Screw Fuser Mounting 12 19 99A1902 2 Standoff Fuser Control Board 12 20 99A0919 1 Standoff Fuser Control Board Parts Catalog 7 31 4069 XXX Assembly 12 Hot Roll Fuser continued 7 32 Service Manual 4069 XXX Part m Index Number Units Description Screw Fuser Cover Assembly 99A0263 12 22 99A0142 12 23 99A0150 12 24 99A0143 12 25 99A1554 12 26 99A1600 12 26 99A1659 Retainer Hot Roll Bearing Bushing Hot Roll Bearing Hot Roll Fuser Cable AC Bellcrank Backup Roll 414 616 61n Bellcrank Backup Roll 010 212 41b 416 41l 21n 01n 23v 23e Guide Fuser Entry Retainer Backup Roll Bellcrank PP 99A0267 Spring Backup Roll Bellcrank Fuser Cable DC Clamp Fuser Cable AC DC m MM 12 27 99A1591 12 28 12 29 99A0410 12 30 99A1648 12 31 99A1597 12 32 99A0157 Gear Hot Roll 12 33 99A0148 Gear Idler 12 34 99A0297 Link Solenoid 12 35 99A1651 12 36 99A1551 12 37 99A0897 12 38 99A0167 12 39 99A1550 12 40 99A1547 12 40 99 1639 12 40 99A1548 12 40 99A1642 NS 99A1658 NS NS 99A0145 NS 99A1599 Sensor Narrow Media Sensor Exit Spring Redrive Idler Roller Redrive Idler Guide Assembly Lower Exit Lamp 115V
27. 17 44 99A0281 1 Cable 500 Auto Connect Top 17 45 99A1702 1 Stud Assembly 500 Frame 17 46 99A1645 1 Arm Paper Out 500 NS 99A0452 4 Washer Frame Mounting NS 99A1665 1 Deflector Base 500 NS 99A1667 2 Bracket 500 Tray Retention NS 99A1928 1 Spring Bellcrank 500 Option Tray NS 99A1950 1 Tray Feature Photo Bag Tray Assembly NS 99A1951 1 Sprint Photo Bag Transfer Parts Catalog 7 61 4069 XXX Assembly 18 Duplex 7 62 Service Manual 4069 XXX 18 10 99A0329 18 11 99A0321 18 12 99A1673 Pulley Main Drive 96 54 Gear Motor Assembly DC Drive Cable D C Motor Tach 250 Duplex am SEH Units Description 18 1 99A1674 1 Cover System Board 18 2 99A0322 1 Main Frame Assembly 250 Duplex 18 2 99A1693 1 Main Frame Assembly 500 Duplex 18 3 99A0324 1 Idler Assembly Belt Tension 18 4 99A0326 3 Spring Aligner 18 5 99A0323 3 Guide Assembly Paper 18 6 99A1675 1 Guide Assembly Paper 18 7 99A1904 2 Spring Chassis Ground 18 8 2 Screw Motor Mount 3 mm PP 99A0413 18 9 99A0328 1 Belt Motor 114 Gear 1 1 1 18 13 1 Cam Follower Assembly Kit PP 99A0299 18 14 99A0312 1 Actuator Assembly Deflector 18 15 2 Screw Actuator Assembly Mounting PP 99A0413 18 16 99A1130 1 Guide Return RH Upper 250 Duplex 18 17 2 Screw Upper Return Guide Mounting PP 99A0413 18 18 99A0340 18 18 99A1680 18 19 99A1579 18 20 99A1133 18 20 99A1134 NS NS Guide Return RH Lower 250 Duplex Guide Return RH Lower 500 Duplex Guid
28. 2 92 Smart Cartridge Service 2 105 Serial Port Service Check 2 106 Toner Sensor Service 2 106 Transfer Roll Service Check 2 107 Diagnostic Alda nx rada tare ded d a E don dard dora c 3 1 Diagrgsuc pre Mer Ree pc HP 3 1 mud eg 3 2 Quek Dik C S CLAMP EE Wes 3 2 Elek Test C aeta 3 2 Flash TOS seu sedare eh eae eee pda 3 3 Disabling Download Emulations 3 3 Duplex Tests EE de E 3 4 Duplex Quick EE Aere Se nema 3 4 Duplex Sensor Test sau eens 3 5 Duplex Motor Test aso rper Rx doe n aos 3 5 Duplex Peed 1 Tests 3 7 Duplex 2 3 7 rg e ep Ice EPIRI ATH ARS gees 3 8 Viewing the Error Log dd ed qaas ode 3 8 the Emor NEE 3 8 Eeer TOS ead dractaduta pay AEN Ed d Open d dd 3 9 LOD TE oou baer 3 9 DOOM tre EE ee DE 3 9 SDRAM Memory 24559234 588228 REP LESS 3 10 Memory dosed E EE RA 3 10 Parallel Wrap Tol 3 11 Wrap 6st EE 3 12 Input Tay TOSS pcos th BAG det 3 14 Input Tray Feed Test isa sex dva Ea E band
29. 21 9 99A1809 1 Deflector Assembly Front 21 7 99A0681 3 Strip Wear 21 8 99A1818 1 Strip Wear Dimple 21 10 3 Screw Deflector Mounting 8 18 x 7 8 inch PP 99A0675 21 11 9941829 1 Label Tray Option Number 21 12 99A0662 2 Transfer Lead Screw Assembly 21 13 99A0716 1 Bearing Leadscrew Bottom NS 6 Washer Printer Support Frame 2 Star PP 99A0677 NS 6 Nut Printer Support Frame 2 8 32 Hex PP 99A0676 Parts Catalog 7 77 4069 XXX Assembly 21 High Capacity Feeder continued 7 78 Service Manual 4069 XXX gua hos Units Description 21 14 4 Nut 6 32 Hinge Mounting PP 99A0676 21 15 4 Washer Hinge Mounting Flat PP 99A0677 21 16 4 Washer Hinge Mounting Star PP 99A0677 21 17 99A0657 2 Hinge Door 21 18 99A0655 1 Door Assembly Front 21 19 99A0658 2 Magnet Door 21 20 99A0650 1 Frame Assembly 21 21 99A0661 1 Tray Assembly Elevator 21 22 99A1806 1 Card Assembly 2000 Option Control 21 23 4 Washer Card Assembly Mounting PP 99A0677 21 24 4 Screw Card Assembly Mounting PP 99A0675 21 25 99A0392 1 Kit Door Switch Spring and Bumper 21 26 1 Washer Door Switch Spring Mounting PP 99A0677 21 27 1 Nut Door Switch Spring Mounting PP 99A0676 NS 99A0690 1 Cable Optical Sensor Parts Catalog 7 79 4069 XXX Assembly 21 High Capacity Feeder continued 7 80 Service Manual 4069 XXX
30. 7 99 Poly 7 54 ret 7 105 7 41 TAF TAS 7 45 7 45 7 43 7 51 1 9 7 97 7 15 7 41 7 31 7 31 7 47 7 106 7 67 1 58 7 57 755 7 33 7 41 7 33 7 9 Tegl 7 61 7 91 7 98 7 105 7 33 7 51 7 31 7 33 7 51 7 105 7 33 7 33 7 31 4069 XXX 99A1661 99A1662 99A1664 99A1665 99A1666 7 31 7 9 7 61 7 61 155 7 59 7 65 7 09 7 78 7 89 7 95 7101 99A1667 99A1668 99A1669 99A1672 99A1673 99A1674 99A1675 99A1676 99A1677 99A1679 99A1680 99A1682 99A1687 99A1688 99A1689 99A1690 99A1691 99A1692 99A1693 99A1694 99A1695 99A1696 99A1697 99A1698 99A1699 99A1700 99A1701 99A1702 99A1704 99A1705 99A1706 99A1707 99A1708 99A1709 99A1710 99A1711 99A1712 99A1713 99A1714 99A1715 99A1716 7 61 7 65 7 65 7 67 7 63 7 63 7 63 7 87 7 65 7 67 7 63 7 65 7 101 7 69 7 97 789 797 7 97 7 67 7 67 7 63 7 73 7 67 7 73 7738 7 75 TTS 7 73 7 95 7 61 7 91 7 93 7 91 27 93 7 91 7 93 7 101 7 101 7 101 7 101 7 101 7 101 7 101 7 103 7 101 99A1717 99A1718 99A1719 99A1720 99A1721 99A1722 99A1723 99A1724 99A1725 99A1726 99A1727 99A1728 99A1729 99A1730 99A1731 99A1732 99A1734 99A1735 99A1736 99A1737 99A1738 99A1739 99A1740 99A1741 99A1742 99A1743 99A1744 99A1745 99A1746 99A1747 99A1748 99A1749 99A1750 99A1751 99A1752 99A1753 99A1754 99A1755 99A1756 99A1757 99A1758 99A1759 99A1773 99A1774 99A1775 99A1777 99A1778 Index 1 9 4069
31. 875W CC Gold Lamp 115V 550W CC Green Lamp 220V 875W CC Silver Lamp 220V 550W CC Brown Cover Fuser Wiper Cavity Screw Hanger PP 99A0263 Clip Fuse Mounting won a 2 42 42 an h e ae ae on on in pp Tray Fuser AC Connector Parts Catalog 7 33 4069 XXX Assembly 13 Transfer 7 34 Service Manual 4069 XXX Part Index Number 13 1 99A1015 13 2 99A0349 13 3 99A0184 13 4 99A0186 Units Description Transfer Roll Assembly Arm Transfer Roll Assembly Right Spring Transfer Roll Right Erase Lamp Assembly Kit 010 212 414 616 01n 21n 61n o Lamp Erase Assembly Lens Erase Lamp Shaft Transfer Pivot 13 6 99A0181 Spring Transfer Roll Left 13 7 99A1578 Arm Transfer Roll Left NS Retainer Pivot Shaft PP 99A0267 13 5 99A0185 Parts Catalog 7 35 4069 XXX Assembly 14 Charging 7 36 Service Manual 4069 XXX GE Units Description 14 1 99A0512 1 Link Assembly Charge Left Kit 14 2 99A0513 1 Link Assembly Charge Right Kit 14 3 99A1017 1 Roll Assembly Charge 14 4 99A1555 1 Bushing Charge Roll NS 1 Screw Charge Roll PP 99A0263 Parts Catalog 7 37 4069 XXX Assembly 15 Electronics 7 38 Service Manual 4069 XXX Asm Part index Nubes Units Description 15 1 99A1869 1 Engine Board Assembly 010 01n 15 1 99A1871 1 Engine Board Assembly 212 21n 23v 23e 15 1 99A192
32. 99A0072 15 38 99A0186 Sensor Input Sensor MPT Paper Out MPT Solenoid Erase Lamp Assembly 010 212 414 616 0In 6In 15 39 99A0576 1 Cable Front Harness 15 40 99A0815 2 Contacts Smart Cartridge Parts Catalog 7 49 4069 XXX Assembly 15 Electronics continued 7 50 Service Manual 4069 XXX am ME Units Description 15 41 99A1526 1 Printhead Assembly 010 01n 15 41 99A1527 1 Printhead Assembly 212 21n 15 41 99 1528 1 Printhead Assembly 414 15 41 99A1873 1 Printhead Assembly 616 61n 15 41 99A1867 1 Printhead Assembly 41b 416e 411 15 42 99A0889 1 Cable Laser 15 43 99A1573 1 Cable Fuser DC EP Autoconnect to Engine Board 15 44 99A0173 1 Solenoid Assembly Envelope Conditioner 15 45 99A1553 1 Board Assembly 15 46 99A1551 1 Sensor Exit 15 47 99A1603 1 Cover Fuser Assembly with Thermistor Thermal Fuse and RH Fuser Lamp Contact Assembly 15 48 99A1648 1 Cable DC EP Autoconnect to Fuser Board 15 49 99A1651 1 Sensor Narrow Media 15 50 99A1554 1 Cable AC EP Autoconnect to Fuser Cover 15 51 99A1575 1 Cable Fuser AC EP Autoconnect to LVPS 15 52 99A0247 1 Cable Hysnc 15 53 99A0250 1 Cable Mirror Motor NS 99A1612 1 Cable Deflector Parts Catalog 7 51 4069 XXX Assembly 16 250 Sheet Tray 7 52 Service Manual 4069 XXX am Sal Units Description 16 1 3 Screw Option Board Mounting PP 99A0263 16 2 99A1967 1 Board O
33. 99A0160 99A0167 99A0173 99A0181 99A0184 99A0185 99A0186 99A0188 99A0191 99A0197 99A0205 99A0206 99A0207 99A0208 99A0214 99A0215 99A0219 99A0226 99A0231 99A0232 99A0234 99A0240 99A0247 99A0250 99A0255 1 23 7 25 1 57 798 7 23 7 b7 7 91 7 93 4 25 7 59 7 91 L 29y 1 99 7 29 7 87 7 11 7 47 7 27 7 47 7 27 7 29 7 91 7 9 7 47 7 33 7 33 7 31 7 33 7 33 7 33 7 33 7 31 7 31 7 31 7 33 7 31 7 51 7 35 7 35 7 35 7 35 7 49 7 106 7 81 7 65 7 91 7 93 7 39 7 45 7 45 7 107 7 41 7 39 7 81 291 7 91 7 93 7 91 7 93 7 107 7 107 7 51 7 54 7 47 99A0256 99A0257 99A0260 99A0267 99A0268 99A0269 99A0271 99A0272 99A0273 99A0274 99A0275 99A0276 99A0277 99A0278 99A0279 99A0280 99A0281 99A0282 99A0286 99A0288 99A0292 99A0297 99A0299 99A0307 99A0308 99A0310 99A0311 99A0312 99A0315 99A0316 99A0317 99A0319 99A0321 99A0322 99A0323 99A0324 99A0325 99A0326 99A0328 99A0329 99A0330 99A0332 99A0334 99A0335 99A0336 99A0337 99A0340 7 47 7 47 7 27 7 45 7 106 7 106 7 106 7 106 7 55 7 87 7 55 7 61 7 87 7 55 7 81 7 85 7 27 b5 7 61 1 53 7 61 7 87 7 53 7 87 355 T 8r 17 55 7 61 7 65 1 55 7 61 7 65 7 55 1 061 7 87 7 58 7 61 1 54 1 01 7 87 7 55 7 59 7 89 20 7 00 7 33 7 106 7 67 7 67 7 65 7 65 7 63 7 65 7 65 7 65 7 67 7 63 7 63 7 63 7 63 7
34. 99A1956 15 13 99A1957 15 13 99A1958 15 13 99A1959 15 13 99A1960 Units Description Controller Board Assembly 010 Controller Board Assembly 212 23v Controller Board Assembly 414 41b Controller Board Assembly 616 Controller Board Assembly 01n Controller Board Assembly 23e 21n Controller Board Assembly 41 411 41 61 15 14 Screw Engine Bd Mtg Bottom PP 99A0263 15 14 Screw Engine Bd Mtg Front PP 99A0263 15 14 Screw Engine Bd Mtg Top PP 99A0263 NS 99A1612 NS 99A0346 Cable Deflector Clip EMC Six Finger M a a a a Parts Catalog 7 43 4069 XXX Assembly 15 Electronics continued 16 7 44 Service Manual 4069 XXX a finer Units Description 15 15 99A0408 1 Cover INA Flat Blank 15 16 6 Screw INA Cover Mounting PP 99A0263 15 16 4 Screw INA Cover Mounting PP 99A0263 15 16 2 Screw INA Cover Mounting PP 99A0263 15 17 99A1566 1 Engine Board Shield Assembly 15 18 99A1570 1 Inner Assembly 1 slot 010 01n 23v e 1 o Cover INA Blank 15 18 99A1571 1 Shield Inner Assembly 2 slot 212 414 616 21n 41b 411 41e 61n 2 o Cover INA Blank 15 19 99A0207 1 Shield Outer 1 slot 010 01n 23v 23e 15 19 99A0206 1 Shield Outer 2 slot 212 414 616 21n 41b 411 41e 61n 15 20 4 Screw Outer Shield Mounting PP 99A0263 15 20 6 Screw Outer Shield Mounting PP 99A0263 15 21 1 Screw Eng Con
35. A from the engine board Place the printer on its side Locate the integrated tray compensator assembly B on the bottom of the printer and disconnect the compensator arm bias spring from the frame Remove the c clip that rests against the right sideframe from the autocompensator pivot shaft Disconnect the compensator sensor cable C from the assembly Remove the compensator assembly mounting screw D 10 Remove the integrated tray compensator assembly 4 38 Service Manual 4069 XXX Integrated Tray Compensator Pick Roll Assembly 1 Remove the paper tray 2 Place the printer on its side 3 Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer 4 Unsnap the pick roll assembly D from its mounting and remove Repair Information 4 39 4069 XXX Interconnect Board Assembly Remove the inner EMC shield Remove the engine board and shield Remove the LVPS Disconnect all cables from the interconnect board 5 Place the printer on its back and remove the mounting screws A Note Go to Interconnect Board on page 5 12 to identify the correct jumper locations for your printer 4 40 Service Manual 4069 XXX 6 Remove the interconnect board assembly Repair Information 4 41 4069 XXX Low Voltage Power Supply 1 2 3 Remove the right cover Remove the LVPS mounting screws A from the rear of the
36. A M i hb h A CO OO E A a pnp a a ao a a Tray Backup Roller Parts Catalog 7 91 4069 XXX Assembly 23 Kiosk Horizontal Paper Adapter 7 92 Service Manual 4069 XXX Asm Part Index Number 23 1 99A0231 23 2 99A1646 23 3 99A1819 Units Description Bail Support Arm Assembly Pivot Mounting Frame Assembly 23 4 2 Retainer PP 99A0240 23 5 5 Screws PP 99A0234 23 6 99A1705 Gear Idler 23 7 99A1704 Gear Idler 23 8 99A0197 23 9 99A0079 23 10 23 11 99A0087 23 12 99A0086 23 18 99A1707 23 14 99A0907 23 15 99A0232 23 16 99A1820 23 17 99A0122 23 18 99A0906 23 19 99A0088 23 20 99A0085 Shaft Drive Rear Tray Assembly Backup Roller Parts Pulley PP 99A0208 Spring Backup Roller Roller Backup Tray Assembly Drive Roller Frame Assembly Right Side Cover Right Belt 185G Shaft Assembly Drive Roller Frame Assembly Left Side Cover Backup Tray a ax pony Ah h A OO OO a aA wp aaa Tray Backup Roller Parts Catalog 7 93 4069 XXX Assembly 24 High Capacity Output Stacker 7 94 Service Manual 4069 XXX Asm Part Index Number 24 1 99A1748 24 2 99A1785 24 3 99A1783 24 4 99A1778 24 5 99A1782 24 6 99A1790 24 7 99A1779 24 8 99A1746 24 9 99A1747 24 10 99A1701 24 11 99 1781 24 12 99A1666 24 13 99 1745 24 NS 99 1751 24 99A1777 24 NS 99A1780 24 NS 99A1744 Units De
37. Assembly Check the transfer roll for any signs of toner buildup surface damage to the roll oil or other contaminants on the surface of the roll Replace the transfer roll as necessary 2 Left Transfer Arm Assembly Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position If the arm is not locked down check to ensure the arm is not broken and will lock into the EP frame correctly Check the left transfer arm assembly spring for proper operation 3 Right Transfer Arm Check the right transfer arm Assembly assembly to make sure it is fastened and locked in the down position If the arm is not locked down check to make sure the arm is not broken and will lock into the EP frame correctly Check the right transfer arm assembly spring for proper operation For any background problems check to ensure the contact to the HVPS board is correct and that there is approximately 0 ohms resistance between the transfer roll shaft and the HVPS contact If correct go to Print Quality Background on page 2 97 2 108 Service Manual 4069 XXX FRU Action 4 5 917 Error Code Check the voltage at J10 3 The voltage changes from 24 V dc with the printer idle to 0 V dc when the printer runs the print test If the voltage is incorrect check the continuity of line J10 3 in the front cable harness to the HVPS If there is no continuity replace the cable ha
38. Check on page 2 107 Note This error also displays if an incorrect level HVPS assembly is installed in a printer that has the erase lamp assembly installed Check to make sure the correct HVPS assembly is installed 920 Fuser Error Indicates that the fuser is below temperature when printing Go to the Fuser Service Check on page 2 47 921 Fuser Error Indicates that the fuser is below standby temperature when the printer is idle Go to the Fuser Service Check on page 2 47 922 Fuser Error Fuser failed to reach standby temperature Go to the Fuser Service Check on page 2 47 923 Fuser Error Fuser is too hot during printing or when printer is idle Go to the Fuser Service Check on page 2 47 924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit Go to the Fuser Service Check on page 2 47 925 Fuser Error Wrong fuser lamp installed Check the fuser lamp for the correct type of lamp that should be installed If the correct lamp has been installed and you still have a 925 error the following may be the cause 1 The fuser may have reached standby temperature too quickly 2 Check too make sure the correct hot roll has been installed 3 Check the line voltage to make sure it is not above the maximum rating for the printer 927 Fan Stalled Indicates a printer fan stalled Go to the Fan Service Check on page 2 46
39. Disable the Download Emulation 1 Turn the printer off 2 Press and hold the Go and Menu buttons Diagnostic Aids 3 3 4069 XXX 3 Turn the printer On and release the buttons once Performing Self Test displays Once the printer is idle the emulation can be downloaded again 4 Program the download emulation into the code overlay SIMM again 5 If these steps do not resolve the problem replace the code overlay SIMM and download the emulation again Duplex Tests Duplex Quick Test This test is used to verify that the Duplex Option Top Margin is set correctly This test prints a duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the backside of the duplexed page You can run one duplexed page Single or continue printing duplexed pages Continues until Return Stop is pressed The paper you choose to print the page on should be either Letter or A4 To run the Duplex Quick Test 1 Select Duplex Quick Test from the menu 2 Select Single or Continuous The single Duplex Quick test cannot be canceled The printer attempts to print the Quick Test Page from the default paper source If the default paper source only supports envelopes then the page is printed from Tray 1 Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet If adjustment is necessary the Top Margin Offset must be adj
40. Drive Shaft Low Gear Feed Roll Gear Bevel Bearing Drive Shaft Cable 250 Auto Connect Option Spring Bellcrank 250 Tray Option a on on on on nn un Parts Catalog 7 55 4069 XXX Assembly 16 250 Sheet Tray continued 7 56 Service Manual 4069 XXX Asm Part Index Number 16 34 99A1601 16 35 99A0120 16 36 99A1536 16 37 99A1894 16 38 99A0119 16 39 99A1637 16 40 99A0121 16 41 99A0126 16 42 99A0124 16 43 99A1952 16 44 99A1537 16 45 99A0893 16 46 99A0127 NS 99A0286 Units Description Latch Back Restraint Restraint Pad Tray Assembly 250 Sheet Option Restraint Side 250 Sheet Tray Wear Strips Label Tray Option Number Clip 250 Tray Wear Finger Autosize Plate Snap In Label Paper Size Knob Paper Size Restraint Back 250 Sheet Tray Slider Autosize 250 Spring Backup Roller oa an on Pa on PA Vv Parts Catalog 7 57 4069 XXX Assembly 17 500 Sheet Tray 7 58 Service Manual 4069 XXX Pam Units Description 17 1 99A0350 Sensor Paper Low 17 2 Screw Auto Comp Mounting PP 99A0263 17 3 99A0405 Pick Arm Assembly 17 4 99A0070 Pick Roll Assembly 17 5 99A1636 Base 500 Tray 17 6 99A0058 Pad Base 500 17 7 99A0419 Spring Tray Bias 17 8 99A0026 Tray Bias Arm Assembly 16 9 99A0288 Sensor Option Pass Thru 17 10 99A1895 17 11 99A0292 17 12 99A1829 17 13 99A1583 17 14 99A0126 17 15 99A0
41. Failures occur randomly throughout the stack of paper FRU Action 1 Pass Through Sensor Check the pass through sensor for correct installation and operation 2 Autocompensator The autocompensator pick roll shaft Assembly assembly is not providing enough torque if the pick rollers are not picking the paper correctly Replace the autocompensator assembly 3 Wear Strips in Tray X Check the wear strips for excessive problem is found wear scratches or rough spots Replace the wear strips if a problem is found 2 88 Service Manual 4069 XXX Paper feed failures occur only near the top of the stack of paper The most common cause of this problem is paper curl Remove the paper from tray x and check for the natural curvature in the paper Reinstall the paper in the correct manner If the problem persists it may be necessary to reduce the stack height Replace both pick rolls if the paper appears to be flat in the tray but there is still a problem Failures occur mainly near the bottom of the stack of paper The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper Also the autocompensator motor may be failing If this problems continues replace the autocompensator assembly Double Feeding Paper Note If double feeding paper occurs mostly from the bottom of the stack check for missing or damaged restraint pads in the tray FRU Action
42. Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt Wahrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige xviii Service Manual 4069 XXX Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen Pautas de Seguridad e Este producto se ha dise ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio Lainformaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento e Existe mayor riesgo de descarga el ctrica y da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informacoes de Seguranca Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem nao ser sempre bvias A Lexmark respons vel pela utiliza o de outros
43. If incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board 2 Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly Diagnostic Information 2 65 4069 XXX Tray X Empty message displays Tray does not respond to loading paper No response from the front door switch FRU Action 1 High Capacity Feeder Option Control Board 2 Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Check the voltage on the board at J4 2 green The voltage measures approximately 5 V dc If incorrect disconnect the cable at J4 and check the voltage again If incorrect replace the high capacity feeder option control board Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate paper in the tray FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder Option Control Board Run the sensor diagnostics for tray X X the number that represents the high capacity input tray If the test fails check the voltage at J3 1 grey The voltage measures approxi
44. Manual 4069 XXX 7 Parts Catalog How To Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description AR As Required in the Units column indicates that the quantity is not the same for all machines CC Color Code in the Description column indicates the part is identified by a color marking on the part NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the Description column indicates the part is contained in a parts packet Parts Catalog 7 1 4069 XXX Printer Serial Label Look at the printer serial label to identify the printer you are working on There are two service levels of Optra T printers Some printers are at a service level B as indicated by the B on the label P N XXXXXXXX XXXXXX Type 4069 XXX S N XX XXXXX P N XXXXXXXX CNFG XXXXXX Type 4069 XXX S N XX XXXXX 7 2 Service Manual 4069 XXX Use the Model Name Type table to identify model specific replacement FRUs The parts catalog uses the Type last three digits to identify model specific FRUs Model Name Type Optra T 610 4069 010 Optra T 610n 4069 01n Optra T 612 4069 21
45. Menu settings used to print the pages Print Test with RIP Controller Board Removed This service mode allows you to test and or service the printer without the controller board installed You can verify that the motors sensors printhead and EP process are working correctly You can also make meter measurements on the engine board connectors with the controller board removed The test page consists of horizontal lines spaced approximately one inch apart down the page To run the test 1 Turn the printer off 2 Remove the controller board and inner shield 3 4 Press Select to start the test after Start Print Test displays The Turn the printer on test is continuous Press Select once again to stop the test Diagnostic Aids 3 25 4069 XXX Printing Menu Settings Page Note This test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Select the TESTS MENU 2 Select Print Menus from the TESTS MENU The page contains the following information A list of all the printer settings contained in the control panel menus and their values e A list of the installed options and features such as RAM memory SIMMs optional input paper trays envelope feeder duplexer output bins flash or disk Printer information such as serial number page count installed RAM engine code level RIP code level envelope feeder code level tray 1 5 code levels output bin 1 3 code levels c
46. Open the upper and bottom front covers 1 Press the two left door latch buttons A and open the left door 2 Release the left door from the rear hinges and remove the door 4 12 Service Manual 4069 XXX Right Cover 1 Open the upper and bottom front covers 2 Release the cover latch A and remove the right cover mounting screw B B 324 Repair Information 4 13 4069 XXX 3 Remove the redrive assembly 4 Remove the right side cover mounting screw B 5 Remove the right side cover B 324 4 14 Service Manual 4069 XXX Upper Front Cover 1 Raise the upper front cover 2 Remove the upper front cover mounting screws A 3 Rotate the cover upward to allow the rear cover hinges to clear the mounting slots and remove the cover A 323 Repair Information 4 15 4069 XXX Laser Assembly Cover Remove the left door Remove the right cover Remove the rear paper deflector Press the fuser wiper cover latch and remove the cover Remove the paper full sensor flag assembly from the mounting bracket 6 Remove the mounting screws A and remove the cover A 102 IRN A 102 A 102 Center Pan Assembly 1 Remove the left and right side frames 2 Remove the pan assembly 4 16 Service Manual 4069 XXX Controller Board Remove the inner EMC shield Remove the controller board mounting screw A Remove the controller board mounting screws Remove the cont
47. Option Screw Deflector Mounting PP 99A0263 Deflector Base 21 96 99A1055 21 97 99A0070 21 98 99A0692 21 99 21 100 99A0678 21 101 99A0288 21 102 99A1812 21 103 99A1666 Sensor Pass Thru Label Tray Option Number Label Options Ra a oa on on an pp a 21 104 Washer Bracket 250 Frame Retention Mounting PP 99A0677 21 105 4 Screw Bracket 250 Frame Retention Mounting PP 99A0263 21 106 99A0679 2 Bracket 250 Frame Retention NS 99A0717 1 Cable Paper Low Switch NS 99A0720 1 Cable Lower Limit Switch Parts Catalog 7 89 4069 XXX Assembly 22 Kiosk Vertical Paper Adapter 7 90 Service Manual 4069 XXX Asm Part Index Number Units Description 22 1 99A0231 22 2 99A1646 22 3 99A1819 Bail Support Arm Assembly Pivot Mounting Frame Assembly 22 4 2 Retainer PP 99A0240 22 5 6 Screws PP 99A0234 22 6 99A1705 Gear Idler 22 7 99A1704 Gear Idler 22 8 99A0197 22 9 99A0079 22 10 22 11 99A0087 22 12 99A0086 22 13 99A1706 22 14 99A0125 22 15 99A0232 22 16 99A1820 22 17 99A0226 22 18 99A0122 22 19 99A0137 22 20 99A0088 22 21 99A0085 Shaft Drive Rear Tray Assembly Backup Roller Parts Pulley PP 99A0208 Spring Backup Roller Roller Backup Tray Assembly Drive Roller Frame Assembly Right Side Cover Right Belt 185G Guide Paper Exit Shaft Assembly Drive Roller Frame Assembly Left Side Cover Backup Tray Mi
48. Parts Catalog 7 69 4069 XXX Assembly 19 Output Expander continued Gg GE gt N 7 70 Service Manual 4069 XXX Asm Part m Index Number Units Description PES 1 Door Assembly Rear Access 19 23 99A0368 Shaft Assembly Lower Also order PP 99A0572 Pulley Drive Cover Right Side Belt 160 Gear Arm Assembly Belt Idler 19 24 99A0363 19 25 99A0371 19 26 99A0361 19 27 99A0362 19 28 99A0364 19 29 99A0351 19 30 99A0913 Spring Belt Tensioner Sensor Output Expander Pass Thru Shaft Assembly Middle 40T Also order PP 99A0572 19 31 99A0912 1 Frame Assembly a ooo o Parts Catalog 7 71 4069 XXX Assembly 20 Envelope Feeder 14 si ses U 7 72 Service Manual 4069 XXX Part Index Number Units Description 20 1 99A0389 Paper Weight Assembly 20 2 99A1694 Guide Edge 20 3 99A1696 Cover Top 20 4 99A0485 20 5 99A0393 20 6 99A1697 20 7 99A0390 20 8 99A0488 20 9 99A0382 20 10 99A1666 20 11 99A0388 20 12 99A1700 NS NS 99A0484 NS 99A0491 NS 99A0400 NS 99A0489 NS 99A0487 Sensor Envelope Pass Thru Clutch Restraint Gear Cover Right Side Support Slide Out Roller Support Motor Stepper D C Label Options Switch Envelope Out Board Assembly Electronic Control Screw Top Motor Board Belt Gear Drive Bracket Stack Limiter Spring Restraint Roll Shaft Spr
49. Reference Adjustment 6 7 99A0559 1 Lever Bellcrank Release NS 2 Screw Alignment Asm Mtg PP 99A0263 Parts Catalog 7 19 4069 XXX Assembly 7 Paper Feed Output 7 20 Service Manual 4069 XXX Part os index Number Units Description 7 1 99A1586 1 Redrive Assembly Inner 250 010 01n 23v 23e 7 1 99A1604 1 Redrive Assembly 212 7 1 99A1533 1 Redrive Assembly Inner 500 414 616 61n 41b 411 41e 21n 7 2 99A1644 1 Door Assembly Redrive 250 010 212 21n 23v 23e 7 2 99A1534 1 Door Assembly Redrive 500 414 616 41b 411 41 61 NS 99A0104 1 Spring Upper Diverter NS 99A1857 1 Deflector Upper Redrive NS 2 Screw SEMS Duplex Path PP 99A0263 Parts Catalog 7 21 4069 XXX Assembly 8 Integrated Paper Tray 250 Sheet 7 22 Service Manual 4069 XXX Asm Part Index Number 8 1 99A1536 8 2 99A1601 8 3 99A0120 8 4 99A1894 8 5 99A0119 8 6 99A1812 8 7 99A0121 8 8 99A0126 8 9 99A0124 8 10 99A0127 8 11 99A1952 8 12 99A0893 8 13 99A1537 Units Description Tray Integrated 250 Sheet 010 01n 23v 23e Latch Back Restraint Restraint Pad Restraint Side 250 Sheet Tray Wear Strips Label Tray Option Number Clip 250 Tray Wear Finger Autosize Plate Snap In Slider Autosize 250 Label Paper Size Restraint Back 250 Sheet Tray Knob Paper Size oa oa oa Roa oa P A pH A a Parts Catalog 7 23
50. and down freely without any binds Also check to make sure the weight assembly rests on all the rear kick rollers when the hopper is empty Replace the weight assembly if it is damaged or does not operate properly 3 Envelope Edge Guide Check the envelope edge guide to make sure it is not warped or set too close to the envelopes in the hopper Replace the edge guide if it is damaged or does not operate properly Diagnostic Information 2 43 4069 XXX 260 Paper Jam displays envelope stops in feeder paper path FRU Action 1 Kick Rolls Feed Rolls Drive Check all the rolls for any signs of oil Rolls grease or other contamination If you find a problem clean the rolls If this does not correct the problem replace the envelope feeder option 2 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow Envelope Feeder multifeeds or may not display a 260 Paper Jam message FRU Action 1 Envelopes Check the envelopes being used in the feeder Check for signs of the envelopes being stuck together or signs of glue Check to make sure the flaps are not interleaved 2 Deflector Check the deflector gap adjustment The adjustment may be too wide 3 Restraint Roll Bias Spring Check for a missing broken or incorrectly installed restraint roll bias spring If incorrect reinstall or replace the spring 260 Paper Jam displ
51. and free movement of the sensor flag Check to make sure the sensor cable is connected to J8 on the system board If no problem is found replace the FRUs in the following order exit sensor assembly duplex option system board 2 36 Service Manual 4069 XXX 230 Paper Jam Check Duplex message displays The page is not duplexed and only exits half way out of the redrive FRU Action 1 Duplex Stepper Motor Check the stepper motor cable for cuts or pinched wiring Check the routing of the motor leads along the left side of the bottom tray Check for correct installation of the motor cable connector at J3 on the system board Check for any shorts between each pin of the motor cable and the motor housing If shorts are found replace the motor Check the resistance of the stepper motor between J3 1 Stpmtr A to J3 2 Stpmtr A The resistance measures approximately 10 ohms The resistance between J3 3 Stpmtr B to J3 4 Stpmtr B measures approximately 10 ohms If the resistance is incorrect replace the stepper motor Check for shorts between windings on pins J3 1 to J3 2 and pins J3 3 to J3 4 If a short is found replace the stepper motor assembly If no short is found replace the duplex system board Diagnostic Information 2 37 4069 XXX Envelope Feeder Option Service Check Service Tip Check the envelope feeder paper path for any debris pieces of envelope and so on If any other
52. as the switch is activated replace the engine board Note It is easier to check the voltages on J4 with the controller board removed Diagnostic Information 2 31 4069 XXX Dead Machine Service Check Note If a high capacity input tray is installed remove the option and check the base printer for correct operation If the base printer operates correctly go to High Capacity Feeder Input Tray Service Check on page 2 55 If the base printer continues to not operate correctly remove any other attached paper handling options Observe all necessary ESD precautions when removing and handling the controller board engine board or any of the installed option cards or assemblies Service Tip When removing the LVPS from the printer observe the following 1 The LVPS uses a Self docking connector that mates with another connector mounted on the left side frame assembly Some force may be required to pull the LVPS loose from the connector Gently remove the LVPS supply using caution not to damage the printed circuit board Pull the LVPS out far enough to reach the fuser lamp cable The fuser lamp cable uses a locking type of connector system Unlock the fuser lamp cable connector disconnect the cable and remove the LVPS from the printer Note If the LVPS is blowing fuses remove the LVPS from the printer Check the metal LVPS shield for signs of damage that causes the shield to touch components on t
53. board contains the printer s NVRAM Memory where the page count is stored To set the Page Count 1 4 5 Select Page Count from the Diagnostic menu The current page count displays The leftmost digit blinks indicating it is the first digit to be changed Press either Menu gt or lt Menu until the value you want displays Press Select to move to the next digit press Menu gt or lt Menu until the value you want displays Continue with each digit until you set the page count You can skip any digit by pressing Select Press Select to save the new page count in NVRAM Press Return Stop to exit the Diagnostic menu Viewing the Permanent Page Count The Permanent Page Count can only be viewed and cannot be changed To view the Permanent Page Count 1 2 Select Permanent Page Count from the menu Press Return Stop to exit the Diagnostic menu 3 20 Service Manual 4069 XXX Maintenance Page Count This counter is reset by the servicer after a 80 Scheduled Maintenance message displays 300K copies and a maintenance kit is installed To view the Maintenance Page Count 1 Select Maintenance Count Value from the diagnostic menu 2 Press Return to go to the previous menu To reset the Maintenance Page Count to zero 1 Select Reset Maintenance Count Pressing Select causes the maintenance page counter to reset to zero Reset Maintenance Count Saved displays momentarily When the reset o
54. bottom pan Pull the LVPS assembly from the right side of the printer Initial resistance is felt as the automate plug disconnects Press the release latch on the fuser lamp cable connector and disconnect from the LVPS Remove the LVPS A 203 4 42 Service Manual 4069 XXX Main Drive Assembly o OO P Go Remove the inner EMC shield Remove the gear guard Remove the developer drive assembly Remove the transfer shaft A through the bottom of the printer Remove all cables from the cable clamps B on the main drive assembly Remove the ground cables F Be sure to reinstall the ground cables to the same location Remove the main drive assembly mounting screws Remove the link D from the rear of the main drive assembly Disconnect the cable from the main drive motor Repair Information 4 43 4069 XXX 10 Remove the main drive assembly Note Do not remove the screws E on the main drive assembly Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly D C E 4 44 Service Manual 4069 XXX Main Drive Motor 1 Remove the main drive assembly 2 Remove the main drive motor mounting screws A 3 Remove the main drive motor A 212 Repair Information 4 45 4069 XXX Multipurpose Tray Lower Deflector Assembly 1 Open the multipurpose tray to a position that allows the left a
55. broken parts or interference Control Board from the sensor cable If incorrect repair as necessary If correct check to make sure the bottom pass thru sensor is correctly connected to J5 on the control board Disconnect the pass thru sensor cable and check the voltage at J5 3 The voltage measures approximately 5V dc If incorrect check the voltage at J5 2 The voltage measures approximately OV dc If incorrect replace the sensor assembly If this does not fix the problem replace the control board 274 Paper Jam Check Bin 4 Displays Service Tip When a 274 Paper Jam Check Bin 4 message displays a problem exists with the top pass thru sensor assembly or the control board FRU Action 1 Top Pass Thru Sensor Check the flag for correct operation Flag Assembly binding broken parts or interference Control Board from the sensor cable If incorrect repair as necessary If correct check to make sure the top pass thru sensor is correctly connected to J11 on the control board Disconnect the pass thru sensor cable and check the voltage at J11 3 The voltage measures approximately 5V dc If incorrect check the voltage at J11 2 The voltage measures approximately OV dc If incorrect replace the sensor assembly If this does not fix the problem replace the lower control board 2 84 Service Manual 4069 XXX Ready Bin X Full message displays May be able to clear message and will feed pap
56. cae es Units Description 21 28 99A0188 3 Guide Rear Paper with retainer arm Use with 9940219 21 29 6 Screw Top Frame Mounting PP 99A0675 21 30 99A0219 1 Frame Assembly Top with labels 21 31 2 Screw Top Frame Clamp Mounting PP 99A0675 21 32 2 Washer Top Frame Clamp PP 99A0677 21 33 99A0719 1 Clamp Top Frame Mounting 21 34 2 Nut Base Mounting PP 99A0676 21 35 2 Washer Base Mounting PP 99A0677 21 36 2 Screw Base Mounting PP 99A0675 21 37 99A0663 1 Pulley Idler 21 38 99A0664 1 Belt Drive 21 39 99A1807 1 Cable AC Internal Wiring 21 40 2 Nut 2 56 Lower Limit Switch Mounting PP 99A0676 21 41 99A0653 1 Switch Lower Limit Microswitch 21 42 2 Nut Power Supply Ground PP 99A0676 21 43 4 Washer Motor Plate Mounting PP 99A0677 21 44 99A1808 1 Cord AC External Jumper 21 45 2 Nut Power Supply Cover PP 99A0676 21 46 99A0714 1 Cover Power Supply 21 47 2 Screw Power Supply Board Mounting PP 99A0675 Parts Catalog 7 81 4069 XXX Assembly 21 High Capacity Feeder continued 7 82 Service Manual 4069 XXX Part T index leet Units Description 21 48 2 Washer Power Supply Board PP 99A0677 21 49 99A0667 1 Power Supply Board 21 50 99A0715 1 Cable Low Voltage Power Supply NS 99A0684 1 Cable HCIT 14Pin Flex 21 51 99A0685 1 Bushing 21 52 2 Nut 2 56 Paper Low Switch Mounting PP 99A0676 21 53 99A0654 1 Switch Pa
57. conform to the requirements of DHHS 21 CFR Subchapter J for Class 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 60825 Class laser products are not considered to be hazardous The printer contains internally a Class 10 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 level during normal operation user maintenance or prescribed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen Landern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 60825 gem amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse 1116 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daB im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemaBer Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen
58. drive motor 3 Main Drive Motor Cable Check the continuity of the main drive motor cable If incorrect replace the cable 2 68 Service Manual 4069 XXX FRU Action 4 Motor does not turn no Check the voltages at J12 on the gear error code 936 or User engine board message 201 Paper Jam displays Pin number and voltage J12 1 24 V dc J12 4 5 V dc static 0 V dc when main drive motor running J12 5 5 V static 0 V dc when main drive motor running J12 6 5 V dc static 2 5 V dc when main drive motor running J12 7 5 V dc static 0 V dc when main drive motor running J12 8 5 V dc static 5 V dc when main drive motor running J12 11 5 V dc static 0 V dc when main drive motor running If the voltage is incorrect replace the FRUs in the following order main drive motor assembly engine board Operator Panel Service Check Operator Panel Buttons Service Check Note Before continuing with this service check do the Button Test on page 3 9 in the diagnostic aids chapter FRU Action Operator Panel Assembly If any button fails the Button Test replace the operator panel assembly Diagnostic Information 2 69 4069 XXX FRU Action D Engine Board No buttons work Check the voltage at J11 5 The voltage measures approximately 5 V dc with the controller board re
59. ii stacker support to right attach 2 side frame M3 5x12 mm engine board shield to attach 1 Thread Cutting left frame GH paper alignment mounting 2 assembly 104 E ii toner cartridge guide mounting 2 ii track 4 Be left side frame to center attach 3 pan right side frame to attach 2 center pan deflector mounting 2 M3x5 mm INA cover attach 6 Taptite 2 screws per cover interconnect board mounting 5 204 4 8 Service Manual 4069 XXX Reference N mber Screw Type Location Purpose Qty M3x6 mm outer shield mounting 6 Taptite inner redrive deflector mounting 2 interconnect board to mounting 2 center pan G engine board mounting 2 202 bottom holes controller board to attach 2 interconnect board ground controller board to inner mounting 2 shield controller board back mounting 2 engine board to attach 1 interconnect shield ground lower stacker duct mounting 1 ground cables to ground attach 1 center pan front cable clip main drive mounting 2 gearbox BTM fuser screw mounting 7 M3x8 mm LVPS mounting 2 Taptite auto compensator mounting 1 hanger bracket e 203 Repair Information 4 9 4069 XXX Reference Number Screw Type Location Purpose Qty M3x12 mm HVPS board mounting 1 Taptite D Panhead 235 GA M3x28 mm developer drive ground attach 1 Taptite bottom hole Panhead M3x6 mm stacker
60. 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 User Status Messages on page 2 12 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 cartridge paper jam option port and so on If a user error message is displayed go to the User Error Messages on page 2 16 If your machine completes the Power On Self Test POST on page 2 24 without an error and you have a symptom go to the Symptom Tables on page 2 25 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 Diagnostic Information 2 1 4069 XXX 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
61. internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder belgeleengdeomradet 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta Tama kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan 1116 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Al katso s teeseen VARNING Osynlig laserstralning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra lander uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IE
62. is computed the motor turns off Diagnostic Aids 3 5 4069 XXX The following appears on the printer display DUPLEX MOTOR AA BB CC DD EE FF To pass the test the following results must display AA 00 BB the range of 20 through inclusively hex CC in the range of 3A through 5D inclusively hex DD in the range of 11 through 1F inclusively hex Ignore bytes EE and FF If the test fails remove the drive belt from the duplex D C motor and run the motor test again For the duplex D C motor to pass the test the following results must display AA 00 in the range of 29 through inclusively hex CC in the range of 35 through 51 inclusively hex DD in the range of OC through 13 inclusively hex For the duplex drive system to pass the test the following results must display AA 00 BB the range of 29 through inclusively hex CC in the range of 3A through 5D inclusively hex DD in the range of 11 through 1F inclusively hex 2 Press Return Stop to exit the test 3 6 Service Manual 4069 XXX Duplex Feed 1 Test This test feeds a blank sheet of paper to the duplex paper stop position 1 To run the Duplex Feed 1 Test 1 Select Duplex Feed 1 from the Duplex Test menu The power indicator blinks while the paper is feeding Duplex Feed 1 Feeding message displays while the paper is feeding through the printer Duplex Feed 1 Clear Paper mes
63. is displayed Activating Menu Changes The printer is reset to activate a printer setting changed in the menus No button actions are possible while this message is displayed Diagnostic Information 2 15 4069 XXX User Error Messages User Error Message Explanation 200 Paper Jam Remove Cartridge Paper is jammed at the printer Input Sensor Open the printer s upper front door and remove the print cartridge to access the paper jam area 201 Paper Jam Remove Cartridge Paper is jammed between the printer s input and exit sensors Open the printer s upper front door and remove the print cartridge to access the jam area 202 Paper Jam Open Rear Door Paper is jammed at the printer exit sensor Open the printer rear door to access the jam area 230 Paper Jam Check Duplex The paper is most likely jammed in the Duplex Unit Remove the duplex front cover to access the jam area If the paper is jammed in the rear of the duplex then replace the duplex front cover and open the duplex rear door If the paper is not jammed in the duplex unit then it may be jammed in the rear of the printer Open the printer rear door to access the jam 24X Paper Jam Check Tray X Paper is jammed around Tray X X tray 1 thru 5 Try opening Tray X If the tray is difficult to remove then you may have to remove the tray above or below tray X to remove the jammed pages 250 Paper Jam Che
64. linkage assembly Note If the DC motor is shorted it may also be necessary to replace the control board 2 Output Expander Control Board Disconnect the motor cable J4 and check the voltages at J4 on the board Note Use caution not to short to adjacent pins on the connector J4 1 J4 2 J4 5 J4 6 Motor Idle 24 V dc Motor Idle 24 V dc Motor Idle 5 V dc Motor Idle 5 V dc a a e If any of the voltages are incorrect replace the control board If the voltages are correct replace the DC motor mechanical linkage assembly 2 78 Service Manual 4069 XXX No indication that Bin X is Full OR No indication that Bin X is Near Full FRU Action 1 Dual Output Bin X Sensor Check for correct installation of Assembly the sensor cable at J5 on the Control Board control board If either the Bin Full F or Bin Near Full NF fail the sensor test then check the voltage at J5 3 and J5 4 The voltage measures approximately 5 V dc If the voltage is incorrect replace the control board If correct replace the sensor assembly High Capacity Output Stacker Service Check Service Tip The majority of the mechanical components can be observed during operation by removing the left right and front covers The high capacity output stacker option functions without the covers installed Models 010 and 010n do not support this output option Determine which paper path stacker ass
65. low they are prioritized in the following order Tray 5 4 3 2 1 Note Tray X Low clears whenever Tray X goes empty or Tray X is removed When Tray X is reinserted it is examined and the appropriate status if any displays 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 The link messages are listed in the following table User Message Explanation Parallel Standard Parallel Port if available Serial Standard Serial Port if available Serial X Serial Port where X 1 2 3 is attached to PCI connector X Network X Network card X X21 2 3 is attached to PCI connector X Diagnostic Information 2 21 4069 XXX User Message Explanation LocalTalk X LocalTalk Card X X 1 2 3 is attached to PCI connector X Infrared Standard Infrared port if available Infrared X Infrared Port X X 1 2 3 is attached to connector X Check Device Connection Messages The messages in the following table display when the printer looses communications with one of the following devices User Status Message Explanation Check Output Bin X Connection Check Output Bin X 1 2 0 3 Check Env Feeder Connection Check Envelope Feeder Option Conne
66. or loosen the motor or drive belt idler pulley Service Tip Excessive belt tension can result in stalling the duplex motor Too little belt tension can result in belt slippage To do the duplex drive belt adjustment 1 2 3 4 Do the removal procedure Duplex Front Cover Door on page 4 19 to access the drive belt idler pulley Loosen the idler pulley mounting screw and position the idler to provide 3 mm 5 mm drive belt deflection Tighten the idler pulley mounting screw being careful to maintain the adjustment Reassemble the duplex unit To do the duplex motor belt adjustment 1 2 Do the removal procedure Duplex Motor on page 4 20 to access the motor mounting screws but do not remove the motor Loosen the screw in the elongated adjustment slot and position the motor to provide 3 mm 5 mm motor belt deflection Tighten both mounting screws being careful to maintain the adjustment Reassemble the duplex unit 4 2 Service Manual 4069 XXX Fuser Solenoid Adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid Adjust the fuser solenoid while installed in the printer Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature Printer Models Solenoid Air Gap 010 212 4 0 mm 414 616 4 5 Gap Adjustment The gap adjustment allows you
67. reads approximately 24 V If incorrect replace the engine board If correct check the voltage at J10 15 The voltage reads between 15 V dc to 20 V dc If incorrect check the continuity of the erase lamp lines in the main harness If incorrect replace the cable harness If correct replace the erase lamp assembly Diagnostic Information 2 45 4069 XXX Fan Service Check Auxiliary Fan Service Check The auxiliary fan is in models 414 and 616 Fan does not run or is noisy FRU Action 1 Fan Assembly Check the fan for proper installation and for excessive noise If incorrect replace the fan and cable assembly 2 Engine Board Check to make sure the auxiliary fan cable is seated on connector J7 on the engine board If correct check for 24 V dc on J7 1 on the engine board If incorrect replace the engine board If correct replace the fan assembly Note When the printer is in warm up the voltage at J7 1 measures approximately 12 V dc When the printer is running the voltage measures approximately 24 V dc Main Fan Service Check Check the cable connections at J1 on the engine board and at the main fan assembly The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode FRU Action 1 Main Fan Manually spin the fan and check that it rotates freely Check the cable connection to the engine board J1 for corr
68. solenoid link B 4 Remove the solenoid from the fuser assembly Note Do the Fuser Solenoid Adjustment on page 4 3 whenever you replace the fuser solenoid ons A 202 B 4 34 Service Manual 4069 XXX Fuser Narrow Media Sensor Flag Assembly Remove the fuser assembly Remove the exit roll assembly Remove the fuser board cover Disconnect the sensors from the fuser board Remove the lower exit guide assembly Remove the sensor flag assembly from the lower exit guide assembly oar Fuser Exit Sensor Flag Assembly 1 Remove the fuser board cover 2 Disconnect the exit sensor from the fuser board 3 Remove the exit sensor flag assembly Note The exit sensor assembly can be removed without removing the lower exit guide assembly Make sure the marrow media sensor flag is correctly positioned before snapping the sensor in place Fuser Lamp 1 Remove the fuser assembly 2 Warning Hold the left lamp bracket and carefully remove the two mounting screws There is pressure against the other end of the lamp therefore care must be used when removing the lamp from the fuser Grip the lamp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp 3 Remove the fuser lamp Repair Information 4 35 4069 XXX The fuser lamp FRU is color coded The left and right fuser lamp bracket access hol
69. the saved data is written back to the disk To run the Quick Disk Test 1 Select the Quick Disk Test from the Device Tests menu The power indicator blinks while the test is in progress Quick Disk Test Test Passed message displays if the test passes and the power indicator turns on solid Quick Disk Test Test Failed message displays if the test failed and the power indicator turns on solid 2 Press Go Return or Stop to return to the Device Tests menu Disk Test Clean WARNING This test destroys all data on the disk and should not be attempted on a good disk Also note that this test may run approximately 1 1 2 hours depending on the disk size To run the Disk Test Clean Test 1 Select Disk Test Clean from the Device Tests menu Files will be lost Go or Stop message displays to warn the user that all contents on the disk will be lost 2 To exit the test immediately and return to the Device Tests menu press Return Stop To continue with the test press Go If go is selected Disk Test Clean BAD 000000 00 message displays The screen updates periodically indicating the percentage of test completed and the number of bad blocks found 3 The power indicator blinks during the test The test can be canceled anytime during the test by pressing Return Stop Once the test is complete the power indicator turns on solid and a message displays 3 2 Service Manual 4069 XXX xxxx Bad Bl
70. the test indicates that a problem is detected replace the controller board 2 90 Service Manual 4069 XXX Printhead Service Check The printhead assembly does not contain any service replaceable parts or components If service error code 930 displays the wrong printhead is installed in the printer Note A 201 paper jam may also indicate a failing printhead The paper may have jammed prior to or at the input sensor Print the error log and see if 201 or 931 errors are logged Service Error Code Explanation 1 Error Code 931 No first HYSNC Signal Error Code 932 Lost HYSNC These errors usually indicate a failure in the HYSNC signal to the printhead Check the continuity of the cables connected to J3 and J8 on the engine board If incorrect replace the defective cable The voltage at J8 4 measures approximately 5 V dc If incorrect replace the engine board The voltage at J3 7 measures approximately 24 V dc If incorrect replace the engine board If correct replace the printhead assembly 2 Error Code 934 Mirror Motor Lost Lock Error Code 935 Mirror Motor unable to reach operating speed These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the engine board cable or engine board assembly Check the continuity of the mirror motor cable connected to J3 on the engine board If incorrect replace the cable The voltage at
71. to increase the minimum gap between sheets of paper as they are fed through the printer This adjustment does not reduce the printer s overall performance such as pages per minute but can help in reducing the amount of curl of some printed media thus improving media stacking in the output bin 1 Enter the Diagnostic Mode 2 Select EP SETUP from the Diagnostic Menu 3 4 The range of the GAP adjustment is 0 to 255 Adjust the gap Select GAP ADJUST setting by using the Menu lt gt button to select the value If GAP 0 displays it indicates a factory setting to minimum gap Select a value and run several copies of the media that displays a curl problem It may take several tries before improvement is noticed Note This setting has no effect when printing in duplex mode Repair Information 4 3 4069 XXX Printhead Assembly Adjustment Do the printhead assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots It is necessary to perform a registration adjustment before locking down the three printhead mounting screws To perform the registration adjustment 1 2 3 Turn the printer off Press and hold Return and Go Turn the printer On and release the button
72. upper cover hinge assembly toward the left to clear the right upper cover pivot arm from the mounting bracket Remove the upper front cover hinge assembly Repair Information 4 61 4069 XXX Upper Front Cover Interlock Switch Assembly Remove the upper front cover Remove the operator panel Remove the inner EMC shield Pull up on the switch A to remove from the mounting posts B Note the routing of the interlock switch assembly cable and disconnect the cable on the engine board 4 62 Service Manual 4069 XXX 5 Connector Locations Low Voltage Power Supply Connector CNS Interconnect Board Pin No Signal 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc Connector Locations 5 1 4069 XXX POWER SUPPLY BOARD 4069 XXX High Voltage Power Supply Connector Pin No Signal CN1 Engine Board 1 Developer PWM 24 V dc Return Charge PWM 24 V dc IN TX PWM TX Enable TX CUR PWM wy SVRO OUT BOIS
73. 0 Service Manual 4069 XXX Fuser Cover 1 2 Remove the fuser assembly Note the thermistor cable routing and disconnect the cable from the fuser board Remove the left and right lamp bracket mounting screws A Remove the left and right fuser cover mounting screws B and lift the cover from the fuser assembly A 202 B 202 Fuser Detack Fingers 1 Remove the fuser assembly 2 Remove the fuser cover assembly 3 4 Gently pry the detack finger and spring from the housing Remove the fuser detack housing assembly assembly Repair Information 4 31 4069 XXX Fuser Detack Housing Assembly Remove the fuser assembly Remove the fuser cover assembly Remove the fuser lamp Use care when handling the lamp Disengage the hotroll bearing clips to free the fuser frame walls Gently apply outward pressure on the left and right fuser side frames A to release the detack housing assembly B 4 32 Service Manual 4069 XXX Fuser Transfer Plate 1 2 3 4 Remove the upper paper deflector Remove the fuser transfer roll Remove the inner paper deflector Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right side from its mounting Remove the fuser transfer plate A Repair Information 4 33 4069 XXX Fuser Envelope Conditioner Solenoid Remove the fuser assembly Remove the solenoid mounting screw A Disconnect the
74. 0B The autocompensator DC motor stalls when attempting to pick a sheet of paper 8E xx 11 The autocompensator DC motor takes too long to ramp up Envelope Feeder Sub Error Codes Status byte 1 contains the most valuable information to help isolate a feed problem with the envelope feeder and is the only byte contained in the following table Ser Explanation 00 There was no envelope feeder error reported 10 Printer failed POST Homing of Envelope feeder 11 Printer failed POST Halted Envelope Feeder 21 The envelope feeder failed to feed envelope jam 30 The D C motor failed to reach operating speed 32 The motor stalled 36 The motor failed to stop 2 10 Service Manual 4069 XXX Duplex Unit Sub Error Codes Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the duplex option and is the only byte contained in the following table Status Explanation Byte 4 00 No duplex error No problem was reported the engine by the duplex system card 01 The leading edge of the sheet of paper never arrived at the input sensor 02 The duplex option system board never received media notification from the printer 03 The trailing edge of the sheet of paper never cleared the input sensor 04 The leading edge of the sheet of paper never arrived at the exit sensor Note This error is the most com
75. 124 17 16 99A1952 17 17 99A1582 17 18 99A0120 17 19 99A1576 17 20 99A1537 17 21 99A1602 17 22 99A1601 17 23 99A1666 17 24 99A1967 17 25 99A0447 Restraint Side 500 Sheet Tray Wear Strips Label Tray Option Number Plate 500 Tray Wear Finger Autosize Plate Snap In Label Paper Size Slider Autosize 500 Restraint Pad Tray Assembly 500 Sheet Knob Paper Size Restraint Back 500 Sheet Tray Latch Back Restraint Label Options Board Tray Shaft 500 Drive l ch oa an an on po se ao ao Pao Pa A on on RPA pO A D Parts Catalog 7 59 4069 XXX Assembly 17 500 Sheet Tray continued 7 60 Service Manual 4069 XXX a os Units Description 17 26 99A0282 1 Cable 500 Auto Connect Bottom 17 27 99A1750 1 Wear Plate Pass Thru 17 28 99A0276 1 Roll Assembly Drive 500 17 29 2 Screw Wear Plate Mounting PP 99A0263 17 30 99A0450 1 Retainer Roller 17 31 99A0451 1 Roller Skewed Backup 17 32 99A0438 2 Bearing Drive Roll 17 33 99A0275 1 Spring Power Takeoff 17 34 3 Screw Board Mounting PP 99A0263 17 35 1 Retainer Aligner Assembly PP 99A0267 17 36 99A0280 1 Bearing Drive Shaft Low 17 37 99A0446 1 Aligner Assembly Paper 17 38 99A0274 1 Gear Feed Roll 17 39 99A0063 1 Spring Switch Activate 17 40 99A0286 1 Spring Backup Roller 17 41 99A1664 1 Bellcrank Roller Release 17 42 99A0273 1 Gear Bevel 17 43 99A0279 1 Bearing Drive Shaft
76. 2 Optra T 612n 4069 21n Optra T 614 4069 414 Optra T 614 4069 41b Optra T 614n 4069 41e Optra T 614nl 4069 411 Optra T 614n 4069 41n Optra T 616 4069 616 Optra T 616n 4069 61n Optra T 23v 4069 23v Optra T 23e 4069 23e Parts Catalog 7 3 4069 XXX Assembly 1 Covers 7 4 Service Manual 4069 XXX Part index Ile Units Description 1 1 99A1512 1 Cover Assembly Redrive Cap 1 2 99A1508 1 Cover Fuser Wick Assembly 1 3 99A1506 1 Cover Asm Laser Assembly 010 212 23v 23e 1 3 99A1507 1 Cover Asm Laser 500 Output 414 616 41b 41 411 1 11 99 1503 1 12 9941504 1 12 99 1505 NS Hinge Upper Front Cover Cover Right Side 010 212 23v 23e Cover Right Side 414 616 41b 416 411 Screw Right Side Cvr Mtg PP 99A0263 NS 6 Screw Laser Cover PP 99A0263 1 4 99A1593 1 Cable Smart Cartridge 1 5 99A0816 1 Contact Smart Cartridge Ground 1 6 99A0815 2 Contact Smart Cartridge 1 7 99A1595 1 Cover Smart Cartridge Contact 1 8 99A0834 1 Plunger Overstress Smart Cartridge 1 9 2 Screws Contact Mounting PP 99A0263 1 10 99A1775 1 Kit Upper Front Cover with Labels NS 5 Screw Upper Front Cvr Mtg PP 99A0263 1 1 1 3 Parts Catalog 7 5 4069 XXX Assembly 1 Covers continued 7 6 Service Manual 4069 XXX Asm Part Index Number 1 13 99A0007 1 14 99A1502 1 15 99A0004 1 16 99A1511 1 17 99A1501 1 18 99A1577 Units Description Label TLI ID Serial No Bl
77. 3 1 Engine Board Assembly 414 41b 416 411 15 1 99A1878 1 Engine Board Assembly 616 61n 15 2 1342514 1 Power Cord Set 8 ft U S Canada LV Nicaragua Venezuela Peru LV Bolivia HV Colombia Costa Rica Ecuador EI Salvador Guatemala Honduras Mexico Panama 15 2 43H5248 1 Power Cord Set 8 ft U S Canada LV Nicaragua Venezuela Peru LV Bolivia Colombia Costa Rica Ecuador El Salvador Guatemala Honduras Mexico Panama 414 41n 616 61n 15 2 1339538 1 Europe 6 ft Paraguay Uruguay 15 2 1342536 1 Power Cord Set 6 ft APG LV 15 2 1339537 1 Power Cord Set 8 ft U K Ireland 15 2 1339539 1 Power Cord Set 6 ft Israel 15 2 1339540 1 Power Cord Set 6 ft Switzerland 15 2 1339541 1 Power Cord Set 6 ft South Africa 15 2 1339546 1 Power Cord Set 6 ft Two Prong Argentina HV 15 2 1342534 1 Power Cord Set 8 ft Chile HV 15 2 1339543 1 Power Cord Set 8 ft Denmark 15 2 1339542 1 Power Cord Set 6 ft Italy 15 2 1374067 1 Power Cord Set 8 ft Peru HV 15 2 1339544 1 Power Cord Set 8 ft Straight Argentina HV 15 2 1339545 1 Power Cord Set 8 ft Right Angle Argentina HV 15 2 1342530 1 Power Cord Set Brazil 15 3 99A0215 1 Fuse 110 V ac LVPS 15 3 99A0205 1 Fuse 220 V ac Parts Catalog 7 39 4069 XXX Assembly 15 Electronics continued 7 40 Service Manual 4069 XXX Part index Number U
78. 4069 XXX Assembly 9 Integrated Paper Tray 500 Sheet 7 24 Service Manual 4069 XXX Asm Part m index Ile Units Description 9 1 99A1601 1 Latch Back Restraint 9 2 99A1576 1 Tray Assembly 500 Sheet 212 414 616 21n 41b 411 41e 61n Restraint Side Strip Wear Label Tray Option Number Plate 500 Tray Wear Finger Autosize 9 3 99A1895 9 4 99A0292 9 5 99A1812 9 6 99A1750 9 7 99A0126 9 8 99A0124 9 9 99A1952 9 10 99A1537 9 11 99A1582 9 12 99A0120 9 13 99A1602 Plate Snap in Label Paper Size Knob Paper Size Slider Autosize 500 Pad Restraint Restraint Back pm 32 wo Ra Parts Catalog 7 25 7 26 Service Manual 4069 XXX Asm Part Index Number 10 1 99A1543 10 1 99A0129 10 1 99A0801 10 2 99A0134 10 2 99A1569 Units Description Gearbox w Motor 010 212 01n 21n 23v 23e Gearbox w Motor 414 41b 411 41e Gearbox w Motor 616 61n Shaft Power Take Off 010 01n 23v 23e Shaft Power Take Off 500 212 414 616 21n 41b 411 41e 61n 10 3 99A0275 1 Spring Power Takeoff Shaft 10 4 99A0954 1 Gear Bevel with Grease Packet NS 4 Screw Gearbox Mounting PP 99A0263 NS 3 Screw Motor Mounting PP 99A0263 2 NS 99A0260 Clip Cable Parts Catalog 7 27 4069 XXX Assembly 11 Developer Drive 7 28 Service Manua 4069 XXX GE Units Description 11 1 99A15
79. 44 1 Developer Drive Assembly 11 2 99A0136 1 Shaft Developer Drive 11 3 99A0564 1 Coupler Gear 55 11 4 1 Screw Developer Drive Ground PP 99A0263 11 5 2 Screw Developer Drive Mtg PP 99A0263 Parts Catalog 7 29 4069 XXX Assembly 12 Hot Roll Fuser 7 30 Service Manual 4069 XXX Part m urbes Units Description 12 1 99A1584 1 Fuser Assembly w 115V 875W Lamp 414 616 41b 411 41n 61n 12 1 99A1585 1 Fuser Assembly w 220V 875W Lamp 414 616 41b 411 41n 61n 12 1 99A1660 1 Fuser Assembly w115V 550W Lamp 010 212 01n 21n 23v 23e 12 1 99A1661 1 Fuser Assembly w220V 550W Lamp 010 212 01n 21n 12 2 99A0725 1 Wiper Assembly Wet 12 3 99A1603 1 Cover Fuser Assembly with Thermistor Thermal Fuse and LH amp RH Fuser Lamp Contact Assemblies 12 4 4 Screw Contact Assembly PP 99A0263 12 5 99A1631 1 Exit Roll Assembly 12 6 99A1520 1 Gear Upper Redrive 12 7 99A0833 1 Detack Assembly 12 8 99A1521 1 Hot Roll 010 212 416 41 411 21 01 23 23e 12 8 99A1549 1 Hot Roll 414 616 61n 12 9 99A0159 2 Spacer BUR 010 212 01n 21n 23v 23e 12 10 99A1621 2 Bearing BUR 12 11 99A0173 1 Solenoid Assembly Envelope Conditioner 12 12 1 Screw Solenoid Mounting PP 99A0263 12 13 1 Screw Board Cover Mounting PP 99A0263 12 14 99A0160 1 Backup Roll 22 mm 010 212 41b 41e 411 01n 21n 23v 23e 12 14 99A0158 1 Backup Roll CBM 28 mm 414 616 61n 12 15 99A1598 1 Shield Fuser Board 12
80. 5 99A1896 1 Guard Gear 2 36 99A0899 1 Pan Motor Drip 2 37 99A0567 1 Link Gear Release 010 212 414 616 01n 21n 61n 41b 41e 411 2 38 99A0556 1 Spring Counterbalance NS 17 Screw PP 99A0263 NS 99A1524 1 Spring Cartridge Load NS 99A1546 1 Shield Gear NS 99A1596 1 Contact LSF Ground NS 99A1538 1 Contact RSF Ground NS 99A1540 4 Nutplate Frame 212 41 4 616 21n 41b 41 e 411 61 NS 99A1541 1 Spring Duplex Ground 212 41 4 616 21n 41b 41e 41l 61n 23v 23e Parts Catalog 7 11 4069 XXX Assembly 3 Printhead 7 12 Service Manual 4069 XXX Asm Part ndas Number Units Description 3 1 99A1526 1 Printhead Assembly 010 01n 3 1 99A1527 1 Printhead Assembly 212 21n 23v 23e 3 1 99A1528 1 Printhead Assembly 414 3 1 99A1867 1 Printhead Assembly 41b 41e 411 3 1 99A1873 1 Printhead Assembly 616 61n NS 3 Screw Printhead Mounting PP 99A0263 Parts Catalog 7 13 4069 XXX Assembly 4 Paper Feed Autocompensator 7 14 Service Manual 4069 XXX Part os index tMumber Units Description 4 1 99A0060 1 Sensor Paper Out Internal Tray 4 2 99A1056 1 Pick Arm Assembly 250 010 01n 23v 23e 4 2 99A1530 1 Pick Arm Assembly 500 212 414 616 21n 41b 411 41e 61n 4 3 99A0070 2 Pick Rolls NS 1 Screw Hanger PP 99A0263 4 4 99A1616 1 Flag Paper Out 500 Tray 212 414 616 21n 41b 411 41e 61n 4 4 99A1609 1 Flag Paper Out 250 Internal Tray 010 01n 23
81. 616 41b 416 411 Support Left Lower Stacker Pan Drip ITC Spring Cartridge Hold Down Extension 500 Input 212 414 616 41b 41 41e 21n 61n Pad Machine Mounting Transfer Plate Assembly Support Right Stacker Plate 0In 0I0 212 2ln Support Right Stacker Plate 4I4 AIb Alc AIL 616 6In Right Sideframe Fan Auxiliary 616 61n Frame Extension Right 500 Internal 212 414 61621n 61n 41b 416 411 Spring Tray Bias Contact Kit PP 99A0585 Contact Doctor Blade TAR Developer Roll Contact PC Drum o Contact Charge Roll o Block Contact Mounting o Screw Contact Mounting Parts Catalog 7 9 4069 XXX Assembly 2 Frame continued 7 10 Service Manual 4069 XXX ae ess Units Description 2 22 99A0466 1 Sensor Toner Cartridge Level 2 23 99A0039 2 Roller Developer Support 2 24 99A0026 1 Tray Bias Arm Assembly 2 25 99A1522 1 Pan Center Assembly 2 26 99A1525 1 Deflector Upper PF 2 27 99A1850 1 Deflector Inner 212 414 616 21 61 410 4 41_ 2 27 99A0055 1 Deflector Inner 0I0 0In 23v 23e 2 28 99A1897 1 Frame EP Module service level B 2 28 99A1833 1 Frame EP Module 010 212 414 616 01n 21n 61n 2 29 99A0053 1 Sensor Input 2 30 99A1517 1 Frame Extension Left 500 Internal 212 414 616 21n 61n 41b 416 411 2 31 99A0549 1 Shield ESD Assembly with label 2 32 99A0063 1 Spring PA Switch Activate 2 33 99A1514 1 Left Side Frame 2 34 99A0128 1 Board Input Tray ITC 2 3
82. 65 7 63 7 63 7 63 7 07 7 67 7 07 7 67 7 67 7 67 7 63 7 87 787 7 87 7 87 Index 1 5 4069 XXX 99A0341 7 65 99A0342 7 65 99A0346 7 43 99A0349 7 35 99A0350 7 53 7 59 99A0351 7 71 7 99 99A0361 7 71 7 99 99A0362 7 71 7 99 99A0363 7 71 7 99 99A0364 7 71 7 99 99A0368 7 71 7 99 99A0369 7 69 7 97 99A0371 7 71 99A0372 7 69 99A0382 7 73 99A0384 7 75 99A0385 7 75 99A0388 7 73 99A0389 7 73 99A0390 7 73 99A0392 7 79 99A0393 7 73 99A0394 7 107 99A0400 7 73 99A0404 7 106 99A0405 7 59 99A0408 7 45 99A0409 7 69 7 97 99A0410 7 33 99A0413 7 106 99A0414 7 69 7 97 99A0415 7 69 7 97 99A0419 7 55 7 59 99A0426 7 41 99A0427 7 75 99A0434 7 65 99A0435 7 67 99A0438 7 55 7 61 99A0445 7 53 7 87 99A0446 7 61 7 87 99A0447 7 59 99A0448 7 53 99A0450 7 53 7 61 99A0451 7 58 7 61 7 87 99A0452 7 61 99A0459 7 104 99A0462 7 99 7 103 7 107 1 6 Service Manual 99A0466 99A0467 99A0469 99A0481 99A0482 99A0484 99A0485 99A0487 99A0488 99A0489 99A0490 99A0491 99A0492 99A0494 99A0512 99A0513 99A0545 99A0549 99A0556 99A0559 99A0560 99A0564 99A0565 99A0566 99A0567 99A0571 99A0572 99A0576 99A0577 99A0585 99A0627 99A0629 99A0650 99A0651 99A0653 99A0654 99A0655 99A0656 99A0657 99A0658 99A0659 99A0660 99A0661 99A0662 99A0663 99A0664 99A0667 7 11 7 49 7 104 7 75 7 69 7 69 P 7 73 1 78 7 73 7 73 TAG TT 7 19 7 75 7 37 7 106 7 37 7 106 7 104 7 11 ek
83. 7 89 7 15 7 67 7 104 7 104 7 104 7 63 7 65 7 63 7 63 7 67 7 67 4507 7 7 7 49 Ju 75 79 TO ries 745 quy K 7 7 7 5 7 101 7 11 T9 7 9 Zeil 7 9 79 7 31 7 31 Index 1 7 4069 XXX 99A1522 7 11 99A1524 7 11 99A1525 7 11 99A1526 7 13 7 51 99A1527 7 13 7 51 99A1528 7 13 7 51 99A1530 7 15 99A1531 7 17 99A1533 7 21 99A1534 7 21 99A1535 7 9 99A1536 7 23 7 57 99A1537 7 23 7 25 7 57 7 59 99A1538 7 11 99A1540 7 11 99A1541 7 11 99A1543 7 27 7 47 99A1544 7 29 99A1546 7 11 99A1547 7 33 99A1548 7 33 99A1549 7 31 99A1550 7 33 99A1551 7 33 7 51 99A1553 7 31 7 51 99A1554 7 33 7 51 99A1555 7 37 99A1566 7 45 99A1569 7 27 99A1570 7 45 99A1571 7 45 99A1573 7 51 99A1575 7 51 99A1576 7 25 7 59 99A1577 7 7 7 49 99A1578 7 35 99A1579 7 63 99A1580 7 9 99a1580 7 69 99A1581 7 41 99A1582 7 25 7 59 99A1583 7 59 99A1584 7 31 99A1585 7 31 99A1586 7 21 99A1587 7 7 99A1588 7 9 1 8 Service Manual 99A1591 99A1592 99A1593 99A1594 99A1595 99A1596 99A1597 99A1598 99A1599 99A1600 99A1601 99A1602 99A1603 99A1604 99A1605 99A1607 99A1608 99A1609 99A1610 99A1611 99A1612 99A1613 99A1616 99A1617 99A1621 99A1631 99A1632 99A1633 99A1634 99A1636 99A1637 99A1638 99A1639 99A1640 99A1642 99A1643 99A1644 99A1645 99A1646 99A1647 99A1648 99A1649 99A1651 99A1654 99A1658 99A1659 99A1660 7 33 7 9 7 5 7 49 Z 7 5 reu 7 33 731 7 33 7 33 17 23 7 25 1 87 7 59 1 85
84. 825 Os produtos laser da Classe n o 540 considerados perigosos Internamente a impressora cont m um produto laser da Classe 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiagao laser superior a um nivel de Classe durante a operac o normal manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse 1 Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse IIIb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Notices and Safety Information xiii 4069 XXX Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 60825 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder
85. 901 Engine Flash Contact the next support level or call Lexmark Indicates that the flash which the engine board code is programmed into is bad Replace the engine board 902 General Engine Software 903 Paperport Link Driver Error 904 Interface Violation by the controller software 905 Interface Violation by Paperport Device 906 Controller Engine Link Driver Error These errors indicate an unrecoverable engine software error Replace the engine board Check for correct location of the jumpers on the interconnect board for the model type printer you are servicing Incorrect jumper settings can cause a 902 service error If jumpers are set correctly replace the engine board 910 DC Pick Motor DC Pick Motor Stall 911 DC Pick Motor Excessive PWM 912 DC pick motor below speed 913 DC pick motor over speed 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 51 2 2 Service Manual 4069 XXX Error Code Action 914 DC pick Check the integrated paper tray tray 1 for correct paper motor No loading Reload the paper and POR the printer If the encoder feedback error continues go to the Input Tray s Option Service Check on page 2 51 917 Transfer Roll Indicates a problem in the transfer roll area Go to the Transfer Roll Service
86. 99A0279 18 37 99A0191 18 38 99A1669 NS 99A0627 18 39 99A1666 18 40 18 41 NS 99A1129 a BR pop aaa a an un ua Parts Catalog 7 65 4069 XXX Assembly 18 Duplex continued 7 66 Service Manual 4069 XXX Part Index Number 18 42 99A1290 18 42 99A1280 18 43 99A1634 18 43 99A1679 NS 18 44 99A0435 18 44 99A1691 18 45 99A1672 18 46 99A0332 18 47 99A0307 18 48 99A0335 18 49 99A0334 18 50 99A0952 Units Description Top Cover Assembly Movable 250 Duplex Top Cover Assembly Movable 500 Duplex Top Cover Assembly Fixed 250 Duplex Top Cover Assembly Fixed 500 Duplex Retainer 6 mm Top Cover PP 99A0404 Guide Lower Entry 250 Duplex Guide Lower Entry 500 Duplex Guide Assembly Paper Decurl Guide Center Drive Upper Air Plenum Spring Decurl Shaft Bushing Decurl Shaft Frame Assembly 250 Duplex 18 51 Screw Outer Frame PP 99A0413 18 52 99A0330 Guide Assembly Center Drive 18 53 Fan Mounting Kit PP 99A0269 o Screw Fan Mounting M4x30 o Washer Fan M4 o Nut Fan M4 Fan Cooling Duplex Retainer 5 mm Main Drive PP 99A0404 Main Drive Assembly 18 54 99A0308 18 55 18 56 99A0337 18 57 99A0319 18 57 99A1676 18 58 18 59 99A0336 18 59 99A1692 NS 99A1695 18 60 99A1059 NS NS NS 99A0058 NS 99A1 164 Sensor Input Optical 250 Duplex Sensor Input Optical 500 Duplex Retainer 6 mm Drive Roll PP 99A0404 Shaft Assembly
87. AUTION Before making any measurements on the LVPS output connector observe all necessary safety precautions before applying AC power Measure the voltage on LVPS output connector CN3 The voltage measures 5 V dc If incorrect replace the LVPS Diagnostic Information 2 33 4069 XXX FRU Action 9 Engine Board Turn the printer off and disconnect all the cables from the engine board Check for 5 V dc at the engine board test point If incorrect replace the FRUs in the following order engine board interconnect board If correct turn the printer off and reconnect one cable at a time until you find the defective assembly Service Tip A short or low resistance load that is attached to the engine board can cause the LVPS to overcurrent and shut the 5 V dc supply down to 0 V dc Service Tip Check the engine board for burn marks or other damage especially R20 R21 R22 and R23 located next to the upper left engine board mounting screw If this screw is overtightened it might deform the engine board shield and cause it to short out these resistors 2 34 Service Manual 4069 XXX Duplex Option Service Check The printer does not recognize the Duplex Option is attached The printer does not recognize tray options below the duplex option are installed FRU Action 1 Fuse F1 on Duplex Option If fuse F1 is blown replace the fuse System Board If fuse F1 continues to blow check th
88. C 60825 XiV Service Manual 4069 XXX Laserprodukter i Klass anses ej halsovadliga Skrivaren har en inbyggd laser av Klass 3b som best r av en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren ar utformade sa att det aldrig finns risk f r att n gon person uts tts f r laserstralning ver Klass l niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 laserprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 60825 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse 3b laser som best r av gallium arsenlaserenhet som avgir str ling i balgelengdeomradet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes laser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 60825 Els productes l ser
89. Error Code Action 939 Controller Engine Communications Error The controller board and the engine board cannot communicate with one another The controller board engine board or interconnect board is defective Check each board for correct installation and secure ground If no problem is found replace the FRUs in the following order controller board engine board interconnect board Note The controller software also can cause a 939 error code Contact your next level for software support 940 Service LV Power Supply The low voltage power supply zero crossover test failed Check the LVPS for correct installation Ensure that the connector on the LVPS assembly is firmly seated with the connector on the interconnect card connector This error can be caused by a noisy AC input power source Check to make sure the correct LVPS has been installed If all the above are correct replace the LVPS assembly 941 Controller Code CRC A 941 error can be created by a defective code overlay SIMM a code upgrade a defective IPDS or a prescribe SIMM These should be checked before replacing the controller board 941 Controller Font CRC Replace the controller board 943 Controller Font Version Indicates that the controller code and FONT ROM are incompatible 944 Controller Board Failure Replace the controller board 945 Controller Board Failure ASIC Failure Replace the contr
90. Error Log To clear the Error Log 1 2 Select Clear Log from the Error Log menu Select YES to clear the Error Log or NO to exit the Clear Log menu If YES is selected the Empty Error Log displays on the screen Press Return Stop to exit the Clear Log menu 3 8 Service Manual 4069 XXX Hardware Tests The following Hardware Tests can be selected from this menu LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap if available Serial Wrap if available Serial 1 Wrap if available Serial 3 Wrap if available LCD Test To run the LCD Test 1 Select LCD Test from the Diagnostic menu The LCD test continually executes the LCD display test 2 Press Return Stop to cancel the test Button Test To run the Button Test 1 Select Button Test from the Diagnostic menu With no buttons pressed several OP Open appear on the display Press each button one at a time and a CL Closed displays in place of an OP The proper operation of each button can be checked Press Return Stop to cancel the test Diagnostic Aids 3 9 4069 XXX SDRAM Memory Test The purpose of this test is to check the validity of SDRAM both standard and optional The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly To run the SDRAM Memory Test 1 Select SDRAM Memory Test from the menu The power indicator blinks in
91. If incorrect replace the link assembly Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame If incorrect replace the link assembly Make sure the charge roll bushing is installed and operating correctly Note The screw that attaches the charge roll lead to the contact must be secure 2 30 Service Manual 4069 XXX Cover Open Switch Cable Service Check FRU Action 1 Toner Cartridge Check the toner cartridge to make sure it is correctly installed and that the right and left cartridge tracks are not loose or broken Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover open switch spring 2 Cover Open Switch Cable Check the cover open switch for Assembly proper mechanical operation If incorrect repair as necessary Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4 3 It measures approximately 5 V dc If the voltage is incorrect replace the engine board If the voltage is correct check the voltage at J4 1 If the voltage measures greater than 1 0 V dc replace the engine board If the voltage is correct check the continuity between J4 1 and J4 3 on the cable If no change in continuity occurs as the switch is activated replace the cover open switch cable assembly If the continuity changes
92. J1 on the envelope system board and measure the following voltages J1 3 measures 5 V J1 5 measures 5 V dc J1 7 measures 24 V dc If any of the voltages are incorrect replace the autoconnect cable connector If the voltages are correct replace the envelope system board Diagnostic Information 2 39 4069 XXX Operator panel displays 260 Paper Jam immediately when envelope feed is requested POST incomplete FRU Action 1 Pass through Sensor 2 40 Service Manual Check for any debris pieces of envelope and so on over the pass thru sensor Check for correct installation of the pass thru sensor flag Make sure the sensor cable is attached to the envelope system board Perform an envelope feeder sensor test to check both the sensor and sensor flag Note It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover Be careful not to damage the flag If the test fails check the flag for any signs of damage or binds If incorrect replace the flag If the flag is operating correctly check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the envelope system board If correct check the voltage at J3 2 The voltage changes from 0 to 5 V dc when the flag is moved in and out of the sensor If incorrect replace the sensor assembly If this does not fix the problem replace the envelope system
93. J2 2 measures between 115 and 135 ohms Also check J2 1 and J2 4 to the motor case for shorts If either the resistance is incorrect or a short if found replace the mechanical linkage DC motor assembly Note If the DC motor is shorted it may also be necessary to replace the control board 2 Control Board Disconnect the motor cable J2 from the control board and check the voltages at J2 on the board Note Use caution not to short adjacent pins on the connector as damage to the board could result 24V dc 24V dc 45V dc 5V dc 1 motor idle 2 Motor ldle 5 motor idle 6 J2 J2 J2 J2 6 motor idle If any of the voltages are incorrect replace the control board If correct replace the mechanical linkage DC motor assembly Diagnostic Information 2 87 4069 XXX Paper Feed Service Check If you have a 936 Transport Motor Error go to the Main Drive Service Check on page 2 68 FRU Action 1 Alignment Assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight Check the alignment assembly for any signs of worn rollers contaminated rollers or binds Replace the alignment assembly if any problem is found 2 Inner Deflector Check the inner paper deflector for correct installation If the deflector is bowed or not fitting correctly replace the deflector Autocompensator fails to feed paper
94. J3 7 measures approximately 24 V dc If incorrect replace the engine board If correct replace the FRUs in the following order engine board printhead assembly Diagnostic Information 2 91 4069 XXX Print Quality Service Check Service Tip Before troubleshooting any print quality problems do the following Install another print cartridge if available before proceeding with the service checks Use Tray 1 to test for print quality of the base printer Replace the charge roll if it is damaged or contaminated Replace the transfer roll if it is damaged or contaminated Make sure the fuser assembly is installed correctly Verify proper paper type texture and weight settings for the media being used Test the printer using plain paper 2010 Select the following menu settings as indicated Be sure and note the original settings so you can return the printer to the original customer printer setup Print Resolution Set to 300 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver Set to OFF PQET Set to OFF Fuser Temperature Set to NORMAL Test the printer using plain paper 20 Ib An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Measure all voltages from the connector to printer ground All voltages measured during the print cycle are m
95. Mounting Parts Packet Duplex Option Cam Follower Assembly Parts Packet Envelope Option Gears Parts Packet Retainers Envelope Option Parts Packet Screws Duplex Parts Packet 500 Sheet Feeder Option Shaft Bearings Parts Packet Cable Ties 10 each Parts Packet Screws High Capacity Feeder Parts Packet Nuts High Capacity Feeder Parts Packet Washers High Capacity Feeder Parts Kit Multipurpose Tray Parts Kit Charge Roll Link Asm Left Side Parts Kit Charge Roll Link Asm Right Side Parts Kit Erase Lamp Lens Printer Stand Caster Non Locking Printer Stand Caster Locking Printer Stand Grommet Wire Printer Stand Lock Cam Printer Stand Storage Shelf Printer Stand Door Assembly Cabinet Printer Stand Filler Rear Top Piece Printer Stand Table Assembly Large Printer Stand Table Assembly Small 7 106 Service Manual 4069 XXX Assembly 27 Miscellaneous continued Asm Index 27 27 27 27 27 27 27 27 27 Part Number 99A0208 99A0234 99A0394 99A0462 99A1852 99A1853 99A1854 99A1855 99A0240 Units Description Parts Packet Pulley Kiosk Parts Packet Screws Kiosk Grease Packet Nyogel 744 Grease Packet IBM 23 Packaging 4069 250 250 printer Packaging 4069 500 250 printer Packaging 4069 500 500 printer Packaging 4069 500 500 plus 500 printer Parts Packet Retainer Parts Catalog 7 107 4069 XXX 7 108 Service Manual 4069 XXX Index A Acronym
96. ORZICHTIG Onzichtbare laserstraling wanneer open en nie vergrendeld Vermijd blootstelling aen straal ATTENZIONE Radiazioni laser invisibili se 1 dispositivo aperto e non bloccato Evitare l aposizione diretta AVISO Radiaci n l ser invisible si la puerta est abierta y dispositivo no esta bloqueado Evite exponerse a la radiaci n CUIDADO Radia o laser invisivel quando a tampa aberta Evite exposi o aos raios VARO Avattaessa suojalukitus ohitottaessa olet atiina n kym t m ile lasers teilylle Ala katso s teeseen VARNING Osyniig laserstr lning denna del ar ppnad och sp rrar ar u kopplade r farlig ADVARSEL Usynlig laserstraling deksel apnes og sikkernedsl s brytes Unng eksponering tor str len ADVARSEL Usynlig laserstraling ved bning n r sikkerhedsafbrydere er ude af funktion Undg undszettelse tor str ling ATENCI Radiaci l ser invisible s obre el tancament nter no s correcte Eviteu exposar vos hi ER SRE I MARUI T ae YTD ERTZERA EE Sa ASH 0181901 EES ER Rica LM ENSOT S ICEMLT CEBU 01121 MON elo aus Notices and Safety Information ix 4069 XXX Class 1 Laser Statement Label X Service Manual CLASS 1 LASER PRODUCT LASER KLASSE 1 LOUKAN 1 LASERLAITE APPAREIL A LASER DE CLASSE 1 TO IEC 60825 4069 XXX Laser Notice The printer is certified in the U S to
97. Parallel Wrap Test This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the menu The power indicator blinks indicating the test is in progress The test runs continuously until canceled Each time the test finishes the screen updates If the test passes the Pass Count increases by 1 however if the test fails one of the following messages displays for approximately three seconds Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error Diagnostic Aids 3 11 4069 XXX DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum count is reached the test stops The power indicator goes on solid and the final results display Press Return Stop to exit the test Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug Each signal is tested To r
98. Print a copy of the Quick Test Page and check the margin adjustments printed on the test page These settings should be within the range specified in Print Registration on page 3 19 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the alignment assembly to the left side frame 3 Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer It is not necessary to completely remove the screw 4 Install the new alignment assembly Turn the reference screw clockwise with a 7 mm nut driver until it touches the back of the reference plate and tighten the nut with a 5 5 mm wrench The reference adjustment screw can be adjusted without loosening the nut Turn the screw clockwise a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want Repair Information 4 5 4069 XXX b Print a copy of the Quick Test Page and check the margin adjustments printed on the test page These settings should be within the range specified in Print Registration on page 3 19 The reference screw can be adjusted without loosening the locknut Turn the screw a few turns and print a copy of the Quick Test Page
99. Switch Assembly 4 49 Optional Paper Tray Assembly 4 50 Paper Alignment Assembly 4 51 Paper Deflectors 4 53 Inner Paper Deflector Assembly 4 53 Upper Paper Deflector Assembly 4 53 Paper Input Sensor 4 54 Paper Size Sensing Board 4 54 Pick Roll 4 55 Printhead 4 56 Redrive Assembly 4 57 Smart Cartridge Contacts 4 58 Toner Sensor 4 59 Transfer Roll Assembly 4 60 Upper Front Cover Hinge Assembly 4 61 Upper Front Cover Interlock Switch Assembly 4 62 Restore EP Factory Defaults 3 22 ROM Memory Test 3 10 S Safety Information xvii Safety Inspection Guide 6 1 Scheduled Maintenance 6 2 Screw Identification Table 4 7 SDRAM Memory Test 3 10 Serial Wrap Test 3 12 Service Checks Charge Roll 2 29 Cover Open Switch Cable 2 31 Dead Machine 2 32 Duplex Option 2 35 Envelope Feeder Option 2 38 Erase Lamp 2 45 Fan 2 46 Fuser 2 47 Hot Roll Fuser 2 47 Fuser Solenoid 2 50 High Capacity Feeder Input Tray 2 55 High Capacity Output Stacker 2 79 Index 1 3 4069 XXX Input Sensor 2 51 Input Tray s Option 2 51 Main Drive 2 68 Operator Panel 2 69 Options 2 71 Output Bin Sensor 2 73 Output Expander 2 74 Paper Feed 2 88 Parallel Port 2 90 Print Quality 2 92 Printhead 2 91 Serial Port 2 106 Smart Cartridge 2 105 Toner Sensor 2 106 Transfer Roll 2 107 5 Bin Mailbox 2 82 Setting Configuration ID 3 21 Setting the Page Count 3 20 Status Messages 2 12 Symptom Tables 2 25 Base Printer 2 25 Duplex 2 27 Envelope Feeder Op
100. Tray 500 Sheet 7 24 Kiosk Horizontal Paper Adapter 7 92 Kiosk Vertical Paper Adapter 7 90 Main Drive 7 26 Miscellaneous 7 106 Options 7 104 Output Expander Paper Feed Alignment 7 18 Autocompensator 7 14 Multipurpose Unit 7 16 Output 7 20 Printhead 7 12 Transfer 7 34 250 Sheet Tray 7 52 5 Bin Mailbox 7 100 500 Sheet Tray 7 58 Power On Self Test POST Preventive Maintenance 6 1 Q Quick Disk Test 3 2 7 68 2 24 4069 XXX R Removal Procedures 4 12 Removals Center Pan Assembly 4 16 Controller Board 4 17 Covers 4 12 Developer Drive Assembly 4 18 Duplex Board 4 19 Duplex Front Cover Assembly 4 19 Duplex Front Cover Door 4 19 Duplex Motor 4 20 EMC Shields 4 21 Inner EMC Shield 4 21 Outer EMC Shield 4 22 Engine Board 4 23 Fans 4 24 Frames 4 26 EP Frame Assembly 4 26 Left Side Frame 4 26 Right Side Frame 4 28 Fuser 4 29 Fuser Board 4 30 Fuser Cover 4 31 Fuser Detack Fingers 4 31 Fuser Detack Housing Assembly 4 32 Fuser Envelope Solenoid 4 34 Fuser Exit Sensor Flag Assembly 4 35 Fuser Lamp 4 35 Fuser Lower Exit Guide Assembly 4 36 Fuser Narrow Media Sensor Flag Assembly 4 35 Fuser Transfer Plate 4 33 HVPS 4 37 Integrated Tray Compensator Assembly 4 38 Integrated Tray Compensator Pick Roll Assembly 4 39 Interconnect Board Assembly 4 40 LVPS 4 42 Main Drive Assembly 4 43 Main Drive Motor 4 45 Multipurpose Tray Lower Deflector Assembly 4 46 Operator Panel 4 48 Operator Panel Cable Cover Open
101. Vdc J4 Autoconnect Top 24 V dc Ground 5 V dc Fused oO Ground 5 12 Service Manual 4069 XXX Connector Pin No Signal J5 Autoconnect 1 24 V dc BTM FNT 2 Ground J6 Engine Board 1 N A J7 Controller Board 1 N A J11 INA 1 1 N A J12 INA 2 1 N A Jumper Connector Position Signal J8 ID 1 1 0 V dc Gnd center pin to top pin of J8 2 5 V dc center pin to bottom pin of J9 J9 ID 2 3 0 V dc Gnd center pin to top pin of J9 4 5 V dc center pin to bot tom pin of J9 J10 10 3 5 0 V dc Gnd center pin to top pin of J10 6 5 V dc center pin to bot tom pin of J10 Note A 902 service error may display if the jumpers are not correctly installed Models 010 and 01n have a jumper on J10 between the center pin and pin 5 Models 212 and 21n have a jumper between the center pin and pin2 of J8 a jumper between the center pin and pin 4 on J9 and a jumper between the center pin and pin 5 of J10 Models 414 41b 41L and 41n have a jumper between the center pin and pin 2 of J8 and a jumper between the center pin and pin 3 of J9 Connector Locations 5 13 4069 XXX Models 616 and 61n have a jumper between the center pin and pint of J8 and a jumper between the center pin and pin of J9 BAR CODE AREA J8 J9 J10 1 1503 505 504 Ise 10 1 10 2 10 3
102. XXX 99A1779 7 95 99A1780 7 95 99A1781 7 95 99A1782 7 95 99A1783 7 95 99A1784 7 23 7 69 99A1785 7 95 7 101 99A1786 7 101 99A1787 7 103 99A1788 7 103 99A1789 7 103 99A1790 7 95 99A1791 7 99 99A1792 7 99 99A1795 7 85 99A1796 7 85 99A1797 7 85 99A1798 7 85 99A1799 7 85 99A1800 7 85 99A1801 7 85 99A1802 7 85 99A1803 7 85 99A1804 7 85 99A1805 7 85 99A1806 7 79 99A1807 7 81 99A1808 7 81 99A1809 7 77 99A1812 7 23 7 25 7 89 99A1817 7 69 99A1818 7 77 99A1819 7 91 7 93 99A1820 7 91 7 93 99A1822 7 41 99A1823 7 41 99A1829 7 59 7 77 99A1830 7 105 99A1832 7 9 99A1833 7 11 99A1850 7 11 99A1852 7 107 99A1853 7 107 99A1854 7 107 99A1855 7 107 99A1857 7 21 7 69 99A1859 7 104 1 10 Service Manual 99A1863 99A1867 99A1869 99A1871 99A1873 99A1875 99A1878 99A1879 99A1884 99A1885 99A1886 99A1887 99A1889 99A1890 99A1894 99A1895 99A1896 99A1897 99A1902 99A1904 99A1923 99A1924 99A1927 99A1928 99A1929 99A1930 99A1943 99A1944 99A1950 99A1951 99A1952 99A1953 99A1954 99A1955 99A1956 99A1957 99A1958 99A1959 99A1960 99A1967 99A1968 7 41 7 13 7 91 7 39 7 39 7 13 7 51 7 41 7 39 79 7 104 7 104 7 104 7 104 7 105 7 105 1 97 7 29 7 99 Zr Feli 7 31 7 63 7 39 T 9 7 15 7 61 755 7915 7 41 7 41 7 61 7 105 7 61 7 105 T 29 7 25 7 51 T09 7 19 7 43 7 43 7 43 7 43 7 43 7 43 7 43 1 53 7 59 7 87 Ke
103. XXX Outer EMC Shield 1 Remove the left door 2 Loosen the outer EMC shield mounting screws A and remove the shield A 202 A 202 4 22 Service Manual 4069 XXX Engine Board 1 Remove the inner EMC shield 2 Disconnect all cables from the engine board 3 Remove the engine board mounting screws A 4 Remove the engine board cage mounting screw B from the main drive motor assembly 5 Remove the engine board Note Anytime the engine board is replaced the Configuration ID must be reset in NVRAM on the new engine board Go to Setting Configuration ID on page 3 21 A 202 B 104 Repair Information 4 23 4069 XXX Fans Auxiliary Fan Models 614 616 1 Remove the right cover 2 Remove the inner EMC shield 3 Remove the fuser wiper cover 4 Disconnect the auxiliary fan cable from the engine board at connector J7 5 Note the routing of the auxiliary fan cable A and remove the fan B 4 24 Service Manual 4069 XXX Main Fan 1 Remove the top rear cover 2 Remove the inner EMC shield 3 Note the routing of the main fan cable A and disconnect the cable from the engine board at connector J1 4 Release the four latches B and remove the fan from the left side frame A Repair Information 4 25 4069 XXX Frames EP Frame Assembly 1 Remove the left and right side frames 2 Remove the EP frame assembly Left Side Frame Remove the engine board Remov
104. a aA RO E A Fb bb Fb E A P Retainer R Ring Parts Catalog 7 103 4069 XXX Assembly 26 Options Asm Index 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 Part Number 99A1752 99A1753 99A1754 99A1755 99A1756 99A1773 99A1757 99A1758 99A1759 99A1774 99A1886 99A1887 99A1885 99A1126 99A1089 99A1884 99A0459 99A1084 99A0629 13A0296 13A0297 99A0545 13A0298 99A0467 99A0923 99A1859 99A1031 Units et sch a sa sch a a a ea a ea sch a a a sch sch sch sch sch Description 4MB SDRAM DIMM 8MB SDRAM DIMM 16MB SDRAM DIMM 32MB SDRAM DIMM 64MB SDRAM DIMM 128MB SDRAM DIMM 2MB Flash DIMM 4MB Flash DIMM 8MB Flash DIMM 16MB Flash DIMM DIMM Font Traditional Chinese DIMM Font Simplified Chinese DIMM COS supports Chinese fonts SIMM Bar Code SIMM Prescribe 5 4 2 Flash SIMM for IPDS and SCS Tne Hard Disk with Control Board 2 1GB SIMM IPDS 5 4 2 Flash Adapter Card SES for SCS Cable Twinax Cable Coax Adapter Serial Cable Serial Board Parallel Port Adapter Board USB Parallel Port SIMM Image Quick Tiff SIMM Image Quick Web 7 104 Service Manual 4069 XXX Assembly 26 Options continued m TQUE Units Description 26 99A1890 1 Tray Assembly 250 Special Media 010 212 414 616 41b 411 23v 23e 26 99A1647 1 Rib Assembly 250 Special Media Tray 010 212 414 616 41b 411 23v 23
105. ages 3 14 Input Tray Sensor Test 3 14 Output Bin Test Standard Bin 3 15 Output Bin Peed s 2g codo d ERRORES Re 3 15 Output Bin Serisor uy oso ade nada 3 16 Output Bin X Sensor Test 3 16 Base Sensor Test sagas ura xa dee hk Ee 3 17 5 Bin Mailbox Diverter 5 3 18 Pull Sedis albi wie ti sad 3 18 Printer sues cam o Bar PAREDES EAE 3 20 Setting the Page 3 20 Viewing the Permanent Page Count 3 20 iV Service Manual 4069 XXX Maintenance Page 3 21 Setting Configuration 3 21 Restore EP Factory Defaults 3 22 URS OS bs cele 3 23 Print Quality Test Pages sod sem 3 24 Print Test with RIP Controller Board Removed 3 25 Printing Menu Settings Page 3 26 Autocompensator Operation 3 26 Autoconnect System Paper Tray Options Envelope Feeder and Output Expander 3 27 Re VE ee MOERS V E eS 3 29 Faber POCO aua dts ecd paio dedito iia 3 30 Repair Information 4 1 Handling ESD Sensitive
106. al 4069 XXX Korean Laser Notice axie 158 olx CHSt DHHS 21 CFR Subchapter 39 FNS Astor Ves 01 2158900 319 9 IEC 825 TUS Ete 158 oly ABSA BIOS LC 158 0 d ses CHS AOS E 5 28 2 770 795 TFHA Siss Class 3b 40 01 zt Veit AAMT BREE BA As RA HS SLE HAE MHA 21719 Class 29 alo x H20 Apeto SO Sae T WEE SEO UECH Safety Information This product is designed tested and approved to meet strict global safety standards with the use of specific Lexmark components The safety features of some parts may not always be obvious Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t concu test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de Notices and Safety Information xvii 4069 XXX s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre ten
107. ank Latch Upper Cover Spring Latch Cover Assembly Lower Front Operator Panel Assembly Switch Cover Open w Operator Panel Cable Assembly Screw Left Side Cvr Mtg PP 99A0263 Cover Left Door 010 23v 23e Cover Left Door 414 616 212 41b 416 411 NS 1 19 99A1509 1 19 99A1510 1 20 99A1587 Support Paper NS 99A0577 Cable Tie NS 99A1594 oco sch c I ER Retainer Cable Parts Catalog 7 7 4069 XXX Assembly 2 Frame 7 8 Service Manual 4069 XXX Asm Index 2 1 2 1 2 2 2 3 2 4 2 4 2 5 2 6 2 6 2 7 2 8 2 9 2 10 2 11 2 13 2 14 2 15 2 16 2 16 2 17 2 18 2 19 2 20 2 21 Part Number 99A1643 99A1592 99A0803 99A0138 99A1580 99A1613 99A1879 99A1515 99A1516 99A0867 99A1832 99A1662 99A0113 99A1924 99A1519 99A0058 99A1588 99A1663 99A1968 99A1535 99A0049 99A1518 99A0028 Units P OD P won a Description Shroud Fan 250 010 01n 23v 23e Shroud Fan 500 212 414 616 41b 41e 411 21n 61n Fan Main Sensor Standard Bin Level 212 414 616 41b 41e 411 21n 61n 23v 23e Flag Output Paper Level 414 616 41b 41e 411 61 Flag Output Paper Level 212 21n 23v 23e Bracket Level Sensor 212 41 4 616 21n 41b 41 411 61 Duct 250 Left Stacker 010 212 01n 21n 23v 23e Duct 500 Left Stacker 414 616 41b 41e 411 Gin Duct Main Body Guide Extension 500 Input 212 41 4
108. ar Door Message displays A sheet of paper is jammed prior to the pass through sensor flag 202 Paper Jam Open Rear Door Message displays A sheet of paper feeds out to the standard bin even though bin x is selected Paper exits half way out of the redrive Service Tip For this type of problem check the sub error codes They can help isolate the problem 202 Paper Jam messages can also occur prior to the output expander pass thru sensor FRU Action 1 Output Expander Drive Belt Drive Pulley Drive Belt Idler Pulley Belt Tension Spring Check to ensure the output expander drive belt is correctly installed on the drive pulley and belt idler pulley Check the belt tension spring to make sure it is not loose or broken Repair as necessary 2 Mechanical Linkage DC Motor Assembly If the DC motor is functioning properly check the gears clutch and other linkage parts for correct operation and any signs of wear broken gear teeth or damaged parts If incorrect replace the mechanical linkage DC motor assembly 2 76 Service Manual 4069 XXX Remove Paper Output Bin X is displayed POST Incomplete Unable to clear the message FRU Action 1 Dual Output Bin Sensor Flag Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary 271 Paper Jam Check Bin X POST Incomplete FRU Action 1 Pa
109. as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want 4 6 Service Manual 4069 XXX Screw Identification Table The following table contains screw types locations and quantities necessary to service the printer Each screw callout in the removal procedure graphic displays the screw reference number listed in the table Pay careful attention to each screw type location when doing removals You must install the correct screw type in each location during reassembly Reference Number Screw Type Location Purpose Qty M3 5x8 mm right side frame to attach 1 Thread Cutting center pan Gi toner level sensor mounting 1 charge roll mountin 1 102 g ii main drive gearbox mounting 3 EP module to left and attach 9 right side frame developer drive mounting 2 assembly stacker duct to frame mounting 2 cartridge hold down mounting 2 assembly MPT deflector mounting 2 interconnect board attach 2 shield ground engine board shield to attach 1 frame laser cover mounting 4 deflector mounting 2 Repair Information 4 7 4069 XXX Reference Number Screw Type Location Purpose Qty M3 5x8 mm spring mounting 1 Thread Cutting controller board mounting 2 e front integrated tray ITC mounting 2 102 board
110. auxiliary fan turns on and continues to run until the printer is powered off Ready appears on the display 2 24 Service Manual 4069 XXX Symptom Tables Symptom Table Base Printer Symptom Action Auxiliary Fan 414 616 fails to run or is noisy Go to the Auxiliary Fan Service Check on page 2 46 Dead Machine Go to the Dead Machine Service Check on page 2 32 Operator Panel One or more buttons do not work Go to the Operator Panel Buttons Service Check on page 2 69 Operator Panel Display is blank Printer sounds 5 beeps Go to the Operator Panel Service Check on page 2 69 Operator Panel Display is blank Printer does not sound 5 beeps Replace the operator panel assembly Operator Panel continuously displays all diamonds sounds 5 beeps and does not complete POST Go to the Operator Panel Service Check on page 2 69 Paperfeed problems Base printer or Integrated 250 Paper Tray Go to the Paper Feed Service Check on page 2 88 Paper jams at exit of Redrive Assembly No Duplex Option installed Go to the Paper Feed Service Check on page 2 88 Paper jams at exit of Redrive Assembly Duplex Option installed Go to the Duplex Option Service Check on page 2 35 Fuser Solenoid fails to operate Go to the Fuser Solenoid Service Check on page 2 50 Print quality Black page Go to
111. ays An envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path FRU Action 1 Latch Lever Check to make sure the tip of the latch lever is centered in the opening in the floor of the paper path The latch lever may not be detented on the latch 2 44 Service Manual 4069 XXX Erase Lamp Service Check 010 212 41 4 616 Error code 928 may be displayed when the printer detects that the erase lamp assembly cable or engine board is defective Note If the erase lamp assembly is defective both the erase lamp and lens are replaced as a kit Models 416 41 411 and any model at service level B do not have erase lamps installed Go to Printer Serial Label on page 7 2 to identify the printer service level Make the following checks when a 928 service error displays FRU Action 1 Cable Front Harness Check the connection of the front harness to connector J10 on the engine board for correct installation If incorrect repair as necessary Check the front harness to erase lamp assembly for correct installation If incorrect repair as necessary 2 Engine Board Remove the controller board and toner cartridge from the machine Ground pin J10 15 The erase lamps turn on The lamps can be observed through the front of the machine with the cover open and print cartridge removed If the lamps do not turn on measure the voltage on J10 14 The voltage
112. board 4069 XXX Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display Load Envelopes after envelopes are placed in the hopper Service Tip The kick rolls rotate during the attempted feed cycles FRU Action 1 Envelope Out Hopper Check the envelope out sensor flag Sensor Flag for damage correct installation and operation If incorrect repair or replace the flag 2 Envelope Out Hopper Input Check the sensor to make sure it is Sensor installed correctly and the sensor cable is properly connected to the envelope system board If correct perform the Envelope Feed Sensor Test to check both the sensor and flag If the test fails remove any envelopes in the hopper turn the printer off and disconnect J3 from the system board Turn the printer on and check the voltage at J3 3 on the System board The voltage measures approximately 5 V dc If incorrect replace the envelope system board If correct replace the input sensor assembly Diagnostic Information 2 41 4069 XXX 990 Service Error Envelopes fail to feed from the hopper FRU Action 1 D C Feed Motor Assembly Check the motor and motor cable for any signs of loose wires or poor connections Check to make sure the motor cable is connected to the envelope system board 2 Envelope Feeder System Check the voltage on J4 1 The Board voltage
113. ception Run the SDRAM Memory Test on page 3 10 from the menu if the SDRAM Memory DIMM is correctly installed and not broken or damaged If the test fails replace the SDRAM DIMM If the problem continues replace the controller board Diagnostic Information 2 71 4069 XXX Hard Disk Option Service Tip The Optra T printers support one hard disk option Check to make sure only one hard disk option is installed 2 1 GB or larger Check to make sure the fixed disk and the fixed disk board are correctly installed Run the Quick Disk Test on page 3 2 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk Note The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If a problem still exists replace the hard disk board The Disk Test Clean on page 3 2 is used to help restore the disk if the disk contains bad data and is unusable This test is divided into a cleaning and a verifying or testing section WARNING This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk Menu operation This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network Card Option Note The network is installed on the control
114. ck MP Feeder Paper is jammed in the multipurpose feeder 260 Paper Jam Check Envelope Feeder 27X Paper Jam Paper is jammed in the envelope feeder Paper is jammed in output bin X X 1 thru 3 Check Output Bin X Open the rear door of Output Bin X to access the jammed pages Insert Cartridge or Close Door This message displays when the printer s front door is open or the print cartridge is missing If this message cannot be cleared go to Cover Open Switch Cable Service Check on page 2 31 2 16 Service Manual 4069 XXX User Error Message Explanation 31 Defective Print Cartridge Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is defective Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print they are not reprinted once a good print cartridge is inserted Note This error indicates the printer was able to read the cartridge ID but the ID did not pass the verification test To pass the verification test the ID read from the print cartridge must match the ID from the last good print cartridge or the same ID must be read from the print cartridge twice The last good print cartridge ID is stored in NVRAM 32 Unsupported Print Cartr
115. componentes de substitui o As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Notices and Safety Information xix 4069 XXX Informacio de Seguretat Aquest producte esta dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi e La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients XX Service Manual 4069 XXX Chinese Safety Information e AP RPA Lexmark TF Ze Ze Er HEA BT WARE HES HE AY EAS DIRE RI ATA ERE EE Lexmark MEAT e AP mA AE RES ERS A AEA TEST H3 e AP MET AMIN IR TE HR A f Re FOX SODAUR BL T f FR DUE TuS dE
116. controller board 962 RAM in Slot 2 is Bad Replace the DIMM in Slot 2 If this does not fix the problem replace the controller board 963 RAM in slot 3 is Bad Replace the DIMM in slot 3 If this does not fix the problem replace the controller board 964 Emulation Error 965 Emulation Error Indicates a failure within the Download Emulation which is programmed into the code overlay SIMM The specific error is as follows 964 Download Emulation CRC Failure Checksum Failure 965 Download Emulation Outdated The Download Emulation and the controller code are incompatible Go to Disabling Download Emulations on page 3 3 2 6 Service Manual 4069 XXX Error Code Action 975 979 Network Card X The following errors indicate a failure with the network card in the specified slot X any card installed in slots 1 2 or 3 975 Unrecognizable Network Card x Replace Network Card x 976 Unrecoverable software error in Network Card x 977 Controller software detects that a Network Card is installed in slot x but cannot establish communications with it 978 Bad checksum while programming Network Card x Replace Network Card x 979 Flash parts failed while programming Network Card x If the printer is a network model replace the controller board 980 lt device gt Comm 981 lt device gt The engine is experiencing unreliable communications to the specified de
117. cronyms CSU DIMM DRAM EDO EP EPROM ESD FRU GB HVPS LASER LCD LED LVPS MROM NVRAM OEM PC POR POST RIP ROM SIMM SDRAM SRAM UPR V dc Customer Setup Dual In Line Memory Module Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Erasable Programmable Read Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte High Voltage Power Supply Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Masked Read Only Memory Nonvolatile Random Access Memory Original Equipment Manufacturer Photoconductor Power On Reset Power On Self Test Raster Imaging Processor Read Only Memory Single In Line Memory Module Synchronous Dual Random Access Memory Static Random Access Memory Used Parts Return Volts alternating current Volts direct current General Information 1 5 4069 XXX 1 6 Service Manual 4069 XXX 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
118. ct replace the smart cartridge cable Serial Port Service Check Run the Serial Wrap Test on page 3 12 Note The Serial Wrap Test is designed to check the serial port hardware by using a wrap plug P N 1329048 and invoking the Serial Post Diagnostic Test The test helps isolate the printer from the serial cable and host The test provides failure information on the display for approximately three seconds If the test indicates a problem replace the controller board Toner Sensor Service Check Service Tip Check the print darkness MENU setting before checking the toner sensor This service check is intended to be used when a 929 Service Error displays FRU Action Developer Drive Assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929 error code Toner Sensor Check the developer drive assembly for correct installation any sign of worn loose or broken parts 2 106 Service Manual 4069 XXX FRU Action 2 Front Harness Cable Check the toner sensor portion of the front harness cable to make sure it is properly seated into the toner sensor If correct at both the sensor and engine board J10 check the continuity of the cable If incorrect replace the cable 3 Toner Sensor The toner sensor cable is part of the front harness and part of connector J10 on the engine board Check the voltage at J1 011 It reads a
119. ction Check Tray X Connection Check Tray X X 1 2 3 4 or 5 Check Duplex Connection Check Duplex Option Connection 2 22 Service Manual 4069 XXX The messages in the following table can occur in two ways The specified device could have been removed from the printer for instance to clear a paper jam Otherwise the device can still be attached to the printer but is experiencing a communications problem not fully connected or having a hardware failure Ifthe device is temporarily removed or not connected properly then reattach it When the option is recognized the printer automatically clears the error and continues fthe option is experiencing a hardware problem turn the printer off and back on If the error occurs again turn the printer off remove the option and call for service User Status Message Explanation Turn Printer OFF to This message displays when a printer option Enable Option Input Tray Output Bin or Envelope Feeder has been attached while the printer is powered On In order to use the option the printer must first be powered off and back on again Data loss results if print jobs are active when the printer is power cycled If a print job is active then remove the option and finish the job The printer automatically clears the message once the option is removed Once the job is complete turn off the printer and attach the option again Insert Duplex Front This m
120. ction automatically or autoconnects requiring no external cables when the option is mechanically installed under the printer Communication between the option and the base printer stops when you remove an option located above or below the printer The printer no longer recognizes the option and deletes associated messages Each installed option below the base printer provides an electrical autoconnect to the Diagnostic Aids 3 27 4069 XXX option attached below it The output expander option attached above the base printer provides power to the option above it We do not recommend to attach or Hot Plug any options with the base printer power turned On Duplex Option The duplex option interface is a six pin autoconnector that provides a 24 V 24 V return serial interface transmit signal serial interface receive signal and two ground pins The duplex option receives the 24 V dc from the base printer for the duplex motors and also converts the voltage to 5 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and base of the printer The ground connection is automatically made when the option is installed below the printer The paper input sensor is located in the rear of the duplex unit under the input paper guide The rear cover open switch is located on the rear cover assembly The paper exit sensor is located on the left
121. ctly into the duplex option 3 30 Service Manual 4069 XXX Error Message 24x x Tray 1 through 5 Paper Jam Check Tray x The paper has not cleared the pass through sensor or reached the pass through sensor of the option above tray x Error Message 250 Paper Jam Check MP Feeder The paper is jammed in the multipurpose feeder and has not reached the base machine input sensor or has not reached the input sensor in time Error Message 260 Paper Jam Check Envelope Feeder An envelope is jammed in the envelope feeder or has not reached the base machine input sensor Error Message 27x Paper Jam Check Bin x Paper is jammed in output bin x X bin 1 thru 3 Generally this message appears when the paper has not cleared the exit sensor in time has jammed in the redrive assembly or has not fed into the output bin selected Diagnostic Aids 3 31 4069 XXX 3 32 Service Manual 4069 XXX 4 Repair Information WARNING Read the following before handling electronic parts Handling ESD Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the lea
122. de classe no es consideren perillosos Aquesta impressora cont un l ser de classe 3b d arseni r de gal li nominalment de 5 mil liwats i funciona a la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci l ser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites Notices and Safety Information xv 4069 XXX Japanese Laser Notice 2 pD 1071 9 15 5 21 CFRYTFF 7FIF J 07241 1 1 4 5 0 ZC 82508677 5 ALOV V WMECHSCEMMPMANTIET a EREL Oti CHET CO 7Zyr sZ i 7ZXHnb 30 OL P AARMELTOIEF CO 95 gt 4 7 0 BH SL UD ybhOAVUDAUMILWMERHITSL P EFT COL LWATACTULS ii HW OH H BW ARM IFALTOVANVELLOL ik Chinese Laser Notice OL ae EIU E DHHS 21 CFR Subchapter I Xj 47 28 I 1 RIT f B9 Es m H Hb X I SEGA ES 825 1 HE SE TIED OLA ah amp 27 Hb 3b B9 Sms SRAM gi EG HAKEE 770 795 nm z VE Xvi Service Manu
123. dicating the test is in progress 2 Press Return Stop to exit the test PAHHHHHE represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F represents the of time the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display If the test fails the message SDRAM Error displays for approximately three seconds and the failure count increases by 1 ROM Memory Test The ROM Memory Test is used to check the validity of the controller board code and fonts To run the ROM Memory Test 1 Select ROM Memory Test from the menu P and F represent the same numbers for DRAM The power indicator blinks indicating the test is in process The test runs continuously 2 Press Return Stop to exit the test 3 10 Service Manual 4069 XXX Each time the test finishes the screen updates with the result If the test passes the Pass Count increases by 1 however if the test fails one of the following messages displays for approximately three seconds ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached the test stops with the power indicator on solid The final results display on the screen
124. duct mounting 1 Taptite Panhead engine board mounting 2 ED controller to shield mounting 2 controller board mounting 2 in pan mounting 2 shield ground attach 1 LVPS mounting 2 fuser cover mounting 2 cable clip mounting 2 outer shield mounting 6 ina cover mounting 4 4 10 Service Manual 4069 XXX Reference 425 NA HAMA amp N mber Screw Type Location Purpose Qty M3 5x8 mm autocompensator mounting 3 Plastite Thread Forming 323 amp i M3 5x10 mm right side cover mounting 1 Plastite Thread Forming right side frame to pan attach 3 XS left side frame to pan attach 1 324 i i t M3x6 mm fuser board mounting 1 SEMS Machine Screw with washer e M3 5x12 mm printhead to EP frame mounting 3 Plastite Thread Forming with washer Repair Information 4 11 4069 XXX Removal Procedures 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 hand grips on the side of the printer Make sure your fingers are not under the printer when you lift or set the printer down Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Covers Left Door 1
125. e Check the autoconect cables and connectors for any signs of damage Replace if necessary Check the cables for continuity If incorrect replace the compensator assembly cable If the cables connectors and connections are good replace the FRUs in the following order autocompensator assembly option System board 2 52 Service Manual 4069 XXX 24X Paper Jam message displays Paper jammed over the Pass Thru Sensor The printer displays the value of X for the paper tray where the error occurs Example 241 is a Paper Jam Tray 1 FRU Action 1 Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Check these parts for signs of Spring Bevel Gear broken or damaged parts Feedroll Gear Drive Roll contamination on the drive rollers or Assembly Wear Plate wear plate and wear or damage to Drive Shaft Bearings and the drive shaft bearings Check the Skewed Backup Rolle
126. e 26 99A1654 1 Tray Universal Adjustable 250 Sheet 26 99A0910 1 Cartridge Empty Shipping 2 26 99A0909 1 Cartridge Empty Shipping 1 26 99A0863 1 Stacking Device Integrated Label Letter 26 99A0864 1 Stacking Device Integrated Label Letter 26 99A0865 1 Stacking Device Legal Label 26 99A0799 1 Drive Forms HD 2 1GB or larger 26 99A1605 1 Kit Cap Stack Bails 500 26 99A0945 1 Kit Paper Stacking Arm 26 99A1830 1 Marknet N2001e 10 100 ethernet 26 12G1696 1 Marknet N2002e 10base2 10baseT 26 12G1697 1 Marknet N2000t 4 16 26 99A0560 1 Adapter Omnibus INA Card 26 99A1889 1 Paper Presentator Front 010 212 23v 23e 41e 0ln 2lIn 26 99A1950 1 Tray Feature Photo Gab Tray Assembly 25v 25e 26 99A1951 1 Spring Photo Bag Transfer 25v 25e Parts Catalog 7 105 4069 XXX Assembly 27 Miscellaneous Asm Index 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 Part Number 99A1633 99A0585 99A0267 99A0268 99A0269 99A0299 99A0271 99A0404 99A0413 99A0572 99A0577 99A0675 99A0676 99A0677 99A0083 99A0512 99A0513 99A0186 99A0702 99A0703 99A0704 99A0705 99A0706 99A0707 99A0710 99A0711 99A0712 Units n ln ln o n n a n os po PS MYO HH nnl Description Parts Packet Screws Parts Packet Contact Kit Parts Packet Retainers Parts Packet Springs Paper Feed Parts Packet Duplex Option Fan
127. e Upper 500 Duplex Tray Assembly Jam Removal 250 Duplex Tray Assembly Jam Removal 500 Duplex Retainer 6 mm Backup Roll PP 99A0404 Screw M3x6L G Supradrive PP 99A0413 fo A a a Parts Catalog 7 63 4069 XXX Assembly 18 Duplex continued 7 64 Service Manual 4069 XXX Part Index Number 18 21 99A0342 18 21 99A1682 18 22 99A1131 18 23 99A0341 18 24 Units Description Guide LH Lower Return 250 Duplex Guide LH Lower Return 500 Duplex Guide Return LH Upper 250 Duplex Sensor Exit Optical Screw LH Upper Return Guide Mounting PP 99A0413 Base Assembly w Tray Bias 250 Duplex Base Assembly w Tray Bias 500 Duplex Shaft Duplex Drive Spring Duplex Shaft Gear Pass Thru Idler Bearing Drive Shaft Low Cable Auto Connect Bottom Gear Pass Thru Drive Roll Cable Auto Connect Top Screw Main Frame Assembly Mounting PP 99A0413 Gear Duplex Bevel Pan System Board Drip Bearing Drive Shaft Fuse 8A SB Board System with Jumper 250 500 Duplex Jumper System Board 250 Duplex Label Options Screw System Board Mounting PP 99A0413 Screw System Board Cover PP 99A0413 Roller Duplex Pass Thru fo A oa 18 25 99A1668 18 25 99A1677 18 26 99A0316 18 27 99A0315 18 28 99A0325 18 29 99A0280 18 30 99A0311 18 31 99A0274 18 32 99A0310 18 33 ch 18 34 99A0317 18 35 99A0434 18 36
128. e fuser hot roll increases The thermistor is connected to the fuser control board connector J2 1 and J2 2 and from J2 to J1 2 and J1 3 on the fuser control board to J2 6 and J2 7 on the engine board J2 6 TEMPIN and J2 7 TEMPIN are connected to module PLCC U9 U9 monitors the change in thermistor resistance and sends a signal HEATON from J20 A25 through the interconnect board to CN3 9 on the LVPS to signal the triac to turn the fuser lamp On or Off to maintain the correct fuser temperature The voltage drop across the thermistor is proportional to the fuser temperature and varies from approximately 2 0 V dc cold to 2 3 V dc warm during idle to approximately 2 7 V dc during continuous printing These voltages are assuming the fuser temperature is set to normal The HEATON signal from CN3 9 varies from 0 V dc lamp On to 5 V dc lamp Off and is connected to the cathode of an Opto triac to control the fuser lamp The second part of the assembly is the fuser frame which contains the hot roll backup roll and associated parts as well as the paper exit guide assembly narrow media sensor fuser control board which has the exit sensor mounted on the board and the envelope conditioner solenoid Diagnostic Aids 3 29 4069 XXX Paper Feed Jams Paper Jams Base Printer Error Message 200 Paper Jam Remove Cartridge This message indicates that paper is jammed at the printer input sensor This condition can be caused by the pape
129. e stepper motor for a short between the motor case and pins J3 1 through J3 4 If no problem is found check the D C servo motor pins J1 1 and J1 2 to the motor housing for a short If a short is found replace the motor assembly If no short is found replace the system board 2 Autoconnect Cables Check the autoconnect cables for Connectors damage to the cables or the pins in the connectors If damaged replace the cable s If no damage is found check to make sure the cables are connected to J9 J10 J11 and J12 on the duplex system board If no problem is found replace the duplex System board Diagnostic Information 2 35 4069 XXX POST fails 230 Paper Jam Check Duplex message displays FRU Action 1 Duplex D C Servo Drive Motor Check the D C servo motor cables for signs of cuts or other damage Check the D C servo motor sensor cable connector for pin damage If no problem is found replace the FRUs in the following order D C motor assembly duplex option system board 2 Input Sensor Input Sensor Flag Run the Duplex Sensor Test from the diagnostics menu If the test fails check the input sensor cable at J5 on the system board for correct installation If no problem is found replace the FRUs in the following order input sensor assembly duplex option system board 3 Paper Exit Sensor and Flag Check the duplex exit sensor for correct installation
130. e the cable If the cable measures continuity replace the engine board 2 50 Service Manual 4069 XXX Input Sensor Service Check Service Tip Run the Base Sensor Test Check the input sensor for proper operation The display changes from open to closed as the sensor flag is manually moved in and out of the sensor Service Tip Run a Diagnostic Print Test in the continuous mode with the controller board removed A defective input sensor or circuit causes the first copy to exit only partially through the fuser assembly FRU Action 1 Input Sensor Flag Check the input sensor flag for damage and proper operation If a problem is found repair as necessary 2 Engine Board Check for approximately 5 V dc at J10 10 on the engine board If incorrect replace the engine board 3 Input Sensor Cable Check the continuity of the input sensor cable section of the front wiring harness If incorrect replace the harness If correct replace the input sensor assembly Input Tray s Option Service Check 250 Sheet and 500 Sheet Trays Service Tip Try all the other input paper sources to make sure they are properly feeding paper For 990 Error Code Service Tray X X displays the number of the tray that has a problem or needs service Diagnostic Information 2 51 4069 XXX FRU Action 1 Tray X option System Board or Compensator Assembly or Autoconnect Cabl
131. e the main drive assembly Remove the upper front cover hinge assembly Remove the mulitpurpose tray lower deflector assembly Remove the paper alignment assembly Remove the left side frame mounting screws A A 102 Paws 4 26 Service Manual 4069 XXX 7 Place the printer on its back and remove the left side frame mounting screws A 8 Remove the left side frame A 104 Repair Information 4 27 4069 XXX Right Side Frame Remove the right side cover Remove the LVPS Remove the multipurpose tray assembly Remove the auxiliary fan assembly Disconnect the auto compensator arm bias spring from the right side frame 6 Remove the toner sensor mounting screw A disconnect the sensor cable and remove the toner sensor 7 Remove the right side frame mounting screws B and remove the right side frame GO 102 102 4 28 Service Manual 4069 XXX Caution Be sure the fuser assembly has cooled before working on any of the fuser FRUs Fuser 1 Remove the redrive assembly 2 Loosen the fuser mounting screws and remove the fuser LEXMARK Repair Information 4 29 4069 XXX Fuser Board Remove the fuser assembly Remove the fuser board cover Disconnect the cables from the fuser board Remove the fuser board mounting screw Release the fuser board from the standoff tab and lift the fuser board from the fuser assembly akon 4 3
132. easured with the controller board removed while running the print test 2 92 Service Manual 4069 XXX Print Quality All Black Page Service Tip An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum FRU Action 1 High Voltage Contacts Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted contaminated or damaged If incorrect replace the contact with one from the HV contact kit Screws are included to attach the contacts to the right side frame in the HV contact kit 3 Charge Roll Conductive Check to make sure the charge roll Bushing bushing is correctly installed in the right charge roll arm 2 HVPS Check the voltages 10 1 thru J10 8 If incorrect replace the engine board 3 HVPS Cable Check the continuity of the HVPS Part of Front cable If incorrect replace the cable Harness Cable assembly If correct replace the engine board Engine Board Print Quality Blank Page FRU Action 1 Print Cartridge Check the print cartridge for any signs of damage especially the PC drum contact on the cartridge Diagnostic Information 2 93 4069 XXX FRU Action 2 High Voltage Contact Check the PC drum contact on the right side frame for damage PC
133. ect replace the engine board 2 70 Service Manual 4069 XXX FRU Action 4 Operator Panel all Check to make sure a SIMM is not diamonds No Beeps plugged in backward This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps 5 Operator Panel all Check the voltage at Pin J11 1 and diamonds 5 Beeps J11 3 The voltage measures approximately 5 V If incorrect replace the FRUs in the following order operator panel assembly engine board Options Service Check Service Tip When you have a problem with any of the options installed in the options slots on the interconnect board on a 212 414 616 the 010 and 010 at service level B have only one slot switch the non operating option to one of the other option slots to isolate the failure Flash Memory Option s Run a copy of the test page and check to see if the option you are checking is listed The printer does not recognize the option being installed if the option is not listed Check to make sure that the Memory DIMM is installed correctly and is not broken or damaged If the Memory DIMM is correctly installed not broken or damaged then run the Flash Test on page 3 3 If the test fails replace the FLASH DIMM If the problem continues replace the controller board DRAM Memory Option s This service check is the same as the flash memory option service check with the following ex
134. ect installation 2 Main Fan to Engine Board Check the continuity of the cable If Cable incorrect replace the cable 2 46 Service Manual 4069 XXX FRU Action 3 Error Code 927 Fan runs Check the voltage at J1 1 on the engine board The voltage measures 5 V dc static 0 V dc fan running If incorrect replace the main fan If this does not fix the problem replace the engine board 4 Error Code 927 Check the voltage at J1 3 on the Fan not running engine board The voltages are as follows 22 V dc to 24 V dc printer and fan running 12 V dc to 15 V dc printer not running fan running about half speed If incorrect replace the engine board If this does not fix the problem replace the main fan Fuser Service Check Hot Roll Fuser Cold Fuser Service Check Error codes 920 921 and 922 may display for a cold fuser failure A 920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again A 925 service error indicates the wrong fuser lamp is installed in the printer and does not match the one stored in the printer code Note Make sure the fuser is correctly installed before proceeding with this service check The fuser must be firmly seated in the two rear connectors Both the right and left lock down screws must be tight Service Tip Set the Fuser Temperature to NORMAL before starting this service check Diagn
135. ect the cable at J9 and check the voltage again If the voltage continues to be incorrect replace the high capacity feeder option System board If the voltage measures correctly check the cable If the cable is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board 2 58 Service Manual 4069 XXX 24X Paper Jam message displays Paper jammed over the Pass Thru Sensor X The printer displays the value of X for the paper tray where the error occurs Example 242 is a Paper Jam Tray 2 FRU Action 1 Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Check these parts for signs of Spring Bevel Gear broken or damaged parts Feedroll Gear Drive Roll contamination on the drive rollers or Assembly Wear Plate wear plate and wear or damage to Drive Shaft Bearings and the drive shaft bearings Check the Skewed Backu
136. embly is not functioning properly Make sure the option s are installed correctly and the machine is configured correctly before attempting to service the high capacity output stacker option Go to High Capacity Output Stacker Board on page 5 22 to identify the correct jumper location at J6 for the upper and lower units Diagnostic Information 2 79 4069 XXX Problems with excessive static electricity buildup FRU Action 1 Front Cover Assembly Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the high capacity option Also check to make sure the ESD brush is not loose or damaged The printer does not recognize one or more output options as installed Service Tip If more than a single output option is installed check each one to see if the printer recognizes any single option as installed If the printer recognizes any of the output options the base printer autoconnect system is operating correctly The problem is in the unrecognized option Continue with this service check or go to the service check for the failing output option FRU Action 1 High Capacity Stacker Option Check the autoconnects cables and connectors of the option for any signs of loose or damaged parts 2 High Capacity Output Stacker Mechanical Linkage Assembly Remove the left and right side covers and check all four autoconnects for damage especia
137. emory options of 2MB 4MB 8MB and 16MB DIMM Integrated network options Token Ring Ethernet Tri Port Adapter IR Adapter IPDS SIMM Prescribe SIMM TIFF SIMM Barcode SIMM Parallel Interface Card SCS USB Parallel Port Marknet Print Servers 250 and 500 sheet paper trays of A5 letter and legal size 250 Sheet Special Media Tray Assembly 500 Sheet Special Media Tray 2000 Sheet High Capacity Feeder Envelope feeder Duplex option 250 Sheet Duplex option 500 Sheet Hard Disk 2 1 GB Forms Hard Disk 2 1 GB Vertical Kiosk Presenter Horizontal Kiosk Presenter Output Expander 5 Bin Mailbox High Capacity Output Stacker General Information 1 3 4069 XXX Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the service error codes user status messages user error messages service checks and diagnostic aids to determine the printer problem and repair the failure After you complete the repair perform tests as needed to verify the repair Tools Required For Service Flat blade screwdriver 1 Phillips screwdriver 2 Phillips screwdriver T10 Torx Screwdriver 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 1 4 Service Manual 4069 XXX A
138. er into Bin selected FRU Action 1 Bin X Sensor Check the sensor and sensor cable for Bin X Sensor Cable the bin that is displaying the message Bin X Sensor Flag to make sure the sensor is seated Control Board correctly in the side of the tray and the cable is connected to the sensor and the control board Check the flag for binding and proper operation If correct replace the Bin X sensor If this does not fix the problem replace the control board Note This sensor is in a normally open position with the flag out of the sensor slot Bin X is full No message that Bin X is full displays FRU Action 1 Bin X Sensor Check the sensor flag for binds Bin X Sensor Cable broken or missing parts If correct Bin X Sensor Flag check the bin sensor for correct Bin X Sensor Flag installation in the side of the tray If the Control Board bin sensor is installed correctly check the sensor cable for correct installation to the sensor and control board If correct replace the Bin X sensor If this does not fix the problem replace the control board Ready Bin X Full displays and paper feeds into Bin X FRU Action 1 Bin X Sensor Check the sensor flag for binds Make Bin X Sensor Control Board sure the sensor flag is not in an up position If the sensor flag is operating correctly replace the bin X sensor If this does not fix the problem replace the control board
139. es let you view the end of the lamp Use the following table to identify and install the correct lamp Description Color Code Fuser Lamp 115V 550W Green Fuser Lamp 115V 875W Gold Fuser Lamp 220V 550W Brown Fuser Lamp 220V 875W Silver Fuser Lower Exit Guide Assembly Remove the fuser assembly Remove the fuser cover assembly Remove the fuser detack housing assembly Disconnect the sensors from the fuser board Gently apply outward pressure on the left and right fuser side frames to release the lower exit guide assembly GAN o mmc 4 36 Service Manual 4069 XXX High Voltage Power Supply 1 2 3 Disconnect the HVPS cable from the HVPS at connector C Disconnect the transfer roll cable from the HVPS board AR Remove the inner paper deflector Remove the toner sensor cable from the retainer A on the front of the HVPS Remove the right side cover Note Use caution when disconnecting the cable from the transformer on the HVPS The cable and connector can be easily damaged Remove the HVPS mounting screw B Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS 2 235 Repair Information 4 37 4069 XXX Integrated Tray Compensator Assembly 8 9 Remove the paper tray Remove the left door Remove the inner EMC shield Disconnect the compensator motor cable
140. es with the toner cartridge lockout function disabled The print quality test consists of three pages Page one contains a mixture of graphics and text Pages two and three only contain graphics If duplex is turned On the pages are duplexed otherwise the pages are printed on one side The Print Quality Test pages are printed in English and must always be printed on letter legal or A4 paper Note The print quality test pages can also be printed from the configuration menu however a cartridge must be installed with a machine class ID matching the machine class ID stored in NVRAM Some diagnostic information may be printed on the pages when printing from this menu 3 24 Service Manual 4069 XXX To run the Print Quality Test Pages aR WD Turn the printer off Press and hold Select and Return Turn on the printer Release the buttons once Performing the Self Test displays The printer performs its normal POR cycle then print one copy of the Print Quality Test pages If you want more than one copy perform these steps again The following is printed on page 1 Diagnostic EP Setup fuser temperature warm up time transfer print contrast and charge roll settings Contents of the Diagnostic Error Log Printer configuration information printer serial number controller code level engine code level operator panel code level smart option code levels font versions and so on Values for the Quality
141. essage displays when the duplex front Cover access cover is not installed Close Duplex Rear Door This message displays when the duplex rear door is open Diagnostic Information 2 23 4069 XXX Power On Self Test POST When you turn the printer On it performs a Power On Self Test Check for correct POST functioning of the base printer by observing the following 1 2 3 The operator panel displays one and a half row of pels and then 9 The LED comes on The operator panel displays one and a half row of pels and then clears Diamonds scroll across the display and then clear clears 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 Performing Self Test appears on the display The 2000 sheet high capacity option elevator tray moves to the uppermost position if installed The duplex option is checked if installed The output expander option exit rollers turn if installed Busy appears on the display The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start The main fan turns on 10 The main drive motor turns on 11 The developer drive assembly drives the developer shaft in the 12 13 14 15 toner cartridge The exit rollers turn The operator panel LED starts blinking Models 414 and 616 only The
142. evator tray fails to stop at the correct position and continues to drive into the bottom frame FRU Action 1 Lower Limit Switch Check continuity of the lower limit Lower Limit Switch Cable Switch If incorrect replace the Switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High Capacity Feeder Disconnect the lower limit switch Control Board cable and check the voltage at J2 1 orange The voltage measures approximately 5 V If incorrect replace the high capacity feeder option control board The elevator tray down button does not operate The tray moves to the upper position Service Tip Open the high capacity feeder option front door and check the black rubber bumper attached to the door switch spring Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly FRU Action 1 Lower Limit Switch Check the lower limit switch to make Lower Limit Switch Cable sure it is not closed normally open High Capacity Feeder If incorrect replace the switch Control Board Check the lower limit switch cable for a short between pins 1 and 2 If incorrect replace the cable If correct replace the high capacity feeder option control board Diagnostic Information 2 61 4069 XXX Paper from the high capacity feeder input tray does not reac
143. f more than a single output option is installed check each one to see if the printer recognizes any single option as being installed If the printer recognizes any of the output options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized option Continue with this service check or go to the service check for the failing output option FRU Action 1 5 Bin Mailbox Option Check the autoconnects cables and connectors of the option for any signs of loose or damaged parts 2 Mechanical Linkage Remove the left and right side covers Assembly and check the two autoconnects for damage especially the connector pins Remove the output option and check the voltages on the standard output bin autoconnect located on the top left rear of the printer Go to Autoconnect Top on page 5 19 If the voltages are correct reinstall the output option noting the position of the torroid on the autoconnect cable of the lower autoconnect Check the voltages on each of the autoconnects If the torroid was moved make sure to move it back to its original position on the cable If the voltages are correct replace the control board If the voltages are incorrect replace the failing autoconnect assembly Diagnostic Information 2 83 4069 XXX 271 Paper Jam Check Bin 1 displays FRU Action 1 Bottom Pass Thru Sensor Check the flag for correct operation Flag Assembly binding
144. fective gear s in the main drive gearbox Replace the FRUs in the following order main drive gearbox reference edge Replace the FRUs in the following order developer drive assembly main drive gearbox assembly Lines spaced 47 19 mm 1 858 inch apart Replace the FRUs in the following order toner cartridge charge roll developer drive assembly Lines spaced 49 16 mm 1 935 inch apart Replace the toner cartridge 2 96 Service Manual 4069 XXX FRU Action 7 Lines spaced 49 74 mm 1 958 inch apart Replace the FRUs in the following order redrive assembly fuser assembly 8 Lines spaced 51 02 mm 2 009 inch apart Replace the transfer roll 9 Lines spaced 52 23 mm 2 056 inch apart Replace the redrive assembly 10 Lines spaced 76 53 mm 3 013 inch apart 11 Lines spaced 95 66 mm 3 766 inch apart Replace the FRUs in the following order alignment assembly main drive gearbox assembly Replace the FRUs in the following order toner cartridge main drive gearbox assembly 12 Lines spaced 99 49 mm 8 917 inch apart Replace the redrive assembly 13 Lines spaced 114 79 mm 4 519 inch apart Print Quality Background Replace the alignment assembly Service Tip Some background problems can be caused by rough papers non Lexmark toner cartridges or if the media texture is set to the rough setting Some slic
145. frame assembly The jam removal tray open switch is located at the end of the left frame assembly There are no switches in the level 2 duplex option Option Microcode The options are Smart Options or options that have a system board The option system board has a microprocessor that controls the option mechanism A software architecture is provided that controls the option and communicates information such as paper path status sensor or switch status motor status and so on to the base printer 3 28 Service Manual 4069 XXX Fuser Operation Hot Roll Fuser The hot roll fuser in the Optra T printer is made up of two primary assemblies The first assembly is the top fuser cover which contains the thermistor cable thermal fuse cable assembly left and right lamp brackets and cover This is a complete assembly and the parts cannot be individually replaced as in previous Lexmark laser printers The thermal fuse two fuses in series protects the fuser assembly and surrounding parts from ignition in the event of a failure in the fuser control circuitry by opening the AC circuit to the lamp The thermistor assembly is designed to keep the temperature of the fuser hot roll within a predetermined temperature by being in contact with the fuser hot roll and changes resistance as the temperature of the hot roll increases The thermistor resistance changes from approximately 150K ohms to approximately 260K ohms as the temperature of th
146. h Voltage Contacts Check the high voltage contacts on the right side frame to ensure they are clean and not bent deformed or pitted If incorrect replace the contact 2 98 Service Manual 4069 XXX FRU Action 5 Engine Board HVPS Check the following voltages at J10 Connector on the engine board Measure the voltages from J10 to printer ground Printer Idle J10 1 approximately 0 V dc J10 2 approximately 4 V dc J10 4 approximately 0 V dc Printer Printing J10 1 varies 0 V dc to 5 V dc J10 2 varies 0 V dc to 4 V dc J10 4 varies 0 V dc to 1 9 V de If J10 1 voltage is incorrect check the continuity of the front harness cable J10 1 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 2 voltage is incorrect or if the voltage remains at 0 V dc check the continuity of the front harness cable J10 2 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 4 voltage is incorrect check the front harness cable J10 3 line If there is not continuity replace the harness cable If correct replace the engine board if this does not correct the problem replace the HVPS Diagnostic Information 2 99 4069 XXX Print Quality Banding Service Tip
147. h the pass thru sensor Service Tip Check to be sure the paper in tray is within specifications FRU Action 1 Autocompensator Check the autocompensator pick Assembly arm rollers for sign of glazing toner or other buildup Replace as necessary 2 Wear Strips Check the wear strips for glazing or contamination Replace as required It is advisable to replace all four wear strips at the same time 2 62 Service Manual 4069 XXX The elevator tray does not move up or down The printer recognizes that the option is installed FRU Action 1 DC Drive Motor High Be sure the motor cable is correctly Capacity Feeder Option installed at J1 on the board Check System Board the cables damaged or loose wires Disconnect the motor Check for a short between each pin and the motor housing If a problem is found replace the motor assembly If no problem is found measure the resistance between the following pins on the motor cable connector Pins 1 brown and pin 2 Yellow The resistance measures between approximately 7 5 and 10 5 ohms If incorrect replace the motor assembly If correct replace the high capacity feeder option system board Diagnostic Information 2 63 4069 XXX The elevator moves in one direction only FRU Action 1 DC Drive Motor Assembly High Capacity Feeder System Board 2 64 Service Manual Check the voltages at J1 on the high capaci
148. he LVPS board assembly FRU Action 1 Line Voltage Check the AC line voltage If the line voltage is incorrect inform the customer 2 AC Line Cord Check the line cord for any signs of damage If correct check the continuity of the line cord and replace if necessary 2 32 Service Manual 4069 XXX FRU Action 5 V dc at any Option Check for 5 V dc on any of the Connector option connectors The easiest to access is the envelope feeder connector located behind the lower front door If 5 V dc is present at any of the connectors go to step 9 If 5 V dc is not present go to step 4 5 V dc at the controller board test point Check for 5 V dc at the 5 V dc test pad located on the controller board If correct go to step 9 5 V dc at the engine board Test Point Check for 5 V dc at the 5 V dc test point on the engine board If correct replace the engine board If incorrect go to step 6 LVPS Fuse F1 Remove the LVPS from the printer and check fuse F1 Replace the fuse if the fuse is blown LVPS Fuse F1 Continues to blow after LVPS installed in the printer LVPS Replace fuse F1 if necessary Turn the LVPS on off switch Off and connect the AC line cord and turn the LVPS On CAUTION Before checking fuse F1 turn the LVPS Off and disconnect the AC line cord Check fuse F1 If the fuse is blown replace the LVPS Remove the LVPS from the machine C
149. he autoconnect from the Tray X System Board printer or option above tray x Check for signs of cuts pinched wiring or damage to the contacts in the connector Check the autoconnect cable s for correct installation at the tray x system board If correct check the continuity of the autoconnect cable s If correct replace the tray x system board If incorrect replace the cable Paper from Tray X does not reach the Pass Thru Sensor Service Tip Check the media in tray x to make sure it is within specifications Some types of labels foil material and slick papers can cause misfeeds and slippage of the rollers FRU Action 1 Autocompensator Check the autocompensator pick Assembly arm rollers for any sign of glazing toner or other buildup Clean or replace as necessary High Capacity Feeder Input Tray Service Check Note Voltage measurements in the high capacity feeder input tray service checks must be made with the high capacity feeder attached to the base printer to obtain accurate results Service Tip Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high capacity feeder tray Service Tip Check the other paper sources to be sure they are operating correctly Diagnostic Information 2 55 4069 XXX The base printer indicates a dead machine condition when the high capac
150. he power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas of the machine Preventive Maintenance 6 1 4069 XXX Scheduled Maintenance The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval It is necessary to replace the fuser assembly transfer roller and charge roll at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers 99A1762 115V 875W Models 414 616 41b 411 41e 41n 61n 99A1763 220V 875W Models 414 616 41b 411 41e 41n 61n 99A1764 115V 550W Models 010 01n 212 21n 99A1765 220V 550W Models 010 01n 212 21n After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message Refer to Maintenance Page Count on page 3 21 6 2 Service
151. hen the flag Remove Paper Standard is out of the sensor If the voltage Bin message Output Bin does not change replace the sensor Sensor Test fails cable assembly If this does not fix the problem replace the engine board 2 Output Bin Sensor Flag Check to make sure the correct flag is installed Check the flag for damage or improper operation If incorrect replace the flag Note A broken or improper operating sensor flag causes a Remove Paper Standard Bin message to display before POST completes and cannot be cleared Diagnostic Information 2 73 4069 XXX Output Expander Service Check Service Tip The majority of the mechanical components can be observed during operation by removing the left right and system board covers The output expander functions without the covers installed Note Make sure the option is correctly installed before attempting to service the unit No jumpers should be installed at connector J6 on the output expander board Problems with excessive static electricity buildup FRU Action 1 Output Expander Control Check the output expander control Board Cover board cover to make sure the ESD brush ground lead is firmly attached to the output expander frame Also check to make sure the ESD brush is not loose Printer does not recognize one or more output expander options as being installed Service Tip If more than a single output expander option is installed
152. high capacity output stacker top position sensor P high capacity output stacker passthru sensor F high capacity output stacker full sensor NF high capacity output stacker near full sensor If the 5 bin mailbox is selected the following is displayed lt output bin gt output bin displayed on line 1 output bin 1 output bin2 output bin3 output bin4 or output bin 5 for the bin selector P1 5 bin mailbox first passthru sensor P2 5 bin mailbox second passthru sensor L EM indicates 5 bin x empty L NL bin contains media but the bin is not near full on full L NF indicates bin is near full L FL indicates bin is full Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly The following sensors can be checked Toner Optical Sensor Input Sensor Output Sensor Fuser Exit Narrow Media Sensor Front Door Sensor Upper Front Cover To run the Base Sensor Test 1 Select the Base Sensor Test The operator panel displays OP for open and CL for closed 2 Manually toggle the sensors by hand to verify that each sensor switches from open to closed Diagnostic Aids 3 17 4069 XXX 5 Bin Mailbox Diverter Test Note This test checks the operation of each mailbox output diverter Also if more than one 5 bin mailbox option is installed the test checks all of the diverters installed on the printer When the test is selected from the diagnostic me
153. icing FRU Action 1 Fuser Cover Assembly Check for damage to the thermistor Assembly includes assembly Check the resistance of Thermistor and Thermal the thermistor Fuses HOT J2 1 to J2 2 2 5K ohms COLD 150K ohms to 260K ohms Check the continuity from each pin of J2 to ground If there is continuity replace the fuser cover assembly 2 Engine Board Error code 924 indicates the engine board detects an open circuit in the thermistor circuit for the fuser assembly The voltage on J2 6 on the engine board measures approximately 5 V If incorrect replace the engine board If correct check the continuity of the DC fuser cable fuser board to auto docking connector in the fuser assembly and the DC fuser cable engine board to auto docking connector in the printer If there is no continuity replace the cable If there is continuity check the voltage on J2 2 on the fuser control board It measures approximately 5 V dc If incorrect replace the fuser control board 3 Fuser Hot Roll Examine the fuser assembly for Backup Roll Bearings signs of overheating or damage Check the hot roll and backup roll for signs of excessive toner label glue labels or other contaminants If any are found repair as necessary or replace the fuser assembly Diagnostic Information 2 49 4069 XXX Fuser Solenoid Service Check Service Tip Try changing the envelope enhance level setting A differe
154. id then the ID is saved in NVRAM and the printer automatically PORs to activate the new setting Note When the printer PORs it does so in the normal mode Restore EP Factory Defaults To restore each of the printer settings contained in the EP Setup menu to their factory default value select Restore from the menu To exit the menu without restoring the settings to the factory default values select Do Not Restore Sometimes this is used to help correct print quality problems Fuser Temperature This adjustment can be used to help solve some customer problems with paper curl on low grade papers and or problems with letter heads on some types of media The fuser temperature can be adjusted as follows NORMAL LOWER LOWEST Warm Up Time You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5 The factory sets the warm up at 0 or no warm up time This time period allows the backup roll to heat up and helps reduce curl in some environments Transfer The transfer can be adjusted as follows LOW MEDIUM HIGH 3 22 Service Manual 4069 XXX Print Contrast The print contrast setting controls the developer voltage offset The print contrast can be adjusted as follows LOW MEDIUM HIGH Charge Roll The charge roll can be adjusted as follows LOW MEDIUM HIGH Print Tests The purpose of the diagnostic Print Tests is to verify tha
155. idge Error 32 is displayed when the top cover 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 setting of the Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print then they are not reprinted once a good print cartridge is inserted If this does not fix the problem go to Smart Cartridge Service Check on page 2 105 34 Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size loaded in the tray For auto size sensing trays this error occurs if the paper stop is in the incorrect position Make sure the Paper Size setting is correct for the size paper that is being used 36 Resolution Reduced The resolution of the page has been reduced from 600 dpi to 300 dpi in order to prevent a Memory Full error This message can only occur if the Resolution Reduction setting is turned on Note 1200 dpi pages are not resolution reduced If a 1200 dpi job runs out of memory a Memory Full error is displayed Diagnostic Information 2 17 4069 XXX User Error Message Explanation 37 Insufficient Collation Memory This message is displayed when the printer memory used to store pages is too full to collate the print job 38 Mem
156. ing Latch Return mr rcv Flag Envelope Out Sensor Parts Catalog 7 73 4069 XXX Assembly 20 Envelope Feeder continued 7 74 Service Manual 4069 XXX Asm Part BN Index Number Units Description 20 13 Gear Kit PP 99A0271 o Gear Feed o Gear Master Cam o Gear Drive Roll Shaft o Gear Master Feed Kick o Gear Drive Idler o Gear Comp Drive Clutch o Gear Kick Roll Connect o Gear Kick CNCT Idler o Gear Feed Shaft Right o Gear Drive Idler Rear 20 14 99A1698 Cover Left Side NS Retainer 4 mm PP 99A0404 NS Retainer Clip 5 mm Shaft PP 99A0404 NS Retainer 6 mm PP 99A0404 NS Retainer 7 mm Shaft PP 99A0404 NS 99A0384 NS 99A0385 NS 99A0494 NS 99A0427 NS 99A0469 NS 99A1699 Shaft Drive Pressure Roller Cable Auto Connect Front Spring Cam Clutch Label Envelope Orientation Icon Deflector Guide Guard Pass Through Sensor ek ek et ee iN o 9 o ool cx Lm ee Parts Catalog 7 75 4069 XXX Assembly 21 High Capacity Feeder 7 76 Service Manual 4069 XXX Units Description 21 1 99A0660 1 Frame Printer Support Frame 2 21 2 3 Screw Printer Support 2 Frame Mounting PP 99A0675 21 3 99A0698 2 Clamp Feed Frame 21 4 4 Screws Feed Frame Clamp PP 99A0675 21 5 99A0691 2 Bearing Nyliner Leadscrew Top 21 6 99A0656 1 Cover Side
157. ity input tray is installed FRU Action 1 AC Line Cord AC Jumper HCIT to Printer AC input and Output Receptacles AC Wiring Harness If the base printer works normally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT check the AC jumper cord If defective replace the cord If not defective check the AC input and output receptacles and wiring harness in the HCIT Repair or replace the receptacles or AC wiring harness as required NOTE Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lockwasher are tightened down 2 56 Service Manual 4069 XXX The base printer does not recognize that the high capacity input tray is installed FRU Action 1 High Capacity Feeder Check the high capacity feeder input Autoconnect Mechanical tray to make sure it is mounted Check correctly and is not pushed down into the frame assembly or damaged Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly 2 Base Printer or option Check the option or base printer mounted above autoconnect for signs of damage Repair the high capacity option autoconnect as necessary 3 LVPS Check the voltages at J11 2 and Option System Board J11 4 The voltage measures 24 V de If the voltage is correct replace
158. k or coated papers may also cause background Some problems occur with printers that run a large amount of graphics in a humid environment The customer may try to improve the print quality by increasing the transfer setting Check the charge roll to make sure it is not at the end of life Diagnostic Information 2 97 4069 XXX FRU Action 1 Erase Lamp Lens Assembly models 010 212 414 616 Check the erase lamp lens for any signs of toner paper dust or other types of contamination Clean the lens with a soft dry cloth if necessary If unable to clean the contamination off the lens replace the lens and lamp assembly Check the erase lamp assembly Use the same procedure as outlined in the Erase Lamp Service Check 010 212 414 616 on page 2 45 2 Printhead The printhead on the Optra T printers cannot be cleaned Try another printhead if all other attempts fail to correct a background problem 3 Transfer Roll Assembly Check the high voltage contact from the HVPS to the transfer roll Check the transfer arm assembly right side bearing for any signs of contamination pitting or a loose cable to the bearing If any problems are found replace the defective part Check the transfer roll shaft for any signs of contamination wear or pitting on the ends of the shaft that go into the bearings If a problem is found clean the ends of the shaft or replace the transfer roll assembly 4 Hig
159. k the flag for correct operation Flag Assembly Upper binding broken parts or interference Control Board from the sensor cable If incorrect repair as necessary If correct check to make sure the lower pass thru sensor is correctly connected to J3 on the lower control board Disconnect the pass thru sensor cable and check the voltage at J3 3 The voltage measures approximately 5V dc If incorrect check the voltage at J3 2 The voltage measures approximately OV dc If incorrect replace the sensor assembly If this does not fix the problem replace the lower control board 5 Bin Mailbox Service Check Service Tip The majority of the mechanical components can be observed during operation by removing the left right side covers Models 010 010n and 010 01n at service level B do not support this output option Make sure the option s are correctly installed before attempting to service the unit Be sure the option is correctly installed and the machine is configured correctly before attempting to service the unit 2 82 Service Manual 4069 XXX Problems with excessive static electricity buildup FRU Action 1 Front Cover Assembly Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the 5 Bin Mailbox frame Also check to make sure the ESD brush is not loose or damaged The printer does not recognize one or more output options as installed Service Tip I
160. keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 60825 relatives aux produits laser de Classe I Notices and Safety Information xi 4069 XXX Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe ID 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprises entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 60825 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono s
161. l Options 25 16 1 Bail order 99A1743 5 Bin Mailbox Asm Kit 25 17 99A1713 5 Support Paper Tray 25 18 99A1687 5 Stop Asm Paper Tray 25 19 99A1735 5 Flag Bin Full 25 20 99A1737 5 Sensor Dual Paper Height 25 21 99A1736 5 Cable Dual Sensor 25 22 99A1718 1 Cable Asm Lower Auto Connect 25 23 99A1716 1 Drive Asm Main DC Drive 25 24 99A1740 1 Board Asm 5 Bin Mailbox System 25 25 99A1726 1 Frame Asm Left w Clutch Asm 25 26 99A1786 1 Gear Drive 25 27 99A1719 1 Cable Asm Upper Auto Connect 25 28 12 Screw Board Mounting PP 99A0263 25 29 99A1709 1 Cover Left Side Parts Catalog 7 101 4069 XXX Assembly 25 5 Bin Mailbox continued 7 102 Service Manual 4069 XXX Asm Part Index Number 25 30 99A1741 25 31 99A1727 25 32 99A1728 25 33 99A1731 25 34 99A1729 25 35 99A1730 25 36 99A1789 25 37 99A1720 25 38 99A1732 25 39 99A1738 25 40 99A1722 25 41 99A1787 25 42 99A1721 25 NS 99A1734 25 NS 99A0462 25 NS 99A1715 25 NS 99A1717 25 NS 99A1788 Units Description Spring Diverter Frame Asm Right Side Cam Diverter Actuator Spring Diverter Actuator Latch Diverter Actuator Arbor Diverter Actuator C Clip Bracket Attach Solenoid Diverter Deflector Paper Exit w Brush Deflector Paper Deflector Deflector Paper Top Bin Spring Static Ground Grease Packet IBM 23 Roller Asm Rear Access Door Gear Drive a
162. ler board on network model printers Error Code 976 Network Card X X Network card 1 2 or 3 A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly installed in the socket on the interconnect board and is properly grounded If you find no problem contact your next level of support before replacing the network card Error Code 977 Network Card X A 977 error displays when the RIP software detects that a network card is installed in slot x on the interconnect board but cannot establish communications with the network card 2 72 Service Manual 4069 XXX Output Bin Sensor Standard Tray Service Check Service Tip If the output bin standard tray fills up and the bin full sensor fails to post the message Remove Paper Standard Bin enter the Diagnostic Mode select Output Bin Tests select Sensor Tests and select Standard Bin Check the sensor and flag for proper operation If you find no problem with the sensor and flag continue with the service check Service Tip Check to make sure the correct flag is installed The Output Bin Sensor is a normally closed sensor with the sensor flag down Therefore unless the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message is not displayed FRU Action 1 Engine Board Check the voltage at J6 3 It measures 5 V dc when the flag is in Printer fails to display the sensor and 0 V dc w
163. lly the connector pins Remove the output option and check the voltages on the standard output bin autoconnect located on the top left rear of the printer Go to Autoconnect Top on page 5 19 If the voltages are correct reinstall the output option and note the positions of the torroids on the autoconnect cables on the upper and lower assemblies and check the voltages on the autoconnects If all voltages are correct and the lower assembly is failing replace the lower control board If the upper assembly is failing replace the upper control board If the voltages are incorrect replace the upper or lower failing mechanical linkage assembly 2 80 Service Manual 4069 XXX 202 Paper Jam Open Rear Door Message displays and a sheet of paper is jammed prior to the pass through sensor flag or 202 Paper Jam Open Rear Door Message displays a sheet of paper feeds out to the standard bin even though bin X is selected and paper exits half way out of the redrive assembly Service Tip For this type of problem check the Base Printer Sub Error Codes on page 2 8 They can help isolate the problem A 202 paper jam message can also occur prior to the high capacity output stacker pass through sensors FRU Action 1 Lower Pass Thru Sensor Check the flag for correct operation Flag Assembly binding broken parts or interference from the sensor cable If incorrect repair as necessary If correct check to make sure the lo
164. maged or contaminated charge roll Service Tip Check to make sure the right charge roll arm bushing is correctly installed and operates correctly To remove the charge roll 1 Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 2 Carefully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing 3 Remove the charge roll from the left side charge roll bearing and remove the roll from the printer Leave the paper wrapped around the charge roll until it is reinstalled FRU Action Charge Roll Assembly Check the charge roll for correct installation toner buildup marks cuts or other signs of contamination or damage Replace as necessary 2 Left Side Charge Roll Link Check the left side charge roll link assembly for correct assembly operation Check for damage to the arm or bearing assembly Diagnostic Information 2 29 4069 XXX FRU Action 3 Right Side Charge Roll Link Right Charge Roll Bushing Check the right side charge roll link assembly for correct assembly operation If incorrect replace the charge roll link assembly with the charge roll link assembly kit If correct check the right charge roll link assembly bearing for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll
165. mart cartridge contacts Service Tip An intermittent 82 Unsupported Cartridge User Error Message can be caused by poor contact between the smart cartridge contacts in the upper front cover and the smart chip Also check for proper seating of the smart cartridge cable to the engine board FRU Action 1 Smart Cartridge Contact Check both contacts to make sure Smart Cartridge Ground they are properly installed and the Contact two contacts are not touching each other Check both contacts for any signs of being bent worn or broken If incorrect replace both contacts 2 Smart Cartridge Cover Check to make sure that the smart cartridge cover is properly snapped into place and is not damaged or broken Replace as necessary 3 Smart Cartridge Plunger Check the plunger for correct installation and any signs of being damaged or broken Correct any problem found or replace the plunger as necessary Diagnostic Information 2 105 4069 XXX FRU Action A Smart Cartridge Cable Engine Board Check the voltage on the smart cartridge contact The voltage measures approximately 5 V dc when not writing data to the engine board If data is being written the voltage measures approximately 12 V de If incorrect disconnect the cable from J21 on the engine board and check the voltage on J21 1 The voltage measures approximately 5 V If incorrect replace the engine board If corre
166. mately 24 V dc If incorrect disconnect the paper low switch cable from J3 and measure the voltage again on J3 1 If incorrect replace the high capacity feeder option control board If correct check the cable for a short between pins 1 and 2 on the cable If incorrect replace the cable If correct check the switch for a bent or deformed actuator lever or defective switch If incorrect replace the switch 2 66 Service Manual 4069 XXX Excessive Noise or Vibration FRU Action 1 DC Motor Assembly Check to make sure all the motor plate mounting screws are tight 2 Idler Pulley Check to make sure the idler pulley DC Motor Assembly is not binding on the pulley shaft Check the pulley for any signs of wear Check the idler pulley shaft on the motor mounting plate for any signs of damage or contamination 3 Drive Pulley Check the drive pulley for any signs of wear binds or damage to the pulley or pulley shaft Make sure the pulley turns freely on the pulley shaft 4 Motor Drive Belt Check the DC motor drive belt for Tray Drive Belt any signs of damage Check to make sure the belt is tracking correctly on the drive pulley idler pulley and motor pulley Check the tray drive belt for any signs of damage Check to make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys Diagnostic Information 2 67 4069 XXX Main Drive Service Check
167. measures approximately 24 V dc If incorrect replace the envelope system board if correct measure the voltage at J4 6 The voltage measures approximately 5 V de If incorrect disconnect J4 and measure the voltage again If incorrect replace the envelope feeder system board If correct replace the D C motor assembly 260 Paper Jam displays unable to clear and envelopes fail to feed from the hopper Kick rolls ARE NOT rotating FRU Action 1 Main Drive Belt Check the belt for correct installation and for signs of damage Replace as necessary 2 Gears Check all the gears for correct installation and for signs of damage Repair or replace parts as necessary 3 Clutch Latch Assembly Check the clutch latch assembly to make sure it moves freely 4 Master Cam Gear Master Check the master cam gear and Kick Gear master kick gear to make sure they rotate together If not then the tenons on the master kick gear may be sheared off If incorrect replace the master kick gear 2 42 Service Manual 4069 XXX 260 Paper Jam displays unable to clear and envelopes fail to feed from the hopper Kick rolls ARE rotating Check the deflector gap adjustment before continuing this service check FRU Action 1 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow 2 Weight Assembly Check the weight assembly to make sure it moves up
168. mon due to the long length of the paper path between the input sensor and the exit sensor 05 The duplex logic thinks a sheet of paper is feeding to the duplex unit due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send a sheet of paper to the duplex unit 06 The exit sensor detected a sheet of paper too early 07 The sheet of paper s trailing edge did not clear the exit sensor in the desired length of time 08 The feed motor experienced a complete motor stall The D C motor is under speed The motor never reached the correct operating speed 13 There is paper left in the duplex option Paper was sensed during the homing operation during POST 15 There is paper left in the duplex option Paper was sensed during the DC motor diagnostic test during POST 18 The D C motor experienced an acceleration error 3D There is paper left in the duplex option Paper was sensed during IR clear during POST Diagnostic Information 2 11 4069 XXX User Status Messages User Status Message Status Action Ready The printer is ready to receive and process data Press Menu gt or lt Menu to take the printer out of Ready and enter all the Menus except the TESTS MENU Busy State Ready Hex The printer is ready and HEX Trace is active which is known as HEX Trace Ready Press Menu gt or lt Menu to take the printer out of Ready and enter the TESTS MENU Bus
169. moved If incorrect replace the engine board If correct check the continuity of the operator panel cable If incorrect replace the cable If correct replace the operator panel assembly Operator Panel Display Service Check SERVICE TIP The printer has detected a problem with the engine board operator panel cable or operator panel assembly if POST does not complete and the printer emits 5 beeps and stops in a continuous pattern until the printer is turned off The operator panel cable is an individual cable on some printers and a combination cable assembly with the cover switch cable on later models Note If the operator panel is operating properly except for a PEL or a few PELS missing or broken run the LCD Test on page 3 9 from the hardware tests before continuing with this diagnostic service check FRU Action 1 Operator Panel Cable Check for proper installation of the cable at the engine board J11 and at the operator panel Check the continuity of the operator panel cable If incorrect replace the cable 2 Operator Panel Display blank 5 beeps LED Off Check the voltage at J11 2 on the engine board It measures approximately 5 V dc If incorrect replace the engine board If correct replace the operator panel assembly 3 Operator Panel Display blank 5 beeps LED On Check for ground between J13 4 and ground If correct replace the operator panel assembly If incorr
170. mp lens assembly models 010 212 414 616 for any signs of paper dust toner buildup or any other contamination Clean with a soft cloth or replace the lens and lamp assembly which are provided together in a kit If the lens is clean then check the erase lamp assembly for failed erase lamps If defective replace the erase lamp assembly 2 Hot Roll Fuser Assembly Check the fuser assembly for signs of toner contamination The hot roll especially might cause toner to be retained and deposited on the page 2 102 Service Manual 4069 XXX Print Quality Light Print Service Tip Check the toner saver and print darkness settings first if the print is light FRU Action 1 Transfer Roll Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll 2 Right Side Transfer Roll Check the right side transfer roll arm Arm Assembly assembly bearing for any signs of wear or contamination Also check to ensure the transfer cable is firmly attached to the bearing If incorrect replace the right side transfer arm assembly Check the connection of the transfer roll assembly cable to the transformer on the HVPS board Check the continuity of the cable from the bearing to the spade terminal on the cable If incorrect replace the right side transfer arm assembly If correct replace the HVPS Diagnostic Information 2 103 4069 XXX P
171. n Sens oa o In Sns In Sens 5 V dc C Sens A N CTSENSE C Sens Co Ground C Sens Aa A 24 V dc Erase L A ERASEPWM Erase L J11 Operator Panel I2CDATA 45 V dc I2CCLK Ground wo bh FPIRQ 5 6 Service Manual 4069 XXX Connector Pin No Signal J12 Transport Motor 24 V dc 24 V dc Return 24 V dc Return Motor3 Motor4 Dir Motor1 5 V dc AJ OJN Motor2 a oa o Ground MotorO J13 Autoconnect Options RXDIN Ground 5 V dc Ground oa Eloi Ground J14 Autoconnect Options RXDIN Ground 5 V dc Ground oa amp wy Ground Connector Locations 5 7 4069 XXX Connector Pin No Signal J15 Integrated Paper Tray Paper Size Sensor J16 Fuser 5 V dc PSIZE2 Ground PSIZE1 24 V dc Ground POUT 45 V dc NI oO oa AJ OJN Paper Low zk oa 5 V dc Exit Sensor Thumpret 45 V dc Thumpleft Ground Therm CO rn oD ki wy dv Thermgnd Narmedia J17 MPT Pick MPT Pick 24 V dc 5 8 Service Manual 4069 XXX Connector Pin No Signal J18 Auto C
172. nd right tray hinge slots A to align with the rectangular mounting posts B Pull upward on each tray hinge to remove the tray from the two mounting posts Be careful not to break the hinges 4 46 Service Manual 4069 XXX 2 Remove the upper deflector 3 Remove the solenoid mounting screw 4 Remove the screws A mounting the multipurpose tray lower deflector assembly 5 Remove the multipurpose tray lower deflector assembly A 102 A 104 Repair Information 4 47 4069 XXX Operator Panel Assembly 1 Remove the upper front cover 2 Disconnect the operator panel cable 3 Gently press the operator panel lens tab A and remove the operator panel 4 48 Service Manual 4069 XXX Operator Panel Cable Cover Open Switch Assembly Note Pay careful attention to the cable routing through the printer before you remove the operator panel cable cover open switch assembly 1 2 Remove the left door left cover upper front cover outer EMC shield and inner EMC shield Disconnect the operator panel cover open switch cable from the engine board Remove the operator panel Pull the cables through the rectangular hole in the hinge pivot arm Plug the new operator panel cable into the operator panel and snap the new cover open switch cable into the bracket assembly Route the cables and torroid through the rectangular window in the cover hinge pivot arm Snap the operator panel into the up
173. ng Directory List A directory of the flash and disk contents is processing or printing because Print Directory is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the paper path Press Go to return to Ready after the page prints Press Menu gt or lt Menu to take the printer out of Ready and enter the TESTS MENU Busy Stat Press Select for the values Press Menu gt until Reset Printer is on the second line of the display Press Select to reset the printer Diagnostic Information 2 13 4069 XXX User Status Message Status Action Restoring Factory The printer is restoring No button actions are Defaults factory defaults possible while this message is displayed Performing Self Tests The printer is running No button actions are the normal series of possible while this start up tests after it is message is displayed powered On When the tests are complete the printer returns to Ready Not Ready The printer is in the Not Press Go to take the Press Go Ready state which printer out of the Not means it is not ready to Ready state Press receive or process data Menu gt or lt Menu to This message displays take the printer out of when Menu gt or lt Menu Ready and enter the is pressed during a print TESTS MENU Busy job state Press Menu gt until Re
174. nits Description 15 4 99A1822 1 LVPS 110 V ac 010 212 01n 21n 23v 23e 15 4 99A0214 1 LVPS 110 V ac 616 61n 15 4 99A1640 1 LVPS 220 V ac 010 212 01n 21n 23v 23e 15 4 99A1944 1 LVPS 220 V ac 616 61n 15 4 99A1875 1 LVPS 110 V ac 411 41b 41e 414 15 4 99A1943 1 LVPS 220 V ac 411 41b 41e 414 15 5 1 Screw HVPS Mounting PP 99A0263 15 6 1 Screw Engine Bd Mounting Top PP 99A0263 15 7 Note Be sure and check the printer service level before replacing the HVPS Go to Printer Serial Label on page 7 2 to identify the correct replacement FRU 99A1823 High Voltage Power Supply 010 212 414 616 01n 21n 61n 99A1863 High Voltage Power Supply all service level B printers 23v 23e 15 8 99A1617 1 Interconnect Board Assembly 212 414 616 41b 411 41n 21n 61n 2 Slot with shield 15 8 99A1581 1 Interconnect Board Assembly 1 Slot with shield 23v 23e 15 8 99A1607 1 Interconnect Board Assembly 010 01n 1 Slot with shield 15 9 2 Screw Int Board Mounting PP 99A0263 15 9 1 Screw Int Board Shield Ground PP 99A0263 15 9 2 Screw Int Shield Mounting PP 99A0263 15 9 3 Screw Int Shield Mounting PP 99A0263 15 10 2 Screw Controller Bd Mounting Front PP 99A0263 15 11 99A0426 2 Screw Parallel Connector Mounting 15 12 2 Screw Controller Bd Mounting Back PP 99A0263 Parts Catalog 7 41 4069 XXX Assembly 15 Electronics continued 7 42 Service Manual 4069 XXX Asm Part Index Number 15 13 99A1954 15 13 99A1955 15 13
175. nt 3 20 Diagnostic Mode 3 1 Disabling Download Emulations 3 3 Disk Test Clean 3 2 Duplex Option Board Connectors 5 17 Duplex Tests 3 4 E Engine Board Connectors 5 4 Envelope Option Board Connectors 5 15 Error Codes Index 1 1 4069 XXX Service Error Codes 2 2 User Error Messages 2 16 Error Log 3 8 ESD Sensitive Parts 4 1 F Flash Test 3 3 Fuser Board 5 11 G Gap Adjustment 4 3 H Hardware Tests 3 9 High Capacity Output Stacker Board 5 22 HVPS Connectors 5 3 Input Tray Feed Test 3 14 Input Tray Sensor Test 3 14 Interconnect Board Connectors 5 12 L Laser Notices LCD Test 3 9 Lubrication Specifications 6 1 LVPS Connectors 5 1 Maintenance Approach 1 4 Maintenance Page Count 3 21 Maintenance Preventive 6 1 Maintenance Scheduled 6 2 Messages Check Device Connection Messages 2 22 Service Error Codes 2 2 User Error Messages 2 16 User Line 2 Link Messages 2 21 User Line 2 Messages 2 20 User Status Messages 2 12 Output Bin Feed Test 3 15 1 2 Service Manual Output Bin Sensor Test 3 16 Output Bin Test Standard 3 15 Output Bin X Sensor Test 3 16 Output Expander Control Board 5 20 P Parallel Wrap Test 3 11 Parts Catalog 7 1 Charging 7 36 Covers 7 4 Developer Drive 7 28 Duplex 7 62 Electronics 7 38 Envelope Feeder Frame 7 8 High Capacity Feeder 7 76 High Capacity Output Stacker 7 94 Hot Roll Fuser 7 30 Integrated Paper Tray 250 Sheet 7 22 Integrated Paper
176. nt setting may correct the problem Note Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section Fuser Solenoid Adjustment on page 4 3 FRU Action 1 Fuser Envelope Conditioner The operation of the fuser solenoid Solenoid can be observed by removing the redrive assembly Check for proper mechanical operation of the solenoid and associated hardware link and so on If correct check the resistance of the solenoid between J4 1 and J4 2 The resistance measures between 5 ohms and 10 ohms If incorrect replace the solenoid assembly 2 Fuser Control Board The solenoid receives power from the engine board The fuser control board receives 42Vdc from the LVPS via the interconnect board Check for approximately 42 V dc at the 42 V dc test point on the fuser control board If the voltage is correct replace the fuser control board 3 LVPS If the 42 V dc test point does not Interconnect Board measure approximately 42 V dc check the voltage at CN3 18 on the LVPS The voltage measures approximately 42 V dc If the voltage is correct replace the interconnect board assembly If the voltage is incorrect replace the LVPS 4 Fuser DC Cable Engine Check for continuity of the DC fuser Board to Fuser Board Cable cable that is attached between J2 on Engine Board the engine board and J1 on the fuser control board If the cable does not measure continuity replac
177. nu the following is displayed Diverter Test Running This is a single test The test terminates upon completion 3 18 Service Manual 4069 XXX Print Registration The print registration range is as follows Bottom Margin 20 to 20 Each increment causes approximately 55 mm shift in the bottom margin Top Margin 25 to 25 Left Margin 25 to 25 Right Margin 10 to 10 To set Print Registration 5 Select Registration from the Diagnostic menu The Top margin sign value pair blinks This indicates it is the margin value being changed To select the margin value to be changed press Select until the margin value pair you want to change is blinking To change the margin value press either Menu gt or lt Menu When the value you want is displayed press Select to save the value To exit the Registration menu press Return To verify the margin values are correct you must print the Quick Test Page from the registration screen Press Go to print the test page While printing the Quick Test Page the Quick Test Printing message displays Once the Quick Test Page completes printing the Registration screen displays again The Quick Test Page should be printed on letter or A4 paper Diagnostic Aids 3 19 4069 XXX Printer Setup Setting the Page Count This lets the servicer change the page count from the diagnostic menu This is used whenever the engine board is replaced because this
178. ocks yyyyyy Usable message displays if fewer than 2000 bad blocks are detected xxxx indicates the number of bad blocks and yyyyyy indicates the number of usable blocks xxxx Bad Blocks Replace Disk message displays if more than 2000 bad blocks are detected The disk cannot be recovered because too many bad blocks exist on the disk 4 Press Go or Return Stop to return to the Device Tests menu Flash Test This test causes the file system to write and read data on the flash to test the flash WARNING This test destroys all data on the flash because the flash is reformatted at the end of the test To run the Flash Test 1 Select Flash Test from the Device Tests menu The power indicator blinks while the test is running Flash Test Test Passed message displays if the test passes and the power indicator turns on solid Flash Test Test Failed message displays if the test fails and the power indicator turns on solid 2 Press Go or Return Stop to return to the Device Tests menu Disabling Download Emulations Error Code 964 Download Emulation CRC Failure Checksum failure detected in the emulation header or emulation file Error Code 965 Download Emulation Outdated Time stamps indicate the download emulation and RIP code are incompatible To help resolve Download Emulation problems the following steps are necessary to instruct the printer to POR without activating any download emulations To
179. oe Service Manual Lexmark Optra T 4069 XXX e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK 4069 XXX Edition March 2001 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark and Optra a
180. of paper 84 xx 0 Paper Tray 3 pass thru sensor is not activated by a sheet of paper 84 xx 0B Paper Tray 2 pass thru sensor is not activated by a sheet of paper 84 xx 0C Paper Tray 5 pass thru sensor is not activated and never deactivated A sheet of paper may still be over the sensor or the flag is still activated 84 xx 00 Paper Tray 4 pass thru sensor is not activated and never deactivated A sheet of paper may still be over the sensor or the flag is still activated 84 xx Paper Tray 3 pass thru sensor is not activated and never deactivated A sheet of paper may still be over the sensor or the flag is still activated 84 xx OF Paper Tray 2 pass thru sensor is not activated and never deactivated A sheet of paper may still be over the sensor 84 xx 10 The main motor is stalled or the incorrect main motor is installed in the printer 84 xx 11 The paper activated the input sensor too soon 84 xx 13 The paper activated the input sensor too soon 84 xx 1D The envelope feeder pass thru sensor is activated and never deactivated 84 xx 1E The envelope feeder pass thru sensor is not activated Diagnostic Information 2 9 4069 XXX See 1 2 3 Explanation 84 xx 1F The paper fed too early from Tray 1 84 xx 21 The smart option did not pick the paper 84 xx 22 The smart option did not pick the paper 8E xx 02 The input sensor is not activated even though the paper is picked from the source 8E xx
181. oller board 946 Controller Board Failure SRAM Failure Replace the controller board Diagnostic Information 2 5 4069 XXX Error Code Action 947 Engine Replace the engine board Board 948 PEL Clock Error Indicates the PEL clock check failed replace the controller board 949 Delay Line Indicates a delay line calibration failure Replace the Calibration controller board Failure 953 NVRAM Indicates the NVRAM chip on the engine board has Failure failed Replace the engine board 954 NVRAM Indicates the NVRAM experienced a CRC failure Failure Replace the engine board 956 Configuration Indicates a problem with the Configuration ID This error ID occurs because the engine received a configuration ID from the controller software which is not valid for the level of engine code existing in the printer Setting the configuration ID correctly should fix this error The ID can be set via the NPA data stream or operator panel Note This error is not generated at POR to allow the servicer a method of resetting the configuration ID However setting the configuration ID is the only operation that the servicer can perform See Setting Configuration ID on page 3 21 960 RAM Indicates a DRAM Memory Error on the controller board Memory Error Replace the controller board 961 RAM in Slot 1 is Bad Replace the DIMM in Slot 1 If this does not fix the problem replace the
182. ompensator 1 24 V 2 N A 3 Ground 4 Ground 5 N A 6 5 V de J19 MPT Paper Out 1 Ground 2 POSENSE 3 5 V de J20 Interconnect Board N A N A J21 Smart Cartridge 1 Scart 2 Scart Ground 3 Ground Connector Locations 5 9 4069 XXX 5 10 Service Manual 4069 XXX Fuser Board Connector Pin No Signal J1 Engine Board 1 NarMedia 2 ThermGnd 3 HRTherm 4 Ground 5 ThumpA 6 5 V dc 7 ThumpB 8 ExitSns J2 Thermistor 1 ThermGnd 2 HRTherm J3 Thumper 1 Ground 2 42V dc J4 Thumper Solenoid 1 ThumpB 2 ThumpA J5 Narrow Media 1 5 V dc Sensor 2 Nar Media 3 Ground OOOOOOOO Connector Locations 5 11 4069 XXX Interconnect Board Connector Pin No Signal J1 Fuser Solenoid 42 V dc Ground 2 LVPS 42 V dc Heaton Xeroxing 24 V dc 24 V dc 24 V dc Ground Ground Qoo oO ay AJ OJN Ground Ground J3 LVPS Ground Ground Ground Ground 45 V dc 45 V dc 45 V dc oi AJ wy 5
183. ontrol panel code levels font ROM version and SRAM availability Autocompensator Operation The autocompensator is a paper pick device that generates its own normal force This force generation is inherent in the fundamental design of the pick arm If light media is used it picks very gently If a heavy media is used it picks very aggressively No customer adjustments are necessary therefore no special trays are needed for card stock or labels The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm This movement produces a downward force at the pick rolls The friction between the pick roll and the paper produces a frictional locking condition If the paper is physically held and not allowed to feed then the motor stalls Slippage between the roll and the paper is theoretically impossible When the motor is energized the pick rolls are driven down into the stack increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam Once this critical threshold is achieved the normal force remains at a level just high enough to reliably feed the paper Rather than having a fixed spring force for 3 26 Service Manual 4069 XXX feeding all weights of paper like the D roll this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness
184. options are installed make sure they are operating normally If only the envelope feeder is failing to operate correctly continue with this service check otherwise go to the Interconnect Card Service Check Service Tip The envelope feeder option receives its 5 V dc operating voltage from the 24 V dc bulk at J1 7 If 24 V dc is not present at J1 7 tray 1 is the only tray option that is recognized Note If a 260 Paper Jam Check Envelope message displays check the Sub Error Codes For 9XX and 2XX Error Codes on page 2 8 Printer does not recognize the envelope feeder as an attached input option FRU 1 Envelope Feeder 2 Front Autoconnect on Printer Action Check to make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer Check the connector for signs of damage to the connector or contacts If you find damage replace the damaged cable connector assembly Remove the envelope feeder option and check the voltages at the autoconnect on the front of the printer If incorrect check the interconnect board If correct reinstall the envelope option and continue with step 3 2 38 Service Manual 4069 XXX FRU Action Autoconnect on the Check the connector for any signs of Envelope Option damage to the connector or contacts If you find damage replace the damaged cable connector assembly Disconnect the autoconnect cable at
185. ory Full This message is displayed when the printer memory used to store pages is full 39 Complex Page This message is displayed when the page is too complex to print 51 Defective Flash This message is displayed when the printer detects a defective flash This error may occur at power on or during flash format and write operations Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved 52 Flash Full This message is displayed when there 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 clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the flash is formatted 54 Standard Serial Error This error is displayed when a serial error framing or parity is detected on the standard serial port This usually indicates the serial port is not set up correctly 54 Serial Option X Error This error is displayed when a serial error framing or parity is detected on the optional serial port This usually indicates the optional serial port is not set up correctly 56 Standard Serial Disabled This error is displayed when data is sent to the printer acros
186. ostic Information 2 47 4069 XXX FRU Action 1 Fuser Lamp Incorrect Lamp 925 Service Error Install the correct voltage and wattage lamp or fuser assembly 2 Fuser Lamp 3 LVPS LVPS to Fuser Auto Docking Connector Fuser AC Cable 4 Fuser Top Cover Assembly Thermal Fuse Thermistor Assembly Remove the controller board Run the Diagnostic Print Test and observe the lamp through the left side frame If the lamp doesn t come on unplug the printer and check the continuity between the two pins on the fuser lamp cable going to the fuser assembly If you do not measure continuity remove the fuser assembly and check the continuity of the lamp If incorrect replace the lamp If correct replace the fuser cover assembly Turn the printer off Remove the fuser assembly Turn the printer power on Measure across the AC fuser cable pins for line voltage with the cable connected If incorrect turn the printer off and disconnect the power cord Check the continuity of the LVPS to fuser AC cable If incorrect replace the cable If correct replace the LVPS Disconnect the thermistor cable from the fuser board at J2 The resistance is as follows HOT J2 1 J2 2 2 5K ohms COLD 150K ohms to 260K ohms 2 48 Service Manual 4069 XXX Hot Fuser Service Check Error codes 923 and 924 may display for a hot fuser failure CAUTION The fuser may be hot use caution before removing or serv
187. ove the inner paper deflector assembly 2 Disconnect the paper input sensor cable from the input sensor 3 Release the input paper sensor from its mounting and remove Paper Size Sensing Board 1 Disconnect the paper size sensing board cable from the board 2 Remove the two paper size sensing board mounting screws A 3 Remove the paper size sensing board 4 54 Service Manual 4069 XXX Pick Roll 1 Remove the upper paper deflector 2 Release the pick roll retaining tab and slide the pick roll off the shaft Repair Information 4 55 4069 XXX Printhead 1 Remove the laser assembly cover 2 Disconnect the printhead cables A from the printhead assembly 3 Remove the printhead mounting screws B and remove the printhead Note Do the Printhead Assembly Adjustment on page 4 4 whenever you remove or replace the printhead assembly or loosen the mounting screws B 435 A 435 4 56 Service Manual 4069 XXX Redrive Assembly 1 Remove the redrive door assembly 2 Remove the redrive exit cover 3 Remove the redrive assembly mounting screws A 4 Release the redrive assembly mounting latches and remove the redrive assembly Latch B Latch B Repair Information 4 57 4069 XXX Smart Cartridge Contacts Remove the upper front cover Release tab A and remove the contact cover Remove the contact plunger B Remove the screws C and remove the contacts D
188. ove the paper tray board 2 Remove the paper size spring comb mounting screw and remove the spring comb 4 50 Service Manual 4069 XXX Paper Alignment Assembly Remove the upper paper deflector assembly Remove the inner paper deflector assembly Release the input paper sensor from its mounting and remove Remove the left door Remove the paper alignment assembly mounting screws A located inside the printer 104 Repair Information 4 51 4069 XXX 6 Locate the paper alignment assembly reference adjustment screw B through the left frame and remove the screw 7 Remove the paper alignment assembly Note Do the when you reinstall the assembly B 99A0492 4 52 Service Manual 4069 XXX Paper Deflectors Inner Paper Deflector Assembly GO Remove the paper tray Remove the upper deflector assembly Place the printer on its side Remove the lower deflector assembly Gently pry the inner paper deflector from the left and right mounting posts A located on the bottom of the printer and remove the deflector Upper Paper Deflector Assembly 1 2 Open the multipurpose tray and remove the tray from the two mounting posts Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right Remove the upper deflector assembly Repair Information 4 53 4069 XXX Paper Input Sensor 1 Rem
189. over Mounting Grommet Top LVPS Cover ch E oa oa an on in in P a Parts Catalog 7 85 4069 XXX Assembly 21 High Capacity Feeder continued 7 86 Service Manual 4069 XXX Asm Part Index Number 21 76 99A0281 21 77 99A0279 21 78 99A0273 21 79 21 80 99A0276 21 81 99A0451 21 82 21 83 21 84 99A0277 NS 99A0286 21 85 99A0445 21 86 99A0280 21 87 99A0275 21 88 99A0272 21 89 99A0446 21 90 21 91 99A0274 21 92 99A0278 21 93 99A1967 21 94 Units Description Cable 250 Auto Connect Bearing Drive Shaft Gear Bevel Screw Frame Mounting PP 99A0263 Roll Assembly Drive 250 Option Roll Skew Backup Retainer Roller PP 99A0267 Screw Wear Plate Mounting PP 99A0675 Plate Wear Pass Thru Spring Backup Roller Stud Assembly 250 Frame Bearing Drive Shaft Low Spring Power Takeoff Shaft 250 Drive Aligner Assembly Paper Retainer Aligner Assembly PP 99A0267 Gear Feed Roll Bellcrank Roller Release Card Assembly 2000 Tray Option Screw 2000 Tray Option Card Mounting PP 99A0263 Ei mE ILL ech ek Xx colo RP Inque uuu Parts Catalog 7 87 4069 XXX Assembly 21 High Capacity Feeder continued 7 88 Service Manual 4069 XXX Asm Part M Index Number Units Description 21 95 3 Screw Auto Comp Assembly Mounting PP 99A0263 Arm Assembly Pick 2000 Roll Assembly Pick Base 2000
190. p Roller drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary Diagnostic Information 2 59 4069 XXX Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder Input System Board Run the sensor diagnostics for tray X X the number that represents the high capacity input tray If the test fails disconnect the paper low switch cable from J3 on the high capacity system board Short pins 1 and 2 together while observing the sensor test on the display If the display does not change replace the high capacity feeder system board If the display changes check the continuity of the switch If incorrect replace the Switch If correct replace the switch cable Tray X empty message displays when there is paper in the high capacity feeder input tray FRU Action 1 Paper Out Sensor Flag 2 Paper Out Sensor On Option System Board Check the paper out sensor flag for correct operation and installation If correct replace the high capacity feeder system board The paper out sensor is mounted on the high capacity feeder system board 2 60 Service Manual 4069 XXX The el
191. parts Replace as necessary 2 100 Service Manual 4069 XXX FRU Action 2 Charge Roll Assembly Check the charge roll for any signs Charge Roll Link Arm of toner buildup or other contamination on the outer edges that correspond to the bands on the page Check the charge links and arms for proper operation binds or incorrectly mounted counterbalance springs Repair or replace as necessary 3 HVPS Check the following voltages at J10 8 on the engine board Printer Idle J10 8 measures 0 V dc Printer Printing Test Page J10 8 voltage changes from 0 V dc to 4 V dc If the voltage does not vary check the continuity of line J10 8 in the front cable harness If there is no continuity replace the cable harness If there is continuity replace the HVPS If this does not correct the problem replace the engine board Turn the printer Off and check the resistance between J10 7 and printer ground The resistance measures approximately 0 ohms If incorrect make sure the engine board is mounted correctly and securely grounded If correct replace the engine board Diagnostic Information 2 101 4069 XXX Print Quality Residual Image Service Tip Install a new print cartridge if available before doing this service check Residual image can be caused by the photoconductor cleaning blade and other parts inside the print cartridge FRU Action 1 Erase Lamp Assembly Check the erase la
192. per Low 21 54 99A0651 1 Sensor Assembly Paper Out Upper Limit 21 55 3 Screw Printer Support 1 Frame Mounting 99A0675 NS 6 Washer Printer Support Frame 1 Star PP 99A0677 NS 6 Nut Printer Support Frame 1 8 32 Hex PP 99A0676 NS 10 Screw Door to Door Frame Mounting PP 99A0675 21 56 99A0659 1 Frame Printer Support 1 21 57 99A0695 1 Parts Kit Paper Size Switch Assembly including cable switch lock washer nut and knob 21 58 2 Washer Sensor Bracket Mounting 99A0677 21 59 2 Screw Sensor Bracket Mounting PP 99A0675 Parts Catalog 7 83 4069 XXX Assembly 21 High Capacity Feeder continued oven H E p XX 7 84 Service Manual 4069 XXX Asm Part Index Number Units Description 21 60 3 Screw w washer Motor Mounting PP 99A1793 21 61 3 Nut w lockwasher Drive Pulley Plate PP 99A1794 21 62 99A1795 21 63 21 64 21 65 99A1796 21 66 99A1797 21 67 99A1798 21 68 99A1799 21 69 99A1800 21 70 99A1801 21 71 99A1802 21 72 99A1803 21 73 99A1804 21 74 99A1804 21 75 99A1805 Motor Assembly DC Foot Stabilizer PP 99A0672 Mounting Feet PP 99A0687 Belt DC Motor Drive Idler Pulley Belt Tension Plate Drive Pulley AC Receptacle Lower AC Pulley Drive Retainer C Clip AC Receptacle Upper AC Cover Top LVPS Nut w lockwasher Top LVPS Cover Mounting Nut w lockwasher Top LVPS C
193. per front cover Be sure the torroid is on the opposite end of the cables near the engine board connectors Route the cables through the printer and down the inside of the engine board shield Plug the cables into the engine board connectors Repair Information 4 49 4069 XXX Optional 250 500 Paper Tray Assembly Note Remove the printer and other paper feed options to access the failing optional paper tray assembly Paper Tray Compensator Assembly 1 Remove the printer and other paper feed options 2 Disconnect the compensator assembly bias spring from the tray frame 3 Disconnect the compensator assembly motor cable 4 Remove the three compensator assembly mounting screws and remove the compensator assembly Paper Tray Frame Assembly 1 Remove the compensator assembly 2 Release the paper pass through sensor from its retaining tabs 3 Release the frame assembly from the front and rear retaining tabs and remove the paper tray frame assembly Paper Tray Board 1 Remove the paper tray frame assembly 2 Disconnect all cables from the paper tray board 3 Remove the three paper tray board mounting screws and remove the board Note Reinstall with the paper out sensor flag positioned in the sensor slot on the paper tray board Paper Tray Paper Out Sensor Flag 1 Remove the paper tray frame assembly 2 Remove the paper tray board 3 Remove the paper out sensor flag Paper Size Spring Comb 1 Rem
194. peration is complete the menu returns to the Printer Setup Reset Maintenance Count screen Setting Configuration ID The configuration ID is used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The Configuration ID is originally set at the factory when the printer is manufactured however it requires resetting whenever you replace the engine board and can be set on the operator panel However the Configuration ID is the only diagnostic function displayed until a valid ID is entered To set the Configuration ID 1 Enter the Diagnostic Mode 2 Select Configuration ID from the Printer Setup menu The current ID displays on the screen The Configuration ID is on a label located inside the printer The label is attached to the top front cover hinge assembly and is visible when the top front cover is open The leftmost digit blinks indicating that it is the first digit to be changed 3 To change the value press either Menu or Menu until the value you want is reached Press Select to move to the next digit or press Select again to skip a digit Change each digit as required When the last digit is changed press Select to Diagnostic Aids 3 21 4069 XXX validate the Configuration ID If the ID is invalid then INVALID ID message displays on Line 2 before the ID redisplays You have to reenter the Configuration ID until a valid ID is verified If the ID is val
195. pproximately 5 V dc If incorrect replace the engine board If correct check the voltage at J10 12 It reads approximately 5 V dc with the controller board removed from the printer If incorrect replace the engine board If correct replace the toner sensor assembly A bad ground connection between J10 13 on the engine board and pin 3 on the toner sensor results in a 929 service error Transfer Roll Service Check Service Tip The transfer roll is 51 02 mm 2 009 inch diameter Any print quality problems such as lines that are spaced 51 02 mm apart indicate you should check the transfer roll for damage toner or foreign material buildup Service Tip The transfer roll assembly is part of the Maintenance Kit and is replaced when a 80 Scheduled Maintenance message displays Ask the customer if they have replaced the transfer roll recently CAUTION Make sure the printer is powered Off before making any checks on the transfer roll or associated parts for personal safety and to prevent damage to the printer Note Error Code 917 A 917 transfer roll error code on all models at service level B may display if an incorrect level HVPS is installed in a printer that has the Diagnostic Information 2 107 4069 XXX erase lamp assembly installed Check to make sure the correct level HVPS is installed Go to Printer Serial Label on page 7 2 to identify the printer service level FRU Action 1 Transfer Roll
196. prtrxd Ground wo J2A Autoconnect 24 V dc Ground m 45 V dc J2B e prtxdout Ground prtrxd AJOJN Ground J3 Pass Thru Sensor Ground m Paper Present RVsnsr J4 DC Motor mtrout1 mtrout2 Ground Ground tach N 5 Vdc 5 22 Service Manual 4069 XXX Connector Pin No Signal J5 Bin Full Near Full 1 Ground Dual Sensor 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper Connector 1 Upper Unit 2 Upper Lower Unit 3 Lower Unit J6 Connector Jumper Locations High Capacity Stacker Board Pin 1 Pin 2 Pin 3 Upper Unit Board X X Not Used Lower Unit Board Not Used X X Connector Locations 5 23 4069 XXX 5 24 Service Manual 4069 XXX 6 Preventive Maintenance This chapter describes procedures for printer preventive mainte nance Following these recommendations can help prevent prob lems and maintain optimum performance Safety Inspection Guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and t
197. ption Tray 16 3 99A0627 1 Jumper 2 pin 16 4 1 Screw Switch Activate Spring Mounting PP 99A0263 16 5 99A0063 Spring Switch Activate 16 6 99A0445 Stud Assembly 250 Frame 16 7 99A0448 Arm Paper Out 250 16 8 Screw Auto Comp Mounting PP 99A0263 16 9 99A1054 Pick Arm Assembly 16 10 99A0277 16 11 16 12 99A0276 16 13 99A0451 16 14 99A0282 16 15 99A0450 16 16 99A0350 16 17 99A0679 Wear Plate Pass Thru 250 Tray Screw Wear Plate Mounting PP 99A0263 Roll Assembly Drive 500 Dual Roller Skewed Backup Cable 250 Tray Option Retainer Roller Sensor Paper Low Bracket 250 Frame Retention BR Mi A o a pp A a a 16 18 Washer Bracket 250 Frame Retention Mounting PP 99A0677 16 19 4 Screw Bracket 250 Frame Retention Mounting PP 99A0263 Parts Catalog 7 53 4069 XXX Assembly 16 250 Sheet Tray continued 7 54 Service Manual 4069 XXX Asm Part Index Number Units Description 16 20 99A0070 Roll Assembly Pick NS 99A0438 Bushing Drive Roll 16 21 99A1638 16 22 99A0026 16 23 99A0419 16 24 99A0058 16 25 99A0288 16 26 99A1666 16 27 99A0272 16 28 99A0275 NS 99A0278 16 29 99A0280 16 30 99A0274 16 31 99A0273 16 32 99A0279 16 33 99A0281 NS 99A1929 Base 250 Option Tray Bias Arm Assembly Spring Tray Bias Pad Machine Mounting Sensor Option Pass Thru Label Options Shaft 250 Drive Spring Power Takeoff Bellcrank Roller Release Bushing
198. r drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary Diagnostic Information 2 53 4069 XXX Tray X Low message displays when Tray X is full or has adequate paper in the tray FRU Action 1 Paper Low Sensor Run the Tray X Sensor Test and Assembly check the sensor for proper Paper Low Sensor Flag operation If incorrect check the Tray X Option System following Board Paper low sensor flag for smooth and correct operation Paper low sensor for correct installation on the autocompensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connector J5 on the system board If no problem is found replace the paper low sensor assembly If this does not correct the problem replace the option system board Tray X Empty message displays when Tray X has paper in the tray FRU Action 1 Paper Out Sensor Flag Check the paper out sensor flag for correct operation and installation If 2 Paper Out Sensor On correct replace the option system Option System Board board The paper out sensor is mounted on the system board 2 54 Service Manual 4069 XXX Printer does not recognize Tray X is installed FRU Action 1 Autoconect Cables Check t
199. r jamming prior to activating the input sensor flag the sensor not detecting paper over the sensor or paper arriving at the sensor too late Note A defective engine board or printhead can also cause a 200 Paper Jam message to occur prior to the paper reaching the input sensor flag This error can display due to a problem with the HSYSC signal to or in the printhead Use the sub error code table to assist in isolating a 200 paper jam message Error Message 201 Paper Jam Remove Cartridge This message indicates the paper is jammed between the printer s input and exit sensors This condition can be caused by the paper exiting the input sensor too late or jamming in the fuser assembly prior to activating the exit sensor flag in time or not at all Error Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at the printer exit sensor This can be caused by the paper arriving at the sensor too late the paper is jammed in the fuser assembly or is jammed exiting the fuser assembly in the redrive assembly or the exit sensor flag is not operating correctly Paper Jams Options Error Message 230 Paper Jam Check Duplex The paper is most likely jammed in the duplex unit however the paper can also be jammed in the redrive at the input to the duplex option The redrive assembly may not be correctly installed or locked in position or the duplex link is bent and not aligned properly to allow paper to feed corre
200. r option Go to the High Capacity Feeder Input Tray Service Check on page 2 55 2 26 Service Manual 4069 XXX Symptom Table Paper Tray Options Symptom Action Paper feed problem with 250 Sheet Paper Tray Option Go to the Input Tray s Option Service Check on page 2 51 Paper feed problem with 500 Sheet Paper Tray Option Go to the Input Tray s Option Service Check on page 2 51 Media fails to pass thru from the lower attached Paper Tray option to the next higher mounted option Go to the Input Tray s Option Service Check on page 2 51 Symptom Table Duplex Symptom Action Paper feed problem with Duplex Go to the Duplex Option Service Check on page 2 35 Paper jams at Paper Removal Tray Go to the Duplex Option Service Check on page 2 35 Paper skews in the Duplex Option Go to the Duplex Option Service Check on page 2 35 Paper fails to pass from lower option thru the Duplex Option Go to the Duplex Option Service Check on page 2 35 Symptom Table Envelope Feeder Option Symptom Action Envelopes do not feed from the envelope feeder Go to the Envelope Feeder Option Service Check on page 2 38 Envelopes do not feed properly into base printer Go to the Envelope Feeder Option Service Check on page 2 38 Diagnostic Information 2 27
201. re trademarks of Lexmark International Inc registered in the United States and or other countries Other trademarks are the property of their respective owners Copyright Lexmark International Inc 1999 2001 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph 1 1 of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 P N 12G3794 4069 XXX Contents Notices and Safety Information ix ions pect Sues y esis We qus Seeds ws ix Safety MOMA ebur Saeed Fone Sepa dienes xvii pro Me MITT xxii General Information 1 1 ase dado aba E deed id dtd EE d ENG ud 1 3 Maintenance 1 4 Tools Required For 1 4 e EE 1 5 Diagnostic 2 1 SIBI 2 1 Sevice Eror CCS 2 2 User Status Messages 2 12 User Error Messages 2 16 Power On Self Test 2 24
202. rint Quality Toner on backside of printed page Service Tip This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper FRU Action 1 Hot Roll Fuser Assembly Toner is being carried out on the backside of the media This problem is generally caused by a toner buildup on the fuser hotroll or backup roll Check the fuser hotroll and backup roll for any noticeable buildup of toner Repair as necessary 2 Transfer Roll Transfer Plate Check the transfer roll for any signs Assembly of toner buildup or loose toner around the area of the transfer plate assembly Clean the area and run another copy If the problem continues replace the FRUs in the following order HVPS engine board 2 104 Service Manual 4069 XXX Smart Cartridge Service Check Note If you are unable to clear a 32 Unsupported Cartridge User Error Message make sure an Optra T print cartridge is correctly installed in the printer The cartridge is easily identified by the smart chip located on the top right side of the cartridge Install another print cartridge before attempting to troubleshoot the printer Check to make sure the smart cable is properly connected to J21 on the engine board Check the print cartridge for any signs of damage or improper installation of the smart chip Also check to make sure there is proper contact between the smart chip and the s
203. rinter 1 24 V dc Autoconnect 2 Ground J12 Printer 1 N A Autoconnect 2 Ground 3 PrtxDin 4 Ground 5 PrtRxD 5 18 Service Manual 4069 XXX Autoconnect Top Connector Pin No Signal Top Autoconnect 0 V dc 45 V dc 0 V dc 0 V dc 0 V dc 45 V dc 0 V dc NI ol oy amp 24 V dc Connector Locations 5 19 4069 XXX Output Expander Control Board Connector Pin No Signal J1A Autoconnect 1 24 V dc Ground m 45 V dc J1B Prtxdin Ground prirxd Ground wo J2A Autoconnect 24 V dc Ground m 45 V dc J2B e prtxdout Ground prtrxd AJOJN Ground J3 Pass Thru Sensor Ground m Paper Present RVsnsr J4 DC Motor mtrout1 mtrout2 Ground Ground tach N 5 Vdc 5 20 Service Manual 4069 XXX Connector Pin No Signal J5 Bin Full Near Full 1 Ground Dual Sensor 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper Connector 1 Not Used 2 Not Used 3 Not Used Connector Locations 5 21 4069 XXX High Capacity Output Stacker Board Connector Pin No Signal J1A Autoconnect 1 24 V dc Ground m 45 V dc J1B Prtxdin Ground
204. rmatted Disk This error code displays when the printer detects an unformatted disk at power on Press Go to clear the message The disk is marked as bad and normal operation continues Disk operations are not allowed until the disk is formatted 80 Scheduled The operator panel displays this message at each Maintenance 300K page count interval It is necessary to replace the fuser assembly transfer roller and charge roll at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit For more information go to Scheduled Maintenance on page 6 2 Diagnostic Information 2 19 4069 XXX User Error Message Explanation 81 Engine Code CRC This error displays when the microcode to be Failure programmed in the engine flash code module has failed a CRC check Press Go to clear the message The microcode data is discarded and must be re transmitted from the host computer 88 Toner Low This message displays when toner low occurs and the toner low alarm is activated Press Go to clear this message User Line 2 Messages If none of the conditions exist that are listed in the following table line 2 is blank If any of the messages in the table are displayed the following actions can be taken Press Menu or Menu to take the printer offline and access the Ready Menu group Note The Menu buttons are not active if Menu Lockout is turned on
205. rness If there is continuity replace the HVPS If the problem continues replace the engine board Note This error displays if the incorrect level HVPS is installed Diagnostic Information 2 109 4069 XXX 2 110 Service Manual 4069 XXX 3 Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem To run the printer diagnostic tests described in this chapter you must put the printer in Diagnostic Mode Diagnostic Mode To enter the Diagnostic Mode 1 Turn the printer off 2 Press and hold the Go and Return buttons 3 Turn the printer on 4 Release the buttons when Performing Self Test displays on the operator panel The tests display on the operator panel in the order shown Print Registration Print Tests Hardware Tests Duplex Tests If installed Input Tray Tests Output Bin Tests Five Bin Mailbox Test Base Sensor Test Printer Setup Error Log EP Factory Defaults Exiting the Diagnostics Mode Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode Diagnostic Aids 3 1 4069 XXX Device Tests Quick Disk Test This test performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good
206. roller board parallel port mounting screws B Remove the serial port mounting screws if present Remove the controller board Oak C 102 Repair Information 4 17 4069 XXX Developer Drive Assembly 1 Remove the inner EMC shield 2 Remove the developer drive assembly mounting screws A 3 Remove the developer drive assembly Note Be sure the developer drive assembly wheel aligns with the hub on the main drive assembly when reinstalling the assembly A 102 4 18 Service Manual 4069 XXX Duplex Board 1 2 3 4 Lift the base printer from the duplex assembly Remove the four duplex board cover mounting screws Gently disconnect the cables from the duplex board Use caution to avoid damage to the cables and connectors Remove the two duplex board mounting screws and remove the duplex board Duplex Front Cover Assembly 1 2 3 4 5 Lift the base printer from the duplex assembly Remove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable at connector J6 Position the duplex assembly on its side Gently release the three front cover assembly latches from the bottom of the duplex assembly Remove the duplex front cover assembly Duplex Front Cover Door 1 2 Remove the duplex front cover assembly Holding the front of the assembly away from you open the cover door and gently pry the left side door pivot from the mounting
207. rough sensor Output Bin Test Standard Bin This test is used to verify if the standard bin sensor is working correctly To run the Standard Bin Sensor Test 1 Select Output Bin Tests from the Diagnostic Menu 2 Select Output Bin Tests Sensor Tests 3 Select Sensor Tests Standard Bin Standard Bin Full CL message displays Manually actuate the bin sensor by moving the flag in and out of the sensor The display indicates OP open when the flag is out of the sensor and CL closed when the flag is in the sensor 4 Press Return Stop to exit the test Output Bin Feed Test Note If the Configure Bins printer setting is link rather than mailbox the printer selects its own internal bin linking regardless of which output bin is selected for the feed test This test is to verify that media can be fed to a specific output bin No information is printed on the media because the printhead is not turned on during this test To run the Output Bin Feed Test 1 Select Feed Test from the Output Bin Test menu 2 Select the output bin you want the paper to exit into All output bins installed on the printer are shown on the feed test menu 3 Select either Single one sheet of media feeds to the selected output bin or Continuous media continues feeding to the selected output bin until Return Stop is pressed 4 Press Return Stop to exit the test Diagnostic Aids 3 15 4069 XXX Output Bin Sensor Test This
208. s 1 5 Adjustment Procedures 4 2 Duplex Motor Drive Belts 4 2 Fuser Solenoid HBR 4 3 Gap Adjustment 4 3 Paper Alignment Assembly 4 5 Printhead Assembly 4 4 Autoconnect 5 19 B Base Sensor Test 3 17 Button Test 3 9 Connector Locations Autoconnect 5 19 Duplex Option Board 5 17 Engine Board 5 4 Envelope Option Board 5 15 Fuser Board 5 11 High Voltage Power Supply 5 3 High Capacity Output Stacker Board 5 22 Interconnect Board 5 12 LVPS 5 1 Output Expander Control Board 5 20 D Diagnostic Aids 3 1 Device Tests 3 2 Disk Test Clean 3 2 Flash Test 3 3 Quick Disk Test 3 2 Diagnostic Mode 3 1 Duplex Tests 3 4 Duplex Feed 1 Test 3 7 Duplex Feed 2 Test 3 7 Duplex Motor Test 3 5 Duplex Quick Test 3 4 Duplex Sensor Test 3 5 Error 3 8 Clearing the Error Log 3 8 Viewing the Error Log 3 8 Hardware Tests 3 9 Button Test 3 9 LCD Test 3 9 Parallel Wrap Test 3 11 ROM Memory Test 3 10 SDRAM Memory Test 3 10 Serial Wrap Test 3 12 Input Tray Tests 3 14 Input Tray Feed Test 3 14 Paper Feed Tests Base Sensor Test 3 17 Input Tray Sensor Test 3 14 Output Bin Feed Test 3 15 Output Bin Sensor Test 3 16 Output Bin Test Standard Bin 3 15 Output Bin X Sensor Test 3 16 5 Bin Mailbox Diverter Test 3 18 Print Registration 3 19 Print Tests 3 23 Printer Setup 3 20 Maintenance Page Count 3 21 Restore EP Factory Defaults 3 22 Setting Configuration ID 3 21 Setting the Page Count 3 20 Viewing the Permanent Page Cou
209. s the laser turns off during this test The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder The paper is placed in the output bin To run the Input Tray Feed Test 1 2 3 4 Select Input Tray Feed Test from the menu Select the input source from the sources displayed on the Feed Test menu All installed sources are listed Select either Single feeds one sheet of media from the selected source or Continuous continues feeding media from the selected source until Return Stop is pressed Press Return Stop to exit test Input Tray Sensor Test This test is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 Select the Sensor Test from the Input Tray Test menu Input Tray Empty OP Pass OP message displays EM Input Tray Empty Sensor LO Input Tray Paper Low Sensor Input Tray Pass Thru Sensor 2 Once this message displays the servicer can manually actuate each sensor The tray empty sensor can be actuated by hand however a sheet of paper can be used to cover the pass through sensor When the sensor is closed CL displays when the sensor is open OP displays 3 Press Return Stop to exit the test 3 14 Service Manual 4069 XXX The multipurpose tray and the envelope feeder do not have a paper low sensor The multipurpose tray does not have a pass th
210. s the standard serial port but the port has been disabled 2 18 Service Manual 4069 XXX User Error Message Explanation 56 Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset 58 Too Many Trays This error code is displayed when too many input Attached trays are attached to the printer 58 Too Many Bins This error code is displayed when too many Attached optional output bins are attached to the printer 58 Too Many Disks This error is displayed when too many disks are Installed attached to the printer 61 Defective Disk This error code is displayed when the printer detects a defective disk This error may occur at power on or during disk format and write operations The following actions may be taken while this message is displayed Press Go to clear the message The disk is marked defective and normal printer operations continue Disk operations are not allowed with a defective disk The Format Disk menu is not shown 62 Disk Full This error code is displayed when there is not enough free space on the disk to hold the resources that have been requested to be written to the disk This message displays for both resource and PostScript Disk operators when the disk is full 63 Unfo
211. s when Performing Self Test displays Select Registration from the menu Select Quick Test Page The test page should only be printed on letter or A4 paper from Tray 1 The Quick Test Page consists of alignment diamonds horizontal lines that can be used for skew adjustment page count setting printer serial number code levels and print registration settings Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and top right of the test page for equal distance from the top of the page If any adjustment is necessary adjust the left or right printhead mounting screws and check the skew again by running another Quick Test Page This procedure may take two or three attempts before you get satisfactory results When you have the correct adjustment gently tighten the printhead mounting screws being careful not to move the printhead assembly 4 4 Service Manual 4069 XXX Paper Alignment Assembly Adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw When replacing the alignment assembly it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one If you are replacing the alignment assembly go to step a If you are only adjusting the reference adjustment screw go to step b a
212. sage displays when the paper reaches paper stop position 1 and the power indicator turns on solid Duplex Feed 2 Test This test feeds a blank sheet of paper to the duplex paper stop position 2 To run the Duplex Feed 2 Test 1 Select Duplex Feed 2 from the Duplex Test menu The power indicator blinks while the paper is feeding Duplex Feed 2 Feeding message displays while the paper is feeding through the printer Duplex Feed 2 Clear Paper message displays when the paper reaches the duplex paper stop position 2 and the power indicator turns on solid Diagnostic Aids 3 7 4069 XXX Error Log Viewing the Error Log The error log is helpful to the servicer by providing a history of printer errors The error log contains the 12 most recent errors that have occurred on the printer The most recent error displays in position 1 and the oldest error displays in position 12 if 12 errors have occurred If an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the Error Log 1 2 3 Select Display Log from the Error Log menu The Error log displays on three screens as only four entries display at a time To move to the next screen press Menu gt to move forward or lt Menu to move backward Press Return Stop to exit the Error Log Clearing the
213. scription Door Asm Rear Access Latch Rear Door Frame Right Pulley Output Tray Shaft Pulley Guide Output Tray Spring Output Tray Cover Right Cover Front Tray Asm Output Frame Left Label Options Cover Left Switch Asm Tray Sensing Flag Tray Sensing Switch Gear Damping Kit High Capacity Output Stacker M po a2 a wp M A YP Parts Catalog 7 95 4069 XXX Assembly 24 High Capacity Output Stacker cont d 7 96 Service Manual 4069 XXX sae Units Description 24 14 99A0107 2 Deflector Upper Also order 99A0104 24 15 99A0104 2 Spring Upper Diverter 24 16 99A0369 1 Shaft Asm Exit Upper Stacker Asm 24 17 99A0052 1 Shaft Asm Stacker Lower Exit Upper Stacker Asm 24 18 12 Bearings Shaft PP 99A0572 24 19 99A1749 2 Board Asm High Capacity Output Stacker 24 20 31 Screws PP 99A0263 24 21 99A1688 1 Arm Diverter 24 22 99A1689 1 Clutch Asm Output Stacker 24 23 99A1784 2 Bracket Attach 24 24 99A0415 2 Spring Swing Arm 24 25 99A0914 2 Drive Asm Output Stacker DC Motor 24 26 99A0409 1 Bracket Dual Sensor Mounting Upper Stacker Asm 24 27 99A1613 1 Flag Bin Full Dual Sensor Upper Stacker Asm 24 28 99A0414 1 Sensor Asm Bin Full Dual Upper Stacker Asm 24 NS 99A1690 1 Belt 95G Lower Stacker Asm Parts Catalog 7 97 4069 XXX Assembly 24 High Capacity Output S
214. set Printer is on the second line of the display Press Select to reset the printer Resetting Printer The printer is deleting No button actions are any print jobs in process possible while this and restoring all settings message is displayed to user defaults Formatting Flash The flash memory is No button actions are Do Not Power Off being formatted possible while this message is displayed Program Flash The flash memory is Do not perform any Do Not Power Off being programmed button actions while which means fonts or this message is macros are being written displayed to flash memory Formatting Disk The disk is being No button actions are formatted possible while this message is displayed 2 14 Service Manual 4069 XXX User Status Message Status Action Programming Disk Do Not Power Off The disk is being programmed which means fonts or macros are being written to disk No button actions are possible while this message is displayed Note If information is written to flash memory and to disk at the same time the Program Flash message is displayed Menus Disabled The printer menus have been disabled This occurs when Menu or lt Menu is pressed while the printer is Ready and Menu Lockout is active The printer display shows this message for one second and then returns to the Ready message No button actions are possible while this message
215. ss Thru Sensor and Flag Check the sensor flag for proper Assembly operation If correct check to Control Board make sure the pass thru sensor cable is correctly connected to J3 on the control board Disconnect the pass thru sensor cable from J3 on the control board and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the control board If correct check the voltage at J3 2 The voltage measures approximately 0 V If incorrect replace the sensor assembly If this does not fix the problem replace the control board 271 Paper Jam Check Bin X POST Complete First Sheet of paper feeds into Output Bin X Note Before performing the following checks run the Output Bin X Sensor Test and check for the failing sensor Sensor Test NF Near Full Upper part of sensor assembly F Full Lower Part of sensor assembly P Pass Thru Sensor Diagnostic Information 2 77 4069 XXX 990 Service BIN X FRU Action 1 D C Motor Check the DC motor cable Mechanical Linkage connector to be sure it is correctly Assembly installed at on the output expander option board If correct disconnect J4 from the option board and check the resistance of the motor on the cable connector J4 1 to J4 2 measures between 115 and 135 ohms Also check J4 1 and J4 2 to the motor case for shorts If either the resistance is incorrect or a short is found replace the motor mechanical
216. st possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair Information 4 1 4069 XXX Adjustment Procedures Duplex Motor Drive Belts Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex motor
217. t the printer can print on media from each of the installed input options Each of the installed options is listed in the following order in the menu Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Multipurpose Feeder if installed Envelope Feeder if installed For each input source selected you have the following choice Single prints the Print Test Page once Continuous continue printing the Print Test Page until Return or Stop is pressed Diagnostic Aids 3 23 4069 XXX The contents of the Print Test Page varies depending on the media installed in the selected input source Note The Print Test Page always prints on one side of the paper regardless of the duplex setting or the presence of a duplex option If a source is selected that contains envelopes an envelope test pattern is printed If continuous is selected the test pattern is printed only on the first envelope To run the Print Test Page 1 Select Print Tests from the Diagnostic menu 2 Select the media source 3 Select Single or Continuous f single is selected no buttons are active during printing f continuous is selected Return or Stop can be selected to cancel the test Check each Test Page from each source to assist in Print Quality and Paper Feed problems Print Quality Test Pages The purpose of this diagnostic function is to allow printing of the print quality test pag
218. tacker cont d z LEM NET 5 WES S lt 1 Ty AS 7 98 Service Manual 4069 XXX Asm Part Index Number Units Description 24 29 99A0913 2 Shaft 40T Middle Output Stacker 24 30 99A0368 2 Shaft Asm Lower 24 31 99A0363 6 Pulley Drive 24 32 99A0361 1 Belt 160G Upper Stacker Asm 24 33 99A0362 1 Arm Asm Belt Idler 24 34 99A0364 2 Spring Belt Tensioner 24 35 99A1791 1 Stacker Asm Paper Path Lower 24 35 99A1792 1 Stacker Asm Paper Path Upper 24 36 99A0351 2 Sensor Stacker Passthru 24 NS 99A1751 1 Switch Asm 24 NS 99A0462 1 Packet Grease IBM 23 24 NS 99A0627 1 Jumper 2 pin Use with 99A1749 Parts Catalog 7 99 4069 XXX Assembly 25 5 Bin Mailbox 7 100 Service Manual 4069 XXX ae Units Description 25 1 99A1512 1 Cover Redrive Cap 25 2 99A1710 1 Cover Wire 25 3 99A1711 1 Cover Top Bin 25 4 99A1785 2 Latch Rear Access Door 25 5 99A0104 1 Spring Upper Diverter 25 6 99A1714 1 Door Rear Access 25 7 99A1723 4 Shaft Asm Drive 25 8 99A1724 1 Shaft Asm Drive W Gear 25 9 99A1708 1 Cover Right Side 25 10 99A1725 1 Packet Drive Shaft Bushing 25 11 99A1742 2 Sensor 5 Bin Mailbox Passthru 25 12 99A1712 5 Tray Paper Cap 25 13 99A1739 1 Bracket Asm Bail Attach w Brush 25 14 99A1743 1 Kit 5 Bin Mailbox Asm 25 15 99A1666 1 Labe
219. tati 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 1 Avisos sobre el l ser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos l ser de Clase 1 establecidos en el subcap tulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s pa ses re ne todas las condiciones expuestas en la norma IEC 60825 para productos l ser de Clase 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 795 nan metros El sistema l ser y la impresora est n disefiados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de xii Service Manual 4069 XXX la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declarac o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcapitulo J para a Classe 1 de produtos laser Em outros locais est certificada como um produto laser da Classe em conformidade com os requisitos da norma IEC 60
220. test is used to verify if the output bin sensors are working correctly To run the Output Bin Sensor Test 1 Select Sensor Test from the Output Bin Test menu Output Bin Full OP Input OP message displays Full Output Bins Full Sensor Pass Output Bins Pass Thru Sensor 2 Once the message displays the servicer can manually actuate each of the output bin sensors The bin full sensor can be actuated by hand however a sheet of paper can be used to cover the bin s pass thru sensor When the sensor is closed CL displays and when the sensor is open OP displays 3 Press Return Stop to exit the test Output Bin X Sensor Test Output Expander or High Capacity Output Stacker To run the Output Bin X Sensor tests 1 Select Output Bin tests from the menu 2 Select Output Bin tests Sensor Tests 3 Select Sensor Tests Output Bin X 4 Press Return Stop to exit the test The following is displayed Output Bin X P OP F OP NF CL P Pass Thru Sensor F BIN FULL Sensor lower part of dual sensor NF Near Full Sensor upper part of dual sensor Once the message displays you can manually actuate each of the output bin sensors For all the sensors except the output level sensor when the sensor is closed CL displays and when the sensor is open OP displays 3 16 Service Manual 4069 XXX If the high capacity output stacker is selected then the following is displayed HC BIN 1 TP OP P OP F OP NF OP IP
221. the high capacity system board assembly If the voltage is incorrect check the continuity of the AC input cable to the LVPS If correct replace the LVPS assembly If incorrect replace the AC cable to the input of the LVPS Diagnostic Information 2 57 4069 XXX FRU Action 4 High Capacity Feeder Option Control Board Check the voltage on J8 1 green The voltage measures 24 V dc If incorrect check the autoconnect system for any problems 24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized If the voltage is correct check the voltages at J11 3 red and J11 4 red The voltages measure 24 V dc If correct replace the high capacity feeder option system board If incorrect disconnect J8 from the System board and measure the voltages again If incorrect check the LVPS cable and the A C internal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housing to each pin on the motor connector If you find a short between any pin and the motor housing replace the motor assembly If no shorts are found replace the high capacity feeder option control board Check the voltage at J9 1 light blue The voltage measures approximately 24 V dc If incorrect disconn
222. tion 2 27 High Capacity Feeder Option 2 26 Output Expander Option 2 28 Paper Tray Options 2 27 U Unique Tools 1 4 User Line 2 Link Messages 2 21 User Line 2 Messages 2 20 User Status Messages 2 12 V Viewing the Permanent Page Count 3 20 Part Numbers 1261696 7 105 12G1697 7 105 13A0296 7 104 13A0297 7 104 13A0298 7 104 1339537 7 39 1339538 7 39 1339539 7 39 1 4 Service Manual 1339540 1339541 1339542 1339543 1339544 1339545 1339546 1342514 1342530 1342534 1342536 1374067 43H5248 99A0004 99A0007 99A0026 99A0028 99A0039 99A0049 99A0052 99A0053 99A0055 99A0058 99A0060 99A0063 99A0070 99A0071 99A0072 99A0073 99A0074 99A0075 99A0076 99A0078 99A0079 99A0081 99A0082 99A0083 99A0084 99A0085 99A0086 99A0087 99A0088 99A0089 99A0104 99A0107 99A0113 99A0119 7 39 7 39 7 39 7 39 7 39 7 39 7 39 7 39 7 39 7 39 7 39 7 39 7 39 Tg Z 1 4 55 7 59 Ke Pie 7 9 7 49 7 69 7 97 7 11 7 49 7 11 7 9 7 95 7 58 7 87 END 7 11 7 58 7 81 7 15 55 7 59 7 89 Ty 7 17 7 49 TIF T Tate M 7 17 7 49 7 91 7 83 TAF TIF 7 17 7 106 SE 7 91 7 99 7 91 7 83 7 91 7 93 7 91 7 93 TIS 7 59 7 97 2 101 1797 758 1 23 7 57 4069 XXX 99A0120 99A0121 99A0122 99A0124 99A0125 99A0126 99A0127 99A0128 99A0129 99A0134 99A0136 99A0137 99A0138 99A0142 99A0143 99A0144 99A0145 99A0148 99A0150 99A0157 99A0158 99A0159
223. troller Mtg Ground PP 99A0263 NS 1 Screw Eng Int Shield Ground PP 99A0263 NS 2 Screw Controller Int Ground PP 99A0263 NS 2 Screw Int Pan Mounting PP 99A0263 NS 1 Screw Eng Int Ground PP 99A0263 NS 99A0260 1 Clip Cable NS 2 Screw Cable Clip PP 99A0263 NS 99A1611 1 Shield Ethernet Blank NS 99A1610 1 Shield Serial Blank Parts Catalog 7 45 4069 XXX Assembly 15 Electronics continued 7 46 Service Manual 4069 XXX Part Index Number 15 22 99A0138 15 23 99A0803 15 24 99A0255 15 25 99A1543 15 25 99A0129 15 25 99A0801 15 26 99A0256 15 27 99A0128 15 28 99A1632 15 29 99A0257 Units Description Sensor Standard Bin Level Fan Main Cable Main Drive Motor Gearbox w Motor 010 212 01n 21n 23v 23e Gearbox w Motor 414 41b 411 41n Gearbox w Motor 616 61n Cable Integrated Tray Board Input Tray ITC Cable Auto Connect Bottom Cable Auto Connect Top 212 414 616 21n 41b 411 41e 61n 23v 23e Parts Catalog 7 47 4069 XXX Assembly 15 Electronics continued 7 48 Service Manual 4069 XXX Asm Part Index Number 15 30 99A0049 15 31 99A0466 15 32 99A1593 15 33 99A1501 15 34 99A1577 Units Description Fan Auxiliary 414 616 Sensor Toner Cartridge Level Cable Smart Cartridge Operator Panel Assembly Switch Cover Open w Operator Panel Cable Assembly 15 35 99A0053 15 36 99A0078 15 37
224. ty system board The voltages measure as follows Static Motor Not Running J1 1 Brown approximately 0 V dc J1 2 yellow approximately OV dc Motor Running Forward J1 1 Brown Approximately 0 V dc J1 2 Yellow Approximately 24V dc Motor Running Reverse J1 1 Brown Approximately 24 V dc J1 2 Yellow Approximately 0 V If any of the voltages are incorrect disconnect the motor and measure the resistance between J 1 and J 2 The resistance measures between 7 5 and 10 5 ohms If incorrect replace the motor If correct replace the system board 4069 XXX Paper size switch not selecting paper size that is selected FRU Action 1 Paper Size Switch High Capacity Feeder Option Control Board Check for continuity between the common pin J5 1 and the pin of the paper size selected 5 1 Black Common Lead 5 2 Blue B5 5 3 Green Executive 5 4 Yellow A4 5 5 Orange Letter 5 6 Red Legal 5 7 Brown A5 If any position does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feeder option control board 24X Paper Jam Check Tray X Message displays when Tray X is empty No Tray X Message displays FRU Action 1 High Capacity Feeder Option Control Board Check the voltages on the board at J4 1 red and J4 3 blue The voltages measure approximately 5 V
225. u responsable de l utilisation d autres pi ces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Norme di sicurezza e prodotto stato progettato testato e approvato in conformit 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 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 pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder
226. un the Serial Wrap Test 1 2 Disconnect the serial interface cable and install the wrap plug Select the appropriate Serial Wrap Test from the menu Serial Wrap Serial 1 Wrap Serial 2 Wrap or Serial 3 Wrap P and F represent the same numbers for DRAM The power indicator blinks indicating the test is running This test runs continuously unless canceled by pressing Return Stop 3 12 Service Manual 4069 XXX Each time the test finishes the screen updates with the result If the test passes the Pass Count increases by 1 however if the test fails one of the following failure messages displays for approximately three seconds and the Fail Count increases by 1 Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum count is reached the test stops The power indicator goes on solid and the final results display Press Return Stop to exit the test Diagnostic Aids 3 13 4069 XXX Input Tray Tests Input Tray Feed Test This test lets the servicer observe the paper path as media is feeding through the printer A blank sheet of paper feeds through the printer a
227. usted first The range of the adjustment is 25 to 25 The Duplex Top Margin Offset range is 20 to 20 Adjustment of this setting lets you shift up or down the position of the Top Margin Changing this parameter by 1 unit moves the margin 3 4 Service Manual 4069 XXX 1 100 inch A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin 3 Press Return Stop to exit the test Check the Top Margin Offset of the base printer Duplex Sensor Test This test is used to determine whether or not the Duplex sensors and switches are working correctly Select Sensor Test from the Duplex Tests menu Manually actuate each of the duplex sensors When the sensor switch is closed CL closed displays when the sensor switch is open OP Open displays Duplex input sensor Duplex exit sensor Press Return Stop to exit the test Duplex Motor Test This test lets you test the duplex unit s paper feed drive system and verify that the power and velocity values are acceptable To run the Duplex Motor Test 1 Select Motor Test from the Duplex Tests menu The duplex motor test continues to run until the printer is powered off The power indicator blinks while the test is running The duplexer runs the motor at a high speed and then a low speed and takes an average of the power required for each speed After all the information
228. v 23e 4 5 99A1927 1 Spring Bellcrank Internal 250 010 01 n 23v 23e 4 5 99A1930 1 Spring Bellcranck Internal 500 212 414 616 41b 411 41e 61n Parts Catalog 7 15 4069 XXX Assembly 5 Paper Feed Multipurpose Unit 7 16 Service Manual 4069 XXX Part Index Number 5 1 99A0075 5 2 99A0071 5 3 99A0076 5 4 99A0081 5 5 99A0083 Units Description Screw Socket Set M4X5 mm Arm Assembly MPT Pick Roll Assembly Spring Assembly Separator MPT Pad Assembly Kit o Restraint Pad o MPT Pad Assembly 5 6 99A1608 1 Deflector Assembly MPT 5 7 99A1531 1 Deflector Lower 5 8 2 Screw Lower Deflector Mounting 8 mm PP 99A0263 5 8 2 Screw Lower Deflector Mounting 12mm PP 99A0263 5 9 99A0084 5 10 99A0082 5 11 99A0078 5 12 99A0073 Flag MPT Paper Out Plate Assembly MPT Sensor MPT Paper Out Screw Damper 5 13 Screw Frame Mounting PP 99A0263 NS 2 Clip Pick Roll Shaft PP 99A0267 5 14 99A0072 1 Solenoid MPT 5 15 99A0074 2 Bushing Pick Roll Shaft Parts Catalog 7 17 4069 XXX Assembly 6 Paper Feed Alignment vice Manu 7 18 Ser 4069 XXX Asm Part fade tMumber Units Description 6 1 99A0089 1 Alignment Assembly Paper Feed 6 2 99A1953 1 Screw Reference Ground Clip 6 3 99A0490 1 Clip Reference Ground 6 4 99A0492 1 Screw Paper Reference Adjustment 6 5 99A0565 1 Washer Reference Adjustment 6 6 99A0566 1 Nut Paper
229. vice The engine protocol violation detected by the specified device 982 device Comm Communications error detected by the specified device 983 device Invalid command received by the specified device 984 device Invalid command parameter received by the specified device Note Service Errors 980 thru 984 device can be one of the following engine board duplex tray x 1 2 3 4 or 5 envelope feeder or output bin x 1 2 or 3 990 device Indicates an equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Note device can be one of the following duplex tray X 1 2 3 4 or 5 envelope feeder or output bin x 1 2 or 3 991 device Card The specified device has detected an equipment check in its system card Note device can be one of the following duplex tray x 1 2 3 4 or 5 envelope feeder or output bin x 1 2 or 3 Diagnostic Information 2 7 4069 XXX Sub Error Codes For 9XX and 2XX Error Codes The sub error codes are helpful troubleshooting a paper path problem especially paper jams in the base printer envelope feeder and duplex unit When a 9XX or 2XX error displays Press and hold return and press select to enter for sub error codes The following is an example of how the printer displays a duplex unit sub error code DU XX DU XX Byte 1 Byte 2 B
230. wer pass thru sensor is correctly connected to J3 on the lower control board Disconnect the pass thru sensor cable and check the voltage at J3 3 The voltage measures approximately 5V dc If incorrect check the voltage at J3 2 The voltage measures approximately OV dc If incorrect replace the sensor assembly If this does not fix the problem replace the lower control board 2 High Capacity Output Check to ensure the output stacker Stacker Drive belt s Drive drive belt or the failing assembly is Pulleys Belt Idlers and Belt correctly installed on the drive pulley Tension Springs and belt idler pulley Check the belt tension spring to make sure it is not loose or broken Repair as necessary 3 Mechanical Linkage Motor If the DC motor is functioning properly Assembly Upper or Lower check the gears clutch and other linkage parts for correct operation and any signs of wear broken gear teeth or damaged parts If incorrect replace the mechanical linkage assembly DC Motor Assembly Diagnostic Information 2 81 4069 XXX Remove Paper Output Bin X Full displays You may not be able to clear the message FRU Action 1 Dual Output Bin Sensor Flag Check the flag for correct operation Upper Assembly binding broken parts or interference from the sensor cable If incorrect repair as necessary 271 Paper Jam Check Bin X POST Incomplete FRU Action 1 Upper Pass Thru Sensor Chec
231. y State Press Select for the values Press Menu gt until Reset Printer is on the second line of the display Press Select to Reset the printer Busy The printer is busy receiving or processing data or printing data Note The printer indicator light blinks while the printer is processing data Press Stop to take the printer out of Busy The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the printer paper path Press Go to return to Ready Flushing Buffer The printer is flushing corrupted print data and the current print job is being discarded No button actions are possible while this message is displayed 2 12 Service Manual 4069 XXX User Status Message Status Action Printing Menu Settings The printer is processing or printing a list of current settings menus because Print Menu Settings is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the printer paper path Press Go to return to Ready after the page prints Press Menu gt or lt Menu to take the printer out of Ready and enter the TESTS MENU Busy State Press Select for the values Press Menu gt until Reset Printer is on the second line of the display Press Select to reset the printer Printi
232. yte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 XX XX XX XX XX XX Base Printer Sub Error Codes Each status byte has a different level of troubleshooting value for each area of the printer The following table displays status bytes 1 2 and 3 This set of status bytes is designed to help isolate paper jams and paper feed problems in the base printer Status Bytes 1 2 3 Explanation 84 xx 00 The input sensor is still covered by the first sheet of paper through the printer and the second sheet is ready to arrive at the sensor 84 xx 01 Video information has not started on the page at the input sensor within two inches after activating the input sensor flag 84 xx 02 The media takes too long to complete a pass through the input sensor 84 xx 04 This can occur when a sheet of paper is in the machine during POST and the input sensor flag has tripped the input sensor 2 8 Service Manual 4069 XXX Status Bytes 1 2 3 Explanation 84 xx 05 This error is generated whenever media is seen at the input sensor before the sensor flag activates the input sensor 84 xx 06 A paper jam is detected by the tray you are trying to feed from 84 xx 07 A paper jam is detected by a smart option and an error message displays 84 xx 08 Paper Tray 5 pass thru sensor is not activated by a sheet of paper 84 xx 09 Paper Tray 4 pass thru sensor is not activated by a sheet

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