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1. 5 16 Service Manual 4069 5XX 7XX 30 PPM Non Network 00000000000000000000 00000000000000000000 3 30 Connector Locations 5 17 4069 5 XX 7XX 40 PPM Network mom J11 1004 99 en o AB se 00000000000000000000 c 5 18 Service Manual 4069 5XX 7XX 40 PPM Non Network
2. 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 Printer 1 24 V dc Autoconnect 2 Ground J12 Printer 1 N A Autoconnect 2 Ground 3 PrtxDin 4 Ground 5 PrtRxD 5 10 Service Manual 4069 5XX 7XX Autoconnect Top Connector Pin No Signal Top Autoconnect 1 0 V dc 5 V dc 0 V dc 0 V dc 0 V dc 5 V dc 0 V dc 24 V dc NI ol oy amp Gol I Connector Locations 5 11 4069 5 XX 7XX Output Expander Control Board Connector Pin No Signal J1A Autoconnect 1 24 V dc Ground m 45 V dc J1B Prtxdin Ground prtrxd Ground OI wo J2A Autoconnect 24 V dc Ground m 45 V dc J2B k 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 12 Service Manual 4069 5XX 7XX 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 13 4069
3. 00000000000000000000 00000000000000000000 J30 Connector Locations 5 19 4069 5XX 7XX System Board Connector Locations Connector Pin No Signal J1 SDRAM Card Assembly J2 Printhead Connector 1 LENA 2 LPOW FB 3 LADJ 4 Ground 5 LPOW 6 5phead 7 Ground 8 VID_CON 9 Ground 10 Ground J3 Cover Closed 1 Cover Closed Connector 2 5 V dc 3 Ground J4 Printhead Fan 1 24 V dc 2 Ground J5 Main Fan 1 FanStall 2 Ground 3 MainFan J6 1 Cartridge Fan Cartridge Fan 2 Ground 722 72n 5 20 Service Manual 4069 5XX 7XX Connector Pin No Signal J7 Mirror Motor 1 Ground 2 Ground 3 Refreq 4 Lock 5 Start 6 Ground 7 24 V dc J8 Output Level Sensor 1 Ground 2 Ground 3 OPT2 4 Ground 5 5 V dc J9 SDRAM Card Assembly J11 USB Connector J12 SDRAM Card Assembly J13 HYSNC 1 Ground 2 HSYNC In 3 HSYNCID 4 5 V dc Connector Locations 5 21 4069 5XX 7XX Connector Pin No Signal J14 Narrow Media Sensor New Fuser ExitSens R
4. 4 17 Card Assembly NAND 4 18 ed 4 19 Developer Drive 4 20 BOA CETTE 4 21 Duplex Front Cover 4 21 Duplex Front Cover 4 21 DIG oss PERS EG TIPS QE Ea 4 22 EMG SHBG aX Rede EE EGGS 4 23 PAN c Pe T EG 4 25 4069 5 XX 7XX FIAMOS ee EE AER ed 4 26 F SOliu suxaa gama kk EE EE EE EE 4 30 FUSE COVE 4 31 Fuser Detack FINQGIS 2 4 31 Fuser Detack Housing Assembly 4 32 Fuser Transfer 24 4 4 nhan nh 4 33 Fuser Envelope Conditioner Solenoid 4 34 Fuser Narrow Media Sensor Flag Assembly 4 35 Fuser Exit Sensor Flag Assembly 4 35 FUSE Lap a nen 4 35 Fuser Lower Exit Guide Assembly 4 36 High Voltage Power Supply 4 37 Integrated Tray Compensator Assembly 4 37 Integrated Tray Compensator Pick Roll Assembly 4 38 Interconnect Board 4 40 Low Voltage Power Supply iiia n Rn mns 4 42 Drive Assembly 2 2 2 42244 2 2 4 43 Main Drive Motor Renan hx nnns 4 45 Multipurpose Tray Lower Deflector Assembly 4 46
5. 2 99 Paper Feed Service 2 105 Parallel Port Service 2 107 Printhead Service 2 108 4069 5 XX 7XX Print Quality Service Check 2 109 Smart Cartridge Contact Assembly Service Check 2 121 Serial Port Service Check cece EEN SEENEN 2 122 Toner Sensor Service Check 2 122 Transfer Roll Service 2 123 StapleSmart Finisher Service Check 2 125 Diagnostic 2 2 2 22 2 3 1 Diagnostic Configuration 3 1 Configuration MENU seng s e xm m REGERE dee wad 3 5 Disgnosuc MOOG 3 6 Exiting the Diagnostics Mode 3 6 Device Tees dips 3 6 Quick DEK ausge nd ss e RR eS e RR 3 6 Disk QA 3 6 eae mated 3 7 Disabling Download Emulations 3 8 Duplex TESS 3 8 Duplex QUICK T88l EE 3 8 Duplex Sensor 3 9 Duplex qd xri ease 3 9 Duplex Fasd Teel ow acid 3 12 Duplex 2 soos cr REUTERS TER
6. 2 1 T 2 1 Sorice EMO Codes ou seca ices E 2 2 User Status a STEE EELER NEES SES 2 24 User Attendance 2 29 Power On Self Test POST 2 41 Symptom Tables was 2 42 Service CHECKS zi dur E RR RUE A 2 46 Charge Roll Service 2 47 Cover Open Switch Cable Service Check 2 49 Dead Machine Service 2 50 Duplex Option Service 2 53 Envelope Feeder Option Service Check 2 56 Service Pad PE 2 63 Cold Fuser Service 2 65 Hot Fuser Service Chia eK esse here RR 2 67 Fuser Solenoid Service 2 68 Input Sensor Service Check 2 68 Input Tray s Option Service Check 2 69 High Capacity Feeder Input Tray Service Check 2 72 Main Drive Service 2 85 Operator Panel Service Check 2 86 Options Service Check E RAO 2 88 Output Bin Sensor Standard Tray Service Check 2 90 Output Expander Service 2 91 High Capacity Output Stacker Service Check 2 96 5 Bin Mailbox Service
7. AJ wy 5Vstpl A stprimed 5 28 Service Manual 4069 5XX 7XX Connector Pin No Signal J4 Accessory Connector 24 V dc accmtr Ground Ground tacha 5Vptt J5 Solenoid Sol1 24 V dc J6 Stapler Ground oO m pfrinstp 5Vsnsr2 J7 Right Side Sensor Board Ground Bottom Top Ground J8 Solenoid J9 Bin Empty Sensor Sol2 24 V dc Ground bnempty m 5Vsnsr2 J10 Left Side Sensor Board Ground full NRFull Wy Ground Connector Locations 5 29 4069 5 XX 7XX Connector Pin No Signal J12 Pass Thru Sensor Ground psthruint m 5Vptt J13 Cover Open Switch 45V dc m Ground cvropin J14A 24V dc Ground m 5V in J14B prtxdout Ground prtrxd Ground OI Ground J15 Stapler Door Open 5 30 Service Manual Dooropin Ground 5Vswitch 4069 5XX 7XX Cables Base Machine Fuser Cable DC Internal Thermisto Exit Sensor Thumper NO Fuser Autoconnect Narrow Media Autoconnect Cable Fuser to LVPS EP Autoconnect LVPS Deflector Cable To
8. 3 31 Setting Configuration ID essc ENEE EE ee STE 3 31 Restore EP Factory Defaults 3 32 PHM TESIS ane RRE EELER EES RR 3 33 Print Quality Test Pages x ark nas 3 34 Printing Menu Settings 3 36 Auto Compensator Operation 3 36 Autoconnect System Paper Tray Options Envelope Feeder and Output Expander 3 37 Electribal a unus Rare hax hd med 3 37 FUSE ODGIBlOI ad dq x RR AR RARE 3 39 Hot Boll FUSS iua x RR ER 3 39 Paper Feed Jams 2 22 4 4 E EIER ER 3 40 Paper Jams Base Printer e hn 3 40 Paper Jams 8 kw RR KDE a Ra S 3 41 Repair Information 2 4 1 Handling ESD Sensitive Parts 4 1 Adjustment PIOCBOdUIGS a isa e rep rreasasess 4 2 Duplex Motor Dive Bella lii csc rs 4 2 Fuser Solenoid 4 3 Gab BE e EE 4 3 Printhead Assembly 4 4 Paper Alignment Assembly Adjustment 4 5 Screw Identification Tabla essen Rma 4 7 Removal Procedur s 4 12 4 12 Genter Pam Assembly Somes sien 4 16 System BOI
9. 5 ESO EG HK WE 770 795 nm dRBOGZSUORTPEDELBJXRYD VE EHE RE A TF AA i AR HE TD E SS SRL Laser Notices xvii 4069 5XX 7XX Korean Laser Notice ere 158 olx ASSO CHE DHHS 21 CFR Subchapter 32 PAS Ves amp 2 2 IEC 8 Tas toe 158 gold ABSA ss 1 404 ASSES How zur 5 AS alo HZA 770 795 LE Ol E S SSste Class ill 3b HOA Aa S Ecc AAMT BREE AA SE SOL RAL BS PAE 82191 Class PEY HoH Apeto Ach Mos So rio xviii Service Manual 4069 5XX 7XX 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 compo
10. 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 3 6 Service Manual 4069 5XX 7XX 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 f 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 xxxx Bad Blocks 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 becaus
11. FRU Action 1 Output Expander Drive Belt Check to ensure the output Drive Pulley Drive Belt expander drive belt is correctly Idler Pulley Belt Tension installed on the drive pulley and belt Spring idler pulley Check the belt tension spring to make sure it is not loose or broken Repair as necessary 2 Mechanical Linkage If the DC motor is functioning DC Motor Assembly 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 Diagnostic Information 2 93 4069 5 XX 7XX 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 Pass 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
12. Lexmark T62X 4069 5xx 7xx Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK 4069 5XX 7XX Edition May 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 ImageQuick O
13. System Board Connector Locations System Board Connector Locations StapleSmart Finisher Option Staple Card Assembly Cables Base Machine Fuser Cable DC Autoconnect Cable Fuser to LVPS Detector Gable 442234458452 d dice aba d oda ebd Fuser Cable AC EP Autoconnect to Fuser Top Cover Integrated Tray Cable HSYNG Cable 5255348 secuereRtQeru p eee iru Mirror Motor Main Drive Motor L ser Gable id Qu Ra Au ee Bd A d Front Harness Cable nma ERR E Fuser Cable DC EP Autoconnect to System Board Autoconnect Cable System Board to Top Interconnect Board ses ska RR eww awe Autoconnect Cable System Board to Front Bottom Interconnect Preventive Maintenance Safety Inspection Guide Lubrication Specifications Scheduled Maintenance Parts Catalog How to Use this Parts Catalog Assembly 17 COVGIS s susc ax ax Rcs xk x an ec n Assembly 2 Frame EEN Assembly 3 Assembly 4 Paper Feed Auto compensator Assembly 5 Paper Feed Multipurpose Unit Assembly 6 Paper Feed Alignment Assembly 7 Paper Feed Assembly 8 Integrated Paper Tray 500 Sheet
14. ThumpRet 5 V dc ThumpLeft Ground Therm Ground Narmedia NI oO ay AJ OJN 5 V dc Ground J15 Serial Port TXD RXD RTS CTS DSR DTR No Connection No Connection J16 Operator Panel 2 5 V dc 2 Ground FPIRQ No Connection 5 22 Service Manual 4069 5XX 7XX Connector Pin No Signal J20 Smart Cartridge 1 SCart 2 Ground 3 Ground J21 Parallel Port Connector Connector Pin No Signal J25 HVPS Cart Sense 1 ATSERVO HVPS Input Sensor 2 TXCURPWM HVPS 3 TxEnable HVPS 4 TXPWM HVPS 5 24 V dc HVPS 6 CHGPWM HVPS 7 Ground HVPS 8 DEV HVPS 9 Ground Input Sensor 10 InSense Input Sensor 11 5 V dc Cart Sensor 12 5 V dc Cart Sensor 13 CTSensen Cart Sensor 14 Ground Cart Sensor Connector Locations 5 23 4069 5XX 7XX Connector Pin No Signal J27 Main Drive Motor 24 V dc Ground Ground Lock Hall BLDC_DIR FG 5 V dc oO ay AJ OJN BLDC_CLKb eo Ground ON OFF J28 Ethernet Connector J30 Option Connector 5 24 Service Manual RDXIn Ground TDXIbr Ground oa Ground 4069 5XX 7XX Co
15. Cover Redrive Cap Cover Wire Cover Top Bin Latch Rear Access Door Spring Upper Diverter Door Rear Access Shaft Asm Drive Shaft Asm Drive W Gear Cover Right Side Packet Drive Shaft Bushing Sensor 5 Bin Mailbox Pass thru Tray Paper Cap Bracket Asm Bail Attach w Brush Kit 5 Bin Mailbox Asm Label Options Bail order 9941743 5 Bin Mailbox Asm Kit Support Paper Tray Stop Asm Paper Tray Flag Bin Full Sensor Dual Paper Height Cable Dual Sensor Cable Asm Lower Auto Connect Drive Asm Main DC Drive Board Asm 5 Bin Mailbox System Frame Asm Left w Clutch Asm Gear Drive Cable Asm Upper Auto Connect 2 Screw Board Mounting PP 99A0263 Cover Left Side ch oan 4 on on 42 an Bae h po a a a Parts Catalog 7 99 4069 5 XX 7XX Assembly 24 5 Bin Mailbox continued 7 100 Service Manual 4069 5XX 7XX Asm Part Index Number Units Description 24 30 99A1741 Spring Diverter 24 31 99A1727 Frame Asm Right Side 24 32 99A1728 Cam Diverter Actuator 24 33 99A1731 24 34 99A1729 24 35 99A1730 24 36 99A1789 24 37 99A1720 24 38 99A1732 24 39 99A1738 24 40 99A1722 24 41 99A1787 24 42 99A1721 24 NS 99A1734 24 NS 99A0462 24 NS 99A1715 24 NS 99A1717 Gear Drive 24 NS 99A1788 Retainer R Ring Spring Diverter Actuator Latch Diverter Actuator Arbor Diverter Actuator C clip Bracket Attach Solenoid Diverter Deflector Pape
16. Diagnostic Information 2 75 4069 5XX 7XX 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 Backup 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 2 76 Service Manual 4069 5XX 7XX Tray X Paper Low Message displays
17. Index Number Units Description 14 22 99A2443 1 Sensor Standard Bin Level 14 23 99A2441 1 Fan Main 14 24 99A2459 1 Cable Main Drive Motor 14 25 99A2446 1 Gearbox w Motor 520 52n 14 25 99A2447 1 Gearbox w Motor 722 72n 14 26 99A2456 1 Cable Integrated Tray 14 27 99A0128 1 Board Input Tray ITC 14 28 99A2463 1 Cable Auto Connect Bottom 14 29 99A2460 1 Cable Auto Connect Top Parts Catalog 7 43 4069 5XX 7XX Assembly 14 Electronics continued 7 44 Service Manual 4069 5XX 7XX Asm Part Index Number 14 30 99A2442 14 31 99A2471 14 32 99A0466 14 33 99A1501 14 34 99A2414 Units Description Fan Cartridge 722 72n Smart Cartridge Contact Assembly Sensor Toner Cartridge Level Operator Panel Assembly Switch Cover Open w Operator Panel Cable Assembly 14 35 99A0053 14 36 99A2440 14 37 99A2438 14 38 99A2457 Sensor Input Sensor MPT Paper Out MPT Solenoid Cable Front Harness Parts Catalog 7 45 4069 5XX 7XX Assembly 14 Electronics continued 7 46 Service Manual 4069 5XX 7XX Asm Part Index Number 14 39 99A2448 14 39 99A2449 14 40 99A2458 14 41 99A2461 14 42 99A2464 Units Description Printhead Assembly 520 52n Printhead Assembly 722 72n Cable Hysnc Cable Laser Cable Fuser DC EP Auto Connect to System Board 14 43 99A2465 14 44 99A2479 14 45 99A2466 14 46 99A2468 Solenoid Assembly E
18. Paper does not feed all the way into the output tray Go to the Output Expander Service Check on page 2 91 Symptom Table StapleSmart Finisher Symptom Action Finisher does not staple Go to the StapleSmart Finisher Service Check on page 2 125 Printer does not recognize StapleSmart Finisher Option as being installed Go to the StapleSmart Finisher Service Check on page 2 125 Close Top Cover displayed Unable to clear or reset message POST incomplete Go to the StapleSmart Finisher Service Check on page 2 125 Close Finisher Side Cover displayed Unable to clear or reset message POST incomplete Go to the StapleSmart Finisher Service Check on page 2 125 Paper feeds into finisher option output tray Paper is not stapled and paper does not align with the right side Go to the StapleSmart Finisher Service Check on page 2 125 Paper feeds into finisher option Paper aligns with the right side The stapler does not staple Go to the StapleSmart Finisher Service Check on page 2 125 Paper is transported into the output tray but is not stapled Go to the StapleSmart Finisher Service Check on page 2 125 Stapled sheets are not transported to the output tray Go to the StapleSmart Finisher Service Check on page 2 125 Diagnostic Information 2 45 4069 5XX 7XX Service Checks
19. e SASS HASHA sr 8 se SA AL JHE VS AHO AE ASAE ol ALES Sale Best als AAS sale 2 A E JB MAR ET dj ER AEN BSE RAR SH EES GIS A XT RD BUS Br T fe SF OR RUD XE T5 AAA MARSH ERSRAWS Safety Information xxiii 4069 5XX 7XX Preface This book is designed for service personnel It is divided into the following chapters 1 General Information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment are listed in this chapter as well as general environmental and safety instructions Diagnostic Information contains an error indicator table symptom tables 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 Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the connector locations and test points on the printer Preventive Maintenance contains the lubrication specifications and recommendations to prevent problems Parts Catalog contains illustrations and part numbers for individual FRUs Service Manual 4069 5XX 7XX 1 General Information The Lexmark T laser printers are letter quality
20. Repair Information 4 7 4069 5 XX 7XX Reference MM Wu Number Screw Type Location Purpose Qty M3 5x8 mm spring cartridge load mounting 1 Thread Cutting system board mounting 2 front 102 integrated tray ITC mounting 2 E board PTS stacker support to right attach 2 side frame M3 5x12 mm paper alignment mounting 2 Thread Cutting assembly E toner cartridge guide mounting 2 104 Ed track yA i i left side frame to center attach 3 PT pan right side frame to attach 2 center pan deflector mounting 4 System board inner mounting 1 shield to frame M3x5 mm INA cover attach 6 Taptite 2 screws per cover 201 interconnect board mounting 5 4 8 Service Manual 4069 5XX 7XX Reference Number 202 GA H TN h 203 41141114114 Screw Type M3x6 mm Taptite M3x8 mm Taptite Location Purpose Qty outer shield mounting 6 inner redrive deflector mounting 2 interconnect board to mounting 2 center pan system board mounting 2 bottom holes system board to attach 2 interconnect board ground system board to inner mounting 2 shield system board back mounting 2 system 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 g
21. on page 2 113 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 Remove the system board and runa Excessive noise or Diagnostic Print Test in the vibration 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 2 Main Drive Motor Assembly A service error code 936 Transport Excessive noise gears Motor may be displayed Check the ratcheting and so on voltage at J27 6 on the system 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 system board If this does not fix the problem replace the main drive motor Main Drive Motor Cable Check the continuity of the main drive motor cable If incorrect replace the cable Diagnostic Information 2 85 4069 5XX 7XX FRU Action 4 Motor does not turn no gear error code 936 or User message 20
22. Assembly 9 Main 2 2 2 4424 4 Assembly 10 Developer Drive Assembly 11 Hot Roll Eeer are s xn RR Ran Assembly 12 Transfer is sss sien RR Assembly 13 Charging xa xxx acts e xxx xc cera Assembly 14 Electronics 4069 5 XX 7XX Assembly 14 Assembly 14 Assembly 15 Assembly 16 Assembly 17 Assembly 18 Assembly 19 Assembly 20 Assembly 21 Assembly 22 Assembly 23 Assembly 24 Assembly 25 Assembly 26 Assembly 27 viii Service Manual Electronics continued 7 36 Electronics continued 7 48 250 Sheet Tray ieiuna es E ce 7 50 5D0 Sheet Trays ssa s km hn Ex x Rm nnn 7 56 issa 7 60 Output Expander 2n nx nmn 7 66 Envelope Feeder 7 70 High Capacity Feeder 7 74 Kiosk Vertical Paper Adapter 7 88 Kiosk Horizontal Paper Adapter 7 90 High Capacity Output Stacker 7 92 5 Bin Mailbox 222222 222u222 NSA AR 7 98 StapleSmart Finisher 7 102 COUONS gie duds RE 4 7 110 Miscellanous 42 n n 7 112 4069 5XX 7XX 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 dispositif est ouvert et non blo
23. Check to make sure the gamma wheel aligner assembly is operating correctly and that the wheel is touching the paper If the gamma wheel is not turning or touching the paper go to step 2 If the wheel is turning and touching the paper check the wheel for any signs of wear damage or contamination If any problem with the wheel is found replace the wheel Check to make sure the aligner assembly and pads are operating correctly Make sure the pads are touching the paper and moving the paper to the right side frame If the aligner pads are not moving into the lower position and touching the paper go to step 3 If the aligner pads are touching the paper then check the pads to make sure they are not worn damaged or contaminated Replace if necessary 2 Paper Wheel Aligner Assembly Check the paper wheel aligner assembly to make sure it is mounted correctly Check to make sure there are no broken gears or other mechanical parts If any are found replace the aligner assembly If no problem is found go to step 3 Diagnostic Information 2 135 4069 5XX 7XX FRU Action Check to make sure the cable to J4 Accessory is properly connected to J4 on the board Turn the printer off disconnect the motor cable from J4 and check for continuity between J4 pins 1 2 3 and 4 to the motor case If you get continuity replace the gearbox drive assembly If you do not get continuity continue with the step 3
24. 3 Select one of the following menus To test the Staple Sensors Select Sensor Tests from the Finisher menu Select Staple Sensor Test from the Sensor Tests menu The following screen is displayed and each sensor can be checked by actuating this flag Staple C CL SL CL SP CL H CL C Cartridge Present Sensor SL Staple Low Sensor SP Self Priming Sensor H Home Signal Sensor 3 24 Service Manual 4069 5XX 7XX To test the Finisher Top Cover and Side Door sensors Select Sensor Tests from the Finisher menu Select Cover and Door from the Sensor Test menu The following screen is displayed and each sensor can be checked by opening or closing the correct cover or door Cover and Door TC CL SD CL TC Finisher Top Cover SD Stapler Side Door To test the Finisher Pass Thru and Media Sensors Select Sensor Tests from the Finisher menu Select Pass Thru and Media from the Sensor menu The following screen is displayed and each sensor can be checked by actuating its flag Pass Thru and Media P OP M OP P Pass Thru Sensor M Media Sensor To test the Bin Level Sensor Select Sensor Tests from the Finisher menu Select Bin Level from the Sensor menu The following screen is displayed and each sensor can be checked Bin Level EM OP NF OP F OP EM Finisher Bin Empty Sensor NF Finisher Bin Full Sensor F Finisher Bin Near Full Sensor Diagnostic Aids 3 25 4069 5XX 7XX To test the Bin Empty Sensor actuate its
25. 7 26 Service Manual 4069 5XX 7XX Asm Part index Number Units Description 11 1 99A2402 1 Fuser Assembly w 115V 875W Lamp 520 52n 11 1 99A2401 1 Fuser Assembly w 220V 875W Lamp 520 52n 11 1 99A2405 1 Fuser Assembly w115V 875W Lamp 722 72n 11 1 99A2404 1 Fuser Assembly w220V 875W Lamp 722 72n 11 2 99A0725 1 Wiper Assembly Wet 11 3 99A2468 1 Cover Fuser Assembly with Thermistor Thermal Fuse and LH amp RH Fuser Lamp Contact Assemblies 11 4 4 Screw Contact Assembly PP 99A0263 11 5 99A2469 1 Exit Roll Assembly 11 6 99A1520 1 Gear Upper Redrive 11 7 99A2472 1 Detack Assembly 11 8 99A1549 1 Hot Roll 11 10 99A1621 2 Bearing BUR 11 11 99A2465 1 Solenoid Assembly Envelope Conditioner 11 12 1 Screw Solenoid Mounting PP 99A0263 11 13 1 Screw Board Cover Mounting PP 99A0263 11 14 99A2470 1 Backup Roll 22 mm 520 52n 11 14 99A0158 1 Backup Roll 28 mm 720 72n 11 15 99A1598 1 Shield Fuser Board 11 16 99A0144 2 Retainer Backup Roll Bearing 11 17 99A1649 2 Screw Fuser Mounting Parts Catalog 7 27 4069 5 XX 7XX Assembly 11 Hot Roll Fuser continued 7 28 Service Manual 4069 5XX 7XX Asm Part index Number Units Description 11 18 2 Screw Fuser Cover Assembly PP 99A0263 11 19 99A0142 2 Retainer Hot Roll Bearing 11 20 99A0143 2 Bearing Hot Roll 11 21 99 0150 2 Bushing Hot Roll 11 22 99A1554 1 Fuser Cable AC Ground 1
26. 934 Printhead Error 935 Printhead Error These errors represent a problem with the printhead Go to the Printhead Service Check on page 2 108 936 937 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 85 939 RIP Engine Communications Lost The RIP and engine cannot communicate with one another The system board or Interconnect board is defective Check for correct installation If no problem is found replace the FRUs in the following order System Board Interconnect Board Note If a problem still exists the RIP software can cause a 939 error code Contact your next level for software support 2 4 Service Manual 4069 5XX 7XX Error Code Action 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 947 PQET Error Indicates that the POET RAM test was incomplete or a PQET RAM test busy failure occurred Replace the System board 948 PEL Clock
27. 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 lock washer are tightened Diagnostic Information 2 73 4069 5 XX 7XX The base printer does not recognize that the high capacity input tray is installed FRU Action 1 High Capacity Feeder Autoconnect Mechanical Check Check the high capacity feeder input tray to make sure it is mounted correctly and is not pushed down into the frame assembly or damaged Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly 2 Base Printer or option mounted above Check the option or base printer autoconnect for signs of damage Repair the high capacity option autoconnect as necessary 3 LVPS Option System Board Check the voltages at J11 2 and J11 4 The voltage measures 24 V dc If the voltage is correct replace the high capacity system board assembly If the voltage is incorrect check the continuity of the AC input cable to the LVPS If correct replace the LVPS assembly If incorrect replace the AC cable to the input of the LVPS 2 74 Service Manual 4069 5XX 7XX FRU Action 4 High Capacity Feeder Check the v
28. on page 2 63 If the fan is noisy replace the fan assembly Dead Machine Go to the Dead Machine Service Check on page 2 50 Operator Panel One or more buttons do not work Operator Panel Display is blank Printer sounds 5 beeps Go to the Operator Panel Buttons Service Check on page 2 86 Go to the Operator Panel Service Check on page 2 86 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 86 Paper feed problems Base printer or Integrated 250 Paper Tray Go to the Paper Feed Service Check on page 2 105 Paper jams at exit of Redrive Assembly No Duplex Option installed Go to the Paper Feed Service Check on page 2 105 Paper jams at exit of Redrive Assembly Duplex Option installed Go to the Duplex Option Service Check on page 2 53 Fuser Solenoid fails to operate Go to the Fuser Solenoid Service Check on page 2 68 Print quality Black page Go to the Print Quality All Black Page on page 2 110 Print quality Blank page Go to the Print Quality Blank Page on page 2 110 2 42 Service Manual 4069 5XX 7XX Symptom Action Print quality Light print Go
29. 2 5 and 6 on the cable and the motor case If you get continuity replace the drive gearbox assembly If you do not measure continuity continue with this step Check the voltages on connector J4 Note All voltages are approximate values Pin Voltage Voltage No Static Feeding 1 24 V dc 24 V dc 2 24 V dc Varies 11 V dc to 24 V dc 3 Not Used 4 Ground 5 5 V dc Varies 3 V dc to 5 V dc 6 45 V dc 5 V dc If the voltages are correct replace the mechanical drive assembly If the voltages are incorrect replace the stapler card assembly 2 130 Service Manual 4069 5XX 7XX FRU Action Swing Arm Spring Check to ensure the swing arm spring is connected and not loose or broken Clutch 99A2551 Assembly Drive Motor Assembly Drive Gear 99A1717 Check the clutch assembly on the right side frame assembly for correct operation and any sign of broken or loose parts Check the drive motor assembly and drive gear for any signs of damage 281 Paper Jam The paper may jam at the upper deflector FRU Upper Deflector Action Check the upper deflector or any signs of broken parts especially the hook that holds the upper deflector spring Check for any signs of bowing of the deflector Move the deflector to make sure it moves smoothly and freely with no signs of binds Upper Deflector Spring Check the upper deflect
30. 2 Ensure that the correct hot roll is installed 3 Check the AC line voltage to ensure it is not above the maximum rating for the printer Note Make sure the fuser is correctly installed before proceeding with this service check The fuser must be firmly seated in the two rear connectors Both the right and left lock down screws must be tight Service Tip Set the Fuser Temperature to NORMAL before starting this service check Diagnostic Information 2 65 4069 5XX 7XX FRU Action Fuser Lamp Incorrect Lamp 925 Service Error Install the correct voltage and wattage lamp or fuser assembly Fuser Lamp Note If the correct lamp is installed and you still have 925 fuser errors try the following 1 The fuser may have reached standby temperature too quickly Check the fuser assembly system board or LVPS 2 Ensure that the correct hot roll is installed 3 Check the AC line voltage to ensure it is not above the maximum rating for the printer 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 LVPS LVPS to Fuser Auto Docking Connector Fuser AC Cable Turn the printer off Remove the fuser assembly Turn the printer power on Measure across the AC fuser cable
31. 23 4 99A1778 23 5 99A1782 23 6 99A1790 23 7 99A1779 23 8 99A1746 23 9 99A1747 23 10 99A1701 23 11 99 1781 23 12 99A1666 23 13 9941745 23 5 99 1751 23 5 9941777 23 5 9941780 23 5 9941744 Units Description 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 po wp YH MH AP Parts Catalog 7 93 4069 5 XX 7XX Assembly 23 High Capacity Output Stacker cont d 7 94 Service Manual 4069 5XX 7XX ns ED Units Description 23 14 99A0107 2 Deflector Upper Also order 99A0104 23 15 99A0104 2 Spring Upper Diverter 23 16 99A0369 1 Shaft Asm Exit Upper Stacker Asm 23 17 99A0052 1 Shaft Asm Stacker Lower Exit Upper Stacker Asm 23 18 12 Bearings Shaft PP 99A0572 23 19 99A1749 2 Board Asm High Capacity Output Stacker 23 20 31 Screws PP 99A0263 23 21 99A1688 1 Arm Diverter 23 22 99A1689 1 Clutch Asm Output Stacker 23 23 99A1784 2 Bracket Attach 23 24 99A0415 2 Spring Swing Arm 23 25 99A0914 2 Drive Asm Output Stacker DC Motor 1 23 26 99A0409 Bracket Dual Sensor Mounting Upper Stacker Asm 23 27 99A1613 1 Flag Bin Full Dual Sensor
32. 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 5XX 7XX 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 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 5XX 7XX Upper Front Cover Interlock Switch Assembly Remove the upper front cover Remove the operator panel Remove the inner EMC shield Pull upon the switch A to remove from the mounting p
33. 7 41 7 67 7 95 7 29 7 61 7 63 7 65 7 112 7 67 7 95 7 57 1 95 Index 1 5 4069 LXT 99A0419 7 53 7 57 99A0427 7 73 99A0434 7 63 99A0438 7 53 7 59 99A0445 7 51 7 85 99A0446 7 59 7 85 99A0447 7 57 99A0448 7 51 99A0450 7 51 7 59 99A0451 7 51 7 59 7 85 99A0452 7 59 99A0462 7 97 7 101 7 113 99A0466 7 9 7 45 99A0469 7 73 99A0481 7 67 99A0482 7 67 99A0484 7 71 99A0485 7 71 99A0487 7 71 99A0488 7 71 99A0489 7 71 99A0490 7 17 99A0491 7 71 99A0492 7 17 99A0494 7 73 99A0512 7 33 7 112 99A0513 7 33 7 112 99A0545 7 110 99A0548 7 109 99A0549 7 9 99A0556 7 9 99A0559 7 17 99A0560 7 111 99A0564 7 25 99A0565 7 17 99A0566 7 17 99A0567 7 9 99A0571 7 67 99A0572 7 67 7 95 7 107 7 112 99A0577 7 5 7 112 99A0585 7 7 7 112 99A0627 7 51 7 97 99A0629 7 110 99A0650 7 77 99A0651 7 81 99A0653 7 79 99A0654 7 81 6 Service Manual 99A0655 99A0656 99A0657 99A0658 99A0659 99A0660 99A0661 99A0662 99A0663 99A0664 99A0667 99A0675 TT 2 13 7 77 2 74 7 81 2 75 2 77 4 15 7 79 7 79 7 81 7 75 7 11 729 FB 7 85 7 112 99A0676 72112 99 0677 7 75 7 11 7 79 781 T9725 4 01 7 18 TBU 7 87 7 112 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 99A0867 99A0893 99A0897 99A0899 7 87 7 01 5
34. 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 Cover Mounting Grommet Top LVPS Cover a A c oL sch lc ol lI c Parts Catalog 7 83 4069 5 XX 7XX Assembly 20 High Capacity Feeder continued o 7 84 Service Manual 4069 5XX 7XX Asm Part Index Number 20 76 99 0281 20 77 99A0279 20 78 9940273 20 79 20 80 9940276 20 81 99A0451 20 82 20 83 20 84 99 0277 20 85 9940445 20 86 9940280 20 87 9940275 20 88 9940272 20 89 9940446 20 90 20 91 9940274 20 92 99A0278 20 93 9941967 20 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 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 Spring Backup Roller EL wb es et cw uu get NS 99A0286 Parts Catalog 7 85 4069 5 XX 7XX Assembly 20 High Capacity Feeder co
35. F Standard Bin s Bin Full Sensor Once the screen is displayed manually actuate the sensor flag to check the Bin Full Sensor When the sensor is closed CL displays and when the sensor is open OP displays Select Return or Stop to exit the test Output Expander 6 Select Output Bin tests from the menu Select Output Bin tests Sensor Tests Select Sensor Tests for Output Bin X x number of the output option to be tested The following screen is displayed Output Bin x P OP F OP NF OP P Pass Thru Sensor F Bin Full Sensor NF Near Full Sensor Once the screen is displayed manually actuate each of the output expander sensors When the sensor is closed CL displays and when the sensor is open OP displays Select Return or Stop to exit the test High Capacity Output Stacker Select Output Bin tests from the menu Select Output Bin tests Sensor Tests Select Sensor Tests for Output Bin x x number of the output option to be tested The following screen is displayed HC Bin x TP OP P OP F OP NF OP 3 22 Service Manual 4069 5XX 7XX TP High Capacity Stacker top position sensor P High Capacity Stacker pass thru sensor F High Capacity Stacker bin full sensor lower par of dual sensor NF High Capacity Stacker near full sensor upper part of dual sensor 5 Once the screen is displayed manually actuate each of the sensors of the High Capacity Stacker When the sensor is closed CL displays a
36. If correct check the switch for a bent or deformed actuator lever or defective switch If incorrect replace the switch Diagnostic Information 2 83 4069 5XX 7XX 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 DC Motor Assembly Check to make sure the idler pulley is not binding on the pulley shaft Check the pulley for any signs of wear Check the idler pulley shaft on the motor mounting plate for any signs of damage or contamination 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 Tray Drive Belt Check the DC motor drive belt for any signs of damage Check to make sure the belt is tracking correctly on the drive pulley idler pulley and motor pulley Check the tray drive belt for any signs of damage Check to make sure the belt is tracking correctly on the lower section of the drive pulley and lead screw pulleys 2 84 Service Manual 4069 5XX 7XX Main Drive Service Check Service Tip Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or system board Service Tip If there are equally spaced horizontal lines across the page go to Print Quality Evenly spaced horizontal lines or marks
37. If the printer is locked on a particular link the link indication displays If the printer is ready to process any link no messages display Link messages are listed in the following table User Message Explanation Parallel Standard Parallel Port if available Serial Standard Serial Port if available Serial X Serial Port where X 1 2 3 is attached to PCI connector X Network X Network card X X 1 2 3 is attached to PCI connector X 2 38 Service Manual 4069 5XX 7XX User Message Explanation LocalTalk X LocalTalk Card X X 1 2 3 is attached to PCI connector X Infrared Standard Infrared port if available Infrared X Infrared Port X X 1 2 3 is attached to PCI connector X Check Device Connection Messages The messages in the following table display when the printer looses communications with one of the following devices User Status Message Explanation Check Output Bin X Connection Check Output Bin X 1 2 0 3 Check Env Feeder Check Envelope Feeder Option Connection Connection Check Tray X Check Tray X X 1 2 3 4 or 5 Connection Check Duplex Check Duplex Option Connection Connection Diagnostic Information 2 39 4069 5XX 7XX The messages in the following table can occur in two ways The specified device could have been removed from the printer for instance to clear a paper jam Otherwise the device can
38. Print Quality Test Pages Print Quality Test Pages on page 3 34 Download Emuls only displayed if at least one downloaded emulator is installed Disabling Download Emulations on page 3 8 Factory Defaults Restore EP Factory Defaults on page 3 32 Exit Configuration Menu Press Select to go to Configuration Menu To run the printer diagnostic tests described in this chapter you must put the printer in Diagnostic Mode Diagnostic Aids 3 5 4069 5XX 7XX Diagnostic Mode To enter the Diagnostic Mode Turn the printer off Press and hold the Go and Return buttons Turn the printer on Release the buttons when Performing Self Test displays on the operator panel S Exiting the Diagnostics Mode Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode 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 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
39. 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 Diagnostic Information 2 33 4069 5XX 7XX User Message Primary User Message Secondary Explanation 36 Resolution Reduced The resolution of the page has been reduced from 600 dpi to 300 dpi 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 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 Memory 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 re
40. approximately O V ac 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 2 94 Service Manual 4069 5XX 7XX 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 J4 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 linkage assembly Note If the DC motor is shorted it may also be necessary to replace the control board 2 Output Expander Control Disconnect the motor cable J4 Board and check the voltages at J4 on the board Note Use caution not to short to adjacent pins on the connector J4 1 Motor Idle 24 V dc J4 2 Motor Idle 24 V dc J4 5 Motor Idle 5 V dc J4 6 Motor Idle 5 V dc If any of the voltages are incorrect replace
41. to remove the job from the finisher If a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the printer does not reprint these sheets Error Message 201 Paper Jam Remove Cartridge This message indicates the paper is jammed between the printer 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 Note When the StapleSmart Finisher option is installed a secondary message may be displayed which advises whether or not to remove the job from the finisher If a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the printer does not reprint these sheets 3 40 Service Manual 4069 5XX 7XX Error Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at or near the printer exit sensor located in the fuser assembly This can be caused by the paper arriving at the sensor too late the paper jammed in the fuser assembly or jammed exiting the fuser assembly in the redrive assembly or the exit sensor flag i
42. which output bin is selected for the feed test This test is used to verify that media can be fed to a specific output bin No information is printed on the media fed to the output bin because the printhead is not turned on during this test This test can be run from any input source and will support any size paper or envelope supported by the printer 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 The standard bin as well as any output option bin installed on the printer is shown on the menu The output bin displayed is in the order installed on the printer 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 Output Bin Sensor Test This test is used to determine whether or not the output bin sensor is working correctly for the Standard Bin or the sensors are working for the Output Expander High Capacity Output Stacker 5 Bin Mailbox or StapleSmart Finisher Options if installed To run the Output Bin Sensor Test for Diagnostic Aids 3 21 4069 5XX 7XX Standard Bin 6 Select Output Bin Test from the menu Select Output Bin tests Sensor Tests Select Standard Bin from the menu The following screen is displayed Standard Bin F OP
43. 20 Service Manual 4069 5XX 7XX Asm Part Index Number Units Description 8 1 99A1601 8 2 99A1576 8 3 9941895 8 4 9940292 8 5 99A1812 8 6 99A1583 8 7 99A0126 8 8 99A0124 8 9 99A1952 8 10 9941537 8 11 99A1582 8 12 9940120 8 13 9941602 Latch Back Restraint Tray Assembly 500 Sheet Restraint Side Latch Side Strip Wear Label Tray Option Number Plate 500 Tray Wear Finger Autosize Plate Snap in Label Paper Size Knob Paper Size Slider Autosize 500 Pad Restraint Restraint Back ee a EE Parts Catalog 7 21 4069 5 XX 7XX Assembly 9 Main Drive 7 22 Service Manua 4069 5XX 7XX ele E Units Description 9 1 99A2446 1 Gearbox w Motor 520 52n 9 1 99A2447 1 Gearbox w Motor 722 72n 9 2 99A1569 1 Shaft Power Take Off 500 9 3 99A0275 1 Spring Power Take Off Shaft 9 4 99A0954 1 Gear Bevel with Grease Packet NS 4 Screw Gearbox Mounting PP 99A0263 NS 3 Screw Motor Mounting PP 99A0263 Parts Catalog 7 23 4069 5XX 7XX Assembly 10 Developer Drive 7 24 Service Manual 4069 5XX 7XX ane SE Units Description 10 1 99A1544 1 Developer Drive Assembly 10 2 99A0136 1 Shaft Developer Drive 10 3 99A0564 1 Coupler Gear 55 10 4 1 Screw Developer Drive Ground PP 99A0263 10 5 2 Screw Developer Drive Mtg PP 99A0263 Parts Catalog 7 25 4069 5XX 7XX Assembly 11 Hot Roll Fuser
44. 30 Service Manual 4069 5XX 7XX Fuser Cover 1 2 3 Remove the fuser assembly Note the thermistor cable routing and disconnect the cable 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 Remove the 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 2 3 Remove the fuser assembly Remove the fuser cover assembly Remove the fuser detack housing assembly Repair Information 4 31 4069 5XX 7XX 4 Gently pry the detack finger and spring from the housing assembly 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 hot roll bearing clips to free the fuser frame walls 5 Gently apply outward pressure on the left and right fuser side frames A to release the detack housing assembly B 4 32 4069 5XX 7XX Fuser Transfer Plate 1 2 3 4 Remove the upper paper deflector Remove t
45. 5 mm Main Drive PP 99A0404 Main Drive Assembly 17 54 99A0308 17 55 17 56 99A0337 17 57 99A1676 17 58 17 59 99A1692 NS 99A1695 17 60 99A1059 NS NS NS 99A0058 NS 99A1164 Sensor Input Optical 500 Duplex Retainer 6 mm Drive Roll PP 99A0404 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 A A P A A M A S Parts Catalog 7 65 4069 5XX 7XX Assembly 18 Output Expander 7 66 Service Manual 4069 5XX 7XX Part e Index Units Description 18 1 99A1857 1 Deflector Upper Redrive Also order 99A0104 18 2 99A0104 1 Spring Upper Diverter 18 3 99A0369 1 Shaft Assembly Exit Also order PP 99A0572 18 4 99A0052 1 Shaft Assembly Lower Exit Also order PP 99A0572 18 5 1 Screw PP 99A0263 18 6 99A0915 18 7 99A0571 18 8 99A1817 18 9 99A1666 18 10 99A1689 18 11 99A1688 18 12 9940482 18 13 9941784 18 14 9940914 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 18 15 99A0372 18 16 99A0415 18 17
46. 69 4069 5XX 7XX 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 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 2 70 Service Manual 4069 5XX 7XX Tray X Low message displays when Tray X is full or has adequate
47. 7 101 1 99 7 99 7 99 7 99 7 99 7 101 7 99 7 99 7 93 7 93 7 93 7 93 7 69 7 93 TD 2599 799 LO 7 110 7 310 7 110 7 110 7 110 42110 7 110 7 110 7 110 7 110 1 94 7 93 7 93 7 93 7 93 7 93 7 93 7 67 7 93 7 99 7 103 4069 5XX 7XX 99A1786 99A1787 99A1788 99A1789 99A1790 99A1791 99A1792 99A1793 99A1794 99A1795 99A1796 99A1797 99A1798 99A1799 99A1800 99A1801 99A1802 99A1803 99A1804 99A1805 99A1806 99A1807 99A1808 99A1809 99A1812 99A1817 99A1818 99A1819 99A1820 99A1829 99A1832 99A1854 99A1855 99A1857 99A1879 99A1888 99A1889 99A1890 99A1894 99A1895 99A1903 99A1924 99A1929 99A1930 99A1952 99A1953 99A1967 7 99 7 101 7 101 7 101 7 93 7 97 7 97 7 83 7 83 7 83 7 83 7 83 7 83 7 83 7 83 7 83 7 83 7 83 7 83 7 83 7 77 7 79 7 79 7579 7 21 7 87 7 67 7 49 27 89 7 91 7 09 7 91 7 105 17585 7 97 7 75 TF 7 113 7 113 7 19 7 67 7 7 759 ri 7 111 7 55 7521 7 97 7 65 7 1593 7 99 7 18 7 21 7 55 7 57 7 17 4 01 7 57 7 85 9941968 99A2200 99A2401 99A2402 99A2404 99A2405 99A2414 99A2415 99A2416 99A2417 99A2418 99A2419 99A2425 99A2430 99A2431 99A2432 99A2433 99A2435 99A2436 99A2438 99A2439 99A2440 99A2441 99A2442 99A2443 99A2444 99A2445 99A2446 99A2447 99A2448 99A2449 99A2451 99A2452 99A2453 99A2454 99A2455 99A2456 99A2457 99A2458 99A2459 99A2460 99A2461 99A2463 99A2464 99A2465 99
48. Assembly Charge Right Kit 13 3 99A1017 1 Roll Assembly Charge 13 4 99A1555 1 Bushing Charge Roll NS 1 Screw Charge Roll PP 99A0263 Parts Catalog 7 33 4069 5XX 7XX Assembly 14 Electronics 8 12 7 34 Service Manual 4069 5XX 7XX Asm Part Index Number 14 1 1342514 1 Power Cord Set 8 ft U S Canada LV Nicaragua Venezuela Peru LV Brazil LV Bolivia HV Colombia Costa Rica Ecuador Dominican Republic El Salvador Guatemala Honduras Mexico Panama Puerto Rico Virgin Islands Saudi Arabia LV AP English LV Taiwan 520 52n 14 1 43H5248 1 Power Cord Set 8 ft U S Canada LV Brazil HV Nicaragua LV Venezuela LV Peru LV Bolivia Puerto Rico LV Virgin Islands Colombia LV Costa Rica LV EI Salvador LV Guatemala LV Honduras LV Mexico LV Panama LV AP English LV 722 72n 14 1 1339538 1 Power Cord Set 6 ft Paraguay Uruguay Austria Germany Hungary Slovakia Finland France Belgium Netherlands Greece Italy Czechoslovakia Lebanon Syria Egypt Jordan Iran Euro English Norway Sweden Poland Russia Turkey CIS Portugal Spain Catalan 14 1 1342536 1 Power Cord Set 6 ft APG LV 14 1 1339537 1 Power Cord Set 8 ft U K Ireland Iceland Kuwait Bahrain Qatar UAE Oman Pakistan Iraq Libya Cyprus Units Description 14 1 1339539 1 Power Cord Set 6 ft Israel 14 1 1339540 1 Power Cord
49. Disk option when installed 3 Flash Test for flash when installed Printer Setup If selected the following menu selections are available 1 Defaults 2 Page Count 3 Permanent Page Count viewing 4 Serial Number printer serial number 5 Envelope Enhance 6 Engine Setting 1 7 Engine Setting 2 8 Engine Setting 3 9 Engine Setting 4 10 Configuration ID 11 Edge to Edge 12 Parallel S Strobe Adjustment only displayed if printer is configured with standard parallel port 13 1 Strobe Adjustment only displayed if a parallel port available via PCI slot 1 14 Par 2 Strobe Adjustment only displayed if a parallel port available via PCI slot 2 Device Tests on page 3 6 Printer Setup on page 3 30 3 4 Service Manual 4069 5XX 7XX Tests Refer to Test Page EP Setup If selected the following menu selections are available 1 EP Defaults 2 Fuser Temperature 3 Warm Up Time 4 Transfer 5 Print Contrast 6 Charge Roll 7 Gap Adjustment envelope solenoid Restore EP Factory Defaults on page 3 32 Error Log Error Log on If selected the following menu selections are page 3 13 available 1 Display Log 2 Clear Log Exit Diagnostics Exiting the Diagnostics Mode on page 3 6 Configuration Menu Maintenance Count Value Viewable only Maintenance Page Count on page 3 31 Reset Maintenance Count Setting the Page Count on page 3 30
50. Error Indicates the PEL clock check failed Replace the System board 949 Delay Line Indicates a delay line calibration failure Replace the NVRAM Failure 955 Code CRC loc Calibration System board Failure 953 954 System board failures 953 NVRAM Chip Failure 954 NVRAM CRC Failure Replace system board Code ROM and NAND failed CRC check loc For a ROM CRC failure the location loc will be a failing block or Bn loc For a NAND CRC failure the location loc will be a failing page or Pn Replace System Board 956 959 System Board Error codes 956 thru 959 are system board failures 956 Processor Failure 957 ASIC Failure 958 SRAM Failure For any of these failures replace the system board Diagnostic Information 2 5 4069 5XX 7XX Error Code Action 958 NAND Before proceeding when a 958 NAND failure is Failure displayed perform a Power On Reset power the printer Off then On to see if the ECC Error Correction Code can reflash NAND 960 963 RAM Error codes 960 thru 963 indicate the following specific Memory Error RAM error 960 RAM soldered on the system board is failing Replace the system board 961 RAM in slot 1 is failing 962 RAM in slot 2 is failing 963 RAM in slot 3 is failing For errors 961 thru 963 if available switch memory from the failing slot with one from a non failing slot to see if it fi
51. Feeder Option 2 43 99A0052 7 67 7 95 Output Expander Option 2 45 99A0053 7 9 7 45 Paper Tray Options 2 44 99A0058 7 7 7 53 7 57 7 65 99A0060 7 13 U 99A0063 7 9 7 51 7 59 Unique Tools 1 3 99A0070 7 13 7 53 7 57 7 87 User Line 2 Link Messages 2 38 99A0073 7 15 User Line 2 Messages 2 37 99A0074 7 15 User Status Messages 2 24 99A0075 7 15 99A0076 7 15 V 99A0079 7 89 7 91 99A0081 7 15 Viewing the Permanent Page Count 99A0082 7 15 en 99A0083 7 15 7 112 99A0084 7 15 Part Numbers 99A0085 7 89 7 91 1261695 7 111 99A0086 7 89 7 91 1261696 7 111 99A0087 7 89 7 91 1201697 7 111 99A0088 7 89 7 91 13A0296 7 110 99A0089 7 17 13A0297 7 110 99A0104 7 19 7 67 7 95 7 99 13A0298 7 110 7 107 1339537 7 35 99A0107 7 95 1339538 7 35 99A0113 7 7 1339539 7 35 99A0119 7 55 1339540 7 35 99A0120 7 21 7 55 7 57 1339541 7 35 99A0121 7 55 1339542 7 35 99A0122 7 89 7 91 1339543 7 35 99A0124 7 21 7 55 7 57 1339544 7 35 99A0125 7 89 1339545 7 35 99A0126 7 21 7 55 7 57 1339546 7 35 99A0127 7 55 1342514 7 35 99A0128 7 9 7 43 1342530 7 35 99A0136 7 25 1342534 7 35 99A0137 7 89 1342536 7 35 99A0142 7 29 1374067 7 35 99A0143 7 29 43H5248 7 35 99A0144 7 27 56 0053 7 39 99A0148 7 29 56 0054 7 39 99A0150 7 29 56 0055 7 39 99A0157 7 29 56 0056 7 39 99A0158 7 27 99A0004 7 5 99A0167 7 29 1 4 Service Manual 4069 5XX 7XX 99A0181 99A0184 99A0185 99A0188 99A0191 99A0196 99A0197 99A0206 99A0208 99A0219 99A0226 99A0227 99A023
52. Flash DIMM 16MB Flash DIMM Card Assembly Bar Code Card Assembly PRESCRIBE 5 4 2 Flash Card Assembly for IPDS and SCS TNe Hard Disk with Control Board 5 0 GB Adapter Card SES for SCS Cable Twinax Cable Coax Adapter Serial Cable Serial Board USB Parallel Interface Card Assembly ImageQuick 7 110 Service Manual 4069 5XX 7XX Assembly 26 Options continued E LL Units Description 26 99A1890 1 Tray Assembly 250 Special Media 26 99A1647 1 Rib Assembly 250 Special Media Tray 26 99A1654 1 Tray Universal Adjustable 250 Sheet 26 99A2489 1 Drive Optra Forms HD 5 0 GB or larger 26 99A1605 1 Kit Cap Stack Bails 500 26 1281695 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 26 99A2485 1 Tray Assembly UAT 400 Sheet 26 99A1683 1 Optra Forms 2 MB Flash DIMM 26 99A1684 1 Optra Forms 4 MB Flash DIMM 26 99A1685 1 Optra Forms 8 MB Flash DIMM 26 99A1686 1 Optra Forms 16 MB Flash DIMM Parts Catalog 7 111 4069 5XX 7XX 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 99A
53. 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 2 68 Service Manual 4069 5XX 7XX 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 System Board Check for approximately 5 V dc at J25 10 on the system board If incorrect replace the system 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 FRU Action 1 Tray X option System Board Check the autoconect cables and or Compensator Assembly connectors for any signs of damage or Autoconnect Cable 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 auto compensator assembly option System board Diagnostic Information 2
54. Kiosk Vertical Paper Adapter 7 88 Main Drive 7 22 Miscellaneous 7 112 Output Expander 7 66 Paper Feed Alignment 7 16 Autocompensator 7 12 Multipurpose Unit 7 14 Output 7 18 Printhead 7 10 Transfer 7 30 250 Sheet Tray 7 50 5 Bin Mailbox 7 98 500 Sheet Tray 7 56 Power On Self Test POST Q Quick Disk Test 3 6 R Removal Procedures 4 12 Removals Card Assembly 8mb NAND Flash 4 18 Center Pan Assembly 4 16 Covers 4 12 Developer Drive Assembly 4 20 Duplex Board 4 21 Duplex Front Cover Assembly 4 21 Duplex Front Cover Door 4 21 Duplex Motor 4 22 EMC Shields 4 23 Inner EMC Shield 4 23 Outer EMC Shield 4 24 Fans 4 25 Frames 4 26 7 70 2 41 4069 5XX 7XX EP Frame Assembly 4 26 Left Side Frame 4 26 Right Side Frame 4 29 Fuser 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 37 Integrated Tray Compensator Pick Roll Assembly 4 38 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 Switch Assembly 4 49 Optional Paper Tray Assembly 4 50 Paper Alignment Assembly 4 51 Paper Deflectors 4 53 Inner Paper Def
55. Lower Pan Deflector Plate L To Outer Motor Plate Connector Locations 5 31 4069 5XX 7XX Fuser Cable AC EP Autoconnect to Fuser Top Cover Fuser Autoconnect Gnd 3d18 B AC Inline Integrated Tray Cable System Board Paper Out Sensor E dE tm d Me mu RE q CC SP Nem dpt M aur LL n Integrated Paper Tray HSYNC Cable System Board Printhead HSYNC Board SI j3 4 5 32 Service Manual 4069 5XX 7XX Mirror Motor Cable System Board Printhead Mirror Motor LfLTLfLfLT 6P Main Drive Motor Cable System Board Main Motor 11P 11P 13 i UL fi V U fi U fi fi Laser Cable Printhead Laser Board System Board N U U 4 PS U U U LAL ru Connector Locations 5 33 4069 5XX 7XX Front Harness Cable System Board 11P Toner Sensor C 51 Input Sensor d L U al U U U 8P UUU fL fi HVPS L fi Fuser Cable DC
56. Maintenance Page Count 3 31 Restore EP Factory Defaults 3 32 Setting Configuration ID 3 31 Setting the Page Count 3 30 Viewing the Permanent Page Count 3 30 Diagnostic Mode 3 6 Disabling Download Emulations 3 8 Disk Test Clean 3 6 Duplex Option Board Connectors 5 9 Duplex Tests 3 8 E Envelope Option Board Connectors 5 7 Error Codes Service Error Codes 2 2 User Error Messages 2 29 ErrorLog 3 13 ESD Sensitive Parts 4 1 F Flash Test 3 7 Index 1 4069 LXT G Gap Adjustment 4 3 H Hardware Tests 3 14 High Capacity Output Stacker Board 5 14 HVPS Connectors 5 3 Input Tray Feed Test 3 19 Input Tray Sensor Test 3 19 Interconnect Board Connectors 5 4 L LCD Test 3 14 Lubrication Specifications 6 1 LVPS Connectors 5 1 Maintenance Approach 1 3 Maintenance Page Count 3 31 Maintenance Scheduled 6 2 Messages CheckDevice Connection Messages 2 39 Service Error Codes 2 2 User Error Messages 2 29 User Line 2 Link Messages 2 38 User Line 2 Messages 2 37 User Status Messages 2 24 Output Bin Feed Test 3 21 Output Bin Sensor Test 3 21 Output Expander Control Board 5 12 P Parallel Wrap Test 3 16 Parts Catalog Charging 7 32 Covers 7 2 Developer Drive 7 24 Duplex 7 60 1 2 Service Manual Electronics 7 34 Envelope Feeder Frame 7 6 High Capacity Feeder 7 74 High Capacity Output Stacker 7 92 Hot Roll Fuser 7 26 Integrated Paper Tray 500 Sheet 7 20 Kiosk Horizontal Paper Adapter 7 90
57. Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemaBer Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Laser Notices xi 4069 5XX 7XX 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 Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe 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 Limprimante 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 I
58. Note Anytime the system board is replaced the Configuration ID must be reset in NVRAM on the new system board Go to Setting Configuration ID on page 3 31 Review the following information before performing any service checks Paper feed problems especially paper jams Go to Viewing the Error Log on page 3 13 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 Paper feed 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 34 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 46 Service Manual 4069 5XX 7XX Charge Roll Service Check Service Tip Close and evenly spaced repetitive marks 47 19 mm 1 86 inch apart or spots on the page can be caused by a damaged or contaminated charge roll Service Tip Check to make sure the right charge roll arm bushing is correctly installed and operates correctly To remove the charge roll 1 Wrap a piece of plain white paper around the charge roll to prevent contamination or damage 2 Carefully remove the roll by pressing outward and to the right o
59. PELEAS 3 12 ENO LOO add 3 13 ViewDo eo Enor sass canard 3 13 Clearing the Error LO soo sese ur 3 13 Hardware esis 5242 44 4 ea qnc RS EE GE S EE E ME RES dE 3 14 LCD 3 14 eh gensis sre mici vwd 3 14 SDRAM MEMO 3 15 ROM Memory 3 15 Parallel Wrap WE rara a we 3 16 ee Wrap E 3 17 EET 3 19 liput Tray 3 19 Input Tray Sensor Test 3 19 Output Bin Feed to all Bins Test 3 20 Output Bin Feed Test xcu ek ERREUR e RR msnm 3 21 Output Bin Sensor Test 3 21 Finisher Tests StapleSmart Finisher Option 3 24 Base Senco lest irse ede 3 26 StapleSmart Finisher 3 26 StapleSmart Finisher Sensor Test 3 27 iv Service Manual 4069 5XX 7XX 5 Bin Mailbox Diverter Test 3 28 Registration 2 2 2 3 28 Printer Setups ea one eee 3 30 Setting the Page Count Rma n EIS STEINS ER 3 30 Viewing the Permanent Page 3 30 Maintenance Page
60. 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 Power Saver Power Saver lt Fax Status gt When in the power saver mode the printer will display this screen instead of the Ready screen When a job is received the power saver screen remains displayed until the printer exits the power saver mode and warms up the printer The printer has been configured to receive or send FAX This screen is displayed Press Menu gt or lt to take the printer offline and access the Ready Menu Group or Press GO to take the printer out of power saver and initiate a printer warm up cycle or Press Stop to take the printer offline The Not Ready message is displayed no more data is processed The Go button must be pressed to return the printer to the previous state 2 24 Service Manual 4069 5XX 7XX User Status Screens Status Action Res Reduced Res Reduced lt Fax Status gt The printer is processing data or printing pages and the resolution of a page belonging to the current job has been reduced from 600 to 300 DPI to prevent a Memory Full Error Will be displayed whenever the printer has been configured to receive or send FAX Press Stop to take the printer offline Not Ready is displayed no more data will be processed and the current job in the paper path is pro
61. 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 or problems with letterheads 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 3 32 Service Manual 4069 5XX 7XX lets the backup roll heat up and helps reduce curl in some environments Transfer The transfer can be adjusted to LOW MEDIUM HIGH Print Contrast The print contrast setting controls the developer voltage offset The print contrast can be adjusted to e LOW MEDIUM HIGH Charge Roll The charge roll can be adjusted to e LOW MEDIUM HIGH Print Tests The purpose of the diagnostic Print Tests is to verify that 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
62. Service Manual 4069 5XX 7XX 4 Place the printer on its back and remove the mounting screws B Note Go to Interconnect Board on page 5 4 to identify the correct jumper locations for your printer B 202 5 Remove the interconnect board assembly Repair Information 4 41 4069 5 XX 7XX Low Voltage Power Supply 1 2 3 Remove the right cover Remove the LVPS mounting screws A from the rear of the 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 5XX 7XX Main Drive Assembly o OO P Go M 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 C 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 5XX 7XX 10 Remove the main drive assembly Note Do not remove the screws E on the main drive assembly Be sure the main drive assembly
63. Set Switzerland French Switzerland German Switzerland Italian 14 1 1339541 1 Power Cord Set South Africa Namibia Lesotho Botswana 14 1 1339546 1 Power Cord Set 6 ft Two Prong Argentina HV Power Cord Set 8 ft Chile HV Power Cord Set 8 ft Denmark Power Cord Set 6 ft Italy Power Cord Set 8 ft Peru HV Power Cord Set 8 ft Straight Argentina HV 14 1 1342534 14 1 1339543 14 1 1339542 14 1 1374067 14 1 1339544 ln ln ln 14 1 1339545 1 Power Cord Set 8 ft Right Angle Argentina HV 14 1 1342530 1 Power Cord Set Brazil 14 1 43H5546 1 Power Cord Set PRC HV 520 Parts Catalog 7 35 4069 5XX 7XX Assembly 14 Electronics continued 8 12 Loi M de x 7 36 Service Manual 4069 5XX 7XX Part Index Number 14 2 99A2491 14 2 99A2492 14 3 99A2452 14 3 99A2453 14 3 99A2454 14 3 99A2455 14 4 14 5 99A2451 14 6 99A2425 Units Description Fuse 110 V ac LVPS 12 5A 250V Fuse 220 V ac 6 3A 250V LVPS 110 V ac 520 52n LVPS 110 V ac 722 72n LVPS 220 V ac 520 52n LVPS 220 V ac 722 72n Screw HVPS Mounting PP 99A0263 High Voltage Power Supply Interconnect Board Assembly 2 Slot with shield 14 7 2 Screw Int Board Mounting PP 99A0263 14 8 3 Screw System Bd Mounting Front PP 99A0263 14 9 99A2490 2 Screw Parallel Connector Mounting 14 11 99A2430 1 Card As
64. Sub Error Code Data Note xx can be any value Explanation 925 Service Fuser Error Wrong Fuser Lamp Installed Note The Sub Error Codes below are only for an incorrect lamp being installed EN 07 xx yy This error code is generated anytime an incorrect lamp is 221 detected EN 2 xx 00 Lamp detection performed and found an error 01 It took long to do lamp detection and NVRAM detected a previous wrong lamp detected yy Actual Temperature zz The temperature that the fuser was trying to reach Envelope Feeder Sub Error Codes First 6 Bytes Sub Error Code Data Note XX can be any value Explanation 84 xx 17 There is an envelope in the feeder during POST Diagnostic Information 2 19 4069 5 XX 7XX First 6 Bytes Sub Error Code Data Note Explanation xx can be any value 84 xx 1D x1 The envelope feeder pass thru sensor activated but never x2 deactivated x1 Media Size x2 Media Source This error can be caused by an envelope over the pass thru sensor Remove the envelope and try to feed an envelope If the envelope stops over the pass thru sensor try the following Select the diagnostic test menu select input tray sensor tests select envelope feeder sensor test Check the envelope pass thru sensor to ensure it is operating correctly If the sensor test fails go to the Envelope Feeder Option Service Check on page 2 56 If the test passe
65. Tray 3 if installed Tray 4 if installed Tray 5 if installed Multipurpose Feeder if installed Diagnostic Aids 3 33 4069 5XX 7XX Envelope Feeder if installed For each input source selected you have the following choices Single prints the Print Test Page once Continuous continue printing the Print Test Page until Return or Stop is pressed 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 pages 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 con
66. adjustments printed on the test page These settings should be within the range specified in Registration on page 3 28 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 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 5XX 7XX 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 toner level sensor mounting 1 102 charge roll mounting 1 i 87 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 laser cover mounting 4 deflector mounting 2 gear cover to left side attach 1 frame
67. are logged Service Error Code Explanation 1 Error Code 932 Lost HSYNC These errors usually indicate a failure in the HSYNC signal to the printhead Check the continuity of the cables connected to J7 and J13 on the system board If incorrect replace the defective cable The voltage at J13 4 measures approximately 5 V dc If incorrect replace the system board The voltage at J7 7 measures approximately 24 V dc If incorrect replace the system 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 system board cable or system board assembly Check the continuity of the mirror motor cable connected to J7 on the system board If incorrect replace the cable The voltage at J7 7 measures approximately 24 V dc If incorrect replace the system board If correct replace the FRUs in the following order system board printhead assembly 2 108 Service Manual 4069 5XX 7XX 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
68. at J25 5 are incorrect replace the system board 4 Front Cable Harness Check the front cable harness at J25 HVPS Section on the system 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 Diagnostic Information 2 111 4069 5XX 7XX 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 1 Random Marks 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 operati
69. 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 on the cartridge and the smart cartridge contact assembly Service Tip An intermittent 82 Unsupported Cartridge User Error Message can be caused by poor contact between the smart cartridge contacts in the printer and the smart chip Also check for proper seating of the smart cartridge cable to the system board FRU Action 1 Smart Cartridge Contact Check the voltage on the smart Assembly cartridge contact The voltage measures approximately 3 8 V dc System Board when not writing data to the system board If data is being written the voltage measures approximately 0 V cc If incorrect disconnect the cable from J20 on the system board and check the voltage on J20 1 The voltage measures approximately 5 V dc If incorrect replace the system board If correct replace the smart cartridge contact assembly Diagnostic Information 2 121 4069 5XX 7XX Serial Port Service Check Run the Serial Wrap Test on page 3 17 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 proble
70. drive assembly when reinstalling the assembly A 237 4 20 Service Manual 4069 5XX 7XX Duplex Board 1 Lift the base printer from the duplex assembly 2 Remove the four duplex board cover mounting screws 3 Gently disconnect the cables from the duplex board Warning Avoid damage to the cables and connectors 4 Remove the two duplex board mounting screws and remove the duplex board Duplex Front Cover Assembly 1 Lift the base printer from the duplex assembly 2 Remove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable at connector J6 3 Position the duplex assembly on its side 4 Gently release the three front cover assembly latches from the bottom of the duplex assembly 5 Remove the duplex front cover assembly Duplex Front Cover Door 1 Remove the duplex front cover assembly 2 Holding the front of the assembly away from you open the cover door and gently pry the left side door pivot from the mounting 3 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 21 4069 5XX 7XX Duplex Motor T 2 3 Remove the duplex front cover door Gently disconnect the cables from the duplex board Warning 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 mountin
71. error code is displayed when too many input trays are attached to the printer 58 Too Many Bins Attached This error code is displayed when too many optional output bins are attached to the printer 58 Too Many Disks Installed 61 Defective Disk This error is displayed when too many disks are attached to the printer 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 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 Diagnostic Information 2 35 4069 5 XX 7XX User Message Jer Primar 9 Message Explanation y Secondary 62 Disk Full This error code is displayed when there 63 Unformatted Disk 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 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 Maintenance The operator panel displays this message at each 300K page count inter
72. flag in the paper output tray To test the Bin Full Sensor and Near Full Sensor first actuate the Bin Empty Sensor and then cover the Bin Full or Bin Near Full Sensor Note OP Open CL Closed 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 StapleSmart Finisher Tests Finisher Feed Test This test is used to verify whether or not media can be fed to a finisher output bin and stapled No information is printed on the test pages as the printhead is not turned on Eight sheets of paper feed and then the pages staple Note This test can be run using any of the paper sizes supported by the printer The media is fed from the selected source and then outputted to the finisher output bin 3 26 Service Manual 4069 5XX 7XX To run the StapleSmart Finisher Feed Test 5 1 Select Finisher Tests from the menu 2 Select Feed Tests from Finisher Tests menu 3 4 Eight sheets of paper feed into the finisher and then staple The feed test runs may take a minute for the test t
73. following 1 2 3 The operator panel displays one and a half row of pels and then 12 13 14 15 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 Amount of memory displayed 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 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 11 The main drive motor turns on The developer drive assembly drives the developer shaft in the toner cartridge Ready appears on the display StapleSmart Finisher option homes if installed The exit rollers turn The output expander option 5 bin mailbox or high capacity output stacker exit rollers turn if installed Diagnostic Information 2 41 4069 5 XX 7XX Symptom Tables Symptom Table Base Printer Symptom Action Cartridge Fan 722 72n fails to run or is noisy Go to the Cartridge Fan Service Check on page 2 64 Printhead Fan fails to run or is noisy 722 72n Go to Printhead Fan Service Check
74. gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly 4 44 Service Manual 4069 5XX 7XX 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 5XX 7XX Multipurpose Tray Lower Deflector Assembly 1 Open the multipurpose tray to a position that allows the left and 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 Warning Be careful not to break the hinges 4 46 Service Manual 4069 5XX 7XX 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 102 Repair Information 4 47 4069 5XX 7XX Operator Panel Assembly 1 Remove the upper front cover 2 Disconnect the operator panel cable 3 Gently press the operator panel lens tabs A and remove the operator panel 4 48 Service Manual 4069 5XX 7XX 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 Remove the left door and upper front cover 2 Disconnect the operator pan
75. 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 buttons 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 5XX 7XX 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
76. latches C and remove the fan from the left side frame ES p d AS j 2j 1 Frames EP Frame Assembly 1 Remove the left and right side frames 2 Remove the EP frame assembly Left Side Frame Remove the main drive assembly Remove the upper front cover hinge assembly Remove the mulitpurpose tray lower deflector assembly Remove the paper alignment assembly 4 26 Service Manual 4069 5XX 7XX 5 Remove the left side frame mounting screws A A 102 A 102 A 102 Repair Information 4 27 4069 5XX 7XX 6 Place the printer on its back and remove the left side frame mounting screws A 7 Remove the left side frame A 104 4 28 Service Manual 4069 5XX 7XX Right Side Frame 1 Remove the right side cover 2 Remove the LVPS 3 Remove the multipurpose tray assembly 4 Disconnect the auto compensator arm bias spring from the right side frame 5 Remove the toner sensor mounting screw A disconnect the sensor cable and remove the toner sensor 6 Remove the right side frame mounting screws B and remove the right side frame 102 B 102 emm gt A 102 B 104 102 104 102 CAUTION Be sure the fuser assembly has cooled before working on any of the fuser FRUs Repair Information 4 29 4069 5XX 7XX Fuser 1 Remove the redrive assembly 2 Loosen the fuser mounting screws A and remove the fuser LEXMARK 4
77. never saw a signal from the duplexer on a page to be picked from the duplex option when the duplex option was waiting on a page to pass over the printer input sensor StapleSmart Finisher Option Sub Error Codes First 6 Bytes Sub Error Code Data Note Explanation xx can be any value 84 xx 07 The Sub Error code indicates that finisher option has detected a paper jam and homing was allowed before the stop Usually associated with 281 Paper Jams in the finisher 2 22 Service Manual 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note can be any value Explanation 8D xx 01 A timeout associated with the stapling operation timed out while waiting for the last page of a job to be safe in the stapler accumulator 98 xx 03 x1 Never saw operation complete on a staple job x2 x3 x12destination Diagnostic Information 2 23 4069 5XX 7XX User Status Screens User Status Screens Status Action Ready Ready lt Fax Status gt Ready Hex The printer is ready to receive and process data or The printer will display the FAX status 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 all the Menus except the TESTS MENU Busy State Press Menu gt or lt to take the printer out of Ready and enter the TESTS MENU Busy State
78. o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem n o ser sempre bvias A Lexmark n o respons vel pela utiliza o de outros componentes de substitui o e 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 Safety Information xxi 4069 5 XX 7XX 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 Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui Elrisc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte personal professional ha d estar ne assabentat i prendre les mesures convenients xxii Service Manual 4069 5XX 7XX A 0 e ASO et RA ABMS AS AA Sos 4 h MEE ASS T
79. 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 Note 722 72n If darker than normal print is noted especially when printing a lot of graphics check the printhead fan to see if it is operating correctly Diagnostic Information 2 109 4069 5XX 7XX 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 the
80. output stacker drive belt or the failing assembly 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 3 Mechanical Linkage Motor Assembly Upper or Lower 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 assembly DC Motor Assembly 2 98 Service Manual 4069 5XX 7XX 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 Check 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 5 V dc If incorrect check the voltage at J3 2 The voltage measures approximately 0 V de If incorrect replace the senso
81. 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 14 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 system board J16 and at the operator panel Check the continuity of the operator panel cable If incorrect replace the cable 2 Operator Panel Display Check the voltage at J16 on the blank 5 beeps LED Off system board It measures approximately 5 V If incorrect replace the system board If correct replace the operator panel assembly 3 Operator Panel Display Check for continuity between J16 4 blank 5 beeps LED On and ground If correct replace the operator panel assembly If incorrect replace the system board 4 Operator Panel All Replace system board Diamonds no beeps Diagnostic Information 2 87 4069 5XX 7XX FRU Action 5 Operator Panel all Check the voltage at Pin J16 1 and diamonds 5 Beeps J16 3 The voltage measures approximately 5 V dc If incorrect replace the FRUs i
82. pass thru sensor The following tray sensors are supported by this test cre at gt Tray 1 YES YES NO Tray 2 YES YES YES Tray 3 YES YES YES Tray 4 YES YES YES Tray 5 YES YES YES Multipurpose YES NO NO Tray Envelope Feeder YES NO YES Output Bin Feed to all Bins Test This test can be used to verify that the printer can feed media to the standard bin or any installed output options No information will be printed on the test pages as the printhead is not turned on during the feed test To run the Feed to all Bins Test 1 Select Feed to all Bins Test from the Menu 2 The media feeds from the default paper source 3 The printer feeds a separate piece of media to the standard bin first then it feeds a separate piece of media to each output bin installed in the following order First Sheet Standard Bin Second Sheet Bin 1 Third Sheet Bin 2 Fourth Sheet Bin 3 Fifth Sheet Bin 4 Sixth Sheet Bin 5 Seventh Sheet Bin 6 Eighth Sheet Bin 7 Ninth Sheet Bin 8 Tenth Sheet Bin 9 Eleventh Sheet Bin 10 3 20 Service Manual 4069 5XX 7XX Twelfth Sheet Bin 10 then the order reverses from Bin 9 to the Standard Bin 4 The test is continuous until either the Return or Stop button is pressed 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
83. 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 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 Laser Notices Xvi 4069 5XX 7XX Japanese Laser Notice L 3 icBiy 1071 9 15 5 21 1 07241 1 176 1 17 5 0 amp 82508677 5 ALOV V WMECHSSCEMMWANTIET 22X1I0v VY Wpiifsl amp tEdizvcxAxoncoxEv co 7Zyr sZ i72zHnb 30 OL P AARMELTOIEF CO LF 0 0 95 4 7 0 BH SL UDybhOAVUDAUMILWMERHITSL P CEHT Got LWATACTULS ii HE OH ARI FATOVANVELLOL ik Chinese Laser Notice FT ELE EI UGE A DHHS 21 CFR Subchapter I Xj 47 28 I 1 mE H db WOLZ 825 1 HE TXIA Bh 0 TIED OLA oy Hb 3b
84. 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 Fuser Top Cover Assembly Thermal Fuse Thermistor Assembly Disconnect the thermistor cable The resistance is HOT J2 1 J2 2 2 5K ohms COLD 150K ohms to 260K ohms 2 66 Service Manual 4069 5XX 7XX Hot Fuser Service Check Error codes 923 and 924 may display for a hot fuser failure CAUTION The fuser may be hot use caution before removing or servicing FRU Action 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 If the resistance is incorrect replace the fuser cover assembly 2 System Board Error code 924 indicates the system board detects an open circuit in the thermistor circuit for the fuser assembly The voltage on J14 6 on the system board measures approximately 5 V If incorrect replace the system board If correct check the continuity of the DC fuser cable in the fuser assembly and the DC fuser cable system board to auto docking connector attached to J14 on the system board If there is no continuity replace the cable 3 Fuser Hot Roll Examine the fuser assem
85. printer ground The resistance measures approximately 0 ohms If incorrect make sure the system board is mounted correctly and securely grounded If correct replace the system board 2 118 Service Manual 4069 5XX 7XX 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 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 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 transf
86. 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 5XX 7XX Paper Input Sensor 1 Remove 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 A 102 Pick Roll 1 Remove the upper paper deflector 2 Release the pick roll retaining tab and slide the pick roll off the shaft 4 54 Service Manual 4069 5XX 7XX Printhead 4069 520 52n 1 Remove the laser assembly cover 2 Disconnect the printhead cables A from the printhead 3 Remove the printhead mounting screws B 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 B 435 A A Repair Information 4 5
87. the FRU in the order shown interconnect board system 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 system board can pull the 5V dc supply down to approximately 0 V dc Check for burn marks or other signs of damage to the system board 2 52 Service Manual 4069 5XX 7XX 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 the stepper motor for a short between the motor case and pins J3 1 through J3 4 If no problem is found check the D C servo motor pins J1 1 and J1 2 to the motor housing for a short If a short is found replace the motor assembly If no short is found replace the system board 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 53 4069 5XX 7XX POST fails 230 Paper Jam Check Duplex me
88. the contact must be secure 2 48 Service Manual 4069 5XX 7XX 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 J3 at the system board and measure the voltage at J4 3 It measures approximately 5 V dc If the voltage is incorrect replace the system board If the voltage is correct check the voltage at J3 1 If the voltage measures greater than 1 0 V dc replace the system board If the voltage is correct check the continuity between J3 1 and J3 3 on the cable If no change in continuity occurs as the switch is activated replace the cover open switch cable assembly If the continuity changes as the switch is activated replace the system board Diagnostic Information 2 49 4069 5XX 7XX Dead Machine Service Check Note 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 Inp
89. 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 5XX 7XX The fuser lamp FRU is color coded The left and right fuser lamp bracket access holes 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 875W Gold 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 cable connectors Gently apply outward pressure on the left and right fuser side frames to release the lower exit guide assembly gU RIO Nr 4 36 Service Manual 4069 5XX 7XX 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 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 Warning Use care 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 t
90. to the Print Quality Toner on backside of printed page on page 2 120 Print quality Background Go to the Print Quality Background on page 2 114 Print quality Residual image Go to the Print Quality Residual Image on page 2 119 Print quality Skew Go to the Paper Feed Service Check on page 2 105 Print quality Banding Go to the Print Quality Banding on page 2 117 Print quality Random marks Go to the Print Quality Random Marks on page 2 112 Print quality Toner on backside Go to the Print Quality Toner on of printed page backside of printed page on page 2 120 Print quality Vertical black bands Go to the Print Quality Black on edge of copy bands on outer edges of the page on page 2 117 Unable to clear a Go to the Smart Cartridge 32 Unsupported Print Cartridge Contact Assembly Service Check User Error Message on page 2 121 Symptom Table High Capacity Feeder Option 2000 Sheet Symptom Action The printer does not recognize Go to the High Capacity Feeder the high capacity feeder option Input Tray Service Check on installed page 2 72 Paper feed problem with the high Go to the High Capacity Feeder capacity feeder option Input Tray Service Check on page 2 72 Diagnostic Information 2 43 4069 5 XX 7XX Symptom Table Paper Tray Options Action Symptom Paper feed problem
91. 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 59 4069 5XX 7XX 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 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 sur
92. when Tray X is full or has adequate paper in the tray FRU Action 1 Paper Low Switch Run the sensor diagnostics for tray X Paper Low Switch Cable X the number that represents the High Capacity Feeder Input high capacity input tray If the test System Board 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 Check the paper out sensor flag for correct operation and installation If 2 Paper Out Sensor correct replace the high capacity On Option System Board feeder system board The paper out sensor is mounted on the high capacity feeder system board Diagnostic Information 2 77 4069 5XX 7XX The elevator tray fails to stop at the correct position and continues to drive into the bottom frame FRU Action 1 Lower Limit Switch Lower Limit Switch Cable Check continuity of the lower limit switch If incorrect replace the switch If correct check the switch cable If incorrect replace the cable If correct replace the hig
93. with 250 Sheet Paper Tray Option Go to the Input Tray s Option Service Check on page 2 69 Paper feed problem with 500 Sheet Paper Tray Option Go to the Input Tray s Option Service Check on page 2 69 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 69 Symptom Table Duplex Option Symptom Action Paper feed problem with Duplex Option Go to the Duplex Option Service Check on page 2 53 Paper jams at Paper Removal Tray Go to the Duplex Option Service Check on page 2 53 Paper skews in the Duplex Option Go to the Duplex Option Service Check on page 2 53 Paper fails to pass from lower option thru the Duplex Option Go to the Duplex Option Service Check on page 2 53 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 56 Envelopes do not feed properly into base printer Go to the Envelope Feeder Option Service Check on page 2 56 2 44 Service Manual 4069 5XX 7XX 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 90
94. 0 52n Kit Upper Front Cover with Lables 722 72n fo po E NS Screw Laser Cover PP 99A0263 NS Screw Upper Front Cvr Mtg PP 99A0263 NS Screw Right Side Cvr Mtg PP 99A0263 Parts Catalog 7 3 4069 5 XX 7XX Assembly 1 Covers continued 7 4 Service Manual 4069 5XX 7XX Part Index Number 1 8 99A0007 1 9 99A1511 1 10 99A1502 1 11 99A0004 1 12 99A1501 1 13 99A2414 Units Description Label TLI ID Serial No Blank Cover Assembly Lower Front Latch Upper Cover Spring Latch Operator Panel Assembly Switch Cover Open w Operator Panel Cable Assembly 1 14 99A1510 1 15 99A1587 NS 99A0577 NS 99A1594 Cover Left Door Support Paper Cable Tie Retainer Cable Parts Catalog 7 5 4069 5XX 7XX Assembly 2 Frame 7 6 Service Manual 4069 5XX 7XX Part Index Number 2 1 99A1592 2 2 99A2441 2 3 99A2443 2 4 99A1580 2 5 99A1879 2 6 99A1516 2 7 99A0867 2 8 99A1832 2 9 99A1662 2 10 99A0113 2 11 99A1924 2 13 99A1519 2 14 99A0058 2 15 99A1588 2 16 99A1968 2 17 99A1535 2 18 99A2484 2 19 99A1518 2 20 99A0028 2 21 Units Description Shroud Fan 500 Fan Main Sensor Standard Bin Level Flag Output Paper Level Bracket Level Sensor Duct 500 Left Stacker Duct Main Body Guide Extension 500 Input Support Left Lower Stacker Pan Drip ITC Spring Cartridge Hold Down Extension 500 Input P
95. 0 Sheet Tray continued 7 58 Service Manual 4069 5XX 7XX Part Index Number 16 26 99A0282 16 27 99A1750 16 28 99A0276 16 29 16 30 99A0450 16 31 99A0451 16 32 99A0438 16 33 99A0275 16 34 16 35 16 36 99A0280 16 37 99A0446 16 38 99A0274 16 39 99A0063 16 40 99A0286 16 41 99A1664 16 42 99A0273 16 43 99A0279 16 44 99A0281 16 45 99A1702 16 46 9941645 5 9940452 NS 99A1665 NS 99A1667 NS 99A1928 Units Description Cable 500 Auto Connect Bottom Wear Plate Pass Thru Roll Assembly Drive 500 Screw Wear Plate Mounting PP 99A0263 Retainer Roller Roller Skewed Backup Bearing Drive Roll Spring Power Takeoff Screw Board Mounting PP 99A0263 Retainer Aligner Assembly PP 99A0267 Bearing Drive Shaft Low Aligner Assembly Paper Gear Feed Roll Spring Switch Activate Spring Backup Roller Bellcrank Roller Release Gear Bevel Bearing Drive Shaft Cable 500 Auto Connect Top Stud Assembly 500 Frame Arm Paper Out 500 Washer Frame Mounting Deflector Base 500 Bracket 500 Tray Retention Spring Bellcrank 500 Option Tray nun wap A a pp a a a Parts Catalog 7 59 4069 5 XX 7XX Assembly 17 Duplex 7 60 Service Manual 4069 5XX 7XX Asm Part index Number Units Description 17 1 99A1674 1 Cover System Board 17 2 99A1693 1 Main Frame Assembly 500 Duplex 17 3 99A0324 1 I
96. 00 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 paper feed drive system and verify that the power and velocity values are acceptable Diagnostic Aids 3 9 4069 5XX 7XX 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 is computed the motor turns off 3 10 Service Manual 4069 5XX 7XX The following appears on the printer display DUPLEX MOTOR AA BB CC DD EE FF To pass the test the following results must display 00 BB in the range of 20 thro
97. 0702 99A0703 99A0704 99A0705 99A0706 99A0707 99A0710 99A0711 99A0712 99A2509 Units n ln ln o n n n n ol ck Description Parts Packet Screws Parts Packet Contact Kit Parts Packet Retainers Parts Packet Springs Paper Feed Parts Packet Duplex Option Fan 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 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 Parts Packet Screws Stapler Option 7 112 Service Manual 4069 5XX 7XX Assembly 27 Miscellaneous continued Asm Index 27 27 27 27 27 27 27 Part Number 99A0208 99A0234 99A0394 99A0462 99A1854 99A1855 99A0240 Units Description Parts Packet Pulley Kiosk
98. 1 99A0232 99A0234 99A0240 99A0260 99A0263 PAL 7219 7 83 25 1 27 7 29 7 33 7 37 7 41 7 51 7 57 7 59 7 31 7 31 7 21 7 79 7 63 1529 7 89 791 7 41 7 89 7 91 7 113 7 79 7 89 7 39 7 89 7 91 7589 791 7 89 7 01 7 113 3 89 7 91 7 118 7 41 7 2 7 9 7 13 7 15 7 61 7 85 7 81 7 95 7 99 99A0312 7 15 7 31 7 69 7 85 Tliz 7 65 7 112 FAVS 7 83 7 95 7 83 7 99 7 85 7 83 7 89 7 63 7 85 7 29 7 52 7 59 7 85 7 81 7 59 7 89 751 7 85 7 53 7 85 7 53 7 59 7 63 7 85 7 53 7 59 7 63 7 85 7 83 7 59 7 85 7 lt 31 7 929 7 55 7 59 7 85 1 53 7 57 7 87 TA 7 57 1 29 7 64 7 112 7 65 7 65 7 63 7 63 7 61 99A0314 99A0315 99A0316 99A0317 99A0321 99A0323 99A0324 99A0325 99A0326 99A0328 99A0329 99A0330 99A0332 99A0334 99A0335 99A0337 99A0341 99A0346 99A0349 99A0350 99A0351 99A0361 99A0362 99A0363 99A0364 99A0368 99A0369 99A0371 99A0372 99A0382 99A0384 99A0385 99A0388 99A0389 99A0390 99A0392 99A0393 99A0394 99A0400 99A0404 99A0405 99A0408 99A0409 99A0410 99A0413 99A0414 99A0415 7 61 7 63 7 63 7 63 7 61 7 61 7 61 7 63 7 61 7 61 7 61 7 65 7 65 7 65 7 65 7 65 7 63 7 39 7 31 2 01 7 7 7 69 7 97 7 69 7 97 1 69 7 97 7 105 7 69 7 87 7 107 7 69 7 97 7 09 7 97 7 107 1 67 7 95 7 69 7 67 7 71 7 73 7 3 7 71 7 71 7 71 TIT 4 71 7113 7 71 TOL 7 13 lle 7 57
99. 1 23 99A1659 2 Bellcrank Backup Roll 520 52n 11 23 99A1600 2 Bellcrank Backup Roll 722 72n 11 24 99A1591 1 Guide Fuser Entry 11 25 2 Retainer Backup Roll Bellcrank PP 99A0267 11 26 99A0410 2 Spring Backup Roll Bellcrank 11 27 99A2466 1 Fuser Cable DC Fuser Internal 11 28 99A0157 1 Gear Hot Roll 11 29 9940148 1 Gear Idler 11 30 99A0297 1 Link Solenoid 11 31 99A2478 1 Sensor Narrow Media 11 32 99A2479 1 Sensor Exit 11 33 99A0897 2 Spring Redrive Idler 11 34 99A0167 4 Roller Redrive Idler 11 35 99A2467 1 Guide Assembly Lower Exit 11 36 99 1547 1 Lamp 115V 875W Gold 11 36 99A1548 1 Lamp 220V 875W CC Silver NS 99A1658 1 Cover Fuser Wiper Cavity NS 7 Screw Hanger PP 99A0263 NS 99A0196 1 Clamp DC Fuser Cable Parts Catalog 7 29 4069 5 XX 7XX Assembly 12 Transfer FK SS 4 7 30 Service Manual 4069 5XX 7XX dac pos Units Description 12 1 99A1015 1 Transfer Roll Assembly 12 2 99A0349 1 Arm Transfer Roll Assembly Right 12 3 99A0184 1 Spring Transfer Roll Right 12 4 99A0185 1 Shaft Transfer Pivot 12 5 99A0181 1 Spring Transfer Roll Left 12 6 99A1578 1 Arm Transfer Roll Left NS 1 Retainer Pivot Shaft PP 99A0267 Parts Catalog 7 31 4069 5 XX 7XX Assembly 13 Charging 7 32 Service Manual 4069 5XX 7XX da EUR Units Description 13 1 99A0512 1 Link Assembly Charge Left Kit 13 2 99A0513 1 Link
100. 1 Fuser Solenoid 42 V dc Ground J2 LVPS 42 V dc Heaton Xeroxing 24 V dc 24 V dc 24 V dc Ground Ground Qoo di oO ay AJ OJN Ground Ground J3 LVPS Ground Ground Ground Ground 45 V dc 45 V dc 45 V dc oi a AJ wy 5 Vdc J4 Autoconnect Top 24 V dc Ground 5 V dc Fused oO Ground 5 4 Service Manual 4069 5XX 7XX Connector Pin No Signal J5 Autoconnect 1 24 V dc BTM FNT 2 Ground J7 system board 1 N A J11 INA 1 1 N A J12 INA 2 1 N A Jumper Connector Position Signal 48 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 bottom 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 bottom pin of J10 Note A 902 service error may display if the jumpers are not correctly installed Connector Locations 5 5 4069 5XX 7XX Jumper locations for J8 J9 and J10 Models Requirement 520 52n No jumpers required 722 72n A jumper on J8 between the center pin of J8 and pin 1 of J8 A jumper is required between the center pin of J9 and pin 4 of J9 A jumper is required between the center pin of J10 and p
101. 1 Paper Jam displays Check the voltages at on the system board Pin number and voltage J27 1 24 V dc J27 4 5 V dc static 0 V dc when main drive motor running J27 5 5 V static 0 V dc when main drive motor running J27 6 5 V static 2 5 V dc when main drive motor running J27 7 5 V dc static 0 V dc when main drive motor running J27 8 5 V dc static 5 V dc when main drive motor running J27 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 system board Operator Panel Service Check Operator Panel Buttons Service Check Note Before continuing with this service check do the Button Test on page 3 14 in the diagnostic aids chapter FRU Action 1 Operator Panel Assembly If any button fails the Button Test replace the operator panel assembly 2 86 Service Manual 4069 5XX 7XX FRU Action 2 System Board Check the voltage at J16 2 The No buttons work voltage measures approximately 5 V dc If incorrect replace the System 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 system board operator
102. 5 4069 5XX 7XX Printhead 4069 722 72n 1 Remove the laser assembly cover 2 Disconnect the printhead cables A from the printhead assembly and remove the printhead 3 Disconnect the printhead fan cable from the system board 4 Remove the printhead mounting screws B Do the Printhead Assembly Adjustment on page 4 4 whenever you remove or replace the printhead assembly or loosen the mounting screws B 435 4 56 Service Manual 4069 5XX 7XX 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 B and remove the redrive assembly Latch B Latch B Repair Information 4 57 4069 5XX 7XX Smart Cartridge Contact Assembly Disconnect smart cartridge cable Remove print cartridge Remove transfer plate Unlatch smart cartridge contact assembly A from the right frame assembly 5 Remove smart cartridge contact B S 4 58 4069 5XX 7XX 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 5XX 7XX 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
103. 5XX 7XX High Capacity Output Stacker Board Connector Pin No Signal J1A Autoconnect 1 24 V dc Ground m 45 V dc J1B Prtxdin Ground prtrxd Ground OI wo J2A Autoconnect 24 V dc Ground m 45 V dc J2B k 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 14 Service Manual 4069 5XX 7XX 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 15 4069 5XX 7XX System Board Connector Locations 30 PPM Network J11 1004 99 en 89 99 89 88 99 85 88 JH1 9o 99 89 99 85 99 88 89 88 89 J36 i J34
104. 7 7 111 7 41 7 41 7 39 7 47 7 99 7 13 Tar 71412 7 57 7 53 7 59 7 89 7 91 7 111 7 27 45111 7 09 7 29 TF 7 59 7 59 7 53 7 57 1 89 7 67 7 11 7 87 7 93 7 99 7 103 99 1667 9941669 99 1672 7 58 7 63 7 65 Index 7 4069 LXT 99A1673 7 61 99A1674 7 61 99A1675 7 61 99A1676 7 65 99A1677 7 63 99A1679 7 65 99A1680 7 61 99A1682 7 63 99A1683 7 111 99A1684 7 111 99A1685 7 111 99A1686 7 111 99A1687 7 99 99A1688 7 67 7 95 99A1689 7 67 7 95 99A1690 7 95 99A1691 7 65 99A1692 7 65 99A1693 7 61 99A1694 7 71 99A1695 7 65 99A1696 7 71 99A1697 7 71 99A1698 7 73 99A1699 7 73 99A1700 7 71 99A1701 7 93 99A1702 7 59 99A1704 7 89 7 91 99A1705 7 88 7 91 99A1706 7 89 99A1707 7 91 99A1708 7 99 99A1709 7 99 99A1710 7 99 99A1711 7 99 99A1712 7 99 99A1713 7 99 99A1714 7 99 99A1715 7 101 99A1716 7 99 99A1717 7 101 7 107 99A1718 7 99 99A1719 7 99 99A1720 7 101 99A1721 7 101 99A1722 7 101 1 8 Service Manual 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 99A1777 99A1778 99A1779 99A1780 99A1781 99A1782 99A1783 99A1784 99A1785 1 99 7 99 7 99 7599 7 101 7 101 7 101 7 101 7 101 7 101
105. 8 2 Screw Lower Deflector Mounting 8 mm PP 99A0263 5 8 2 Screw Lower Deflector Mounting 12 mm PP 99A0263 5 9 99A0084 5 10 99A0082 5 11 99A2440 5 12 99A0073 Flag MPT Paper Out Plate Assembly MPT Sensor MPT Paper Out Screw Damper a 5 13 Screw Frame Mounting PP 99A0263 5 14 99A2438 1 Solenoid MPT 5 15 99A0074 2 Bushing Pick Roll Shaft NS 2 Clip Pick Roll Shaft PP 99A0267 Parts Catalog 7 15 4069 5XX 7XX Assembly 6 Paper Feed Alignment 7 16 Service Manua 4069 5XX 7XX Asm Part Index 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 Reference Adjustment 6 7 99A0559 1 Lever Bellcrank Release NS 2 Screw Alignment Asm Mtg PP 99A0263 Parts Catalog 7 17 4069 5 XX 7XX Assembly 7 Paper Feed Output S Ka 7 18 Service Manual 4069 5XX 7XX a E Units Description 7 1 99A1533 1 Redrive Assembly Inner 500 7 2 99A1534 1 Door Assembly Redrive 500 NS 99A0104 1 Spring Upper Diverter NS 99A1857 1 Deflector Upper Redrive NS 2 Screw SEMS Duplex Path PP 99A0263 Parts Catalog 7 19 4069 5 XX 7XX Assembly 8 Integrated Paper Tray 500 Sheet 7
106. 87 2 13 7 81 7 81 fags Tala 7 87 7 81 7 75 7 112 TUS 7 112 7 112 T9112 T5112 K 7 81 PD 7 87 7 79 7 87 2 21 7 7 1 55 7 29 49 4069 5XX 7XX 99A0906 99A0907 99A0912 99A0913 99A0914 99A0915 99A0923 99A0954 99A1015 99A1017 99A1054 99A1055 99A1059 99A1129 99A1134 99A1164 99A1280 99A1501 99A1502 99A1504 99A1505 99A1507 99A1508 99A1510 99A1511 99A1512 99A1516 99A1517 99A1518 99A1519 99A1520 99A1522 99A1524 99A1525 99A1531 99A1533 99A1534 99A1535 99A1536 99A1537 99A1538 99A1540 99A1541 99A1544 99A1546 99A1547 99A1548 7 91 7 91 7 69 7 69 7 97 2 107 7 7 95 7 67 7 110 7 23 7 31 7 33 7 51 7 87 7 65 7 63 7 61 7 65 7 65 7 5 7 45 255 7 3 7 3 7 3 7 3 759 7 9 7 2 7599 IT is 7 7 7 7 7 27 7 9 7 9 7 9 7 15 7 19 1 19 7 7 1599 1521 795 7 97 759 7 9 ig 7 29 7 9 7 29 T29 99A1549 99A1554 99A1555 99A1569 99A1575 99A1576 99A1578 99A1579 99A1580 99a1580 99A1582 99A1583 99A1587 99A1588 99A1591 99A1592 99A1594 99A1596 99A1598 99A1600 99A1601 99A1602 99A1605 99A1610 99A1611 99A1612 99A1613 99A1616 99A1621 99A1633 99A1636 99A1638 99A1645 99A1646 99A1647 99A1649 99A1654 99A1658 99A1659 99A1662 99A1664 99A1665 99A1666 1 27 7 29 7 47 7 33 7 03 7 47 7581 7 57 7 31 7 61 7 67 4 57 Tel 7 07 7 8 qu 7 29 2 7 7 8 7 9 4527 7 29 7 21 155 197 7 81 7 0
107. 99 0481 18 18 18 19 9940409 18 20 9941580 18 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 Parts Catalog 7 67 4069 5 XX 7XX Assembly 18 Output Expander continued 7 68 Service Manual 4069 5XX 7XX Asm Part m Index Number Units Description pos ica Door Assembly Rear Access 18 23 99A0368 Shaft Assembly Lower Also order PP 99A0572 Pulley Drive Cover Right Side Belt 160 Gear Arm Assembly Belt Idler 18 24 99A0363 18 25 99A0371 18 26 99A0361 18 27 99A0362 18 28 99A0364 18 29 99A0351 18 30 99A0913 Spring Belt Tensioner Sensor Output Expander Pass Thru Shaft Assembly Middle 40T Also order PP 99A0572 18 31 99A0912 1 Frame Assembly a ooo o Parts Catalog 7 69 4069 5XX 7XX Assembly 19 Envelope Feeder 7 70 Service Manual 4069 5XX 7XX Asm Part Index Number Units Description 19 1 99A0389 Paper Weight Assembly 19 2 99A1694 Guide Edge 19 3 99A1696 Cover Top 19 4 99A0485 19 5 99A0393 19 6 99A1697 19 7 99A0390 19 8 99A0488 19 9 99A0382 19 10 99A1666 19 11 99A0388 19 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 St
108. A2466 99A2467 TF 7 110 Tar 4527 Tar 7507 7 5 7 45 7 3 7 3 7 9 7 9 7 8 7 37 1537 7 41 7 41 7 3 7 9 7515 7 15 7 45 7 15 7 15 7 45 7 7 7 43 7 11 7 45 7 49 7 7 7 43 7 13 7 8 7 03 7 43 7 03 7 43 7 11 7 47 7 11 7 47 7 37 7 37 7 37 7 37 7 37 7 43 7 45 7 47 7 43 7 43 7 47 7 43 7 47 7 27 7 47 7 29 7 47 7 29 Index 1 9 4069 LXT 99A2468 7 27 7 47 99A2469 7 27 99A2470 7 27 99A2471 7 3 7 45 99A2472 7 27 99A2474 7 9 99A2477 7 47 99A2478 7 29 7 47 99A2479 7 29 7 47 99A2480 7 109 99A2482 7 3 99A2484 7 7 99A2485 7 111 99A2486 7 110 99A2487 7 110 99A2488 7 110 99A2489 7 111 99A2490 7 37 99A2491 7 37 99A2492 7 37 99A2500 7 103 99A2501 7 103 99A2502 7 103 99A2503 7 103 99A2504 7 109 99A2505 7 103 99A2506 7 103 99A2507 7 103 99A2508 7 103 99A2509 7 103 7 112 99A2510 7 103 99A2511 7 103 99A2512 7 103 99A2513 7 107 99A2515 7 107 99A2516 7 107 99A2517 7 107 99A2518 7 107 99A2519 7 103 99A2520 7 103 99A2521 7 103 99A2523 7 105 99A2524 7 109 99A2525 7 109 99A2526 7 105 99A2527 7 107 99A2528 7 105 1 10 Service Manual 99A2529 99A2530 99A2531 99A2532 99A2533 99A2534 99A2537 99A2538 99A2539 99A2540 99A2541 99A2542 99A2543 99A2544 99A2545 99A2546 99A2547 99A2548 99A2549 99A2551 99A2552 99A2556 99A2557 99A2558 99A2559 99A2560 99A2575
109. Assembly Remove the left and right side covers 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 11 If the voltages are correct reinstall the output option noting the position of the toroid on the autoconnect cable of the lower autoconnect Check the voltages on each of the autoconnects If the toroid 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 2 100 Service Manual 4069 5XX 7XX 271 Paper Jam Check Bin 1 displays FRU Action 1 Bottom 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 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 5 V If incorrect check the voltage at J5 2 The voltage measures approximately 0 V dc If incorrect replace the sensor assembly If this does not fix the problem replace the control board 274 Paper Jam Check B
110. Board Check to make sure the printhead fan cable is seated on connector J4 on the system board If correct check for 24 V dc on J4 1 on the system board If incorrect replace the system board If correct replace the fan assembly Note When the printer is in warm up the voltage at J4 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 J5 on the system 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 system board J5 for correct installation Diagnostic Information 2 63 4069 5XX 7XX FRU Action 2 Main Fan to System Board Cable 3 Error Code 927 Fan runs Check the continuity of the cable If incorrect replace the cable Check the voltage at J5 1 on the system 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 system board 4 Error Code 927 Fan not running Check the voltage at J5 3 on the system board The voltages are 22 V dc to 24 V dc printer and fan running 12 V dc to 15 V dc printer not running fan ru
111. D C5 Env E B5 Env F Legal Env First 6 Bytes Sub Error Code Data Note can be any value Explanation 84 xx 00 x1 This code indicates that the input sensor in the printer is still x2 actuated from the first sheet and the second sheet is ready to arrive at the sensor x1 media size x2 media source Check the printer input sensor and flag for correct operation The flag should operate freely Check for any signs of debris in the area of the input sensor Check the area of the transfer plate and input to the fuser for anything that might cause the paper to remain over the input sensor 84 xx 01 x1 Video never started on the page x 1 media size The video signal never started within 2 inches after actuating the input sensor Check input sensor and flag 2 10 Service Manual 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 84 xx 02 x1 This error is the most common type of paper jam Possible causes are x12media size Multi sheet feeding A tray size sensing problem media feeding from the paper source is slipping or media is slipping in input to the printer 84 xx 04 The input sensor was covered during POST by a piece of media still in the machine when it was turned on Clear the media from the printer Run the base sensor test input sensor from the diagnostic tests menu to test the input sensor and
112. D 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 system 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 Diagnostic Aids 3 31 4069 5XX 7XX 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 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 validate the Configuration ID If the ID is invalid then INVALID ID message displays on Line 2 before the ID redisplays Reenter the Configuration ID until a valid ID is verified If the ID is valid 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
113. Diagnostic Information 2 113 4069 5 XX 7XX FRU Action 7 Lines spaced 49 74 mm Replace the FRUs in the following 1 958 inch apart order redrive assembly fuser assembly 8 Lines spaced 51 02 mm Replace the transfer roll 2 009 inch apart 9 Lines spaced 52 23 mm Replace the redrive assembly 2 056 inch apart 10 Lines spaced 76 53 mm Replace the FRUs in the following 3 013 inch apart order alignment assembly main drive gearbox assembly 11 Lines spaced 95 66 mm Replace the FRUs in the following 3 766 inch apart order toner cartridge main drive gearbox assembly 12 Lines spaced 99 49 mm Replace the redrive assembly 3 917 inch apart 13 Lines spaced 114 79 mm Replace the alignment assembly 4 519 inch apart Print Quality Background 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 slick 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 2 114 Service Manual 4069 5XX 7XX FRU Action 1 Printhead The printhead on the Lexmark T printers cannot be cleaned Try another printhead if all other attempts fail to correct a background proble
114. EP Autoconnect to System Board EP Autoconnect System Board 10P 10 fi Y Ly Autoconnect Cable System Board to Top Interconnect Board Inter connect Board J W 8P E 5P y L E A 0000 Panel Receptacle System Board 5 34 Service Manual 4069 5XX 7XX Autoconnect Cable System Board to Front Bottom Interconnect Board Inter connect Board Auto connect Bottom Plug um 2 D c System Board Ld 6P Auto connect Front Receptacle 6P Connector Locations 5 35 4069 5XX 7XX 5 36 Service Manual 4069 5XX 7XX 6 Preventive Maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems 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 the power supply Damaged missing or altered covers especially in the area of t
115. Explanation xx can be any value x1 0B The DC auto compensator failed or stalled when trying to feed a sheet of media 8b xx 11 It took too long for the DC auto compensator motor to come up to speed xx 13 x1 Late feeding from a paper source interfered with the next pick x2 retry x 1 Media Size x 2 Media Source Base Printer Fuser Sub Error Codes The following Sub Error Codes could be a help in diagnosing Fuser Assembly failures First 6 Bytes Sub Error Code Data Note Explanation xx can be any value 920 Service Fuser Error Under temperature while printing EN 08 xx xx Actual Fuser Temperature 1 yy The temperature that the fuser wants to reach EN zz 2 When zz 00 The Hot Roll took too long to heat up zz 01 The Hot Roll fell too far below the desired temperature while printing Zz 02 The Hot Roll was too cool while the system was doing some checking zz 03 The Hot Roll was too cool when heating to the desired temperature 921 Service Fuser Error Fuser under temperature while at standby Diagnostic Information 2 17 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note Explanation xx can be any value EN 41 xx yy xx Actual Fuser Temperature 1 yy The temperature that the fuser wants to reach EN zz 22 00 The fuser temperature did not change enough from the 2 fuser lamp temperature at turn on 01 The fuser tempera
116. IIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Laser Notices xii 4069 5XX 7XX Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los dem s pa ses reune todas las condiciones expuestas en la norma IEC 60825 para productos l ser de Clase I 1 Los productos l ser de Clase no se consideran peligrosos La impresora contiene en su interior un l ser de Clase 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n dise ados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcapitulo J p
117. Operator Panel 4 48 Operator Panel Cable Cover Open Switch Assembly 4 49 Optional 250 500 Paper Tray Assembly 4 50 Paper Alignment 4 51 Paper 0 2 4 4 4 42 4 aw eae 4 53 Paper Input Sensor EELER 4 54 Paper Size Sensing Board il RR nnn 4 54 Pick Holl cuit oe bliss RR Sine hes ERE RE Rue 4 54 Printhead 4069 520 52n 4 55 Printhead 4069 722 72n 4 56 Redrve 2244 4 nan 4 57 Smart Cartridge Contact Assembly 4 58 Toner Senso deed sea cR d 4 59 Transfer Roll Assembly 1 222222 2252 arma 4 60 Upper Paper Deflector Assembly 4 60 Upper Front Cover Hinge 4 61 Upper Front Cover Interlock Switch Assembly 4 62 2 2 22 2 4 5 1 Low Voltage Power 5 1 High Voltage Power Supply 5 8 Morcone BOSE aas ae rr edP P dear 5 4 Envelops Option Boald esum m E EET EE ETE 5 7 Duplex Option Board 5 9 vi Service Manual 4069 5XX 7XX Autoconnect aassiasskkcesacc kam crea naw Output Expander Control Board High Capacity Output Stacker Board
118. Option 25 48 99A2547 1 Pulley Belt Idler 25 49 99A2552 1 Bushing Tensioner CBM 25 50 99A2531 1 Switch Assembly Top Cover Open 25 51 99A2537 1 System Card Assembly Stapler Option Parts Catalog 7 107 4069 5 XX 7XX Assembly 25 StapleSmart Finisher continued 7 108 Service Manual 4069 5XX 7XX ae om Units Description 25 55 99A2559 1 Paper Alignment Wheel 25 56 99A2560 1 Gearbox Drive Assembly Paper Aligner NS 99A2480 1 Kit Maintenance StapleSmart Wheels NS 99A2525 1 Sensor Stapler Pass Thru NS 99A2530 1 Cable Assembly Right Stapler Bin Level NS 99A2534 2 Ground Cable Stapler Tray Bar NS 99A2524 1 Cable Stapler NS 99A2532 1 Cable Ground NS 99A2504 1 Cable Assembly Left Stapler Bin Level NS 99A2546 1 Label Pinch Point NS 99A0548 1 Tie Cable Parts Catalog 7 109 4069 5XX 7XX 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 Part Number 99A1752 99A1753 99A1754 99A1755 99A1756 99A1773 99A1757 99A1758 99A1759 99A1774 99A2486 99A2487 99A2200 99A2488 99A0629 13A0296 13A0297 99A0545 13A0298 99A0923 99A2558 Units et sech esch sek mer me Cm sch sch sek seh ca sch zeck 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
119. Parts Packet Screws Kiosk Grease Packet Nyogel 744 Grease Packet IBM 23 Packaging 4069 500 500 printer Packaging 4069 500 500 plus 500 Optional Tray Parts Packet Retainer Parts Catalog 7 113 4069 5XX 7XX 7 114 Service Manual 4069 5XX 7XX Index A Acronyms 1 4 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 11 B Base Sensor Test 3 26 Button Test 3 14 C Connector Locations Autoconnect 5 11 Duplex Option Board 5 9 Envelope Option Board 5 7 High Voltage Power Supply 5 3 High Capacity Output Stacker Board 5 14 Interconnect Board 5 4 LVPS 5 1 Output Expander Control Board 5 12 D Diagnostic Aids Device Tests 3 6 Disk Test Clean 3 6 Flash Test 3 7 Quick Disk Test 3 6 Diagnostic Mode 3 6 Duplex Tests 3 8 Duplex Feed 1 Test 3 12 Duplex Feed 2 Test 3 12 Duplex Motor Test 3 9 Duplex Quick Test 3 8 Duplex Sensor Test 3 9 Error Log 3 13 Clearing the Error Log 3 13 Viewing the Error Log 3 13 Hardware Tests 3 14 Button Test 3 14 LCD Test 3 14 Parallel Wrap Test 3 16 ROM Memory Test 3 15 SDRAM Memory Test 3 15 Serial Wrap Test 3 17 Input Tray Tests 3 19 Input Tray Feed Test 3 19 Paper Feed Tests Base Sensor Test 3 26 Input Tray Sensor Test 3 19 Output Bin Feed Test 3 21 Output Bin Sensor Test 3 21 Print Registration 3 28 Print Tests 3 33 Printer Setup 3 30
120. Read Only Memory Synchronous Dual Random Access Memory Static Random Access Memory Used Parts Return Volts alternating current Volts direct current 1 4 Service Manual 4069 5XX 7XX 2 Diagnostic Information Start CAUTION Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer Use the handholds on the side of the printer Make sure your fingers are not under the printer when you lift or set the printer down Use the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer Service error codes are indicated by a three digit error code If a service error code is displayed go to the Service Error Codes on page 2 2 User status messages provide the user with information on the current status of the printer Ready is displayed on the first line of the display unless Power Saver is invoked and then Power Saver is displayed If a user status message is displayed go to the User Status Screens on page 2 24 User error messages are indicated by a two or three digit error code that provides the user with information that explains a problem with a print cartridge paper jam option port and so on If a user error message is displayed go to t
121. SER PRODUCT LASER KLASSE 1 LOUKAN 1 LASERLAITE APPAREIL A LASER DE CLASSE 1 TO IEC 60825 4069 5XX 7XX Laser Notice The printer is certified in the U S to 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 L ndern 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 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
122. Stapler Board Pin Voltage Voltage No Static Feeding Motor not Motor Running Running 1 24 V dc 24 V dc 2 24 V dc Should vary when motor running 3 Not Used 4 Ground 5 5 V dc Should vary when motor running 6 5 V dc 5 V dc If the voltages are correct replace the gearbox drive assembly If the voltages are incorrect replace the stapler board 2 136 Service Manual 4069 5XX 7XX Misalignment of sheets to be stapled FRU Action 1 Left Side Bail Assembly Check the left side bail assembly for any signs of binding missing or broken parts 2 Stapler Gearbox Assembly Check the stapler gearbox assembly for correct operation Sheets are transported into output tray but not stapled FRU Action 1 Sol 1 Stapler Drive Stapler Assembly Stapler Card Assembly Disconnect Sol 1 cable from J5 on the stapler card and measure the resistance of the solenoid across the cable connector It should measure approximately 48 ohms when cold If incorrect replace the Stapler Gearbox assembly If correct replace the stapler card assembly Stapled Sheets are not transported to the output tray FRU Action 1 Sol 2 Stapler Gearbox Assembly Stapler Card Assembly Disconnect Sol 2 cable from J8 on the stapler card and measure the resistance of the solenoid across the cable connector It should measu
123. Upper Stacker Asm 23 28 99A0414 1 Sensor Asm Bin Full Dual Upper Stacker Asm 23 NS 99A1690 1 Belt 95G Lower Stacker Asm Parts Catalog 7 95 4069 5 XX 7XX Assembly 23 High Capacity Output Stacker cont d 7 96 Service Manual 4069 5XX 7XX Asm Part Index Number Units Description 23 29 99A0913 2 Shaft 40T Middle Output Stacker 23 30 99A0368 2 Shaft Asm Lower 23 31 99A0363 6 Pulley Drive 23 32 99A0361 1 Belt 160G Upper Stacker Asm 23 33 99A0362 1 Arm Asm Belt Idler 23 34 99A0364 2 Spring Belt Tensioner 23 35 99A1791 1 Stacker Asm Paper Path Lower 23 35 99A1792 1 Stacker Asm Paper Path Upper 23 36 99A0351 2 Sensor Stacker Pass thru 23 NS 99A1751 1 Switch Asm 23 NS 99A0462 1 Packet Grease IBM 23 23 NS 99A0627 1 Jumper 2 pin Use with 99A1749 Parts Catalog 7 97 Assembly 24 5 Bin Mailbox 4069 5XX 7XX S gt 7 98 Service Manual 4069 5XX 7XX Asm Part Index Number 24 1 99A1512 24 2 99A1710 24 3 99A1711 24 4 99A1785 24 5 99A0104 24 6 99A1714 24 7 99A1723 24 8 99A1724 24 9 99A1708 24 10 99A1725 24 11 99A1742 24 12 99A1712 24 13 99A1739 24 14 99A1743 24 15 9941666 24 16 24 17 99 1713 24 18 99 1687 24 19 9941735 24 20 99 1737 24 21 99A1736 24 22 99A1718 24 23 99A1716 24 24 99A1740 24 25 99 1726 24 26 99A1786 24 27 99 1719 24 28 24 29 99 1709 Units Description
124. XX 7XX FRU Action Stapler Board Stapler Assembly Check the voltages on connector J3 on the board Note All voltages are approximate values Pin Voltage Voltage No Static Feeding 1 24 V dc 24 V dc 2 24 V dc 24 V dc 3 24 V dc 24 V dc 4 24 V dc 24 V dc 5 0V dc 0 V dc 6 0V dc 0 V dc 7 0 V dc Varies 0 V 1 5 V dc 8 GND 9 5V dc 5V dc 10 OV dc OV dc If the voltages are correct replace the stapler assembly If the voltages are incorrect replace the stapler board 2 134 Service Manual 4069 5XX 7XX 283 Staple Jam Check Stapler displayed FRU Action 1 Staple Cartridge Holder Check the staple cartridge holder for any signs of damage and for any jammed staples in the cartridge Replace the staple cartridge holder if damaged If staples are jammed in the cartridge replace the old strip of staples with a new strip and try the finisher feed test from the diagnostic menu 2 Staple Unit Remove the staple cartridge holder from the staple unit and remove the staple unit Check for any staples that might be in the staple unit mechanism Check for correct operation and for any signs of damage Paper feeds into finisher option output tray Paper is not stapled Paper does not align with the right side FRU Action 1 Paper Alignment Wheel if installed Paper Alignment Pad
125. acket 250 Frame Retention 15 18 4 Washer Bracket 250 Frame Retention Mounting PP 99A0677 15 19 4 Screw Bracket 250 Frame Retention Mounting PP 99A0263 Parts Catalog 7 51 4069 5XX 7XX Assembly 15 250 Sheet Tray continued 7 52 Service Manual 4069 5XX 7XX Asm Part Index Number 15 20 99A0070 15 21 99A1638 15 22 99A0026 15 23 99A0419 15 24 99A0058 15 25 99A0288 15 26 99A1666 15 27 99A0272 15 28 99A0275 15 29 99A0280 15 30 99A0274 15 31 99A0273 15 32 99A0279 15 33 99A0281 Units Description Roll Assembly Pick 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 Bushing Drive Shaft Low Gear Feed Roll Gear Bevel Bearing Drive Shaft Cable 250 Auto Connect Option a sch RI ear a a ech ol c c qvo ol NM NS 99A0438 Bushing Drive Roll NS 99A0278 Bellcrank Roller Release NS 99A1929 Spring Bellcrank 250 Tray Option Parts Catalog 7 53 4069 5XX 7XX Assembly 15 250 Sheet Tray continued 7 54 Service Manual 4069 5XX 7XX Asm Part Index Number 15 34 99A1601 15 35 99A0120 15 36 99A1536 15 37 99A1894 15 38 99A0119 15 43 99A1952 15 39 99A1829 15 40 99A0121 15 41 99A0126 15 42 99A0124 15 44 99A1537 15 45 99A0893 Restraint Back 250 Sheet Tray 15 46 99A0127 Slider Autosize 250 NS 99A0286 Spring Backup Rolle
126. ad Machine Mounting Transfer Plate Assembly Support Right Stacker Plate Right Sideframe Fan Cartridge 722 72n Frame Extension Right 500 Internal Spring Tray Bias Contact Kit PP 99A0585 Contact Doctor Blade TAR Developer Roll Contact PC Drum o Contact Charge Roll o Block Contact Mounting op wo h hb oa on on on on P A Mi A ow on on on on on i a Screw Contact Mounting Parts Catalog 7 7 4069 5XX 7XX Assembly 2 Frame continued 7 8 Service Manual 4069 5XX 7XX Part Index Number 2 22 99A0466 2 23 99A0039 2 24 99A0026 2 25 99A1522 2 26 99A1525 2 27 99A1888 Units Description Sensor Toner Cartridge Level Roller Developer Support Tray Bias Arm Assembly Pan Center Assembly Deflector Upper PF ao 2 oW oa Kit Inner Deflector o Inner Deflector Side Restraint Frame EP Module Sensor Input 2 28 99A2418 2 29 99A0053 2 30 99A1517 2 81 99A0549 2 32 99A0063 2 33 99A2417 2 34 99A0128 2 35 99A2445 2 36 99A0899 2 37 99A0567 2 38 99A0556 NS NS 99A1524 NS 99A1546 NS 99A1596 NS 99A1538 NS 99A1540 NS 99A1541 NS 99A2419 NS 99A2474 NS 99A2435 Frame Extension Left 500 Internal Shield ESD Assembly with label Spring Switch Activate Left Side Frame Assembly Board Input Tray ITC Guard Gear Pan Motor Drip Link Gear Release Spring Counterbalance Screw PP 99A0263 Spring Cartridge Load Shield Gear C
127. after the jam will not be stapled 2 30 Service Manual 4069 5XX 7XX User Message Primary User Message Secondary Explanation 260 Paper Jam Check Envelope Feeder Leave Job in Finisher Primary Paper is jammed in the envelope feeder Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 27X Paper Jam Check Output Bin X Leave Job in Finisher Primary Paper is jammed in output bin X X 1 thru 3 Open the rear door of Output Bin X to access the jammed pages Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 280 Paper Jam Check Finisher Leave Job in Finisher Primary Paper is jammed in the finisher option Open the finisher option side door or top cover to access the jammed pages Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the protion of the job printed after the jam will not be st
128. all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the printer does not reprint these sheets Error Message 282 Check Stapler This message indicates that a staple jam has been detected during normal operation when printing and stapling jobs The printer alternately flashes the primary and secondary message to indicate that all accumulated sheets should be removed during the jam clearance procedure Error Message 283 Check Stapler This message indicates that a staple jam has been detected during a stapler priming operation There is no secondary message displayed Note After the error has been cleared the printer does not reprint any pages which existed in the accumulator for stapling Note Use of the Sub Error chart should be used to help diagnose problems when 281 282 and 283 are displayed Diagnostic Aids 3 43 4069 5 XX 7XX 201 Paper Jam 200 Paper Jam 27x Paper Jam 28x Paper Jam occurs in the 260 Paper Jam finisher option only 250 Paper Jam m 202 230 24 230 3 44 Service Manual 4069 5XX 7XX 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 sens
129. apled 281 Paper Jam Check Finisher Remove Job From Finisher Primary Paper is jammed in the finisher option Open the finisher option side door or top cover to access the jammed pages Secondary When this message is displayed remove the job from the finisher The printer will not reprint the removed sheets Diagnostic Information 2 31 4069 5 XX 7XX User Message Explanation Secondary User Message Primary 282 Staple Jam Remove Job Primary A staple jam has been Check Stapler from Finisher detected during normal stapler operation Secondary The printer flashes the secondary message to indicate that all accumulated sheets should be removed during the jam clearance 283 Staple Jam Remove Job Primary A staple jam has been Check Stapler from Finisher detected during the priming operation Secondary The printer flashes the secondary message to indicate that all accumulated sheets should be removed during the jam clearance Note The following actions can be taken while either of the primary or secondary messages is displayed 1 Press GO to initiate priming and resume printing Insert Cartridge or This message displays when the printer Close Door front door is open or the print cartridge is missing If this message cannot be cleared go to the Cover Open Switch Cable Service Check on page 2 49 2 32 Service Manual 4069 5XX 7XX User Message Pr
130. ara 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 60825 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe 16 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 radia o laser superior a um nivel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laser Notices xiii 4069 5XX 7XX Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 60825 Laserprodukten van klasse 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 Lasermeddelelse Printeren er godkendt s
131. ard 20 50 99 0715 1 Cable Low Voltage Power Supply 20 51 99A0685 1 Bushing 20 52 2 Nut 2 56 Paper Low Switch Mounting 99A0676 20 53 99A0654 1 Switch Paper Low 20 54 99A0651 1 Sensor Assembly Paper Out Upper Limit 20 55 3 Screw Printer Support 1 Frame Mounting PP 99A0675 20 56 99A0659 1 Frame Printer Support 1 20 57 99A0695 1 Parts Kit Paper Size Switch Assembly including cable switch lock washer nut and knob 20 58 2 Washer Sensor Bracket Mounting 99A0677 20 59 2 Screw Sensor Bracket Mounting PP 99A0675 NS 99A0684 1 Cable HCIT 14Pin Flex 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 Parts Catalog 7 81 4069 5 XX 7XX Assembly 20 High Capacity Feeder continued 7 82 Service Manual 4069 5XX 7XX Asm Part Index Number Units Description 20 60 3 Screw w washer Motor Mounting PP 99A1793 20 61 3 Nut w lockwasher Drive Pulley Plate PP 99A1794 20 62 99A1795 20 63 20 64 20 65 9941796 20 66 9941797 20 67 9941798 20 68 9941799 20 69 9941800 20 70 99A1801 20 71 9941802 20 72 9941803 20 73 9941804 20 74 9941804 20 75 9941805 Motor Assembly DC Foot Stabilizer PP 99A0672 Mounting Feet PP 99A0687 Belt DC Motor Drive Idler Pulley Belt Tension Plate
132. 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 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 Registration on page 3 28 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 5XX 7XX b Print a copy of the Quick Test Page and check the margin
133. bly 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 67 4069 5XX 7XX Fuser Solenoid Service Check Service Tip Try changing the envelope enhance level setting A different setting may correct the problem Note Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section Fuser Solenoid Adjustment on page 4 3 FRU Action 1 Fuser Envelope Conditioner The operation of the fuser solenoid Solenoid can be observed by removing the redrive assembly Check for proper Fuser Solenoid Cable to DC mechanical operation of the solenoid Cable inside Fuser Assembly and associated hardware link and so on If correct check the resistance of the solenoid The resistance measures between 5 ohms and 10 ohms If incorrect replace the solenoid assembly Check continuity of the fuser solenoid cable to DC autoconnect connector If incorrect replace the cable 2 Fuser DC Cable System Check for continuity of the DC fuser Board to Fuser cable that is attached between J4 on the system board and the DC autocount on the fuser assembly If the cable does not measure continuity replace the cable If the cable measures continuity replace the system board
134. cessed Press Go to return the printer to the previous state or Press Menu gt or lt to access the Busy Waiting Menu group The following functions may be available via the Busy Waiting Menu group Cancel Job Reset Printer Reset Active Bin Cancel FAX Waiting lt Interpreter gt These screens will be displayed until the current job is terminated or until additional data is received on the active link PCL1 PS PJL PPDS SIC or HEX may be displayed for interpreter if the printer is not configured for FAX Press Go to print the contents of the printer buffer staple the accumulated sheets or terminate the collation set Note Go does not terminate the current print job or Press Menu or lt to access the Busy Waiting Menu group The following functions may be available via the Busy Waiting Manu group Cancel Job Reset Printer Reset Active Bin Print Buffer Diagnostic Information 2 25 4069 5XX 7XX User Status Screens Status Action 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 pri
135. ck the continuity of the front harness cable J25 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 system board If J25 4 voltage is incorrect check the front harness cable J25 4 line If there is not continuity replace the harness cable If correct replace the System board if this does not correct the problem replace the HVPS 2 116 Service Manual 4069 5XX 7XX Print Quality Banding Service Tip 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 through 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 1 Charge Roll If the problem
136. ckup 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 h A CO OO E aA hp ABA Aa aa a a Tray Backup Roller Parts Catalog 7 89 4069 5 XX 7XX Assembly 22 Kiosk Horizontal Paper Adapter 7 90 Service Manual 4069 5XX 7XX Asm Part Index Number 22 1 99A0231 22 2 99A1646 22 3 99A1819 Units Description Bail Support Arm Assembly Pivot Mounting Frame Assembly 22 4 2 Retainer PP 99A0240 22 5 5 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 99A1707 22 14 9940907 22 15 9940232 22 16 9941820 22 17 99 0122 22 18 9940906 22 19 9940088 22 20 99 0085 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 h A OO OO E aA M i ABA aaa a a Tray Backup Roller Parts Catalog 7 91 4069 5 XX 7XX Assembly 23 High Capacity Output Stacker 7 92 Service Manual 4069 5XX 7XX Part Index Number 23 1 99A1748 23 2 99A1785 23 3 99A1783
137. cting 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 Diagnostic Information 2 103 4069 5XX 7XX 990 Service Error displays FRU Action 1 Mechanical Linkage DC Motor Assembly Check the DC motor cable connector 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 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 c
138. d by erratic operation of exit sensor flag or exit sensor or a defective piece of media 89 xx 04 x1 The fuser exit sensor never actuated from the sheet going through the fuser before the next page begins feeding x 1 Media Size 89 xx 07 The narrow media sensor in the fuser was covered by a sheet of paper when not expected or a piece of media is in the machine during POST This error can occur when 202 paper jam has occurred Remove any piece of media that is over the narrow media sensor Try to feed a piece of paper through the printer could run the print test from the diagnostic test menu If the media stops over the narrow media sensor again check the flag and sensor for correct operation 89 xx OB x1 The fuser exit sensor may be bouncing This error can be caused by a failing exit sensor or system board Diagnostic Information 2 15 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 89 xx OD The fuser exit sensor bounced Check the exit sensor for correct operation Check the fuser DC cable to J14 on the system board Also the system board may be failing 8D 00 00 The fuser exit sensor was never activated by the leading edge of the media fed through the printer This error can be displayed after a 201 paper jam This can be caused by a defective fuser exit sensor assembly Enter the diagnostic tests menu select base
139. dler Assembly Belt Tension 17 4 99A0326 3 Spring Aligner 17 5 99A0323 3 Guide Assembly Paper 17 6 99A1675 1 Guide Assembly Paper 17 7 99A0314 2 Spring Chassis Ground 17 8 2 Screw Motor Mount 3 mm PP 99A0413 17 9 99A0328 1 Belt Motor 114 Gear 17 10 99A0329 1 Pulley Main Drive 96 54 Gear 17 11 99A0321 1 Motor Assembly DC Drive 17 12 99A1673 1 Cable D C Motor Tach 250 Duplex 17 13 1 Cam Follower Assembly Kit PP 99A0299 17 14 99A0312 1 Actuator Assembly Deflector 17 15 2 Screw Actuator Assembly Mounting PP 99A0413 17 16 99A1130 1 Guide Return RH Upper 250 Duplex 17 17 2 Screw Upper Return Guide Mounting PP 99A0413 17 18 99A1680 1 Guide Return RH Lower 500 Duplex 17 19 99A1579 1 Guide Upper 500 Duplex 17 20 99A1134 1 Tray Assembly Jam Removal 500 Duplex NS 2 Retainer 6 mm Backup Roll PP 99A0404 NS 2 Screw M3x6L G Supradrive PP 99A0413 Parts Catalog 7 61 4069 5 XX 7XX Assembly 17 Duplex continued 7 62 Service Manual 4069 5XX 7XX Asm Part Index Number 17 21 99A1682 17 22 99A1131 17 23 99A0341 17 24 Units Description Guide LH Lower Return 500 Duplex Guide Return LH Upper 250 Duplex Sensor Exit Optical a Screw LH Upper Return Guide Mounting PP 9940413 17 25 99A1677 Base Assembly w Tray Bias 500 Duplex 17 26 99 0316 17 27 99 0315 17 28 99 0325 17 29 99A0280 17 30 99 0311 17 31 99 0274 17 32 99 0310 17 33 Shaft Duplex D
140. e 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 connection automatically or autoconnects requiring no external cables when the option is Diagnostic Aids 3 37 4069 5XX 7XX 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 autocon
141. e 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 60 Service Manual 4069 5XX 7XX 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 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 61 4069 5XX 7XX 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 fe
142. e 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 Diagnostic Aids 3 7 4069 5XX 7XX 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 Disable the Download Emulation 1 Turn the printer off 2 Press and hold the Go and Menu buttons 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 Pro
143. earbox BTM fuser screw mounting 7 LVPS mounting 2 auto compensator mounting 1 hanger bracket Repair Information 4 9 4069 5 XX 7XX Reference Number Screw Type Location Purpose Qty M3x12 mm HVPS board mounting 1 Taptite D Panhead 235 GS M3x28 mm developer drive ground attach 1 Taptite bottom hole Panhead M3x6 mm stacker duct mounting 1 Taptite Panhead system board mounting 2 ED System board to shield mounting 2 system 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 5XX 7XX Reference N mber Screw Type Location Purpose Qty M3 5x8 mm autocompensator mounting 3 Plastite Thread Forming M3 5x10 mm right side cover mounting 1 Plastite Thread Forming right side frame to pan attach 3 324 p left side frame to pan attach 1 ANS i i extra screw mounting 2 I fe ZX M3 5x12 printhead to EP frame mounting 3 Plastite Thread Forming with washer 425 MM Yt rN Z 3 6 Repair Information 4 11 4069 5XX 7XX 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
144. ed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 201 Paper Jam Remove Cartridge Leave Job in Finisher Primary Paper is jammed between the printer input and exit sensors Open the printer upper front door and remove the print cartridge to access the jam area Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 202 Paper Jam Open Rear Door Leave Job in Finisher Primary Paper is jammed at the printer exit sensor Open the printer rear door to access the jam area Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled Diagnostic Information 2 29 4069 5XX 7XX User Message Primary User Message Secondary Explanation 230 Paper Jam Check Duplex Leave Job in Finisher Primary The paper is most likely jammed in the Duplex Unit Remove the duplex front cover to acc
145. eder 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 displays an envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path FRU Action 1 Latch Lever Check to make sure the tip of the latch lever is centered in the opening in the floor of the paper path The latch lever may not be detented on the latch 2 62 Service Manual 4069 5XX 7XX Fan Service Check Printhead Fan Service Check The printhead fan is in models 722 72n Note If the printhead fan is inoperative and a lot of graphics are printed you may see darker than normal copies 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 System
146. eeder c Envelope Feeder if installed 2 Sensor Test If selected the following menu selections are available a Tray x x Tray 1 2 3 4 or 5 where installed b MP Feeder c Envelope Feeder if installed Input Tray Tests on page 3 19 Output Bin Tests If selected the following menu selections are available 1 Feed Tests If selected the following menu selections are available a Standard Bin b Output Bin x x Output Bin 1 2 3 4 5 6 7 8 9 or 10 when installed 2 Feed to all bins test 3 Sensor Tests If selected the following menu selections are available a Standard Bin b Output Bin x x Output Bin 1 2 3 4 5 6 7 8 9 or 10 when installed Output Bin Feed to all Bins Test on page 3 20 Output Bin Feed Test on page 3 21 Output Bin Sensor Test on page 3 21 Finisher Tests If selected the following menu selections are available 1 Feed Tests 2 Sensor Tests Finisher Tests StapleSmart Finisher Option on page 3 24 Diagnostic Aids 3 3 4069 5 XX 7XX Tests Refer to Test Page Base Sensor Test If selected the following menu selections are available 1 Toner 2 Input 3 Output 4 Narrow Media 5 Front Door Base Sensor Test on page 3 26 Device Tests only displayed if flash or disk option is installed If selected the following menu selections are available 1 Quick Disk Test Disk option when installed 2 Disk Test Clean
147. el cover open switch cable from the system board 3 Cut the black cable tie that holds the operator panel switch cable and front harness 4 Remove the operator panel Pull the cables through the rectangular hole in the hinge pivot arm 5 Plug the new operator panel cable into the operator panel and snap the new cover open switch cable into the bracket assembly 6 Route the cables and toroid through the rectangular window in the cover hinge pivot arm 7 Snap the operator panel into the upper front cover 8 Be sure the toroid is on the opposite end of the cables near the system board connectors 9 Route the cables through the printer and down the inside of the system board shield 10 Plug the cables into the system board connectors Repair Information 4 49 4069 5XX 7XX 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 thru sensor from its retaining tabs 3 Release the frame assembly from the front and rear retaining tabs and remove
148. elevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zustandige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen XX Service Manual 4069 5XX 7XX Pautas de Seguridad Este producto se ha disenado 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 Existe mayor riesgo de descarga el ctrica y de 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 Informa es de Seguran a e Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza
149. em 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 Auto compensator Check the auto compensator 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 2 72 Service Manual 4069 5XX 7XX The base printer indicates a dead machine condition when the high capacity input tray is installed FRU Action 1 AC Line Cord If the base printer works normally AC Jumper HCIT to using the AC line cord from the AC Printer wall outlet and does not work when AC input and Output using the AC jumper from the HCIT Receptacles check the AC jumper cord If AC Wiring Harness defective replace the cord If not
150. emove Paper Standard Bin message to display before POST completes and cannot be cleared 2 90 Service Manual 4069 5XX 7XX 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 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 Diagnostic Information 2 91 4069 5 XX 7XX FRU Action 1 Output Expander Option Make sure the output expander option is the only option that is not recognized by the base prin
151. emove the right side cover Use care when removing the cover as the right side door switch and cable assembly are easily damaged Do not allow the right side cover to hang down by the switch and cable assembly 2 Disconnect the 10 pin cable from the stapler assembly 3 Hold the stapler assembly with one hand while removing the three screws from the assembly The assembly is heavy and easy to drop 4 Check the stapler assembly for any signs of damaged or broken parts Check the flag and spring assembly on the front of the stapler assembly to see if the flag or spring are broken or missing If any problem is found replace the stapler assembly If no problem is found continue with step 5 5 Carefully cycle the large gear on the side of the stapler assembly and try to free the cartridge holder assembly Note Look for staples jammed at the throat of the cartridge holder and remove any that are found Gently try to remove the cartridge holder from the stapler assembly It may be necessary to manually cycle the large gear on the side of the stapler assembly to release the cartridge holder 6 Reinstall the stapler assembly with a new stapler cartridge holder and staples Run the Finisher Feed Test to check the option If the problem continues go to step 2 2 Stapler to Stapler Board J3 Cable Check the continuity of the cable If a problem is found replace the cable Diagnostic Information 2 133 4069 5
152. ensor 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 board 4069 5XX 7XX 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
153. epper 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 Spring Latch Return mr rcv Flag Envelope Out Sensor Parts Catalog 7 71 4069 5XX 7XX Assembly 19 Envelope Feeder continued 7 72 Service Manual 4069 5XX 7XX Asm Part m Index Number Units Description 19 13 Gear Kit PP 99A0271 0 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 19 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 Thru Sensor un EA Mi E a os oa on on pow a a a Parts Catalog 7 73 4069 5 XX 7XX Assembly 20 High Capacity Feeder 7 74 Service Manual 4069 5XX 7XX see CH Units Description 20 1 99A0660 1 Frame Printer Support Frame 2 20 2 3 Screw Printer Support 2 Frame Mo
154. er arm assembly If correct replace the HVPS Diagnostic Information 2 119 4069 5XX 7XX Print 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 system board 2 120 Service Manual 4069 5XX 7XX Smart Cartridge Contact Assembly Service Check Note If you are unable to clear a 32 Unsupported Cartridge User Error Message make sure a Lexmark T print cartridge is correctly installed in the printer The cartridge is easily identified by the contact board located on the right side rear of the cartridge Install another print cartridge before attempting to troubleshoot the printer Check to make sure the smart contact assembly cable is properly connected to J20 on the system board Check the print
155. ess 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 Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 24X Paper Jam Check Tray X Leave Job in Finisher Primary Paper is jammed around Tray X 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 Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 250 Paper Jam Check MP Feeder Leave Job in Finisher Primary Paper is jammed in the multipurpose feeder Secondary When this message is displayed do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets Also if the accumulated sheets are removed the portion of the job printed
156. exit the test 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 menu the following is displayed Diverter Test Running This is a single test The test terminates upon completion Registration The Video Frequency Test runs automatically when Registration is selected from the menu 3 28 Service Manual 4069 5XX 7XX To run the Registration 1 Select Registration from the main diagnostic menu 2 The Video Frequency Test runs automatically 3 When the Video Frequency Test is complete the following Registration values screen are displayed L sxx B Bottom Margin T Top Margin L Left Margin R Right Margin Sxx S negative values This space blank positive values xx the margin value is displayed next to the default value 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 Registration 1 2 3 Select Registration from the Diagnostic menu The Top margin sign value pair blinks This indicates it is the margin value being changed To change the value press Menu Once the va
157. f 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 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 Lexmark T620 4069 520 Lexmark T620n 4069 52n Network Lexmark T622 4069 722 Lexmark T622n 4069 72n Network Parts Catalog 7 1 4069 5XX 7XX Assembly 1 Covers 7 2 Service Manual 4069 5XX 7XX Part Index Number 1 1 99A1512 1 2 99A1508 1 3 99A1507 1 4 99A2471 1 5 99A2482 1 5 99A1505 1 6 99A2433 1 7 99A2415 1 7 99A2416 Units Description Cover Assembly Redrive Cap Cover Fuser Wick Assembly Cover Asm Laser 500 Output Contact Asm Smart Cartridge Cover Right Side 520 52n Cover Right Side 722 72n Hinge Assembly Upper Front Cover Kit Upper Front Cover with Labels 52
158. flag for correct operation 84 xx 05 There was a media at the input sensor too early There was not enough time between printhead start and the printhead mirror motor to lock Possible causes for this error are Paper might be pre staged in the paper source tray Paper is picking too fast A defective input sensor 84 00 06 A paper jam has been declared by a smart device Immediate stop homing not allowed 84 00 07 A paper jam has been declared by a smart device Homing was allowed before the stop 84 xx OB x1 x2 x3 The option tray pass thru sensor was never actuated by a piece of media x 1 media size x 2 media source x 3 paper source where paper jam was detected Run the sensor test for the option tray that is displaying the error code and check the pass thru sensor for that tray for correct operation Check for paper picking from the selected paper input Source f the error is being detected from a lower paper source see if paper is feeding correctly from a paper source above the detected source Diagnostic Information 2 11 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 84 xx Of x1 x2 x3 The option Tray pass thru sensor was never deactivated x 1 media size x 2 media source x 3 media source where paper jam was detected Check the pass thru sensor and flag for correct operation Check to see if paper has c
159. found Diagnostic Information 2 105 4069 5XX 7XX 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 auto compensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper Also the auto compensator motor may be failing If this problems continues replace the auto compensator 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 1 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 Auto compensator Make sure the counterbalance spring is not missing loose or broken at the top of the auto compensator arm assemb
160. g properly Go to the Envelope Feeder Option Service Check on page 2 56 84 xx 1E x1 x2 The envelope feeder pass thru sensor was never activated x1 Media Size x2 Media Source Ensure that envelopes are feeding over the sensor If an envelope feeds over the sensor but the sensor does not activate check the sensor and flag for correct operation If the sensor and flag are operating correctly go to the Envelope Feeder Option Service Check on page 2 56 Diagnostic Information 2 13 4069 5 XX 7XX First 6 Bytes Sub Error Code e Data Note Explanation xx can be any value 84 xx 20 x1 The imaged page is not the expected page x2 x1 Media Size x2 Media Source Check the pass thru sensor to make sure it is operating properly If no problem is found it may be necessary to try a new pass thru sensor 84 xx 21 x1 The smart tray x did not pick a sheet of paper x2 x1 Media Size x2 Media Source Check tray x auto compensator and tray parts for correct operation If no problem is found go to the Input Tray s Option Service Check on page 2 69 84 xx 22 x1 This code indicates that the media activated the input sensor x2 before the printer EP was ready x1 Leading Edge of Media State x2 Trailing Edge of Media State 84 xx 23 x1 The transfer servo never started x2 x1 Media Size x2 Leading Edge of Media State 84 xx 25 This code indicates that the media has acti
161. g 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 22 Service Manual 4069 5XX 7XX EMC Shields Inner EMC Shield Remove the left door Remove the outer EMC shield Remove all option boards from the connector board slots Remove the inner EMC shield mounting screws A and B Remove the inner EMC shield 200 m 102 102 Repair Information 4 23 4069 5XX 7XX 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 24 Service Manual 4069 5XX 7XX Fan Main Fan 1 Remove the top rear cover 2 Remove the inner EMC shield 3 Remove the fan shroud A 4 Note the routing of the main fan cable B and disconnect the cable from the system board at connector J5 Repair Information 4 25 4069 5XX 7XX 5 Release the four
162. gram the download emulation into the code overlay card assembly again 5 If these steps do not resolve the problem replace the code overlay card assembly 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 3 8 Service Manual 4069 5XX 7XX 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 adjusted 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 1 1
163. h capacity feeder option control board 2 High Capacity Feeder Control Board The elevator tray down button does not operate The tray moves to the upper position Disconnect the lower limit switch cable and check the voltage at J2 1 orange The voltage measures approximately 5 V dc If incorrect replace the high capacity feeder option control board Service Tip Open the high capacity feeder option front door and check the black rubber bumper attached to the door switch spring Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly FRU Action 1 Lower Limit Switch Lower Limit Switch Cable High Capacity Feeder Control Board Check the lower limit switch to make sure it is not closed normally open If incorrect replace the switch 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 2 78 Service Manual 4069 5XX 7XX Paper from the high capacity feeder input tray does not reach the pass thru sensor Service Tip Check to be sure the paper in tray is within specifications FRU Action 1 Auto compensator Assembly Check the auto compensator pick arm rollers for sign of glazing toner or other buildup Replace as necessary 2 Wear Strips Check the wear s
164. has been detected by the specified device 982 Communications error detected by the specified device 983 Invalid command received by the specified device 984 Invalid command parameter received by the specified device Diagnostic Information 2 7 4069 5XX 7XX Error Code Action 990 Service This error will be displayed when an equipment check lt device gt condition has occurred in the specified device lt device gt but the device is unable to identify the exact component failure Specified device lt device gt can be one of the following System Board Duplex Tray x x 1 2 3 4 or 5 Envelope Feeder Output Bin x x 1 2 3 to 6 Will be displayed for single bin output options Output Bins x to y x to y 1 to 5 2 to 6 6 to 10 Will be displayed for multiple bin output options StapleSmart Finisher Option 991 Service This message will be displayed when the specified device Card device has detected an equipment check in its system card Specified device device can be one of the following Duplex Tray x x 1 2 3 4 or 5 Envelope Feeder Output Bin x x 1 2 3 to 6 Will be displayed for single bin output options Output Bins x to y x to y 1 to 5 2 to 6 6 to 10 Will be displayed for multiple bin output options StapleSmart Finisher Option Sub Error Codes for 9XX and 2XX Error Codes The sub error codes are helpful troubleshooting a
165. he User Attendance Messages on page 2 29 If your machine completes the Power On Self Test POST on page 2 41 without an error and you have a symptom go to the Symptom Tables on page 2 42 Locate your symptom and take the appropriate action If a service error code appears while you are working on the machine go to the Service Error Codes on page 2 2 and take the indicated action for that error Diagnostic Information 2 1 4069 5 XX 7XX 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 901 Engine Flash Contact the next support level or call Lexmark Indicates that the flash which the engine code is programmed into is bad Replace the system 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 system 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 system board 910 DC Pick Motor DC Pick Motor S
166. he 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 2 102 Service Manual 4069 5XX 7XX 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 conta
167. he 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 Check the autoconnects cables and Option connectors of the option for any signs of loose or damaged parts 2 High Capacity Output Remove the left and right side covers Stacker Mechanical Linkage and check all four autoconnects for Assembly 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 11 If the voltages are correct reinstall the output option and note the positions of the toroids 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
168. he HVPS to the left to release the mounting tab from the center pan and remove the HVPS LI Ew C c 3095 Low m D S Res RU Je 235 Integrated Tray Compensator Assembly 1 2 Remove the paper tray Remove the left door Repair Information 4 37 4069 5XX 7XX Remove the inner EMC shield Disconnect the compensator motor cable A from the system 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 side frame from the auto compensator pivot shaft Disconnect the compensator sensor cable C from the assembly Remove the compensator assembly mounting screw D Remove the integrated tray compensator assembly B D 203 Integrated Tray Compensator Pick Roll Assembly 1 2 Remove the paper tray Place the printer on its side 4 38 Service Manual 4069 5XX 7XX 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 5XX 7XX Interconnect Board Assembly 1 Remove the inner EMC shield 2 Remove the LVPS 3 Disconnect all cables A from the interconnect board 4 yy 4 40
169. he 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 5XX 7XX Fuser Envelope Conditioner Solenoid Remove the fuser assembly Remove the solenoid mounting screw A Disconnect the 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 5XX 7XX Fuser Narrow Media Sensor Flag Assembly Remove the fuser assembly Remove the exit roll assembly Remove the cables cover Disconnect the sensors from the cable connectors 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 cables cover 2 Disconnect the exit sensor from the fuser cable connector 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 narrow 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
170. he primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the printer does not reprint these sheets Diagnostic Aids 3 41 4069 5 XX 7XX Error Message 24x x Tray 1 through 5 Paper Jam Check Tray x The paper has not cleared the pass thru sensor or reached the pass thru sensor of the option above tray x Note When the StapleSmart Finisher option is installed a secondary message may be displayed which advises whether or not to remove the job from the finisher If a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the printer does not reprint these sheets 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 Note When the StapleSmart Finisher option is installed a secondary message may be displayed which advises whether or not to remove the job from the finisher If a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the pr
171. he 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 ona 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 5XX 7XX 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 99A2408 115V 875W Models 520 52n 99A2407 220V 875W Models 520 52n 99 2411 115V 875W Models 722 72n 99A2410 220V 875W Models 722 72n 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 31 6 2 Service Manual 4069 5XX 7XX 7 Parts Catalog How to Use this Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority o
172. his 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 General Information 1 3 4069 5XX 7XX Acronyms CSU DIMM DRAM EDO EP EPROM ESD FRU GB HVPS LASER LCD LED LVPS MROM NAND NVRAM OEM PC POR POST RIP ROM SDRAM SRAM UPR Vac Vdc 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
173. imary User Message Secondary 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 Cartridge 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 the Smart Cartridge Contact Assembly Service Check on page 2 121 34 Short Paper
174. in 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 5 V dc If incorrect check the voltage at J11 2 The voltage measures approximately 0 V de If incorrect replace the sensor assembly If this does not fix the problem replace the lower control board Diagnostic Information 2 101 4069 5XX 7XX Ready Bin X Full message displays May be able to clear message and will feed paper 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 t
175. in 5 of J10 1 1 1 1 42 J2 J4 J5 BAR CODE AREA EIF C1 F2 Co Co J8 JQ Jio 1 ens E dp EIE 10 1 10 2 10 3 J11 Co R1 J12 5 6 Service Manual 4069 5XX 7XX 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 7 4069 5 XX 7XX 5 8 Service Manual 4069 5XX 7XX 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 9 4069 5 XX 7XX
176. int Contrast Charge Roll and Gap Adjustment Error Log Prints the contents of the Error Log Diagnostic Aids 3 35 4069 5XX 7XX Minimum Stroke Width Paper Source and Formatted Size All three pages contain print quality test information including one page of grayscale with two black squares and one all black page 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 e A list of all the printer settings contained in the operator panel menus and their values Alist ofthe installed options and features such as RAM memory card assembly 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 operator panel code levels font ROM version and SRAM availability Auto Compensator Operation The auto compensator 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 st
177. inter as 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 P 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 thru sensor When the sensor is closed CL displays when the sensor is open OP displays 3 Press Return Stop to exit the test Diagnostic Aids 3 19 4069 5XX 7XX The multipurpose tray and the envelope feeder do not have a paper low sensor The multipurpose tray does not have a
178. inter does not reprint these sheets 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 Note A 271 paper jam Bin 1 may be displayed when the StapleSmart Finisher is installed and a piece of media is actuating the pass thru sensor of the finisher 3 42 Service Manual 4069 5XX 7XX Error Message 28x Paper Jam x StapleSmart Finisher Error Message 280 Check Finisher or Error Message 281 Check Finisher When either of these two messages are displayed they indicate that paper is jammed in the finisher option Open the finisher rear door and top cover to remove the jam Note If the paper is still covering the finisher pass thru sensor then a 271 Error Message is displayed A 281 paper jam message may also be displayed when there is a problem with the stapler assembly or the stapler card Note When the StapleSmart Finisher option is installed a secondary message may be displayed which advises whether or not to remove the job from the finisher If a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that
179. is just on one side of Counterbalance Springs 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 parts Replace as necessary Diagnostic Information 2 117 4069 5 XX 7XX FRU Action 2 Charge Roll Assembly Charge Roll Link Arm Check the charge roll for any signs 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 J25 8 on the system board Printer Idle J25 8 measures 0 V dc Printer Printing Test Page J25 8 voltage changes from 0 V dc to 4 V dc If the voltage does not vary check the continuity of line J25 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 system board Turn the printer off and check the resistance between J25 7 and
180. is opened and Toner Low displays again if the condition exists after the upper front door is closed 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 Diagnostic Information 2 37 4069 5 XX 7XX 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 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
181. isher Ensure that the StapleSmart finisher Option is the only option that is not recognized by the base printer If the finisher 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 connectors 2 Stapler Motor Drive Check the autoconnects for signs of Assembly damage especially the connector pins Remove the right side cover Stapler Card Assembly and check the cables at J1A J1B bottom autoconnect J14A J14B top autoconnect to the stapler card assembly to make sure they are attached securely Check the voltages at the printer top autoconnect If incorrect remove the finisher option and go to Autoconnect Top on page 5 11 If voltages are correct reinstall the finisher option and check the voltages at J1A and J1B on the connector If correct replace the stapler card assembly If incorrect replace the stapler motor drive mechanical assembly 2 126 Service Manual 4069 5XX 7XX Close Finisher Top Cover displayed Unable to clear or reset message POST incomplete FRU Action 1 Top Cover Assembly 2 Top Cover Switch Stapler Card Assembly Check the top cover assembly to ensure that it is actuating the top cover switch and the cover is opening and closing correctly Check continuity of the stapler top cover open switch If incorrect replace the swi
182. it the test PuHHHHHE represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 represents the number of times 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 system 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 Diagnostic Aids 3 15 4069 5XX 7XX 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 results appears on the screen Parallel Wrap Test This test is used with a wrap plug
183. itive 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 least 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 wi
184. l sensor flag from the mounting bracket Use care when removing the flag as it can be easily damaged 6 Remove the mounting screws A and remove the cover A 102 102 102 Center Pan Assembly 1 Remove the left and right side frames 2 Remove the pan assembly 4 16 Service Manual 4069 5XX 7XX System Board No Ox 4 ai ba Remove the outer EMC shield Disconnect all cables to the system board Remove the system board mounting screws A Remove the serial port mounting hex studs B Remove the parallel port mounting screws C Remove the USB connection screw D Remove the system board D 232 B A 232 102 C 002 A 232 102 Repair Information 4 17 4069 5XX 7XX Card Assembly NAND Flash 1 Using your index fingers and thumbs remove the card assembly from the system board as indicated in the photo and illustration below 2 To replace the card assembly align guide pins and locating pin with corresponding holes 3 Carefully press the card assembly into place Warning To avoid damage to the connectors do not use excessive force 4 18 Service Manual 4069 5XX 7XX Repair Information 4 19 4069 5XX 7XX 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
185. leared the pass thru area of the option where the paper jam occurred 84 00 10 The main motor ID failed to identify either motor after two tries Possible causes for this error are main drive motor has stalled An incorrect main drive motor gearbox assembly has been installed 84 xx 17 There is an envelope or envelopes in the envelope feeder during warm up An envelope may have partially fed from the envelope feeder Remove any envelopes from the feeder and check the envelope feeder for correct operation 84 xx 18 There is media over the Tray 2 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 2 and see if Tray 2 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 19 There is media over the Tray 3 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 3 and see if Tray 3 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 2 12 Service Manual 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note xx can be a
186. lector Assembly 4 53 Upper Paper Deflector Assembly 4 53 Paper Input Sensor 4 54 Paper Size Sensing Board 4 54 Pick Roll 4 54 Printhead 4069 520 52n 4 55 Printhead 4069 722 72n 4 56 Redrive Assembly 4 57 Smart Cartridge Contacts 4 58 System Board 4 17 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 32 ROM Memory Test 3 15 S Safety Information xix Safety Inspection Guide 6 1 Scheduled Maintenance 6 2 Screw Identification Table 4 7 SDRAM Memory Test 3 15 Serial Wrap Test 3 17 Service Checks Charge Roll 2 47 Cover Open Switch Cable 2 49 Dead Machine 2 50 Duplex Option 2 53 Envelope Feeder Option 2 56 Fan 2 63 Fuser Solenoid 2 68 High Capacity Feeder Input Tray 2 72 High Capacity Output Stacker 2 96 Input Sensor 2 68 Input Tray s 2 69 Main Drive 2 85 Operator Panel 2 86 Options 2 88 Output Bin Sensor 2 90 Output Expander 2 91 Paper Feed 2 105 Parallel Port 2 107 Print Quality 2 109 Printhead 2 108 Serial Port 2 122 Smart Cartridge 2 121 StapleSmart Finisher 2 125 Toner Sensor 2 122 Transfer Roll 2 123 5 Bin Mailbox 2 99 Setting Configuration ID 3 31 Setting the Page Count 3 30 Status Messages 2 24 Index I 3 4069 LXT Symptom Tables 2 42 99A0007 7 5 Base Printer 2 42 99A0026 7 9 7 53 7 57 Duplex Option 2 44 99A0028 7 7 Envelope Feeder Option 2 44 99A0039 7 9 High Capacity
187. lue you want is displayed press Select to save the value and move to the next margin value To skip a margin value its value is correct then press Select and the default value remains the same If Return is pressed to exit the Registration menu after a margin value has been incremented or deremented but not saved via the Select button then the default is changed The quick test page prints with the new value To verify that the margin values are correct print the Quick Test Page This page can be printed from the Registration values Diagnostic Aids 3 29 4069 5XX 7XX screen by pressing the Go button Once the Quick Test Page completes printing the Registration screen displays again Note The Quick Test Page should be printed on A4 or Letter paper only 5 To exit the Registration menu press Return Printer Setup Setting the Page Count This lets the servicer change the page count from the diagnostic menu This is used whenever the system board is replaced because this board contains the printer 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 until the value you want displays Press Select to move to the next digit press Menu until the value you want displays Continue with each digit until you se
188. ly If you find a problem replace the auto compensator assembly 2 106 Service Manual 4069 5XX 7XX 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 16 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 the test indicates that a problem is detected replace the system board Diagnostic Information 2 107 4069 5XX 7XX 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 932 errors
189. m 2 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 3 High 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 Diagnostic Information 2 115 4069 5 XX 7XX FRU Action 4 System Board HVPS Connector Check the following voltages at J25 on the system board Measure the voltages from J25 to printer ground Printer Idle J25 1 approximately 0 V dc J25 2 approximately 4 V dc J25 4 approximately 0 V dc Printer Printing J25 1 varies 0 V dc to 5 V dc J25 2 varies 0 V dc to 4 V dc J25 4 varies 0 V dc to 1 9 V dc If J25 1 voltage is incorrect check the continuity of the front harness cable J25 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 system board If J25 2 voltage is incorrect or if the voltage remains at 0 V dc che
190. m replace the system 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 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 system board J25 check the continuity of the cable If incorrect replace the cable 2 122 Service Manual 4069 5XX 7XX FRU Action Toner Sensor The toner sensor cable is part of the front harness and part of connector J25 on the system board Check the voltage at J25 11 It reads approximately 5 V dc If incorrect replace the system board If correct check the voltage at J10 12 It reads approximately 5 V dc with the System board removed from the printer If incorrect replace the system board If correct replace the toner sensor assembly A bad ground connection between J25 14 on the system board and pin 3 on the toner sensor results in a 929 Service error Transfer Roll Service Check Service Tip The tra
191. macros are being written to flash memory Do not perform any button actions while this message is displayed Formatting Disk The disk is being formatted No button actions are possible while this message is displayed 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 gt 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 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 2 28 Service Manual 4069 5XX 7XX User Attendance Messages User Message Primary User Message Secondary Explanation 200 Paper Jam Remove Cartridge Leave Job in Finisher Primary Paper is jammed at the printer Input Sensor Open the printer upper front door and remove the print cartridge to access the paper jam area Secondary When this message is display
192. n 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 47 4069 5 XX 7XX FRU Action 3 Right Side Charge Roll Link Right Charge Roll Bushing Check the right side charge roll link assembly for correct assembly operation If incorrect replace the charge roll link assembly with the charge roll link assembly kit If correct check the right charge roll link assembly bearing for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the link assembly Check 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
193. n 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 Diagnostic Aids 3 17 4069 5XX 7XX 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 3 18 Service Manual 4069 5XX 7XX 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 pr
194. n the following order operator panel assembly System 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 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 card assembly is installed correctly and is not broken or damaged If the Memory card assembly is correctly installed not broken or damaged then run the Flash Test on page 3 7 If the test fails replace the Flash card assembly If the problem continues replace the system board DRAM Memory Option s This service check is the same as the flash memory option service check with the following exception Run the SDRAM Memory Test on page 3 15 from the menu if the SDRAM Memory card assembly is correctly installed and not broken or damaged If the test fails replace the SDRAM card assembly If the problem continues replace the system board 2 88 Service Manual 4069 5XX 7XX Hard Disk Option Service Tip The Lexmark T printers support one hard disk option Check to make sure only one hard disk option is installed 3 2 GB or larger Check to make sure the fixed disk and the fixed disk b
195. nd 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 55 4069 5XX 7XX 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 options are installed make sure they are operating normally If only the envelope feeder is failing to operate correctly continue with this 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 a260 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 Action 1 Envelope Feeder Check to make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the p
196. nd when the sensor is open OP displays 6 Select Return or Stop to exit the test 5 Bin Mailbox Option 1 Select Output Bin tests from the menu 2 Select Output Bin tests Sensor Tests 3 Select Sensor Tests for Output Bin x x number of the output option to be tested 4 The following screen is displayed Output Bin x P1 OP P2 OP L NL P1 5 Bin Mailbox first pass thru sensor P2 5 Bin Mailbox second pass thru sensor L EM 5 Bin x empty L NL bin contains media but the bin is NOT near full nor full L NF the bin is near full L FL the bin is full 5 Once the screen is displayed manually actuate each of the sensors of the High Capacity Stacker except for the output level sensor When the sensor is closed CL displays and when the sensor is open OP displays 6 Select Return or Stop to exit the test Diagnostic Aids 3 23 4069 5XX 7XX Finisher Tests StapleSmart Finisher Option Feed Tests This test feeds eight blank sheets of paper through the finisher option and staples them Note No buttons are active during this test and the test cannot be terminated until it is complete To run this test 1 Go to Diagnostic menu 2 Select Finisher Tests from the Diagnostic menu 3 Select Feed Tests from the menu Sensor Tests This test consists of four menus which tests all the sensors in the finisher option To run this test 1 Go to the Diagnostic menu 2 Select Finisher Tests from the Diagnostic menu
197. nect to the 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 dc 24 V dc 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 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 statu
198. nnector Pin No Signal J31 Options Connector 1 RDXIn 2 Ground 3 TDXIbr 4 Ground 5 Ground J32 MPF Paper Out 1 Ground 2 POSense 3 5 V dc J33 System Board Edge Connector J35 Auto Compensator 1 24 V dc Motor 2 Autocomp 3 Ground 4 Ground 5 Encoder 6 5 V dc Connector Locations 5 25 4069 5XX 7XX Connector Pin No Signal J36 Paper Size Sensor k 5 V dc PSize2 Ground PSize1 24 V dc Ground POut PaperLow AJ OJN 5 V dc J37 MPF PICK MPFPick 24 5 26 Service Manual 4069 5XX 7XX StapleSmart Finisher Option Staple Card Assembly 1 J3 Connector Pin No Signal J1A Bottom Autoconnect 1 24 V dc 2 Ground 3 45 V in Connector Locations 5 27 4069 5 XX 7XX Connector Pin No Signal J1B Bottom Autoconnect J2 Feed Motor rtxdin Ground prtrxd Ground i Ground fdmtr1 fdmtr2 Ground Ground tachft 5Vptt J3 Stepper Motor stpmtr stpmtr stpmtr stpmtr crtprsnt stplow stpphomo Ground
199. nning about half speed If incorrect replace the system board If this does not fix the problem replace the main fan Cartridge Fan Service Check This cartridge fan is used in models 722 and 72n Fan does not run or is noisy FRU Action 1 Fan Assembly noisy Check the fan for proper installation and for excessive noise If incorrect replace the fan and cable assembly 2 64 Service Manual 4069 5XX 7XX FRU Action Fan Assembly Check to make sure the auxiliary fan System Board cable is seated on connector J6 on the system board If correct check for 24 V dc on J6 1 on the system board If incorrect replace the system board If correct replace the cartridge fan Note When the printer is in warm up the voltage at J6 1 measures approximately 12 V dc When the printer is running the voltage measures approximately 24 V dc 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 If the correct lamp is installed and you still have 925 fuser errors try the following 1 The fuser may have reached standby temperature too quickly Check the fuser assembly system board or LVPS
200. nsfer roll is 51 02 mm 2 009 inch circumference 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 FRU Action Transfer Roll 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 Diagnostic Information 2 123 4069 5 XX 7XX FRU Action 2 Left Transfer Arm Assembly 3 Right 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 Check the right transfer arm 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 co
201. nstalled 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 All Models 4 5 mm Gap Adjustment The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the printer This adjustment does not reduce the printer 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 Select GAP ADJUST 4 The range of the GAP adjustment is 0 to 255 Adjust the gap setting by using the Menu 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 duplexing Repair Information 4 3 4069 5XX 7XX 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
202. nter is flushing corrupted print data and the current print job is being discarded No button actions are possible while this message is displayed 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 2 26 Service Manual 4069 5XX 7XX User Status Screens Status Action Printing Directory List A directory of the flash and disk contents is processing or printing because Print Directory is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the 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
203. ntinued 7 86 Service Manual 4069 5XX 7XX Asm Part pM Index Number Units Description 20 95 3 Screw Auto Comp Assembly Mounting PP 99A0263 Arm Assembly Pick 2000 Roll Assembly Pick Base 2000 Option Screw Deflector Mounting PP 99A0263 Deflector Base 20 96 99A1055 20 97 99A0070 20 98 99A0692 20 99 20 100 99A0678 20 101 99A0288 20 102 99A1812 20 103 99A1666 Sensor Pass Thru Label Tray Option Number Label Options Ra a oa on on pp a 20 104 Washer Bracket 250 Frame Retention Mounting PP 99A0677 20 105 4 Screw Bracket 250 Frame Retention Mounting PP 99A0263 20 106 99A0679 2 Bracket 250 Frame Retention NS 99A0717 1 Cable Paper Low Switch NS 99A0720 1 Cable Lower Limit Switch Parts Catalog 7 87 4069 5 XX 7XX Assembly 21 Kiosk Vertical Paper Adapter 7 88 Service Manual 4069 5XX 7XX Asm Part Index Number 21 1 99A0231 21 2 99A1646 21 3 99A1819 Units Description Bail Support Arm Assembly Pivot Mounting Frame Assembly 21 4 2 Retainer PP 99A0240 21 5 6 Screws PP 99A0234 21 6 99A1705 Gear Idler 21 7 99A1704 Gear Idler 21 8 99A0197 21 9 99A0079 21 10 21 11 9940087 21 12 9940086 21 13 9941706 21 14 99 0125 21 15 9940232 21 16 9941820 21 17 9940226 21 18 9940122 21 19 9940137 21 20 9940088 21 21 9940085 Shaft Drive Rear Tray Assembly Backup Roller Parts Pulley PP 99A0208 Spring Ba
204. nuity replace the motor drive assembly If you do not measure continuity continue with this step Reconnect J2 and check the voltages on connector J2 Note All voltages are approximate values Pin Voltage Voltage No Static Feeding 1 24 V dc 24 V dc 2 24 V dc Varies 11 4 V dc to 24 V dc 3 Not Used 4 Ground 5 45 V dc Varies 3 6 V dc to 5 V dc 6 45 V dc 5 V dc If the voltages are correct replace the motor drive assembly If the voltages are incorrect replace the stapler card assembly Drive Motor Assembly Check the drive motor assembly 2 mechanical 99A2513 for normal operation Normal operation for this assembly during POST is the motor turns motor pinion gear turns drive gear turn the clutch rotates and sets Diagnostic Information 2 129 4069 5XX 7XX Step 2 During POST the stapler option tries to home Note When a 990 Service Error is displayed during POST the failure is usually in the stapler mechanical unit or stapler card 281 Paper Jam The paper feeds partway into the Standard Bin even if Finisher Option selected Note When a 900 Service Error is displayed during POST the failure is usually in the stapler gearbox assembly or stapler cartridge FRU 1 DC Motor in Drive Gearbox Assembly Stapler Card Assembly Action Turn the printer off disconnect the motor from J4 and check for continuity between J4 pins 1
205. nvelope Conditioner Sensor Exit Cable Fuser DC Fuser Internal Cover Fuser Assembly with Thermistor Thermal Fuse and RH Fuser Lamp Contact Assembly 14 47 99A2478 14 49 99A1554 14 50 99A1575 14 51 99A2477 NS 99A1612 Sensor Narrow Media Cable AC Input Cable Fuser AC EP Auto Connect to LVPS Cable Mirror Motor Cable Deflector ee ln ol Parts Catalog 7 47 4069 5XX 7XX Assembly 14 Electronics continued 7 48 Service Manual 4069 5XX 7XX Asm Part Index Number Units Description 14 52 99A2442 1 Printhead Fan Parts Catalog 7 49 4069 5 XX 7XX Assembly 15 250 Sheet Tray 7 50 Service Manual 4069 5XX 7XX Asm Part index Number Units Description 15 1 3 Screw Option Board Mounting PP 99A0263 15 2 99A1967 1 Board Option Tray 15 3 99A0627 1 Jumper 2 pin 15 4 1 Screw Switch Activate Spring Mounting PP 99A0263 15 5 99A0063 1 Spring Switch Activate 15 6 99A0445 1 Stud Assembly 250 Frame 15 7 99A0448 1 Arm Paper Out 250 15 8 3 Screw Auto Comp Mounting PP 99A0263 15 9 99A1054 1 Pick Arm Assembly 15 10 99A0277 1 Wear Plate Pass Thru 250 Tray 15 11 2 Screw Wear Plate Mounting PP 99A0263 15 12 99A0276 1 Roll Assembly Drive 500 Dual 15 13 99A0451 1 Roller Skewed Backup 15 14 99A0282 1 Cable 250 Tray Option 15 15 99A0450 1 Retainer Roller 15 16 99A0350 1 Sensor Paper Low 15 17 99A0679 2 Br
206. ny value Explanation 84 xx 1A There is media over the Tray 4 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 4 and see if Tray 4 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 1B There is media over the Tray 5 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 5 and see if Tray 5 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 1C There is media over the Tray 6 pass thru sensor during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 6 and see if Tray 6 is feeding paper correctly and all the sensors are working correctly Check to make sure the paper size setting is correct for the size paper in the tray 84 xx 1D The envelope feeder pass thru sensor never deactivated The display of this code indicates that an envelope never crossed over the sensor flag and passed beyond the sensor or the flag and sensor are not operatin
207. o complete Note This test cannot be stopped until the test is completed Select Return Stop to exit the test StapleSmart Finisher Sensor Test This test can be used to verify whether or not the Finisher sensors are working correctly To run the Finisher Sensor Test 1 2 3 Select Finisher Tests from main menu Select Sensor Tests from the Finisher Tests menu There are four sensor tests that can be selected from the Sensor Tests Staple Sensors Cover and Door Sensor Pass and Media Sensor Bin Level Sensor Select the test for the sensors you want to test from the menu The following appear on the display for each test selected 1 Staple Sensor Test Staple C CL SL CL SP CL H CL C Cartridge Presence Sensor SL Staple Low Sensor SP Self Priming Sensor H Home Signal Sensor Cover and Door Sensors Cover and Door TC CL SD CL TC Finisher Top Cover Sensor Diagnostic Aids 3 27 4069 5XX 7XX SD Finisher Stapler access door 3 Pass and Media Sensors Pass and Media P OP M OP P Finisher Pass Thru Sensor M Finisher Medium Sensor 4 Bin Level Sensor Bin Level EM OP NF OP F OP EM Finisher Bin Empty Sensor NF Finisher Bin Near Full Sensor F Finisher Bin Full Sensor 5 Once the screen is displayed for the test you have selected manually actuate the sensor you want to test When the sensor is closed CL displays and when the sensor is open OP displays 6 Select Return or Stop to
208. oard are correctly installed Run the Quick Disk Test on page 3 6 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 6 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 system 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 sl
209. ock 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 3 36 Service Manual 4069 5XX 7XX 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 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 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 auto compensating phenomena This spring is not to b
210. of the display Press Select to reset the printer Restoring Factory Defaults The printer is restoring factory defaults No button actions are possible while this message is displayed Performing Self Tests Not Ready Press Go The printer is running the normal series of start up tests after it is powered On When the tests are complete the printer returns to Ready The printer is in the Not Ready state which means it is not ready to receive or process data This message displays when Menu gt or lt Menu is pressed during a print job No button actions are possible while this message is displayed Press Go to take the printer out of the Not Ready state Press Menu gt or lt Menu to take the printer out of Ready and enter the TESTS MENU Busy state Press Menu gt until Reset Printer is on the second line of the display Press Select to reset the printer Diagnostic Information 2 27 4069 5 XX 7XX User Status Screens Status Action Resetting Printer The printer is deleting any print jobs in process and restoring all settings to user defaults No button actions are possible while this message is displayed Formatting Flash Do Not Power Off The flash memory is being formatted No button actions are possible while this message is displayed Program Flash Do Not Power Off The flash memory is being programmed which means fonts or
211. oltage on J8 1 green Option Control Board 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 The voltages measure 24 V dc If correct replace the high capacity feeder option system board If incorrect disconnect J8 from the System board and measure the voltages again If incorrect check the LVPS cable and the A C internal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housing to each pin on the motor connector If you find a short between any pin and the motor housing replace the motor assembly If no shorts are found replace the high capacity feeder option control board Check the voltage at J9 1 light blue The voltage measures approximately 24 V dc If incorrect disconnect the cable at J9 and check the voltage again If the voltage continues to be incorrect replace the high capacity feeder option System board If the voltage measures correctly check the cable If the cable is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board
212. om et Klasse l laserprodukt i overenstemmelse med kravene i IEC 60825 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder 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 l niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Laser Notices xiv 4069 5XX 7XX Huomautus laserlaitteesta kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden IEC 60825 m rityksen mukainen Luokan 1 laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan 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 laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA ce
213. on 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 option or envelope feeder Check the high voltage contacts to ensure they are not bent corroded or damaged Replace as necessary 2 112 Service Manual 4069 5XX 7XX FRU Print Quality Evenly spaced horizontal lines or marks 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 defective 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
214. ontact LSF Ground Contact RSF Ground Nutplate Frame Spring Duplex Ground Block Cartridge Spacer Cartridge Block L se oa Rae oa ow eo on on on on on on on on on in a Spring Cartridge Load Parts Catalog 7 9 4069 5 XX 7XX Assembly 3 Printhead 7 10 Service Manual 4069 5XX 7XX m pon Units Description 3 1 99A2448 1 Printhead Assembly 520 52n 3 1 99A2449 1 Printhead Assembly 722 72n NS 3 Screw Printhead Mounting PP 99A0263 NS 99A2442 1 Fan Printhead Cooling 722 72n Parts Catalog 7 11 4069 5 XX 7XX Assembly 4 Paper Feed Auto compensator 0 Was 7 12 Service Manual 4069 5XX 7XX ram VoL Units Description 4 1 99A0060 1 Sensor Paper Out Internal Tray 4 2 99A2444 1 Pick Arm Assembly 500 4 3 99A0070 2 Pick Rolls 4 4 99A1616 1 Flag Paper Out 500 Tray 4 5 99A1930 1 Spring Bellcrank Internal 500 NS 1 Screw Hanger PP 99A0263 Parts Catalog 7 13 4069 5 XX 7XX Assembly 5 Paper Feed Multipurpose Unit 7 14 Service Manual 4069 5XX 7XX Part Index Number 5 1 99A0075 5 2 99A2436 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 99A2439 1 Deflector Assembly MPT 5 7 99 1531 1 Deflector Lower 5
215. or Parts Catalog 7 77 4069 5 XX 7XX Assembly 20 High Capacity Feeder continued 7 78 Service Manual 4069 5XX 7XX an res Units Description 20 28 99A0188 3 Guide Rear Paper with retainer arm Use with 9940219 20 29 6 Screw Top Frame Mounting PP 99A0675 20 30 99A0219 1 Frame Assembly Top with labels 20 31 2 Screw Top Frame Clamp Mounting PP 99A0675 20 32 2 Washer Top Frame Clamp PP 99A0677 20 33 99A0719 1 Clamp Top Frame Mounting 20 34 2 Nut Base Mounting PP 99A0676 20 35 2 Washer Base Mounting PP 99A0677 20 36 2 Screw Base Mounting PP 99A0675 20 37 99A0663 1 Pulley Idler 20 38 99A0664 1 Belt Drive 20 39 99A1807 1 Cable AC Internal Wiring 20 40 2 Nut 2 56 Lower Limit Switch Mounting PP 99A0676 20 41 99A0653 1 Switch Lower Limit Microswitch 20 42 2 Nut Power Supply Ground PP 99A0676 20 43 4 Washer Motor Plate Mounting PP 99A0677 20 44 99A1808 1 Cord AC External Jumper 20 45 2 Nut Power Supply Cover PP 99A0676 20 46 99A0714 1 Cover Power Supply 20 47 2 Screw Power Supply Board Mounting PP 99A0675 Parts Catalog 7 79 4069 5 XX 7XX Assembly 20 High Capacity Feeder continued 7 80 Service Manual 4069 5XX 7XX Asm Part Index Units Description 20 48 2 Washer Power Supply Board PP 99A0677 20 49 99A0667 1 Power Supply Bo
216. or spring to make sure it is not loose or broken 281 Paper Jam Paper jams into stapler output bin FRU Center Stapler Bail Action Check the center stapler bail for any signs of broken parts and that the bail moves freely on the upper exit shaft assembly Upper Exit Shaft Assembly Lower Exit Shaft Assembly Exit Shaft Bearings Check the upper and lower shaft assembly for any signs of wear binds or damage Check the exit shaft bearings for any signs of damage or binding Diagnostic Information 2 131 4069 5XX 7XX 282 Staple Jam Check Stapler displayed FRU Action 1 Stapler Assembly Check the stapler assembly for any signs of broken or damaged parts Post Incomplete Insert Stapler Cartridge Displayed Cartridge Holder is installed and cannot clear message When this failure occurs the following may also occur in the order shown 1 Insert Staple Cartridge displayed The stapler assembly may cycle or fire a few times 2 282 Stapler Jam displayed The stapler assembly may try to cycle or fire 3 990 Service Check Bin 1 displayed 2 132 Service Manual 4069 5XX 7XX FRU Action 1 Stapler Cartridge Holder Stapler Assembly Before proceeding with the service check gently try to remove the stapler cartridge holder from the stapler assembly If the holder is jammed in the stapler assembly do the following 1 Turn the printer off and r
217. osts B Note the routing of the interlock switch assembly cable and disconnect the cable on the system board oR 4 62 Service Manual 4069 5XX 7XX 5 Connector Locations Low Voltage Power Supply Connector Pin No Signal Interconnect 1 5 V dc Peale 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 5XX 7XX POWER SUPPLY BOARD 4069 5XX 7XX High Voltage Power Supply Connector Pin No Signal CN1 System Board 1 Developer PWM 24 V dc Return Charge PWM 24 V dc IN TX PWM TX Enable TX CUR PWM a wy SVRO OUT CCNI em es es z pe E E eum m 5 ar e Zog SEH S l EI pr PRO v el b d Gi TRANSFER meih HE made gar SE Connector Locations 5 3 4069 5XX 7XX Interconnect Board Connector Pin No Signal J
218. ot x on the interconnect board but cannot establish communications with the network card Diagnostic Information 2 89 4069 5XX 7XX 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 System Board Printer fails to display Remove Paper Standard Bin message Output Bin Sensor Test fails Check the voltage at J8 3 It measures approximately 5 V dc when the flag is in the sensor and 0 V dc when the flag is out of the sensor If the voltage does not change replace the sensor cable assembly If this does not fix the problem replace the system 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 R
219. ould result J2 1 motor idle 24 V dc J2 2 motor Idle 24 V dc J2 5 motor idle 5 V dc J2 6 motor idle 5 V dc If any of the voltages are incorrect replace the control board If correct replace the mechanical linkage DC motor assembly 2 104 Service Manual 4069 5XX 7XX Paper Feed Service Check If you have a 936 Transport Motor Error go to the Main Drive Service Check on page 2 85 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 Auto compensator fails to feed paper Failures occur randomly throughout the stack of paper FRU Action 1 Pass Thru Sensor Check the pass thru sensor for correct installation and operation 2 Auto compensator The auto compensator pick roll shaft Assembly assembly is not providing enough torque if the pick rollers are not picking the paper correctly Replace the auto compensator 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
220. oximately 0 V dc If any of the voltages are incorrect disconnect the motor and measure the resistance between J 1 and J 2 The resistance measures between 7 5 and 10 5 ohms If incorrect replace the motor If correct replace the system board Diagnostic Information 2 81 4069 5XX 7XX 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 dc If incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board 2 Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Check the continuity of the sensor cable If incorrect re
221. page printers designed to attach to IBM compatible PC s and to most computer networks The Lexmark T laser printer is available in the following models Model Name Type Lexmark T620 4069 520 Lexmark T620n 4069 52n Network Lexmark T622 4069 722 Lexmark T622n 4069 72n Network General Information 1 1 4069 5XX 7XX 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 Card Assembly Flash memory options of 2MB 4MB 8MB and 16MB Card Assembly Integrated network options Token Ring Ethernet Tri Port Adapter IR Adapter IPDS Card Assembly and SCS TNe PRESCRIBE Card Assembly TIFF Card Assembly Bar Code Card Assembly Parallel Interface Card SCS USB Parallel Port MarkNet Print Servers ImageQuick Card Assembly 250 and 500 sheet paper trays of A5 letter and legal size 250 Sheet Special Media Tray Assembly 500 Sheet Special Media Tray 2000 Sheet High Capacity Feeder Envelope Feeder Duplex Option 250 Sheet Duplex Option 500 Sheet Hard Disk 5 0 GB Optra Forms Hard Disk 5 0 GB Vertical Kiosk Presenter Horizontal Kiosk Presenter Output Expander 5 Bin Mailbox High Capacity Output Stacker StapleSmart Finisher Option 1 2 Service Manual 4069 5XX 7XX Maintenance Approach The diagnostic information in t
222. 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 auto compensator 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 Diagnostic Information 2 71 4069 5XX 7XX Printer does not recognize Tray X is installed FRU Action 1 Autoconect Cables Check the 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 syst
223. paper path problem especially paper jams in the base printer envelope feeder and duplex unit When a 9XX or 2XX error displays 1 Press and hold Return and press Select to enter for sub error codes 2 The first screen of information is displayed Write down the information 2 8 Service Manual 4069 5XX 7XX 3 Continue pressing Return and Select until each screen of information is obtained 4 When the last screen displays the original message displays The following is an example of how the printer shows a duplex unit sub error code Byte 1 Byte 2 Byte 3 Byte 4 DU XX XX XX XX DU XX XX XX XX Byte 5 Byte 6 Byte 7 Byte 8 Diagnostic Information 2 9 4069 5 XX 7XX Base Printer Sub Error Codes Each status byte has a different level of troubleshooting value for each area of the printer The following table displays up to 8 status bytes of data Some or all of these bytes may be used to help diagnose a printer problem These status bytes are designed to help isolate paper jams and paper feed problems in the base printer Legend for Tray Source x 10 MPT x 11 Tray 1 x 12 Tray 2 13 Tray 3 14 Tray 4 x 15 Tray 5 x 31 Env Feeder X 40 Manual Legend for Stacker Destination x 91 Stacker 1 x 92 Stacker 2 x 93 Stacker 3 Legend for media size x 1 letter x 2 legal x 3 B5 x 4 A4 x 5 Executive x 6 A5 x 7 Custom x 9 73 4 Env A 9 Env B 10 Env C 8 661 Env
224. place the cable If correct replace the top optical sensor assembly 2 82 Service Manual 4069 5XX 7XX 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 gray The voltage measures approximately 24 V dc If incorrect disconnect the paper low switch cable from J3 and measure the voltage again on J3 1 If incorrect replace the high capacity feeder option control board If correct check the cable for a short between pins 1 and 2 on the cable If incorrect replace the cable
225. ptra Forms PictureGrade and StapleSmart are trademarks of Lexmark International Inc Lexmark and Lexmark with diamond design Prebate and MarkNet are trademarks of Lexmark International Inc registered in the United States and or other countries PostScript is a registered trademark of Adobe Systems Incorporated PCL is a registered trademark of the Hewlett Packard Company Other trademarks are the property of their respective owners Copyright Lexmark International Inc 2001 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 P N 12G3959 4069 5XX 7XX Table of Content Laser NOlCBS EN ANS ix Safety Informations issu xx xix Preface celsus use RR ERROR ecard EES ER xxiv General Informallon 2222222 i e RR 1 1 OPON a ve naue dece 1 2 Maintenance ads ES 1 3 Tools Required for Service REES RES 1 3 E QU UM E EGRE 1 4 Diagnostic Information
226. que Eviter exposition au rayon VORSICHT Unsichtbare laserstrahlung wenn drucker offen und sperre Nicht dem strahi aussetzen VOORZICHTIG Onzichtbare laserstraling wanneer open on niet vergrendeld blootstelling aan straal ATTENZIONE Radiaziori lasar invisibili se 1 dispositivo aperto e non bloccato Evitare l eposizione AVISO Radiaci n l ser invisible sila puerta est abierta y ol dispositivo no est bloqueado Evite exponerse a ta radiaci n CUIDADO Radia o laser invisivel quando a tampa aberta Evite exposi o acs raios VARO Avattaessa ja suojalukitus ohitettaesse olet altina naxymattimalle lasersateilylle Ald katso s teeseen VARNING Osynlig aserstr ining nar denna del r ppnad och sp rrar ar urkopplade Sir len ar arlig ADVARSEL Usynlig laserstr ling n r deksel apros og sikkarhedsias brytes Unng eksponering for str len ADVARSEL Usynlig laserstr lng ved bning nar sikkerhedsafbrydere er ude af funktion Undg undsaettelse for str ling ATENCI Radiaci l ser invisible s s obre el tancament intern no s correcte Eviteu ER BUSES GE NENEI gt BR y FONE 9 ER AS LERO almi 0 Ga ME AIM 810151 ga edit als Laser Notices ix 4069 5XX 7XX Class 1 Laser Statement Label X Service Manual CLASS 1 LA
227. r 25 18 99A2557 25 18A 99A2575 25 19 99A2526 25 20 99A2556 25 21 99A1820 25 22 99A2544 25 23 99A0362 25 24 99A2545 25 25 99A2548 25 26 99A2533 25 27 99A2523 25 28 99A2543 25 29 99A2528 Units Description Clip Static Ground Stapler Cartridge Holder 321 C Stapler Assembly Bracket Attach Belt Main Drive Card Assembly Right Stapler Bin Level Arm Assembly Belt Idler Spring Swing Arm Bumper Output Tray Bar Upper Output Tray Spring Output Tray Cover Optical Sensor PO YO Lon Frame Assembly Right Parts Catalog 7 105 4069 5 XX 7XX Assembly 25 StapleSmart Finisher continued 7 106 Service Manual 4069 5XX 7XX Nan bay Units Description 25 30 99A0104 1 Spring Upper Diverter 25 31 99A2516 1 Deflector Upper 25 32 99A2539 1 Flange Pulley 25 33 99A2540 4 Bearing Redrive 25 34 99A2517 1 Shaft Assembly Upper Exit 25 35 1 Bushings PP 99A0572 25 36 99A2515 1 Shaft Assembly Upper Drive 25 37 99A0913 1 Shaft Assembly 40T Middle Stacker 25 38 99A0363 1 Pulley Drive 25 39 99A0368 1 Shaft Assembly Lower 25 40 99A2538 1 Belt FHT 86T 25 41 99A2518 1 Shaft Assembly Lower Exit 25 42 99A2529 1 Guide Inner Bias 25 43 99A2527 1 Frame Assembly Left 25 44 99A2549 1 Card Assembly Left Stapler Bin Level 25 45 99A1717 1 Gear Drive 25 46 99A2513 1 Motor Assembly Drive 25 47 99A2551 1 Clutch Assembly Stapler
228. r Units Description Latch Back Restraint Restraint Pad Tray Assembly 250 Sheet Option Restraint Side 250 Sheet Tray Wear Strips Label Paper Size Label Tray Option Number Clip 250 Tray Wear Finger Autosize Plate Snap In Knob Paper Size oe oa oa RP a oa on PA an Vv Parts Catalog 7 55 4069 5XX 7XX Assembly 16 500 Sheet Tray 7 56 Service Manual 4069 5XX 7XX wel Nd Units Description 16 1 99A0350 Sensor Paper Low 16 2 Screw Auto Comp Mounting PP 99A0263 16 3 99A0405 Pick Arm Assembly 16 4 99A0070 Pick Roll Assembly 16 5 99A1636 Base 500 Tray 16 6 99A0058 Pad Base 500 16 7 99A0419 Spring Tray Bias 16 8 99A0026 Tray Bias Arm Assembly 16 9 99A0288 Sensor Option Pass Thru 16 10 99A1895 16 11 99A0292 16 12 99A1829 16 13 99A1583 16 14 99A0126 16 15 99A0124 16 16 99A1952 16 17 99A1582 16 18 99A0120 16 19 99A1576 16 20 99A1537 16 21 99A1602 16 22 99A1601 16 23 99A1666 16 24 99A1967 16 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 4 on pose ao ao Pao Pa A on on RPA pO A D Parts Catalog 7 57 4069 5 XX 7XX Assembly 16 50
229. r 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 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 Diagnostic Information 2 99 4069 5XX 7XX 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 If 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
230. r 3 or check the option below stacker 3 95 xx 00 x1 Stacker sensor x never became uncovered x2 x1 sensor s stacker x2 stacker destination Check stacker x to see if a piece of paper is over the sensor If not check to see if the sensor and flag are working correctly 95 xx 01 x1 Stacker sensor x never was covered or actuated x2 x1 sensor s stacker x2 stacker destination Check stacker x to see if the sensor and flag are operating correctly 98 xx 02 x1 Stacker x did not indicate that a page had been received in x2 x3 the output x1 stacker destination Diagnostic Information 2 21 4069 5XX 7XX Duplex Unit Sub Error Codes First 6 Bytes Sub Error Code Data Note Explanation Xx can be any value 89 xx 00 The duplex unit did not send back a device control 89 xx 02 The duplex unit did not send an Option Ready response 89 xx 06 The duplex option did not send back a page in output response 8E xx 00 x1 A sheet of paper being fed through the duplexer never made it to the printer input sensor The sheet was slow or delayed being fed from the duplex option x12media source 8E xx 03 The error code is displayed whenever the printer never sent a Select Output device control signal to the duplex option This can happen when a sheet of paper is leaving the duplex option and the duplex option never sent a Select Input device signal to the printer 8E xx 04 The printer
231. r Exit w Brush Deflector Paper Deflector Deflector Paper Top Bin Spring Static Ground Grease Packet IBM 23 Roller Asm Rear Access Door RO BRA RR RA AD Parts Catalog 7 101 4069 5XX 7XX Assembly 25 StapleSmart Finisher 7 102 Service Manual 4069 5XX 7XX ace o Units Description 25 1 99A2505 1 Cover Top Assembly 25 2 99A2510 1 Clip Brush Ground 25 3 99A2506 1 Top Cover Bail Plate Right Side 25 4 99A2512 1 Door Rear Access 25 5 99A1785 2 Latch Rear Access Door 25 6 99A2501 1 Cover Right Base Assembly 25 7 99A2503 1 Cover Stapler Access 25 8 99A2502 1 Switch Stapler Access Door Assembly 25 9 2 Screws Switch Stapled Access Mounting 99A2509 Parts Packet 25 10 99A2519 1 Cover Accumulator Assembly 25 11 99A2520 1 Tray Output Assembly 25 11 99A2542 1 Tray Output 25 11A 99A1666 1 Label Tray Options 25 12 99A2521 1 Sensor Stapler Bin Empty 25 13 99A2541 1 Sensor Cover Stapler Bin Empty 25 14 99A2511 1 Bail Center Stapler 25 15 99A2508 1 Kit Stacking Bail 25 16 99A2500 1 Cover Left Base Assembly 25 17 99A2507 1 Top Cover Bail Plate Left Side Parts Catalog 7 103 4069 5 XX 7XX Assembly 25 StapleSmart Finisher continued 20 01 Sp lo 0 MSS o Je 9 P 0 7 104 Service Manual 4069 5XX 7XX Asm Part Index Numbe
232. re approximately 48 ohms cold If incorrect replace the stapler gearbox assembly If correct replace the stapler card assembly POST incomplete Stapler cycles several times FRU Action 1 Stapler Assembly Replace the stapler assembly Note When replacing the stapler assembly observe the location of the ground lead from the stapler assembly and the finisher frame and make sure the ground lead is correctly reattached Flag or spring off stapler unit Will also happen when pin 7 of J3 open Diagnostic Information 2 137 4069 5XX 7XX 2 138 Service Manual 4069 5XX 7XX 3 Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem Diagnostic Configuration Menu Diagnostic Menu Used to help test and diagnose printer and attached option problems Configuration Menu Contains a set of menus settings and operations that are generally used to configure the printer for operation Such menu setting as Resetting the Maintenance Count is included in this menu The following table lists the tests as they are displayed on the Diagnostic Test Menu screens Tests Registration If selected the following menu selections are available The Video Frequency Test runs automatically then the margin values Screen is displayed Refer to Test Page Registration on page 3 28 Print Test
233. rinter 2 Front Autoconnect on Check the connector for signs of Printer 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 56 Service Manual 4069 5XX 7XX FRU Action 3 Autoconnect on the Check for any signs of damage to Envelope Option the connector or contacts If you find damage replace the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc J1 7 measures 24 V dc If any of the voltages are incorrect replace the autoconnect cable connector If the voltages are correct replace the envelope system board Diagnostic Information 2 57 4069 5XX 7XX Operator panel displays 260 Paper Jam immediately when envelope feed is requested POST incomplete FRU Action 1 Pass thru Sensor 2 58 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 s
234. rive Spring Duplex Shaft Gear Pass Thru Idler Bearing Drive Shaft Low Cable Auto Connect Bottom Gear Pass Thru Drive Roll Cable Auto Connect Top P ae oa ow on ow on Screw Main Frame Assembly Mounting PP 99A0413 17 34 99A0317 Gear Duplex Bevel 17 35 99A0434 17 36 99A0279 17 37 99A0191 17 38 99A1669 17 39 99A1666 17 40 17 41 NS 99A1129 Pan System Board Drip Bearing Drive Shaft Fuse 8A SB Board System with Jumper Label Options Screw System Board Mounting PP 99A0413 Screw System Board Cover PP 99A0413 Roller Duplex Pass Thru sch US ne Lu Parts Catalog 7 63 4069 5 XX 7XX Assembly 17 Duplex continued 7 64 Service Manual 4069 5XX 7XX Asm Part Index Number 17 42 99A1280 17 43 99A1679 NS 17 44 99A1691 17 45 99A1672 17 46 99A0332 17 47 99A0307 17 48 99A0335 17 49 99A0334 17 50 99A1903 Units Description Top Cover Assembly Movable 500 Duplex Top Cover Assembly Fixed 500 Duplex Retainer 6 mm Top Cover PP 99A0404 Guide Lower Entry 500 Duplex Guide Assembly Paper Decurl Guide Center Drive Upper Air Plenum Spring Decurl Shaft Bushing Decurl Shaft Frame Assembly Outer 17 51 Screw Outer Frame PP 99A0413 17 52 99A0330 Guide Assembly Center Drive 17 53 Parts Packet Duplex Option PP 99A0269 o Screw Fan Mounting M4x30 o Washer Fan M4 o Nut Fan M4 Fan Cooling Duplex Retainer
235. rn Stop to exit the Clear Log menu Diagnostic Aids 3 13 4069 5 XX 7XX 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 Parallel 1 Wrap only displayed if PCL installed in slot 1 Parallel 2 Wrap only displayed if PCL installed in slot 2 Serial Wrap if available Serial Wrap 1 only displayed if PCL installed in slot 1 Serial Wrap 2 only displayed if PCL installed in slot 2 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 3 14 Service Manual 4069 5XX 7XX 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 indicating the test is in progress 2 Press Return Stop to ex
236. rop 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 paper exit sensor and the envelope conditioner solenoid Diagnostic Aids 3 39 4069 5XX 7XX 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 can be caused by the paper 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 system 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 HSYNC signal to or in the printhead Use the sub error code table to assist in isolating a 200 paper jam message Note When the StapleSmart Finisher option is installed a secondary message may be displayed which advises whether or not
237. rrectly 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 2 114 4 HVPS 917 Error Code Check the voltage at J25 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 J25 3 in the front cable harness to the HVPS If there is no continuity replace the cable harness If there is continuity replace the HVPS If the problem continues replace the system board 2 124 Service Manual 4069 5XX 7XX StapleSmart Finisher Service Check Note When removing the stapler mechanism 99A2526 from the option first remove the staple supply cartridge Note When replacing staples in the supply cartridge discard any old staples in the cartridge and replace with a fresh strip Problems with static electricity buildup Action i Top Cover Check the top cover assembly to make sure the brush is attached to the cover the ground clips are installed and the brush is grounded Diagnostic Information 2 125 4069 5 XX 7XX Printer does not recognize StapleSmart Finisher option as being installed FRU Action 1 StapleSmart Fin
238. rror Fuser is too hot during printing or when printer is idle Go to the Hot Fuser Service Check on page 2 67 Use of the Base Printer Fuser Sub Error Codes on page 2 17 may help diagnose fuser failure 924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit Go to the Hot Fuser Service Check on page 2 67 Use of the Base Printer Fuser Sub Error Codes on page 2 17 may help diagnose fuser failure 925 Fuser Error 1 Indicates the wrong fuser lamp is installed Check the fuser lamp for the correct type of lamp that should be installed 2 Check the line voltage to ensure it is not above the maximum rating for the printer 3 This error may also indicate the fuser reached standby temperature too quickly 4 The hot roll may not be correct for this fuser Ensure that the correct hot roll is installed 927 Fan Stalled Indicates a printer fan stalled Go to the Fan Service Check on page 2 63 Diagnostic Information 2 3 4069 5XX 7XX Error Code Action 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 2 122 930 Printhead Error The wrong printhead is installed Replace with the correct printhead 932 935 Printhead Error 932 Printhead Error 933 Printhead Error
239. rtifierad 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 IEC 60825 Laserprodukter i Klass anses ej halsovadliga Skrivaren har en inbyggd laser av Klass IIIb 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 att n gon person uts tts f r laserstralning ver Klass I niva vid normal anv ndning underh ll som utf rs av anvandaren eller annan f reskriven serviceatgard Laser Notices XV 4069 5XX 7XX 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 a betrakte som farlige Skriveren inneholder internt en klasse 3b laser som best r av en 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
240. s If selected the following menu selections are available 1 Tray x is displayed x Tray selected 1 2 3 4 0 5 2 MP Feeder is displayed 3 Envelope Feeder if installed 4 Print Quality Test Pages are displayed Print Tests on page 3 33 Diagnostic Aids 3 1 4069 5 XX 7XX Tests Refer to Test Page Hardware Tests Hardware Tests on If selected the following menu selections are page 3 14 available 1 LCD Test Operator Panel 2 Button Test Operator Panel 3 DRAM Memory Test 4 ROM Memory Test 5 Parallel Wrap Test Displayed if configured with Standard Parallel Port 6 Parallel 1 Wrap only displayed if port available via PCI in slot 1 7 Parallel 2 Wrap only displayed if port available via PCI in slot 2 8 Serial Wrap only displayed if printer configured with Serial Port 9 Serial 1 Wrap only displayed if serial port available via PCI slot 1 10 Serial 2 Wrap only displayed if serial port available via PCI slot 2 Duplex Tests is displayed only if option Duplex Tests on installed page 3 8 1 Quick Test 2 Top Margin 3 Sensor Test 4 Motor Test 5 Duplex Feed 1 6 Duplex Feed 2 3 2 Service Manual 4069 5XX 7XX Tests Refer to Test Page Input Tray Tests If selected the following menu selections are available 1 Feed Tests If selected the following menu selections are available a Tray x x Tray 1 2 3 4 or 5 where installed b MP F
241. s look for anything that might cause the envelope to stop over the sensor 84 xx 1E x1 An envelope never activated the envelope feeder pass thru x2 sensor or the sensor never sensed the presence of an envelope x1 Media Size x2 Media Source Check to make sure the envelope feeds to the pass thru sensor Check to see if the envelope actuates the pass thru sensor flag 2 20 Service Manual 4069 5XX 7XX Stacker Sub Error Codes First 6 Bytes Sub Error Code Data Note Explanation xx can be any value 84 xx 14 There is media in stacker 1 during POST Usually associated with a 271 Paper Jam Error message May be displayed when a finisher option is installed in lowest or first position above the printer If present remove the media from stacker 1 If the error continues to be displayed or there is no media present in the stacker check the pass thru sensor and flag of stacker 1 or if installed check the option below stacker 1 84 xx 15 There is media in stacker 2 during POST If present remove the media from stacker 2 If the error continues to be displayed or there is no media present in the stacker check the pass thru sensor and flag of stacker 2 or check the option below stacker 2 84 xx 16 There is media in stacker 3 during POST If present remove the media from stacker 3 If the error continues to be displayed or there is no media present in the stacker check the pass thru sensor and flag of stacke
242. s sensor or switch status motor status and so on to the base printer 3 38 Service Manual 4069 5XX 7XX Fuser Operation Hot Roll Fuser The hot roll fuser in the Lexmark 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 the fuser hot roll increases The thermistor is connected to J14 6 and J14 7 on the system board Pin J14 6 Therm is connected to module U15 The system board monitors the resistance changes of the thermistor and sends a signal via J33 system board edge board connector 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 d
243. s not operating correctly If an output option is installed on the printer a 202 paper jam may be displayed if the option is not operating properly especially the pass thru sensor of the output option Remove the output options from the printer and check the printer for correct operation If the printer operates correctly then install one output option at a time and check which one fails Note When the StapleSmart Finisher option is installed a secondary message may be displayed which advises whether or not to remove the job from the finisher If a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the printer does not reprint these sheets Paper Jams Options Error Message 230 Paper Jam Check Duplex Option 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 correctly into the duplex option Note When the StapleSmart Finisher is installed a secondary message may be displayed which advises whether or not to remove the job from the finisher If a job has accumulated in the finisher then the printer alternately flashes t
244. 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 Open the upper and bottom front covers 2 Press the two left door latch buttons A and open the left door 3 Release the left door from the rear hinges and remove the door 4 12 Service Manual 4069 5XX 7XX Right Cover 1 Open the upper and bottom front covers 2 Remove the print cartridge 3 Release the cover latch A and remove the right cover mounting screw B B 324 Repair Information 4 13 4069 5XX 7XX 4 Remove the redrive assembly 5 Remove the right side cover mounting screw B 6 Remove the right side cover B 324 4 14 Service Manual 4069 5XX 7XX 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 5XX 7XX 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 ful
245. sants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu 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 Safety Information xix 4069 5XX 7XX 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 e 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 sicherheitsr
246. sembly NAND Flash Parts Catalog 7 37 4069 5XX 7XX Assembly 14 Electronics continued 7 38 Service Manual 4069 5XX 7XX Asm Part Index TE Units Description 14 12 56P0053 1 System Board Assembly 520 14 12 56P0054 1 System Board Assembly 52n 14 12 56P0055 1 System Board Assembly 722 14 12 56P0056 1 System Board Assembly 72n NS 99A1612 1 Cable Deflector NS 99A0346 1 Clip EMC Six Finger NS 99A0227 1 Clip EMC Gnd Two Finger Parts Catalog 7 39 4069 5XX 7XX Assembly 14 Electronics continued 7 40 Service Manual 4069 5XX 7XX Asm Part Index Number Units Description NS 99A0260 NS 99A1611 NS 99A1610 NS 99A2432 Clip Cable Shield Ethernet Blank Shield Serial Blank Shield Parallel Blank 14 15 99A0408 1 Cover INA Flat Blank 14 16 6 Screw INA Cover Mounting PP 99A0263 14 16 4 Screw INA Cover Mounting PP 99A0263 14 16 2 Screw INA Cover Mounting PP 99A0263 1 o Cover INA Blank 14 17 99A2431 1 Shield Inner Assembly 2 slot 2 o Cover INA Blank 14 18 99A0206 1 Shield Outer 2 slot 14 19 4 Screw Outer Shield Mounting PP 99A0263 14 19 6 Screw Outer Shield Mounting PP 99A0263 NS 2 Screw Int Pan Mounting PP 99A0263 1 1 1 1 Parts Catalog 7 41 4069 5XX 7XX Assembly 14 Electronics continued 7 42 Service Manual 4069 5XX 7XX Asm Part
247. sensor tests select output sensor test and check the fuser exit sensor for correct operation If the test fails check the internal fuser cabling DC autoconnect on the fuser frame fuser DC autoconnect to the system board cable and the cable connection to J14 on the system board 8E xx 02 x1 x2 This error can be caused by the input sensor not being activated by a page that was known to have been picked by a source other than the duplex option Ensure the correct source has been selected and the media is feeding from that source 8E xx 06 x1 8E xx 07 x1 The second pick failed from a paper source when paper was in the source and the only sheet in the paper path The second pick failed from a paper source when paper was in the source Other sheets may have started to feed but none were in the paper path 8E xx 08 The paper in the output bin was flushed The paper ahead of it in the paper path never made it past the output bin sensor or into the tray 8E xx 09 x1 The second pick from the MPT Tray 1 or feeder failed when paper was in the source Other sheets may be in the paper path x1 Media Source 8E xx 0A x1 The second pick from the MPT Tray 1 or feeder failed when paper was in the source Other sheets may have started to pick but none were in the paper path x1 Media Source 2 16 Service Manual 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note
248. solved 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 2 34 Service Manual 4069 5XX 7XX User Message Sat Primar 9 Message Explanation y Secondary 54 Standard Serial This error is displayed when a serial Error 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 across the standard serial port but the port has been disabled 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 Attached This
249. ssage 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 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 54 Service Manual 4069 5XX 7XX 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 a
250. still be attached to the printer but is experiencing a communications problem not fully connected or having a hardware failure e 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 e Ifthe 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 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 message 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 2 40 Service Manual 4069 5XX 7XX 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
251. t 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 30 Service Manual 4069 5XX 7XX 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 Enter the Configuration menu Turn the machine off press and hold the Return and Select buttons Turn the machine on and wait until Performing Self Test is displayed before releasing the buttons 2 The Configuration Menu will be displayed 3 Select Maintenance Page Count value from the menu 4 Press Return to go to the previous menu To reset the Maintenance Page Count to zero 1 Select Reset Maintenance Count from the Configuration menu The following is displayed Reset Maintenance Count Reset 2 To reset the Maintenance Count press Select for Reset Selecting Reset causes the maintenance page counter to reset to zero 3 When the operation is complete the menu returns to the Reset Maintenance Count screen in the Configuration menu Setting Configuration ID The configuration I
252. t on the system board If correct replace the system board If incorrect go to step 4 ART B 4 LVPS Fuse F1 Remove the LVPS from the printer and check fuse F1 Replace the fuse if the fuse is blown If the fuse is not blown go to step 6 CAUTION Before removing the LVPS from the printer and checking fuse F1 turn the LVPS off and remove the AC line cord 5 LVPS Fuse F1 continues Replace fuse F1 if necessary Turn to blow F1 after LVPS the LVPS off and pull the LVPS far reinstalled enough out of the printer to break contact with the interconnect card autoconnector Connect the AC line cord turn the LVPS on If fuse 1 blows again replace the LVPS assembly If the fuse does not blow turn the LVPS off reinstall the LVPS back into the printer and go to step 7 CAUTION Before checking fuse F1 turn the LVPS off and remove the AC line cord Diagnostic Information 2 51 4069 5XX 7XX FRU Action 6 LVPS Remove the LVPS from the printer CAUTION Before making any measurements on the LVPS output connector CN3 observe all necessary safety precautions before applying AC power Measure the voltage on CN3 1 2 10 or 11 The voltage measures approximately 5V dc If incorrect replace the LVPS 7 System Board Turn the printer off and disconnect all the cables from the system board Check for 5V dc at the system board test point If incorrect replace
253. tain 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 3 34 Service Manual 4069 5XX 7XX 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 To run the Print Quality Test Pages Turn the printer off Press and hold Select and Return Turn on the printer Release the buttons once Performing the Self Test displays Select Print Quality Test Pages from the menu The printer performs its normal POR cycle then prints one copy of the Three Test pages If you want more than one copy perform these steps again Page 1 of the Print Quality Test pages contains Printer Information Page Count Printhead Type Installed Memory Staple Cartridge Processor Speed Serial Number Engine Boot Panel Font and Output Bin Cartridge Information Toner Level Serial Number Capacity Prebate and Type Margin Settings Top Bottom Left and Right Margin Values Quality Menu Printer Resolution Toner Darkness PQET PictureGrade and IET Type EP Settings Fuser Temperature Warm Up Time Transfer Pr
254. tall 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 69 2 2 Service Manual 4069 5XX 7XX 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 69 917 Transfer Roll Indicates a problem in the transfer roll area Go to the Transfer Roll Service Check on page 2 123 920 Fuser Error Indicates that the fuser is below temperature when printing Go to the Cold Fuser Service Check on page 2 65 Use of the Base Printer Fuser Sub Error Codes on page 2 17 may help diagnose fuser failure 921 Fuser Error Indicates that the fuser is below standby temperature when the printer is idle Go to the Cold Fuser Service Check on page 2 65 Use of the Base Printer Fuser Sub Error Codes on page 2 17 may help diagnose fuser failure 922 Fuser Error Fuser failed to reach standby temperature Go to the Cold Fuser Service Check on page 2 65 Use of the Base Printer Fuser Sub Error Codes on page 2 17 may help diagnose fuser failure 923 Fuser E
255. tch assembly If correct replace the stapler card assembly Close Finished Side Door displayed Unable to clear or reset message POST incomplete FRU Action 1 Side Cover Door Check the stapler access door for any signs of damage or broken parts Make sure the door correctly actuates the stapler side access door switch 2 Side Cover Door Switch Stapler Card Assembly Check the continuity of the stapler access door switch If incorrect replace the stapler access door switch assembly If correct replace the stapler card assembly Diagnostic Information 2 127 4069 5XX 7XX POST incomplete Stapler cycles several times FRU Action Stapler Assembly Replace the stapler assembly Note When replacing the stapler assembly observe the location of the ground lead from the stapler assembly and the finisher frame Make sure the ground lead is correctly reattached 990 Service Error Code Check Bin X displayed Post Incomplete Step 1 During POST the stapler option does not try to home Step 2 During POST the stapler option tries to home 2 128 Service Manual 4069 5XX 7XX Step 1 During POST the stapler option does not try to home FRU Action 1 Stapler Card Assembly Turn the printer off disconnect the motor from J2 and check for continuity Drive Motor Assembly between J2 pins 1 2 5 and 6 on the cable and the motor case If you get conti
256. ter 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 Mechanical Linkage Check the autoconnects for damage 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 11 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 2 92 Service Manual 4069 5XX 7XX 202 Paper Jam Open Rear Door Message displays A sheet of paper is jammed prior to the pass thru 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
257. th ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair Information 4 1 4069 5XX 7XX Adjustment Procedures Duplex Motor Drive Belts Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex motor 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 21 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 22 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 5XX 7XX Fuser Solenoid Adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid Adjust the fuser solenoid while i
258. the control board If the voltages are correct replace the DC motor mechanical linkage assembly Diagnostic Information 2 95 4069 5XX 7XX 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 Determine which paper path stacker assembly 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 14 to identify the correct jumper location at J6 for the upper and lower units 2 96 Service Manual 4069 5XX 7XX Problems with excessive static electricity buildup FRU Action 1 Front Cover Assembly Check the front cover assembly to make sure t
259. 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 Remove the paper tray board 2 Remove the paper size spring comb mounting screw and remove the spring comb 4 50 Service Manual 4069 5XX 7XX 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 OO m Remove the paper alignment assembly mounting screws A A 104 A 104 Repair Information 4 51 4069 5XX 7XX 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 Paper Alignment Assembly Adjustment on page 4 5 when you reinstall the assembly B 99A0492 4 52 Service Manual 4069 5XX 7XX Paper Deflectors Inner Paper Deflector Assembly aR Go Remove the paper tray Remove the upper deflector assembly Place the printer on its
260. 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 Parallel Wrap Parallel 1 Wrap or Parallel 2 Wrap 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 3 16 Service Manual 4069 5XX 7XX DMA Count Error 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 ru
261. trips for glazing or contamination Replace as required It is advisable to replace all four wear strips at the same time Diagnostic Information 2 79 4069 5 XX 7XX The elevator tray does not move up or down The printer recognizes that the option is installed FRU Action 1 DC Drive Motor High Capacity Feeder Option System Board Be sure the motor cable is correctly installed at J1 on the board Check the cables damaged or loose wires Disconnect the motor Check for a short between each pin and the motor housing If a problem is found replace the motor assembly If no problem is found measure the resistance between the following pins on the motor cable connector Pins 1 brown and pin 2 Yellow The resistance measures between approximately 7 5 and 10 5 ohms If incorrect replace the motor assembly If correct replace the high capacity feeder option system board 2 80 Service Manual 4069 5XX 7XX The elevator moves in one direction only FRU Action 1 DC Drive Motor Check the voltages at J1 on the high Assembly High capacity system board The voltages Capacity Feeder measure as follows System Board Static Motor Not Running J1 1 Brown approximately 0 V dc J1 2 yellow approximately 0 V dc Motor Running Forward J1 1 Brown Approximately 0 V dc J1 2 Yellow Approximately 24 V dc Motor Running Reverse J1 1 Brown Approximately 24 V dc J1 2 Yellow Appr
262. ture rose more than desired from the fuser temperature at turn on 922 Service Fuser Error Fuser failed to reach standby temperature EN 42 xx yy xx Actual Fuser Temperature yy The temperature that the fuser wants to reach EN 21 22 22 00 The fuser temperature did not change enough from the 2 fuser lamp temperature at turn on 01 The fuser temperature rose more than desired from the fuser temperature at turn on z2 00 The Hot Roll did not reach standby temperature in time during standby 01 The Hot Roll took too long to reach the beginning lamp detection temperature 02 The Hot Roll reached final lamp detection temperature but took longer than expected 03 The Hot Roll timed out trying to reach the final lamp detection temperature 04 After Hot Roll lamp detection did not reach steady state control in time 05 The Hot Roll did not reach operating temperature in time 923 Service Fuser Error Fuser over temperature EN 12 xx yy This sub error code is displayed anytime that the Hot Roll has reached a higher than desired temperature EN xx Actual Fuser Temperature 2 yy The temperature that the fuser wants to reach 924 Service Fuser Error Open Thermistor Failure EN 18 xx This code is usually generated when an open circuit check is 1 made of the thermistor circuit in the fuser EN 00 xx Actual Fuser Temperature 2 2 18 Service Manual 4069 5XX 7XX First 6 Bytes
263. ugh 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 BB 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 00 BB in 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 Diagnostic Aids 3 11 4069 5XX 7XX 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 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 message 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 Select Duple
264. unting PP 99A0675 20 3 99A0698 2 Clamp Feed Frame 20 4 4 Screws Feed Frame Clamp PP 99A0675 20 5 99A0691 2 Bearing Nyliner Leadscrew Top 20 6 99A0656 Cover Side 20 7 99A0681 3 Strip Wear 20 8 99A1818 1 Strip Wear Dimple 20 9 99A1809 1 Deflector Assembly Front 20 10 3 Screw Deflector Mounting 8 18 x 7 8 inch PP 99A0675 20 11 99A1829 1 Label Tray Option Number 20 12 99A0662 2 Transfer Lead Screw Assembly 20 13 99 0716 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 75 4069 5 XX 7XX Assembly 20 High Capacity Feeder continued 7 76 Service Manual 4069 5XX 7XX Units Description 20 14 4 Nut 6 32 Hinge Mounting PP 99A0676 20 15 4 Washer Hinge Mounting Flat PP 99A0677 20 16 4 Washer Hinge Mounting Star PP 99A0677 20 17 99A0657 2 Hinge Door 20 18 99A0655 1 Door Assembly Front 20 19 99A0658 2 Magnet Door 20 20 99A0650 1 Frame Assembly 20 21 99A0661 1 Tray Assembly Elevator 20 22 99A1806 1 Card Assembly 2000 Option Control 20 23 4 Washer Card Assembly Mounting PP 99A0677 20 24 4 Screw Card Assembly Mounting PP 99A0675 20 25 99A0392 1 Kit Door Switch Spring and Bumper 20 26 1 Washer Door Switch Spring Mounting PP 99A0677 20 27 1 Nut Door Switch Spring Mounting PP 99A0676 NS 99A0690 1 Cable Optical Sens
265. upper control board If the voltages are incorrect replace the upper or lower failing mechanical linkage assembly Diagnostic Information 2 97 4069 5XX 7XX 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 10 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 Flag Assembly Check the flag for correct operation binding broken parts or interference 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 5 V dc If incorrect check the voltage at J3 2 The voltage measures approximately 0 V dc If incorrect replace the sensor assembly If this does not fix the problem replace the lower control board 2 High Capacity Output Stacker Drive belt s Drive Pulleys Belt Idlers and Belt Tension Springs Check to ensure the
266. ut Tray Service Check on page 2 72 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 system 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 the LVPS board assembly FRU Action 1 Line Voltage Check the AC line voltage If the line voltage is incorrect inform the customer 2 ACLine Cord Check the line cord for any signs of damage If correct check the continuity of the line cord and replace if necessary 2 50 Service Manual 4069 5XX 7XX FRU Action 3 5 Vdc atthe system Check for 5 V dc at the 5V dc test board test point poin
267. val 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 the Scheduled Maintenance on page 6 2 81 Engine Code CRC Failure This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check Press Go to clear the message The microcode data is discarded and must be re transmitted from the host computer 88 Toner Low This message displays when toner low occurs and the toner low alarm is activated Press Go to clear this message 2 36 Service Manual 4069 5XX 7XX User Line 2 Messages If none of the conditions exist that are listed in the following table line 2 is blank If any of the messages in the table are displayed the following actions can be taken Press Menu or Menu to take the printer offline and access the Ready Menu group Note The Menu buttons are not active if Menu Lockout is turned on Press Stop to take the printer offline The Not Ready message is displayed No more data is processed from the host computer Press Go to return the printer to the Ready state User Message Explanation Toner Low Tray X Missing If the toner cartridge is low then Toner Low displays The Toner Low condition clears whenever the upper front door
268. vated the input sensor before the printhead has locked Enough time has elapsed since printhead start to expect a lock One of the following may be failing Printhead Assembly System Board Printhead Cables 84 xx 26 This code indicates that media has activated the input sensor however the printhead fell out of lock condition or not enough time elapsed since the printhead start to expect a stable lock The media may have also reached the input sensor early 2 14 Service Manual 4069 5XX 7XX First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 89 00 01 The exit sensor in the fuser is activated by a piece of media indicating there is a piece of media in the machine during POST Check for media in the exit of the fuser assembly or redrive assembly Feed a sheet of paper and if the same error occurs after clearing the fuser or the same error occurs when no media is present check the exit sensor assembly internal fuser assembly cabling DC fuser cable to the system board and the cable connection to J14 on the system board TIP Turn the printer off enter the diagnostic tests menu and select the base sensor test Select output sensor and check the sensor for correct operation 89 xx 03 The fuser exit sensor did not detect the trailing edge of the media going through the fuser assembly This failure can be caused by a broken fuser exit sensor flag This may also be cause
269. x 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 3 12 Service Manual 4069 5XX 7XX 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 to move forward or Menu to move backward Press Return Stop to exit the Error Log Clearing the 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 Retu
270. xes the problem If it does fix the problem replace the System board If this fixes the problem replace the defective RAM 964 Emulation Error Download Emulation CRC failure has occurred 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 system board 2 6 Service Manual 4069 5XX 7XX Error Code Action 980 984 Service lt device gt Comm These error codes indicate the specified device lt device gt has detected a paper port failure Specified device lt device gt can be one of the following System Board Duplex Tray x 1 2 3 4 or 5 Envelope Feeder Output Bin x x 1 2 3 to 6 Will be displayed for single bin output options Output Bins x to y x to 1 to 5 2 to 6 6 to 10 Will be displayed for multiple bin output options 980 The engine is experiencing unreliable communications to the specified device 981 Engine protocol violation
271. y 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 2 Charge Roll Conductive Check to make sure the charge roll Bushing bushing is correctly installed in the right charge roll arm 3 HVPS Check the voltages on J25 1 thru J25 8 If incorrect replace the System board 4 HVPS Cable Check the continuity of the HVPS Part of Front cable If incorrect replace the cable Harness Cable assembly If correct replace the system board System 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 2 110 Service Manual 4069 5XX 7XX FRU Action 2 High Voltage Contact Check the PC drum contact on the right side frame for damage PC 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 J25 on the system board Measure the following voltages from connector J25 to printer ground Printer Idle J25 5 measures 24 V dc Printer Printing J25 5 measures 24 V dc In the voltages

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