Lexmark T63 Series, Service Manual

Page 1: ...ncluding 4060 000 4060 010 4060 200 4060 210 4060 400 4060 410 Table of Contents Start Diagnostics Safety and Notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries ...

Page 2: ... West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark L...

Page 3: ...tics 1 7 Environment 1 7 Media specifications 1 8 Print area 1 12 Media guidelines 1 12 Paper 1 12 Envelopes 1 13 Transparencies 1 13 Labels 1 13 Tools required 1 14 Acronyms 1 15 Diagnostic information 2 1 Start 2 1 Messages and error codes 2 2 Service error codes 2 2 Sub error codes 2 5 Sub error codes for 9xx and 2xx error codes 2 5 Base printer sub error codes 2 6 Base printer fuser sub error ...

Page 4: ...d service check 2 55 High capacity feeder input tray service check 2 56 High capacity output stacker service check 2 62 Input sensor service check 2 64 Input tray s service check 2 64 Internal tray card paper size sensing service check 2 66 Main drive service check 2 68 Main fan service check 2 69 Operator panel service check 2 70 Operator panel buttons service check 2 70 Operator panel display se...

Page 5: ...ror log 3 8 Hardware tests 3 8 LCD Test 3 8 Button Test 3 8 SDRAM Memory Test 3 9 ROM Memory Test 3 9 Parallel Wrap Test 3 9 Input tray tests 3 10 Input Tray Feed Test 3 10 Input Tray Sensor Test 3 10 Output Bin Tests 3 11 Output Bin Test Standard Bin 3 11 Output Bin Feed Test 3 11 Feed to All Bins Test 3 12 Output Bin Sensor Test 3 12 Finisher Tests for StapleSmart Finisher 3 14 Finisher Feed Tes...

Page 6: ... Feeder 3 25 Error Message 27x Paper Jam Check Bin x 3 25 Error Message 28x Paper Jam x StapleSmart finisher 3 25 Error Message 282 Check Stapler 3 26 Error Message 283 Check Stapler 3 26 Repair information 4 1 Handling ESD sensitive parts 4 1 Adjustment procedures 4 2 Duplex motor drive belt adjustment 4 2 Fuser solenoid adjustment 4 2 Gap adjustment 4 3 Printhead assembly adjustment 4 3 Paper al...

Page 7: ...tor panel cable removal 4 50 Optional 250 or 500 sheet paper tray assembly removal 4 51 Paper tray autocompensator assembly removal 4 51 Paper tray frame assembly removal 4 51 Paper tray board removal 4 51 Paper tray paper out sensor flag removal 4 51 Paper size spring comb removal 4 51 Outer shield removal 4 52 Paper alignment assembly removal 4 52 Paper bin full sensor flag assembly removal 4 54...

Page 8: ...wer supplies 7 28 Assembly 16 Electronics card assemblies 7 30 Assembly 17 Electronics shields 7 32 Assembly 18 Cabling diagrams 1 7 34 Assembly 19 Cabling diagrams 2 7 36 Assembly 20 Cabling diagrams 3 7 38 Assembly 21 250 sheet paper tray 7 40 Assembly 22 500 sheet paper tray 7 44 Assembly 23 Duplex option 7 48 Assembly 24 Envelope feeder 7 50 Assembly 25 Output expander 7 52 Assembly 26 High ca...

Page 9: ...serprodukte der Klasse I gelten als unschädlich Im Inneren des Druckers befindet sich ein Laser der Klasse IIIb 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Länge 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daß im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laser...

Page 10: ...áser de Clase I 1 Los productos láser de Clase I no se consideran peligrosos La impresora contiene en su interior un láser de Clase IIIb 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanómetros El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse afectada por ningún tipo de radiación láser superior al nive...

Page 11: ...inelt er en 5 milliwatt galliumarsenid laser som arbejder på bølgelængdeområdet 770 795 nanometer Lasersystemet og printeren er udformet således at mennesker aldrig udsættes for en laserstråling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapt...

Page 12: ...som farlige Skriveren inneholder internt en klasse IIIb 3b laser som består av en gallium arsenlaserenhet som avgir stråling i bølgelengdeområdet 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I nivå under vanlig bruk vedlikehold som utføres av brukeren eller foreskrevne serviceoperasjoner Avís sobre el Làser Segons ha esta...

Page 13: ...Laser notices xiii 4060 xxx Japanese Laser Notice ...

Page 14: ...xiv Service Manual 4060 xxx Korean Laser Notice ...

Page 15: ...ignes d entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vous travail...

Page 16: ...re el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo con la que e...

Page 17: ...producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu treballant...

Page 18: ...rmation provides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Definitions Note ...

Page 19: ...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 Model name Configuration Machine type Lexmark T630 Non network 4060 000 Lexmark T630n Network 4060...

Page 20: ...yption card Media handling operations 250 and 500 sheet paper trays of A4 letter A5 B5 Executive folio statement and legal size 250 sheet universally adjustable tray 250 and 500 sheet paper drawers 400 sheet universally adjustable tray 2000 sheet high capacity feeder Envelope feeder Duplex option 250 sheet For Lexmark T630 and Lexmark T630n Duplex option 500 sheet For Lexmark T632 Lexmark T632n Le...

Page 21: ...lution and media size Lexmark T630 Lexmark T630n Lexmark T632 Lexmark T632n Lexmark T634 Lexmark T634n 300 600 1200 image quality 1200 dpi 300 600 1200 image quality 1200 dpi 300 600 1200 image quality 1200 dpi Simplex printing on full size media pages per minute Letter 8 5 in x 11 in 35 1 18 0 40 1 21 5 45 A4 8 3 in x 11 7 in 33 2 17 1 38 0 20 4 43 Legal 8 5 in x 14 in 28 4 14 6 32 8 17 4 Duplex ...

Page 22: ...exmark T634n Time from standby mode 8 5 sec 10 sec Time from Power Saver mode 42 sec 42 sec All first copy times are measured for 600 dpi simplex printing on letter size paper The test job consists of the character A followed by a form feed single page job The first copy time is defined as the elapsed time from pressing Enter on the PC keyboard to the page exiting to the output bin All tests pick ...

Page 23: ...500 Sheet drawer 15 6 in 398 mm 20 5 in 520 mm 5 3 in 134 mm 7 lb 3 2 kg 250 Sheet drawer 15 6 in 398 mm 19 5 in 495 mm 3 5 in 90 mm 6 lb 2 7 kg 5 Bin Mailbox 15 7 in 399 mm 12 2 in 310 mm 13 1 in 332 mm 8 2 lb 3 7 kg High capacity output stacker 15 7 in 399 mm 18 in 457 mm 11 4 in 290 mm 10 lb 4 5 kg StapleSmart finisher 17 6 in 447 7 mm 19 5 in 495 3 mm 9 0 in 228 6 mm 13 lb 5 9 kg Envelope opti...

Page 24: ...de Measurement Left and right side 12 in 304 8 mm Front 20 in 508 mm Rear 12 in 304 8 mm Top 54 in 1 371 6 mm Allow clearance above the printer front door clearance and for adding options such as additional input drawers output expander high capacity output stacker or StapleSmart finisher Printing states Lexmark T630 Lexmark T630n Lexmark T632 Lexmark T632n Lexmark T634 Lexmark T634n Printing aver...

Page 25: ...ackaged Temperature 40 to 43 C 40 to 110 F Relative humidity 5 to 95 Altitude equivalent to 10 300 meters 0 to 34 000 feet Storage environment unpacked Temperature 0 to 40 C 32 to 104 F Relative humidity 5 to 80 Model Status 1 Meter average sound pressure Declared sound power Lexmark T630 n Idle standby mode 31 dBA 4 6 Bels Simplex printing 52 dBA 6 7 Bels Duplex printing 55 dBA N M Bels Lexmark T...

Page 26: ...00 Sheet drawer Duplex Standard output 5 Bin Mailbox Output Expander Finisher to staple hole punch offset stack or with output bin Paper x x x x x x x x Card stock x x x x x Transparencies x x x x Envelopes x Vinyl labels x x Paper labels x x Polyester labels x x Dual web labels x x x Integrated labels x x x ...

Page 27: ... x 11 in 216 mm x 279 mm x x x x x x x x x x x x Legal 8 5 in x 14 in 216 mm x 355 6 mm x x x x x x x x x x x x Executive 7 25 in x 10 5 in 184 mm x 267 mm x x x x x x x x x x x Folio 8 5 in x 13 in 216 mm x 330 mm 1 x x x x x x x x x x x Statement 5 5 in x 8 5 in 140 mm x 216 mm 1 x x x x x x x Universal 2 5 5 x 8 27 in to 8 5 x 14 in 139 7 x 210 mm to 215 9 x 355 6 mm x x x x x x x x x 2 75 x 5 ...

Page 28: ... x x x x x x x x x Transparencies x x x x x x x x x x x Vinyl labels 3 x x x x x x x x Paper labels 3 x x x x x x x x x Polyester labels 3 x x x x x x x x x Dual web and integrated labels 3 x x x x x x x x x 3 Printing label application on the printer requires a special label fuser cleaner which prevents duplexing The label fuser cleaner is included with a special label cartridge for label applica...

Page 29: ...d Dual web paper 180 g m2 48 lb bond Polyester 220 g m2 59 lb bond Vinyl 3 300 g m2 92 lb liner Integrated forms Pressure sensitive area 2 140 to 175 g m2 Paper base grain long 75 to 135 g m2 20 to 36 lb bond Multipurpose feeder and optional 250 sheet drawer Paper Xerographic or business paper 60 to 135 g m2 grain long 16 to 36 lb bond Card stock maximum grain long 1 Index Bristol 120 g m2 67 lb b...

Page 30: ...nter s user information The chemical process used in preprinting may render some papers unsuitable for use with this printer Integrated forms Pressure sensitive area 2 140 to 175 g m2 Paper base grain long 75 to 135 g m2 20 to 36 lb bond Envelope Sulfite wood free or up to 100 cotton bond 60 to 105 g m2 16 to 28 lb bond 3 4 Envelope feeder Envelope Sulfite wood free or up to 100 cotton bond 60 to ...

Page 31: ...weight should not be less than 75 g m2 20 lb The following envelopes should not be used Envelopes with windows holes perforations cutouts or deep embossing Envelopes with metal clasps string ties or metal folding bars Envelopes with exposed flap adhesive when the flap is in the closed position For best results printing on new 90 g m2 24 lb sulfite or 25 cotton bond envelopes is recommended Under h...

Page 32: ...ivers various sizes Phillips screwdrivers various sizes 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Flash light optional ...

Page 33: ...Card LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply MPF Multipurpose feeder MROM Masked Read Only Memory MS Microswitch NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer OPT Optical Sensor PC Photoconductor pel Picture element POR Power On Reset POST Power On Self Test PWM Puls...

Page 34: ...1 16 Service Manual 4060 xxx ...

Page 35: ...e error codes on page 2 2 User status messages provide the user with information on the current status of the printer Ready displays on the first line of the display unless Power Saver is invoked and then Power Saver displays If a user status message is displayed go to User status displays on page 2 14 User error messages are indicated by a two or three digit error code that provides the user with...

Page 36: ...914 are indications that a Tray 1 paper feed problem has been detected Go to Input tray s service check on page 2 64 911 DC Pick Motor Excessive PWM 912 DC Pick Motor below speed 913 DC Pick Motor over speed 914 DC Pick Motor No encoder feedback Check the integrated paper tray Tray 1 for correct paper loading Reload the paper and POR the printer If the error continues go to Input tray s service ch...

Page 37: ...check on page 2 78 932 Printhead Lost Hsync 933 Mirror Motor Locks Lost Hsync 934 Mirror Motor Lost Lock 935 Mirror Motor unable to reach operating speed 936 937 Transport Motor Indicates a problem with the main drive motor Go to Main drive service check on page 2 68 936 Main Drive Motor initial lock failure 937 Main Drive Motor lost lock 940 Service LV Power Supply The low voltage power supply ze...

Page 38: ...ry in slot 1 now works correctly replace the failing DIMM that was in slot 1 If this does not fix the problem replace the system board If another DIMM is not available replace the memory option If this does not fix the problem replace the system board 964 Emulation Error Indicates a failure within the Download Emulation which is programmed into the code overlay card The specific error is as follow...

Page 39: ...ys The following is an example of how the printer displays a duplex option sub error code Printed error codes Additional information is available by printing the error log See Printing the error log on page 3 7 990 device Indicates an equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Note device can be one of the followi...

Page 40: ... isolate paper jams and paper feed problems in the base printer Sub error code variable values Displayed value of x Printer area Values for tray sources 10 Multipurpose Tray MPT 11 Tray 1 12 Tray 2 13 Tray 3 14 Tray 4 15 Tray 5 31 Envelope feeder 40 Manual feeder Values for stacker destinations 91 Stacker 1 92 Stacker 2 93 Stacker 3 Values for media size 1 Letter 2 Legal 3 B5 4 A4 5 Executive 6 A5...

Page 41: ...x 05 There was 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 de...

Page 42: ...the Input Tray Tests for Tray 5 and see if Tray 5 is feeding paper correctly and all the sensors are working correctly 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...

Page 43: ...4 on the system board Service 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 caused by erratic operation ...

Page 44: ...e when paper was in the source and the only sheet in the paper path 8E xx 07 x1 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 fro...

Page 45: ...er Error fuser failed to reach standby temperature EN 42 xx yy 1 EN z1 z2 2 xx Actual fuser temperature yy The temperature that the fuser wants to reach zz 00 The fuser temperature did not change enough from the 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 ...

Page 46: ... cleared the input sensor 04 The leading edge of the sheet of paper never arrived at the exit sensor Note This error is the most common due to the long length of the paper path between the input sensor and the exit sensor 05 The duplex logic thinks a sheet of paper is feeding to the duplex option due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send ...

Page 47: ... pass thru sensor try the following Enter 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 Envelope feeder service check on page 2 49 If the test passes look for anything that might cause the envelope to stop over the sensor 84 xx 1E x1 x2 An envelope nev...

Page 48: ...ower saver mode and the printer warms up Press Menu 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 Not Ready is displayed and no more data is processed Press Go to return the printer to the previous state When the printer has been configured to receive or s...

Page 49: ...r 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 Press Menu to access the Busy Waiting Menu group The following functions may be available Cancel Job Reset Printer Reset Active Bin Print Buffer User status displays Status Action Waiting interp...

Page 50: ... 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 If the Tray 1 Missing message does not clear when tray 1 is inserted go to Parallel port service check on page 2 77 If Tray 2 through 5 Missing message does not clear by inserting the tray go to Input tray s service check on page 2 64 Tray x Empty If any of...

Page 51: ... is selected from the menu Press Stop to take the printer out of Ready status Not Ready displays No additional 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 to take the printer out of Ready and enter the Tests Menu Busy state Press Select for the values Press Menu until Reset Printer displays on the se...

Page 52: ...lays Note If information is written to flash memory and to disk at the same time the Program Flash message displays The printer menus have been disabled This occurs when 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 displays The print...

Page 53: ...ge input source custom string This message displays when the user should change the media installed in one of the input options input source Tray 1 Tray 2 Tray 3 Tray 4 Tray 5 MPF Feeder Envelope Feeder custom string a user definable name Change input source size This message displays when the user should change the media installed in one of the input options input source Tray 1 Tray 2 Tray 3 Tray...

Page 54: ... to the printer but a communications problem may prevent the printer from detecting the option For example there may be a poor connection or a hardware failure The following actions may be taken If the option was temporarily removed or not connected properly reattach or reconnect it Press Go to execute a configuration change which notifies the printer the option has been hot unplugged removed with...

Page 55: ...fter the finisher side door has been closed Before the first page of a job requesting hole punch The message displays once per job The following actions can be taken Install the hole punch box Press Go to ignore the message The Box M Missing message appears on the status line A job that is set for hole punching will not be punched The message continues to display on all subsequent jobs that reques...

Page 56: ...ss Menu until Busy Waiting displays Select one of the following Cancel Job Reset Printer Reset Active Bin If the message cannot be cleared go to Input tray s service check on page 2 64 Install Duplex or Cancel Job This message is displayed when a duplex option has been hot unplugged The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter be...

Page 57: ...he staple cartridge is low The printer does not detect the staple cartridge is present The following actions may be taken Install a new staple cartridge to clear this message and select Start or Continue to resume printing the staple job Choose to ignore the Load Staples message for this print job by pressing Go or Select The printer starts or resumes printing but does not staple the rest of the j...

Page 58: ...e failure The following actions may be taken If the option was temporarily removed or not connected properly reattach or reconnect it Press Go to execute a configuration change which notifies the printer the option has been hot unplugged removed with the power on Note This action is not available if the printer is in Diagnostics Mode or running diagnostics If the device is experiencing a hardware ...

Page 59: ...Smart contact assembly service check on page 2 85 34 Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size loaded in the tray For auto size sensing trays this error occurs if the paper stop is in the incorrect position Make sure the Paper Size setting is correct for the size paper that is being ...

Page 60: ...essage displays when the page is too complex to print The following actions may be taken Press Go to clear the message and continue the job Some data loss may occur Simplify the print job and reprint if necessary Press Menu until Busy Waiting appears The following selections are possible Cancel Job Reset Printer Reset Active Bin 50 PPDS Font Error This message displays when the PPDS interpreter ha...

Page 61: ...led This error displays when data is sent to the printer across an optional parallel port but the port has been disabled Once this message displays reporting of further errors is suppressed until the menus are entered or the printer is reset 56 Standard USB Port Disabled Displayed when status is requested over the USB port but the port has been disabled Once the error has been displayed for the fi...

Page 62: ...obs from the disk because the configuration of the printer has changed This message alternates with the secondary message Held jobs may not be restored Some configuration changes that may cause this condition are Code version change Paper handling option is removed Disk has been moved to a different model printer Press Go to clear the message Some of the Print and Hold jobs stored on the disk will...

Page 63: ...n to the disk This message displays for both resource and PostScript Disk operators when the disk is full 63 Unformatted Disk This error code displays when the printer detects 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 64 Unsupported Disk Format The printer detect...

Page 64: ...imary A piece of media did not arrive at the duplex input sensor but did leave the printer exit sensor 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 232 Duplex Paper Jam Rear Lea...

Page 65: ...printed after the jam will not be stapled 238 Duplex Paper Jam Leave Job in Finisher Primary A piece of media is over one of the duplex sensors during a reset 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 t...

Page 66: ...y A staple jam has been 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 Check Stapler A staple jam has been detected during the priming operation Note Press Go to initiate priming and resume printing while either of the primary or secondary messages display...

Page 67: ...If the error occurs again the user is advised to turn the printer off remove the option and call for service User status message Explanation Check Env Feeder Connection Check envelope feeder connection Check Tray x Connection Check tray x where x 1 2 3 4 or 5 Check Duplex Connection Check duplex option connection User status message Explanation Turn Printer OFF to Enable Option A printer option In...

Page 68: ...orming Self Test appears on the display The high capacity option elevator tray moves to the uppermost position if installed The duplex option is checked if installed 7 Busy appears on the display If present the following errors or messages may display Close Door or Insert Cartridge display if the upper front cover is open or the print cartridge is missing Any cartridge errors such as Defective Car...

Page 69: ...quality black page Go to Print quality all black page on page 2 79 Print quality blank page Go to Print quality blank page on page 2 79 Print quality light print Go to Print quality light print on page 2 84 Print quality background Go to Print quality background on page 2 82 Print quality residual image Go to Print quality residual image on page 2 83 Print quality skew Go to Paper feed service che...

Page 70: ...aper Removal Tray Go to Duplex option service check on page 2 47 Paper skews in the Duplex Option Go to Duplex option service check on page 2 47 Paper fails to pass from lower option through the Duplex Option Go to Duplex option service check on page 2 47 Envelope feeder symptoms Symptom Action Envelopes do not feed from the envelope feeder Go to Envelope feeder service check on page 2 49 Envelope...

Page 71: ...yed Unable to clear or reset message POST incomplete Go to StapleSmart finisher service check on page 2 86 Paper feeds into finisher option output tray Paper is not stapled and paper does not align with the right side Go to StapleSmart finisher service check on page 2 86 Paper feeds into finisher option Paper aligns with the right side The stapler does not staple Go to StapleSmart finisher service...

Page 72: ...ems Go to Print quality test pages on page 3 20 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 5 Bin mailbox service check Service tip The majority of the mechanical components can be observed during operation by removi...

Page 73: ... 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 FRU Action 1 Bottom pass thru sensor flag assembly Control board Check the flag for correct operation binding brok...

Page 74: ...rect 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 FRU Action 1 Bin x sensor Bin x sensor control board Check the sensor flag for binds Make 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...

Page 75: ...uld result If any of the voltages are incorrect replace the control board If correct replace the mechanical linkage DC motor assembly FRU Action 1 Printer POR Turn the printer off and on several times If Error Code 900 continues to display go to step 2 2 System board Make sure the system board is properly seated in connector J7 on the interconnect board Turn the machine off and on several times wa...

Page 76: ...ce the interconnect board assembly Turn the printer on If a 950 error still displays replace the system board assembly FRU Action 1 System board Note Make sure you have the correct system board FRU number before installing the board in the printer Replace the system board FRU Action 1 Interconnect board Note Before replacing the interconnect board make absolutely sure you have the correct FRU numb...

Page 77: ...ll 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 3 Right side charge roll link Right charge roll bushing Check the right side charge roll link assembly for correct assembly operat...

Page 78: ...essary Disconnect the cover closed switch cable from J3 at the system board and measure the voltage at J3 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 I...

Page 79: ... if the printer must receive power in order to perform the task Remove any input and output paper handling options from the printer FRU Action 1 Line voltage Check the AC line voltage If the line voltage is incorrect inform the customer 2 AC line cord Unplug the line cord from the wall outlet and check the line cord for damage such as a damaged plug or cut or damaged cord If incorrect replace the ...

Page 80: ... test point on the interconnect board The voltage should measure 5 V dc If correct go to step 11 If incorrect go to step 8 8 Communications card Turn the printer off and remove the communications card Check the voltage at the 5 V test point on the interconnect board If the voltage is correct replace the communication card assembly If the voltage is incorrect go to step 9 9 Features or option insta...

Page 81: ...ed to the system board Turn the printer off and disconnect each cable connected to the system board and each option installed on the system board until the problem is located Warning When removing any card installed on the system board observe all ESD precautions when handling these options 23x jam code Jam location 231 Rear Media did not arrive at the duplex input sensor but did leave the fuser e...

Page 82: ... to the duplex input sensor and in the base machine repair as necessary If the jam occurs in the duplex option prior to the duplex input sensor go to step 2 2 Duplex input sensor If the paper does not reach the duplex input sensor make sure the sensor is connected to the duplex system board If correct check for any paper or other objects that might cause a paper jam If none are found replace the d...

Page 83: ...ect check the interconnect board If correct reinstall the envelope feeder and continue with step 3 3 Autoconnect on the envelope feeder Check for damage to the connector or contacts If you find damage replace the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc J1 7 meas...

Page 84: ... system board The voltage measures approximately 5 V dc If incorrect replace the envelope system board If correct replace the input sensor assembly FRU Action 1 DC feed motor assembly Check the motor and motor cable for loose wires or poor connections Make sure the motor cable is connected to the envelope system board 2 Envelope feeder system board Check the voltage on J4 1 The voltage measures ap...

Page 85: ...ge 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 FRU Action 1 Kick rolls feed rolls drive rolls Check all the rolls for oil grease or other contamination If you find a problem clean the rolls If this does not correct the problem replace the envelope feeder 2 Defl...

Page 86: ...stalled and the 925 error remains the fuser may have reached standby temperature too quickly Check that the line voltage is not exceeding the maximum rating for the printer 2 Fuser lamp fuser top cover assembly Observe the lamp through the left side frame If the lamp does not come on do the following Remove the redrive assembly Remove the fuser assembly disconnect the LVPS to fuser AC cable from t...

Page 87: ...the fuser control board at J6 Resistance HOT J2 1 J2 2 10K ohms COLD approximately 450K ohms If the resistance is incorrect replace the fuser top cover assembly If the resistance is correct check each pin of J6 to ground If there is continuity replace the fuser cover assembly See Fuser cover removal on page 4 25 FRU Action J2 1 J1 J6 J4 J5 1 1 1 1 ...

Page 88: ... approximately 450K ohms If the resistance is incorrect replace the fuser top cover assembly If the resistance is correct check each pin of J6 to ground If there is continuity replace the fuser cover assembly See Fuser cover removal on page 4 25 2 Fuser assembly Check for continuity between J6 1 and J1 2 and between J6 2 and J1 3 If incorrect replace the fuser assembly If correct go to step 3 3 Fu...

Page 89: ...ce of the solenoid between J4 1 and J4 2 on the fuser control board The resistance measures between 5 ohms and 10 ohms If incorrect replace the fuser assembly If correct go to step 2 2 System board Measure the voltage at the 42 V dc test point on the system board The voltage should measure approximately 42 V dc If incorrect go to step 3 If incorrect go to step 4 3 LVPS Measure the voltage at CN2 1...

Page 90: ...r cord If defective replace the cord If not defective check the AC input and output receptacles and wiring harness in the HCIT Repair or replace the receptacles or AC wiring harness as required Note Make sure the ground wire is installed correctly from the AC wiring harness to the frame of the HCIT and the nut and lock washer are tightened FRU Action 1 high capacity feeder autoconnect mechanical c...

Page 91: ...e cable is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board FRU Action 1 Pass thru sensor and flag assembly The tray x option system board did not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the...

Page 92: ... system board 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 high capacity feeder option control board 2 High capacity feeder control board Disconnect the lower limit switch cable and check the voltage at J2 1 orange The voltag...

Page 93: ...wn 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 FRU Action 1 DC drive motor assembly high capacity feeder system board Check the voltages at J1 on the high capacity system board The voltages measure approximately as follows If any of the voltages are incorrect...

Page 94: ...asure 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 replace the cable If correct replace the top optical sensor assembly FRU Action 1 High capacity feeder option contr...

Page 95: ...If incorrect replace the cable If correct check the switch for a bent or deformed actuator lever or defective switch If incorrect replace the switch FRU Action 1 DC motor assembly Make sure all the motor plate mounting screws are tight 2 Idler pulley DC motor assembly Make sure the idler pulley is not binding on the pulley shaft Check the pulley for wear Check the idler pulley shaft on the motor m...

Page 96: ...cognized option Continue with this service check or go to the service check for the failing output option FRU Action 1 Front Cover Assembly Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the high capacity option Also check to make sure the ESD brush is not loose or damaged FRU Action 1 High capacity stacker feeder Check the autoconnects cables and conne...

Page 97: ...lem replace the lower control board 2 High capacity output stacker drive belt s Drive pulleys Belt idlers Belt tension springs Check to ensure the 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 lowe...

Page 98: ...ensor 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 FRU Action 1 Tray x Option system board or compensator assembly or autoconnect cable Check the autoconnect cables and connectors for damage Replace if necessary Check the cables for continuity If incorrect replace the compensat...

Page 99: ...Test and check the sensor for proper operation If incorrect check the following Paper low sensor flag for smooth and correct operation Paper low sensor for correct installation on the autocompensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connector J5 on the system board If no problem is found replace the paper low sensor assembly If this does...

Page 100: ... 2 3 PSIZE1 SW0 X X X 3 4 PSIZE3 SW2 X X X 4 FRU Action 1 Tray 1 Check Tray 1 for damaged or broken autosize fingers Check for anything that would prevent the autosize fingers from activating the paper activate springs and ITC switches If a problem is found repair as necessary If no problem is found go to step 2 2 Integrated card autocompensator cable Check for correct installation of the cable at...

Page 101: ...r size and corresponding paper switch from table below If the voltage on J34 does not change go to step 4 If the voltage changes recheck the printer If Tray 1Missing is still displayed replace the system board assembly 4 System board Ground the appropriate pin on connector J34 on the system board Tray 1 Missing should not be displayed If it is not displayed go to step 5 If it still displays replac...

Page 102: ...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 excessive noise gears ratcheting and so on A service error code 936 Transport Motor may be displayed Check the voltage at J24 6 on the system board It measures approximately 5 V dc when the moto...

Page 103: ...n fan to system board cable Check the continuity of the cable If incorrect replace the cable 3 Error code 927 fan runs Check the voltage at J7 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 J7 3 on the system board The voltag...

Page 104: ... the system board If incorrect replace the cable If correct replace the operator panel assembly FRU Action 1 Operator panel cable Check for proper installation of the cable at the system board J15 and at the operator panel Check the continuity of the operator panel cable If incorrect replace the cable 2 Operator panel display blank 5 beeps LED off Check for correct installation of the operator pan...

Page 105: ... the fixed disk board are correctly installed Run the Quick Disk Test on page 3 2 from the Device Test on the Diagnostics 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 Tes...

Page 106: ...covers installed 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 System board Printer fails to display Remove Paper Standard Bin message Output Bin Sensor Test fails Check the voltage at J11 1 It measures 5 V dc when the flag ...

Page 107: ... 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 Rem...

Page 108: ...he pass thru sensor cable is correctly connected to J3 on the control board Disconnect the pass thru sensor cable from J3 on the control board and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the control board If correct check the voltage at J3 2 The voltage measures approximately 0 V dc If incorrect replace the sensor assembly If this does not fix the p...

Page 109: ... motor mechanical linkage assembly FRU Action 1 Dual output bin x sensor assembly Output expander control board Check for correct installation of the sensor cable at J5 on the output expander 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 output...

Page 110: ...tact the paper Also the autocompensator motor may be failing If this problems continues replace the autocompensator assembly 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 worn rollers contaminated rollers or binds Replace the alignment assembly if any problem is ...

Page 111: ... 9 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 controller board FRU Action 1 P...

Page 112: ...rint 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 lb An incorrect printer driver for the installed software can cause problems Incorrect characters could print and the copy may not fit the page correctly Service Error Code Explanation 1 Er...

Page 113: ... assembly If correct replace the system board FRU Action 1 Print cartridge Check the print cartridge for damage especially the PC drum contact on the cartridge 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 damage or...

Page 114: ...idge for 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 FRU Action 1 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 2 Lines spaced 22 32 mm 882 inch apart Lines spaced 28 7 mm 1 130 inch apart Lines space...

Page 115: ...ask 8 Lines spaced 51 02 mm 2 009 inch apart Replace the transfer roll 9 Lines spaced 52 23 mm 2 056 inch apart Replace the redrive assembly 10 Lines spaced 76 53 mm 3 013 inch apart Replace the FRUs in the following order Alignment assembly Main drive gearbox assembly 11 Lines spaced 95 66 mm 3 766 inch apart Replace the FRUs in the following order Toner cartridge Main drive gearbox assembly 12 L...

Page 116: ... 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 4 System board HVPS connector Check the following voltages at J22 on the system board Measure the voltages from J22 to printer ground If J22 1 voltage is incorrect check the...

Page 117: ...ee 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 2 Charge r...

Page 118: ...ssembly Check the connection of the transfer roll assembly cable to the transformer on the HVPS board Check the continuity of the cable from the bearing to the spade terminal on the cable If incorrect replace the right side transfer arm assembly If correct replace the HVPS 3 Printhead A contaminated printhead may be the cause of light print If no other cause is found install a new printhead FRU Ac...

Page 119: ...the smart chip on the cartridge and the smart contact assembly Service tip An intermittent 32 Unsupported Cartridge User Error message can be caused by poor contact between the smart cartridge contacts in the upper front cover and the smart chip Also check for proper seating of the smart cartridge cable to the system board FRU Action 1 Smart contact assembly System board Check the voltage on the s...

Page 120: ...oconnects of the options not recognized and the interconnect board and cable connectors 2 Stapler motor drive assembly stapler card assembly Check the autoconnects for signs of damage especially the connector pins Remove the right side cover 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 vo...

Page 121: ...y 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 FRU Action 1 Stapler assembly Replace the stapler assembly Note When replacing the stapler assembly observe the location of the ground lead from ...

Page 122: ...between J2 pins 1 2 5 and 6 on the cable and the motor case If you get continuity 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 If the voltages are correct replace the motor drive assembly If the voltages are incorrect replace the stapler card assembly 2 Drive mo...

Page 123: ...ges are correct replace the mechanical drive assembly If the voltages are incorrect replace the stapler card assembly FRU Action 1 Swing arm spring Make sure the swing arm spring is connected and not loose or broken 2 Clutch assembly Drive motor assembly Drive gear Check the clutch assembly on the right side frame assembly for correct operation and broken or loose parts Check the drive motor assem...

Page 124: ... and remove 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 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 Ch...

Page 125: ... 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...

Page 126: ...no broken gears or other mechanical parts If any are found replace the aligner assembly If no problem is found go to step 3 3 Stapler board 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...

Page 127: ...ag or spring off stapler unit Will also happen when pin 7 of J3 is open FRU Action 1 Developer drive assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929 error code Toner Sensor Check the developer drive assembly for correct installation any sign of worn loose or broken parts 2 Front harness cable Check the toner sensor portion of the front harness ca...

Page 128: ...ure it is fastened and locked in the down position If the arm is not locked down make sure the arm is not broken and locks into the EP frame correctly Check the left transfer arm assembly spring for proper operation 3 Right transfer arm assembly 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 make sure the arm is not b...

Page 129: ... Go and Return buttons 3 Turn the printer on 4 Release the buttons when Performing Self Test displays on the operator panel Available tests The tests display on the operator panel in the order shown Print Registration Print Tests Hardware Tests Duplex Tests if installed Input Tray Tests Output Bin Tests Finisher Tests if installed Base Sensor Test Device Tests displayed only if flash or disk optio...

Page 130: ...ng on the disk size To run the Disk Test Clean Test 1 Select Disk Test Clean from the Device Tests menu Files will be lost Go or Stop message displays to warn the user that all contents on the disk will be lost 2 To exit the test immediately and return to the Device Tests menu press Return Stop To continue with the test press Go If Go is selected Disk Test Clean BAD 000000 00 message displays The ...

Page 131: ...d 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 d...

Page 132: ...set 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 1 100 inch...

Page 133: ... EE and FF If the test fails remove the drive belt from the duplex DC motor and run the motor test again For the duplex DC motor to pass the test the following results must display AA 00 BB in the range of 29 through 3E inclusively hex CC in the range of 35 through 51 inclusively hex DD in the range of 0C through 13 inclusively hex For the duplex drive system to pass the test the following results...

Page 134: ...he error log The error log provides a history of printer errors It 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...

Page 135: ...or each 9xx or 2xx error Note The 900 error code does not have sub error codes The printed error log can be faxed to Lexmark or your next level of support for verification or diagnosis To print the error log 1 Select Print Log from the Error Log menu 2 To move to the next screen press Menu 3 Press Return Stop to exit the Error Log menu ERROR LOG Print Log Model and Serial number Printer informatio...

Page 136: ...ROM Memory Test Parallel Wrap if available Serial Wrap if available Serial 1 Wrap if available Serial 3 Wrap if available 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 1 Select Button Test from the Diagnostic menu With no buttons pressed several OP Open appear on the display 2 Press each...

Page 137: ... 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 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 ...

Page 138: ...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 Emptying 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 sen...

Page 139: ...wn internal bin linking regardless of 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 ...

Page 140: ...ensor 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 if installed To run the Output Bin Sensor Test for Standard Bin 1 Select Output Bin Test from the menu 2 Select Output Bin Tests Sensor Tests 3 Select Standard Bin from the menu The following screen is displayed Standard Bin F OP F St...

Page 141: ...top to exit the test High Capacity Output Stacker 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 The following screen is displayed HC Bin x TP OP P OP F OP NF OP TP High Capacity Stacker top position sensor P High Capacity Stacker pass thru sensor F High Capacity Stacker bin full senso...

Page 142: ... Tests 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 b...

Page 143: ... priming sensor H Home signal sensor Cover and Door Sensors Cover and Door TC CL SD CL TC Finisher top cover sensor SD Finisher stapler access door Pass and Media Sensors Pass and Media P OP M OP P Finisher pass thru sensor M Finisher medium sensor 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 Once the screen is...

Page 144: ...being changed 2 To select the margin value to be changed press Select until the margin value pair you want to change is blinking The print registration range is 3 To change the margin value press Menu When the value you want displays press Select to save the value 4 To exit the Registration menu press Return To verify the margin values are correct you must print the Quick Test Page from the regist...

Page 145: ...new page count in NVRAM 5 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 Select Permanent Page Count from the menu 2 Press Return Stop to exit the Diagnostic menu Maintenance page count This counter is reset by the servicer after a 80 Scheduled Maintenance message di...

Page 146: ... 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 displays You have to 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 pri...

Page 147: ...rints 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 ...

Page 148: ...opy of the Print Quality Test pages If you want more than one copy perform these steps again The following is printed Diagnostic EP Setup Fuser temperature warm up time transfer print contrast and charge roll settings Contents of the Diagnostic Error Log Printer configuration information Printer serial number controller code level engine code level operator panel code level smart option code level...

Page 149: ... on the pick arm to reduce weight in the rest state This spring is factory set to exert no more than ten to fifteen grams on the stack This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down ...

Page 150: ...matically made when the option is installed below the printer The paper input sensor is located in the rear of the duplex option under the input paper guide The paper exit sensor is located on the left frame assembly 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 architect...

Page 151: ...ime 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 a...

Page 152: ... the duplex exit sensor 235 Duplex Paper Jam Front A piece of media is over the duplex doublefeed sensor 236 Duplex Paper Jam Front A piece of media did not leave the duplex exit sensor 237 Duplex Paper Jam Front A piece of media did not reach the printer input sensor 238 Duplex Paper Jam A piece of media is over one of the duplex sensors during a reset 239 Duplex Paper Jam A paper jam has occurre...

Page 153: ...eck 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 through 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 ...

Page 154: ...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 Do not use the Sub Error chart...

Page 155: ...ctricity 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 electrica...

Page 156: ...y mounting screw being careful to maintain the adjustment 4 Reassemble the Duplex Option To do the duplex motor belt adjustment 1 Do the removal procedure Duplex motor removal on page 4 19 to access the motor mounting screws but do not remove the motor 2 Loosen the screw in the elongated adjustment slot and position the motor to provide 3 mm 5 mm motor belt deflection 3 Tighten both mounting screw...

Page 157: ... printhead frame assembly Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots It is necessary to perform a registration adjustment before locking down the three printhead mounting screws To perform the registration adjustment 1 Turn the printer off 2 Press and hold Return and Go 3 Turn the printer on and release the buttons when Performing Self ...

Page 158: ...registration on page 3 16 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...

Page 159: ...n the range specified in Print registration on page 3 16 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 ...

Page 160: ...n attach 1 toner level sensor mounting 1 charge roll bracket mounting 1 main drive gearbox mounting 3 EP module to left and right side frame attach 9 developer drive assembly mounting 2 stacker duct to frame mounting 2 cartridge hold down assembly mounting 2 MPT deflector mounting 2 laser cover mounting 4 deflector mounting 2 spring mounting 1 system board mounting front 2 integrated tray ITC boar...

Page 161: ...1 ground cables to ground center pan front attach 1 cable clip main drive gearbox BTM mounting 2 M3x8 mm Taptite LVPS mounting 2 autocompensator hanger bracket mounting 1 M3x6 mm Taptite Panhead stacker duct mounting 1 system board to shield mounting 2 system board mounting 2 shield ground attach 1 LVPS mounting 2 fuser cover mounting 2 cable clip mounting 2 outer shield mounting 6 INA cover mount...

Page 162: ...g autocompensator mounting 3 M3 5x10 mm Plastite Thread Forming right side cover mounting 1 right side frame to pan attach 3 left side frame to pan attach 1 right side frame to right side cover attach 1 M3 5x12 mm Plastite Thread Forming with washer printhead to EP frame mounting 3 Reference number Screw type Location Purpose Qty ...

Page 163: ...nter 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 removals Left door removal 1 Open the upper and bottom front covers 2 Press the two left door latch buttons A an...

Page 164: ...emove the redrive cap 2 Remove the redrive assembly 3 Open the upper and lower front covers 4 Remove the print cartridge 5 Remove the right cover mounting screw A and release the cover latch B 6 Remove the right side cover mounting screw C B A 324 C 324 ...

Page 165: ...formation 4 11 4060 xxx 7 Remove the right side cover Note When replacing the right side cover make sure the cover retainers are correctly located in the appropriate slots in the right side frame Cover retainers ...

Page 166: ...4 12 Service Manual 4060 xxx Upper front cover removal 1 Raise the upper front cover 2 Remove the upper front cover mounting screws A A 323 ...

Page 167: ...e When removing the cover hold the upper and lower latch and spring to prevent them from falling into the printer Note Use caution to avoid scratching or damaging the operator panel lens cover 4 Set aside the operator panel overlay Note Be sure to replace the overlay when you replace the upper front cover ...

Page 168: ...ight cover See Right cover removal on page 4 10 3 Remove the paper support 4 Remove the redrive cap 5 Press the fuser wiper cover latch and remove the cover 6 Loosen screw A and remove the two screws B on the right side 7 Remove the mounting screws C from the left side B 102 A 323 C 102 ...

Page 169: ...ssembly from the mounting bracket See Paper bin full sensor flag assembly removal on page 4 54 9 Unlatch the front right and front cover posts left and remove cover 10 Remove fan grill cover Note Be sure to reseat the fan grill cover before replacing the laser assembly cover ...

Page 170: ... 2 Remove the inner shield 3 Remove the gear guard 4 Remove the power takeoff shaft and spring A through the bottom of the printer 5 Place your thumb on the top of the gear and press firmly down and away Note You need to exert firm pressure to snap the bevel gear out A ...

Page 171: ...portion and press or pull into position Note You should hear two distinct snaps If you only hear one the bevel gear is only partially engaged and you should continue to press until the second snap is heard Very firm pressure is required CAUTION Do not brace your hands below the bevel gear itself When the gear double snaps into place it may pinch your hand 5 Install the power takeoff shaft and spri...

Page 172: ...See Handling ESD sensitive parts on page 4 1 3 Remove the communications board mounting screw A 4 Remove the communications board shield mounting screw B 5 The communications board is held in place by a ground clip C on the shield that attaches the communications board shield to the side frame Pull the board up to unclip the shield 6 Remove the screws that hold the shield to the communications boa...

Page 173: ...move the left cover upper front cover and outer system board shield 2 Disconnect the cover closed switch cable from the system board J3 3 Remove the screw A that attaches the cover closed switch 4 Remove the cable retainer from the left side of the upper front cover hinge assembly Note the routing of the cover closed switch and operator panel cables 5 Remove the cover closed switch cable assembly ...

Page 174: ...talling the assembly Frames removals EP frame assembly 1 Remove the left and right side frames See Left side frame on page 4 20 and Right side frame on page 4 22 2 Remove the EP frame assembly Left side frame 1 Remove the covers 2 Remove the inner shield See Inner shield removal on page 4 34 3 Remove the main drive assembly See Main drive assembly removal on page 4 44 4 Remove the upper front cove...

Page 175: ...e paper alignment assembly See Paper alignment assembly removal on page 4 52 7 Remove the left side frame mounting screws A 8 Place the printer on its back and remove the left side frame mounting screws B 9 Remove the left side frame A 102 B 104 ...

Page 176: ...on page 4 42 4 Remove the multipurpose tray assembly 5 Disconnect the autocompensator arm bias spring from the right side frame 6 Remove the toner sensor mounting screw A disconnect the sensor cable and remove the toner sensor 7 Remove the smart cartridge contact assembly mounting screw C 8 Remove the right side frame mounting screws B and remove the right side frame CAUTION Be sure the fuser asse...

Page 177: ... See Redrive assembly removal on page 4 57 2 Remove the fuser mounting screws A 3 Disconnect the AC fuser lamp cable C from the fuser lamp connector D 4 Pull the fuser assembly out far enough to remove the fuser lamp cable 5 Disconnect the DC fuser cable E from the fuser board 6 Pull the cables free and remove the fuser A A D C E ...

Page 178: ... reinstall the fuser be sure to route the fuser lamp cable through the channel F on the right side frame above the LVPS under the clip G and through the notch in the frame H 2 Route the fuser lamp cable through the opening in the fuser as shown J F G H J ...

Page 179: ... removal CAUTION Unplug the printer before you begin 1 Remove the fuser assembly See Fuser assembly removal on page 4 23 2 Note the thermistor cable A routing 3 Clip the cable tie B and disconnect the thermistor cable C from the fuser board A B C ...

Page 180: ...ual 4060 xxx 4 Disconnect the AC fuser lamp cable A from the top left side of the fuser cover 5 Remove the two screws C from the right side fuser lamp contact cover 6 Release the latch D and remove the cover A C 202 D ...

Page 181: ... xxx 7 Remove screw A that attaches the fuser lamp contact to the fuser cover 8 Remove the two screws B one on each side of the fuser that attach the fuser upper cover assembly to the fuser frame 9 Remove the fuser laser cover A B ...

Page 182: ...er exit guide assembly Fuser lamp removal 1 Remove the fuser assembly See Fuser assembly removal on page 4 23 2 Disconnect the fuser lamp AC cable from the left side of the top cover assembly 3 Remove the two screws A from the left side fuser lamp contact cover Warning Take care when removing the screw as the lamp is under spring tension When the contact is released damage to the lamp or contact m...

Page 183: ... 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 Use the following table to identify and install the correct lamp Description P N Fuser Lamp 115 V 56P1362 Fuser Lamp 220 V 56P1363 ...

Page 184: ...ner paper deflector See Inner paper deflector assembly removal on page 4 33 4 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 5 Remove the screw that attaches the transfer plate ground wire to the center pan 6 Remove the fuser transfer plate 7 Remove the screw that attaches the deflector cable to the transfer plate A ...

Page 185: ...ive power in order to perform the task 1 Remove the inner paper deflector See Inner paper deflector assembly removal on page 4 33 2 Remove the right side cover See Right cover removal on page 4 10 3 Disconnect the HVPS cable from the HVPS at connector A 4 Disconnect the transfer roll cable B from the HVPS board Warning Use care when disconnecting the cable from the transformer on the HVPS The cabl...

Page 186: ...4 32 Service Manual 4060 xxx 5 Remove the HVPS mounting screws C 6 Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS C 235 ...

Page 187: ...63 3 Place the printer on its side 4 Remove the MPT deflector assembly See Inner paper deflector assembly removal on page 4 33 5 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 6 Disengage the two latches B on the upper part of the deflector from the upper edge of the frame C and lift to remove A B C C ...

Page 188: ...ecautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 4 Disconnect all cables from the system board 5 Remove the inner shield mounting screws A 6 Remove the USB connector mounting screw B if present 7 Remove the inner shield Input sensor removal 1 Remove the inner paper deflector assembly 2 Disconnect the input sensor cable from the input sensor 3 Release the in...

Page 189: ...r assembly removal 1 Remove the paper tray 2 Remove the left door 3 Remove the outer shield See Outer shield removal on page 4 52 4 Disconnect the autocompensator motor cable from the system board J28 5 Cut cable tie A on left side 6 Place the printer on its back A ...

Page 190: ...ssembly A on the bottom of the printer and disconnect the autocompensator arm bias spring B Note When you remove the spring note the larger loop attaches to the side frame 8 Remove the C clip C that rests against the right side frame from the autocompensator pivot shaft A B C ...

Page 191: ...isconnect the autocompensator sensor cable D from the assembly 10 Remove the autocompensator assembly mounting screw E 11 Remove the integrated tray autocompensator assembly Note When you reinstall the assembly reinstall the cable tie D E ...

Page 192: ...emove the integrated tray and look underneath the printer for the autocompensator arm Pull the arm down 2 Press on the end of the tab and pull the pick roll off the arm Repeat this step for the pick roll on the other side Next gently release the autocompensator arm Discard the used pick rolls ...

Page 193: ...on the pick roll and align it with the tab on the arm There are two arrows on each pick roll Make sure the bottom arrow faces you as you align the recessed area with the tab 3 Push the pick roll onto the arm with the tab aligned Repeat this step on the other side to install the other pick roll 4 Gently release the autocompensator arm Insert integrated tray ...

Page 194: ...Any time the interconnect board assembly is replaced the Configuration ID must be reset in NVRAM on the new interconnect board Go to Setting configuration ID on page 3 18 1 Remove any feature or option cards from the interconnect board 2 Remove the inner shield See Inner shield removal on page 4 34 3 Remove the LVPS access plate and disconnect the LVPS cable from CN2 A 4 Disconnect cables J4 and J...

Page 195: ...interconnect board assembly Internal tray card ITC Paper size sensing board removal 1 Remove the paper size sensing board mounting screw A 2 Disconnect the paper size sensing board cable B from the board 3 Remove the paper size sensing board from the ITC latch C 4 Remove the paper size sensing board A 202 A C B ...

Page 196: ...ge 4 10 2 Remove fuser assembly See Fuser assembly removal on page 4 23 3 Remove the LVPS mounting screws A from the rear of the bottom pan 4 Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser lamp cable Warning The LVPS assembly may be difficult to remove from the printer Do not use excessive force in the removal A 203 ...

Page 197: ...Repair information 4 43 4060 xxx 5 Remove the LVPS access plate 6 Disconnect the interconnect card cable from the LVPS A 7 Remove the LVPS A ...

Page 198: ...al 4060 xxx Main drive assembly removal 1 Remove the inner shield See Inner shield removal on page 4 34 2 Remove the gear guard A 3 Remove the developer drive assembly See Developer drive assembly removal on page 4 20 A ...

Page 199: ...ect the cable from the main drive motor 10 Remove the main drive assembly Note Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly Warning Whenever the main drive assembly is removed from the printer 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 a...

Page 200: ...al on page 4 14 2 Remove the inner shield See Inner shield removal on page 4 34 3 Remove the fan grill cover 4 Note the routing of the main fan cable A and disconnect the cable from the system board at connector J7 5 Release the four latches B and remove the fan from the left side frame B B A ...

Page 201: ...g 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 2 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 63 3 Remove the solenoid mounting screw C 4 Remove the screws D mounting the multipurpose tray lower deflector assembly 5 Remove the multipurpose tray lower deflector assembly B A D...

Page 202: ...assembly removal 1 Remove the upper front cover 2 Remove the operator panel overlay A and set it aside 3 Gently press the operator panel lens tabs to loosen the operator panel 4 Disconnect the operator panel cable and remove the operator panel A ...

Page 203: ...e upper front cover See Upper front cover removal on page 4 12 2 With the upper front cover upside down on a soft non scratching surface release the clips and remove the operator panel lens cover Note Use caution to avoid scratching or damaging the operator panel lens cover ...

Page 204: ...system board shield See Outer shield removal on page 4 52 4 Disconnect the operator panel cable from connector J15 on the system board 5 Remove the operator panel See Operator panel assembly removal on page 4 48 6 Remove the cable retainer from the left side of the upper front cover hinge assembly Note the routing of the operator panel and cover closed switch cables 7 Remove the old cable from the...

Page 205: ...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 the paper tray frame assembly Paper tray board removal 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 th...

Page 206: ... and remove the shield Paper alignment assembly removal 1 Remove the upper paper deflector assembly See Upper paper deflector assembly removal on page 4 63 2 Remove the inner paper deflector assembly See Inner paper deflector assembly removal on page 4 33 3 Release the input paper sensor from its mounting and remove 4 Remove the left door A 202 A 202 ...

Page 207: ...embly mounting screws A 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 4 when you reinstall the assembly B ...

Page 208: ...al 1 Remove the left door 2 Remove the right cover 3 Remove the rear paper deflector 4 Press the fuser wiper cover latch and remove the cover 5 Loosen screw A and remove the two screws B on the left side 6 Remove the mounting screws C from the right side B 102 A 323 C 102 ...

Page 209: ...e flag 8 Use your thumb to bend the paper full flag assembly slightly to unlatch it from the mounting bracket Pick roll removal MPT 1 Remove the upper paper deflector See Upper paper deflector assembly removal on page 4 63 2 Release the pick roll retaining tab and slide the pick roll off the shaft ...

Page 210: ...ing screws B and remove the printhead Note Do the Printhead assembly adjustment on page 4 3 whenever you remove or replace the printhead assembly or loosen the mounting screws Note The 000 010 machine type printhead is shown Cables for the 200 210 and for the 400 410 machine type are different See Printhead 1 000 010 on page 7 10 Printhead 2 200 210 on page 7 11 and Printhead 3 400 410 on page 7 1...

Page 211: ...60 xxx Redrive assembly removal 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 ...

Page 212: ... contact assembly mounting screw B Note the routing of the smart cartridge contact assembly cable C 6 Remove the assembly A Note Be sure to route the cable in the same location as shown C when replacing the assembly System board removal Warning Observe all ESD precautions while handling ESD sensitive parts See Handling ESD sensitive parts on page 4 1 1 Remove the outer shield See Outer shield remo...

Page 213: ...ications board shield mounting screw D 9 The communications board is held in place by a ground clip E that attaches the communications board shield to the side frame Pull the board up to unclip the shield 10 For the non network system board remove the two screws that hold the shield to the communications board Note Retain the shield and any screws to install on the new board B A 102 A 232 C 232 D ...

Page 214: ...d to separate the boards 2 For non network models connect the communications board bracket to the communication board with two screws A 3 Clip the communications board shield ground clip on the frame and insert the communications card into the interconnect card slot 4 Replace the communications board shield mounting screw to connect the bracket to the frame 5 Insert the communications board mounti...

Page 215: ...e toner sensor mounting screw A 3 Disconnect the toner sensor cable and remove the toner sensor Transfer roll assembly removal 1 Open the upper front cover and remove the print cartridge 2 Unsnap the transfer roll assembly from the left pivot arm 3 Lift the transfer roll assembly toward the left and remove it from the printer A 102 ...

Page 216: ...ch hinge 4 Detach the two springs B from the upper front cover hinges 5 Detach spring C from the left side of the hinge assembly 6 Remove the cover closed switch assembly 7 Disconnect the operator panel cable from the operator panel assembly 8 Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket D 9 Lift the left pivot arm from th...

Page 217: ...tor assembly removal 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 ...

Page 218: ...4 64 Service Manual 4060 xxx ...

Page 219: ...gnal static Bottom autoconnect 1 24 V dc 2 0 V dc 3 5 V dc 4 0 V dc 5 0 V dc 6 0 V dc Front autoconnect 1 0 V dc 2 0 V dc 3 0 V dc 4 5 V dc 5 0 V dc 6 24 V dc Top autoconnect 1 0 V dc 2 5 V dc 3 0 V dc 4 0 V dc 5 0 V dc 6 5 V dc 7 0 V dc 8 24 V dc 3 5 2 6 4 1 3 5 2 6 4 1 3 2 1 4 5 6 7 8 ...

Page 220: ...6 24 V dc Return 7 24 V dc J2 1 Ground 2 Paper Present 3 5 V dc J3 1 Ground 2 Paper Present 3 5 V dc J4 1 Motor Phase B 2 Motor Phase A 3 Motor Phase B 4 Motor Phase A Fuser Board not a FRU Connectors J1 System board J2 Narrow media sensor J3 N A J4 Solenoid J5 Exit sensor J6 Thermistor J3 J1 1 1 J2 J4 1 1 J2 1 J1 J6 J4 J5 1 1 1 1 ...

Page 221: ...out 2 Ground 3 prtrxd 4 Ground J3 Pass thru sensor 1 Ground 2 Paper Present 3 RVsnsr J4 DC motor 1 mtrout1 2 mtrout2 3 Ground 4 Ground 5 tach 6 5 V dc J5 Bin full near full dual sensor 1 Ground 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper connector 1 Upper unit 2 Upper Lower Unit 3 Lower Unit J6 1 M S J6 connector jumper locations High capacity stacker board Pin 1 Pin 2 Pin 3 Upper unit board X X...

Page 222: ...oltage power supply Connector CN no Signal CN1 System board 1 Developer PWM 2 24 V dc Return 3 Charge PWM 4 24 V dc IN 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO OUT JC1 JC2 JC3 JC4 JC5 JC6 JC7 JC8 Dr B JC10 TAR Dev PCD Chg JC9 T302 CN1 1 ...

Page 223: ...round 10 Ground J3 LVPS 1 Ground 2 Ground 3 Ground 4 Ground 5 5 V dc 6 5 V dc 7 5 V dc 8 5 V dc J4 Autoconnect 1 0 V dc 2 5 V dc 3 0 V dc 4 24 V dc J5 Autoconnect 1 24 V dc 2 Ground J6 Autoconnect BTM FNT 1 24 V dc 2 Ground J7 System board 1 N A J11 Feature option 1 N A J12 Feature option 1 N A BAR CODE AREA 1 1 J2 J3 J1 J7 J11 J4 J5 F2 F1 J12 24V 5V U3 1 1 4 BAR CODE AREA 1 1 J2 J3 J1 J7 J11 J4 J...

Page 224: ...l CN1 Fuser lamp AC 1 AC fuser lamp 2 Not used 3 AC fuser lamp CN2 DC output 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc CN1 SK1 CN2 F1 F2 1 9 10 18 ...

Page 225: ...d 4 Ground 5 N C J2A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J2B 1 prtxdout 2 Ground 3 prtrxd 4 Ground J3 Pass thru sensor 1 Ground 2 Paper Present 3 RVsnsr J4 DC motor 1 mtrout1 2 mtrout2 3 Ground 4 Ground 5 tach 6 5 V dc J5 Bin full near full dual sensor 1 Ground 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper connector 1 Not used 2 Not used 3 Not used J6 1 M S ...

Page 226: ...J2 Feed motor 1 fdmtr1 2 fdmtr2 3 Ground 4 Ground 5 tachft 6 5Vptt J3 Stepper motor 1 stpmtr 2 stpmtr 3 stpmtr 4 stpmtr 5 crtprsnt 6 stplow 7 stpphomo 8 Ground 9 5Vstpl 10 stprimed J4 Accessory connector 1 24 V dc 2 accmtr 3 Ground 4 Ground 5 tacha 6 5Vptt J5 Solenoid 1 Sol1 2 24 V dc J6 Stapler 1 Ground 2 pfrinstp 3 5Vsnsr2 J14B J13 J12 J10 J9 J8 J7 J6 J5 J15 J4 J3 J2 J1B J1A J14A 1 1 1 1 1 1 1 1...

Page 227: ...0 Left side sensor board 1 Ground 2 full 3 NRFull 4 Ground J12 Pass thru sensor 1 Ground 2 psthruint 3 5Vptt J13 Cover open switch 1 5V dc 2 Ground 3 cvropin J14A 1 24V dc 2 Ground 3 5V in J14B 1 prtxdout 2 Ground 3 prtrxd 4 Ground 5 Ground J15 Stapler door open 1 Dooropin 2 Ground 3 5Vswitch Connector Pin no Signal J14B J13 J12 J10 J9 J8 J7 J6 J5 J15 J4 J3 J2 J1B J1A J14A 1 1 1 1 1 1 1 1 1 1 1 1 ...

Page 228: ...d non network OPTION CARD OPTION CARD OPTION CARD OPTION CARD J14 J15 J19 J22 J26 1 J32 J34 J28 J29 J4 J24 J7 J31 J3 J2 99 J5 J27 J11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 J13 49 100 50 1 J8 J10 J20 1 GND 1 3 3V 24V HEAT 5V 42V J16 J9 FRU No XXXXXX ...

Page 229: ...board network OPTION CARD OPTION CARD OPTION CARD OPTION CARD J14 J15 J19 J22 J26 1 J32 J34 J28 J29 J4 J24 J7 J31 J3 J2 99 J5 J27 J11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 J13 49 100 50 1 J8 J10 1 GND 1 3 3V 24V HEAT 5V 42V J23 J16 J9 FRU No XXXXXX ...

Page 230: ...J 7 LPOW FB 8 LENA J3 Cover closed switch 1 Cov Closed 2 Ground 3 5V dc J4 Printhead HSYNC 1 5V dc 2 HSYNC ID 3 HSYNC IN 4 Ground J5 Printhead mirror motor 1 Ground 2 Ground 3 MM REF R 4 MM LOCK 5 MM Stgart 6 Ground 7 24V dc J6 Printhead fan 400 410 1 24V dc 2 PH FAN J7 Main fan 1 FANSTALL 2 Ground 3 MAINFAN J8 SDRAM memory J9 Cartridge fan 1 CARTFAN 2 Ground J10 SDRAM memory J11 Output level outp...

Page 231: ...MPRET 8 EXIT SNS J15 Operator Panel 1 OPPAN INT 2 Ground 3 I2C CLK R 4 5V dc 5 I2C DAT R J16 not used J17 not used J18 not used J19 Smart cartridge 1 SM Cart 2 Ground 3 Ground J20 Parallel port not used for network model J21 not used System board non network and network see System board non network on page 5 10 or System board network on page 5 11 Connector Pin no Signal 99 1 49 100 50 J20 J16 ...

Page 232: ...r 11 5V dc 12 TONER WHEEL 13 Ground J23 not used for non network model J24 BLDC main drive motor 1 ON OFF 2 Ground 3 BLDC CLK 4 5V dc 5 MTR1 6 DIR 7 BLDC HALL 8 BLDC LOCK 9 Ground 10 Ground 11 24V dc System board non network and network see System board non network on page 5 10 or System board network on page 5 11 Connector Pin no Signal 99 1 49 100 50 J16 J23 ...

Page 233: ...UT 2 Ground 3 MPF LED J27 not used J28 Autocompensator 1 24V dc internal tray 2 AutoComp J29 Bottom options 1 RXD1R 2 Ground 3 TXD1BR 4 Ground J30 not used J31 top options 1 RXD1R 2 Ground 3 TXD1BR 4 Ground J32 MPF pick solenoid 1 MPFPick 2 24V dc J33 Ethernet connector System board non network and network see System board non network on page 5 10 or System board network on page 5 11 Connector Pin...

Page 234: ...round 6 TRAY1 POUT 7 TRAY1 PLOW 8 3 3V dc autocomp motor 9 ENCODER 10 5V dc J35 System board edge connector J36 not used J37 not used J40 SDRAM on board System board non network and network see System board non network on page 5 10 or System board network on page 5 11 Connector Pin no Signal ...

Page 235: ... cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication specifications No requirements for this printer 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 charge roll and pick tires at this interval to maintain the print ...

Page 236: ...6 2 Service Manual 4060 xxx ...

Page 237: ...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 The parts catalog uses the last three digits of the type to identify model specific replacement FRUs Model name Configuration Machine type Parts catalog Lexmark T630 Non network 4060 000 000 Lexmark T630n Network 4060...

Page 238: ...7 2 Service Manual 4060 xxx Assembly 1 Covers ...

Page 239: ... French and Spanish 13 56P1754 1 Kit operator panel overlay Dutch French German and Italian 13 56P1755 1 Kit operator panel overlay Czech and Hungarian 13 56P1756 1 Kit operator panel overlay Danish Finnish Norwegian and Swedish 13 56P1757 1 Kit operator panel overlay Polish Russian and Turkish 13 56P1758 1 Kit operator panel overlay WW English and Spanish 13 56P1759 1 Kit operator panel overlay W...

Page 240: ...7 4 Service Manual 4060 xxx Assembly 2 Frame 1 5 2 1 3 4 3 4 8 6 7 ...

Page 241: ... 1 56P1347 1 Frame EP module 200 210 400 410 2 56P1320 1 Right side frame assembly 3 99A1540 4 Nut plate frame extension 200 210 400 410 4 99A0263 4 Parts packet screw 5 99A1518 1 Frame extension right 200 210 400 410 6 99A1538 1 Contact RSF ground 7 99A1517 1 Frame extension left 200 210 400 410 8 56P1321 1 Left side frame ...

Page 242: ...7 6 Service Manual 4060 xxx Assembly 3 Frame 2 3 7 5 9 2 10 6 1 11 13 18 16 15 17 12 19 23 28 26 24 22 27 25 21 31 30 29 8 14 4 32 14 5 8 5 8 8 33 34 35 36 5 20 37 38 ...

Page 243: ...l 3 Contact PC drum 1 Contact charge roll 1 Block contact mounting 4 Screw contact mounting 5 13 99A0028 1 Spring tray bias 14 99A2019 2 Spring cartridge hold down 15 99A0026 1 Tray bias arm assembly 16 99A0039 2 Roller developer support 17 99A1525 1 Deflector upper PF 18 56P1334 1 Deflector inner 000 010 18 56P1336 1 Deflector inner 200 210 400 410 19 99A0053 1 Sensor input 20 99A1546 1 Shield ge...

Page 244: ...7 8 Service Manual 4060 xxx Assembly 3 cont Frame 2 3 7 5 9 2 10 6 1 11 13 18 16 15 17 12 19 23 28 26 24 22 27 25 21 31 30 29 8 14 4 32 14 5 8 5 8 8 33 34 35 36 5 20 37 38 ...

Page 245: ...250 sheet 000 010 35 99A2016 1 Duct left stacker 500 sheet 200 210 400 410 36 56P1351 1 Door assembly redrive 250 sheet 36 56P1329 1 Door assembly redrive 500 sheet 37 99A1613 1 Flag output paper level 000 010 37 56P1316 1 Flag output paper level 200 210 400 410 38 99A2017 1 Guide extension NS 99A1541 1 Clip external ground NS 99A0263 17 Parts packet screw ...

Page 246: ...0 Asm index Part number Units Description 4 1 56P1386 1 Cable laser 2 99A0263 3 Parts packet screw printhead mounting 3 56P1396 1 Printhead assembly includes all cables 000 010 4 56P1387 1 Cable HSYNC 5 56P1388 1 Cable mirror motor 000 010 000 010 1 2 3 4 2 5 ...

Page 247: ...d 2 200 210 Asm index Part number Units Description 5 1 56P1386 1 Cable laser 2 99A0263 3 Parts packet screw printhead mounting 3 56P1443 1 Printhead assembly includes all cables 200 210 4 56P1387 1 Cable HSYNC 2 1 2 3 4 200 210 Top View Bottom View ...

Page 248: ...d 3 400 410 Asm index Part number Units Description 6 1 56P1386 1 Cable laser 2 99A0263 3 Parts packet screw printhead mounting 3 56P1854 1 Printhead assembly includes all cables 400 410 4 56P1387 1 Cable HSYNC 400 410 Bottom View 2 1 2 4 3 Top View ...

Page 249: ...s packet bellcrank and spring for 250 tray 000 010 2 56P1331 1 Parts packet bellcrank and spring for 500 tray 200 210 400 410 3 99A0070 2 Pick roll assembly 4 56P1324 1 Flag paper out 250 sheet tray 000 010 4 56P1323 1 Flag paper out 500 sheet tray 200 210 400 410 5 99A0263 1 Parts packet screw hanger 6 56P1406 1 Card asm paper wt paper low out sensor 7 56P1382 1 Int card autocomp card cable paper...

Page 250: ...7 14 Service Manual 4060 xxx Assembly 8 Paper feed multipurpose feeder 3 11 7 5 9 2 6 4 8 1 7 13 5 12 10 ...

Page 251: ...t Pad separator Housing separator pad Spring sep pad Arm separator Spring sep 6 99A1531 1 MPF lower deflector 7 99A0263 2 Parts packet screw lower deflector mounting 8 mm 7 99A0263 2 Parts packet screw lower deflector mounting 12 mm 8 99A2071 1 Sensor MPF paper out 9 99A0081 1 Spring assembly separator 10 99A0263 1 Parts packet screw frame mounting 11 99A0073 2 Screw damper 12 99A0074 2 Bushing pi...

Page 252: ...7 16 Service Manual 4060 xxx Assembly 9 Paper feed alignment 3 2 1 4 ...

Page 253: ...1327 1 Alignment assembly paper feed 2 99A0263 1 Parts packet screw clip ref ground mounting 3 56P1349 1 Clip reference ground 4 56P1346 1 Parts packet reference adjust Screw paper reference adjust Washer paper reference adjust Nut paper reference adjust NS 99A0263 3 Parts packet screw alignment asm mounting ...

Page 254: ...7 18 Service Manual 4060 xxx Assembly 10 Integrated paper tray 250 sheet 3 11 7 5 9 2 10 6 4 8 1 ...

Page 255: ...250 sheet 2 99A1601 1 Latch back restraint 3 99A2160 1 Restraint back 250 sheet tray 4 99A0120 2 Restraint pad 5 99A1894 1 Restraint side 250 sheet tray 6 99A0119 4 Wear strips 7 99A1812 1 Label tray option number 8 99A0121 1 Clip 250 sheet tray wear 9 99A0126 3 Finger autosize 10 99A0124 1 Plate snap in 11 99A0127 1 Slider autosize 250 sheet ...

Page 256: ...7 20 Service Manual 4060 xxx Assembly 11 Integrated paper tray 500 sheet 3 11 7 5 9 2 10 6 4 8 1 ...

Page 257: ...Tray assembly 500 sheet 2 99A1895 1 Restraint side 3 99A0292 4 Strip wear 4 99A1812 1 Label tray option number 5 99A1583 1 Plate 500 sheet tray wear 6 99A0126 3 Finger autosize 7 99A0124 1 Plate snap in 8 99A1582 1 Slider autosize 500 sheet 9 99A0120 2 Restraint pad 10 99A2093 1 Restraint back 11 99A1601 1 Latch back restraint ...

Page 258: ...7 22 Service Manual 4060 xxx Assembly 12 Drives Main drive and developer drive 3 2 4 1 7 6 5 ...

Page 259: ...9A0134 1 Shaft power takeoff 250 000 010 2 99A1569 1 Shaft power takeoff 500 200 210 400 410 3 99A0275 1 Spring power takeoff shaft 4 56P2162 1 Gear bevel with grease packet and washer 5 99A1544 1 Developer drive assembly 6 99A2081 1 Parts packet developer drive shaft coupler gear 55 7 99A0263 3 Parts packet screw developer drive ground NS 99A0263 4 Parts packet screw gearbox mounting NS 99A0263 3...

Page 260: ...7 24 Service Manual 4060 xxx Assembly 13 Hot roll fuser 3 7 5 2 6 4 1 5 8 7 9 ...

Page 261: ...20V lamp 400 410 1 56P2547 1 Fuser assembly w 100V lamp 400 410 2 99A1658 1 Cover fuser wiper cavity 3 56P1415 1 Wiper assembly wet 4 56P1348 1 Kit fuser cover assembly with thermistor thermal fuse and L R fuser lamp contact assemblies w fuser cover control card 5 99A0263 4 Parts packet screws Contact assembly 4 Solenoid mounting 1 Board cover mounting 1 Fuser cover assembly 4 Hanger 7 6 56P1362 1...

Page 262: ...7 26 Service Manual 4060 xxx Assembly 14 Transfer charging 3 2 4 1 5 6 7 9 10 8 ...

Page 263: ...55 1 Bushing charge roll 4 99A0513 1 Parts kit charge roll link asm right side 5 56P1357 1 Transfer roll assembly 6 99A0349 1 Arm transfer roll assembly right 7 99A0184 1 Spring transfer roll right 8 99A0185 1 Shaft transfer pivot 9 99A0181 1 Spring transfer roll left 10 99A1578 1 Arm transfer roll left NS 99A0263 1 Parts packet screw charge roll NS 99A0267 1 Parts packet retainer pivot shaft ...

Page 264: ...7 28 Service Manual 4060 xxx Assembly 15 Electronics power supplies 3 7 5 2 6 4 1 ...

Page 265: ...BlueMark Catalan CIS Czechoslovakia Finland France Germany Greece Hungary Italy Netherlands Norway Poland Portugal Russia Slovak countries Spain Sweden Turkey 4 1339537 1 Power cord set Ireland U K 4 1339539 1 Power cord set Israel 4 1339552 1 Power cord set Japan 4 1339540 1 Power cord set Switzerland 4 1339541 1 Power cord set Botswana Lesotho Namibia Pakistan South Africa 4 1342534 1 Power cord...

Page 266: ...7 30 Service Manual 4060 xxx Assembly 16 Electronics card assemblies 3 1 4 5 6 9 2 4 7 8 10 ...

Page 267: ...ystem board assembly network 210 includes 56P1445 2 56P2415 1 System board assembly network 410 includes 45P1445 3 56P1340 1 Interconnect board assembly 1 slot 000 010 4 2 Screws PP 99A0263 5 56P1339 1 Interconnect board assembly 2 slot 200 210 400 410 6 56P1850 1 Card assembly Bar code 6 56P2468 1 Card assembly IPDS and SC5 TNe 6 56P2182 1 Card assembly ImageQuick 6 56P1851 1 Card assembly PrintC...

Page 268: ...7 32 Service Manual 4060 xxx Assembly 17 Electronics shields ...

Page 269: ...6 Parts packet screw outer shield mounting 3 99A0263 1 Parts packet screw inner shield mounting 4 56P1341 1 Cover INA flat blank 5 56P2404 1 Shield INA flat non network 6 56P2405 1 Shield INA flat network 7 56P1342 1 Shield inner assembly 2 slot 200 210 400 410 8 56P1343 1 Shield inner assembly 1 slot 000 010 9 56P1345 1 Shield outer 1 slot 000 010 10 56P1344 1 Shield outer 2 slot 200 210 400 410 ...

Page 270: ...7 34 Service Manual 4060 xxx Assembly 18 Cabling diagrams 1 3 1 2 4 5 6 7 8 7 4 ...

Page 271: ...1 Sensor standard bin level with cable 4 56P1382 1 Int card autocomp card cable paper low out sensors 5 56P1326 1 Pick arm assembly 250 sheet 000 010 5 56P1325 1 Pick arm assembly 500 sheet 200 210 400 410 6 56P1383 1 Cable autoconnect bottom 7 56P1400 1 Cable autoconnect top 000 010 7 56P1401 1 Cable autoconnect top 200 210 400 410 8 56P1384 1 Cable main drive motor ...

Page 272: ...7 36 Service Manual 4060 xxx Assembly 19 Cabling diagrams 2 HVPS LVPS 3 5 4 1 2 6 ...

Page 273: ...scription 19 1 56P1394 1 Cable assembly operator panel 2 56P1385 1 Cable front harness HVPS input sensor toner sensor 3 56P1395 1 Switch cover closed w cable 4 56P1398 1 Sensor MPF cable 5 56P2407 1 MPF solenoid w cable 6 56P1399 1 Smart contact assembly w cable NS 56P1389 1 Cable deflector ...

Page 274: ...7 38 Service Manual 4060 xxx Assembly 20 Cabling diagrams 3 3 4 5 6 1 2 400 410 2 000 010 1 1 2 200 210 2 7 ...

Page 275: ...ndex Part number Units Description 20 1 56P1386 1 Cable laser 2 56P1387 1 Cable HSYNC 3 56P1390 1 Cable system board to fuser board 4 56P1403 1 Exit sensor 5 56P1402 1 Narrow media sensor 6 56P1405 1 Cable AC fuser lamp to LVPS 7 56P1388 1 Cable mirror motor 000 010 ...

Page 276: ...7 40 Service Manual 4060 xxx Assembly 21 250 sheet paper tray ...

Page 277: ...1 500 Drive roll assembly 13 99A0451 1 Roll skewed backup 14 99A0282 1 Cable 250 sheet autoconnect 15 99A0450 1 Retainer roller 16 99A0350 1 Sensor paper low 17 99A0679 2 Bracket 250 sheet frame retention 18 99A0677 4 Parts packet washer 19 99A0263 4 Parts packet screw 20 99A0070 2 Pick roll assembly 21 99A1638 1 Base 250 sheet option 22 99A0026 1 Tray bias arm assembly 23 99A0419 1 Spring tray bi...

Page 278: ...7 42 Service Manual 4060 xxx Assembly 21 cont 250 sheet paper tray 43 41 42 38 36 34 39 37 35 40 46 45 44 ...

Page 279: ...mber 38 99A0121 1 Clip 250 sheet tray wear 39 99A0126 3 Finger autosize 40 99A0127 1 Slider autosize 250 sheet 41 99A0124 1 Plate snap in 42 99A1952 1 Label paper size 43 99A1537 1 Knob paper size 44 99A0120 2 Restraint pad 45 99A0893 1 Restraint back 250 sheet tray 46 99A1601 1 Latch back restraint NS 99A0286 1 Spring backup roller NS 99A1928 1 Spring bellcrank 250 sheet tray option NS 99A0438 2 ...

Page 280: ...7 44 Service Manual 4060 xxx Assembly 22 500 sheet paper tray 43 41 46 44 42 45 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 33 28 38 21 31 26 36 24 34 29 39 22 32 27 37 25 35 30 40 6 6 6 2 ...

Page 281: ...er size 17 99A1582 1 Slider autosize 500 sheet 18 99A0120 2 Restraint pad 19 99A1576 1 Tray assembly 500 sheet 20 99A1537 1 Knob paper size 21 99A1602 1 Restraint back 500 sheet tray 22 99A1601 1 Latch back restraint 23 99A1666 1 Label options 24 56P0557 1 Board option tray 25 99A0447 1 Shaft 500 sheet drive 26 99A0282 1 Cable 250 autoconnect 27 99A1750 1 Wear plate pass thru 28 99A0276 1 500 Driv...

Page 282: ... 46 Service Manual 4060 xxx Assembly 22 cont 500 sheet paper tray 43 41 46 44 42 45 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 33 28 38 21 31 26 36 24 34 29 39 22 32 27 37 25 35 30 40 6 6 6 2 ...

Page 283: ... Bellcrank roller release 42 99A0273 1 Gear bevel 43 99A0279 1 Bearing drive shaft 44 99A0281 1 Cable 250 sheet autoconnect 45 99A1702 1 Stud assembly 500 frame 46 99A1645 1 Arm paper out 500 NS 99A0452 4 Washer frame mounting NS 99A1665 1 Deflector base 500 NS 99A1667 2 Bracket 500 sheet tray retention NS 99A1929 1 Spring bellcrank 500 sheet option tray ...

Page 284: ...7 48 Service Manual 4060 xxx Assembly 23 Duplex option 1 ...

Page 285: ...Parts catalog 7 49 4060 xxx Assembly 23 Duplex option Asm index Part number Units Description 23 1 56P1414 1 250 duplex assembly 1 56P1416 1 500 duplex assembly ...

Page 286: ...7 50 Service Manual 4060 xxx Assembly 24 Envelope feeder 3 11 7 13 5 9 2 10 6 4 12 8 14 1 ...

Page 287: ...13 99A0271 1 Parts packet gear kit 14 99A1698 1 Cover left side NS 99A0404 1 Parts packet retainer 4 mm PP NS 99A0404 3 Parts packet retainer clip 5 mm shaft NS 99A0404 2 Parts packet retainer 6 mm NS 99A0404 3 Parts packet retainer 7 mm shaft NS 99A0384 1 Shaft drive pressure roller NS 99A0385 1 Cable auto connect front NS 99A0494 1 Spring cam clutch NS 99A0427 1 Label envelope orientation icon N...

Page 288: ...7 52 Service Manual 4060 xxx Assembly 25 Output expander ...

Page 289: ...d output expander DC motor 7 99A0571 1 Cover front control board with ESD brush 8 99A1817 1 Tray output expander 9 99A1666 1 Label options 10 99A1689 1 Spring clutch assembly 11 99A1688 1 Diverter arm 12 99A0482 1 Spring output tray 13 99A1784 2 Bracket attach 14 99A0914 1 Output expander assembly mechanical linkage 15 99A0372 1 Cover left side 16 99A0415 2 Spring swing arm 17 99A0481 1 Latch outp...

Page 290: ...7 54 Service Manual 4060 xxx Assembly 25 cont Output expander ...

Page 291: ...23 99A0368 1 Shaft assembly lower also order PP 99A0572 24 99A0363 3 Pulley drive 25 99A0371 1 Cover right side 26 99A0361 1 Belt 160 gear 27 99A0362 1 Arm assembly belt idler 28 99A0364 1 Spring belt tensioner 29 99A0351 1 Sensor output expander pass thru 30 99A0913 1 Shaft assembly middle 40T also order PP 99A0572 31 99A0912 1 Frame assembly ...

Page 292: ...7 56 Service Manual 4060 xxx Assembly 26 High capacity output expander ...

Page 293: ...8 2 Pulley output tray 5 99A1782 2 Shaft pulley 6 99A1790 2 Guide output tray 7 99A1779 2 Spring output tray 8 99A1746 1 Cover right 9 99A1747 1 Cover front 10 99A1701 1 Tray asm output 11 99A1781 1 Frame left 12 99A1666 1 Label options 13 99A1745 1 Cover left NS 99A1751 1 Switch asm tray sensing NS 99A1777 1 Flag tray sensing switch NS 99A1780 2 Gear damping NS 99A1744 2 Kit high capacity output ...

Page 294: ...acker asm 18 12 Bearings shaft PP 99A0572 19 99A1749 2 Board asm high capacity output stacker 20 31 Screws PP 99A0263 21 99A1688 1 Arm diverter 22 99A1689 1 Clutch asm output stacker 23 99A1784 2 Bracket attach 24 99A0415 2 Spring swing arm 25 99A0914 2 Drive asm output stacker DC motor 26 99A0409 1 Bracket dual sensor mounting upper stacker asm 27 99A1613 1 Flag bin full dual sensor upper stacker...

Page 295: ... 2 Shaft asm lower 31 99A0363 6 Pulley drive 32 99A0361 1 Belt 160G upper stacker asm 33 99A0362 1 Arm asm belt idler 34 99A0364 2 Spring belt tensioner 35 99A1791 1 Stacker asm paper path lower 35 99A1792 1 Stacker asm paper path upper 36 99A0351 2 Sensor stacker pass thru NS 99A1751 1 Switch asm NS 99A0462 1 Packet grease IBM 23 NS 99A0627 1 Jumper 2 pin use with 99A1749 ...

Page 296: ...7 60 Service Manual 4060 xxx Assembly 27 5 bin mailbox ...

Page 297: ...s thru 12 99A1712 5 Tray paper cap 13 99A1739 1 Bracket asm bail attach w brush 14 99A1743 1 Kit 5 bin mailbox asm 15 99A1666 1 Label options 16 1 Bail order 99A1743 5 bin mailbox asm kit 17 99A1713 5 Support paper tray 18 99A1687 5 Stop asm paper tray 19 99A1735 5 Flag bin full 20 99A1737 5 Sensor dual paper height 21 99A1736 5 Cable dual sensor 22 99A1718 1 Cable asm lower auto connect 23 99A171...

Page 298: ...7 62 Service Manual 4060 xxx Assembly 27 cont 5 bin mailbox ...

Page 299: ...99A1729 4 Latch diverter actuator 35 99A1730 4 Arbor diverter actuator 36 99A1789 4 C clip 37 99A1720 1 Bracket attach 38 99A1732 4 Solenoid diverter 39 99A1738 5 Deflector paper exit w brush 40 99A1722 4 Deflector paper 41 99A1787 4 Deflector 42 99A1721 1 Deflector paper top bin NS 99A1734 1 Spring static ground NS 99A0462 1 Grease packet IBM 23 NS 99A1715 1 Roller asm rear access door NS 99A1717...

Page 300: ...7 64 Service Manual 4060 xxx Assembly 28 High capacity feeder 1 ...

Page 301: ...62 2 Transfer leadscrew assembly 12 99A0716 2 Bearing leadscrew bottom 13 99A0676 4 Parts packet nut 6 32 hinge mounting 14 99A0677 4 Parts packet washer hinge mounting flat 15 99A0677 4 Parts packet washer hinge mounting star 16 99A0657 2 Hinge door 17 99A0655 1 Door assembly front 18 99A0658 2 Magnet door 19 99A0650 1 Frame assembly 20 99A0661 1 Tray assembly elevator 21 99A1806 1 Card assembly ...

Page 302: ...7 66 Service Manual 4060 xxx Assembly 29 High capacity feeder 2 20 3 11 7 5 9 2 10 6 4 8 1 2 2 2 2 2 13 18 16 15 17 12 14 19 2 2 2 4 4 6 4 6 2 4 2 4 2 2 6 2 4 2 6 6 ...

Page 303: ...sor bracket mtg 2 5 99A0719 1 Clamp top frame mounting 6 99A0676 Parts packet nuts including Base mounting 2 2 56 switch mounting 2 Power supply cover 2 Power supply ground 2 7 99A0663 1 Pulley idler 8 99A0664 1 Belt drive 9 99A1807 1 Cable AC internal wiring 10 99A0653 1 Switch lower limit microswitch 11 99A1808 1 Cord AC external jumper 12 99A0714 1 Cover power supply 13 99A0667 1 Power supply b...

Page 304: ...7 68 Service Manual 4060 xxx Assembly 30 High capacity feeder 3 3 11 7 13 9 15 2 10 6 4 12 8 14 1 1 3 5 ...

Page 305: ... 4 99A1795 1 Motor assembly DC 5 99A1798 1 Plate drive pulley 6 99A1794 3 Parts packet nut and washer drive pulley plate 7 99A1796 1 Belt DC motor drive 8 99A1797 1 Idler pulley belt tension 9 99A1800 1 Pulley drive 10 99A1799 1 AC receptacle lower AC 11 99A1801 1 Retainer C clip 12 99A1802 1 AC receptacle upper AC 13 99A1803 1 Cover top LVPS 14 99A1804 3 Nut w lock washer top LVPS cover mounting ...

Page 306: ...7 70 Service Manual 4060 xxx Assembly 31 High capacity feeder 4 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 4 ...

Page 307: ... assembly 250 sheet frame 11 99A0280 1 Bearing drive shaft low 12 99A0275 1 Spring power takeoff 13 99A0272 1 Shaft 250 sheet drive 14 99A0446 1 Aligner assembly paper 15 99A0267 1 Parts packet retainer aligner assembly 16 99A0274 1 Gear feed roll 17 99A0278 1 Bellcrank roller release 18 56P0556 1 Card assembly 2000 tray option 19 99A0263 3 Parts packet screw tray option card mounting NS 99A0675 1...

Page 308: ...7 72 Service Manual 4060 xxx Assembly 32 High capacity feeder 5 3 11 7 5 9 2 10 6 4 12 8 1 10 10 10 12 ...

Page 309: ...000 option 5 99A0263 1 Parts packet screw deflector mounting 6 99A0678 1 Deflector base 7 99A0288 1 Sensor pass thru 8 99A1812 1 Label tray option number 9 99A1666 1 Label options 10 99A0677 4 Parts packet washer bracket 250 sheet frame retention mounting 11 99A0263 4 Parts packet screw bracket 250 sheet frame retention mounting 12 99A0679 2 Bracket 250 sheet frame retention NS 99A0717 1 Cable pap...

Page 310: ...7 74 Service Manual 4060 xxx Assembly 33 Kiosk vertical paper adapter 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 21 4 4 4 4 4 4 4 11 11 12 5 5 5 6 5 5 6 7 10 10 ...

Page 311: ...idler 7 99A1704 2 Gear idler 8 99A0197 1 Shaft drive rear 9 99A0079 1 Tray assembly backup roller 10 99A0208 3 Parts packet pulley 11 99A0087 6 Spring backup roller 12 99A0086 6 Roller backup 13 99A1706 1 Tray assembly drive roller 14 99A0125 1 Frame assembly right side 15 99A0232 1 Cover right 16 99A1820 2 Belt 185G 17 99A0226 1 Guide paper exit 18 99A0122 2 Shaft assembly drive roller 19 99A0137...

Page 312: ...7 76 Service Manual 4060 xxx Assembly 34 Kiosk horizontal paper adapter 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 5 5 5 5 5 11 11 12 7 4 4 4 4 4 4 4 5 10 10 ...

Page 313: ... 99A1705 1 Gear idler 7 99A1704 2 Gear idler 8 99A0197 1 Shaft drive rear 9 99A0079 1 Tray assembly backup roller 10 99A0208 3 Parts packet pulley 11 99A0087 6 Spring backup roller 12 99A0086 6 Roller backup 13 99A1707 1 Tray assembly drive roller 14 99A0907 1 Frame assembly right side 15 99A0232 1 Cover right 16 99A1820 2 Belt 185G 17 99A0122 2 Shaft assembly drive roller 18 99A0906 1 Frame assem...

Page 314: ...7 78 Service Manual 4060 xxx Assembly 35 StapleSmart finisher I 3 11 7 13 5 16 9 15 2 10 6 17 4 12 8 14 1 5 18 ...

Page 315: ...embly 7 99A2503 1 Cover stapler access 8 99A2502 1 Switch stapler access door assembly 9 2 Screws switch stapled access mounting 99A2509 Parts Packet 10 99A2519 1 Cover accumulator assembly 11 99A2520 1 Tray output assembly 11 99A2542 1 Tray output 12 99A1666 1 Label tray options 13 99A2521 1 Sensor stapler bin empty 14 99A2541 1 Sensor cover stapler bin empty 15 99A2511 1 Bail center stapler 16 9...

Page 316: ...7 80 Service Manual 4060 xxx Assembly 36 StapleSmart finisher 2 3 11 7 13 5 9 2 10 6 4 12 8 14 1 4 4 4 4 ...

Page 317: ...56 1 Bracket attach 4 99A0263 1 Parts packet screws 5 99A1820 1 Belt 185G 6 99A2544 1 Card assembly right stapler bin level 7 99A0362 1 Arm assembly belt idler 8 99A2545 1 Spring swing arm 9 99A2548 1 Bumper output tray 10 99A2533 1 Bar upper output tray 11 99A2523 2 Spring output tray 12 99A2543 2 Cover optical sensor 13 99A2528 1 Frame assembly right 14 99A2557 1 Clip static ground ...

Page 318: ...7 82 Service Manual 4060 xxx Assembly 37 StapleSmart finisher 3 3 11 7 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 21 26 24 22 27 25 1 4 6 10 10 13 10 10 1 1 1 1 ...

Page 319: ...0 sheet stacker PP 99A0572 11 99A0368 1 Shaft assembly lower 12 99A0913 1 Shaft assembly 40T middle stacker 13 99A2515 1 Shaft assembly upper drive 14 99A2518 1 Shaft assembly lower exit 15 99A2538 1 Belt FHT 86T 16 99A2543 1 Cover optical sensor 17 99A2529 1 Guide inner bias 18 99A2527 1 Frame assembly left 19 99A2533 1 Bar upper output tray 20 99A2523 1 Spring output tray 21 99A2548 1 Bumper out...

Page 320: ...7 84 Service Manual 4060 xxx Assembly 38 StapleSmart finisher 4 1 ...

Page 321: ...l 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 ...

Page 322: ...adapter NS 13A0298 1 Cable serial NS 56P2182 1 Card assembly ImageQuick NS 56P1424 1 Optra Forms hard disk with adapter 20 GB NS 99A1890 1 Tray assembly 250 sheet special media NS 99A1647 1 Rib assembly 250 sheet special media tray NS 99A1654 1 Tray universal adjustable 250 sheet NS 56P1100 1 Cartridge empty shipping NS 99A1605 1 Kit cap stack bails 500 sheet NS 56P1742 1 MarkNet N2101e Ethernet 1...

Page 323: ...Forms 32MB Flash card NS 56P1428 1 Optra Forms 16MB Flash card NS 56P1429 1 Simplified Chinese font card NS 56P1430 1 Traditional Chinese font card NS 56P1438 1 Japanese font card NS 56P1101 1 Cable assembly 6 parallel A C NS 56P0161 1 Cable assembly SER PAR 1284C INA NS 56P0162 1 Cable parallel 1284 C B adapter ...

Page 324: ...0676 1 Parts packet nuts high capacity feeder NS 99A0677 1 Parts packet washers high capacity feeder NS 99A0083 1 Parts kit multipurpose tray NS 99A0512 1 Parts kit charge roll link asm left side NS 99A0513 1 Parts kit charge roll link asm right side NS 99A0702 2 Printer stand caster non locking NS 99A0703 2 Printer stand caster locking NS 99A0704 1 Printer stand grommet wire NS 99A0705 2 Printer ...

Page 325: ...e service check 2 41 950 error code service check 2 42 A acronyms 1 15 adjustments 4 2 duplex motor drive belts 4 2 fuser solenoid 4 2 gap adjustment 4 3 paper alignment assembly 4 4 printhead assembly 4 3 alignment assembly adjustment 4 4 parts catalog 7 16 removal 4 52 autocompensator integrated tray parts catalog 7 13 pick roll installation 4 39 removal 4 35 autoconnect connections top 5 1 B ba...

Page 326: ...t 3 17 diagnostic mode 3 1 disabling download emulations 3 3 disk test clean 3 2 duplex option parts catalog 7 48 service check 2 47 sub error codes 2 12 duplex tests 3 4 E envelope feeder connections 5 2 parts catalog 7 50 service check 2 49 sub error codes 2 13 EP frame removal 4 20 error codes 2 2 error log 3 6 ESD sensitive parts 4 1 F fan removal main 4 46 feed tests finisher 3 14 feed to all...

Page 327: ...ifications 6 1 M main drive assembly parts catalog 7 22 removal 4 44 service check 2 68 main fan removal 4 46 maintenance ESD sensitive parts 4 1 lubrication 6 1 maintenance kit 6 1 preventive 6 1 safety inspection guide 6 1 maintenance approach 1 1 maintenance kits 6 1 maintenance page count 3 17 messages check device connection messages 2 33 service error codes 2 2 user attendance messages 2 19 ...

Page 328: ...per tray 7 40 optional 500 sheet paper tray 7 44 options 7 86 output expander 7 52 7 54 paper feed alignment 7 16 autocompensator 7 13 multipurpose feeder 7 14 printhead 000 010 7 10 200 210 7 11 400 410 7 12 StapleSmart finisher 7 79 transfer charging 7 26 pick roll MPT removal 4 55 pick rolls integrated tray autocompensator 4 38 power on self test POST 2 34 preventive maintenance 6 1 printhead a...

Page 329: ...ensor integrated paper tray 2 72 paper bin full 4 54 paper size sensing board 4 41 toner 4 61 service checks 5 bin mailbox 2 38 900 error code 2 41 950 error code 2 42 charge roll 2 43 cover closed switch cable 2 44 cover open switch cable 2 44 dead machine 2 45 duplex option 2 47 envelope feeder 2 49 fuser 2 52 fuser solenoid 2 55 high capacity feeder input tray 2 56 high capacity output stacker ...

Page 330: ...transfer roll assembly parts catalog 7 26 removal 4 61 service check 2 94 U unique tools 1 14 upper front cover hinge assembly removal 4 62 upper front cover removal 4 12 upper paper deflector 4 63 user attendance messages 2 19 user line 2 link messages 2 32 user status displays 2 14 user status messages 2 17 V vertical paper adapter 7 74 viewing the permanent page count 3 17 W warning messages us...

Page 331: ...exico Nicaragua Panama Puerto Rico Saudi Arabia Taiwan LV Venezuela Virgin Islands 7 29 43H5546 Power cord set PRC HV 7 29 56P0161 Cable assembly SER PAR 1284C INA 7 87 56P0162 Cable parallel 1284 C B adapter 7 87 56P0556 Card assembly 2000 tray option 7 71 56P0557 Board option tray 7 41 7 45 56P0695 8MB memory option 7 86 56P0696 16MB memory option 7 86 56P0697 32MB memory option 7 86 56P0698 64M...

Page 332: ...31 56P1341 Cover INA flat blank 7 33 56P1342 Shield inner assembly 2 slot 200 210 400 410 7 33 56P1343 Shield inner assembly 1 slot 000 010 7 33 56P1344 Shield outer 2 slot 200 210 400 410 7 33 56P1345 Shield outer 1 slot 000 010 7 33 56P1346 Parts packet reference adjust 7 17 56P1347 Frame EP module 200 210 400 410 7 5 56P1348 Kit fuser cover assembly 7 25 56P1349 Clip reference ground 7 17 56P13...

Page 333: ...ance kit 6 1 56P1414 250 duplex assembly 7 49 56P1415 Wiper assembly wet 7 25 56P1416 500 duplex assembly 7 49 56P1417 16MB Flash card 7 86 56P1418 32MB Flash card 7 86 56P1419 Hard disk with adapter 20 GB 7 86 56P1424 Optra Forms hard disk with adapter 20 GB 7 86 56P1427 Optra Forms 32MB Flash card 7 87 56P1428 Optra Forms 16MB Flash card 7 87 56P1429 Simplified Chinese font card 7 87 56P1430 Tra...

Page 334: ...tem board assembly non network 200 includes 56P1444 7 31 56P2413 System board assembly network 210 7 31 56P2414 System board assembly non network 400 includes 45P1444 7 31 56P2415 System board assembly network 410 7 31 56P2468 Card assembly IPDS and SCS TNe 7 86 56P2468 Card assembly IPDS and SC5 TNe 7 31 56P2542 Fuser assembly w 115V lamp 000 010 200 210 7 25 56P2543 Fuser assembly w 220V lamp 00...

Page 335: ...ansfer roll right 7 27 99A0185 Shaft transfer pivot 7 27 99A0188 Guide rear paper use with 99A0219 7 67 99A0197 Shaft drive rear 7 75 7 77 99A0208 Parts packet pulley 7 75 7 77 7 88 99A0219 Frame assembly top with labels 7 67 99A0226 Guide paper exit 7 75 99A0231 Bail support 7 75 7 77 99A0232 Cover right 7 75 7 77 99A0234 Parts packet screw 7 75 7 77 99A0234 Parts packet screw kiosk 7 88 99A0240 ...

Page 336: ...ners 7 88 99A0268 Parts packet springs paper feed 7 88 99A0269 Parts packet duplex option fan mounting 7 88 99A0271 Parts packet envelope option gears 7 88 99A0271 Parts packet gear kit 7 51 99A0272 Shaft 250 sheet drive 7 41 7 71 99A0273 Gear bevel 7 41 7 47 7 71 99A0274 Gear feed roll 7 41 7 45 7 71 99A0275 Spring power takeoff 7 41 7 45 7 71 99A0275 Spring power takeoff shaft 7 23 99A0276 500 D...

Page 337: ...g upper stacker asm 7 58 99A0409 Level sensor bracket 7 53 99A0413 Parts packet screw duplex 7 88 99A0413 Screw top motor board 7 51 99A0414 Sensor asm bin full dual upper stacker asm 7 58 99A0414 Sensor dual bin full 7 53 99A0415 Spring swing arm 7 53 7 58 99A0419 Spring tray bias 7 41 7 45 99A0426 Screws parallel connector mounting 7 31 99A0427 Label envelope orientation icon 7 51 99A0438 Bushin...

Page 338: ...7 99A0672 Parts packet foot stabilizer 7 69 99A0675 Parts packet screw card asm mounting 7 65 99A0675 Parts packet screw deflector mt 8 18 x 7 8 inch 7 65 99A0675 Parts packet screw door to door frame mounting 7 71 99A0675 Parts packet screw feed frame clamp 7 65 99A0675 Parts packet screw printer support 2 frame mounting 7 65 99A0675 Parts packet screw wear plate mounting 7 71 99A0675 Parts packe...

Page 339: ...2 Restraint side 250 sheet tray 7 43 99A0893 Restraint back 250 sheet tray 7 43 99A0895 Restraint side 500 sheet tray 7 45 99A0906 Frame assembly left side 7 77 99A0907 Frame assembly right side 7 77 99A0912 Frame assembly 7 55 99A0913 Shaft assembly 40T middle stacker 7 83 99A0913 Shaft assembly middle 40T 7 55 99A0913 Shaft 40T middle output stacker 7 59 99A0914 Drive asm output stacker DC motor...

Page 340: ...tray 7 86 99A1654 Tray universal adjustable 250 sheet 7 86 99A1658 Cover fuser wiper cavity 7 25 99A1664 Bellcrank roller release 7 47 99A1665 Deflector base 500 7 47 99A1666 Label options 7 45 7 51 7 53 7 57 7 61 7 73 99A1666 Label tray options 7 41 7 79 99A1667 Bracket 500 sheet tray retention 7 47 99A1687 Stop asm paper tray 7 61 99A1688 Arm diverter 7 58 99A1688 Diverter arm 7 53 99A1689 Clutc...

Page 341: ...or paper exit w brush 7 63 99A1739 Bracket asm bail attach w brush 7 61 99A1740 Board asm 5 bin mailbox system 7 61 99A1741 Spring diverter 7 63 99A1742 Sensor 5 bin mailbox pass thru 7 61 99A1743 Kit 5 bin mailbox asm 7 61 99A1743 Parts packet 7 61 99A1744 Kit high capacity output stacker 7 57 99A1745 Cover left 7 57 99A1746 Cover right 7 57 99A1747 Cover front 7 57 99A1748 Door asm rear access 7...

Page 342: ...tor upper redrive 7 53 99A1857 Upper redrive deflector 7 7 99A1890 Tray assembly 250 sheet special media 7 86 99A1894 Restraint side 250 sheet tray 7 19 99A1895 Restraint side 7 21 99A1928 Spring bellcrank 250 sheet tray option 7 43 99A1929 Spring bellcrank 500 sheet option tray 7 47 99A1952 Label paper size 7 43 7 45 99A2016 Duct left stacker 500 sheet 200 210 400 410 7 9 99A2017 Guide extension ...

Page 343: ...thru 7 85 99A2526 Stapler assembly 7 81 99A2527 Frame assembly left 7 83 99A2528 Frame assembly right 7 81 99A2529 Guide inner bias 7 83 99A2530 Cable assembly right stapler bin level 7 85 99A2531 Switch assembly top cover open 7 83 99A2532 Cable ground 7 85 99A2533 Bar upper output tray 7 81 7 83 99A2534 Ground cable stapler tray bar 7 85 99A2538 Belt FHT 86T 7 83 99A2539 Flange pulley 7 83 99A25...

Page 344: ...I 20 Service Manual 4060 xxx ...

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