Page 1 This is trial version, If you want get full version,please register it,thank you. Web site: http://www.adultpdf.com/ E-mail: support@adultpdf.com...
Page 2 Lexmark Optra 4069-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 3 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners.
Page 4: Table Of Contents
4069-XXX Contents Notices and Safety Information ..... . . ix Laser Notices........ix Safety Information .
Page 5 4069-XXX Printhead Service Check ......2-92 Print Quality Service Check ..... . . 2-93 Smart Cartridge Service Check .
Page 6 4069-XXX Maintenance Page Count ......3-21 Setting Configuration ID ......3-21 Restore EP Factory Defaults .
Page 7 4069-XXX Fuser Lower Exit Guide Assembly (Hot Roll) ..4-31 High Voltage Power Supply ..... . . 4-32 Inner EMC Shield.
Page 8 4069-XXX Lubrication Specifications ......6-1 Scheduled Maintenance ......6-2 Parts Catalog .
Page 9 4069-XXX viii Service Manual...
Page 10: Notices And Safety Information
4069-XXX Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown: Laser Advisory Label Notices and Safety Information...
Page 11 4069-XXX Class 1 Laser Statement Label Service Manual...
Page 12: Laser Notice
4069-XXX Laser Notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825.
Page 13 4069-XXX Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres.
Page 14 4069-XXX la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico. Declaração sobre Laser A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser.
Page 15 4069-XXX Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Page 16 4069-XXX Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770- 795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå...
Page 17 4069-XXX Japanese Laser Notice Chinese Laser Notice Service Manual...
Page 18: Safety Information
This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
Page 19 4069-XXX sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. • Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié.
Page 20 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
Page 21 Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d’aquest producte està...
Page 22: Ozone Information
4069-XXX Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of ozone gas. Notices and Safety Information...
Page 23: Preface
4069-XXX Preface This manual is divided into the following chapters: • “General Information” contains a general description of the printer, options, and the maintenance approach used to repair it. General environmental and safety instructions as well as special tools and test equipment are listed in this chapter. •...
Page 24: General Information
4069-XXX 1. General Information The Optra™ T laser printers are letter quality page printers designed to attach to IBM-compatible PC’s and to most computer networks. The Optra T laser printer is available in the following models. Model Name Type Optra T 610 4069-010 Optra T 610n 4069-01n...
Page 25 4069-XXX Look at the printer serial label to identify the printer you are working on. There are two service levels of Optra T printers. Some printers are at a service level B as indicated by the B on the label. Service Manual...
Page 26: Options
4069-XXX Options The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country. Memory options of 4MB, 8MB, 16MB, 32MB, 64MB and 128MB SDRAM DIMM Flash memory options of 2MB, 4MB, 8MB and 16MB DIMM Integrated network options Token-Ring Ethernet...
Page 27: Maintenance Approach
4069-XXX Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the printer problem and repair the failure.
Page 28: Acronyms
4069-XXX Acronyms Customer Setup DIMM Dual In-Line Memory Module DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable, Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode...
Page 29 4069-XXX Service Manual...
Page 30: Diagnostic Information
4069-XXX 2. Diagnostic Information Start CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
Page 31: Service Error Codes
Error Code Action 900 RIP Software Contact the next support level or call Lexmark. 901 Engine Flash Indicates that the flash which the engine board code is programmed into is bad. Replace the engine board.
Page 32 4069-XXX Error Code Action 914 DC pick Check the integrated paper tray (tray 1) for correct paper motor: No loading. Reload the paper and POR the printer. If the encoder feedback error continues, go to the “Input Tray(s) Option Service Check”...
Page 33 4069-XXX Error Code Action 928 Erase Lamps Models 010/212/414/616/31v/01n/21n/31e/41n/61n Indicates that the engine has detected that either the erase lamp assembly is missing or disconnected. Go to “Erase Lamp Service Check (010/212/414/616/31v/ 01n/21n/31e/41n/61n)” on page 2-45. Models 41b/41e/41l and models 010/212/414/616/31v/ 01n/21n/31e/41n/61n at service level B do not have erase lamps installed.
Page 34 4069-XXX Error Code Action 939 Controller - The controller board and the engine board cannot Engine communicate with one another. The controller board, Communications engine board or interconnect board is defective. Check Error each board for correct installation and secure ground. If no problem is found, replace the FRUs in the following order: controller board...
Page 35 4069-XXX Error Code Action 956 Configuration Indicates a problem with the Configuration ID. This error occurs because the engine received a configuration ID from the controller software which is not valid for the level of engine code existing in the printer. Setting the configuration ID correctly should fix this error.
Page 36 4069-XXX Error Code Action 980 <device> The engine is experiencing unreliable communications Comm to the specified device. 981 <device> The engine protocol violation detected by the specified device. 982 <device> Communications error detected by the specified device. Comm 983 <device> Invalid command received by the specified device.
Page 37 4069-XXX The following is an example of how the printer displays a duplex unit sub error code. Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Base Printer Sub Error Codes Each status byte has a different level of troubleshooting value for each area of the printer.
Page 38 4069-XXX Status Explanation Bytes 1, 2,3 84 xx 09 Paper Tray 4 pass thru sensor is not activated by a sheet of paper. 84 xx 0A Paper Tray 3 pass thru sensor is not activated by a sheet of paper. 84 xx 0B Paper Tray 2 pass thru sensor is not activated by a sheet of paper.
Page 39 4069-XXX Status Explanation Bytes 1, 2,3 8E xx 0B The autocompensator DC motor stalls when attempting to pick a sheet of paper. 8E xx 11 The autocompensator DC motor takes too long to ramp up. Envelope Feeder Sub Error Codes Status byte 1 contains the most valuable information to help isolate a feed problem with the envelope feeder and is the only byte contained in the following table.
Page 40 4069-XXX Status Explanation Byte 4 The duplex option system board never received media notification from the printer. The trailing edge of the sheet of paper never cleared the input sensor. The leading edge of the sheet of paper never arrived at the exit sensor.
Page 41: User Status Messages
4069-XXX User Status Messages User Status Message Status Action Ready The printer is ready to Press Menu> or receive and process <Menu to take the data. printer out of Ready and enter all the Menus except the TESTS MENU (Busy State).
Page 42 4069-XXX User Status Message Status Action Printing Menu Settings The printer is processing Press Stop to take the or printing a list of printer out of Ready. current settings menus The Not Ready because Print Menu message is displayed. Settings is selected from No more data is the menu.
Page 43 4069-XXX User Status Message Status Action Restoring Factory The printer is restoring No button actions are Defaults factory defaults. possible while this message is displayed. Performing Self Tests The printer is running No button actions are the normal series of possible while this start-up tests after it is message is displayed.
Page 44 4069-XXX User Status Message Status Action Programming Disk The disk is being No button actions are (Do Not Power Off) programmed, which possible while this means fonts or macros message is displayed. are being written to disk. Note: If information is written to flash memory and to disk at the same time, the...
Page 45: User Error Messages
4069-XXX User Error Messages User Error Message Explanation 200 Paper Jam Paper is jammed at the printer Input Sensor. Remove Cartridge Open the printer’s upper front door and remove the print cartridge to access the paper jam area. 201 Paper Jam Paper is jammed between the printer’s input and Remove Cartridge exit sensors.
Page 46 4069-XXX User Error Message Explanation 31 Defective Print Error code 31 is displayed when the top front Cartridge cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval.
Page 47 4069-XXX User Error Message Explanation 37 Insufficient Collation This message is displayed when the printer Memory memory used to store pages is too full to collate the print job. 38 Memory Full This message is displayed when the printer memory used to store pages is full. 39 Complex Page This message is displayed when the page is too complex to print.
Page 48 4069-XXX User Error Message Explanation 56 Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset.
Page 49 4069-XXX User Error Message Explanation 81 Engine Code CRC This error displays when the microcode to be Failure programmed in the engine flash code module has failed a CRC check. Press Go to clear the message. The microcode data is discarded and must be re-transmitted from the host computer.
Page 50 4069-XXX User Message Explanation Tray X Empty If any of the input trays are empty, then “Tray X Empty” displays where X designates which tray (Tray 1 through 5) is empty. If multiple trays are empty, then they are prioritized in this order: Tray 5, Tray 4,...Tray 1.
Page 51 4069-XXX User Message Explanation LocalTalk X LocalTalk Card X,X=1,2,3, is attached to PCI connector X. Infrared Standard Infrared port, if available. Infrared X Infrared Port X, X=1,2,3, is attached to PCI connector X. Check Device Connection Messages The messages in the following table display when the printer looses communications with one of the following devices.
Page 52 4069-XXX The messages in the following table can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure.
Page 53: Power-On Self Test (Post)
4069-XXX Power-On Self Test (POST) When you turn the printer On, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: 1. The LED comes on. 2. The operator panel displays one and a half row of pels, and then clears.
Page 54: Symptom Tables
4069-XXX Symptom Tables Symptom Table - Base Printer Symptom Action Auxiliary Fan (414/616) fails to run Go to the “Auxiliary Fan Service or is noisy. Check” on page 2-46. Dead Machine Go to the “Dead Machine Service Check” on page 2-32.
Page 55 4069-XXX Symptom Action Print quality - Background Go to “Print Quality - Background” on page 2-98. Print quality - Residual image Go to “Print Quality - Residual Image” on page 2-103. Print quality - Skew Go to the “Paper Feed Service Check”...
Page 56 4069-XXX Symptom Table: Paper Tray Options Symptom Action Paper feed problem with 250 Go to the “Input Tray(s) Option Sheet Paper Tray Option. Service Check” on page 2-53. Paper feed problem with 500 Go to the “Input Tray(s) Option Sheet Paper Tray Option. Service Check”...
Page 57: Service Checks
4069-XXX Symptom Table - Output Expander Symptom Action Printer does not display Output Go to the “Output Bin Sensor Bin Full Standard Tray Service Check” on page 2-74. Paper does not feed all the way Go to the “Output Expander Service into the output tray.
Page 58: Charge Roll Service Check
4069-XXX Charge Roll Service Check Service Tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 inch) apart or spots on the page can be caused by a damaged or contaminated charge roll. Service Tip: Check to make sure the right charge roll arm bushing is correctly installed and operates correctly.
Page 59 4069-XXX Action Right Side Charge Roll Link Check the right side charge roll link Right Charge Roll Bushing assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination.
Page 60: Cover Open Switch/Cable Service Check
4069-XXX Cover Open Switch/Cable Service Check Action Toner Cartridge Check the toner cartridge to make sure it is correctly installed and that the right and left cartridge tracks are not loose or broken. Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover open switch...
Page 61: Dead Machine Service Check
4069-XXX Dead Machine Service Check Note: If a high capacity input tray is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, go to “High Capacity Feeder Input Tray Service . If the base printer continues to not operate Check”...
Page 62 4069-XXX Action +5 V dc at any Option Check for +5 V dc on any of the Connector option connectors. The easiest to access is the envelope feeder connector located behind the lower front door. If +5 V dc is present at any of the connectors, go to step 9.
Page 63 4069-XXX Action Engine Board Turn the printer off and disconnect all the cables from the engine board. Check for +5 V dc at the engine board test point. If incorrect, replace the FRUs in the following order: engine board interconnect board If correct, turn the printer off and reconnect one cable at a time until you find the defective assembly.
Page 64: Duplex Option Service Check
4069-XXX Duplex Option Service Check The printer does not recognize the Duplex Option is attached. The printer does not recognize tray options below the duplex option are installed. Action Fuse F1 on Duplex Option If fuse F1 is blown, replace the fuse. System Board If fuse F1 continues to blow, check the stepper motor for a short...
Page 65 4069-XXX POST fails, 230 Paper Jam, Check Duplex message displays. Action Duplex D.C. Servo Drive Check the D.C. servo motor cables Motor for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage. If no problem is found, replace the FRUs in the following order: D.C.
Page 66 4069-XXX 230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way out of the redrive. Action Duplex Stepper Motor Check the stepper motor cable for cuts or pinched wiring. Check the routing of the motor leads along the left side of the bottom tray.
Page 67: Envelope Feeder Option Service Check
4069-XXX Envelope Feeder Option Service Check Service Tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise go to the Interconnect Card Service Check.
Page 68 4069-XXX Action Autoconnect on the Check the connector for any signs of Envelope Option damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages: J1-3 measures +5 V dc J1-5 measures +5 V dc...
Page 69 4069-XXX Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete. Action Pass through Sensor Check for any debris, pieces of envelope and so on over the pass thru sensor. Check for correct installation of the pass thru sensor flag.
Page 70 4069-XXX Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display "Load Envelopes" after envelopes are placed in the hopper. Service Tip: The kick rolls rotate during the attempted feed cycles. Action Envelope Out Hopper Check the envelope out sensor flag...
Page 71 4069-XXX 990 Service Error, Envelopes fail to feed from the hopper. Action D.C. Feed Motor Assembly Check the motor and motor cable for any signs of loose wires or poor connections. Check to make sure the motor cable is connected to the envelope system board.
Page 72 4069-XXX 260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls ARE rotating. Check the deflector gap adjustment before continuing this service check. Action Deflector Gap Adjustment Check the deflector gap adjustment. The adjustment may be too narrow. Weight Assembly Check the weight assembly to make sure it moves up and down freely...
Page 73 4069-XXX 260 Paper Jam displays, envelope stops in feeder paper path. Action Kick Rolls/Feed Rolls/Drive Check all the rolls for any signs of oil, Rolls grease or other contamination. If you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder option.
Page 74: Erase Lamp Service Check (010/212/414/616/31V)
4069-XXX Erase Lamp Service Check (010/212/414/616/31v/01n/ 21n/31e/41n/61n) Error code 928 may be displayed when the printer detects that the erase lamp assembly, cable or engine board is defective. Note: If the erase lamp assembly is defective, both the erase lamp and lens are replaced as a kit.
Page 75: Fan Service Check
4069-XXX Fan Service Check Auxiliary Fan Service Check The auxiliary fan is in models 414/616/41l/61n. Fan does not run or is noisy. Action Fan Assembly Check the fan for proper installation and for excessive noise. If incorrect, replace the fan and cable assembly. Engine Board Check to make sure the auxiliary fan cable is seated on connector J7 on...
Page 76: Fuser Service Check
4069-XXX Action Error Code 927 (Fan runs) Check the voltage at J1-1 on the engine board. The voltage measures +5 V dc (static) 0 V dc (fan running). If incorrect, replace the main fan. If this does not fix the problem, replace the engine board.
Page 77 4069-XXX Action Fuser Lamp (Incorrect Install the correct voltage and Lamp/925 Service Error) wattage lamp or fuser assembly. Fuser Lamp Remove the controller board. Run the Diagnostic Print Test and observe the lamp through the left side frame. If the lamp doesn’t come on, unplug the printer and check the continuity between the two pins on the fuser lamp cable going to the...
Page 78 4069-XXX Hot Fuser Service Check Error codes 923 and 924 may display for a hot fuser failure. CAUTION: The fuser may be hot, use caution before removing or servicing. Action Fuser Cover Assembly Check for damage to the thermistor (Assembly includes assembly.
Page 79 4069-XXX Belt Fuser Hot Fuser Service Check Error codes 923 and 924 may display for a hot fuser failure. Note: The belt fuser assembly is a FRU. Do not attempt to disassemble and repair the belt fuser. CAUTION: The fuser may be hot, use caution before removing or servicing.
Page 80: Fuser Solenoid Service Check
4069-XXX Fuser Solenoid Service Check The fuser solenoid is in all models except the 31v and 31e. Service Tip: Try changing the envelope enhance level setting. A different setting may correct the problem. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment”...
Page 81: Input Sensor Service Check
4069-XXX Action LVPS If the +42 V dc test point does not Interconnect Board measure approximately +42 V dc, check the voltage at CN3-18 on the LVPS. The voltage measures approximately +42 V dc. If the voltage is correct, replace the interconnect board assembly.
Page 82: Input Tray(S) Option Service Check
4069-XXX Action Input Sensor Cable Check the continuity of the input sensor cable section of the front wiring harness. If incorrect, replace the harness. If correct, replace the input sensor assembly. Input Tray(s) Option Service Check 250 Sheet and 500 Sheet Trays Service Tip: Try all the other input paper sources to make sure they are properly feeding paper.
Page 83 4069-XXX 24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (The printer displays the value of X for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1) Action Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating...
Page 84 4069-XXX Tray X Low message displays when Tray X is full or has adequate paper in the tray. Action Paper Low Sensor Run the Tray X Sensor Test and Assembly check the sensor for proper Paper Low Sensor Flag operation. If incorrect, check the Tray X Option System following: Board...
Page 85: High Capacity Feeder Input Tray Service Check
4069-XXX Printer does not recognize Tray X is installed. Action Autoconect Cables Check the autoconnect from the Tray X System Board printer or option above tray x. Check for signs of cuts, pinched wiring or damage to the contacts in the connector.
Page 86 4069-XXX The base printer indicates a dead machine condition when the high capacity input tray is installed. Action AC Line Cord If the base printer works normally AC Jumper (HCIT to using the AC line cord from the AC Printer) wall outlet and does not work when AC input and Output using the AC jumper from the HCIT,...
Page 87 4069-XXX The base printer does not recognize that the high capacity input tray is installed. Action High Capacity Feeder Check the high capacity feeder input Autoconnect Mechanical tray to make sure it is mounted Check correctly and is not pushed down into the frame assembly or damaged.
Page 88 4069-XXX Action High Capacity Feeder Check the voltage on J8-1 (green). Option Control Board The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized.
Page 89 4069-XXX 24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (X=The printer displays the value of X for the paper tray where the error occurs. Example: 242 is a Paper Jam Tray 2) Action Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating...
Page 90 4069-XXX Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray. Action Paper Low Switch Run the sensor diagnostics for tray X Paper Low Switch Cable (X=the number that represents the High Capacity Feeder Input high capacity input tray).
Page 91 4069-XXX The elevator tray fails to stop at the correct position and continues to drive into the bottom frame. Action Lower Limit Switch Check continuity of the lower limit Lower Limit Switch Cable switch. If incorrect, replace the switch. If correct, check the switch cable.
Page 92 4069-XXX Paper from the high capacity feeder input tray does not reach the pass thru sensor. Service Tip: Check to be sure the paper in tray is within specifications. Action Autocompensator Check the autocompensator pick Assembly arm rollers for sign of glazing, toner or other buildup.
Page 93 4069-XXX The elevator tray does not move up or down. The printer recognizes that the option is installed. Action DC Drive Motor High Be sure the motor cable is correctly Capacity Feeder Option installed at J1 on the board. Check System Board the cables, damaged or loose wires.
Page 94 4069-XXX The elevator moves in one direction only. Action DC Drive Motor Check the voltages at J1 on the high Assembly High capacity system board. The voltages Capacity Feeder measure as follows: System Board Static (Motor Not Running) J1-1 (Brown): approximately 0 V dc J1-2 (yellow): approximately 0V dc Motor Running Forward J1-1 (Brown): Approximately 0 V dc...
Page 95 4069-XXX Paper size switch not selecting paper size that is selected. Action Paper Size Switch Check for continuity between the High Capacity Feeder common pin (J5-1) and the pin of the Option Control Board paper size selected. J5-1 (Black): Common Lead J5-2 (Blue)B5 J5-3 (Green) Executive J5-4 (Yellow) A4...
Page 96 4069-XXX Tray X Empty message displays. Tray does not respond to loading paper. No response from the front door switch. Action High Capacity Feeder Check the voltage on the board at Option Control Board J4-2 (green). The voltage measures approximately +5 V dc. If incorrect, disconnect the cable at J4 and check the voltage again.
Page 97 4069-XXX Excessive Noise or Vibration Action DC Motor Assembly Check to make sure all the motor plate mounting screws are tight. Idler Pulley Check to make sure the idler pulley DC Motor Assembly is not binding on the pulley shaft. Check the pulley for any signs of wear.
Page 98: Main Drive Service Check
4069-XXX Main Drive Service Check Service Tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or engine board. Service Tip: If there are equally spaced horizontal lines across the page, go to “Print Quality - Evenly spaced horizontal lines or marks” on page 2-97 WARNING: Whenever the gearbox assembly is removed from the machine it must be handled very carefully.
Page 99: Operator Panel Service Check
4069-XXX Action Motor does not turn, no Check the voltages at J12 on the gear error code 936 or User engine board. message 201 Paper Jam displays. Pin number and voltage: J12-1 = +24 V dc J12-4 = +5 V dc (static) 0 V dc (when main drive motor running) J12-5 = + 5 V dc (static) 0 V dc (when main drive motor running)
Page 100 4069-XXX Action Engine Board Check the voltage at J11-5. The (No buttons work) voltage measures approximately +5 V dc with the controller board removed. If incorrect, replace the engine board. If correct, check the continuity of the operator panel cable. If incorrect, replace the cable. If correct, replace the operator panel assembly.
Page 101: Options Service Check
4069-XXX Action Operator Panel all Check to make sure a SIMM is not diamonds, No Beeps plugged in backward. This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps. Operator Panel all Check the voltage at Pin J11-1 and diamonds, 5 Beeps J11-3.
Page 102 4069-XXX Hard Disk Option Service Tip: The Optra T printers support one hard disk option. Check to make sure only one hard disk option is installed. • 2.1 GB or larger Check to make sure the fixed disk and the fixed disk board are correctly installed.
Page 103: Output Bin Sensor Standard Tray Service Check
4069-XXX Output Bin Sensor Standard Tray Service Check Service Tip: If the output bin standard tray fills up and the bin full sensor fails to post the message "Remove Paper Standard Bin", enter the Diagnostic Mode, select Output Bin Tests, select Sensor Tests and select Standard Bin.
Page 104: Output Expander Service Check
4069-XXX Output Expander Service Check Service Tip: The majority of the mechanical components can be observed during operation by removing the left, right and system board covers. The output expander functions without the covers installed. Note: Make sure the option is correctly installed before attempting to service the unit.
Page 105 4069-XXX Action Output Expander Option Make sure the output expander option is the only option that is not recognized by the base printer. If the output expander is the only option not recognized by the printer, continue with step 2. If not, check the autoconnects of the options not recognized and the interconnect board and cable connections.
Page 106 4069-XXX 202 Paper Jam Open Rear Door Message displays. A sheet of paper is jammed prior to the pass through sensor flag. 202 Paper Jam Open Rear Door Message displays. A sheet of paper feeds out to the standard bin even though bin x is selected. Paper exits half way out of the redrive.
Page 107 4069-XXX Remove Paper - Output Bin X is displayed, POST Incomplete, Unable to clear the message. Action Dual Output Bin Sensor Flag Check the flag for correct operation, binding, broken parts or interference from the sensor cable, If incorrect, repair as necessary.
Page 108 4069-XXX 990 Service - BIN X Action D.C. Motor Check the DC motor cable Mechanical Linkage connector to be sure it is correctly Assembly installed at J4 on the output expander option board. If correct, disconnect J4 from the option board and check the resistance of the motor on the cable connector: J4-1 to J4-2: measures between...
Page 109: High-Capacity Output Stacker Service Check
4069-XXX No indication that Bin X is Full OR No indication that Bin X is Near Full Action Dual Output Bin X Sensor Check for correct installation of Assembly the sensor cable at J5 on the Control Board control board. If either the Bin Full (F) or Bin Near Full (NF) fail the sensor test then check the voltage at J5-3 and J5-4.
Page 110 4069-XXX Problems with excessive static electricity buildup Action Front Cover Assembly Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the high capacity option. Also check to make sure the ESD brush is not loose or damaged. The printer does not recognize one or more output options as installed Service Tip: If more than a single output option is installed, check...
Page 111 4069-XXX 202 Paper Jam Open Rear Door Message displays and a sheet of paper is jammed prior to the pass through sensor flag or 202 Paper Jam Open Rear Door Message displays, a sheet of paper feeds out to the standard bin even though bin X is selected and paper exits half way out of the redrive assembly.
Page 112: 5-Bin Mailbox Service Check
4069-XXX Remove Paper - Output Bin X Full displays. You may not be able to clear the message. Action Dual Output Bin Sensor Flag Check the flag for correct operation, (Upper Assembly) binding, broken parts or interference from the sensor cable. If incorrect, repair as necessary.
Page 113 4069-XXX Problems with excessive static electricity buildup Action Front Cover Assembly Check the front cover assembly to make sure the ESD brush ground lead is firmly attached to the 5-Bin Mailbox frame. Also check to make sure the ESD brush is not loose or damaged. The printer does not recognize one or more output options as installed.
Page 114 4069-XXX 271 Paper Jam - Check Bin 1 displays Action Bottom Pass Thru Sensor Check the flag for correct operation, Flag Assembly binding, broken parts or interference Control Board from the sensor cable. If incorrect, repair as necessary. If correct, check to make sure the bottom pass thru sensor is correctly connected to J5 on the control board.
Page 115 4069-XXX Ready Bin X Full message displays - May be able to clear message and will feed paper into Bin selected. Action Bin X Sensor Check the sensor and sensor cable for Bin X Sensor Cable the bin that is displaying the message Bin X Sensor Flag to make sure the sensor is seated Control Board...
Page 116 4069-XXX Paper does not feed into the bin selected. 271 Paper Jam - Check Bin 1 displays Action Deflector Check all the bin parts for signs of Deflector Spring missing or loose springs, binds in the Deflector Cover deflector or deflector cover, broken or Deflector Cover Spring binding shaft assemblies or broken Shaft assemblies...
Page 117 4069-XXX 990 Service Error displays Action Mechanical Linkage Check the DC motor cable connector DC Motor Assembly to be sure it is correctly installed at J2 on the control board. If correct, disconnect J2 from the control board and check the resistance of the motor on the cable connector.
Page 118: Paper Feed Service Check
4069-XXX Paper Feed Service Check If you have a 936 Transport Motor Error go to the “Main Drive Service Check” on page 2-69 Action Alignment Assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight.
Page 119 4069-XXX Paper feed failures occur only near the top of the stack of paper. The most common cause of this problem is paper curl. Remove the paper from tray x and check for the natural curvature in the paper. Reinstall the paper in the correct manner. If the problem persists, it may be necessary to reduce the stack height.
Page 120: Parallel Port Service Check
4069-XXX Multipurpose Tray Paper fails to feed from the multipurpose tray. The pick roll should make one complete revolution and stop with the flat side down. If the pick roll turns but does not pick paper, check the roll for signs of wear, oil or grease on the surface of the pick roll or slick spots.
Page 121: Printhead Service Check
4069-XXX Printhead Service Check The printhead assembly does not contain any service replaceable parts or components. If service error code 930 displays, the wrong printhead is installed in the printer. Note: A 201 paper jam may also indicate a failing printhead. The paper may have jammed prior to or at the input sensor.
Page 122: Print Quality Service Check
4069-XXX Print Quality Service Check Service Tip: Before troubleshooting any print quality problems do the following: • Install another print cartridge if available before proceeding with the service checks. • Use Tray 1 to test for print quality of the base printer. •...
Page 123 4069-XXX Print Quality - All Black Page Service Tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.
Page 124 4069-XXX Action High Voltage Contact Check the PC drum contact on the right side frame for damage, PC drum contact wear or contamination. If the contact is bent or damaged, replace the contact. Note: Inspect the HVPS PC drum contact on the board for any signs of damage or contamination.
Page 125 4069-XXX Print Quality - Random Marks Service Tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll or transfer roll. Symptom Action Random Marks Check the print cartridge for any signs of loose or foreign material that might be on the photoconductor.
Page 126 4069-XXX Print Quality - Evenly spaced horizontal lines or marks Action Lines spaced 3.19 mm This can be caused by the motor (.126 inch) apart pinion gear on the main drive motor. Replace the main drive motor. Lines spaced 22.32 mm This can be caused by a defective (.882 inch) apart gear in the main drive gearbox...
Page 127 (4.519 inch) apart Print Quality - Background Service Tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background. Some problems occur with printers that run a large amount of graphics in a humid environment.
Page 128 4069-XXX Action Erase Lamp/Lens Check the erase lamp lens for any Assembly (models 010/ signs of toner, paper dust or other 212/414/616/31v/01n/21n/ types of contamination. Clean the 31e/41n/61n) lens with a soft dry cloth if necessary. If unable to clean the contamination off the lens, replace the lens and lamp assembly.
Page 129 4069-XXX Action Engine Board HVPS Check the following voltages at J10 Connector on the engine board. Measure the voltages from J10 to printer ground. Printer Idle J10-1 approximately 0 V dc J10-2 approximately 4 V dc J10-4 approximately 0 V dc Printer Printing J10-1 varies 0 V dc to +5 V dc J10-2 varies 0 V dc to +4 V dc...
Page 130 4069-XXX Print Quality - Banding Service Tip: Banding is difficult to detect except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds thru the printer, especially in the development and transfer process.
Page 131 4069-XXX Action Charge Roll Assembly Check the charge roll for any signs Charge Roll Link Arm of toner buildup or other contamination on the outer edges that correspond to the bands on the page. Check the charge links and arms for proper operation, binds or incorrectly mounted counterbalance springs.
Page 132 4069-XXX Print Quality - Residual Image Service Tip: Install a new print cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade and other parts inside the print cartridge. Action Erase Lamp Assembly Check the erase lamp lens assembly (models 010/212/414/616/ for any signs of paper dust, toner...
Page 133 4069-XXX Print Quality - Light Print Service Tip: Check the toner saver and print darkness settings first if the print is light. Action Transfer Roll Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll.
Page 134 4069-XXX Print Quality - Toner on backside of printed page Service Tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper. Action Hot Roll Fuser Assembly Toner is being carried out on the backside of the media.
Page 135: Smart Cartridge Service Check
4069-XXX Smart Cartridge Service Check Note: If you are unable to clear a “32-Unsupported Cartridge” User Error Message, make sure an Optra T print cartridge is correctly installed in the printer. The cartridge is easily identified by the smart chip located on the top right side of the cartridge. Install another print cartridge before attempting to troubleshoot the printer.
Page 136: Serial Port Service Check
4069-XXX Action Smart Cartridge Cable Check the voltage on the smart Engine Board cartridge contact. The voltage measures approximately +5 V dc when not writing data to the engine board. If data is being written, the voltage measures approximately +12 V dc. If incorrect, disconnect the cable from J21 on the engine board and check the voltage on J21-1.
Page 137: Transfer Roll Service Check
4069-XXX Action Front Harness Cable Check the toner sensor portion of the front harness cable to make sure it is properly seated into the toner sensor. If correct at both the sensor and engine board (J10), check the continuity of the cable. If incorrect, replace the cable.
Page 138 4069-XXX is installed in a printer that has the erase lamp assembly installed. Check to make sure the correct level HVPS is installed. Go to “Printer to identify the printer service level. Serial Label” on page 7-2 Action Transfer Roll Assembly Check the transfer roll for any signs of toner buildup, surface damage to the roll, oil or other contaminants on...
Page 139 4069-XXX Action HVPS - 917 Error Code Check the voltage at J10-3. The voltage changes from +24 V dc with the printer idle to 0 V dc when the printer runs the print test. If the voltage is incorrect, check the continuity of line J10-3 in the front cable harness to the HVPS.
Page 140: Diagnostic Aids
4069-XXX 3. Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostic Mode To enter the Diagnostic Mode: 1.
Page 141: Device Tests
4069-XXX Device Tests Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block.
Page 142: Flash Test
4069-XXX – “xxxx Bad Blocks/yyyyyy Usable” message displays if fewer than 2000 bad blocks are detected. xxxx indicates the number of bad blocks and yyyyyy indicates the number of usable blocks. – “xxxx Bad Blocks/Replace Disk” message displays if more than 2000 bad blocks are detected.
Page 143: Duplex Tests
4069-XXX 3. Turn the printer On and release the buttons once “Performing Self Test” displays. – Once the printer is idle, the emulation can be downloaded again. 4. Program the download emulation into the code overlay SIMM again. 5. If these steps do not resolve the problem, replace the code overlay SIMM and download the emulation again.
Page 144: Duplex Sensor Test
4069-XXX 1/100 inch. A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin. 3. Press Return/Stop to exit the test. Check the Top Margin Offset of the base printer. Duplex Sensor Test This test is used to determine whether or not the Duplex sensors and switches are working correctly.
Page 145 4069-XXX The following appears on the printer display: DUPLEX MOTOR AA BB CC DD EE FF To pass the test the following results must display: AA = 00 BB = in the range of 20 through 3F inclusively (hex) CC = in the range of 3A through 5D inclusively (hex) DD = in the range of 11 through 1F inclusively (hex) Ignore bytes EE and FF.
Page 146: Duplex Feed 1 Test
4069-XXX Duplex Feed 1 Test This test feeds a blank sheet of paper to the duplex paper stop position 1. To run the Duplex Feed 1 Test: 1. Select Duplex Feed 1 from the Duplex Test menu. – The power indicator blinks while the paper is feeding. –...
Page 147: Error Log
4069-XXX Error Log Viewing the Error Log The error log is helpful to the servicer by providing a history of printer errors. The error log contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred).
Page 148: Hardware Tests
4069-XXX Hardware Tests The following Hardware Tests can be selected from this menu: LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap (if available) Serial Wrap (if available) Serial 1 Wrap (if available) Serial 3 Wrap (if available) LCD Test To run the LCD Test: 1.
Page 149: Sdram Memory Test
4069-XXX SDRAM Memory Test The purpose of this test is to check the validity of SDRAM, both standard and optional. The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly. To run the SDRAM Memory Test: 1.
Page 150: Parallel Wrap Test
4069-XXX Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following messages displays for approximately three seconds: ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached, the test stops with the power indicator on solid.
Page 151: Serial Wrap Test
4069-XXX DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum count is reached the test stops.
Page 152 4069-XXX Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following failure messages displays for approximately three seconds and the Fail Count increases by 1: Receive Status Interrupt Error Status Error Receive Data Interrupt Error...
Page 153: Input Tray Tests
4069-XXX Input Tray Tests Input Tray Feed Test This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder.
Page 154: Output Bin Test - Standard Bin
4069-XXX The multipurpose tray and the envelope feeder do not have a paper low sensor. The multipurpose tray does not have a pass through sensor. Output Bin Test - Standard Bin This test is used to verify if the standard bin sensor is working correctly.
Page 155: Output Bin Sensor Test
4069-XXX Output Bin Sensor Test This test is used to verify if the output bin sensors are working correctly. To run the Output Bin Sensor Test: 1. Select Sensor Test from the Output Bin Test menu. – "Output Bin/Full=OP/Input=OP" message displays. –...
Page 156: Base Sensor Test
4069-XXX If the high capacity output stacker is selected then the following is displayed: HC BIN 1 TP=OP , P=OP , F=OP , NF=OP IP = high capacity output stacker top position sensor P = high capacity output stacker passthru sensor F = high capacity output stacker full sensor NF = high capacity output stacker near full sensor If the 5-bin mailbox is selected the following is displayed:...
Page 157: 5-Bin Mailbox Diverter Test
4069-XXX 5-Bin Mailbox Diverter Test Note: This test checks the operation of each mailbox output diverter. Also if more than one 5-bin mailbox option is installed, the test checks all of the diverters installed on the printer. When the test is selected from the diagnostic menu the following is displayed: Diverter Test Running This is a single test.
Page 158: Print Registration
4069-XXX Print Registration The print registration range is as follows: Bottom Margin: -20 to +20 Each increment causes approximately.55 mm shift in the bottom margin. Top Margin: -25 to +25 Left Margin: -25 to +25 Right Margin: -10 to +10 To set Print Registration: 1.
Page 159: Printer Setup
4069-XXX Printer Setup Setting the Page Count This lets the servicer change the page count from the diagnostic menu. This is used whenever the engine board is replaced because this board contains the printer's NVRAM Memory where the page count is stored. To set the Page Count: 1.
Page 160: Maintenance Page Count
4069-XXX Maintenance Page Count This counter is reset by the servicer after a “80 Scheduled Maintenance” message displays (250K copies) and a maintenance kit is installed. To view the Maintenance Page Count: 1. Select Maintenance Count Value from the diagnostic menu. 2.
Page 161: Restore Ep Factory Defaults
4069-XXX validate the Configuration ID. If the ID is invalid then "INVALID ID" message displays on Line 2 before the ID redisplays. You have to reenter the Configuration ID until a valid ID is verified. If the ID is valid then the ID is saved in NVRAM and the printer automatically PORs to activate the new setting.
Page 162: Print Tests
4069-XXX Print Contrast The print contrast setting controls the developer voltage offset. The print contrast can be adjusted as follows: • • MEDIUM • HIGH Charge Roll The charge roll can be adjusted as follows: • • MEDIUM • HIGH Print Tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options.
Page 163: Print Quality Test Pages
4069-XXX The contents of the Print Test Page varies depending on the media installed in the selected input source. Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting or the presence of a duplex option. If a source is selected that contains envelopes, an envelope test pattern is printed.
Page 164: Printing Menu Settings Page
4069-XXX To run the Print Quality Test Pages: 1. Turn the printer off. 2. Press and hold Select and Return. 3. Turn on the printer. 4. Release the buttons once Performing the Self Test displays. 5. The printer performs its normal POR cycle then print one copy of the Print Quality Test pages.
Page 165: Autocompensator Operation
4069-XXX Autocompensator Operation The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively.
Page 166: Autoconnect System, Paper Tray Options, Envelope Feeder And Output Expander Operations
4069-XXX Poor gear efficiency can cause the arm to generate higher normal forces. If the pick assembly is noisy, replacement may be required. The arm must pivot freely through its full range of motion. On 500 sheet trays there are wrap springs located on the pivot arbors of the arm.
Page 167 4069-XXX Duplex Option The duplex option interface is a six pin autoconnector that provides a +24 V dc, +24 V dc return, serial interface transmit signal, serial interface receive signal and two ground pins. The duplex option receives the +24 V dc from the base printer for the duplex motors and also converts the voltage to +5 V dc for duplex electronics.
Page 168: Fuser Operation
This is a complete assembly and the parts cannot be individually replaced as in previous Lexmark laser printers. The thermal fuse (two fuses in series) protects the fuser assembly and surrounding parts from ignition in the event of a failure in the fuser control circuitry by opening the AC circuit to the lamp.
Page 169 4069-XXX Belt Fuser The belt fuser utilizes a ceramic heating element inside a cylindrically formed belt as the heating element of the fusing process. The contact area of the belt is heated to fusing temperature. The media passes between the belt and a back-up roller, fusing the image to the media.
Page 170: Paper Feed Jams
4069-XXX Paper Feed Jams Paper Jams - Base Printer Error Message 200 - Paper Jam - Remove Cartridge This message indicates that paper is jammed at the printer input sensor. This condition can be caused by the paper jamming prior to activating the input sensor flag, the sensor not detecting paper over the sensor or paper arriving at the sensor too late.
Page 171 4069-XXX Error Message 24x (x=Tray 1 through 5) Paper Jam Check Tray x. The paper has not cleared the pass through sensor or reached the pass through sensor of the option above tray x. Error Message 250 - Paper Jam - Check MP Feeder The paper is jammed in the multipurpose feeder and has not reached the base machine input sensor or has not reached the input sensor in time.
Page 172: Repair Information
4069-XXX 4. Repair Information WARNING: Read the following before handling electronic parts. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: •...
Page 173: Adjustment Procedures
4069-XXX Adjustment Procedures Duplex Motor Drive Belts Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex motor or loosen the motor or drive belt idler pulley. Service Tip: Excessive belt tension can result in stalling the duplex motor.
Page 174: Fuser Solenoid Adjustment
4069-XXX Fuser Solenoid Adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature.
Page 175: Printhead Assembly Adjustment
4069-XXX Printhead Assembly Adjustment Do the printhead assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws. Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly. Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots.
Page 176: Paper Alignment Assembly Adjustment
4069-XXX Paper Alignment Assembly Adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one.
Page 177 4069-XXX b. Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings should be within the range specified in “Print Registration” on page 3-19. The reference screw can be adjusted without loosening the locknut.
Page 178: Screw Identification Table
4069-XXX Screw Identification Table The following table contains screw types, locations, and quantities necessary to service the printer. Each screw callout in the removal procedure graphic displays the screw reference number listed in the table. Pay careful attention to each screw type location when doing removals.
Page 179 4069-XXX Reference Screw Type Location Purpose Number M3.5x8 mm spring mounting Thread Cutting controller board mounting (front) integrated tray ITC mounting board stacker support to right attach side frame M3.5x12 mm engine board shield to attach Thread Cutting left frame paper alignment mounting assembly...
Page 180 4069-XXX Reference Screw Type Location Purpose Number M3x6 mm outer shield mounting Taptite inner redrive deflector mounting interconnect board to mounting center pan engine board mounting (bottom holes) controller board to attach interconnect board ground controller board to inner mounting shield controller board (back) mounting...
Page 181 4069-XXX Reference Screw Type Location Purpose Number M3x12 mm HVPS board mounting Taptite Panhead M3x28 mm developer drive ground attach Taptite (bottom hole) Panhead M3x6 mm stacker duct mounting Taptite engine board mounting Panhead controller to shield mounting controller board mounting in pan mounting...
Page 182 4069-XXX Reference Screw Type Location Purpose Number M3.5x8 mm autocompensator mounting Plastite Thread Forming M3.5x10 mm right side cover mounting Plastite Thread right side frame to pan attach Forming left side frame to pan attach M3x6 mm fuser board mounting SEMS Machine Screw with washer...
Page 183: Removal Procedures
4069-XXX Removal Procedures CAUTION: Remove the power cord from the printer or wall outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the hand grips on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
Page 184 4069-XXX Right Cover 1. Open the upper and bottom front covers. 2. Release the cover latch (A) and remove the right cover mounting screw (B). 4-13 Repair Information...
Page 185 4069-XXX 3. Remove the redrive assembly. 4. Remove the right side cover mounting screw (B). 5. Remove the right side cover. 4-14 Service Manual...
Page 186 4069-XXX Upper Front Cover 1. Raise the upper front cover. 2. Remove the upper front cover mounting screws (A). 3. Rotate the cover upward to allow the rear cover hinges to clear the mounting slots and remove the cover. 4-15 Repair Information...
Page 187: Center Pan Assembly
4069-XXX Laser Assembly Cover 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. Remove the paper full sensor flag assembly from the mounting bracket.
Page 188: Controller Board
4069-XXX Controller Board 1. Remove the inner EMC shield. 2. Remove the controller board mounting screw (A). 3. Remove the controller board mounting screws (C). 4. Remove the controller board parallel port mounting screws (B). 5. Remove the serial port mounting screws if present. 6.
Page 189: Developer Drive Assembly
4069-XXX Developer Drive Assembly 1. Remove the inner EMC shield. 2. Remove the developer drive assembly mounting screws (A). 3. Remove the developer drive assembly. Note: Be sure the developer drive assembly wheel aligns with the hub on the main drive assembly when reinstalling the assembly. 4-18 Service Manual...
Page 190: Duplex Board
4069-XXX Duplex Board 1. Lift the base printer from the duplex assembly. 2. Remove the four duplex board cover mounting screws. 3. Gently disconnect the cables from the duplex board. Use caution to avoid damage to the cables and connectors. 4.
Page 191: Duplex Motor
4069-XXX Duplex Motor 1. Remove the duplex front cover door. 2. Gently disconnect the cables from the duplex board. Use caution to avoid damage to the cables and connectors. 3. Remove the four mounting screws from the left and right return guides and remove the guides.
Page 192: Engine Board
4069-XXX Engine Board 1. Remove the inner EMC shield. 2. Disconnect all cables from the engine board. 3. Remove the engine board mounting screws (A). 4. Remove the engine board cage mounting screw (B) from the main drive motor assembly. 5.
Page 193: Fans
4069-XXX Fans Auxiliary Fan (Models 614/616) 1. Remove the right cover. 2. Remove the inner EMC shield. 3. Remove the fuser wiper cover. 4. Disconnect the auxiliary fan cable from the engine board at connector J7. 5. Note the routing of the auxiliary fan cable (A) and remove the fan (B).
Page 194 4069-XXX Main Fan 1. Remove the top rear cover. 2. Remove the inner EMC shield. 3. Note the routing of the main fan cable (A) and disconnect the cable from the engine board at connector J1. 4. Release the four latches (B) and remove the fan from the left side frame.
Page 195: Fuser
4069-XXX Note: The fuser in models 31v and 31e must be replaced with a complete fuser FRU. Caution: Be sure the fuser assembly has cooled before working on any of the fuser FRUs. Fuser 1. Remove the redrive assembly. 2. Loosen the fuser mounting screws and remove the fuser. 4-24 Service Manual...
Page 196: Fuser Board (Hot Roll)
4069-XXX Fuser Board (Hot Roll) 1. Remove the fuser assembly. 2. Remove the fuser board cover. 3. Disconnect the cables from the fuser board. 4. Remove the fuser board mounting screw. 5. Release the fuser board from the standoff tab and lift the fuser board from the fuser assembly.
Page 197: Fuser Cover (Hot Roll)
4069-XXX Fuser Cover (Hot Roll) 1. Remove the fuser assembly. 2. Note the thermistor cable routing and disconnect the cable from the fuser board. 3. Remove the left and right lamp bracket mounting screws (A). 4. Remove the left and right fuser cover mounting screws (B) and lift the cover from the fuser assembly.
Page 198: Fuser Detack Housing Assembly (Hot Roll)
4069-XXX Fuser Detack Housing Assembly (Hot Roll) 1. Remove the fuser assembly. 2. Remove the fuser cover assembly. 3. Remove the fuser lamp. Use care when handling the lamp. 4. Disengage the hotroll bearing clips to free the fuser frame walls. 5.
Page 199: Fuser Transfer Plate (Hot Roll)
4069-XXX Fuser Transfer Plate (Hot Roll) 1. Remove the upper paper deflector. 2. Remove the fuser transfer roll. 3. Remove the inner paper deflector. 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.
Page 200: Fuser Envelope Conditioner Solenoid (Hot Roll)
4069-XXX Fuser Envelope Conditioner Solenoid (Hot Roll) The solenoid is in all models except 31v/31e and 31v/31e at service level B. 1. Remove the fuser assembly. 2. Remove the solenoid mounting screw (A). 3. Disconnect the solenoid link (B). 4. Remove the solenoid from the fuser assembly. Note: Do the “Fuser Solenoid Adjustment”...
Page 201: Fuser Narrow Media Sensor/Flag Assembly (Hot Roll)
4069-XXX Fuser Narrow Media Sensor/Flag Assembly (Hot Roll) 1. Remove the fuser assembly. 2. Remove the exit roll assembly. 3. Remove the fuser board cover. 4. Disconnect the sensors from the fuser board. 5. Remove the lower exit guide assembly 6.
Page 202: Fuser Lower Exit Guide Assembly (Hot Roll)
4069-XXX The fuser lamp FRU is color coded. The left and right fuser lamp bracket access holes let you view the end of the lamp. Use the following table to identify and install the correct lamp. Description Color Code Fuser Lamp 115V 550W Green Fuser Lamp 115V 875W Gold...
Page 203: High Voltage Power Supply
4069-XXX High Voltage Power Supply 1. Remove the inner paper deflector. 2. Remove the toner sensor cable from the retainer (A) on the front of the HVPS. 3. Remove the right side cover. 4. Disconnect the HVPS cable from the HVPS at connector (C). 5.
Page 204: Inner Emc Shield
4069-XXX Inner EMC Shield 1. Remove the left door. 2. Remove the outer EMC shield. 3. Remove all option boards from the connector board slots. 4. Remove the inner EMC shield mounting screws (A). 5. Remove the inner EMC shield. 4-33 Repair Information...
Page 205: Inner Paper Deflector Assembly
4069-XXX Inner Paper Deflector Assembly 1. Remove the paper tray. 2. Remove the upper deflector assembly. 3. Place the printer on its side. 4. Remove the lower deflector assembly. 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.
Page 206: Integrated Tray Compensator Assembly
4069-XXX Integrated Tray Compensator Assembly 1. Remove the paper tray. 2. Remove the left door. 3. Remove the inner EMC shield. 4. Disconnect the compensator motor cable (A) from the engine board. 5. Place the printer on its side. 6. Locate the integrated tray compensator assembly (B) on the bottom of the printer and disconnect the compensator arm bias spring from the frame.
Page 207: Integrated Tray Compensator Pick Roll Assembly
4069-XXX Integrated Tray Compensator Pick Roll Assembly 1. Remove the paper tray. 2. Place the printer on its side. 3. Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer. 4. Unsnap the pick roll assembly (D) from its mounting and remove.
Page 208: Interconnect Board Assembly
4069-XXX Interconnect Board Assembly 1. Remove the inner EMC shield. 2. Remove the engine board and shield. 3. Remove the LVPS. 4. Disconnect all cables from the interconnect board. 5. Place the printer on its back and remove the mounting screws (A).
Page 209 4069-XXX 6. Remove the interconnect board assembly. 4-38 Service Manual...
Page 210: Left Side Frame
4069-XXX Left Side Frame 1. Remove the engine board. 2. Remove the main drive assembly. 3. Remove the upper front cover hinge assembly. 4. Remove the mulitpurpose tray/lower deflector assembly. 5. Remove the paper alignment assembly. 6. Remove the left side frame mounting screws (A). 4-39 Repair Information...
Page 211 4069-XXX 7. Place the printer on its back and remove the left side frame mounting screws (A). 8. Remove the left side frame. 4-40 Service Manual...
Page 212: Low Voltage Power Supply
4069-XXX Low Voltage Power Supply 1. Remove the right cover. 2. Remove the LVPS mounting screws (A) from the rear of the bottom pan. 3. Pull the LVPS assembly from the right side of the printer. Initial resistance is felt as the automate plug disconnects. 4.
Page 213: Main Drive Assembly
4069-XXX Main Drive Assembly 1. Remove the inner EMC shield. 2. Remove the gear guard. 3. Remove the developer drive assembly. 4. Remove the transfer shaft (A) through the bottom of the printer. 5. Remove all cables from the cable clamps (B) on the main drive assembly.
Page 214 4069-XXX 10. Remove the main drive assembly. Note: Do not remove the screws (E) on the main drive assembly. Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly. 4-43 Repair Information...
Page 215: Main Drive Motor
4069-XXX Main Drive Motor 1. Remove the main drive assembly. 2. Remove the main drive motor mounting screws (A). 3. Remove the main drive motor. 4-44 Service Manual...
Page 216: Multipurpose Tray/Lower Deflector Assembly
4069-XXX Multipurpose Tray/Lower Deflector Assembly 1. Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the rectangular mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts.
Page 217 4069-XXX 2. Remove the upper deflector. 3. Remove the solenoid mounting screw. 4. Remove the screws (A) mounting the multipurpose tray/lower deflector assembly. 5. Remove the multipurpose tray/lower deflector assembly. 4-46 Service Manual...
Page 218: Operator Panel Assembly
4069-XXX Operator Panel Assembly 1. Remove the upper front cover. 2. Disconnect the operator panel cable. 3. Gently press the operator panel lens tab (A) and remove the operator panel. 4-47 Repair Information...
Page 219: Operator Panel Cable/Cover Open Switch Assembly
4069-XXX Operator Panel Cable/Cover Open Switch Assembly Note: Pay careful attention to the cable routing through the printer before you remove the operator panel cable/cover open switch assembly. 1. Remove the left door, left cover, upper front cover, outer EMC shield and inner EMC shield.
Page 220: Optional 250/500 Paper Tray Assembly
4069-XXX Optional 250/500 Paper Tray Assembly Note: Remove the printer and other paper feed options to access the failing optional paper tray assembly. Paper Tray Compensator Assembly 1. Remove the printer and other paper feed options. 2. Disconnect the compensator assembly bias spring from the tray frame.
Page 221: Outer Emc Shield
4069-XXX Outer EMC Shield 1. Remove the left door. 2. Loosen the outer EMC shield mounting screws (A) and remove the shield. 4-50 Service Manual...
Page 222: Paper Alignment Assembly
4069-XXX Paper Alignment Assembly 1. Remove the upper paper deflector assembly. 2. Remove the inner paper deflector assembly. 3. Release the input paper sensor from its mounting and remove. 4. Remove the left door. 5. Remove the paper alignment assembly mounting screws (A) located inside the printer.
Page 223: Paper Input Sensor
4069-XXX 6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame and remove the screw. 7. Remove the paper alignment assembly. Note: Do the “Paper Alignment Assembly Adjustment” on page 4-5 when you reinstall the assembly. Paper Input Sensor 1.
Page 224: Paper Size Sensing Board
4069-XXX Paper Size Sensing Board 1. Disconnect the paper size sensing board cable from the board. 2. Remove the two paper size sensing board mounting screws (A). 3. Remove the paper size sensing board. Pick Roll 1. Remove the upper paper deflector. 2.
Page 225: Printhead
4069-XXX Printhead 1. Remove the laser assembly cover. 2. Disconnect the printhead cables (A) from the printhead assembly. 3. Remove the printhead mounting screws (B) and remove the printhead. Note: Do the “Printhead Assembly Adjustment” on page 4-4 whenever you remove or replace the printhead assembly or loosen the mounting screws.
Page 226: Redrive Assembly
4069-XXX Redrive Assembly 1. Remove the redrive door assembly. 2. Remove the redrive exit cover. 3. Remove the redrive assembly mounting screws (A). 4. Release the redrive assembly mounting latches (B) and remove the redrive assembly. 4-55 Repair Information...
Page 227: Right Side Frame
4069-XXX Right Side Frame 1. Remove the right side cover. 2. Remove the LVPS. 3. Remove the multipurpose tray assembly. 4. Remove the auxiliary fan assembly. 5. Disconnect the auto compensator arm bias spring from the right side frame. 6. Remove the toner sensor mounting screw (A), disconnect the sensor cable and remove the toner sensor.
Page 228: Smart Cartridge Contacts
4069-XXX Smart Cartridge Contacts 1. Remove the upper front cover. 2. Release tab (A) and remove the contact cover. 3. Remove the contact plunger (B). 4. Remove the screws (C) and remove the contacts (D). 4-57 Repair Information...
Page 229: Toner Sensor
4069-XXX Toner Sensor 1. Remove the right side cover. 2. Remove the toner sensor mounting screw (A). Disconnect the toner sensor cable and remove the toner sensor. 4-58 Service Manual...
Page 230: Transfer Roll Assembly
4069-XXX Transfer Roll Assembly 1. Open the upper front cover and remove the print cartridge. 2. Unsnap the transfer roll assembly from the left pivot arm. 3. Lift the transfer roller assembly toward the left and remove the transfer roller assembly from the printer. Upper Paper Deflector Assembly 1.
Page 231: Upper Front Cover Hinge Assembly
4069-XXX Upper Front Cover Hinge Assembly 1. Remove the upper front cover. 2. Remove the laser assembly cover. 3. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins and remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge.
Page 232: Upper Front Cover Interlock Switch Assembly
4069-XXX Upper Front Cover Interlock Switch Assembly 1. Remove the upper front cover. 2. Remove the operator panel. 3. Remove the inner EMC shield. 4. Pull up on the switch (A) to remove from the mounting posts (B). 5. Note the routing of the interlock switch assembly cable and disconnect the cable on the engine board.
Page 233 4069-XXX 4-62 Service Manual...
Page 234: Connector Locations
4069-XXX 5. Connector Locations Low Voltage Power Supply Connector Pin No. Signal CN3 Interconnect +5 V dc Board +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc Ground Ground Ground Ground...
Page 235 4069-XXX Service Manual...
Page 236: High Voltage Power Supply
4069-XXX High Voltage Power Supply Connector Pin No. Signal CN1 Engine Board Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT Connector Locations...
Page 237: Engine Board
4069-XXX Engine Board Connector Pin No. Signal J1 Main Fan Fan Stall Ground Main Fan J3 Printhead (Mirror +24 V dc Return Motor) +24 V dc Return ReFREQ LOCKn Start* +24 V dc Return +24 V dc J4 Cover Closed Switch Cover Closed Ground +5 V dc...
Page 238 4069-XXX Connector Pin No. Signal J6 Output Level Sensor Ground Ground Opt2 Ground +5 V dc J7 Auxiliary Fan Cartfan 414/616 Ground J8 Printhead HYSNC Ground HSYNC* Ground +5 V dc Connector Locations...
Page 239 4069-XXX Connector Pin No. Signal J10 Erase/Cartridge/ AT Servo (HVPS) Sensor/Input Sensor/ Servo OutT (HVPS) HVPS TXENABLE (HVPS) Transfer (HVPS) +24 V dc (HVPS) Charge (HVPS) Ground (HVPS) Developer (HVPS) Ground (In Sens) In Sns* (In Sens) +5 V dc (C-Sens) CTSENSE* (C-Sens) Ground (C-Sens) +24 V dc (Erase L)
Page 240 4069-XXX Connector Pin No. Signal J12 Transport Motor +24 V dc +24 V dc Return +24 V dc Return Motor3 Motor4 Motor1 +5 V dc Motor2 Ground Motor0 J13 Autoconnect RXDIN (Options) Ground +5 V dc Ground Ground J14 Autoconnect RXDIN (Options) Ground...
Page 241 4069-XXX Connector Pin No. Signal J15 Integrated Paper +5 V dc Tray - Paper Size Sensor PSIZE2 Ground PSIZE1 +24 V dc Ground POUT +5 V dc Paper Low +5 V dc J16 Fuser Exit Sensor Thumpret +5 V dc Thumpleft Ground Therm...
Page 242 4069-XXX Connector Pin No. Signal J18 Auto Compensator +24 V dc Ground Ground +5 V dc J19 MPT Paper Out Ground POSENSE +5 V dc J20 Interconnect Board J21 Smart Cartridge Scart Scart Ground Ground Connector Locations...
Page 243 4069-XXX 5-10 Service Manual...
Page 244: Fuser Board
4069-XXX Fuser Board Connector Pin No. Signal J1 Engine Board NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* J2 Thermistor ThermGnd HRTherm J3 Thumper Ground +42V dc J4 Thumper Solenoid ThumpB ThumpA J5 Narrow Media +5 V dc Sensor Nar Media Ground...
Page 245: Interconnect Board
4069-XXX Interconnect Board Connector Pin No. Signal J1 Fuser Solenoid +42 V dc Ground J2 LVPS +42 V dc Heaton Xeroxing +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground J3 LVPS Ground Ground Ground Ground +5 V dc +5 V dc +5 V dc...
Page 246 4069-XXX Connector Pin No. Signal J5 Autoconnect +24 V dc BTM/FNT Ground J6 Engine Board J7 Controller Board J11 INA 1 J12 INA 2 Jumper Connector Signal Position J8 ID-1 0 V dc (Gnd) center pin to top pin of J8 + 5 V dc center pin to bottom pin of J9 J9 ID-2...
Page 247 4069-XXX • Models 414, 41b, 41L and 41n have a jumper between the center pin and pin 2 of J8 and a jumper between the center pin and pin 3 of J9. • Models 616 and 61n have a jumper between the center pin and pin1 of J8 and a jumper between the center pin and pin 3 of J9.
Page 248: Envelope Option Board
4069-XXX Envelope Option Board Connector Pin No. Signal Ground Tx (EOC) Ground Rx (EOC) +24 V dc Return +24 V dc Ground Paper Present +5 V dc Ground Paper Present +5 V dc Motor - Phase B- Motor - Phase A- Motor - Phase B+ Motor - Phase A+ 5-15...
Page 249 4069-XXX 5-16 Service Manual...
Page 250: Duplex Option Board
4069-XXX Duplex Option Board Note: Duplex connectors J10 and J11 are interchangeable. No problem results if the connectors are switched. Connector Pin No. Signal J1 Motor Motor - Motor + J2 DC Motor +5 V dc Sensor Sensor/Encoder Board Tach + Ground J3 Stepper Motor STPMOTA -...
Page 251 4069-XXX Connector Pin No. Signal J9 Autoconnect, Ground Option Below PrtxDout Ground PrtRxd J10 Autoconnect, +24 V dc Option Below Ground J11 Printer +24 V dc Autoconnect Ground J12 Printer Autoconnect Ground PrtxDin Ground PrtRxD 5-18 Service Manual...
Page 252: Autoconnect - Top
4069-XXX Autoconnect - Top Connector Pin No. Signal Top Autoconnect 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc +5 V dc 0 V dc +24 V dc 5-19 Connector Locations...
Page 253: Output Expander Control Board
4069-XXX Output Expander Control Board Connector Pin No. Signal J1A Autoconnect +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground J2A Autoconnect +24 V dc Ground +5 V dc prtxdout Ground prtrxd Ground J3 Pass Thru Sensor Ground Paper Present RVsnsr J4 DC Motor...
Page 254 4069-XXX Connector Pin No. Signal J5 Bin Full/Near Full Ground Dual Sensor Ground binful binful RVsnsr J6 Jumper Connector Not Used Not Used Not Used 5-21 Connector Locations...
Page 255: High-Capacity Output Stacker Board
4069-XXX High-Capacity Output Stacker Board Connector Pin No. Signal J1A Autoconnect +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground J2A Autoconnect +24 V dc Ground +5 V dc prtxdout Ground prtrxd Ground J3 Pass Thru Sensor Ground Paper Present RVsnsr J4 DC Motor...
Page 256 4069-XXX Connector Pin No. Signal J5 Bin Full/Near Full Ground Dual Sensor Ground binful binful RVsnsr J6 Jumper Connector Upper Unit Upper/Lower Unit Lower Unit J6 Connector Jumper Locations High-Capacity Pin 1 Pin 2 Pin 3 Stacker Board Upper Unit Board Not Used Lower Unit Board Not Used...
Page 257 4069-XXX 5-24 Service Manual...
Page 258: Preventive Maintenance
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis.
Page 259: Scheduled Maintenance
4069-XXX Scheduled Maintenance The operator panel displays the message “80 Scheduled Maintenance” at each 300K page count interval. It is necessary to replace the fuser assembly, transfer roller and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers: 99A1762 - 115V 875W Models 414/616/41b/41l/41e/41n/61n...
Page 260: Parts Catalog
4069-XXX 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.
Page 261: Printer Serial Label
4069-XXX Printer Serial Label Look at the printer serial label to identify the printer you are working on. There are two service levels of Optra T printers. Some printers are at a service level B as indicated by the B on the label. Service Manual...
Page 262 4069-XXX Use the Model Name/Type table to identify model specific replacement FRUs. The parts catalog uses the Type last three digits to identify model specific FRUs. Model Name Type Optra T 610 4069-010 Optra T 610n 4069-01n Optra T 612 4069-212 Optra T 612n 4069-21n...
Page 263: Assembly 1: Covers
4069-XXX Assembly 1: Covers Service Manual...
Page 264 4069-XXX Asm- Part Units Description Index Number 99A1587 Support, Paper 99A1825 Cover, Fuser Wick Assembly 31v 99A1508 Cover, Fuser Wick Assembly 010/212/414/616 1-2A 99A1512 Cover Assembly, Redrive Cap 99A1506 Cover Asm, Laser Assembly 010/212/31v 99A1507 Cover Asm, Laser 500 Output 414/616 Screw, Laser Cover PP 99A0263 99A1593 Cable, Smart Cartridge...
Page 265 4069-XXX Assembly 1: Covers (continued) Service Manual...
Page 266 4069-XXX Asm- Part Units Description Index Number 1-13 99A0007 Label, TLI/ID/Serial No. - Blank 1-14 99A1502 Latch, Upper Cover 1-15 99A0004 Spring, Latch 1-17 99A1511 Cover Assembly, Lower Front 1-18 99A1501 Operator Panel Assembly 1-19 99A1577 Switch, Cover Open w/Operator Panel Cable Assembly Screw, Left Side Cvr Mtg PP 99A0263 1-20...
Page 267: Assembly 2: Frame
4069-XXX Assembly 2: Frame Service Manual...
Page 268 4069-XXX Asm- Part Units Description Index Number 99A1515 Duct, 250 Left Stacker 010/212/31v 99A1516 Duct, 500 Left Stacker 414/616 99A0867 Duct, Main Body 99A1662 Support, Left Lower Stacker 99A0113 Pan, Drip ITC 99A0045 Latch, Cartridge Assembly 99A0039 Roller, Developer Support 99A0058 Pad, Machine Mounting 2-7B...
Page 269 4069-XXX Assembly 2: Frame (continued) 7-10 Service Manual...
Page 270 4069-XXX Asm- Part Units Description Index Number 2-17 99A1525 Deflector, Upper PF 2-18 99A0055 Deflector, Inner 2-19 99A1833 Frame, EP Module, SERV LVL B 2-19 99A1833 Frame, EP Module, 010, 212, 414, 616 2-20 99A0053 Sensor, Input 2-21 99A0063 Spring, PA Out Activate 2-22 99A0549 Shield, ESD Assembly with label...
Page 271: Assembly 3: Printhead
4069-XXX Assembly 3: Printhead 7-12 Service Manual...
Page 272 4069-XXX Asm- Part Units Description Index Number 99A1526 Printhead Assembly, 010 99A1527 Printhead Assembly, 212/31v 99A1528 Printhead Assembly, 414 99A1867 Printhead Assembly, 41b/41e/41l 99A1873 Printhead Assembly, 616 Screw, Printhead Mounting PP 99A0263 7-13 Parts Catalog...
Page 273: Assembly 4: Paper Feed (Autocompensator)
4069-XXX Assembly 4: Paper Feed (Autocompensator) 7-14 Service Manual...
Page 274 4069-XXX Asm- Part Units Description Index Number 99A0060 Sensor, Paper Out Internal Tray 99A1056 Pick Arm Assembly (250) 010/31v 99A1530 Pick Arm Assembly (500) 212/414/616 99A0070 Pick Rolls Screw, Hanger PP 99A0263 99A1616 Flag, Paper Out 500 Tray 212/414/616 99A1609 Flag, Paper Out 250 Internal Tray 010/31v 7-15 Parts Catalog...
Page 275: Assembly 5: Paper Feed - Multipurpose Unit
4069-XXX Assembly 5: Paper Feed - Multipurpose Unit 7-16 Service Manual...
Page 276 4069-XXX Asm- Part Units Description Index Number 99A0075 Screw, Socket Set M4X5 mm 99A0071 Arm Assembly, MPT 99A0076 Pick Roll Assembly 99A0081 Spring Assembly, Separator 99A0083 MPT Pad Assembly Kit o Restraint Pad o MPT Pad Assembly 99A1608 Deflector Assembly, MPT 99A1531 Deflector, Lower Screw, Lower Deflector Mounting 8 mm...
Page 277: Assembly 6: Paper Feed - Alignment
4069-XXX Assembly 6: Paper Feed - Alignment 7-18 Service Manual...
Page 278 4069-XXX Asm- Part Units Description Index Number 99A0089 Alignment Assembly Paper Feed 99A0492 Screw, Paper Reference Adjustment 99A0566 Nut, Paper Reference Adjustment 99A0559 Lever, Bellcrank Release 99A0565 Washer, Reference Adjustment 99A0490 Clip, Reference Ground Screw, Alignment Asm Mtg PP 99A0263 7-19 Parts Catalog...
Page 279: Assembly 7: Paper Feed - Output
4069-XXX Assembly 7: Paper Feed - Output 7-20 Service Manual...
Page 280 4069-XXX Asm- Part Units Description Index Number 99A1586 Redrive Assembly, Inner 250 010 99A1604 Redrive Assembly, 212 99A1533 Redrive Assembly, Inner 500 414/616 99A1532 Redrive Assembly, Inner 250 Belt 31v 99A1644 Door Assembly, Redrive 250 010/212/31v 99A1534 Door Assembly, Redrive 500 414/616 99A0104 Spring, Upper Diverter 99A1857...
Page 281: Assembly 8: Integrated Paper Tray - 250 Sheet
4069-XXX Assembly 8: Integrated Paper Tray - 250 Sheet 7-22 Service Manual...
Page 282 4069-XXX Asm- Part Units Description Index Number 99A1536 Tray, Integrated 250 Sheet 010/31v 99A1601 Latch, Back Restraint 99A0120 Restraint Pad 99A0892 Restraint, Side 250 Sheet Tray 99A0119 Wear Strips 99A1537 Knob, Paper Size 8-6A 99A1879 Label, Paper Size 99A1812 Label, Tray Option Number 99A0121 Clip, 250 Tray Wear 99A0126...
Page 283: Assembly 9: Integrated Paper Tray - 500 Sheet
4069-XXX Assembly 9: Integrated Paper Tray - 500 Sheet 7-24 Service Manual...
Page 284 4069-XXX Asm- Part Units Description Index Number 99A1601 Latch, Back Restraint 99A1576 Tray Assembly 500 Sheet 212/414/616 99A0895 Restraint, Side 99A0292 Strip, Wear 99A1537 Knob, Paper Size 9-5A 99A1879 Label, Paper Size 99A1812 Label, Tray Option Number 99A1750 Plate, 500 Tray Wear 99A0126 Finger, Autosize 99A1582...
Page 285: Assembly 10: Main Drive
4069-XXX Assembly 10: Main Drive 7-26 Service Manual...
Page 286 4069-XXX Asm- Part Units Description Index Number 10-1 99A1542 Gearbox, w/Motor 31v 10-1 99A1543 Gearbox, w/Motor 010/212 10-1 99A0129 Gearbox, w/Motor 414/41b/41l 10-1 99A0801 Gearbox, w/Motor 616 10-2 99A0134 Shaft, Power Take Off 010/31v 10-2 99A1569 Shaft, Power Take Off 500 212/414/616 10-3 99A0275 Spring, Power Takeoff Shaft...
Page 287: Assembly 11: Developer Drive
4069-XXX Assembly 11: Developer Drive 7-28 Service Manual...
Page 288 4069-XXX Asm- Part Units Description Index Number 11-1 99A1544 Developer Drive Assembly 11-2 99A0136 Shaft, Developer Drive 11-3 99A0564 Coupler, Gear #55 11-4 Screw, Developer Drive Ground PP 99A0263 11-5 Screw, Developer Drive Mtg PP 99A0263 7-29 Parts Catalog...
Page 289: Assembly 12: Hot Roll Fuser
4069-XXX Assembly 12: Hot Roll Fuser 7-30 Service Manual...
Page 290 4069-XXX Asm- Part Units Description Index Number 12-1 99A1584 Fuser Assembly w/115V 875W Lamp 414/616 12-1 99A1585 Fuser Assembly w/220V 875W Lamp 414/616 12-1 99A1660 Fuser Assembly w115V 550W Lamp 010/212 12-1 99A1661 Fuser Assembly w220V 550W Lamp 010/212 12-2 99A0725 Wiper Assembly, Wet 12-3...
Page 291 4069-XXX Assembly 12: Hot Roll Fuser (continued) 7-32 Service Manual...
Page 292 4069-XXX Asm- Part Units Description Index Number 12-21 99A0143 Bearing, Hot Roll 12-22 99A0150 Bushing, Hot Roll 12-23 99A1600 Bellcrank, Backup Roll 414/616 12-23 99A1659 Bellcrank, Backup Roll 010/212/41b/41e/41l 12-24 99A1591 Guide, Fuser Entry 12-25 99A0410 Spring, Backup Roll Bellcrank 12-26 Retainer, Backup Roll Bellcrank PP 99A0267 12-27...
Page 293: Assembly 13: Belt Fuser
4069-XXX Assembly 13: Belt Fuser 7-34 Service Manual...
Page 294 4069-XXX Asm- Part Units Description Index Number 13-1 99A1811 Fuser Asm (Belt Fuser) 110V 31v/31e 13-1 99A1653 Fuser Asm (Belt Fuser) 220V 31v/31e 99A1649 Screw, Fuser Mounting 7-35 Parts Catalog...
Page 295: Assembly 14: Transfer
4069-XXX Assembly 14: Transfer 7-36 Service Manual...
Page 296 4069-XXX Asm- Part Units Description Index Number 14-1 99A1015 Transfer Roll Assembly 14-2 99A0349 Arm, Transfer Roll Assembly Right 14-3 99A0184 Spring, Transfer Roll Right 14-4 99A0186 Erase Lamp Assembly Kit 010/212/414/616/31v o Lamp, Erase Assembly o Lens, Erase Lamp 14-5 99A0185 Shaft, Transfer Pivot...
Page 297: Assembly 15: Charging
4069-XXX Assembly 15: Charging 7-38 Service Manual...
Page 298 4069-XXX Asm- Part Units Description Index Number 15-1 99A0512 Link Assembly, Charge Left Kit 15-2 99A0513 Link Assembly, Charge Right Kit 15-3 99A1017 Roll Assembly, Charge 15-4 99A1555 Bushing, Charge Roll Screw, Charge Roll PP 99A0263 7-39 Parts Catalog...
Page 299: Assembly 16: Electronics
4069-XXX Assembly 16: Electronics 7-40 Service Manual...
Page 300 4069-XXX Asm- Part Units Description Index Number 16-1 99A1869 Engine Board Assembly 010/01n 16-1 99A1871 Engine Board Assembly 212/21n 16-1 99A1877 Engine Board Assembly 414/41b/41e/41l 16-1 99A1878 Engine Board Assembly 616/61n 16-1 99A1872 Engine Board Assembly 31v/31e 16-2 1342514 Power Cord Set, 8 ft. - U.S., Canada (LV), Nicaragua, Venezuela, Peru (LV), Bolivia, Colombia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Panama...
Page 301 4069-XXX Assembly 16: Electronics (continued) 7-42 Service Manual...
Page 302 4069-XXX Asm- Part Units Description Index Number 16-5 Screw, HVPS Mounting PP 99A0263 16-6 Screw, Engine Bd Mounting Top PP 99A0263 16-7 Note: Be sure and check the printer service level before replacing the HVPS. Go to “Printer Serial Label” on page 7-2 to identify the correct replacement FRU.
Page 303 4069-XXX Assembly 16: Electronics (continued) 7-44 Service Manual...
Page 304 4069-XXX Asm- Part Units Description Index Number 16-15 99A0408 Cover, INA Flat (Blank) 16-16 Screw, INA Cover Mounting PP 99A0263 16-16 Screw, INA Cover Mounting PP 99A0263 16-16 Screw, INA Cover Mounting PP 99A0263 16-17 99A1566 Engine Board Shield Assembly 16-18 99A1570 Shield, Inner Assembly, 1 slot 010/31v...
Page 305 4069-XXX Assembly 16: Electronics (continued) 7-46 Service Manual...
Page 306 4069-XXX Asm- Part Units Description Index Number 16-22 99A0138 Sensor, Standard Bin Level 16-23 99A0803 Fan, Main 16-24 99A0255 Cable, Main Drive Motor 16-25 99A1542 Gearbox, w/Motor 31v 16-25 99A1543 Gearbox, w/Motor 010/212 16-25 99A0129 Gearbox, w/Motor 414 16-25 99A0801 Gearbox, w/Motor 616 16-26 99A0256...
Page 307 4069-XXX Assembly 16: Electronics (continued) 7-48 Service Manual...
Page 308 4069-XXX Asm- Part Units Description Index Number 16-30 99A0049 Fan, Auxiliary 414/616 16-31 99A0466 Sensor, Toner Cartridge Level 16-32 99A1593 Cable, Smart Cartridge 16-33 99A1501 Operator Panel Assembly 16-34 99A1577 Switch, Cover Open w/Operator Panel Cable Assembly 16-35 99A0053 Sensor, Input 16-36 99A0186 Erase Lamp Assembly...
Page 309 4069-XXX Assembly 16: Electronics (continued) 7-50 Service Manual...
Page 310 4069-XXX Asm- Part Units Description Index Number 16-39 99A1526 Printhead Assembly 010 16-39 99A1527 Printhead Assembly 212/31v 16-39 99A1528 Printhead Assembly 414 16-39 99A1873 Printhead Assembly, 616 16-39 99A1867 Printhead Assembly, 41b/41e/41l 16-40 99A0889 Cable, Laser 16-40A 99A1573 Cable, Fuser DC EP Autoconnect to Engine Board 010/212/414/616 16-40A 99A1590...
Page 311: Assembly 17: 250 Sheet Tray
4069-XXX Assembly 17: 250 Sheet Tray 7-52 Service Manual...
Page 312 4069-XXX Asm- Part Units Description Index Number 17-1 99A1054 Pick Arm Assembly 17-2 Screw, Auto Comp Mounting PP 99A0263 17-3 99A0070 Roll Assembly, Pick 99A0438 Bushing, Drive Roll 17-4 99A0448 Arm, Paper Out 250 17-4A 99A0350 Sensor, Paper Low 17-5 99A1638 Base, 250 Option 17-6...
Page 313 4069-XXX Assembly 17: 250 Sheet Tray (continued) 7-54 Service Manual...
Page 314 4069-XXX Asm- Part Units Description Index Number 17-24 Screw, Option Board Mounting PP 99A0263 17-25 99A0397 Board, Option Tray 17-25A 99A0627 Jumper, 2-pin 17-26 99A0063 Spring, Switch Activate 17-27 99A1536 Tray Assembly, 250 Sheet Option 17-28 99A0119 Wear Strips 17-29 99A0120 Restraint Pad 17-30...
Page 315: Assembly 18: 500 Sheet Tray
4069-XXX Assembly 18: 500 Sheet Tray 7-56 Service Manual...
Page 316 4069-XXX Asm- Part Units Description Index Number 18-1 99A0350 Sensor, Paper Low 18-2 Screw, Auto Comp Mounting PP 99A0263 18-3 99A0405 Pick Arm Assembly 18-4 99A0070 Pick Roll Assembly 18-5 99A1636 Base, 500 Tray 18-6 99A0058 Pad, Base 500 18-7 99A0419 Spring, Tray Bias 18-8...
Page 317 4069-XXX Assembly 18: 500 Sheet Tray (continued) 7-58 Service Manual...
Page 318 4069-XXX Asm- Part Units Description Index Number 18-31 99A0286 Spring, Backup Roller 18-32 99A1664 Bellcrank, Roller Release 18-33 99A0273 Gear, Bevel 18-34 99A0279 Bearing, Drive Shaft 18-35 99A0281 Cable, 500 Auto Connect Top 18-36 99A1702 Stud Assembly, 500 Frame 18-37 99A0282 Cable, 500 Auto Connect Bottom 18-38...
Page 319: Assembly 19: Duplex
4069-XXX Assembly 19: Duplex 7-60 Service Manual...
Page 320 4069-XXX Asm- Part Units Description Index Number 19-1 99A1674 Cover, System Board 19-2 99A0322 Main Frame Assembly 250 Duplex 19-2 99A1693 Main Frame Assembly 500 Duplex 19-3 99A0324 Idler Assembly, Belt Tension 19-4 99A0326 Spring, Aligner 19-5 99A0323 Guide Assembly, Paper 19-6 99A1675 Guide Assembly, Paper...
Page 321 4069-XXX Assembly 19: Duplex (continued) 7-62 Service Manual...
Page 322 4069-XXX Asm- Part Units Description Index Number 19-20 99A0342 Guide, LH Lower Return 250 Duplex 19-20 99A1682 Guide, LH Lower Return 500 Duplex 19-21 99A1131 Guide, Return LH Upper 250 Duplex 19-22 99A0341 Sensor, Exit - Optical 19-23 Screw, LH Upper Return Guide Mounting PP 99A0413 19-24 99A1668...
Page 323 4069-XXX Assembly 19: Duplex (continued) 7-64 Service Manual...
Page 324 4069-XXX Asm- Part Units Description Index Number 19-41 99A1290 Top Cover Assembly, Movable 250 Duplex 19-41 99A1280 Top Cover Assembly, Movable 500 Duplex 19-42 99A1634 Top Cover Assembly, Fixed 250 Duplex 19-42 99A1679 Top Cover Assembly, Fixed 500 Duplex Retainer, 6 mm Top Cover PP 99A0404 19-43 99A0435 Guide, Lower Entry 250 Duplex...
Page 325: Assembly 20: Output Expander
4069-XXX Assembly 20: Output Expander 7-66 Service Manual...
Page 326 4069-XXX Asm- Part Units Description Index Number 20-1 99A1857 Deflector, Upper Redrive Also order 99A0104 20-2 99A0104 Spring, Upper Diverter 20-3 99A0369 Shaft Assembly, Exit Also order PP 99A0572 20-4 99A0052 Shaft Assembly, Lower Exit Also order PP 99A0572 20-5 Screw, PP 99A0263 20-6 99A0915...
Page 327 4069-XXX Assembly 20: Output Expander (continued) 7-68 Service Manual...
Page 328 4069-XXX Asm- Part Units Description Index Number 20-22 99A1748 Door Assembly, Rear Access 20-23 99A0368 Shaft Assembly, Lower Also order PP 99A0572 20-24 99A0363 Pulley, Drive 20-25 99A0371 Cover, Right Side 20-26 99A0361 Belt, 160 Gear 20-27 99A0362 Arm Assembly, Belt Idler 20-28 99A0364 Spring, Belt Tensioner...
Page 329: Assembly 21: Envelope Feeder
4069-XXX Assembly 21: Envelope Feeder 7-70 Service Manual...
Page 330 4069-XXX Asm- Part Units Description Index Number 21-1 99A0389 Paper Weight Assembly 99A1694 Guide, Edge 21-2 21-3 99A1696 Cover, Top 21-4 99A0485 Sensor, Envelope Pass Thru 21-5 99A0393 Clutch, Restraint/Gear 21-6 99A1697 Cover, Right Side 21-8 99A0390 Support, Slide Out 21-9 99A0488 Roller, Support...
Page 331 4069-XXX Assembly 21: Envelope Feeder (continued) 7-72 Service Manual...
Page 332 4069-XXX Asm- Part Units Description Index Number 21-14 Gear Kit, PP 99A0271 o Gear, Feed o Gear, Master Cam o Gear, Drive Roll Shaft o Gear, Master/Feed Kick o Gear, Drive Idler o Gear, Comp Drive/Clutch o Gear, Kick Roll Connect o Gear, Kick CNCT Idler o Gear, Feed Shaft Right o Gear, Drive Idler Rear...
Page 333: Assembly 22: High Capacity Feeder
4069-XXX Assembly 22: High Capacity Feeder 7-74 Service Manual...
Page 334 4069-XXX Asm- Part Units Description Index Number 22-1 99A0660 Frame, Printer Support Frame 2 22-2 Screw, Printer Support 2 Frame Mounting PP 99A0675 Washer, Printer Support Frame 2 Star PP 99A0677 Nut, Printer Support Frame 2, 8-32 Hex PP 99A0676 22-3 99A0698 Clamp, Feed Frame...
Page 335 4069-XXX Assembly 22: High Capacity Feeder (continued) 7-76 Service Manual...
Page 336 4069-XXX Asm- Part Units Description Index Number 22-13 99A0658 Magnet, Door 22-14 99A0650 Frame Assembly 21-15 99A0661 Tray Assembly, Elevator 22-16 99A1806 Card Assembly, 2000 Option Control 22-17 Nut, 6-32 Hinge Mounting PP 99A0676 22-18 Washer, Hinge Mounting Flat PP 99A0677 99A0690 Cable, Optical Sensor 22-19...
Page 337 4069-XXX Assembly 22: High Capacity Feeder (continued) 7-78 Service Manual...
Page 338 4069-XXX Asm- Part Units Description Index Number 22-27 99A0188 Guide, Rear Paper with retainer arm Use with 99A0219 22-28 Screw, Top Frame Mounting PP 99A0675 22-29 99A0219 Frame Assembly, Top with labels 21-30 Screw, Top Frame Clamp Mounting PP 99A0675 22-31 Washer, Top Frame Clamp PP 99A0677 22-32...
Page 339 4069-XXX Assembly 22: High Capacity Feeder (continued) 7-80 Service Manual...
Page 340 4069-XXX Asm- Part Units Description Index Number 22-47 Washer, Power Supply Board PP 99A0677 22-48 99A0667 Power Supply Board 22-49 99A0715 Cable, Low Voltage Power Supply 99A0684 Cable, HCIT-14Pin Flex 22-50 99A0685 Bushing 22-51 Nut, 2-56 Paper Low Switch Mounting PP 99A0676 22-52 99A0654...
Page 341 4069-XXX Assembly 22: High Capacity Feeder (continued) 7-82 Service Manual...
Page 342 4069-XXX Asm- Part Units Description Index Number 22-59 Screw w/washer, Motor Mounting PP 99A1793 22-60 Nut w/lockwasher, Drive Pulley Plate PP 99A1794 22-61 99A1795 Motor Assembly, DC 22-62 Mounting Feet PP 99A0687 22-63 Foot, Stabilizer PP 99A0672 22-64 99A1796 Belt, DC Motor Drive 22-65 99A1797 Idler Pulley, Belt Tension...
Page 343 4069-XXX Assembly 22: High Capacity Feeder (continued) 7-84 Service Manual...
Page 344 4069-XXX Asm- Part Units Description Index Number 22-75 99A0281 Cable, 250 Auto Connect 22-76 99A0279 Bearing, Drive Shaft 22-77 99A0273 Gear, Bevel 22-78 Screw, Frame Mounting PP 99A0263 22-79 99A0276 Roll Assembly, Drive 250 Option 22-80 99A0451 Roll, Skew Backup 22-81 Retainer, Roller PP 99A0267 22-82...
Page 345 4069-XXX Assembly 22: High Capacity Feeder (continued) 7-86 Service Manual...
Page 346 4069-XXX Asm- Part Units Description Index Number 22-94 Screw, Auto Comp Assembly Mounting PP 99A0263 22-95 99A1055 Arm Assembly, Pick 2000 22-96 99A0070 Roll Assembly, Pick 22-22- 99A0692 Base, 2000 Option 21-98 Screw, Deflector Mounting PP 99A0263 22-99 99A0678 Deflector, Base 22-100 99A0288 Sensor, Pass Thru...
Page 347: Assembly 23: Kiosk - Vertical Paper Adapter
4069-XXX Assembly 23: Kiosk - Vertical Paper Adapter 7-88 Service Manual...
Page 348 4069-XXX Asm- Part Units Description Index Number 23-1 99A0231 Bail, Support 23-2 99A1819 Mounting, Frame Assembly 23-3 99A0197 Shaft, Drive Rear 23-4 Retainer PP 99A0240 23-5 99A1705 Gear, Idler 23-5B 99A1646 Arm Assembly, Pivot 23-6 Screws PP 99A0234 23-7 Parts, Pulley PP 99A0208 23-7B 99A1704 Gear, Idler...
Page 349: Assembly 24: Kiosk - Horizontal Paper Adapter
4069-XXX Assembly 24: Kiosk - Horizontal Paper Adapter 7-90 Service Manual...
Page 350 4069-XXX Asm- Part Units Description Index Number 24-1 99A0231 Bail, Support 24-2 99A1819 Mounting, Frame Assembly 24-3 99A0197 Shaft, Drive Rear 24-4 Retainer PP 99A0240 24-5 99A1705 Gear, Idler 24-5B 99A1647 Arm Assembly, Pivot 24-6 Screws PP 99A0234 24-7 Parts, Pulley PP 99A0208 24-7B 99A1704 Gear, Idler...
Page 351: Assembly 25: High-Capacity Output Stacker
4069-XXX Assembly 25: High-Capacity Output Stacker 7-92 Service Manual...
Page 352 4069-XXX Asm- Part Units Description Index Number 25-1 99A1748 Door Asm, Rear Access 25-2 99A1785 Latch, Rear Door 25-3 99A1783 Frame, Right 25-4 99A1778 Pulley, Output Tray 25-5 99A1782 Shaft, Pulley 25-6 99A1790 Guide, Output Tray 25-7 99A1779 Spring, Output Tray 25-8 99A1746 Cover, Right...
Page 353 4069-XXX Assembly 25: High-Capacity Output Stacker (cont’d) 7-94 Service Manual...
Page 354 4069-XXX Asm- Part Units Description Index Number 25-14 99A0107 Deflector, Upper Also order 99A0104 25-15 99A0104 Spring, Upper Diverter 25-16 99A0369 Shaft Asm, Exit Upper Stacker Asm 25-17 99A0052 Shaft Asm, Stacker Lower Exit Upper Stacker Asm 25-18 Bearings, Shaft PP 99A0572 25-19 99A1749 Board Asm, High-Capacity Output Stacker...
Page 355 4069-XXX Assembly 25: High-Capacity Output Stacker (cont’d) 7-96 Service Manual...
Page 356 4069-XXX Asm- Part Units Description Index Number 25-29 99A0913 Shaft, 40T Middle Output Stacker 25-30 99A0368 Shaft Asm Lower 25-31 99A0363 Pulley, Drive 25-32 99A0361 Belt, 160G Upper Stacker Asm 25-33 99A0362 Arm Asm, Belt Idler 25-34 99A0364 Spring, Belt Tensioner 25-35 99A1791 Stacker Asm, Paper Path Lower...
Page 357: Assembly 26: 5-Bin Mailbox
4069-XXX Assembly 26: 5-Bin Mailbox 7-98 Service Manual...
Page 358 4069-XXX Asm- Part Units Description Index Number 26-1 99A1512 Cover, Redrive Cap 26-2 99A1710 Cover, Wire 26-3 99A1711 Cover, Top Bin 26-4 99A1785 Latch, Rear Access Door 26-5 99A0104 Spring, Upper Diverter 26-6 99A1714 Door, Rear Access 26-7 99A1723 Shaft Asm, Drive 26-8 99A1724 Shaft Asm, Drive W/Gear...
Page 359 4069-XXX Assembly 26: 5-Bin Mailbox (continued) 7-100 Service Manual...
Page 360 4069-XXX Asm- Part Units Description Index Number 26-30 99A1741 Spring, Diverter 26-31 99A1727 Frame Asm, Right Side 26-32 99A1728 Cam, Diverter Actuator 26-33 99A1731 Spring, Diverter Actuator 26-34 99A1729 Latch, Diverter Actuator 26-35 99A1730 Arbor, Diverter Actuator 26-36 99A1789 C-Clip 26-37 99A1720 Bracket, Attach...
Page 361: Assembly 27: Options
4069-XXX Assembly 27: Options Asm- Part Units Description Index Number 99A1752 4MB SDRAM DIMM 99A1753 8MB SDRAM DIMM 99A1754 16MB SDRAM DIMM 99A1755 32MB SDRAM DIMM 99A1756 64MB SDRAM DIMM 99A1773 128MB SDRAM DIMM 99A1757 2MB Flash DIMM 99A1758 4MB Flash DIMM 99A1759 8MB Flash DIMM 99A1774...
Page 362 4069-XXX Assembly 27: Options (continued) Asm- Part Units Description Index Number 99A1890 Tray Assembly, 250 Special Media 010/212/414/616/41b/41l/31v 99A1647 Rib Assembly, 250 Special Media Tray 010/212/414/616/41b/41l/31v 99A1654 Tray, Universal Adjustable 99A0910 Cartridge, Empty Shipping (2) 99A0909 Cartridge, Empty Shipping (1) 99A0863 Stacking Device, Integrated Label/Letter 99A0864...
Page 363: Assembly 28: Miscellaneous
4069-XXX Assembly 28: Miscellaneous Asm- Part Units Description Index Number 99A1633 Parts Packet, Screws 99A0585 Parts Packet, Contact Kit 99A0267 Parts Packet, Retainers 99A0268 Parts Packet, Springs Paper Feed 99A0269 Parts Packet, Duplex Option Fan Mounting 99A0299 Parts Packet, Duplex Option Cam Follower Assembly 99A0271 Parts Packet, Envelope Option Gears...
Page 364 4069-XXX Assembly 28:Miscellaneous (continued) Asm- Part Units Description Index Number 99A0208 Parts Packet, Pulley - Kiosk 99A0234 Parts Packet, Screws - Kiosk 99A0394 Grease Packet, Nyogel 744 99A0462 Grease Packet, IBM 23 99A1852 Packaging, 4069 250/250 printer 99A1853 Packaging, 4069 500/250 printer 99A1854 Packaging, 4069 500/500 printer 99A1855...
Page 365 4069-XXX 7-106 Service Manual...
Page 366 4069-XXX Index Error Log Clearing the Error Log Acronyms Viewing the Error Log Adjustment Procedures Hardware Tests Duplex Motor Drive Belts Button Test Fuser Solenoid (HBR) LCD Test Gap Adjustment Parallel Wrap Test 3-11 Paper Alignment Assembly ROM Memory Test 3-10 Printhead Assembly SDRAM Memory Test...
Page 367 4069-XXX Service Error Codes Output Bin Sensor Test 3-16 User Error Messages 2-16 Output Bin Test - Standard Bin 3-15 Error Log Output Bin X Sensor Test 3-16 ESD-Sensitive Parts Output Expander Control Board 5-20 Flash Test Parallel Wrap Test 3-11 Fuser Board 5-11...
Page 368 4069-XXX Operator Panel 4-47 Operator Panel Cable/Cover Open Removal Procedures 4-12 Switch Assembly 4-48 Removals Optional Paper Tray Assembly 4-49 Center Pan Assembly 4-16 Outer EMC Shield 4-50 Controller Board 4-17 Paper Alignment Assembly 4-51 Covers 4-12 Paper Input Sensor 4-52 Developer Drive Assembly 4-18...
Page 369 4069-XXX Input Sensor 2-52 1339540 7-41 Input Tray(s) Option 2-53 1339541 7-41 Main Drive 2-69 1339542 7-41 Operator Panel 2-70 1339543 7-41 Options 2-72 1342514 7-41 Output Bin Sensor 2-74 1342530 7-41 Output Expander 2-75 1342534 7-41 Paper Feed 2-89 1342536 7-41 Parallel Port...
Page 370 4069-XXX 99A0121 7-23 7-55 99A0267 7-104 99A0122 7-89 7-91 99A0268 7-104 99A0124 7-23 7-25 7-55 7-57 99A0269 7-104 99A0125 7-89 99A0271 7-104 99A0126 7-23 7-25 7-55 7-57 99A0272 7-53 7-85 99A0127 7-23 7-55 99A0273 7-53 7-59 7-85 99A0128 7-11 7-47 99A0274 7-53 7-57...
Page 371 4069-XXX 99A0342 7-63 99A0462 7-97 7-101 7-105 99A0343 7-63 99A0466 7-49 99A0346 7-43 99A0467 7-102 99A0349 7-37 99A0469 7-73 99A0350 7-53 7-57 99A0481 7-67 99A0351 7-69 7-97 99A0482 7-67 99A0361 7-69 7-97 99A0484 7-71 99A0362 7-69 7-97 99A0485 7-71 99A0363 7-69 7-97 99A0487...
Page 372 4069-XXX 99A0664 7-79 99A0897 7-33 99A0667 7-81 99A0899 7-11 99A0675 7-104 99A0904 99A0676 7-104 99A0906 7-91 99A0677 7-104 99A0907 7-91 99A0678 7-87 99A0909 7-103 99A0679 7-53 7-87 99A0910 7-103 99A0681 7-75 99A0912 7-69 99A0684 7-81 99A0913 7-69 7-97 99A0685 7-81 99A0914 7-67 7-95...
Page 373 4069-XXX 99A1514 7-11 99A1576 7-25 7-57 99A1515 99A1577 7-49 99A1516 99A1578 7-37 99A1517 7-11 99A1579 7-61 99A1518 99A1580 7-11 99A1519 7-11 99a1580 7-67 99A1520 7-31 99A1581 7-43 99A1521 7-31 99A1582 7-25 7-57 99A1522 99A1583 7-57 99A1524 7-11 99A1584 7-31 99A1525 7-11 99A1585 7-31...
Page 374 4069-XXX 99A1639 7-33 99A1698 7-73 99A1640 7-41 99A1699 7-73 99A1642 7-33 99A1700 7-71 99A1643 7-11 99A1701 7-93 99A1644 7-21 99A1702 7-59 99A1645 7-59 99A1704 7-89 7-91 99A1646 7-89 99A1705 7-89 7-91 99A1647 7-91 7-103 99A1706 7-89 99A1648 7-31 7-51 99A1707 7-91 99A1649 7-31...
Page 375 4069-XXX 99A1747 7-93 99A1812 7-23 7-25 7-87 99A1748 7-69 7-93 99A1817 7-67 99A1749 7-95 99A1818 7-75 99A1750 7-25 7-59 99A1819 7-89 7-91 99A1751 7-93 7-97 99A1820 7-89 7-91 99A1752 7-102 99A1822 7-41 99A1753 7-102 99A1823 7-43 99A1754 7-102 99A1825 99A1755 7-102 99A1829 7-57...
Page 376 May 2000 Form You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.
Page 377 UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 2659 LEXINGTON, KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC D22A BUILDING 035 3 740 WEST NEW CIRCLE ROAD LEXINGTON KY 40511 9954 | | | | | |...

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Lexmark Optra T 4069 series Service Manual

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