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Service Manual

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Summary of Contents for T62X

Page 1: ...rk and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start Diagno...

Page 2: ...or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you ImageQuick O...

Page 3: ...Check 2 50 Duplex Option Service Check 2 53 Envelope Feeder Option Service Check 2 56 Fan Service Check 2 63 Cold Fuser Service Check 2 65 Hot Fuser Service Check 2 67 Fuser Solenoid Service Check 2...

Page 4: ...wnload Emulations 3 8 Duplex Tests 3 8 Duplex Quick Test 3 8 Duplex Sensor Test 3 9 Duplex Motor Test 3 9 Duplex Feed 1 Test 3 12 Duplex Feed 2 Test 3 12 Error Log 3 13 Viewing the Error Log 3 13 Clea...

Page 5: ...3 37 Fuser Operation 3 39 Hot Roll Fuser 3 39 Paper Feed Jams 3 40 Paper Jams Base Printer 3 40 Paper Jams Options 3 41 Repair Information 4 1 Handling ESD Sensitive Parts 4 1 Adjustment Procedures 4...

Page 6: ...ive Motor 4 45 Multipurpose Tray Lower Deflector Assembly 4 46 Operator Panel Assembly 4 48 Operator Panel Cable Cover Open Switch Assembly 4 49 Optional 250 500 Paper Tray Assembly 4 50 Paper Alignme...

Page 7: ...4 Fuser Cable DC EP Autoconnect to System Board 5 34 Autoconnect Cable System Board to Top Interconnect Board 5 34 Autoconnect Cable System Board to Front Bottom Interconnect Board 5 35 Preventive Mai...

Page 8: ...put Expander 7 60 Assembly 19 Envelope Feeder 7 64 Assembly 20 High Capacity Feeder 7 68 Assembly 21 Kiosk Vertical Paper Adapter 7 82 Assembly 22 Kiosk Horizontal Paper Adapter 7 84 Assembly 23 High...

Page 9: ...Laser Notices ix 4069 5XX 7XX Laser Notices The following laser notice labels may be affixed to this printer as shown Laser Advisory Label...

Page 10: ...x Service Manual 4069 5XX 7XX Class 1 Laser Statement Label...

Page 11: ...ed service condition Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klass...

Page 12: ...ien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe I Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere...

Page 13: ...ior al nivel de la Clase I durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora est certificada nos E U A e...

Page 14: ...o ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 Laserme...

Page 15: ...ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle l katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser noti...

Page 16: ...er foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe I 1...

Page 17: ...Laser Notices xvii 4069 5XX 7XX Japanese Laser Notice Chinese Laser Notice...

Page 18: ...xviii Service Manual 4069 5XX 7XX Korean Laser Notice...

Page 19: ...mbly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t con u test et approuv pour respecter les nor...

Page 20: ...onale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die welt...

Page 21: ...a reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a Este produto foi concebido testado e aprovado para sa...

Page 22: ...t d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte est orientada exclusivament a profes...

Page 23: ...Safety Information xxiii 4069 5XX 7XX...

Page 24: ...or indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer probl...

Page 25: ...e letter quality page printers designed to attach to IBM compatible PC s and to most computer networks The Lexmark T laser printer is available in the following models Model Name Type Lexmark T620 406...

Page 26: ...IPDS Card Assembly and SCS TNe PRESCRIBE Card Assembly TIFF Card Assembly Bar Code Card Assembly Parallel Interface Card SCS USB Parallel Port MarkNet Print Servers ImageQuick Card Assembly 250 and 5...

Page 27: ...e the printer problem and repair the failure After you complete the repair perform tests as needed to verify the repair Tools Required for Service Flat blade screwdriver 1 Phillips screwdriver 2 Phill...

Page 28: ...LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply MROM Masked Read Only Memory NAND NVRAM Nonvolatile Ran...

Page 29: ...odes on page 2 2 User status messages provide the user with information on the current status of the printer Ready is displayed on the first line of the display unless Power Saver is invoked and then...

Page 30: ...eplace the system board Check for correct location of the jumpers on the interconnect board for the model type printer you are servicing Incorrect jumper settings can cause a 902 service error If jump...

Page 31: ...ure Go to the Cold Fuser Service Check on page 2 65 Use of the Base Printer Fuser Sub Error Codes on page 2 17 may help diagnose fuser failure 923 Fuser Error Fuser is too hot during printing or when...

Page 32: ...rror 933 Printhead Error 934 Printhead Error 935 Printhead Error 936 937 Transport Motor Indicates a problem with the main drive motor Go to the Main Drive Service Check on page 2 85 936 Main Drive Mo...

Page 33: ...QET Error Indicates that the PQET RAM test was incomplete or a PQET RAM test busy failure occurred Replace the system board 948 PEL Clock Error Indicates the PEL clock check failed Replace the system...

Page 34: ...If this does not fix the problem replace the system board 960 963 RAM Memory Error Error codes 960 thru 963 indicate the following specific RAM error 960 RAM soldered on the system board is failing R...

Page 35: ...del replace the system board 980 984 Service device Comm These error codes indicate the specified device device has detected a paper port failure Specified device device can be one of the following Sy...

Page 36: ...ponent failure Specified device device can be one of the following System Board Duplex Tray x x 1 2 3 4 or 5 Envelope Feeder Output Bin x x 1 2 3 to 6 Will be displayed for single bin output options O...

Page 37: ...t until each screen of information is obtained 4 When the last screen displays the original message displays The following is an example of how the printer shows a duplex unit sub error code DU DU Byt...

Page 38: ...B5 x 4 A4 x 5 Executive x 6 A5 x 7 Custom x 9 73 4 Env A 9 Env B 10 Env C 8 661 Env D C5 Env E B5 Env F Legal Env First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 84 xx 00 x1 x2...

Page 39: ...Possible causes for this error are Paper might be pre staged in the paper source tray Paper is picking too fast A defective input sensor 84 00 06 A paper jam has been declared by a smart device Immedi...

Page 40: ...from the feeder and check the envelope feeder for correct operation 84 xx 18 There is media over the Tray 2 pass thru sensor during warm up Check for media over the sensor If no media is present check...

Page 41: ...during warm up Check for media over the sensor If no media is present check the pass thru sensor flag and cables Try running the Input Tray Tests for Tray 6 and see if Tray 6 is feeding paper correct...

Page 42: ...sor before the printer EP was ready x1 Leading Edge of Media State x2 Trailing Edge of Media State 84 xx 23 x1 x2 The transfer servo never started x1 Media Size x2 Leading Edge of Media State 84 xx 25...

Page 43: ...assembly This failure can be caused by a broken fuser exit sensor flag This may also be caused by erratic operation of exit sensor flag or exit sensor or a defective piece of media 89 xx 04 x1 The fus...

Page 44: ...being activated by a page that was known to have been picked by a source other than the duplex option Ensure the correct source has been selected and the media is feeding from that source 8E xx 06 x1...

Page 45: ...urce First 6 Bytes Sub Error Code Data Note xx can be any value Explanation 920 Service Fuser Error Under temperature while printing EN 08 xx yy 1 EN zz 2 xx Actual Fuser Temperature yy The temperatur...

Page 46: ...e during standby 01 The Hot Roll took too long to reach the beginning lamp detection temperature 02 The Hot Roll reached final lamp detection temperature but took longer than expected 03 The Hot Roll...

Page 47: ...d anytime an incorrect lamp is detected xx 00 Lamp detection performed and found an error 01 It took long to do lamp detection and NVRAM detected a previous wrong lamp detected yy Actual Temperature z...

Page 48: ...or test Check the envelope pass thru sensor to ensure it is operating correctly If the sensor test fails go to the Envelope Feeder Option Service Check on page 2 56 If the test passes look for anythin...

Page 49: ...here is no media present in the stacker check the pass thru sensor and flag of stacker 2 or check the option below stacker 2 84 xx 16 There is media in stacker 3 during POST If present remove the medi...

Page 50: ...ption x1 media source 8E xx 03 The error code is displayed whenever the printer never sent a Select Output device control signal to the duplex option This can happen when a sheet of paper is leaving t...

Page 51: ...ed with the stapling operation timed out while waiting for the last page of a job to be safe in the stapler accumulator 98 xx 03 x1 x2 x3 Never saw operation complete on a staple job x1 destination Fi...

Page 52: ...the second line of the display Press Select to Reset the printer Power Saver Power Saver Fax Status When in the power saver mode the printer will display this screen instead of the Ready screen When...

Page 53: ...iting Menu group The following functions may be available via the Busy Waiting Menu group Cancel Job Reset Printer Reset Active Bin Cancel FAX Waiting Interpreter These screens will be displayed until...

Page 54: ...No button actions are possible while this message is displayed Printing Menu Settings The printer is processing or printing a list of current settings menus because Print Menu Settings is selected fr...

Page 55: ...Restoring Factory Defaults The printer is restoring factory defaults No button actions are possible while this message is displayed Performing Self Tests The printer is running the normal series of s...

Page 56: ...this message is displayed Programming Disk Do Not Power Off The disk is being programmed which means fonts or macros are being written to disk No button actions are possible while this message is dis...

Page 57: ...Primary Paper is jammed between the printer input and exit sensors Open the printer upper front door and remove the print cartridge to access the jam area Secondary When this message is displayed do n...

Page 58: ...Jam Check Tray X Leave Job in Finisher Primary Paper is jammed around Tray X X tray 1 thru 5 Try opening Tray X If the tray is difficult to remove then you may have to remove the tray above or below t...

Page 59: ...the removed sheets Also if the accumulated sheets are removed the portion of the job printed after the jam will not be stapled 280 Paper Jam Check Finisher Leave Job in Finisher Primary Paper is jamm...

Page 60: ...ing the priming operation Secondary The printer flashes the secondary message to indicate that all accumulated sheets should be removed during the jam clearance Note The following actions can be taken...

Page 61: ...print cartridge ID is stored in NVRAM 32 Unsupported Print Cartridge Error 32 is displayed when the top cover is closed and an unsupported print cartridge is detected It may take the printer 10 20 sec...

Page 62: ...the page is too complex to print 51 Defective Flash This message is displayed when the printer detects a defective flash This error may occur at power on or during flash format and write operations P...

Page 63: ...as been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset 58 Too Many Trays Attached This error code is displayed wh...

Page 64: ...operator panel displays this message 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 r...

Page 65: ...s displayed No more data is processed from the host computer Press Go to return the printer to the Ready state User Message Explanation Toner Low If the toner cartridge is low then Toner Low displays...

Page 66: ...s Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder Tray X Low If any of the input trays are low then Tray X Low displays where X designates which tray 1 thro...

Page 67: ...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 User Status Message Explanation Check Output Bin X Connection...

Page 68: ...again turn the printer off remove the option and call for service User Status Message Explanation Turn Printer OFF to Enable Option This message displays when a printer option Input Tray Output Bin or...

Page 69: ...e until all sixteen blocks display and then they all turn off 6 Amount of memory displayed 7 Performing Self Test appears on the display The 2000 sheet high capacity option elevator tray moves to the...

Page 70: ...r Panel Display is blank Printer does not sound 5 beeps Replace the operator panel assembly Operator Panel continuously displays all diamonds sounds 5 beeps and does not complete POST Go to the Operat...

Page 71: ...int Quality Random Marks on page 2 112 Print quality Toner on backside of printed page Go to the Print Quality Toner on backside of printed page on page 2 120 Print quality Vertical black bands on edg...

Page 72: ...to the Input Tray s Option Service Check on page 2 69 Symptom Action Paper feed problem with Duplex Option Go to the Duplex Option Service Check on page 2 53 Paper jams at Paper Removal Tray Go to the...

Page 73: ...to clear or reset message POST incomplete Go to the StapleSmart Finisher Service Check on page 2 125 Close Finisher Side Cover displayed Unable to clear or reset message POST incomplete Go to the Sta...

Page 74: ...the printer error log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option Paper feed problems with error message Use the Sub Error Codes...

Page 75: ...Carefully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing 3 Remove the charge roll from the left si...

Page 76: ...k assembly bearing for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the link assembly Check for continuity of the ri...

Page 77: ...open switch for proper mechanical operation If incorrect repair as necessary Disconnect the cover open switch cable from J3 at the system board and measure the voltage at J4 3 It measures approximate...

Page 78: ...ther connector mounted on the left side frame assembly Some force may be required to pull the LVPS loose from the connector 2 Gently remove the LVPS supply using caution not to damage the printed circ...

Page 79: ...from the printer and checking fuse F1 turn the LVPS off and remove the AC line cord 5 LVPS Fuse F1 continues to blow F1 after LVPS reinstalled Replace fuse F1 if necessary Turn the LVPS off and pull...

Page 80: ...stem Board Turn the printer off and disconnect all the cables from the system board Check for 5V dc at the system board test point If incorrect replace the FRU in the order shown interconnect board sy...

Page 81: ...t between the motor case and pins J3 1 through J3 4 If no problem is found check the D C servo motor pins J1 1 and J1 2 to the motor housing for a short If a short is found replace the motor assembly...

Page 82: ...nput Sensor Flag Run the Duplex Sensor Test from the diagnostics menu If the test fails check the input sensor cable at J5 on the system board for correct installation If no problem is found replace t...

Page 83: ...the system board Check for any shorts between each pin of the motor cable and the motor housing If shorts are found replace the motor Check the resistance of the stepper motor between J3 1 Stpmtr A t...

Page 84: ...Note If a 260 Paper Jam Check Envelope message displays check the Sub Error Codes for 9XX and 2XX Error Codes on page 2 8 Printer does not recognize the envelope feeder as an attached input option FRU...

Page 85: ...lace the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc J1 7 measures...

Page 86: ...nsor flag Note It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover Be careful not to damage the flag If the test fails check the flag for any...

Page 87: ...n and operation If incorrect repair or replace the flag 2 Envelope Out Hopper Input Sensor Check the sensor to make sure it is installed correctly and the sensor cable is properly connected to the env...

Page 88: ...sure the voltage at J4 6 The voltage measures approximately 5 V dc If incorrect disconnect J4 and measure the voltage again If incorrect replace the envelope feeder system board If correct replace the...

Page 89: ...ment may be too narrow 2 Weight Assembly Check the weight assembly to make sure it moves up and down freely without any binds Also check to make sure the weight assembly rests on all the rear kick rol...

Page 90: ...pe feeder option 2 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow FRU Action 1 Envelopes Check the envelopes being used in the feeder Check for signs of t...

Page 91: ...FRU Action 1 Fan Assembly Check the fan for proper installation and for excessive noise If incorrect replace the fan and cable assembly 2 System Board Check to make sure the printhead fan cable is se...

Page 92: ...n running If incorrect replace the main fan If this does not fix the problem replace the system board 4 Error Code 927 Fan not running Check the voltage at J5 3 on the system board The voltages are 22...

Page 93: ...is installed 3 Check the AC line voltage to ensure it is not above the maximum rating for the printer Note Make sure the fuser is correctly installed before proceeding with this service check The fuse...

Page 94: ...the fuser lamp cable going to the fuser assembly If you do not measure continuity remove the fuser assembly and check the continuity of the lamp If incorrect replace the lamp If correct replace the f...

Page 95: ...924 indicates the system board detects an open circuit in the thermistor circuit for the fuser assembly The voltage on J14 6 on the system board measures approximately 5 V dc If incorrect replace the...

Page 96: ...ser Solenoid Cable to DC Cable inside Fuser Assembly The operation of the fuser solenoid can be observed by removing the redrive assembly Check for proper mechanical operation of the solenoid and asso...

Page 97: ...pproximately 5 V dc at J25 10 on the system board If incorrect replace the system board 3 Input Sensor Cable Check the continuity of the input sensor cable section of the front wiring harness If incor...

Page 98: ...check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray...

Page 99: ...for smooth and correct operation Paper low sensor for correct installation on the auto compensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connect...

Page 100: ...rect paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high capacity feeder tray Service Tip Check the other paper sources to be sure the...

Page 101: ...rmally using the AC line cord from the AC wall outlet and does not work when using the AC jumper from the HCIT check the AC jumper cord If defective replace the cord If not defective check the AC inpu...

Page 102: ...perly connected to the high capacity feeder tray option board assembly 2 Base Printer or option mounted above Check the option or base printer autoconnect for signs of damage Repair the high capacity...

Page 103: ...C internal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housin...

Page 104: ...s check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tra...

Page 105: ...nnect the paper low switch cable from J3 on the high capacity system board Short pins 1 and 2 together while observing the sensor test on the display If the display does not change replace the high ca...

Page 106: ...it switch If incorrect replace the switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High Capacity Feeder Contr...

Page 107: ...e sure the paper in tray is within specifications FRU Action 1 Auto compensator Assembly Check the auto compensator pick arm rollers for sign of glazing toner or other buildup Replace as necessary 2 W...

Page 108: ...eck the cables damaged or loose wires Disconnect the motor Check for a short between each pin and the motor housing If a problem is found replace the motor assembly If no problem is found measure the...

Page 109: ...ng J1 1 Brown approximately 0 V dc J1 2 yellow approximately 0 V dc Motor Running Forward J1 1 Brown Approximately 0 V dc J1 2 Yellow Approximately 24 V dc Motor Running Reverse J1 1 Brown Approximate...

Page 110: ...position does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feeder option control board FRU Actio...

Page 111: ...Sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Fe...

Page 112: ...e for any signs of damage or contamination 3 Drive Pulley Check the drive pulley for any signs of wear binds or damage to the pulley or pulley shaft Make sure the pulley turns freely on the pulley sha...

Page 113: ...in Drive Assembly Excessive noise or vibration Remove the system board and run a Diagnostic Print Test in the continuous mode Check the main drive assembly for any excessive noise or vibration Determi...

Page 114: ...J27 4 5 V dc static 0 V dc when main drive motor running J27 5 5 V dc static 0 V dc when main drive motor running J27 6 5 V dc static 2 5 V dc when main drive motor running J27 7 5 V dc static 0 V dc...

Page 115: ...he voltage at J16 2 The voltage measures approximately 5 V dc If incorrect replace the system board If correct check the continuity of the operator panel cable If incorrect replace the cable If correc...

Page 116: ...d assembly is correctly installed not broken or damaged then run the Flash Test on page 3 7 If the test fails replace the Flash card assembly If the problem continues replace the system board DRAM Mem...

Page 117: ...fying or testing section WARNING This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk...

Page 118: ...the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message is not displayed FRU Action 1 System Board Printer fails to display Remove Paper Standard Bin message Outp...

Page 119: ...tricity buildup Printer does not recognize one or more output expander options as being installed Service Tip If more than a single output expander option is installed check each one to see if the pri...

Page 120: ...ects for damage especially the connector pins Remove the left and right side covers Remove the front control board cover Check the cables at J1A J1B J2A and J2B on the control board to make sure they...

Page 121: ...es can also occur prior to the output expander pass thru sensor FRU Action 1 Output Expander Drive Belt Drive Pulley Drive Belt Idler Pulley Belt Tension Spring Check to ensure the output expander dri...

Page 122: ...lag Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary FRU Action 1 Pass Thru Sensor and Flag Assembly Control Board Check...

Page 123: ...otor case for shorts If either the resistance is incorrect or a short is found replace the motor mechanical linkage assembly Note If the DC motor is shorted it may also be necessary to replace the con...

Page 124: ...ion s are installed correctly and the machine is configured correctly before attempting to service the high capacity output stacker option Go to High Capacity Output Stacker Board on page 5 14 to iden...

Page 125: ...loose or damaged FRU Action 1 High Capacity Stacker Option Check the autoconnects cables and connectors of the option for any signs of loose or damaged parts 2 High Capacity Output Stacker Mechanical...

Page 126: ...s thru sensor is correctly connected to J3 on the lower control board Disconnect the pass thru sensor cable and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect check t...

Page 127: ...Flag Upper Assembly Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary FRU Action 1 Upper Pass Thru Sensor Flag Assembly...

Page 128: ...e Also check to make sure the ESD brush is not loose or damaged FRU Action 1 5 Bin Mailbox Option Check the autoconnects cables and connectors of the option for any signs of loose or damaged parts 2 M...

Page 129: ...The voltage measures approximately 5 V dc If incorrect check the voltage at J5 2 The voltage measures approximately 0 V dc If incorrect replace the sensor assembly If this does not fix the problem re...

Page 130: ...he problem replace the control board Note This sensor is in a normally open position with the flag out of the sensor slot FRU Action 1 Bin X Sensor Bin X Sensor Cable Bin X Sensor Flag Bin X Sensor Fl...

Page 131: ...embly Control Board Check the solenoid for any binds Make sure the solenoid is contacting the latch correctly If incorrect repair as necessary If the solenoid appears to be operating mechanically chec...

Page 132: ...If either the resistance is incorrect or a short if found replace the mechanical linkage DC motor assembly Note If the DC motor is shorted it may also be necessary to replace the control board 2 Cont...

Page 133: ...rollers or binds Replace the alignment assembly if any problem is found 2 Inner Deflector Check the inner paper deflector for correct installation If the deflector is bowed or not fitting correctly re...

Page 134: ...t the paper Also the auto compensator motor may be failing If this problems continues replace the auto compensator assembly Double Feeding Paper Note If double feeding paper occurs mostly from the bot...

Page 135: ...ssembly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications Parallel Port Service Check Run the Parallel Wrap Test on page 3 16 No...

Page 136: ...If incorrect replace the defective cable The voltage at J13 4 measures approximately 5 V dc If incorrect replace the system board The voltage at J7 7 measures approximately 24 V dc If incorrect replac...

Page 137: ...r 20lb Select the following menu settings as indicated Be sure and note the original settings so you can return the printer to the original customer printer setup Print Resolution Set to 300 dpi print...

Page 138: ...incorrect replace the contact with one from the HV contact kit Screws are included to attach the contacts to the right side frame in the HV contact kit 2 Charge Roll Conductive Bushing Check to make...

Page 139: ...dc Printer Printing J25 5 measures 24 V dc In the voltages at J25 5 are incorrect replace the system board 4 Front Cable Harness HVPS Section Check the front cable harness at J25 on the system board...

Page 140: ...l bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect feeding...

Page 141: ...d by a defective gear in the main drive gearbox assembly Replace the main drive gearbox assembly 3 Lines spaced 38 26 mm 1 506 inch apart This can be caused by defective gear s in the main drive gearb...

Page 142: ...t at the end of life 7 Lines spaced 49 74 mm 1 958 inch apart Replace the FRUs in the following order redrive assembly fuser assembly 8 Lines spaced 51 02 mm 2 009 inch apart Replace the transfer roll...

Page 143: ...ight side bearing for any signs of contamination pitting or a loose cable to the bearing If any problems are found replace the defective part Check the transfer roll shaft for any signs of contaminati...

Page 144: ...If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the system board If J25 2 voltage is incorrect or if the volta...

Page 145: ...ck the charge roll contact for any signs of damage and for proper connection to the HVPS and print cartridge Print Quality Black bands on outer edges of the page This print quality problem appears as...

Page 146: ...oard Printer Idle J25 8 measures 0 V dc Printer Printing Test Page J25 8 voltage changes from 0 V dc to 4 V dc If the voltage does not vary check the continuity of line J25 8 in the front cable harnes...

Page 147: ...o be retained and deposited on the page FRU Action 1 Transfer Roll Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll 2 Right Side...

Page 148: ...ut on the backside of the media This problem is generally caused by a toner buildup on the fuser hotroll or backup roll Check the fuser hotroll and backup roll for any noticeable buildup of toner Repa...

Page 149: ...ere is proper contact between the smart chip on the cartridge and the smart cartridge contact assembly Service Tip An intermittent 32 Unsupported Cartridge User Error Message can be caused by poor con...

Page 150: ...ice Check Service Tip Check the print darkness MENU setting before checking the toner sensor This service check is intended to be used when a 929 Service Error displays FRU Action 1 Developer Drive As...

Page 151: ...s for personal safety and to prevent damage to the printer 3 Toner Sensor The toner sensor cable is part of the front harness and part of connector J25 on the system board Check the voltage at J25 11...

Page 152: ...lock into the EP frame correctly Check the right transfer arm assembly spring for proper operation For any background problems check to ensure the contact to the HVPS board is correct and that there i...

Page 153: ...ve the staple supply cartridge Note When replacing staples in the supply cartridge discard any old staples in the cartridge and replace with a fresh strip Problems with static electricity buildup FRU...

Page 154: ...tapler Motor Drive Assembly Stapler Card Assembly Check the autoconnects for signs of damage especially the connector pins Remove the right side cover and check the cables at J1A J1B bottom autoconnec...

Page 155: ...tly 2 Top Cover Switch Stapler Card Assembly Check continuity of the stapler top cover open switch If incorrect replace the switch assembly If correct replace the stapler card assembly FRU Action 1 Si...

Page 156: ...1 During POST the stapler option does not try to home Step 2 During POST the stapler option tries to home FRU Action 1 Stapler Assembly Replace the stapler assembly Note When replacing the stapler ass...

Page 157: ...onnect J2 and check the voltages on connector J2 Note All voltages are approximate values If the voltages are correct replace the motor drive assembly If the voltages are incorrect replace the stapler...

Page 158: ...Drive Gearbox Assembly Stapler Card Assembly Turn the printer off disconnect the motor from J4 and check for continuity between J4 pins 1 2 5 and 6 on the cable and the motor case If you get continuit...

Page 159: ...eflector Check the upper deflector or any signs of broken parts especially the hook that holds the upper deflector spring Check for any signs of bowing of the deflector Move the deflector to make sure...

Page 160: ...ssage When this failure occurs the following may also occur in the order shown 1 Insert Staple Cartridge displayed The stapler assembly may cycle or fire a few times 2 282 Stapler Jam displayed The st...

Page 161: ...any signs of damaged or broken parts Check the flag and spring assembly on the front of the stapler assembly to see if the flag or spring are broken or missing If any problem is found replace the sta...

Page 162: ...imate values If the voltages are correct replace the stapler assembly If the voltages are incorrect replace the stapler board FRU Action Pin No Voltage Static Voltage Feeding 1 24 V dc 24 V dc 2 24 V...

Page 163: ...Check to make sure the gamma wheel aligner assembly is operating correctly and that the wheel is touching the paper If the gamma wheel is not turning or touching the paper go to step 2 If the wheel is...

Page 164: ...otor case If you get continuity replace the gearbox drive assembly If you do not get continuity continue with the step If the voltages are correct replace the gearbox drive assembly If the voltages ar...

Page 165: ...ss the cable connector It should measure approximately 48 ohms when cold If incorrect replace the Stapler Gearbox assembly If correct replace the stapler card assembly FRU Action 1 Sol 2 Stapler Gearb...

Page 166: ...2 138 Service Manual 4069 5XX 7XX...

Page 167: ...uch menu setting as Resetting the Maintenance Count is included in this menu The following table lists the tests as they are displayed on the Diagnostic Test Menu screens Tests Refer to Test Page Regi...

Page 168: ...ble via PCl in slot 1 7 Parallel 2 Wrap only displayed if port available via PCl in slot 2 8 Serial Wrap only displayed if printer configured with Serial Port 9 Serial 1 Wrap only displayed if serial...

Page 169: ...ected the following menu selections are available 1 Feed Tests If selected the following menu selections are available a Standard Bin b Output Bin x x Output Bin 1 2 3 4 5 6 7 8 9 or 10 when installed...

Page 170: ...ice Tests on page 3 6 Printer Setup If selected the following menu selections are available 1 Defaults 2 Page Count 3 Permanent Page Count viewing 4 Serial Number printer serial number 5 Envelope Enha...

Page 171: ...lections are available 1 Display Log 2 Clear Log Error Log on page 3 13 Exit Diagnostics Exiting the Diagnostics Mode on page 3 6 Configuration Menu Maintenance Count Value Viewable only Maintenance P...

Page 172: ...s to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 Select the Quick Disk Test from the Device...

Page 173: ...essage 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 mor...

Page 174: ...Self Test displays Once the printer is idle the emulation can be downloaded again 4 Program the download emulation into the code overlay card assembly again 5 If these steps do not resolve the problem...

Page 175: ...rgin Changing this parameter by 1 unit moves the margin 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 narro...

Page 176: ...u The duplex motor test continues to run until the printer is powered off The power indicator blinks while the test is running The duplexer runs the motor at a high speed and then a low speed and take...

Page 177: ...drive belt from the duplex D C motor and run the motor test again For the duplex D C motor to pass the test the following results must display AA 00 BB in the range of 29 through 3E inclusively hex C...

Page 178: ...ear Paper message displays when the paper reaches paper stop position 1 and the power indicator turns on solid Duplex Feed 2 Test This test feeds a blank sheet of paper to the duplex paper stop positi...

Page 179: ...consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the Error Log 1 Select Display Log from the Error Log menu The Error log displays on thr...

Page 180: ...if PCL installed in slot 1 Serial Wrap 2 only displayed if PCL installed in slot 2 LCD Test To run the LCD Test 1 Select LCD Test from the Diagnostic menu The LCD test continually executes the LCD dis...

Page 181: ...999 999 F represents the number of times the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail coun...

Page 182: ...l signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the menu Parallel Wrap Parallel 1...

Page 183: ...oes on solid and the final results display Press Return Stop to exit the test Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug Each signal is tes...

Page 184: ...nterrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Ov...

Page 185: ...either Single feeds one sheet of media from the selected source or Continuous continues feeding media from the selected source until Return Stop is pressed 4 Press Return Stop to exit test Input Tray...

Page 186: ...ll Bins Test 1 Select Feed to all Bins Test from the Menu 2 The media feeds from the default paper source 3 The printer feeds a separate piece of media to the standard bin first then it feeds a separa...

Page 187: ...or envelope supported by the printer To run the Output Bin Feed Test 1 Select Feed Test from the Output Bin Test menu 2 Select the output bin you want the paper to exit into The standard bin as well...

Page 188: ...menu 2 Select Output Bin tests Sensor Tests 3 Select Sensor Tests for Output Bin X x number of the output option to be tested 4 The following screen is displayed Output Bin x P OP F OP NF OP P Pass T...

Page 189: ...n 1 Select Output Bin tests from the menu 2 Select Output Bin tests Sensor Tests 3 Select Sensor Tests for Output Bin x x number of the output option to be tested 4 The following screen is displayed O...

Page 190: ...Tests from the menu Sensor Tests This test consists of four menus which tests all the sensors in the finisher option To run this test 1 Go to the Diagnostic menu 2 Select Finisher Tests from the Diagn...

Page 191: ...e Finisher Pass Thru and Media Sensors Select Sensor Tests from the Finisher menu Select Pass Thru and Media from the Sensor menu The following screen is displayed and each sensor can be checked by ac...

Page 192: ...r Front Door Sensor Upper Front Cover To run the Base Sensor Test 1 Select the Base Sensor Test The operator panel displays OP for open and CL for closed 2 Manually toggle the sensors by hand to verif...

Page 193: ...ot the Finisher sensors are working correctly To run the Finisher Sensor Test 1 Select Finisher Tests from main menu 2 Select Sensor Tests from the Finisher Tests menu 3 There are four sensor tests th...

Page 194: ...to test When the sensor is closed CL displays and when the sensor is open OP displays 6 Select Return or Stop to exit the test 5 Bin Mailbox Diverter Test Note This test checks the operation of each...

Page 195: ...gin 25 to 25 Left Margin 25 to 25 Right Margin 10 to 10 To set Registration 1 Select Registration from the Diagnostic menu 2 The Top margin sign value pair blinks This indicates it is the margin value...

Page 196: ...age Count 1 Select Page Count from the Diagnostic menu The current page count displays The leftmost digit blinks indicating it is the first digit to be changed 2 Press either Menu until the value you...

Page 197: ...The following is displayed Reset Maintenance Count Reset 2 To reset the Maintenance Count press Select for Reset Selecting Reset causes the maintenance page counter to reset to zero 3 When the operat...

Page 198: ...e ID is valid then the ID is saved in NVRAM and the printer automatically PORs to activate the new setting Note When the printer PORs it does so in the normal mode Restore EP Factory Defaults To resto...

Page 199: ...int contrast can be adjusted to LOW MEDIUM HIGH Charge Roll The charge roll can be adjusted to LOW MEDIUM HIGH Print Tests The purpose of the diagnostic Print Tests is to verify that the printer can p...

Page 200: ...enu 2 Select the media source 3 Select Single or Continuous If Single is selected no buttons are active during printing If Continuous is selected Return or Stop can be selected to cancel the test Chec...

Page 201: ...then prints one copy of the Three Test pages If you want more than one copy perform these steps again Page 1 of the Print Quality Test pages contains Printer Information Page Count Printhead Type Inst...

Page 202: ...code level envelope feeder code level tray 1 5 code levels output bin 1 3 code levels operator panel code levels font ROM version and SRAM availability Auto Compensator Operation The auto compensator...

Page 203: ...o compensating phenomena This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has com...

Page 204: ...ter for the duplex motors and also converts the voltage to 5 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to...

Page 205: ...tely 260K ohms as the temperature of the fuser hot roll increases The thermistor is connected to J14 6 and J14 7 on the system board Pin J14 6 Therm is connected to module U15 The system board monitor...

Page 206: ...a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance pro...

Page 207: ...finisher If a job has accumulated in the finisher then the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam c...

Page 208: ...sensor in time Note When the StapleSmart Finisher option is installed a secondary message may be displayed which advises whether or not to remove the job from the finisher If a job has accumulated in...

Page 209: ...n the printer alternately flashes the primary and secondary messages to indicate that all accumulated sheets should not be removed during the jam clearance procedure If the sheets are removed then the...

Page 210: ...3 44 Service Manual 4069 5XX 7XX...

Page 211: ...ectricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the...

Page 212: ...n page 4 21 to access the drive belt idler pulley 2 Loosen the idler pulley mounting screw and position the idler to provide 3 mm 5 mm drive belt deflection 3 Tighten the idler pulley mounting screw b...

Page 213: ...tment does not reduce the printer overall performance such as pages per minute but can help in reducing the amount of curl of some printed media thus improving media stacking in the output bin 1 Enter...

Page 214: ...Self Test displays 4 Select Registration from the menu 5 Select Quick Test Page The test page should only be printed on letter or A4 paper from Tray 1 The Quick Test Page consists of alignment diamond...

Page 215: ...gistration on page 3 28 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the...

Page 216: ...n the range specified in Registration on page 3 28 The reference screw can be adjusted without loosening the locknut Turn the screw a few turns and print a copy of the Quick Test Page as you check the...

Page 217: ...e correct screw type in each location during reassembly Reference Number Screw Type Location Purpose Qty M3 5x8 mm Thread Cutting right side frame to center pan attach 1 toner level sensor mounting 1...

Page 218: ...e attach 2 M3 5x12 mm Thread Cutting paper alignment assembly mounting 2 toner cartridge guide track mounting 2 left side frame to center pan attach 3 right side frame to center pan attach 2 deflector...

Page 219: ...ct board ground attach 2 system board to inner shield mounting 2 system board back mounting 2 system board to interconnect shield ground attach 1 lower stacker duct mounting 1 ground cables to ground...

Page 220: ...le attach 1 M3x6 mm Taptite Panhead stacker duct mounting 1 system board mounting 2 system board to shield mounting 2 system board mounting 2 in pan mounting 2 shield ground attach 1 LVPS mounting 2 f...

Page 221: ...unting 3 M3 5x10 mm Plastite Thread Forming right side cover mounting 1 right side frame to pan attach 3 left side frame to pan attach 1 extra screw mounting 2 M3 5x12 mm Plastite Thread Forming with...

Page 222: ...f the printer Make sure your fingers are not under the printer when you lift or set the printer down Note Some removal procedures require removing cable ties You must replace cable ties during reassem...

Page 223: ...Repair Information 4 13 4069 5XX 7XX Right Cover 1 Open the upper and bottom front covers 2 Remove the print cartridge 3 Release the cover latch A and remove the right cover mounting screw B...

Page 224: ...4 14 Service Manual 4069 5XX 7XX 4 Remove the redrive assembly 5 Remove the right side cover mounting screw B 6 Remove the right side cover...

Page 225: ...15 4069 5XX 7XX Upper Front Cover 1 Raise the upper front cover 2 Remove the upper front cover mounting screws A 3 Rotate the cover upward to allow the rear cover hinges to clear the mounting slots a...

Page 226: ...deflector 4 Press the fuser wiper cover latch and remove the cover 5 Remove the paper full sensor flag from the mounting bracket Use care when removing the flag as it can be easily damaged 6 Remove th...

Page 227: ...he outer EMC shield 2 Disconnect all cables to the system board 3 Remove the system board mounting screws A 4 Remove the serial port mounting hex studs B 5 Remove the parallel port mounting screws C 6...

Page 228: ...ove the card assembly from the system board as indicated in the photo and illustration below 2 To replace the card assembly align guide pins and locating pin with corresponding holes 3 Carefully press...

Page 229: ...Repair Information 4 19 4069 5XX 7XX...

Page 230: ...bly 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 t...

Page 231: ...emove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable at connector J6 3 Position the duplex assembly on its side 4 Gently release the three front cover as...

Page 232: ...Position the duplex assembly on its side 6 Gently release the center drive deflector assembly latch from the bottom front left side of the duplex assembly 7 Remove the center drive deflector assembly...

Page 233: ...XX 7XX EMC Shields 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 and B...

Page 234: ...4 24 Service Manual 4069 5XX 7XX Outer EMC Shield 1 Remove the left door 2 Loosen the outer EMC shield mounting screws A and remove the shield...

Page 235: ...25 4069 5XX 7XX Fan Main Fan 1 Remove the top rear cover 2 Remove the inner EMC shield 3 Remove the fan shroud A 4 Note the routing of the main fan cable B and disconnect the cable from the system bo...

Page 236: ...side frame Frames EP Frame Assembly 1 Remove the left and right side frames 2 Remove the EP frame assembly Left Side Frame 1 Remove the main drive assembly 2 Remove the upper front cover hinge assembl...

Page 237: ...Repair Information 4 27 4069 5XX 7XX 5 Remove the left side frame mounting screws A...

Page 238: ...4 28 Service Manual 4069 5XX 7XX 6 Place the printer on its back and remove the left side frame mounting screws A 7 Remove the left side frame...

Page 239: ...4 Disconnect the auto compensator arm bias spring from the right side frame 5 Remove the toner sensor mounting screw A disconnect the sensor cable and remove the toner sensor 6 Remove the right side...

Page 240: ...4 30 Service Manual 4069 5XX 7XX Fuser 1 Remove the redrive assembly 2 Loosen the fuser mounting screws A and remove the fuser...

Page 241: ...t be used when removing the lamp from the fuser Grip the lamp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the lif...

Page 242: ...using Assembly 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 hot roll bearing clips to free the fuser frame wall...

Page 243: ...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 rig...

Page 244: ...itioner Solenoid 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 245: ...ve the exit sensor flag assembly Note The exit sensor assembly can be removed without removing the lower exit guide assembly Make sure the narrow media sensor flag is correctly positioned before snapp...

Page 246: ...l the correct lamp Fuser Lower Exit Guide Assembly 1 Remove the fuser assembly 2 Remove the fuser cover assembly 3 Remove the fuser detack housing assembly 4 Disconnect the sensors from the cable conn...

Page 247: ...le from the HVPS at connector C 5 Disconnect the transfer roll cable from the HVPS board Warning Use care when disconnecting the cable from the transformer on the HVPS The cable and connector can be e...

Page 248: ...rinter and disconnect the compensator arm bias spring from the frame 7 Remove the C clip that rests against the right side frame from the auto compensator pivot shaft 8 Disconnect the compensator sens...

Page 249: ...Information 4 39 4069 5XX 7XX 3 Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer 4 Unsnap the pick roll assembly D from its mounting and...

Page 250: ...4 40 Service Manual 4069 5XX 7XX Interconnect Board Assembly 1 Remove the inner EMC shield 2 Remove the LVPS 3 Disconnect all cables A from the interconnect board...

Page 251: ...41 4069 5XX 7XX 4 Place the printer on its back and remove the mounting screws B Note Go to Interconnect Board on page 5 4 to identify the correct jumper locations for your printer 5 Remove the interc...

Page 252: ...ve 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 Press the releas...

Page 253: ...fer shaft A through the bottom of the printer 5 Remove all cables from the cable clamps B on the main drive assembly 6 Remove the ground cables F Be sure to reinstall the ground cables to the same loc...

Page 254: ...X 7XX 10 Remove the main drive assembly Note Do not remove the screws E on the main drive assembly Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalli...

Page 255: ...Repair Information 4 45 4069 5XX 7XX Main Drive Motor 1 Remove the main drive assembly 2 Remove the main drive motor mounting screws A 3 Remove the main drive motor...

Page 256: ...ssembly 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 fr...

Page 257: ...4 47 4069 5XX 7XX 2 Remove the upper deflector 3 Remove the solenoid mounting screw 4 Remove the screws A mounting the multipurpose tray lower deflector assembly 5 Remove the multipurpose tray lower...

Page 258: ...48 Service Manual 4069 5XX 7XX Operator Panel Assembly 1 Remove the upper front cover 2 Disconnect the operator panel cable 3 Gently press the operator panel lens tabs A and remove the operator panel...

Page 259: ...and front harness 4 Remove the operator panel Pull the cables through the rectangular hole in the hinge pivot arm 5 Plug the new operator panel cable into the operator panel and snap the new cover op...

Page 260: ...embly 2 Release the paper pass thru sensor from its retaining tabs 3 Release the frame assembly from the front and rear retaining tabs and remove the paper tray frame assembly Paper Tray Board 1 Remov...

Page 261: ...ignment 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 t...

Page 262: ...cate 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...

Page 263: ...embly 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 Upper Paper Deflector Assembly 1 Open the multipurpo...

Page 264: ...lease the input paper sensor from its mounting and remove Paper Size Sensing Board 1 Disconnect the paper size sensing board cable from the board 2 Remove the two paper size sensing board mounting scr...

Page 265: ...move the laser assembly cover 2 Disconnect the printhead cables A from the printhead 3 Remove the printhead mounting screws B Note Do the Printhead Assembly Adjustment on page 4 4 whenever you remove...

Page 266: ...printhead cables A from the printhead assembly and remove the printhead 3 Disconnect the printhead fan cable from the system board 4 Remove the printhead mounting screws B Do the Printhead Assembly A...

Page 267: ...069 5XX 7XX Redrive Assembly 1 Remove the redrive door assembly 2 Remove the redrive exit cover 3 Remove the redrive assembly mounting screws A 4 Release the redrive assembly mounting latches B and re...

Page 268: ...XX Smart Cartridge Contact Assembly 1 Disconnect smart cartridge cable 2 Remove print cartridge 3 Remove transfer plate 4 Unlatch smart cartridge contact assembly A from the right frame assembly 5 Rem...

Page 269: ...Repair Information 4 59 4069 5XX 7XX Toner Sensor 1 Remove the right side cover 2 Remove the toner sensor mounting screw A Disconnect the toner sensor cable and remove the toner sensor...

Page 270: ...m 3 Lift the transfer roller assembly toward the left and remove the transfer roller assembly from the printer Upper Paper Deflector Assembly 1 Open the multipurpose tray and remove the tray from the...

Page 271: ...n the inside of each hinge 4 Detach the two springs B from the upper front cover hinges 5 Disconnect the operator panel cable from the operator panel assembly 6 Raise the upper front cover hinge assem...

Page 272: ...ch 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 s...

Page 273: ...eath the printer for the pick roller arm Pull the arm down 2 Press on the end of the tab and pull the pick roller off the arm Repeat this step for the pick roller on the other side Next gently release...

Page 274: ...the tab on the arm There are two arrows on each pick roller Make sure the bottom arrow faces you as you align the recessed area with the tab 4 Push the pick roller onto the arm with the tab aligned Re...

Page 275: ...tions Low Voltage Power Supply Connector Pin No Signal CN3 Interconnect Board 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Groun...

Page 276: ...5 2 Service Manual 4069 5XX 7XX...

Page 277: ...ector Locations 5 3 4069 5XX 7XX High Voltage Power Supply Connector Pin No Signal CN1 System Board 1 Developer PWM 2 24 V dc Return 3 Charge PWM 4 24 V dc IN 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO...

Page 278: ...user Solenoid 1 42 V dc 2 Ground J2 LVPS 1 42 V dc 2 Heaton 3 Xeroxing 4 24 V dc 5 24 V dc 6 24 V dc 7 Ground 8 Ground 9 Ground 10 Ground J3 LVPS 1 Ground 2 Ground 3 Ground 4 Ground 5 5 V dc 6 5 V dc...

Page 279: ...oard 1 N A J11 INA 1 1 N A J12 INA 2 1 N A Connector Jumper Position Signal J8 ID 1 1 0 V dc Gnd center pin to top pin of J8 2 5 V dc center pin to bottom pin of J9 J9 ID 2 3 0 V dc Gnd center pin to...

Page 280: ...and J10 Models Requirement 520 52n No jumpers required 722 72n A jumper on J8 between the center pin of J8 and pin 1 of J8 A jumper is required between the center pin of J9 and pin 4 of J9 A jumper i...

Page 281: ...tion Board Connector Pin No Signal J1 1 N A 2 Ground 3 Tx EOC 4 Ground 5 Rx EOC 6 24 V dc Return 7 24 V dc J2 1 Ground 2 Paper Present 3 5 V dc J3 1 Ground 2 Paper Present 3 5 V dc J4 1 Motor Phase B...

Page 282: ...5 8 Service Manual 4069 5XX 7XX...

Page 283: ...otor 1 Motor 2 Motor J2 DC Motor Sensor Encoder Board 1 5 V dc Sensor 2 Tach 3 Ground J3 Stepper Motor 1 STPMOTA 2 STPMOTA 3 STPMOTB 4 STPMOTB J4 Fan 1 24 V dc 2 Fan On J5 Paper Input Sensor 1 5 V dc...

Page 284: ...connect Option Below 1 Ground 2 PrtxDout 3 Ground 4 PrtRxd J10 Autoconnect Option Below 1 24 V dc 2 Ground J11 Printer Autoconnect 1 24 V dc 2 Ground J12 Printer Autoconnect 1 N A 2 Ground 3 PrtxDin 4...

Page 285: ...Connector Locations 5 11 4069 5XX 7XX Autoconnect Top Connector Pin No Signal Top Autoconnect 1 0 V dc 2 5 V dc 3 0 V dc 4 0 V dc 5 0 V dc 6 5 V dc 7 0 V dc 8 24 V dc...

Page 286: ...utoconnect 1 24 V dc 2 Ground 3 5 V dc J1B 1 Prtxdin 2 Ground 3 prtrxd 4 Ground 5 N C J2A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J2B 1 prtxdout 2 Ground 3 prtrxd 4 Ground J3 Pass Thru Sensor 1 Ground...

Page 287: ...Connector Locations 5 13 4069 5XX 7XX J5 Bin Full Near Full Dual Sensor 1 Ground 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper Connector 1 Not Used 2 Not Used 3 Not Used Connector Pin No Signal...

Page 288: ...A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J1B 1 Prtxdin 2 Ground 3 prtrxd 4 Ground 5 N C J2A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J2B 1 prtxdout 2 Ground 3 prtrxd 4 Ground J3 Pass Thru Sensor 1 Gro...

Page 289: ...Bin Full Near Full Dual Sensor 1 Ground 2 Ground 3 binful 4 binful 5 RVsnsr J6 Jumper Connector 1 Upper Unit 2 Upper Lower Unit 3 Lower Unit High Capacity Stacker Board Pin 1 Pin 2 Pin 3 Upper Unit Bo...

Page 290: ...5 16 Service Manual 4069 5XX 7XX System Board Connector Locations 30 PPM Network...

Page 291: ...Connector Locations 5 17 4069 5XX 7XX 30 PPM Non Network...

Page 292: ...5 18 Service Manual 4069 5XX 7XX 40 PPM Network...

Page 293: ...Connector Locations 5 19 4069 5XX 7XX 40 PPM Non Network...

Page 294: ...ssembly J2 Printhead Connector 1 LENA 2 LPOW FB 3 LADJ 4 Ground 5 LPOW 6 5phead 7 Ground 8 VID_CON 9 Ground 10 Ground J3 Cover Closed Connector 1 Cover Closed 2 5 V dc 3 Ground J4 Printhead Fan 1 24 V...

Page 295: ...al J7 Mirror Motor 1 Ground 2 Ground 3 Refreq 4 Lock 5 Start 6 Ground 7 24 V dc J8 Output Level Sensor 1 Ground 2 Ground 3 OPT2 4 Ground 5 5 V dc J9 SDRAM Card Assembly J11 USB Connector J12 SDRAM Car...

Page 296: ...ew Fuser 1 ExitSens R 2 ThumpRet 3 5 V dc 4 ThumpLeft 5 Ground 6 Therm 7 Ground 8 Narmedia 9 5 V dc 10 Ground J15 Serial Port 2 TXD 3 RXD 4 RTS 5 CTS 6 DSR 20 DTR 8 19 No Connection 21 25 No Connectio...

Page 297: ...Port Connector Connector Pin No Signal J25 HVPS Cart Sense Input Sensor 1 ATSERVO HVPS 2 TXCURPWM HVPS 3 TxEnable HVPS 4 TXPWM HVPS 5 24 V dc HVPS 6 CHGPWM HVPS 7 Ground HVPS 8 DEV HVPS 9 Ground Input...

Page 298: ...Connector Pin No Signal J27 Main Drive Motor 1 24 V dc 2 Ground 3 Ground 4 Lock 5 Hall 6 BLDC_DIR 7 FG 8 5 V dc 9 BLDC_CLKb 10 Ground 11 ON OFF J28 Ethernet Connector J30 Option Connector 1 RDXIn 2 G...

Page 299: ...or Pin No Signal J31 Options Connector 1 RDXIn 2 Ground 3 TDXIbr 4 Ground 5 Ground J32 MPF Paper Out 1 Ground 2 POSense 3 5 V dc J33 System Board Edge Connector J35 Auto Compensator Motor 1 24 V dc 2...

Page 300: ...5 26 Service Manual 4069 5XX 7XX Connector Pin No Signal J36 Paper Size Sensor 1 5 V dc 2 PSize2 3 Ground 4 PSize1 5 24 V dc 6 Ground 7 POut 8 PaperLow 9 5 V dc J37 MPF PICK 1 MPFPick 2 24 V dc...

Page 301: ...Connector Locations 5 27 4069 5XX 7XX StapleSmart Finisher Option Staple Card Assembly Connector Pin No Signal J1A Bottom Autoconnect 1 24 V dc 2 Ground 3 5 V in...

Page 302: ...ct 1 rtxdin 2 Ground 3 prtrxd 4 Ground 5 Ground J2 Feed Motor 1 fdmtr1 2 fdmtr2 3 Ground 4 Ground 5 tachft 6 5Vptt J3 Stepper Motor 1 stpmtr 2 stpmtr 3 stpmtr 4 stpmtr 5 crtprsnt 6 stplow 7 stpphomo 8...

Page 303: ...ha 6 5Vptt J5 Solenoid 1 Sol1 2 24 V dc J6 Stapler 1 Ground 2 pfrinstp 3 5Vsnsr2 J7 Right Side Sensor Board 1 Ground 2 Bottom 3 Top 4 Ground J8 Solenoid 1 Sol2 2 24 V dc J9 Bin Empty Sensor 1 Ground 2...

Page 304: ...Sensor 1 Ground 2 psthruint 3 5Vptt J13 Cover Open Switch 1 5V dc 2 Ground 3 cvropin J14A 1 24V dc 2 Ground 3 5V in J14B 1 prtxdout 2 Ground 3 prtrxd 4 Ground 5 Ground J15 Stapler Door Open 1 Dooropi...

Page 305: ...Connector Locations 5 31 4069 5XX 7XX Cables Base Machine Fuser Cable DC Internal Autoconnect Cable Fuser to LVPS Deflector Cable...

Page 306: ...5 32 Service Manual 4069 5XX 7XX Fuser Cable AC EP Autoconnect to Fuser Top Cover Integrated Tray Cable HSYNC Cable...

Page 307: ...Connector Locations 5 33 4069 5XX 7XX Mirror Motor Cable Main Drive Motor Cable Laser Cable...

Page 308: ...5 34 Service Manual 4069 5XX 7XX Front Harness Cable Fuser Cable DC EP Autoconnect to System Board Autoconnect Cable System Board to Top Interconnect Board...

Page 309: ...Connector Locations 5 35 4069 5XX 7XX Autoconnect Cable System Board to Front Bottom Interconnect Board...

Page 310: ...5 36 Service Manual 4069 5XX 7XX...

Page 311: ...ltered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety expos...

Page 312: ...interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers 99A2408 115V 875W Models 520 52n 99A2407 220V 875W Mo...

Page 313: ...me for all machines CC Color Code in the Description column indicates the part is identified by a color marking on the part NS Not Shown in the Asm Index column indicates that the part is procurable b...

Page 314: ...7 2 Service Manual 4069 5XX 7XX Assembly 1 Covers 3 11 7 13 5 9 15 2 10 6 4 12 8 14 1 18 16 17...

Page 315: ...artridge Load Spring 1 6 99A2435 1 Cartridge Load Spring 1 7 99A2471 1 Contact Asm Smart Cartridge 1 8 99A2482 1 Cover RIght Side 520 52n 1 8 99A1505 1 Cover Right Side 722 72n 1 9 99A2433 1 Hinge Ass...

Page 316: ...7 4 Service Manual 4069 5XX 7XX Assembly 1 cont Covers 3 11 7 13 5 9 15 2 10 6 4 12 8 14 1 18 16 17...

Page 317: ...TLI ID Serial No Blank 1 12 99A1502 1 Latch Upper Cover 1 13 99A1511 1 Cover Assembly Lower Front 1 14 99A0004 1 Spring Latch 1 15 99A1501 1 Operator Panel Assembly 1 16 99A2414 1 Switch Cover Open w...

Page 318: ...7 6 Service Manual 4069 5XX 7XX Assembly 2 Frame...

Page 319: ...Support Left Lower Stacker 2 10 99A0113 1 Pan Drip ITC 2 11 99A1924 2 Spring Cartridge Hold Down 2 13 99A1519 1 Extension 500 Input 2 14 99A0058 4 Pad Machine Mounting 2 15 99A1588 1 Transfer Plate As...

Page 320: ...7 8 Service Manual 4069 5XX 7XX Assembly 2 cont Frame...

Page 321: ...0053 1 Sensor Input 2 30 99A1517 1 Frame Extension Left 500 Internal 2 31 99A0549 1 Shield ESD Assembly with label 2 32 99A0063 1 Spring Switch Activate 2 33 99A2417 1 Left Side Frame Assembly 2 34 99...

Page 322: ...XX Assembly 3 Printhead Asm Index Part Number Units Description 3 1 99A2448 1 Printhead Assembly 520 52n 3 1 99A2449 1 Printhead Assembly 722 72n NS 3 Screw Printhead Mounting PP 99A0263 NS 99A2442 1...

Page 323: ...mber Units Description 4 1 99A0060 1 Sensor Paper Out Internal Tray 4 2 99A2444 1 Pick Arm Assembly 500 4 3 56P1228 1 Spring Arm Bellcrank 4 4 99A1930 1 Spring Bellcrank Internal 500 4 5 99A0070 2 Pic...

Page 324: ...7 12 Service Manual 4069 5XX 7XX Assembly 5 Paper Feed Multipurpose Unit...

Page 325: ...Kit o Restraint Pad o MPT Pad Assembly 5 6 99A2439 1 Deflector Assembly MPT 5 7 99A1531 1 Deflector Lower 5 8 2 Screw Lower Deflector Mounting 8 mm PP 99A0263 5 8 2 Screw Lower Deflector Mounting 12 m...

Page 326: ...7 14 Service Manual 4069 5XX 7XX Assembly 6 Paper Feed Alignment...

Page 327: ...lignment Assembly Paper Feed 6 2 99A1953 1 Screw Reference Ground Clip 6 3 99A0490 1 Clip Reference Ground 6 4 99A0492 1 Screw Paper Reference Adjustment 6 5 99A0565 1 Washer Reference Adjustment 6 6...

Page 328: ...7 16 Service Manual 4069 5XX 7XX Assembly 7 Paper Feed Output...

Page 329: ...r Feed Output Asm Index Part Number Units Description 7 1 99A1857 1 Deflector Upper Redrive 7 2 99A1534 1 Door Assembly Redrive 500 7 3 99A1533 1 Redrive Assembly Inner 500 7 4 99A0104 1 Spring Upper...

Page 330: ...7 18 Service Manual 4069 5XX 7XX Assembly 8 Integrated Paper Tray 500 Sheet...

Page 331: ...ssembly 500 Sheet 8 3 99A1895 1 Restraint Side Latch Side 8 4 99A0292 4 Strip Wear 8 5 99A1812 1 Label Tray Option Number 8 6 99A1583 1 Plate 500 Tray Wear 8 7 99A0126 3 Finger Autosize 8 8 99A0124 1...

Page 332: ...7 20 Service Manual 4069 5XX 7XX Assembly 9 Main Drive...

Page 333: ...cription 9 1 99A2446 1 Gearbox w Motor 520 52n 9 1 99A2447 1 Gearbox w Motor 722 72n 9 2 99A1569 1 Shaft Power Take Off 500 9 3 99A0275 1 Spring Power Take Off Shaft 9 4 99A0954 1 Gear Bevel with Grea...

Page 334: ...7 22 Service Manual 4069 5XX 7XX Assembly 10 Developer Drive...

Page 335: ...oper Drive Asm Index Part Number Units Description 10 1 99A1544 1 Developer Drive Assembly 10 2 99A0564 1 Coupler Gear 55 10 3 99A0136 1 Shaft Developer Drive 10 4 1 Screw Developer Drive Ground PP 99...

Page 336: ...7 24 Service Manual 4069 5XX 7XX Assembly 11 Hot Roll Fuser...

Page 337: ...mistor Thermal Fuse and LH RH Fuser Lamp Contact Assemblies 11 4 4 Screw Contact Assembly PP 99A0263 11 5 99A2469 1 Exit Roll Assembly 11 6 99A1520 1 Gear Upper Redrive 11 7 99A2472 1 Detack Assembly...

Page 338: ...7 26 Service Manual 4069 5XX 7XX Assembly 11 cont Hot Roll Fuser...

Page 339: ...uide Fuser Entry 11 25 2 Retainer Backup Roll Bellcrank PP 99A0267 11 26 99A0410 2 Spring Backup Roll Bellcrank 11 27 99A2466 1 Fuser Cable DC Fuser Internal 11 28 99A0157 1 Gear Hot Roll 11 29 99A014...

Page 340: ...iption 12 1 99A1015 1 Transfer Roll Assembly 12 2 99A0349 1 Arm Transfer Roll Assembly Right 12 3 99A0184 1 Spring Transfer Roll Right 12 4 99A0185 1 Shaft Transfer Pivot 12 5 99A0181 1 Spring Transfe...

Page 341: ...Charging Asm Index Part Number Units Description 13 1 99A0512 1 Link Assembly Charge Left Kit 13 2 99A0513 1 Link Assembly Charge Right Kit 13 3 99A1017 1 Roll Assembly Charge 13 4 99A1555 1 Bushing C...

Page 342: ...7 30 Service Manual 4069 5XX 7XX Assembly 14 Electronics...

Page 343: ...uay Austria Germany Hungary Slovakia Finland France Belgium Netherlands Greece Italy Czechoslovakia Lebanon Syria Egypt Jordan Iran Euro English Norway Sweden Poland Russia Turkey CIS Portugal Spain C...

Page 344: ...7 32 Service Manual 4069 5XX 7XX Assembly 14 cont Electronics...

Page 345: ...2n 14 3 99A2455 1 LVPS 220 V ac 722 72n 14 4 1 Screw HVPS Mounting PP 99A0263 14 5 99A2451 1 High Voltage Power Supply 14 6 99A2425 1 Interconnect Board Assembly o 2 Slot with shield 14 7 2 Screw Int...

Page 346: ...7 34 Service Manual 4069 5XX 7XX Assembly 14 cont Electronics...

Page 347: ...14 16 2 Screw INA Cover Mounting PP 99A0263 1 o Cover INA Blank 14 17 99A2431 1 Shield Inner Assembly 2 slot 2 o Cover INA Blank 14 18 99A0206 1 Shield Outer 2 slot 14 19 4 Screw Outer Shield Mountin...

Page 348: ...7 36 Service Manual 4069 5XX 7XX Assembly 14 cont Electronics...

Page 349: ...or Standard Bin Level 14 23 99A2441 1 Fan Main 14 24 99A2459 1 Cable Main Drive Motor 14 25 99A2446 1 Gearbox w Motor 520 52n 14 25 99A2447 1 Gearbox w Motor 722 72n 14 26 99A2456 1 Cable Integrated T...

Page 350: ...7 38 Service Manual 4069 5XX 7XX Assembly 14 cont Electronics...

Page 351: ...72n 14 31 99A2471 1 Smart Cartridge Contact Assembly 14 32 99A0466 1 Sensor Toner Cartridge Level 14 33 99A1501 1 Operator Panel Assembly 14 34 99A2414 1 Switch Cover Open w Operator Panel Cable Assem...

Page 352: ...7 40 Service Manual 4069 5XX 7XX Assembly 14 cont Electronics...

Page 353: ...ble Fuser DC EP Auto Connect to System Board 14 43 99A2465 1 Solenoid Assembly Envelope Conditioner 14 44 99A2479 1 Sensor Exit 14 45 99A2466 1 Cable Fuser DC Fuser Internal 14 46 99A2468 1 Cover Fuse...

Page 354: ...7 42 Service Manual 4069 5XX 7XX Assembly 14 cont Electronics...

Page 355: ...Parts Catalog 7 43 4069 5XX 7XX Assembly 14 cont Electronics Asm Index Part Number Units Description 14 52 99A2442 1 Printhead Fan...

Page 356: ...7 44 Service Manual 4069 5XX 7XX Assembly 15 250 Sheet Tray...

Page 357: ...A0448 1 Arm Paper Out 250 15 8 3 Screw Auto Comp Mounting PP 99A0263 15 9 99A1054 1 Pick Arm Assembly 15 10 99A0277 1 Wear Plate Pass Thru 250 Tray 15 11 2 Screw Wear Plate Mounting PP 99A0263 15 12 9...

Page 358: ...7 46 Service Manual 4069 5XX 7XX Assembly 15 cont 250 Sheet Tray...

Page 359: ...4 Pad Machine Mounting 15 25 99A0288 1 Sensor Option Pass Thru 15 26 99A1666 1 Label Options 15 27 99A0272 1 Shaft 250 Drive 15 28 99A0275 1 Spring Power Takeoff 15 29 99A0280 1 Bushing Drive Shaft Lo...

Page 360: ...7 48 Service Manual 4069 5XX 7XX Assembly 15 cont 250 Sheet Tray...

Page 361: ...Sheet Option 15 37 99A1894 1 Restraint Side 250 Sheet Tray 15 38 99A0119 4 Wear Strips 15 43 99A1952 1 Label Paper Size 15 39 99A1829 1 Label Tray Option Number 15 40 99A0121 1 Clip 250 Tray Wear 15 4...

Page 362: ...7 50 Service Manual 4069 5XX 7XX Assembly 16 500 Sheet Tray...

Page 363: ...1 Sensor Option Pass Thru 16 10 99A1895 1 Restraint Side 500 Sheet Tray 16 11 99A0292 4 Wear Strips 16 12 99A1829 1 Label Tray Option Number 16 13 99A1583 1 Plate 500 Tray Wear 16 14 99A0126 4 Finger...

Page 364: ...7 52 Service Manual 4069 5XX 7XX Assembly 16 cont 500 Sheet Tray...

Page 365: ...ard Mounting PP 99A0263 16 35 1 Retainer Aligner Assembly PP 99A0267 16 36 99A0280 1 Bearing Drive Shaft Low 16 37 99A0446 1 Aligner Assembly Paper 16 38 99A0274 1 Gear Feed Roll 16 39 99A0063 1 Sprin...

Page 366: ...7 54 Service Manual 4069 5XX 7XX Assembly 17 Duplex...

Page 367: ...Motor 114 Gear 17 10 99A0329 1 Pulley Main Drive 96 54 Gear 17 11 99A0321 1 Motor Assembly DC Drive 17 12 99A1673 1 Cable D C Motor Tach 250 Duplex 17 13 1 Cam Follower Assembly Kit PP 99A0299 17 14 9...

Page 368: ...7 56 Service Manual 4069 5XX 7XX Assembly 17 cont Duplex...

Page 369: ...plex Shaft 17 28 99A0325 1 Gear Pass Thru Idler 17 29 99A0280 1 Bearing Drive Shaft Low 17 30 99A0311 1 Cable Auto Connect Bottom 17 31 99A0274 1 Gear Pass Thru Drive Roll 17 32 99A0310 1 Cable Auto C...

Page 370: ...7 58 Service Manual 4069 5XX 7XX Assembly 17 cont Duplex...

Page 371: ...me Assembly Outer 17 51 3 Screw Outer Frame PP 99A0413 17 52 99A0330 1 Guide Assembly Center Drive 17 53 1 Parts Packet Duplex Option PP 99A0269 2 o Screw Fan Mounting M4x30 2 o Washer Fan M4 2 o Nut...

Page 372: ...7 60 Service Manual 4069 5XX 7XX Assembly 18 Output Expander...

Page 373: ...der DC motor 18 7 99A0571 1 Cover Front Control Board with ESD Brush 18 8 99A1817 1 Tray Output Expander 18 9 99A1666 1 Label Options 18 10 99A1689 1 Spring Clutch Assembly 18 11 99A1688 1 Diverter Ar...

Page 374: ...7 62 Service Manual 4069 5XX 7XX Assembly 18 cont Output Expander...

Page 375: ...1 Shaft Assembly Lower Also order PP 99A0572 18 24 99A0363 3 Pulley Drive 18 25 99A0371 1 Cover Right Side 18 26 99A0361 1 Belt 160 Gear 18 27 99A0362 1 Arm Assembly Belt Idler 18 28 99A0364 1 Spring...

Page 376: ...7 64 Service Manual 4069 5XX 7XX Assembly 19 Envelope Feeder...

Page 377: ...aint Gear 19 6 99A1697 1 Cover Right Side 19 7 99A0390 1 Support Slide Out 19 8 99A0488 7 Roller Support 19 9 99A0382 1 Motor Stepper D C 19 10 99A1666 1 Label Options 19 11 99A0388 1 Switch Envelope...

Page 378: ...7 66 Service Manual 4069 5XX 7XX Assembly 19 cont Envelope Feeder...

Page 379: ...Roll Connect 1 o Gear Kick CNCT Idler 1 o Gear Feed Shaft Right 1 o Gear Drive Idler Rear 19 14 99A1698 1 Cover Left Side NS 1 Retainer 4 mm PP 99A0404 NS 3 Retainer Clip 5 mm Shaft PP 99A0404 NS 2 R...

Page 380: ...7 68 Service Manual 4069 5XX 7XX Assembly 20 High Capacity Feeder...

Page 381: ...s Feed Frame Clamp PP 99A0675 20 5 99A0691 2 Bearing Nyliner Leadscrew Top 20 6 99A0656 1 Cover Side 20 7 99A0681 4 Strip Wear 20 8 99A1818 1 Strip Wear Dimple 20 9 3 Screw Deflector Mounting 8 18 x 7...

Page 382: ...7 70 Service Manual 4069 5XX 7XX Assembly 20 cont High Capacity Feeder...

Page 383: ...20 17 99A0655 1 Door Assembly Front 20 18 99A0658 2 Magnet Door 20 19 99A0650 1 Frame Assembly 20 20 99A0661 1 Tray Assembly Elevator 20 21 99A1806 1 Card Assembly 2000 Option Control 20 22 4 Washer...

Page 384: ...7 72 Service Manual 4069 5XX 7XX Assembly 20 cont High Capacity Feeder...

Page 385: ...ame Mounting 20 33 2 Nut Base Mounting PP 99A0676 20 34 2 Washer Base Mounting PP 99A0677 20 35 2 Screw Base Mounting PP 99A0675 20 36 99A0663 1 Pulley Idler 20 37 99A0664 1 Belt Drive 20 38 99A1807 1...

Page 386: ...7 74 Service Manual 4069 5XX 7XX Assembly 20 cont High Capacity Feeder...

Page 387: ...ow 20 53 99A0651 1 Sensor Assembly Paper Out Upper Limit 20 54 3 Screw Printer Support 1 Frame Mounting PP 99A0675 20 55 99A0659 1 Frame Printer Support 1 20 56 99A0695 1 Parts Kit Paper Size Switch A...

Page 388: ...7 76 Service Manual 4069 5XX 7XX Assembly 20 cont High Capacity Feeder...

Page 389: ...20 62 4 Foot Stabilizer PP 99A0672 20 63 4 Mounting Feet PP 99A0687 20 64 99A1796 1 Belt DC Motor Drive 20 65 99A1797 1 Idler Pulley Belt Tension 20 66 99A1798 1 Plate Drive Pulley 20 67 99A1799 1 AC...

Page 390: ...7 78 Service Manual 4069 5XX 7XX Assembly 20 cont High Capacity Feeder...

Page 391: ...ner Roller PP 99A0267 20 81 2 Screw Wear Plate Mounting PP 99A0675 20 82 99A0277 1 Plate Wear Pass Thru 20 83 99A0445 1 Stud Assembly 250 Frame 20 84 99A0280 1 Bearing Drive Shaft Low 20 85 99A0275 1...

Page 392: ...7 80 Service Manual 4069 5XX 7XX Assembly 20 cont High Capacity Feeder...

Page 393: ...92 1 Base 2000 Option 20 97 1 Screw Deflector Mounting PP 99A0263 20 98 99A0678 1 Deflector Base 20 99 99A0288 1 Sensor Pass Thru 20 100 99A1812 1 Label Tray Option Number 20 101 99A1666 1 Label Optio...

Page 394: ...7 82 Service Manual 4069 5XX 7XX Assembly 21 Kiosk Vertical Paper Adapter...

Page 395: ...2 Gear Idler 21 8 99A0197 1 Shaft Drive Rear 21 9 99A0079 1 Tray Assembly Backup Roller 21 10 3 Parts Pulley PP 99A0208 21 11 99A0087 6 Spring Backup Roller 21 12 99A0086 6 Roller Backup 21 13 99A1706...

Page 396: ...7 84 Service Manual 4069 5XX 7XX Assembly 22 Kiosk Horizontal Paper Adapter...

Page 397: ...r 22 7 99A1704 2 Gear Idler 22 8 99A0197 1 Shaft Drive Rear 22 9 99A0079 1 Tray Assembly Backup Roller 22 10 3 Parts Pulley PP 99A0208 22 11 99A0087 6 Spring Backup Roller 22 12 99A0086 6 Roller Backu...

Page 398: ...7 86 Service Manual 4069 5XX 7XX Assembly 23 High Capacity Output Stacker...

Page 399: ...put Tray 23 5 99A1782 2 Shaft Pulley 23 6 99A1790 2 Guide Output Tray 23 7 99A1779 2 Spring Output Tray 23 8 99A1746 1 Cover Right 23 9 99A1747 1 Cover Front 23 10 99A1701 1 Tray Asm Output 23 11 99A1...

Page 400: ...7 88 Service Manual 4069 5XX 7XX Assembly 23 cont High Capacity Output Stacker...

Page 401: ...8 12 Bearings Shaft PP 99A0572 23 19 99A1749 2 Board Asm High Capacity Output Stacker 23 20 31 Screws PP 99A0263 23 21 99A1688 1 Arm Diverter 23 22 99A1689 1 Clutch Asm Output Stacker 23 23 99A1784 2...

Page 402: ...7 90 Service Manual 4069 5XX 7XX Assembly 23 cont High Capacity Output Stacker...

Page 403: ...Lower 23 31 99A0363 6 Pulley Drive 23 32 99A0361 1 Belt 160G Upper Stacker Asm 23 33 99A0362 1 Arm Asm Belt Idler 23 34 99A0364 2 Spring Belt Tensioner 23 35 99A1791 1 Stacker Asm Paper Path Lower 23...

Page 404: ...7 92 Service Manual 4069 5XX 7XX Assembly 24 5 Bin Mailbox...

Page 405: ...2 99A1712 5 Tray Paper Cap 24 13 99A1739 1 Bracket Asm Bail Attach w Brush 24 14 99A1743 1 Kit 5 Bin Mailbox Asm 24 15 99A1666 1 Label Options 24 16 1 Bail order 99A1743 5 Bin Mailbox Asm Kit 24 17 99...

Page 406: ...7 94 Service Manual 4069 5XX 7XX Assembly 24 cont 5 Bin Mailbox...

Page 407: ...tch Diverter Actuator 24 35 99A1730 4 Arbor Diverter Actuator 24 36 99A1789 4 C clip 24 37 99A1720 1 Bracket Attach 24 38 99A1732 4 Solenoid Diverter 24 39 99A1738 5 Deflector Paper Exit w Brush 24 40...

Page 408: ...7 96 Service Manual 4069 5XX 7XX Assembly 25 StapleSmart Finisher...

Page 409: ...9A2503 1 Cover Stapler Access 25 8 99A2502 1 Switch Stapler Access Door Assembly 25 9 2 Screws Switch Stapled Access Mounting 99A2509 Parts Packet 25 10 99A2519 1 Cover Accumulator Assembly 25 11 99A2...

Page 410: ...7 98 Service Manual 4069 5XX 7XX Assembly 25 cont StapleSmart Finisher...

Page 411: ...99A2526 1 Stapler Assembly 25 20 99A2556 1 Bracket Attach 25 21 99A1820 1 Belt Main Drive 25 22 99A2544 1 Card Assembly Right Stapler Bin Level 25 23 99A0362 1 Arm Assembly Belt Idler 25 24 99A2545 1...

Page 412: ...7 100 Service Manual 4069 5XX 7XX Assembly 25 cont StapleSmart Finisher...

Page 413: ...haft Assembly 40T Middle Stacker 25 38 99A0363 1 Pulley Drive 25 39 99A0368 1 Shaft Assembly Lower 25 40 99A2538 1 Belt FHT 86T 25 41 99A2518 1 Shaft Assembly Lower Exit 25 42 99A2529 1 Guide Inner Bi...

Page 414: ...7 102 Service Manual 4069 5XX 7XX Assembly 25 cont StapleSmart Finisher...

Page 415: ...ox Drive Assembly Paper Aligner NS 99A2480 1 Kit Maintenance StapleSmart Wheels NS 99A2525 1 Sensor Stapler Pass Thru NS 99A2530 1 Cable Assembly Right Stapler Bin Level NS 99A2534 2 Ground Cable Stap...

Page 416: ...MM 26 99A1758 1 4MB Flash DIMM 26 99A1759 1 8MB Flash DIMM 26 99A1774 1 16MB Flash DIMM 26 56P1118 1 Card Assembly Bar Code 26 56P0582 1 Card Assembly PRESCRIBE 5 4 2 Flash 26 56P1200 1 Card Assembly...

Page 417: ...10 100 ethernet 26 12G1696 1 MarkNet N2002e 10base2 10baseT 26 12G1697 1 MarkNet N2000t 4 16 26 99A0560 1 Adapter Omnibus INA Card 26 99A1889 1 Paper Presentator Front 26 99A2485 1 Tray Assembly UAT...

Page 418: ...rts Packet Cable Ties 10 each 27 99A0675 1 Parts Packet Screws High Capacity Feeder 27 99A0676 1 Parts Packet Nuts High Capacity Feeder 27 99A0677 1 Parts Packet Washers High Capacity Feeder 27 99A008...

Page 419: ...ription 27 99A0208 1 Parts Packet Pulley Kiosk 27 99A0234 1 Parts Packet Screws Kiosk 27 99A0394 1 Grease Packet Nyogel 744 27 99A0462 1 Grease Packet IBM 23 27 99A1854 1 Packaging 4069 500 500 printe...

Page 420: ...7 108 Service Manual 4069 5XX 7XX...

Page 421: ...ex Sensor Test 3 9 Error Log 3 13 Clearing the Error Log 3 13 Viewing the Error Log 3 13 Hardware Tests 3 14 Button Test 3 14 LCD Test 3 14 Parallel Wrap Test 3 16 ROM Memory Test 3 15 SDRAM Memory Te...

Page 422: ...Charging 7 29 Covers 7 2 Developer Drive 7 22 Duplex 7 54 Electronics 7 30 Envelope Feeder 7 64 Frame 7 6 High Capacity Feeder 7 68 High Capacity Output Stacker 7 86 Hot Roll Fuser 7 24 Integrated Pap...

Page 423: ...4 54 Pick Roll 4 54 Pick Roller Replacement 4 63 Printhead 4069 520 52n 4 55 Printhead 4069 722 72n 4 56 Redrive Assembly 4 57 Smart Cartridge Contacts 4 58 System Board 4 17 Toner Sensor 4 59 Transfe...

Page 424: ...3 1342534 7 31 1342536 7 31 1374067 7 31 40X0070 7 81 43H5248 7 31 56P0161 7 105 56P0162 7 105 56P0557 7 45 7 51 7 79 56P0582 7 104 56P1100 7 105 56P1101 7 105 56P1118 7 104 56P1200 7 104 56P1220 7 33...

Page 425: ...7 79 99A0274 7 47 7 53 7 57 7 79 99A0275 7 21 7 47 7 53 7 79 99A0276 7 45 7 53 7 79 99A0277 7 45 7 79 99A0278 7 47 7 79 99A0279 7 47 7 53 7 57 7 79 99A0280 7 47 7 53 7 57 7 79 99A0281 7 47 7 53 7 79 9...

Page 426: ...7 106 99A0513 7 29 7 106 99A0545 7 104 99A0548 7 103 99A0549 7 9 99A0556 7 9 99A0559 7 15 99A0560 7 105 99A0564 7 23 99A0565 7 15 99A0566 7 15 99A0567 7 9 99A0571 7 61 99A0572 7 61 7 89 7 101 7 106 99...

Page 427: ...512 7 3 7 93 99A1516 7 7 99A1517 7 9 99A1518 7 7 99A1519 7 7 99A1520 7 25 99A1522 7 9 99A1524 7 3 99A1525 7 9 99A1531 7 13 99A1533 7 17 99A1534 7 17 99A1535 7 7 99A1536 7 49 99A1537 7 19 7 49 7 51 99A...

Page 428: ...7 67 99A1699 7 67 99A1700 7 65 99A1701 7 87 99A1702 7 53 99A1704 7 83 7 85 99A1705 7 83 7 85 99A1706 7 83 99A1707 7 85 99A1708 7 93 99A1709 7 93 99A1710 7 93 99A1711 7 93 99A1712 7 93 99A1713 7 93 99A...

Page 429: ...5 99A1820 7 83 7 85 7 99 99A1829 7 49 7 51 7 69 99A1832 7 7 99A1854 7 107 99A1855 7 107 99A1857 7 17 7 61 99A1879 7 7 99A1888 7 9 99A1889 7 105 99A1890 7 105 99A1894 7 49 99A1895 7 19 7 51 99A1903 7 5...

Page 430: ...97 99A2503 7 97 99A2504 7 103 99A2505 7 97 99A2506 7 97 99A2507 7 97 99A2508 7 97 99A2509 7 97 7 106 99A2510 7 97 99A2511 7 97 99A2512 7 97 99A2513 7 101 99A2515 7 101 99A2516 7 101 99A2517 7 101 99A...

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