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Lexmark T642 Service Manual - Page 114

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4061-xx0 Ready-Bin x Full displays and paper feeds into bin x FRU 1 Bin x sensor Bin x sensor control board Action Check the sensor flag for binds. Make sure the sensor flag is not in an up position. If the sensor flag is operating correctly, replace the bin x sensor. If this does not fix the problem, replace the control board. 271.xx Paper Jam - Check Bin 1 displays-paper does not feed into the bin selected FRU 1 Deflector Deflector spring Deflector cover Deflector cover spring Shaft assemblies 2 Bin x solenoid assembly Control board 3 Mechanical linkage Motor assembly Action Check all the bin parts for missing or loose springs, binds in the deflector or deflector cover, broken or binding shaft assemblies, or broken gear teeth. If incorrect, repair as necessary. 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, check the resistance of the solenoid. It measures between 30 and 50 ohms. If incorrect, replace the failing solenoid assembly. If correct, replace the control board. If the DC motor is functioning properly, check the gears, clutch, and other linkage parts for correct operation and wear, broken gear teeth, or damaged parts. If incorrect, replace the mechanical linkage assembly/DC motor assembly. 990.xx Service Error displays FRU 1 Mechanical linkage DC motor assembly 2 Control board Action Check the DC motor cable connector to be sure it is correctly installed at J2 on the control board. If correct, disconnect J2 from the control board and check the resistance of the motor on the cable connector. J2-1 to J2-2 measures between 115 and 135 ohms. Also check J2-1 and J2-4 to the motor case for shorts. If either the resistance is incorrect or a short is 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. Disconnect the motor cable J2 from the control board and check the voltages at J2 on the board. Warning: Use caution not to short adjacent pins on the connector as damage to the board could result. Pin Measured (motor idle) J2-1 +24 V dc J2-2 +24 V dc J2-5 +5 V dc J2-6 +5 V dc If any of the voltages are incorrect, replace the control board. If correct, replace the mechanical linkage/ DC motor assembly. 2-74 Service Manual

Section	Page
Table of contents	3
Laser notices	11
Laser notice	11
Laser	11
Avis relatif à l’utilisation de laser	11
Avvertenze sui prodotti laser	12
Avisos sobre el láser	12
Declaração sobre Laser	12
Laserinformatie	13
Lasermeddelelse	13
Huomautus laserlaitteesta	13
Laser-notis	14
Laser-melding	14
Avís sobre el Làser	14
Japanese Laser Notice	15
Korean Laser Notice	16
Safety information	17
Consignes de sécurité	17
Norme di sicurezza	17
Sicherheitshinweise	18
Pautas de Seguridad	18
Informações de Segurança	18
Informació de Seguretat	19
Preface	20
Definitions	20
1. General information	21
Maintenance approach	21
Options	21
Configured models	22
Specifications	23
Resolution	23
Data streams	23
Print speed and performance print speed	23
Performance	23
Time to first print	23
Memory configuration	24
Operating clearances	24
Dimensions	25
Power requirements	26
Electrical specifications	26
Environment	27
Acoustics	27
Media specifications	28
Paper and specialty media guidelines	28
Supported print media	28
Selecting print media	35
Paper	35
Paper characteristics	35
Weight	35
Unacceptable paper	35
Transparencies	36
Selecting transparencies	36
Envelopes	36
Labels	37
Card stock	38
Storing print media	38
Avoiding jams	39
Print area	39
Tools required	39
Acronyms	40
2. Diagnostic information	41
Start	41
Symptom tables	41
Service errors (9xx.xx’s)	41
User status and attendance messages	41
Additional information	41
Understanding the printer operator panel	42
Understanding the menus	43
Power-On Self Test (POST) sequence	44
Symptom tables	45
Base printer symptoms	45
High-capacity feeder (2000-sheet) symptoms	45
Paper tray symptoms	46
Duplex option symptoms	46
Envelope feeder symptoms	46
Output expander	46
StapleSmart finisher	47
Messages and error codes	48
Service error codes	48
User status displays	71
User attendance messages	72
User line 2 link messages	83
Check device connection messages	83
User attendance messages-paper jams and paper handling errors (2xx.xx)	84
Service checks	112
5-Bin mailbox service check	112
900.xx Error code service check	115
927.xx Fan service check	116
Main fan	116
Cartridge fan service check	116
950.00 through 950.29 EPROM mismatch failure	117
950.30 through 950.60 EPROM mismatch failure	118
Charge roll service check	119
Cover closed switch/cable service check	120
Dead machine service check	120
Duplex option service check	122
Envelope feeder service check	124
Fuser service checks	127
920.xx-Cold fuser service check	127
922.xx-Cold fuser check	129
923.xx-Hot fuser service check	130
924.xx-Hot fuser service check	131
925.xx-Hot fuser service check	131
Fuser exit sensor service check	132
Fuser narrow media sensor service check	133
Fuser solenoid service check	134
High-capacity feeder input tray service check	135
High-capacity output stacker service check	140
Input sensor service check	142
Input tray(s) service check	142
Interconnect card service check	144
Main drive service check	145
Operator panel service check	146
One or more operator panel buttons fail	146
No buttons work	146
Operator panel display	147
Options service check	148
Flash Memory Option(s)	148
DRAM Memory Option(s)	148
Hard Disk Option	148
Output bin sensor standard tray service check	149
Output expander service check	150
Paper feed service check	152
Paper size sensing service check	153
Parallel port service check	156
Print quality service check	156
Printhead service check	162
Signature button assembly service check	162
StapleSmart finisher service check	163
System board service check	166
Toner sensor service check	167
Transfer roll service check	168
3. Diagnostic aids	169
Accessing service menus	169
Diagnostics mode	170
Entering Diagnostics mode	170
Available tests	170
Exiting Diagnostics mode	172
REGISTRATION	172
Quick Test	173
PRINT TESTS	174
Input source tests	174
Print quality pages (Prt Quality Pgs)	174
HARDWARE TESTS	175
Panel Test	175
Button Test	175
DRAM Test	175
CACHE Test	176
Parallel Wrap tests	176
Serial Wrap tests	177
DUPLEX TESTS	177
Quick Test (duplex)	177
Top Margin (duplex)	178
Sensor Test (duplex)	178
Motor Test (duplex)	179
Duplex Feed 1	180
Duplex Feed 2	180
INPUT TRAY TESTS	181
Feed Tests (input tray)	181
Sensor Test (input tray)	181
OUTPUT BIN TESTS	182
Feed Tests (output bins)	182
Feed To All Bins	182
Sensor Test (standard output bin)	183
Sensor Test (Output Expander)	183
Sensor Test (high capacity output stacker)	184
Sensor Tests (5-bin mailbox)	184
Diverter Test	184
FINISHER TESTS	185
Staple Test	185
Feed Tests (finisher)	185
Sensor Test (finisher)	185
BASE SENSOR TEST	186
DEVICE TESTS	186
Quick Disk Test	186
Disk Test/Clean	187
Flash Test	187
PRINTER SETUP	188
Defaults	188
Page Count	188
Perm Page Count (permanent page count)	188
Serial Number	188
Envelope Enhance	188
Engine Setting 1 through 4	188
Model Name	188
Configuration ID	189
Edge to Edge	189
Parallel strobe adjustment (Par x Strobe Adj)	189
EP SETUP	190
EP Defaults	190
Fuser Temperature (Fuser Temp)	190
Fuser Page Count	190
Warm Up Time	190
Transfer	190
Print Contrast	190
Charge Roll	190
Gap Adjust	190
EVENT LOG	191
Display Log	191
Print Log	191
Clear Log	192
EXIT DIAGNOSTICS	192
Configuration menu (CONFIG MENU)	193
Entering Configuration Menu	193
Available menus	193
Maintenance page count (Maint Cnt Value)	193
Maintenance page counter reset (Reset Maint Cnt)	194
Print quality pages (Prt Quality Pgs)	194
SIZE SENSING	195
Panel Menus	195
PPDS Emulation	195
Download Emuls	195
Demo Mode	195
Factory Defaults	196
Energy Conserve	196
EVENT LOG	196
Paper Prompts	196
Env Prompts	196
Jobs On Disk	196
Disk Encryption	196
Font Sharpening	197
LCD Brightness	197
LCD Contrast	197
Exit Config Menu	197
Additional useful menu locations	197
Hex Trace	197
Menu settings page	198
Printing menu settings page	198
Theory	199
Autocompensator operation	199
Autoconnect system, paper tray options, envelope feeder-electrical	200
Autoconnect cabling and connectors	200
Duplex Option	200
Option microcode	200
Print quality troubleshooting	201
Paper feed jams	205
Access doors and trays	205
Clearing printer jams	205
250 Paper Jam Check MP Feeder	206
260 Paper Jam Check Env Feeder	207
23x and 24x jams	208
200 and 201 Paper Jam Remove Cartridge	209
202 Paper Jam Open Rear Door	211
23x Paper Jam Open Duplex Rear Door	212
270 and 280 Paper Jams	213
27x Paper Jam Check Bin x	213
28x Paper Jam Check Finisher	214
Clearing staple jams	216
4. Repair information	219
Handling ESD-sensitive parts	219
Adjustment procedures	220
Fuser solenoid adjustment	220
Gap adjustment	220
Printhead assembly adjustment	220
Paper alignment assembly adjustment	221
Removal procedures	222
Covers removals	222
Fuser wiper cover assembly removal	222
Redrive cap cover removal	223
Paper support removal	223
Left door removal	224
Redrive door	225
Right cover removal	226
Upper front cover removal	229
Upper front cover latch removal	231
Upper front cover outer bezel removal	232
Multipurpose feeder/lower front cover assembly removal	233
Left cover handle holder removal	234
Right cover handle holder removal	234
Left and right frame extensions	235
Pass thru plate	236
Laser cover removal	237
Bevel gear removal	239
Cartridge duct removal	241
Developer drive assembly removal	242
Developer drive coupler kit removal	243
ESD cover removal	243
Fuser assembly removal	244
Fuser exit sensor removal	246
Fuser exit sensor flag and spring removal	248
Fuser lamp removal	250
Fuser narrow media sensor removal	252
Fuser narrow media flag and spring removal	254
Fuser to LVPS AC cable removal	256
Fuser top cover removal	259
Fuser transfer plate removal	261
Gear release link removal	262
High voltage power supply removal	263
Inner paper deflector assembly removal	265
Input sensor removal	266
Integrated tray autocompensator assembly removal	267
Integrated tray autocompensator pick roll assembly removal	269
Interconnect card assembly removal	271
Low voltage power supply removal	272
Main fan removal	274
Main drive assembly removal	275
MPF arm assembly removal	278
MPF lower paper deflector	279
MPF pick tire removal	280
MPF solenoid assembly removal	280
Operator panel board removal	284
Operator panel buttons removal	285
Outer shield removal	285
Paper alignment assembly removal	286
Paper bin full sensor flag removal	288
Paper size sensing board removal	289
Power takeoff shaft and spring removal	290
Printhead removal	291
Redrive assembly removal	292
Signature button contact assembly removal	293
System board and inner shield removal	294
Toner sensor removal	295
Transfer roll assembly removal	295
Upper front cover hinge assembly removal	296
Upper paper deflector assembly removal	297
USB board assembly removal	298
5. Connector locations and connections	299
Connections	299
System board	299
Autoconnect	304
Fuser Board	305
High-capacity output stacker board	306
High voltage power supply	307
Interconnect card	307
Low voltage power supply	308
Output expander control board	309
StapleSmart finisher	310
6. Preventive maintenance	313
Safety inspection guide	313
Lubrication specifications	313
Scheduled maintenance	313
Maintenance kit	313
7. Parts catalog	315
How to use this parts catalog	315
Assembly 1: Covers	316
Assembly 2: Frame 1	318
Assembly 3: Frame 2	320
Assembly 4: Frame 3	322
Assembly 5: Printhead	324
Assembly 6: Paper feed-autocompensator	326
Assembly 7: Paper feed-multipurpose feeder	328
Assembly 8: Paper feed-alignment	330
Assembly 9: Integrated 250-sheet paper tray	332
Assembly 10: Integrated 500-sheet paper tray	334
Assembly 11: Drives-Main drive and developer drive	336
Assembly 12: Hot roll fuser	338
Assembly 13: Transfer/charging	340
Assembly 14: Electronics-power supplies	342
Assembly 15: Electronics-card assemblies	344
Assembly 16: Electronics-shields	346
Assembly 17: Cabling diagrams 1	348
Assembly 18: Cabling diagrams 2	349
Assembly 19: Cabling diagrams 3	350
Assembly 20: Cabling diagrams 4	352
Assembly 21: Cabling diagrams 5	354
Assembly 22: Optional 250-sheet paper drawer	356
Assembly 23: Optional 250-sheet paper tray	357
Assembly 24: Optional 500-sheet paper drawer	358
Assembly 25: Optional 500-sheet paper tray	359
Assembly 26: Duplex option	360
Assembly 27: Envelope feeder	361
Assembly 28: Output expander 1	362
Assembly 29: Output expander 2	363
Assembly 30: High-capacity output expander 1	364
Assembly 31: High-capacity output expander 2	365
Assembly 32: High-capacity output expander 3	366
Assembly 33: 5-bin mailbox 1	368
Assembly 34: 5-bin mailbox 2	370
Assembly 35: High-capacity feeder 1	372
Assembly 36: High-capacity feeder 2	374
Assembly 37: High-capacity feeder 4	376
Assembly 38: High-capacity feeder 5	377
Assembly 39: Kiosk-vertical and horizontal paper adapters	378
Assembly 40: StapleSmart finisher I	379
Assembly 41: StapleSmart finisher 2	380
Assembly 42: StapleSmart finisher 3	381
Assembly 43: StapleSmart finisher 4	382
Assembly 44: Options	383
Appendix A-Options and features	385
Installing input options	385
Order of installation	385
Installing a 250-sheet or 500-sheet drawer	385
Installing a duplex unit	387
Installing memory or option cards	388
Accessing the printer system board	389
Removing or installing a memory card	391
Removal	391
Installation	392
Removing or installing a flash memory or firmware card	392
Removal	392
Installation	393
Installing an option card	394
Replacing the shield	395
Printing and using features	395
Canceling a print job	395
Printing the menu settings page	397
Printing a network setup page	397
Printing a font sample list	398
Printing a directory list	398
Printing confidential and held jobs	398
Linking trays	401
Identifying and linking output bins	402
Linking output bins	404
Index	405
Part number index	413
Print defects guide	421

Match case Limit results 1 per page

2-74

Service Manual

4061-xx0

Ready—Bin x Full

displays and paper feeds into bin

271.xx Paper Jam - Check Bin 1

displays—paper does not feed into the bin selected

990.xx Service Error displays

FRU

Action

Bin

sensor

Bin

sensor control board

Check the sensor flag for binds. Make sure the sensor flag is not in

an up position. If the sensor flag is operating correctly, replace the bin

sensor. If this does not fix the problem, replace the control board.

FRU

Action

Deflector

Deflector spring

Deflector cover

Deflector cover spring

Shaft assemblies

Check all the bin parts for missing or loose springs, binds in the

deflector or deflector cover, broken or binding shaft assemblies, or

broken gear teeth. If incorrect, repair as necessary.

Bin

solenoid assembly

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, check the resistance

of the solenoid. It measures between 30 and 50 ohms. If incorrect,

replace the failing solenoid assembly. If correct, replace the control

board.

Mechanical linkage

Motor assembly

If the DC motor is functioning properly, check the gears, clutch, and

other linkage parts for correct operation and wear, broken gear teeth,

or damaged parts. If incorrect, replace the mechanical linkage

assembly/DC motor assembly.

FRU

Action

Mechanical linkage

DC motor assembly

Check the DC motor cable connector to be sure it is correctly

installed at J2 on the control board. If correct, disconnect J2 from the

control board and check the resistance of the motor on the cable

connector. J2-1 to J2-2 measures between 115 and 135 ohms. Also

check J2-1 and J2-4 to the motor case for shorts. If either the

resistance is incorrect or a short is 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.

Control board

Disconnect the motor cable J2 from the control board and check the

voltages at J2 on the board.

Warning

: Use caution not to short adjacent pins on the connector as

damage to the board could result.

If any of the voltages are incorrect, replace the control board. If

correct, replace the mechanical linkage/ DC motor assembly.

Measured (motor idle)

J2-1

+24 V dc

J2-2

+24 V dc

J2-5

+5 V dc

J2-6

+5 V dc