Lexmark 10G1664 Service Manual
Lexmark 10G1664 - T 634dtnf B/W Laser Printer Manual
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- Lexmark 10G1664 | Service Manual - Page 1
-xxx (including 4060-000, 4060-010, 4060-200, 4060-210, 4060-400, 4060-410) • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. - Lexmark 10G1664 | Service Manual - Page 2
, Inc., registered in the United States and/or other countries. ImageQuick, Optra Forms, PrintCryption, and StapleSmart are trademarks of Lexmark International, Inc. LEXFAX is a service mark of Lexmark International, Inc. Other trademarks are the property of their respective owners. © 2003 - Lexmark 10G1664 | Service Manual - Page 3
1-14 Acronyms 1-15 Diagnostic information 2-1 Start 2-1 Messages and error codes 2-2 Service error codes 2-2 Sub error codes 2-5 Sub error codes for 9xx and 2xx error codes 2-5 Base printer sub error codes 2-6 Base printer (fuser) sub error codes 2-11 Duplex option sub error codes 2-12 - Lexmark 10G1664 | Service Manual - Page 4
72 Paper feed service check 2-76 Parallel port service check 2-77 Printhead service check 2-78 Print quality service check 2-78 Smart contact assembly service check 2-85 StapleSmart finisher service check 2-86 Toner sensor service check 2-93 Transfer roll service check 2-94 iv Service Manual - Lexmark 10G1664 | Service Manual - Page 5
4060-xxx Diagnostic aids 3-1 Diagnostics mode 3-1 Entering Diagnostic Mode 3-1 Available tests 3-1 Exiting Diagnostics Mode 3-1 Device tests 3-2 Quick Disk Test 3-2 Disk Test/Clean 3-2 Flash Test 3-3 Disabling Download Emulations 3-3 Duplex tests 3-4 Duplex Quick Test 3-4 Duplex Sensor - Lexmark 10G1664 | Service Manual - Page 6
and connectors 3-21 Duplex Option 3-21 Option microcode 3-22 Paper feed jams 3-22 Paper jams-base printer 3-23 Paper jams-options 3-24 Error Message 23x Paper Jam - Check Duplex Option 3-24 Error Message 20 Frames removals 4-20 EP frame assembly 4-20 Left side frame 4-20 vi Service Manual - Lexmark 10G1664 | Service Manual - Page 7
4060-xxx Right side frame 4-22 Fuser assembly removal 4-23 Fuser cover removal 4-25 Fuser exit sensor or fuser narrow media sensor removal 4-28 Fuser lamp removal 4-28 Fuser transfer plate removal 4-30 High voltage power supply removal 4-31 Inner paper deflector assembly removal 4-33 Inner - Lexmark 10G1664 | Service Manual - Page 8
-network 5-10 System board-network 5-11 Preventive maintenance 6-1 Safety inspection guide 6-1 Lubrication specifications 6-1 Scheduled maintenance 6-1 Parts catalog 7-1 How to 72 Assembly 36: Options 7-74 Assembly 37: Miscellaneous 7-76 Index I-1 Part number index I-7 viii Service Manual - Lexmark 10G1664 | Service Manual - Page 9
in the wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class I level during normal operation, user maintenance, or prescribed service condition. Laser Der Drucker erfüllt gemäß amtlicher Bestätigung der - Lexmark 10G1664 | Service Manual - Page 10
possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal, a manutenção feita pelo utilizador ou condições de assistência prescritas. x Service Manual - Lexmark 10G1664 | Service Manual - Page 11
deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770 - Lexmark 10G1664 | Service Manual - Page 12
ver Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd. Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for d'usuari ni durant els serveis que satisfacin les condicions prescrites. xii Service Manual - Lexmark 10G1664 | Service Manual - Page 13
Japanese Laser Notice 4060-xxx Laser notices xiii - Lexmark 10G1664 | Service Manual - Page 14
4060-xxx Korean Laser Notice xiv Service Manual - Lexmark 10G1664 | Service Manual - Page 15
for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. • There may be an increased risk of electric shock and personal injury during - Lexmark 10G1664 | Service Manual - Page 16
çar, desligue o produto da tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para realizar a tarefa necessária. xvi Service Manual - Lexmark 10G1664 | Service Manual - Page 17
4060-xxx Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. • La informació pel - Lexmark 10G1664 | Service Manual - Page 18
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 problems. 4. Repair information provides instructions for making printer adjustments and removing and installing - Lexmark 10G1664 | Service Manual - Page 19
Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the printer problem and repair the failure. After you - Lexmark 10G1664 | Service Manual - Page 20
Parallel interface card - MarkNet™ Print Servers - Lexmark PrintCryption™ card • Media handling operations - Lexmark T630 and Lexmark T630n) - Duplex option-500-sheet (For Lexmark T632, Lexmark T632n, Lexmark T634, and Lexmark • Application solutions - Lexmark Document Solutions - Optra Forms - Lexmark 10G1664 | Service Manual - Page 21
application • Page complexity and content • Printer options installed or selected • Available printer memory • Media size and type • Resolution The following table specifies throughput based on resolution and media size. Lexmark T630, Lexmark T630n Lexmark T632, Lexmark T632n 300, 600, 1200 image - Lexmark 10G1664 | Service Manual - Page 22
features used, additional memory may be required to optimize performance. Available memory options Optional 8MB, 16MB, 32MB, 64MB, and 128MB SDRAM DIMMs are available from Lexmark. The memory options are 168-pin synchronous DRAM DIMMs. Flash memory options include 16MB and 32MB. 1-4 Service Manual - Lexmark 10G1664 | Service Manual - Page 23
in. (399 mm) 15.7 in. (399 mm) 17.6 in. (447.7 mm) * Envelope option (support fully * extended) Printer cabinet 30.4 in. (772 mm) Printer cabinet stand 34.8 in. (883 mm) * Envelope option fits within height and width of printer. Depth 19.6 in. (498 mm) 20.2 in. (513 mm) 20.2 in. (513 mm) 19 - Lexmark 10G1664 | Service Manual - Page 24
with the 110 volt printer is not recommended. Electrical specifications Low voltage model • 100 to 127 V ac at 50 to 60 Hz nominal • 99 to 137 V ac, extreme High voltage model • 220 to 240 V ac at 50 to 60 Hz nominal (not available in all countries) • 190 to 259 V ac, extreme 1-6 Service Manual - Lexmark 10G1664 | Service Manual - Page 25
7779 and conform with ISO 9296. Model Lexmark T630(n) Lexmark T632(n) Lexmark T634(n) Status Idle (standby mode) Simplex Bels N/M Bels Measurements apply to 300 dpi, 600 dpi, and 1200 dpi printing. Environment Printer temperature and humidity • Operating - Temperature: 16 to 32° C (60° to 90° - Lexmark 10G1664 | Service Manual - Page 26
type Media type Paper Card stock Transparencies Envelopes Vinyl labels Paper labels Polyester labels Dual web labels Integrated labels xxxxxxxx xx xx x xx x x x x x x x x x x xx x xx 1-8 Service Manual - Lexmark 10G1664 | Service Manual - Page 27
sheet drawer Envelope feeder Duplex Standard output bin Output Expander 5-Bin Mailbox High-capacity output stacker StapleSmart output bin StapleSmart-Staple/jogger Media size supported A4 8.27 in. x 11.7 in. (210 mm x 297 mm) xx x xx xxxxxxx A5 5.83 in. x 8.27 in. (148 mm x 210 mm) xx x xx - Lexmark 10G1664 | Service Manual - Page 28
output bin StapleSmart-Staple/jogger 4060-xxx Media size supported Envelopes 7¾ Envelope 3.875 in. x 7.5 in. printer requires a special label fuser cleaner which prevents duplexing. The label fuser cleaner is included with a special label cartridge for label applications. 1-10 Service Manual - Lexmark 10G1664 | Service Manual - Page 29
or business paper Card stock-maximum (grain long) 1 Card stock-maximum (grain short) 1 Transparencies Labels-maximum 2 Index Bristol Tag Cover Index Bristol Tag Cover Laser printer Paper Dual-web paper Polyester Vinyl 3 Weight 60 to 176 g/m2 grain long (16 to 47 lb bond) 163 g/m2 (90 lb bond) 163 - Lexmark 10G1664 | Service Manual - Page 30
passed Lexmark's criteria is available at Lexmark's Web site (www.lexmark.com). Search for "converter list." You can also check Lexmark's the printer's user information. The chemical process used in preprinting may render some papers unsuitable for use with this printer. 1-12 Service Manual - Lexmark 10G1664 | Service Manual - Page 31
• Transparencies specifically designed for xerographic copy machines or laser printers may be used with this printer. Labels Select labels using guidelines from in this printer's user information, refer to the Card Stock and Label Guide, or depend upon tested acceptability. General information 1-13 - Lexmark 10G1664 | Service Manual - Page 32
screwdrivers, various sizes Phillips screwdrivers, various sizes 7.0 mm nut driver 5.5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax/serial debug cable 1381963 Flash light (optional) 1-14 Service Manual - Lexmark 10G1664 | Service Manual - Page 33
4060-xxx Acronyms BLDC CSU DIMM DRAM DVM EDO EEPROM EP EPROM ESD FRU GB HCIT HVPS ITC LASER LCD LED LVPS MPF MROM MS NVRAM OEM OPT PC pel POR POST PWM RIP ROM SDRAM SIMM SRAM UPR V ac V dc VOM Brushless DC motor Customer setup Dual Inline Memory Module Dynamic Random Access Memory Digital - Lexmark 10G1664 | Service Manual - Page 34
4060-xxx 1-16 Service Manual - Lexmark 10G1664 | Service Manual - Page 35
printer. Service error codes are indicated by a three-digit error code. If a service error code displays, go to "Service error or three-digit error code that provides the user with information that explains a problem with a print cartridge, paper jam, option, port, and so on. If a user error - Lexmark 10G1664 | Service Manual - Page 36
Tray 1) for correct paper loading. Reload the paper and POR the printer. If the error continues, go to "Input tray(s) service check" on page 2-64. 917 Transfer Roll Indicates a problem in the transfer roll area. Go to "Transfer roll service check" on page 2-94. 920 Fuser Error Indicates that the - Lexmark 10G1664 | Service Manual - Page 37
is an indication that a printer fan has stalled. Go to "Main fan service check" on page 2-69. 929 Toner Sensor The toner sensor is not operating properly, the developer drive assembly is not operating properly or the print cartridge is defective. Go to "Toner sensor service check" on page 2-93 - Lexmark 10G1664 | Service Manual - Page 38
ECC error correction code can reflash NAND. If this does not fix the problem, replace the system board. 960 RAM Memory Error Indicates a DRAM Memory parts failed while programming network card x. If the printer is a network model, replace the system board. 980 or output bin. 2-4 Service Manual - Lexmark 10G1664 | Service Manual - Page 39
-xxx Sub error codes Sub error codes for 9xx and 2xx error codes The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder, and duplex option. Displayed error codes When a 9xx or 2xx error displays: 1. Press and hold Return and - Lexmark 10G1664 | Service Manual - Page 40
troubleshooting value for each area of the printer. The following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help diagnose a printer problem B #10 Envelope C 8.661 in. Envelope D C5 Envelope E B5 Envelope F Legal envelope 2-6 Service Manual - Lexmark 10G1664 | Service Manual - Page 41
type of paper jam. Possible causes are: (x1=media size) • Multi sheet feeding. • A tray size sensing problem. • The media feeding from the paper source is slipping or media is slipping in input to the printer. 84 xx 04 The input sensor was covered during POST by a piece of media still in the - Lexmark 10G1664 | Service Manual - Page 42
4060-xxx Base printer sub error codes (continued) First 6 bytes sub error code data (xx can be any value) x1=media size, x2=media source) Check tray x auto compensator and tray parts for correct operation. If no problem is found, go to "Input tray(s) service check" on page 2-64. 2-8 Service Manual - Lexmark 10G1664 | Service Manual - Page 43
assembly, internal fuser assembly cabling, DC fuser cable to the system board, and the cable connection to J14 on the system board. Service tip: Turn the printer off, enter the diagnostic tests menu, and select the base sensor test. Select output sensor and check the sensor for correct operation - Lexmark 10G1664 | Service Manual - Page 44
Explanation 8D 00 00 The fuser exit sensor was never activated by the leading edge of the media fed through the printer. • This error can be displayed after a 201 paper jam. • This can be caused by a defective fuser with the next pick retry. (x1=media size, x2=media source) 2-10 Service Manual - Lexmark 10G1664 | Service Manual - Page 45
error codes The following sub error codes could help in diagnosing fuser assembly failures: Base printer (fuser) sub error codes First 6 bytes sub error code data (xx can be any value) Explanation 920 Service - Fuser Error (under temperature while printing) EN 08 xx yy - 1 EN- zz - - 2 xx= yy - Lexmark 10G1664 | Service Manual - Page 46
4060-xxx Base printer (fuser) sub error codes (continued) First 6 bytes sub error code data (xx can be any value) Explanation 925 Service - Fuser 06 07 08 0E 13 15 18 3D Explanation No duplex error. No problem was reported to the engine by the duplex system card. The leading 12 Service Manual - Lexmark 10G1664 | Service Manual - Page 47
Feeder Sensor Test. • Check the envelope pass thru sensor to ensure it is operating correctly. If the sensor test fails, go to "Envelope feeder service check" on page 2-49. If the test passes, look for anything that might cause the envelope to stop over the sensor. An envelope never activated - Lexmark 10G1664 | Service Manual - Page 48
state. Res Reduced Displayed whenever the printer has been configured to receive or send faxes. or Press Menu to access the Busy/ Waiting Menu. The following functions may be available: • Cancel Job • Reset Printer • Reset Active Bin • Cancel FAX 2-14 Service Manual - Lexmark 10G1664 | Service Manual - Page 49
link. (PCL, PS, PJL, PPDS, SIC, or HEX) may be displayed for the value for interpreter if the printer is not configured for fax. Action Press Go to print the contents of the printer buffer, staple the accumulated sheets, or terminate the collation set. Note: Go does not terminate the current print - Lexmark 10G1664 | Service Manual - Page 50
to return the printer to the Ready state. User message Toner Low Tray x Missing Tray x Empty Tray x Low Explanation If the toner cartridge is low, then the appropriate status, if any, displays. The printer cannot detect when the envelope feeder or multipurpose feeder are low. 2-16 Service Manual - Lexmark 10G1664 | Service Manual - Page 51
return to Ready. No button actions are possible while this message displays. Printing Menu Settings Printing Directory List Restoring Factory Defaults The printer is processing or printing a list of current settings menus because Print Menu Settings is selected from the menu. Press Stop to take - Lexmark 10G1664 | Service Manual - Page 52
display shows this message for one second and then returns to the Ready message. No button actions are possible while this message displays. The printer is reset to activate a printer No button actions are possible while setting changed in the menus. this message displays. 2-18 Service Manual - Lexmark 10G1664 | Service Manual - Page 53
. • Press and hold Select and press Return to display debug data for the engine and cartridge code. Note: This message may help diagnose a potential printer problem. This message displays when the user should change the media installed in one of the input options. • =Tray 1, Tray - Lexmark 10G1664 | Service Manual - Page 54
printer but a communications problem may prevent the printer printer the option printer but a communications problem may prevent the printer printer the option problem, turn the printer off and on. If the message continues to be displayed, go to "Input tray(s) service "StapleSmart finisher service check" on - Lexmark 10G1664 | Service Manual - Page 55
request hole punching. If this message cannot be cleared after inserting the box, go to "StapleSmart finisher service check" on page 2-86. This message displays when the printer front door is open or the print cartridge is missing. If this message cannot be cleared, go to "Cover closed switch/cable - Lexmark 10G1664 | Service Manual - Page 56
. The following actions may be taken: • Install the envelope feeder. • Press Menu until Busy/Waiting displays. Select one of the following: - Cancel Job - Reset Printer - Reset Active Bin If the message cannot be cleared, go to "Envelope feeder service check" on page 2-49. 2-22 Service Manual - Lexmark 10G1664 | Service Manual - Page 57
(s) service check" on page 2-64. This message displays when the Staples Empty Alarm is activated and one of the following occurs: • There are no staples in the stapler. • The maximum number of staples have been fired after the engine has reported that the staple cartridge is low. • The printer does - Lexmark 10G1664 | Service Manual - Page 58
on). Note: This action is not available if the printer is in Diagnostics Mode or running diagnostics. • If the device is experiencing a hardware problem, turn the printer off and on. If the message continues to be displayed, go to"Output expander service check" on page 2-72. 2-24 Service Manual - Lexmark 10G1664 | Service Manual - Page 59
cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine Class ID the printer cartridge is inserted. If this does not fix the problem, go to "Smart contact assembly service check" on page 2-85. The printer - Lexmark 10G1664 | Service Manual - Page 60
52 Flash Full Explanation This message displays when the printer memory used to restore the Print and Hold problem is resolved. This message displays when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash. 2-26 Service Manual - Lexmark 10G1664 | Service Manual - Page 61
parallel port, but the port has been disabled. Once this message displays, reporting of further errors is suppressed until the menus are entered, or the printer is reset. Displayed when status is requested over the USB port, but the port has been disabled. Once the error has been displayed for the - Lexmark 10G1664 | Service Manual - Page 62
are: • Code version change • Paper handling option is removed • Disk has been moved to a different model printer. Press Go to clear the message. Some of the Print and Hold jobs stored on the disk will not should reinstall an associated compatible option or hot unplug the option. 2-28 Service Manual - Lexmark 10G1664 | Service Manual - Page 63
to clear the message. The disk is marked as bad and normal operation continues. Disk operations are not allowed until the disk is formatted. The printer detects an unsupported disk format at POR. Press Go to clear the message. The disk is marked as bad and normal operation continues. Further disk - Lexmark 10G1664 | Service Manual - Page 64
printer input sensor. Open the printer upper front door and remove the print cartridge printer input and exit sensors. Open the printer upper front door and remove the print cartridge printer exit sensor. Open the printer the printer printer exit sensor. Secondary: When printer printer printer printer - Lexmark 10G1664 | Service Manual - Page 65
is over the duplex double feed sensor. Secondary: When this message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, the portion of the job printed after the jam will not - Lexmark 10G1664 | Service Manual - Page 66
message is displayed, do not remove accumulated sheets during the jam clearance procedure as the printer will not reprint the removed sheets. Also, if the accumulated sheets are removed, Infrared port, if available. Infrared Port x is attached to PCI connector x, x=1, 2, or 3. 2-32 Service Manual - Lexmark 10G1664 | Service Manual - Page 67
option is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, the user is advised to turn the printer off, remove the option, and call for service. User status message Explanation Turn Printer OFF to Enable Option A printer option, Input Tray, or Envelope - Lexmark 10G1664 | Service Manual - Page 68
functioning of the base printer by observing the following: Cartridge display if the upper front cover is open or the print cartridge is missing. • Any cartridge errors, such as Defective Cartridge, Prebate Violation, or Missing Cartridge the toner cartridge. 12. The exit rollers turn. 13. The operator - Lexmark 10G1664 | Service Manual - Page 69
service check" on page 2-70. Replace the operator panel assembly. Go to "Operator panel service check" on page 2-70. Paper feed problems-base printer black bands on edge of copy. Unable to clear a 32-Unsupported Print Cartridge user error message. Go to "Print quality-toner on backside of printed - Lexmark 10G1664 | Service Manual - Page 70
service check" on page 2-49. Output expander Symptom Printer does not display Output Bin Full. Paper does not feed all the way into the output tray. Action Go to "Output bin sensor standard tray service check" on page 2-72. Go to "Output expander service check" on page 2-72. 2-36 Service Manual - Lexmark 10G1664 | Service Manual - Page 71
4060-xxx StapleSmart finisher Symptom Action Finisher does not staple. Printer does not recognize StapleSmart Finisher Option as being installed. Go to "StapleSmart finisher service check" on page 2-86. Go to "StapleSmart finisher service check" on page 2-86. Close Top Cover displayed. Unable - Lexmark 10G1664 | Service Manual - Page 72
. Go to "Setting configuration ID" on page 3-18. Review the following information before performing any service checks. • Paper feed problems (especially paper jams): Go to "Viewing the error log" on page 3-6 and check the printer error log for indications of repetitive entries that help to isolate - Lexmark 10G1664 | Service Manual - Page 73
any single option as being installed. If the printer recognizes any of the output options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized option. Continue with this service check or go to the service check for the failing output option. FRU - Lexmark 10G1664 | Service Manual - Page 74
flag for binding and proper operation. If correct, replace the bin x sensor. If this does not fix the problem, replace the control board. Note: This sensor is in a normally open position with the flag out of incorrect, replace the mechanical linkage assembly/DC motor assembly. 2-40 Service Manual - Lexmark 10G1664 | Service Manual - Page 75
. 900 Error Code service check FRU 1 Printer POR 2 System board 3 Factory defaults 4 Sub error codes Action Turn the printer off and on several "Base printer sub error codes" on page 2-6. If none of the Sub Error Codes are listed, then call your next level of support or call Lexmark. Diagnostic - Lexmark 10G1664 | Service Manual - Page 76
49 100 50 Action Note: Make sure you have the correct system board FRU number before installing the board in the printer. J8 J10 1 J3 1 J2 J5 1 1 J4 J7 1 11 J9 J11 J14 J15 J19 99 1 11 If this does not clear the message, contact the next level of support or Lexmark. 2-42 Service Manual - Lexmark 10G1664 | Service Manual - Page 77
on the page can be caused by a damaged or contaminated charge roll. Service tip: Make sure the right charge roll arm bushing is correctly installed and from the left side charge roll bearing and remove the roll from the printer. Leave the paper wrapped around the charge roll until it is reinstalled. - Lexmark 10G1664 | Service Manual - Page 78
closed switch/cable service check FRU 1 Toner cartridge 2 Cover closed switch/cable assembly Action Make sure the toner cartridge is correctly installed and that the right and left cartridge tracks are not 1-2 Switch status Cover open Open Closed Cover closed Closed Open 2-44 Service Manual - Lexmark 10G1664 | Service Manual - Page 79
input tray is installed, remove the option and check the base printer for correct operation. If the base printer operates correctly, go to "High-capacity feeder input tray service check" on page 2-56. If the base printer continues to not operate correctly, remove any other attached paper handling - Lexmark 10G1664 | Service Manual - Page 80
away from the printer to access the 8. 8 Communications card Turn the printer off and remove the communications card. precautions and turn the printer off on the interconnect , remove the LVPS from the printer, and check the continuity of fuse printer for a dead machine condition. If the printer is - Lexmark 10G1664 | Service Manual - Page 81
the printer off and disconnect each cable connected to the system board and each option installed on the system board until the problem is located. Warning: When removing any card installed on the system board observe all ESD precautions when handling these options. Duplex option service - Lexmark 10G1664 | Service Manual - Page 82
reach the double feed sensor during turnaround, check for any signs of paper or other objects that might cause the paper to jam. If no problem is found, replace the duplex option assembly. 2-48 Service Manual - Lexmark 10G1664 | Service Manual - Page 83
, continue with this service check, otherwise verify the interconnect card is functioning properly. Service tip: The envelope feeder mated to the autoconnect at the front of the printer. Check the connector for signs of damage to problem, replace the envelope system board. Diagnostic information 2-49 - Lexmark 10G1664 | Service Manual - Page 84
the printer on and check the voltage at J3-3 on the system board. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, replace the input sensor assembly. 990 Service be sheared off. If incorrect, replace the master kick gear. 2-50 Service Manual - Lexmark 10G1664 | Service Manual - Page 85
this service check. FRU 1 Deflector gap adjustment 2 Weight assembly 3 Envelope edge guide Action you find a problem, clean the rolls. If this does not correct the problem, replace the envelope feeder and an envelope also stopped in the base printer paper path. FRU 1 Latch lever Action Make sure - Lexmark 10G1664 | Service Manual - Page 86
line voltage may be above the maximum rating for the printer. Note: A 920, 921 or 922 fuser error may be caused by an incorrectly mounted thermistor. Service tip: Set the Fuser Temperature to NORMAL before starting this service check. FRU Action 1 Fuser lamp (incorrect lamp/ Install the correct - Lexmark 10G1664 | Service Manual - Page 87
4060-xxx FRU 4 Fuser top cover assembly (assembly includes thermistor and thermal fuses) Action Disconnect the thermistor cable from the fuser control board at J6. 1 J2 1 J1 1 J4 1 J5 1 J6 Resistance: • HOT J2-1-J2-2 - Lexmark 10G1664 | Service Manual - Page 88
or servicing. CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must glue, labels, or other contaminants. If problems are found, replace the fuser assembly. 2-54 Service Manual - Lexmark 10G1664 | Service Manual - Page 89
in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. Service tip: Try changing the envelope enhance level setting. A different setting may correct the problem. Note: Check the fuser - Lexmark 10G1664 | Service Manual - Page 90
high-capacity feeder attached to the base printer to obtain accurate results. Service tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for incorrect, replace the AC cable to the input of the LVPS. 2-56 Service Manual - Lexmark 10G1664 | Service Manual - Page 91
the voltage on J8-1 (green). The voltage measures +24 V dc. control board If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high-capacity input for the high-capacity feeder to be recognized. If the voltage - Lexmark 10G1664 | Service Manual - Page 92
control board. The elevator tray down button does not operate. The tray moves to the upper position. Service tip: Open the high-capacity feeder front door and check the black rubber bumper attached to the door switch advisable to replace all four wear strips at the same time. 2-58 Service Manual - Lexmark 10G1664 | Service Manual - Page 93
elevator tray does not move up or down. The printer recognizes that the option is installed. FRU 1 DC for a short between each pin and the motor housing. If a problem is found, replace the motor assembly. If no problem is found, measure the resistance between the following pins on the motor cable - Lexmark 10G1664 | Service Manual - Page 94
feeder option control board. Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly. 2-60 Service Manual - Lexmark 10G1664 | Service Manual - Page 95
4060-xxx Tray x Paper Low displays when the high-capacity feeder input tray is full or has adequate paper in the tray. FRU 1 Paper low switch Paper low switch cable High-capacity feeder option control board Action Run the sensor diagnostics for tray x (x=the number that represents the high- - Lexmark 10G1664 | Service Manual - Page 96
printer recognizes any of the output options, the base printer autoconnect system is operating correctly. The problem is in the unrecognized option. Continue with this service check or go to the service incorrect, replace the upper or lower failing mechanical linkage assembly. 2-62 Service Manual - Lexmark 10G1664 | Service Manual - Page 97
bin even though bin x is selected and paper exits half way out of the redrive assembly. Service tip: For this type of problem check the "Base printer sub error codes" on page 2-6. They can help isolate the problem. A 202 paper jam message can also occur prior to the high-capacity output stacker pass - Lexmark 10G1664 | Service Manual - Page 98
manually moved in and out of the sensor. FRU 1 Input sensor flag 2 System board 3 Input sensor cable Action Check the input sensor flag for damage and proper operation. If a problem Service Tray x, x= displays the number of the tray that has a problem or needs service from the printer and check - Lexmark 10G1664 | Service Manual - Page 99
If no problem is found, replace the paper low sensor assembly. If this does not correct the problem, replace the on the system board). system board) Printer does not recognize Tray x is installed. FRU Tray x does not reach the pass thru sensor. Service tip: Check the media in tray x to make sure - Lexmark 10G1664 | Service Manual - Page 100
Integrated card/ autocompensator cable 3 System board If a problem is found, repair as necessary. If no problem is found, go to step 2. Check for correct printer. Check the continuity between J34-2 on the system board and ground. It should measure approximately 0 ohms. 2-66 Service Manual - Lexmark 10G1664 | Service Manual - Page 101
. If no problem is found, go to step 2. Make sure the switch activate spring is not bent or broken. Replace the spring if damaged. If the spring is not damaged, go to step 3. Set the tray for the paper size that is not recognized and install the tray in the printer. Select - Lexmark 10G1664 | Service Manual - Page 102
. Determine if the noise is in the main drive, toner cartridge, fuser, or main drive gearbox. Look for any loose or incorrect, replace the system board. If this does not fix the problem, replace the main drive motor. Check the continuity of the main motor assembly • System board 2-68 Service Manual - Lexmark 10G1664 | Service Manual - Page 103
, replace the main fan. If this does not fix the problem, replace the system board. Check the voltage at J7-3 on the system board. The voltages are: • +22 V dc to +24 V dc (printer and fan running) • +12 V dc to +15 V dc (printer not running-fan running about half speed). If incorrect, replace - Lexmark 10G1664 | Service Manual - Page 104
operator panel assembly. Operator panel display service check Service tip: The printer has detected a problem with the system board, operator panel cable sure a card is not plugged in backward. This condition causes the printer to fail POST, displaying all diamonds on the operator panel with no - Lexmark 10G1664 | Service Manual - Page 105
is correctly installed and not broken or damaged. If the test fails, replace the SDRAM card. If the problem continues, replace the controller board. Hard Disk Option Service tip: These printers support one hard disk option. Make sure only one hard disk option is installed. Make sure the fixed disk - Lexmark 10G1664 | Service Manual - Page 106
Problems with excessive static electricity buildup. FRU 1 Output expander control board cover Action Check the output expander control board cover to make sure the ESD brush ground lead is firmly attached to the output expander frame. Also make sure the ESD brush is not loose. 2-72 Service Manual - Lexmark 10G1664 | Service Manual - Page 107
. Service tip: If more than a single output expander option is installed, check each one to see if the printer recognizes any single option as being installed. If the printer recognizes any of the output expander options then the base printer autoconnect system is operating correctly and the problem - Lexmark 10G1664 | Service Manual - Page 108
voltage measures approximately 0 V dc. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the control board. 271 Paper jam - Check Bin x, POST complete, first sheet of paper feeds shorted, it may also be necessary to replace the control board. 2-74 Service Manual - Lexmark 10G1664 | Service Manual - Page 109
4060-xxx FRU 2 Output expander control board Action Disconnect the motor cable J4 and check the voltages at J4 on the board. Note: Use caution not to short to adjacent pins on the connector. Pin Status Voltage J4-1 (Motor Idle) +24 V dc J4-2 (Motor Idle) +24 V dc J4-5 (Motor Idle) +5 - Lexmark 10G1664 | Service Manual - Page 110
for the natural curvature in the paper. Reinstall the paper in the correct manner. If the problem persists, it may be necessary to reduce the stack height. Replace both pick rolls if the motor may be failing. If this problems continues, replace the autocompensator assembly. 2-76 Service Manual - Lexmark 10G1664 | Service Manual - Page 111
pick roll or slick spots. If you find a problem, replace the pick roll assembly. Check to ensure the assembly meets recommended paper specifications. Parallel port service check Run the "Parallel Wrap Test" on Diagnostic Test. This test helps isolate the printer from the parallel cable and host. The - Lexmark 10G1664 | Service Manual - Page 112
Printhead assembly Print quality service check Service tip: Before troubleshooting any print quality problems do the following: • Install another print cartridge if available before proceeding with the service checks. • Use Tray 1 to test for print quality of the base printer. • Replace the charge - Lexmark 10G1664 | Service Manual - Page 113
printer ground. All voltages measured during the print cycle are measured with the controller board removed while running the print test. Print quality-all black page Service tip: An all black page is generally caused by a problem cartridge for damage, especially the PC drum contact on the cartridge. - Lexmark 10G1664 | Service Manual - Page 114
4060-xxx Print quality-random marks Service tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll, or transfer roll. Symptom 1 Random marks Action Check the print cartridge for loose or foreign material - Lexmark 10G1664 | Service Manual - Page 115
caution if the printer must receive power in order to perform the task. Replace the transfer roll. Replace the redrive assembly. Replace the FRUs in the following order: • Alignment assembly • Main drive gearbox assembly Replace the FRUs in the following order: • Toner cartridge • Main drive gearbox - Lexmark 10G1664 | Service Manual - Page 116
Service tip: Some background problems can be caused by rough papers, non-Lexmark toner cartridges or if the media texture is set to the rough setting. Some slick or coated papers may also cause background. Some problems occur with printers problems problem correct the problem, replace the the problem, - Lexmark 10G1664 | Service Manual - Page 117
HVPS Action If the problem is just on one printer ground. The resistance measures approximately 0 ohms. If incorrect, make sure the system board is mounted correctly and securely grounded. If correct, replace the system board. Print quality-residual image Service tip: Install a new print cartridge - Lexmark 10G1664 | Service Manual - Page 118
on backside of printed page Service tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the another copy. If the problem continues, replace the FRUs in the following order: • HVPS • System board 2-84 Service Manual - Lexmark 10G1664 | Service Manual - Page 119
User Error message, be sure a Lexmark T63x print cartridge is correctly installed in the printer. The cartridge is easily identified by the contact board on the right side rear of the cartridge. Install another print cartridge before attempting to troubleshoot the printer. Make sure the smart cable - Lexmark 10G1664 | Service Manual - Page 120
service check Note: When removing the stapler mechanism from the option, first remove the staple supply cartridge. Note: When replacing staples in the supply cartridge, discard any old staples in the cartridge and replace with a fresh strip. Problems at the printer top autoconnect. Service Manual - Lexmark 10G1664 | Service Manual - Page 121
4060-xxx Close Finished Side Door displayed-unable to clear or reset message. (POST incomplete) FRU 1 Side cover door 2 Side cover door switch Stapler card assembly Action Check the stapler access door for any signs of damage or broken parts. Make sure the door correctly actuates the stapler side - Lexmark 10G1664 | Service Manual - Page 122
-xxx 990 Service Error Code assembly Drive motor assembly 2 Drive motor assembly (mechanical) Action Turn the printer off, disconnect the motor from J2 and check for continuity between J2 pins . Note: When a 990 Service Error is displayed during POST, the failure is usually in the stapler - Lexmark 10G1664 | Service Manual - Page 123
even if finisher is selected Note: When a 900 Service Error is displayed during POST the failure is usually in the stapler gearbox assembly or stapler cartridge. FRU 1 DC motor in drive gearbox assembly Stapler card assembly Action Turn the printer off, disconnect the motor from J4 and check for - Lexmark 10G1664 | Service Manual - Page 124
release the cartridge holder. 6. Reinstall the stapler assembly with a new stapler cartridge holder and staples. Run the Finisher Feed Test to check the option. If the problem continues, go to step 2. Check the continuity of the cable. If a problem is found, replace the cable. 2-90 Service Manual - Lexmark 10G1664 | Service Manual - Page 125
, replace the old strip of staples with a new strip and try the finisher feed test from the diagnostic menu. Remove the staple cartridge holder from the staple unit and remove the staple unit. Check for any staples that might be in the staple unit mechanism. Check for correct - Lexmark 10G1664 | Service Manual - Page 126
paper, check the wheel for wear, damage, or contamination. If any problem with the wheel is found, replace the wheel. Check to make sure J4 (Accessory) is properly connected to J4 on the board. Turn the printer off, disconnect the motor cable from J4, and check for continuity between Service Manual - Lexmark 10G1664 | Service Manual - Page 127
before checking the toner sensor. This service check is intended to be used when a 929 Service Error displays. FRU 1 Developer drive assembly 2 Front harness cable 3 Toner sensor Action Incorrect operation of the developer drive assembly can cause the printer to display a 929 error code (Toner - Lexmark 10G1664 | Service Manual - Page 128
the printer runs the print test. If the voltage is incorrect, check the continuity of line J22-3 in the front cable harness to the HVPS. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If the problem continues, replace the system board. 2-94 Service - Lexmark 10G1664 | Service Manual - Page 129
aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostics mode Entering Diagnostic Mode: 1. Turn the - Lexmark 10G1664 | Service Manual - Page 130
disk cannot be recovered because too many bad blocks exist on the disk. 4. Press Go or Return/Stop to return to the Device Tests menu. 3-2 Service Manual - Lexmark 10G1664 | Service Manual - Page 131
Emulation Outdated. Time stamps indicate the download emulation and RIP code are incompatible. To help resolve download emulation problems the following steps are necessary to instruct the printer to POR without activating any download emulations. To disable the download emulation: 1. Turn the - Lexmark 10G1664 | Service Manual - Page 132
printer attempts to print the Quick Test Page from the default paper source. If the default paper source only supports Check the Top Margin Offset of the base printer. Duplex Sensor Test This test is used Sensor Test from the Duplex Tests menu. 2. Manually actuate each of the duplex sensors. When the - Lexmark 10G1664 | Service Manual - Page 133
are acceptable. To run the Duplex Motor Test: 1. Select Motor Test from the Duplex Tests menu. The duplex motor test continues to run until the printer is powered off. • The power indicator blinks while the test is running. • The duplex option runs the motor at a high speed and then a low speed - Lexmark 10G1664 | Service Manual - Page 134
the paper is feeding. • "Duplex Feed 2/Feeding" message displays while the paper is feeding through the printer. • "Duplex Feed 2/Clear Paper" message displays when the paper reaches the duplex paper stop position next screen press Menu. 3. Press Return/Stop to exit the Error Log. 3-6 Service Manual - Lexmark 10G1664 | Service Manual - Page 135
code does not have sub error codes. Model and Serial number Printer information Page count Panel display when error occurred Sub error codes Next error code The printed error log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the error log: 1. Select - Lexmark 10G1664 | Service Manual - Page 136
and a CL (Closed) displays in place of an OP. The proper operation of each button can be checked. 3. Press Return/Stop to cancel the test. 3-8 Service Manual - Lexmark 10G1664 | Service Manual - Page 137
4060-xxx SDRAM Memory Test The purpose of this test is to check the validity of SDRAM, both standard and optional. The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly. To run the SDRAM Memory Test: 1. Select SDRAM Memory Test from the menu. The - Lexmark 10G1664 | Service Manual - Page 138
servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer Sensor 2. Once this message displays, the servicer can manually actuate each sensor. The tray empty sensor a pass thru sensor. Tray sensor support by source Source Tray 1 Tray 2 - Lexmark 10G1664 | Service Manual - Page 139
Select Sensor Tests - Standard Bin. "Standard Bin/Full=CL" message displays. Manually actuate the bin sensor by moving the flag in and out of the sensor. test can be run from any input source and will support any size paper or envelope supported by the printer. To run the Output Bin Feed Test: 1. - Lexmark 10G1664 | Service Manual - Page 140
to verify that the printer can feed media to • The media feeds from the default paper source. • The printer feeds a separate piece of media to the standard bin first, Standard Bin's Bin Full Sensor 4. Once the screen is displayed, manually actuate the sensor flag to check the Bin Full Sensor. When - Lexmark 10G1664 | Service Manual - Page 141
bin full sensor (lower part of dual sensor) NF=High-Capacity Stacker near full sensor (upper part of dual sensor) 4. Once the screen is displayed, manually actuate each of the sensors of the high-capacity stacker. When the sensor is closed CL displays, and when the sensor is open OP displays - Lexmark 10G1664 | Service Manual - Page 142
feed and then the pages staple. Note: This test can be run using any of the paper sizes supported by the printer. The media is fed from the selected source and then outputted to the finisher output bin. To run from main menu. 2. Select Sensor Tests from the Finisher Tests menu. 3-14 Service Manual - Lexmark 10G1664 | Service Manual - Page 143
selected. Staple Sensor Test Staple C=CL SL=CL SP=CL H=CL C=Cartridge present sensor SL=Staple low sensor SP=Self-priming sensor H=Home signal sensor sensor Once the screen is displayed for the test you have selected, manually actuate the sensor you want to test. When the sensor is closed CL - Lexmark 10G1664 | Service Manual - Page 144
4060-xxx Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly. The following sensors can be checked: • Toner optical sensor • Input sensor • Output sensor displays again. Print the Quick Test Page on letter or A4 paper. 3-16 Service Manual - Lexmark 10G1664 | Service Manual - Page 145
setup Setting the page count This lets the servicer change the page count from the Diagnostics Menu. This is used whenever the system board is replaced because this board contains the printer NVRAM Memory where the page count is stored. To set the page count: 1. Select Page Count from the Diagnostic - Lexmark 10G1664 | Service Manual - Page 146
problems with paper curl on low grade papers and problems with letterheads on some types of media. The fuser temperature can be adjusted to: NORMAL, LOWER, LOWEST Warm Up Time You can change the amount of time the printer Transfer The transfer can be adjusted to: LOW, MEDIUM, HIGH 3-18 Service Manual - Lexmark 10G1664 | Service Manual - Page 147
: LOW, MEDIUM, HIGH Print tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. Each of the installed options is listed Page from each source to assist in print quality and paper feed problems. Diagnostic aids 3-19 - Lexmark 10G1664 | Service Manual - Page 148
cartridge lockout however a cartridge must be printer off. 2. Press and hold Select and Return. 3. Turn on the printer. 4. Release the buttons once Performing the Self Test displays. 5. The printer Printer configuration information: Printer all the printer settings contained in • Printer information - Lexmark 10G1664 | Service Manual - Page 149
, the counterbalance spring is not to be considered an adjustment for feeding problems. Autoconnect system, paper tray options, envelope feeder-electrical Autoconnect cabling and connectors The printer options make electrical connection automatically, requiring no external cables when the option - Lexmark 10G1664 | Service Manual - Page 150
printer to the duplex option through a ground spring attached to the frame and base of the printer. The ground connection is automatically made when the option is installed below the printer . The paper input sensor is located in the rear of the duplex option under the input paper guide printer - Lexmark 10G1664 | Service Manual - Page 151
the paper reaching the input sensor flag. This error can display due to a problem with the HSYSC signal to or in the printhead. Use the sub error code printer does not reprint these sheets. Error Message 201 Paper Jam - Remove Cartridge This message indicates the paper is jammed between the printer - Lexmark 10G1664 | Service Manual - Page 152
but did leave the printer exit sensor. • 232 Duplex Paper Jam duplex input sensor but did leave the printer exit sensor. • 233 Duplex Paper Jam - Front-A piece of media did not reach the printer input sensor. • 238 Duplex Paper Jam-A piece the finisher, then the printer alternately flashes the primary - Lexmark 10G1664 | Service Manual - Page 153
during the jam clearance procedure. If the sheets are removed, then the printer does not reprint these sheets. Error Message 250 Paper Jam - Check MP A 281 Paper Jam message may also be displayed when there is a problem with the stapler assembly or the stapler card. Note: When the StapleSmart - Lexmark 10G1664 | Service Manual - Page 154
operation. There is no secondary message displayed. Note: After the error has been cleared, the printer does not reprint any pages which existed in the accumulator for stapling. Note: Do not use the Sub Error chart to help diagnose problems when 281, 282, and 283 are displayed. 3-26 Service Manual - Lexmark 10G1664 | Service Manual - Page 155
electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: • Keep the ESD-sensitive part in - Lexmark 10G1664 | Service Manual - Page 156
replace the duplex motor or loosen the motor or drive belt idler pulley. Service tip: Excessive belt tension can result in stalling the duplex motor. Too little fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing - Lexmark 10G1664 | Service Manual - Page 157
between sheets of paper as they are fed through the printer. This adjustment reduces the printer overall performance, such as pages per minute, but can a value and run several copies of the media that displays a curl problem. It may take several tries before improvement is noticed. Note: This - Lexmark 10G1664 | Service Manual - Page 158
assembly to be removed from the printer. It is not necessary to completely remove the screw. 4. Install the new alignment assembly. Turn the reference screw clockwise with a 7 mm nut driver until it touches the back of on a new test page until you obtain the results you want. 4-4 Service Manual - Lexmark 10G1664 | Service Manual - Page 159
4060-xxx Step B Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings should be within the range specified in "Print registration" on page 3-16. The reference screw can be adjusted without loosening the locknut. Turn the screw a few turns and - Lexmark 10G1664 | Service Manual - Page 160
locations, and quantities necessary to service the printer. Each screw callout in the ITC) board stacker support to right side frame paper alignment assembly toner cartridge guide track left side 1 attach 2 mounting 2 mounting 2 attach 3 attach 2 mounting 2 attach 6 4-6 Service Manual - Lexmark 10G1664 | Service Manual - Page 161
Reference number Screw type M3x6 mm Taptite M3x8 mm Taptite Location outer shield inner redrive deflector interconnect board to center pan system board to interconnect board ground system board to inner shield system board (back) lower stacker duct ground cables to ground (center pan-front) - Lexmark 10G1664 | Service Manual - Page 162
pan right side frame to right side cover M3.5x12 mm Plastite Thread Forming with washer printhead to EP frame mounting 1 attach 3 attach 1 attach 1 mounting 3 4-8 Service Manual - Lexmark 10G1664 | Service Manual - Page 163
or electronic board or assembly for personal safety and to prevent damage to the printer. Use the handholds on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down. Note: Some removal procedures require removing cable ties. You must replace - Lexmark 10G1664 | Service Manual - Page 164
Right cover removal 1. Remove the redrive cap 2. Remove the redrive assembly. 3. Open the upper and lower front covers. 4. Remove the print cartridge. 5. Remove the right cover mounting screw (A) and release the cover latch (B). A(324) B 6. Remove the right side cover mounting screw (C). C(324 - Lexmark 10G1664 | Service Manual - Page 165
7. Remove the right side cover. 4060-xxx Cover retainers Note: When replacing the right side cover, make sure the cover retainers are correctly located in the appropriate slots in the right side frame. Repair information 4-11 - Lexmark 10G1664 | Service Manual - Page 166
4060-xxx Upper front cover removal 1. Raise the upper front cover. 2. Remove the upper front cover mounting screws (A). A(323) 4-12 Service Manual - Lexmark 10G1664 | Service Manual - Page 167
latches, lift off the cover. Note: When removing the cover, hold the upper and lower latch and spring to prevent them from falling into the printer. Note: Use caution to avoid scratching or damaging the operator panel lens cover. 4. Set aside the operator panel overlay. Note: Be sure to replace the - Lexmark 10G1664 | Service Manual - Page 168
4060-xxx Laser cover removal 1. Remove the left door. 2. Remove the right cover. See "Right cover removal" on page 4-10. 3. Remove the paper support. 4. Remove the redrive cap. 5. Press the fuser wiper cover latch and remove the cover. 6. Loosen screw (A) and remove the two screws (B) on the right - Lexmark 10G1664 | Service Manual - Page 169
4060-xxx 8. Remove the paper bin full sensor flag assembly from the mounting bracket. See "Paper bin full sensor flag assembly removal" on page 4-54. 9. Unlatch the front right and front cover posts (left) and remove cover. 10. Remove fan grill cover. Note: Be sure to reseat the fan grill cover - Lexmark 10G1664 | Service Manual - Page 170
exert firm pressure to snap the bevel gear out. Warning: Whenever the main drive assembly is removed from the printer, it must be handled very carefully. Do not allow any of the gears to come in contact with any come in contact with the grease in the main drive assembly gears. 4-16 Service Manual - Lexmark 10G1664 | Service Manual - Page 171
Installation 1. Lubricate areas that engage the journal (A). 4060-xxx A B 2. Insert the bottom portion and press or pull into position. Note: You should hear two distinct snaps. If you only hear one, the bevel gear is only partially engaged and you should continue to press until the second snap - Lexmark 10G1664 | Service Manual - Page 172
shield. 6. Remove the screws that hold the shield to the communications board. Note: Retain the shield and screws to install on the new board. 4-18 Service Manual - Lexmark 10G1664 | Service Manual - Page 173
4060-xxx Cover closed switch/cable removal Note: Pay careful attention to the cable routing through the printer before you remove the cover closed switch and cable assembly. 1. Remove the left cover, upper front cover, and outer system board shield. 2. Disconnect the cover - Lexmark 10G1664 | Service Manual - Page 174
. 4. Remove the upper front cover hinge assembly. See "Upper front cover hinge assembly removal" on page 4-62. 5. Remove the multipurpose tray/lower deflector assembly. 4-20 Service Manual - Lexmark 10G1664 | Service Manual - Page 175
Remove the paper alignment assembly. See "Paper alignment assembly removal" on page 4-52. 7. Remove the left side frame mounting screws (A). A(102) 8. Place the printer on its back and remove the left side frame mounting screws (B). 9. Remove the left side frame. B(104) Repair information 4-21 - Lexmark 10G1664 | Service Manual - Page 176
4060-xxx Right side frame CAUTION: Unplug the printer before you begin. 1. Remove the right side cover. screw (A), disconnect the sensor cable and remove the toner sensor. 7. Remove the smart cartridge contact assembly mounting screw (C) 8. Remove the right side frame mounting screws (B) and remove - Lexmark 10G1664 | Service Manual - Page 177
Fuser assembly removal CAUTION: Unplug the printer before you begin. 4060-xxx 1. Remove the redrive assembly. See "Redrive assembly removal" on page 4-57. 2. Remove the fuser mounting screws (A). A A 3. Disconnect the AC fuser - Lexmark 10G1664 | Service Manual - Page 178
LVPS, under the clip (G), and through the notch in the frame (H) F G H 2. Route the fuser lamp cable through the opening in the fuser as shown (J). J 4-24 Service Manual - Lexmark 10G1664 | Service Manual - Page 179
Fuser cover removal CAUTION: Unplug the printer before you begin. 1. Remove the fuser assembly. See "Fuser assembly removal" on page 4-23. 2. Note the thermistor cable (A) routing. 4060-xxx A 3. Clip the cable tie (B) - Lexmark 10G1664 | Service Manual - Page 180
4060-xxx 4. Disconnect the AC fuser lamp cable (A) from the top left side of the fuser cover. A 5. Remove the two screws (C) from the right side fuser lamp contact cover. 6. Release the latch (D) and remove the cover. D C(202) 4-26 Service Manual - Lexmark 10G1664 | Service Manual - Page 181
7. Remove screw (A) that attaches the fuser lamp contact to the fuser cover. 4060-xxx B A 8. Remove the two screws (B), one on each side of the fuser, that attach the fuser upper cover assembly to the fuser frame. 9. Remove the fuser laser cover. Repair information 4-27 - Lexmark 10G1664 | Service Manual - Page 182
Sensor 3. Unplug the sensor from the fuser control board. 4. Remove the sensor from the lower exit guide assembly. Fuser lamp removal 1. Remove the fuser assembly. See "Fuser assembly removal" on page 4-23. contact may occur. A(202) 4. Remove the left lamp contact assembly. 4-28 Service Manual - Lexmark 10G1664 | Service Manual - Page 183
4060-xxx 5. Remove the fuser lamp. Warning: The lamp is under spring tension and care must be used when removing the lamp from the fuser. Grip the lamp by the ceramic end piece and remove it from the fuser assembly. Be careful not to touch the glass as skin oils and acids can reduce the life of the - Lexmark 10G1664 | Service Manual - Page 184
plate ground wire to the center pan. 6. Remove the fuser transfer plate. 7. Remove the screw that attaches the deflector cable to the transfer plate. 4-30 Service Manual - Lexmark 10G1664 | Service Manual - Page 185
High voltage power supply removal CAUTION: There is a danger from hazardous voltage in the area of the printer where you are working. Unplug the printer before you begin, or use caution if the printer must receive power in order to perform the task. 1. Remove the inner paper deflector. See "Inner - Lexmark 10G1664 | Service Manual - Page 186
4060-xxx 5. Remove the HVPS mounting screws (C). C(235) 6. Slide the HVPS to the left to release the mounting tab from the center pan and remove the HVPS. 4-32 Service Manual - Lexmark 10G1664 | Service Manual - Page 187
assembly removal" on page 4-33. 5. Gently pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer and remove the deflector. A 6. Disengage the two latches (B) on the upper part of the deflector from the upper edge of the frame (C) and lift - Lexmark 10G1664 | Service Manual - Page 188
1. Remove the inner paper deflector assembly. 2. Disconnect the input sensor cable from the input sensor. 3. Release the input sensor from its mounting and remove. 4-34 Service Manual - Lexmark 10G1664 | Service Manual - Page 189
shield removal" on page 4-52. 4. Disconnect the autocompensator motor cable from the system board (J28). 5. Cut cable tie (A) on left side. 4060-xxx A 6. Place the printer on its back. Repair information 4-35 - Lexmark 10G1664 | Service Manual - Page 190
on the bottom of the printer and disconnect the autocompensator arm bias spring (B). Note: When you remove the spring, note the larger loop attaches to the side frame. 8. Remove the C-clip (C) that rests against the right side frame from the autocompensator pivot shaft. A C B 4-36 Service Manual - Lexmark 10G1664 | Service Manual - Page 191
9. Disconnect the autocompensator sensor cable (D) from the assembly. 10. Remove the autocompensator assembly mounting screw (E). 4060-xxx D E 11. Remove the integrated tray autocompensator assembly. Note: When you reinstall the assembly, reinstall the cable tie. Repair information 4-37 - Lexmark 10G1664 | Service Manual - Page 192
4060-xxx Integrated tray autocompensator pick roll assembly removal 1. Remove the integrated tray and look underneath the printer for the autocompensator arm. Pull the arm down. 2. Press on the end of the tab and pull the pick roll off the arm. Repeat this - Lexmark 10G1664 | Service Manual - Page 193
4060-xxx Installation 1. Remove the new pick rolls from their packaging. 2. Pull the autocompensator arm down. Locate the recessed area on the pick roll and align it with the tab on the arm. There are two arrows on each pick roll. Make sure the bottom arrow faces you as you align the recessed area - Lexmark 10G1664 | Service Manual - Page 194
4060-xxx Interconnect board assembly removal CAUTION: Unplug the printer before you begin. Warning: Observe all ESD precautions while handling ESD-sensitive parts. See "Handling disconnect the LVPS cable from CN2 (A). A 4. Disconnect cables J4 and J5 from the interconnect board. 4-40 Service Manual - Lexmark 10G1664 | Service Manual - Page 195
5. Place the printer on its side and remove the mounting screws (A). 4060-xxx A(202) 6. Remove the interconnect board assembly. Internal tray card (ITC)/Paper size sensing board removal 1. - Lexmark 10G1664 | Service Manual - Page 196
bottom pan. A(203) 4. Pull the LVPS assembly far enough out from the right side of the printer to disconnect the fuser lamp cable. Warning: The LVPS assembly may be difficult to remove from the printer. Do not use excessive force in the removal. 5. Remove the LVPS access plate. 4-42 Service Manual - Lexmark 10G1664 | Service Manual - Page 197
6. Disconnect the interconnect card cable from the LVPS (A). 4060-xxx A 7. Remove the LVPS. Repair information 4-43 - Lexmark 10G1664 | Service Manual - Page 198
4060-xxx Main drive assembly removal 1. Remove the inner shield. See "Inner shield removal" on page 4-34. 2. Remove the gear guard (A). A 3. Remove the developer drive assembly. See "Developer drive assembly removal" on page 4-20. 4-44 Service Manual - Lexmark 10G1664 | Service Manual - Page 199
Remove the power takeoff shaft and spring (A) through the bottom of the printer. 5. Remove all cables from the cable clamps (B) on the main main drive assembly. Warning: Whenever the main drive assembly is removed from the printer it must be handled very carefully. Do not allow any of the gears to - Lexmark 10G1664 | Service Manual - Page 200
(A) and disconnect the cable from the system board at connector J7. B A B 5. Release the four latches (B) and remove the fan from the left side frame. 4-46 Service Manual - Lexmark 10G1664 | Service Manual - Page 201
4060-xxx Multipurpose tray/lower deflector assembly removal 1. Open the multipurpose tray to a position that allows the left and right tray hinge slots (A) to align with the rectangular mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts. Warning: Be - Lexmark 10G1664 | Service Manual - Page 202
4060-xxx Operator panel assembly removal 1. Remove the upper front cover. 2. Remove the operator panel overlay (A) and set it aside. A 3. Gently press the operator panel lens tabs to loosen the operator panel. 4. Disconnect the operator panel cable and remove the operator panel. 4-48 Service Manual - Lexmark 10G1664 | Service Manual - Page 203
4060-xxx Operator panel bezel removal 1. Remove the upper front cover. See "Upper front cover removal" on page 4-12. 2. With the upper front cover upside down on a soft, non-scratching surface, release the clips and remove the operator panel lens cover. Note: Use caution to avoid scratching or - Lexmark 10G1664 | Service Manual - Page 204
removal Note: Pay careful attention to the cable routing through the printer before you remove the operator panel cable. 1. Remove the left cover and cover closed switch cables. 7. Remove the old cable from the printer. 8. Plug the new operator panel cable into the operator panel. 9. Snap the operator - Lexmark 10G1664 | Service Manual - Page 205
and other paper feed options to access the failing optional paper tray assembly. Paper tray autocompensator assembly removal 1. Remove the printer and other paper feed options. 2. Disconnect the autocompensator assembly bias spring from the tray frame. 3. Disconnect the autocompensator assembly - Lexmark 10G1664 | Service Manual - Page 206
assembly. See "Inner paper deflector assembly removal" on page 4-33. 3. Release the input paper sensor from its mounting and remove. 4. Remove the left door. 4-52 Service Manual - Lexmark 10G1664 | Service Manual - Page 207
5. Remove the paper alignment assembly mounting screws (A). 4060-xxx 6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame and remove the screw. B 7. Remove the paper alignment assembly. Note: Do the "Paper alignment assembly adjustment" on page 4-4 when you - Lexmark 10G1664 | Service Manual - Page 208
the cover. 5. Loosen screw (A) and remove the two screws (B) on the left side. B(102) A(323) 6. Remove the mounting screws (C) from the right side. C(102) 4-54 Service Manual - Lexmark 10G1664 | Service Manual - Page 209
7. Lift the right corner of the laser assembly cover to access the flag. 4060-xxx 8. Use your thumb to bend the paper full flag assembly slightly to unlatch it from the mounting bracket. Pick roll removal (MPT) 1. Remove the upper paper deflector. See "Upper paper deflector assembly removal" on - Lexmark 10G1664 | Service Manual - Page 210
machine type are different. See "Printhead 1 (000/010)" on page 7-10, "Printhead 2 (200/210)" on page 7-11, and "Printhead 3 (400/410)" on page 7-12. 4-56 Service Manual - Lexmark 10G1664 | Service Manual - Page 211
4060-xxx Redrive assembly removal 1. Remove the redrive door assembly. 2. Remove the redrive exit cover. 3. Remove the redrive assembly mounting screws (A). 4. Release the redrive assembly mounting latches (B) and remove the redrive assembly. Repair information 4-57 - Lexmark 10G1664 | Service Manual - Page 212
52. 4. Disconnect smart cartridge cable from connector J19 on the system board. 5. Remove smart cartridge contact assembly mounting screw (B). Note the routing of the smart cartridge contact assembly cable (C). board. 3. Remove all features and options from the interconnect board. 4-58 Service Manual - Lexmark 10G1664 | Service Manual - Page 213
4. Remove the five system board mounting screws (A). 5. Remove the USB screw (B) 4060-xxx B A(232) 6. Remove the system board. 7. Remove the communications board mounting screw (C). A(102) D(201) E C(232) 8. Remove the communications board shield mounting screw (D). 9. The communications - Lexmark 10G1664 | Service Manual - Page 214
board mounting screw. 6. Install the system board. 7. Insert the USB screw. 8. Replace the five mounting screws. 9. Replace the features/options and reconnect all cables. 4-60 Service Manual - Lexmark 10G1664 | Service Manual - Page 215
the toner sensor cable and remove the toner sensor. 4060-xxx A(102) Transfer roll assembly removal 1. Open the upper front cover and remove the print cartridge. 2. Unsnap the transfer roll assembly from the left pivot arm. 3. Lift the transfer roll assembly toward the left and remove it from the - Lexmark 10G1664 | Service Manual - Page 216
assembly toward the left to clear the right upper cover pivot arm from the mounting bracket. 10. Remove the upper front cover hinge assembly. 4-62 Service Manual - Lexmark 10G1664 | Service Manual - Page 217
4060-xxx Upper paper deflector assembly removal 1. Open the multipurpose tray and remove the tray from the two mounting posts. 2. Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right. 3. Remove the upper deflector assembly. Repair - Lexmark 10G1664 | Service Manual - Page 218
4060-xxx 4-64 Service Manual - Lexmark 10G1664 | Service Manual - Page 219
5. Connector locations Autoconnect Connector Bottom autoconnect 1 2 3 Front autoconnect 6 5 4 1 2 3 Top autoconnect 6 5 4 1 2 34 8765 4060-xxx Pin no. 1 2 3 4 5 6 Signal (static) +24 V dc 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc 1 0 V dc 2 0 V dc 3 0 V dc 4 +5 V dc 5 0 V - Lexmark 10G1664 | Service Manual - Page 220
Fuser Board (not a FRU) 1 J2 1 J1 1 J4 1 J5 1 J6 Connectors J1-System board J2-Narrow media sensor J3-N/A J4-Solenoid J5-Exit sensor J6-Thermistor 5-2 Service Manual - Lexmark 10G1664 | Service Manual - Page 221
High-capacity output stacker board 1 J6 MS J6 connector jumper locations High-capacity stacker board Upper unit board Lower unit board Pin 1 Pin 2 X X Not used X Pin 3 Not used X 4060-xxx Connector J1A Autoconnect J1B J2A Autoconnect J2B J3 Pass thru sensor J4 DC motor J5 Bin full/near - Lexmark 10G1664 | Service Manual - Page 222
4060-xxx High voltage power supply Connector CN1 System board T302 JC1 Chg JC2 JC3 PCD JC4 JC5 Dev JC6 JC7 TAR JC8 JC9 Dr.B JC10 1 CN1 CN no. 1 2 3 4 5 6 7 8 Signal Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT 5-4 Service Manual - Lexmark 10G1664 | Service Manual - Page 223
Interconnect board 200/210/400/410 1 J2 BAR CODE AREA J1 U3 J11 J12 000/010 1 J3 4 11 J4 J5 +24V F1 +5V F2 J7 1 J2 BAR CODE AREA J1 U3 J11 1 J3 4 11 J4 J5 +24V F1 +5V F2 J7 4060-xxx Connector J1 System board (comm board) J2 LVPS J3 LVPS J4 Autoconnect J5 Autoconnect J6 Autoconnect BTM/ - Lexmark 10G1664 | Service Manual - Page 224
8 +24 V dc 9 Heat on 10 +5 V dc 11 +5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 +24 V dc 17 ZC Out* 18 +42 V dc 5-6 Service Manual - Lexmark 10G1664 | Service Manual - Page 225
Output expander control board 1 J6 MS 4060-xxx Connector J1A Autoconnect J1B J2A Autoconnect J2B J3 Pass thru sensor J4 DC motor J5 Bin full/near full dual sensor J6 Jumper connector Pin no. 1 2 3 1 2 3 4 5 1 2 3 1 2 3 4 1 2 3 1 2 3 4 5 6 1 2 3 4 5 1 2 3 Signal +24 V dc Ground +5 V dc Prtxdin - Lexmark 10G1664 | Service Manual - Page 226
Ground fdmtr1 fdmtr2 Ground Ground tachft 5Vptt stpmtrstpmtrstpmtr+ stpmtr+ crtprsntstplow+ 'stpphomoGround 5Vstpl stprimed+24 V dc accmtrGround Ground tacha+ 5Vptt Sol1+24 V dc Ground pfrinstp+ 5Vsnsr2 5-8 Service Manual - Lexmark 10G1664 | Service Manual - Page 227
Staple card assembly (continued) 1 J14B 1 J14A J13 1 J12 1 1 J10 J9 1 J8 1 J7 J15 1 J6 1 J5 1 1 J1A J4 1 1 J1B 1 J2 1 J3 4060-xxx Connector J7 Right side sensor board J8 Solenoid J9 Bin empty sensor J10 Left side sensor board J12 Pass thru sensor J13 Cover open switch J14A J14B J15 - Lexmark 10G1664 | Service Manual - Page 228
4060-xxx System board-non-network 11 1 11 J9 J11 J14 J15 J19 J7 1 J5 1 1 J4 J22 1 +42V +5V HEAT +24V 1+3 3V GND 11 J24 1 J26 J32 J34 J29 J31 11 1 1 J28 1 J3 1 J2 OPTION CARD OPTION CARD FRU No XXXXXX J27 J8 J10 50 99 49 100 J13 J16 1 J20 5-10 Service Manual - Lexmark 10G1664 | Service Manual - Page 229
System board-network 11 1 11 J9 J11 J14 J15 J19 J7 1 J5 1 1 J4 J22 1 +42V +5V HEAT +24V 1+3 3V GND 11 J24 1 J26 J32 J34 J29 J31 11 1 1 J28 1 J3 1 J2 4060-xxx OPTION CARD OPTION CARD FRU No XXXXXX J27 J8 J10 50 99 49 100 J13 J16 1 J23 Connector locations 5-11 - Lexmark 10G1664 | Service Manual - Page 230
closed switch J4 Printhead (HSYNC) J5 Printhead (mirror motor) J6 Printhead fan (400/410) J7 Main fan J8 SDRAM memory J9 Cartridge fan J10 SDRAM memory J11 Output level (output bin sensor) J12 (not used) Pin no. 1 2 3 4 5 6 7 8 1 1 HOP FULL* 2 Ground 3 HOP LED 4 Ground 1 5-12 Service Manual - Lexmark 10G1664 | Service Manual - Page 231
page 5-11) Connector J13 USB connector J14 Fuser DC J15 Operator Panel J16 (not used) J17 (not used) J18 (not used) J19 Smart cartridge J20 Parallel port (not used for network model) Pin no. J1 G12 1 2 3 4 J1 G2 1 2 3 4 5 6 7 8 1 2 3 4 5 Signal Ground USB +5 USB MINUS 2 USB PLUS 3 Ground Ground - Lexmark 10G1664 | Service Manual - Page 232
"System board-network" on page 5-11) Connector J22 HVPS J23 (not used for non-network model) input sensor cartridge sensor Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 13 Signal ATSERVO TXCURPWM TXENABLE TDXPWM 6 DIR 7 BLDC HALL 8 BLDC LOCK 9 Ground 10 Ground 11 +24V dc 5-14 Service Manual - Lexmark 10G1664 | Service Manual - Page 233
4060-xxx System board-non-network and network (see "System board-non-network" on page 5-10 or "System board-network" on page 5-11) Connector J25 Autocomp motor J26 MPF paper out J27 (not used) J28 Autocompensator J29 Bottom options J30 (not used) J31 top options J32 MPF pick solenoid J33 Ethernet - Lexmark 10G1664 | Service Manual - Page 234
SDRAM (on board) autocomp motor Pin no. 1 2 3 4 5 6 7 8 9 10 Signal PSIZE2 Ground PSIZE1 PSIZE3 Ground TRAY1 POUT TRAY1 PLOW* +3.3V dc ENCODER +5V dc connector 5-16 Service Manual - Lexmark 10G1664 | Service Manual - Page 235
printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance. Safety inspection guide The purpose of this inspection guide any non-Lexmark attachments. Lubrication specifications No requirements for this printer. Scheduled maintenance - Lexmark 10G1664 | Service Manual - Page 236
4060-xxx 6-2 Service Manual - Lexmark 10G1664 | Service Manual - Page 237
catalog uses the last three digits of the type to identify model specific replacement FRUs. Model name Lexmark T630 Lexmark T630n Lexmark T632 Lexmark T632n Lexmark T634 Lexmark T634n Configuration Non-network Network Non-network Network Non-network Network Machine type 4060-000 4060-010 4060 - Lexmark 10G1664 | Service Manual - Page 238
4060-xxx Assembly 1: Covers 1 2 4 3 4 18 17 16 3 5 15 14 13 12 11 8 9 10 6 7 7-2 Service Manual - Lexmark 10G1664 | Service Manual - Page 239
assembly, 500-sheet output, 200/210/400/410 1 Support, paper 1 Hinge, upper front cover 1 Cover, , TLI/ID/serial number-blank 1 Upper front cover with Lexmark logo 1 Latch, upper cover 1 Cover assembly, lower front left door, 250 1-slot, 000/010 1 Cartridge load spring 1 Switch, cover closed w/cable - Lexmark 10G1664 | Service Manual - Page 240
4060-xxx Assembly 2: Frame 1 8 3 7 4 1 2 3 6 4 5 7-4 Service Manual - Lexmark 10G1664 | Service Manual - Page 241
Assembly 2: Frame 1 Asmindex 2-1 1 2 3 4 5 6 7 8 Part number 56P1322 56P1347 56P1320 99A1540 99A0263 99A1518 99A1538 99A1517 56P1321 Units Description 1 Frame, EP module, 000/010 1 Frame, EP module, 200/210/400/410 1 Right side frame assembly 4 Nut plate, frame extension, 200/210/400/410 4 Parts - Lexmark 10G1664 | Service Manual - Page 242
4060-xxx Assembly 3: Frame 2 38 1 31 30 37 32 33 2 36 35 29 28 27 26 25 24 23 5 22 4 5 34 7 3 6 8 9 10 21 20 14 85 8 19 18 16 11 5 15 13 12 14 8 17 7-6 Service Manual - Lexmark 10G1664 | Service Manual - Page 243
drum (1) • Contact, charge roll (1) • Block, contact mounting (4) • Screw, contact mounting (5) 1 Spring, tray bias 2 Spring, cartridge hold down 1 Tray bias arm assembly 2 Roller, developer support 1 Deflector, upper PF 1 Deflector, inner, 000/010 1 Deflector, inner, 200/210/400/410 1 Sensor, input - Lexmark 10G1664 | Service Manual - Page 244
4060-xxx Assembly 3 (cont.): Frame 2 38 1 31 30 37 32 33 2 36 35 29 28 27 26 25 24 23 5 22 4 5 34 7 3 6 8 9 10 21 20 14 85 8 19 18 16 11 5 15 13 12 14 8 17 7-8 Service Manual - Lexmark 10G1664 | Service Manual - Page 245
, 500-sheet, 200/210/400/410 1 Door assembly, redrive 250 sheet 1 Flag, output paper level, 000/010 1 Flag, output paper level, 200/210/400/410 1 Guide, extension 1 Clip, external ground 17 Parts packet, screw 4060-xxx Parts catalog 7-9 - Lexmark 10G1664 | Service Manual - Page 246
56P1388 Units 1 3 1 1 1 Description Cable, laser Parts packet, screw (printhead mounting) Printhead assembly (includes all cables), 000/010 Cable, HSYNC Cable, mirror motor, 000/010 7-10 Service Manual - Lexmark 10G1664 | Service Manual - Page 247
Assembly 5: Printhead 2 (200/210) 1 2 3 2 Top View 4 4060-xxx 200/210 Bottom View Asmindex 5-1 2 3 4 Part number 56P1386 99A0263 56P1443 56P1387 Units 1 3 1 1 Description Cable, laser Parts packet, screw (printhead mounting) Printhead assembly (includes all cables), 200/210 Cable, HSYNC - Lexmark 10G1664 | Service Manual - Page 248
6-1 2 3 4 Part number 56P1386 99A0263 56P1854 56P1387 Units 1 3 1 1 Description Cable, laser Parts packet, screw (printhead mounting) Printhead assembly (includes all cables), 400/410 Cable, HSYNC 7-12 Service Manual - Lexmark 10G1664 | Service Manual - Page 249
Assembly 7: Paper feed-autocompensator 4060-xxx 7 6 5 4 3 2 1 Asmindex 7-1 1 2 2 3 4 4 5 6 7 Part number 56P1325 56P1326 56P1337 56P1331 99A0070 56P1324 56P1323 99A0263 56P1406 56P1382 Units 1 1 1 1 2 1 1 1 1 1 Description Pick arm assembly (500-sheet), 200/210/400/410 Pick arm assembly (250- - Lexmark 10G1664 | Service Manual - Page 250
4060-xxx Assembly 8: Paper feed-multipurpose feeder 1 2 3 13 12 4 11 10 7 9 5 8 5 6 7 7-14 Service Manual - Lexmark 10G1664 | Service Manual - Page 251
Assembly 8: Paper feed-multipurpose feeder Asmindex 8-1 2 3 4 5 6 7 7 8 9 10 11 12 13 NS Part number 99A0075 99A0071 99A0076 99A0084 56P1352 99A1531 99A0263 99A0263 99A2071 99A0081 99A0263 99A0073 99A0074 99A2027 99A0267 Units Description 1 Screw, socket set M4X5 mm 1 Arm assembly, MPF 1 Pick - Lexmark 10G1664 | Service Manual - Page 252
4060-xxx Assembly 9: Paper feed-alignment 1 2 3 4 7-16 Service Manual - Lexmark 10G1664 | Service Manual - Page 253
Assembly 9: Paper feed-alignment Asmindex 9-1 2 3 4 NS Part number 56P1327 99A0263 56P1349 56P1346 99A0263 Units Description 1 Alignment assembly paper feed 1 Parts packet, screw (clip ref ground mounting) 1 Clip, reference ground 1 Parts packet (reference adjust) • Screw, paper reference adjust - Lexmark 10G1664 | Service Manual - Page 254
4060-xxx Assembly 10: Integrated paper tray-250-sheet 10 11 9 8 7 1 2 4 3 5 6 7-18 Service Manual - Lexmark 10G1664 | Service Manual - Page 255
Assembly 10: Integrated paper tray-250-sheet Asmindex 10-1 2 3 4 5 6 7 8 9 10 11 Part number 99A1536 99A1601 99A2160 99A0120 99A1894 99A0119 99A1812 99A0121 99A0126 99A0124 99A0127 Units Description 1 Tray, integrated 250-sheet 1 Latch, back restraint 1 Restraint, back 250-sheet tray 2 Restraint - Lexmark 10G1664 | Service Manual - Page 256
4060-xxx Assembly 11: Integrated paper tray-500-sheet 10 9 7 8 6 5 11 1 4 2 3 7-20 Service Manual - Lexmark 10G1664 | Service Manual - Page 257
Assembly 11: Integrated paper tray-500-sheet Asmindex 11-1 2 3 4 5 6 7 8 9 10 11 Part number 99A1576 99A1895 99A0292 99A1812 99A1583 99A0126 99A0124 99A1582 99A0120 99A2093 99A1601 Units Description 1 Tray assembly 500-sheet 1 Restraint, side 4 Strip, wear 1 Label, tray option number 1 Plate, 500 - Lexmark 10G1664 | Service Manual - Page 258
4060-xxx Assembly 12: Drives-Main drive and developer drive 1 7 4 5 3 2 6 7-22 Service Manual - Lexmark 10G1664 | Service Manual - Page 259
Assembly 12: Drives-Main drive and developer drive Asmindex 12-1 1 1 2 2 3 4 5 6 7 NS NS Part number 56P1330 56P1332 56P1858 99A0134 99A1569 99A0275 56P2136 99A1544 99A2081 99A0263 99A0263 99A0263 Units 1 1 1 1 1 1 1 1 1 3 4 3 Description Gearbox, w/motor, 000/010 Gearbox, w/motor, 200/210 - Lexmark 10G1664 | Service Manual - Page 260
4060-xxx Assembly 13: Hot roll fuser 1 5 9 2 3 4 5 6 7 8 7 7-24 Service Manual - Lexmark 10G1664 | Service Manual - Page 261
4060-xxx Assembly 13: Hot roll fuser Asmindex 13-1 1 1 1 1 1 2 3 4 5 6 6 7 8 9 Part number 56P1333 56P1338 56P1335 56P1859 56P1860 56P1861 99A1658 56P1415 56P1348 99A0263 56P1362 56P1363 56P1402 56P1403 Units Description 1 Fuser assembly w/115V lamp, 000/010/200/210 1 Fuser assembly w/100V lamp, - Lexmark 10G1664 | Service Manual - Page 262
4060-xxx Assembly 14: Transfer/charging 1 2 4 3 10 5 6 9 7 8 7-26 Service Manual - Lexmark 10G1664 | Service Manual - Page 263
Assembly 14: Transfer/charging Asmindex 14-1 2 3 4 5 6 7 8 9 10 NS NS Part number 99A0512 99A1017 99A1555 99A0513 56P1357 99A0349 99A0184 99A0185 99A0181 99A1578 99A0263 99A0267 Units 1 1 1 1 1 1 1 1 1 1 1 1 Description Parts kit, charge roll link asm, left side Roll assembly, charge Bushing, - Lexmark 10G1664 | Service Manual - Page 264
4060-xxx Assembly 15: Electronics-power supplies 7 6 5 1 4 32 7-28 Service Manual - Lexmark 10G1664 | Service Manual - Page 265
4060-xxx Assembly 15: Electronics-power supplies Asmindex 15-1 1 1 1 2 2 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 5 6 7 Part number 56P1369 56P1371 56P1372 56P1374 56P1365 56P1367 56P1366 56P1364 43H5248 1332514 1339538 1339537 1339539 1339552 1339540 1339541 1342534 1339543 1339545 1342530 43H5546 - Lexmark 10G1664 | Service Manual - Page 266
4060-xxx Assembly 16: Electronics-card assemblies 1 2 10 9 8 7 6 3 4 5 4 7-30 Service Manual - Lexmark 10G1664 | Service Manual - Page 267
Assembly 16: Electronics-card assemblies Asmindex 16-1 1 1 2 2 2 3 4 5 6 6 6 7 8 9 10 Part number 56P2131 56P2133 56P1852 56P2130 56P2132 56P1853 56P1340 56P1339 56P1850 56P1740 56P1422 56P1445 56P1444 99A0426 99A0263 Units Description 1 System board assembly (non-network), 000 includes 56P1444 1 - Lexmark 10G1664 | Service Manual - Page 268
4060-xxx Assembly 17: Electronics-shields 3 5 4 1 2 9 3 6 4 1 7 8 2 7-32 Service Manual - Lexmark 10G1664 | Service Manual - Page 269
Assembly 17: Electronics-shields Asmindex 16-1 2 3 4 5 6 7 8 9 Part number 99A0263 56P1341 99A0263 99A0263 56P1344 56P1342 99A1611 56P1343 56P1345 Units Description 1 Parts packet, screw (INA cover mounting) 1 Cover, INA flat (blank) 6 Parts packet, screw (outer shield mounting) 1 Parts packet, - Lexmark 10G1664 | Service Manual - Page 270
4060-xxx Assembly 18: Cabling diagrams 1 1 2 3 7 8 7 4 5 4 6 7-34 Service Manual - Lexmark 10G1664 | Service Manual - Page 271
18: Cabling diagrams 1 Asmindex 18-1 2 3 4 5 5 6 7 7 8 Part number 56P1408 56P1360 56P1391 56P1382 56P1326 56P1325 56P1383 56P1400 56P1401 56P1384 Units Description 1 Cartridge fan 1 Fan, main w/cable 1 Sensor, standard bin level with cable 1 Int. card/autocomp card cable (paper low/out sensors - Lexmark 10G1664 | Service Manual - Page 272
4060-xxx Assembly 19: Cabling diagrams 2 6 2 1 3 HVPS 4 5 LVPS 7-36 Service Manual - Lexmark 10G1664 | Service Manual - Page 273
Assembly 19: Cabling diagrams 2 Asmindex 19-1 2 3 4 5 6 NS Part number 56P1394 56P1385 56P1395 56P1398 99A2438 56P1399 56P1389 Units Description 1 Switch, cover closed w/cable assembly 1 Cable, front harness (HVPS/input sensor/toner sensor) 1 Switch, cover closed 1 Sensor, MPF cable 1 MPF - Lexmark 10G1664 | Service Manual - Page 274
4060-xxx Assembly 20: Cabling diagrams 3 000/010 200/210 1 1 2 7 2 400/410 1 2 5 3 6 4 7-38 Service Manual - Lexmark 10G1664 | Service Manual - Page 275
Assembly 20: Cabling diagrams 3 Asmindex 20-1 2 3 4 5 6 7 Part number 56P1386 56P1387 56P1390 56P1403 56P1402 56P1405 56P1388 Units Description 1 Cable, laser 1 Cable, HSYNC 1 Cable, system board to fuser board 1 Exit sensor 1 Narrow media sensor 1 Cable, AC fuser lamp to LVPS 1 Cable, mirror - Lexmark 10G1664 | Service Manual - Page 276
4060-xxx Assembly 21: 250-sheet paper tray 7-40 Service Manual - Lexmark 10G1664 | Service Manual - Page 277
Assembly 21: 250-sheet paper tray Asmindex 21-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Part number 99A0263 56P0557 99A0627 99A0263 99A0063 99A0445 99A0448 99A0263 99A1054 99A0277 99A0263 99A0276 99A0451 99A0282 99A0450 99A0350 99A0679 99A0677 - Lexmark 10G1664 | Service Manual - Page 278
4060-xxx Assembly 21 (cont.): 250-sheet paper tray 43 42 41 40 34 46 44 45 39 38 35 37 36 7-42 Service Manual - Lexmark 10G1664 | Service Manual - Page 279
Assembly 21 (cont.): 250-sheet paper tray Asmindex 21-34 35 36 37 38 39 40 41 42 43 44 45 46 NS NS NS NS Part number 99A1536 99A0892 99A0119 99A1829 99A0121 99A0126 99A0127 99A0124 99A1952 99A1537 99A0120 99A0893 99A1601 99A0286 99A1928 99A0438 99A0278 Units Description 1 Tray assembly, 250-sheet - Lexmark 10G1664 | Service Manual - Page 280
4060-xxx Assembly 22: 500-sheet paper tray 45 44 43 46 39 41 42 40 1 38 34 35 37 36 33 25 31 30 32 29 28 27 26 24 23 22 21 6 20 16 15 18 19 17 6 14 13 9 6 2 3 2 4 5 6 7 8 12 10 11 7-44 Service Manual - Lexmark 10G1664 | Service Manual - Page 281
Assembly 22: 500-sheet paper tray Asmindex 22-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Part number 99A0350 99A0263 99A0405 99A0070 99A1636 99A0058 99A0419 99A0026 99A0288 99A0895 99A0292 99A1829 99A1583 99A0126 99A0124 99A1952 - Lexmark 10G1664 | Service Manual - Page 282
4060-xxx Assembly 22 (cont.): 500-sheet paper tray 45 44 43 46 39 41 42 40 1 38 34 35 37 36 33 25 31 30 32 29 28 27 26 24 23 22 21 6 20 16 15 18 19 17 6 14 13 9 6 2 3 2 4 5 6 7 8 12 10 11 7-46 Service Manual - Lexmark 10G1664 | Service Manual - Page 283
Assembly 22 (cont.): 500-sheet paper tray Asmindex 22-40 41 42 43 44 45 46 NS NS NS NS Part number 99A0286 99A1664 99A0273 99A0279 99A0281 99A1702 99A1645 99A0452 99A1665 99A1667 99A1929 Units Description 1 Spring, backup roller 1 Bellcrank, roller release 1 Gear, bevel 1 Bearing, drive shaft 1 - Lexmark 10G1664 | Service Manual - Page 284
4060-xxx Assembly 23: Duplex option 1 7-48 Service Manual - Lexmark 10G1664 | Service Manual - Page 285
Assembly 23: Duplex option Asmindex 23-1 1 Part number 56P1414 56P1416 Units Description 1 250 duplex assembly 1 500 duplex assembly 4060-xxx Parts catalog 7-49 - Lexmark 10G1664 | Service Manual - Page 286
4060-xxx Assembly 24: Envelope feeder 14 1 2 9 8 7 13 12 11 10 4 3 5 6 7-50 Service Manual - Lexmark 10G1664 | Service Manual - Page 287
99A0484 99A0491 99A0400 99A0489 99A0487 Units Description 1 Paper weight assembly 1 Guide, edge 1 Cover, top 1 Sensor, envelope pass thru 1 Clutch, restraint/gear 1 Cover, right side 1 Support, slide out 7 Roller, support 1 Motor, stepper DC 1 Label, options 1 Switch, envelope out 1 Board assembly - Lexmark 10G1664 | Service Manual - Page 288
4060-xxx Assembly 25: High-capacity feeder 1 5 2 1 2 5 3 4 8 7 6 9 11 12 10 11 12 18 20 19 13 14 15 21 6 26 25 24 23 16 17 22 7-52 Service Manual - Lexmark 10G1664 | Service Manual - Page 289
99A0657 99A0655 99A0658 99A0650 99A0661 99A1806 99A0677 99A0675 99A0392 99A0677 99A0676 99A0690 Units Description 1 Frame, printer support frame 2 3 Parts packet, screw (printer support 2 frame mounting) 2 Clamp, feed frame 4 Parts packet, screw (feed frame clamp) 2 Bearing, Nyliner leadscrew top - Lexmark 10G1664 | Service Manual - Page 290
4060-xxx Assembly 26: High-capacity feeder 2 2 2 2 4 1 2 3 20 2 19 2 14 15 2 2 2 2 18 17 6 16 6 4 2 4 5 2 24 12 2 4 6 13 6 11 24 46 10 6 9 8 7 7-54 Service Manual - Lexmark 10G1664 | Service Manual - Page 291
99A0667 99A0715 99A0698 99A0685 99A0654 99A0651 99A0659 99A0695 Units Description 3 Guide, rear paper, use with 99A0219 Parts packet, screws (including paper low 1 Sensor assembly, paper out/upper limit 1 Frame, printer support 1 1 Parts kit, paper size switch assembly 4060-xxx Parts catalog 7-55 - Lexmark 10G1664 | Service Manual - Page 292
4060-xxx Assembly 27: High-capacity feeder 3 15 14 13 12 11 6 9 10 5 1 8 3 3 7 4 2 1 7-56 Service Manual - Lexmark 10G1664 | Service Manual - Page 293
Assembly 27: High-capacity feeder 3 Asmindex 27-1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part number 99A0687 99A0672 99A1793 99A1795 99A1798 99A1794 99A1796 99A1797 99A1800 99A1799 99A1801 99A1802 99A1803 99A1804 99A1805 Units Description 4 Parts packet, mounting feet 4 Parts packet, foot (stabilizer) - Lexmark 10G1664 | Service Manual - Page 294
4060-xxx Assembly 28: High-capacity feeder 4 4 1 2 3 4 56 7 18 17 19 8 9 10 14 16 15 11 12 13 7-58 Service Manual - Lexmark 10G1664 | Service Manual - Page 295
, screw (tray option card mounting) 10 Parts packet, screw (door to door frame mounting) 6 Parts packet, nut support frame 1 hex, support frame 2, hex 6 Parts packet, washer (support frame 1 star, support frame 2 star) 1 Cable, HCIT-14 pin flex 1 Spring, backup roller 4060-xxx Parts catalog 7-59 - Lexmark 10G1664 | Service Manual - Page 296
4060-xxx Assembly 29: High-capacity feeder 5 1 10 11 12 10 2 3 4 10 12 10 9 8 5 6 7 7-60 Service Manual - Lexmark 10G1664 | Service Manual - Page 297
Assembly 29: High-capacity feeder 5 Asmindex 29-1 2 3 4 5 6 7 8 9 10 11 12 NS NS Part number 99A0263 99A1055 99A0070 99A0692 99A0263 99A0678 99A0288 99A1812 99A1666 99A0677 99A0263 99A0679 99A0717 99A0720 Units 3 1 2 1 1 1 1 1 1 4 4 2 1 1 Description Parts packet, screw (auto comp assembly - Lexmark 10G1664 | Service Manual - Page 298
4060-xxx Assembly 30: Kiosk-vertical paper adapter 1 4 2 3 5 7 21 5 4 4 7 68 4 5 4 20 19 5 10 11 12 9 5 11 12 13 14 11 5 18 17 6 15 6 10 4 4 10 16 4 7-62 Service Manual - Lexmark 10G1664 | Service Manual - Page 299
99A1820 99A0226 99A0122 99A0137 99A0088 99A0085 Units Description 1 Bail, support 1 Arm assembly, pivot 1 Mounting, frame assembly 12 Parts , drive roller 1 Frame assembly, right side 1 Cover, right 2 Belt, 185G 1 Guide, paper exit 2 Shaft assembly, drive roller 1 Frame assembly, left side 1 Cover, - Lexmark 10G1664 | Service Manual - Page 300
4060-xxx Assembly 31: Kiosk-horizontal paper adapter 1 4 2 3 5 7 20 5 4 4 7 68 4 5 4 19 18 5 5 11 12 10 11 12 9 13 14 11 5 5 15 17 10 4 4 10 16 4 7-64 Service Manual - Lexmark 10G1664 | Service Manual - Page 301
99A0234 99A1705 99A1704 99A0197 99A0079 99A0208 99A0087 99A0086 99A1707 99A0907 99A0232 99A1820 99A0122 99A0906 99A0088 99A0085 Units Description 1 Bail, support 1 Arm assembly, pivot 1 Mounting, frame assembly 12 Parts packet, retainer 15 Parts packet, screw 1 Gear, idler 2 Gear, idler 1 Shaft - Lexmark 10G1664 | Service Manual - Page 302
4060-xxx Assembly 32: StapleSmart finisher I 1 18 2 17 16 5 15 3 4 5 98 6 7 10 11 14 13 12 7-66 Service Manual - Lexmark 10G1664 | Service Manual - Page 303
Assembly 32: StapleSmart finisher 1 Asmindex 32-1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 Part number 99A2505 99A2510 99A2506 99A2512 99A1785 99A2501 99A2503 99A2502 99A2519 99A2520 99A2542 99A1666 99A2521 99A2541 99A2511 99A2508 99A2500 99A2507 Units Description 1 Cover, top assembly 1 - Lexmark 10G1664 | Service Manual - Page 304
4060-xxx Assembly 33: StapleSmart finisher 2 14 1 13 12 2 3 5 7 6 4 11 4 4 9 10 4 8 4 7-68 Service Manual - Lexmark 10G1664 | Service Manual - Page 305
14 Part number 99A2575 99A2526 99A2556 99A0263 99A1820 99A2544 99A0362 99A2545 99A2548 99A2533 99A2523 99A2543 99A2528 99A2557 Units Description 1 Stapler cartridge holder 321-C 1 Stapler assembly 1 Bracket, attach 1 Parts packet, screws 1 Belt, 185G 1 Card assembly, right stapler bin level 1 Arm - Lexmark 10G1664 | Service Manual - Page 306
4060-xxx Assembly 34: StapleSmart finisher 3 1 24 25 1 26 27 1 22 23 21 1 1 20 19 18 17 2 1 3 5 4 6 8 7 15 14 4 10 13 12 16 10 6 10 9 10 11 10 7-70 Service Manual - Lexmark 10G1664 | Service Manual - Page 307
, lower 1 Shaft assembly, 40T middle stacker 1 Shaft assembly, upper drive 1 Shaft assembly, lower exit 1 Belt, FHT 86T 1 Cover, optical sensor 1 Guide, inner bias 1 Frame assembly, left 1 Bar, upper output tray 1 Spring, output tray 1 Bumper, output tray 1 Card assembly, left stapler bin level - Lexmark 10G1664 | Service Manual - Page 308
4060-xxx Assembly 35: StapleSmart finisher 4 1 7-72 Service Manual - Lexmark 10G1664 | Service Manual - Page 309
Assembly 35: StapleSmart finisher 4 Asmindex 35-1 NS NS NS NS NS NS NS NS NS Part number 99A2559 99A2480 99A2525 99A2530 99A2534 99A2524 99A2532 99A2504 99A2546 99A0548 Units Description 1 Paper alignment wheel 1 Kit, maintenance StapleSmart wheels 1 Sensor, stapler pass thru 1 Cable assembly, - Lexmark 10G1664 | Service Manual - Page 310
media 1 Rib assembly, 250-sheet special media tray 1 Tray, universal adjustable 250-sheet 1 Cartridge, empty shipping 1 Kit, cap/stack bails 500-sheet 1 MarkNet N2101e Ethernet 10BaseT/100Base , UAT 400-sheet 1 PrintCryption card assembly 1 Serial adapter, int w/out +5 V ac 7-74 Service Manual - Lexmark 10G1664 | Service Manual - Page 311
Assembly 36 (cont.): Options Asmindex NS NS NS NS NS NS NS NS Part number 56P1427 56P1428 56P1429 56P1430 56P1438 56P1101 56P0161 56P0162 Units Description 1 Optra Forms 32MB Flash card 1 Optra Forms 16MB Flash card 1 Simplified Chinese font card 1 Traditional Chinese font card 1 Japanese font - Lexmark 10G1664 | Service Manual - Page 312
assembly, cabinet Printer stand filler, rear top piece Printer stand table assembly, large Printer stand table assembly, small Parts packet, pulley Parts packet, screw-kiosk Grease packet, Nyogel 744 Relocation kit, 250/250-sheet printer Relocation kit, 500/250-sheet printer 7-76 Service Manual - Lexmark 10G1664 | Service Manual - Page 313
Emul Option 2-32 200 Paper Jam - Remove Cartridge 2-30 201 Paper Jam - Remove Cartridge 2-30 202 Paper Jam - Open Rear Door Check MP Feeder 2-31 250-sheet paper tray, option parts catalog 7-40 removals 4-51 service check 2-64 260 Paper Jam - Check Envelope Feeder 2-31 27x Paper Jam - Check Output - Lexmark 10G1664 | Service Manual - Page 314
bin test - standard bin 3-11 print registration 3-16 print tests 3-19 printer setup 3-17 maintenance page count 3-17 restore EP factory defaults 3-18 setting 5-3 parts catalog 7-52 service check 2-56 high-capacity output stacker service check 2-62 horizontal paper adapter 7-64 I-2 Service Manual - Lexmark 10G1664 | Service Manual - Page 315
ESD-sensitive parts 4-1 lubrication 6-1 maintenance kit 6-1 preventive 6-1 safety inspection guide 6-1 maintenance approach 1-1 maintenance kits 6-1 maintenance page count 3-17 messages check device connection messages 2-33 service error codes 2-2 user attendance messages 2-19 user line 2 link - Lexmark 10G1664 | Service Manual - Page 316
paper deflector assembly inner 4-33 upper 4-63 paper jam base printer 3-23 diagram 3-22 duplex option 3-24 envelope feeder 3-25 (POST) 2-34 preventive maintenance 6-1 I-4 Service Manual printhead adjustment 4-3 parts catalog 7-10, 7-11, 7-12 removal 4-56 service check 2-78 Q quick disk test 3-2 - Lexmark 10G1664 | Service Manual - Page 317
22 ROM memory test 3-9 S safety information xv safety inspection guide 6-1 scheduled maintenance 6-1 screw identification table 4-6 SDRAM memory test 1-8 power and electrical 1-6 printer 1-5 speed and performance 1-3 StapleSmart finisher locations 5-8 parts catalog 7-67 service check 2-86 tests feed - Lexmark 10G1664 | Service Manual - Page 318
T toner sensor removal 4-61 tools 1-14 transfer roll assembly parts catalog 7-26 removal 4-61 service check 2-94 U unique tools 1-14 upper front cover hinge assembly removal 4-62 upper front 7-62 viewing the permanent page count 3-17 W warning messages (user status displays) 2-16 I-6 Service Manual - Lexmark 10G1664 | Service Manual - Page 319
64MB memory option 7-74 56P0699 128MB memory option 7-74 56P1100 Cartridge, empty shipping 7-74 56P1101 Cable assembly, 6' parallel, A-C sheet output, 200/210/400/410 7-3 56P1303 Upper front cover with labels w/Lexmark logo 7-3 56P1305 Hinge, upper front cover 7-3 56P1306 Cover, right side, - Lexmark 10G1664 | Service Manual - Page 320
400/410 7-9 56P1317 Duct, left stacker, 250-sheet, 000/010 7-9 56P1318 Duct, main cap 7-7 56P1319 Support, right stacker plate, 200/210/400/410 7-7 56P1320 Right side frame assembly 7-5 56P1321 Left side frame V ac, 200/210/400/410 7-29 56P1372 LVPS, 220 V ac, 000/010 7-29 I-8 Service Manual - Lexmark 10G1664 | Service Manual - Page 321
Sensor, exit 7-25 56P1405 Cable, AC fuser lamp to LVPS 7-39 56P1406 Card asm, paper wt/paper low sensor 7-13 56P1408 Cartridge fan 7-7, 7-35 56P1409 115 V Maintenance kit 6-1 56P1412 220 V Maintenance kit 6-1 56P1413 100 V Maintenance kit 6-1 56P1414 250 duplex assembly 7-49 56P1415 Wiper - Lexmark 10G1664 | Service Manual - Page 322
printer 7-76 90A2485 Tray assembly, UAT 400-sheet 7-74 99A0004 Spring, latch 7-3 99A0007 Label, TLI/ID/serial number - blank 7-3 99A0026 Tray bias arm assembly 7-7, 7-41, 7-45 99A0028 Spring, tray bias 7-7 99A0039 Roller, developer support Spring, backup roller 7-63, 7-65 I-10 Service Manual - Lexmark 10G1664 | Service Manual - Page 323
, drive rear 7-63, 7-65 99A0208 Parts packet, pulley 7-63, 7-65, 7-76 99A0219 Frame assembly, top with labels 7-55 99A0226 Guide, paper exit 7-63 99A0231 Bail, support 7-63, 7-65 99A0232 Cover, right 7-63, 7-65 99A0234 Parts packet, screw 7-63, 7-65 99A0234 Parts packet, screw - kiosk 7-76 - Lexmark 10G1664 | Service Manual - Page 324
, auto connect front 7-51 99A0388 Switch, envelope out 7-51 99A0389 Paper weight assembly 7-51 99A0390 Support, slide out 7-51 99A0392 Kit, door switch spring and bumper 7-53 99A0393 Clutch, restraint/gear Parts packet, screw duplex 7-76 99A0413 Screw, top/motor/board 7-51 I-12 Service Manual - Lexmark 10G1664 | Service Manual - Page 325
, skewed backup 7-45 99A0452 Washer, frame mounting 7-47 99A0469 Deflector guide 7-51 99A0484 Belt, gear drive 7-51 99A0485 Sensor, envelope pass thru 53 99A0658 Magnet, door 7-53 99A0659 Frame, printer support 1 7-55 99A0660 Frame, printer support frame 2 7-53 99A0661 Tray assembly, elevator - Lexmark 10G1664 | Service Manual - Page 326
Parts packet, nut support frame 1 hex, support frame 2, hex Printer stand caster, locking 7-76 99A0704 Printer stand grommet, wire 7-76 99A0705 Printer stand lock, cam 7-76 99A0706 Printer stand storage shelf 7-76 99A0707 Printer stand door assembly, cabinet 7-76 99A0710 Printer Service Manual - Lexmark 10G1664 | Service Manual - Page 327
99A1524 Cartridge load 7-45 99A1583 Plate, 500-sheet tray wear 7-21, 7-45 99A1587 Support, paper 7-3 99A1594 Retainer, cable 7-3 99A1596 Contact, LSF ground 7-41, 7-67 99A1667 Bracket, 500-sheet tray retention 7-47 99A1694 Guide, edge 7-51 99A1696 Cover, top 7-51 99A1697 Cover, right side - Lexmark 10G1664 | Service Manual - Page 328
/210/400/410 7-9 99A2017 Guide, extension 7-9 99A2018 Support, left lower stacker 7-7 99A2019 Spring, cartridge hold down 7-7 99A2020 Transfer plate assembly 7-7 99A2021 Support, right stacker plate, 000/010 top assembly 7-67 99A2506 Top cover bail/plate, right side 7-67 I-16 Service Manual - Lexmark 10G1664 | Service Manual - Page 329
assembly 7-69 99A2527 Frame assembly, left 7-71 99A2528 Frame assembly, right 7-69 99A2529 Guide, inner bias 7-71 99A2530 Cable assembly, right stapler bin level 7-73 99A2531 Switch 7-69 99A2559 Paper alignment wheel 7-73 99A2575 Stapler cartridge holder 321-C 7-69 Part number index I-17 - Lexmark 10G1664 | Service Manual - Page 330
4060-xxx I-18 Service Manual - Lexmark 10G1664 | Service Manual - Page 331
Lexmark T630/T632/T634 System Board Wiring Diagram OPTION CARD OPTION CARD +5V F1 J1 J7 Interconnect Card Printhead 4 3 2 1 987654321 1234567 Toroid Toroid Toroid Toroid Main Fan 123 Cartridge Fan FANSTALL Gnd MAINFAN Gnd HYSNC IN HYSNC ID +5Vdc Gnd Gnd MM REF R MM LOCK* MM Stgart*
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Lexmark™ T63x
(including Lexmark T630, Lexmark T632, Lexmark T634)
4060-xxx
(including 4060-000, 4060-010, 4060-200,
4060-210, 4060-400, 4060-410)
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.