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Lexmark T632 Service Manual - Page 97

Remove Paper - Output Bin, Paper Jam - Check Bin - error code 202

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4060-xxx 202 Paper Jam Open Rear Door displays and a sheet of paper is jammed prior to the pass thru sensor flag or 202 Paper Jam Open Rear Door displays, a sheet of paper feeds out to the standard bin even though bin x is selected and paper exits half way out of the redrive assembly. 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 thru sensors. FRU 1 Lower Pass Thru Sensor/ Flag Assembly 2 High-capacity output stacker drive belt(s) Drive pulleys Belt idlers Belt tension springs 3 Mechanical linkage/motor assembly (upper or lower) Action Check the flag for correct operation, binding, broken parts, or interference from the sensor cable. If incorrect, repair as necessary. If correct, check to make sure the lower pass thru sensor is correctly connected to J3 on the lower control board. Disconnect the pass thru sensor cable and check the voltage at J3-3. The voltage measures approximately +5 V dc. If incorrect, check the voltage at J3-2. The voltage measures approximately 0 V dc. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the lower control board. Check to ensure the output stacker drive belt or the failing assembly is correctly installed on the drive pulley and belt idler pulley. Check the belt tension spring to make sure it is not loose or broken. Repair as necessary. If the DC motor is functioning properly check the gears, clutch and other linkage parts for correct operation and wear, broken gear teeth, or damaged parts. If incorrect, replace the mechanical linkage assembly/DC motor assembly. Remove Paper - Output Bin x Full displays. You may not be able to clear the message. FRU 1 Dual output bin sensor flag (upper assembly) Action Check the flag for correct operation, binding, broken parts, or interference from the sensor cable. If incorrect, repair as necessary. 271 Paper Jam - Check Bin x, POST incomplete. FRU 1 Upper pass thru sensor flag assembly Upper control board Action Check the flag for correct operation, binding, broken parts, or interference from the sensor cable. If incorrect, repair as necessary. If correct, make sure the lower pass thru sensor is correctly connected to J3 on the lower control board. Disconnect the pass thru sensor cable and check the voltage at J3-3. The voltage measures approximately +5 V dc. If incorrect, check the voltage at J3-2. The voltage measures approximately 0 V dc. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the lower control board. Diagnostic information 2-63

Section	Page
Table of contents	3
Laser notices	9
Laser notice	9
Laser	9
Avis relatif à l’utilisation de laser	9
Avvertenze sui prodotti laser	10
Avisos sobre el láser	10
Declaração sobre Laser	10
Laserinformatie	11
Lasermeddelelse	11
Huomautus laserlaitteesta	11
Laser-notis	12
Laser-melding	12
Avís sobre el Làser	12
Japanese Laser Notice	13
Korean Laser Notice	14
Safety information	15
Consignes de sécurité	15
Norme di sicurezza	15
Sicherheitshinweise	16
Pautas de Seguridad	16
Informações de Segurança	16
Informació de Seguretat	17
Preface	18
Definitions	18
1. General information	19
Maintenance approach	19
Options	20
Print speed and performance print speed	21
Performance	21
Time to first print	22
Memory configuration	22
Printer specifications	23
Dimensions	23
Operating clearances	24
Power and electrical specifications	24
Electrical specifications	24
Acoustics	25
Environment	25
Media specifications	26
Print area	30
Media guidelines	30
Paper	30
Envelopes	31
Transparencies	31
Labels	31
Tools required	32
Acronyms	33
2. Diagnostic information	35
Start	35
Messages and error codes	36
Service error codes	36
Sub error codes	39
Sub error codes for 9xx and 2xx error codes	39
Base printer sub error codes	40
Base printer (fuser) sub error codes	45
Duplex option sub error codes	46
Envelope feeder sub error codes	47
User status displays	48
User status messages	51
User attendance messages	53
User line 2 link messages	66
Check device connection messages	67
Power-On Self Test (POST)	68
Symptom tables	69
Base printer symptoms	69
High-capacity feeder (2000-sheet) symptoms	69
Paper tray symptoms	70
Duplex option symptoms	70
Envelope feeder symptoms	70
Output expander	70
StapleSmart finisher	71
Service Checks	72
5-Bin mailbox service check	72
900 Error Code service check	75
950 Error Code service check	76
Charge roll service check	77
Cover closed switch/cable service check	78
Dead machine service check	79
Duplex option service check	81
Envelope feeder service check	83
Fuser service checks	86
Cold fuser service check	86
Hot fuser service check	88
Fuser solenoid service check	89
High-capacity feeder input tray service check	90
High-capacity output stacker service check	96
Input sensor service check	98
Input tray(s) service check	98
Internal tray card/paper size sensing service check	100
Main drive service check	102
Main fan service check	103
Operator panel service check	104
Operator panel buttons service check	104
Operator panel display service check	104
Options service check	105
Flash Memory Option(s)	105
DRAM Memory Option(s)	105
Hard Disk Option	105
Output bin sensor standard tray service check	106
Output expander service check	106
Paper feed service check	110
Parallel port service check	111
Printhead service check	112
Print quality service check	112
Smart contact assembly service check	119
StapleSmart finisher service check	120
Toner sensor service check	127
Transfer roll service check	128
3. Diagnostic aids	129
Diagnostics mode	129
Entering Diagnostic Mode:	129
Available tests	129
Exiting Diagnostics Mode	129
Device tests	130
Quick Disk Test	130
Disk Test/Clean	130
Flash Test	131
Disabling Download Emulations	131
Duplex tests	132
Duplex Quick Test	132
Duplex Sensor Test	132
Duplex Motor Test	133
Duplex Feed 1 Test	133
Duplex Feed 2 Test	134
Error log	134
Viewing the error log	134
Printing the error log	135
Clearing the error log	136
Hardware tests	136
LCD Test	136
Button Test	136
SDRAM Memory Test	137
ROM Memory Test	137
Parallel Wrap Test	137
Input tray tests	138
Input Tray Feed Test	138
Input Tray Sensor Test	138
Output Bin Tests	139
Output Bin Test-Standard Bin	139
Output Bin Feed Test	139
Feed to All Bins Test	140
Output Bin Sensor Test	140
Finisher Tests for StapleSmart Finisher	142
Finisher Feed Tests	142
Finisher Sensor Tests	142
Staple Sensor Test	143
Cover and Door Sensors	143
Pass and Media Sensors	143
Bin Level Sensor	143
Base Sensor Test	144
Print registration	144
Printer setup	145
Setting the page count	145
Viewing the permanent page count	145
Maintenance page count	145
Setting configuration ID	146
Restore EP Factory Defaults	146
Print tests	147
Print quality test pages	148
Printing menu settings page	148
Theory	149
Autocompensator operation	149
Autoconnect system, paper tray options, envelope feeder-electrical	149
Autoconnect cabling and connectors	149
Duplex Option	150
Option microcode	150
Paper feed jams	150
Paper jams-base printer	151
Paper jams-options	152
Error Message 23x Paper Jam - Check Duplex Option	152
Error Message 24x (x=tray 1 through 5) Paper Jam Check Tray x	153
Error Message 250 Paper Jam - Check MP Feeder	153
Error Message 260 Paper Jam - Check Envelope Feeder	153
Error Message 27x Paper Jam - Check Bin x	153
Error Message 28x Paper Jam (x=StapleSmart finisher)	153
Error Message 282 - Check Stapler	154
Error Message 283 - Check Stapler	154
4. Repair information	155
Handling ESD-sensitive parts	155
Adjustment procedures	156
Duplex motor drive belt adjustment	156
Fuser solenoid adjustment	156
Gap adjustment	157
Printhead assembly adjustment	157
Paper alignment assembly adjustment	158
Screw identification table	160
Removal procedures	163
Covers removals	163
Left door removal	163
Right cover removal	164
Upper front cover removal	166
Laser cover removal	168
Bevel gear removal	170
Installation	171
Communications board removal	172
Cover closed switch/cable removal	173
Developer drive assembly removal	174
Frames removals	174
EP frame assembly	174
Left side frame	174
Right side frame	176
Fuser assembly removal	177
Fuser cover removal	179
Fuser exit sensor or fuser narrow media sensor removal	182
Fuser lamp removal	182
Fuser transfer plate removal	184
High voltage power supply removal	185
Inner paper deflector assembly removal	187
Inner shield removal	188
Input sensor removal	188
Integrated tray autocompensator assembly removal	189
Integrated tray autocompensator pick roll assembly removal	192
Interconnect board assembly removal	194
Internal tray card (ITC)/Paper size sensing board removal	195
Low voltage power supply removal	196
Main drive assembly removal	198
Main fan removal	200
Multipurpose tray/lower deflector assembly removal	201
Operator panel assembly removal	202
Operator panel bezel removal	203
Operator panel cable removal	204
Optional 250 or 500-sheet paper tray assembly removal	205
Paper tray autocompensator assembly removal	205
Paper tray frame assembly removal	205
Paper tray board removal	205
Paper tray paper out sensor flag removal	205
Paper size spring comb removal	205
Outer shield removal	206
Paper alignment assembly removal	206
Paper bin full sensor flag assembly removal	208
Pick roll removal (MPT)	209
Printhead removal	210
Redrive assembly removal	211
Smart contact assembly removal	212
System board removal	212
Toner sensor removal	215
Transfer roll assembly removal	215
Upper front cover hinge assembly removal	216
Upper paper deflector assembly removal	217
5. Connector locations	219
Autoconnect	219
Envelope feeder board	220
Fuser Board	220
High-capacity output stacker board	221
High voltage power supply	222
Interconnect board	223
Low voltage power supply	224
Output expander control board	225
StapleSmart finisher	226
System board-non-network	228
System board-network	229
6. Preventive maintenance	235
Safety inspection guide	235
Lubrication specifications	235
Scheduled maintenance	235
7. Parts catalog	237
How to use this parts catalog	237
Assembly 1: Covers	238
Assembly 2: Frame 1	240
Assembly 3: Frame 2	242
Assembly 4: Printhead 1 (000/010)	246
Assembly 5: Printhead 2 (200/210)	247
Assembly 6: Printhead 3 (400/410)	248
Assembly 7: Paper feed-autocompensator	249
Assembly 8: Paper feed-multipurpose feeder	250
Assembly 9: Paper feed-alignment	252
Assembly 10: Integrated paper tray-250-sheet	254
Assembly 11: Integrated paper tray-500-sheet	256
Assembly 12: Drives-Main drive and developer drive	258
Assembly 13: Hot roll fuser	260
Assembly 14: Transfer/charging	262
Assembly 15: Electronics-power supplies	264
Assembly 16: Electronics-card assemblies	266
Assembly 17: Electronics-shields	268
Assembly 18: Cabling diagrams 1	270
Assembly 19: Cabling diagrams 2	272
Assembly 20: Cabling diagrams 3	274
Assembly 21: 250-sheet paper tray	276
Assembly 22: 500-sheet paper tray	280
Assembly 23: Duplex option	284
Assembly 24: Envelope feeder	286
Assembly 25: Output expander	288
Assembly 26: High-capacity output expander	292
Assembly 27: 5-bin mailbox	296
Assembly 28: High-capacity feeder 1	300
Assembly 29: High-capacity feeder 2	302
Assembly 30: High-capacity feeder 3	304
Assembly 31: High-capacity feeder 4	306
Assembly 32: High-capacity feeder 5	308
Assembly 33: Kiosk-vertical paper adapter	310
Assembly 34: Kiosk-horizontal paper adapter	312
Assembly 35: StapleSmart finisher I	314
Assembly 36: StapleSmart finisher 2	316
Assembly 37: StapleSmart finisher 3	318
Assembly 38: StapleSmart finisher 4	320
Assembly 39: Options	322
Assembly 40: Miscellaneous	324
Index	325
Part number index	331

Match case Limit results 1 per page

Diagnostic information

2-63

4060-

xxx

202 Paper Jam Open Rear Door displays and a sheet of paper is jammed prior

to the pass thru sensor flag or 202 Paper Jam Open Rear Door displays, a

sheet of paper feeds out to the standard bin even though bin

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 thru sensors.

Remove Paper - Output Bin

Full displays. You may not be able to clear the

message.

271 Paper Jam - Check Bin

, POST incomplete.

FRU

Action

Lower Pass Thru Sensor/

Flag Assembly

Check the flag for correct operation, binding, broken parts, or

interference from the sensor cable. If incorrect, repair as necessary.

If correct, check to make sure the lower pass thru sensor is correctly

connected to J3 on the lower control board. Disconnect the pass thru

sensor cable and check the voltage at J3-3. The voltage measures

approximately +5 V dc. If incorrect, check the voltage at J3-2. The

voltage measures approximately 0 V dc. If incorrect, replace the

sensor assembly. If this does not fix the problem, replace the lower

control board.

High-capacity output

stacker drive belt(s)

Drive pulleys

Belt idlers

Belt tension springs

Check to ensure the output stacker drive belt or the failing assembly

is correctly installed on the drive pulley and belt idler pulley. Check

the belt tension spring to make sure it is not loose or broken. Repair

as necessary.

Mechanical linkage/motor

assembly (upper or lower)

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

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

or damaged parts. If incorrect, replace the mechanical linkage

assembly/DC motor assembly.

FRU

Action

Dual output bin sensor flag

(upper assembly)

Check the flag for correct operation, binding, broken parts, or

interference from the sensor cable. If incorrect, repair as necessary.

FRU

Action

Upper pass thru sensor flag

assembly

Upper control board

Check the flag for correct operation, binding, broken parts, or

interference from the sensor cable. If incorrect, repair as necessary. If

correct, make sure the lower pass thru sensor is correctly connected

to J3 on the lower control board. Disconnect the pass thru sensor

cable and check the voltage at J3-3. The voltage measures

approximately +5 V dc. If incorrect, check the voltage at J3-2. The

voltage measures approximately 0 V dc. If incorrect, replace the

sensor assembly. If this does not fix the problem, replace the lower

control board.