Lexmark Optra S 1620 Manual

							Diagnostic Information2-74
4059-XXX
Operator Panel Service Check
Operator Panel Buttons Service Check
Note:Before continuing with this service check do the“Button Test”
on page 3-9in the diagnostic aids chapter. The operator panel cable
is a individual cable on some printers and a combination cable
assembly with the cover switch cable on later models.
4 Motor does not turn, no
gear error code 936 or User
message 201 Paper Jam
displays.Check the voltages at J12 on the
engine board.
Pin number and voltage:
J12-1 = +24 V dc
J12-4 = +5 V dc (static) 0 V dc
(when main drive motor running)
J12-5 = + 5 V dc (static) 0 V dc
(when main drive motor running)
J12-6 = +5 V dc (static) +2.5 V dc
(when main drive motor running)
J12-7 = +5 V dc (static) 0 V dc
(when main drive motor running)
J12-8 = +5 V dc (static) +5 V dc
(when main drive motor running)
J12-11 = + 5 V dc (static) 0 V dc
(when main drive motor running)
If the voltage is incorrect, replace the
FRUs in the following order:
main drive motor assembly
engine board
FRU Action
1 Operator Panel Assembly If any button fails the Button Test,
replace the operator panel assembly. FRU Action 
						

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Operator Panel Display Service Check
SERVICE TIP: The printer has detected a problem with the engine
board, operator panel cable or operator panel assembly if POST
does not complete and the printer emits 5 beeps and stops in a
continuous pattern until the printer is turned off. The operator panel
cable is a individual cable on some printers and a combination cable
assembly with the cover switch cable on later models.
Note:If the operator panel is operating properly except for a PEL or
a few PELS missing or broken, run the“LCD Test” on page 3-9from
the hardware tests before continuing with this diagnostic service
check.
2EngineBoard
(No buttons work)Check the voltage at J11-5. The
voltage measures approximately
+5 V dc with the controller board
removed. If incorrect, replace the
engine board. If correct, check the
continuity of the operator panel
cable. If incorrect, replace the cable.
If correct, replace the operator panel
assembly.
FRU Action
1 Operator Panel Cable Check for proper installation of the
cable at the engine board (J11) and
at the operator panel. Check the
continuity of the operator panel
cable. If incorrect, replace the cable.
2 Operator Panel Display
blank, 5 beeps, LED OffCheck the voltage at J11-2 on the
engine board. It measures
approximately +5 V dc. If incorrect,
replace the engine board. If correct,
replace the operator panel assembly.
3 Operator Panel Display
blank, 5 beeps, LED OnCheck for ground between J13-4 and
ground. If correct, replace the
operator panel assembly. If incorrect,
replace the engine board. FRU Action 
						

							Diagnostic Information2-76
4059-XXX
Options Service Check
Service Tip: When you have a problem with any of the options
installed in the options slots on the interconnect board on a 2450 or
1650 (the 1250 has only one slot), switch the non operating option to
one of the other option slots to isolate the failure.
Flash Memory Option(s)
Run a copy of the test page and check to see if the option you are
checking is listed. The printer does not recognize the option being
installed if the option is not listed. Check to make sure that the
Memory SIMM is installed correctly and is not broken or damaged. If
the Memory SIMM is correctly installed not broken or damaged then
run the“Flash Test” on page 3-3. If the test fails, replace the FLASH
SIMM. If the problem continues, replace the controller board.
DRAM Memory Option(s)
This service check is the same as the flash memory option service
check with the following exception:
Run the“DRAM Memory Test” on page 3-10from the menu if the
DRAM Memory SIMM is correctly installed and not broken or
damaged. If the test fails, replace the DRAM SIMM. If the problem
continues, replace the controller board.
4 Operator Panel all
diamonds, No BeepsCheck to make sure a SIMM is not
plugged in backwards. This condition
causes the printer to fail POST
displaying all diamonds on the
operator panel with no beeps
5 Operator Panel all
diamonds, 5 BeepsCheck the voltage at Pin J11-1 and
J11-3. The voltage measures
approximately +5 V dc. If incorrect,
replace the FRUs in the following
order:
operator panel assembly
engine board FRU Action 
						

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Hard Disk Option
Service Tip: The Optra S printers support one hard disk option.
Check to make sure only one hard disk option is installed.
•1.4 GB - 1250/1620/1650/2420/2450
•2.1 GB - 1255/1625/1855/2455/3455
Check to make sure the fixed disk and the fixed disk board are
correctly installed. Run the“Quick Disk Test” on page 3-2from the
Device Test on the Diagnostic Menu when a problem is suspected
either with the hard disk system board or with the hard disk.
Note:The Quick Disk Test is a non-destructive test and indicates
Pass or Fail. If the test fails, replace the hard disk. If a problem still
exists, replace the hard disk board.
The“Disk Test/Clean” on page 3-2is used to help restore the disk if
the disk contains bad data and is unusable. This test is divided into a
cleaning and a verifying or testing section.
Note:This can be a very lengthy test depending on the disk size.
This test leaves the hard disk unformatted. The servicer or user
must reformat the disk using the Format Disk Menu operation. This
is a destructive type of test. All the data on the disk is destroyed and
should not be performed on a known good disk.
Network Card Option
Error Code 976 - Network Card X (X=Network card 1, 2, or 3)
A 976 error code indicates an unrecoverable software error in
network card x. Verify that network card x is correctly installed in the
socket on the interconnect board and is properly grounded. If you
find no problem, contact your next level of support before replacing
the network card.
Error Code 977 - Network Card X
A 977 error displays when the RIP software detects that a network
card is installed in slot x on the interconnect board but cannot
establish communications with the network card. If you are servicing
a 1650, 1855, 2420, 2450 or 2455 and the network card works in
another slot, replace the interconnect board. 
						

							Diagnostic Information2-78
4059-XXX
Output Bin Sensor Standard Tray Service Check
Service Tip: If the output bin standard tray fills up and the bin full
sensor fails to post the message Remove Paper Standard Bin,
enter the Diagnostic Mode, select Output Bin Tests, select Sensor
Tests and select Standard Bin. Check the sensor and flag for proper
operation. If you find no problem with the sensor and flag, continue
with the service check.
Service Tip: Check to make sure the correct flag is installed. The
Output Bin Sensor is a normally closed sensor with the sensor flag
down. Therefore, unless the flag is in the up position or out of the
sensor slot, a Remove Paper Standard Bin message is not
displayed.
FRU Action
1EngineBoard
Printer fails to display
Remove Paper Standard
Bin message. Output Bin
Sensor Test failsCheck the voltage at J6-3. It
measures +5 V dc when the flag is in
the sensor and 0 V dc when the flag
is out of the sensor. If the voltage
does not change, replace the sensor
cable assembly. If this does not fix
the problem, replace the engine
board.
2 Output Bin Sensor Flag Check to make sure the correct flag
is installed. Check the flag for
damage or improper operation. If
incorrect, replace the flag.
Note:Abrokenorimproper
operating sensor flag causes a
Remove Paper Standard Bin
message to display before POST
completes and cannot be cleared. 
						

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Output Expander Service Check
There are two levels of the 500 Sheet Output Expander Option.
•Level 1 is equipped with a stepper motor/mechanical linkage
assembly.
•Level 2 is equipped with a DC servo motor and a new
mechanical linkage assembly and has fewer mechanical
components.
Service Tip: The majority of the mechanical components can be
observed during operation by removing the left, right and system
board covers. The output expander functions without the covers
installed.
Note:Make sure the option is correctly installed before attempting
to service the unit.
Problems with excessive static electricity buildup.
Printer does not recognize one or more output expander options
as being installed.
Service Tip: If more than a single output expander option is installed,
check each one to see if the 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 is in the unrecognized expander option.
FRU Action
1 Output Expander Control
Board CoverCheck the output expander control
board cover to make sure the ESD
brush ground lead is firmly attached
to the output expander frame. Also
checktomakesuretheESDbrushis
not loose. 
						

							Diagnostic Information2-80
4059-XXX
FRU Action
1 Output Expander Option Make sure the output expander
option is the only option that is not
recognized by the base printer. If the
output expander is the only option
not recognized by the printer,
continue with step 2. If not, check the
autoconnects of the options not
recognized and the interconnect
board and cable connections.
2 Output Expander Assembly
Mechanical LinkageCheck the autoconnects for damage,
especially the connector pins.
Remove the left and right side
covers. Remove the front control
board cover. Check the cables at
J1A, J1B, J2A and J2B on the
control board to make sure they are
attached securely and correctly.
Remove the output expander and
check the voltages on the output bin
autoconnect located on the top left
rear of the printer. Go to
“Autoconnect - Top” on page 5-21.If
the voltages are correct, reinstall the
output expander unit and check the
voltages at J1A and J1B on the
connector. If correct, replace the
output expander control board. If
incorrect, replace the output
expander assembly mechanical
linkage. 
						

							2-814059 Service Manual
4059-XXX
202 Paper Jam Open Rear Door Message displays. A sheet of
paper is jammed prior to the pass through sensor flag.
202 Paper Jam Open Rear Door Message displays. A sheet of
paper feeds out to the standard bin even though bin x is selected.
Paper exits half way out of the redrive.
Service Tip: For this type of problem check the sub error codes.
They can help isolate the problem. 202 Paper Jam messages can
also occur prior to the output expander pass thru sensor.
FRU Action
1 Output Expander Drive Belt
Drive Pulley Drive Belt
Idler Pulley Belt Tension
SpringCheck to ensure the output
expander drive belt 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.
2 Mechanical Linkage
DC Motor Assembly Level 2If the DC motor is functioning
properly check the gears, clutch and
other linkage parts for correct
operation and any signs of wear,
broken gear teeth or damaged parts.
If incorrect, replace the mechanical
linkage/DC motor assembly. 
						

							Diagnostic Information2-82
4059-XXX
3 Stepper Motor Level 1 Check the stepper motor connector
to ensure it is correctly installed at J4
on the output expander option board.
Go to“Output Expander Control
Board - Level 1 Stepper Motor” on
page 5-22. If correct, disconnect J4
from the option board and check the
resistance of the stepper motor at
J4:
J4-1 to J4-2: Approximately 10 ohms
J4-3 to J4-4: Approximately 10
ohms.
Also check each winding for shorts
between J4-1 thru J4-4 and the
motor housing. If you find a problem,
replace the stepper motor. If you do
not find a problem, replace the
output expander mechanical linkage
assembly. FRU Action 
						

							2-834059 Service Manual
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4 Output Expander Control
Board Level 1Check the voltages at connector J4.
Go to“Output Expander Control
Board - Level 1 Stepper Motor” on
page 5-22.
Printer idle
J4-1 +21 V dc to +24 V dc
J4-2 +21 V dc to +24 V dc
J4-3 +21 V dc to +24 V dc
J4-4 +21 V dc to +24 V dc
Printer Feeding Paper
J4-1 Approximately +16 V dc
J4-2 Approximately +16 V dc
J4-3 Approximately +16 V dc
J4-4 Approximately +16 V dc
The voltage drops to approximately
+16 V dc as the output expander bin
stepper motor turns on and a sheet
of paper is fed through the redrive
into the output expander assembly. If
any of the voltages fail to change,
replace the output expander option
board. If that does not correct the
problem, replace the output
expander mechanical linkage
assembly. FRU Action