Lexmark Optra S 1620 Manual

							Diagnostic Information2-84
4059-XXX
Remove Paper - Output Bin X is displayed, POST Incomplete,
Unable to clear the message.
271 Paper Jam - Check Bin X. POST Incomplete
271 Paper Jam - Check Bin X, POST Complete, First Sheet of paper
feeds into Output Bin X.
Note:Before performing the following checks run the Output Bin X
Sensor Test and check for the failing sensor.
Sensor Test: NF = Near Full (Upper part of sensor assembly)
F = Full (Lower Part of sensor assembly)
P = Pass Thru Sensor
FRU Action
1 Dual Output Bin Sensor Flag Check the flag for correct
operation, binding, broken parts or
interference from the sensor
cable, If incorrect, repair as
necessary.
FRU Action
1 Pass Thru Sensor and Flag
Assembly
Control BoardCheck the sensor flag for proper
operation. If correct, check to
make sure the pass thru sensor
cable is correctly connected to J3
on the control board. Disconnect
the pass thru sensor cable from J3
on the control board and check
the voltage at J3-3. The voltage
measures approximately +5 V dc.
If incorrect, replace the control
board. If correct, 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 control board. 
						

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990 Service - BIN X
FRU Action
1D.C.Motor
Mechanical Linkage
Assembly (Level 2)Check the DC motor cable
connector to be sure it is correctly
installed at J4 on the output
expander option board. Go to
“Output Expander Control Board -
Level 2 DC Motor” on page 5-24.
If correct, disconnect J4 from the
option board and check the
resistance of the motor on the
cable connector: J4-1 to J4-2:
measures between 115 and 135
ohms. Also check J4-1 and J4-2 to
the motor case for shorts. If either
the resistance is incorrect or a
short is found, replace the motor/
mechanical linkage assembly.
Note:If the DC motor is shorted, it
may also be necessary to replace
the control board.
2 Output Expander Control
Board (Level 2)Disconnect the motor cable J4
and check the voltages at J4 on
theboard.Goto“Output
Expander Control Board - Level 2
DC Motor” on page 5-24.
Note:Use caution not to short to
adjacent pins on the connector.
J4-1 (Motor Idle) +24 V dc
J4-2 (Motor Idle) +24 V dc
J4-5 (Motor Idle) +5 V dc
J4-6 (Motor Idle) +5 V dc
If any of the voltages are incorrect,
replace the control board. If the
voltages are correct, replace the
DC motor/mechanical linkage
assembly. 
						

							Diagnostic Information2-86
4059-XXX
No indication that Bin X is Full OR No indication that Bin X is Near
Full
Note:The NF or Near Full sensor will only be displayed on models
that support an Output Expander that has a Dual Sensor installed.
Paper Feed Service Check
If you have a 936 Transport Motor Error go to the“Main Drive
Service Check” on page 2-73.
FRU Action
1 Dual Output Bin X Sensor
Assembly
Control BoardCheck for correct installation of
the sensor cable at J5 on the
control board. If either the Bin Full
(F) or Bin Near Full (NF) fail the
sensor test then check the voltage
at J5-3 and J5-4. The voltage
measures approximately +5 V dc.
If the voltage is incorrect, replace
the control board. If correct,
replace the sensor assembly.
FRU Action
1 Alignment Assembly Check to ensure the alignment
assembly is correctly attached to the
left side frame and the mounting
screws are tight. Check the
alignment assembly for any signs of
worn rollers, contaminated rollers or
binds. Replace the alignment
assembly if any problem is found.
2 Inner Deflector Check the inner paper deflector for
correct installation. If the deflector is
bowed or not fitting correctly, replace
the deflector. 
						

							2-874059 Service Manual
4059-XXX
Autocompensator fails to feed paper. Failures occur randomly
throughout the stack of paper.
Paper feed failures occur only near the top of the stack of paper.
The most common cause of this problem is paper curl. Remove the
paper from tray x and check 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 paper appears to be flat in the tray but the there is still a
problem.
Failures occur mainly near the bottom of the stack of paper.
The autocompensator pick arm may not be coming down far enough
to allow the pick rolls to properly contact the paper. Also the
autocompensator motor may be failing. If this problems continues,
replace the autocompensator assembly.
FRU Action
1 Pass Through Sensor Check the pass through sensor for
correct installation and operation.
2 Autocompensator
AssemblyThe autocompensator pick roll shaft
assembly is not providing enough
torque if the pick rollers are not
picking the paper correctly. Replace
the autocompensator assembly.
3 Wear Strips in Tray X
problem is found.Check the wear strips for excessive
wear, scratches or rough spots.
Replace the wear strips if a problem
is found. 
						

							Diagnostic Information2-88
4059-XXX
Double Feeding Paper
Note:If double feeding paper occurs mostly from the bottom of the
stack, check for missing or damaged restraint pads in the tray.
Multipurpose Tray
Paper fails to feed from the multipurpose tray.
The pick roll should make one complete revolution and stop with the
flat side down. If the pick roll turns but does not pick paper, check the
roll for signs of wear, oil or grease on the surface of the pick roll or
slick spots. If you find a problem, replace the pick roll assembly.
Check to ensure the media that is being fed through the
multipurpose tray assembly meets recommended paper
specifications.
FRU Action
1 Paper Paper is usually the primary cause of
a double feeding paper problem.
Flex the paper before placing the
paper in the tray. Edge welded paper
is the most common cause of double
feeding. Loading the paper in the
tray in different locations and
directions and using rough paper
and short grain paper also causes
double feeding.
2 Autocompensator Make sure the counterbalance
spring is not missing, loose or
broken at the top of the
autocompensator arm assembly. If
you find a problem, replace the
autocompensator assembly. 
						

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4059-XXX
Parallel Port Service Check
Run the“Parallel Wrap Test” on page 3-11.
Note:The Parallel Wrap Test is designed to check the parallel port
hardware by using a wrap plug (P/N 1319128) and invoking the
Parallel Diagnostic Test. This test helps isolate the printer from the
parallel cable and host. The test provides failure information on the
display for approximately 3 seconds. If the test indicates that a
problem is detected, replace the controller board.
Printhead Service Check
The printhead assembly does not contain any service replaceable
parts or components. If service error code 930 displays, the wrong
printhead is installed in the printer.
Service Error Code Explanation
1 Error Code 931
No first HYSNC Signal
Error Code 932
Lost HYSNCThese errors usually indicate a
failure in the HYSNC signal to the
printhead. Check the continuity of
the cables connected to J3 and J8
on the engine board. If incorrect,
replace the defective cable. The
voltage at J8-4 measures
approximately +5 V dc. If incorrect,
replace the engine board. The
voltage at J3-7 measures
approximately +24 V dc. If incorrect,
replace the engine board. If correct,
replace the printhead assembly. 
						

							Diagnostic Information2-90
4059-XXX
2 Error Code 934
Mirror Motor Lost Lock
Error Code 935
Mirror Motor unable to
reach operating speedThese error codes indicate a
problem with the mirror motor circuit
in the printhead assembly or the
mirror motor cable to the engine
board cable or engine board
assembly. Check the continuity of
the mirror motor cable connected to
J3 on the engine board. If incorrect,
replace the cable. The voltage at
J3-7 measures approximately
+24 V dc. If incorrect, replace the
engine board. If correct, replace the
FRUs in the following order:
engine board
printhead assembly Service Error Code Explanation 
						

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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.
Select the following menu settings as indicated. Be sure and note
the original settings so you can return the printer to the original
customer printer setup.
•Print Resolution: Set to 300 dpi (print quality problems should
be checked at different resolution settings).
•Print Darkness: Set to NORMAL.
•Toner Saver: Set to OFF.
•PQET: Set to OFF.
•Fuser Temperature: Set to NORMAL.
An incorrect printer driver for the installed software can cause
problems. Incorrect characters could print and the copy may not fit
the page correctly.
Measure all voltages from the connector to printer ground. All
voltages measured during the print cycle are measured with the
controller board removed while running the print test. 
						

							Diagnostic Information2-92
4059-XXX
Print Quality - All Black Page
Service Tip: An all black page is generally caused by a problem in
the high voltage system or an incorrect high voltage in the printing
process resulting in toner development on the entire photoconductor
drum.
Print Quality - Blank Page
FRU Action
1 High Voltage Contacts Check the high voltage contacts on
the right side frame to ensure they fit
securely and are not pitted,
contaminated or damaged. If
incorrect, replace the contact with
one from the HV contact kit.
Screws are included to attach the
contacts to the right side frame in the
HV contact kit.
2 HVPS Check the voltages on J10-1 thru
J10-8. If incorrect, replace the
engine board.
3HVPSCable
(PartofFront
Harness Cable)
Engine BoardCheck the continuity of the HVPS
cable. If incorrect, replace the cable
assembly.Ifcorrect,replacethe
engine board.
FRU Action
1 Print Cartridge Check the print cartridge for any
signs of damage, especially the PC
drum contact on the cartridge. 
						

							2-934059 Service Manual
4059-XXX
2 High Voltage Contact Check the PC drum contact on the
right side frame for damage, PC
drum contact wear or contamination.
If the contact is bent or damaged,
replace the contact.
Note:Inspect the HVPS PC drum
contact on the board for any signs of
damage or contamination.
3 HVPS Check the fuse on the HVPS. If
open, replace the HVPS. Check the
voltages at J10 on the engine board.
Measure the following voltages from
connector J10 to printer ground:
Printer Idle
J10-5 measures +24 V dc
Printer Printing
J10-5 measures +24 V dc
In the voltages at J10-5 are
incorrect, replace the engine board.
4 Front Cable Harness
HVPS SectionCheck the front cable harness at J10
on the engine board and at CN1 on
the HVPS to make sure the harness
is connected properly. If connected
properly, check the continuity of the
cable harness. If there is no
continuity, replace the front cable
harness.
5 Printhead Assembly Generally a 93x service error is
posted if the printhead assembly
fails and the printer does not give a
blank copy symptom.
The printhead used in the printer
does not have a mechanical shutter
as previous laser printers. The
printer is interlocked through the
front top cover interlock switch. FRU Action