Lexmark Optra S 1620 Manual

							Diagnostic Information2-34
4059-XXX
9 Engine Board Turn the printer off and disconnect
all the cables from the engine board.
Check for +5 V dc at the engine
board test point. If incorrect, replace
the FRUs in the following order:
engine board
interconnect board
If correct, turn the printer off and
reconnect one cable at a time until
you find the defective assembly.
Service Tip: A short or low
resistance load that is attached to
the engine board can cause the
LVPS to overcurrent and shut the
+5 V dc supply down to 0 V dc.
Service Tip: Check the engine board
for burn marks or other damage,
especially R20,R21, R22 and R23
located next to the upper left engine
board mounting screw. If this screw
is overtightened it might deform the
engine board shield and cause it to
short out these resistors. FRU Action 
						

							2-354059 Service Manual
4059-XXX
Duplex Option Service Check
The printer does not recognize the Duplex Option is attached. The
printer does not recognize tray options below the duplex option
are installed.
FRU Action
1 FuseF1onDuplexOption
System BoardIf fuse F1 is blown, replace the fuse.
If fuse F1 continues to blow, check
the stepper motor for a short
between the motor case and pins
J3-1 through J3-4. If no problem is
found, check the D.C. servo motor
pins J1-1 and J1-2 to the motor
housing for a short. If a short is
found, replace the motor assembly. If
no short is found, replace the system
board.
2 Autoconnect Cables/
ConnectorsCheck the autoconnect cables for
damage to the cables or the pins in
the connectors. If damaged, replace
the cable(s). If no damage is found,
check to make sure the cables are
connected to J9, J10, J11 and J12
on the duplex system board. If no
problem is found, replace the duplex
system board. 
						

							Diagnostic Information2-36
4059-XXX
POST fails, 230 Paper Jam, Check Duplex message displays.
FRU Action
1 Duplex D.C. Servo Drive
MotorCheck the D.C. servo motor cables
for signs of cuts or other damage.
Check the D.C. servo motor sensor
cable connector for pin damage. If
no problem is found, replace the
FRUs in the following order:
D. C. m o t o r a s s e m b l y
duplex option system board
2 Input Sensor, Input Sensor
FlagRun the Duplex Sensor Test from the
diagnostics menu. If the test fails,
check the input sensor cable at J5
on the system board for correct
installation. If no problem is found,
replace the FRUs in the following
order:
input sensor assembly
duplex option system board
3 Paper Exit Sensor and Flag Check the duplex exit sensor for
correct installation and free
movement of the sensor flag. Check
to make sure the sensor cable is
connected to J8 on the system
board. If no problem is found,
replace the FRUs in the following
order:
exit sensor assembly
duplex option system board 
						

							2-374059 Service Manual
4059-XXX
230 Paper Jam - Check Duplex message displays. The page is not
duplexed and only exits half way out of the redrive.
FRU Action
1 Duplex Stepper Motor Check the stepper motor cable for
cuts or pinched wiring. Check the
routing of the motor leads along the
left side of the bottom tray. Check for
correct installation of the motor cable
connector at J3 on the system
board. Check for any shorts between
each pin of the motor cable and the
motor housing. If shorts are found,
replace the motor. Check the
resistance of the stepper motor
between J3-1 (Stpmtr A-) to J3-2
(Stpmtr A+). The resistance
measures approximately 10 ohms.
The resistance between J3-3
(Stpmtr B-) to J3-4 (Stpmtr B+)
measures approximately 10 ohms. If
the resistance is incorrect, replace
the stepper motor. Check for shorts
between windings on pins J3-1 to
J3-2 and pins J3-3 to J3-4. If a short
is found, replace the stepper motor
assembly. If no short is found,
replace the duplex system board. 
						

							Diagnostic Information2-38
4059-XXX
POST fails with Close Duplex Rear Door displayed when Duplex
Rear Door is closed.
POST fails with Insert Duplex Front Cover message displayed.
FRU Action
1RearDoorSwitch
(Not installed on some
duplex units)Check the rear door for correct
installation and operation. Check to
ensure the cable or connector is not
damaged and is properly connected
at J6 on the duplex system board.
The rear door switch can be checked
by measuring the continuity between
J6-1 and J6-2 on the cable
connector while actuating the rear
door switch. If there is no continuity,
replace the rear door switch
assembly. If there is continuity,
replace the duplex option system
board.
FRU Action
1 Front Cover Switch
(Not installed on some
duplex units)Check the switch for correct
installation and that the jam removal
tray actuates the switch. Check to
make sure the switch cable is
connected to J7 on the system
board. If no problem is found, check
the continuity between J7-1 and J7-2
on the cable connector while
actuating the front cover switch. If
there is no continuity, replace the
front cover switch assembly. If there
is continuity, replace the duplex
option system board. 
						

							2-394059 Service Manual
4059-XXX
Envelope Feeder Option Service Check
Service Tip: Check the envelope feeder paper path for any debris,
pieces of envelope and so on. If any other options are installed make
sure they are operating normally. If only the envelope feeder is failing
to operate correctly, continue with this service check, otherwise go to
the Interconnect Card Service Check.
Service Tip: The envelope feeder option receives its +5 V dc
operating voltage from the +24 V dc bulk at J1-7. If +24 V dc is not
present at J1-7, tray 1 is the only tray option that is recognized.
Note:If a 260 Paper Jam Check Envelope message displays, check
the“Sub Error Codes For 9XX and 2XX Error Codes” on page 2-7.
Printer does not recognize the envelope feeder as an attached
input option.
FRU Action
1 Envelope Feeder Check to make sure the envelope
feeder is correctly installed and
mated to the autoconnect at the front
of the printer.
2 Front Autoconnect on
PrinterCheck the connector for signs of
damage to the connector or
contacts. If you find damage, replace
the damaged cable/connector
assembly. Remove the envelope
feeder option and check the voltages
at the autoconnect on the front of the
printer. If incorrect, check the
interconnect board. If correct,
reinstall the envelope option and
continue with step 3. 
						

							Diagnostic Information2-40
4059-XXX
3 Autoconnect on the
Envelope OptionCheck the connector for any signs of
damage to the connector or
contacts. If you find damage, replace
the damaged cable/connector
assembly. Disconnect the
autoconnect cable at J1 on the
envelope system board and
measure the following voltages:
J1-3 measures +5 V dc
J1-5 measures +5 V dc
J1-7 measures +24 V dc
If any of the voltages are incorrect,
replace the autoconnect
cable/connector. If the voltages are
correct, replace the envelope system
board. FRU Action 
						

							2-414059 Service Manual
4059-XXX
Operator panel displays 260 Paper Jam immediately when
envelope feed is requested - POST incomplete.
FRU Action
1 Pass through Sensor Check for any debris, pieces of
envelope and so on over the pass
thru sensor. Check for correct
installation of the pass thru sensor
flag. Make sure the sensor cable is
attached to the envelope system
board. Perform an envelope feeder
sensor test to check both the sensor
and sensor flag.
Note:It may be necessary to use a
small tool to actuate the sensor flag
because it is located under the front
cover. Be careful not to damage the
flag.
If the test fails, check the flag for any
signs of damage or binds. If
incorrect, replace the flag. If the flag
is operating correctly, check the
voltage at J3-3. The voltage
measures approximately +5 V dc. If
incorrect, replace the envelope
system board. If correct, check the
voltage at J3-2. The voltage changes
from0to+5Vdcwhentheflagis
moved in and out of the sensor. If
incorrect, replace the sensor
assembly. If this does not fix the
problem, replace the envelope
system board. 
						

							Diagnostic Information2-42
4059-XXX
Operator panel displays 260 Paper Jam after attempted feed but
before envelopes are put in the hopper OR the operator panel
continues to display Load Envelopes after envelopes are placed
in the hopper.
Service Tip: The kick rolls rotate during the attempted feed cycles.
FRU Action
1 Envelope Out Hopper
Sensor FlagCheck the envelope out sensor flag
for damage, correct installation and
operation. If incorrect, repair or
replace the flag.
2 Envelope Out Hopper Input
SensorCheck the sensor to make sure it is
installed correctly and the sensor
cable is properly connected to the
envelope system board. If correct,
perform the Envelope Feed Sensor
Test to check both the sensor and
flag. If the test fails, remove any
envelopes in the hopper, turn the
printer off and disconnect J3 from
the system board. Turn 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. 
						

							2-434059 Service Manual
4059-XXX
990 Service Error, Envelopes fail to feed from the hopper.
260 Paper Jam displays, unable to clear and envelopes fail to feed
from the hopper. Kick rolls ARE NOT rotating.
FRU Action
1 D.C. Feed Motor Assembly Check the motor and motor cable for
any signs of loose wires or poor
connections. Check to make sure
the motor cable is connected to the
envelope system board.
2 Envelope Feeder System
BoardCheck the voltage on J4-1. The
voltage measures approximately
+24 V dc. If incorrect, replace the
envelope system board, if correct,
measure the voltage at J4-6. The
voltage measures approximately
+5 V dc. If incorrect, disconnect J4
and measure the voltage again. If
incorrect, replace the envelope
feeder system board. If correct,
replace the D.C. motor assembly.
FRU Action
1 Main Drive Belt Check the belt for correct installation
and for signs of damage. Replace as
necessary.
2 Gears Check all the gears for correct
installation and for signs of damage.
Repair or replace parts as
necessary.
3 Clutch Latch Assembly Check the clutch latch assembly to
make sure it moves freely.
4 Master Cam Gear Master/
Kick GearCheck the master cam gear and
master/kickgeartomakesurethey
rotate together. If not, then the
tenons on the master kick gear may
be sheared off. If incorrect, replace
the master kick gear.