Lexmark Optra S 1620 Manual

							Diagnostic Information2-44
4059-XXX
260 Paper Jam displays, unable to clear and envelopes fail to feed
from the hopper. Kick rolls ARE rotating.
Check the deflector gap adjustment before continuing this service
check.
FRU Action
1 Deflector Gap Adjustment Check the deflector gap adjustment.
The adjustment may be too narrow.
2 Weight Assembly Check the weight assembly to make
sure it moves up and down freely
without any binds. Also check to
make sure the weight assembly
rests on all the rear kick rollers when
the hopper is empty. Replace the
weight assembly if it is damaged or
does not operate properly.
3 Envelope Edge Guide Check the envelope edge guide to
make sure it is not warped or set too
close to the envelopes in the hopper.
Replace the edge guide if it is
damaged or does not operate
properly. 
						

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260 Paper Jam displays, envelope stops in feeder paper path.
Envelope Feeder multifeeds or may not display a 260 Paper Jam
message.
260 Paper Jam displays. An envelope stopped in the paper path of
the feeder and an envelope also stopped in the base printer paper
path.
FRU Action
1 Kick Rolls/Feed Rolls/Drive
RollsCheck all the rolls for any signs of oil,
grease or other contamination. If you
find a problem, clean or replace
parts as required.
2 Deflector Gap Adjustment Check the deflector gap adjustment.
The adjustment may be too narrow.
FRU Action
1 Envelopes Check the envelopes being used in
the feeder. Check for signs of the
envelopes being stuck together or
signs of glue. Check to make sure
the flaps are not interleaved.
2 Deflector Check the deflector gap adjustment.
The adjustment may be too wide.
3 Restraint Roll Bias Spring Check for a missing, broken or
incorrectly installed restraint roll bias
spring. If incorrect, reinstall or
replace the spring.
FRU Action
1 Latch Lever Check to make sure the tip of the
latch lever is centered in the opening
in the floor of the paper path. The
latch lever may not be detented on
the latch. 
						

							Diagnostic Information2-46
4059-XXX
Erase Lamp Service Check
Error code 928 may be displayed when the printer detects that the
erase lamp assembly, cable or engine board is defective.
Note:If the erase lamp assembly is defective, both the erase lamp
and lens are replaced as a kit.
Make the following checks when a 928 service error displays.
FRU Action
1 Cable, Front Harness Check the connection of the front
harness to connector J10 on the
engine board for correct installation.
If incorrect, repair as necessary.
Check the front harness to erase
lamp assembly for correct
installation. If incorrect, repair as
necessary.
2 Engine Board Remove the controller board and
toner cartridge from the machine.
Ground pin J10-15. The erase lamps
turn on. The lamps can be observed
through the front of the machine with
the cover open and print cartridge
removed. If the lamps do not turn on,
measure the voltage on J10-14. The
voltage reads approximately
+24 V dc. If incorrect, replace the
engine board. If correct, check the
voltage at J10-15. The voltage reads
between +15 V dc to +20 V dc. If
incorrect, check the continuity of the
erase lamp lines in the main
harness. If incorrect, replace the
cableharness.Ifcorrect,replacethe
erase lamp assembly. 
						

							2-474059 Service Manual
4059-XXX
Fan Service Check
Auxiliary Fan Service Check
The auxiliary fan is in models 2420, 2450, 2455 and 3455.
Fan does not run or is noisy.
Main Fan Service Check
Check the cable connections at J1 on the engine board and at the
main fan assembly. The main fan runs continuously when the printer
is powered on unless the printer is in the Power Saver mode.
FRU Action
1 Fan Assembly Check the fan for proper installation
and for excessive noise. If incorrect,
replace the fan and cable assembly.
2 Engine Board Check to make sure the auxiliary fan
cable is seated on connector J7 on
the engine board. If correct, check
for +24 V dc on J7-1 on the engine
board. If incorrect, replace the
engine board. If correct, replace the
fan assembly.
Note:When the printer is in warm-
up the voltage at J7-1 measures
approximately +12 V dc. When the
printer is running, the voltage
measures approximately +24 V dc.
FRU Action
1 Main Fan Manually spin the fan and check that
it rotates freely. Check the cable
connection to the engine board, J1
for correct installation.
2 Main Fan to Engine Board
CableCheck the continuity of the cable. If
incorrect, replace the cable. 
						

							Diagnostic Information2-48
4059-XXX
Fuser Service Check
Cold Fuser Service Check
Error codes 920, 921, and 922 may display for a cold fuser failure. A
920 error caused by low line voltage can sometimes be cleared by
turning the machine off and then on again. A 925 service error
indicates the wrong fuser lamp is installed in the printer and does not
match the one stored in the printer code.
Service Tip: Set the Fuser Temperature to NORMAL before starting
this service check.
3 Error Code 927 (Fan runs) Check the voltage at J1-1 on the
engine board. The voltage measures
+5 V dc (static) 0 V dc (fan running).
If incorrect, replace the main fan. If
this does not fix the problem, replace
the engine board.
4 Error Code 927
(Fan not running)Check the voltage at J1-3 on the
engine board. The voltages are as
follows:
+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 the engine
board. If this does not fix the
problem, replace the main fan.
FRU Action
1 Fuser Lamp (Incorrect
Lamp/925 Service Error)Install the correct voltage and
wattage lamp or fuser assembly. FRU Action 
						

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2 Fuser Lamp Remove the controller board. Run
the Diagnostic Print Test and
observe the lamp through the left
side frame. If the lamp doesn’t come
on, unplug the printer and check the
continuity between the two pins on
the fuser lamp cable going to the
fuser assembly. If you do not
measure continuity, remove the fuser
assembly and check the continuity of
the lamp. If incorrect, replace the
lamp. If correct, replace the fuser
cover assembly.
3LVPSandACFuserLamp
CableTurn the printer off. Disconnect the
fuser lamp connector at the fuser
assembly. Turn the printer on and
check across the pins on LVPS end
of the cable for line voltage. If
incorrect, turn the printer off and
disconnect the power cord and
check the continuity of the AC fuser
lamp cable. If incorrect, replace the
cable. If correct, replace the LVPS.
4 Fuser Top Cover Assembly
(Thermal Fuse/Thermistor
Assembly)Disconnect the thermistor cable from
the fuser board at J2. The resistance
is as follows:
HOT - J2-1 - J2-2 = 2.5K ohms
COLD = 150K ohms to 260K ohms FRU Action 
						

							Diagnostic Information2-50
4059-XXX
Hot Fuser Service Check
Error codes 923 and 924 may display for a hot fuser failure.
CAUTION:The fuser may be hot, use caution before removing or
servicing.
FRU Action
1 Fuser Cover Assembly
(Assembly includes
Thermistor and Thermal
Fuses.)Check for damage to the thermistor
assembly. Check the resistance of
the themistor:
HOT - J2-1 to J2-2 = 2.5K ohms
COLD =150K ohms to 260K ohms
Check the continuity from each pin
of J2 to ground. If there is continuity,
replace the fuser cover assembly
2 Engine Board Error code 924 indicates the engine
board detects an open circuit in the
thermistor circuit for the fuser
assembly. The voltage on J2-6 on
the engine board measures
approximately +5 V dc. If incorrect,
replace the engine board. If correct,
check the continuity of the DC fuser
cable connected between J2 on the
engine board and J1 on the fuser
control board. In there is no
continuity, replace the cable. If there
is continuity, check the voltage on
J2-2 on the fuser control board. It
measures approximately +5 V dc. If
incorrect, replace the fuser control
board.
3 Fuser Hot Roll
Backup Roll BearingsExamine the fuser assembly for
signs of overheating or damage.
Check the hot roll and backup roll for
signs of excessive toner, label glue,
labels or other contaminants. If any
are found, repair as necessary or
replace the fuser assembly. 
						

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4059-XXX
Fuser Envelope Conditioner Solenoid Service Check
The fuser solenoid is in models 3455, 2455, 2450, 2420, 1855,
1650, 1625 and 1620 and the World Trade printer model 2450.
Service Tip: Try changing the envelope enhance level setting. A
different setting may correct the problem.
Note:The level I fuser board uses +42 V dc which is derived from
the LVPS via the interconnect board (J1) and the envelope
conditioner cable. The solenoid is controlled by logic located on the
engine board. The level II fuser board does not use the +42 V dc and
receives control for the solenoid from logic located on the engine
board. A level II engine board can be used with a level I fuser board
provided that the jumpers at JP-1 and JP-2 are correctly positioned
as described in configuration 2. If the jumpers are not correctly
positioned on the engine board, damage can result to the fuser
board.
Engine Board Jumper Configurations
Refer to the“Fuser Board” on page 5-11,“Level 1 Engine Board” on
page 5-9and“Level 2 Engine Board” on page 5-10to identify the
level boards installed in your printer.
1. A level I fuser board and a level I engine board require a
envelope conditioner cable and no jumpers on the engine
board.
2. A level I fuser board and level II engine board require jumpers at
locations JP1-2 to JP1-3 and JP2-2 to JP2-3 on the engine
board.
3. A level II fuser board and level II engine board require jumpers
at locations JP1-1 to JP1-2 and JP2-1 to JP2-2 on the engine
board. 
						

							Diagnostic Information2-52
4059-XXX
Configuration 1
A level 1 fuser board and level 1 engine board are installed in
configuration 1.
Note:Check the fuser envelope conditioner solenoid adjustment as
described in the adjustment section“Fuser Solenoid Adjustment” on
page 4-3.
FRU Action
1 Fuser Envelope Conditioner
SolenoidThe operation of the fuser solenoid
can be observed by removing the
redrive assembly. Check for proper
mechanical operation of the solenoid
and associated hardware, link and so
on. If correct, check the resistance of
the solenoid between J4-1 and J4-2.
The resistance measures between 5
ohms and 10 ohms. If incorrect,
replace the solenoid assembly.
2 Fuser Control Board The solenoid receives power from the
fuser control board. The fuser control
board receives +42Vdc from the LVPS
via the interconnect board and
envelope conditioner cable. Check for
approximately +42 V dc at the
+42 V dc test point on the fuser control
board. If the voltage is correct, replace
the fuser control board. 
						

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3LVPS
Interconnect BoardIf the +42 V dc test point does not
measure approximately +42 V dc,
check the continuity of the cable
connected between J3 on the fuser
control and J1 on the interconnect
board. If the cable does not measure
continuity, replace the cable. If the
cable measures continuity, check the
voltage at CN3-18 on the LVPS. The
voltage measures approximately
+42 V dc. If the voltage is correct,
replace the interconnect board
assembly. If the voltage is incorrect,
replace the LVPS.
4 Fuser DC Cable (Engine
Board to Fuser Board Cable)
Engine BoardCheck for continuity of the DC fuser
cable that is attached between J2 on
the engine board and J1 on the fuser
control board. If the cable does not
measure continuity, replace the cable.
If the cable measures continuity,
replace the engine board. FRU Action