Page 1 Optra 4059-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 2 Comments may be addressed to Lexmark International, Inc., D22A/035-3, 740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.
Page 3: Table Of Contents
4059-XXX Contents Notices and Safety Information ..... . . ix Laser Notices........ix Safety Information .
Page 4 4059-XXX Smart Cartridge Service Check ....2-102 Serial Port Service Check ..... . . 2-104 Toner Sensor Service Check.
Page 5 4059-XXX Print Tests ........3-22 Print Quality Test Pages.
Page 6 4059-XXX Inner EMC Shield....... 4-35 Inner Paper Deflector Assembly ....4-36 Integrated Tray Compensator Assembly .
Page 7 4059-XXX Parts Catalog ......... 7-1 How To Use This Parts Catalog .
Page 8: Notices And Safety Information
4059-XXX Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown: Laser Advisory Label 4059 Service Manual...
Page 9: Class 1 Laser Statement Label
4059-XXX Class 1 Laser Statement Label CLASS 1 LASER PRODUCT LASER KLASSE 1 LUOKAN 1 LASERLAITE APPAREIL À LASER DE CLASSE 1 TO IEC 825 Notices and Safety Information...
Page 10: Laser Notice
4059-XXX Laser Notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 825.
Page 11 4059-XXX Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres.
Page 12 4059-XXX la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico. Declaração sobre Laser A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser.
Page 13 4059-XXX Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Page 14 4059-XXX Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770- 795 nanometer. Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för laserstrålning över Klass I-nivå...
Page 15 4059-XXX Japanese Laser Notice Chinese Laser Notice Notices and Safety Information...
Page 16: Safety Information
This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
Page 17 4059-XXX sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. • Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié.
Page 18 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
Page 19 Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d’aquest producte està...
Page 20: Ozone Information
4059-XXX Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of ozone gas. 4059 Service Manual...
Page 21: Preface
4059-XXX Preface This manual is divided into the following chapters: • “General Information” contains a general description of the printer, options, and the maintenance approach used to repair it. General environmental and safety instructions as well as special tools and test equipment are listed in this chapter. •...
Page 22: General Information
4059-XXX 1. General Information The Optra™ S Laser Printers are letter quality page printers designed to attach to IBM-compatible PC’s and to most computer networks. The printer is available in eleven models. Optra S Model 1250 (4059-121) 1255 (4059-125) 4059 Service Manual...
Page 23 4059-XXX Optra S Models 1620 (4059-162) 1625 (4059-165) 1650 (4059-160) 1855 (4059-185) 1855 (4059-C01) General Information...
Page 24 4059-XXX Optra S Models 2420 (4059-242) 2450 (4059-240) 2455 (4059-245) 3455 (4059-345) 4059 Service Manual...
Page 25: Options
4059-XXX Options The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country. Memory options of 4MB, 8MB, 16MB and 32MB Flash memory options of 4MB and 8MB Integrated network options Token-Ring Ethernet...
Page 26: Maintenance Approach
4059-XXX Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the printer problem and repair the failure.
Page 27: Acronyms
4059-XXX Acronyms Customer Setup DRAM Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process EPROM Erasable, Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Giga Byte HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode LVPS Low Voltage Power Supply...
Page 28: Diagnostic Information
4059-XXX 2. Diagnostic Information Start CAUTION: Remove power from the printer before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the hand grips on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
Page 29: Service Error Codes
4059-XXX Service Error Codes Service Error Codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition. Error Code Action 900 RIP Software Replace the controller board. 901 Engine Flash This error indicates that the flash which the engine board code is programmed into is bad.
Page 30 4059-XXX Error Code Action 910 DC Pick Error Codes 910,911,912,913 and 914 are indications Motor DC Pick that a Tray 1 paper feed problem has been detected. Go Motor Stall to the “Input Tray(s) Option Service Check” on page 2-58. 911 DC Pick Motor Excessive 912 DC pick...
Page 31 4059-XXX Error Code Action 929 Toner Sensor The toner sensor is not operating properly, the developer drive assembly is not operating properly or the print cartridge is defective. Go to the “Remove Paper - Output Bin X is displayed, POST Incomplete, Unable to clear the message.”...
Page 32 4059-XXX Error Code Action 939 Controller - The controller board and the engine board cannot Engine communicate with one another. The controller board, Communications engine board or interconnect board is defective. Check Error each board for correct installation and secure ground. If no problem is found, replace the FRUs in the following order: controller board...
Page 33 4059-XXX Error Code Action 956 Configuration Indicates a problem with the Configuration ID. This error occurs because the engine received a configuration ID from the controller software which is not valid for the level of engine code existing in the printer. Setting the configuration ID correctly should fix this error.
Page 34 4059-XXX Error Code Action 982 <device> Communications error detected by the specified device. Comm 983 <device> Invalid command received by the specified device. 984 <device> Invalid command parameter received by the specified device. Note: Service Errors 980 thru 984 <device> can be one of the following: engine board, duplex, tray x (1,2,3,4 or 5), envelope feeder or bin x (1,2 or 3).
Page 35 4059-XXX Base Printer Sub Error Codes Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays status bytes 1, 2 and 3. This set of status bytes is designed to help isolate paper jams and paper feed problems in the base printer.
Page 36 4059-XXX Status Explanation Bytes 1, 2,3 84 xx 0D Paper Tray 4 pass thru sensor is not activated and never deactivated. A sheet of paper may still be over the sensor or the flag is still activated. 84 xx 0E Paper Tray 3 pass thru sensor is not activated and never deactivated.
Page 37 4059-XXX Envelope Feeder Sub Error Codes Status byte 1 contains the most valuable information to help isolate a feed problem with the envelope feeder and is the only byte contained in the following table. Status Explanation Byte 1 There was no envelope feeder error reported. Printer failed POST - Homing of Envelope feeder Printer failed POST - Halted Envelope Feeder The envelope feeder failed to feed, envelope jam.
Page 38 4059-XXX Status Explanation Byte 4 The leading edge of the sheet of paper never arrived at the exit sensor. Note: This error is the most common due to the long length of the paper path between the input sensor and the exit sensor. The duplex logic thinks a sheet of paper is feeding to the duplex unit due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send a sheet of paper to the...
Page 39: User Status Messages
4059-XXX User Status Messages User Status Message Status Action Ready The printer is ready to Press Menu> or receive and process <Menu to take the data. printer out of Ready and enter all the Menus except the TESTS MENU (Busy State).
Page 40 4059-XXX User Status Message Status Action Printing Menu Settings The printer is processing Press Stop to take the or printing a list of printer out of Ready. current settings menus The Not Ready because Print Menu message is displayed. Settings is selected from No more data is the menu.
Page 41 4059-XXX User Status Message Status Action Restoring Factory The printer is restoring No button actions are Defaults factory defaults. possible while this message is displayed. Performing Self Tests The printer is running No button actions are the normal series of possible while this start-up tests after it is message is displayed.
Page 42 4059-XXX User Status Message Status Action Programming Disk The disk is being No button actions are (Do Not Power Off) programmed, which possible while this means fonts or macros message is displayed. are being written to disk. Note: If information is written to flash memory and to disk at the same time, the...
Page 43: User Error Messages
4059-XXX User Error Messages User Error Message Explanation 200 Paper Jam Paper is jammed at the printer Input Sensor. Remove Cartridge Open the printer’s upper front door and remove the print cartridge to access the paper jam area. 201 Paper Jam Paper is jammed between the printer’s input and Remove Cartridge exit sensors.
Page 44 4059-XXX User Error Message Explanation 31 Defective Print Error code 31 is displayed when the top front Cartridge cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval.
Page 45 4059-XXX User Error Message Explanation 36 Resolution Reduced The resolution of the page has been reduced from 600 dpi to 300 dpi in order to prevent a Memory Full error. This message can only occur if the Resolution Reduction setting is turned on. Note: 1200 dpi pages are not resolution reduced.
Page 46 4059-XXX User Error Message Explanation 56 Standard Serial This error is displayed when data is sent to the Disabled printer across the standard serial port, but the port has been disabled. 56 Parallel Port Disabled This error is displayed when data is sent to the printer across the parallel port, but the parallel port has been disabled.
Page 47 4059-XXX User Error Message Explanation 80 Scheduled The operator panel displays this message at each Maintenance 250K page count interval. It is necessary to replace the fuser assembly, transfer roller, compensator pick-rolls and charge roll at this interval to maintain the print quality and reliability of the printer.
Page 48 4059-XXX User Message Explanation Toner Low If the toner cartridge is low, then “Toner Low” displays. The Toner Low condition clears whenever the upper front door is opened, and Toner Low displays again if the condition exists after the upper front door is closed. Tray X Missing If any of the input trays are missing, then “Tray X Missing”...
Page 49 4059-XXX User Line 2 Link Messages If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, none display. The link messages are listed in the following table. User Message Explanation Parallel Standard Parallel Port, if available.
Page 50 4059-XXX The messages in the following table can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure.
Page 51: Power-On Self Test (Post)
4059-XXX Power-On Self Test (POST) When you turn the printer On, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following: 1. The LED comes on. 2. The operator panel displays one and a half row of pels, then clears.
Page 52: Symptom Tables
4059-XXX Symptom Tables Symptom Table - Base Printer Symptom Action Auxiliary Fan (2420/2450/2455/ Go to the “Auxiliary Fan Service 3455) fails to run or is noisy. Check” on page 2-47. Dead Machine Go to the “Dead Machine Service Check” on page 2-32.
Page 53 4059-XXX Symptom Action Print quality - Background Go to “Print Quality - Background” on page 2-96. Print quality - Residual image Go to “Print Quality - Residual Image” on page 2-100. Print quality - Skew Go to the “Paper Feed Service Check”...
Page 54 4059-XXX Symptom Table: Paper Tray Options Symptom Action Paper feed problem with 250 Go to the “Input Tray(s) Option Sheet Paper Tray Option. Service Check” on page 2-58. Paper feed problem with 500 Go to the “Input Tray(s) Option Sheet Paper Tray Option. Service Check”...
Page 55: Service Checks
4059-XXX Symptom Table - Output Expander Symptom Action Printer does not display Output Go to the “Output Bin Sensor Bin Full Standard Tray Service Check” on page 2-78. Paper does not feed all the way Go to the “Toner Sensor Service into the output tray.
Page 56: Charge Roll Service Check
4059-XXX Charge Roll Service Check Service Tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 inch) apart or spots on the page can be caused by a damaged or contaminated charge roll. To remove the charge roll: 1. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.
Page 57 4059-XXX Action Right Side Charge Roll Link Check the right side charge roll link assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination.
Page 58: Cover Open Switch/Cable Service Check
4059-XXX Cover Open Switch/Cable Service Check Action Toner Cartridge Check the toner cartridge to make sure it is correctly installed and that the right and left hand cartridge tracks are not loose or broken. Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover...
Page 59: Dead Machine Service Check
4059-XXX Dead Machine Service Check Note: Remove any paper handling options before servicing the printer for a dead machine condition. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemblies. Service Tip: When removing the LVPS from the printer observe the following: 1.
Page 60 4059-XXX Action +5 V dc at the engine board Check for +5 V dc at the +5 V dc test Test Point point on the engine board. If correct, replace the engine board. If incorrect, go to step 6. LVPS Fuse F1 Remove the LVPS from the printer and check fuse F1.
Page 61 4059-XXX Action 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.
Page 62: Duplex Option Service Check
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. Action Fuse F1 on Duplex Option If fuse F1 is blown, replace the fuse. System Board If fuse F1 continues to blow, check the stepper motor for a short...
Page 63 4059-XXX POST fails, 230 Paper Jam, Check Duplex message displays. Action Duplex D.C. Servo Drive Check the D.C. servo motor cables Motor 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.
Page 64 4059-XXX 230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way out of the redrive. Action 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.
Page 65 4059-XXX POST fails with Close Duplex Rear Door displayed when Duplex Rear Door is closed. Action Rear Door Switch Check the rear door for correct (Not installed on some installation and operation. Check to duplex units) ensure the cable or connector is not damaged and is properly connected at J6 on the duplex system board.
Page 66: Envelope Feeder Option Service Check
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.
Page 67 4059-XXX Action Autoconnect on the Check the connector for any signs of Envelope Option 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...
Page 68 4059-XXX Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete. Action 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.
Page 69 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. Action Envelope Out Hopper Check the envelope out sensor flag...
Page 70 4059-XXX 990 Service Error, Envelopes fail to feed from the hopper. Action 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.
Page 71 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. Action Deflector Gap Adjustment Check the deflector gap adjustment. The adjustment may be too narrow. Weight Assembly Check the weight assembly to make sure it moves up and down freely...
Page 72 4059-XXX 260 Paper Jam displays, envelope stops in feeder paper path. Action Kick Rolls/Feed Rolls/Drive Check all the rolls for any signs of oil, Rolls grease or other contamination. If you find a problem, clean or replace parts as required. Deflector Gap Adjustment Check the deflector gap adjustment.
Page 73: Erase Lamp Service Check
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.
Page 74: Fan Service Check
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. Action Fan Assembly Check the fan for proper installation and for excessive noise. If incorrect, replace the fan and cable assembly.
Page 75: Fuser Service Check
4059-XXX Action 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.
Page 76 4059-XXX Action 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.
Page 77 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. Action Fuser Cover Assembly Check for damage to the thermistor (Assembly includes assembly.
Page 78: Fuser Envelope Conditioner Solenoid Service Check
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.
Page 79 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. Action Fuser Envelope Conditioner The operation of the fuser solenoid Solenoid can be observed by removing the...
Page 80 4059-XXX Action LVPS If the +42 V dc test point does not Interconnect Board 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.
Page 81 4059-XXX Configuration 2 A level I fuser board and level II engine board are installed in configuration 2. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3. Action Engine Board Jumpers Check to make sure a jumper is installed between JP1-2 and JP1-3 and also between JP2-2 and JP2-3 on...
Page 82 4059-XXX Action LVPS Interconnect Board Check the +42 V dc test point on the Envelope Conditioner Cable fuser control board. If the voltage is incorrect, check the continuity of the envelope conditioner cable. If the cable does not measure continuity, replace the cable.
Page 83 4059-XXX Configuration 3 A level II fuser board and level II engine board without the solenoid cable is installed in configuration 3. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3.
Page 84: Input Sensor Service Check
4059-XXX Action Engine Board Check the +42 V dc test point on the engine board. Go to “Engine Board” on page 5-4 in the locations section to find the +42 V dc test point. Be careful not to short between the test point and any other pin.
Page 85: Input Tray(S) Option Service Check
4059-XXX Input Tray(s) Option Service Check 250 Sheet, 500 Sheet and 500/500 Sheet Input Tray Option Service Tip: Try all the other input paper sources to make sure they are properly feeding paper. For 990 Error Code- Service Tray X, X= displays the number of the tray that has a problem or needs service.
Page 86 4059-XXX 24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (The printer displays the value of X for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1) Action Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating...
Page 87 4059-XXX Tray X Low message displays when Tray X is full or has adequate paper in the tray. Action Paper Low Sensor Run the Tray X Sensor Test and Assembly check the sensor for proper Paper Low Sensor Flag operation. If incorrect, check the Tray X Option System following: Board...
Page 88: High Capacity Feeder Input Tray Service Check
4059-XXX Printer does not recognize Tray X is installed. Action Autoconect Cables Check the autoconnect from the Tray X System Board printer or option above tray x. Check for signs of cuts, pinched wiring or damage to the contacts in the connector.
Page 89 4059-XXX The base printer does not recognize that the high capacity input tray is installed. Action High Capacity Feeder Check the high capacity feeder input Autoconnect Mechanical tray autoconnect to make sure it is Check mounted correctly and is not pushed down into the frame assembly or damaged.
Page 90 4059-XXX Action High Capacity Feeder Check the voltage on J8-1 (green). Option Control Board The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized.
Page 91 4059-XXX 24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (X=The printer displays the value of X for the paper tray where the error occurs. Example: 242 is a Paper Jam Tray 2) Action Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating...
Page 92 4059-XXX Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray. Action Paper Low Switch Run the sensor diagnostics for tray X Paper Low Switch Cable (X=the number that represents the High Capacity Feeder Input high capacity input tray).
Page 93 4059-XXX The elevator tray fails to stop at the correct position and continues to drive into the bottom frame. Action Lower Limit Switch Check continuity of the lower limit Lower Limit Switch Cable switch. If incorrect, replace the switch. If correct, check the switch cable.
Page 94 4059-XXX Paper from the high capacity feeder input tray does not reach the pass thru sensor. Service Tip: Check to be sure the paper in tray is within specifications. Action Autocompensator Check the autocompensator pick Assembly arm rollers for sign of glazing, toner or other buildup.
Page 95 4059-XXX The elevator tray does not move up or down. The printer recognizes that the option is installed. Action Stepper Motor Be sure the motor cable is correctly High Capacity Feeder installed at J1 on the high capacity Option Control Board feeder system board.
Page 96 4059-XXX The elevator moves in one direction only. Action Stepper Motor Check the voltages at J1 on the high High Capacity Feeder capacity system board. The voltage Option Control Board measures as follows: static (motor connected) J1-1 (Orange) +24 V dc J1-2 (Yellow) +24 V dc J1-3 (Green) +24 V dc J1-4 (White) +24 V dc...
Page 97 4059-XXX Paper size switch not selecting paper size that is selected. Action Paper Size Switch Check for continuity between the High Capacity Feeder common pin (J5-1) and the pin of the Option Control Board paper size selected. J5-1 (Black): Common Lead J5-2 (Blue)B5 J5-3 (Green) Executive J5-4 (Yellow) A4...
Page 98 4059-XXX Tray X Empty message displays. Tray does not respond to loading paper. No response from the front door switch. Action High Capacity Feeder Check the voltage on the board at Option Control Board J4-2 (green). The voltage measures approximately +5 V dc. If incorrect, disconnect the cable at J4 and check the voltage again.
Page 99 4059-XXX Excessive Noise or Vibration Action Motor Plate Assembly Be sure the motor plate assembly screws are tight. Be sure the motor mounting screws are tight. Motor Drive Belt Check the belt to be sure it is not too tight. The motor can be adjusted while the motor is running for minimum belt noise and optimum performance.
Page 100: Main Drive Service Check
4059-XXX Main Drive Service Check Service Tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or engine board. Service Tip: If there are equally spaced horizontal lines across the page, go to “Print Quality - Evenly spaced horizontal lines or marks” on page 2-95.
Page 101: Operator Panel Service Check
4059-XXX Action Motor does not turn, no Check the voltages at J12 on the gear error code 936 or User engine board. message 201 Paper Jam displays. 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)
Page 102 4059-XXX Action Engine Board Check the voltage at J11-5. The (No buttons work) 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.
Page 103: Options Service Check
4059-XXX Action Operator Panel all Check to make sure a SIMM is not diamonds, No Beeps plugged in backwards. This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps Operator Panel all Check the voltage at Pin J11-1 and diamonds, 5 Beeps J11-3.
Page 104 4059-XXX 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.
Page 105: Output Bin Sensor Standard Tray Service Check
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.
Page 106: Output Expander Service Check
4059-XXX 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.
Page 107 4059-XXX Action 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.
Page 108 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.
Page 109 4059-XXX Action 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 J4-1 to J4-2: Approximately 10 ohms...
Page 110 4059-XXX Action Output Expander Control Check the voltages at connector J4. Board Level 1 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...
Page 111 4059-XXX Remove Paper - Output Bin X is displayed, POST Incomplete, Unable to clear the message. Action 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.
Page 112 4059-XXX 990 Service - BIN X Action D.C. Motor Check the DC motor cable Mechanical Linkage connector to be sure it is correctly Assembly (Level 2) installed at J4 on the output expander option board. Go to “Output Expander Control Board - Level 2 DC Motor”...
Page 113: Paper Feed Service Check
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. Action Dual Output Bin X Sensor Check for correct installation of...
Page 114 4059-XXX Autocompensator fails to feed paper. Failures occur randomly throughout the stack of paper. Action Pass Through Sensor Check the pass through sensor for correct installation and operation. Autocompensator The autocompensator pick roll shaft Assembly assembly is not providing enough torque if the pick rollers are not picking the paper correctly.
Page 115 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. Action Paper Paper is usually the primary cause of a double feeding paper problem. Flex the paper before placing the paper in the tray.
Page 116: Parallel Port Service Check
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.
Page 117 4059-XXX Service Error Code Explanation Error Code 934 These error codes indicate a Mirror Motor Lost Lock problem with the mirror motor circuit Error Code 935 in the printhead assembly or the Mirror Motor unable to mirror motor cable to the engine reach operating speed board cable or engine board assembly.
Page 118: Print Quality Service Check
4059-XXX 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.
Page 119 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.
Page 120 4059-XXX Action 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.
Page 121 4059-XXX Print Quality - Random Marks Service Tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll or transfer roll. Symptom Action Random Marks Check the print cartridge for any signs of loose or foreign material that might be on the photoconductor.
Page 122 4059-XXX Print Quality - Evenly spaced horizontal lines or marks Action Lines spaced 3.19 mm This can be caused by the motor (.126 inch) apart pinion gear on the main drive motor. Replace the main drive motor. Lines spaced 22.32 mm This can be caused by a defective (.882 inch) apart gear in the main drive gearbox...
Page 123 Print Quality - Background Service Tip: Some background problems can be caused by rough papers or non-Lexmark toner cartridges. If the rough paper mode is on, turn it off and run the print test. Some slick or coated papers may also cause background. Some problems occur with printers that run a large amount of graphics in a humid environment.
Page 124 4059-XXX Action Erase Lamp/Lens Check the erase lamp lens for any Assembly signs of toner, paper dust or other types of contamination. Clean the lens with a soft dry cloth if necessary. If unable to clean the contamination off the lens, replace the lens and lamp assembly.
Page 125 4059-XXX Action Engine Board HVPS Check the following voltages at J10 Connector on the engine board. Measure the voltages from J10 to printer ground. Printer Idle J10-1 approximately 0 V dc J10-2 approximately 4 V dc J10-4 approximately 0 V dc Printer Printing J10-1 varies 0 V dc to +5 V dc J10-2 varies 0 V dc to +4 V dc...
Page 126 4059-XXX Print Quality - Banding Service Tip: Banding is difficult to detect except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds thru the printer, especially in the development and transfer process.
Page 127 4059-XXX Action Charge Roll Assembly Check the charge roll for any signs Charge Roll Link Arm of toner buildup or other contamination on the outer edges that correspond to the bands on the page. Check the charge links and arms for proper operation, binds or incorrectly mounted counterbalance springs.
Page 128 4059-XXX Action Erase Lamp Assembly Check the erase lamp lens assembly for any signs of paper dust, toner buildup or any other contamination. Clean with a soft cloth or replace the lens and lamp assembly which are provided together in a kit. If the lens is clean then check the erase lamp assembly for failed erase lamps.
Page 129: Smart Cartridge Service Check
4059-XXX Print Quality - Toner on backside of printed page Service Tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper. Action Fuser Assembly Toner is being carried out on the backside of the media.
Page 130 4059-XXX Service Tip: An intermittent “32-Unsupported Cartridge” User Error Message can be caused by poor contact between the smart cartridge contacts in the upper front cover and the smart chip. Also check for proper seating of the smart cartridge cable to the engine board.
Page 131: Serial Port Service Check
4059-XXX Serial Port Service Check Run the “Serial Wrap Test” on page 3-12. Note: The Serial Wrap Test is designed to check the serial port hardware by using a wrap plug (P/N 1329048) and invoking the Serial Post Diagnostic Test. The test helps isolate the printer from the serial cable and host.
Page 132: Transfer Roll Service Check
4059-XXX Action Toner Sensor The toner sensor cable is part of the front harness and part of connector J10 on the engine board. Check the voltage at J1-011. It reads approximately +5 V dc. If incorrect, replace the engine board. If correct, check the voltage at J10-12.
Page 133 4059-XXX Action Left Transfer Arm Assembly Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, check to ensure the arm is not broken and will lock into the EP frame correctly.
Page 134: Diagnostic Aids
4059-XXX 3. Diagnostic Aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode. Diagnostic Mode To enter the Diagnostic Mode: 1.
Page 135: Device Tests
4059-XXX Device Tests Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block.
Page 136: Flash Test
4059-XXX – “xxxx Bad Blocks/yyyyyy Usable” message displays if fewer than 2000 bad blocks are detected. xxxx indicates the number of bad blocks and yyyyyy indicates the number of usable blocks. – “xxxx Bad Blocks/Replace Disk” message displays if more than 2000 bad blocks are detected.
Page 137: Duplex Tests
4059-XXX 3. Turn the printer On and release the buttons once “Performing Self Test” displays. – Once the printer is idle, the emulation can be downloaded again. 4. Program the download emulation into the code overlay SIMM again. 5. If these steps do not resolve the problem, replace the code overlay SIMM and download the emulation again.
Page 138: Duplex Sensor Test
4059-XXX 1/100 inch. A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin. 3. Press Return/Stop to exit the test. Check the Top Margin Offset of the base printer. Duplex Sensor Test This test is used to determine whether or not the Duplex sensors and switches are working correctly.
Page 139 4059-XXX The following appears on the printer display: DUPLEX MOTOR AA BB CC DD EE FF To pass the test the following results must display: AA = 00 BB = in the range of 20 through 3F inclusively (hex) CC = in the range of 3A through 5D inclusively (hex) DD = in the range of 11 through 1F inclusively (hex) Ignore bytes EE and FF.
Page 140: Duplex Feed 1 Test
4059-XXX Duplex Feed 1 Test This test feeds a blank sheet of paper to the duplex paper stop position 1. To run the Duplex Feed 1 Test: 1. Select Duplex Feed 1 from the Duplex Test menu. – The power indicator blinks while the paper is feeding. –...
Page 141: Error Log
4059-XXX Error Log Viewing the Error Log The error log is helpful to the servicer by providing a history of printer errors. The error log contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred).
Page 142: Hardware Tests
4059-XXX Hardware Tests The following Hardware Tests can be selected from this menu: LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap (if available) Serial Wrap (if available) Serial 1 Wrap (if available) Serial 3 Wrap (if available) LCD Test To run the LCD Test: 1.
Page 143: Dram Memory Test
4059-XXX DRAM Memory Test The purpose of this test is to check the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Memory Test: 1.
Page 144: Parallel Wrap Test
4059-XXX Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following messages displays for approximately 3 seconds: ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached, the test stops with the power indicator on solid.
Page 145: Serial Wrap Test
4059-XXX DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum count is reached the test stops. The power indicator goes on solid and the final results display.
Page 146 4059-XXX Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following failure messages displays for approximately 3 seconds and the Fail Count increases by 1: Receive Status Interrupt Error Status Error Receive Data Interrupt Error...
Page 147: Input Tray Tests
4059-XXX Input Tray Tests Input Tray Feed Test This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder.
Page 148: Output Bin Test - Standard Bin
4059-XXX The multipurpose tray and the envelope feeder do not have a paper low sensor. The multipurpose tray does not have a pass thru sensor. Output Bin Test - Standard Bin This test is used to verify if the standard bin sensor is working correctly.
Page 149: Output Bin Sensor Test
4059-XXX Output Bin Sensor Test This test is used to verify if the output bin sensors are working correctly. To run the Output Bin Sensor Test: 1. Select Sensor Test from the Output Bin Test menu. – "Output Bin/Full=OP/Input=OP" message displays. –...
Page 150: Base Sensor Test
4059-XXX Output Expander with Dual Sensor: The following is displayed: Output Bin X P=OP F=OP NF=CL P = Pass Thru Sensor F = BIN FULL Sensor (lower part of dual sensor) NF = Near Full Sensor (upper part of dual sensor) Once the message displays, the servicer can manually actuate each of the output bin sensors.
Page 151: Print Registration
4059-XXX Print Registration The print registration range is as follows: Bottom Margin: -20 to +20 Top Margin: -25 to +25 Left Margin: -25 to +25 Right Margin: -10 to +10 To set Print Registration: 1. Select Registration from the Diagnostic menu. 2.
Page 152: Printer Setup
4059-XXX Printer Setup Setting the Page Count This lets the servicer change the page count from the diagnostic menu. This is used whenever the engine board is replaced because this board contains the printer's NVRAM Memory where the page count is stored. To set the Page Count: 1.
Page 153: Maintenance Page Count (2420/2450/2455/3455)
4059-XXX Maintenance Page Count (2420/2450/2455/3455) This counter is reset by the servicer after a “80 Scheduled Maintenance” message displays (250K copies) and a maintenance kit is installed. To view the Maintenance Page Count: 1. Select Maintenance Count Value from the diagnostic menu. 2.
Page 154: Restore Ep Factory Defaults
4059-XXX ID" message displays on Line 2 before the ID redisplays. You have to reenter the Configuration ID until a valid ID is verified. If the ID is valid then the ID is saved in NVRAM and the printer automatically PORs to activate the new setting. Note: When the printer PORs it does so in the normal mode.
Page 155: Print Tests
4059-XXX Print Contrast The print contrast setting controls the developer voltage offset. The print contrast can be adjusted as follows: • • MEDIUM • HIGH Charge Roll The charge roll can be adjusted as follows: • • MEDIUM • HIGH Print Tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options.
Page 156: Print Quality Test Pages
4059-XXX The contents of the Print Test Page varies depending on the media installed in the selected input source. Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting or the presence of a duplex option. To run the Print Test Page: 1.
Page 157: Contents
4059-XXX The following is printed on page 1. • Diagnostic EP Setup: – fuser temperature, warm up time, transfer, print contrast and charge roll settings. • Contents of the Diagnostic Error Log. • Printer configuration information: – printer serial number, controller code level, engine code level, operator panel code level, smart option code levels, font versions, and so on.
Page 158: Autocompensator Operation
4059-XXX Autocompensator Operation The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively.
Page 159: Autoconnect System, Paper Tray Options, Envelope Feeder And Output Expander Operations
4059-XXX Poor gear efficiency can cause the arm to generate higher normal forces. If the pick assembly is noisy, replacement may be required. The arm must pivot freely through its full range of motion. On 500 sheet trays there are wrap springs located on the pivot arbors of the arm.
Page 160: Fuser Operation
This is a complete assembly and the parts cannot be individually replaced as in previous Lexmark laser printers. The thermal fuse protects the fuser assembly from overheating or problems with the fuser lamp by opening the ac circuit to the lamp.
Page 161 4059-XXX the hot roll increases. The thermistor resistance changes from approximately 150K ohms to approximately 260K ohms as the temperature of the fuser hot roll increases. The thermistor is connected to the fuser control board connector J2-1 and J2-2 and from J2 to J1-2 and J1-3 on the fuser control board to J2-6 and J2-7 on the engine board.
Page 162: Paper Feed Jams
4059-XXX Paper Feed Jams Paper Jams - Base Printer Error Message 200 - Paper Jam - Remove Cartridge This message indicates that paper is jammed at the printer input sensor. This condition can be caused by the paper jamming prior to activating the input sensor flag, the sensor not detecting paper over the sensor or paper arriving at the sensor too late.
Page 163 4059-XXX Error Message 250 - Paper Jam - Check MP Feeder The paper is jammed in the multipurpose feeder and has not reached the base machine input sensor or has not reached the input sensor in time. Error Message 260 Paper Jam - Check Envelope Feeder An envelope is jammed in the envelope feeder or has not reached the base machine input sensor.
Page 164: Repair Information
4059-XXX 4. Repair Information WARNING: Read the following before handling electronic parts. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: •...
Page 165: Adjustment Procedures
4059-XXX Adjustment Procedures Duplex Motor Drive Belts Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex motor or loosen the motor or drive belt idler pulley. Service Tip: Excessive belt tension can result in stalling the duplex motor.
Page 166: Fuser Solenoid Adjustment
4059-XXX Fuser Solenoid Adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature.
Page 167: Printhead Assembly Adjustment
4059-XXX Printhead Assembly Adjustment Do the printhead assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws. Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly. Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots.
Page 168: Paper Alignment Assembly Adjustment
4059-XXX Paper Alignment Assembly Adjustment Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one.
Page 169 4059-XXX b. Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings should be within the range specified in “Print Registration” on page 3-18. The reference screw can be adjusted without loosening the locknut.
Page 170: Screw Identification Table
4059-XXX Screw Identification Table The following table contains screw types, locations, and quantities necessary to service the printer. Each screw callout in the removal procedure graphic displays the screw reference number listed in the table. Pay careful attention to each screw type location when doing removals.
Page 171 4059-XXX Reference Screw Type Location Purpose Number M3.5x8 mm spring mounting Thread Cutting controller board mounting (front) integrated tray ITC mounting board left side cover mounting stacker support to right attach side frame M3.5x12 mm engine board shield to attach Thread Cutting left frame paper alignment...
Page 172 4059-XXX Reference Screw Type Location Purpose Number M3x6 mm outer shield mounting Taptite inner redrive deflector mounting interconnect board to mounting center pan engine board mounting (bottom holes) controller board to attach interconnect board ground controller board to inner mounting shield fuser ground wire mounting...
Page 173 4059-XXX Reference Screw Type Location Purpose Number M3x8 mm LVPS mounting Taptite auto compensator mounting hanger bracket M3x12 mm HVPS board mounting Taptite M3x28 mm developer drive ground attach Taptite (bottom hole) M3.5x8 mm upper front cover mounting Plastite Thread left side cover mounting Forming...
Page 174 4059-XXX Reference Screw Type Location Purpose Number M3.5x10 mm right side cover mounting Plastite Thread left side cover mounting Forming left side frame to pan attach M3.5x12 mm left side cover mounting Plastite Thread Forming M3x6 mm fuser board mounting SEMS Machine Screw with washer...
Page 175: Removal Procedures
4059-XXX Removal Procedures CAUTION: Remove power from the printer before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the hand grips on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down.
Page 176 4059-XXX Left Cover 1. Remove the left door. 2. Remove the five mounting screws (A). 4-13 4059 Service Manual...
Page 177 4059-XXX 3. Raise the upper front cover. 4. Remove the three mounting screws (B), the print cartridge and remove the left cover. 4-14 Repair Information...
Page 178 4059-XXX Right Cover 1. Raise the upper front cover. 2. Release the cover latch (A) and remove the right cover mounting screw (B). 4-15 4059 Service Manual...
Page 179 4059-XXX 3. Remove the redrive assembly. 4. Remove the right side cover mounting screws (B) and (C). 5. Remove the right side cover. 4-16 Repair Information...
Page 180 4059-XXX Upper Front Cover 1. Raise the upper front cover. 2. Remove the five upper front cover mounting screws (A) and remove the cover. 4-17 4059 Service Manual...
Page 181: Center Pan Assembly
4059-XXX Laser Assembly Cover 1. Remove the left door. 2. Remove the left cover. 3. Remove the right cover. 4. Remove the rear paper deflector. 5. Press the fuser wiper cover latch and remove the cover. 6. Remove the paper full sensor flag assembly from the mounting bracket.
Page 182: Controller Board
4059-XXX Controller Board 1. Remove the inner EMC shield. 2. Remove the controller board mounting screws (A). 3. Remove the two controller board parallel port mounting screws (B). 4. Remove the serial port mounting screws if present. 5. Remove the controller board. 4-19 4059 Service Manual...
Page 183: Developer Drive Assembly
4059-XXX Developer Drive Assembly 1. Remove the inner EMC shield. 2. Remove the three developer drive assembly mounting screws (A). 3. Remove the developer drive assembly. Note: Be sure the developer drive assembly wheel aligns with the hub on the main drive assembly when reinstalling the assembly. 4-20 Repair Information...
Page 184: Duplex Board
4059-XXX Duplex Board 1. Lift the base printer from the duplex assembly. 2. Remove the four duplex board cover mounting screws. 3. Gently disconnect the cables from the duplex board. Use caution to avoid damage to the cables and connectors. 4.
Page 185: Duplex Motor
4059-XXX Duplex Motor 1. Remove the duplex front cover door. 2. Gently disconnect the cables from the duplex board. Use caution to avoid damage to the cables and connectors. 3. Remove the four mounting screws from the left and right return guides and remove the guides.
Page 186: Engine Board
4059-XXX Engine Board 1. Remove the inner EMC shield. 2. Disconnect all cables from the engine board. 3. Remove the four engine board mounting screws (A). 4. Remove the engine board cage mounting screw (B) from the main drive motor assembly. 5.
Page 187: Fans
4059-XXX Fans Auxiliary Fan (Models 2420/2450/2455/3455) 1. Remove the right cover. 2. Remove the inner EMC shield. 3. Remove the fuser wiper cover. 4. Disconnect the auxiliary fan cable from the engine board at connector J7. 5. Note the routing of the auxiliary fan cable (A) and remove the fan (B).
Page 188 4059-XXX Main Fan 1. Remove the top rear cover. 2. Remove the inner EMC shield. 3. Note the routing of the main fan cable (A) and disconnect the cable from the engine board at connector J1. 4. Release the four latches (B) and remove the fan from the left side frame.
Page 189: Fuser
4059-XXX Caution: Be sure the fuser assembly has cooled before working on any of the fuser FRUs. Note: You must replace cable ties (B) if removed during the fuser removals. The cable ties prevent the fuser wiring from obstructing the paper path through the fuser assembly. Fuser 1.
Page 190: Fuser Board
4059-XXX Fuser Board 1. Remove the fuser assembly. 2. Disconnect the cables (A) from the fuser board. 3. Remove the fuser board mounting screw (B). 4. Release the fuser board from the standoff tab (C) and lift the fuser board from the fuser assembly. 4-27 4059 Service Manual...
Page 191: Fuser Cover
4059-XXX Fuser Cover 1. Remove the fuser assembly. 2. Note the thermistor cable routing and disconnect the cable from the fuser board. 3. Disconnect the thermal fuse cable from the left and right lamp brackets (A). 4. Loosen the left and right lamp bracket mounting screws (B) and remove the thermal fuse cable from the bracket.
Page 192: Fuser Detack Fingers
4059-XXX Fuser Detack Fingers 1. Remove the fuser assembly. 2. Remove the fuser cover assembly. 3. Remove the fuser detack housing assembly. 4. Gently pry the detack finger and spring (A) from the housing assembly. Fuser Detack Housing Assembly 1. Remove the fuser assembly. 2.
Page 193: Fuser Transfer Plate
4059-XXX Fuser Transfer Plate 1. Remove the upper paper deflector. 2. Remove the fuser transfer roll. 3. Remove the inner paper deflector. 4. Lift the left side of the fuser transfer plate (A) and move the plate to the left to clear the right side from its mounting. 5.
Page 194: Fuser Envelope Conditioner Solenoid
4059-XXX Fuser Envelope Conditioner Solenoid The fuser solenoid is in all the models except 1250 and 1255. 1. Remove the fuser assembly. 2. Remove the solenoid mounting screw (A). 3. Disconnect the solenoid link (B). 4. Remove the solenoid from the fuser assembly. Note: Do the “Fuser Solenoid Adjustment”...
Page 195: Fuser Exit Roll Assembly
4059-XXX Fuser Exit Roll Assembly 1. Remove the fuser assembly. 2. Press the exit shaft bushing retaining tabs and slide the left and right bushings (A) toward the inside of the fuser assembly. 3. Remove the exit roll assembly from the slots in the side frame. Note: Be sure the fuser idler gear (B) is in place and the bushing alignment tab is rotated to the correct position in the side frame slot as you snap each bushing in place when reinstalling the exit roll...
Page 196: Fuser Lamp
4059-XXX Fuser Lamp 1. Remove the fuser assembly. 2. Caution: Hold the left lamp bracket and carefully remove the two mounting screws. There is pressure against the other end of the lamp therefore care must be used when removing the lamp from the fuser.
Page 197: High Voltage Power Supply
4059-XXX High Voltage Power Supply 1. Remove the inner paper deflector. 2. Remove the toner sensor cable from the retainer (A) on the front of the HVPS. 3. Remove the right side cover. 4. Disconnect the JVPS cable from the HVPS at connector (C). 5.
Page 198: Inner Emc Shield
4059-XXX Inner EMC Shield 1. Remove the left door. 2. Remove outer EMC shield. 3. Remove all option boards from the connector board slots. 4. Remove the inner EMC shield mounting screws (A). 5. Remove the inner EMC shield. 4-35 4059 Service Manual...
Page 199: Inner Paper Deflector Assembly
4059-XXX Inner Paper Deflector Assembly 1. Remove the paper tray. 2. Remove the upper deflector assembly. 3. Place the printer on its side. 4. Remove the lower deflector assembly. 5. Gently pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer and remove the deflector.
Page 200: Integrated Tray Compensator Assembly
4059-XXX Integrated Tray Compensator Assembly 1. Remove the paper tray. 2. Remove the left door. 3. Remove the inner EMC shield. 4. Disconnect the compensator motor cable from the engine board at connector J18. 5. Place the printer on its side. 6.
Page 201: Integrated Tray Compensator Pick Roll Assembly
4059-XXX Integrated Tray Compensator Pick Roll Assembly 1. Remove the paper tray. 2. Place the printer on its side. 3. Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer. 4. Unsnap the pick roll assembly (D) from its mounting and remove.
Page 202: Interconnect Board Assembly
4059-XXX Interconnect Board Assembly 1. Remove the inner EMC shield. 2. Remove the engine board and shield. 3. Remove the LVPS. 4. Disconnect all cables from the interconnect board. 5. Remove the interconnect board assembly mounting screws (A). 4-39 4059 Service Manual...
Page 203 4059-XXX 6. Place the printer on its back and remove the two mounting screws (A). 7. Remove the interconnect board assembly. 4-40 Repair Information...
Page 204: Left Side Frame
4059-XXX Left Side Frame 1. Remove the main drive assembly. 2. Remove the left side frame mounting screws (A). 4-41 4059 Service Manual...
Page 205 4059-XXX 3. Place the printer on its back and remove the four left side frame mounting screws (A). 4. Remove the left side frame. 4-42 Repair Information...
Page 206: Low Voltage Power Supply
4059-XXX Low Voltage Power Supply 1. Remove the right cover. 2. Remove the two LVPS mounting screws (A) from the rear of the bottom pan. 3. Pull the LVPS assembly from the right side of the printer. Initial resistance is felt as the automate plug disconnects. 4.
Page 207: Main Drive Assembly
4059-XXX Main Drive Assembly 1. Remove the inner EMC shield. 2. Remove the developer drive assembly. 3. Remove the transfer shaft (A) through the bottom of the printer. 4. Remove all cables from the cable clamps (B) on the main drive assembly.
Page 208: Main Drive Motor
4059-XXX Main Drive Motor 1. Remove the main drive assembly. 2. Remove the three main drive motor mounting screws (A). 3. Remove the main drive motor. 4-45 4059 Service Manual...
Page 209: Multipurpose Tray/Lower Deflector Assembly
4059-XXX Multipurpose Tray/Lower Deflector Assembly 1. Open the multipurpose tray to a position that let the left and right tray hinge slots (A) align with the rectangular mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts.
Page 210 4059-XXX 2. Remove the upper deflector. 3. Remove the paper out sensor. (1250, 1620,1650 and 2420) 4. Remove the screws (A) mounting the multipurpose tray/lower deflector assembly. 5. Remove the multipurpose tray/lower deflector assembly. 4-47 4059 Service Manual...
Page 211: Operator Panel
4059-XXX Operator Panel 1. Remove the upper front cover. 2. Gently press the three operator panel lens cover retaining tabs (A) and remove the lens cover. The button membrane is free to remove from the assembly. 3. Disconnect the operator panel cable and remove the operator panel board.
Page 212: Operator Panel Cable/Cover Open Switch Assembly
4059-XXX Operator Panel Cable/Cover Open Switch Assembly Note: Pay careful attention to the cable routing through the printer before you remove the operator panel cable/cover open switch assembly. 1. Remove the left door, left cover, upper front cover, outer EMC shield and inner EMC shield.
Page 213: Optional 250/500 Paper Tray Assembly
4059-XXX Optional 250/500 Paper Tray Assembly Note: Remove the printer and other paper feed options to access the failing optional paper tray assembly. Paper Tray Compensator Assembly 1. Remove the printer and other paper feed options. 2. Disconnect the compensator assembly bias spring from the tray frame.
Page 214: Outer Emc Shield
4059-XXX Outer EMC Shield 1. Remove the left door. 2. Loosen the six outer EMC shield mounting screws (A) and remove the shield. 4-51 4059 Service Manual...
Page 215: Paper Alignment Assembly
4059-XXX Paper Alignment Assembly 1. Remove the upper paper deflector assembly. 2. Remove the inner paper deflector assembly. 3. Release the input paper sensor from its mounting and remove. 4. Remove the left door. 5. Remove the two paper alignment assembly mounting screws (A) located inside the printer.
Page 216: Paper Input Sensor
4059-XXX 6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame and remove the screw. 7. Remove the paper alignment assembly. Note: Do the “Paper Alignment Assembly Adjustment” on page 4-5 when you reinstall the assembly. Paper Input Sensor 1.
Page 217: Paper Size Sensing Board
4059-XXX Paper Size Sensing Board 1. Disconnect the paper size sensing board cable from the board. 2. Remove the two paper size sensing board mounting screws (A). 3. Remove the paper size sensing board. Pick Roll 1. Remove the upper paper deflector. 2.
Page 218: Printhead
4059-XXX Printhead 1. Remove the laser assembly cover. 2. Disconnect the printhead cables (A) from the printhead assembly. 3. Remove the three printhead mounting screws (B) and remove the printhead. Note: Do the “Printhead Assembly Adjustment” on page 4-4 whenever you remove or replace the printhead assembly or loosen the mounting screws.
Page 219: Redrive Assembly
4059-XXX Redrive Assembly 1. Open the redrive door assembly, remove the restraint strap mounting screw and remove the door assembly. 2. Remove the redrive exit cover. 3. Remove the two redrive assembly mounting screws (A). 4. Release the two redrive assembly mounting latches (B) and remove the redrive assembly.
Page 220: Right Side Frame
4059-XXX Right Side Frame 1. Remove the right side cover. 2. Remove the LVPS. 3. Remove the multipurpose tray assembly. 4. Remove the auxiliary fan assembly. 5. Disconnect the auto compensator arm bias spring from the right side frame. 6. Remove the toner sensor mounting screw (A), disconnect the sensor cable and remove the toner sensor.
Page 221: Smart Cartridge Contacts
4059-XXX Smart Cartridge Contacts 1. Remove the upper front cover. 2. Release tab (A) and remove the contact cover. 3. Remove the contact plunger (B). 4. Remove the two screws (C) and remove the contacts (D). 4-58 Repair Information...
Page 222: Toner Sensor
4059-XXX Toner Sensor 1. Remove the right side cover. 2. Remove the toner sensor mounting screw (A). Disconnect the toner sensor cable and remove the toner sensor. 4-59 4059 Service Manual...
Page 223: Transfer Roll Assembly
4059-XXX Transfer Roll Assembly 1. Open the upper front cover and remove the print cartridge. 2. Pivot the transfer roll assembly toward the front of the printer. 3. Unsnap the transfer roll assembly from the left and right pivot arms and remove the transfer roll assembly. Upper Paper Deflector Assembly 1.
Page 224: Upper Front Cover Hinge Assembly
4059-XXX Upper Front Cover Hinge Assembly 1. Remove the upper front cover. 2. Remove the laser assembly cover. 3. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins and remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge.
Page 225: Upper Front Cover Interlock Switch Assembly
4059-XXX Upper Front Cover Interlock Switch Assembly 1. Remove the upper front cover. 2. Remove the operator panel. 3. Remove the inner EMC shield. 4. Press the retaining tabs (A) and remove the interlock switch assembly. 5. Note the routing of the interlock switch assembly cable and disconnect the cable at connector J4 on the engine board.
Page 226: Connector Locations
4059-XXX 5. Connector Locations Low Voltage Power Supply Connector Pin No. Signal CN3 Interconnect +5 V dc Board +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc Ground Ground Ground Ground...
Page 227 4059-XXX Connector Locations...
Page 228: High Voltage Power Supply
4059-XXX High Voltage Power Supply Connector Pin No. Signal CN1 Engine Board Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT 4059 Service Manual...
Page 229: Engine Board
4059-XXX Engine Board Connector Pin No. Signal J1 Main Fan Fan Stall Ground Fan On J2 Fuser Board Exit Sns* Thump B +5 V dc Thump A Ground Hrtherm Thermgnd Narrow Media J3 Printhead (Mirror +24 V dc Return Motor) +24 V dc Return ReFREQ LOCKn...
Page 230 4059-XXX Connector Pin No. Signal J5 Printhead LENA* Ground LAOJ* Ground LASERPWM +5 V dc Ground Video* Ground Ground J6 Output Level Sensor Ground Ground Opt2 Opt1 +5 V dc J7 Auxiliary Fan CRFANONn (Model 2420/2450/2455/ Ground 3455) J8 Printhead HYSNC Ground HSYNC* Ground...
Page 231 4059-XXX Connector Pin No. Signal J10 Erase/Toner AT Servo Sensor/Input Sensor Servo OutT TXENABLE Transfer +24 V dc Charge Ground Developer Ground In Sns* +5 V dc CTSENSE* Ground +24 V dc ERASEPWM* J11 Operator Panel I2COTA +5 V dc PCLKP Ground FPIRQ...
Page 232 4059-XXX Connector Pin No. Signal J12 BLDC Motor +24 V dc +24 V dc Return +24 V dc Return Motor3 Motor4 Motor1 +5 V dc Motor2 Ground Motor0 J13 Autoconnect Ground +5 V dc Ground Ground J14 Autoconnect Ground +5 V dc Ground Ground 4059 Service Manual...
Page 233 4059-XXX Connector Pin No. Signal J15 Integrated Paper +5 V dc Tray PSIZE2 Ground PSIZE1 +24 V dc Ground POUT +5 V dc Paper Low +5 V dc J16 Staging Motor (Not used) J17 MPT Pick MPT Pick +24 V dc J18 Auto Compensator +24 V dc Ground...
Page 234 4059-XXX Level 1 Engine Board 4059 Service Manual...
Page 235 4059-XXX Level 2 Engine Board 5-10 Connector Locations...
Page 236: Fuser Board
4059-XXX Fuser Board Level 1 Connector Pin No. Signal J1 Engine Board NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* J2 Thermistor ThermGnd HRTherm J3 Thumper Ground +42V dc J4 Thumper Solenoid ThumpB ThumpA J5 Narrow Media +5 V dc Sensor Nar Media Ground...
Page 237 4059-XXX Level 2 Connector Pin No. Signal J1 Engine Board NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* J2 Thermistor ThermGnd HRTherm Not Used J4 Thumper Solenoid ThumpB ThumpA J5 Narrow Media +5 V dc Sensor Nar Media Ground 5-12 Connector Locations...
Page 238 4059-XXX 5-13 4059 Service Manual...
Page 239: Interconnect Board
4059-XXX Interconnect Board Connector Pin No. Signal J1 Fuser Solenoid +42 V dc (Model1620/1625/ Ground 1650/1855/2420/2450/ 2455) J2 LVPS +42 V dc Heaton Xeroxing +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground J3 LVPS Ground Ground Ground Ground...
Page 240 4059-XXX Connector Pin No. Signal J5 Autoconnect +24 V dc BTM/FNT Ground J6 Engine Board J7 Controller Board J8 ID-1 J9 ID-2 J10 ID-3 J11 INA 1 (1250/1255) J12 INA 2 (1620/1625/1650/ 1855/2420) J13 INA 3 (2450/2455/3455) Models 1250 and 1255 5-15 4059 Service Manual...
Page 241 4059-XXX Models 1620, 1625, 1650, 1855, 2420, 2450, 2455 and 3455 • Models 1650, 1855, and 2420 do not have connector J13. • Models 1620 and 1625 have a jumper on J10 between the center pin and pin 5. • Model 1855 has a jumper on J8 between the center pin and pin 2, on J9 between the center pin and pin 4 and on J10 between the center pin and pin 5.
Page 242: Envelope Option Board
4059-XXX Envelope Option Board Connector Pin No. Signal Ground Tx (EOC) Ground Rx (EOC) +24 V dc Return +24 V dc Ground Paper Present +5 V dc Ground Paper Present +5 V dc Motor - Phase B- Motor - Phase A- Motor - Phase B+ Motor - Phase A+ 5-17...
Page 243 4059-XXX 5-18 Connector Locations...
Page 244: Duplex Option Board
4059-XXX Duplex Option Board Note: Duplex connectors J10 and J11 are interchangeable. No problem results if the connectors are switched. Connector Pin No. Signal J1 Motor Motor - Motor + J2 DC Motor +5 V dc Sensor Sensor/Encoder Board Tach + Ground J3 Stepper Motor STPMOTA -...
Page 245 4059-XXX Connector Pin No. Signal J9 Autoconnect, Ground Option Below PrtxDout Ground PrtRxd J10 Autoconnect, +24 V dc Option Below Ground J11 Printer +24 V dc Autoconnect Ground J12 Printer Autoconnect Ground PrtxDin Ground PrtRxD Level 1 Duplex Option Board 5-20 Connector Locations...
Page 246: Autoconnect - Top
4059-XXX Level 2 Duplex Option Board Autoconnect - Top Connector Pin No. Signal Top Autoconnect 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc +5 V dc 0 V dc +24 V dc 5-21 4059 Service Manual...
Page 247: Output Expander Control Board - Level 1 Stepper Motor
4059-XXX Output Expander Control Board - Level 1 Stepper Motor Connector Pin No. Signal J1A Autoconnect +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground J2A Autoconnect +24 V dc Ground +5 V dc prtxdout Ground prtrxd Ground J3 Pass Thru Sensor Ground Paper Present...
Page 248 4059-XXX Connector Pin No. Signal J5 Bin Full Sensor Ground Single Sensor +5 V dc RVsnsr 5-23 4059 Service Manual...
Page 249: Output Expander Control Board - Level 2 Dc Motor
4059-XXX Output Expander Control Board - Level 2 DC Motor Connector Pin No. Signal J1A Autoconnect +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground J2A Autoconnect +24 V dc Ground +5 V dc prtxdout Ground prtrxd Ground J3 Pass Thru Sensor Ground Paper Present...
Page 250 4059-XXX Connector Pin No. Signal J4 DC Motor mtrout1 mtrout2 Ground Ground tach + +5 V dc J5 Bin Full/Near Full Ground Dual Sensor Ground binful binful RVsnsr 5-25 4059 Service Manual...
Page 251: Preventive Maintenance
Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover • Possible safety exposure from any non-Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis.
Page 252: Scheduled Maintenance (2420/2450/2455/3455)
4059-XXX Scheduled Maintenance (2420/2450/2455/3455) The operator panel displays the message “80 Scheduled Maintenance” at each 250K page count interval. It is necessary to replace the fuser assembly, transfer roller, compensator pick-rolls and charge roll at this interval to maintain the print quality and reliability of the printer.
Page 253: Parts Catalog
4059-XXX 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.
Page 254: Assembly 1: Covers
4059-XXX Assembly 1: Covers 4059 Service Manual...
Page 255 4059-XXX Asm- Part Units Description Index Number 99A0553 Support, Paper 99A0463 Spacer, Front 2450/2455/3455 99A0464 Spacer, Front 1620/1650/2420/1250/1255/1855/1625 99A0016 Cover, Fuser Wick Assembly 99A0004 Spring, Latch Screw, Right Side Cvr Mtg PP 99A0263 99A0011 Cover, RIght Side 1250/1620/1650/2420/1855/1625 99A0012 Cover, Right Side 2450/2455/3455 99A0008 Hinge, Upper Front Cover 99A0007...
Page 256 4059-XXX Assembly 1: Covers (continued) 4059 Service Manual...
Page 257 4059-XXX Asm- Part Units Description Index Number 1-12 99A0001 Operator Panel Assembly 1-13 99A0009 Cover, Left Side 1250/1255/1620/1650/2420/1855/1625 1-13 99A0010 Cover, Left Side 2450/2455/3455 Screw, Left Side Cvr Mtg PP 99A0263 1-14 99A0017 Door, Left Panel 1650/1855/2420 1-14 99A0019 Door, Left Panel 1250/1255/1620/1625 1-14 99A0018 Door, Left Panel 2450/2455/3455...
Page 258: Assembly 2: Frame
4059-XXX Assembly 2: Frame 4059 Service Manual...
Page 259 4059-XXX Asm- Part Units Description Index Number 99A0425 Support, Cross Brace 99A0463 Spacer, Front 2450/2455/3455 99A0464 Spacer, Front 1250/1255/1620/1650/2420/1855/1625 99A0033 Duct, Left Stacker 2450/2455/3455 99A0034 Duct, Left Stacker 1250/1620/1650/2420/1855/1625 99A0867 Duct, Main Body 99A0551 Support, Left Lower Stacker 99A0114 Duct, LVPS Left Side 99A0113 Pan, Drip ITC 99A0045...
Page 260 4059-XXX Assembly 2: Frame (continued) 4059 Service Manual...
Page 261 4059-XXX Asm- Part Units Description Index Number 2-21 99A0056 Deflector, Upper PF 2-22 99A0055 Deflector, Inner 2-23 99A0042 Frame, EP Module 2-24 99A0053 Sensor, Input 2-25 99A0063 Spring, PA Out Activate 2-26 99A0046 Cover, Gap 1620/1625/1650/1855/2420/2450/2455 2-26 99A0804 Cover, Gap 3455 2-27 99A0549 Shield, ESD Assembly with label...
Page 262: Assembly 3: Printhead
4059-XXX Assembly 3: Printhead 7-10 4059 Service Manual...
Page 263 4059-XXX Asm- Part Units Description Index Number 99A0065 Printhead Assembly, 1620/1625/1650/1250/1255 99A0398 Printhead Assembly, 1855 99A0066 Printhead Assembly, 2420/2450/2455 99A0829 Printhead Assembly, 3455 Screw, Printhead Mounting PP 99A0263 7-11 Parts Catalog...
Page 264: Assembly 4: Paper Feed (Autocompensator)
4059-XXX Assembly 4: Paper Feed (Autocompensator) 7-12 4059 Service Manual...
Page 265 4059-XXX Asm- Part Units Description Index Number 99A0060 Sensor, Paper Out Internal Tray 99A0067 Pick Arm Assembly (250) 99A0070 Pick Rolls Screw, Hanger PP 99A0263 7-13 Parts Catalog...
Page 266: Assembly 5: Paper Feed - Multipurpose Unit
4059-XXX Assembly 5: Paper Feed - Multipurpose Unit 7-14 4059 Service Manual...
Page 267 4059-XXX Asm- Part Units Description Index Number 99A0075 Screw, Socket Set M4X5 mm 1250/1255/1650/1620/2420/1855/1625 99A0071 Arm Assembly, MPT 1620/1650/1250/1255/2420/1855/1625 99A0076 Pick Roll Assembly 1250/1255/1620/1650/2420/1855/1625 99A0081 Spring Assembly, Separator 1620/1650/1250/1255/2420/1855/1625 99A0083 MPT Pad Assembly Kit o Restraint Pad o MPT Pad Assembly 1250/1255/1620/1650/2420/1855/1625 99A0077 Deflector Assembly, MPT...
Page 268: Assembly 6: Paper Feed - Alignment
4059-XXX Assembly 6: Paper Feed - Alignment 7-16 4059 Service Manual...
Page 269 4059-XXX Asm- Part Units Description Index Number 99A0089 Alignment Assembly Paper Feed 99A0492 Screw, Paper Reference Adjustment 99A0566 99A0559 Lever, Bellcrank Release 99A0565 Washer, Reference Adjustment 99A0490 Clip, Reference Ground Screw, Alignment Asm Mtg PP 99A0263 7-17 Parts Catalog...
Page 270: Assembly 7: Paper Feed - Output
4059-XXX Assembly 7: Paper Feed - Output 7-18 4059 Service Manual...
Page 271 4059-XXX Asm- Part Units Description Index Number 99A0090 Deflector Assembly, Inner 500 2450/2455 99A0091 Deflector Assembly, Inner 250 1620/1650/1250/1255/2420/1855/1625 99A0502 Deflector Assembly, Inner 250 1855-C01 99A0109 Deflector Assembly Outer 500 2450/2455 99A0110 Deflector Assembly Outer 250 1620/1650/1250/1255/2420/1855/1625 99A0104 Spring, Upper Diverter 99A0107 Separator, Upper Screw, SEMS-Duplex Path PP 99A0263...
Page 272: Assembly 8: Integrated Paper Tray - 250 Sheet
4059-XXX Assembly 8: Integrated Paper Tray - 250 Sheet 7-20 4059 Service Manual...
Page 273 4059-XXX Asm- Part Units Description Index Number 99A0115 Tray, Integrated 250 Sheet 99A0504 Tray, Integrated 250 Sheet 1855-C01 99A0894 Latch, Back Restraint 99A0120 Restraint Pad 99A0892 Restraint, Side 250 Sheet Tray 99A0119 Wear Strips 99A0123 Indicator Assembly, Paper Size 99A0461 Label, Tray Number 99A0121 Clip, 250 Tray Wear...
Page 274: Assembly 9: Main Drive
4059-XXX Assembly 9: Main Drive 7-22 4059 Service Manual...
Page 275 4059-XXX Asm- Part Units Description Index Number 99A0129 Gearbox, w/Motor 2420/2450/2455 99A0130 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 99A0801 Gearbox, w/Motor 3455 99A0134 Shaft, Power Takeoff 99A0275 Spring, Power Takeoff Shaft 99A0954 Gear, Bevel Screw, Gearbox Mounting PP 99A0263 Screw, Motor Mounting PP 99A0263 99A0260 Clip, Cable 7-23...
Page 276: Assembly 10: Developer Drive
4059-XXX Assembly 10: Developer Drive 7-24 4059 Service Manual...
Page 277 4059-XXX Asm- Part Units Description Index Number 10-1 99A0135 Developer Drive Assembly 10-2 99A0136 Shaft, Developer Drive 10-3 99A0564 Coupler, Gear #55 10-4 Screw, Developer Drive Ground PP 99A0263 10-5 Screw, Developer Drive Mtg PP 99A0263 7-25 Parts Catalog...
Page 278: Assembly 11: Fuser
4059-XXX Assembly 11: Fuser 7-26 4059 Service Manual...
Page 279 4059-XXX Asm- Part Units Description Index Number 11-1 99A0473 Fuser Assembly w/100V 750W Lamp 2420/2450/2455 11-1 99A0474 Fuser Assembly w/115V 750W Lamp 2420/2450/2455 11-1 99A0475 Fuser Assembly w/220V 750W Lamp 2420/2450/2455 11-1 99A0476 Fuser Assembly w/100V 500W Lamp 1620/1650/1855/1625 11-1 99A0477 Fuser Assembly w/115V 500W Lamp 1620/1650/1855/1625...
Page 280 4059-XXX Assembly 11: Fuser (continued) 7-28 4059 Service Manual...
Page 281 4059-XXX Asm- Part Units Description Index Number 11-9 99A0158 Backup Roll, CBM 30 mm 2420/2450/3455 11-9 99A0160 Backup Roll, CBM 22 mm 1620/1650/1250/1255/1855/1625 99A0159 Spacer, Backup Roll 1620/ 1650/1250/1255/1855 11-10 99A0173 Solenoid Assembly, Envelope Conditioner 1620/1625/1650/1855/2420/2450/2455/3455 11-11 Screw, Solenoid Mounting PP 99A0263 11-12 Screw, Board Cover Mounting PP 99A0263 11-13...
Page 282 4059-XXX Assembly 11: Fuser (continued) 7-30 4059 Service Manual...
Page 283 4059-XXX Asm- Part Units Description Index Number 11-29 99A0297 Link, Solenoid 1620/1650/2420/2450/1855/1625/2455/3455 11-30 99A0169 Sensor, Narrow Media 11-31 99A0172 Flag, Exit Sensor 11-32 99A0166 Guide Assembly, Lower Exit w/Narrow Media Sensor 11-33 99A0897 Spring, Redrive Idler 11-34 99A0167 Roller, Redrive Idler 11-35 Tie, Wire PP 99A0577 11-36...
Page 284: Assembly 12: Transfer
4059-XXX Assembly 12: Transfer 7-32 4059 Service Manual...
Page 285 4059-XXX Asm- Part Units Description Index Number 12-1 99A0179 Transfer Roll Assembly 12-1 99A0498 Transfer Roll Assembly 1855-C01 PRC 12-2 99A0349 Arm, Transfer Roll Assembly Right 12-3 99A0184 Spring, Transfer Roll Right 12-4 99A0186 Erase Lamp Assembly Kit o Lamp, Erase Assembly o Lens, Erase Lamp 12-5 99A0185...
Page 286: Assembly 13: Charging
4059-XXX Assembly 13: Charging 7-34 4059 Service Manual...
Page 287 Asm- Part Units Description Index Number 13-1 99A0512 Link Assembly, Charge Left Kit 13-2 99A0513 Link Assembly, Charge Right Kit 13-3 99A1033 Roll Assembly, Charge Screw, Charge Roll PP 99A0263 7-35 Parts Catalog...
Page 288: Assembly 14: Electronics
4059-XXX Assembly 14: Electronics 7-36 4059 Service Manual...
Page 289 4059-XXX Asm- Part Units Description Index Number 14-1 99A0900 Engine Board Assembly with laser cable 1250/1255 14-1 99A0901 Engine Board Assembly with laser cable 1620/1625/1650 14-1 99A0902 Engine Board Assembly with laser cable 1855/1855-C01 14-1 99A0903 Engine Board Assembly with laser cable 2420/2450/2455 14-1 99A0946...
Page 290 4059-XXX Assembly 14: Electronics (continued) 7-38 4059 Service Manual...
Page 291 4059-XXX Asm- Part Units Description Index Number 14-5 Screw, HVPS Mounting PP 99A0263 14-6 Screw, Engine Bd Mounting Top PP 99A0263 14-7 99A0220 High Voltage Power Supply 14-7 99A0827 High Voltage Power Supply 3455 14-8 99A0376 Interconnect Board Assembly 2450/2455/3455 o 3 Slot 14-8 99A0930...
Page 292 4059-XXX Assembly 14: Electronics (continued) 7-40 4059 Service Manual...
Page 293 4059-XXX Asm- Part Units Description Index Number 14-15 99A0236 Cover, INA Blank 99A0408 Cover, INA Flat (Blank) 14-16 Screw, INA Cover Mounting PP 99A0263 2450 14-16 Screw, INA Cover Mounting PP 99A0263 14-16 Screw, INA Cover Mounting PP 99A0263 14-17 99A0213 Engine Board Shield Assembly 14-18...
Page 294 4059-XXX Assembly 14: Electronics (continued) 7-42 4059 Service Manual...
Page 295 4059-XXX Asm- Part Units Description Index Number 14-22 99A0138 Sensor, Standard Bin Level 14-23 99A0030 Fan, Main 14-23 99A0803 Fan, Main 3455 14-24 99A0255 Cable, Main Drive Motor 14-25 99A0129 Gearbox, w/Motor 2450/2420/2455 14-25 99A0130 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 14-25 99A0801 Gearbox, w/Motor 3455 14-26 99A0256...
Page 296 4059-XXX Assembly 14: Electronics (continued) 7-44 4059 Service Manual...
Page 297 4059-XXX Asm- Part Units Description Index Number 14-30 99A0049 Fan, Auxiliary 2450/2455/3455 14-31 99A0466 Sensor, Toner Cartridge Level 14-32 99A0296 Switch, Cover Open w/Operator Panel Cable Assembly 14-33 99A0001 Operator Panel Assembly 14-34 99A0576 Cable, Front Harness 14-34A 99A0815 Contacts, Smart Cartridge 14-34B 99A0814 Cable, Smart Cartridge 3455...
Page 298 4059-XXX Assembly 14: Electronics (continued) 7-46 4059 Service Manual...
Page 299 4059-XXX Asm- Part Units Description Index Number 14-35 99A0065 Printhead Assembly, 1620/1625/1650/1250/1255 14-35 99A0398 Printhead Assembly, 1855/1855-C01 14-35 99A0066 Printhead Assembly, 2420/2450/2455 14-35 99A0829 Printhead Assembly, 3455 14-36 99A0247 Cable, Hysnc 14-37 99A0251 Cable, Laser 14-37 99A0889 Cable, Laser 3455 14-37 99A0888 Cable, Laser 1855/1855-C01...
Page 300: Assembly 15: 250 Sheet Tray
4059-XXX Assembly 15: 250 Sheet Tray 7-48 4059 Service Manual...
Page 301 4059-XXX Asm- Part Units Description Index Number 15-1 99A0287 Pick Arm Assembly 15-2 Screw, Auto Comp Mounting PP 99A0263 15-3 99A0070 Roll Assembly, Pick 99A0438 Bearing, Drive Roll 15-4 99A0448 Arm, Paper Out 250 15-5 99A0266 Base, 250 Option 15-6 99A0026 Tray Bias Arm Assembly 15-7...
Page 302 4059-XXX Assembly 15: 250 Sheet Tray (continued) 7-50 4059 Service Manual...
Page 303 4059-XXX Asm- Part Units Description Index Number 15-27 99A0115 Tray Assembly, 250 Sheet Option 15-27 99A0504 Tray Assembly, 250 Sheet 1855-C01 15-28 99A0119 Wear Strips 15-29 99A0120 Restraint Pad 15-30 99A0123 Indicator Assembly, Paper Size 15-31 99A0461 Label, Tray Number (2-5) 15-32 99A0121 Clip, 250 Tray Wear...
Page 304: Assembly 16: 500 Sheet Tray
4059-XXX Assembly 16: 500 Sheet Tray 7-52 4059 Service Manual...
Page 305 4059-XXX Asm- Part Units Description Index Number 16-1 99A0350 Sensor, Paper Low 16-2 Screw, Auto Comp Mounting PP 99A0263 16-3 99A0405 Pick Arm Assembly 16-4 99A0070 Pick Roll Assembly 16-5 99A0298 Base, 500 Bottom 16-6 99A0058 Pad, Base 500 16-7 99A0419 Spring, Tray Bias 16-8...
Page 306 4059-XXX Assembly 16: 500 Sheet Tray (continued) 7-54 4059 Service Manual...
Page 307 4059-XXX Asm- Part Units Description Index Number 16-31 99A0286 Spring, Backup Roller 16-32 99A0278 Bellcrank, Roller Release 16-33 99A0273 Gear, Bevel 16-34 99A0279 Bearing, Drive Shaft 16-35 99A0281 Cable, 500 Auto Connect Top 16-36 99A0444 Stud Assembly, 500 Frame 16-37 99A0282 Cable, 500 Auto Connect Bottom 16-38...
Page 308: Assembly 17: 500/500 Dual Tray
4059-XXX Assembly 17: 500/500 Dual Tray 7-56 4059 Service Manual...
Page 309 4059-XXX Asm- Part Units Description Index Number 17-1 99A0350 Sensor, Paper Low 17-2 Screw, Auto Comp Mounting PP 99A0263 17-3 99A0405 Pick Arm Assembly 17-4 99A0070 Pick Roll Assembly 17-5 99A0293 Base, 500 Top 17-5 99A0298 Base, 500 Bottom 17-6 99A0514 Screw, Dual 500 Mounting 17-7...
Page 310 4059-XXX Assembly 17: 500/500 Dual Tray (continued) 7-58 4059 Service Manual...
Page 311 4059-XXX Asm- Part Units Description Index Number 17-31 99A0275 Spring, Power Takeoff 17-32 99A0280 Bearing, Drive Shaft Low 17-33 99A0446 Aligner Assembly, Paper 17-34 Retainer, Aligner Assembly PP 99A0267 17-35 99A0300 Board, Tray (Bottom) 17-36 99A0898 Cable, 500 Tray Board to Board Power 17-37 99A0274 Gear, Feed Roll...
Page 312: Assembly 18: Duplex
4059-XXX Assembly 18: Duplex 7-60 4059 Service Manual...
Page 313 4059-XXX Asm- Part Units Description Index Number 18-1 99A0344 Cover, System Board 18-2 99A0322 Main Frame Assembly 18-3 99A0324 Idler Assembly, Belt Tension 18-4 99A0326 Spring, Aligner 18-5 99A0323 Guide Assembly, Paper 18-6 99A0314 Spring, Chassis Ground 18-7 Screw, Motor Mount 3 mm PP 99A0413 18-8 99A0328 Belt, Motor 114 Gear...
Page 314 4059-XXX Assembly 18: Duplex (continued) 7-62 4059 Service Manual...
Page 315 4059-XXX Asm- Part Units Description Index Number 18-20 Screw, Tray Open Switch Mounting PP 99A413 18-21 99A0341 Sensor, Exit - Optical 18-22 99A0342 Guide, LH Lower 18-23 99A0343 Guide, Return LH Upper 18-24 Screw, LH Upper Return Guide Mounting PP 99A0413 18-25 99A0306 Base Assembly, w/Tray Bias...
Page 316 4059-XXX Assembly 18: Duplex (continued) 7-64 4059 Service Manual...
Page 317 4059-XXX Asm- Part Units Description Index Number 18-41 99A0305 Top Cover Assembly, Movable 18-42 99A0303 Top Cover Assembly, Fixed Retainer, 6 mm Top Cover PP 99A0404 18-43 99A0435 Guide, Lower Entry 18-44 99A0338 Guide Assembly, Paper Decurl 18-45 99A0332 Guide, Center Drive Upper 18-46 99A0307 Air Plenum...
Page 318: Assembly 19: Output Expander
4059-XXX Assembly 19: Output Expander 7-66 4059 Service Manual...
Page 319 4059-XXX Asm- Part Units Description Index Number 19-1 99A0107 Diverter, Upper Also order 99A0104 19-2 99A0104 Spring, Upper Diverter 19-3 99A0369 Shaft Assembly, Exit Also order PP 99A0572 19-4 99A0052 Shaft Assembly, Lower Exit Also order PP 99A0572 19-5 Screw, PP 99A0263 19-6 99A0347 Board, Output Expander Level 1...
Page 320 4059-XXX Assembly 19: Output Expander (continued) 7-68 4059 Service Manual...
Page 321 4059-XXX Asm- Part Units Description Index Number 19-21 99A0062 Level Sensor Bracket Level 1 1650/2420/2450 19-21 99A0409 Level Sensor Bracket Level 2 1855/2455/3455 19-22 99A0914 Output Expander Assembly, Mechanical Linkage 19-22 99A0374 Door Assembly, Rear Access 19-23 99A0368 Shaft Assembly, Lower Also order PP 99A0572 19-24 99A0363...
Page 322: Assembly 20: Envelope Feeder
4059-XXX Assembly 20: Envelope Feeder 7-70 4059 Service Manual...
Page 323 4059-XXX Asm- Part Units Description Index Number 20-1 99A0389 Paper Weight Assembly 20-2 99A0391 Guide, Edge 20-3 99A0379 Cover, Top 20-4 99A0393 Clutch, Restraint/Gear 20-5 99A0380 Cover, Right Side 20-5A 99A0407 Base Assembly 20-6 99A0390 Support, Slide Out 20-7 99A0488 Roller, Support 20-8 99A0382...
Page 324 4059-XXX Assembly 20: Envelope Feeder (continued) 7-72 4059 Service Manual...
Page 325 4059-XXX Asm- Part Units Description Index Number 20-11 Gear Kit, PP 99A0271 o Gear, Feed o Gear, Master Cam o Gear, Drive Roll Shaft o Gear, Master/Feed Kick o Gear, Drive Idler o Gear, Comp Drive/Clutch o Gear, Kick Roll Connect o Gear, Kick CNCT Idler o Gear, Feed Shaft Right o Gear, Drive Idler Rear...
Page 326: Assembly 21: High Capacity Feeder
4059-XXX Assembly 21: High Capacity Feeder 7-74 4059 Service Manual...
Page 327 4059-XXX Asm- Part Units Description Index Number 21-1 99A0660 Frame, Printer Support Frame 2 21-2 Screw, Printer Support 2 Frame Mounting PP 99A0675 Washer, Printer Support Frame 2 Star PP 99A0677 Nut, Printer Support Frame 2, 8-32 Hex PP 99A0676 21-3 99A0698 Clamp, Feed Frame...
Page 328 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-76 4059 Service Manual...
Page 329 4059-XXX Asm- Part Units Description Index Number 21-24 Nut, Door Switch Spring Mounting PP 99A0676 21-25 Washer, Card Assembly Mounting PP 99A0677 21-26 99A0686 Guide, Rear Paper with thumb screws Use with 99A0696 21-26 99A0188 Guide, Rear Paper with retainer arm Use with 99A0219 21-27 Screw, Top Frame Mounting PP 99A0675...
Page 330 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-78 4059 Service Manual...
Page 331 4059-XXX Asm- Part Units Description Index Number 21-50 Washer, Power Supply Board PP 99A0677 21-51 99A0667 Power Supply Board 21-52 99A0715 Cable, Low Voltage Power Supply 99A0682 Cable, HCIT-TOC Power 99A0683 Cable, HCIT Power Passthru 99A0684 Cable, HCIT-14Pin Flex 21-53 99A0685 Bushing 21-54...
Page 332 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-80 4059 Service Manual...
Page 333 4059-XXX Asm- Part Units Description Index Number 21-62 99A0281 Cable, 250 Auto Connect 21-63 99A0279 Bearing, Drive Shaft 21-64 99A0273 Gear, Bevel 21-65 Screw, Frame Mounting PP 99A0263 21-66 99A0276 Roll Assembly, Drive 250 Option 21-67 99A0451 Roll, Skew Backup 21-68 Retainer, Roller PP 99A0267 21-69...
Page 334 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-82 4059 Service Manual...
Page 335 4059-XXX Asm- Part Units Description Index Number 21-81 Screw, Auto Comp Assembly Mounting PP 99A0263 21-82 99A0674 Arm Assembly, Pick 2000 21-83 99A0070 Roll Assembly, Pick 21-84 99A0692 Base, 2000 Option 21-85 Screw, Deflector Mounting PP 99A0263 21-86 99A0678 Deflector, Base 21-87 99A0288 Sensor, Pass Thru...
Page 336: Assembly 22: Kiosk - Vertical Paper Adapter
4059-XXX Assembly 22: Kiosk - Vertical Paper Adapter 7-84 4059 Service Manual...
Page 337 4059-XXX Asm- Part Units Description Index Number 22-1 99A0231 Bail, Support 22-2 99A0112 Mounting, Frame Assembly 22-3 99A0197 Shaft, Drive Rear 22-4 Retainer PP 99A0240 22-5 99A0209 Arm Assembly, Pivot 22-6 Screws PP 99A0234 22-7 Parts, Pulley PP 99A0208 22-7B Gear, Idler PP 99A0237 22-8 99A0079...
Page 338: Assembly 23: Kiosk - Horizontal Paper Adapter
4059-XXX Assembly 23: Kiosk - Horizontal Paper Adapter 7-86 4059 Service Manual...
Page 339 4059-XXX Asm- Part Units Description Index Number 23-1 99A0231 Bail, Support 23-2 99A0112 Mounting, Frame Assembly 23-3 99A0197 Shaft, Drive Rear 23-4 Retainer PP 99A0240 23-5 99A0209 Arm Assembly, Pivot 23-6 Screws PP 99A0234 23-7 Parts, Pulley PP 99A0208 23-7B Gear, Idler PP 99A0237 23-8 99A0079...
Page 340: Assembly 24: Options
4059-XXX Assembly 24: Options Asm- Part Units Description Index Number 1328589 2MB DRAM SIMM 99A0517 4MB DRAM SIMM 99A0518 8MB DRAM SIMM 99A0519 16MB DRAM SIMM 99A0520 32MB DRAM SIMM 99A0724 64MB EDO DRAM SIMM 99A0726 DBCS SIMM, Japan 99A0521 1MB Flash SIMM 99A0522 2MB Flash SIMM...
Page 341 4059-XXX Assembly 24: Options (continued) Asm- Part Units Description Index Number 99A0911 Tray Assembly, 250 Special Media 99A0910 Cartridge, 4059 Shipping (2) 99A0909 Cartridge, 4059 Shipping (1) 99A0863 Hopper, Integrated Label/Letter 99A0864 Hopper, Integrated Label/Letter Stacker 99A0865 Hopper, Legal Label Stacker 99A0799 Drive, Forms HD 2.1GB 99A0417...
Page 342: Assembly 25: Miscellaneous
4059-XXX Assembly 25: Miscellaneous Asm- Part Units Description Index Number 99A0263 Parts Packet, Screws 99A0585 Parts Packet, Contact Kit 99A0267 Parts Packet, Retainers 99A0268 Parts Packet, Springs Paper Feed 99A0269 Parts Packet, Duplex Option Fan Mounting 99A0299 Parts Packet, Duplex Option Cam Follower Assembly 99A0271 Parts Packet, Envelope Option Gears...
Page 343 4059-XXX Assembly 25:Miscellaneous (continued) Asm- Part Units Description Index Number 99A0208 Parts Packet, Pulley - Kiosk 99A0234 Parts Packet, Screws - Kiosk 99A0265 Packaging, Short 99A0295 Packaging, Tall with 500/500 Option Tray 99A0248 Packaging, 500/500 Dual Option Tray Assembly 99A0301 Packaging, w/o 500/500 Option Tray 99A0394 Grease Packet, Nyogel 744...
Page 344: Index
4059-XXX Index Error Log Clearing the Error Log Acronyms Viewing the Error Log Adjustment Procedures Hardware Tests Duplex Motor Drive Belts Button Test Fuser Solenoid 3-10 DRAM Memory Test Gap Adjustment LCD Test Paper Alignment Assembly 3-11 Parallel Wrap Test Printhead Assembly 3-10 ROM Memory Test...
Page 345 4059-XXX Error Codes Service Error Codes 3-15 Output Bin Feed Test 2-16 User Error Messages 3-16 Output Bin Sensor Test Error Log 3-15 Output Bin Test - Standard Bin ESD-Sensitive Parts 3-16 Output Bin X Sensor Test Output Expander Control Board-Level 5-22 1 Stepper Motor Flash Test...
Page 346 4059-XXX 4-49 Switch Assembly Optional Paper Tray Assembly 4-12 Removal Procedures 4-50 Removals 4-51 Outer EMC Shield 4-18 Center Pan Assembly 4-52 Paper Alignment Assembly 4-19 Controller Board 4-53 Paper Input Sensor 4-12 Covers 4-54 Paper Size Sensing Board 4-20 Developer Drive Assembly 4-54 Pick Roll...
Page 347 4059-XXX 2-76 Options 2-78 Output Bin Sensor 2-79 Output Expander 2-86 Paper Feed 2-89 Parallel Port 2-91 Print Quality 2-89 Printhead 2-104 Serial Port 2-102 Smart Cartridge 2-104 Toner Sensor 2-105 Transfer Roll 3-20 Setting Configuration ID 3-19 Setting the Page Count 2-12 Status Messages 2-25...

This manual is also suitable for:

43j2200 - optra s 1620 b/w laser printer 43j2600 - optra s 1625 b/w laser printer Optra s 4059 series

Lexmark 43J3400 - Optra S 2455 B/W Laser Printer Service Manual

Notices and Safety Information

Preface

General Information

Diagnostic Information

4059 XXX

Diagnostic Aids

4059 XXX

Repair Information

4059 XXX

Connector Locations

4059 XXX

Parts Catalog

Index

Quick Links

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Summary of Contents for Lexmark 43J3400 - Optra S 2455 B/W Laser Printer