Lexmark 4059-XXX Service Manual
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Lexmark 4059-XXX Service Manual

Lexmark 4059-XXX Service Manual

Lexmark laser printer service manual
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TM
Optra
S
4059-XXX
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
Lexmark and Optra are trademarks of
Lexmark International, Inc., registered
in the United States and/or other
countries.

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Summary of Contents for Lexmark 4059-XXX

  • Page 1 Optra 4059-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index 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 Laser Notices........ix Safety Information .
  • Page 4 Printer Setup ........3-19...
  • 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 Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 825.
  • 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...
  • 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

    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...

  • Page 26: Maintenance Approach

    (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. After you complete the repair, perform tests as needed to verify the repair.

  • 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...

  • Page 28: Diagnostic Information

    2-2. User status messages provide the user with information on the current status of the printer. Ready is displayed on the first line of the display unless Power Saver is invoked, then Power Saver is displayed. If a user status message is displayed, go to the Status Messages”...

  • Page 29: Service Error Codes

    Error Code Action 900 RIP Software Contact the next support level or call Lexmark. 901 Engine Flash This error indicates that the flash which the engine board code is programmed into is bad. Replace the engine board.
  • Page 30 Fuser failed to reach standby temperature. Go to the “Cold Fuser Service Check” on page 923 Fuser Error Fuser is too hot during printing or when printer is idle. Go to the 924 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit.
  • 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 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...
  • Page 33 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. The ID can be set via the NPA data stream or operator panel.
  • Page 34 The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit. The following is an example of how the printer displays a duplex unit sub error code. Byte 1...
  • Page 35 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 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. The D.C. motor failed to reach operating speed.
  • Page 38 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 duplex unit.

  • Page 39: User Status Messages

    4059-XXX User Status Messages User Status Message Ready Ready/Hex Busy Flushing Buffer Status The printer is ready to receive and process data. The printer is ready and HEX Trace is active, which is known as HEX Trace Ready. The printer is busy receiving or processing data, or printing data.
  • Page 40 4059-XXX User Status Message Printing Menu Settings Printing Directory List 2-13 4059 Service Manual Status The printer is processing or printing a list of current settings menus because Print Menu Settings is selected from the menu. A directory of the flash...
  • Page 41 4059-XXX User Status Message Restoring Factory Defaults Performing Self Tests Not Ready (Press Go) Resetting Printer Formatting Flash (Do Not Power Off) Program Flash (Do Not Power Off) Formatting Disk Status The printer is restoring factory defaults. The printer is running...
  • Page 42 4059-XXX User Status Message Programming Disk (Do Not Power Off) Menus Disabled Activating Menu Changes 2-15 4059 Service Manual Status The disk is being programmed, which means fonts or macros are being written to disk. The printer menus have been disabled. This occurs when Menu>...

  • Page 43: User Error Messages

    If the paper is not jammed in the duplex unit, then it may be jammed in the rear of the printer. Open the printer rear door to access the jam. Paper is jammed around Tray X (X=tray 1 thru 5).
  • Page 44 Error code 31 is displayed when the top front 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 36 Resolution Reduced 37 Insufficient Collation Memory 38 Memory Full 39 Complex Page 51 Defective Flash 52 Flash Full 53 Unformatted Flash 54 Standard Serial Error 54 Serial Option X Error Explanation The resolution of the page has been reduced from 600 dpi to 300 dpi in order to prevent a Memory Full error.
  • Page 46 4059 Service Manual Explanation This error is displayed when data is sent to the printer across the standard serial port, but the port has been 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 2 is blank. If any of the messages in the table are displayed the following actions can be taken: Press Menu> or <Menu to take the printer offline and access the Ready Menu group. Note: The Menu buttons are not active if Menu Lockout is turned Press Stop to take the printer offline.
  • Page 48 4059-XXX User Message Toner Low Tray X Missing Tray X Empty Tray X Low 2-21 4059 Service Manual Explanation 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.
  • 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...
  • Page 50 • If the option is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, turn the printer off, remove the option and call for service. User Status Message...

  • 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 Auxiliary Fan (2420/2450/2455/ 3455) fails to run or is noisy. Dead Machine Operator Panel - One or more buttons do not work. Operator Panel - Display is blank. Printer sounds 5 beeps.
  • Page 53 4059-XXX Symptom Print quality - Background Print quality - Residual image Print quality - Skew Print quality - Banding Print quality - Random marks Print quality - Toner on backside of printed page Print quality - Vertical black bands on edge of copy Unable to clear a “32-Unsupported Print Cartridge”...
  • Page 54 4059-XXX Symptom Table: Paper Tray Options Symptom Paper feed problem with 250 Sheet Paper Tray Option. Paper feed problem with 500 Sheet Paper Tray Option. Paper feed problem with 500/500 sheet paper tray option. Media fails to pass thru from the lower attached Paper Tray option to the next higher mounted option.

  • Page 55: Service Checks

    Print Quality Problems: Go to page 3-23 and print a test page to help diagnose problems before changing any settings or working on the printer. • Use the resident diagnostics test provided to help isolate a problem before taking the machine apart or removing any options.

  • Page 56: Charge Roll Service Check

    3. Remove the charge roll from the left side charge roll bearing and remove the roll from the printer. Leave the paper wrapped around the charge roll until it is reinstalled. Charge Roll Assembly...
  • Page 57 4059-XXX Right Side Charge Roll Link Action 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 Toner Cartridge Cover Open Switch/Cable Assembly 2-31 4059 Service Manual Action 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.

  • Page 59: Dead Machine Service Check

    Service Tip: When removing the LVPS from the printer observe the following: 1. The LVPS uses a self docking connector that mates with another connector mounted on the left side frame assembly.
  • Page 60 4059-XXX +5 V dc at the engine board Test Point LVPS Fuse F1 LVPS Fuse F1 - Continues to blow after LVPS installed in the printer. LVPS 2-33 4059 Service Manual Action Check for +5 V dc at the +5 V dc test point on the engine board.
  • Page 61 4059-XXX Engine Board Action 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...

  • 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. Fuse F1 on Duplex Option System Board Autoconnect Cables/ Connectors 2-35 4059 Service Manual Action If fuse F1 is blown, replace the fuse.
  • Page 63 4059-XXX POST fails, 230 Paper Jam, Check Duplex message displays. Duplex D.C. Servo Drive Motor Input Sensor, Input Sensor Flag Paper Exit Sensor and Flag Action Check the D.C. servo motor cables for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage.
  • 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. Duplex Stepper Motor 2-37 4059 Service Manual Action 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. Rear Door Switch (Not installed on some duplex units) POST fails with Insert Duplex Front Cover message displayed. Front Cover Switch (Not installed on some...

  • Page 66: Envelope Feeder Option Service Check

    J1-7, tray 1 is the only tray option that is recognized. Note: If a 260 Paper Jam Check Envelope message displays, check “Sub Error Codes For 9XX and 2XX Error Codes” on page Printer does not recognize the envelope feeder as an attached input option. Envelope Feeder...
  • Page 67 4059-XXX Autoconnect on the Envelope Option Action Check the connector for any signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and...
  • Page 68 4059-XXX Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete. Pass through Sensor 2-41 4059 Service Manual Action 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.
  • Page 70 4059-XXX 990 Service Error, Envelopes fail to feed from the hopper. D.C. Feed Motor Assembly Envelope Feeder System Board 260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls ARE NOT rotating. Main Drive Belt...
  • 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. Deflector Gap Adjustment Weight Assembly Envelope Edge Guide Action Check the deflector gap adjustment.
  • Page 72 Envelope Feeder multifeeds or may not display a 260 Paper Jam message. Envelopes Deflector Restraint Roll Bias Spring 260 Paper Jam displays. An envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path. Latch Lever 2-45 4059 Service Manual Action Check all the rolls for any signs of oil, grease or other contamination.

  • 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.

  • Page 74: Fan Service Check

    Check the cable connections at J1 on the engine board and at the main fan assembly. The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode. Main Fan Main Fan to Engine Board...

  • Page 75: Fuser Service Check

    920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error indicates the wrong fuser lamp is installed in the printer and does not match the one stored in the printer code.
  • Page 76 4059-XXX Fuser Lamp LVPS and AC Fuser Lamp Cable Fuser Top Cover Assembly (Thermal Fuse/Thermistor Assembly) 2-49 4059 Service Manual Action Remove the controller board. Run the Diagnostic Print Test and observe the lamp through the left side frame. If the lamp doesn’t come...
  • 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. Fuser Cover Assembly (Assembly includes Thermistor and Thermal Fuses.) Engine Board...

  • Page 78: Fuser Envelope Conditioner Solenoid Service Check

    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.
  • 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 page 4-3. Fuser Envelope Conditioner Solenoid Fuser Control Board “Fuser Solenoid Adjustment”...
  • Page 80 4059-XXX LVPS Interconnect Board Fuser DC Cable (Engine Board to Fuser Board Cable) Engine Board 2-53 4059 Service Manual Action If the +42 V dc test point does not measure approximately +42 V dc, check the continuity of 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 page 4-3. Engine Board Jumpers Fuser Envelope Conditioner...
  • Page 82 4059-XXX LVPS Interconnect Board Envelope Conditioner Cable Fuser DC Cable (Engine board to Fuser Board cable) Engine Board 2-55 4059 Service Manual Action Check the +42 V dc test point on the fuser control board. If the voltage is incorrect, check the continuity of the envelope conditioner 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 page 4-3. Engine Board Jumpers...

  • Page 84: Input Sensor Service Check

    4059-XXX Engine Board LVPS Interconnect Board Input Sensor Service Check Service Tip: Run the base sensor test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor.

  • 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) Pass Thru Sensor and Flag...
  • Page 87 4059-XXX Tray X Low message displays when Tray X is full or has adequate paper in the tray. Paper Low Sensor Assembly Paper Low Sensor Flag Tray X Option System Board Tray X Empty message displays when Tray X has paper in the tray.

  • Page 88: High Capacity Feeder Input Tray Service Check

    4059-XXX Printer does not recognize Tray X is installed. Autoconect Cables Tray X System Board Paper from Tray X does not reach the Pass Thru Sensor. Service Tip: Check the media in tray x to make sure it is within specifications.
  • Page 89 4059-XXX The base printer does not recognize that the high capacity input tray is installed. High Capacity Feeder Autoconnect Mechanical Check Base Printer or option mounted above 14 Pin HCIT Flex Cable Action Check the high capacity feeder input tray autoconnect to make sure it is...
  • Page 90 4059-XXX High Capacity Feeder Option Control Board 2-63 4059 Service Manual Action Check the voltage on J8-1 (green). The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer...
  • 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) Pass Thru Sensor and Flag...
  • Page 92 4059-XXX Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray. Paper Low Switch Paper Low Switch Cable High Capacity Feeder Input System Board Tray X empty message displays when there is paper in the high capacity feeder input tray.
  • Page 93 4059-XXX The elevator tray fails to stop at the correct position and continues to drive into the bottom frame. Lower Limit Switch Lower Limit Switch Cable High Capacity Feeder Control Board The elevator tray down button does not operate. The tray moves to the upper position.
  • 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. Autocompensator Assembly Wear Strips 2-67 4059 Service Manual Action Check the autocompensator pick 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. Stepper Motor High Capacity Feeder Option Control Board Stepper Motor Extension Cable Action Be sure the motor cable is correctly installed at J1 on the high capacity feeder system board.
  • Page 96 4059-XXX The elevator moves in one direction only. Stepper Motor High Capacity Feeder Option Control Board 2-69 4059 Service Manual Action Check the voltages at J1 on the high capacity system board. The voltage measures as follows: static (motor connected)
  • Page 97 4059-XXX Paper size switch not selecting paper size that is selected. Paper Size Switch High Capacity Feeder Option Control Board 24X Paper Jam Check Tray X Message displays when Tray X is empty. No Tray X Message displays. High Capacity Feeder...
  • Page 98 4059-XXX Tray X Empty message displays. Tray does not respond to loading paper. No response from the front door switch. High Capacity Feeder Option Control Board Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate paper in the tray.
  • Page 99 4059-XXX Excessive Noise or Vibration Motor Plate Assembly Motor Drive Belt Lead Screw Bearings Idler Pulley Action Be sure the motor plate assembly screws are tight. Be sure the motor mounting screws are tight. Check the belt to be sure it is not too tight.

  • 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”...

  • Page 101: Operator Panel Service Check

    4059-XXX Motor does not turn, no gear error code 936 or User message 201 Paper Jam displays. Operator Panel Service Check Operator Panel Buttons Service Check Note: Before continuing with this service check do the on page 3-9 in the diagnostic aids chapter. The operator panel cable is a individual cable on some printers and a combination cable assembly with the cover switch cable on later models.
  • Page 102 SERVICE TIP: The printer has detected a problem with the engine board, operator panel cable or operator panel assembly if POST does not complete and the printer emits 5 beeps and stops in a continuous pattern until the printer is turned off. The operator panel cable is a individual cable on some printers and a combination cable assembly with the cover switch cable on later models.

  • Page 103: Options Service Check

    Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Check to make sure that the Memory SIMM is installed correctly and is not broken or damaged.
  • 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

    Service Tip: If more than a single output expander option is installed, check each one to see if the printer recognizes any single option as being installed. If the printer recognizes any of the output expander options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized expander option.
  • Page 107 4059-XXX Output Expander Option Output Expander Assembly Mechanical Linkage Action 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.
  • 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.
  • Page 109 4059-XXX Stepper Motor Level 1 Action 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...
  • Page 110 4059-XXX Output Expander Control Board Level 1 2-83 4059 Service Manual Action Check the voltages at connector J4. Go to “Output Expander Control Board - Level 1 Stepper Motor” on page 5-22. Printer idle J4-1 +21 V dc to +24 V dc...
  • Page 111 4059-XXX Remove Paper - Output Bin X is displayed, POST Incomplete, Unable to clear the message. Dual Output Bin Sensor Flag 271 Paper Jam - Check Bin X. POST Incomplete Pass Thru Sensor and Flag Assembly Control Board 271 Paper Jam - Check Bin X, POST Complete, First Sheet of paper feeds into Output Bin X.
  • Page 112 4059-XXX 990 Service - BIN X D.C. Motor Mechanical Linkage Assembly (Level 2) Output Expander Control Board (Level 2) 2-85 4059 Service Manual Action Check the DC motor cable connector to be sure it is correctly installed at J4 on the output expander option board.

  • 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.
  • Page 114 4059-XXX Autocompensator fails to feed paper. Failures occur randomly throughout the stack of paper. Pass Through Sensor Autocompensator Assembly Wear Strips in Tray X problem is found. Paper feed failures occur only near the top of the stack of paper.
  • 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. Paper Autocompensator Multipurpose Tray Paper fails to feed from the multipurpose tray. The pick roll should make one complete revolution and stop with the flat side down.

  • Page 116: Parallel Port Service Check

    Note: The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug (P/N 1319128) and invoking the Parallel Diagnostic Test. This test helps isolate the printer from the parallel cable and host. The test provides failure information on the display for approximately 3 seconds.
  • Page 117 4059-XXX Service Error Code Error Code 934 Mirror Motor Lost Lock Error Code 935 Mirror Motor unable to reach operating speed Explanation These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the engine board cable or engine board assembly.

  • Page 118: Print Quality Service Check

    Install another print cartridge if available before proceeding with the service checks. • Use Tray 1 to test for print quality of the base printer. Select the following menu settings as indicated. Be sure and note the original settings so you can return the printer to the original customer printer setup.
  • 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 Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom. The printhead used in the printer does not have a mechanical shutter as previous laser printers.
  • 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 Random Marks Print Quality - Blurred or Fuzzy Print...
  • Page 122 4059-XXX Print Quality - Evenly spaced horizontal lines or marks Lines spaced 3.19 mm (.126 inch) apart Lines spaced 22.32 mm (.882 inch) apart Lines spaced 28.7 mm (1.130 inch) apart Lines spaced 47.83 mm (1.883 inch) apart Lines spaced 63.77 mm (2.511 inch) apart...
  • 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 Erase Lamp/Lens Assembly Printhead Transfer Roll Assembly High Voltage Contacts 2-97 4059 Service Manual Action Check the erase lamp lens for any signs of toner, paper dust or other types of contamination. Clean the lens with a soft dry cloth if necessary.
  • Page 125 4059-XXX Engine Board HVPS Connector Action Check the following voltages at J10 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...
  • Page 126 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. Inspect the alignment assembly, main drive assembly and all other paper feed components for signs of wear, dirt, binds, or damage, especially the drive gears.
  • Page 127 4059-XXX Charge Roll Assembly Charge Roll Link Arm HVPS Print Quality - Residual Image Service Tip: Install a new print cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade and other parts inside the print cartridge.
  • Page 128 4059-XXX Erase Lamp Assembly Fuser Assembly Print Quality - Light Print Transfer Roll Right Side Transfer Roll Arm Assembly 2-101 4059 Service Manual Action Check the erase lamp lens assembly for any signs of paper dust, toner buildup or any other contamination.

  • 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. Fuser Assembly Transfer Roll Transfer Plate...
  • 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

    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. The test provides failure information on the display for approximately three seconds.

  • Page 132: Transfer Roll Service Check

    Scheduled Maintenance” message displays. Ask the customer if they have replaced the transfer roll recently. CAUTION: Make sure the printer is powered Off before making any checks on the transfer roll or associated parts for personal safety and to prevent damage to the printer.
  • Page 133 Quality - Background” on page 2-96 Check the voltage at J10-3. The voltage changes from +24 V dc with the printer idle to 0 V dc when the printer runs the print test. If the voltage is incorrect, check the continuity of line J10-3 in the front cable harness to the HVPS.

  • Page 134: Diagnostic Aids

    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

    Error Code 965: Download Emulation Outdated. Time stamps indicate the download emulation and RIP code are incompatible. To help resolve Download Emulation problems the following steps are necessary to instruct the printer to POR without activating any download emulations. To Disable the Download Emulation: 1.

  • Page 137: Duplex Tests

    2. Select Single or Continuous. – The single Duplex Quick test cannot be canceled. The printer attempts to print the Quick Test Page from the default paper source. If the default paper source only supports envelopes, then the page is printed from Tray 1.

  • Page 138: Duplex Sensor Test

    To run the Duplex Motor Test: 1. Select Motor Test from the Duplex Tests menu. The duplex motor test continues to run until the printer is powered off. – The power indicator blinks while the test is running. – The duplexer runs the motor at a high speed and then a low speed and takes an average of the power required for each speed.
  • 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

    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)

  • 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.

  • 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...

  • 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:...

  • Page 147: Input Tray Tests

    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

    1. Select Feed Test from the Output Bin Test menu. 2. Select the output bin you want the paper to exit into. All output bins installed on the printer are shown on the feed test menu. 3. Select either Single (one sheet of media feeds to the selected output bin) or Continuous (media continues feeding to the selected output bin) until Return/Stop is pressed.

  • 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.

  • Page 152: Printer Setup

    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)

    1. Select Configuration ID from the Printer Setup menu. – The current ID displays on the screen. The Configuration ID is on a label located inside the printer. The label is attached to the top front cover hinge assembly and is visible when the top front cover is open.

  • Page 154: Restore Ep Factory Defaults

    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.

  • Page 155: Print Tests

    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. Each of the installed options is listed in the following order in the menu:...

  • Page 156: Print Quality Test Pages

    3. Turn on the printer. 4. Release the buttons once Performing the Self Test displays. 5. The printer performs its normal POR cycle then print one copy of the Print Quality Test pages. If you want more than one copy, perform these steps again.

  • Page 157: Contents

    2. Select Print Menus from the TESTS MENU. The page contains the following information: • A list of all the printer settings contained in the control panel menus and their values. • A list of the installed options and features such as RAM memory SIMMs, optional input paper trays, envelope feeder, duplexer, output bins, flash or disk.

  • 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

    The output expander option attached above the base printer provides power to the option above it. We do not recommend to attach or “Hot Plug” any options with the base printer power turned On.

  • 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 2420, 2450, 2455, 3455, 1620, 1625, 1650 and 1855. The model 2420, 2450 and 2455 printer fuser temperature is 200.8 degrees C while printing at 600 dpi and 163.9 degrees C while printing at 1200 dpi.

  • Page 162: 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

    Gap Adjustment The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the printer. This adjustment does not reduce the printer's overall performance such as pages per minute but can help in reducing the amount of curl of some printed media thus improving media stacking in the output bin.

  • Page 167: Printhead Assembly Adjustment

    To perform the registration adjustment: 1. Turn the printer off. 2. Press and hold: Return and Go. 3. Turn the printer On and release the buttons when “Performing Self Test" displays. 4. Select Registration from the menu. 5. Select Quick Test Page. The test page should only be printed on letter or A4 paper from Tray 1.

  • Page 168: Paper Alignment Assembly Adjustment

    3. Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer. It is not necessary to completely remove the screw. 4. Install the new alignment assembly. Turn the reference screw clockwise with a 7 mm nut driver until it touches the back of the reference plate and tighten the nut with a 5.5 mm wrench.
  • 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

    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 Number M3.5x8 mm Thread Cutting M3.5x12 mm Thread Cutting M3x5 mm Taptite Location spring controller board integrated tray ITC board left side cover stacker support to right side frame engine board shield to left frame paper alignment...
  • Page 172 4059-XXX Reference Screw Type Number M3x6 mm Taptite 4059 Service Manual Location outer shield inner redrive deflector interconnect board to center pan engine board (bottom holes) controller board to interconnect board ground controller board to inner shield fuser ground wire...
  • Page 173 4059-XXX Reference Screw Type Number M3x8 mm Taptite M3x12 mm Taptite M3x28 mm Taptite M3.5x8 mm Plastite Thread Forming Location LVPS auto compensator hanger bracket HVPS board developer drive ground (bottom hole) upper front cover left side cover autocompensator Repair Information...
  • Page 174 4059-XXX Reference Screw Type Number M3.5x10 mm Plastite Thread Forming M3.5x12 mm Plastite Thread Forming M3x6 mm SEMS Machine Screw with washer M3.5x12 mm Plastite Thread Forming with washer 4-11 4059 Service Manual Location right side cover left side cover...

  • Page 175: 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.

  • 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.

  • 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.

  • 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.

  • 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.

  • 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.

  • 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.

  • 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.

  • 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.

  • 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.

  • 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).

  • 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...

  • Page 199: Inner Paper 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. 4-36...

  • Page 200: Integrated Tray Compensator Assembly

    5. Place the printer on its side. 6. Locate the integrated tray compensator assembly (E) on the bottom of the printer and disconnect the compensator arm bias spring (A) from the frame. 7. Disconnect the compensator sensor cable (B) from the assembly.

  • Page 201: 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

    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. Press the release latch on the fuser lamp cable connector and disconnect from the LVPS.

  • Page 207: Main Drive Assembly

    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

    Be sure the torroid is on the opposite end of the cables near the engine board connectors. 10. Route the cables through the printer and down the inside of the engine board shield. 11. Plug the cables into the engine board connectors.

  • 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.

  • 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.

  • 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

    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.

  • 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 CN3 Interconnect Board 4059 Service Manual Pin No. Signal +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc...
  • Page 227 4059-XXX Connector Locations...

  • Page 228: High Voltage Power Supply

    4059-XXX High Voltage Power Supply Connector CN1 Engine Board 4059 Service Manual Pin No. Signal Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT...

  • Page 229: Engine Board

    4059-XXX Engine Board Connector J1 Main Fan J2 Fuser Board J3 Printhead (Mirror Motor) J4 Cover Closed Switch Pin No. Signal Fan Stall Ground Fan On Exit Sns* Thump B +5 V dc Thump A Ground Hrtherm Thermgnd Narrow Media...
  • Page 230 4059-XXX Connector J5 Printhead J6 Output Level Sensor J7 Auxiliary Fan (Model 2420/2450/2455/ 3455) J8 Printhead HYSNC J9 Fuser Inductor Sense WT 2450 Only 4059 Service Manual Pin No. Signal LENA* Ground LAOJ* Ground LASERPWM +5 V dc Ground Video*...
  • Page 231 4059-XXX Connector J10 Erase/Toner Sensor/Input Sensor J11 Operator Panel Pin No. Signal AT Servo Servo OutT TXENABLE Transfer +24 V dc Charge Ground Developer Ground In Sns* +5 V dc CTSENSE* Ground +24 V dc ERASEPWM* I2COTA +5 V dc...
  • Page 232 4059-XXX Connector J12 BLDC Motor J13 Autoconnect J14 Autoconnect 4059 Service Manual Pin No. Signal +24 V dc +24 V dc Return +24 V dc Return Motor3 Motor4 Motor1 +5 V dc Motor2 Ground Motor0 Ground +5 V dc Ground...
  • Page 233 4059-XXX Connector J15 Integrated Paper Tray J16 Staging Motor J17 MPT Pick J18 Auto Compensator J19 MPT Paper Out J20 Interconnect Board J21 Smart Cartridge (Model 3455 only) Pin No. Signal +5 V dc PSIZE2 Ground PSIZE1 +24 V dc...
  • 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 J1 Engine Board J2 Thermistor J3 Thumper J4 Thumper Solenoid J5 Narrow Media Sensor 5-11 4059 Service Manual Pin No. Signal NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* ThermGnd HRTherm Ground...
  • Page 237 4059-XXX Level 2 Connector J1 Engine Board J2 Thermistor J4 Thumper Solenoid J5 Narrow Media Sensor Pin No. Signal NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* ThermGnd HRTherm Not Used ThumpB ThumpA +5 V dc Nar Media...
  • Page 238 4059-XXX 5-13 4059 Service Manual...

  • Page 239: Interconnect Board

    4059-XXX Interconnect Board Connector J1 Fuser Solenoid (Model1620/1625/ 1650/1855/2420/2450/ 2455) J2 LVPS J3 LVPS J4 Autoconnect Top (Model1620/1625/ 1650/1855/2420/2450/ 2455) Pin No. Signal +42 V dc Ground +42 V dc Heaton Xeroxing +24 V dc +24 V dc +24 V dc...
  • Page 240 4059-XXX Connector J5 Autoconnect BTM/FNT 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 Pin No.
  • 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. •...

  • Page 242: Envelope Option Board

    4059-XXX Envelope Option Board Connector 5-17 4059 Service Manual 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-...
  • 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 J1 Motor J2 DC Motor Sensor/Encoder Board J3 Stepper Motor J4 Fan J5 Paper Input Sensor J6 Rear Cover...
  • Page 245 4059-XXX Connector J9 Autoconnect, Option Below J10 Autoconnect, Option Below J11 Printer Autoconnect J12 Printer Autoconnect Level 1 Duplex Option Board Pin No. Signal Ground PrtxDout Ground PrtRxd +24 V dc Ground +24 V dc Ground Ground PrtxDin Ground PrtRxD...

  • Page 246: Autoconnect - Top

    4059-XXX Level 2 Duplex Option Board Autoconnect - Top Connector Top Autoconnect 5-21 4059 Service Manual Pin No. Signal 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc +5 V dc 0 V dc...

  • Page 247: Output Expander Control Board - Level 1 Stepper Motor

    4059-XXX Output Expander Control Board - Level 1 Stepper Motor Connector J1A Autoconnect J2A Autoconnect J3 Pass Thru Sensor J4 Stepper Motor Pin No. Signal +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground +24 V dc Ground...
  • Page 248 4059-XXX Connector J5 Bin Full Sensor Single Sensor 5-23 4059 Service Manual Pin No. Signal Ground +5 V dc RVsnsr...

  • Page 249: Output Expander Control Board - Level 2 Dc Motor

    4059-XXX Output Expander Control Board - Level 2 DC Motor Connector J1A Autoconnect J2A Autoconnect J3 Pass Thru Sensor Pin No. Signal +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground +24 V dc Ground +5 V dc...
  • Page 250 4059-XXX Connector J4 DC Motor J5 Bin Full/Near Full Dual Sensor 5-25 4059 Service Manual Pin No. Signal mtrout1 mtrout2 Ground Ground tach + +5 V dc Ground Ground binful binful RVsnsr...

  • 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)

    The parts are available as a maintenance kit with the following part numbers: 99A0290 - 100V/750W 2450...

  • Page 253: Parts Catalog

    (Two dot) o o Detail part of a one-dot subassembly (Two dot) o o Subassembly of a one-dot subassembly The Optra S laser printer is available in eleven models. The model designations are as follows: 1250 (4059-121) 1255 (4059-125) 1620 (4059-162)

  • Page 254: Assembly 1: Covers

    4059-XXX Assembly 1: Covers 4059 Service Manual...
  • Page 255 4059-XXX Asm- Part Index Number 99A0553 99A0463 99A0464 99A0016 99A0004 99A0011 99A0012 99A0008 99A0007 99A0023 99A0020 1-8A 99A0022 99A0021 1-10 99A0917 99A0458 1-11 99A0630 1-11 99A0631 1-11 99A0632 1-11 99A0633 1-11 99A0634 1-11 99A0535 1-11 99A0536 1-11 99A0537 1-11 99A0538...
  • Page 256 4059-XXX Assembly 1: Covers (continued) 4059 Service Manual...
  • Page 257 4059-XXX Asm- Part Index Number 1-12 99A0001 1-13 99A0009 1-13 99A0010 1-14 99A0017 1-14 99A0019 1-14 99A0018 1-15 99A0296 1-16 99A0003 1-17 99A0013 99A0552 99A0573 1-18 99A0550 1-19 99A0031 1-20 99A0036 1-21 1-22 99A0814 1-23 99A0816 1-24 99A0815 1-25 99A0817...

  • Page 258: Assembly 2: Frame

    4059-XXX Assembly 2: Frame 4059 Service Manual...
  • Page 259 4059-XXX Asm- Part Index Number 99A0425 99A0463 99A0464 99A0033 99A0034 99A0867 99A0551 99A0114 99A0113 99A0045 99A0039 2-10 99A0058 2-11 99A0558 2-11 99A0828 2-12 99A0904 2-12 99A0561 2-13 99A0111 2-14 99A0043 2-15 99A0049 2-16 2-16A 99A0805 2-17 99A0466 2-18 99A0026 2-19...
  • Page 260 4059-XXX Assembly 2: Frame (continued) 4059 Service Manual...
  • Page 261 4059-XXX Asm- Part Index Number 2-21 99A0056 2-22 99A0055 2-23 99A0042 2-24 99A0053 2-25 99A0063 2-26 99A0046 2-26 99A0804 2-27 99A0549 2-28 99A0029 2-29 99A0128 2-30 99A0189 2-30 99A0037 2-31 99A0899 2-32 99A0044 2-33 99A0567 2-34 99A0555 2-35 99A0556 2-36...

  • Page 262: Assembly 3: Printhead

    4059-XXX Assembly 3: Printhead 7-10 4059 Service Manual...
  • Page 263 4059-XXX Asm- Part Index Number 99A0065 99A0398 99A0066 99A0829 Units Description Printhead Assembly, 1620/1625/1650/1250/1255 Printhead Assembly, 1855 Printhead Assembly, 2420/2450/2455 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 Index Number 99A0060 99A0067 99A0070 Units Description Sensor, Paper Out Internal Tray Pick Arm Assembly (250) 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 Asm- Part Units Index Number 99A0075 99A0071 99A0076 99A0081 99A0083 99A0077 99A0080 99A0021 5-10 99A0084 5-11 99A0082 5-12 99A0078 5-13 99A0073 5-14 5-15 99A0072 5-16 99A0074 Description Screw, Socket Set M4X5 mm 1250/1255/1650/1620/2420/1855/1625 Arm Assembly, MPT 1620/1650/1250/1255/2420/1855/1625 Pick Roll Assembly 1250/1255/1620/1650/2420/1855/1625 Spring Assembly, Separator 1620/1650/1250/1255/2420/1855/1625...

  • 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 Index Number 99A0089 99A0492 99A0566 99A0559 99A0565 99A0490 Units Description Alignment Assembly Paper Feed Screw, Paper Reference Adjustment Lever, Bellcrank Release Washer, Reference Adjustment 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 Index Number 99A0090 99A0091 99A0502 99A0109 99A0110 99A0104 99A0107 99A0891 99A0921 Units Description Deflector Assembly, Inner 500 2450/2455 Deflector Assembly, Inner 250 1620/1650/1250/1255/2420/1855/1625 Deflector Assembly, Inner 250 1855-C01 Deflector Assembly Outer 500 2450/2455 Deflector Assembly Outer 250...

  • 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 Index Number 99A0115 99A0504 99A0894 99A0120 99A0892 99A0119 99A0123 99A0461 99A0121 99A0126 8-10 99A0124 8-11 99A0127 8-12 99A0893 99A0452 99A0501 Units Description Tray, Integrated 250 Sheet Tray, Integrated 250 Sheet 1855-C01 Latch, Back Restraint Restraint Pad Restraint, Side 250 Sheet Tray...

  • Page 274: Assembly 9: Main Drive

    4059-XXX Assembly 9: Main Drive 7-22 4059 Service Manual...
  • Page 275 4059-XXX Asm- Part Index Number 99A0129 99A0130 99A0801 99A0134 99A0275 99A0954 99A0260 Units Description Gearbox, w/Motor 2420/2450/2455 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 Gearbox, w/Motor 3455 Shaft, Power Takeoff Spring, Power Takeoff Shaft Gear, Bevel Screw, Gearbox Mounting PP 99A0263 Screw, Motor Mounting PP 99A0263...

  • Page 276: Assembly 10: Developer Drive

    4059-XXX Assembly 10: Developer Drive 7-24 4059 Service Manual...
  • Page 277 4059-XXX Asm- Part Index Number 10-1 99A0135 10-2 99A0136 10-3 99A0564 10-4 10-5 Units Description Developer Drive Assembly Shaft, Developer Drive Coupler, Gear #55 Screw, Developer Drive Ground PP 99A0263 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 Index Number 11-1 99A0473 11-1 99A0474 11-1 99A0475 11-1 99A0476 11-1 99A0477 11-1 99A0478 11-1 99A0524 11-1 99A0525 11-1 99A0526 11-1 99A0830 11-1 99A0831 11-2 99A0146 11-2 99A0725 11-3 99A0918 11-4 11-5 99A0147 11-6 99A0156 11-6 99A0833...
  • Page 280 4059-XXX Assembly 11: Fuser (continued) 7-28 4059 Service Manual...
  • Page 281 4059-XXX Asm- Part Index Number 11-9 99A0158 11-9 99A0160 99A0159 11-10 99A0173 11-11 11-12 11-13 99A0557 11-14 99A0547 11-15 11-16 99A0196 11-17 99A0170 11-17 99A0171 11-17 99A0826 11-18 99A0546 11-19 11-20 99A0142 11-21 99A0143 11-22 99A0150 11-23 99A0163 11-23 99A0162...
  • Page 282 4059-XXX Assembly 11: Fuser (continued) 7-30 4059 Service Manual...
  • Page 283 4059-XXX Asm- Part Index Number 11-29 99A0297 11-30 99A0169 11-31 99A0172 11-32 99A0166 11-33 99A0897 11-34 99A0167 11-35 11-36 99A0140 11-36 99A0141 11-36 99A0177 11-36 99A0178 11-36 99A0175 11-36 99A0176 99A0145 99A0919 Units Description Link, Solenoid 1620/1650/2420/2450/1855/1625/2455/3455 Sensor, Narrow Media...

  • Page 284: Assembly 12: Transfer

    4059-XXX Assembly 12: Transfer 7-32 4059 Service Manual...
  • Page 285 4059-XXX Asm- Part Index Number 12-1 99A0179 12-1 99A0498 12-2 99A0349 12-3 99A0184 12-4 99A0186 12-5 99A0185 12-6 99A0181 12-7 99A0354 Units Description Transfer Roll Assembly Transfer Roll Assembly 1855-C01 PRC Arm, Transfer Roll Assembly Right Spring, Transfer Roll Right...

  • Page 286: Assembly 13: Charging

    4059-XXX Assembly 13: Charging 7-34 4059 Service Manual...
  • Page 287 Asm- Part Units Index Number 13-1 99A0512 13-2 99A0513 13-3 99A1033 Description Link Assembly, Charge Left Kit Link Assembly, Charge Right Kit 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 Index Number 14-1 99A0900 14-1 99A0901 14-1 99A0902 14-1 99A0903 14-1 99A0946 14-2 1342514 14-2 1339538 14-2 1342536 14-2 1342537 14-2 1339539 14-2 1339540 14-2 1339541 14-2 1342534 14-2 1339543 14-2 1339542 14-2 1374067 14-2 99A0471 14-2...
  • Page 290 4059-XXX Assembly 14: Electronics (continued) 7-38 4059 Service Manual...
  • Page 291 4059-XXX Asm- Part Index Number 14-5 14-6 14-7 99A0220 14-7 99A0827 14-8 99A0376 14-8 99A0930 14-8 99A0960 14-9 14-9 14-9 14-9 14-10 14-11 99A0426 14-12 14-13 99A0187 14-13 99A0840 14-13 99A0841 14-13 99A0183 14-13 99A0842 14-13 99A0139 14-13 99A0844 14-13...
  • Page 292 4059-XXX Assembly 14: Electronics (continued) 7-40 4059 Service Manual...
  • Page 293 4059-XXX Asm- Part Index Number 14-15 99A0236 99A0408 14-16 14-16 14-16 14-17 99A0213 14-18 99A0239 14-18 99A0238 14-18 99A0235 14-19 99A0207 14-19 99A0206 14-19 99A0204 99A0224 99A0229 99A0230 99A0243 99A0244 99A0245 14-20 14-20 14-21 99A0260 Units Description Cover, INA Blank...
  • Page 294 4059-XXX Assembly 14: Electronics (continued) 7-42 4059 Service Manual...
  • Page 295 4059-XXX Asm- Part Index Number 14-22 99A0138 14-23 99A0030 14-23 99A0803 14-24 99A0255 14-25 99A0129 14-25 99A0130 14-25 99A0801 14-26 99A0256 14-27 99A0128 14-28 99A0254 14-29 99A0257 Units Description Sensor, Standard Bin Level Fan, Main Fan, Main 3455 Cable, Main Drive Motor...
  • Page 296 4059-XXX Assembly 14: Electronics (continued) 7-44 4059 Service Manual...
  • Page 297 4059-XXX Asm- Part Index Number 14-30 99A0049 14-31 99A0466 14-32 99A0296 14-33 99A0001 14-34 99A0576 14-34A 99A0815 14-34B 99A0814 Units Description Fan, Auxiliary 2450/2455/3455 Sensor, Toner Cartridge Level Switch, Cover Open w/Operator Panel Cable Assembly Operator Panel Assembly Cable, Front Harness...
  • Page 298 4059-XXX Assembly 14: Electronics (continued) 7-46 4059 Service Manual...
  • Page 299 4059-XXX Asm- Part Index Number 14-35 99A0065 14-35 99A0398 14-35 99A0066 14-35 99A0829 14-36 99A0247 14-37 99A0251 14-37 99A0889 14-37 99A0888 14-38 99A0249 14-39 99A0173 14-40 99A0170 14-40 99A0171 14-40 99A0826 14-41 99A0027 14-42 99A0169 14-43 99A0252 14-44 99A0258 14-45...

  • 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 Index Number 15-1 99A0287 15-2 15-3 99A0070 99A0438 15-4 99A0448 15-5 99A0266 15-6 99A0026 15-7 99A0419 15-8 99A0058 15-9 99A0288 15-10 99A0272 15-11 99A0275 15-12 99A0282 15-13 99A0451 15-13B 99A0450 15-14 99A0276 15-15 15-16 99A0277 99A0278 15-17...
  • Page 302 4059-XXX Assembly 15: 250 Sheet Tray (continued) 7-50 4059 Service Manual...
  • Page 303 4059-XXX Asm- Part Index Number 15-27 99A0115 15-27 99A0504 15-28 99A0119 15-29 99A0120 15-30 99A0123 15-31 99A0461 15-32 99A0121 15-33 99A0126 15-34 99A0124 15-35 99A0127 15-36 99A0894 15-37 99A0893 15-38 99A0892 99A0429 99A0286 99A0446 99A0501 Units Description Tray Assembly, 250 Sheet Option...

  • 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 Index Number 16-1 99A0350 16-2 16-3 99A0405 16-4 99A0070 16-5 99A0298 16-6 99A0058 16-7 99A0419 16-8 99A0026 16-9 99A0288 16-10 99A0895 16-11 99A0292 16-12 99A0123 16-13 99A0461 16-14 99A0457 16-15 99A0126 16-16 99A0124 16-17 99A0418 16-18 99A0120...
  • Page 306 4059-XXX Assembly 16: 500 Sheet Tray (continued) 7-54 4059 Service Manual...
  • Page 307 4059-XXX Asm- Part Index Number 16-31 99A0286 16-32 99A0278 16-33 99A0273 16-34 99A0279 16-35 99A0281 16-36 99A0444 16-37 99A0282 16-38 99A0438 16-39 99A0277 16-40 16-41 99A0451 16-42 99A0450 16-43 99A0276 16-44 99A0443 99A0429 Units Description Spring, Backup Roller Bellcrank, Roller Release...

  • 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 Index Number 17-1 99A0350 17-2 17-3 99A0405 17-4 99A0070 17-5 99A0293 17-5 99A0298 17-6 99A0514 17-7 99A0026 17-8 99A0419 17-9 99A0058 17-10 99A0288 17-11 99A0895 17-12 99A0292 17-13 99A0123 17-14 99A0461 17-15 99A0457 17-16 99A0126 17-17 99A0124...
  • Page 310 4059-XXX Assembly 17: 500/500 Dual Tray (continued) 7-58 4059 Service Manual...
  • Page 311 4059-XXX Asm- Part Index Number 17-31 99A0275 17-32 99A0280 17-33 99A0446 17-34 17-35 99A0300 17-36 99A0898 17-37 99A0274 17-38 99A0286 17-39 99A0472 17-40 99A0278 17-41 99A0273 17-42 99A0063 17-43 99A0279 17-44 99A0281 17-45 99A0444 17-46 99A0443 17-47 99A0284 17-47 99A0397...

  • Page 312: Assembly 18: Duplex

    4059-XXX Assembly 18: Duplex 7-60 4059 Service Manual...
  • Page 313 4059-XXX Asm- Part Index Number 18-1 99A0344 18-2 99A0322 18-3 99A0324 18-4 99A0326 18-5 99A0323 18-6 99A0314 18-7 18-8 99A0328 18-9 99A0329 18-10 99A0321 18-11 99A0320 18-12 18-13 99A0312 18-14 18-15 99A0339 18-16 18-17 99A0340 18-18 99A0345 18-19 99A0261 99A0432...
  • Page 314 4059-XXX Assembly 18: Duplex (continued) 7-62 4059 Service Manual...
  • Page 315 4059-XXX Asm- Part Index Number 18-20 18-21 99A0341 18-22 99A0342 18-23 99A0343 18-24 18-25 99A0306 18-26 99A0316 18-27 99A0315 18-28 99A0325 18-29 99A0280 18-30 99A0311 18-31 99A0274 18-32 99A0310 18-33 18-34 99A0317 18-35 99A0434 18-36 99A0279 18-37 99A0191 18-38 99A0403...
  • Page 316 4059-XXX Assembly 18: Duplex (continued) 7-64 4059 Service Manual...
  • Page 317 4059-XXX Asm- Part Index Number 18-41 99A0305 18-42 99A0303 18-43 99A0435 18-44 99A0338 18-45 99A0332 18-46 99A0307 18-47 99A0335 18-48 99A0334 18-49 99A0327 18-50 18-51 99A0330 18-52 18-53 99A0308 18-54 18-55 99A0337 18-56 99A0319 18-57 99A0433 18-58 99A0304 18-59 18-60...

  • Page 318: Assembly 19: Output Expander

    4059-XXX Assembly 19: Output Expander 7-66 4059 Service Manual...
  • Page 319 4059-XXX Asm- Part Index Number 19-1 99A0107 19-2 99A0104 19-3 99A0369 19-4 99A0052 19-5 19-6 99A0347 19-6 99A0406 19-6 99A0915 19-7 99A0571 19-8 99A0483 19-9 99A0924 19-10 99A0925 19-11 99A0482 19-12 99A0366 19-13 99A0480 19-13 99A0914 19-14 99A0372 19-15 99A0415...
  • Page 320 4059-XXX Assembly 19: Output Expander (continued) 7-68 4059 Service Manual...
  • Page 321 4059-XXX Asm- Part Index Number 19-21 99A0062 19-21 99A0409 19-22 99A0914 19-22 99A0374 19-23 99A0368 19-24 99A0363 19-25 99A0371 19-26 99A0361 19-27 99A0362 19-28 99A0364 19-29 99A0351 19-30 99A0370 19-30 99A0913 19-31 99A0912 99A0429 Units Description Level Sensor Bracket Level 1 1650/2420/2450...

  • Page 322: Assembly 20: Envelope Feeder

    4059-XXX Assembly 20: Envelope Feeder 7-70 4059 Service Manual...
  • Page 323 4059-XXX Asm- Part Index Number 20-1 99A0389 20-2 99A0391 20-3 99A0379 20-4 99A0393 20-5 99A0380 20-5A 99A0407 20-6 99A0390 20-7 99A0488 20-8 99A0382 20-9 99A0383 20-9 99A0402 99A0484 99A0491 99A0400 99A0489 99A0487 Units Description Paper Weight Assembly Guide, Edge Cover, Top...
  • Page 324 4059-XXX Assembly 20: Envelope Feeder (continued) 7-72 4059 Service Manual...
  • Page 325 4059-XXX Asm- Part Index Number 20-11 20-12 99A0381 20-13 99A0388 20-14 99A0485 99A0384 99A0385 99A0494 99A0429 99A0427 99A0469 Units Description Gear Kit, PP 99A0271 o Gear, Feed o Gear, Master Cam o Gear, Drive Roll Shaft o Gear, Master/Feed Kick...

  • 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 Index Number 21-1 99A0660 21-2 21-3 99A0698 21-4 21-5 99A0691 21-6 99A0656 21-7 99A0680 21-7A 99A0681 21-8 99A0662 21-9 99A0461 21-10 21-11 99A0716 21-12 99A0658 21-13 99A0650 21-14 99A0661 21-15 99A0671 21-16 21-17 99A0690 21-18 21-19 99A0655...
  • Page 328 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-76 4059 Service Manual...
  • Page 329 4059-XXX Asm- Part Index Number 21-24 21-25 21-26 99A0686 21-26 99A0188 21-27 21-28 99A0696 21-28 99A0219 21-29 21-30 21-31 99A0719 21-32 21-33 21-34 21-35 99A0663 21-36 99A0697 21-37 99A0699 21-38 99A0653 21-39 21-40 99A0665 21-41 21-41A 21-42 99A0664 21-43 21-44...
  • Page 330 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-78 4059 Service Manual...
  • Page 331 4059-XXX Asm- Part Index Number 21-50 21-51 99A0667 21-52 99A0715 99A0682 99A0683 99A0684 21-53 99A0685 21-54 21-55 99A0654 21-56 99A0651 21-57 21-58 99A0659 21-59 99A0695 21-60 21-61 Units Description Washer, Power Supply Board PP 99A0677 Power Supply Board Cable, Low Voltage Power Supply...
  • Page 332 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-80 4059 Service Manual...
  • Page 333 4059-XXX Asm- Part Index Number 21-62 99A0281 21-63 99A0279 21-64 99A0273 21-65 21-66 99A0276 21-67 99A0451 21-68 21-69 21-70 99A0277 99A0286 21-71 99A0445 21-72 99A0280 21-73 99A0275 21-74 99A0272 21-75 99A0446 21-76 21-77 99A0274 21-78 99A0278 21-79 99A0688 21-79 99A0401...
  • Page 334 4059-XXX Assembly 21: High Capacity Feeder (continued) 7-82 4059 Service Manual...
  • Page 335 4059-XXX Asm- Part Index Number 21-81 21-82 99A0674 21-83 99A0070 21-84 99A0692 21-85 21-86 99A0678 21-87 99A0288 21-88 99A0461 21-89 21-90 21-91 99A0679 99A0448 99A0429 Units Description Screw, Auto Comp Assembly Mounting PP 99A0263 Arm Assembly, Pick 2000 Roll Assembly, Pick...

  • 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 Index Number 22-1 99A0231 22-2 99A0112 22-3 99A0197 22-4 22-5 99A0209 22-6 22-7 22-7B 22-8 99A0079 22-9 99A0087 22-10 99A0086 22-11 99A0116 22-12 99A0125 22-13 99A0232 22-14 99A0217 22-15 99A0226 22-16 99A0122 22-17 99A0137 22-18 99A0088 22-19...

  • 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 Index Number 23-1 99A0231 23-2 99A0112 23-3 99A0197 23-4 23-5 99A0209 23-6 23-7 23-7B 23-8 99A0079 23-9 99A0087 23-10 99A0086 23-11 99A0905 23-12 99A0907 23-13 99A0232 23-14 99A0217 23-15 99A0122 23-16 99A0906 23-17 99A0088 23-18 99A0085 Units...

  • Page 340: Assembly 24: Options

    4059-XXX Assembly 24: Options Asm- Part Index Number 1328589 99A0517 99A0518 99A0519 99A0520 99A0724 99A0726 99A0521 99A0522 99A0523 99A0873 99A0420 99A0421 99A0422 99A0560 99A0424 99A0515 99A0459 99A0516 99A0628 99A0871 99A0629 13A0296 13A0297 99A0545 13A0298 99A0467 99A0923 7-88 4059 Service Manual...
  • Page 341 4059-XXX Assembly 24: Options (continued) Asm- Part Index Number 99A0911 99A0910 99A0909 99A0863 99A0864 99A0865 99A0799 99A0417 99A0920 99A0945 Units Description Tray Assembly, 250 Special Media Cartridge, 4059 Shipping (2) Cartridge, 4059 Shipping (1) Hopper, Integrated Label/Letter Hopper, Integrated Label/Letter Stacker Hopper, Legal Label Stacker Drive, Forms HD 2.1GB...

  • Page 342: Assembly 25: Miscellaneous

    4059-XXX Assembly 25: Miscellaneous Asm- Part Index Number 99A0263 99A0585 99A0267 99A0268 99A0269 99A0299 99A0271 99A0404 99A0413 99A0572 99A0577 99A0675 99A0676 99A0677 99A0083 99A0512 99A0513 99A0186 99A0702 99A0703 99A0704 99A0705 99A0706 99A0707 99A0710 99A0711 99A0712 7-90 4059 Service Manual Units...
  • Page 343 4059-XXX Assembly 25:Miscellaneous (continued) Asm- Part Index Number 99A0208 99A0234 99A0265 99A0295 99A0248 99A0301 99A0394 99A0462 Units Description Parts Packet, Pulley - Kiosk Parts Packet, Screws - Kiosk Packaging, Short Packaging, Tall with 500/500 Option Tray Packaging, 500/500 Dual Option Tray...

  • Page 344: Index

    4059-XXX Index Acronyms Adjustment Procedures Duplex Motor Drive Belts Fuser Solenoid Gap Adjustment Paper Alignment Assembly Printhead Assembly 5-21 Autoconnect 3-17 Base Sensor Test Button Test Connector Locations 5-21 Autoconnect Duplex Option Board Engine Board Envelope Option Board 5-11 Fuser Board...
  • Page 345 4059-XXX Error Codes Service Error Codes User Error Messages Error Log ESD-Sensitive Parts Flash Test 5-11 Fuser Board Gap Adjustment Hardware Tests HVPS Connectors 3-14 Input Tray Feed Test Input Tray Sensor Test Interconnect Board Connectors Laser Notices LCD Test...
  • Page 346 4059-XXX 4-12 Removal Procedures Removals Center Pan Assembly 4-19 Controller Board 4-12 Covers Developer Drive Assembly 4-21 Duplex Board Duplex Front Cover Assembly Duplex Front Cover Door Duplex Front Cover Door Switch 4-21 4-22 Duplex Motor 4-23 Engine Board EP Frame Assembly...
  • 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 Setting Configuration ID Setting the Page Count...

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Optra s 4059 series

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