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1. 2 32 Duplex Option Service 2 35 Envelope Feeder Option Service Check 2 39 Erase Lamp Service 2 46 Fan Service 2 47 Fuser Service Check 2 48 Fuser Envelope Conditioner Solenoid Service Check 2 51 Input Sensor Service 2 57 Input Tray s Option Service 2 58 High Capacity Feeder Input Tray Service Check 2 61 Main Drive Service 2 73 Operator Panel Service 2 74 Options Service 2 76 Output Bin Sensor Standard Tray Service Check 2 78 Output Expander Service Check 2 79 Paper Feed Service 2 86 Parallel Port Service 2 89 Printhead Service 2 89 Print Quality Service 2 91 Contents iii 4059 XXX Smart Cartridge Service 2 102 Serial Port Service 2 104 Toner Sensor Service 2 104 Transfer Roll Service 2 105 Diagnostic AidS e AE eese RR Rem 3 1 MOS Lu lacs cee E Rod BRONCE OC Rcs 3 1 Device ccs cece ens eek EX er
2. Envelope Feeder multifeeds or may not display a 260 Paper Jam message FRU Action 1 Envelopes Check the envelopes being used in the feeder Check for signs of the envelopes being stuck together or signs of glue Check to make sure the flaps are not interleaved 2 Deflector Check the deflector gap adjustment The adjustment may be too wide 3 Restraint Roll Bias Spring Check for a missing broken or incorrectly installed restraint roll bias spring If incorrect reinstall or replace the spring 260 Paper Jam displays An envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path FRU Action 1 Latch Lever Check to make sure the tip of the latch lever is centered in the opening in the floor of the paper path The latch lever may not be detented on the latch 2 45 4059 Service Manual 4059 XXX Erase Lamp Service Check Error code 928 may be displayed when the printer detects that the erase lamp assembly cable or engine board is defective Note If the erase lamp assembly is defective both the erase lamp and lens are replaced as a kit Make the following checks when a 928 service error displays FRU Action 1 Cable Front Harness Check the connection of the front harness to connector J10 on the engine board for correct installation If incorrect repair as necessary Check the front harness
3. 7 56 Assembly 18 CUBES dd d oW R Ed a E RR Ran 7 60 Assembly 19 Output Expander 7 66 Assembly 20 Envelope Feeder 7 70 Assembly 21 High Capacity Feeder 7 74 Assembly 22 Kiosk Vertical Paper Adapter 7 84 Assembly 23 Kiosk Horizontal Paper Adapter 7 86 Assembly 24 7 88 Assembly 25 Miscellaneous 7 90 po RENE RR TC daca Li Contents vii 4059 XXX Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown Laser Advisory Label Invisible laser radiation when open and interlock defeated Avoid exposure to beam Radiation laser invisible si le dispos tf est ouvert et non bloque Eviter l exposition au rayon Unsichtbare laserstrahlung wann drucker offen und sperre gel st Nicht dem strahl aussetzen Onzichtbaro laserstraling wanneer open on niet vergrendeld Vermijd blootstelling aan straal Radiazioni laser visibili se I dispositivo aperto e non bloccato Evitare l eposizione direta Radiaci n l ser invisible si la puerta est abierta y el dispositivo no est bloqueado Evite exponerse a la radiaci n Radia o laser invisivel quando a tampa aberta Evite exposi o aos raios Avattaessa ja suojalukitus ohitettaessa olet n kym tt m lle lasers teilylle A
4. e Ae Units Description 16 1 99A0350 1 Sensor Paper Low 16 2 3 Screw Auto Comp Mounting PP 99A0263 16 3 99A0405 1 Pick Arm Assembly 16 4 99A0070 2 Pick Roll Assembly 16 5 99A0298 1 Base 500 Bottom 16 6 99A0058 4 Pad Base 500 16 7 99A0419 1 Spring Tray Bias 16 8 99A0026 1 Tray Bias Arm Assembly 16 9 99A0288 1 Sensor Option Pass Thru 16 10 99A0895 1 Restraint Side 500 Sheet Tray 16 11 99A0292 4 Wear Strips 16 12 99A0123 1 Indicator Assembly Paper Size 16 13 99A0461 1 Label Tray Number 2 5 16 14 99A0457 1 Clip 500 Tray Wear 16 15 99A0126 4 Finger Autosize 16 16 99A0124 1 Plate Snap In 16 17 99A0418 1 Slider Autosize 500 16 18 99A0120 2 Restraint Pad 16 19 99A0289 1 Tray 500 Sheet 16 20 99A0896 1 Restraint Back 500 Sheet Tray 16 21 99A0894 1 Latch Back Restraint 16 22 99A0447 1 Shaft 500 Drive 16 23 99A0284 1 Board Tray 1250 1620 1650 2420 2450 16 23 99A0397 1 Board Tray 1255 1625 1855 2455 3455 16 24 99A0275 1 Spring Power Takeoff 16 25 3 Screw Board Mounting PP 99A0263 16 26 99A0280 1 Bearing Drive Shaft Low 16 27 99A0446 1 Aligner Assembly Paper 16 28 1 Retainer Aligner Assembly PP 99A0267 16 29 99A0274 1 Gear Feed Roll 16 30 99A0063 1 Spring Switch Activate Parts Catalog 7 53 4059 XXX Assembly 16 500 Sheet Tray continued 7 54 4059 Service Manual 4059 XXX Asm Part Index Number 16 31 99A0286 16 32
5. a sx 5 21 Output Expander Control Board Level 1 Stepper Motor 5 22 Output Expander Control Board Level 2 DC Motor 5 24 Preventive 6 1 Safety Inspection Guide 6 1 Lubrication lt 6 1 Scheduled Maintenance 2420 2450 2455 3455 6 2 vi 4059 Service Manual 4059 XXX Parts Catalog coco dices css 665 6 4 7 1 How To Use This Parts Catalog 7 1 Assembly 1 Covers sso ss Ex vases AEN 7 2 UK ELE 7 6 Assembly 3 7 10 Assembly 4 Paper Feed Autocompensator 7 12 Assembly 5 Paper Feed Multipurpose Unit 7 14 Assembly 6 Paper Feed Alignment 7 16 Assembly 7 Paper Feed Output 7 18 Assembly 8 Integrated Paper Tray 250 Sheet 7 20 Assembly 9 Main 7 22 Assembly 10 Developer 7 24 Assembly 11 FUSBI ii sous sec ned g 7 26 Assembly 12 Transfer csse esas es auo NEEN 7 32 Assembly 13 Charging 7 34 Assembly TA e TEE 7 36 Assembly 15 250 Sheet Tray 7 48 Assembly 16 500 Sheet Tray 7 52 Assembly 17 500 500 Dual
6. Level 2 Connector Locations 5 10 4059 XXX Fuser Board Level 1 Connector Pin No Signal J1 Engine Board NarMedia ThermGnd HRTherm Ground ThumpA 5 V dc ThumpB AJ wy ExitSns J2 Thermistor ThermGnd HRTherm J3 Thumper Ground 42V J4 Thumper Solenoid ThumpB ThumpA J5 Narrow Media Sensor 5 V dc Nar Media Ground 5 11 4059 Service Manual 4059 XXX Level 2 Connector Pin No Signal J1 Engine Board 1 NarMedia 2 ThermGnd 3 HRTherm 4 Ground 5 ThumpA 6 5 V dc 7 ThumpB 8 ExitSns J2 Thermistor 1 ThermGnd 2 HRTherm J3 NA Not Used J4 Thumper Solenoid 1 ThumpB 2 ThumpA J5 Narrow Media 1 5 V de Sensor 2 Nar Media 3 Ground Connector Locations 5 12 4059 XXX Level 1 5 13 4059 Service Manual 4059 XXX Interconnect Board Connector Pin No Signal J1 Fuser Solenoid Model1620 1625 42 V dc 1650 1855 2420 2450 2455 Ground J2 LVPS 42 V dc Heaton Xeroxing 24 V dc 24 V dc 24 V dc Ground Ground oo NI oOo ay AJ OJN Groun
7. 2 89 4059 Service Manual 4059 XXX Service Error Code Explanation 2 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 Check the continuity of the mirror motor cable connected to J3 on the engine board If incorrect replace the cable The voltage at J3 7 measures approximately 24 V If incorrect replace the engine board If correct replace the FRUs in the following order engine board printhead assembly Diagnostic Information 2 90 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 Be sure and note the original settings so you can return the printer to the original customer printer setup Print Resolution Set to 300 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver Set to OFF PQET Set to OFF Fuser Temperature Set to NORMAL An incorrect printer driver for the installed software can cause problems Incorrect char
8. Route the cables and torroid through the rectangular window in the cover hinge pivot arm Snap the operator panel and the cover open switch bracket assembly into the upper front cover Twist the cables together and attach to the cover hinge pivot arm with a wire tie Be sure the torroid is on the opposite end of the cables near the engine board connectors Route the cables through the printer and down the inside of the engine board shield Plug the cables into the engine board connectors 4 49 4059 Service Manual 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 3 Disconnect the compensator assembly motor cable 4 Remove the three compensator assembly mounting screws and remove the compensator assembly Paper Tray Frame Assembly 1 Remove the compensator assembly 2 Release the paper pass through sensor from its retaining tabs 3 Release the frame assembly from the front and rear retaining tabs and remove the paper tray frame assembly Paper Tray Board 1 Remove the paper tray frame assembly 2 Disconnect all cables from the paper tray board 3 Remove the three paper tray board mounting screws and remove the board Note Rein
9. 2 15 4059 Service Manual 4059 XXX User Error Messages User Error Message Explanation 200 Paper Jam Remove Cartridge Paper is jammed at the printer Input Sensor Open the printer s upper front door and remove the print cartridge to access the paper jam area 201 Paper Jam Remove Cartridge Paper is jammed between the printer s input and exit sensors Open the printer s upper front door and remove the print cartridge to access the jam area 202 Paper Jam Open Rear Door Paper is jammed at the printer exit sensor Open the printer rear door to access the jam area 230 Paper Jam Check Duplex The paper is most likely jammed in the Duplex Unit Remove the duplex front cover to access the jam area If the paper is jammed in the rear of the duplex then replace the duplex front cover and open the duplex rear door 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 24X Paper Jam Check Tray X Paper is jammed around Tray X X tray 1 thru 5 Try opening Tray X If the tray is difficult to remove then you may have to remove the tray above or below tray X to remove the jammed pages 250 Paper Jam Check MP Feeder Paper is jammed in the multipurpose feeder 260 Paper Jam Check Envelope Feeder 27X Paper Jam Check Output Bin X Paper is jammed in the envelope feeder Paper is jammed in
10. The fuser lamp FRU is color coded The left and right fuser lamp bracket access holes let you view the end of the lamp Use the following table to identify and install the correct lamp Description Color Code Fuser Lamp 115V 750W Red Fuser Lamp 115V 500W White Fuser Lamp 220V 750W Orange Fuser Lamp 220V 500W Black Fuser Lamp 100V 750W Purple Fuser Lamp 100V 500W Yellow Fuser Lower Exit Guide Assembly Remove the fuser assembly Remove the fuser cover assembly Remove the fuser detack housing assembly Remove the fuser flag assembly Gently apply outward pressure on the left and right fuser side frames to release the lower exit guide assembly 4 33 4059 Service Manual 4059 XXX High Voltage Power Supply 1 2 3 Disconnect the JVPS cable from the HVPS at connector C Disconnect the transfer roll cable from the HVPS board A Remove the inner paper deflector Remove the toner sensor cable from the retainer A on the front of the HVPS Remove the right side cover Note Use caution when disconnecting the cable from the transformer on the HVPS The cable and connector can be easily damaged Remove the HVPS mounting screw B Slide the HVPS to the left to release the mounting tab and remove the HVPS C A B 205 Repair Information 4 34 4059 XXX Inner EMC Shield Remove the left door Remove outer EMC shield Remove all option
11. 4 47 4059 Service Manual 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 Repair Information 4 48 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 2 Remove the left door left cover upper front cover outer EMC shield and inner EMC shield Disconnect the operator panel cover open switch cable from the engine board Release the cables from the three cable retainers Cut and remove the wire tie on the upper front cover hinge pivot arm Remove the operator panel and cover open switch bracket Pull the cables through the rectangular hole in the hinge pivot arm Note If a large snap on torroid is present on the old cable remove the torroid before pulling the cables through the hinge pivot arm Plug the new operator panel cable into the operator panel and snap the new cover open switch cable into the bracket assembly Note If you remove a large snap on torroid from the old cable you must break the small torroid from the new cable assembly and replace it with the snap on torroid Be careful not to damage the cable
12. BAR CODE AREA J8 J9 J10 J1 s03 SE le 504 506 10 1 10 2 10 3 J11 Q Connector Locations 5 16 4059 XXX Envelope Option Board Connector Pin No Signal J1 1 N A Ground Tx EOC Ground Rx EOC 24 V Return OO oO AJ 24 V dc J2 Ground Paper Present 5 V dc J3 Ground m Paper Present 5 V dc J4 Motor Phase B Motor Phase A Motor Phase B AJOJN Motor Phase A 5 17 4059 Service Manual 4059 XXX Connector Locations 5 18 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 1 Motor 2 Motor J2 DC Motor 1 5 V dc Sensor Sensor Encoder Board 2 Tach 3 Ground J3 Stepper Motor 1 STPMOTA 2 STPMOTA 3 STPMOTB 4 STPMOTB J4 Fan 1 24 V dc 2 Fan On J5 Paper Input Sensor 1 5 V dc Sensor 2 Input 3 Ground J6 Rear Cover 1 Top Cover Open Open Switch Level 2 does not use 2 Ground J7 Jam Removal Tray 1 Front Drawer Open Open Switch Level 2 does not use 2 Ground J8 Paper Exit Sensor 1 5 V dc Sensor 2 Exit 4 3 Ground 5 19 4059 Service Manual
13. 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 on page 2 84 930 Printhead Error The wrong printhead is installed Replace with the correct printhead 931 935 Printhead Error 931 Printhead no first Hsync 932 Printhead Lost HSYNCS 934 Mirror Motor Lost Lock 935 Mirror Motor unable to reach operating speed These errors represent a problem with the printhead Go to the Printhead Service Check on page 2 89 936 937 Transport Motor 936 Main Drive Motor initial lock failure 937 Main Drive Motor lost lock Indicates a problem with the main drive motor Go to the Main Drive Service Check on page 2 73 Diagnostic Information 2 4 4059 XXX Action Error Code 939 Controller Engine Communications Error The controller board and the engine board cannot communicate with one another The controller board engine board or interconnect board is defective Check each board for correct installation and secure ground If no problem is found replace the FRUs in the following order controller board engine board interconnect board Note The controller software also can cause a 939 error code Contact your next le
14. Random Marks Check the print cartridge for any signs of loose or foreign material that might be on the photoconductor Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls Print Quality Blurred or Fuzzy Print Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly alignment assembly any feed roller or in the transfer roll bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect feeding from one of the input paper sources paper trays duplex or envelope feeder Check the high voltage contacts to ensure they are not bent corroded or damaged Replace as necessary Diagnostic Information 2 94 4059 XXX Print Quality Evenly spaced horizontal lines or marks FRU Action 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 Lines spaced 38 26 mm 1 506 inch apart This can be caused by the motor pinion gear on the main drive motor Replace the main drive motor This can be caused by a defective gear in the main drive gearbox assembly Replace the main drive gearbox assembly This can be caused by defective gear s in the main drive gea
15. Signal J4 DC Motor 1 mtrout1 mtrout2 Ground Ground tach oO oa AJ wl 5 V de J5 Bin Full Near Full 1 Ground Dual Sensor Ground binful binful ox RVsnsr 5 25 4059 Service Manual 4059 XXX 6 Preventive Maintenance This chapter describes procedures for printer preventive mainte nance Following these recommendations can help prevent prob lems and maintain optimum performance Safety Inspection Guide The purpose of this inspection guide is to aid you in identifying unsafe conditions If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and the power supply 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 Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Dari
16. To run the Disk Test Clean Test 1 Select Disk Test Clean from the Device Tests menu Files will be lost Go or Stop message displays to warn the user that all contents on the disk will be lost 2 To exit the test immediately and return to the Device Tests menu press Return Stop To continue with the test press Go If gois selected Disk Test Clean BAD 000000 00 message displays The screen updates periodically indicating the percentage of test completed and the number of bad blocks found 3 The power indicator blinks during the test The test can be canceled anytime during the test by pressing Return Stop Once the test is complete the power indicator turns on solid and a message displays Diagnostic Aids 3 2 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 The disk cannot be recovered because too many bad blocks exist on the disk 4 Press Go or Return Stop to return to the Device Tests menu Flash Test This test causes the file system to write and read data on the flash to test the flash WARNING This test destroys all data on the flash because the flash is reformatted at the end of the test To run the Flash Test 1 Select Flash Test from the Device Te
17. 19 28 99A0364 1 Spring Belt Tensioner 19 29 99A0351 1 Sensor Output Expander Pass Thru 19 30 99A0370 1 Shaft Assembly Middle Level 1 1650 1855 2420 2450 2455 Also order PP 99A0572 19 30 99A0913 1 Shaft Assembly Middle 40T Level 2 3455 Also order PP 99A0572 19 31 99A0912 1 Frame Assembly Output Expander Level 2 3455 NS 99A0429 1 Label Options Circle 1855 2455 3455 Parts Catalog 7 69 4059 XXX Assembly 20 Envelope Feeder 7 70 4059 Service Manual 4059 XXX ie EDS Units Description 20 1 99A0389 1 Paper Weight Assembly 20 2 99A0391 1 Guide Edge 20 3 99A0379 1 Cover Top 20 4 99A0393 1 Clutch Restraint Gear 20 5 99A0380 1 Cover Right Side 20 99 0407 1 Base Assembly 20 6 99A0390 1 Support Slide Out 20 7 99A0488 7 Roller Support 20 8 99A0382 1 Motor Stepper D C 20 9 99A0383 1 Board Assembly Electronic Control 20 9 99A0402 1 Board Assembly Electronic Control 1855 2455 3455 NS 6 Screw Top Motor Board NS 99A0484 1 Belt Gear Drive NS 99A0491 1 Bracket Stack Limiter NS 99A0400 1 Spring Restraint Roll Shaft NS 99A0489 1 Spring Latch Return NS 99A0487 1 Flag Envelope Out Sensor Parts Catalog 7 71 4059 XXX Assembly 20 Envelope Feeder continued 7 72 4059 Service Manual 4059 XXX ae Ge Units Description 20 11 1 Gear Kit PP 99A0271 1 o Gear Feed 1 o Gear Master Cam 1 o Gear Drive Roll Shaft 3 o Gear Master Feed K
18. 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 The model 1620 1625 and 1650 printer fuser temperature is 185 5 degrees C while printing at 600 dpi and 145 5 degrees C while printing at 1200 dpi The model 1250 and 1255 printer fuser temperature is 206 9 degrees C while printing at 600 dpi and 151 5 degrees C while printing at 1200 dpi The model 3455 printer fuser temperature is 270 degrees C while printing at 600 dpi and 170 degrees C while printing at 1200 dpi Diagnostic Aids 3 28 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 Error Message 201 Paper Jam Remove Cartridge This message indicates the paper is jammed between the printer s input and exit sensors This condition can be caused by the paper exiting the input sensor too late or jamming in the fuser assembly prior to activating the exit sensor flag in time or not at all Error Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at the printer exit sensor This can be caused b
19. 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 NS 99A0429 Units Description Spring Backup Roller Bellcrank Roller Release Gear Bevel Bearing Drive Shaft Cable 500 Auto Connect Top Stud Assembly 500 Frame Cable 500 Auto Connect Bottom Bearing Drive Roll Wear Plate Pass Thru Screw Wear Plate Mounting PP 99A0263 Roller Skewed Backup Retainer Roller Roll Assembly Drive 500 Arm Paper Out 500 Label Options Circle 1255 1625 1855 2455 a ch 828 4a wp h pH a a oa oa ao a Parts Catalog 7 55 4059 XXX Assembly 17 500 500 Dual Tray 7 56 4059 Service Manual 4059 XXX esche EE Units Description 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 99A0026 Tray Bias Arm Assembly 17 8 99A0419 Spring Tray Bias 17 9 99A0058 Pad Base 500 17 10 99A0288 17 11 99A0895 17 12 99A0292 17 18 99A0123 17 14 99A0461 17 15 99A0457 17 16 99A0126 17 17 99A0124 17 18 99A0418 17 19 99A0120 17 20 99A0289 17 21 99A0896 17 22 99A0894 17 23 99A0569 17 24 99A0277 17 25 17 26 99A0276 17 27 99A0450 17 28 99A0451 17 29 99A0438 17 3
20. If multiple trays are low they are prioritized in the following order Tray 5 4 3 2 1 Note Tray X Low clears whenever Tray X goes empty or Tray X is removed When Tray X is reinserted it is examined and the appropriate status if any displays Note The printer cannot detect when the envelope feeder or multipurpose feeder are low 2 21 4059 Service Manual 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 Serial Standard Serial Port if available Serial X Serial Port where X 1 2 3 is attached to PCI connector X Network X Network card X X 1 2 3 is attached to PCI connector X LocalTalk X LocalTalk Card X X 1 2 3 is attached to PCI connector X Infrared Standard Infrared port if available Infrared X Infrared Port X X 1 2 3 is attached to PCI connector X Check Device Connection Messages The messages in the following table display when the printer looses communications with one of the following devices User Status Message Explanation Check Output Bin X Connection Check Output Bin X 1 2 0 3 Check Env Feeder Check Envelope Feeder Option Connection Connection Check Tray X
21. Output Expander Models 1650 1855 2450 2455 and 3455 General Information 1 4 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 After you complete the repair perform tests as needed to verify the repair Tools Required For Service Flat blade screwdriver 1 Phillips screwdriver 2 Phillips screwdriver 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Serial wrap plug 1329048 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 1 5 4059 Service Manual 4059 XXX Acronyms CSU DRAM EDO EP EPROM ESD FRU GB HVPS LASER LCD LED LVPS MROM NVRAM OEM PC POST RIP ROM SIMM SRAM UPR Vac Vdc Customer Setup Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Erasable Programmable Read Only Memory Electrostatic Discharge Field Replaceable Unit Giga Byte High Voltage Power Supply Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Masked Read Only Memory Nonvolatile Random Access Memory Original Equipment Manufacturer
22. Photoconductor Power On Self Test Raster Imaging Processor Read Only Memory Single In Line Memory Module Static Random Access Memory Used Parts Return Volts alternating current Volts direct current General Information 1 6 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 Use the service error code user status message user error message symptom table service checks and diagnostic aids in this chapter to determine the corrective action necessary to repair a malfunctioning printer Service error codes are indicated by a three digit error code If a service error code is displayed go to the Service Error Codes on page 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 User Status Messages on page 2 12 User error messages are indicated by a two or three digit error code that provides the user with information that explains a problem with a print cartridge paper jam option port and so on If a user erro
23. Short pins 1 and 2 together while observing the sensor test on the display If the display does not change replace the high capacity feeder system board If the display changes check the continuity of the switch If incorrect replace the Switch If correct replace the switch cable Tray X empty message displays when there is paper in the high capacity feeder input tray FRU Action 1 Paper Out Sensor Flag 2 Paper Out Sensor On Option System Board Check the paper out sensor flag for correct operation and installation If correct replace the high capacity feeder system board The paper out sensor is mounted on the high capacity feeder system board Tray X Empty Message displays when Tray X has paper in the tray FRU Action 1 Paper Out Sensor Flag Check the flag for correct operation and installation on the High Capacity 2 Paper Out Sensor Located Feeder Tray Option Board Run the Tray X sensor diagnostic If incorrect replace the high capacity feeder tray option board 2 65 4059 Service Manual 4059 XXX The elevator tray fails to stop at the correct position and continues to drive into the bottom frame FRU Action 1 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 If incorrect replace the cable If correct
24. ary ok 2 25 ii 4 11 4059 Service Manual 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 Note Some removal procedures require removing cable ties You must replace cable ties during reassembly to avoid pinching wires obstructing the paper path or restricting mechanical movement Covers Left Door Release the two left door latches A and remove the door A Repair Information 4 12 4059 XXX Left Cover 1 Remove the left door 2 Remove the five mounting screws A A 102 4 13 4059 Service Manual 4059 XXX 3 Raise the upper front cover 4 Remove the three mounting screws B the print cartridge and remove the left cover B 324 Repair Information 4 14 4059 XXX Right Cover 1 Raise the upper front cover 2 Release the cover latch A and remove the right cover mounting screw B 324 4 15 4059 Service Manual 4059 XXX 3 Remove the redrive assembly 4 Remove the right side cover mounting screws B and C 5 Remove the right side cover B 324 102 Repair Information 4 16 4059 XXX Upper Front Cover 1 Raise the upper front cover 2 R
25. 10 Serial Wrap Test 3 12 Input Tray Tests 3 14 Input Tray Feed Test 3 14 Paper Feed Tests Base Sensor Test 3 17 Input Tray Sensor Test 3 14 Output Bin Feed Test 3 15 Output Bin Sensor Test 3 16 Output Bin Test Standard Bin 3 15 Output Bin X Sensor Test 3 16 Print Registration 3 18 Print Tests 3 22 Printer Setup 3 19 Maintenance Page Count 2420 2450 2455 3455 3 20 Restore EP Factory Defaults 3 21 Setting Configuration ID 3 20 Setting the Page Count 3 19 Viewing the Permanent Page Count 3 19 Diagnostic Mode 3 1 Disabling Download Emulations 3 3 Disk Test Clean 3 2 DRAM Memory Test 3 10 Duplex Option Board Connectors 5 19 Duplex Tests 3 4 E Engine Board Connectors 5 4 Envelope Option Board Connectors 5 17 Index 1 1 4059 XXX Error Codes Service Error Codes 2 2 User Error Messages 2 16 Error Log 3 8 ESD Sensitive Parts 4 1 F Flash Test 3 3 Fuser Board 5 11 G Gap Adjustment 4 3 H Hardware Tests 3 9 HVPS Connectors 5 3 Input Tray Feed Test 3 14 Input Tray Sensor Test 3 14 Interconnect Board Connectors 5 14 L Laser Notices ix LCD Test 3 9 Lubrication Specifications 6 1 LVPS Connectors 5 1 Maintenance Approach 1 5 Maintenance Page Count 2420 2450 2455 3455 3 20 Maintenance Preventive 6 1 Maintenance Scheduled Model 2420 2450 2455 3455 6 2 Messages Check Device Connection Messages 2 22 Service Error Codes 2 2 User Error Messages 2 16 User Line 2 Link Messages 2 22 User Line
26. 21 80 3 Screw 2000 Tray Option Card Mounting PP 9940263 NS 4 Foot Stabilizer PP 99A0672 NS 4 Mounting Feet PP 99A0687 Parts Catalog 7 81 4059 XXX Assembly 21 High Capacity Feeder continued 7 82 4059 Service Manual 4059 XXX e EDS Units Description 21 81 3 Screw Auto Comp Assembly Mounting PP 99A0263 21 82 99A0674 1 Arm Assembly Pick 2000 21 83 99A0070 2 Roll Assembly Pick 21 84 99A0692 1 Base 2000 Option 21 85 1 Screw Deflector Mounting PP 99A0263 21 86 99 0678 1 Deflector Base 21 87 99A0288 1 Sensor Pass Thru 21 88 99A0461 1 Label Tray Option Numbers 21 89 4 Washer Bracket 250 Frame Retention Mounting PP 99A0677 21 90 4 Screw Bracket 250 Frame Retention Mounting PP 99A0263 21 91 99A0679 2 Bracket 250 Frame Retention NS 99A0448 1 Arm Paper Out 250 Sheet NS 99A0429 1 Label Options Circle 1255 1625 1855 2455 Parts Catalog 7 83 4059 XXX Assembly 22 Kiosk Vertical Paper Adapter 7 84 4059 Service Manual 4059 XXX ie EDS Units Description 22 1 99A0231 1 Bail Support 22 2 99A0112 1 Mounting Frame Assembly 22 3 99A0197 1 Shaft Drive Rear 22 4 12 Retainer PP 99A0240 22 5 99A0209 1 Arm Assembly Pivot 22 6 16 Screws PP 99A0234 22 7 7 Parts Pulley PP 99A0208 22 7B 3 Gear Idler PP 99A0237 22 8 99A0079 1 Tray Assembly Backup Roller 22 9 99A0087 6 Spring Backup Roller 22 10 99A0086 6 Roller Backup 22 11 99A01
27. 250 Sheet Paper Tray Option Go to the Input Tray s Option Service Check on page 2 58 Paper feed problem with 500 Sheet Paper Tray Option Go to the Input Tray s Option Service Check on page 2 58 sheet paper tray option Paper feed problem with 500 500 Go to the Input Tray s Option Service Check on page 2 58 Media fails to pass thru from the lower attached Paper Tray option to the next higher mounted option Go to the Input Tray s Option Service Check on page 2 58 Symptom Table Duplex Symptom Action Paper feed problem with Duplex Go to the Duplex Option Service Check on page 2 35 Paper jams at Paper Removal Tray Go to the Duplex Option Service Check on page 2 35 Paper skews in the Duplex Option Go to the Duplex Option Service Check on page 2 35 Paper fails to pass from lower option thru the Duplex Option Go to the Duplex Option Service Check on page 2 35 Symptom Table Envelope Feeder Option Symptom Action Envelopes do not feed from the envelope feeder Go to the Envelope Feeder Option Service Check on page 2 39 Envelopes do not feed properly into base printer Go to the Envelope Feeder Option Service Check on page 2 39 2 27 4059 Service Manual 4059 XXX Symptom Table Output Expander Symptom Action Printer doe
28. 3 seconds Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error 3 11 4059 Service Manual 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 Press Return Stop to exit the test Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug Each signal is tested To run the Serial Wrap Test 1 2 Disconnect the serial interface cable and install the wrap plug Select the appropriate Serial Wrap Test from the menu Serial Wrap Serial 1 Wrap Serial 2 Wrap or Serial 3 Wrap P amp F represent the same numbers for DRAM The power indicator blinks indicating the test is running This test runs continuously unless canceled by pressing Return Stop Diagnostic Aids 3 12 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 follow
29. 4 and the motor housing If you find a problem replace the stepper motor If you do not find a problem replace the output expander mechanical linkage assembly Diagnostic Information 2 82 4059 XXX FRU Action 4 Output Expander Control Board Level 1 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 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 J4 1 Approximately 16 V dc J4 2 Approximately 16 V dc J4 3 Approximately 16 V dc J4 4 Approximately 16 V dc The voltage drops to approximately 16 V dc as the output expander bin stepper motor turns on and a sheet of paper is fed through the redrive into the output expander assembly If any of the voltages fail to change replace the output expander option board If that does not correct the problem replace the output expander mechanical linkage assembly 2 83 4059 Service Manual 4059 XXX Remove Paper Output Bin X is displayed POST Incomplete Unable to clear the message FRU Action 1 Dual Output Bin Sensor Flag Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary 271 Paper Jam Check Bin X POST Incomplete FRU Action 1 Pass Thru Sensor and Flag Ch
30. 4059 XXX Configuration 3 A level 11 fuser board and level Il 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 FRU Action 1 Engine Board Jumpers Check to make sure a jumper is installed between JP1 1 and JP1 2 and also between JP2 1 and JP2 2 on the engine board 2 Fuser Envelope Conditioner The operation of the fuser solenoid Solenoid Fuser Control can be observed by removing the Board redrive assembly Check for proper mechanical operation of the solenoid and associated hardware link and so on If correct disconnect the DC fuser cable from J1 on the fuser control board and check the resistance of the solenoid between J1 2 and J1 4 on connector J1 The resistance measures between 5 ohms and 10 ohms If incorrect disconnect the solenoid from J4 and check the resistance of the solenoid between J4 1 and J4 2 If incorrect replace the solenoid assembly If correct replace the fuser control board 3 Fuser Cable Check the continuity of the fuser cable If the cable does not measure continuity replace the cable Diagnostic Information 2 56 4059 XXX FRU Action 4 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 poin
31. 419 Developer Drive 4 20 Duplex Board T 2 4 21 Duplex Front Cover Assembly 4 21 Duplex Front Cover Door EE 2 421 Duplex Front Cover Door Switch 4 21 Duplex Motor hou us TE susa 4 22 EMMO eM ER 4 23 EP Frame Assembly T er 423 ui PM KEEPER TREE ia deh poe ee ae bok kate 4 24 Fuser EE brad 2 426 FUSO 4 27 Fuser Cover cesses erem mes beu DEE 2 428 Fuser Detack 4 29 Fuser Detack Housing Assembly Fusor Transiter 2552225 em a ace ace d 4 30 Fuser Envelope Conditioner Solenoid 2 4 31 Fuser Exit Flag Assembly n anaana nannaa 4 31 Fuser Exit Roll Assembly TETEE sese 4 32 ak a ORE EE 4 33 Fuser Lower Exit Guide Assembly ae eer 4 22 High Voltage Power 4 34 Contents 4059 XXX Itiner EMO Shield 22 54 RA REPE PE 4 35 Inner Paper Deflector Assembly 4 36 Integrated Tray Compensator Assembly 4 37 Integrated Tray Compensator Pick Roll Assembly 4 38 Interconnect Board 4 39 La SiGe FUNG iso dass asa Re dpa aque 4 41 Low
32. 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 It is necessary to perform a registration adjustment before locking down the three printhead mounting screws To perform the registration adjustment 2 3 Turn the printer off Press and hold Return and Go Turn the printer On and release the buttons when Performing Self Test displays Select Registration from the menu Select Quick Test Page The test page should only be printed on letter or A4 paper from Tray 1 The Quick Test Page consists of alignment diamonds horizontal lines that can be used for skew adjustment page count setting printer serial number code levels and print registration settings Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and top right of the test page for equal distance from the top of the page If any adjustment is necessary adjust the left or right printhead mounting screws and check the skew again by running another Quick Test Page This procedure may take two or three attempts before you get satisfactory results When you have the correct adjustment gently tighten the printhead mount
33. Alignment Assembly Paper Feed 6 2 99A0492 1 Screw Paper Reference Adjustment 6 3 99A0566 1 Nut 6 4 99A0559 1 Lever Bellcrank Release 6 5 99A0565 1 Washer Reference Adjustment NS 99A0490 1 Clip Reference Ground NS 2 Screw Alignment Asm Mtg PP 99A0263 Parts Catalog 7 17 4059 XXX Assembly 7 Paper Feed Output 7 18 4059 Service Manual 4059 XXX etd ELS Units Description 7 1 99A0090 1 Deflector Assembly Inner 500 2450 2455 7 1 99A0091 1 Deflector Assembly Inner 250 1620 1650 1250 1255 2420 1855 1625 7 1 99A0502 1 Deflector Assembly Inner 250 1855 01 7 2 99A0109 1 Deflector Assembly Outer 500 2450 2455 7 2 99A0110 1 Deflector Assembly Outer 250 1620 1650 1250 1255 2420 1855 1625 Spring Upper Diverter Separator Upper Screw SEMS Duplex Path PP 99A0263 Deflector Assembly Inner 500 3455 Restraint Door Hinge NS 99A0104 NS 99A0107 NS NS 99A0891 NS 99A0921 Mi Parts Catalog 7 19 4059 XXX Assembly 8 Integrated Paper Tray 250 Sheet 7 20 4059 Service Manual 4059 XXX ae o Units Description 8 1 99A0115 1 Tray Integrated 250 Sheet 8 1 99A0504 1 Tray Integrated 250 Sheet 1855 C01 8 2 99A0894 1 Latch Back Restraint 8 3 99A0120 2 Restraint Pad 8 4 99A0892 1 Restraint Side 250 Sheet Tray 8 5 99A0119 4 Wear Strips 8 6 99A0123 1 Indicator Assembly Paper Size 8 7 99A0461 1 Label Tray Number 8 8
34. CBM 22 mm 1620 1650 1250 1255 1855 1625 NS 99A0159 2 Spacer Backup Roll 1620 1650 1250 1255 1855 11 10 99A0173 1 Solenoid Assembly Envelope Conditioner 1620 1625 1650 1855 2420 2450 2455 3455 11 11 1 Screw Solenoid Mounting PP 99A0263 11 12 1 Screw Board Cover Mounting PP 99A0263 11 13 99A0557 1 Cover Fuser Board 1620 1650 2420 2450 2455 1855 1625 11 14 99A0547 1 Wire Ground 11 15 1 Screw Ground Wire PP 99A0263 11 16 99A0196 1 Clamp DC Fuser Cable 11 17 99A0170 1 Board Assembly Fuser w o Driver 1250 1255 11 17 99A0171 1 Board Assembly Fuser w Driver 1620 1650 2420 2450 2455 1855 1625 11 17 99A0826 1 Board Assembly Fuser 3455 11 18 99A0546 2 Clamp AC Fuser Cable 11 19 2 Screw Fuser Cover Assembly PP 99A0263 11 20 99A0142 2 Retainer Hot Roll Bearing 11 21 99 0143 2 Bearing Hot Roll 11 22 99A0150 2 Bushing Hot Roll 11 23 99A0163 2 Bellcrank Backup Roll 1250 1255 11 23 99A0162 2 Bellcrank Backup Roll 1620 1650 1855 1625 11 23 99A0161 2 Bellcrank Backup Roll 2420 2450 2455 11 23 99A0890 1 Bellcrank Backup Roll 3455 11 24 99A0164 1 Guide Fuser Entry 1620 1650 2420 2450 2455 1855 1625 3455 11 24 99 0713 1 Guide Fuser Entry 1250 1255 11 25 99A0412 2 Spring Backup Roll Bellcrank 1250 1255 11 25 99A0410 2 Spring Backup Roll Bellcrank 1620 1650 2420 2450 2455 1 855 1625 3455 11 26 2 Retainer Backup Roll Bellcrank PP 99A0267 11 27 99 0157 1 Gear Hot Roll 11
35. Check Tray X X 1 2 3 4 or 5 Connection Check Duplex Check Duplex Option Connection Connection Diagnostic Information 2 22 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 f the device is temporarily removed or not connected properly then reattach it When the option is recognized the printer automatically clears the error and continues fthe 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 Explanation Turn Printer OFF to Enable Option This message displays when a printer option Input Tray Output Bin or Envelope Feeder has been attached while the printer is powered On In order to use the option the printer must first be powered off and back on again Data loss results if print jobs are active when the printer is power cycled If a print job is active then remove the option and finish the job The printer automatically clears the message once the option is removed Once the job is complete turn off the printer and attach the option again Insert Duplex Front Cover This message displ
36. Driver 1250 1255 14 40 99 0171 1 Board Assembly Fuser with Driver 1620 1625 1650 1855 2420 2450 2455 14 40 99A0826 1 Board Assembly Fuser 3455 14 41 99A0027 1 Cover Fuser Assembly with Thermistor Thermal Fuse and RH Fuser Lamp Contact Assembly 14 42 99A0169 1 Sensor Narrow Media 14 43 99A0252 1 Cable Fuser D C 14 44 99A0258 1 Cable Fuser A C 14 45 99A0250 1 Cable Mirror Motor Parts Catalog 7 47 4059 XXX Assembly 15 250 Sheet Tray 7 48 4059 Service Manual 4059 XXX ie EE Units Description 15 1 99A0287 Pick Arm Assembly 15 2 Screw Auto Comp Mounting PP 99A0263 15 3 99A0070 Roll Assembly Pick NS 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 99A0419 Spring Tray Bias 15 8 99A0058 Pad Machine Mounting 15 9 99A0288 Sensor Option Pass Thru 15 10 99A0272 15 11 99A0275 15 12 99A0282 15 13 99A0451 15 13B 99A0450 15 14 99A0276 Shaft 250 Drive Spring Power Takeoff Cable 250 Tray Option Roller Skewed Backup Retainer Roller Roll Assembly Drive 500 Dual 15 15 Screw Wear Plate Mounting PP 99A0263 15 16 99A0277 Wear Plate Pass Thru 250 Tray NS 99A0278 Bellcrank Roller Release 15 17 99A0280 15 18 99A0274 15 19 99A0273 15 20 99A0279 15 21 99A0445 15 22 99A0281 Bearing Drive Shaft Low Gear Feed Roll Gear Bevel Bearing Drive Shaft Stud Assembly 250 Frame Cab
37. Error Code Service Tray X X displays the number of the tray that has a problem or needs service FRU Action 1 Tray X option System Board Check the autoconect cables and or Compensator Assembly connectors for any signs of damage or Autoconnect Cable Replace if necessary Check the cables for continuity If incorrect replace the compensator assembly cable If the cables connectors and connections are good replace the FRUs in the following order autocompensator assembly option System board Diagnostic Information 2 58 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 FRU Action 1 Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating the pass thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Check these parts for signs of Spring Bevel Gear broken or damaged parts
38. FRU Action 2 Charge Roll Assembly Charge Roll Link Arm Check the charge roll for any signs 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 Repair or replace as necessary 3 HVPS Check the following voltages at J10 8 on the engine board Printer Idle J10 8 measures 0 V dc Printer Printing Test Page J10 8 voltage changes from 0 V dc to 4 V dc If the voltage does not vary check the continuity of line J10 8 in the front cable harness If there is no continuity replace the cable harness If there is continuity replace the HVPS If this does not correct the problem replace the engine board Turn the printer Off and check the resistance between J10 7 and printer ground The resistance measures approximately 0 ohms If incorrect make sure the engine board is mounted correctly and securely grounded If correct replace the engine board 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 Residual image on model 3455 can also be caused by the charge brush contact Diagnostic Information 2 100 4059 XXX FRU Action 1 Erase Lamp Assembly C
39. Feedroll Gear Drive Roll contamination on the drive rollers or Assembly Wear Plate wear plate and wear or damage to Drive Shaft Bearings and the drive shaft bearings Check the Skewed Backup Roller drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary 2 59 4059 Service Manual 4059 XXX Tray X Low message displays when Tray X is full or has adequate paper in the tray FRU Action 1 Paper Low Sensor Assembly Paper Low Sensor Flag Tray X Option System Board Run the Tray X Sensor Test and check the sensor for proper operation If incorrect check the following Paper low sensor flag for smooth and correct operation Paper low sensor for correct installation on the autocompensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connector J5 on the system board If no problem is found replace the paper low sensor assembly If this does not correct the problem replace the option system board Tray X Empty message displays when Tray X has paper in the tray FRU Action 1 Paper Out Sensor Flag 2 Paper Out Sensor On Option System Board Check the paper out sensor flag for correct operation and installation If correct replace
40. J11 1 and diamonds 5 Beeps J11 3 The voltage measures approximately 5 V dc If incorrect replace the FRUs in the following order operator panel assembly engine board Options Service Check Service Tip When you have a problem with any of the options installed in the options slots on the interconnect board on a 2450 or 1650 the 1250 has only one slot switch the non operating option to one of the other option slots to isolate the failure Flash Memory Option s 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 If the Memory SIMM is correctly installed not broken or damaged then run the Flash Test on page 3 3 If the test fails replace the FLASH SIMM If the problem continues replace the controller board DRAM Memory Option s This service check is the same as the flash memory option service check with the following exception Run the DRAM Memory Test on page 3 10 from the menu if the DRAM Memory SIMM is correctly installed and not broken or damaged If the test fails replace the DRAM SIMM If the problem continues replace the controller board Diagnostic Information 2 76 4059 XXX Hard Disk Option Service Tip The Optra S printers support one hard disk option Check to make sure only
41. LCD Test To run the LCD Test 1 Select LCD Test from the Diagnostic menu The LCD test continually executes the LCD display test 2 Press Return Stop to cancel the test Button Test To run the Button Test 1 Select Button Test from the Diagnostic menu With no buttons pressed several OP Open appear on the display Press each button one at a time and a CL Closed displays in place of an OP The proper operation of each button can be checked Press Return Stop to cancel the test 3 9 4059 Service Manual 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 Select DRAM Memory Test from the menu The power indicator blinks indicating the test is in progress 2 Press Return Stop to exit the test P represents the number of times the memory test has passed and finished successfully Initially 000000 displays with the maximum pass count being 999 999 F represents the of time the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display If the test fails the message DRAM Error d
42. Laser Der Drucker erf llt gem amtlicher Best tigung der USA die Anforderungen der Bestimmung DHHS Department of Health and Human Services 21 CFR Teil J f r Laserprodukte der Klasse 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse der die Anforderungen der IEC International Electrotechnical Commission 825 gemaB amtlicher Best tigung erf llt Laserprodukte der Klasse gelten als unsch dlich Im Inneren des Druckers befindet sich ein Laser der Klasse 1116 3b bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt der Wellen der Lange 770 795 Nanometer ausstrahlt Das Lasersystem und der Drucker sind so konzipiert daB im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgem Ber Wartung durch den Kundendienst Laserbestrahlung die die Klasse bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux provisions DHHS 21 CFR alin a J concernant les produits laser de Classe 1 Pour les autres pays cette imprimante r pond aux normes IEC 825 relatives aux produits laser de Classe l Xi 4059 Service Manual 4059 XXX Les produits laser de Classe sont consid r s comme des produits non dangereux Cette imprimante est quip e d un laser de Classe 3b ars niure de gallium d une puissance nominale de 5 milliwatts mettant sur des longueurs d onde comprise
43. Return Stop to exit test Input Tray Sensor Test This test is used to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 Select the Sensor Test from the Input Tray Test menu Input Tray Empty OP Pass OP message displays EM Input Tray Empty Sensor LO Input Tray Paper Low Sensor Input Tray Pass Thru Sensor 2 Once this message displays the servicer can manually actuate each sensor The tray empty sensor can be actuated by hand however a sheet of paper can be used to cover the pass through sensor When the sensor is closed CL displays when the sensor is open OP displays 3 Press Return Stop to exit the test Diagnostic Aids 3 14 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 To run the Standard Bin Sensor Test 1 Select Output Bin Tests from the Diagnostic Menu 2 Select Output Bin Tests Sensor Tests 3 Select Sensor Tests Standard Bin Standard Bin Full CL message displays Manually actuate the bin sensor by moving the flag in and out of the sensor The display indicates OP open when the flag is out of the sensor and CL closed when the flag is in the sensor 4 Press Return Stop to exit the test Output Bin Fee
44. Service Check on page 2 73 FRU Action 1 Alignment Assembly Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight Check the alignment assembly for any signs of worn rollers contaminated rollers or binds Replace the alignment assembly if any problem is found 2 Inner Deflector Check the inner paper deflector for correct installation If the deflector is bowed or not fitting correctly replace the deflector Diagnostic Information 2 86 4059 XXX Autocompensator fails to feed paper Failures occur randomly throughout the stack of paper FRU Action 1 Pass Through Sensor Check the pass through sensor for correct installation and operation 2 Autocompensator Assembly The autocompensator pick roll shaft assembly is not providing enough torque if the pick rollers are not picking the paper correctly Replace the autocompensator assembly 3 Wear Strips in Tray X problem is found Check the wear strips for excessive wear scratches or rough spots Replace the wear strips if a problem is found Paper feed failures occur only near the top of the stack of paper The most common cause of this problem is paper curl Remove the paper from tray x and check for the natural curvature in the paper Reinstall the paper in the correct manner If the problem persists it may be necessary to reduce the st
45. V dc 0 V dc CO Jl oO A 24 V dc 5 21 4059 Service Manual 4059 XXX Output Expander Control Board Level 1 Stepper Motor Connector Pin No Signal J1A Autoconnect 1 24 V dc Ground wo N 5 V dc J1B e Prtxdin Ground prtrxd Ground oa AJOJN J2A Autoconnect 24 V dc Ground Co N 5 V dc J2B prtxdout Ground prtrxd wo N Ground i J3 Pass Thru Sensor Ground Paper Present wo N RVsnsr J4 Stepper Motor Phase B Phase B Phase A Phase A Connector Locations 5 22 4059 XXX Connector Pin No Signal J5 Bin Full Sensor 1 Ground Single Sensor e Et 2 N C 3 5 V dc 4 N C 5 RVsnsr IW nana 5 23 4059 Service Manual 4059 XXX Output Expander Control Board Level 2 DC Motor Connector Pin No Signal J1A Autoconnect 1 24 V dc 2 Ground 3 5 V de J1B 1 Prtxdin 2 Ground 3 prtrxd 4 Ground 5 N C J2A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J2B 1 prtxdout 2 Ground 3 prtrxd 4 Ground J3 Pass Thru Sensor 1 Ground 2 Paper Present 3 RVsnsr Connector Locations 5 24 4059 XXX Connector Pin No
46. are possible while this message is displayed Formatting Flash Do Not Power Off The flash memory is being formatted No button actions are possible while this message is displayed Program Flash Do Not Power Off The flash memory is being programmed which means fonts or macros are being written to flash memory Do not perform any button actions while this message is displayed Formatting Disk The disk is being formatted No button actions are possible while this message is displayed Diagnostic Information 2 14 4059 XXX User Status Message Status Action Programming Disk Do Not Power Off The disk is being programmed which means fonts or macros are being written to disk No button actions are possible while this message is displayed Note If information is written to flash memory and to disk at the same time the Program Flash message is displayed Menus Disabled Activating Menu Changes The printer menus have been disabled This occurs when Menu or lt Menu is pressed while the printer is Ready and Menu Lockout is active The printer display shows this message for one second and then returns to the Ready message The printer is reset to activate a printer setting changed in the menus No button actions are possible while this message is displayed No button actions are possible while this message is displayed
47. 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 The LVPS uses a self docking connector that mates with another connector mounted on the left side frame assembly Some force may be required to pull the LVPS loose from the connector 2 Gently remove the LVPS supply using caution not to damage the printed circuit board Pull the LVPS out far enough to reach the fuser lamp cable 3 The fuser lamp cable uses a locking type of connector system Unlock the fuser lamp cable connector disconnect the cable and remove the LVPS from the printer FRU Action 1 Line Voltage Check the AC line voltage If the line voltage is incorrect inform the customer 2 Line Cord Check the line cord for any signs of damage If correct check the continuity of the line cord and replace if necessary 3 5 Vdc at any Option Connector Check for 5 V dc on any of the option connectors The easiest to access is the envelope feeder connector located behind the lower front door If 5 V dc is present at any of the connectors go to step 9 If 5 V dc is not present go to step 4 4 5V dc at the controller board test point Check for 5 V dc at the 5 V dc test pad
48. boards from the connector board slots Remove the inner EMC shield mounting screws A Remove the inner EMC shield Ne 4 35 4059 Service Manual 4059 XXX Inner Paper Deflector Assembly ar WD Remove the paper tray Remove the upper deflector assembly Place the printer on its side Remove the lower deflector assembly 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 Repair Information 4 36 4059 XXX Integrated Tray Compensator Assembly Remove the paper tray Remove the left door Remove the inner EMC shield Disconnect the compensator motor cable from the engine board at connector J18 Place the printer on its side Locate the integrated tray compensator assembly E on the bottom of the printer and disconnect the compensator arm bias spring A from the frame Disconnect the compensator sensor cable B from the assembly Remove the compensator assembly mounting screw C Remove the integrated tray compensator assembly 203 B 4 37 4059 Service Manual 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 mount
49. frame for damage PC drum contact wear or contamination If the contact is bent or damaged replace the contact Note Inspect the HVPS PC drum contact on the board for any signs of damage or contamination 3 HVPS Check the fuse on the HVPS If open replace the HVPS Check the voltages at J10 on the engine board Measure the following voltages from connector J10 to printer ground Printer Idle J10 5 measures 24 V dc Printer Printing J10 5 measures 24 V dc In the voltages at J10 5 are incorrect replace the engine board 4 Front Cable Harness HVPS Section Check the front cable harness at J10 on the engine board and at CN1 on the HVPS to make sure the harness is connected properly If connected properly check the continuity of the cable harness If there is no continuity replace the front cable harness 5 Printhead Assembly Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom The printhead used in the printer does not have a mechanical shutter as previous laser printers The printer is interlocked through the front top cover interlock switch 2 93 4059 Service Manual 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 s
50. 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 5 Remove the left and right fuser cover mounting screws C and lift the cover from the fuser assembly A C 202 B 202 Repair Information 4 28 4059 XXX Fuser Detack Fingers Remove the fuser assembly Remove the fuser cover assembly Remove the fuser detack housing assembly Gently pry the detack finger and spring A from the housing assembly co uoce Fuser Detack Housing Assembly Remove the fuser assembly Remove the fuser cover assembly Remove the fuser lamp Gently apply outward pressure on the left and right fuser side frames B to release the detack housing assembly gt 4 29 4059 Service Manual 4059 XXX Fuser Transfer Plate 1 Remove the upper paper deflector 2 Remove the fuser transfer roll 3 4 Lift the left side of the fuser transfer plate A and move the plate Remove the inner paper deflector to the left to clear the right side from its mounting Remove the fuser transfer plate A Repair Information 4 30 4059 XXX Fuser Envelope Conditioner Solenoid The fuser solenoid is in all the models except 1250 and 1255 Remove the fuser assembly Remove the
51. incorrect or a short is found replace the motor mechanical linkage assembly Note If the DC motor is shorted it may also be necessary to replace the control board 2 Output Expander Control Board Level 2 Disconnect the motor cable J4 and check the voltages at J4 on the board Go to Output Expander Control Board Level 2 DC Motor on page 5 24 Note Use caution not to short to adjacent pins on the connector J4 1 Motor Idle 24 V dc J4 2 Motor Idle 24 V dc J4 5 Motor Idle 5 V dc J4 6 Motor Idle 5 V dc If any of the voltages are incorrect replace the control board If the voltages are correct replace the DC motor mechanical linkage assembly 2 85 4059 Service Manual 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 FRU Action 1 Dual Output Bin X Sensor Check for correct installation of Assembly the sensor cable at J5 on the Control Board control board If either the Bin Full F or Bin Near Full NF fail the sensor test then check the voltage at J5 3 and J5 4 The voltage measures approximately 5 V dc If the voltage is incorrect replace the control board If correct replace the sensor assembly Paper Feed Service Check If you have a 936 Transport Motor Error go to the Main Drive
52. installation and that the jam removal tray actuates the switch Check to make sure the switch cable is connected to J7 on the system board If no problem is found check the continuity between J7 1 and J7 2 on the cable connector while actuating the front cover switch If there is no continuity replace the front cover switch assembly If there is continuity replace the duplex option system board Diagnostic Information 2 38 4059 XXX Envelope Feeder Option Service Check Service Tip Check the envelope feeder paper path for any debris pieces of envelope and so on If any other options are installed make sure they are operating normally If only the envelope feeder is failing to operate correctly continue with this service check otherwise go to the Interconnect Card Service Check Service Tip The envelope feeder option receives its 5 V dc operating voltage from the 24 V dc bulk at J1 7 If 24 V dc is not present at J1 7 tray 1 is the only tray option that is recognized Note If a260 Paper Jam Check Envelope message displays check the Sub Error Codes For 9XX and 2XX Error Codes on page 2 7 Printer does not recognize the envelope feeder as an attached input option FRU Action 1 Envelope Feeder Check to make sure the envelope feeder is correctly installed and mated to the autoconnect at the front of the printer 2 Front Autoconnect on Printer Check the connector for
53. ln ln on 14 25 99A0801 14 26 99A0256 14 27 99A0128 14 28 99A0254 14 29 99A0257 n ln ln Cable Auto Connect Top 1650 1855 2420 2450 2455 3455 Parts Catalog 7 43 4059 XXX Assembly 14 Electronics continued 7 44 4059 Service Manual 4059 XXX Asm Part Index Number Description 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 99 0815 Contacts Smart Cartridge 14 34B 99A0814 Cable Smart Cartridge 3455 Parts Catalog 7 45 4059 XXX Assembly 14 Electronics continued 1 A 4 1 D 1 D Li 7 46 4059 Service Manual 4059 XXX a EDS Units Description 14 35 99A0065 1 Printhead Assembly 1620 1625 1650 1250 1255 14 35 99A0398 1 Printhead Assembly 1855 1855 01 14 35 99 0066 1 Printhead Assembly 2420 2450 2455 14 35 99A0829 1 Printhead Assembly 3455 14 36 99A0247 1 Cable Hysnc 14 37 99A0251 1 Cable Laser 14 37 99A0889 1 Cable Laser 3455 14 37 99A0888 1 Cable Laser 1855 1855 C01 14 38 99A0249 1 Cable Envelope Conditioner 1620 1625 1650 1855 2420 2450 2455 14 39 99A0173 1 Solenoid Assembly Envelope Conditioner 1620 1625 1650 1855 2420 2450 2455 3455 14 40 99A0170 1 Board Assembly Fuser w o
54. output bin X X 1 thru 3 Open the rear door of Output Bin X to access the jammed pages Insert Cartridge or Close Door This message displays when the printer s front door is open or the print cartridge is missing If this message cannot be cleared go to Cover Open Service Check Diagnostic Information 2 16 4059 XXX User Error Message Explanation 31 Defective Print Cartridge 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 If pages are allowed to print they are not reprinted once a good print cartridge is inserted Note This error indicates the printer was able to read the cartridge ID but the ID did not pass the verification test To pass the verification test the ID read from the print cartridge must match the ID from the last good print cartridge or the same ID must be read from the print cartridge twice The last good print cartridge ID is stored in NVRAM 32 Unsupported Print Cartridge Error 32 is displayed when the top cover is closed and an unsupported print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is supported Depending on the setting of th
55. personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table f possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity 4 1 4059 Service Manual 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 Too little belt tension can result in belt slippage To do the duplex drive belt adjustment 1 2 3 4 Do the removal procedure Duplex Front Cover Door on page 4 21 to access the drive belt idler pulley Loosen the idler pulley mounting screw and position the idler to provide 3 mm 5 mm drive belt deflection Tighten the idler pulley mounting screw being careful to maintain the adjustment Reassemble the duplex unit To do the duplex motor belt adjustment 1 2 Do the removal procedure Duplex Motor on page 4 22 to access the motor mounting screws but do not remove the motor Loosen the screw in the elongated adjustment slot and position the motor to provide 3 mm 5 mm motor belt deflection Tighten both mounting screws being carefu
56. printer indicator light blinks while the printer is processing data Press Stop to take the printer out of Busy The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the printer paper path Press Go to return to Ready Flushing Buffer The printer is flushing corrupted print data and the current print job is being discarded No button actions are possible while this message is displayed Diagnostic Information 2 12 4059 XXX User Status Message Status Action Printing Menu Settings The printer is processing or printing a list of current settings menus because Print Menu Settings is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No more data is processed but the printer processes all paper currently in the printer paper path Press Go to return to Ready after the page prints Press Menu gt or lt Menu to take the printer out of Ready and enter the TESTS MENU Busy State Press Select for the values Press Menu gt until Reset Printer is on the second line of the display Press Select to reset the printer Printing Directory List A directory of the flash and disk contents is processing or printing because Print Directory is selected from the menu Press Stop to take the printer out of Ready The Not Ready message is displayed No mo
57. replace the high capacity feeder option control board 2 High Capacity Feeder Disconnect the lower limit switch Control Board cable and check the voltage at J2 1 orange The voltage measures approximately 5 V dc If incorrect replace the high capacity feeder option control board The elevator tray down button does not operate The tray moves to the upper position Service Tip Open the high capacity feeder option front door and check the black rubber bumper attached to the door switch spring Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly FRU Action 1 Lower Limit Switch Check the lower limit switch to make Lower Limit Switch Cable sure it is not closed normally open High Capacity Feeder If incorrect replace the switch Control Board Check the lower limit switch cable for a short between pins 1 and 2 If incorrect replace the cable If correct replace the high capacity feeder option control board Diagnostic Information 2 66 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 FRU Action 1 Autocompensator Check the autocompensator pick Assembly arm rollers for sign of glazing toner or other buildup Replace as necessary 2 Wear Strips Check the wear strips for glazing or contaminat
58. 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 FRU Action 1 Smart Cartridge Contact Check both contacts to make sure Smart Cartridge Ground they are properly installed and the Contact two contacts are not touching each other Check both contacts for any signs of being bent worn or broken If incorrect replace both contacts 2 Smart Cartridge Cover Check to make sure that the smart cartridge cover is properly snapped into place and is not damaged or broken Replace as necessary 3 Smart Cartridge Plunger Check the plunger for correct installation and any signs of being damaged or broken Correct any problem found or replace the plunger as necessary 4 Smart Cartridge Cable Check the voltage on the smart Engine Board cartridge contact The voltage measures approximately 5 V dc when not writing data to the engine board If data is being written the voltage measures approximately 12 V dc If incorrect disconnect the cable from J21 on the engine board and check the voltage on J21 1 The voltage measures approximately 5 V dc If incorrect replace the engine board If correct replace the smart cartridge cable 2 103 4059 Service Manual 4059 XXX Serial Port Service Check To Run the Serial Wrap Test on page 3 12 Note The Serial Wrap Test is designed to check the serial por
59. thru sensor Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu If the test fails check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray x option pass thru sensor assembly 2 Power Takeoff Shaft and Check these parts for signs of Spring Bevel Gear broken or damaged parts Feedroll Gear Drive Roll contamination on the drive rollers or Assembly Wear Plate wear plate and wear or damage to Drive Shaft Bearings and the drive shaft bearings Check the Skewed Backup Roller drive roll assembly and skewed backup roller for signs of wear slick spots material buildup and oil or grease on the rollers Also check for proper operation of the paper aligning assembly Repair or replace parts as necessary Diagnostic Information 2 64 4059 XXX Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray FRU Action 1 Paper Low Switch Paper Low Switch Cable System Board High Capacity Feeder Input Run the sensor diagnostics for tray X X the number that represents the high capacity input tray If the test fails disconnect the paper low switch cable from J3 on the high capacity system board
60. voltage measures approximately 24 V dc Main Fan Service Check Check the cable connections at J1 on the engine board and at the main fan assembly The main fan runs continuously when the printer is powered on unless the printer is in the Power Saver mode FRU Action 1 Main Fan Manually spin the fan and check that it rotates freely Check the cable connection to the engine board J1 for correct installation 2 Main Fan to Engine Board Cable Check the continuity of the cable If incorrect replace the cable 2 47 4059 Service Manual 4059 XXX FRU 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 Error Code 927 Check the voltage at J1 3 on the Fan not running engine board The voltages are as follows 22 V dc to 24 V dc printer and fan running 12 V dc to 15 V dc printer not running fan running about half speed If incorrect replace the engine board If this does not fix the problem replace the main fan Fuser Service Check Cold Fuser Service Check Error codes 920 921 and 922 may display for a cold fuser failure A 920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again A 925 service error indicate
61. 0 1650 2420 2450 17 47 99A0397 1 Board Tray Top 1255 1625 1855 2455 3455 17 48 3 Screw Board Mounting PP 99A0263 17 49 99A0460 2 Nut Dual 500 Mounting NS 99A0429 1 Label Options Circle 1255 1625 1855 2455 Parts Catalog 7 59 4059 XXX Assembly 18 Duplex 7 60 4059 Service Manual 4059 XXX Ae Units Description 18 1 99A0344 1 Cover System Board 18 2 99A0322 1 Main Frame Assembly 18 3 99A0324 1 Idler Assembly Belt Tension 18 4 99A0326 4 Spring Aligner 18 5 99A0323 4 Guide Assembly Paper 18 6 99A0314 2 Spring Chassis Ground 18 7 2 Screw Motor Mount 3 mm PP 99A0413 18 8 99A0328 1 Belt Motor 114 Gear 18 9 99A0329 1 Pulley Main Drive 96 54 Gear 18 10 99A0321 1 Motor Assembly 18 11 99A0320 1 Cable D C Motor Tach 18 12 1 Cam Follower Assembly Kit PP 99A0299 18 13 99A0312 1 Actuator Assembly Deflector 18 14 2 Screw Actuator Assembly Mounting PP 9940413 18 15 99A0339 1 Guide Return RH Upper 18 16 2 Screw Upper Return Guide Mounting PP 99A0413 18 17 99A0340 1 Guide Return RH Lower 18 18 99A0345 1 Tray Assembly Jam Removal 18 19 99A0261 1 Switch Assembly Front Cover NS 99A0432 1 Roll Debuckle NS 99A0428 1 Shaft Debuckle NS 2 Retainer 6 mm Backup Roll PP 99A0404 NS 2 Screw M3x6L G Supradrive PP 99A0413 Parts Catalog 7 61 4059 XXX Assembly 18 Duplex continued 7 62 4059 Service Manual 4059 XXX ie ELS
62. 0 1855 2420 2450 2455 3455 19 7 99A0571 1 Cover Front Control Board with ESD Brush 19 8 99A0483 1 Tray Output Expander 19 9 99A0924 1 Spring Diverter 19 10 99A0925 1 Diverter Actuator Arm 19 11 99 0482 1 Spring Output Tray 19 12 99A0366 2 Bracket Attach 19 13 99A0480 1 Output Expander Assembly Mechanical Linkage Level 1 1650 1855 2420 2450 2455 19 13 99A0914 1 Output Expander Assembly Mechanical Linkage Level 2 1855 2455 3455 19 14 99A0372 1 Cover Left Side 19 15 99A0415 2 Spring Diverter 19 16 99A0416 1 Spring Sector Bias 19 17 99A0481 1 Latch Output Tray 19 18 2 Shaft Bearing PP 99A0572 19 19 99A0350 1 Sensor Bin Full Level 1 1650 2420 2450 19 19 99A0414 1 Sensor Dual Bin Full Level 2 1855 2455 3455 19 20 99A0378 1 Flag Kit Output Paper Level Parts Catalog 7 67 4059 XXX Assembly 19 Output Expander continued 7 68 4059 Service Manual 4059 XXX Asm Part Index Number Units Description 19 21 99A0062 1 Level Sensor Bracket Level 1 1650 2420 2450 19 21 99A0409 1 Level Sensor Bracket Level 2 1855 2455 3455 19 22 99A0914 1 Output Expander Assembly Mechanical Linkage 19 22 99A0374 1 Door Assembly Rear Access 19 23 99A0368 1 Shaft Assembly Lower Also order PP 99A0572 19 24 99A0363 3 Pulley Drive 19 25 99A0371 1 Cover Right Side 19 26 99A0361 1 Belt 160 Gear 19 27 99A0362 1 Arm Assembly Belt Idler
63. 0 99A0447 Sensor Option Pass Thru Restraint Side 500 Sheet Tray Wear Strips Indicator Assembly Paper Size Label Tray Number 2 5 Clip 500 Tray Wear Finger Autosize Plate Snap In Slider Autosize 500 Restraint Pad Tray 500 Sheet Restraint Back 500 Sheet Tray Latch Back Restraint Cable Assembly Dual Tray Auto Connect Wear Plate Pass Thru 500 Tray Screw Wear Plate Mounting PP 99A0263 Roll Assembly Drive 500 Dual Retainer Roller Roller Skewed Backup Bearing Drive Roll Shaft 500 Drive P A Ah M A vx Parts Catalog 7 57 4059 XXX Assembly 17 500 500 Dual Tray continued 7 58 4059 Service Manual 4059 XXX e EDS Units Description 17 31 99A0275 1 Spring Power Takeoff 17 32 99A0280 1 Bearing Drive Shaft Low 17 33 99A0446 1 Aligner Assembly Paper 17 34 1 Retainer Aligner Assembly PP 99A0267 17 35 99A0300 1 Board Tray Bottom 17 36 99A0898 1 Cable 500 Tray Board to Board Power 17 37 99A0274 1 Gear Feed Roll 17 38 99A0286 1 Spring Backup Roller 17 39 99A0472 1 Cable Assembly 500 500 Dual 17 40 99A0278 1 Bellcrank Roller Release 17 41 99 0273 1 Gear Bevel 17 42 99A0063 1 Spring Switch Activate 17 43 99A0279 1 Bearing Drive Shaft 17 44 99A0281 1 Cable 500 Auto Connect Top 17 45 99A0444 1 Stud Assembly 500 Frame 17 46 99A0443 1 Arm Paper Out 500 17 47 99A0284 1 Board Tray Top 1250 162
64. 0058 4 Pad Machine Mounting 2 11 99A0558 1 Transfer Plate Assembly 2 11 99A0828 1 Transfer Plate Assembly 3455 2 12 99A0904 1 Plate Assembly Stacker Ground 2450 2455 3455 2 12 99A0561 1 Support Right Stacker 1250 1255 1620 1650 2420 1855 1625 2 13 99A0111 1 Right Sideframe 2 14 99A0043 1 Track Cartridge Guide RH 2 15 99A0049 1 Fan Auxiliary 2420 2450 3455 2 16 1 Contact Kit PP 99A0585 3 Contact Doctor Blade TAR Developer Roll 1 o Contact PC Drum 1 o Contact Charge Roll 4 Block Contact Mounting 5 Screw Contact Mounting 2 16A 99A0805 1 Contact Charge Brush 3455 2 17 99A0466 1 Sensor Toner Cartridge Level 2 18 99A0026 1 Tray Bias Arm Assembly 2 19 99A0028 1 Spring Tray Bias 2 20 99A0038 1 Pan Center Assembly Parts Catalog 7 7 4059 XXX Assembly 2 Frame continued 7 8 4059 Service Manual 4059 XXX Asm Part Index Number Units Description 2 21 99A0056 2 22 99A0055 2 23 99A0042 2 24 99A0053 2 25 99A0063 2 26 99A0046 Deflector Upper PF Deflector Inner Frame EP Module Sensor Input Spring PA Out Activate Cover Gap 1620 1625 1650 1855 2420 2450 2455 Cover Gap 3455 Shield ESD Assembly with label Left Side Frame Board Input Tray ITC Frame Extension 1650 2420 1855 Frame Extension 2450 2455 3455 Pan Motor Drip Track Cartridge Guide LH Link Gear Release ee ln lon 2 26 99A0804 2 27 99A0549 2 28 99A0029 2 29 99A0128 2 30 99A0189 2 30 99A0037
65. 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 Release the pick roll retaining tab and slide the pick roll off the shaft Repair Information 4 54 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 B 425 4 55 4059 Service Manual 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 Remove the two redrive assembly mounting screws A 4 Release the two redrive assembly mounting latches B and remove the redrive assembly 202 Repair Information 4 56 4059 XXX Right Side Frame Remove the right side cover Remove the LVPS Remove the multipurpose tray assembly Remove the auxiliary fan assembly 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 7 Remove the right side fr
66. 16 1 Tray Assembly Drive Roller 22 12 99 0125 1 Frame Assembly Right Side 22 13 99A0232 1 Cover Right 22 14 99A0217 2 Belt 160G 22 15 99A0226 1 Guide Paper Exit 22 16 99A0122 2 Shaft Assembly Drive Roller 22 17 99A0137 1 Frame Assembly Left Side 22 18 99A0088 1 Cover Backup Tray 22 19 99A0085 1 Tray Backup Roller Parts Catalog 7 85 4059 XXX Assembly 23 Kiosk Horizontal Paper Adapter 7 86 4059 Service Manual 4059 XXX EDS Units Description 23 1 99A0231 1 Bail Support 23 2 99A0112 1 Mounting Frame Assembly 23 3 99A0197 1 Shaft Drive Rear 23 4 12 Retainer PP 99A0240 23 5 99A0209 1 Arm Assembly Pivot 23 6 15 Screws PP 99A0234 23 7 7 Parts Pulley PP 99A0208 23 7B 3 Gear Idler PP 99A0237 23 8 99A0079 1 Tray Assembly Backup Roller 23 9 99A0087 6 Spring Backup Roller 23 10 99A0086 6 Roller Backup 23 11 99A0905 1 Tray Assembly Drive Roller 23 12 99A0907 1 Frame Assembly Right Side 23 13 99A0232 1 Cover Right 23 14 99A0217 2 Belt 160G 23 15 99 0122 2 Shaft Assembly Drive Roller 23 16 99A0906 1 Frame Assembly Left Side 23 17 99A0088 1 Cover Backup Tray 23 18 99A0085 1 Tray Backup Roller Parts Catalog 7 87 4059 XXX Assembly 24 Options ena LN Units Description 24 1328589 1 2MB DRAM SIMM 24 99A0517 1 4MB DRAM SIMM 24 99A0518 1 8MB DRAM SIMM 24 99A0519 1 16MB DRAM SIMM 24 99A0520 1 32MB DRAM S
67. 2 31 99A0899 2 32 99A0044 2 33 99A0567 2 34 99A0555 2 35 99A0556 NS 2 36 99A0030 2 36 99A0803 2 37 99A0377 Bracket Counterbalance Hinge Spring Spring Counterbalance 7 Screw PP 99A0263 Fan Main Fan Main 3455 Flag Kit Standard Bin Level 1650 1855 2420 Flag Kit Standard Bin Level 2450 2455 3455 Flag Standard Bin Level 1855 01 Flap 250 Paper Output Bin 1855 C01 Bracket Level Sensor 1650 2420 2450 3455 Sensor Standard Bin Level 1620 1625 1650 1855 2420 2450 2455 3455 cl cl sch lll 2 37 99A0378 2 37 99A0794 NS 99A0499 2 38 99A0062 2 39 99A0138 n ln ln Parts Catalog 7 9 4059 XXX Assembly 3 Printhead 7 10 4059 Service Manual 4059 XXX ae Ae Units Description 3 1 99A0065 1 Printhead Assembly 1620 1625 1650 1250 1255 3 1 99A0398 1 Printhead Assembly 1855 3 1 99A0066 1 Printhead Assembly 2420 2450 2455 3 1 99A0829 1 Printhead Assembly 3455 NS 3 Screw Printhead Mounting PP 99A0263 Parts Catalog 7 11 4059 XXX Assembly 4 Paper Feed Autocompensator 7 12 4059 Service Manual 4059 XXX dm Units Description 4 1 99A0060 1 Sensor Paper Out Internal Tray 4 2 99A0067 1 Pick Arm Assembly 250 4 3 99A0070 2 Pick Rolls NS 1 Screw Hanger PP 99A0263 Parts Catalog 7 13 4059 XXX Assembly 5 Paper Feed Multipurpose Unit 7 14 4059 Service Manual Part 42 In
68. 2 Messages 2 20 User Status Messages 2 12 Output Bin Feed Test 3 15 Output Bin Sensor Test 3 16 Output Bin Test Standard Bin 3 15 Output Bin X Sensor Test 3 16 Output Expander Control Board Level 1 Stepper Motor 5 22 Output Expander Control Board Level 2 DC Motor 5 24 P Parallel Wrap Test 3 11 Parts Catalog 7 1 Charging 7 34 Covers 7 2 Developer Drive 7 24 Duplex 7 60 Electronics 7 36 Envelope Feeder Frame 7 6 Fuser 7 26 High Capacity Feeder 7 74 Integrated Paper Tray 250 Sheet 7 20 Kiosk Horizontal Paper Adapter 7 86 Kiosk Vertical Paper Adapter 7 84 Main Drive 7 22 Miscellaneous 7 90 Options 7 88 Output Expander 7 66 Paper Feed Alignment 7 16 Autocompensator 7 12 Multipurpose Unit 7 14 Output 7 18 Printhead 7 10 Transfer 7 32 250 Sheet Tray 7 48 500 Sheet Tray 7 52 500 500 Dual Tray 7 56 Power On Self Test POST Preventive Maintenance 6 1 Q Quick Disk Test 3 2 7 70 2 24 Index 1 2 4059 XXX R Switch Assembly 4 49 Removal Procedures 4 12 Papel Removals Outer EMC Shield 4 51 Paper Alignment Assembly 4 52 Paper Input Sensor 4 53 Paper Size Sensing Board 4 54 Pick Roll 4 54 Printhead 4 55 Redrive Assembly 4 56 Right Side Frame 4 57 Smart Cartridge Contacts 4 58 Toner Sensor 4 59 Transfer Roll Assembly 4 60 Upper Front Cover Hinge Assembly 4 61 Upper Front Cover Interlock Switch Assembly 4 62 Upper Paper Deflector Assembly 4 60 Restore EP Factory
69. 21 34 2 Screw Base Mounting PP 99A0675 21 35 99A0663 1 Pulley Idler 21 36 99A0697 4 Spacer Motor Mounting 21 37 99A0699 1 Cable PS Internal Wiring 21 38 99A0653 1 Switch Lower Limit Microswitch 21 39 2 Nut 2 56 Lower Limit Switch Mounting PP 99A0676 21 40 99A0665 1 Motor Assembly 21 41 4 Washer Motor Plate Mounting PP 99A0677 21 41A 2 Washer Power Supply Ground PP 99A0677 21 42 99A0664 1 Belt Drive 21 43 2 Nut Power Supply Ground PP 99A0676 21 44 4 Screw Motor Plate Mounting PP 99A0675 21 45 99A0669 1 Connector Appliance Inlet with Tye Wrap 21 46 99A0670 1 Cord AC External Jumper 21 47 2 Nut Power Supply Cover PP 99A0676 21 48 99A0714 1 Cover Power Supply 21 49 2 Screw Power Supply Board Mounting PP 99A0675 Parts Catalog 7 77 4059 XXX Assembly 21 High Capacity Feeder continued 7 78 4059 Service Manual 4059 XXX Asm Part e 422 index Number Units Description 21 50 2 Washer Power Supply Board PP 99A0677 21 51 99A0667 1 Power Supply Board 21 52 99A0715 1 Cable Low Voltage Power Supply NS 99A0682 1 Cable HCIT TOC Power NS 99A0683 1 Cable HCIT Power Passthru NS 99A0684 1 Cable HCIT 14Pin Flex 21 53 99A0685 1 Bushing 21 54 2 Nut 2 56 Paper Low Switch Mounting PP 99A0676 21 55 99A0654 1 Switch Paper Low 21 56 99A0651 1 Sensor Assembly Paper Out Upper Limit 21 57 3 Screw Printer Support 1 Frame Mounting PP
70. 28 99A0148 1 Gear Idler Parts Catalog 7 29 4059 XXX Assembly 11 Fuser continued 7 30 4059 Service Manual 4059 XXX Asm Part 4227 Index Number Units Description 11 29 99A0297 1 Link Solenoid 1620 1650 2420 2450 1855 1625 2455 3455 11 30 99A0169 1 Sensor Narrow Media 11 31 99A0172 1 Flag Exit Sensor 11 32 99A0166 1 Guide Assembly Lower Exit w Narrow Media Sensor 11 33 99A0897 2 Spring Redrive Idler 11 34 99A0167 2 Roller Redrive Idler 11 35 1 Tie Wire PP 99A0577 11 36 99A0140 1 Lamp 115V 750W CC Red 2420 2450 2455 3455 11 36 99A0141 1 Lamp 115V 500W CC White 1250 1255 1620 1625 1650 1855 11 36 99A0177 1 Lamp 100V 500W CC Yellow 1250 1255 1620 1625 1650 1855 11 36 99A0178 1 Lamp 100V 750W CC Purple 2420 2450 2455 11 36 99A0175 1 Lamp 220V 750W CC Orange 2420 2450 2455 3455 11 36 99A0176 1 Lamp 220V 500W CC Black 1250 1255 1620 1650 2455 NS 7 Screw Hanger PP 99A0263 2450 1250 NS 99A0145 3 Clip Fuse Mounting NS 99A0919 2 Standoff Fuser Control Board Parts Catalog 7 31 4059 XXX Assembly 12 Transfer 7 32 4059 Service Manual 4059 XXX EDS Units Description 12 1 99A0179 1 Transfer Roll Assembly 12 1 99A0498 1 Transfer Roll Assembly 1855 C01 PRC 12 2 99A0349 1 Arm Transfer Roll Assembly Right 12 3 99A0184 1 Spring Transfer Roll Right 12 4 99A0186 1 Erase Lamp Assembly Kit o Lamp Erase Assembl
71. 307 1 Air Plenum 18 47 99A0335 2 Spring Decurl Shaft 18 48 99A0334 2 Bushing 18 49 99A0327 1 Frame Outer 18 50 3 Screw Outer Frame PP 99A0413 18 51 99A0330 1 Guide Assembly Center Drive 18 52 1 Fan Mounting Kit PP 99A0269 2 Screw Fan Mounting M4x30 2 o Washer Fan M4 2 o Nut Fan M4 18 53 99A0308 1 Fan Cooling Duplex 18 54 2 Retainer 5 mm Main Drive PP 99A0404 18 55 99 0337 1 Main Drive Assembly 18 56 99A0319 1 Sensor Input Optical 18 57 99A0433 1 Spring Decurl Shaft 18 58 99A0304 1 Switch Assembly Top Cover Open 18 59 4 Retainer 6 mm Drive Roll PP 99A0404 18 60 99A0336 1 Shaft Assembly Drive 18 61 99A0333 1 Shaft Assembly Decurl NS 1 Screw Tensioner PP 99A0413 NS 2 Retainer 6 mm Clutch Roll PP 99A0404 NS 99A0058 4 Feet Duplex Base NS 99A0429 1 Label Options Circle 1255 1625 1855 2455 Parts Catalog 7 65 4059 XXX Assembly 19 Output Expander 7 66 4059 Service Manual 4059 XXX Asm Part 4227 Index Number Units Description 19 1 99A0107 1 Diverter Upper Also order 99A0104 19 2 99A0104 1 Spring Upper Diverter 19 3 99A0369 1 Shaft Assembly Exit Also order PP 99A0572 19 4 99A0052 1 Shaft Assembly Lower Exit Also order PP 99A0572 19 5 11 Screw PP 99A0263 19 6 99A0347 1 Board Output Expander Level 1 1650 2420 2450 19 6 99A0406 1 Board Output Expander Level 2 1855 2455 1650 2420 2450 19 6 99A0915 1 Board Output Expander DC motor Level 3 165
72. 4059 XXX Connector Pin No Signal J9 Autoconnect 1 Ground Option Below 2 PrtxDout 3 Ground 4 PrtRxd J10 Autoconnect 1 24 V dc Option Below 2 Ground J11 Printer 1 424 V dc Autoconnect 2 Ground J12 Printer 1 N A Autoconnect 2 Ground 3 PrtxDin 4 Ground 5 PrtRxD Level 1 Duplex Option Board QO ol J1 oooonnnan 27 Uuuuuuuu 5 5 1 LTULTULILILILI 1 nnnnnnnnn 00000000 J6 Level 1 Connector Locations 5 20 4059 XXX Level 2 Duplex Option Board nnnnnnnnn LILTLILTLTCT LIC LT nnnnnnnn af nnnnnnnmn 0000000 Autoconnect Top Level 2 Connector Pin No Signal Top Autoconnect 0 V dc 45 V dc 0 V dc 0 V dc 0 V dc 45
73. 455 11 1 99A0474 1 Fuser Assembly w 115V 750W Lamp 2420 2450 2455 11 1 99A0475 1 Fuser Assembly w 220V 750W Lamp 2420 2450 2455 11 1 99A0476 1 Fuser Assembly w 100V 500W Lamp 1620 1650 1855 1625 11 1 99A0477 1 Fuser Assembly w 115V 500W Lamp 1620 1650 1855 1625 11 1 99A0478 1 Fuser Assembly w 220V 500W Lamp 1620 1650 1855 1625 11 1 99 0524 1 Fuser Assembly w 100V 500W Lamp 1250 1255 11 1 99A0525 1 Fuser Assembly w 115V 500W Lamp 1250 1255 11 1 99A0526 1 Fuser Assembly w 220V 500W Lamp 1250 1255 11 1 99A0830 1 Fuser Assembly w 115V 750W Lamp 3455 11 1 99A0831 1 Fuser Assembly w 220V 750W Lamp 3455 11 2 99A0146 1 Wiper Assembly Dry 11 2 99A0725 1 Wiper Assembly Wet 11 3 99A0918 1 Cover Fuser Assembly with Thermistor Thermal Fuse and LH amp RH Fuser Lamp Contact Assemblies 11 4 4 Screw Contact Assembly PP 99A0263 11 5 99A0147 1 Exit Roll Assembly 11 6 99A0156 1 Detack Assembly 1250 1255 1620 16251650 1855 2420 2450 2455 11 6 99A0833 1 Detack Assembly 3455 11 7 99A0562 1 Hot Roll Assembly 1250 1255 11 7 99A0563 1 Hot Roll Assembly 1620 1650 1855 11 7 99A0149 1 Hot Roll Assembly 2420 2450 2455 11 7 99A0832 1 Hot Roll Assembly 3455 11 8 99A0144 2 Retainer Backup Roll Bearing Parts Catalog 7 27 4059 XXX Assembly 11 Fuser continued 7 28 4059 Service Manual 4059 XXX ie EDS Units Description 11 9 99A0158 1 Backup Roll CBM 30 mm 2420 2450 3455 11 9 99A0160 1 Backup Roll
74. 455 3455 Hinge Upper Front Cover Label TLI ID Serial No Blank Cover Assembly Lower Front 1250 1255 1620 1625 1650 1855 2420 1 8 99A0020 1 Cover Assembly Lower Front 2450 2455 3455 Cap MPT 2450 2455 3455 O Ring Lower Front Door Screw Upper Front Cvr Mtg PP 99A0263 Kit Upper Front Cover with Labels oO a 1 5 99A0012 1 6 99A0008 1 7 99A0007 1 8 99A0023 ln n 1 8A 99A0022 1 9 99A0021 NS 1 10 99A0917 NS 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 1 11 99A0539 1 11 99A0540 1 11 99A0541 Labels Upper Front Cover Bezel Operator Panel English Bezel Operator Panel France Bezel Operator Panel Italy Bezel Operator Panel Germany Bezel Operator Panel Spain Bezel Operator Panel Denmark Bezel Operator Panel Netherlands Bezel Operator Panel Norway Bezel Operator Panel Sweden Bezel Operator Panel Brazil Portugal Bezel Operator Panel Finland Ce Ce Ce Ce Ce Cs Cs Ce Cs Ce CS oe Ce Bezel Operator Panel Japan Parts Catalog 7 3 4059 XXX Assembly 1 Covers continued 7 4 4059 Service Manual 4059 XXX ae EDS Units Description 1 12 99A0001 1 Operator Panel Assembly 1 13 99A0009 1 Cover Left Side 1250 1255 1620 1650 2420 1855 1625 1 13 99A0010 1 Cover Left Side 2450 2455 3455 NS 5 Screw Left Side Cvr Mtg PP 99A0263 1 14 99A0017 1 Door L
75. 5 3 0 Cover INA Blank 14 19 99A0207 1 Shield Outer 1250 1255 1620 1625 14 19 99A0206 1 Shield Outer 1650 2420 1855 14 19 99A0204 1 Shield Outer 2450 2455 NS 99A0224 1 Shield Interconnect Board 2450 2455 3455 NS 99A0229 1 Shield Interconnect Board 1625 1650 1855 2420 NS 99A0230 1 Shield Interconnect Board 1250 1255 NS 99A0243 1 Shield Interconnect Board Mylar 2450 2455 3455 NS 99A0244 1 Shield Interconnect Board Mylar 1625 1650 1855 2420 NS 99A0245 1 Shield Interconnect Board Mylar 1250 1255 14 20 4 Screw Outer Shield Mounting PP 99A0263 14 20 6 Screw Outer Shield Mounting PP 99A0263 2450 14 21 1 Screw Eng Controller Mtg Ground PP 99A0263 NS 1 Screw Eng Int Shield Ground PP 99A0263 NS 2 Screw Controller Int Ground PP 99A0263 NS 2 Screw Int Pan Mounting PP 99A0263 NS 1 Screw Eng Int Ground PP 99A0263 NS 99A0260 1 Clip Cable NS 2 Screw Cable Clip PP 99A0263 Parts Catalog 7 41 4059 XXX Assembly 14 Electronics continued 7 42 4059 Service Manual 4059 XXX Asm Part Index Number 14 22 99A0138 14 23 99A0030 14 23 99A0803 14 24 99A0255 14 25 99A0129 14 25 99A0130 Units Description Sensor Standard Bin Level Fan Main Fan Main 3455 Cable Main Drive Motor Gearbox w Motor 2450 2420 2455 Gearbox w Motor 1620 1650 1250 1255 1855 1625 Gearbox w Motor 3455 Cable Integrated Tray Board Input Tray ITC Cable Auto Connect Bottom n
76. 5 21 CERSZT v 75 ODIVFAI 1 LEV V HMCHSSCEMUEWS NATOR T 825086175 ALOV YV WMECHSCEMEWS NTE EBA GCHTWETF 20 7Zyr sZ i 72zHb 30 OL P AAMLTTIETF 20 LF 0 T7T95T 72 72 08388B8C BH SL UDybhOAVDAULWERHITSLU P CF Got YAFLESPVVYS itk BORE 2A VPOA YFIHVAL D EL BW Ti ARR FATOVANVE LOL P ik Chinese Laser Notice A 4U ae EIU GEA DHHS 21 CFR Subchapter I 272 1 1 Tm ER Hh p uL SEA ES 3 825 ES tr TE SELB PE TT EN EL A BBS A35 1 3b AY ROC amp 7 EEGEN EG HBR 770 795 om 218 RMI ARRITNPM RIT cp VE HABA AWA ARSE APR ROE TD SAY Notices and Safety Information xvi 4059 XXX Korean Laser Notice ere 158 olx ASSO CHE DHHS 21 CFR Subchapter 32 PAS Zei ges ozo oHe 2 2 EC 8 TAS tse 158 olx xEesgs ess HHEH 158 AOA ASSES HNE AOS HFHH ugaas 5 PASE 2 770 795 IHH SISStE Class 3b alo x1 amp cyto 213 Veit Aj BA 45 HA B SLE Weg MHA SERA 4219 Class EY al o x Ao SO Sog MSs ABO rio Safety Information e 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 par
77. 55 3455 fails to run or is noisy Go to the Auxiliary Fan Service Check on page 2 47 Dead Machine Go to the Dead Machine Service Check on page 2 32 Operator Panel One or more buttons do not work Go to the Operator Panel Buttons Service Check on page 2 74 Operator Panel Display is blank Printer sounds 5 beeps Go to the Operator Panel Service Check on page 2 74 Operator Panel Display is blank Printer does not emit 5 beeps Replace the operator panel assembly Operator Panel continuously displays all diamonds 5 beeps and does not complete POST Go to the Operator Panel Service Check on page 2 74 Paperfeed problems Base printer or Integrated 250 Paper Tray Go to the Paper Feed Service Check on page 2 86 Paper jams at exit of Redrive Assembly No Duplex Option installed Go to the Paper Feed Service Check on page 2 86 Paper jams at exit of Redrive Assembly Duplex Option installed Go to the Duplex Option Service Check on page 2 35 Fuser Solenoid Models 1620 1650 2420 2450 3455 fails to operate Go to the Fuser Envelope Conditioner Solenoid Service Check on page 2 51 Print quality Black page Go to Print Quality All Black Page on page 2 92 Print quality Blank page Go to Print Quality Blank Page on page 2 92 Print quality Light print 2 25 4059 Service Manual Go to Print
78. 99A0121 1 Clip 250 Tray Wear 8 9 99A0126 4 Finger Autosize 8 10 99A0124 1 Plate Snap In 8 11 99A0127 1 Slider Autosize 250 8 12 99A0893 1 Restraint Back 250 Sheet Tray NS 2 Screw Deflector Mounting PP 99A0263 NS 99A0452 1 Washer Latch Mounting NS 1 Screw Latch Mounting PP 99A0263 NS 99A0501 1 Strip Assembly Paper Tray Insert 1855 01 Parts Catalog 7 21 4059 XXX Assembly 9 Main Drive 7 22 4059 Service Manua 4059 XXX ae Ae Units Description 9 1 99A0129 1 Gearbox w Motor 2420 2450 2455 9 1 99A0130 1 Gearbox w Motor 1620 1650 1250 1255 1855 1625 9 1 99A0801 1 Gearbox w Motor 3455 9 2 99A0134 1 Shaft Power Takeoff 9 3 99A0275 1 Spring Power Takeoff Shaft 9 4 99A0954 1 Gear Bevel NS 4 Screw Gearbox Mounting PP 99A0263 NS 3 Screw Motor Mounting PP 99A0263 NS 99A0260 2 Clip Cable Parts Catalog 7 23 4059 XXX Assembly 10 Developer Drive 7 24 4059 Service Manual 4059 XXX Units Description 10 1 99A0135 1 Developer Drive Assembly 10 2 99A0136 1 Shaft Developer Drive 10 3 99A0564 1 Coupler Gear 55 10 4 1 Screw Developer Drive Ground PP 99A0263 10 5 2 Screw Developer Drive Mtg 99A0263 Parts Catalog 7 25 4059 XXX Assembly 11 Fuser 7 26 4059 Service Manual 4059 XXX Asm Part 421 Index Number Units Description 11 1 99A0473 1 Fuser Assembly w 100V 750W Lamp 2420 2450 2
79. 99A0675 NS 6 Washer Printer Support Frame 1 Star PP 99A0677 NS 6 Nut Printer Support Frame 1 8 32 Hex PP 99A0676 NS 10 Screw Door to Door Frame Mounting PP 99A0675 21 58 99A0659 1 Frame Printer Support 1 21 59 99A0695 1 Parts Kit Paper Size Switch Assembly including cable switch lockwasher nut and knob 21 60 2 Washer Sensor Bracket Mounting 99A0677 21 61 2 Screw Sensor Bracket Mounting PP 99A0675 Parts Catalog 7 79 4059 XXX Assembly 21 High Capacity Feeder continued 7 80 4059 Service Manual 4059 XXX ei ii Units Description 21 62 99A0281 1 Cable 250 Auto Connect 21 63 99A0279 1 Bearing Drive Shaft 21 64 99A0273 1 Gear Bevel 21 65 2 Screw Frame Mounting PP 99A0263 21 66 99A0276 1 Roll Assembly Drive 250 Option 21 67 99 0451 1 Roll Skew Backup 21 68 1 Retainer Roller PP 99A0267 21 69 2 Screw Wear Plate Mounting PP 99A0675 21 70 99A0277 1 Plate Wear Pass Thru NS 99A0286 1 Spring Backup Roller 21 71 99 0445 1 Stud Assembly 250 Frame 21 72 99A0280 1 Bearing Drive Shaft Low 21 73 99A0275 1 Spring Power Takeoff 21 74 99A0272 1 Shaft 250 Drive 21 75 99A0446 1 Aligner Assembly Paper 21 76 1 Retainer Aligner Assembly PP 99A0267 21 77 99A0274 1 Gear Feed Roll 21 78 99A0278 1 Bellcrank Roller Release 21 79 99A0688 1 Card Assembly 2000 Tray Option 21 79 99A0401 1 Card Assembly 2000 Tray Option 1255 1625 1855 2455 3455
80. AM Memory Error on the controller board Replace the controller board 961 RAM in Slot 1 is Bad Replace the SIMM in Slot 1 If this does not fix the problem replace the controller board 962 RAM in Slot 2 is Bad 964 Emulation Error 965 Emulation Error Replace the SIMM in Slot 2 If this does not fix the problem replace the controller board Indicates a failure within the Download Emulation which is programmed into the code overlay SIMM The specific error is as follows 964 Download Emulation CRC Failure Checksum Failure 965 Download Emulation Outdated The Download Emulation and the controller code are incompatible Go to Disabling Download Emulations on page 3 3 975 979 Network Card X The following errors indicate a failure with the network card in the specified slot X any card installed in slots 1 2 or 3 975 Unrecognizable Network Card x Replace Network Card x 976 Unrecoverable software error in Network Card x 977 Controller software detects that a Network Card is installed in slot x but cannot establish communications with it 978 Bad checksum while programming Network Card x Replace Network Card x 979 Flash parts failed while programming Network Card x 980 device Comm The engine is experiencing unreliable communications to the specified device 981 device The engine protocol violation detected by the specified device Diagno
81. Cable Elevator Top Optical Sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly Diagnostic Information 2 70 4059 XXX Tray X Empty message displays Tray does not respond to loading paper No response from the front door switch FRU Action 1 High Capacity Feeder Option Control Board Check the voltage on the board at J4 2 green The voltage measures approximately 5 V dc If incorrect disconnect the cable at J4 and check the voltage again If incorrect replace the high capacity feeder option control board 2 Elevator Top Optical Sensor Cable Elevator Top Optical Sensor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate paper in the tray FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder Option Control Board Run the sensor diagnostics for tray X X the number that represents the high capacity input tray If the test fails check the voltage at J3 1 grey The voltage measures approximately 24 V dc If incorrect disconnect the paper low switch cable from J3 and measure the voltage again on J3 1 If incorrect replace the high capacity feeder option control board I
82. Defaults 3 21 ROM Memory Test 3 10 Center Pan Assembly 4 18 Controller Board 4 19 Covers 4 12 Developer Drive Assembly 4 20 Duplex Board 4 21 Duplex Front Cover Assembly 4 21 Duplex Front Cover Door 4 21 Duplex Front Cover Door Switch 4 21 Duplex Motor 4 22 Engine Board 4 23 EP Frame Assembly 4 23 Fans 4 24 Fuser 4 26 Fuser Board 4 27 Fuser Cover 4 28 Fuser Detack Fingers 4 29 Fuser Detack Housing Assembly 4 29 Fuser Envelope Solenoid 4 31 5 Fuser Exit Flag Assembly 4 31 8 Fuser Exit Roll Assembly 4 32 Safety Information xvii FuserLamp 4 33 Safety Inspection Guide 6 1 Fuser Lower Exit Guide Assembly Scheduled Maintenance 2420 2450 4 33 2455 3455 6 2 Fuser Transfer Plate 4 30 Screw Identification Table 4 7 HVPS 4 34 Serial Wrap Test 3 12 Inner EMC Shield 4 35 Service Checks Inner Paper Deflector Assembly Charge Roll 2 29 4 36 Cover Open Switch Cable 2 31 Integrated Tray Compensator Dead Machine 2 32 Assembly 4 37 Duplex Option 2 35 Integrated Tray Compensator Pick Envelope Feeder Option 2 39 Roll Assembly 4 38 Erase Lamp 2 46 Interconnect Board Assembly 4 39 Fan 2 47 Left Side Frame 4 41 Fuser 2 48 LVPS 4 43 Fuser Solenoid 2 51 Main Drive Assembly 4 44 High Capacity Feeder Input Tray Main Drive Motor 4 45 2 61 Multipurpose Tray Lower Deflector Input Sensor 2 57 Assembly 4 46 Input Tray s Option 2 58 Operator Panel 4 48 Main Drive 2 73 Operator Panel Cable Cover Open Operator Panel 2 74 1 3 4059
83. E Units Description 18 20 1 Screw Tray Open Switch Mounting PP 99A413 18 21 99A0341 1 Sensor Exit Optical 18 22 99A0342 1 Guide LH Lower 18 23 99A0343 1 Guide Return LH Upper 18 24 2 Screw LH Upper Return Guide Mounting PP 99A0413 18 25 99A0306 1 Base Assembly w Tray Bias 18 26 99A0316 1 Shaft Duplex Drive 18 27 99A0315 1 Spring Duplex Shaft 18 28 99A0325 1 Gear Pass Thru Idler 18 29 99A0280 1 Bearing Drive Shaft Low 18 30 99A0311 1 Cable Auto Connect Bottom 18 31 99A0274 1 Gear Pass Thru Drive Roll 18 32 99A0310 1 Cable Auto Connect Top 18 33 4 Screw Main Frame Assembly Mounting PP 99A0413 18 834 99A0317 1 Gear Duplex Bevel 18 35 99A0434 1 Pan System Board Drip 18 36 99A0279 1 Bearing Drive Shaft 18 37 99A0191 1 Fuse 8A SB 18 38 99A0403 1 Board System Level 1 18 38 99A0916 1 Board System Level 2 NS 99A0956 1 Kit Duplex Option Card Jumper 18 39 2 Screw System Board Mounting PP 99A0413 18 40 4 Screw System Board Cover PP 99A0413 Parts Catalog 7 63 4059 XXX Assembly 18 Duplex continued 7 64 4059 Service Manual 4059 XXX Ae Units Description 18 41 99A0305 1 Top Cover Assembly Movable 18 42 99A0303 1 Top Cover Assembly Fixed NS 1 Retainer 6 mm Top Cover PP 99A0404 18 43 99 0435 1 Guide Lower 18 44 99A0338 1 Guide Assembly Paper Decurl 18 45 99A0332 1 Guide Center Drive Upper 18 46 99A0
84. Ground Ground Opt2 Opt1 Ei Gol N 5 V dc J7 Auxiliary Fan Model 2420 2450 2455 3455 CRFANONn Ground J8 Printhead HYSNC ak Ground HSYNC Ground AJOJN 5 V dc J9 Fuser Inductor Sense WT 2450 Only FISENSEn Ground 5 5 4059 Service Manual 4059 XXX Connector Pin No Signal J10 Erase Toner Sensor Input Sensor gt k AT Servo Servo OutT TXENABLE Transfer 24 V dc Charge Ground Developer Oli ol NI oOo a AJ Ground In Sns 5 V dc x N CTSENSE Ground a4 A 24 V dc E ERASEPWM J11 Operator Panel I2COTA 5 V dc PCLKP Ground a AJOJN FPIRQ Connector Locations 5 6 4059 XXX Connector Pin No Signal J12 BLDC Motor 24 V dc 424 V dc Return 24 V dc Return Motor3 Motor4 Dir Motor1 5 V dc Qoo NI oO ay AJ OJN Motor2 E Ground MotorO J13 Autoconnect RXD Ground 5 V dc Ground Si Ground J14 Autoconnect RXD Ground 5 V dc Ground AJ wy N Ground 5 7 4059 Service Manual 4059 XXX Connector Pin No Signal J15 Integrated Paper Tray gt k 5 V d
85. IMM 24 99A0724 1 64MB EDO DRAM SIMM 24 99A0726 1 DBCS SIMM Japan 24 99A0521 1 1MB Flash SIMM 24 99A0522 1 2MB Flash SIMM 24 99A0523 1 4MB Flash SIMM 24 99A0873 1 SIMM Bar Code 3455 24 99A0420 1 Token Ring Card 24 99A0421 1 10 100 Ethernet Card 24 99A0422 1 10Base2 10BaseT Card with T connector 24 99A0560 1 Omni Bus INA Card 24 99A0424 1 IR Adapter 24 99A0515 1 Hard Disk w o Control Board 1250 1620 1650 2420 2450 24 99A0459 1 Hard Disk w o Control Board 2 1GB 1255 1625 1855 2455 3455 24 99A0516 1 Board Hard Disk Control 24 99A0628 1 SIMM IPDS Board 1250 1620 1650 2420 2450 24 99A0871 1 SIMM IPDS Board 1255 1625 1855 2455 3455 24 99A0629 1 Adapter Card SES for SCS 24 13A0296 1 Cable Twinax 24 13A0297 1 Cable Coax 24 99A0545 1 Adapter Serial 24 13A0298 1 Cable Serial 24 99A0467 1 Board Parallel Port Adapter 24 99A0923 1 Board USB Parallel Port 7 88 4059 Service Manual 4059 XXX Assembly 24 Options continued am TARN Units Description 24 99A0911 1 Tray Assembly 250 Special Media 24 99A0910 1 Cartridge 4059 Shipping 2 24 99A0909 1 Cartridge 4059 Shipping 1 24 99A0863 1 Hopper Integrated Label Letter 24 99A0864 1 Hopper Integrated Label Letter Stacker 24 99A0865 1 Hopper Legal Label Stacker 24 99A0799 1 Drive Forms HD 2 1GB 24 99A0417 1 Kit Cap Stack Bails 250 24 99A0920 1 Kit Cap Stack Bails 500 24 99A0945 1 Kit Paper Stacking Arm Parts Catal
86. Models 1620 4059 162 1625 4059 165 1650 4059 160 1855 4059 185 1855 4059 01 Optional 500 sheet Output Expanders Standard Output Bin Optional Envelope 250 sheet Input Tray Duplex Option Optional 250 sheet Drawer Optional 500 sheet Drawer General Information 1 2 4059 XXX Optra S Models 2420 2450 2455 3455 4059 242 4059 240 4059 245 4059 345 a Optional 500 sheet Output Expanders Optional Envelope Feeder 250 sheet Input Tray Duplex Option Optional 500 sheet Drawer Bt Optional 250 sheet N Drawer Optional 500 sheet Drawer 1 3 4059 Service Manual 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 Tri Port IR Adapter IPDS SCS USB Parallel Port 250 and 500 sheet paper trays of A5 letter and legal size 250 Sheet Special Media Tray Assembly 500 500 sheet dual trays Models 2450 2455 and 3455 2000 Sheet High Capacity Feeder Envelope feeder Duplex option Hard Disk 1 4 GB Models 1250 1620 1650 2420 and 2450 Hard Disk 2 1 GB Models 1255 1625 1855 2455 and 3455 Forms Hard Disk 2 1 GB Infrared Adapter Kiosk Adapter
87. Note The screw that attaches the charge roll lead to the contact must be secure Diagnostic Information 2 30 4059 XXX Cover Open Switch Cable Service Check FRU Action 1 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 open switch spring 2 Cover Open Switch Cable Assembly Check the cover open switch for proper mechanical operation If incorrect repair as necessary Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4 3 It measures approximately 5 V dc If the voltage is incorrect replace the engine board If the voltage is correct check the voltage at J4 1 If the voltage measures greater than 1 0 V dc replace the engine board If the voltage is correct check the continuity between J4 1 and J4 3 on the cable If no change in continuity occurs as the switch is activated replace the cover open switch cable assembly If the continuity changes as the switch is activated replace the engine board Note It is easier to check the voltages on J4 with the controller board removed 2 31 4059 Service Manual 4059 XXX Dead Machine Service Check Note Remove any paper handling options
88. P RR Rear dee 3 2 TOOL 3 2 nee 3 2 3 3 Disabling Download Emulations 3 3 Dur EE 3 4 Duplex QUICK osos OR Rs 3 4 D plex Sensor Test ciscus exea dure a ienaa 3 5 Duplex Motor Test secessit s 3 5 Duplex Feed 1 TESI a caua docebo gy EK EC 3 7 D plex Feed 2 Tests Kata ge 3 7 LOS be ee adc dee Se EAE 3 8 Viewing the Error log ee e MES Rm 3 8 riedia rea niaaa 3 8 Hardware TOS S dE mr mem ege AER 3 9 EID TESI snap dE d jede d ded D e AR A c dod ral ee 3 9 Button c ines sx seed A REESE 3 9 DRAM Memory Test iius eus seas sk RR ee ek 3 10 Memory Ist RR RR es 3 10 Parallel Wrap Test sus ees 3 11 Gela Wap 5 5 wc ceeds deca gee Pee ead eed 3 12 Tay TOSS ore AC yk 3 14 Input Tray Feed Tests csse dee ERR same 3 14 Input Tray Sensor 3 14 Output Bin Test Standard Bin 3 15 Outp t Bin Feed Test ius caus dos esser 3 15 Bin Sensor Tee 2 sues eee RR RR RES 3 16 Output Bin X Sensor 3 16 Base Sensor sp acaces eee eect d
89. Quality Light Print on page 2 101 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 on page 2 86 Print quality Banding Go to Print Quality Banding on page 2 99 Print quality Random marks Go to Print Quality Random Marks on page 2 94 Print quality Toner on backside of printed page Go to Print Quality Toner on backside of printed page on page 2 102 Print quality Vertical black bands on edge of copy Go to Print Quality Black bands on outer edges of the page on page 2 99 Unable to clear a 32 Unsupported Print Cartridge User Error Message Go to Smart Cartridge Service Check on page 2 102 Symptom Table High Capacity Feeder Option 2000 Sheet Symptom Action The printer does not recognize the high capacity feeder option installed Go to the High Capacity Feeder Input Tray Service Check on page 2 61 Paper feed problem with the high capacity feeder option Go to the High Capacity Feeder Input Tray Service Check on page 2 61 Diagnostic Information 2 26 4059 XXX Symptom Table Paper Tray Options Symptom Action Paper feed problem with
90. Remove the transfer shaft A through the bottom of the printer assembly Remove the three main drive assembly mounting screws C Remove the link D from the rear of the main drive assembly Disconnect the cable from the main drive motor Remove the main drive assembly Note Do not remove the screws E on the main drive assembly Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly 102 Repair Information 4 44 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 A 212 5 72 Lef i id E mr ai r SN A 212 4 45 4059 Service Manual 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 Be careful not to break the hinges or lose the O ring from the left mounting post Side View Repair Information 4 46 4059 XXX 2 Remove the paper out sensor 1250 1620 1650 and 2420 Remove the screws A mounting the multipurpose tray lower Remove the upper deflector deflector assembly Remove the multipurpose tray lower deflector assembly A 102 A 104
91. Return Stop to exit the test Output Bin X Sensor Test Note Some output expanders have a single output bin sensor installed while others have a dual sensor assembly Both versions have a single pass thru sensor This test is used to verify if the Output Bin X sensors are working correctly To run the Output Bin X Sensor tests 1 Select Output Bin tests from the menu 2 Select Output Bin tests Sensor Tests 3 Select Sensor Tests Output Bin X Output Expander with Single Sensor The following is displayed Output Bin X P OP Full Bin Full Sensor P Pass Thru Sensor Diagnostic Aids 3 16 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 The bin full sensor can also be actuated by hand Use a sheet of paper to cover the bin s pass thru sensor When the sensor is closed CL displays and when the sensor is open OP displays 4 Press Return Stop to exit the test Base Sensor Test This test is used to determine if the sensors located inside the printer are working correctly The following sensors can be checked Toner Optical Sensor Input Sensor Output Sensor Fuser Exit Narrow Media Sensor Front Door Sensor Upper Front Cover To run
92. Service Manual 4059 XXX Options 2 76 Output Bin Sensor 2 78 Output Expander 2 79 Paper Feed 2 86 Parallel Port 2 89 Print Quality 2 91 Printhead 2 89 Serial Port 2 104 Smart Cartridge 2 102 Toner Sensor 2 104 Transfer Roll 2 105 Setting Configuration ID 3 20 Setting the Page Count 3 19 Status Messages 2 12 Symptom Tables 2 25 Base Printer 2 25 Duplex 2 27 Envelope Feeder Option 2 27 High Capacity Feeder Option 2 26 Output Expander Option 2 28 Paper Tray Options 2 27 U Unique Tools 1 5 User Line 2 Link Messages 2 22 User Line 2 Messages 2 20 User Status Messages 2 12 V Viewing the Permanent Page Count 3 19 Index LA
93. T does not complete and the printer emits 5 beeps and stops ina 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 Note If the operator panel is operating properly except for a PEL or a few PELS missing or broken run the LCD Test on page 3 9 from the hardware tests before continuing with this diagnostic service check FRU Action 1 Operator Panel Cable Check for proper installation of the cable at the engine board J11 and at the operator panel Check the continuity of the operator panel cable If incorrect replace the cable 2 Operator Panel Display blank 5 beeps LED Off Check the voltage at J11 2 on the engine board It measures approximately 5 V dc If incorrect replace the engine board If correct replace the operator panel assembly 3 Operator Panel Display blank 5 beeps LED On Check for ground between J13 4 and ground If correct replace the operator panel assembly If incorrect replace the engine board 2 75 4059 Service Manual 4059 XXX FRU Action 4 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 5 Operator Panel all Check the voltage at Pin
94. The voltages measure 24 V dc If correct replace the high capacity feeder option system board If incorrect disconnect J8 from the System board and measure the voltages again If incorrect check the LVPS cable and the A C internal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housing to each pin on the motor connector If you find a short between any pin and the motor housing replace the motor assembly If no shorts are found replace the high capacity feeder option control board Check the voltage at J9 1 light blue The voltage measures approximately 24 V dc If incorrect disconnect the cable at J9 and check the voltage again If the voltage continues to be incorrect replace the high capacity feeder option System board If the voltage measures correctly check the cable If the cable is damaged replace as necessary If no problem is found with the cable replace the high capacity feeder option control board 2 63 4059 Service Manual 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 FRU Action 1 Pass Thru Sensor and Flag The tray x option system board did Assembly not detect a piece of paper actuating the pass
95. Top Margin for the backside of the duplexed page You can run one duplexed page Single or continue printing duplexed pages Continues until Return Stop is pressed The paper you choose to print the page on should be either Letter or A4 To run the Duplex Quick Test 1 Select Duplex Quick Test from the menu 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 Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet If adjustment is necessary the Top Margin Offset must be adjusted first The range of the adjustment is 25 to 25 The Duplex Top Margin Offset range is 20 to 20 Adjustment of this setting lets you shift up or down the position of the Top Margin Changing this parameter by 1 unit moves the margin Diagnostic Aids 3 4 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 Select Sensor Test from the D
96. Voltage Power 4 43 Main Drive AStem Dy iis evan Ee er 4 44 Main Drive MOU us snas vada ee eR RE dds 4 45 Multipurpose Tray Lower Deflector Assembly 4 46 Operator EE 4 48 Operator Panel Cable Cover Open Switch Assembly 4 49 Optional 250 500 Paper Tray Assembly 4 50 Outer EMG Shield eier Nd RE 4 51 Paper Alignment 4 52 Paper Input ZER ade rd eod ice 4 53 Paper Size Sensing 4 54 da 58 can pani 4 54 aner 4 55 gung ASCO 4 56 Right Side 2 2 5 gt gt lt 55 EE SR 4 57 Smart Cartridge Contacts 4 58 TES UBI DONE Pu e OE POE PR 4 59 Transiar Holl Assembly occ ace vedendo be que e Es 4 60 Upper Paper Deflector Assembly 4 60 Upper Front Cover Hinge Assembly 4 61 Upper Front Cover Interlock Switch Assembly 4 62 Connector Lacall ns iin cius cocos sius e Erde dr wpd 5 1 Low Voltage Power 5 1 High Voltage Power 5 3 Engine Beet iioc seco keene Sate hm ewww amend 5 4 SE 5 11 Intereognnect Board se eme sm mmm me mm 5 14 Envelope Option 5 17 Duplex Option Board a Zeg EE ee bd hme 5 19
97. X Fans Auxiliary Fan Models 2420 2450 2455 3455 1 Remove the right cover 2 Remove the inner EMC shield 3 4 Disconnect the auxiliary fan cable from the engine board at Remove the fuser wiper cover connector J7 Note the routing of the auxiliary fan cable A and remove the fan B B Repair Information 4 24 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 4 25 4059 Service Manual 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 Remove the redrive assembly 2 Remove the two fuser mounting screws A 3 Remove the fuser ground wire and remove the fuser assembly A 102 Repair Information 4 26 4059 XXX Fuser Board Remove the fuser assembly Disconnect the cables A from the fuser board Remove the fuser board mounting screw B Release the fuser board from the standoff tab C and lift the fuser board from the fuser assembly Ron A B 202 4 27 4059 Service Manual 4059 XXX Fuser Cover 1 Remove the
98. ack height Replace both pick rolls if the paper appears to be flat in the tray but the there is still a problem Failures occur mainly near the bottom of the stack of paper The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper Also the autocompensator motor may be failing If this problems continues replace the autocompensator assembly 2 87 4059 Service Manual 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 FRU Action Paper Paper is usually the primary cause of a double feeding paper problem Flex the paper before placing the paper in the tray Edge welded paper is the most common cause of double feeding Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding Autocompensator Make sure the counterbalance spring is not missing loose or broken at the top of the autocompensator arm assembly If you find a problem replace the autocompensator assembly Multipurpose Tray Paper fails to feed from the multipurpose tray The pick roll should make one complete revolution and stop with the flat side down If the pick roll turns but does not pick paper check the roll for signs of wear oil or grease on the surface of the pick r
99. acters could print and the copy may not fit the page correctly Measure all voltages from the connector to printer ground All voltages measured during the print cycle are measured with the controller board removed while running the print test 2 91 4059 Service Manual 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 FRU Action 1 High Voltage Contacts Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted contaminated or damaged If incorrect replace the contact with one from the HV contact kit Screws are included to attach the contacts to the right side frame in the HV contact kit 2 HVPS Check the voltages on J10 1 thru J10 8 If incorrect replace the engine board 3 HVPS Cable Check the continuity of the HVPS Part of Front cable If incorrect replace the cable Harness Cable assembly If correct replace the engine board Engine Board Print Quality Blank Page FRU Action 1 Print Cartridge Check the print cartridge for any signs of damage especially the PC drum contact on the cartridge Diagnostic Information 2 92 4059 XXX FRU Action 2 High Voltage Contact Check the PC drum contact on the right side
100. agnostic Information 2 50 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 fuser board uses 42 V dc which is derived from the LVPS via the interconnect board J1 and the envelope conditioner cable The solenoid is controlled by logic located on the engine board The level Il fuser board does not use the 42 V dc and receives control for the solenoid from logic located on the engine board A level Il engine board can be used with a level fuser board provided that the jumpers at JP 1 and JP 2 are correctly positioned as described in configuration 2 If the jumpers are not correctly positioned on the engine board damage can result to the fuser board Engine Board Jumper Configurations Refer to the Fuser Board on page 5 11 Level 1 Engine Board on page 5 9 and Level 2 Engine Board on page 5 10 to identify the level boards installed in your printer 1 A level fuser board and a level engine board require envelope conditioner cable and no jumpers on the engine board 2 A level fuser board and level Il engine board require jumpers at locations JP1 2 to JP1 3 and JP2 2 to JP2 3 on the engine board A level Il fuser board and level Il engine board require jumper
101. ame mounting screws B and remove the right side frame ar Go B 102 A 102 B 104 B 102 4 57 4059 Service Manual 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 Repair Information 4 58 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 A 102 4 59 4059 Service Manual 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 Open the multipurpose tray and remove the tray from the two mounting posts Be careful not to lose the O ring on the right mounting post 2 Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right 3 Remove the upper deflector assembly Repair Information 4 60 4059 XXX Upper Front Cover Hinge Assembly 1 2 3 Remove the upper front cover Remove the laser assembly cover Remove the C clips A from the upper front cover hinge assembly left and right hinge pins
102. and remove the pins Note the pin orientation and the C clip location on the inside of each hinge Detach the two springs B from the upper front cover hinges Disconnect the operator panel cable from the operator panel assembly Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket C Lift the left pivot arm from the bracket and move the upper cover hinge assembly toward the left to clear the right upper cover pivot arm from the mounting bracket Remove the upper front cover hinge assembly 4 61 4059 Service Manual 4059 XXX Upper Front Cover Interlock Switch Assembly 1 Remove the upper front cover 2 Remove the operator panel 3 4 Remove the inner EMC shield Press the retaining tabs A and remove the interlock switch assembly Note the routing of the interlock switch assembly cable and disconnect the cable at connector J4 on the engine board Repair Information 4 62 4059 XXX 5 Connector Locations Low Voltage Power Supply Connector Pin No Signal Interconnect 1 5 V dc poe 2 5 V de 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 Vdc 11 5 Vdc 12 Ground 13 Ground 14 Ground 15 Ground 16 24 V dc 17 ZC Out 18 42 V dc 5 1 4059 Service Manual 4059 XXX POWER SUPPLY BOARD 4059 XXX Hi
103. 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 The customer may try to improve the print quality by increasing the transfer setting Diagnostic Information 2 96 4059 XXX FRU Action 1 Erase Lamp Lens Assembly 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 If unable to clean the contamination off the lens replace the lens and lamp assembly Check the erase lamp assembly Use the same procedure as outlined in the Erase Lamp Service Check on page 2 46 2 Printhead The printhead on the Optra S printers cannot be cleaned Try another printhead if all other attempts fail to correct a background problem 3 Transfer Roll Assembly Check the high voltage contact from the HVPS to the transfer roll Check the transfer arm assembly right side bearing for any signs of contamination pitting or a loose cable to the bearing If any problems are found replace the defective part Check the transfer roll shaft for any signs of contamination wear or pitting on the ends of the shaft that go into the bearings If a problem is found clean the ends of the shaft or replace the transfer roll assembly 4 High Voltage Contacts Check the high voltage contacts on the ri
104. apacity feeder tray Service Tip Check the other paper sources to be sure they are operating correctly 2 61 4059 Service Manual 4059 XXX The base printer does not recognize that the high capacity input tray is installed FRU Action 1 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 Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly 2 Base Printer or option Check the option or base printer mounted above autoconnect for signs of damage Repair the high capacity option autoconnect as necessary 3 14 Pin HCIT Flex Cable Check the 14 pin flexible cable to be sure it is installed correctly and properly seated in the connectors on both boards Check the cable for damage Repair or replace as necessary Diagnostic Information 2 62 4059 XXX FRU Action 5 High Capacity Feeder Option Control Board 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 through the autoconnect system to the high capacity input for the high capacity feeder to be recognized If the voltage is correct check the voltages at J11 3 red and J11
105. aper may still be over the sensor or the flag is still activated Diagnostic Information 2 8 4059 XXX Status Bytes 1 2 3 Explanation 84 xx OD 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 Paper Tray 3 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 OF Paper Tray 2 pass thru sensor is not activated and never deactivated A sheet of paper may still be over the sensor 84 xx 11 The paper activated the input sensor too soon 84 xx 13 The paper activated the input sensor too soon 84 xx 1D The envelope feeder pass thru sensor is activated and never deactivated 84 xx 1E The envelope feeder pass thru sensor is not activated 84 xx 1F The paper fed too early from Tray 1 84 xx 21 The smart option did not pick the paper 84 xx 22 The smart option did not pick the paper 8E xx 02 The input sensor is not activated even though the paper is picked from the source 8E xx 0B The autocompensator DC motor stalls when attempting to pick a sheet of paper 8E xx 11 The autocompensator DC motor takes too long to ramp up 2 9 4059 Service Manual 4059 XXX Envelope Feeder Sub Error Codes Status byte 1 contains the most valuable information to help isolate a feed problem with the envelo
106. aracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento e Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informacoes de Seguranca Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem nao ser sempre bvias A Lexmark nao respons vel pela utiliza o de outros componentes de substitui o As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios xix 4059 Service Manual 4059 XXX Informacio de Seguretat Aquest producte est dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter st
107. ator turns on solid 3 7 4059 Service Manual 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 If an error occurs after the log is full the oldest error is discarded Identical errors in consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the Error Log 1 Select Display Log from the Error Log menu The Error log displays on 3 screens as only 4 entries display at a time 2 To move to the next screen press Menu gt to move forward or lt Menu to move backward 3 Press Return Stop to exit the Error Log Clearing the Error Log To clear the Error Log 1 Select Clear Log from the Error Log menu 2 Select YES to clear the Error Log or NO to exit the Clear Log menu If YES is selected the Empty Error Log displays on the Screen 3 Press Return Stop to exit the Clear Log menu Diagnostic Aids 3 8 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
108. ays when the duplex front access cover is not installed Close Duplex Rear Door This message displays when the duplex rear door is open 2 23 4059 Service Manual 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 2 3 Performing Self Test appears on the display 10 11 12 13 The LED comes on The operator panel displays one and a half row of pels then clears Diamonds scroll across the display then clear The 2000 sheet high capacity option elevator tray moves to the uppermost position if installed The duplex option is checked if installed The output expander option exit rollers turn if installed Busy appears on the display The fuser lamp turns on The fuser takes longer to warm up from a cold start than a warm start The main fan turns on The main drive motor turns on The developer drive assembly drives the developer shaft in the toner cartridge The exit rollers turn The operator panel LED starts blinking Models 2420 2450 2455 and 3455 only The auxiliary fan turns on and continues to run until the printer is powered off Ready appears on the display Diagnostic Information 2 24 4059 XXX Symptom Tables Symptom Table Base Printer Symptom Action Auxiliary Fan 2420 2450 24
109. ble If the cable measures continuity check the voltage at CN3 18 on the LVPS The voltage measures approximately 42 V dc If the voltage is correct replace the interconnect board assembly If the voltage is incorrect replace the LVPS 4 Fuser DC Cable Engine Board to Fuser Board Cable Engine Board 2 53 4059 Service Manual Check for continuity of the DC fuser cable that is attached between J2 on the engine board and J1 on the fuser control board If the cable does not measure continuity replace the cable If the cable measures continuity replace the engine board 4059 XXX Configuration 2 A level fuser board and level 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 FRU Action 1 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 the engine board Note If the jumpers are not in the correct position on the engine board damage can result to the fuser board 2 Fuser Envelope Conditioner The operation of the fuser solenoid Solenoid can be observed by removing the redrive assembly Check for proper mechanical operation of the solenoid and associated hardware link and so on If correct check the resistance of the solenoid between J4 1 and J4 2 The resistance measur
110. board Turn the printer on and check the voltage at J3 3 on the system board The voltage measures approximately 5 V dc If incorrect replace the envelope system board If correct replace the input sensor assembly Diagnostic Information 2 42 4059 XXX 990 Service Error Envelopes fail to feed from the hopper FRU Action 1 D C Feed Motor Assembly Check the motor and motor cable for any signs of loose wires or poor connections Check to make sure the motor cable is connected to the envelope system board 2 Envelope Feeder System Check the voltage on J4 1 The Board voltage measures approximately 24 V dc If incorrect replace the envelope system board if correct measure the voltage at J4 6 The voltage measures approximately 5 V If incorrect disconnect J4 and measure the voltage again If incorrect replace the envelope feeder system board If correct replace the D C motor assembly 260 Paper Jam displays unable to clear and envelopes fail to feed from the hopper Kick rolls ARE NOT rotating FRU Action 1 Main Drive Belt Check the belt for correct installation and for signs of damage Replace as necessary 2 Gears Check all the gears for correct installation and for signs of damage Repair or replace parts as necessary 3 Clutch Latch Assembly Check the clutch latch assembly to make sure it moves freely 4 Master Cam Gear Master Check the master ca
111. c PSIZE2 Ground PSIZE1 24 V dc Ground POUT 5 V dc Oli ol a AJ Paper Low 5 V dc J16 Staging Motor Not used J17 MPT Pick MPT Pick 24 V de J18 Auto Compensator 24 V de N A Ground Ground N A 5 V dc J19 MPT Paper Out Ground POSENSE 5 V dc J20 Interconnect Board J21 Smart Cartridge Model 3455 only N A N A Scart Scart Ground Connector Locations 5 8 4059 XXX Level 1 Engine Board J1 1 Tisa T J4 1 set Ba 5 25 OQ E 1 9 J10 1 J11 1 J12 1 O J13 J14 J15 1 J17 4 Q a J16 J19 Q Q 1 1 Level 1 5 9 4059 Service Manual 4059 XXX Level 2 Engine Board Ji Tessa 411 1 05 Q OF J cc H2O 42V dc Test Point J10 4 J11 1 Je1 1 J12 1 J13 J14 J15 1 Wee Q7 1 1 J19 118 O 1
112. cs and text Pages two and three only contain graphics If duplex is turned On the pages are duplexed otherwise the pages are printed on one side The Print Quality Test pages must always be printed on letter legal or A4 paper To run the Print Quality Test Pages Turn the printer off Press and hold Select and Return Turn on the printer Release the buttons once Performing the Self Test displays 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 3 23 4059 Service Manual 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 Values for the Quality Menu settings used to print the pages Printing Menu Settings Page Note This test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 2 Select the TESTS MENU 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 a
113. d Ground J3 LVPS Ground Ground Ground Ground 5 V dc 5 V dc 5 V dc Did OO N 5 V dc J4 Autoconnect Top 24 V dc Model1620 1625 1650 1855 2420 2450 Ground 2455 5 V dc Fused Ground Connector Locations 5 14 4059 XXX Connector Pin No Signal J5 Autoconnect 1 24 V dc BTM FNT 2 Ground J6 Engine Board 1 N A J7 Controller Board 1 N A J8 ID 1 1 N A 2 N A J9 ID 2 3 N A 4 N A J10 10 3 5 N A 6 N A J11 INA 1 1 N A 1250 1255 J12 INA 2 1 N A 1620 1625 1650 1855 2420 J13 INA 3 1 N A 2450 2455 3455 Models 1250 and 1255 J8 J9 J10 1 3 4 6 10 1 10 2 10 3 5 15 4059 Service Manual 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 Models 2420 2450 and 2455 have a jumper on J8 between the center pin and pin 2 and a jumper on J9 between the center pin and pin 3 Model 3455 has a jumper on J8 between the center pin and pin 1 and on J9 between the center pin and pin 1 11 1 DIR J6
114. d Test Note If the Configure Bins printer setting is link rather than mailbox the printer selects its own internal bin linking regardless of which output bin is selected for the feed test This test is to verify that media can be fed to a specific output bin No information is printed on the media because the printhead is not turned on during this test To run the Output Bin Feed Test 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 4 Press Return Stop to exit the test 3 15 4059 Service Manual 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 Full Output Bins Full Sensor Pass Output Bins Pass Thru Sensor 2 Once the message displays the servicer can manually actuate each of the output bin sensors The bin full sensor can be actuated by hand however a sheet of paper can be used to cover the bin s pass thru sensor When the sensor is closed CL displays and when the sensor is open OP displays 3 Press
115. d is replaced because this board contains the printer s NVRAM Memory where the page count is stored To set the Page Count 1 4 5 Select Page Count from the diagnostic menu The current page count displays The leftmost digit blinks indicating it is the first digit to be changed Press either Menu gt or lt Menu until the value you want displays Press Select to move to the next digit press Menu gt or lt Menu until the value you want displays Continue with each digit until you set the page count You can skip any digit by pressing Select Press Select to save the new page count in NVRAM Press Return Stop to exit the diagnostic menu Viewing the Permanent Page Count The Permanent Page Count can only be viewed and cannot be changed To view the Permanent Page Count 1 2 Select Permanent Page Count from the menu Press Return Stop to exit the diagnostic menu 3 19 4059 Service Manual 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 Press Return to go to the previous menu To reset the Maintenance Page Count to zero 1 Select Reset Maintenance Count Pressing Select causes the maintenance page counter to reset to zero Reset Maintena
116. dc Green approximately 12 Vd J1 1 J1 2 J1 3 J1 4 White approximately 12 V dc p If any of the voltages are incorrect disconnect the motor and measure the resistance between pin J1 1 to J1 3 and J1 2 and J1 4 The resistance measures between 10 and 15 ohms If incorrect replace the motor If correct replace the high capacity feeder control board 2 69 4059 Service Manual 4059 XXX Paper size switch not selecting paper size that is selected FRU Action 1 Paper Size Switch High Capacity Feeder Option Control Board Check for continuity between the common pin J5 1 and the pin of the paper size selected 5 1 Black Common Lead 5 2 Blue B5 5 3 Green Executive 5 4 Yellow A4 e 5 Orange Letter J5 6 Red Legal J5 7 Brown A5 If any position does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feeder option control board 24X Paper Jam Check Tray X Message displays when Tray X is empty No Tray X Message displays FRU Action 1 High Capacity Feeder Option Control Board Check the voltages on the board at J4 1 red and J4 3 blue The voltages measure approximately 5 V dc If incorrect disconnect J4 from the board and measure the voltages again If incorrect replace the high capacity feeder option control board 2 Elevator Top Optical Sensor
117. de displays when the printer detects an unformatted disk at power on Press Go to clear the message The disk is marked as bad and normal operation continues Disk operations are not allowed until the disk is formatted 2 19 4059 Service Manual 4059 XXX User Error Message Explanation 80 Scheduled Maintenance The operator panel displays this message 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 The parts are available as a maintenance kit For more information go to Scheduled Maintenance 2420 2450 2455 3455 on page 6 2 81 Engine Code CRC Failure This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check Press Go to clear the message The microcode data is discarded and must be re transmitted from the host computer 88 Toner Low This error displays when toner low occurs and the toner low alarm is activated Press Go to clear this message User Line 2 Messages If none of the conditions exist that are listed in the following table line 2 is blank If any of the messages in the table are displayed the following actions can be taken Press Menu gt or lt Menu to take the printer offline and access the Ready Menu group Note The Menu buttons are not active if M
118. dex Number Units Description 5 1 99A0075 1 Screw Socket Set M4X5 mm 1250 1255 1650 1620 2420 1855 1625 5 2 99A0071 1 Arm Assembly MPT 1620 1650 1250 1255 2420 1855 1625 5 3 99A0076 1 Pick Roll Assembly 1250 1255 1620 1650 2420 1855 1625 5 4 99A0081 1 Spring Assembly Separator 1620 1650 1250 1255 2420 1855 1625 5 5 99A0083 1 MPT Pad Assembly Kit o Restraint Pad o MPT Pad Assembly 1250 1255 1620 1650 2420 1855 1625 5 6 99A0077 1 Deflector Assembly MPT 1620 1650 1250 1255 2420 1855 1625 5 7 99A0080 1 Deflector Lower 5 8 2 Screw Lower Deflector Mounting 8 mm PP 99A0263 2450 5 8 2 Screw Lower Deflector Mounting 12mm PP 99A0263 1250 1255 1620 1650 2420 1855 1625 5 9 99A0021 1 O Ring Lower Front Door 5 10 99A0084 1 Flag MPT Paper Out 1250 1255 1650 1620 2420 1855 1625 5 11 99A0082 1 Plate Assembly MPT 1620 1650 1250 1255 2420 1855 1625 5 12 99A0078 1 Sensor MPT Paper Out 1250 1255 1620 1650 2420 1855 1625 5 13 99A0073 2 Screw Damper 1620 1650 1250 1255 2420 1855 1625 5 14 1 Screw Frame Mounting PP 99A0263 1620 1650 1250 1255 2420 1855 1625 NS 2 Clip Pick Roll Shaft PP 99A0267 5 15 99A0072 1 Solenoid MPT Frame 1620 1650 1250 1255 2420 1855 1625 5 16 99A0074 2 Bushing Pick Roll Shaft 1250 1255 1620 1650 2420 1855 1625 Parts Catalog 7 15 4059 XXX Assembly 6 Paper Feed Alignment 7 16 4059 Service Manual 4059 XXX e EDS Units Description 6 1 99A0089 1
119. e Machine Class ID the printer may be allowed to print pages during this 10 20 second interval If pages are allowed to print then they are not reprinted once a good print cartridge is inserted This error message also displays ona model 3455 printer if the smart cartridge or smart cartridge hardware is not operating correctly Try another model 3455 print cartridge If this does not fix the problem go to Smart Cartridge Service Check on page 2 102 34 Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the printer does not know the actual paper size loaded in the tray For auto size sensing trays this error occurs if the paper stop is in the incorrect position Make sure the Paper Size setting is correct for the size paper that is being used 2 17 4059 Service Manual 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 If a 1200 dpi job runs out of memory a Memory Full error is displayed 37 Insufficient Collation Memory This message is displayed when the printer memory used to store pages is too full to collate the print job 38 Memory Full This message is displayed when the print
120. e of the printer The ground connection is automatically made when the option is installed below the printer The paper input sensor is located in the rear of the duplex unit under the input paper guide The rear cover open switch is located on the rear cover assembly The paper exit sensor is located on the left frame assembly The jam removal tray open switch is located at the end of the left frame assembly There are no switches in the level 2 duplex option Option Microcode The options are Smart Options or options that have a system board The option system board has a microprocessor that controls the option mechanism A software architecture is provided that controls the option and communicates information such as paper path status sensor or switch status motor status and so on to the base printer Fuser Operation The fuser in the Optra S printers is made up of two primary assemblies The first assembly is the top fuser cover which contains the thermistor cable thermal fuse cable assembly left and right lamp brackets and cover 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 The thermistor assembly is designed to keep the temperature of the fuser hot roll within a predetermined temperature by being in contact with the fuser
121. e output expander options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized expander option 2 79 4059 Service Manual 4059 XXX FRU Action 1 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 2 Output Expander Assembly Check the autoconnects for damage Mechanical Linkage especially the connector pins Remove the left and right side covers Remove the front control board cover Check the cables at J1A J1B J2A and J2B on the control board to make sure they are attached securely and correctly Remove the output expander and check the voltages on the output bin autoconnect located on the top left rear of the printer Go to Autoconnect Top on page 5 21 If the voltages are correct reinstall the output expander unit and check the voltages at J1A and J1B on the connector If correct replace the output expander control board If incorrect replace the output expander assembly mechanical linkage Diagnostic Information 2 80 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 Doo
122. e per l utilizzo di parti di ricambio di altri produttori Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt Wahrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Notices and Safety Information xviii 4059 XXX Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen Pautas de Seguridad e Este producto se ha dise ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las c
123. e sensor flag because it is located under the front cover Be careful not to damage the flag If the test fails check the flag for any signs of damage or binds If incorrect replace the flag If the flag is operating correctly check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the envelope System board If correct check the voltage at J3 2 The voltage changes from 0 to 5 V dc when the flag is moved in and out of the sensor If incorrect replace the sensor assembly If this does not fix the problem replace the envelope System board 2 41 4059 Service Manual 4059 XXX Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display Load Envelopes after envelopes are placed in the hopper Service Tip The kick rolls rotate during the attempted feed cycles FRU Action 1 Envelope Out Hopper Check the envelope out sensor flag Sensor Flag for damage correct installation and operation If incorrect repair or replace the flag 2 Envelope Out Hopper Input Check the sensor to make sure it is Sensor installed correctly and the sensor cable is properly connected to the envelope system board If correct perform the Envelope Feed Sensor Test to check both the sensor and flag If the test fails remove any envelopes in the hopper turn the printer off and disconnect J3 from the system
124. eck the sensor flag for proper Assembly operation If correct check to Control Board make sure the pass thru sensor cable is correctly connected to J3 on the control board Disconnect the pass thru sensor cable from J3 on the control board and check the voltage at J3 3 The voltage measures approximately 5 V dc If incorrect replace the control board If correct check the voltage at J3 2 The voltage measures approximately 0 V dc If incorrect replace the sensor assembly If this does not fix the problem replace the control board 271 Paper Jam Check Bin X POST Complete First Sheet of paper feeds into Output Bin X Note Before performing the following checks run the Output Bin X Sensor Test and check for the failing sensor Sensor Test NF Near Full Upper part of sensor assembly F Full Lower Part of sensor assembly P Pass Thru Sensor Diagnostic Information 2 84 4059 XXX 990 Service BIN X FRU Action 1 D C Motor Mechanical Linkage Assembly Level 2 Check the DC motor cable connector to be sure it is correctly installed at J4 on the output expander option board Go to Output Expander Control Board Level 2 DC Motor on page 5 24 If correct disconnect J4 from the option board and check the resistance of the motor on the cable connector J4 1 to J4 2 measures between 115 and 135 ohms Also check J4 1 and J4 2 to the motor case for shorts If either the resistance is
125. eed E 3 17 Pim PSO SI Roda e Ale ea Sc dcn 3 18 Piel SED 2 rg ebe r dee 3 19 Setting the Page Count eee 3 19 Viewing the Permanent Page Count 3 19 Maintenance Page Count 2420 2450 2455 3455 3 20 Setting Configuration ID m 3 20 Restore EP Factory 3 21 iv 4059 Service Manual 4059 XXX Print Tests ne er EE Print Quality Test Pages EM Printing Menu Settings Page DERE ESSO SUAM EERE AERE Autocompensator Operation dae S29 Autoconnect System Paper Tray Options Envelope Feeder and Output Expander AGELESS OL Rome eas Fuser Operation LAU LPOG ADE e Paper Feed Jams ee ee d Se wur dre ee eee Repair Information T TEN TUTTI das 4 1 Handling ESD Sensitive Parts boue bd pus ded dpa dS 4 1 Adjustment Procedures OT EX Lex 4 2 Duplex Motor Drive Belts 42 Fuser Solenoid Adjustment bic spine Im 4 3 Gap Adjustment 4 3 Printhead Assembly Adjustment EEN eer 4 4 Paper Alignment Assembly Adjustment 45 Screw Identification Table EE 4 7 Removal 4 12 Covers ee eu dde T Popes aactor 2 4 12 Center Pan Assembly p prp 4 18 Controller Board i a RR bag dn 2
126. eft Panel 1650 1855 2420 1 14 99A0019 1 Door Left Panel 1250 1255 1620 1625 1 14 99A0018 1 Door Left Panel 2450 2455 3455 1 15 99A0296 1 Switch Cover Open w Operator Panel Cable Assembly 1 16 99A0003 1 Latch Upper Cover 1 17 99A0013 1 Cover Laser Assembly NS 6 Screw Laser Cover PP 99A0263 NS 99A0552 1 Cover Assembly Redrive Cap NS 99A0573 2 Nut Front Spacer Mounting 2450 2455 3455 1 18 99A0550 1 Shield ESD Cover Open 1 19 99A0031 1 Bracket Cover Open Switch 1 20 99A0036 1 Spring Cover Open Switch 1 21 2 Screws Contact Mounting PP 99A0263 1 22 99A0814 1 Cable Smart Cartridge 3455 1 23 99A0816 1 Contact Smart Cartridge Ground 3455 1 24 99A0815 2 Contact Smart Cartridge 3455 1 25 99A0817 1 Cover Smart Cartridge Contact 3455 1 26 99A0834 1 Plunger Overstress Smart Cartridge 3455 NS 99A0577 1 Cable Tie Parts Catalog 7 5 4059 XXX Assembly 2 Frame 7 6 4059 Service Manual 4059 XXX aie Ae Units Description 2 1 99A0425 1 Support Cross Brace 2 2 99A0463 1 Spacer Front 2450 2455 3455 2 2 99A0464 1 Spacer Front 1250 1255 1620 1650 2420 1855 1625 2 3 99A0033 1 Duct Left Stacker 2450 2455 3455 2 3 99A0034 1 Duct Left Stacker 1250 1620 1650 2420 1855 1625 2 4 99A0867 1 Duct Main Body 2 5 99A0551 1 Support Left Lower Stacker 2 6 99A0114 1 Duct LVPS Left Side 2 7 99A0113 1 Pan Drip ITC 2 8 99A0045 2 Latch Cartridge Assembly 2 9 99A0039 2 Roller Developer Support 2 10 99A
127. emove the five upper front cover mounting screws A and remove the cover A 323 4 17 4059 Service Manual 4059 XXX Laser Assembly Cover Remove the left door Remove the left cover Remove the right cover Remove the rear paper deflector Press the fuser wiper cover latch and remove the cover Remove the paper full sensor flag assembly from the mounting bracket oo Ek 7 Remove the five screws A mounting the laser assembly cover and remove the cover Center Pan Assembly 1 Remove the left and right side frames 2 Remove the pan assembly Repair Information 4 18 4059 XXX Controller Board 1 2 3 Remove the inner EMC shield Remove the controller board mounting screws A Remove the two controller board parallel port mounting screws B Remove the serial port mounting screws if present Remove the controller board B 321 202 4 19 4059 Service Manual 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 A 102 Repair Information 4 20 4059 XXX Duplex Board 1 2 3 4 Lift the base printer from the duplex assembly Remove the four duplex board cover mounting screws Gently disc
128. en laserprodukt van klasse Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 825 Laserprodukten van klasse worden niet als ongevaarlijk aangemerkt De printer is voorzien van een laser van klasse IIIb 3b dat wil zeggen een gallium arsenide laser van 5 milliwatt met een golflengte van 770 795 nanometer Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik bij onderhoud of reparatie conform de voorschriften nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals voorgeschreven is voor klasse 1 xiii 4059 Service Manual 4059 XXX Lasermeddelelse Printeren er godkendt som et Klasse l laserprodukt i overenstemmelse med kravene i IEC 825 Klasse l laserprodukter betragtes ikke som farlige Printeren indeholder internt en Klasse IIIB 3b laser der nominelt er en 5 milliwatt galliumarsenid laser som arbejder p belgelaengdeomr det 770 795 nanometer Lasersystemet og printeren er udformet s ledes at mennesker aldrig udsaettes for en laserstr ling over Klasse I niveau ved normal drift brugervedligeholdelse eller obligatoriske servicebetingelser Huomautus laserlaitteesta kirjoitin on Yhdysvalloissa luokan 1 laserlaitteiden DHHS 21 CFR Subchapter J m rityksen mukainen ja muualla luokan laserlaitteiden 825 m rityksen mukainen Luokan laserlaitteiden ei katsota olevan vaarallisia k ytt j l
129. enu Lockout is turned on Press Stop to take the printer offline The Not Ready message is displayed No more data is processed from the host computer Press the Go button to return the printer to the Ready state Diagnostic Information 2 20 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 Tray X Empty If any of the input trays are missing then Tray X Missing displays where X designates which Tray 1 through 5 is missing If multiple trays are missing they are prioritized in this order Tray 1 2 then tray 5 Tray X Missing status clears whenever Tray X is reinserted If any of the input trays are empty then Tray X Empty displays where X designates which tray Tray 1 through 5 is empty If multiple trays are empty then they are prioritized in this order Tray 5 Tray 4 Tray 1 Note Tray X Empty status clears whenever Tray X is removed When Tray X is reinserted it is examined and the appropriate status if any displays Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder Tray X Low If any of the input trays are low then Tray X Low displays where X designates which tray 1 through 5 displays
130. er memory used to store pages is full 39 Complex Page 51 Defective Flash This message is displayed when the page is too complex to print This message is displayed when the printer detects a defective flash This error may occur at power on or during flash format and write operations Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved 52 Flash Full This message is displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash 53 Unformatted Flash 54 Standard Serial Error This message is displayed when the printer detects an unformatted flash at power on Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the flash is formatted This error is displayed when a serial error framing or parity is detected on the standard serial port This usually indicates the serial port is not set up correctly 54 Serial Option X Error This error is displayed when a serial error framing or parity is detected on the optional serial port This usually indicates the optional serial port is not set up correctly Diagnostic Information 2 18 4059 XXX User Error Message Explanation 56 Standard Serial Disabled This error is displayed when data i
131. es between 5 ohms and 10 ohms If the resistance is incorrect replace the solenoid assembly 3 Fuser Control Board The solenoid receives power from the fuser control board The fuser control board receives 42Vdc from the LVPS via the interconnect board and envelope conditioner cable Check for approximately 42 V dc at the 42 V dc test point on the fuser control board If the voltage is incorrect replace the fuser control board Diagnostic Information 2 54 4059 XXX FRU Action 4 LVPS Interconnect Board Envelope Conditioner Cable 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 If the cable does not measure continuity replace the cable If the cable measures continuity check the voltage at J1 2 on the interconnect board The voltage measures approximately 42 V dc If incorrect check the voltage at CN3 18 on the LVPS It measures approximately 42 V dc If incorrect replace the LVPS If correct replace the interconnect board assembly 5 Fuser DC Cable Engine board to Fuser Board cable Engine Board Check for continuity of the DC fuser cable that is attached between J2 on the engine board and J1 on the fuser control board If the cable does not measure continuity replace the cable If the cable measures continuity replace the engine board 2 55 4059 Service Manual
132. ex column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the Description column indicates the part is contained in a parts packet INDENTURE The indenture is marked by a series of dots located before the parts description The indenture indicates the relationship of a part to the next higher assembly For example INDENTURE RELATIONSHIP OF PARTS No dot MAIN ASSEMBLY One dot o Detail parts of a main assembly One dot o Subassembly of the main assembly 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 1625 4059 165 1650 4059 160 1855 4059 185 2420 4059 242 2450 4059 240 2455 4059 245 1855 01 4059 185 3455 4059 345 The parts catalog uses the four digit model number to identify model specific FRUs Parts Catalog 7 1 4059 XXX Assembly 1 Covers 7 2 4059 Service Manual 4059 XXX erus NDS Units Description 1 1 99A0553 1 Support Paper 1 2 99A0463 1 Spacer Front 2450 2455 3455 1 2 99A0464 1 Spacer Front 1620 1650 2420 1250 1255 1855 1625 1 3 99A0016 Cover Fuser Wick Assembly 1 4 99A0004 NS 1 5 99A001 1 Spring Latch Screw Right Side Cvr Mtg PP 99A0263 Cover Right Side 1250 1620 1650 2420 1855 1625 Cover Right Side 2450 2
133. f correct check the cable for a short between pins 1 and 2 on the cable If incorrect replace the cable If correct check the switch for a bent or deformed actuator lever or defective switch If incorrect replace the switch 2 71 4059 Service Manual 4059 XXX Excessive Noise or Vibration FRU Action 1 Motor Plate Assembly Be sure the motor plate assembly screws are tight Be sure the motor mounting screws are tight 2 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 Note If the belt is too tight a high pitch noise results Lead Screw Bearings If the bearings are worn or defective the lead screw may wobble Be sure the bearings and leadscrew are operating properly with no binds 4 Idler Pulley Be sure the idler pulley is not binding worn or broken Diagnostic Information 2 72 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 CAUTION Whenever the gearbox assembly is removed from the machine it must be handled very carefully Do not allow any of the gears to come in contact with any metal or other hard
134. gh Voltage Power Supply Connector Pin No Signal CN1 Engine Board 1 Developer PWM 24 V Return Charge PWM 24 V dc IN TX PWM TX Enable TX CUR PWM Did nm SVRO OUT HAZ LARNING FOR CONT TRUES PROTECTION AGATNST FITE DEVELOPER DEL M E E Wi E E 5 3 4059 Service Manual TRANSFER T500 4059 XXX Engine Board Connector Pin No Signal J1 Main Fan 1 Fan Stall Ground wo N Fan On J2 Fuser Board Exit Sns Thump B 5 V dc Thump A Ground Hrtherm Thermgnd AJ Gol Narrow Media J3 Printhead Mirror Motor 24 V dc Return 24 V dc Return ReFREQ LOCKn Start 24 V dc Return AJ 24 V de J4 Cover Closed Switch 1 Cover Closed 2 Ground 3 5 V dc Connector Locations 5 4 4059 XXX Connector Pin No Signal J5 Printhead LENA Ground LAOJ Ground LASERPWM 5 V dc Ground Video Qoo NI oO ay AJ OJN Ground E Ground J6 Output Level Sensor
135. ght side frame to ensure they are clean and not bent deformed or pitted If incorrect replace the contact 2 97 4059 Service Manual 4059 XXX FRU Action 5 Engine Board HVPS Connector 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 Printer Printing J10 1 varies 0 V dc to 5 V dc J10 2 varies 0 V dc to 4 V dc J10 4 varies 0 V dc to 1 9 V dc If J10 1 voltage is incorrect check the continuity of the front harness cable J10 1 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 2 voltage is incorrect or if the voltage remains at 0 V dc check the continuity of the front harness cable J10 2 line If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 4 voltage is incorrect check the front harness cable J10 3 line If there is not continuity replace the harness cable If correct replace the engine board if this does not correct the problem replace the HVPS Diagnostic Information 2 98 4059 XXX Print Quality Banding Service Tip Banding is difficult to detect except on a page with a unifor
136. heck 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 If defective replace the erase lamp assembly 2 Fuser Assembly Print Quality Light Print FRU Check the fuser assembly for signs of toner contamination The hot roll especially might cause toner to be retained and deposited on the page Action 1 Transfer Roll 2 Right Side Transfer Roll Arm Assembly Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll Check the right side transfer roll arm assembly bearing for any signs of wear or contamination Also check to ensure the transfer cable is firmly attached to the bearing If incorrect replace the right side transfer arm assembly Check the connection of the transfer roll assembly cable to the transformer on the HVPS board Check the continuity of the cable from the bearing to the spade terminal on the cable If incorrect replace the right side transfer arm assembly If correct replace the HVPS 2 101 4059 Service Manual 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 ca
137. hot roll and changes resistance as the temperature of 3 27 4059 Service Manual 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 J2 6 TEMPIN and J2 7 TEMPIN are connected to module PLCC U9 U9 monitors the change in thermistor resistance and sends a signal HEATON from J20 A25 through the interconnect board to CN3 9 on the LVPS to signal the triac to turn the fuser lamp On or Off to maintain the correct fuser temperature The voltage drop across the thermistor is proportional to the fuser temperature and varies from approximately 2 0 V dc cold to 2 3 V dc warm during idle to approximately 2 7 V dc during continuous printing These voltages are assuming the fuser temperature is set to normal The HEATON signal from CN3 9 varies from 0 V dc lamp On to 5 V dc lamp Off and is connected to the cathode of an Opto triac to control the fuser lamp The second part of the assembly is the fuser frame which contains the hot roll backup roll and associated parts as well as the paper exit guide assembly narrow media sensor fuser control board which has the exit sensor mounted on the board and the envelope conditioner solenoid on the model 2420
138. hout loosening the nut Turn the screw clockwise a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want 4 5 4059 Service Manual 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 Turn the screw a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want Repair Information 4 6 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 You must install the correct screw type in each location during reassembly 4 7 4059 Service Manual Reference Number Screw Type Location Purpose Qty M3 5x8 mm right side frame to attach 1 Thread Cutting center pan toner level sen
139. ick 2 o Gear Drive Idler 1 o Gear Comp Drive Clutch 1 o Gear Kick Roll Connect 1 o Gear Kick CNCT Idler 1 o Gear Feed Shaft Right 1 o Gear Drive Idler Rear 20 12 99A0381 1 Cover Left Side 20 13 99A0388 1 Switch Envelope Out 20 14 99A0485 1 Sensor Envelope Pass Thru NS 1 Retainer 4 mm PP 99A0404 NS 3 Retainer Clip 5 mm Shaft PP 99A0404 NS 2 Retainer 6 mm PP 99A0404 NS 3 Retainer 7 mm Shaft PP 99A0404 NS 99A0384 1 Shaft Drive Pressure Roller NS 99A0385 1 Cable Auto Connect Front NS 99A0494 1 Spring Cam Clutch NS 99A0429 1 Label Options Circle 1255 1625 1855 2455 NS 99A0427 1 Label Envelope Orientation Icon 1255 1625 1855 2455 NS 99A0469 1 Deflector Guide Parts Catalog 7 73 4059 XXX Assembly 21 High Capacity Feeder 7 74 4059 Service Manual 4059 XXX ei bs Units Description 21 1 99A0660 1 Frame Printer Support Frame 2 21 2 3 Screw Printer Support 2 Frame Mounting PP 99A0675 NS 6 Washer Printer Support Frame 2 Star PP 99A0677 NS 6 Nut Printer Support Frame 2 8 32 Hex PP 99A0676 21 3 99A0698 2 Clamp Feed Frame 21 4 4 Screws Feed Frame Clamp PP 99A0675 21 5 99A0691 2 Bearing Nyliner Leadscrew Top 21 6 99A0656 1 Cover Side 21 7 99A0680 1 Deflector Assembly Front 21 7A 99A0681 4 Strip Wear 21 8 99A0662 2 Transfer Lead Screw Assembly 21 9 99A0461 1 Label Tray Option Numbers 21 10 3 Screw Deflector Mounting 8 18 x 7 8 i
140. ies Copyright Lexmark International Inc 1998 2002 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 4059 XXX Contents Notices and Safety Information ix Laser 59 PRES CREDA ERR HORA ix Safety JEE EE EEN dade ELE d ean xvii 1c eM xxii General Information 1 1 DRONE soak EE 1 4 Maintenance 1 5 Tools Required For 1 5 DORONEITIBI S o eh e ur X AD dup dr P Oda 1 6 Diagnostic 2 1 i o is ee T SENT ee ee eee ee 2 1 service Error Codes cic ANNER dade ka bh tame a 2 2 User Status Messages me 2 12 User Error 0 56 2 16 Power On Self Test 2 24 SVN rs EE 2 25 Ger Vice CHECKS usua waa oe ea be RRR NR E ERAR 2 28 Charge Roll Service Check 2 29 Cover Open Switch Cable Service Check 2 31 Dead Machine Service
141. ine board If correct replace the toner sensor assembly A bad ground connection between J10 13 on the engine board and pin 3 on the toner sensor results in a 929 service error Transfer Roll Service Check Service Tip The transfer roll is 17 0 mm 669 inch diameter Any print quality problems such as lines that are spaced 17 mm apart indicate you should check the transfer roll for damage toner or foreign material buildup Service Tip The transfer roll assembly is part of the Maintenance Kit for models 2450 2455 and 3455 printers and is replaced when a 80 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 FRU Action Transfer Roll Assembly Check the transfer roll for any signs of toner buildup surface damage to the roll oil or other contaminants on the surface of the roll Replace the transfer roll as necessary 2 105 4059 Service Manual 4059 XXX FRU Action 2 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 Check the left transfer arm assembly spring for pr
142. ing and remove Repair Information 4 38 4059 XXX Interconnect Board Assembly Remove the inner EMC shield Remove the engine board and shield Remove the LVPS Disconnect all cables from the interconnect board Remove the interconnect board assembly mounting screws A Nc 323 4 39 4059 Service Manual 4059 XXX 6 Place the printer on its back and remove the two mounting screws A 7 Remove the interconnect board assembly A 202 Repair Information 4 40 4059 XXX Left Side Frame 1 Remove the main drive assembly 2 Remove the left side frame mounting screws A A 102 102 4 41 4059 Service Manual 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 Repair Information 4 42 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 Press the release latch on the fuser lamp cable connector and disconnect from the LVPS 5 Remove the LVPS 4 43 4059 Service Manual 4059 XXX Main Drive Assembly 5 6 7 8 1 Remove the inner EMC shield 2 Remove the developer drive assembly 3 4 Remove all cables from the cable clamps B on the main drive
143. ing failure messages displays for approximately 3 seconds and the Fail Count increases by 1 Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum count is reached the test stops The power indicator goes on solid and the final results display Press Return Stop to exit the test 3 13 4059 Service Manual 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 The paper is placed in the output bin To run the Input Tray Feed Test 1 2 3 4 Select Input Tray Feed Test from the menu Select the input source from the sources displayed on the Feeds Test menu All installed sources are listed Select either Single feeds one sheet of media from the selected source or Continuous continues feeding media from the selected source until Return Stop is pressed Press
144. ing screws being careful not to move the printhead assembly Repair Information 4 4 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 If you are replacing the alignment assembly go to step a If you are only adjusting the reference adjustment screw go to step b a 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 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the alignment assembly to the left side frame 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 The reference adjustment screw can be adjusted wit
145. ion 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 Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Putthe ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other
146. ion Replace as required It is advisable to replace all four wear strips at the same time 2 67 4059 Service Manual 4059 XXX The elevator tray does not move up or down The printer recognizes that the option is installed FRU Action 1 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 Be sure the Stepper Motor Extension motor extension cable is properly Cable connected to the motor cable Check the cables for damage or loose wires Disconnect the motor and check for a short between each pin and the motor housing If a problem is found replace the motor Measure the resistance between the following pins on the motor cable connector Pins 1 orange and 3 green Pins 2 yellow and 4 white They measure between 10 and 15 ohms If incorrect replace the motor assembly If correct replace the high capacity feeder control board Diagnostic Information 2 68 4059 XXX The elevator moves in one direction only FRU Action 1 Stepper Motor High Capacity Feeder Option Control Board Check the voltages at J1 on the high capacity system board The voltage measures as follows static motor connected 1 1 Orange 24 V dc n 2 Yellow 24 V dc 1 3 Green 24 V dc i 4 White 24 V de motor running Orange approximately 12 V dc Yellow approximately 12 V
147. iques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui Elrisc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients Notices and Safety Information XX 4059 XXX Chinese Safety Information zov AP EA Lexmark BS cA dier MWK AACS Ay BE BY BEAR BA E AA PRE Lexmark MARA e APTA EP AES RSS A A SEED AE H3 e AP MERE EX BEA m Efe ix dU Br T fg HERVE TRU T 6 Korean Safety Information are e HAZE SS Lexmark TH 259 9 01 AA 1 CPS Ho PSE Sa 99 Heol MAS St PAS Suct Lexmark wal Bo ch st deich e HES HASH Mule as AIA S22 WALL AMS elm 980 AMUc Ae Malz 2 0 AMS maleta Bost oe BAS lot S Ozone Information This product does not produce measurable amounts of ozone gas XXi 4059 Service Manual 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 env
148. ironmental and safety instructions as well as special tools and test equipment are listed in this chapter Diagnostic Information contains a service error code table user status message table user error message table symptom table and service checks used to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Printer operation information is provided to enhance the tests and checks Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components and test points on the printer Preventive Maintenance contains safety inspection guidelines lubrication specifications and maintenance information to prevent problems and maintain performance Parts Catalog contains illustrations and part numbers for individual FRUs Preface xxii 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 Standard Output Bin Optional Envelope Feeder Duplex Option 2 Optional 500 sheet Drawer p Optional 250 sheet Drawer 250 sheet Input Tray 1 1 4059 Service Manual 4059 XXX Optra S
149. isplays for approximately 3 seconds and the failure count increases by 1 ROM Memory Test The ROM Memory Test is used to check the validity of the RIP code and fonts To run the ROM Memory Test 1 Select ROM Memory Test from the menu P and F represent the same numbers for DRAM The power indicator blinks indicating the test is in process The test runs continuously 2 Press Return Stop to exit the test Diagnostic Aids 3 10 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 The final results display on the screen Parallel Wrap Test This test is used with a wrap plug to check operation of the parallel port hardware Each parallel signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the menu The power indicator blinks indicating the test is in progress The test runs continuously until canceled Each time the test finishes the screen updates If the test passes the Pass Count increases by 1 however if the test fails one of the following messages displays for approximately
150. l to maintain the adjustment Reassemble the duplex unit Repair Information 4 2 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 Printer Model Solenoid Air Gap 2420 2450 2455 4 4 mm 170 inch 1620 1625 1650 1855 3 9 mm 153 inch 3455 4 8 mm 153 inch 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 Enter the Diagnostic Mode Select EP SETUP from the Diagnostic Menu Select GAP ADJUST The range of the GAP adjustment is 0 to 255 Adjust the gap setting by using the Menu lt gt button to select the value If GAP 0 displays it indicates a factory setting to minimum gap Select a value and run several copies of the media that displays a curl problem It may take several tries before improvement is noticed Note This setting has no effect when printing in duplex mode Beg Le 4 3 4059 Service Manual 4059 XXX Printhead Assembly
151. la katso s teeseen Osynlig laserstr lning nar denna del ppnad och sp rrar r urkopplade Str len r farlig Usynlig laserstrling deksel apres og sikkerhedsl s brytes Unng eksponering for str len Usynlig laserstr ling ved bning n r sikkerhedsafbrydere er ude af funktion Undga unds ttelse tor str ling Radiaci laser invisible s s obre el tancament intem no s correcte Eviteu exposar vos hi MERA GE TE ENBNRAN hy DAN DEM SCA YF RATER OMEN SOT Vd CIS NL CE EAL HS QO 0 eat 015 01512 dei 24014 WOH edd EM BAAS ix 4059 Service Manual 4059 XXX Class 1 Laser Statement Label CLASS 1 LASER PRODUCT LASER KLASSE 1 LUOKAN 1 LASERLAITE APPAREIL A LASER DE CLASSE 1 TO IEC 825 Notices and Safety Information X 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 1 laser products and elsewhere is certified as a Class laser product conforming to the requirements of IEC 825 Class laser products are not considered to be hazardous The printer contains internally a Class IIIb 3b laser that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770 795 nanometers The laser system and printer are designed so there is never any human access to laser radiation above a Class level during normal operation user maintenance or prescribed service condition
152. le Kirjoittimessa on sis inen luokan Illb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometri Laserj rjestelm ja kirjoitin on suunniteltu siten ett k ytt j ei altistu luokan m rityksi voimakkaammalle s teilylle kirjoittimen normaalin toiminnan k ytt j n tekemien huoltotoimien tai muiden huoltotoimien yhteydess VARO Avattaessa ja suojalukitus ohitettaessa olet alttiina n kym tt m lle lasers teilylle Al katso s teeseen VARNING Osynlig laserstr lning n r denna del r ppnad och sp rren r urkopplad Betrakta ej str len Laser notis Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J f r laserprodukter av Klass 1 andra lander uppfyller skrivaren kraven f r laserprodukter av Klass enligt kraven i IEC 825 Notices and Safety Information xiv 4059 XXX Laserprodukter i Klass anses ej h lsov dliga Skrivaren har en inbyggd laser av Klass 1110 3b som best r en laserenhet av gallium arsenid pa 5 milliwatt som arbetar i vaglangdsomradet 770 795 nanometer Lasersystemet och skrivaren ar utformade sa att det aldrig finns risk f r att n gon person uts tts for laserstr lning ver Klass I niva vid normal anv ndning underh ll som utf rs av anvandaren eller annan f reskriven serviceatgard Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse 1 la
153. le 250 Auto Connect Option E sc LA ech zeck sch ech sch se Ki ch zb zb l l l lx hi Ai 0 zech 15 23 Screw Switch Activate Spring Mounting PP 99A0263 15 24 3 Screw Option Board Mounting PP 99A0263 15 25 99A0284 1 Board Option Tray 1250 1620 1650 2420 2450 15 25 99A0397 1 Board Option Tray 1255 1625 1855 2455 3455 15 25A 99A0627 1 Jumper 2 pin 15 26 99A0063 1 Spring Switch Activate Parts Catalog 7 49 4059 XXX Assembly 15 250 Sheet Tray continued 7 50 4059 Service Manual 4059 XXX Ae Units Description 15 27 99 0115 1 Tray Assembly 250 Sheet Option 15 27 99A0504 1 Tray Assembly 250 Sheet 1855 C01 15 28 99A0119 4 Wear Strips 15 29 99A0120 2 Restraint Pad 15 30 99A0123 1 Indicator Assembly Paper Size 15 31 99A0461 1 Label Tray Number 2 5 15 32 99A0121 1 Clip 250 Tray Wear 15 33 99A0126 4 Finger Autosize 15 34 99A0124 1 Plate Snap In 15 35 99A0127 1 Slider Autosize 250 15 36 99A0894 1 Latch Back Restraint 15 37 99A0893 1 Restraint Back 250 Sheet Tray 15 38 99A0892 1 Restraint Side 250 Sheet Tray NS 99A0429 1 Label Options Circle 1255 1625 1855 2455 NS 99A0286 1 Spring Backup Roller NS 99A0446 1 Aligner Assembly Paper NS 99A0501 1 Strip Assembly Paper Tray Insert 1855 01 Parts Catalog 7 51 4059 XXX Assembly 16 500 Sheet Tray 7 52 4059 Service Manual 4059 XXX
154. led Check the flag for damage or improper operation If incorrect replace the flag Note A broken or improper operating sensor flag causes a Remove Paper Standard Bin message to display before POST completes and cannot be cleared Diagnostic Information 2 78 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 Service Tip The majority of the mechanical components can be observed during operation by removing the left right and system board covers The output expander functions without the covers installed Note Make sure the option is correctly installed before attempting to service the unit Problems with excessive static electricity buildup FRU Action 1 Output Expander Control Check the output expander control Board Cover board cover to make sure the ESD brush ground lead is firmly attached to the output expander frame Also check to make sure the ESD brush is not loose Printer does not recognize one or more output expander options as being installed 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 th
155. ller board to attach 2 interconnect board ground controller board to inner mounting 2 shield fuser ground wire mounting 1 controller board back mounting 2 engine board to attach 1 interconnect shield ground fuser ground wire mounting 1 lower stacker duct mounting 1 ground cables to ground attach 1 center pan front cross brace to right attach 1 stacker duct cable clip main drive mounting 2 gearbox BTM fuser screw mounting 7 door restraint mounting 1 4 9 4059 Service Manual 4059 XXX Reference Number Screw Type Location Purpose Qty M3x8 mm LVPS mounting 2 Taptite auto compensator mounting 1 hanger bracket M3x12 mm HVPS board mounting 1 Taptite 205 M3x28 mm developer drive ground attach 1 Taptite bottom hole 207 M3 5x8 mm upper front cover mounting 5 Plastite Thread E Forming left side cover mounting 3 323 autocompensator mounting 3 E Repair Information 4 10 4059 XXX Reference e Number Screw Type Location Purpose M3 5x10 mm right side cover mounting Plastite Thread e Forming left side cover mounting 324 D left side frame to pan attach 2 E H ii M3 5x12 mm left side cover mounting Plastite Thread E Forming 325 CP ii ii ud A M3x6 mm fuser board mounting SEMS Machine D Screw with washer 397 M3 5x12 mm printhead to EP frame mounting Plastite Thread Forming with washer 425 D
156. located on the controller board If correct go to step 9 Diagnostic Information 2 32 4059 XXX FRU Action 5 5 V dc atthe engine board Test Point Check for 5 V dc at the 5 V dc test point on the engine board If correct replace the engine board If incorrect go to step 6 6 LVPS Fuse F1 Remove the LVPS from the printer and check fuse F1 Replace the fuse if the fuse is blown 7 LVPS Fuse F1 Continues to blow after LVPS installed in the printer Replace fuse F1 if necessary Turn the LVPS on off switch Off and connect the AC line cord and turn the LVPS On CAUTION Before checking fuse F1 turn the LVPS Off and disconnect the AC line cord Check fuse F1 If the fuse is blown replace the LVPS 8 LVPS Remove the LVPS from the machine CAUTION Before making any measurements on the LVPS output connector observe all necessary safety precautions before applying AC power Measure the voltage on LVPS output connector CN3 The voltage measures 5 V dc If incorrect replace the 2 33 4059 Service Manual 4059 XXX FRU Action 9 Engine Board Turn the printer off and disconnect all the cables from the engine board Check for 5 V dc at the engine board test point If incorrect replace the FRUs in the following order engine board interconnect board If correct turn the printer off and reconnect one cable at a time until you find the defective asse
157. m gear and Kick Gear master kick gear to make sure they rotate together If not then the tenons on the master kick gear may be sheared off If incorrect replace the master kick gear 2 43 4059 Service Manual 4059 XXX 260 Paper Jam displays unable to clear and envelopes fail to feed from the hopper Kick rolls ARE rotating Check the deflector gap adjustment before continuing this service check FRU Action 1 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow 2 Weight Assembly 3 Envelope Edge Guide Check the weight assembly to make sure it moves up and down freely without any binds Also check to make sure the weight assembly rests on all the rear kick rollers when the hopper is empty Replace the weight assembly if it is damaged or does not operate properly Check the envelope edge guide to make sure it is not warped or set too close to the envelopes in the hopper Replace the edge guide if it is damaged or does not operate properly Diagnostic Information 2 44 4059 XXX 260 Paper Jam displays envelope stops in feeder paper path FRU Action 1 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 2 Deflector Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow
158. m 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 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 Banding appears as light or dark horizontal lines on a uniformly gray page Banding on model 3455 can also be caused by a defective charge roll brush contact or HVPS Check the charge roll contact for any signs of damage and for proper connection to the HVPS and print cartridge Print Quality Black bands on outer edges of the page This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide narrow light or dark FRU Action Charge Roll If the problem is just on one side of Counterbalance Springs the page check the charge roll counterbalance spring on that side You can check to see if enough force is being applied to the charge roll by applying a slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample See if the problem changes or goes away If this fixes or changes the problem then check the springs and charge roll link arm assemblies for binds or defective parts Replace as necessary 2 99 4059 Service Manual 4059 XXX
159. mbly Service Tip A short or low resistance load that is attached to the engine board can cause the LVPS to overcurrent and shut the 5 V dc supply down to 0 V dc Service Tip Check the engine board for burn marks or other damage especially R20 R21 R22 and R23 located next to the upper left engine board mounting screw If this screw is overtightened it might deform the engine board shield and cause it to short out these resistors Diagnostic Information 2 34 4059 XXX Duplex Option Service Check The printer does not recognize the Duplex Option is attached The printer does not recognize tray options below the duplex option are installed FRU Action 1 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 between the motor case and pins J3 1 through J3 4 If no problem is found check the D C servo motor pins J1 1 and J1 2 to the motor housing for a short If a short is found replace the motor assembly If no short is found replace the system board 2 Autoconnect Cables Check the autoconnect cables for Connectors damage to the cables or the pins in the connectors If damaged replace the cable s If no damage is found check to make sure the cables are connected to J9 J10 J11 and J12 on the duplex system board If no problem is found replace the duplex System board 2 35 4059 Service Ma
160. mbly 25 Miscellaneous continued ee LR Units Description 25 99A0208 1 Parts Packet Pulley Kiosk 25 99A0234 1 Parts Packet Screws Kiosk 25 99A0265 1 Packaging Short 25 99A0295 1 Packaging Tall with 500 500 Option Tray 25 99A0248 1 Packaging 500 500 Dual Option Tray Assembly 25 99A0301 1 Packaging w o 500 500 Option Tray 25 99A0394 1 Grease Packet Nyogel 744 25 99A0462 1 Grease Packet IBM 23 Parts Catalog 7 91 4059 XXX Index A Acronyms 1 6 Adjustment Procedures 4 2 Duplex Motor Drive Belts 4 2 Fuser Solenoid 4 3 Gap Adjustment 4 3 Paper Alignment Assembly 4 5 Printhead Assembly 4 4 Autoconnect 5 21 Base Sensor Test 3 17 Button Test 3 9 Connector Locations Autoconnect 5 21 Duplex Option Board 5 19 Engine Board 5 4 Envelope Option Board 5 17 Fuser Board 5 11 High Voltage Power Supply 5 3 Interconnect Board 5 14 LVPS 5 1 Output Expander Control Board Level 1 Stepper Motor 5 22 Output Expander Control Board Level 2 DC Motor 5 24 D Diagnostic Aids 3 1 Device Tests 3 2 Disk Test Clean 3 2 Flash Test 3 3 Quick Disk Test 3 2 Diagnostic Mode 3 1 Duplex Tests 3 4 Duplex Feed 1 Test 3 7 Duplex Feed 2 Test 3 7 Duplex Motor Test 3 5 Duplex Quick Test 3 4 Duplex Sensor Test 3 5 Error Log 3 8 Clearing the Error Log 3 8 Viewing the Error Log 3 8 Hardware Tests 3 9 Button Test 3 9 DRAM Memory Test 3 10 LCD Test 3 9 Parallel Wrap Test 3 11 ROM Memory Test 3
161. na 1 and grease P N 1329301 to lubricate appropriate areas of the machine Preventive Maintenance 6 1 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 The parts are available as a maintenance kit with the following part numbers 99A0290 100V 750W 2450 99A0500 115V 750W 2420 2450 2455 99A0503 220V 750W 2420 2450 2455 99A0823 115V 750W 3455 99A0824 220V 750W 3455 After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message Refer to Maintenance Page Count 2420 2450 2455 3455 on page 3 20 6 2 4059 Service Manual 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 AR As Required in the Units column indicates that the quantity is not the same for all machines CC Color Code in the Description column indicates the part is identified by a color marking on the part NS Not Shown in the Asm Ind
162. nce Count Saved displays momentarily When the reset operation is complete the menu returns to the Printer Setup Reset Maintenance Count screen Setting Configuration ID The configuration ID is used to communicate information about certain areas of the printer that cannot be determined using hardware sensors The Configuration ID is originally set at the factory when the printer is manufactured however it requires resetting whenever you replace the engine board and can be set on the operator panel However the Configuration ID is the only diagnostic function displayed until a valid ID is entered To set the Configuration ID 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 The leftmost digit blinks indicating that it is the first digit to be changed 2 To change the value press either Menu gt or lt Menu until the value you want is reached Press Select to move to the next digit or press Select again to skip a digit Change each digit as required When the last digit is changed press Select to validate the Configuration ID If the ID is invalid then INVALID Diagnostic Aids 3 20 4059 XXX ID message displays on Line 2 before the ID redisplays You have to reenter the Configuration ID until a valid ID is
163. nch PP 99A0675 21 11 99A0716 1 Bearing Leadscrew Bottom 21 12 99A0658 2 Magnet Door 21 13 99A0650 1 Frame Assembly 21 14 99A0661 1 Tray Assembly Elevator 21 15 99A0671 1 Card Assembly 2000 Option Control 21 16 4 Nut 6 32 Hinge Mounting PP 99A0676 21 17 4 Washer Hinge Mounting Flat PP 99A0677 NS 99A0690 1 Cable Optical Sensor 21 18 4 Washer Hinge Mounting Star PP 99A0677 21 19 99A0655 1 Door Assembly Front 21 20 99A0657 2 Hinge Door 21 21 99A0948 1 Kit Door Switch Spring and Bumper 21 22 1 Washer Door Switch Spring Mounting PP 99A0677 21 23 4 Screw Card Assembly Mounting PP 99A0675 Parts Catalog 7 75 4059 XXX Assembly 21 High Capacity Feeder continued 7 76 4059 Service Manual 4059 XXX ae Units Description 21 24 1 Nut Door Switch Spring Mounting PP 99A0676 21 25 4 Washer Card Assembly Mounting PP 99A0677 21 26 99A0686 3 Guide Rear Paper with thumb screws Use with 99A0696 21 26 99A0188 3 Guide Rear Paper with retainer arm Use with 99A0219 21 27 6 Screw Top Frame Mounting PP 99A0675 21 28 99A0696 1 Frame Assembly Top with labels 21 28 99A0219 1 Frame Assembly Top with labels 21 29 2 Screw Top Frame Clamp Mounting PP 99A0675 21 30 2 Washer Top Frame Clamp PP 99A0677 21 31 99A0719 1 Clamp Top Frame Mounting 21 32 2 Nut Base Mounting PP 99A0676 21 33 2 Washer Base Mounting PP 99A0677
164. ng results must display AA 00 BB in the range of 29 through 3E inclusively hex CC in the range of 35 through 51 inclusively hex DD in the range of OC through 13 inclusively hex For the duplex drive system to pass the test the following results must display AA 00 BB in the range of 29 through 3F inclusively hex CC in the range of 3A through 5D inclusively hex DD in the range of 11 through 1F inclusively hex 2 Press Return Stop to exit the test Diagnostic Aids 3 6 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 Duplex Feed 1 Feeding message displays while the paper is feeding through the printer Duplex Feed 1 Clear Paper message displays when the paper reaches paper stop position 1 and the power indicator turns on solid Duplex Feed 2 Test This test feeds a blank sheet of paper to the duplex paper stop position 2 To run the Duplex Feed 2 Test 1 Select Duplex Feed 2 from the Duplex Test menu The power indicator blinks while the paper is feeding Duplex Feed 2 Feeding message displays while the paper is feeding through the printer Duplex Feed 2 Clear Paper message displays when the paper reaches the duplex paper stop position 2 and the power indic
165. ns at a level just high enough to reliably feed the paper Rather than having a fixed spring force for feeding all weights of paper like the D roll this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness High normal force is one of the most significant contributors to double feeding paper The pick arm is counter balanced by an extension spring located on the pick arm to reduce weight in the rest state This spring is factory set to exert no more than ten to fifteen grams on the stack This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has come loose 3 25 4059 Service Manual 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 These springs aid to prevent the arm from bouncing If the arm appears to be binding or sticky near the bottom of the tray these springs may be the problem Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at bott
166. nsideran peligrosos La impresora contiene en su interior un l ser de Clase 3b de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nan metros El sistema l ser y la impresora est n disefiados de forma que ninguna persona pueda verse afectada por ning n tipo de radiaci n l ser superior al nivel de Notices and Safety Information xii 4059 XXX la Clase durante su uso normal el mantenimiento realizado por el usuario o cualquier otra situaci n de servicio t cnico Declara o sobre Laser A impressora esta certificada nos E U A em conformidade com os requisitos da regulamenta o DHHS 21 CFR Subcapitulo J para Classe 1 de produtos laser Em outros locais esta certificada como um produto laser da Classe em conformidade com os requisitos da norma IEC 825 Os produtos laser da Classe n o s o considerados perigosos Internamente a impressora cont m um produto laser da Classe 1116 3b designado laser de arseneto de pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um nivel de Classe durante a opera o normal a manuten o feita pelo utilizador ou condi es de assist ncia prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan e
167. nting PP 99A0263 14 9 3 Screw Int Shield Mounting PP 99A0263 14 10 2 Screw Controller Bd Mounting Front PP 99A0263 14 11 99A0426 2 Screw Parallel Connector Mounting 14 12 2 Screw Controller Bd Mounting Back PP 99A0263 14 13 99A0187 1 Controller Board Assembly 1250 1620 14 13 99A0840 1 Controller Board Assembly 1255 14 13 99A0841 1 Controller Board Assembly 1625 14 13 99A0183 1 Controller Board Assembly 1650 2420 14 13 99A0842 1 Controller Board Assembly 1855 14 13 99A0139 1 Controller Board Assembly 2450 14 13 99A0844 1 Controller Board Assembly 2455 14 13 99A0845 1 Controller Board Assembly 3455 14 14 2 Screw Engine Bd Mtg Bottom PP 99A0263 14 14 2 Screw Engine Bd Mtg Front PP 99A0263 14 14 2 Screw Engine Bd Mtg Top PP 99A0263 NS 99A0575 1 Cable Deflector NS 99A0346 1 Clip EMC Six Finger Parts Catalog 7 39 4059 XXX Assembly 14 Electronics continued 7 40 4059 Service Manual 4059 XXX ae EDS Units Description 14 15 99A0236 1 Cover INA Blank NS 99A0408 1 Cover INA Flat Blank 14 16 6 Screw INA Cover Mounting PP 99A0263 2450 14 16 4 Screw INA Cover Mounting PP 99A0263 14 16 2 Screw INA Cover Mounting PP 99A0263 14 17 99A0213 1 Engine Board Shield Assembly 14 18 99A0239 1 Shield Inner Assembly 1250 1620 1625 1 0 Cover INA Blank 14 18 99A0238 1 Shield Inner Assembly 1650 2420 1855 2 0 Cover INA Blank 14 18 99A0235 1 Shield Inner Assembly 2450 2455 345
168. nual 4059 XXX POST fails 230 Paper Jam Check Duplex message displays FRU Action 1 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 motor assembly duplex option system board 2 Input Sensor Input Sensor Run the Duplex Sensor Test from the Flag diagnostics menu If the test fails check the input sensor cable at J5 on the system board for correct installation If no problem is found replace the FRUs in the following order input sensor assembly duplex option system board 3 Paper Exit Sensor and Flag Check the duplex exit sensor for correct installation and free movement of the sensor flag Check to make sure the sensor cable is connected to J8 on the system board If no problem is found replace the FRUs in the following order exit sensor assembly duplex option system board Diagnostic Information 2 36 4059 XXX 230 Paper Jam Check Duplex message displays The page is not duplexed and only exits half way out of the redrive FRU Action 1 Duplex Stepper Motor Check the stepper motor cable for cuts or pinched wiring Check the routing of the motor leads along the left side of the bottom tray Check for correct installation of the motor cable connector at J3 on the system board Check fo
169. oe Service Manual Opa S 4059 XXX e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index LEXMARK 4059 XXX First Edition September 2002 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase 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 Lexmark and Optra are trademarks of Lexmark International Inc registered in the United States and or other countr
170. og 7 89 4059 XXX Assembly 25 Miscellaneous quus EN Units Description 25 99A0263 1 Parts Packet Screws 25 99A0585 1 Parts Packet Contact Kit 25 99A0267 1 Parts Packet Retainers 25 99A0268 1 Parts Packet Springs Paper Feed 25 99A0269 1 Parts Packet Duplex Option Fan Mounting 25 99A0299 1 Parts Packet Duplex Option Cam Follower Assembly 25 99A0271 1 Parts Packet Envelope Option Gears 25 99A0404 1 Parts Packet Retainers Envelope Option 25 99A0413 1 Parts Packet Screws Duplex 25 99A0572 1 Parts Packet 500 Sheet Feeder Option Shaft Bearings 25 99A0577 1 Parts Packet Cable Ties 10 each 25 99A0675 1 Parts Packet Screws High Capacity Feeder 25 99A0676 1 Parts Packet Nuts High Capacity Feeder 25 99A0677 1 Parts Packet Washers High Capacity Feeder 25 99A0083 1 Parts Kit Multipurpose Tray 25 99A0512 1 Parts Kit Charge Roll Link Asm Left Side 25 99A0513 1 Parts Kit Charge Roll Link Asm Right Side 25 99A0186 1 Parts Kit Erase Lamp Lens 25 99A0702 2 Printer Stand Caster Non Locking 25 99A0703 2 Printer Stand Caster Locking 25 99A0704 1 Printer Stand Grommet Wire 25 99A0705 2 Printer Stand Lock Cam 25 99A0706 1 Printer Stand Storage Shelf 25 99A0707 1 Printer Stand Door Assembly Cabinet 25 99A0710 1 Printer Stand Filler Rear Top Piece 25 99A0711 1 Printer Stand Table Assembly Large 25 99A0712 1 Printer Stand Table Assembly Small 7 90 4059 Service Manual 4059 XXX Asse
171. oll or slick spots If you find a problem replace the pick roll assembly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications Diagnostic Information 2 88 4059 XXX Parallel Port Service Check Run the Parallel Wrap Test on page 3 11 Note The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug P N 1319128 and invoking the Parallel Diagnostic Test This test helps isolate the printer from the parallel cable and host The test provides failure information on the display for approximately 3 seconds If the test indicates that a problem is detected replace the controller board Printhead Service Check The printhead assembly does not contain any service replaceable parts or components If service error code 930 displays the wrong printhead is installed in the printer Service Error Code 1 Error Code 931 No first HYSNC Signal Error Code 932 Lost HYSNC Explanation These errors usually indicate a failure in the HYSNC signal to the printhead Check the continuity of the cables connected to J3 and J8 on the engine board If incorrect replace the defective cable The voltage at J8 4 measures approximately 5 V dc If incorrect replace the engine board The voltage at J3 7 measures approximately 24 V dc If incorrect replace the engine board If correct replace the printhead assembly
172. om until the pick assembly can be replaced However the counterbalance spring is not to be considered an adjustment for feeding problems Autoconnect System Paper Tray Options Envelope Feeder and Output Expander Operations Electrical Autoconnect Cabling and Connectors The printer options make electrical connection automatically or autoconnects requiring no external cables when the option is mechanically installed under the printer Communication between the option and the base printer stops when you remove an option located above or below the printer The printer no longer recognizes the option and deletes associated messages Each installed option below the base printer provides an electrical autoconnect to the option attached below it 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 Diagnostic Aids 3 26 4059 XXX Duplex Option The duplex option interface is a six pin autoconnector that provides a 24 V 24 V return serial interface transmit signal serial interface receive signal and two ground pins The duplex option receives the 24 V dc from the base printer for the duplex motors and also converts the voltage to 5 V dc for duplex electronics Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and bas
173. 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 Run the Quick Disk Test on page 3 2 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk Note The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If a problem still exists replace the hard disk board The Disk Test Clean on page 3 2 is used to help restore the disk if the disk contains bad data and is unusable This test is divided into a cleaning and a verifying or testing section Note This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk Menu operation This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network Card Option Error Code 976 Network Card X X Network card 1 2 or 3 A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly installed in the Socket on the interconnect board and is properly grounded If you find no problem contact your next level of support before replacing the network card Error Code 977 Network Card X A 977 erro
174. onnect the cables from the duplex board Use caution to avoid damage to the cables and connectors Remove the two duplex board mounting screws and remove the duplex board Duplex Front Cover Assembly 5 Lift the base printer from the duplex assembly Remove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable at connector J6 Position the duplex assembly on its side Gently release the three front cover assembly latches from the bottom of the duplex assembly Remove the duplex front cover assembly Duplex Front Cover Door 1s 2 Remove the duplex front cover assembly Holding the front of the assembly away from you open the cover door and gently pry the left side door pivot from the mounting Move the cover door to the left to clear the right door pivot from the mounting and remove the duplex front cover door Duplex Front Cover Door Switch 2 3 Remove the duplex front cover assembly Remove the four duplex board cover screws and disconnect the cover door switch cable at connector J6 Loosen the cover door switch mounting screw and remove the switch Note Be sure the cover door switch is properly positioned in the mounting slots when reinstalling to allow the duplex cover door actuator arm to operate the switch 4 21 4059 Service Manual 4059 XXX Duplex Motor 2 3 Remove the duplex front cover door Gently disconnect the cables from the duple
175. oper operation 3 Right Transfer Arm Check the right transfer arm Assembly assembly to make sure it is fastened and locked in the down position If the arm is not locked down check to make sure the arm is not broken and will lock into the EP frame correctly Check the right transfer arm assembly spring for proper operation For any background problems check to ensure the contact to the HVPS board is correct and that there is approximately 0 ohms resistance between the transfer roll shaft and the HVPS contact If correct go to Print Quality Background on page 2 96 4 HVPS 917 Error Code Check the voltage at J10 3 The voltage changes from 24 V 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 If there is no continuity replace the cable harness If there is continuity replace the HVPS If the problem continues replace the engine board Diagnostic Information 2 106 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 Turn the printer off Press and hold the Go and Return buttons Turn the printer on Release
176. oting 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 Status Bytes 1 2 3 Explanation 84 xx 00 The input sensor is still covered by the first sheet of paper through the printer and the second sheet is ready to arrive at the sensor 84 xx 01 Video information has not started on the page at the input sensor within two inches after activating the input sensor flag 84 xx 02 The media takes too long to complete a pass through the input sensor 84 xx 04 This can occur when a sheet of paper is in the machine during POST and the input sensor flag has tripped the input sensor 84 xx 05 This error is generated whenever media is seen at the input sensor before the sensor flag activates the input sensor 84 xx 06 A paper jam is detected by the tray you are trying to feed from 84 xx 07 A paper jam is detected by a smart option and an error message displays 84 xx 08 Paper Tray 5 pass thru sensor is not activated by a sheet of paper 84 xx 09 Paper Tray 4 pass thru sensor is not activated by a sheet of paper 84 xx 0A Paper Tray 3 pass thru sensor is not activated by a sheet of paper 84 xx 0B Paper Tray 2 pass thru sensor is not activated by a sheet of paper 84 xx 0C Paper Tray 5 pass thru sensor is not activated and never deactivated A sheet of p
177. pe feeder and is the only byte contained in the following table Explanation 00 There was no envelope feeder error reported 10 Printer failed POST Homing of Envelope feeder 11 Printer failed POST Halted Envelope Feeder 21 The envelope feeder failed to feed envelope jam 30 The D C motor failed to reach operating speed 32 The motor stalled 36 The motor failed to stop Duplex Unit Sub Error Codes Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the duplex option and is the only byte contained in the following table Status Byte 4 Explanation 00 No duplex error No problem was reported to the engine by the duplex system card 01 The leading edge of the sheet of paper never arrived at the input sensor 02 The duplex option system board never received media notification from the printer 03 The trailing edge of the sheet of paper never cleared the input sensor Diagnostic Information 2 10 4059 XXX Statys Explanation Byte 4 04 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 05 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 no
178. piece of plain white paper around the charge roll to prevent contamination or damage 2 Carefully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing 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 FRU Action Charge Roll Assembly Check the charge roll for correct installation toner buildup marks cuts or other signs of contamination or damage Replace as necessary N Left Side Charge Roll Link Check the left side charge roll link assembly for correct assembly operation Check for damage to the arm or bearing assembly 2 29 4059 Service Manual 4059 XXX FRU Action 3 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 Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the link assembly Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame If incorrect replace the link assembly
179. r message is displayed go to the User Error Messages on page 2 16 If your machine completes the Power On Self Test POST on page 2 24 without an error and you have a symptom go to the Symptom Tables on page 2 25 Locate your symptom and take the appropriate action If a service error code appears while you are working on the machine go to the Service Error Codes on page 2 2 and take the indicated action for that error 2 1 4059 Service Manual 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 901 Engine Flash Contact the next support level or call Lexmark This error indicates that the flash which the engine board code is programmed into is bad Replace the engine board 902 General Engine Software 903 Paperport Link Driver Error 904 Interface Violation by the controller software 905 Interface Violation by Paperport Device 906 Controller Engine Link Driver Error These errors indicate an unrecoverable engine software error Replace the engine board Diagnostic Information 2 2 4059 XXX Motor Excessive PWM 912 DC pick motor below speed 913 DC pick motor over speed 914 DC pick motor No encoder feedback Error Code Action 910 DC Pick Error Code
180. r 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 Service Tip For this type of problem check the sub error codes They can help isolate the problem 202 Paper Jam messages can also occur prior to the output expander pass thru sensor FRU Action 1 Output Expander Drive Belt Drive Pulley Drive Belt Idler Pulley Belt Tension Spring Check to ensure the output expander drive belt is correctly installed on the drive pulley and belt idler pulley Check the belt tension spring to make sure it is not loose or broken Repair as necessary 2 Mechanical Linkage DC Motor Assembly Level 2 2 81 4059 Service Manual If the DC motor is functioning properly check the gears clutch and other linkage parts for correct operation and any signs of wear broken gear teeth or damaged parts If incorrect replace the mechanical linkage DC motor assembly 4059 XXX FRU Action 3 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 J4 1 to J4 2 Approximately 10 ohms J4 3 to J4 4 Approximately 10 ohms Also check each winding for shorts between J4 1 thru J4
181. r any shorts between each pin of the motor cable and the motor housing If shorts are found replace the motor Check the resistance of the stepper motor between J3 1 Stpmtr A to J3 2 Stpmtr A The resistance measures approximately 10 ohms The resistance between J3 3 Stpmtr B to J3 4 Stpmtr B measures approximately 10 ohms If the resistance is incorrect replace the stepper motor Check for shorts between windings on pins J3 1 to J3 2 and pins J3 3 to J3 4 If a short is found replace the stepper motor assembly If no short is found replace the duplex system board 2 37 4059 Service Manual 4059 XXX POST fails with Close Duplex Rear Door displayed when Duplex Rear Door is closed FRU Action 1 Rear Door Switch Not installed on some duplex units Check the rear door for correct installation and operation Check to ensure the cable or connector is not damaged and is properly connected at J6 on the duplex system board The rear door switch can be checked by measuring the continuity between J6 1 and J6 2 on the cable connector while actuating the rear door switch If there is no continuity replace the rear door switch assembly If there is continuity replace the duplex option system board POST fails with Insert Duplex Front Cover message displayed FRU Action 1 Front Cover Switch Not installed on some duplex units Check the switch for correct
182. r displays when the RIP software detects that a network card is installed in slot x on the interconnect board but cannot establish communications with the network card If you are servicing a 1650 1855 2420 2450 or 2455 and the network card works in another slot replace the interconnect board 2 77 4059 Service Manual 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 Check the sensor and flag for proper operation If you find no problem with the sensor and flag continue with the service check Service Tip Check to make sure the correct flag is installed The Output Bin Sensor is a normally closed sensor with the sensor flag down Therefore unless the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message is not displayed FRU Action 1 Engine Board Check the voltage at J6 3 It measures 5 V dc when the flag is in Printer fails to display the sensor and 0 V dc when the flag Remove Paper Standard is out of the sensor If the voltage Bin message Output Bin does not change replace the sensor Sensor Test fails cable assembly If this does not fix the problem replace the engine board 2 Output Bin Sensor Flag Check to make sure the correct flag is instal
183. rbox Replace the FRUs in the following order main drive gearbox reference edge Lines spaced 44 64 mm 1 757 inch apart Replace the FRUs in the following order developer drive assembly main drive gearbox assembly Lines spaced 47 19 mm 1 858 inch apart Replace the FRUs in the following order toner cartridge charge roll developer drive assembly Lines spaced 49 16 mm 1 935 inch apart Replace the toner cartridge 2 95 4059 Service Manual 4059 XXX FRU Action 7 Lines spaced 49 74 1 958 inch apart Replace the FRUs in the following order redrive assembly fuser assembly 8 Lines spaced 51 02 mm 2 009 inch apart Replace the transfer roll 9 Lines spaced 52 23 mm 2 056 inch apart Replace the redrive assembly 10 Lines spaced 76 53 mm 3 013 inch apart Replace the FRUs in the following order alignment assembly main drive gearbox assembly 11 Lines spaced 95 66 mm 3 766 inch apart Replace the FRUs in the following order toner cartridge main drive gearbox assembly 12 Lines spaced 99 49 mm 3 917 inch apart 13 Lines spaced 114 79 mm 4 519 inch apart Print Quality Background Replace the redrive assembly Replace the alignment assembly 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
184. re data is processed but the printer processes all paper currently in the paper path Press Go to return to Ready after the page prints Press Menu gt or lt Menu to take the printer out of Ready and enter the TESTS MENU Busy Stat Press Select for the values Press Menu gt until Reset Printer is on the second line of the display Press Select to reset the printer 2 13 4059 Service Manual 4059 XXX User Status Message Status Action Restoring Factory Defaults The printer is restoring factory defaults No button actions are possible while this message is displayed Performing Self Tests Not Ready Press Go The printer is running the normal series of start up tests after it is powered On When the tests are complete the printer returns to Ready The printer is in the Not Ready State which means it is not ready to receive or process data This message displays when Menu or Menu is pressed during a print job No button actions are possible while this message is displayed Press Go to take the printer out of the Not Ready state Press Menu or Menu to take the printer out of Ready and enter the TESTS MENU Busy State Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Resetting Printer The printer is deleting any print jobs in process and restoring all settings to user defaults No button actions
185. rried through the printer on the backside of the paper FRU Action Fuser Assembly Toner is being carried out on the backside of the media This problem is generally caused by a toner buildup on the fuser hotroll or backup roll Check the fuser hotroll and backup roll for any noticeable buildup of toner Repair as necessary Transfer Roll Transfer Plate Check the transfer roll for any signs Assembly of toner buildup or loose toner around the area of the transfer plate assembly Clean the area and run another copy If the problem continues replace the FRUs in the following order HVPS engine board Smart Cartridge Service Check Note If you are unable to clear a 32 Unsupported Cartridge User Error Message make sure an Optra Se print cartridge is correctly installed in the printer The cartridge is easily identified by the smart chip located on the top right side of the cartridge Install another Optra Se cartridge before attempting to troubleshoot the printer Check to make sure the smart cable is properly connected to J21 on the engine board Check the print cartridge for any signs of damage or improper installation of the smart chip Also check to make sure there is proper contact between the smart chip and the smart cartridge contacts Diagnostic Information 2 102 4059 XXX Service Tip An intermittent 82 Unsupported Cartridge User Error Message can be caused by poor contact between the
186. s at locations JP1 1 to JP1 2 and JP2 1 to JP2 2 on the engine board 2 51 4059 Service Manual 4059 XXX Configuration 1 A level 1 fuser board and level 1 engine board are installed in configuration 1 Note Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section Fuser Solenoid Adjustment on page 4 3 FRU Action 1 Fuser Envelope Conditioner The operation of the fuser solenoid Solenoid can be observed by removing the redrive assembly Check for proper mechanical operation of the solenoid and associated hardware link and so on If correct check the resistance of the solenoid between J4 1 and J4 2 The resistance measures between 5 ohms and 10 ohms If incorrect replace the solenoid assembly 2 Fuser Control Board The solenoid receives power from the fuser control board The fuser control board receives 42Vdc from the LVPS via the interconnect board and envelope conditioner cable Check for approximately 42 V dc at the 42 V dc test point on the fuser control board If the voltage is correct replace the fuser control board Diagnostic Information 2 52 4059 XXX FRU Action 3 LVPS Interconnect Board If the 42 V dc test point does not measure approximately 42 V dc check the continuity of the cable connected between J3 on the fuser control and J1 on the interconnect board If the cable does not measure continuity replace the ca
187. s 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 917 Transfer Roll Indicates a problem in the transfer roll area Go to the Transfer Roll Service Check on page 2 105 920 Fuser Error Indicates that the fuser is below temperature when printing Go to the Cold Fuser Service Check on page 2 48 921 Fuser Error Indicates that the fuser is below standby temperature when the printer is idle Go to the Cold Fuser Service Check on page 2 48 922 Fuser Error Fuser failed to reach standby temperature Go to the Cold Fuser Service Check on page 2 48 923 Fuser Error Fuser is too hot during printing or when printer is idle Go to the Hot Fuser Service Check on page 2 50 924 Fuser Error 925 Fuser Error An open circuit has been detected in the Fuser Thermistor Circuit Go to the Hot Fuser Service Check on page 2 50 Wrong fuser lamp installed Check the fuser lamp for the correct type of lamp that should be installed 927 Fan Stalled Indicates a printer fan stalled Go to the Fan Service Check on page 2 47 928 Erase Lamps Indicates that the engine has detected that either the erase lamp assembly is missing or disconnected Go to the Erase Lamp Service Check on page 2 46 2 3 4059 Service Manual 4059 XXX
188. s RAM memory SIMMS optional input paper trays envelope feeder duplexer output bins flash or disk Printer information such as serial number page count installed RAM engine code level RIP code level envelope feeder code level tray 1 5 code levels output bin 1 3 code levels control panel code levels font ROM version and SRAM availability Diagnostic Aids 3 24 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 No customer adjustments are necessary therefore no special trays are needed for card stock or labels The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm This movement produces a downward force at the pick rolls The friction between the pick roll and the paper produces a frictional locking condition If the paper is physically held and not allowed to feed then the motor stalls Slippage between the roll and the paper is theoretically impossible When the motor is energized the pick rolls are driven down into the stack increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam Once this critical threshold is achieved the normal force remai
189. s entre 770 et 795 nanom tres L imprimante et son syst me laser sont con us pour impossible dans des conditions normales d utilisation d entretien par l utilisateur ou de r vision l exposition des rayonnements laser sup rieurs des rayonnements de Classe Avvertenze sui prodotti laser Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825 prodotti laser di classe non sono considerati pericolosi La stampante contiene al suo interno un laser di classe IIIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante durante il normale funzionamento le operazioni di servizio o quelle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Avisos sobre el laser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos laser de Clase 1 establecidos en el subcapitulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los demas paises reune todas las condiciones expuestas en la norma IEC 825 para productos laser de Clase 1 Los productos laser de Clase no se co
190. s not display Output Bin Full Paper does not feed all the way into the output tray Go to the Output Bin Sensor Standard Tray Service Check on page 2 78 Go to the Toner Sensor Service Check on page 2 104 Service Checks Note Anytime the engine board is replaced the Configuration ID must be reset in NVRAM on the new engine board Go to Setting Configuration ID on page 3 20 Review the following information before performing any service checks Paperfeed Problems especially paper jams Go to Viewing the Error Log on page 3 8 and check the printer error log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option Paperfeed Problems with error message Use the Sub Error Codes For 9XX and 2XX Error Codes on page 2 7 to help diagnose the problem Print Quality Problems Go to Print Quality Test Pages on 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 Diagnostic Information 2 28 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
191. s sent to the printer across the standard serial port but the port has been disabled 56 Parallel Port Disabled 58 Too Many Trays Attached This error is displayed when data is sent to the printer across the parallel port but the parallel port has been disabled Once this message is displayed reporting of further errors is suppressed until the menus are entered or the printer is reset This error code is displayed when too many input trays are attached to the printer 58 Too Many Bins Attached This error code is displayed when too many optional output bins are attached to the printer 58 Too Many Disks Installed This error is displayed when too many disks are attached to the printer 61 Defective Disk 62 Disk Full This error code is displayed when the printer detects a defective disk This error may occur at power on or during disk format and write operations The following actions may be taken while this message is displayed Press Go to clear the message The disk is marked defective and normal printer operations continue Disk operations are not allowed with a defective disk The Format Disk menu is not shown This error code is displayed when there is not enough free space on the disk to hold the resources that have been requested to be written to the disk This message displays for both resource and PostScript Disk operators when the disk is full 63 Unformatted Disk This error co
192. s the wrong fuser lamp is installed in the printer and does not match the one stored in the printer code Service Tip Set the Fuser Temperature to NORMAL before starting this service check FRU Action 1 Fuser Lamp Incorrect Install the correct voltage and Lamp 925 Service Error wattage lamp or fuser assembly Diagnostic Information 2 48 4059 XXX FRU Action 2 Fuser Lamp Remove the controller board Run the Diagnostic Print Test and observe the lamp through the left side frame If the lamp doesn t come on unplug the printer and check the continuity between the two pins on the fuser lamp cable going to the fuser assembly If you do not measure continuity remove the fuser assembly and check the continuity of the lamp If incorrect replace the lamp If correct replace the fuser cover assembly 3 LVPS and AC Fuser Lamp Cable Turn the printer off Disconnect the fuser lamp connector at the fuser assembly Turn the printer on and check across the pins on LVPS end of the cable for line voltage If incorrect turn the printer off and disconnect the power cord and check the continuity of the AC fuser lamp cable If incorrect replace the cable If correct replace the LVPS 4 Fuser Top Cover Assembly Thermal Fuse Thermistor Assembly Disconnect the thermistor cable from the fuser board at J2 The resistance is as follows HOT J2 1 J2 2 2 5K ohms COLD 150K ohm
193. s to 260K ohms 2 49 4059 Service Manual 4059 XXX Hot Fuser Service Check Error codes 923 and 924 may display for a hot fuser failure CAUTION The fuser may be hot use caution before removing or servicing FRU Action 1 Fuser Cover Assembly Check for damage to the thermistor Assembly includes assembly Check the resistance of Thermistor and Thermal the themistor Fuses HOT J2 1 to J2 2 2 5K ohms COLD 150K ohms to 260K ohms Check the continuity from each pin of J2 to ground If there is continuity replace the fuser cover assembly 2 Engine Board Error code 924 indicates the engine board detects an open circuit in the thermistor circuit for the fuser assembly The voltage on J2 6 on the engine board measures approximately 5 V dc If incorrect replace the engine board If correct check the continuity of the DC fuser cable connected between J2 on the engine board and J1 on the fuser control board In there is no continuity replace the cable If there is continuity check the voltage on J2 2 on the fuser control board It measures approximately 5 V dc If incorrect replace the fuser control board 3 Fuser Hot Roll Examine the fuser assembly for Backup Roll Bearings signs of overheating or damage Check the hot roll and backup roll for signs of excessive toner label glue labels or other contaminants If any are found repair as necessary or replace the fuser assembly Di
194. serprodukter og er i andre land godkjent som et Klasse l laserprodukt i samsvar med kravene i IEC 825 Klasse l laserprodukter er ikke betrakte som farlige Skriveren inneholder internt en klasse 1116 3b laser som best r av en gallium arsenlaserenhet som avgir str ling i belgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niv under vanlig bruk vedlikehold som utf res av brukeren eller foreskrevne serviceoperasjoner Av s sobre el L ser Segons ha estat certificat als Estats Units aquesta impressora compleix els requisits de DHHS 21 CFR apartat J pels productes l ser de classe 1 i segons ha estat certificat en altres llocs s un producte l ser de classe que compleix els requisits d IEC 825 Els productes l ser de classe no es consideren perillosos Aquesta impressora cont un l ser de classe 1116 3b d arseni r de gal li nominalment de 5 mil liwats i funciona la regi de longitud d ona de 770 795 nan metres El sistema l ser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci laser per sobre d un nivell de classe durant una operaci normal durant les tasques de manteniment d usuari ni durant els serveis que satisfacin les condicions prescrites XV 4059 Service Manual 4059 XXX Japanese Laser Notice L 3 icBiy 107 9 18
195. signs of damage to the connector or contacts If you find damage replace the damaged cable connector assembly Remove the envelope feeder option and check the voltages at the autoconnect on the front of the printer If incorrect check the interconnect board If correct reinstall the envelope option and continue with step 3 2 39 4059 Service Manual 4059 XXX FRU 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 J1 7 measures 24 V dc If any of the voltages are incorrect replace the autoconnect cable connector If the voltages are correct replace the envelope system board Diagnostic Information 2 40 4059 XXX Operator panel displays 260 Paper Jam immediately when envelope feed is requested POST incomplete FRU Action 1 Pass through Sensor Check for any debris pieces of envelope and so on over the pass thru sensor Check for correct installation of the pass thru sensor flag Make sure the sensor cable is attached to the envelope system board Perform an envelope feeder sensor test to check both the sensor and sensor flag Note It may be necessary to use a small tool to actuate th
196. solenoid mounting screw A Disconnect the solenoid link B 4 Remove the solenoid from the fuser assembly Note Do the Fuser Solenoid Adjustment on page 4 3 whenever you replace the fuser solenoid on gt A 202 B Fuser Exit Flag Assembly 1 Remove the fuser assembly 2 Remove the fuser exit flag assembly 4 31 4059 Service Manual 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 assembly B Repair Information 4 32 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 Grip the lamp by the ceramic end piece and remove it from the fuser assembly Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp 3 Remove the fuser lamp Note Be sure to position the left lamp mounting bracket around the fuser lower exit guide mounting pin when reinstalling the lamp
197. sor mounting 1 102 i i charge roll mounting 1 Wr main drive gearbox mounting 3 EP module to left and attach 9 right side frame developer drive mounting 2 assembly left side cover gap to left attach 2 frame stacker duct to frame mounting 2 cartridge hold down mounting 2 assembly MPT deflector mounting 2 fuser to frame mounting 2 interconnect board attach 2 shield ground engine board shield to attach 1 frame laser cover mounting 5 4059 XXX a Screw Type Location Purpose Qty M3 5x8 mm spring mounting 1 Thread Cutting E controller board mounting 2 front 102 CC ii integrated tray ITC mounting 2 i board left side cover mounting 5 stacker support to right attach 2 side frame M3 5x12 mm engine board shield to attach 1 Thread Cutting left frame D paper alignment mounting 2 104 CD assembly T E i i toner cartridge guide mounting 2 i track left side frame to center attach 3 pan right side frame to attach 2 center pan deflector mounting 2 M3x5 mm INA cover attach 6 Taptite 2 screws per cover 201 t interconnect board mounting 5 Repair Information 4 8 4059 XXX Reference Number Screw Type Location Purpose Qty M3x6 mm outer shield mounting 6 Taptite inner redrive deflector mounting 2 interconnect board to mounting 2 center pan engine board mounting 2 bottom holes contro
198. stall with the paper out sensor flag positioned in the sensor slot on the paper tray board Paper Tray Paper Out Sensor Flag 1 Remove the paper tray frame assembly 2 Remove the paper tray board 3 Remove the paper out sensor flag Paper Size Spring Comb 1 Remove the paper tray board 2 Remove the paper size spring comb mounting screw and remove the spring comb Repair Information 4 50 4059 XXX Outer EMC Shield 1 Remove the left door 2 Loosen the six outer EMC shield mounting screws A and remove the shield A 202 A 202 4 51 4059 Service Manual 4059 XXX Paper Alignment Assembly Remove the upper paper deflector assembly Remove the inner paper deflector assembly Release the input paper sensor from its mounting and remove Remove the left door Remove the two paper alignment assembly mounting screws A located inside the printer 104 Repair Information 4 52 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 when you reinstall the assembly 9940492 Paper Input Sensor 1 Remove the inner paper deflector assembly 2 Disconnect the paper input sensor cable from the input sensor 3 Release the input paper sensor from its mounting and remove 4 53 4059 Service Manual 4059 XXX Paper Size Sensing Board
199. stic Information 2 6 4059 XXX Error Code Action 982 lt device gt Communications error detected by the specified device Comm 983 lt device gt Invalid command received by the specified device 984 lt device gt Bs command parameter received by the specified evice 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 3 990 device Indicates an equipment check condition has occurred in the specified device but the device is unable to identify the exact component failure Note device can be one of the following duplex tray X 1 2 3 4 or 5 envelope feeder or output bin x 1 2 or 3 991 device The specified device has detected an equipment check Card in its system card Note device can be one of the following duplex tray x 1 2 3 4 or 5 envelope feeder or output bin x 1 2 or 3 Sub Error Codes For 9XX and 2XX Error Codes 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 Byte 2 Byte 3 Byte 4 DU XX XX XX XX DU XX XX XX XX Byte 5 Byte 6 Byte 7 Byte 8 2 7 4059 Service Manual 4059 XXX Base Printer Sub Error Codes Each status byte has a different level of troublesho
200. sts menu The power indicator blinks while the test is running Flash Test Test Passed message displays if the test passes and the power indicator turns on solid Flash Test Test Failed message displays if the test fails and the power indicator turns on solid 2 Press Go or Return Stop to return to the Device Tests menu Disabling Download Emulations Error Code 964 Download Emulation CRC Failure Checksum failure detected in the emulation header or emulation file 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 Turn the printer off 2 Press and hold the Go and Menu buttons 3 3 4059 Service Manual 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 Duplex Tests Duplex Quick Test This test is used to verify that the Duplex Option Top Margin is set correctly This test prints a duplexed version of the Quick Test Page that can be used to adjust the
201. surface to avoid gear damage It is also very important not to let any dirt paper staples or other material come intact with the grease in the gearbox assembly FRU Action Main Drive Assembly Remove the controller board and run Excessive noise or a Diagnostic Print Test in the vibration continuous mode Check the main drive assembly for any excessive noise or vibration Determine if the noise is in the main drive toner cartridge fuser or main drive gearbox Look for any loose or worn parts in the developer drive assembly main drive gearbox or fuser Repair as necessary Main Drive Motor Assembly A service error code 936 Transport Excessive noise gears Motor may be displayed Check the ratcheting and so on voltage at J12 6 on the engine board It measures approximately 5 V dc when the motor is not running and goes to 0 V dc when the motor is running If incorrect replace the engine board If this does not fix the problem replace the main drive motor Main Drive Motor Cable Check the continuity of the main drive motor cable If incorrect replace the cable 2 73 4059 Service Manual 4059 XXX FRU Action 4 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 static 0 V dc
202. t Be careful not to short between the test point and any other pin The voltage measures approximately 42 V dc If correct replace the engine board 5 LVPS Interconnect Board Check the voltage at CN3 18 on the LVPS It measures approximately 42 V dc If incorrect replace the LVPS If correct replace the 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 Service Tip Run a Diagnostic Print Test in the continuous mode with the controller board removed A defective input sensor or circuit causes the first copy to exit only partially through the fuser assembly FRU Action 1 Input Sensor Flag Check the input sensor flag for damage and proper operation If a problem is found repair as necessary 2 Engine Board Check for approximately 5 V dc at J10 10 on the engine board If incorrect replace the engine board 3 Input Sensor Cable Check the continuity of the input sensor cable If incorrect replace the cable If correct replace the input sensor assembly 2 57 4059 Service Manual 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
203. t 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 If the test indicates a problem replace the controller board ner Sensor Service Check Service Tip Check the print darkness MENU setting before checking the toner sensor This service check is intended to be used when a 929 Service Error displays FRU Action Developer Drive Assembly Incorrect operation of the developer drive assembly can cause the printer to display a 929 error code Toner Sensor Check the developer drive assembly for correct installation any sign of worn loose or broken parts Toner Sensor Cable Check the toner sensor assembly cable to make sure it is properly seated into the toner sensor If correct at both the sensor and engine board J10 check the continuity of the cable If incorrect replace the cable Diagnostic Information 2 104 4059 XXX FRU 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 It reads approximately 5 V dc with the controller board removed from the printer If incorrect replace the eng
204. t sent a command to send a sheet of paper to the duplex unit 06 The exit sensor detected a sheet of paper too early 07 The sheet of paper s trailing edge did not clear the exit sensor in the desired length of time 08 The feed motor experienced a complete motor stall The D C motor is under speed The motor never reached the correct operating speed 13 There is paper left in the duplex option Paper was sensed during the homing operation during POST 15 There is paper left in the duplex option Paper was sensed during the DC motor diagnostic test during POST 18 The D C motor experienced an acceleration error 3D There is paper left in the duplex option Paper was sensed during IR clear during POST 2 11 4059 Service Manual 4059 XXX User Status Messages User Status Message Status Action Ready Ready Hex 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 Press Menu gt or lt Menu to take the printer out of Ready and enter all the Menus except the TESTS MENU Busy State Press Menu gt or lt Menu to take the printer out of Ready and enter the TESTS MENU Busy State Press Select for the values Press Menu gt until Reset Printer is on the second line of the display Press Select to Reset the printer Busy The printer is busy receiving or processing data or printing data Note The
205. the Base Sensor Test 1 Select the Base Sensor Test The operator panel displays OP for open and CL for closed 2 Manually toggle the sensors by hand to verify that each sensor switches from open to closed 3 17 4059 Service Manual 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 5 Select Registration from the Diagnostic menu The Top margin sign value pair blinks This indicates it is the margin value being changed To select the margin value to be changed press Select until the margin value pair you want to change is blinking To change the margin value press either Menu or Menu When the value you want is displayed press Select to save the value To exit the Registration menu press Return To verify the margin values are correct you must print the Quick Test Page from the registration screen Press Go to print the test page While printing the Quick Test Page the Quick Test Printing message displays Once the Quick Test Page completes printing the Registration screen displays again The Quick Test Page should be printed on letter or A4 paper Diagnostic Aids 3 18 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 boar
206. the buttons when Performing Self Test displays on the operator panel Boo qe The tests display on the operator panel in the order shown Print Registration Print Tests Hardware Tests Duplex Tests If installed Input Tray Tests Output Bin Tests Base Sensor Tests Printer Setup Error Log EP Factory Defaults Exiting the Diagnostics Mode Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode 3 1 4059 Service Manual 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 If the block is good the saved data is written back to the disk To run the Quick Disk Test 1 Select the Quick Disk Test from the Device Tests menu The power indicator blinks while the test is in progress Quick Disk Test Test Passed message displays if the test passes and the power indicator turns on solid Quick Disk Test Test Failed message displays if the test failed and the power indicator turns on solid 2 Press Go Return or Stop to return to the Device Tests menu Disk Test Clean WARNING This test destroys all data on the disk and should not be attempted on a good disk Also note that this test may run approximately 1 1 2 hours depending on the disk size
207. the option system board The paper out sensor is mounted on the system board Diagnostic Information 2 60 4059 XXX Printer does not recognize Tray X is installed FRU Action 1 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 Check the autoconnect cable s for correct installation at the tray x system board If correct check the continuity of the autoconnect cable s If correct replace the tray x system board If incorrect replace the cable 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 Some types of labels foil material and slick papers can cause misfeeds and slippage of the rollers FRU Action 1 Autocompensator Check the autocompensator pick Assembly arm rollers for any sign of glazing toner or other buildup Clean or replace as necessary High Capacity Feeder Input Tray Service Check Note Voltage measurements in the high capacity feeder input tray service checks must be made with the high capacity feeder attached to the base printer to obtain accurate results Service Tip Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high c
208. tic 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 Tray 1 Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed Multipurpose Feeder if installed Envelope Feeder if installed For each input source selected you have the following choice Single prints the Print Test Page once Continuous continue printing the Print Test Page until Return or Stop is pressed Diagnostic Aids 3 22 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 Select Print Tests from the Diagnostic menu 2 Select the media source 3 Select Single or Continuous If single is selected no buttons are active during printing If continuous is selected Return or Stop can be selected to cancel the test Check each Test Page from each source to assist in Print Quality and Paper Feed problems Print Quality Test Pages The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled The print quality test consists of three pages Page one contains a mixture of graphi
209. to erase lamp assembly for correct installation If incorrect repair as necessary 2 Engine Board Remove the controller board and toner cartridge from the machine Ground pin J10 15 The erase lamps turn on The lamps can be observed through the front of the machine with the cover open and print cartridge removed If the lamps do not turn on measure the voltage on J10 14 The voltage reads approximately 24 V If incorrect replace the engine board If correct check the voltage at J10 15 The voltage reads between 15 V dc to 20 V dc If incorrect check the continuity of the erase lamp lines in the main harness If incorrect replace the cable harness If correct replace the erase lamp assembly Diagnostic Information 2 46 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 FRU Action 1 Fan Assembly Check the fan for proper installation and for excessive noise If incorrect replace the fan and cable assembly 2 Engine Board Check to make sure the auxiliary fan cable is seated on connector J7 on the engine board If correct check for 24 V dc on J7 1 on the engine board If incorrect replace the engine board If correct replace the fan assembly Note When the printer is in warm up the voltage at J7 1 measures approximately 12 V dc When the printer is running the
210. ts may not always be obvious Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t concu test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de xvii 4059 Service Manual 4059 XXX s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de l utilisation d autres pi ces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Norme di sicurezza prodotto stato progettato testato e approvato in conformit a severi standard di sicurezza e per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non responsabil
211. uplex Tests menu Manually actuate each of the duplex sensors When the sensor switch is closed CL closed displays when the sensor switch is open OP Open displays Duplex input sensor Duplex exit sensor Duplex front cover switch not installed on all duplex options Duplex rear door switch not installed on all duplex options Press Return Stop to exit the test Duplex Motor Test This test lets you test the duplex unit s paper feed drive system and verify that the power and velocity values are acceptable 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 After all the information is computed the motor turns off 3 5 4059 Service Manual 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 If the test fails remove the drive belt from the duplex D C motor and run the motor test again For the duplex D C motor to pass the test the followi
212. uth Africa 14 2 1342534 1 Power Cord Set 8 ft Chile HV 14 2 1339543 1 Power Cord Set 8 ft Denmark 14 2 1339542 1 Power Cord Set 6 ft Italy 14 2 1374067 1 Power Cord Set 8 ft Peru HV 14 2 99A0471 1 Power Cord Set 8 ft straight 1855 01 14 2 99A0493 1 Power Cord Set 6 ft straight 1855 01 14 2 99A0496 1 Power Cord Set 8 ft right angle 1855 01 14 2 99A0497 1 Power Cord Set 6 ft right angle 1855 01 14 3 99A0215 1 Fuse 110 V ac LVPS 14 3 99A0205 1 Fuse 220 V ac 14 4 99A0214 1 LVPS 110 V ac 2420 2450 2455 3455 14 4 99A0216 1 LVPS 110 V ac 1620 1650 1625 1855 14 4 99A0218 1 LVPS 110 V ac 1250 1255 14 4 99A0199 1 LVPS 220 V ac 2420 2450 2455 3455 14 4 99A0201 1 LVPS 220 V ac 1620 1650 1855 1625 14 4 99A0203 1 LVPS 220 V ac 1250 1255 Parts Catalog 7 37 4059 XXX Assembly 14 Electronics continued 7 38 4059 Service Manual 4059 XXX ELSE Units Description 14 5 1 Screw HVPS Mounting PP 99A0263 14 6 1 Screw Engine Bd Mounting Top PP 99A0263 14 7 99A0220 1 High Voltage Power Supply 14 7 99A0827 1 High Voltage Power Supply 3455 14 8 99A0376 1 Interconnect Board Assembly 2450 2455 3455 o 3 Slot 14 8 99A0930 1 Interconnect Board Assembly 1650 1855 2420 2 Slot 14 8 99A0960 1 Interconnect Board Assembly 1250 1255 1620 1625 01 Slot 14 9 2 Screw Int Board Mounting PP 99A0263 14 9 1 Screw Int Board Shield Ground PP 99A0263 14 9 2 Screw Int Shield Mou
213. vel for software support 941 Controller Code CRC Replace the controller board 941 Controller Font CRC Replace the controller board 943 Controller Font Version 944 Controller Indicates that the controller code and FONT ROM are incompatible Replace the controller board Board Failure 945 Controller Board Failure ASIC Failure Replace the controller board 946 Controller Board Failure Replace the controller board SRAM Failure 947 Engine Replace the engine board Board 953 NVRAM Indicates the NVRAM Chip on the engine board has Failure failed Replace the engine board 954 NVRAM Indicates the NVRAM experienced a CRC failure Failure Replace the engine board 2 5 4059 Service Manual 4059 XXX Error Code Action 956 Configuration ID 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 The ID can be set via the NPA data stream or operator panel Note This error is not generated at POR to allow the servicer a method of resetting the configuration ID However setting the configuration ID is the only operation that the servicer can perform See Setting Configuration ID on page 3 20 960 RAM Memory Error Indicates a DR
214. 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 Restore EP Factory Defaults To restore each of the printer settings contained in the EP Setup menu to their factory default value select Restore from the menu To exit the menu without restoring the settings to the factory default values select Do Not Restore Sometimes this is used to help correct print quality problems Fuser Temperature This adjustment can be used to help solve some customer problems with paper curl on low grade papers and or problems with letter heads on some types of media The fuser temperature can be adjusted as follows NORMAL LOWER LOWEST Warm Up Time You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5 The factory sets the warm up at 0 or no warm up time This time period allows the backup roll to heat up and helps reduce curl in some environments Transfer The transfer can be adjusted as follows e LOW MEDIUM HIGH 3 21 4059 Service Manual 4059 XXX Print Contrast The print contrast setting controls the developer voltage offset The print contrast can be adjusted as follows LOW MEDIUM HIGH Charge Roll The charge roll can be adjusted as follows LOW MEDIUM HIGH Print Tests The purpose of the diagnos
215. when main drive motor running J12 6 5 V static 2 5 V dc when main drive motor running J12 7 5 V static 0 V dc when main drive motor running J12 8 5 V static 5 V dc when main drive motor running J12 11 5 V dc static 0 V dc when main drive motor running If the voltage is incorrect replace the FRUs in the following order main drive motor assembly engine board Operator Panel Service Check Operator Panel Buttons Service Check Note Before continuing with this service check do the Button Test 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 FRU Action Operator Panel Assembly If any button fails the Button Test replace the operator panel assembly Diagnostic Information 2 74 4059 XXX FRU Action IW Engine Board No buttons work Check the voltage at J11 5 The voltage measures approximately 5 V 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 Operator Panel Display Service Check SERVICE TIP The printer has detected a problem with the engine board operator panel cable or operator panel assembly if POS
216. x board Use caution to avoid damage to the cables and connectors Remove the four mounting screws from the left and right return guides and remove the guides Remove the four mounting screws on the right side of the duplex frame assembly Position the duplex assembly on its side Gently release the center drive deflector assembly latch from the bottom front left side of the duplex assembly Remove the center drive deflector assembly and the frame assembly from the duplexer Remove the two duplex motor mounting screws and remove the motor Note Pay attention to cable routing to avoid pinching or cutting wires during reassembly Ensure cables are securely placed into the cable retaining tabs Do the adjustment Duplex Motor Drive Belts on page 4 2 whenever you remove or replace the duplex motor Repair Information 4 22 4059 XXX Engine Board Remove the inner EMC shield Disconnect all cables from the engine board Remove the four engine board mounting screws A Remove the engine board cage mounting screw B from the main drive motor assembly 5 Remove the engine board Note Anytime the engine board is replaced the Configuration ID must be reset in NVRAM on the new engine board Go to Setting Configuration ID on page 3 20 a ce A 202 B 104 A 202 EP Frame Assembly 1 Remove the left and right side frames 2 Remove the EP frame assembly 4 23 4059 Service Manual 4059 XX
217. y o Lens Erase Lamp 12 5 99A0185 1 Shaft Transfer Pivot 12 6 99A0181 1 Spring Transfer Roll Left 12 7 99A0354 1 Arm Transfer Roll Left NS 1 Retainer Pivot Shaft PP 99A0267 Parts Catalog 7 33 4059 XXX Assembly 13 Charging 7 34 4059 Service Manual ma LE Units Description 13 1 99A0512 1 Link Assembly Charge Left Kit 13 2 99A0513 1 Link Assembly Charge Right Kit 13 3 99A1033 1 Roll Assembly Charge NS 1 Screw Charge Roll PP 99A0263 Parts Catalog 7 35 4059 XXX Assembly 14 Electronics 7 36 4059 Service Manual 4059 XXX e Ae Units Description 14 1 99A0900 1 Engine Board Assembly with laser cable 1250 1255 14 1 99A0901 1 Engine Board Assembly with laser cable 1620 1625 1650 14 1 99A0902 1 Engine Board Assembly with laser cable 1855 1855 01 14 1 99A0903 1 Engine Board Assembly with laser cable 2420 2450 2455 14 1 99A0946 1 Engine Board Assembly with jumpers 3455 14 2 1342514 1 Power Cord Set 8 ft U S Canada LV Nicaragua Venezuela Peru LV Bolivia Colombia Costa Rica Ecuador El Salvador Guatemala Honduras Mexico Panama 14 2 1339538 1 Europe 6 ft 14 2 1342536 1 Power Cord Set 6 ft Argentina HV Paraguay HV Uruguay HV APG LV 14 2 1342537 1 Power Cord Set 8 ft U K Ireland 14 2 1339539 1 Power Cord Set 6 ft Israel 14 2 1339540 1 Power Cord Set 6 ft Switzerland 14 2 1339541 1 Power Cord Set 6 ft So
218. y the paper arriving at the sensor too late the paper is jammed in the fuser assembly or is jammed exiting the fuser assembly in the redrive assembly or the exit sensor flag is not operating correctly Paper Jams Options Error Message 230 Paper Jam Check Duplex The paper is most likely jammed in the duplex unit however the paper can also be jammed in the redrive at the input to the duplex option The redrive assembly may not be correctly installed or locked in position or the duplex link is bent and not aligned properly to allow paper to feed correctly into the duplex option Error Message 24x x Tray 1 through 5 Paper Jam Check Tray x The paper has not cleared the pass through sensor or reached the pass through sensor of the option above tray x 3 29 4059 Service Manual 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 Error Message 27x Paper Jam Check Bin x Paper is jammed in output bin x X bin 1 thru 3 Generally this message appears when the paper has not cleared the exit sensor in time has jammed in the redrive assembly or has not fed into the output bin selected Diagnostic Aids 3 30 4059 XXX 4 Repair Informat

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