Lexmark 4059-XXX manual

4059-XXX Optra TM S Le xmark and Optra are trademarks of Le xmark Inter national, Inc., registered in the United States and/or other countries. • T able of Contents • Inde x • Safety and Notices • T rademarks • Star t Diagnostics[...]

Fi r s t E ditio n: September 2002 The follo wing paragraph does not apply to an y country where such pro visions are inconsistent with local law: LEXMARK INTERNA TIONAL, INC . PRO VIDES THIS PUBLICA TION “AS IS” WITHOUT W ARRANTY OF ANY KIND , EITHER EXPRESS OR IMPLIED , INCLUDING, BUT NO T LIMITED T O, THE IMPLIED W ARRANTIES OF MERCHANT ABIL[...]

Contents iii 4059-XXX Content s Notices and Safety Information ....................... i x L a s e rN o t i c e s ....................................... i x S a f e t yI n f o r m a t i o n .................................. x v i i Preface ............................................. x x i i General Information ..................................[...]

iv 4059 Ser vice Manual 4059-XXX S m a r tC a r t r i d g eS e r v i c eC h e c k ................... 2 - 1 0 2 S e r i a lP o r tS e r v i c eC h e c k ....................... 2 - 1 0 4 T o n e rS e n s o rS e r v i c eC h e c k ..................... 2 - 1 0 4 T r a n s f e rR o l lS e r v i c eC h e c k ..................... 2 - 1 0 5 Diagnostic [...]

Contents v 4059-XXX P r i n tT e s t s....................................... 3 - 2 2 P r i n tQ u a l i t yT e s tP a g e s .......................... 3 - 2 3 P r i n t i n gM e n uS e t t i n g sP a g e ...................... 3 - 2 4 A u t o c o m p e n s a t o rO p e r a t i o n ......................... 3 - 2 5 Autoconnect System, Paper Tray Op[...]

vi 4059 Ser vice Manual 4059-XXX Inner EMC Shield ............................... 4 - 3 5 Inner Paper Deflector Assembly ................... 4 - 3 6 Integrated Tray Compensator Assembly ............. 4 - 3 7 Integrated Tray Compensator Pick Roll Assembly ..... 4 - 3 8 Interconnect Board Assembly ..................... 4 - 3 9 L e f tS i d eF r a m e[...]

Contents vii 4059-XXX Parts Catalog ......................................... 7-1 H o wT oU s eT h i sP a r t sC a t a l o g ....................... 7 - 1 A s s e m b l y 1 :C o v e r s.............................. 7 - 2 A s s e m b l y 2 :F r a m e ............................... 7 - 6 Assembly 3: Printhead . .......................... 7 - 1 0 As[...]

ix 4059 Ser vice Manual 4059-XXX Notices and Safety Information Laser Notices The f ollowing laser notice labels ma y be affixed to this printer as shown: Laser Advisory Label[...]

Notices and Saf ety Inf or mation x 4059-XXX Class 1 Laser St atement Label APPAREIL À LASER DE CLASSE 1 CLASS 1 LASER PRODUCT LASER KLASSE 1 LUOKAN 1 LASERLAITE TO IEC 825[...]

xi 4059 Ser vice Manual 4059-XXX Laser Notice The printer is cer tified in the U .S. to conf or m to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 825. Class I laser products are not considered to be hazardous. The printer cont[...]

Notices and Saf ety Inf ormation xii 4059-XXX Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L ’impriman[...]

xiii 4059 Ser vice Manual 4059-XXX la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situación de ser vicio técnico . Declaração sobre Laser A impressora está cer tificada nos E.U .A. em conformidade com os requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a Classe I (1) de produtos laser[...]

Notices and Saf ety Inf orm ation xiv 4059-XXX Lasermeddelelse Printeren er godkendt som et Klasse I-laser produkt, i ov erenstemmelse med krav ene i IEC 825. Klasse I-laser produkter betragtes ikk e som f arlige. Printeren indeholder internt en Klasse IIIB (3b)-laser , der nominelt er en 5 milliwatt galliumarsenid laser , som arbejder på bø lgel[...]

xv 4059 Ser vice Manual 4059-XXX Laser produkter i Klass I anses ej hälso vådliga. Skrivaren har en inbyggd laser a v Klass IIIb (3b) som består a v en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770- 795 nanometer . Lasersystemet och skr iv aren är utformade så att det aldrig finns r isk för att någon per[...]

Notices and Saf ety Inf orm ation xvi 4059-XXX Jap anese Laser Notice Chinese Laser Notice[...]

xvii 4059 Ser vice Manual 4059-XXX Korean Laser Notice Safety Information • This product is designed, tested and approv ed to meet str ict global saf ety standards with the use of specific Le xmark components. The saf ety features of some par ts ma y not always be obvious . Le xmar k is not responsib le f or the use of other replacement par ts. ?[...]

Notices and Saf ety Inf ormation xviii 4059-XXX sécurité de cer tains éléments ne sont pas toujours évidentes. Le xmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. • Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. [...]

xix 4059 Ser vice Manual 4059-XXX F achpersonal sollte entsprechende V orsichtsmaßnahmen treff en. Paut as de Seguridad • Este producto se ha diseñado , v erificado y aprobado para cumplir los más estrictos estándares de segur idad global usando los componentes específicos de Le xmark. Puede que las características de seguridad de algunas p[...]

Notices and Saf ety Inf ormation xx 4059-XXX Informació de Seguret at • Aquest producte està disseny at, comprov at i aprovat per tal d'acomplir les estrictes nor mes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies [...]

xxi 4059 Ser vice Manual 4059-XXX Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of oz one gas.[...]

Pref ace xxii 4059-XXX Preface This manual is divided into the f ollowing chapters: • “General Inf or mation” contains a general description of the printer , options, and the maintenance approach used to repair it. General en vironmental and saf ety instructions as well as special tools and test equipment are listed in this chapter . • “D[...]

1-1 4059 Ser vice Manual 4059-XXX 1. General Information The Optra™ S Laser Printers are letter quality page pr inters designed to attach to IBM-compatible PC’ s and to most computer networks. The printer is av ailab le in ele v en models. Optra S Model 1250 (4059-121) 1255 (4059-125)[...]

General Inf or mation 1-2 4059-XXX Optra S Models 1620 (4059-162) 1625 (4059-165) 1650 (4059-160) 1855 (4059-185) 1855 (4059-C01)[...]

1-3 4059 Ser vice Manual 4059-XXX Optra S Models 2420 (4059-242) 2450 (4059-240) 2455 (4059-245) 3455 (4059-345)[...]

General Inf or mation 1-4 4059-XXX Options The f ollowing options are a vailab le. Some options are not a v ailab le in e v er y country . Contact your point of purchase f or options a v ailable in your country . Memor y options of 4MB , 8MB, 16MB and 32MB Flash memor y options of 4MB and 8MB Integrated netw ork options T oken-Ring Ethernet Tr i - [...]

1-5 4059 Ser vice Manual 4059-XXX Maintenance Appr oach The diagnostic inf ormation in this manual leads you to the correct field replaceable unit (FR U) or par t. Use the ser vice error codes, user status messages, user error messages, service checks , and diagnostic aids to determine the printer prob lem and repair the f ailure. After y ou comple[...]

General Inf or mation 1-6 4059-XXX Acr on yms CSU Customer Setup DRAM Dynamic Random Access Memor y EDO Enhanced Data Out EP Electrophotographic Process EPROM Erasab le, Prog rammab le Read-Only Memor y ESD Electrostatic Discharge FR U Field Replaceable Unit GB Giga Byte HVPS High V oltage P ow er Supply LASER Light Amplification by Stimulated Emis[...]

2-1 4059 Ser vice Manual 4059-XXX 2. Diagnostic Information St art CA UTION: Remov e pow er from the printer before y ou connect or disconnect any cab le or electronic board or assembly f or personal saf ety and to pre v ent damage to the printer . Use the hand grips on the side of the printer . Mak e sure your fingers are not under the printer whe[...]

Diagno stic Informa tion 2-2 4059-X XX Service Error Codes Ser vice E rror Codes a re generally non-recoverab le except in a n inter mittent c ondition when you can POR the printer to temporar ily recov er from th e error cond ition. Error Code Action 900 RIP Sof tware Con tact the n e xt s uppor t l e vel or c all Lexmar k. 901 Engin e Flash This [...]

2-3 4059 Ser vice Manual 4059-XXX 910 DC Pick Motor DC Pick Motor Stall Error Codes 910,911,912,913 and 914 are indications that a T ray 1 paper f eed problem has been detected. Go to the “Input T ray(s) Option Service Check” on page 2-58 . 911 DC Pick Motor Excessiv e PWM 912 DC pick motor below speed 913 DC pick m o t o ro v e rs p e e d 914 [...]

Diagnostic Inf ormation 2-4 4059-XXX 929 T oner Sensor The toner sensor is not operating properly , the dev eloper drive assemb ly is not operating properly or the print car tridge is defectiv e. Go to the “Remo v e P aper - Output B i nXi sd i s p l a y e d ,P O S TI n c o m p l e t e ,U n a b l et oc l e a rt h e message.” on page 2-84 . 930 [...]

2-5 4059 Ser vice Manual 4059-XXX 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 def ectiv e. Chec k each board for correct installation and secure g round. If no problem is f ound, replace the FRUs in the f ollo[...]

Diagnostic Inf ormation 2-6 4059-XXX 956 Configuration ID Indicates a problem with the Configuration ID . This error occurs because the engine receive d a configuration ID from the controller software which is not valid f or the le vel of engine code existing in the printer . Setting the configuration ID correctly should fix this error . The ID can[...]

2-7 4059 Ser vice Manual 4059-XXX 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 , env elope f eeder and duple x unit. The f ollowing is an e xample of how the printer displays a duple x unit sub error code. 982 <de vice> Comm Communic[...]

Diagnostic Inf ormation 2-8 4059-XXX Base Printer Sub Error Codes Each status byte has a diff erent lev el of troubleshooting value f or each area of the printer . The f ollowing table displa ys status bytes 1, 2 and 3. This set of status bytes is designed to help isolate paper jams and paper f eed problems in the base printer . Statu s Bytes 1, 2,[...]

2-9 4059 Ser vice Manual 4059-XXX 84 xx 0D P aper T ray 4 pass thru sensor is not activated and ne v er deactivated. A sheet of paper ma y still be over the sensor or the flag is still activated. 84 xx 0E P aper T ray 3 pass thr u sensor is not activated and ne ver deactivated. A sheet of paper ma y still be over the sensor or the flag is still act[...]

Diagnostic Inf ormation 2-10 4059-XXX Envelope Feeder Sub Error Codes Status byte 1 contains the most v aluab le inf or mation to help isolate a f eed problem with the en velope f eeder and is the only b yte contained in the f ollowing tab le. Duplex Unit Sub Error Codes Status byte 4 contains the most v aluab le inf or mation to help isolate a f a[...]

2-11 4059 Ser vice Manual 4059-XXX 04 The leading edge of the sheet of paper nev er arr iv ed 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 e xit sensor . 05 The duple x logic thinks a sheet of paper is f eeding to the duplex unit due to a sensor malfunction in the[...]

Diagnostic Inf ormation 2-12 4059-XXX User St atus Messages User St atus Message St atus Action Ready The printer is ready to receive and process data. Press Menu> or <Menu to tak e the printer out of Ready and enter all the Menus e xcept the TESTS MENU (Busy State). Ready/He x The printer is ready and HEX T race is active , which is known as[...]

2-13 4059 Ser vice Manual 4059-XXX Printing Menu Settings The printer is processing or printing a list of current settings menus because Print Menu Settings is selected from the menu. P r e s sS t o pt ot a k et h e printer out of Ready . The Not Ready message is displa yed. No more data is processed, but the printer processes all paper currently i[...]

Diagnostic Inf ormation 2-14 4059-XXX Restoring F actory Def aults The printer is restor ing f actor y def aults. No button actions are possible while this message is displa yed. P erforming Self T ests The printer is r unning the nor mal series of star t-up tests after it is powered On. When the tests are complete, the printer retur ns to Ready . [...]

2-15 4059 Ser vice Manual 4059-XXX Programming Disk (Do Not P ower Off) The disk is being programmed, which means f onts or macros a r eb e i n gw r i t t e nt od i s k . No button actions are possible while this message is displa yed. Note: If inf ormation is w r i t t e nt of l a s h memor y and to disk at t h es a m et i m e ,t h e Program Flash[...]

Diagnostic Inf ormation 2-16 4059-XXX User Error Messages User Error Message Explanation 200 P aper J am Remov e Car tr idge P aper is jammed at the printer Input Sensor. Open the printer’ s upper front door and remov e the print car tridge to access the paper jam area. 201 P aper J am Remov e Car tr idge P aper is jammed between the pr inter’ [...]

2-17 4059 Ser vice Manual 4059-XXX 31 Def ective Print Car tridge Error code 31 is display ed when the top front cov er is closed and a def ective print car tridge is detected. It ma y take the printer 10-20 seconds to determine if the pr int car tridge is def ective . Depending on the setting of the Machine Class ID the printer may be allo wed to [...]

Diagnostic Inf ormation 2-18 4059-XXX 36 Resolution Reduced The resolution of the page has been reduced from 600 dpi to 300 dpi in order to pre v ent a Memor y Full error . This message can only occur if the Resolution Reduction setting is tur ned on. Note : 1200 dpi pages are not resolution reduced. If a 1200 dpi job runs out of memor y , a Memor [...]

2-19 4059 Ser vice Manual 4059-XXX 56 Standard Serial Disabled This error is displa yed when data is sent to the printer across the standard ser ial port, but the por t has been disabled. 56 P arallel P or t Disab led This error is displa yed when data is sent to the printer across the parallel por t, but the parallel por t has been disab led. Once[...]

Diagnostic Inf ormation 2-20 4059-XXX User Line 2 Messages If none of the conditions e xist that are listed in the f ollowing tab le, line 2 is blank. If an y of the messages in the table are displa yed the f ollowing actions can be tak en: Press Menu> or <Menu to tak e the pr inter offline and access the Ready Menu group . Note: The Menu b u[...]

2-21 4059 Ser vice Manual 4059-XXX . User Message Explanation T oner Low If the toner car tridge is low , then “T oner Low” displa ys. The T oner Low condition clears whene ver the upper front door is opened, and T oner Low displays again if the condition e xists after the upper front door is closed. T ray X Missing If any of the input tr a ys [...]

Diagnostic Inf ormation 2-22 4059-XXX User Line 2 Link Messages If the printer is lock ed on a par ticular link, the link indication displa ys. If the printer is ready to process any link, none displa y . The link messages are listed in the f ollowing tab le. Check Device Connection Messages The messages in the f ollowing tab le displa y when the p[...]

2-23 4059 Ser vice Manual 4059-XXX The messages in the f ollowing tab le can occur in two w a ys. The specified de vice could hav e been removed from the printer , f or instance to clear a paper jam. Otherwise, the de vice can still be attached to the printer , b ut is e xperiencing a communications problem, not fully connected, or ha ving a hardw [...]

Diagnostic Inf ormation 2-24 4059-XXX Power-On Self T est (POST) When you turn the printer On, it performs a P ower-On Self T est. Check f or correct POST functioning of the base pr inter b y obser ving the f ollowing: 1. The LED comes on. 2. The operator panel displa ys one and a half row of pels, then clears. 3. Diamonds scroll across the displa [...]

2-25 4059 Ser vice Manual 4059-XXX Symptom T ables Symptom T able - B ase Printer Symptom Action A uxiliar y F an (2420/2450/2455/ 3455) f ails to run or is noisy . Go to the “A uxiliar y F an Ser vice Check” on page 2-47 . Dead Machine Go to the “Dead Machine Ser vice Check” on page 2-32 . Operator P anel - One or more buttons do not work.[...]

Diagnostic Inf ormation 2-26 4059-XXX Symptom T able - High Cap acity Feeder Option (2000 Sheet) 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 F eed Ser vice Check” on page 2-86 . Pri[...]

2-27 4059 Ser vice Manual 4059-XXX Symptom T able: Paper T ray Options Symptom T able - D uplex Symptom T able - Envelope Feeder Option Symptom Action P a per f eed problem with 250 Sheet P aper T ra y Option. Go to the “Input T ra y(s) Option Ser vice Chec k” on page 2-58 . P a per f eed problem with 500 Sheet P aper T ra y Option. Go to the ?[...]

Diagnostic Inf ormation 2-28 4059-XXX Symptom T able - O utput Exp ander Service Checks Note: Anytime the engine board is replaced, the Configuration I D must be reset in NVRAM on the ne w engine board. Go to “Setting Configuration ID” on page 3-20 . Re view the f ollowing inf ormation bef ore performing any service checks . • P aperfeed Prob[...]

2-29 4059 Ser vice Manual 4059-XXX Charge Roll Service Check Ser vice Tip: Close and e venly spaced repetitiv e marks 47.19 mm (1.86 inch) apar t or spots on the page can be caused by a damaged or contaminated charge roll. T o remov e the charge roll: 1. Wrap a piece of plain white paper around the charge roll to pre v ent contamination or damage. [...]

Diagnostic Inf ormation 2-30 4059-XXX 3 Right Side Charge Roll Link Check the right side charge roll link assembly f or 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 f or signs of wear or contamination. Excessiv e [...]

2-31 4059 Ser vice Manual 4059-XXX Cover Open Switch/Cable Service Check FRU Action 1 T oner Car tridge Chec k the toner car tridge to make sure it is correctly installed and that the right and left hand car tridge tracks are not loose or broken. Check to mak e sure the cov er open s witch activ ation tab on the toner car tridge is not broken and t[...]

Diagnostic Inf ormation 2-32 4059-XXX Dead Machine Service Check Note: Remov e any paper handling options before servicing the printer for a dead machine condition. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemb lies. Ser vice Tip: When removing the [...]

2-33 4059 Ser vice Manual 4059-XXX 5 +5 V dc at the engine board Te s t P o i n t Chec k f or +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 L VPS Fuse F1 Remov e the L VPS from the pr inter and check fuse F1. Replace the fuse if the fuse is blo wn. 7 L VPS Fuse F1 - Contin[...]

Diagnostic Inf ormation 2-34 4059-XXX 9 Engine Board T ur n the printer off and disconnect all the cables from the engine board. Check f or +5 V dc at the engine board test point. If incorrect, replace the FR Us in the f ollowing order : engine board interconnect board If correct, tur n the printer off and reconnect one cable at a time until you fi[...]

2-35 4059 Ser vice Manual 4059-XXX Duplex Option Service Check The printer does not recognize the Duplex Option is att ached. The printer does not recognize tray options below the duplex option are inst alled. FRU Action 1 F u s eF 1o nD u p l e xO p t i o n System Board If fuse F1 is blown, replace the fuse . If fuse F1 continues to b low , check [...]

Diagnostic Inf ormation 2-36 4059-XXX POST fails, 230 Paper Jam, Check Duplex message displays. FRU Action 1 Duplex D .C. Servo Drive Motor Check the D .C. servo motor cables f or signs of cuts or other damage. Check the D .C. servo motor sensor cable connector f or pin damage. If no problem is f ound, replace the FR Us in the f ollowing order: D. [...]

2-37 4059 Ser vice Manual 4059-XXX 230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way out of the redrive. FRU Action 1 Duple x Stepper Motor Check the stepper motor cable f or cuts or pinched wiring. Check the routing of the motor leads along the left side of the bottom tra y . Check f or correct install[...]

Diagnostic Inf ormation 2-38 4059-XXX POST fails with Close Duplex Rear Door displayed when Duplex Rear Door is closed. POST fails with Insert Duplex Front Cover message displayed. FRU Action 1R e a r D o o r S w i t c h (Not installed on some duple x units) Check the rear door f or correct installation and operation. Check to ensure the cable or c[...]

2-39 4059 Ser vice Manual 4059-XXX Envelope Feeder Option Service Check Ser vice Tip: Chec k the env elope feeder paper path f or any debris, pieces of env elope and so on. If any other options are installed make sure they are oper ating normally . If only the env elope f e eder is f ailing to operate correctly , continue with this ser vice chec k,[...]

Diagnostic Inf ormation 2-40 4059-XXX 3 Autoconnect on the Env elope Option Check the connector f or any signs of damage to the connector or contacts. If y ou find damage, replace the damaged cable/connector assembly . Disconnect the autoconnect cable at J1 on the env elope system board and measure the f ollowing v oltages: J1-3 measures +5 V dc J1[...]

2-41 4059 Ser vice Manual 4059-XXX Operator p anel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete. FRU Action 1 P ass through Sensor Chec k f or any debris, pieces of env elope and so on over the pass thru sensor . Check f or correct installation of the pass thru sensor flag. Make sure the sensor cab le is atta[...]

Diagnostic Inf ormation 2-42 4059-XXX Operator p anel 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 . Ser vice Tip: The kic k rolls rotate during the attempted feed cycles . FRU Action 1 Env elope O[...]

2-43 4059 Ser vice Manual 4059-XXX 990 Service Error , Envelopes fail to feed from the hopper . 260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper . Kick rolls ARE NOT rotating. FRU Action 1 D .C . Feed Motor Assembly Chec k the motor and motor cab le f or any signs of loose wires or poor connections. Check to mak e [...]

Diagnostic Inf ormation 2-44 4059-XXX 260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper . Kick rolls ARE rotating. Check the deflector gap adjustment bef ore continuing this ser vice check. FRU Action 1 Deflector Gap Adjustment Chec k the deflector gap adjustment. The adjustment may be too narrow . 2 Weight Assemb l[...]

2-45 4059 Ser vice Manual 4059-XXX 260 Paper Jam displays, envelope stops in feeder p aper path. Envelope Feeder multifeeds or may not display a 260 Paper Jam message. 260 Paper Jam displays. An envelope stopped in the p aper pa th of the feeder and an envelope also stopped in the base printer p aper pa th . FRU Action 1 Kick Rolls/F eed Rolls/Dr i[...]

Diagnostic Inf ormation 2-46 4059-XXX Erase Lamp Service Check Error code 928 ma y be displa yed when the printer detects that the erase lamp assemb ly , cable or engine board is defectiv e. Note: If the erase lamp assemb ly is def ectiv e, both the er ase lamp and lens are replaced as a kit. Make the f ollowing checks when a 928 service error disp[...]

2-47 4059 Ser vice Manual 4059-XXX Fan Service Check Auxiliary Fan Service Check The auxiliar y f an is in models 2420, 2450, 2455 and 3455. Fan does not run or is noisy . Main Fan Service Check Check the cab le connections at J1 on the engine board and at the main f an assembly . The main f an runs continuously when the printer is pow ered on unle[...]

Diagnostic Inf ormation 2-48 4059-XXX Fuser Service Check Cold Fuser Service Check Error codes 920, 921, and 922 ma y displa y for a cold fuser f ailure. A 920 error caused by lo w line v oltage can sometimes be cleared by turning the machine off and then on again. A 925 ser vice error indicates the wrong fuser lamp is installed in the printer and [...]

2-49 4059 Ser vice Manual 4059-XXX 2 Fuser Lamp Remov e the controller board. Run the Diagnostic Print T est and obser v e the lamp through the left side frame. If the lamp doesn’t come on, unplug the printer and check the continuity between the tw o pins on the fuser lamp cable going to the fuser assembly . If you do not measure continuity , rem[...]

Diagnostic Inf ormation 2-50 4059-XXX Hot Fuser Service Check Error codes 923 and 924 ma y displa y f or a hot fuser f ailure. CA UTION: The fuser may be hot, use caution bef ore removing or ser vicing. FRU Action 1 Fuser Cov er Assembly (Assembly includes Thermistor and Ther mal Fuses.) Check f or damage to the ther mistor assembly . Check the res[...]

2-51 4059 Ser vice Manual 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 W orld T rade printer model 2450. Ser vice Tip: T ry changing the env elope enhance le v el setting. A diff erent setting ma y correct the problem. Note: The le v el I fuser b[...]

Diagnostic Inf ormation 2-52 4059-XXX Configuration 1 A le v el 1 fuser board and le v el 1 engine board are installed in configuration 1. Note: Check the fuser en v elope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3 . FRU Action 1 Fuser Env elope Conditioner Solenoid The operati[...]

2-53 4059 Ser vice Manual 4059-XXX 3L V P S Interconnect Board If the +42 V dc test point does not measure appro ximately +42 V dc, check the contin uity of the cable connected between J3 on the fuser control and J1 on the interconnect board. If the cable does not measure continuity , replace t he cab le. If the cable measures continuity , check th[...]

Diagnostic Inf ormation 2-54 4059-XXX Configuration 2 A le v el I fuser board and le v el II engine board are installed in configuration 2. Note: Check the fuser en v elope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3 . FRU Action 1 Engine Board Jumpers Chec k to make sure a jump[...]

2-55 4059 Ser vice Manual 4059-XXX 4 L VPS Interconnect Board Env elope Conditioner Cable Check the +42 V dc test point on the fuser control board. If the voltage is incorrect, check the contin uity of the env elope conditioner c ab le. If the cable does not measure contin uity , replace the cable . If the cable measures continuity , check the volt[...]

Diagnostic Inf ormation 2-56 4059-XXX Configuration 3 A le v el II fuser board and le v el II engine board without the solenoid cable is installed in configuration 3. Note: Check the fuser en v elope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3 . FRU Action 1 Engine Board Jumpers[...]

2-57 4059 Ser vice Manual 4059-XXX Input Sensor Service Check Ser vice Tip: Run the base sensor test. Chec k the input sensor f or proper operation. The displa y changes from open to closed as the sensor flag is manually mov ed in and out of the sensor . Ser vice Tip: Run a Diagnostic Print T est in the continuous mode with the controller board rem[...]

Diagnostic Inf ormation 2-58 4059-XXX Input T ray(s) Option Service Check 250 Sheet, 500 Sheet and 500/500 Sheet Input T ray Option Ser vice Tip: T ry all the other input paper sources to mak e sure the y are properly feeding paper . F or 990 Error Code- Ser vice T ra y X, X= displa ys the number of the tra y that has a problem or needs ser vice. F[...]

2-59 4059 Ser vice Manual 4059-XXX 24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor . (The printer displays the value of X for the p aper tray where the error occurs. Example: 241 is a Paper Jam T ray 1) FRU Action 1 P ass Thru Sensor and Flag Assembly The tr a y x option system board did not detect a piece of paper actuating [...]

Diagnostic Inf ormation 2-60 4059-XXX T ray X Low message displays when T ray X is full or has adequate p aper in the tray . T ray X Empty message displays when T ray X has paper in the tray . FRU Action 1 P aper Low Sensor Assembly P aper Low Sensor Flag Tr a y X O p t i o n S y s t e m Board Run the T ray X Sensor T est and check the sensor f or [...]

2-61 4059 Ser vice Manual 4059-XXX Printer does not recognize T ray X is installed. Paper from T ray X does not reach the Pass Thru Sensor . Ser vice Tip: Chec k the media in tra y x to make sure it is within specifications. Some types of labels, f oil mater ial and slic k papers can cause misf eeds and slippage of the rollers. High Cap acity Feede[...]

Diagnostic Inf ormation 2-62 4059-XXX The base printer does not recognize that the high cap acity input tray is installed. FRU Action 1 High Capacity Feeder A utoconnect Mechanical Check Check the high capacity f eeder input tra y autoconnect to make sure it is mounted correctly and is not pushed down into the frame assemb ly or damaged. Be sure th[...]

2-63 4059 Ser vice Manual 4059-XXX 5 High Capacity F eeder Option Control Board Check the voltage on J8-1 (green). The voltage measures +24 V dc. If incorrect, check the autoconnect system f or any prob lems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity f eeder to be recogn[...]

Diagnostic Inf ormation 2-64 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 T ray 2) FRU Action 1 P ass Thru Sensor and Flag Assembly The tr a y x option system board did not detect a piece of paper actuat[...]

2-65 4059 Ser vice Manual 4059-XXX T ray X Paper Low Message displays when T ray X is full or has adequate Paper in the tray . T ray X empty message displays when there is paper in the high cap acity feeder input tray . T ray X Empty Message displays when T ray X has paper in the tray . FRU Action 1 P aper Low Switch P aper Low Switch Cab l e High [...]

Diagnostic Inf ormation 2-66 4059-XXX The elevator tray fails to stop at the correct position and continues to drive into the bottom frame. The elevator tray down button does not operate. The tray moves to the upper position. Ser vice Tip: Open the high capacity f eeder option front door and check the b lack rubber bumper attached to the door s wit[...]

2-67 4059 Ser vice Manual 4059-XXX Paper from the high cap acity feeder input tray does not reach the p ass thru sensor . Ser vice Tip: Chec k to be sure the paper in tra y is within specifications. FRU Action 1 A utocompensator Assembly Chec k the autocompensator pick arm rollers for sign of glazing, toner or other buildup . Replace as necessar y [...]

Diagnostic Inf ormation 2-68 4059-XXX The elevator tray does not move up or down. The printer recognizes that the option is inst alled. FRU Action 1 Stepper Motor High Capacity Feeder Option Control Board Stepper Motor Extension Cable Be sure the motor cable is correctly installed at J1 on the high capacity f eeder system board. Be sure the motor e[...]

2-69 4059 Ser vice Manual 4059-XXX The elevator moves in one direction only . FRU Action 1 Stepper Motor High Capacity F eeder Option Control Board Check the v oltages at J1 on the high capacity system board. The voltage measures as f ollows: static (motor connected) J1-1 (Orange) +24 V dc J1-2 (Y ellow) +24 V dc J1-3 (Green) +24 V dc J1-4 (White) [...]

Diagnostic Inf ormation 2-70 4059-XXX Paper size switch not selecting paper size that is selected. 24X Paper Jam Check T ray X Message displays when T ray X is empty . No T ray X M essage displays. FRU Action 1 P aper Size Switch High Capacity Feeder Option Control Board Check f or continuity between the common pin (J5-1) and the pin of the paper s[...]

2-71 4059 Ser vice Manual 4059-XXX T ray X Empty message displays. T ray does not respond to loading p aper . No response from the front door switch. T ray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate p aper in the tray . FRU Action 1 High Capacity F eeder Option Control Board Check the voltage on th[...]

Diagnostic Inf ormation 2-72 4059-XXX Excessive Noise or Vibration FRU Action 1 Motor Plate Assembly Be sure the motor plate assemb ly s c r e w sa r et i g h t .B es u r et h em o t o r mounting screws are tight. 2 Motor Dr iv e Belt Check the belt to be sure it is not too t i g h t .T h em o t o rc a nb ea d j u s t e d while the motor is running[...]

2-73 4059 Ser vice Manual 4059-XXX Main Drive Service Check Ser vice Tip: Excessiv e gear or main dr iv e assembly noise is usually caused by a def ective motor assemb ly or engine board. Ser vice 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 . CA [...]

Diagnostic Inf ormation 2-74 4059-XXX Operator Panel Service Check Operator Panel Buttons Service Check Note: Bef ore continuing with this service check do the “Button T est” on page 3-9 in the diagnostic aids chapter . The operator panel cab le is a individual cable on some printers and a combination cable assembly with the co v er s witch cab[...]

2-75 4059 Ser vice Manual 4059-XXX Operator Panel Display Service Check SER VICE TIP: The pr inter has detected a prob lem with the engine board, operator panel cab le or operator panel assemb ly if POST does not complete and the printer emits 5 beeps and stops in a continuous pattern until the pr inter is turned off. The operator panel cable is a [...]

Diagnostic Inf ormation 2-76 4059-XXX Options Service Check Ser vice Tip: When y ou hav e 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), s witch the non operating option to one of the other option slots to isolate the f ailure. Flash Memory Option(s) Run a c[...]

2-77 4059 Ser vice Manual 4059-XXX Hard Disk Option Ser vice Tip: The Optra S printers suppor t one hard disk option. Check to mak e sure only one hard disk option is installed. • 1.4 GB - 1250/1620/1650/2420/2450 • 2.1 GB - 1255/1625/1855/2455/3455 Check to mak e sure the fix ed disk and the fixed disk board are correctly installed. Run the ?[...]

Diagnostic Inf ormation 2-78 4059-XXX Output Bin Sensor St andard T ray Service Check Ser vice Tip: If the output bin standard tr a y fills up and the bin full sensor f ails to post the message "Remov e Paper Standard Bin", enter the Diagnostic Mode, select Output Bin T ests, select Sensor T ests and select Standard Bin. Check the sensor [...]

2-79 4059 Ser vice Manual 4059-XXX Output Exp ander Service Check There are two le v els of the 500 Sheet Output Expander Option. • Le v el 1 is equipped with a stepper motor/mechanical linkage assembly . • Le v el 2 is equipped with a DC ser v o motor and a ne w mechanical linkage assembly and has f ewer mechanical components. Ser vice Tip: Th[...]

Diagnostic Inf ormation 2-80 4059-XXX FRU Action 1 Output Expander Option Make sure the output e xpander option is the only option that is not recognized b y the base printer . If the output e xpander is the only option not recognized b y the printer , continue with step 2. If not, check the autoconnects of the options not recognized and the interc[...]

2-81 4059 Ser vice Manual 4059-XXX 202 Paper Jam Open Rear Door Message displays. A sheet of p aper is jammed prior to the p ass through sensor flag. 202 Paper Jam Open Rear Door Message displays. A sheet of p aper feeds out to the st andard bin even though bin x is selected. Paper exit s half way out of the redrive. Ser vice Tip: F or this type of[...]

Diagnostic Inf ormation 2-82 4059-XXX 3 Stepper Motor Le vel 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 - Le vel 1 Stepper Motor” on page 5-22 . If correct, disconnect J4 from the option board and check the resistance of the stepper moto[...]

2-83 4059 Ser vice Manual 4059-XXX 4 Output Expander Control Board Le vel 1 Check the v oltages at connector J4. Go to “Output Expander Control Board - Le vel 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 P aper J4-1 Appro xima[...]

Diagnostic Inf ormation 2-84 4059-XXX Remove Paper - Output Bin X is displayed, POST Incomplete, Unable to clear the message. 271 Paper Jam - Check Bin X. POST Incomplete 271 Paper Jam - Check Bin X, POST Complete, First Sheet of paper feeds into Output Bin X. Note: Bef ore perf orming the follo wing checks run the Output Bin X Sensor T est and che[...]

2-85 4059 Ser vice Manual 4059-XXX 990 Service - BIN X FRU Action 1D . C . M o t o r Mechanical Linkage Assembly (Le vel 2) Check the DC motor cab le connector to be sure it is correctly installed at J4 on the output e xpander option board. Go to “Output Expander Control Board - Le vel 2 DC Motor” on page 5-24 . If correct, disconnect J4 from t[...]

Diagnostic Inf ormation 2-86 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 displa yed on models that suppor t an Output Expander that has a Dual Sensor installed. Paper Feed Service Check If you ha ve a 936 T ransport Motor Error go to the “Main Drive Ser vice Chec[...]

2-87 4059 Ser vice Manual 4059-XXX Autocompensator fails to feed paper . Failures occur randomly throughout the st ack of p aper . Paper feed failures occur only near the top of the stack of p aper . The most common cause of this problem is paper curl. Remov e the paper from tra y x and check f or the natural curvature in the paper . Reinstall the [...]

Diagnostic Inf ormation 2-88 4059-XXX Double Feeding Paper Note: If double f eeding paper occurs mostly from the bottom of the stack, chec k for missing or damaged restraint pads in the tr a y . Multipurpose T ray Paper fails to feed from the multipurpose tray . The pick roll should mak e one complete rev olution and stop with the flat side down. I[...]

2-89 4059 Ser vice Manual 4059-XXX Parallel Port Service Check Run the “P arallel Wrap T est” on page 3-11 . Note: The P arallel Wrap T est is designed to check the parallel port hardware b y using a wrap plug (P/N 1319128) and in v oking the P arallel Diagnostic T est. This test helps isolate the printer from the parallel cab le and host. The [...]

Diagnostic Inf ormation 2-90 4059-XXX 2 Error Code 934 Mirror Motor Lost Lock Error Code 935 Mirror Motor unable to reach operating speed These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the engine board cable or engine board assembly . Check the continuity of the mirror motor[...]

2-91 4059 Ser vice Manual 4059-XXX Print Quality Service Check Ser vice Tip: Bef ore troubleshooting any print quality problems do the f ollowing: • Install another print car tri dge if a v ailab le bef ore proceeding with the ser vice chec ks. • Use T ra y 1 to test f or pr int quality of the base printer . Select the f ollowing men u settings[...]

Diagnostic Inf ormation 2-92 4059-XXX Print Quality - All Black Page Ser vice Tip: An all b lack page is gener ally caused by a prob lem in the high voltage system or an incorrect high v oltage in the pr inting process resulting in toner de v elopment on the entire photoconductor drum. Print Quality - Blank Page FRU Action 1 High V oltage Contacts [...]

2-93 4059 Ser vice Manual 4059-XXX 2 High V oltage Contact Check the PC drum contact on the right side frame for damage , PC drum contact wear or contamination. If the contact is bent or damaged, replace the contact. Note: Inspect the HVPS PC drum contact on the board f or any signs of damage or contamination. 3 HVPS Check the fuse on the HVPS . If[...]

Diagnostic Inf ormation 2-94 4059-XXX Print Quality - Random Marks Ser vice Tip: The primar y cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor , charge roll or transfer roll. Print Quality - Blurred or Fuzzy Print Blurred of fuzzy print is usually caused by a problem in the main dri[...]

2-95 4059 Ser vice Manual 4059-XXX Print Quality - Evenly spaced horizont al lines or marks FRU Action 1 Lines spaced 3.19 mm (.126 inch) apar t T h i sc a nb ec a u s e db yt h em o t o r pinion gear on the main drive motor . Replace the main drive motor . 2 Lines spaced 22.32 mm (.882 inch) apar t Lines spaced 28.7 mm (1.130 inch) apar t Lines sp[...]

Diagnostic Inf ormation 2-96 4059-XXX Print Quality - Background Ser vice Tip: Some bac kground prob lems can be caused by rough papers or non-Lexmark toner car tridges. If the rough paper mode is on, turn it off and run the print test. Some slick or coated papers ma y also cause background. Some problems occur with printers that run a large amount[...]

2-97 4059 Ser vice Manual 4059-XXX FRU Action 1 Erase Lamp/Lens Assembly Chec k the erase lamp lens f or any signs of toner , paper dust or other types of contamination. Clean the lens with a soft dry cloth if necessar y . If unable to clean the contamination off the lens, replace the lens and lamp assembly . Check the erase lamp assembly . Use the[...]

Diagnostic Inf ormation 2-98 4059-XXX 5E n g i n e B o a r d H V P S Connector Check the f ollowing voltages at J10 on the engine board. Measure the voltages from J10 to printer ground. Printer Idle J10-1 appro ximately 0 V dc J10-2 appro ximately 4 V dc J10-4 appro ximately 0 V dc Printer Pr inting J10-1 varies 0 V dc to +5 V dc J10-2 varies 0 V d[...]

2-99 4059 Ser vice Manual 4059-XXX Print Quality - Banding Ser vice Tip: Banding is difficult to detect e xcept on a page with a unif orm gra y or a large amount of gr aphics printed on the page. Banding is primar ily due to a v ariation in the speed of the paper as it f eeds thru the pr inter , especially in the de v elopment and transf er process[...]

Diagnostic Inf ormation 2-100 4059-XXX Print Quality - Residual Image Ser vice Tip: Install a ne w print car tridge if av ailable bef ore doing this ser vice chec k. Residual image can be caused by the photoconductor , cleaning blade and other par ts inside the print car tridge. Residual image on model 3455 can also be caused b y the charge brush c[...]

2-101 4059 Ser vice Manual 4059-XXX Print Quality - Light Print FRU Action 1 Erase Lamp Assembly Check the erase lamp lens assemb ly f or any signs of paper dust, toner buildup or an y other contamination. C l e a nw i t has o f tc l o t ho rr e p l a c et h e lens and lamp assembly which are provided together in a kit. If the lens is clean then ch[...]

Diagnostic Inf ormation 2-102 4059-XXX Print Quality - T oner on backside of printed p age Ser vice Tip: This is generally caused b y loose toner in the machine in the paper path being carried through the pr inter on the bac kside of the paper . Smart Cartridge Service Check Note: If you are unab le to clear a “32-Unsuppor ted Car tridge” User [...]

2-103 4059 Ser vice Manual 4059-XXX Ser vice Tip: An intermittent “32-Unsuppor ted Car tr idge” User Error Message can be caused by poor contact between the smart car tridge contacts in the upper front cov er and the smar t chip . Also check f or proper seating of the smar t car tr idge cab le to the engine board. FRU Action 1 S m art C art ri [...]

Diagnostic Inf ormation 2-104 4059-XXX Serial Port Service Check Run the “Serial Wrap T est” on page 3-12 . Note: The Serial Wrap T est is designed to check the serial por t hardware b y using a wrap plug (P/N 1329048) and in v oking the Serial P ost Diagnostic T est. The test helps isolate the printer from the serial cable and host. The test p[...]

2-105 4059 Ser vice Manual 4059-XXX T ransfer Roll Service Check Ser vice Tip: The transf er roll is 17.0 mm (.669 inch) diameter . Any print quality problems such as lines that are spaced 17 mm apar t indicate you should chec k the transf er roll for damage , toner or f oreign material buildup . Ser vice Tip: The transf er roll assembly is par t o[...]

Diagnostic Inf ormation 2-106 4059-XXX 2 Left T ransfer Arm Assembly Chec k the left transf er roll ar m assembly to mak e sure it is f astened and lock ed in the down position. If t h ea r mi sn o tl o c k e dd o w n ,c h e c kt o ensure the ar m is not brok en and will lock into the EP fr ame correctly . Check the left transf er ar m assembly spr[...]

3-1 4059 Ser vice Manual 4059-XXX 3. Diagnostic Aids This chapter e xplains the tests and procedures to identify printer f ailures and verify repairs ha v e corrected the problem. T o run the pr inter diagnostic tests described in this chapter , you must put the printer in Diagnostic Mode. Diagnostic Mode T o enter the Diagnostic Mode: 1. T ur n th[...]

Diagnostic Aids 3-2 4059-XXX Device T ests Quick Disk T est This test performs a non-destructive read/write on one bloc k per trac k on the disk. The test reads one bloc k o n each tr ack, sa v es the data, and proceeds to write and read four test patterns to the bytes in the bloc k. If the block is good, the sa ved data is written back to the disk[...]

3-3 4059 Ser vice Manual 4059-XXX – “xxxx Bad Bloc k s/yyyyyy Usab le” message displa ys if f e wer than 2000 bad bloc ks are detected. xxxx indicates the number of bad b locks and yyyyyy indicates the n umber of usable b loc ks. – “xxxx Bad B loc ks/Replace Disk” message displa ys if more than 2000 bad bloc ks are detected. The disk ca[...]

Diagnostic Aids 3-4 4059-XXX 3. T ur n the printer On and release the buttons once “P erf or ming Self T est” displays . – Once the printer is idle, the emulation can be do wnloaded again. 4. Program the do wnload emulation into the code ov erlay SIMM again. 5. If these steps do not resolv e the problem, replace the code ov er la y SIMM and d[...]

3-5 4059 Ser vice Manual 4059-XXX 1/100 inch. A positiv e offset mov es the text down the page and widens the top margin while a negative offset mo ves the te xt up the page and narrows the top margin. 3. Press Retur n/Stop to e xit the test. Check the T op Margin Offset of the base printer . Duplex Sensor T est This test is used to deter mine whet[...]

Diagnostic Aids 3-6 4059-XXX The f ollowing appears on the printer displa y: DUPLEX MO TOR AA BB CC DD EE FF T o pass the test the f ollowing results must displa y: AA = 00 BB = in the range of 20 through 3F inclusiv ely (he x) CC = in the range of 3A through 5D inclusiv ely (he x) DD = in the range of 11 through 1F inclusiv ely (he x) Ignore bytes[...]

3-7 4059 Ser vice Manual 4059-XXX Duplex Feed 1 T est This test f eeds a blank sheet of paper to the duple x paper stop position 1. T o run the Duplex F eed 1 T est: 1. Select Duple x F eed 1 from the Duple x T est menu. – The power indicator blinks while the paper is f eeding. – "Duplex F eed 1/F eeding" message displa ys while the p[...]

Diagnostic Aids 3-8 4059-XXX Error Log Viewing the Error Log The error log is helpful to the ser vicer b y providing a history of printer errors. The error log contains the 12 most recent errors that hav e occurred on the pr inter . The most recent error displa ys in position 1 and the oldest error displa ys in position 12 (if 12 errors hav e occur[...]

3-9 4059 Ser vice Manual 4059-XXX Hardware T ests The f ollowing Hardw are T ests can be selected from this menu: LCD T est Button T est DRAM Memor y T est ROM Memory T est P arallel Wrap (if av ailable) Serial Wrap (if av ailable) S e r i a l1W r a p( i fa v a i l a b l e ) S e r i a l3W r a p( i fa v a i l a b l e ) LCD T est T o run the LCD T es[...]

Diagnostic Aids 3-10 4059-XXX DRAM Memory T est The pur pose of this test is to chec k the v alidity of DRAM, both standard and optional. The test writes patter ns of data to DRAM to v erify that each bit in memor y can be set and read correctly . T o run the DRAM Memor y T est: 1. Select DRAM Memor y T est from the menu. – The pow er indicator b[...]

3-11 4059 Ser vice Manual 4059-XXX Each time the test finishes, the screen updates with the result. If the test passes, the P ass Count increases by 1, ho we ver if the test f ails, one of the f ollowing m essages displa ys f or appro ximately 3 seconds: ROM Chec ksum Error ROM Burst Read Error Once the maximum pass count or f ail count is reached,[...]

Diagnostic Aids 3-12 4059-XXX DMA Interrupt Error DMA Memor y Error DMA Backg round Error Clear Init Rise Error F alse Init Rise Error A utof eed Rising Interrupt Error Clear A utof eed Rise Error F alse Autof eed Rise Error A utof eed F alling Interrupt Error Clear A utof eed F all Error Once the maximum count is reached the test stops. The po wer[...]

3-13 4059 Ser vice Manual 4059-XXX Each time the test finishes, the screen updates with the result. If the test passes, the P ass Count increases by 1, ho we ver if the test f ails, one of the f ollowing f ailure messages displays f or appro ximately 3 seconds and the F ail Count increases by 1: Receive Status Interrupt Error Status Error Receive D[...]

Diagnostic Aids 3-14 4059-XXX Input T ray T est s Input T ray Feed T est This test lets the ser vicer observe the paper path as media is f eeding through the printer . A blank sheet of paper f eeds through the printer as the laser tur ns off during this test. The only wa y to obser ve the paper path is to open the lower front door that is used to a[...]

3-15 4059 Ser vice Manual 4059-XXX The multipurpose tray and the en v elope f eeder do not hav e a paper low sensor . The multipurpose tra y does not hav e a pass thr u sensor . O u t p u tB i nT e s t-S t a n d a r dB i n This test is used to verify if the standard bin sensor is working correctly . T o run the Standard Bin Sensor T est: 1. Select [...]

Diagnostic Aids 3-16 4059-XXX Output Bin Sensor T est This test is used to verify if the output bin sensors are working correctly . T o run the Output Bin Sensor T est: 1. Select Sensor T est from the Output Bin T est menu. – "Output Bin/Full=OP/Input=OP" message displa ys. – Full = Output Bins Full Sensor – P ass = Output Bins Pass[...]

3-17 4059 Ser vice Manual 4059-XXX Output Exp ander with Dual Sensor: The f ollowing is displa yed: Output Bin X P=OP F=OP NF=CL P = P ass Thr u Sensor F = BIN FULL Sensor (lower part of dual sensor) NF = Near Full Sensor (upper par t of dual sensor) Once the message displays , the ser vicer can manually actuate each of the output bin sensors. The [...]

Diagnostic Aids 3-18 4059-XXX Print Registration The print registration range is as f ollows: Bottom Margin: -20 to +20 T op Margin: -25 to +25 Left Margin: -25 to +25 Right Margin: -10 to +10 T o set Print Registration: 1. Select Registration from the Diagnostic menu. 2. The T op margin sign/value pair b links. This indicates it is the margin v al[...]

3-19 4059 Ser vice Manual 4059-XXX Printer Setup Setting the Page Count This lets the ser vicer change the page count from the diagnostic menu. This is used whene ver the engine board is replaced because this board contains the printer's NVRAM Memor y where the page count is stored. T o set the P age Count: 1. Select P age Count from the diagn[...]

Diagnostic Aids 3-20 4059-XXX Maintenance Page Count (2420/2450/2455/3455) This counter is reset by the servicer after a “80 Scheduled Maintenance” message displa ys (250K copies) and a maintenance kit is installed. T o view the Maintenance P age Count: 1. Select Maintenance Count V alue from the diagnostic men u. 2. Press Retur n to go to the [...]

3-21 4059 Ser vice Manual 4059-XXX ID" message displa ys on Line 2 bef ore the ID redispla ys. Y ou hav e to reenter the Configuration ID until a valid ID is verified. If the ID is v alid then the ID is sav ed in NVRAM and the pr inter automatically PORs to activate the ne w setting. Note: When the printer PORs it does so in the nor mal mode. [...]

Diagnostic Aids 3-22 4059-XXX Print Contrast The print contrast setting controls the dev eloper voltage offset. The print contrast can be adjusted as follo ws: • LO W • MEDIUM • HIGH Charge Roll The charge roll can be adjusted as follo ws: • LO W • MEDIUM • HIGH Print T ests The pur pose of the diagnostic Print T ests is to verify that [...]

3-23 4059 Ser vice Manual 4059-XXX The contents of the Print T est Page v ar ies depending on the media installed in the selected input source. Note: The Print T est Page alw ays prints on one side of the paper , regardless of the duple x setting or the presence of a duple x option. T o run the Pr int T est P age: 1. Select Print T ests from the D [...]

Diagnostic Aids 3-24 4059-XXX The f ollowing is printed on page 1. • Diagnostic EP Setup: – fuser temperature , warm up time, transf er , pr int contr ast and charge roll settings. • Contents of the Diagnostic Error Log. • Printer configuration information: – printer ser ial number , controller code lev el, engine code le v el, operator p[...]

3-25 4059 Ser vice Manual 4059-XXX Autocompensator Operation The autocompensator is a paper pick de vice that generates its own norm al f orce. This f orce generation is inherent in the fundamental design of the pick arm. If light media is used, it picks v er y gently . If a heavy media is used, it pic ks v er y aggressiv ely . No customer adjustme[...]

Diagnostic Aids 3-26 4059-XXX P oor gear efficiency can cause the ar m to generate higher normal f orces. If the pic k assembly is noisy , replacement may be required. The ar m must piv ot freely through its full range of motion. On 500 sheet tra ys there are wrap spr ings located on the piv ot arbors of the arm. These spr ings aid to pre vent the [...]

3-27 4059 Ser vice Manual 4059-XXX Duplex Option The duple x option interf ace is a six pin autoconnector that provides a +24 V dc, +24 V dc return, ser ial interf ace transmit signal, ser ial interf ace receiv e signal and two ground pins . The duple x option receiv es the +24 V dc from the base printer for the duple x motors and also conv er ts t[...]

Diagnostic Aids 3-28 4059-XXX the hot roll increases. The thermistor resistance changes from appro ximately 150K ohms to appro ximately 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[...]

3-29 4059 Ser vice Manual 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 o v er the sensor or paper[...]

Diagnostic Aids 3-30 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 env elope is jammed in the envelope f eeder or has not reached the base mac[...]

4-1 4059 Ser vice Manual 4059-XXX 4. Rep air Information W ARNING: Read the f ollowing bef ore handling electronic par ts. Handling ESD-Sensitive Part s Many electronic products use parts that are known to be sensitive t o electrostatic discharge (ESD). T o pre vent damage to ESD-sensitiv e par ts, f ollow the instructions below in addition to all [...]

Repair Inf ormation 4-2 4059-XXX Adjustment Procedures Duplex Motor Drive Belt s Do the duple x motor belt and drive belt adjustment whene v er you remov e or replace the duplex motor or loosen the motor or drive belt idler pulley . Ser vice Tip: Excessiv e belt tension can result in stalling the duple x motor . T oo little belt tension can result [...]

4-3 4059 Ser vice Manual 4059-XXX Fuser Solenoid Adjustment P erform the fuser solenoid adjustment whenev er 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 armat[...]

Repair Inf ormation 4-4 4059-XXX Printhead Assembly Adjustment Do the printhead assembly adjustment whene v er y ou remov e or replace the printhead assembly or loosen the mounting screws . Install the new printhead with the three mounting scre ws centered in the slots in the printhead frame assembly . Leav e the scre ws loose enough to allow the p[...]

4-5 4059 Ser vice Manual 4059-XXX Paper Alignment Assembly Adjustment Do the alignment assembly adjustment whene ver y ou replace the alignment assembly . Alwa ys pr int a cop y of the Quick T est Page bef ore making any adjustments to the alignment assemb ly ref erence adjustment screw . When replacing the alignment assembly , it is necessar y to [...]

Repair Inf ormation 4-6 4059-XXX b . Pr int a cop y of the Quic k T est P age 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 ref erence screw can be adjusted without loosening the lockn ut. T urn the screw a f e w turns and pr int a cop y [...]

4-7 4059 Ser vice Manual 4059-XXX Screw Identification T able The f ollowing tab le contains scre w types, locations , and quantities necessar y to service the pr inter . Each screw callout in the remo v al procedure graphic displa ys the screw ref erence number listed in the table . P ay careful attention to each scre w type location when doing re[...]

Repair Inf ormation 4-8 4059-XXX M3.5x8 mm Thread Cutting spring mounting 1 controller board mounting (front) 2 integrated tra y ITC board mounting 2 left side cov er mounting 5 stack e r support to r ight side frame attach 2 M3.5x12 mm Thread Cutting engine board shield to left frame attach 1 paper alignment assembly mounting 2 toner car tridge gu[...]

4-9 4059 Ser vice Manual 4059-XXX M3x6 mm Ta p t i t e outer shield mounting 6 inner redrive deflector mounting 2 interconnect board to center pan mounting 2 engine board (bottom holes) mounting 2 controller board to interconnect board ground attach 2 controller board to inner shield mounting 2 fuser ground wire mounting 1 controller board (back) m[...]

Repair Inf ormation 4-10 4059-XXX M3x8 mm T aptite L VPS mounting 2 auto compensator hanger brac ket mounting 1 M3x12 mm T aptite HVPS board mounting 1 M3x28 mm T aptite dev eloper drive ground (bottom hole) attach 1 M3.5x8 mm Plastite Thread Fo r mi n g upper front cov er mounting 5 left side cov er mounting 3 autocompensator mounting 3 Reference [...]

4-11 4059 Ser vice Manual 4059-XXX M3.5x10 mm Plastite Thread Fo r mi n g right side cov er mounting 3 left side cov er mounting 3 left side frame to pan attach 1 M3.5x12 mm Plastite Thread Fo r mi n g left side cov er mounting 1 M3x6 mm SEMS Machine Screw with was her fuser board mounting 1 M3.5x12 mm Plastite Thread F orming with was her printhea[...]

Repair Inf ormation 4-12 4059-XXX Removal Procedures CA UTION: Remov e pow er from the printer before y ou connect or disconnect any cab le or electronic board or assembly f or personal saf ety and to pre v ent 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 s[...]

4-13 4059 Ser vice Manual 4059-XXX Left Cover 1. Remov e the left door . 2. Remov e the five mounting scre ws (A).[...]

Repair Inf ormation 4-14 4059-XXX 3. Raise the upper front cov er . 4. Remov e the three mounting screws (B), the print car tr idge and remov e the left cover .[...]

4-15 4059 Ser vice Manual 4059-XXX Right Cover 1. Raise the upper front cov er . 2. Release the cov er latch (A) and remov e the r ight cov er mounting screw (B).[...]

Repair Inf ormation 4-16 4059-XXX 3. Remov e the r edrive assemb ly . 4. Remov e the r ight side cov er mounting screws (B) and (C). 5. Remov e the r ight side cov er .[...]

4-17 4059 Ser vice Manual 4059-XXX Upper Front Cover 1. Raise the upper front cov er . 2. Remov e the five upper front cov er mounting screws (A) and remov e the cover .[...]

Repair Inf ormation 4-18 4059-XXX Laser Assembly Cover 1. Remov e the l eft door . 2. Remov e the l eft co v er . 3. Remov e the r ight cov er . 4. Remov e the rear paper deflector . 5. Press the fuser wiper cov er latch and remove the co v er . 6. Remov e the paper full sensor flag assembly from the mounting brac ket. 7. Remov e the five screws (A[...]

4-19 4059 Ser vice Manual 4059-XXX Controller Board 1. Remov e the inner EMC shield. 2. Remov e the c ontroller board mounting scre ws (A). 3. Remov e the two controller board parallel por t mounting screws (B). 4. Remov e the s erial por t mounting screws i f present. 5. Remov e the c ontroller board.[...]

Repair Inf ormation 4-20 4059-XXX Developer Drive Assembly 1. Remov e the inner EMC shield. 2. Remov e the three dev eloper drive assemb ly mounting scre ws (A). 3. Remov e the dev eloper drive assemb ly . Note: Be sure the de v eloper drive assemb ly wheel aligns with the hub on the main drive assemb ly when reinstalling the assembly .[...]

4-21 4059 Ser vice Manual 4059-XXX Duplex Board 1. Lift the base printer from the duplex assemb ly . 2. Remov e the four duple x board co ver mounting scre ws. 3. Gently disconnect the cables from the duple x board. Use caution to av oid damage to the cables and connectors. 4. Remov e the two duplex board mounting scre ws and remov e the duple x bo[...]

Repair Inf ormation 4-22 4059-XXX Duplex Motor 1. Remov e the duplex front cov er door . 2. Gently disconnect the cables from the duple x board. Use caution to av oid damage to the cables and connectors. 3. Remov e the four mounting screws from the left and right return guides and remov e the guides. 4. Remov e the four mounting screws on the right[...]

4-23 4059 Ser vice Manual 4059-XXX Engine Board 1. Remov e the inner EMC shield. 2. Disconnect all cables from the engine board. 3. Remov e the four engine board mounting scre ws (A). 4. Remov e the engine board cage mounting scre w (B) from the main drive motor assembly . 5. Remov e the engine board. Note: Anytime the engine board is replaced, the[...]

Repair Inf ormation 4-24 4059-XXX Fans Auxiliary Fan (Models 2420/2450/2455/3455) 1. Remov e the r ight cov er . 2. Remov e the inner EMC shield. 3. Remov e the fuser wiper co v er . 4. Disconnect the auxiliar y f an cable from the engine board at connector J7. 5. Note the routing of the auxiliar y f an cable (A) and remov e the fa n (B ) .[...]

4-25 4059 Ser vice Manual 4059-XXX Main Fan 1. Remov e the top rear cover . 2. Remov e the inner EMC shield. 3. Note the routing of the main f an cable (A) and disconnect the cable from the engine board at connector J1. 4. Release the f our latches (B) and remov e the fan from the left side frame .[...]

Repair Inf ormation 4-26 4059-XXX Caution: Be sure the fuser assembly has cooled bef ore working on any of the fuser FR Us. Note: Y ou must replace cable ties (B) if remov ed dur ing the fuser remov als. The cable ties pre vent the fuser wiring from obstructing the paper path through the fuser assembly . Fuser 1. Remov e the r edrive assemb ly . 2.[...]

4-27 4059 Ser vice Manual 4059-XXX Fuser Board 1. Remov e the fuser assembly . 2. Disconnect the cables (A) from the fuser board. 3. Remov e the fuser board mounting screw (B). 4. Release the fuser board from the standoff tab (C) and lift the fuser board from the fuser assembly .[...]

Repair Inf ormation 4-28 4059-XXX Fuser Cover 1. Remov e the fuser assembly . 2. Note the thermistor cable routing and disconnect the cab le from the fuser board. 3. Disconnect the thermal fuse cable from the left and right lamp brac kets (A). 4. Loosen the left and right lamp brack et mounting screws (B) and remov e the ther mal fuse cable from th[...]

4-29 4059 Ser vice Manual 4059-XXX Fuser Det ack Fingers 1. Remov e the fuser assembly . 2. Remov e the fuser cover assemb ly . 3. Remov e the fuser detack housing assembly . 4. Gently pr y the detac k finger and spring (A) from the housing assembly . Fuser Det ack Housing Assembly 1. Remov e the fuser assembly . 2. Remov e the fuser cover assemb l[...]

Repair Inf ormation 4-30 4059-XXX Fuser T ransfer Plate 1. Remov e the upper paper deflector . 2. Remov e the fuser tr ansf er roll. 3. Remov e the inner paper deflector . 4. Lift the left side of the fuser transf er plate (A) and move the plate to the left to clear the right side from its mounting. 5. Remov e the fuser tr ansf er plate.[...]

4-31 4059 Ser vice Manual 4059-XXX Fuser Envelope Conditioner Solenoid The fuser solenoid is in all the models e xcept 1250 and 1255. 1. Remov e the fuser assembly . 2. Remov e the s olenoid mounting scre w (A). 3. Disconnect the solenoid link (B). 4. Remov e the s olenoid from the fuser assemb ly . Note: Do the “Fuser Solenoid Adjustment” on p[...]

Repair Inf ormation 4-32 4059-XXX Fuser Exit Roll Assembly 1. Remov e the fuser assembly . 2. Press the e xit shaft b ushing retaining tabs and slide the left and right bushings (A) tow ard the inside of the fuser assembly . 3. Remov e the exit roll assembly from the slots in the side fr ame. Note: Be sure the fuser idler gear (B) is in place and t[...]

4-33 4059 Ser vice Manual 4059-XXX Fuser Lamp 1. Remov e the fuser assembly . 2. Caution: Hold the left lamp brack et and carefully remove the two mounting scre ws. There is pressure against the other end of the lamp theref ore care must be used when remo ving the lamp from the fuser . Gr ip the lamp by the cer amic end piece and remov e it from th[...]

Repair Inf ormation 4-34 4059-XXX High V olt age Power Supply 1. Remov e the inner paper deflector . 2. Remov e the toner sensor cable from the retainer (A) on the front of the HVPS. 3. Remov e the r ight side cov er . 4. Disconnect the JVPS cable from the HVPS at connector (C). 5. Disconnect the transf er roll cable from the HVPS board. Note: Use [...]

4-35 4059 Ser vice Manual 4059-XXX Inner EMC Shield 1. Remov e the left door . 2. Remov e outer EMC shield. 3. Remov e all option boards from the connector board slots. 4. Remov e the inner EMC shield mounting screws (A). 5. Remov e the inner EMC shield.[...]

Repair Inf ormation 4-36 4059-XXX Inner Paper Deflector Assembly 1. Remov e the paper tray . 2. Remov e the upper deflector assembly . 3. Place the printer on its side. 4. Remov e the l o wer deflector assemb ly . 5. Gently pr y the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer and remov e the[...]

4-37 4059 Ser vice Manual 4059-XXX Integrated T r ay Compensator Assembly 1. Remov e the paper tray . 2. Remov e the left door . 3. Remov e the inner EMC shield. 4. Disconnect the compensator motor cable from the engine board at connector J18. 5. Place the printer on its side. 6. Locate the integrated tr a y compensator assemb ly (E) on the bottom [...]

Repair Inf ormation 4-38 4059-XXX Integrated T ray Compensator Pick Roll Assembly 1. Remov e 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 awa y from the pr inter . 4. Unsnap the pick roll assemb ly (D) from its mounting and remov e.[...]

4-39 4059 Ser vice Manual 4059-XXX Interconnect Board Assembly 1. Remov e the inner EMC shield. 2. Remov e the engine board and shield. 3. Remov e the L VPS. 4. Disconnect all cables from the interconnect board. 5. Remov e the interconnect board a ssemb ly mounting scre ws (A).[...]

Repair Inf ormation 4-40 4059-XXX 6. Place the printer on its back and remov e the two mounting screws (A). 7. Remov e the i nterconnect board assemb ly.[...]

4-41 4059 Ser vice Manual 4059-XXX Left Side Frame 1. Remov e the main driv e assemb ly . 2. Remov e the left side frame mounting screws (A).[...]

Repair Inf ormation 4-42 4059-XXX 3. Place the printer on its back and remo v e the f our left side frame mounting screws (A). 4. Remov e the left side frame.[...]

4-43 4059 Ser vice Manual 4059-XXX Low V olt age Power Supply 1. Remov e the r ight cov er . 2. Remov e the two L VPS mounting screws (A) from the rear of the bottom pan. 3. Pull the L VPS assembly from the right side of the pr inter . Initial resistance is f elt as the automate plug disconnects. 4. Press the release latch on the fuser lamp cable c[...]

Repair Inf ormation 4-44 4059-XXX Main Drive Assembly 1. Remov e the inner EMC shield. 2. Remov e the dev eloper drive assemb ly . 3. Remov e the transfer shaft (A) through the bottom of the printer . 4. Remov e all cab les from the cable clamps (B) on the main drive assembly . 5. Remov e the three main driv e assembly mounting scre ws (C). 6. Remo[...]

4-45 4059 Ser vice Manual 4059-XXX Main Drive Motor 1. Remov e the main driv e assemb ly . 2. Remov e the three main dr iv e motor mounting screws ( A). 3. Remov e the main driv e motor .[...]

Repair Inf ormation 4-46 4059-XXX Multipurpose T ray/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 tra y hinge to remove the tr a y from the two mounting posts. Be careful not to break the hinges or lose the O-r[...]

4-47 4059 Ser vice Manual 4059-XXX 2. Remov e the upper deflector . 3. Remov e the paper out sensor . (1250, 1620,1650 and 2420) 4. Remov e the s cre ws (A) mounting the multipurpose tray/lo wer deflector assembly . 5. Remov e the multipur pose tra y/lo wer deflector assemb ly .[...]

Repair Inf ormation 4-48 4059-XXX Operator Panel 1. Remov e the upper front cover . 2. Gently press the three operator panel lens cov er retaining tabs (A) and remov e the lens cover . The button membrane is free to remov e from the assemb ly . 3. Disconnect the operator panel cab le and remov e the operator panel board.[...]

4-49 4059 Ser vice Manual 4059-XXX Operator Panel Cable/Cover Open Switch Assembly Note: P ay careful attention to the cab le routing through the printer bef ore y ou remov e the operator panel cable/cov er open switch assembly . 1. Remov e the left door , left cov er , upper front cov er , outer EMC shield and inner EMC shield. 2. Disconnect the o[...]

Repair Inf ormation 4-50 4059-XXX Optional 250/500 Paper T ray Assembly Note: Remov e the pr inter and other paper f eed options to access the f ailing optional paper tra y assemb ly . Paper T ray Compensator Assembly 1. Remov e the pr inter and other paper f eed options. 2. Disconnect the compensator assembly bias spring from the tra y frame. 3. D[...]

4-51 4059 Ser vice Manual 4059-XXX Outer EMC Shield 1. Remov e the left door . 2. Loosen the six outer EMC shield mounting screws (A) and remov e the shield.[...]

Repair Inf ormation 4-52 4059-XXX Paper Alignment Assembly 1. Remov e the upper paper deflector assemb ly . 2. Remov e the inner paper deflector assemb ly . 3. Release the input paper sensor from its mounting and remov e. 4. Remov e the l eft door . 5. Remov e the two paper alignment assembly mounting screws (A) located inside the printer .[...]

4-53 4059 Ser vice Manual 4059-XXX 6. Locate the paper alignment assembly ref erence adjustment screw (B) through the left fr ame and remov e the screw . 7. Remov e the paper alignment assembly . Note: Do the “P aper Alignment Assemb ly Adjustment” on page 4-5 when you reinstall the assemb ly . Paper Input Sensor 1. Remov e the inner paper defl[...]

Repair Inf ormation 4-54 4059-XXX Paper Size Sensing Board 1. Disconnect the paper size sensing board cab le from the board. 2. Remov e the two paper size sensing board mounting scre ws (A). 3. Remov e the paper size sensing board. Pick Roll 1. Remov e the upper paper deflector . 2. Release the pick roll retaining tab and slide the pic k roll off t[...]

4-55 4059 Ser vice Manual 4059-XXX Printhead 1. Remov e the laser assembly cov er . 2. Disconnect the printhead cables (A) from the printhead assembly . 3. Remov e the three pr inthead mounting screws (B) and remove the printhead. Note: Do the “Printhead Assembly Adjustment” on page 4-4 whene v er you remo v e or replace the printhead assembly [...]

Repair Inf ormation 4-56 4059-XXX Redrive Assembly 1. Open the redrive door assemb ly , remove the restr aint strap mounting screw and remo v e the door assembly . 2. Remov e the r edrive e xit cov er . 3. Remov e the two redr iv e assembl y mounting screws (A). 4. Release the two redrive assemb ly mounting latches (B) and remov e the redr iv e ass[...]

4-57 4059 Ser vice Manual 4059-XXX Right Side Frame 1. Remov e the r ight side cov er . 2. Remov e the L VPS. 3. Remov e the multipur pose tra y assemb ly . 4. Remov e the auxiliar y fan assemb ly . 5. Disconnect the auto compensator ar m bias spring from the right side frame . 6. Remov e the toner sensor mounting screw (A), disconnect the sensor c[...]

Repair Inf ormation 4-58 4059-XXX Smart Cartridge Cont act s 1. Remov e the upper front cover . 2. Release tab (A) and remov e the contact cov er . 3. Remov e the c ontact plunger (B). 4. Remov e the two screws (C) and remov e the c ontacts (D).[...]

4-59 4059 Ser vice Manual 4059-XXX T oner Sensor 1. Remov e the r ight side cov er . 2. Remov e the toner sensor mounting screw (A). Disconnect the toner sensor cable and remo v e the toner sensor .[...]

Repair Inf ormation 4-60 4059-XXX T ransfer Roll Assembly 1. Open the upper front cov er and remove the print car tridge. 2. Pivot t he transf er roll assembly tow ard the front of the printer . 3. Unsnap the transf er roll assembly from the left and right pivot arms and remove the tr ansf er roll assemb ly . Upper Paper Deflector Assembly 1. Open [...]

4-61 4059 Ser vice Manual 4059-XXX Upper Front Cover Hinge Assembly 1. Remov e the upper front cover . 2. Remov e the laser assembly cov er . 3. Remov e the C -clips (A) from the upper front co v er hinge assembly left and right hinge pins and remov e the pins. Note the pin orientation and the C-clip location on the inside of each hinge. 4. Detach [...]

Repair Inf ormation 4-62 4059-XXX Upper Front Cover Interlock Switch Assembly 1. Remov e the upper front cover . 2. Remov e the operator panel. 3. Remov e the inner EMC shield. 4. Press the retaining tabs (A) and remov e the inter loc k s witch assembly . 5. Note the routing of the interlock s witch assemb ly cable and disconnect the cable at conne[...]

5-1 4059 Ser vice Manual 4059-XXX 5. Connector Locations Low Volt age Power Supply Connector Pin No. Signal CN3 Interconnect Board 1+ 5 V d c 2+ 5 V d c 3G r o u n d 4G r o u n d 5G r o u n d 6G r o u n d 7+ 2 4 V d c 8+ 2 4 V d c 9 Heat on 10 +5 V dc 11 +5 V dc 12 Ground 13 Ground 14 Ground 15 Ground 16 +24 V dc 17 ZC Out* 18 +42 V dc[...]

Connector Locations 5-2 4059-XXX[...]

5-3 4059 Ser vice Manual 4059-XXX High V olt age Power Supply Connector Pin No. Signal CN1 Engine Board 1 De v eloper PWM 2 +24 V dc Retur n 3 Charge PWM 4+ 2 4 V d c I N 5T X P W M 6T X E n a b l e 7 TX CUR PWM 8S V R O O U T[...]

Connector Locations 5-4 4059-XXX Engine Board Connector Pin No. Signal J 1 M a i n Fa n 1 Fa n S t a l l 2 Ground 3F a n O n J2 Fuser Board 1 Exit Sns* 2T h u m p B 3+ 5 V d c 4T h u m p A 5 Ground 6 Hr therm 7 Therm gnd 8N a r r o w M e d i a J3 Printhead (Mirror Motor) 1 +24 V dc Retur n 2 +24 V dc Retur n 3R e F R E Q 4L O C K n 5S t a r t * 6 +[...]

5-5 4059 Ser vice Manual 4059-XXX J5 Printhead 1 LENA* 2 Ground 3L A O J * 4 Ground 5 LASERPWM 6+ 5 V d c 7 Ground 8V i d e o * 9 Ground 10 Ground J6 Output Le vel Sensor 1 Ground 2 Ground 3O p t 2 4O p t 1 5+ 5 V d c J7 A uxiliary F an (Model 2420/2450/2455/ 3455) 1 CRF ANONn 2 Ground J8 Printhead HYSNC 1 Ground 2 HSYNC* 3 Ground 4+ 5 V d c J9 Fus[...]

Connector Locations 5-6 4059-XXX J10 Erase/T oner Sensor/Input Sensor 1A T S e r v o 2S e r v o O u t T 3T X E N A B L E 4T r a n s f e r 5+ 2 4 V d c 6C h a r g e 7 Ground 8 De veloper 9 Ground 10 In Sns* 11 +5 V dc 12 CTSENSE* 13 Ground 14 +24 V dc 15 ERASEPWM* J11 Operator P anel 1 I2CO T A 2+ 5 V d c 3P C L K P 4 Ground 5F P I R Q Connector Pin[...]

5-7 4059 Ser vice Manual 4059-XXX J12 BLDC Motor 1 +24 V dc 2 +24 V dc Retur n 3 +24 V dc Retur n 4M o t o r 3 5M o t o r 4 6D i r 7M o t o r 1 8+ 5 V d c 9M o t o r 2 10 Ground 11 Motor0 J13 A utoconnect 1 RXD 2 Ground 3+ 5 V d c 4 Ground 5 Ground J14 A utoconnect 1 RXD 2 Ground 3+ 5 V d c 4 Ground 5 Ground Connector Pin No. Signal[...]

Connector Locations 5-8 4059-XXX J15 Integrated P aper Tr a y 1+ 5 V d c 2P S I Z E 2 3 Ground 4P S I Z E 1 5+ 2 4 V d c 6 Ground 7P O U T 8+ 5 V d c 9 P aper Low 10 +5 V dc J16 Staging Motor x (Not used) J17 MPT Pick 1 MPT Pick 2+ 2 4 V d c J18 A uto Compensator 1 +24 V dc 2N / A 3 Ground 4 Ground 5N / A 6+ 5 V d c J19 MPT P aper Out 1 Ground 2P O[...]

5-9 4059 Ser vice Manual 4059-XXX Level 1 Engine Board[...]

Connector Locations 5-10 4059-XXX Level 2 Engine Board[...]

5-11 4059 Ser vice Manual 4059-XXX Fuser Board Level 1 Connector Pin No. Signal J1 Engine Board 1 NarMedia 2 Ther mGnd 3H R T h e r m 4 Ground 5 ThumpA 6+ 5 V d c 7 ThumpB 8E x i t S n s * J2 Thermistor 1 ThermGnd 2H R T h e r m J3 Thumper 1 Ground 2+ 4 2 V d c J4 Thumper Solenoid 1 ThumpB 2 ThumpA J5 Narrow Media Sensor 1+ 5 V d c 2 Nar Media 3 Gr[...]

Connector Locations 5-12 4059-XXX Level 2 Connector Pin No. Signal J1 Engine Board 1 NarMedia 2T h e r m G n d 3H R T h e r m 4 Ground 5T h u m p A 6+ 5 V d c 7T h u m p B 8E x i t S n s * J2 Thermistor 1 ThermGnd 2H R T h e r m J3 NA Not Used J4 Thumper Solenoid 1 ThumpB 2T h u m p A J5 Narrow Media Sensor 1+ 5 V d c 2 Nar Media 3 Ground[...]

5-13 4059 Ser vice Manual 4059-XXX[...]

Connector Locations 5-14 4059-XXX Interconnect Board Connector Pin No. Signal J1 Fuser Solenoid (Model1620/1625/ 1650/1855/2420/2450/ 2455) 1+ 4 2 V d c 2 Ground J2 L V PS 1 +42 V dc 2H e a t o n 3X e r o x i n g 4+ 2 4 V d c 5+ 2 4 V d c 6+ 2 4 V d c 7 Ground 8 Ground 9 Ground 10 Ground J3 L V PS 1 Ground 2 Ground 3 Ground 4 Ground 5+ 5 V d c 6+ 5[...]

5-15 4059 Ser vice Manual 4059-XXX Models 1250 and 1255 J5 A utoconnect BTM/FNT 1+ 2 4 V d c 2G r o u n d J6 Engine Board 1 N/A J7 Controller Board 1 N/A J8 ID-1 1 N/A 2N / A J9 ID-2 3 N/A 4N / A J10 ID-3 5 N/A 6N / A J11 INA 1 (1250/1255) 1N / A J12 INA 2 (1620/1625/1650/ 1855/2420) 1N / A J13 INA 3 (2450/2455/3455) 1N / A Connector Pin No. Signal[...]

Connector Locations 5-16 4059-XXX Models 1620, 1625, 1650, 1855, 2420, 2450, 2455 and 3455 • Models 1650, 1855, and 2420 do not hav e connector J13. • Models 1620 and 1625 hav e 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 [...]

5-17 4059 Ser vice Manual 4059-XXX Envelope Option Board Connector Pin No. Signal J1 1 N/A 2G r o u n d 3T x ( E O C ) 4G r o u n d 5R x ( E O C ) 6 +24 V dc Retur n 7+ 2 4 V d c J2 1 Ground 2 P aper Present 3+ 5 V d c J3 1 Ground 2 P aper Present 3+ 5 V d c J4 1 Motor - Phase B- 2 Motor - Phase A- 3 Motor - Phase B+ 4 Motor - Phase A+[...]

Connector Locations 5-18 4059-XXX[...]

5-19 4059 Ser vice Manual 4059-XXX Duplex Option Board Note: Duple x connectors J10 and J11 are interchangeabl e. No problem results if the connectors are s witched. Connector Pin No. Signal J1 Motor 1 Motor - 2M o t o r + J2 DC Motor Sensor/Encoder Board 1 +5 V dc Sensor 2T a c h + 3G r o u n d J3 Stepper Motor 1 STPMO T A - 2S T P M O T A + 3 STP[...]

Connector Locations 5-20 4059-XXX Level 1 Duplex Option Board J9 A utoconnect, Option Below 1 Ground 2 Pr txDout 3 Ground 4P r t R x d J10 A utoconnect, Option Below 1+ 2 4 V d c 2 Ground J11 Printer A utoconnect 1+ 2 4 V d c 2 Ground J12 Printer A utoconnect 1N / A 2 Ground 3P r t x D i n 4 Ground 5P r t R x D Connector Pin No. Signal[...]

5-21 4059 Ser vice Manual 4059-XXX Level 2 Duplex Option Board Autoconnect - T op Connector Pin No. Signal T op Autoconnect 1 0 V dc 2+ 5 V d c 30 V d c 40 V d c 50 V d c 6+ 5 V d c 70 V d c 8+ 2 4 V d c[...]

Connector Locations 5-22 4059-XXX Output Exp ander Control Board - Level 1 Stepper Motor Connector Pin No. Signal J1A A utoconnect 1 +24 V dc 2 Ground 3+ 5 V d c J1B 1 Pr txdin 2 Ground 3p r t r x d 4 Ground 5N / C J2A A utoconnect 1 +24 V dc 2 Ground 3+ 5 V d c J2B 1 pr txdout 2 Ground 3p r t r x d 4 Ground J3 P ass Thru Sensor 1 Ground 2 P aper P[...]

5-23 4059 Ser vice Manual 4059-XXX J5 Bin Full Sensor Single Sensor 1 Ground 2N / C 3+ 5 V d c 4N / C 5R V s n s r Connector Pin No. Signal[...]

Connector Locations 5-24 4059-XXX Output Exp ander Control Board - Level 2 DC Motor Connector Pin No. Signal J1A A utoconnect 1 +24 V dc 2 Ground 3+ 5 V d c J1B 1 Pr txdin 2 Ground 3p r t r x d 4 Ground 5N / C J2A A utoconnect 1 +24 V dc 2 Ground 3+ 5 V d c J2B 1 pr txdout 2 Ground 3p r t r x d 4 Ground J3 P ass Thru Sensor 1 Ground 2 P aper Presen[...]

5-25 4059 Ser vice Manual 4059-XXX J4 DC Motor 1 mtrout1 2m t r o u t 2 3 Ground 4 Ground 5t a c h + 6+ 5 V d c J5 Bin Full/Near Full Dual Sensor 1 Ground 2 Ground 3b i n f u l 4b i n f u l 5R V s n s r Connector Pin No. Signal[...]

Pre v entiv e Maintenance 6-1 4059-XXX 6. Preventive Maintenance This chapter describes procedures for printer prev entive mainte- nance. F ollowing these recommendations can help pre vent prob- lems and maintain optimum perf or mance. Safety Inspection Guide The pur pose of this inspection guide is to aid y ou in identifying unsaf e conditions. If[...]

6-2 4059 Ser vice Manual 4059-XXX Scheduled Maintenance (2420/2450/2455/3455) The operator panel displa ys the message “80 Scheduled Maintenance” at each 250K page count inter v al. It is necessar y to replace the fuser assembly , transf er roller , compensator pic k-rolls and charge roll at this inter v al to maintain the print quality and rel[...]

P ar ts Catalog 7-1 4059-XXX 7. Part s Catalog How T o Use This Part s Cat alog • SIMILAR ASSEMBLIES: If two assemb lies contain a majority of identical par ts, the y a re sho wn on the same list. Common par ts are shown b y one inde x number . P ar ts peculiar to one or the other of the assemblies are listed separ ately and identified by descrip[...]

7-2 4059 Ser vice Manual 4059-XXX Assembly 1: Covers[...]

P ar ts Catalog 7-3 4059-XXX Asm- Index Part Number Unit s Description 1-1 99A0553 1 Suppor t, P aper 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 1 Cov er , Fuser Wick Assembly 1-4 99A0004 1 Spring, Latch NS 3 Screw , Right Side Cvr Mtg PP 99A0263 1-5 99A0011 1 Cov er , RIg[...]

7-4 4059 Ser vice Manual 4059-XXX Assembly 1: Covers (continued)[...]

P ar ts Catalog 7-5 4059-XXX Asm- Index Part Number Unit s Description 1-12 99A0001 1 Operator P anel Assembly 1-13 99A0009 1 Cov er, Left Side 1250/1255/1620/1650/2420/1855/1625 1-13 99A0010 1 Cov er, Left Side 2450/2455/3455 NS 5 Screw , Left Side Cvr Mtg PP 99A0263 1-14 99A0017 1 Door , Left Panel 1650/1855/2420 1-14 99A0019 1 Door , Left Panel [...]

7-6 4059 Ser vice Manual 4059-XXX Assembly 2: Frame[...]

P ar ts Catalog 7-7 4059-XXX Asm- Index Part Number Unit s Description 2-1 99A0425 1 Suppor t, 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 Stack er 2450/2455/3455 2-3 99A0034 1 Duct, Left Stack er 1250/1620/1650/2420/1855/1625 2-4 99A0867 1 Duct, Ma[...]

7-8 4059 Ser vice Manual 4059-XXX Assembly 2: Frame (continued)[...]

P ar ts Catalog 7-9 4059-XXX Asm- Index Part Number Unit s Description 2-21 99A0056 1 Deflector , Upper PF 2-22 99A0055 1 Deflector , Inner 2-23 99A0042 1 F rame, EP Module 2-24 99A0053 1 Sensor , Input 2-25 99A0063 1 Spring, P A Out Activate 2-26 99A0046 1 Cov er , Gap 1620/1625/1650/1855/2420/2450/2455 2-26 99A0804 1 Cov er , Gap 3455 2-27 99A054[...]

7-10 4059 Ser vice Manual 4059-XXX Assembly 3: Printhead[...]

P ar ts Catalog 7-11 4059-XXX Asm- Index Part Number Unit s 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[...]

7-12 4059 Ser vice Manual 4059-XXX Assembly 4: Paper Feed (Autocompensator)[...]

P ar ts Catalog 7-13 4059-XXX Asm- Index Part Number Unit s Description 4-1 99A0060 1 Sensor , Paper Out Internal T ray 4-2 99A0067 1 Pick Arm Assembly (250) 4-3 99A0070 2 Pick Rolls NS 1 Screw , Hanger PP 99A0263[...]

7-14 4059 Ser vice Manual 4059-XXX Assembly 5: Paper Feed - Multipurpose Unit[...]

Pa r t s Ca t a lo g 7-15 Asm- Index Part Number Unit s Description 5-1 99A0075 1 Screw , Socke t Set M4X5 mm 1250/1255 /1650/1 620/24 20/1855/1 625 5-2 99A00 71 1 Ar m As sembly , MPT 1620/1650 /1250/1 255/24 20/1855/1 625 5-3 99A0076 1 Pick Roll As semb ly 1250/1255 /1620/1 650/24 20/1855/1 625 5-4 99A0081 1 Spring Assembl y , Separato r 1620/165[...]

7-16 4059 Ser vice Manual 4059-XXX Assembly 6: Paper Feed - Alignment[...]

P ar ts Catalog 7-17 4059-XXX Asm- Index Part Number Unit s Description 6-1 99A0089 1 Alignment Assembly P aper Feed 6-2 99A0492 1 Screw , Paper Ref erence Adjustment 6-3 99A0566 1 Nut 6-4 99A0559 1 Lev er , Bellcrank Release 6-5 99A0565 1 W asher , Reference Adjustment NS 99A0490 1 Clip , Reference Ground NS 2 Screw , Alignment Asm Mtg PP 99A0263[...]

7-18 4059 Ser vice Manual 4059-XXX Assembly 7: Paper Feed - Output[...]

P ar ts Catalog 7-19 4059-XXX Asm- Index Part Number Unit s 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-C01 7-2 99A0109 1 Deflector Assembly Outer 500 2450/2455 7-2 99A0110 1 Deflector Assembly Out[...]

7-20 4059 Ser vice Manual 4059-XXX Assembly 8: Integrated Paper T ray - 250 Sheet[...]

P ar ts Catalog 7-21 4059-XXX Asm- Index Part Number Unit s Description 8-1 99A0115 1 T ray , Integrated 250 Sheet 8-1 99A0504 1 T ray , Integrated 250 Sheet 1855-C01 8-2 99A0894 1 Latch, Back Restraint 8-3 99A0120 2 Restraint P a d 8-4 99A0892 1 Restraint, Side 250 Sheet T ray 8-5 99A0119 4 Wear Strips 8-6 99A0123 1 Indicator Assembly , Paper Siz [...]

7-22 4059 Ser vice Manual 4059-XXX Assembly 9: Main Drive[...]

P ar ts Catalog 7-23 4059-XXX Asm- Index Part Number Unit s 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, P ower T akeoff 9-3 99A0275 1 Spring, Po wer T akeoff Shaft 9-4 99A0954 1 Gear , Bev el NS 4 Screw , Gearbox Mo[...]

7-24 4059 Ser vice Manual 4059-XXX Assembly 10: Developer Drive[...]

P ar ts Catalog 7-25 4059-XXX Asm- Index Part Number Unit s Description 10-1 99A0135 1 De v eloper Drive Assemb ly 10-2 99A0136 1 Shaft, De ve loper Drive 10-3 99A0564 1 Coupler , Gear #55 10-4 1 Screw , De v eloper Drive Ground PP 99A0263 10-5 2 Screw , De v eloper Drive Mtg PP 99A0263[...]

7-26 4059 Ser vice Manual 4059-XXX Assembly 1 1: Fuser[...]

P ar ts Catalog 7-27 4059-XXX Asm- Index Part Number Unit s Description 11-1 99A0473 1 Fuser Assembly w/100V 750W Lamp 2420/2450/2455 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 Asse[...]

7-28 4059 Ser vice Manual 4059-XXX Assembly 1 1: Fuser (continued)[...]

P ar ts Catalog 7-29 4059-XXX Asm- Index Part Number Unit s Description 11-9 99A0158 1 Back up Roll, CBM 30 mm 2420/2450/3455 11-9 99A0160 1 Back up Roll, 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 1620/1625/1650/1855/2420/2450/2455/345[...]

7-30 4059 Ser vice Manual 4059-XXX Assembly 1 1: Fuser (continued)[...]

P ar ts Catalog 7-31 4059-XXX Asm- Index Part Number Unit s 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, Redr iv e Idler 11-34 99A0167 2 Roller , Redr[...]

7-32 4059 Ser vice Manual 4059-XXX Assembly 12: T ransfer[...]

P ar ts Catalog 7-33 4059-XXX Asm- Index Part Number Unit s Description 12-1 99A0179 1 T ransf er Roll Assembly 12-1 99A0498 1 T ransf er Roll Assembly 1855-C01 PRC 12-2 99A0349 1 Arm, T ransf er Roll Assembly Right 12-3 99A0184 1 Spring, T ransf er Roll Right 12-4 99A0186 1 Erase Lamp Assemb ly Kit o Lamp , Erase Assemb ly o Lens, Erase Lamp 12-5 [...]

7-34 4059 Ser vice Manual 4059-XXX Assembly 13: Charging[...]

Pa r t s Ca t a lo g 7-35 Asm- Index Part Number Unit s Description 13-1 9 9 A0512 1 Link Ass embl y , Charge Left Kit 13-2 99A051 3 1 Link Assemb ly , Charge Righ t Kit 13-3 99A1033 1 Roll Assemb ly , Charge NS 1 Screw , Charge Roll PP 99A026 3[...]

7-36 4059 Ser vice Manual 4059-XXX Assembly 14: Electronics[...]

P ar ts Catalog 7-37 4059-XXX Asm- Index Part Number Unit s Description 14-1 99A0900 1 Engine Board Assemb ly with laser cable 1250/1255 14-1 99A0901 1 Engine Board Assemb ly with laser cable 1620/1625/1650 14-1 99A0902 1 Engine Board Assemb ly with laser cable 1855/1855-C01 14-1 99A0903 1 Engine Board Assemb ly with laser cable 2420/2450/2455 14-1[...]

7-38 4059 Ser vice Manual 4059-XXX Assembly 14: Electronics (continued)[...]

P ar ts Catalog 7-39 4059-XXX Asm- Index Part Number Unit s Description 14-5 1 Screw , HVPS Mounting PP 99A0263 14-6 1 Screw , Engine Bd Mounting T op PP 99A0263 14-7 99A0220 1 High V oltage P ow er Supply 14-7 99A0827 1 High V oltage P ow er Supply 3455 14-8 99A0376 1 Interconnect Board Assemb ly 2450/2455/3455 o3S l o t 14-8 99A0930 1 Interconnec[...]

7-40 4059 Ser vice Manual 4059-XXX Assembly 14: Electronics (continued)[...]

P ar ts Catalog 7-41 4059-XXX Asm- Index Part Number Unit s Description 14-15 99A0236 1 Cov er , INA Blank NS 99A0408 1 Cov er , INA Flat (Blank) 14-16 6 Scre w , INA Cover Mounting PP 99A0263 2450 14-16 4 Scre w , INA Cover Mounting PP 99A0263 14-16 2 Scre w , INA Cover Mounting PP 99A0263 14-17 99A0213 1 Engine Board Shield Assembly 14-18 99A0239[...]

7-42 4059 Ser vice Manual 4059-XXX Assembly 14: Electronics (continued)[...]

P ar ts Catalog 7-43 4059-XXX Asm- Index Part Number Unit s Description 14-22 99A0138 1 Sensor , Standard Bin Lev el 14-23 99A0030 1 F an, Main 14-23 99A0803 1 F an, Main 3455 14-24 99A0255 1 Cable , Main Drive Motor 14-25 99A0129 1 Gearbox, w/Motor 2450/2420/2455 14-25 99A0130 1 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 14-25 99A0801 1 Gearbo[...]

7-44 4059 Ser vice Manual 4059-XXX Assembly 14: Electronics (continued)[...]

P ar ts Catalog 7-45 4059-XXX Asm- Index Part Number Units Description 14-30 99A0049 1 F an, Au xiliar y 2450/2455/3455 14-31 99A0466 1 Sensor , T oner Car tr idge Le vel 14-32 99A0296 1 Switch, Cover Open w/Oper ator P anel Ca ble A sse mbl y 14-33 99A0001 1 Operator P anel Assembly 14-34 99A0576 1 Cab le, F ront Har ness 14-34A 99A0815 2 Contacts[...]

7-46 4059 Ser vice Manual 4059-XXX Assembly 14: Electronics (continued)[...]

P ar ts Catalog 7-47 4059-XXX Asm- Index Part Number Unit s Description 14-35 99A0065 1 Printhead Assembly , 1620/1625/1650/1250/1255 14-35 99A0398 1 Printhead Assembly , 1855/1855-C01 14-35 99A0066 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 99A08[...]

7-48 4059 Ser vice Manual 4059-XXX Assembly 15: 250 Sheet T ray[...]

P ar ts Catalog 7-49 4059-XXX Asm- Index Part Number Units Description 15-1 99A0287 1 Pick Arm Assembly 15-2 3 Screw , Auto Comp Mounting PP 99A0263 15-3 99A0070 2 Roll Assembly , Pick NS 99A0438 2 Bearing, Dr iv e Roll 15-4 99A0448 1 Ar m, P aper Out 250 15-5 99A0266 1 Base, 250 Option 15-6 99A0026 1 T ray Bias Arm Assembly 15-7 99A0419 1 Spring, [...]

7-50 4059 Ser vice Manual 4059-XXX Assembly 15: 250 Sheet T ray (continued)[...]

P ar ts Catalog 7-51 4059-XXX Asm- Index Part Number Unit s Description 15-27 99A0115 1 T ray Assemb ly , 250 Sheet Option 15-27 99A0504 1 T ray Assemb ly , 250 Sheet 1855-C01 15-28 99A0119 4 Wear Strips 15-29 99A0120 2 Restraint P a d 15-30 99A0123 1 Indicator Assembly , Paper Size 15-31 99A0461 1 Label, T ray Number (2-5) 15-32 99A0121 1 Clip , 2[...]

7-52 4059 Ser vice Manual 4059-XXX Assembly 16: 500 Sheet T ray[...]

P ar ts Catalog 7-53 4059-XXX Asm- Index Part Number Unit s Description 16-1 99A0350 1 Sensor , Paper Lo w 16-2 3 Screw , A uto Comp Mounting PP 99A0263 16-3 99A0405 1 Pick Arm Assembly 16-4 99A0070 2 Pick Roll Assemb ly 16-5 99A0298 1 Base, 500 Bottom 16-6 99A0058 4 P ad, Base 500 16-7 99A0419 1 Spring, T ra y Bias 16-8 99A0026 1 T ra y Bias Ar m [...]

7-54 4059 Ser vice Manual 4059-XXX Assembly 16: 500 Sheet T ray (continued)[...]

P ar ts Catalog 7-55 4059-XXX Asm- Index Part Number Unit s Description 16-31 99A0286 1 Spring, Backup Roller 16-32 99A0278 1 Bellcrank, Roller Release 16-33 99A0273 1 Gear , Bev el 16-34 99A0279 1 Bearing, Dr iv e Shaft 16-35 99A0281 1 Cable , 500 A uto Connect T op 16-36 99A0444 1 Stud Assembly , 500 Fr ame 16-37 99A0282 1 Cable , 500 A uto Conne[...]

7-56 4059 Ser vice Manual 4059-XXX Assembly 17: 500/500 Dual T r ay[...]

P ar ts Catalog 7-57 4059-XXX Asm- Index Part Number Units Description 17-1 99A0350 1 Sensor , Paper Lo w 17-2 3 Screw , Auto Comp Mounting PP 99A0263 17-3 99A0405 1 Pick Arm Assembly 17-4 99A0070 2 Pick Roll Assemb ly 17-5 99A0293 1 Base, 500 T op 17-5 99A0298 1 Base, 500 Bottom 17-6 99A0514 2 Screw , Dual 500 Mounting 17-7 99A0026 1 T ray Bias Ar[...]

7-58 4059 Ser vice Manual 4059-XXX Assembly 17: 500/500 Dual T r ay (continued)[...]

P ar ts Catalog 7-59 4059-XXX Asm- Index Part Number Unit s Description 17-31 99A0275 1 Spring, Po wer T akeoff 17-32 99A0280 1 Bearing, Dr iv e Shaft Low 17-33 99A0446 1 Aligner Assembly , Paper 17-34 1 Retainer , Aligner Assembly PP 99A0267 17-35 99A0300 1 Board, T ray (Bottom) 17-36 99A0898 1 Cable , 500 T ray Board to Board P ower 17-37 99A0274[...]

7-60 4059 Ser vice Manual 4059-XXX Assembly 18: Duplex[...]

P ar ts Catalog 7-61 4059-XXX Asm- Index Part Number Unit s Description 18-1 99A0344 1 Cov er, System Board 18-2 99A0322 1 Main F rame Assembly 18-3 99A0324 1 Idler Assemb ly , Belt T ension 18-4 99A0326 4 Spring, Aligner 18-5 99A0323 4 Guide Assembly , P aper 18-6 99A0314 2 Spring, Chassis Ground 18-7 2 Screw , Motor Mount 3 mm PP 99A0413 18-8 99A[...]

7-62 4059 Ser vice Manual 4059-XXX Assembly 18: Duplex (continued)[...]

P ar ts Catalog 7-63 4059-XXX Asm- Index Part Number Unit s Description 18-20 1 Scre w , T ray Open Switch Mounting PP 99A413 18-21 99A0341 1 Sensor , Exit - Optical 18-22 99A0342 1 Guide, LH Low er 18-23 99A0343 1 Guide, Return LH Upper 18-24 2 Scre w , LH Upper Retur n Guide Mounting PP 99A0413 18-25 99A0306 1 Base Assembly , w/T ra y Bias 18-26 [...]

7-64 4059 Ser vice Manual 4059-XXX Assembly 18: Duplex (continued)[...]

P ar ts Catalog 7-65 4059-XXX Asm- Index Part Number Unit s Description 18-41 99A0305 1 T op Cover Assemb ly , Mov ab le 18-42 99A0303 1 T op Cover Assemb ly , Fix ed NS 1 Retainer , 6 mm T op Cover PP 99A0404 18-43 99A0435 1 Guide, Low er Entr y 18-44 99A0338 1 Guide Assembly , P aper Decur l 18-45 99A0332 1 Guide, Center Drive Upper 18-46 99A0307[...]

7-66 4059 Ser vice Manual 4059-XXX Assembly 19: Output Exp ander[...]

P ar ts Catalog 7-67 4059-XXX Asm- Index Part Number Unit s Description 19-1 99A0107 1 Div er ter , Upper Also order 99A0104 19-2 99A0104 1 Spring, Upper Diver ter 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 Expand[...]

7-68 4059 Ser vice Manual 4059-XXX Assembly 19: Output Exp ander (continued)[...]

P ar ts Catalog 7-69 4059-XXX Asm- Index Part Number Unit s Description 19-21 99A0062 1 Lev el Sensor Bracke t Lev el 1 1650/2420/2450 19-21 99A0409 1 Lev el Sensor Bracke t Lev el 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 or[...]

7-70 4059 Ser vice Manual 4059-XXX Assembly 20: Envelope Feeder[...]

P ar ts Catalog 7-71 4059-XXX Asm- Index Part Number Unit s Description 20-1 99A0389 1 P aper Weight Assembly 20-2 99A0391 1 Guide, Edge 20-3 99A0379 1 Cov er, T op 20-4 99A0393 1 Clutch, Restraint/Gear 20-5 99A0380 1 Cov er, Right Side 20-5A 99A0407 1 Base Assembly 20-6 99A0390 1 Suppor t, Slide Out 20-7 99A0488 7 Roller , Suppor t 20-8 99A0382 1 [...]

7-72 4059 Ser vice Manual 4059-XXX Assembly 20: Envelope Feeder (continued)[...]

P ar ts Catalog 7-73 4059-XXX Asm- Index Part Number Unit s Description 20-11 1 Gear Kit, PP 99A0271 1 o Gear , Feed 1 o Gear , Master Cam 1 o Gear , Dr iv e Roll Shaft 3 o Gear , Master/Feed Kic k 2 o Gear , Dr iv e Idler 1 o Gear , Comp Dr iv e/Clutch 1 o Gear , Kick Roll Connect 1 o Gear , Kick CNCT Idler 1 o Gear , Feed Shaft Right 1 o Gear , D[...]

7-74 4059 Ser vice Manual 4059-XXX Assembly 21: High Cap acity Feeder[...]

P ar ts Catalog 7-75 4059-XXX Asm- Index Part Number Unit s Description 21-1 99A0660 1 F rame, Printer Suppor t F rame 2 21-2 3 Screw , Printer Suppor t 2 F rame Mounting PP 99A0675 NS 6 Washer , Pr inter Suppor t F rame 2 Star PP 99A0677 NS 6 Nut, Printer Suppor t F rame 2, 8-32 He x PP 99A0676 21-3 99A0698 2 Clamp , F eed F rame 21-4 4 Screws, Fe[...]

7-76 4059 Ser vice Manual 4059-XXX Assembly 21: High Cap acity Feeder (continued)[...]

P ar ts Catalog 7-77 4059-XXX Asm- Index Part Number Units Description 21-24 1 Nut, Door Switch Spring Mounting PP 99A0676 21-25 4 W asher , Card Assembly Mounting PP 99A0677 21-26 99A0686 3 Guide, Rear P aper with thumb scre ws U s ew i t h9 9 A 0 6 9 6 21-26 99A0188 3 Guide, Rear P aper with retainer arm U s ew i t h9 9 A 0 2 1 9 21-27 6 Screw , [...]

7-78 4059 Ser vice Manual 4059-XXX Assembly 21: High Cap acity Feeder (continued)[...]

P ar ts Catalog 7-79 4059-XXX Asm- Index Part Number Unit s Description 21-50 2 W asher , P ower Supply Board PP 99A0677 21-51 99A0667 1 P ower Supply Board 21-52 99A0715 1 Cable , Low V oltage P ower Supply NS 99A0682 1 Cable , HCIT -T OC Po wer NS 99A0683 1 Cable , HCIT P ower P assthru NS 99A0684 1 Cable , HCIT -14Pin Fle x 21-53 99A0685 1 Bushi[...]

7-80 4059 Ser vice Manual 4059-XXX Assembly 21: High Cap acity Feeder (continued)[...]

P ar ts Catalog 7-81 4059-XXX Asm- Index Part Number Unit s Description 21-62 99A0281 1 Cable , 250 A uto Connect 21-63 99A0279 1 Bearing, Dr iv e Shaft 21-64 99A0273 1 Gear , Bev el 21-65 2 Scre w , F rame Mounting PP 99A0263 21-66 99A0276 1 Roll Assembly , Dr iv e 250 Option 21-67 99A0451 1 Roll, Ske w Back up 21-68 1 Retainer , Roller PP 99A0267[...]

7-82 4059 Ser vice Manual 4059-XXX Assembly 21: High Cap acity Feeder (continued)[...]

P ar ts Catalog 7-83 4059-XXX Asm- Index Part Number Unit s Description 21-81 3 Scre w , Auto Comp Assemb ly Mounting PP 99A0263 21-82 99A0674 1 Ar m Assemb ly , Pick 2000 21-83 99A0070 2 Roll Assembly , Pick 21-84 99A0692 1 Base, 2000 Option 21-85 1 Scre w , Deflector Mounting PP 99A0263 21-86 99A0678 1 Deflector , Base 21-87 99A0288 1 Sensor , P [...]

7-84 4059 Ser vice Manual 4059-XXX Assembly 22: Kiosk - V ertical Paper Adapter[...]

P ar ts Catalog 7-85 4059-XXX Asm- Index Part Number Unit s Description 22-1 99A0231 1 Bail, Suppor t 22-2 99A0112 1 Mounting, F rame Assembly 22-3 99A0197 1 Shaft, Drive Rear 22-4 12 Retainer PP 99A0240 22-5 99A0209 1 Arm Assembly , Piv ot 22-6 16 Screws PP 99A0234 22-7 7 P ar ts, Pulle y PP 99A0208 22-7B 3 Gear , Idler PP 99A0237 22-8 99A0079 1 T[...]

7-86 4059 Ser vice Manual 4059-XXX Assembly 23: Kiosk - Horizont al Paper Adapter[...]

P ar ts Catalog 7-87 4059-XXX Asm- Index Part Number Unit s Description 23-1 99A0231 1 Bail, Suppor t 23-2 99A0112 1 Mounting, F rame Assembly 23-3 99A0197 1 Shaft, Drive Rear 23-4 12 Retainer PP 99A0240 23-5 99A0209 1 Arm Assembly , Piv ot 23-6 15 Screws PP 99A0234 23-7 7 P ar ts, Pulle y PP 99A0208 23-7B 3 Gear , Idler PP 99A0237 23-8 99A0079 1 T[...]

7-88 4059 Ser vice Manual 4059-XXX Assembly 24: Options Asm- Index Part Number Unit s 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 SIMM 24 99A0724 1 64MB EDO DRAM SIMM 24 99A0726 1 DBCS SIMM, J apan 24 99A0521 1 1MB Flash SIMM 24 99A0522 1 2MB Flash S[...]

P ar ts Catalog 7-89 4059-XXX Assembly 24: Options (continued) Asm- Index Part Number Units Description 24 99A0911 1 T ra y A ssemb ly , 250 Special Media 24 99A0910 1 Cartr idge , 4059 Shipping (2) 24 99A0909 1 Cartr idge , 4059 Shipping (1) 24 99A0863 1 Hopper , Integrated Label/Letter 24 99A0864 1 Hopper , Integrated Label/Letter Stac ker 24 99A[...]

7-90 4059 Ser vice Manual 4059-XXX Assembly 25: Miscellaneous Asm- Index Part Number Unit s Description 25 99A0263 1 P ar ts P acket, Scre ws 25 99A0585 1 P ar ts P acket, Contact Kit 25 99A0267 1 P ar ts P acket, Retainers 25 99A0268 1 P ar ts P acket, Springs P aper F eed 25 99A0269 1 P ar ts P acket, Duple x Option F an Mounting 25 99A0299 1 P a[...]

P ar ts Catalog 7-91 4059-XXX Assembly 25:Miscellaneous (continued) Asm- Index Part Number Unit s Description 25 99A0208 1 P ar ts P acket, Pulle y - Kiosk 25 99A0234 1 P ar ts P acket, Scre ws - Kiosk 25 99A0265 1 P ackaging, Short 25 99A0295 1 P ackaging, T all with 500/500 Option T ra y 25 99A0248 1 P ackaging, 500/500 Dual Option T ra y Assembl[...]

Inde x I-1 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 B Base Sensor Test 3-17 Button Test 3-9 C Connector Locations Autoconnect 5-21 Duplex Option Board 5-19 Engine Board 5-4 Envelope Option Board 5-17[...]

Inde x I-2 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 I 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 [...]

I-3 4059 Ser vice Manual 4059-XXX R Removal Procedures 4-12 Removals 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[...]

Inde x I-4 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[...]