Lexmark Optra S 4059 Series Service Manual Download Page 1

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4059-XXX

Optra

Lexmark and Optra are trademarks of
Lexmark International, Inc., registered
in the United States and/or other
countries.

• Table of Contents

• Index

• Safety and Notices

• Trademarks

• Start Diagnostics

Summary of Contents for Optra S 4059 Series

Page 1: ...XXX OptraTM S Lexmark and Optra are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start Diagnost...

Page 2: ...ny time Publications are not stocked at the address given below requests for publications should be made to your point of purchase Comments may be addressed to Lexmark International Inc D22A 035 3 740...

Page 3: ...ck 2 31 Dead Machine Service Check 2 32 Duplex Option Service Check 2 35 Envelope Feeder Option Service Check 2 39 Erase Lamp Service Check 2 46 Fan Service Check 2 47 Fuser Service Check 2 48 Fuser E...

Page 4: ...7 Error Log 3 8 Viewing the Error Log 3 8 Clearing the Error Log 3 8 Hardware Tests 3 9 LCD Test 3 9 Button Test 3 9 DRAM Memory Test 3 10 ROM Memory Test 3 10 Parallel Wrap Test 3 11 Serial Wrap Test...

Page 5: ...t Assembly Adjustment 4 5 Screw Identification Table 4 7 Removal Procedures 4 12 Covers 4 12 Center Pan Assembly 4 18 Controller Board 4 19 Developer Drive Assembly 4 20 Duplex Board 4 21 Duplex Front...

Page 6: ...per Size Sensing Board 4 54 Pick Roll 4 54 Printhead 4 55 Redrive Assembly 4 56 Right Side Frame 4 57 Smart Cartridge Contacts 4 58 Toner Sensor 4 59 Transfer Roll Assembly 4 60 Upper Paper Deflector...

Page 7: ...Assembly 9 Main Drive 7 22 Assembly 10 Developer Drive 7 24 Assembly 11 Fuser 7 26 Assembly 12 Transfer 7 32 Assembly 13 Charging 7 34 Assembly 14 Electronics 7 36 Assembly 15 250 Sheet Tray 7 48 Asse...

Page 8: ...ix 4059 Service Manual 4059 XXX Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown Laser Advisory Label...

Page 9: ...Notices and Safety Information x 4059 XXX Class 1 Laser Statement Label APPAREIL LASER DE CLASSE 1 CLASS 1 LASER PRODUCT LASER KLASSE 1 LUOKAN 1 LASERLAITE TO IEC 825...

Page 10: ...and Human Services 21 CFR Teil J f r Laserprodukte der Klasse I 1 In anderen L ndern gilt der Drucker als Laserprodukt der Klasse I der die Anforderungen der IEC International Electrotechnical Commiss...

Page 11: ...ser di classe IIIb 3b all arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d onda compresa tra 770 e 795 nanometri Il sistema laser e la stampante sono stati progettati in modo tale...

Page 12: ...e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radia o laser superior a um n vel de Classe I durante a opera o normal a manuten o feita pelo u...

Page 13: ...la luokan I laserlaitteiden IEC 825 m rityksen mukainen Luokan I laserlaitteiden ei katsota olevan vaarallisia k ytt j lle Kirjoittimessa on sis inen luokan IIIb 3b 5 milliwatin galliumarsenidilaser j...

Page 14: ...r str ling i b lgelengdeomr det 770 795 nanometer Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstr ling ut over klasse I niv under vanlig bruk vedlikehold som utf re...

Page 15: ...Notices and Safety Information xvi 4059 XXX Japanese Laser Notice Chinese Laser Notice...

Page 16: ...intenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal...

Page 17: ...i riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse...

Page 18: ...les durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a Este produto foi concebi...

Page 19: ...uretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte est orientada exclusivament a p...

Page 20: ...xxi 4059 Service Manual 4059 XXX Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of ozone gas...

Page 21: ...ed to isolate failing field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Printer operation information is provided to enhance...

Page 22: ...General Information The Optra S Laser Printers are letter quality page printers designed to attach to IBM compatible PC s and to most computer networks The printer is available in eleven models Optra...

Page 23: ...General Information 1 2 4059 XXX Optra S Models 1620 4059 162 1625 4059 165 1650 4059 160 1855 4059 185 1855 4059 C01...

Page 24: ...1 3 4059 Service Manual 4059 XXX Optra S Models 2420 4059 242 2450 4059 240 2455 4059 245 3455 4059 345...

Page 25: ...ions Token Ring Ethernet Tri Port IR Adapter IPDS SCS USB Parallel Port 250 and 500 sheet paper trays of A5 letter and legal size 250 Sheet Special Media Tray Assembly 500 500 sheet dual trays Models...

Page 26: ...determine the printer problem and repair the failure After you complete the repair perform tests as needed to verify the repair Tools Required For Service Flat blade screwdriver 1 Phillips screwdriver...

Page 27: ...ly LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply MROM Masked Read Only Memory NVRAM Nonvolatile Random...

Page 28: ...e 2 2 User status messages provide the user with information on the current status of the printer Ready is displayed on the first line of the display unless Power Saver is invoked then Power Saver is...

Page 29: ...tact the next support level or call Lexmark 901 Engine Flash This error indicates that the flash which the engine board code is programmed into is bad Replace the engine board 902 General Engine Softw...

Page 30: ...below standby temperature when the printer is idle Go to the Cold Fuser Service Check on page 2 48 922 Fuser Error Fuser failed to reach standby temperature Go to the Cold Fuser Service Check on page...

Page 31: ...printhead is installed Replace with the correct printhead 931 935 Printhead Error These errors represent a problem with the printhead Go to the Printhead Service Check on page 2 89 931 Printhead no f...

Page 32: ...level for software support 941 Controller Code CRC Replace the controller board 941 Controller Font CRC Replace the controller board 943 Controller Font Version Indicates that the controller code and...

Page 33: ...oes not fix the problem replace the controller board 964 Emulation Error Indicates a failure within the Download Emulation which is programmed into the code overlay SIMM The specific error is as follo...

Page 34: ...e Note Service Errors 980 thru 984 device can be one of the following engine board duplex tray x 1 2 3 4 or 5 envelope feeder or bin x 1 2 or 3 990 device Indicates an equipment check condition has oc...

Page 35: ...the input sensor 84 xx 04 This can occur when a sheet of paper is in the machine during POST and the input sensor flag has tripped the input sensor 84 xx 05 This error is generated whenever media is s...

Page 36: ...4 xx 11 The paper activated the input sensor too soon 84 xx 13 The paper activated the input sensor too soon 84 xx 1D The envelope feeder pass thru sensor is activated and never deactivated 84 xx 1E T...

Page 37: ...xplanation 00 There was no envelope feeder error reported 10 Printer failed POST Homing of Envelope feeder 11 Printer failed POST Halted Envelope Feeder 21 The envelope feeder failed to feed envelope...

Page 38: ...sensor detected a sheet of paper too early 07 The sheet of paper s trailing edge did not clear the exit sensor in the desired length of time 08 The feed motor experienced a complete motor stall 0E The...

Page 39: ...ect for the values Press Menu until Reset Printer is on the second line of the display Press Select to Reset the printer Busy The printer is busy receiving or processing data or printing data Note The...

Page 40: ...lues Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Printing Directory List A directory of the flash and disk contents is processing or printing...

Page 41: ...ess Menu or Menu to take the printer out of Ready and enter the TESTS MENU Busy State Press Menu until Reset Printer is on the second line of the display Press Select to reset the printer Resetting Pr...

Page 42: ...age is displayed Menus Disabled The printer menus have been disabled This occurs when Menu or Menu is pressed while the printer is Ready and Menu Lockout is active The printer display shows this messa...

Page 43: ...the rear of the duplex then replace the duplex front cover and open the duplex rear door If the paper is not jammed in the duplex unit then it may be jammed in the rear of the printer Open the printe...

Page 44: ...e Error 32 is displayed when the top cover is closed and an unsupported print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is supported Depending on...

Page 45: ...at and write operations Press Go to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved 52 Flash Full This messag...

Page 46: ...to the printer 61 Defective Disk This error code is displayed when the printer detects a defective disk This error may occur at power on or during disk format and write operations The following action...

Page 47: ...The operator panel displays this message at each 250K page count interval It is necessary to replace the fuser assembly transfer roller compensator pick rolls and charge roll at this interval to main...

Page 48: ...plays where X designates which tray Tray 1 through 5 is empty If multiple trays are empty then they are prioritized in this order Tray 5 Tray 4 Tray 1 Note Tray X Empty status clears whenever Tray X i...

Page 49: ...rallel Port if available Serial Standard Serial Port if available Serial X Serial Port where X 1 2 3 is attached to PCI connector X Network X Network card X X 1 2 3 is attached to PCI connector X Loca...

Page 50: ...n turn the printer off remove the option and call for service User Status Message Explanation Turn Printer OFF to Enable Option This message displays when a printer option Input Tray Output Bin or Env...

Page 51: ...tray moves to the uppermost position if installed The duplex option is checked if installed The output expander option exit rollers turn if installed 5 Busy appears on the display 6 The fuser lamp tur...

Page 52: ...sly displays all diamonds 5 beeps and does not complete POST Go to the Operator Panel Service Check on page 2 74 Paperfeed problems Base printer or Integrated 250 Paper Tray Go to the Paper Feed Servi...

Page 53: ...uality Toner on backside of printed page Go to Print Quality Toner on backside of printed page on page 2 102 Print quality Vertical black bands on edge of copy Go to Print Quality Black bands on outer...

Page 54: ...d Paper Tray option to the next higher mounted option Go to the Input Tray s Option Service Check on page 2 58 Symptom Action Paper feed problem with Duplex Go to the Duplex Option Service Check on pa...

Page 55: ...articular area of the printer or option Paperfeed Problems with error message Use the Sub Error Codes For 9XX and 2XX Error Codes on page 2 7 to help diagnose the problem Print Quality Problems Go to...

Page 56: ...ight on the charge roll link arm and remove the charge roll from the right side charge roll bearing 3 Remove the charge roll from the left side charge roll bearing and remove the roll from the printer...

Page 57: ...he right charge roll link assembly bearing for signs of wear or contamination Excessive contamination could cause intermittent charging of the charge roll If incorrect replace the link assembly Check...

Page 58: ...ion If incorrect repair as necessary Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4 3 It measures approximately 5 V dc If the voltage is incorrect rep...

Page 59: ...the LVPS out far enough to reach the fuser lamp cable 3 The fuser lamp cable uses a locking type of connector system Unlock the fuser lamp cable connector disconnect the cable and remove the LVPS from...

Page 60: ...d in the printer Replace fuse F1 if necessary Turn the LVPS on off switch Off and connect the AC line cord and turn the LVPS On CAUTION Before checking fuse F1 turn the LVPS Off and disconnect the AC...

Page 61: ...nect one cable at a time until you find the defective assembly Service Tip A short or low resistance load that is attached to the engine board can cause the LVPS to overcurrent and shut the 5 V dc sup...

Page 62: ...etween the motor case and pins J3 1 through J3 4 If no problem is found check the D C servo motor pins J1 1 and J1 2 to the motor housing for a short If a short is found replace the motor assembly If...

Page 63: ...Input Sensor Flag Run the Duplex Sensor Test from the diagnostics menu If the test fails check the input sensor cable at J5 on the system board for correct installation If no problem is found replace...

Page 64: ...system board Check for any shorts between each pin of the motor cable and the motor housing If shorts are found replace the motor Check the resistance of the stepper motor between J3 1 Stpmtr A to J3...

Page 65: ...6 1 and J6 2 on the cable connector while actuating the rear door switch If there is no continuity replace the rear door switch assembly If there is continuity replace the duplex option system board F...

Page 66: ...option that is recognized Note If a 260 Paper Jam Check Envelope message displays check the Sub Error Codes For 9XX and 2XX Error Codes on page 2 7 Printer does not recognize the envelope feeder as an...

Page 67: ...e replace the damaged cable connector assembly Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages J1 3 measures 5 V dc J1 5 measures 5 V dc J1 7 mea...

Page 68: ...sensor flag Note It may be necessary to use a small tool to actuate the sensor flag because it is located under the front cover Be careful not to damage the flag If the test fails check the flag for a...

Page 69: ...and operation If incorrect repair or replace the flag 2 Envelope Out Hopper Input Sensor Check the sensor to make sure it is installed correctly and the sensor cable is properly connected to the envel...

Page 70: ...sure the voltage at J4 6 The voltage measures approximately 5 V dc If incorrect disconnect J4 and measure the voltage again If incorrect replace the envelope feeder system board If correct replace the...

Page 71: ...nt may be too narrow 2 Weight Assembly Check the weight assembly to make sure it moves up and down freely without any binds Also check to make sure the weight assembly rests on all the rear kick rolle...

Page 72: ...or Gap Adjustment Check the deflector gap adjustment The adjustment may be too narrow FRU Action 1 Envelopes Check the envelopes being used in the feeder Check for signs of the envelopes being stuck t...

Page 73: ...eck the front harness to erase lamp assembly for correct installation If incorrect repair as necessary 2 Engine Board Remove the controller board and toner cartridge from the machine Ground pin J10 15...

Page 74: ...replace the fan and cable assembly 2 Engine Board Check to make sure the auxiliary fan cable is seated on connector J7 on the engine board If correct check for 24 V dc on J7 1 on the engine board If...

Page 75: ...check 3 Error Code 927 Fan runs Check the voltage at J1 1 on the engine board The voltage measures 5 V dc static 0 V dc fan running If incorrect replace the main fan If this does not fix the problem...

Page 76: ...f correct replace the fuser cover assembly 3 LVPS and AC Fuser Lamp Cable Turn the printer off Disconnect the fuser lamp connector at the fuser assembly Turn the printer on and check across the pins o...

Page 77: ...ects an open circuit in the thermistor circuit for the fuser assembly The voltage on J2 6 on the engine board measures approximately 5 V dc If incorrect replace the engine board If correct check the c...

Page 78: ...engine board can be used with a level I fuser board provided that the jumpers at JP 1 and JP 2 are correctly positioned as described in configuration 2 If the jumpers are not correctly positioned on...

Page 79: ...ssembly Check for proper mechanical operation of the solenoid and associated hardware link and so on If correct check the resistance of the solenoid between J4 1 and J4 2 The resistance measures betwe...

Page 80: ...tinuity check the voltage at CN3 18 on the LVPS The voltage measures approximately 42 V dc If the voltage is correct replace the interconnect board assembly If the voltage is incorrect replace the LVP...

Page 81: ...2 Fuser Envelope Conditioner Solenoid The operation of the fuser solenoid can be observed by removing the redrive assembly Check for proper mechanical operation of the solenoid and associated hardwar...

Page 82: ...e interconnect board The voltage measures approximately 42 V dc If incorrect check the voltage at CN3 18 on the LVPS It measures approximately 42 V dc If incorrect replace the LVPS If correct replace...

Page 83: ...rol Board The operation of the fuser solenoid can be observed by removing the redrive assembly Check for proper mechanical operation of the solenoid and associated hardware link and so on If correct d...

Page 84: ...s section to find the 42 V dc test point Be careful not to short between the test point and any other pin The voltage measures approximately 42 V dc If correct replace the engine board 5 LVPS Intercon...

Page 85: ...isplays the number of the tray that has a problem or needs service FRU Action 1 Tray X option System Board or Compensator Assembly or Autoconnect Cable Check the autoconect cables and connectors for a...

Page 86: ...check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the tray...

Page 87: ...or smooth and correct operation Paper low sensor for correct installation on the autocompensator housing Paper low sensor cable for signs of cuts pinched wiring or other damage especially at connector...

Page 88: ...orrect paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high capacity feeder tray Service Tip Check the other paper sources to be sure t...

Page 89: ...embly or damaged Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly 2 Base Printer or option mounted above Check the o...

Page 90: ...ternal wiring from the input appliance receptacle If incorrect replace as necessary If correct replace the LVPS If the voltages are correct check the stepper motor for shorts from the motor housing to...

Page 91: ...ils check the sensor for correct installation and the flag for proper operation Also check the sensor cable to make sure it is correctly connected to the option system board If incorrect replace the t...

Page 92: ...r while observing the sensor test on the display If the display does not change replace the high capacity feeder system board If the display changes check the continuity of the switch If incorrect rep...

Page 93: ...imit switch If incorrect replace the switch If correct check the switch cable If incorrect replace the cable If correct replace the high capacity feeder option control board 2 High Capacity Feeder Con...

Page 94: ...ure the paper in tray is within specifications FRU Action 1 Autocompensator Assembly Check the autocompensator pick arm rollers for sign of glazing toner or other buildup Replace as necessary 2 Wear S...

Page 95: ...tem board Be sure the motor extension cable is properly connected to the motor cable Check the cables for damage or loose wires Disconnect the motor and check for a short between each pin and the moto...

Page 96: ...V dc J1 2 Yellow 24 V dc J1 3 Green 24 V dc J1 4 White 24 V dc motor running J1 1 Orange approximately 12 V dc J1 2 Yellow approximately 12 V dc J1 3 Green approximately 12 V d J1 4 White approximatel...

Page 97: ...ny position does not measure continuity when selected replace the paper size switch assembly If the switch assembly is operating correctly replace the high capacity feeder option control board FRU Act...

Page 98: ...sor Check the continuity of the sensor cable If incorrect replace the cable If correct replace the top optical sensor assembly FRU Action 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder...

Page 99: ...belt to be sure it is not too tight The motor can be adjusted while the motor is running for minimum belt noise and optimum performance Note If the belt is too tight a high pitch noise results 3 Lead...

Page 100: ...ve Assembly Excessive noise or vibration Remove the controller board and run a Diagnostic Print Test in the continuous mode Check the main drive assembly for any excessive noise or vibration Determine...

Page 101: ...voltages at J12 on the engine board Pin number and voltage J12 1 24 V dc J12 4 5 V dc static 0 V dc when main drive motor running J12 5 5 V dc static 0 V dc when main drive motor running J12 6 5 V dc...

Page 102: ...k Check the voltage at J11 5 The voltage measures approximately 5 V dc with the controller board removed If incorrect replace the engine board If correct check the continuity of the operator panel cab...

Page 103: ...h Test on page 3 3 If the test fails replace the FLASH SIMM If the problem continues replace the controller board DRAM Memory Option s This service check is the same as the flash memory option service...

Page 104: ...g or testing section Note This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk Menu o...

Page 105: ...re unless the flag is in the up position or out of the sensor slot a Remove Paper Standard Bin message is not displayed FRU Action 1 Engine Board Printer fails to display Remove Paper Standard Bin mes...

Page 106: ...nstalled before attempting to service the unit Problems with excessive static electricity buildup Printer does not recognize one or more output expander options as being installed Service Tip If more...

Page 107: ...nnects for damage especially the connector pins Remove the left and right side covers Remove the front control board cover Check the cables at J1A J1B J2A and J2B on the control board to make sure the...

Page 108: ...also occur prior to the output expander pass thru sensor FRU Action 1 Output Expander Drive Belt Drive Pulley Drive Belt Idler Pulley Belt Tension Spring Check to ensure the output expander drive bel...

Page 109: ...tepper Motor on page 5 22 If correct disconnect J4 from the option board and check the resistance of the stepper motor at J4 J4 1 to J4 2 Approximately 10 ohms J4 3 to J4 4 Approximately 10 ohms Also...

Page 110: ...Printer Feeding Paper J4 1 Approximately 16 V dc J4 2 Approximately 16 V dc J4 3 Approximately 16 V dc J4 4 Approximately 16 V dc The voltage drops to approximately 16 V dc as the output expander bin...

Page 111: ...Flag Check the flag for correct operation binding broken parts or interference from the sensor cable If incorrect repair as necessary FRU Action 1 Pass Thru Sensor and Flag Assembly Control Board Che...

Page 112: ...case for shorts If either the resistance is incorrect or a short is found replace the motor mechanical linkage assembly Note If the DC motor is shorted it may also be necessary to replace the control...

Page 113: ...oard If either the Bin Full F or Bin Near Full NF fail the sensor test then check the voltage at J5 3 and J5 4 The voltage measures approximately 5 V dc If the voltage is incorrect replace the control...

Page 114: ...ilures occur mainly near the bottom of the stack of paper The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper Also the autocompensator...

Page 115: ...roblem replace the pick roll assembly Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications FRU Action 1 Paper Paper is usually the...

Page 116: ...Service Check The printhead assembly does not contain any service replaceable parts or components If service error code 930 displays the wrong printhead is installed in the printer Service Error Code...

Page 117: ...rinthead assembly or the mirror motor cable to the engine board cable or engine board assembly Check the continuity of the mirror motor cable connected to J3 on the engine board If incorrect replace t...

Page 118: ...n the printer to the original customer printer setup Print Resolution Set to 300 dpi print quality problems should be checked at different resolution settings Print Darkness Set to NORMAL Toner Saver...

Page 119: ...e they fit securely and are not pitted contaminated or damaged If incorrect replace the contact with one from the HV contact kit Screws are included to attach the contacts to the right side frame in t...

Page 120: ...Printer Printing J10 5 measures 24 V dc In the voltages at J10 5 are incorrect replace the engine board 4 Front Cable Harness HVPS Section Check the front cable harness at J10 on the engine board and...

Page 121: ...r roll bearings or transfer roll Check the gearbox assembly for correct operation Check the transfer roll for binds or a contaminated shaft or bearings Blurred print can also be caused by incorrect fe...

Page 122: ...a defective gear in the main drive gearbox assembly Replace the main drive gearbox assembly 3 Lines spaced 38 26 mm 1 506 inch apart This can be caused by defective gear s in the main drive gearbox R...

Page 123: ...Lines spaced 49 74 mm 1 958 inch apart Replace the FRUs in the following order redrive assembly fuser assembly 8 Lines spaced 51 02 mm 2 009 inch apart Replace the transfer roll 9 Lines spaced 52 23...

Page 124: ...other attempts fail to correct a background problem 3 Transfer Roll Assembly Check the high voltage contact from the HVPS to the transfer roll Check the transfer arm assembly right side bearing for a...

Page 125: ...ne If there is no continuity replace the harness cable If there is continuity replace the HVPS If this does not correct the problem replace the engine board If J10 2 voltage is incorrect or if the vol...

Page 126: ...eck the charge roll contact for any signs of damage and for proper connection to the HVPS and print cartridge Print Quality Black bands on outer edges of the page This print quality problem appears as...

Page 127: ...operation binds or incorrectly mounted counterbalance springs Repair or replace as necessary 3 HVPS Check the following voltages at J10 8 on the engine board Printer Idle J10 8 measures 0 V dc Printer...

Page 128: ...e toner to be retained and deposited on the page FRU Action 1 Transfer Roll Check the right end of the transfer roll shaft for signs of wear or contamination If incorrect replace the transfer roll 2 R...

Page 129: ...sure the smart cable is properly connected to J21 on the engine board Check the print cartridge for any signs of damage or improper installation of the smart chip Also check to make sure there is pro...

Page 130: ...rt Cartridge Cover Check to make sure that the smart cartridge cover is properly snapped into place and is not damaged or broken Replace as necessary 3 Smart Cartridge Plunger Check the plunger for co...

Page 131: ...er Sensor Service Check Service Tip Check the print darkness MENU setting before checking the toner sensor This service check is intended to be used when a 929 Service Error displays FRU Action 1 Deve...

Page 132: ...ated parts for personal safety and to prevent damage to the printer 3 Toner Sensor The toner sensor cable is part of the front harness and part of connector J10 on the engine board Check the voltage a...

Page 133: ...l lock into the EP frame correctly Check the right transfer arm assembly spring for proper operation For any background problems check to ensure the contact to the HVPS board is correct and that there...

Page 134: ...ostic Mode 1 Turn the printer off 2 Press and hold the Go and Return buttons 3 Turn the printer on 4 Release the buttons when Performing Self Test displays on the operator panel The tests display on t...

Page 135: ...turn to the Device Tests menu Disk Test Clean WARNING This test destroys all data on the disk and should not be attempted on a good disk Also note that this test may run approximately 1 1 2 hours depe...

Page 136: ...elect Flash Test from the Device Tests menu The power indicator blinks while the test is running Flash Test Test Passed message displays if the test passes and the power indicator turns on solid Flash...

Page 137: ...es Continues until Return Stop is pressed The paper you choose to print the page on should be either Letter or A4 To run the Duplex Quick Test 1 Select Duplex Quick Test from the menu 2 Select Single...

Page 138: ...switch is open OP Open displays Duplex input sensor Duplex exit sensor Duplex front cover switch not installed on all duplex options Duplex rear door switch not installed on all duplex options Press...

Page 139: ...ive belt from the duplex D C motor and run the motor test again For the duplex D C motor to pass the test the following results must display AA 00 BB in the range of 29 through 3E inclusively hex CC i...

Page 140: ...ear Paper message displays when the paper reaches paper stop position 1 and the power indicator turns on solid Duplex Feed 2 Test This test feeds a blank sheet of paper to the duplex paper stop positi...

Page 141: ...consecutive positions in the log are entered All 2xx and 9xx error messages are stored in the error log To view the Error Log 1 Select Display Log from the Error Log menu The Error log displays on 3...

Page 142: ...Test To run the LCD Test 1 Select LCD Test from the Diagnostic menu The LCD test continually executes the LCD display test 2 Press Return Stop to cancel the test Button Test To run the Button Test 1 S...

Page 143: ...t being 999 999 F represents the of time the memory test has failed and finished with errors Initially 00000 displays with the maximum fail count being 99 999 Once the maximum pass count or fail count...

Page 144: ...ach parallel signal is tested To run the Parallel Wrap Test 1 Disconnect the parallel interface cable and install the wrap plug P N 1319128 2 Select the Parallel Wrap Test from the menu The power indi...

Page 145: ...the final results display Press Return Stop to exit the test Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug Each signal is tested To run the Se...

Page 146: ...terrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Ove...

Page 147: ...ther Single feeds one sheet of media from the selected source or Continuous continues feeding media from the selected source until Return Stop is pressed 4 Press Return Stop to exit test Input Tray Se...

Page 148: ...is in the sensor 4 Press Return Stop to exit the test Output Bin Feed Test Note If the Configure Bins printer setting is link rather than mailbox the printer selects its own internal bin linking rega...

Page 149: ...sed to cover the bin s pass thru sensor When the sensor is closed CL displays and when the sensor is open OP displays 3 Press Return Stop to exit the test Output Bin X Sensor Test Note Some output exp...

Page 150: ...s pass thru sensor When the sensor is closed CL displays and when the sensor is open OP displays 4 Press Return Stop to exit the test Base Sensor Test This test is used to determine if the sensors lo...

Page 151: ...s Select until the margin value pair you want to change is blinking 4 To change the margin value press either Menu or Menu When the value you want is displayed press Select to save the value 5 To exit...

Page 152: ...g it is the first digit to be changed 2 Press either Menu or Menu until the value you want displays 3 Press Select to move to the next digit press Menu or Menu until the value you want displays Contin...

Page 153: ...d using hardware sensors The Configuration ID is originally set at the factory when the printer is manufactured however it requires resetting whenever you replace the engine board and can be set on th...

Page 154: ...the settings to the factory default values select Do Not Restore Sometimes this is used to help correct print quality problems Fuser Temperature This adjustment can be used to help solve some custome...

Page 155: ...is to verify that the printer can print on media from each of the installed input options Each of the installed options is listed in the following order in the menu Tray 1 Tray 2 if installed Tray 3...

Page 156: ...problems Print Quality Test Pages The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled The print quality test...

Page 157: ...test page must be printed on letter legal or A4 paper To print the Menu Settings Page 1 Select the TESTS MENU 2 Select Print Menus from the TESTS MENU The page contains the following information A lis...

Page 158: ...he stack increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam Once this critical threshold is achieved the normal fo...

Page 159: ...ot to be considered an adjustment for feeding problems Autoconnect System Paper Tray Options Envelope Feeder and Output Expander Operations Electrical Autoconnect Cabling and Connectors The printer op...

Page 160: ...frame assembly There are no switches in the level 2 duplex option Option Microcode The options are Smart Options or options that have a system board The option system board has a microprocessor that c...

Page 161: ...ng the fuser temperature is set to normal The HEATON signal from CN3 9 varies from 0 V dc lamp On to 5 V dc lamp Off and is connected to the cathode of an Opto triac to control the fuser lamp The seco...

Page 162: ...r Message 202 Paper Jam Open Rear Door This message indicates the paper is jammed at the printer exit sensor This can be caused by the paper arriving at the sensor too late the paper is jammed in the...

Page 163: ...r in time Error Message 260 Paper Jam Check Envelope Feeder An envelope is jammed in the envelope feeder or has not reached the base machine input sensor Error Message 27x Paper Jam Check Bin x Paper...

Page 164: ...ctricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the E...

Page 165: ...n page 4 21 to access the drive belt idler pulley 2 Loosen the idler pulley mounting screw and position the idler to provide 3 mm 5 mm drive belt deflection 3 Tighten the idler pulley mounting screw b...

Page 166: ...performance such as pages per minute but can help in reducing the amount of curl of some printed media thus improving media stacking in the output bin 1 Enter the Diagnostic Mode 2 Select EP SETUP fro...

Page 167: ...Self Test displays 4 Select Registration from the menu 5 Select Quick Test Page The test page should only be printed on letter or A4 paper from Tray 1 The Quick Test Page consists of alignment diamond...

Page 168: ...egistration on page 3 18 Do the reference adjustment if you are sure the margins are set correctly 1 Loosen the locknut on the inside rear of the alignment assembly 2 Remove the two screws holding the...

Page 169: ...he range specified in Print Registration on page 3 18 The reference screw can be adjusted without loosening the locknut Turn the screw a few turns and print a copy of the Quick Test Page as you check...

Page 170: ...ach location during reassembly Reference Number Screw Type Location Purpose Qty M3 5x8 mm Thread Cutting right side frame to center pan attach 1 toner level sensor mounting 1 charge roll mounting 1 ma...

Page 171: ...side frame attach 2 M3 5x12 mm Thread Cutting engine board shield to left frame attach 1 paper alignment assembly mounting 2 toner cartridge guide track mounting 2 left side frame to center pan attac...

Page 172: ...roller board to inner shield mounting 2 fuser ground wire mounting 1 controller board back mounting 2 engine board to interconnect shield ground attach 1 fuser ground wire mounting 1 lower stacker duc...

Page 173: ...r bracket mounting 1 M3x12 mm Taptite HVPS board mounting 1 M3x28 mm Taptite developer drive ground bottom hole attach 1 M3 5x8 mm Plastite Thread Forming upper front cover mounting 5 left side cover...

Page 174: ...de cover mounting 3 left side frame to pan attach 1 M3 5x12 mm Plastite Thread Forming left side cover mounting 1 M3x6 mm SEMSMachine Screw with washer fuser board mounting 1 M3 5x12 mm Plastite Threa...

Page 175: ...o the printer Use the hand grips on the side of the printer Make sure your fingers are not under the printer when you lift or set the printer down Note Some removal procedures require removing cable t...

Page 176: ...4 13 4059 Service Manual 4059 XXX Left Cover 1 Remove the left door 2 Remove the five mounting screws A...

Page 177: ...Repair Information 4 14 4059 XXX 3 Raise the upper front cover 4 Remove the three mounting screws B the print cartridge and remove the left cover...

Page 178: ...4 15 4059 Service Manual 4059 XXX Right Cover 1 Raise the upper front cover 2 Release the cover latch A and remove the right cover mounting screw B...

Page 179: ...Repair Information 4 16 4059 XXX 3 Remove the redrive assembly 4 Remove the right side cover mounting screws B and C 5 Remove the right side cover...

Page 180: ...4 17 4059 Service Manual 4059 XXX Upper Front Cover 1 Raise the upper front cover 2 Remove the five upper front cover mounting screws A and remove the cover...

Page 181: ...Remove the rear paper deflector 5 Press the fuser wiper cover latch and remove the cover 6 Remove the paper full sensor flag assembly from the mounting bracket 7 Remove the five screws A mounting the...

Page 182: ...roller Board 1 Remove the inner EMC shield 2 Remove the controller board mounting screws A 3 Remove the two controller board parallel port mounting screws B 4 Remove the serial port mounting screws if...

Page 183: ...1 Remove the inner EMC shield 2 Remove the three developer drive assembly mounting screws A 3 Remove the developer drive assembly Note Be sure the developer drive assembly wheel aligns with the hub o...

Page 184: ...embly latches from the bottom of the duplex assembly 5 Remove the duplex front cover assembly Duplex Front Cover Door 1 Remove the duplex front cover assembly 2 Holding the front of the assembly away...

Page 185: ...5 Position the duplex assembly on its side 6 Gently release the center drive deflector assembly latch from the bottom front left side of the duplex assembly 7 Remove the center drive deflector assemb...

Page 186: ...screws A 4 Remove the engine board cage mounting screw B from the main drive motor assembly 5 Remove the engine board Note Anytime the engine board is replaced the Configuration ID must be reset in N...

Page 187: ...dels 2420 2450 2455 3455 1 Remove the right cover 2 Remove the inner EMC shield 3 Remove the fuser wiper cover 4 Disconnect the auxiliary fan cable from the engine board at connector J7 5 Note the rou...

Page 188: ...an 1 Remove the top rear cover 2 Remove the inner EMC shield 3 Note the routing of the main fan cable A and disconnect the cable from the engine board at connector J1 4 Release the four latches B and...

Page 189: ...FRUs Note You must replace cable ties B if removed during the fuser removals The cable ties prevent the fuser wiring from obstructing the paper path through the fuser assembly Fuser 1 Remove the redri...

Page 190: ...XX Fuser Board 1 Remove the fuser assembly 2 Disconnect the cables A from the fuser board 3 Remove the fuser board mounting screw B 4 Release the fuser board from the standoff tab C and lift the fuser...

Page 191: ...ct the cable from the fuser board 3 Disconnect the thermal fuse cable from the left and right lamp brackets A 4 Loosen the left and right lamp bracket mounting screws B and remove the thermal fuse cab...

Page 192: ...fuser detack housing assembly 4 Gently pry the detack finger and spring A from the housing assembly Fuser Detack Housing Assembly 1 Remove the fuser assembly 2 Remove the fuser cover assembly 3 Remov...

Page 193: ...emove the upper paper deflector 2 Remove the fuser transfer roll 3 Remove the inner paper deflector 4 Lift the left side of the fuser transfer plate A and move the plate to the left to clear the right...

Page 194: ...5 1 Remove the fuser assembly 2 Remove the solenoid mounting screw A 3 Disconnect the solenoid link B 4 Remove the solenoid from the fuser assembly Note Do the Fuser Solenoid Adjustment on page 4 3 wh...

Page 195: ...e left and right bushings A toward the inside of the fuser assembly 3 Remove the exit roll assembly from the slots in the side frame Note Be sure the fuser idler gear B is in place and the bushing ali...

Page 196: ...und the fuser lower exit guide mounting pin when reinstalling the lamp The fuser lamp FRU is color coded The left and right fuser lamp bracket access holes let you view the end of the lamp Use the fol...

Page 197: ...ove the right side cover 4 Disconnect the JVPS cable from the HVPS at connector C 5 Disconnect the transfer roll cable from the HVPS board Note Use caution when disconnecting the cable from the transf...

Page 198: ...Manual 4059 XXX Inner EMC Shield 1 Remove the left door 2 Remove outer EMC shield 3 Remove all option boards from the connector board slots 4 Remove the inner EMC shield mounting screws A 5 Remove the...

Page 199: ...ove the paper tray 2 Remove the upper deflector assembly 3 Place the printer on its side 4 Remove the lower deflector assembly 5 Gently pry the inner paper deflector from the left and right mounting p...

Page 200: ...able from the engine board at connector J18 5 Place the printer on its side 6 Locate the integrated tray compensator assembly E on the bottom of the printer and disconnect the compensator arm bias spr...

Page 201: ...ator Pick Roll Assembly 1 Remove the paper tray 2 Place the printer on its side 3 Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer 4 Unsn...

Page 202: ...XXX Interconnect Board Assembly 1 Remove the inner EMC shield 2 Remove the engine board and shield 3 Remove the LVPS 4 Disconnect all cables from the interconnect board 5 Remove the interconnect boar...

Page 203: ...Repair Information 4 40 4059 XXX 6 Place the printer on its back and remove the two mounting screws A 7 Remove the interconnect board assembly...

Page 204: ...4 41 4059 Service Manual 4059 XXX Left Side Frame 1 Remove the main drive assembly 2 Remove the left side frame mounting screws A...

Page 205: ...Repair Information 4 42 4059 XXX 3 Place the printer on its back and remove the four left side frame mounting screws A 4 Remove the left side frame...

Page 206: ...e the two LVPS mounting screws A from the rear of the bottom pan 3 Pull the LVPS assembly from the right side of the printer Initial resistance is felt as the automate plug disconnects 4 Press the rel...

Page 207: ...lamps B on the main drive assembly 5 Remove the three main drive assembly mounting screws C 6 Remove the link D from the rear of the main drive assembly 7 Disconnect the cable from the main drive moto...

Page 208: ...4 45 4059 Service Manual 4059 XXX Main Drive Motor 1 Remove the main drive assembly 2 Remove the three main drive motor mounting screws A 3 Remove the main drive motor...

Page 209: ...e multipurpose tray to a position that let the left and right tray hinge slots A align with the rectangular mounting posts B Pull upward on each tray hinge to remove the tray from the two mounting pos...

Page 210: ...4059 XXX 2 Remove the upper deflector 3 Remove the paper out sensor 1250 1620 1650 and 2420 4 Remove the screws A mounting the multipurpose tray lower deflector assembly 5 Remove the multipurpose tray...

Page 211: ...emove the upper front cover 2 Gently press the three operator panel lens cover retaining tabs A and remove the lens cover The button membrane is free to remove from the assembly 3 Disconnect the opera...

Page 212: ...remove the torroid before pulling the cables through the hinge pivot arm 6 Plug the new operator panel cable into the operator panel and snap the new cover open switch cable into the bracket assembly...

Page 213: ...bly 2 Release the paper pass through sensor from its retaining tabs 3 Release the frame assembly from the front and rear retaining tabs and remove the paper tray frame assembly Paper Tray Board 1 Remo...

Page 214: ...4 51 4059 Service Manual 4059 XXX Outer EMC Shield 1 Remove the left door 2 Loosen the six outer EMC shield mounting screws A and remove the shield...

Page 215: ...Remove the upper paper deflector assembly 2 Remove the inner paper deflector assembly 3 Release the input paper sensor from its mounting and remove 4 Remove the left door 5 Remove the two paper align...

Page 216: ...ve the screw 7 Remove the paper alignment assembly Note Do the Paper Alignment Assembly Adjustment on page 4 5 when you reinstall the assembly Paper Input Sensor 1 Remove the inner paper deflector ass...

Page 217: ...the paper size sensing board cable from the board 2 Remove the two paper size sensing board mounting screws A 3 Remove the paper size sensing board Pick Roll 1 Remove the upper paper deflector 2 Rele...

Page 218: ...r 2 Disconnect the printhead cables A from the printhead assembly 3 Remove the three printhead mounting screws B and remove the printhead Note Do the Printhead Assembly Adjustment on page 4 4 whenever...

Page 219: ...edrive door assembly remove the restraint strap mounting screw and remove the door assembly 2 Remove the redrive exit cover 3 Remove the two redrive assembly mounting screws A 4 Release the two redriv...

Page 220: ...tipurpose tray assembly 4 Remove the auxiliary fan assembly 5 Disconnect the auto compensator arm bias spring from the right side frame 6 Remove the toner sensor mounting screw A disconnect the sensor...

Page 221: ...nformation 4 58 4059 XXX Smart Cartridge Contacts 1 Remove the upper front cover 2 Release tab A and remove the contact cover 3 Remove the contact plunger B 4 Remove the two screws C and remove the co...

Page 222: ...4 59 4059 Service Manual 4059 XXX Toner Sensor 1 Remove the right side cover 2 Remove the toner sensor mounting screw A Disconnect the toner sensor cable and remove the toner sensor...

Page 223: ...l assembly from the left and right pivot arms and remove the transfer roll assembly Upper Paper Deflector Assembly 1 Open the multipurpose tray and remove the tray from the two mounting posts Be caref...

Page 224: ...the inside of each hinge 4 Detach the two springs B from the upper front cover hinges 5 Disconnect the operator panel cable from the operator panel assembly 6 Raise the upper front cover hinge assemb...

Page 225: ...1 Remove the upper front cover 2 Remove the operator panel 3 Remove the inner EMC shield 4 Press the retaining tabs A and remove the interlock switch assembly 5 Note the routing of the interlock switc...

Page 226: ...ons Low Voltage Power Supply Connector Pin No Signal CN3 Interconnect Board 1 5 V dc 2 5 V dc 3 Ground 4 Ground 5 Ground 6 Ground 7 24 V dc 8 24 V dc 9 Heat on 10 5 V dc 11 5 V dc 12 Ground 13 Ground...

Page 227: ...Connector Locations 5 2 4059 XXX...

Page 228: ...3 4059 Service Manual 4059 XXX High Voltage Power Supply Connector Pin No Signal CN1 Engine Board 1 Developer PWM 2 24 V dc Return 3 Charge PWM 4 24 V dc IN 5 TX PWM 6 TX Enable 7 TX CUR PWM 8 SVRO OU...

Page 229: ...all 2 Ground 3 Fan On J2 Fuser Board 1 Exit Sns 2 Thump B 3 5 V dc 4 Thump A 5 Ground 6 Hrtherm 7 Thermgnd 8 Narrow Media J3 Printhead Mirror Motor 1 24 V dc Return 2 24 V dc Return 3 ReFREQ 4 LOCKn 5...

Page 230: ...7 Ground 8 Video 9 Ground 10 Ground J6 Output Level Sensor 1 Ground 2 Ground 3 Opt2 4 Opt1 5 5 V dc J7 Auxiliary Fan Model 2420 2450 2455 3455 1 CRFANONn 2 Ground J8 Printhead HYSNC 1 Ground 2 HSYNC 3...

Page 231: ...nput Sensor 1 AT Servo 2 Servo OutT 3 TXENABLE 4 Transfer 5 24 V dc 6 Charge 7 Ground 8 Developer 9 Ground 10 In Sns 11 5 V dc 12 CTSENSE 13 Ground 14 24 V dc 15 ERASEPWM J11 Operator Panel 1 I2COTA 2...

Page 232: ...4 V dc 2 24 V dc Return 3 24 V dc Return 4 Motor3 5 Motor4 6 Dir 7 Motor1 8 5 V dc 9 Motor2 10 Ground 11 Motor0 J13 Autoconnect 1 RXD 2 Ground 3 5 V dc 4 Ground 5 Ground J14 Autoconnect 1 RXD 2 Ground...

Page 233: ...5 V dc 9 Paper Low 10 5 V dc J16 Staging Motor x Not used J17 MPT Pick 1 MPT Pick 2 24 V dc J18 Auto Compensator 1 24 V dc 2 N A 3 Ground 4 Ground 5 N A 6 5 V dc J19 MPT Paper Out 1 Ground 2 POSENSE...

Page 234: ...5 9 4059 Service Manual 4059 XXX Level 1 Engine Board...

Page 235: ...Connector Locations 5 10 4059 XXX Level 2 Engine Board...

Page 236: ...Pin No Signal J1 Engine Board 1 NarMedia 2 ThermGnd 3 HRTherm 4 Ground 5 ThumpA 6 5 V dc 7 ThumpB 8 ExitSns J2 Thermistor 1 ThermGnd 2 HRTherm J3 Thumper 1 Ground 2 42V dc J4 Thumper Solenoid 1 Thump...

Page 237: ...r Pin No Signal J1 Engine Board 1 NarMedia 2 ThermGnd 3 HRTherm 4 Ground 5 ThumpA 6 5 V dc 7 ThumpB 8 ExitSns J2 Thermistor 1 ThermGnd 2 HRTherm J3 NA Not Used J4 Thumper Solenoid 1 ThumpB 2 ThumpA J5...

Page 238: ...5 13 4059 Service Manual 4059 XXX...

Page 239: ...2420 2450 2455 1 42 V dc 2 Ground J2 LVPS 1 42 V dc 2 Heaton 3 Xeroxing 4 24 V dc 5 24 V dc 6 24 V dc 7 Ground 8 Ground 9 Ground 10 Ground J3 LVPS 1 Ground 2 Ground 3 Ground 4 Ground 5 5 V dc 6 5 V dc...

Page 240: ...nnect BTM FNT 1 24 V dc 2 Ground J6 Engine Board 1 N A J7 Controller Board 1 N A J8 ID 1 1 N A 2 N A J9 ID 2 3 N A 4 N A J10 ID 3 5 N A 6 N A J11 INA 1 1250 1255 1 N A J12 INA 2 1620 1625 1650 1855 24...

Page 241: ...pin and pin 5 Model 1855 has a jumper on J8 between the center pin and pin 2 on J9 between the center pin and pin 4 and on J10 between the center pin and pin 5 Models 2420 2450 and 2455 have a jumper...

Page 242: ...ion Board Connector Pin No Signal J1 1 N A 2 Ground 3 Tx EOC 4 Ground 5 Rx EOC 6 24 V dc Return 7 24 V dc J2 1 Ground 2 Paper Present 3 5 V dc J3 1 Ground 2 Paper Present 3 5 V dc J4 1 Motor Phase B 2...

Page 243: ...Connector Locations 5 18 4059 XXX...

Page 244: ...2 DC Motor Sensor Encoder Board 1 5 V dc Sensor 2 Tach 3 Ground J3 Stepper Motor 1 STPMOTA 2 STPMOTA 3 STPMOTB 4 STPMOTB J4 Fan 1 24 V dc 2 Fan On J5 Paper Input Sensor 1 5 V dc Sensor 2 Input 3 Groun...

Page 245: ...Board J9 Autoconnect Option Below 1 Ground 2 PrtxDout 3 Ground 4 PrtRxd J10 Autoconnect Option Below 1 24 V dc 2 Ground J11 Printer Autoconnect 1 24 V dc 2 Ground J12 Printer Autoconnect 1 N A 2 Grou...

Page 246: ...5 21 4059 Service Manual 4059 XXX Level 2 Duplex Option Board Autoconnect Top Connector Pin No Signal Top Autoconnect 1 0 V dc 2 5 V dc 3 0 V dc 4 0 V dc 5 0 V dc 6 5 V dc 7 0 V dc 8 24 V dc...

Page 247: ...No Signal J1A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J1B 1 Prtxdin 2 Ground 3 prtrxd 4 Ground 5 N C J2A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J2B 1 prtxdout 2 Ground 3 prtrxd 4 Ground J3 Pass Thru...

Page 248: ...5 23 4059 Service Manual 4059 XXX J5 Bin Full Sensor Single Sensor 1 Ground 2 N C 3 5 V dc 4 N C 5 RVsnsr Connector Pin No Signal...

Page 249: ...l 2 DC Motor Connector Pin No Signal J1A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J1B 1 Prtxdin 2 Ground 3 prtrxd 4 Ground 5 N C J2A Autoconnect 1 24 V dc 2 Ground 3 5 V dc J2B 1 prtxdout 2 Ground 3 pr...

Page 250: ...25 4059 Service Manual 4059 XXX J4 DC Motor 1 mtrout1 2 mtrout2 3 Ground 4 Ground 5 tach 6 5 V dc J5 Bin Full Near Full Dual Sensor 1 Ground 2 Ground 3 binful 4 binful 5 RVsnsr Connector Pin No Signa...

Page 251: ...tered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposu...

Page 252: ...ll at this interval to maintain the print quality and reliability of the printer The parts are available as a maintenance kit with the following part numbers 99A0290 100V 750W 2450 99A0500 115V 750W 2...

Page 253: ...P Parts Packet in the Description column indicates the part is contained in a parts packet INDENTURE The indenture is marked by a series of dots located before the parts description The indenture indi...

Page 254: ...7 2 4059 Service Manual 4059 XXX Assembly 1 Covers...

Page 255: ...0 1 Cover Assembly Lower Front 2450 2455 3455 1 8A 99A0022 1 Cap MPT 2450 2455 3455 1 9 99A0021 1 O Ring Lower Front Door NS 5 Screw Upper Front Cvr Mtg PP 99A0263 1 10 99A0917 1 Kit Upper Front Cover...

Page 256: ...7 4 4059 Service Manual 4059 XXX Assembly 1 Covers continued...

Page 257: ...Panel Cable Assembly 1 16 99A0003 1 Latch Upper Cover 1 17 99A0013 1 Cover Laser Assembly NS 6 Screw Laser Cover PP 99A0263 NS 99A0552 1 Cover Assembly Redrive Cap NS 99A0573 2 Nut Front Spacer Mount...

Page 258: ...7 6 4059 Service Manual 4059 XXX Assembly 2 Frame...

Page 259: ...0 99A0058 4 Pad Machine Mounting 2 11 99A0558 1 Transfer Plate Assembly 2 11 99A0828 1 Transfer Plate Assembly 3455 2 12 99A0904 1 Plate Assembly Stacker Ground 2450 2455 3455 2 12 99A0561 1 Support R...

Page 260: ...7 8 4059 Service Manual 4059 XXX Assembly 2 Frame continued...

Page 261: ...20 1855 2 30 99A0037 1 Frame Extension 2450 2455 3455 2 31 99A0899 1 Pan Motor Drip 2 32 99A0044 1 Track Cartridge Guide LH 2 33 99A0567 1 Link Gear Release 2 34 99A0555 1 Bracket Counterbalance Hinge...

Page 262: ...7 10 4059 Service Manual 4059 XXX Assembly 3 Printhead...

Page 263: ...mber Units Description 3 1 99A0065 1 Printhead Assembly 1620 1625 1650 1250 1255 3 1 99A0398 1 Printhead Assembly 1855 3 1 99A0066 1 Printhead Assembly 2420 2450 2455 3 1 99A0829 1 Printhead Assembly...

Page 264: ...7 12 4059 Service Manual 4059 XXX Assembly 4 Paper Feed Autocompensator...

Page 265: ...arts Catalog 7 13 4059 XXX Asm Index Part Number Units Description 4 1 99A0060 1 Sensor Paper Out Internal Tray 4 2 99A0067 1 Pick Arm Assembly 250 4 3 99A0070 2 Pick Rolls NS 1 Screw Hanger PP 99A026...

Page 266: ...7 14 4059 Service Manual 4059 XXX Assembly 5 Paper Feed Multipurpose Unit...

Page 267: ...0 1 Deflector Lower 5 8 2 Screw Lower Deflector Mounting 8 mm PP 99A0263 2450 5 8 2 Screw Lower Deflector Mounting 12mm PP 99A0263 1250 1255 1620 1650 2420 1855 1625 5 9 99A0021 1 O Ring Lower Front D...

Page 268: ...7 16 4059 Service Manual 4059 XXX Assembly 6 Paper Feed Alignment...

Page 269: ...n 6 1 99A0089 1 Alignment Assembly Paper Feed 6 2 99A0492 1 Screw Paper Reference Adjustment 6 3 99A0566 1 Nut 6 4 99A0559 1 Lever Bellcrank Release 6 5 99A0565 1 Washer Reference Adjustment NS 99A049...

Page 270: ...7 18 4059 Service Manual 4059 XXX Assembly 7 Paper Feed Output...

Page 271: ...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 Outer 250 1620 1650 1250 1255 2420 1855 1625 N...

Page 272: ...7 20 4059 Service Manual 4059 XXX Assembly 8 Integrated Paper Tray 250 Sheet...

Page 273: ...Sheet Tray 8 5 99A0119 4 Wear Strips 8 6 99A0123 1 Indicator Assembly Paper Size 8 7 99A0461 1 Label Tray Number 8 8 99A0121 1 Clip 250 Tray Wear 8 9 99A0126 4 Finger Autosize 8 10 99A0124 1 Plate Sna...

Page 274: ...7 22 4059 Service Manual 4059 XXX Assembly 9 Main Drive...

Page 275: ...450 2455 9 1 99A0130 1 Gearbox w Motor 1620 1650 1250 1255 1855 1625 9 1 99A0801 1 Gearbox w Motor 3455 9 2 99A0134 1 Shaft Power Takeoff 9 3 99A0275 1 Spring Power Takeoff Shaft 9 4 99A0954 1 Gear Be...

Page 276: ...7 24 4059 Service Manual 4059 XXX Assembly 10 Developer Drive...

Page 277: ...ndex Part Number Units Description 10 1 99A0135 1 Developer Drive Assembly 10 2 99A0136 1 Shaft Developer Drive 10 3 99A0564 1 Coupler Gear 55 10 4 1 Screw Developer Drive Ground PP 99A0263 10 5 2 Scr...

Page 278: ...7 26 4059 Service Manual 4059 XXX Assembly 11 Fuser...

Page 279: ...amp 1250 1255 11 1 99A0526 1 Fuser Assembly w 220V 500W Lamp 1250 1255 11 1 99A0830 1 Fuser Assembly w 115V 750W Lamp 3455 11 1 99A0831 1 Fuser Assembly w 220V 750W Lamp 3455 11 2 99A0146 1 Wiper Asse...

Page 280: ...7 28 4059 Service Manual 4059 XXX Assembly 11 Fuser continued...

Page 281: ...1 1 Board Assembly Fuser w Driver 1620 1650 2420 2450 2455 1855 1625 11 17 99A0826 1 Board Assembly Fuser 3455 11 18 99A0546 2 Clamp AC Fuser Cable 11 19 2 Screw Fuser Cover Assembly PP 99A0263 11 20...

Page 282: ...7 30 4059 Service Manual 4059 XXX Assembly 11 Fuser continued...

Page 283: ...drive Idler 11 35 1 Tie Wire PP 99A0577 11 36 99A0140 1 Lamp 115V 750W CC Red 2420 2450 2455 3455 11 36 99A0141 1 Lamp 115V 500W CC White 1250 1255 1620 1625 1650 1855 11 36 99A0177 1 Lamp 100V 500W C...

Page 284: ...7 32 4059 Service Manual 4059 XXX Assembly 12 Transfer...

Page 285: ...mbly 1855 C01 PRC 12 2 99A0349 1 Arm Transfer Roll Assembly Right 12 3 99A0184 1 Spring Transfer Roll Right 12 4 99A0186 1 Erase Lamp Assembly Kit o Lamp Erase Assembly o Lens Erase Lamp 12 5 99A0185...

Page 286: ...7 34 4059 Service Manual 4059 XXX Assembly 13 Charging...

Page 287: ...log 7 35 Asm Index Part Number Units Description 13 1 99A0512 1 Link Assembly Charge Left Kit 13 2 99A0513 1 Link Assembly Charge Right Kit 13 3 99A1033 1 Roll Assembly Charge NS 1 Screw Charge Roll P...

Page 288: ...7 36 4059 Service Manual 4059 XXX Assembly 14 Electronics...

Page 289: ...et 8 ft U K Ireland 14 2 1339539 1 Power Cord Set 6 ft Israel 14 2 1339540 1 Power Cord Set 6 ft Switzerland 14 2 1339541 1 Power Cord Set 6 ft South Africa 14 2 1342534 1 Power Cord Set 8 ft Chile HV...

Page 290: ...7 38 4059 Service Manual 4059 XXX Assembly 14 Electronics continued...

Page 291: ...4 9 3 Screw Int Shield Mounting PP 99A0263 14 10 2 Screw Controller Bd Mounting Front PP 99A0263 14 11 99A0426 2 Screw Parallel Connector Mounting 14 12 2 Screw Controller Bd Mounting Back PP 99A0263...

Page 292: ...7 40 4059 Service Manual 4059 XXX Assembly 14 Electronics continued...

Page 293: ...99A0206 1 Shield Outer 1650 2420 1855 14 19 99A0204 1 Shield Outer 2450 2455 NS 99A0224 1 Shield Interconnect Board 2450 2455 3455 NS 99A0229 1 Shield Interconnect Board 1625 1650 1855 2420 NS 99A0230...

Page 294: ...7 42 4059 Service Manual 4059 XXX Assembly 14 Electronics continued...

Page 295: ...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 Gearbox w Motor 3455 14 26 99A0256 1 Ca...

Page 296: ...7 44 4059 Service Manual 4059 XXX Assembly 14 Electronics continued...

Page 297: ...iary 2450 2455 3455 14 31 99A0466 1 Sensor Toner Cartridge Level 14 32 99A0296 1 Switch Cover Open w Operator Panel Cable Assembly 14 33 99A0001 1 Operator Panel Assembly 14 34 99A0576 1 Cable Front H...

Page 298: ...7 46 4059 Service Manual 4059 XXX Assembly 14 Electronics continued...

Page 299: ...01 14 38 99A0249 1 Cable Envelope Conditioner 1620 1625 1650 1855 2420 2450 2455 14 39 99A0173 1 Solenoid Assembly Envelope Conditioner 1620 1625 1650 1855 2420 2450 2455 3455 14 40 99A0170 1 Board As...

Page 300: ...7 48 4059 Service Manual 4059 XXX Assembly 15 250 Sheet Tray...

Page 301: ...1 Roller Skewed Backup 15 13B 99A0450 1 Retainer Roller 15 14 99A0276 1 Roll Assembly Drive 500 Dual 15 15 2 Screw Wear Plate Mounting PP 99A0263 15 16 99A0277 1 Wear Plate Pass Thru 250 Tray NS 99A02...

Page 302: ...7 50 4059 Service Manual 4059 XXX Assembly 15 250 Sheet Tray continued...

Page 303: ...99A0461 1 Label Tray Number 2 5 15 32 99A0121 1 Clip 250 Tray Wear 15 33 99A0126 4 Finger Autosize 15 34 99A0124 1 Plate Snap In 15 35 99A0127 1 Slider Autosize 250 15 36 99A0894 1 Latch Back Restrai...

Page 304: ...7 52 4059 Service Manual 4059 XXX Assembly 16 500 Sheet Tray...

Page 305: ...1 1 Label Tray Number 2 5 16 14 99A0457 1 Clip 500 Tray Wear 16 15 99A0126 4 Finger Autosize 16 16 99A0124 1 Plate Snap In 16 17 99A0418 1 Slider Autosize 500 16 18 99A0120 2 Restraint Pad 16 19 99A02...

Page 306: ...7 54 4059 Service Manual 4059 XXX Assembly 16 500 Sheet Tray continued...

Page 307: ...able 500 Auto Connect Top 16 36 99A0444 1 Stud Assembly 500 Frame 16 37 99A0282 1 Cable 500 Auto Connect Bottom 16 38 99A0438 2 Bearing Drive Roll 16 39 99A0277 1 Wear Plate Pass Thru 16 40 2 Screw We...

Page 308: ...7 56 4059 Service Manual 4059 XXX Assembly 17 500 500 Dual Tray...

Page 309: ...92 4 Wear Strips 17 13 99A0123 1 Indicator Assembly Paper Size 17 14 99A0461 1 Label Tray Number 2 5 17 15 99A0457 1 Clip 500 Tray Wear 17 16 99A0126 4 Finger Autosize 17 17 99A0124 1 Plate Snap In 17...

Page 310: ...7 58 4059 Service Manual 4059 XXX Assembly 17 500 500 Dual Tray continued...

Page 311: ...ing Backup Roller 17 39 99A0472 1 Cable Assembly 500 500 Dual 17 40 99A0278 1 Bellcrank Roller Release 17 41 99A0273 1 Gear Bevel 17 42 99A0063 1 Spring Switch Activate 17 43 99A0279 1 Bearing Drive S...

Page 312: ...7 60 4059 Service Manual 4059 XXX Assembly 18 Duplex...

Page 313: ...ain Drive 96 54 Gear 18 10 99A0321 1 Motor Assembly 18 11 99A0320 1 Cable D C Motor Tach 18 12 1 Cam Follower Assembly Kit PP 99A0299 18 13 99A0312 1 Actuator Assembly Deflector 18 14 2 Screw Actuator...

Page 314: ...7 62 4059 Service Manual 4059 XXX Assembly 18 Duplex continued...

Page 315: ...28 99A0325 1 Gear Pass Thru Idler 18 29 99A0280 1 Bearing Drive Shaft Low 18 30 99A0311 1 Cable Auto Connect Bottom 18 31 99A0274 1 Gear Pass Thru Drive Roll 18 32 99A0310 1 Cable Auto Connect Top 18...

Page 316: ...7 64 4059 Service Manual 4059 XXX Assembly 18 Duplex continued...

Page 317: ...0413 18 51 99A0330 1 Guide Assembly Center Drive 18 52 1 Fan Mounting Kit PP 99A0269 2 o Screw Fan Mounting M4x30 2 o Washer Fan M4 2 o Nut Fan M4 18 53 99A0308 1 Fan Cooling Duplex 18 54 2 Retainer 5...

Page 318: ...7 66 4059 Service Manual 4059 XXX Assembly 19 Output Expander...

Page 319: ...A0571 1 Cover Front Control Board with ESD Brush 19 8 99A0483 1 Tray Output Expander 19 9 99A0924 1 Spring Diverter 19 10 99A0925 1 Diverter Actuator Arm 19 11 99A0482 1 Spring Output Tray 19 12 99A03...

Page 320: ...7 68 4059 Service Manual 4059 XXX Assembly 19 Output Expander continued...

Page 321: ...wer Also order PP 99A0572 19 24 99A0363 3 Pulley Drive 19 25 99A0371 1 Cover Right Side 19 26 99A0361 1 Belt 160 Gear 19 27 99A0362 1 Arm Assembly Belt Idler 19 28 99A0364 1 Spring Belt Tensioner 19 2...

Page 322: ...7 70 4059 Service Manual 4059 XXX Assembly 20 Envelope Feeder...

Page 323: ...A0407 1 Base Assembly 20 6 99A0390 1 Support Slide Out 20 7 99A0488 7 Roller Support 20 8 99A0382 1 Motor Stepper D C 20 9 99A0383 1 Board Assembly Electronic Control 20 9 99A0402 1 Board Assembly Ele...

Page 324: ...7 72 4059 Service Manual 4059 XXX Assembly 20 Envelope Feeder continued...

Page 325: ...ive Idler Rear 20 12 99A0381 1 Cover Left Side 20 13 99A0388 1 Switch Envelope Out 20 14 99A0485 1 Sensor Envelope Pass Thru NS 1 Retainer 4 mm PP 99A0404 NS 3 Retainer Clip 5 mm Shaft PP 99A0404 NS 2...

Page 326: ...7 74 4059 Service Manual 4059 XXX Assembly 21 High Capacity Feeder...

Page 327: ...Transfer Lead Screw Assembly 21 9 99A0461 1 Label Tray Option Numbers 21 10 3 Screw Deflector Mounting 8 18 x 7 8 inch PP 99A0675 21 11 99A0716 1 Bearing Leadscrew Bottom 21 12 99A0658 2 Magnet Door 2...

Page 328: ...7 76 4059 Service Manual 4059 XXX Assembly 21 High Capacity Feeder continued...

Page 329: ...ut Base Mounting PP 99A0676 21 33 2 Washer Base Mounting PP 99A0677 21 34 2 Screw Base Mounting PP 99A0675 21 35 99A0663 1 Pulley Idler 21 36 99A0697 4 Spacer Motor Mounting 21 37 99A0699 1 Cable PS I...

Page 330: ...7 78 4059 Service Manual 4059 XXX Assembly 21 High Capacity Feeder continued...

Page 331: ...Mounting PP 99A0676 21 55 99A0654 1 Switch Paper Low 21 56 99A0651 1 Sensor Assembly Paper Out Upper Limit 21 57 3 Screw Printer Support 1 Frame Mounting PP 99A0675 NS 6 Washer Printer Support Frame...

Page 332: ...7 80 4059 Service Manual 4059 XXX Assembly 21 High Capacity Feeder continued...

Page 333: ...Wear Pass Thru NS 99A0286 1 Spring Backup Roller 21 71 99A0445 1 Stud Assembly 250 Frame 21 72 99A0280 1 Bearing Drive Shaft Low 21 73 99A0275 1 Spring Power Takeoff 21 74 99A0272 1 Shaft 250 Drive 2...

Page 334: ...7 82 4059 Service Manual 4059 XXX Assembly 21 High Capacity Feeder continued...

Page 335: ...0 Option 21 85 1 Screw Deflector Mounting PP 99A0263 21 86 99A0678 1 Deflector Base 21 87 99A0288 1 Sensor Pass Thru 21 88 99A0461 1 Label Tray Option Numbers 21 89 4 Washer Bracket 250 Frame Retentio...

Page 336: ...7 84 4059 Service Manual 4059 XXX Assembly 22 Kiosk Vertical Paper Adapter...

Page 337: ...PP 99A0208 22 7B 3 Gear Idler PP 99A0237 22 8 99A0079 1 Tray Assembly Backup Roller 22 9 99A0087 6 Spring Backup Roller 22 10 99A0086 6 Roller Backup 22 11 99A0116 1 Tray Assembly Drive Roller 22 12 9...

Page 338: ...7 86 4059 Service Manual 4059 XXX Assembly 23 Kiosk Horizontal Paper Adapter...

Page 339: ...7 Parts Pulley PP 99A0208 23 7B 3 Gear Idler PP 99A0237 23 8 99A0079 1 Tray Assembly Backup Roller 23 9 99A0087 6 Spring Backup Roller 23 10 99A0086 6 Roller Backup 23 11 99A0905 1 Tray Assembly Driv...

Page 340: ...99A0421 1 10 100 Ethernet Card 24 99A0422 1 10Base2 10BaseT Card with T connector 24 99A0560 1 Omni Bus INA Card 24 99A0424 1 IR Adapter 24 99A0515 1 Hard Disk w o Control Board 1250 1620 1650 2420 24...

Page 341: ...910 1 Cartridge 4059 Shipping 2 24 99A0909 1 Cartridge 4059 Shipping 1 24 99A0863 1 Hopper Integrated Label Letter 24 99A0864 1 Hopper Integrated Label Letter Stacker 24 99A0865 1 Hopper Legal Label S...

Page 342: ...1 Parts Packet Cable Ties 10 each 25 99A0675 1 Parts Packet Screws High Capacity Feeder 25 99A0676 1 Parts Packet Nuts High Capacity Feeder 25 99A0677 1 Parts Packet Washers High Capacity Feeder 25 99...

Page 343: ...ts Packet Pulley Kiosk 25 99A0234 1 Parts Packet Screws Kiosk 25 99A0265 1 Packaging Short 25 99A0295 1 Packaging Tall with 500 500 Option Tray 25 99A0248 1 Packaging 500 500 Dual Option Tray Assembly...

Page 344: ...Duplex Quick Test 3 4 Duplex Sensor Test 3 5 Error Log 3 8 Clearing the Error Log 3 8 Viewing the Error Log 3 8 Hardware Tests 3 9 Button Test 3 9 DRAM Memory Test 3 10 LCD Test 3 9 Parallel Wrap Tes...

Page 345: ...essages 2 20 User Status Messages 2 12 O Output Bin Feed Test 3 15 Output Bin Sensor Test 3 16 Output Bin Test Standard Bin 3 15 Output Bin X Sensor Test 3 16 Output Expander Control Board Level 1 Ste...

Page 346: ...44 Main Drive Motor 4 45 Multipurpose Tray Lower Deflector Assembly 4 46 Operator Panel 4 48 Operator Panel Cable Cover Open Switch Assembly 4 49 Optional Paper Tray Assembly 4 50 Outer EMC Shield 4 5...

Page 347: ...Transfer Roll 2 105 Setting Configuration ID 3 20 Setting the Page Count 3 19 Status Messages 2 12 Symptom Tables 2 25 Base Printer 2 25 Duplex 2 27 Envelope Feeder Option 2 27 High Capacity Feeder Op...

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