Lexmark 2450, 2420, 1855, 1650, 1625 Service Manual

4059-XXX

Optra

TM

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 Diagnostics

FirstEdition: September 2002

The following paragraph does not apply to any country where such

provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC.

PROVIDESTHIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND,

EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE

IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE. Some states do not allow disclaimer of express or

implied warranties in certain transactions, therefore, this statement may not apply

to you.

This publication could include technical inaccuracies or typographical errors.

Changes are periodically made to the information herein; these changes will be

incorporated in later editions. Improvements or changes in the products or the

programs described maybemadeat any time. Publications are not stocked at the

address given below; requests for publications should be made to your point of

purchase.

Comments may be addressed to Lexmark International, Inc., D22A/035-3,

740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may use

or distribute any of the information you supply in any way it believes appropriate

without incurring any obligation to you.

Lexmark and Optra are trademarks of Lexmark International, Inc., registered in

the United States and/or other countries.

©CopyrightLexmarkInternational,Inc.1998, 2002

All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,

duplication or disclosure by the Government is subject to restrictions as set forth in

subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software

clause at DFARS252.227-7013 and in applicable FAR provisions: Lexmark

International, Inc., Lexington, KY 40550.

4059-XXX

Contents iii

4059-XXX

Contents

Notices and Safety Information.......................ix

LaserNotices....................................... ix

SafetyInformation.................................. xvii

Preface.............................................xxii

General Information ................................... 1-1

Options .......................................... 1-4

Maintenance Approach . . . ........................... 1-5

Tools Required For Service........................... 1-5

Acronyms......................................... 1-6

Diagnostic Information ................................. 2-1

Start............................................. 2-1

ServiceErrorCodes.............................. 2-2

User Status Messages . .......................... 2-12

User Error Messages . . .......................... 2-16

Power-OnSelfTest(POST)....................... 2-24

SymptomTables................................ 2-25

ServiceChecks................................... 2-28

ChargeRollServiceCheck ....................... 2-29

CoverOpenSwitch/CableServiceCheck............ 2-31

DeadMachineServiceCheck ..................... 2-32

DuplexOptionServiceCheck...................... 2-35

Envelope Feeder Option Service Check ............. 2-39

EraseLampServiceCheck....................... 2-46

FanServiceCheck.............................. 2-47

FuserServiceCheck............................ 2-48

Fuser Envelope Conditioner Solenoid Service Check . . . 2-51

Input Sensor Service Check....................... 2-57

Input Tray(s) Option Service Check ................. 2-58

High Capacity Feeder Input Tray Service Check ....... 2-61

MainDriveServiceCheck ........................ 2-73

Operator Panel Service Check..................... 2-74

OptionsServiceCheck........................... 2-76

OutputBinSensorStandardTrayServiceCheck ...... 2-78

Output Expander Service Check . . ................. 2-79

Paper Feed Service Check........................ 2-86

ParallelPortServiceCheck....................... 2-89

Printhead Service Check ......................... 2-89

PrintQualityServiceCheck....................... 2-91

iv 4059 Service Manual

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SmartCartridgeServiceCheck................... 2-102

SerialPortServiceCheck....................... 2-104

TonerSensorServiceCheck..................... 2-104

TransferRollServiceCheck..................... 2-105

Diagnostic Aids ...................................... 3-1

Diagnostic Mode. .................................. 3-1

DeviceTests...................................... 3-2

QuickDiskTest................................. 3-2

DiskTest/Clean................................. 3-2

FlashTest..................................... 3-3

DisablingDownloadEmulations.................... 3-3

DuplexTests...................................... 3-4

DuplexQuickTest............................... 3-4

DuplexSensorTest.............................. 3-5

DuplexMotorTest............................... 3-5

DuplexFeed1Test.............................. 3-7

DuplexFeed2Test.............................. 3-7

ErrorLog......................................... 3-8

ViewingtheErrorLog............................ 3-8

ClearingtheErrorLog............................ 3-8

HardwareTests.................................... 3-9

LCDTest...................................... 3-9

ButtonTest .................................... 3-9

DRAMMemoryTest ............................ 3-10

ROMMemoryTest ............................. 3-10

ParallelWrapTest.............................. 3-11

SerialWrapTest............................... 3-12

Input Tray Tests . ................................. 3-14

Input Tray Feed Test ............................ 3-14

Input Tray Sensor Test . . ........................ 3-14

OutputBinTest-StandardBin.................... 3-15

OutputBinFeedTest............................ 3-15

OutputBinSensorTest.......................... 3-16

OutputBinXSensorTest........................ 3-16

BaseSensorTest .............................. 3-17

PrintRegistration ................................. 3-18

PrinterSetup..................................... 3-19

SettingthePageCount.......................... 3-19

Viewing the Permanent Page Count . ............... 3-19

Maintenance Page Count (2420/2450/2455/3455) ..... 3-20

SettingConfigurationID.......................... 3-20

RestoreEPFactoryDefaults...................... 3-21

Contents v

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PrintTests....................................... 3-22

PrintQualityTestPages.......................... 3-23

PrintingMenuSettingsPage...................... 3-24

AutocompensatorOperation......................... 3-25

Autoconnect System, Paper Tray Options, Envelope Feeder and

OutputExpanderOperations......................... 3-26

FuserOperation................................... 3-27

Paper Feed Jams ................................. 3-29

Repair Information .................................... 4-1

HandlingESD-SensitiveParts......................... 4-1

AdjustmentProcedures.............................. 4-2

DuplexMotorDriveBelts.......................... 4-2

Fuser Solenoid Adjustment ........................ 4-3

GapAdjustment................................. 4-3

Printhead Assembly Adjustment. . . .................. 4-4

Paper Alignment Assembly Adjustment ............... 4-5

Screw Identification Table . ........................... 4-7

RemovalProcedures............................... 4-12

Covers....................................... 4-12

CenterPanAssembly............................ 4-18

ControllerBoard................................ 4-19

DeveloperDriveAssembly........................ 4-20

DuplexBoard.................................. 4-21

DuplexFrontCoverAssembly..................... 4-21

DuplexFrontCoverDoor......................... 4-21

DuplexFrontCoverDoorSwitch................... 4-21

DuplexMotor .................................. 4-22

EngineBoard.................................. 4-23

EPFrameAssembly............................. 4-23

Fans......................................... 4-24

Fuser ........................................ 4-26

FuserBoard................................... 4-27

FuserCover................................... 4-28

Fuser Detack Fingers. . .......................... 4-29

FuserDetackHousingAssembly................... 4-29

FuserTransferPlate............................. 4-30

Fuser Envelope Conditioner Solenoid ............... 4-31

FuserExitFlagAssembly......................... 4-31

FuserExitRollAssembly......................... 4-32

FuserLamp ................................... 4-33

FuserLowerExitGuideAssembly.................. 4-33

High Voltage Power Supply ....................... 4-34

vi 4059 Service Manual

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Inner EMC Shield............................... 4-35

Inner Paper Deflector Assembly ................... 4-36

Integrated Tray Compensator Assembly ............. 4-37

Integrated Tray Compensator Pick Roll Assembly ..... 4-38

Interconnect Board Assembly ..................... 4-39

LeftSideFrame................................ 4-41

Low Voltage Power Supply ....................... 4-43

MainDriveAssembly............................ 4-44

MainDriveMotor............................... 4-45

MultipurposeTray/LowerDeflectorAssembly......... 4-46

Operator Panel ................................ 4-48

Operator Panel Cable/Cover Open Switch Assembly . . . 4-49

Optional 250/500 Paper Tray Assembly ............. 4-50

OuterEMCShield.............................. 4-51

Paper Alignment Assembly ....................... 4-52

Paper Input Sensor ............................. 4-53

Paper Size Sensing Board........................ 4-54

PickRoll...................................... 4-54

Printhead ..................................... 4-55

RedriveAssembly.............................. 4-56

RightSideFrame............................... 4-57

SmartCartridgeContacts ........................ 4-58

TonerSensor.................................. 4-59

TransferRollAssembly.......................... 4-60

UpperPaperDeflectorAssembly .................. 4-60

UpperFrontCoverHingeAssembly................ 4-61

UpperFrontCoverInterlockSwitchAssembly ........ 4-62

Connector Locations .................................. 5-1

Low Voltage Power Supply ........................ 5-1

High Voltage Power Supply........................ 5-3

EngineBoard................................... 5-4

FuserBoard................................... 5-11

Interconnect Board ............................. 5-14

EnvelopeOptionBoard.......................... 5-17

DuplexOptionBoard............................ 5-19

Autoconnect - Top .............................. 5-21

Output Expander Control Board - Level 1 Stepper Motor 5-22

OutputExpanderControlBoard-Level2DCMotor.... 5-24

Preventive Maintenance................................ 6-1

SafetyInspectionGuide............................. 6-1

Lubrication Specifications. . . ......................... 6-1

Scheduled Maintenance (2420/2450/2455/3455). . . ....... 6-2

Contents vii

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Parts Catalog ......................................... 7-1

HowToUseThisPartsCatalog ....................... 7-1

Assembly1:Covers.............................. 7-2

Assembly2:Frame............................... 7-6

Assembly 3: Printhead . .......................... 7-10

Assembly 4: Paper Feed (Autocompensator). . ........ 7-12

Assembly 5: Paper Feed - Multipurpose Unit. . ........ 7-14

Assembly 6: Paper Feed - Alignment................ 7-16

Assembly 7: Paper Feed - Output . ................. 7-18

Assembly 8: Integrated Paper Tray - 250 Sheet ....... 7-20

Assembly9:MainDrive.......................... 7-22

Assembly10:DeveloperDrive..................... 7-24

Assembly11:Fuser............................. 7-26

Assembly12:Transfer........................... 7-32

Assembly13:Charging .......................... 7-34

Assembly14:Electronics......................... 7-36

Assembly 15: 250 Sheet Tray ..................... 7-48

Assembly 16: 500 Sheet Tray ..................... 7-52

Assembly 17: 500/500 Dual Tray . . ................. 7-56

Assembly18:Duplex............................ 7-60

Assembly 19: Output Expander . . . ................. 7-66

Assembly 20: Envelope Feeder . . . ................. 7-70

Assembly 21: High Capacity Feeder ................ 7-74

Assembly22:Kiosk-VerticalPaperAdapter.......... 7-84

Assembly 23: Kiosk - Horizontal Paper Adapter........ 7-86

Assembly24:Options............................ 7-88

Assembly 25: Miscellaneous ...................... 7-90

Index................................................I-1

ix 4059 Service Manual

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Notices and Safety Information

Laser Notices

The following laser notice labels may be affixed to this printer as

shown:

Laser Advisory Label

Notices and Safety Information x

4059-XXX

Class 1 Laser Statement Label

APPAREIL À LASER DE CLASSE 1

CLASS 1 LASER PRODUCT

LASER KLASSE 1

LUOKAN 1 LASERLAITE

TO IEC 825

xi 4059 Service Manual

4059-XXX

Laser Notice

The printer is certified in the U.S. to conform to the requirements of

DHHS 21 CFR Subchapter J for Class I (1) laser products, and

elsewhere is certified as a Class I laser product conforming to the

requirements of IEC 825.

Class I laser products are not considered to be hazardous. The

printer contains internally a Class IIIb (3b) laser that is nominally a 5

milliwatt gallium arsenide laser operating in the wavelengthregion of

770-795 nanometers. The laser system and printer are designed so

there is never any human access to laser radiation above a Class I

level during normal operation, user maintenance, or prescribed

service condition.

Laser

Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die

Anforderungen der Bestimmung DHHS (Department of Health and

Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1).

In anderen Ländern gilt der Drucker als Laserprodukt der Klasse I,

der die Anforderungen der IEC (International Electrotechnical

Commission) 825 gemäß amtlicher Bestätigung erfüllt.

Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des

Druckers befindet sich ein Laser der Klasse IIIb (3b), bei dem es

sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen

der Länge 770-795 Nanometer ausstrahlt. Das Lasersystem und der

Drucker sind so konzipiert, daß im Normalbetrieb, bei der Wartung

durch den Benutzer oder bei ordnungsgemäßer Wartung durch den

KundendienstLaserbestrahlung, die die Klasse I übersteigen würde,

Menschen keinesfalls erreicht.

Avis relatif à l’utilisation de laser

Pour les Etats-Unis : cette imprimante est certifiée conforme aux

provisions DHHS 21 CFR alinéa J concernant les produits laser de

Classe I (1). Pour les autres pays : cette imprimante répond aux

normes IEC 825 relatives aux produits laser de Classe I.

Notices and Safety Information 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’imprimante et son système laser sont conçus

pour impossible, dans des conditions normales d’utilisation,

d’entretien par l’utilisateur ou de révision, l’exposition à des

rayonnements laser supérieurs à des rayonnements de C lasse I .

Avvertenze sui prodotti laser

Questa stampante è certificata negli Stati Uniti per essere conforme

ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di

classe 1 ed è certificata negli altri Paesi come prodotto laser di

classe 1 conforme ai requisiti della norma CEI 825.

I prodotti laser di classe non sono considerati pericolosi. La

stampante contiene al suo interno un laser di classe IIIb (3b)

all’arseniuro di gallio della potenza di 5mW che opera sulla

lunghezza d’onda compresa tra 770 e 795 nanometri. Il sistema

laser e la stampante sono stati progettati in modo tale che le

persone a contatto con la stampante, durante il normale

funzionamento, le operazioni di servizio o quelle di assistenza

tecnica, non ricevano radiazioni laser superiori al livello della classe

1.

Avisos sobre el láser

Se certifica que, en los EE.UU., esta impresora cumple los

requisitos para los productos láser de Clase I (1) establecidos en el

subcapítulo J de la norma CFR 21 del DHHS (Departamento de

Sanidad y Servicios) y, en los demás países, reúne todas las

condiciones expuestas en la norma IEC 825 para productos láser de

Clase I (1).

Los productos láser de Clase I no se consideran peligrosos. La

impresora contiene en su interior un láser de Clase IIIb (3b) de

arseniuro de galio de funcionamiento nominal a 5 milivatios en una

longitud de onda de 770 a 795 nanómetros. El sistema láser y la

impresora están diseñados de forma que ninguna persona pueda

verse afectada por ningún tipo de radiación láser superior al nivel de

xiii 4059 Service Manual

4059-XXX

la Clase I durante su uso normal, el mantenimiento realizado por el

usuario o cualquier otra situación de servicio técnico.

Declaração sobre Laser

A impressora está certificada nos E.U.A. em conformidade com os

requisitos da regulamentação DHHS 21 CFR Subcapítulo J para a

Classe I (1) de produtos laser. Em outros locais, está certificada

como um produto laser da Classe I, em conformidade com os

requisitos da norma IEC 825.

Os produtos laser da Classe I não são considerados perigosos.

Internamente, a impressora contém um produto laser da Classe IIIb

(3b), designado laser de arseneto de potássio, de 5 milliwatts

,operando numa faixa de comprimento de onda entre 770 e 795

nanómetros. O sistema e a impressora laser foram concebidos de

forma a nunca existir qualquer possiblidade de acesso humano a

radiação laser superior a um nível de Classe I durante a operação

normal, a manutenção feita pelo utilizador ou condições de

assistência prescritas.

Laserinformatie

De printer voldoet aan de eisen die gesteld worden aan een

laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen

vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in

IEC 825.

Laserprodukten van klasse I worden niet als ongevaarlijk

aangemerkt. De printer is voorzien van een laser van klasse IIIb

(3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met

een golflengte van 770-795 nanometer. Het lasergedeelte en de

printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of

reparatie conform de voorschriften, nooit blootstelling mogelijk is

aan laserstraling boven een niveau zoals voorgeschreven is voor

klasse 1.

Notices and Safety Information xiv

4059-XXX

Lasermeddelelse

Printeren er godkendt som et Klasse I-laserprodukt, i

overenstemmelse med kravene i IEC 825.

Klasse I-laserprodukter betragtes ikke som farlige. Printeren

indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5

milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet

770-795 nanometer. Lasersystemet og printeren er udformet

således, at mennesker aldrig udsættes for en laserstråling over

Klasse I-niveau ved normal drift, brugervedligeholdelse eller

obligatoriske servicebetingelser.

Huomautus laserlaitteesta

Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS

21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I

laserlaitteiden IEC 825 -määrityksen mukainen.

Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle.

Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin

galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.

Laserjärjestelmä ja kirjoitin on suunniteltu siten, että käyttäjä ei

altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen

normaalin toiminnan, käyttäjän tekemien huoltotoimien tai muiden

huoltotoimien yhteydessä.

VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina

näkymättömälle lasersäteilylle. Älä katso säteeseen.

VARNING! Osynlig laserstrålning när denna del är öppnad och

spärren är urkopplad. Betrakta ej strålen.

Laser-notis

Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21

CFR, underparagraf J för laserprodukter av Klass I (1). I andra

länder uppfyller skrivaren kraven för laser produkter av Klass I enligt

kraven i IEC 825.

xv 4059 Service Manual

4059-XXX

Laserprodukter i Klass I anses ej hälsovådliga. Skrivaren har en

inbyggd laser av Klass IIIb (3b) som består av en laserenhet av

gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-

795 nanometer. Lasersystemet och skrivarenär utformade så att det

aldrig finns risk för att någon person utsätts för laserstrålning över

Klass I-nivå vid normal användning, underhåll som utförs av

användaren eller annan föreskriven serviceåtgärd.

Laser-melding

Skriveren er godkjent i USA etter kravene i DHHS 21 CFR,

underkapittel J, for klasse I (1) laserprodukter, og er i andre land

godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC

825.

Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren

inneholder internt en klasse IIIb (3b)-laser, som består av en

gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet

770-795 nanometer. Lasersystemet og skriveren er utformet slik at

personer aldri utsettes for laserstråling ut over klasse I-nivå under

vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne

serviceoperasjoner.

Avís sobre el Làser

Segons ha estat certificat als Estats Units, aquesta impressora

compleix els requisits de DHHS 21 CFR, apartat J, pels productes

làser de classe I (1), i segons ha estat certificat en altres llocs, és un

producte làser de classe I que compleix els requisits d’IEC 825.

Els productes làser de classe I no es consideren perillosos. Aquesta

impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li,

nominalment de 5 mil.liwats, i funciona a la regió de longitud d’ona

de 770-795 nanòmetres. El sistema làser i la impressora han sigut

concebuts de manera que mai hi hagi exposició a la radiació làser

per sobre d’un nivell de classe I durant una operació normal, durant

les tasques de manteniment d’usuari ni durant els serveis que

satisfacin les condicions prescrites.

Notices and Safety Information xvi

4059-XXX

Japanese Laser Notice

Chinese Laser Notice

xvii 4059 Service Manual

4059-XXX

Korean Laser Notice

Safety Information

•

This product is designed, tested and approved to meet strict

global safety standards with the use of specific Lexmark

components. The safety features of some parts may not always

be obvious. Lexmark is not responsible for the use of other

replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not

intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.

Professional service personnel should understand this and take

necessary precautions.

Consignes de Sécurité

•

Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécurité globale lors de l'utilisation de

composants Lexmark spécifiques. Les caractéristiques de

Notices and Safety Information xviii

4059-XXX

sécurité de certains éléments ne sont pas toujours évidentes.

Lexmark ne peut être tenu responsable de l'utilisation d'autres

pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance

qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié

devra prendre toutes les précautions nécessaires.

Norme di sicurezza

•

Il prodotto è stato progettato,testato e approvatoin conformità a

severi standard di s icurezza e per l’utilizzo con componenti

Lexmark specifici. Le caratteristiche di sicurezza di alcune parti

non sempre sono di immediata comprensione. Lexmark non è

responsabile per l’utilizzo di parti di ricambio di altri produttori.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettriche e danni alla persona è più

elevato. Il personale di assistenza autorizzato, deve, quindi,

adottare le precauzioni necessarie.

Sicherheitshinweise

•

Dieses Produkt und die zugehörigen Komponenten wurden

entworfen und getestet, um beim E insatz die weltweit gültigen

Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten

Funktionen der Bauteile und Optionen sind nicht immer

offensichtlich. Sofern Teile eingesetzt werden, die nicht von

Lexmark sind, wird von Lexmark keinerlei Verantwortung oder

Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen

Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen

Schlags und körperlicher Verletzung. Das zuständige

xix 4059 Service Manual

4059-XXX

Fachpersonal sollte entsprechende Vorsichtsmaßnahmen

treffen.

Pautas de Seguridad

•

Este producto se ha diseñado, verificado y aprobado para

cumplir los más estrictos estándares de seguridad global

usando los componentes específicos de Lexmark. Puede que

las características de seguridad de algunas piezas no sean

siempre evidentes.Lexmark no se hace responsable del uso de

otras piezas de recambio.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de

mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la

máquina. El personal cualificado debe ser consciente de este

peligro y tomar las precauciones necesarias.

Informações de Segurança

•

Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes

específicos da Lexmark. As funções de segurança de alguns

dos componentes podem não ser sempre óbvias. A Lexmark

não é responsável pela utilização de outros componentes de

substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser

utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais

destes serviços devem estar avisados deste facto e tomar os

cuidados necessários.

Notices and Safety Information xx

4059-XXX

Informació de Seguretat

•

Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes normes 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. Lexmark no es responsabilitza de l'us

d'altres peces de recanvi.

• La informació pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada a

ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de servei d’aquest producte.

El personal professional ha d’estar-ne assabentat i prendre les

mesures convenients.

xxi 4059 Service Manual

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Chinese Safety Information

Korean Safety Information

Ozone Information

This product does not produce measurable amounts of ozone gas.

Preface xxii

4059-XXX

Preface

This manual is divided into the following chapters:

• “General Information” contains a general description of the

printer,options, and the maintenance approach used to repair it.

General environmental and safety instructions as well as

special tools and test equipment are listed in this chapter.

• “Diagnostic Information” contains a service error code table,

user status message table, user error message table, symptom

table,and service checks used to isolate failing field replaceable

units (FRUs).

• “Diagnostic Aids” contains tests and checks used to locate or

repeat symptoms of printer problems. Printer operation

information is provided to enhance the tests and checks.

• “Repair Information” provides instructions for making printer

adjustments and removing and installing FRUs.

• “Connector Locations” uses illustrations to identify the major

components and test points on the printer.

• “PreventiveMaintenance” contains safety inspection guidelines,

lubrication specifications, and maintenance information to

prevent problems and maintain performance.

• “Parts Catalog” contains illustrations and part numbers for

individual FRUs.

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1. General Information

The Optra™ S Laser Printers are letter quality page printers

designed to attach to IBM-compatible PC’s and to most computer

networks.

The printer is available in eleven models.

Optra S Model

1250 (4059-121)

1255 (4059-125)

General Information 1-2

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Optra S Models

1620 (4059-162)

1625 (4059-165)

1650 (4059-160)

1855 (4059-185)

1855 (4059-C01)

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Optra S Models

2420 (4059-242)

2450 (4059-240)

2455 (4059-245)

3455 (4059-345)

General Information 1-4

4059-XXX

Options

The following options are available. Some options are not available

in every country. Contact your point of purchase for options available

in your country.

Memory options of 4MB, 8MB, 16MB and 32MB

Flash memory options of 4MB and 8MB

Integrated network options

Token-Ring

Ethernet

Tri-Port

IR Adapter

IPDS

SCS

USB/Parallel Port

250 and 500-sheet paper trays of A5, letter, and legal size.

250 Sheet Special Media Tray Assembly

500/500-sheet dual trays (Models 2450, 2455 and 3455)

2000 Sheet High Capacity Feeder

Envelope feeder

Duplex option

Hard Disk - 1.4 GB (Models 1250, 1620, 1650, 2420 and 2450)

Hard Disk - 2.1 GB (Models 1255, 1625, 1855, 2455 and 3455)

Forms Hard Disk - 2.1 GB

Infrared Adapter

Kiosk Adapter

Output Expander (Models 1650, 1855, 2450, 2455 and 3455)

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Maintenance Approach

The diagnostic information in this manual leads you to the correct

field replaceable unit (FRU) or part. Use the service error codes,

user status messages, user error messages, service checks, and

diagnostic aids to determine the printer problem and repair the

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

verify the repair.

Tools Required For Service

Flat-blade screwdriver

#1 Phillips screwdriver

#2 Phillips screwdriver

7.0 mm nut driver

5.5 mm wrench

Needlenose pliers

Diagonal pliers

Spring hook

Feeler gauges

Analog or digital multimeter

Parallel wrap plug 1319128

Serial wrap plug 1329048

Twinax/serial debug cable 1381963

Coax/serial debug cable 1381964

General Information 1-6

4059-XXX

Acronyms

CSU Customer Setup

DRAM Dynamic Random Access Memory

EDO Enhanced Data Out

EP Electrophotographic Process

EPROM Erasable, Programmable Read-Only

Memory

ESD Electrostatic Discharge

FRU Field Replaceable Unit

GB Giga Byte

HVPS High Voltage Power Supply

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 Access Memory

OEM Original Equipment Manufacturer

PC Photoconductor

POST Power-On Self Test

RIP Raster Imaging Processor

ROM Read Only Memory

SIMM Single In-Line Memory Module

SRAM Static Random Access Memory

UPR Used Parts Return

V ac Volts alternating current

V dc Volts direct current

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2. Diagnostic Information

Start

CAUTION: Remove power from the printer before you connect or

disconnect any cable or electronic board or assembly for personal

safety and to prevent damage to the printer. Use the hand grips on

the side of the printer. Make sure your fingers are not under the

printer when you lift or set the printer down.

Use the service error code, user status message, user error

message, symptom table, service checks, and diagnostic aids in this

chapter to determine the corrective action necessary to repair a

malfunctioning printer.

Service error codes are indicated by a three digit error code. If a

service error code is displayed, go to the “Service Error Codes” on

page 2-2.

User status messages provide the user with information on the

current status of the printer. Ready is displayed on the first line of the

display unless Power Saver is invoked, then Power Saver is

displayed. If a user status message is displayed, go to the “User

Status Messages” on page 2-12.

User error messages are indicated by a two or three digit error code

that provides the user with information that explains a problem with a

print cartridge, paper jam, option, port, and so on. If a user error

message is displayed, go to the “User Error Messages” on

page 2-16.

If your machine completes the “Power-On Self Test (POST)” on

page 2-24 without an error, and you have a symptom, go to the

“Symptom Tables” on page 2-25. Locate your symptom and take the

appropriate action.

If a service error code appears while you are working on the

machine, go to the “Service Error Codes” on page 2-2 and take the

indicated action for that error.

Diagnostic Information 2-2

4059-XXX

Service Error Codes

Service Error Codes are generally non-recoverable except in an

intermittent condition when you can POR the printer to temporarily

recover from the error condition.

Error Code Action

900 RIP Software Contact the next support level or call Lexmark.

901 Engine Flash This error indicates that the flash which the engine board

code is programmed into is bad. Replace the engine

board.

902 General

Engine Software

These errors indicate an unrecoverable engine software

error. Replace the engine board.

903 Paperport

Link Driver Error

904 Interface

Violation by the

controller

software

905 Interface

Violation by

Paperport Device

906 Controller-

Engine Link

Driver Error

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910 DC Pick

Motor DC Pick

Motor Stall

Error Codes 910,911,912,913 and 914 are indications

that a Tray 1 paper feed problem has been detected. Go

to the “Input Tray(s) Option Service Check” on

page 2-58.

911 DC Pick

Motor Excessive

PWM

912 DC pick

motor below

speed

913 DC pick

motoroverspeed

914 DC pick

motor: No

encoder feedback

917 Transfer Roll Indicates a problem in the transfer roll area. Go to the

“Transfer Roll Service Check” on page 2-105.

920 Fuser Error Indicates that the fuser is below temperature when

printing. Go to the “Cold Fuser Service Check” on

page 2-48.

921 Fuser Error Indicates that the fuser is below standby temperature

when the printer is idle. Go to the “Cold Fuser Service

Check” on page 2-48.

922 Fuser Error Fuser failed to reach standby temperature. Go to the

“Cold Fuser Service Check” on page 2-48.

923 Fuser Error Fuser is too hot during printing or when printer is idle. Go

to the “Hot Fuser Service Check” on page 2-50.

924 Fuser Error An open circuit has been detected in the Fuser

Thermistor Circuit. Go to the “Hot Fuser Service Check”

on page 2-50.

925 Fuser Error Wrong fuser lamp installed. Check the fuser lamp for the

correct type of lamp that should be installed.

927 Fan Stalled Indicates a printer fan stalled. Go to the “Fan Service

Check” on page 2-47.

928 Erase Lamps Indicates that the engine has detected that either the

erase lamp assembly is missing or disconnected. Go to

the “Erase Lamp Service Check” on page 2-46.

Error Code Action