Lexmark Optra S Service Manual

Download

Revised: 11/1/06

• Table of Contents

•Start Diagnostics

Optra™ S

4059-XXX

• Safety and Notices

• Trademarks

•Index

Lexmark and Lexmark with diamond design are trade ma rks of Lexmark International, Inc., registered i n the United States and/or ot her countries.

First Edition: November 1, 2006

The followin g paragraph does not apply to any country where such provisions are inc o n s istent with local law: LEXMARK INTERNATIONAL,

INC. PRO VIDES THIS PUBL ICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EI THER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTI CULAR PURPO SE. Some states do not allow disclaimer of express or implied warr anties in certain transact ions, therefore, this statement may not apply to you.

This publica tion could include te chnical inaccuracies or typog raphical errors. Changes are periodi cally made t o the inf ormati on herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Publications are not stocked at the address giv en bel ow; request s f or publ icati ons shoul d be made to yo ur p oint of purchase.

A form for reader’s comments is provided at the back of this publication. If the form has been removed, comments may be addressed to Le xmark International, Inc., D22A/035-3, 740 New Circle Road NW, Lexington, K entucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believ es 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.

©Copyright Lexmark International, Inc. 1998, 2006

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplicat ion or disclosure by the Government is subj ect to restrictions as set forth in subpar ag raph ( c)(1) (ii) o f the Ri ghts i n Technical Data and Comp uter Software clause at DFARS 252.227-7013 and in applicable FAR pr ovisions: Lexmark International, Inc., Lexington, KY 40550.

USA P/N: 12G0139

Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . 1-ix

Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-ix

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xvii

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-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

Service Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

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

Power-On Self Test (POST). . . . . . . . . . . . . . . . . . . . . . . 2-24

Symptom Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Charge Roll Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-29

Cover Open Switch/Cable Service Check . . . . . . . . . . . . 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 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

Main Drive Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-73

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

Options Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76

Output Bin Sensor Standard Tray Service Check . . . . . . 2-78

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

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

Parallel Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-89

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

Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-91

Contents iii

Smart Cartridge Service Check . . . . . . . . . . . . . . . . . . . 2-102

Serial Port Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-104

Toner Sensor Service Check. . . . . . . . . . . . . . . . . . . . . 2-104

Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . . 2-105

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

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

Device Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Quick Disk Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Disk Test/Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Disabling Download Emulations . . . . . . . . . . . . . . . . . . . . 3-3

Duplex Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Duplex Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Motor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Duplex Feed 1 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Duplex Feed 2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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

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

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

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

Output Bin Test - Standard Bin . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Feed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Bin Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Output Bin X Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Base Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Printer Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

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

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

Setting Configuration ID. . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Restore EP Factory Defaults . . . . . . . . . . . . . . . . . . . . . . 3-21

iv 4059 Service Manual

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Print Quality Test Pages. . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Printing Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . 3-24

Autocompensator Operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Autoconnect System, Paper Tray Options, Envelope Feeder and

Output Expander Operations. . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Fuser Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

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

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

Handling ESD-Sensitive Parts. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Duplex Motor Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

Paper Alignment 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 Cover Assembly . . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Front Cover Door . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Duplex Front Cover Door Switch . . . . . . . . . . . . . . . . . . . 4-21

Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

EP Frame Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

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

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

Fuser Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Fuser Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

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

Fuser Detack Housing Assembly . . . . . . . . . . . . . . . . . . . 4-29

Fuser Transfer Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

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

Fuser Exit Flag Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Fuser Exit Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Fuser Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

Fuser Lower Exit Guide Assembly . . . . . . . . . . . . . . . . . . 4-33

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

Contents v

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

Left Side Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

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

Main Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

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

Outer EMC Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51

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

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

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

Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

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

Redrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56

Right Side Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57

Smart Cartridge Contacts . . . . . . . . . . . . . . . . . . . . . . . . 4-58

Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59

Transfer Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60

Upper Paper Deflector Assembly . . . . . . . . . . . . . . . . . . 4-60

Upper Front Cover Hinge Assembly . . . . . . . . . . . . . . . . 4-61

Upper Front Cover Interlock Switch Assembly . . . . . . . . 4-62

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

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

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

Engine Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Fuser Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

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

Envelope Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Duplex Option Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

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

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

Output Expander Control Board - Level 2 DC Motor . . . . 5-24

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

Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

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

vi 4059 Service Manual

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

How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . 7-1

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Assembly 2: 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

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

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

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

Assembly 18: Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60

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

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

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

Assembly 22: Kiosk - Vertical Paper Adapter. . . . . . . . . . 7-84

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

Assembly 24: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-88

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

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

Contents vii

viii 4059 Service Manual

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 ix

Class 1 Laser Statement Label

CLASS 1 LASER PRODUCT LASER KLASSE 1 LUOKAN 1 LASERLAITE APPAREIL À LASER DE CLASSE 1 TO IEC 825

x 4059 Service Manual

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 wavelength region of 770-795 nanometers. The laser system and printer are designed so there is never any human access to laser radiation above a Class 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 Kundendienst Laserbestrahlung, 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 xi

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 Classe 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

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

xii 4059 Service Manual

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 xiii

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 laserprodukter av Klass I enligt kraven i IEC 825.

xiv 4059 Service Manual

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 770795 nanometer. Lasersystemet och skrivaren är 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 xv

Japanese Laser Notice

Chinese Laser Notice

xvi 4059 Service Manual

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 xvii

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 approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non 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 Einsatz 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

xviii 4059 Service Manual

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 xix

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.

xx 4059 Service Manual

Chinese Safety Information

Korean Safety Information

Ozone Information

This product does not produce measurable amounts of ozone gas.

Notices and Safety Information xxi

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.

• “Preventive Maintenance” contains safety inspection guidelines,

lubrication specifications, and maintenance information to prevent problems and maintain performance.

• “Parts Catalog” contains illustrations and part numbers for

individual FRUs.

xxii 4059 Service Manual

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 1-1

Optra S Models

1620 (4059-162) 1625 (4059-165) 1650 (4059-160) 1855 (4059-185) 1855 (4059-C01)

1-2 4059 Service Manual

Optra S Models

2420 (4059-242) 2450 (4059-240) 2455 (4059-245) 3455 (4059-345)

General Information 1-3

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 Tr i - Po r t 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)

1-4 4059 Service Manual

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 1-5

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

1-6 4059 Service Manual

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 2-1

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

902 General Engine Software

903 Paperport Link Driver Error

904 Interface Violation by the controller software

905 Interface Violation by Paperport Device

906 ControllerEngine Link Driver Error

code is programmed into is bad. Replace the engine board.

These errors indicate an unrecoverable engine software error. Replace the engine board.

2-2 4059 Service Manual

Error Code Action

910 DC Pick Motor DC Pick Motor Stall

911 DC Pick Motor Excessive PWM

912 DC pick motor below speed

913 DC pick motor over speed

914 DC pick motor: No encoder feedback

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

920 Fuser Error Indicates that the fuser is below temperature when

921 Fuser Error Indicates that the fuser is below standby temperature

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.

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

printing. Go to the “Cold Fuser Service Check” on page 2-48.

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

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

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

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

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

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

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

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

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

correct type of lamp that should be installed.

Check” on page 2-47.

erase lamp assembly is missing or disconnected. Go to the “Erase Lamp Service Check” on page 2-46.

Diagnostic Information 2-3

Error Code Action

929 Toner Sensor The toner sensor is not operating properly, the developer

drive assembly is not operating properly or the print cartridge is defective. Go to the “Toner Sensor Service Check” on page 2-104.

930 Printhead Error

931-935 Printhead Error

931 - Printhead: no first Hsync

932 - Printhead: Lost HSYNCS

934 - Mirror Motor Lost Lock

935 - Mirror Motor unable to reach operating speed.

936-937 Transport Motor

936 - Main Drive Motor initial lock failure

937 - Main Drive Motor lost lock

939 Controller Engine Communications Error

The wrong printhead is installed. Replace with the correct printhead.

These errors represent a problem with the printhead. Go to the “Printhead Service Check” on page 2-89.

Indicates a problem with the main drive motor. Go to the “Main Drive Service Check” on page 2-73.

The controller board and the engine board cannot communicate with one another. The controller board, engine board or interconnect board is defective. Check each board for correct installation and secure ground. If no problem is found, replace the FRUs in the following order:

controller board

engine board

interconnect board

Note: The controller software also can cause a 939 error code. Contact your next level for software support.

2-4 4059 Service Manual

Error Code Action

941 Controller Code CRC

941 Controller Font CRC

943 Controller Font Version

944 Controller Board Failure

945 Controller Board Failure ASIC Failure

946 Controller Board Failure SRAM Failure

947 Engine Board

953 NVRAM Failure

954 NVRAM Failure

956 Configuration IDIndicates a problem with the Configuration ID. This error

Replace the controller board.

Indicates that the controller code and FONT ROM are incompatible.

Replace the controller board.

Replace the engine board.

Indicates the NVRAM Chip on the engine board has failed. Replace the engine board.

Indicates the NVRAM experienced a CRC failure. Replace the engine board.

occurs because the engine received a configuration ID from the controller software which is not valid for the level of engine code existing in the printer. Setting the configuration ID correctly should fix this error. The ID can be set via the NPA data stream or operator panel.

960 RAM Memory Error

961 RAM in Slot 1 is Bad.

Note: This error is not generated at POR to allow the servicer a method of resetting the configuration ID. However, setting the configuration ID is the only operation that the servicer can perform. See “Setting Configuration ID” on page 3-20.

Indicates a DRAM Memory Error on the controller board. Replace the controller board.

Replace the SIMM in Slot 1. If this does not fix the problem, replace the controller board.

Diagnostic Information 2-5

Error Code Action

962 RAM in Slot 2 is Bad.

964 Emulation Error

965 Emulation Error

975 - 979 Network Card X

980 <device> Comm

981 <device> The engine protocol violation detected by the specified

Replace the SIMM in Slot 2. If this does not fix the problem, replace the controller board.

Indicates a failure within the Download Emulation which is programmed into the code overlay SIMM. The specific error is as follows: 964 - Download Emulation CRC Failure. Checksum Failure. 965 - Download Emulation Outdated, The Download Emulation and the controller code are incompatible. Go to “Disabling Download Emulations” on page 3-3.

The following errors indicate a failure with the network card in the specified slot. X=any card installed in slots 1,2 or 3. 975 - Unrecognizable Network Card x. Replace Network Card x. 976 - Unrecoverable software error in Network Card x. 977 - Controller software detects that a Network Card is installed in slot x but cannot establish communications with it. 978 - Bad checksum while programming Network Card x. Replace Network Card x. 979 - Flash parts failed while programming Network Card x.

The engine is experiencing unreliable communications to the specified device.

device.

982 <device> Comm

983 <device> Invalid command received by the specified device.

984 <device> Invalid command parameter received by the specified

Communications error detected by the specified device.

device.

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).

2-6 4059 Service Manual

Error Code Action

990 <device> Indicates an equipment check condition has occurred in

the specified device, but the device is unable to identify the exact component failure.

Note: <device> can be one of the following: duplex, tray x (1,2,3,4 or 5), envelope feeder or output bin x(1,2 or 3).

991 <device> Card

The specified device has detected an equipment check in its system card.

Note: <device> can be one of the following: duplex, tray x(1,2,3,4 or 5), envelope feeder or output bin x (1,2 or 3).

Sub Error Codes For 9XX and 2XX Error Codes

The sub error codes are helpful troubleshooting a paper path problem, especially paper jams in the base printer, envelope feeder and duplex unit.

The following is an example of how the printer displays a duplex unit sub error code.

Byte 4

Byte 8

Byte 1

Byte 5

Byte 2

Byte 6

Byte 3

Byte 7

Diagnostic Information 2-7

Base Printer Sub Error Codes

Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays status bytes 1, 2 and 3. This set of status bytes is designed to help isolate paper jams and paper feed problems in the base printer.

Status Bytes 1, 2,3

84 xx 00 The input sensor is still covered by the first sheet of paper

84 xx 01 Video information has not started on the page at the input

84 xx 02 The media takes too long to complete a pass through the

84 xx 04 This can occur when a sheet of paper is in the machine

84 xx 05 This error is generated whenever media is seen at the input

84 xx 06 A paper jam is detected by the tray you are trying to feed

84 xx 07 A paper jam is detected by a smart option and an error

84 xx 08 Paper Tray 5 pass thru sensor is not activated by a sheet of

84 xx 09 Paper Tray 4 pass thru sensor is not activated by a sheet of

Explanation

through the printer and the second sheet is ready to arrive at the sensor.

sensor within two inches after activating the input sensor flag.

input sensor.

during POST and the input sensor flag has tripped the input sensor.

sensor before the sensor flag activates the input sensor.

from.

message displays.

paper.

84 xx 0A Paper Tray 3 pass thru sensor is not activated by a sheet of

paper.

84 xx 0B Paper Tray 2 pass thru sensor is not activated by a sheet of

84 xx 0C Paper Tray 5 pass thru sensor is not activated and never

paper.

deactivated. A sheet of paper may still be over the sensor or the flag is still activated.

2-8 4059 Service Manual

Status Bytes 1, 2,3

Explanation

84 xx 0D Paper Tray 4 pass thru sensor is not activated and never

84 xx 0E Paper Tray 3 pass thru sensor is not activated and never

84 xx 0F Paper Tray 2 pass thru sensor is not activated and never

84 xx 11 The paper activated the input sensor too soon.

84 xx 13 The paper activated the input sensor too soon.

84 xx 1D The envelope feeder pass thru sensor is activated and never

84 xx 1E The envelope feeder pass thru sensor is not activated.

84 xx 1F The paper fed too early from Tray 1.

84 xx 21 The smart option did not pick the paper.

84 xx 22 The smart option did not pick the paper.

8E xx 02 The input sensor is not activated even though the paper is

8E xx 0B The autocompensator DC motor stalls when attempting to

deactivated. A sheet of paper may still be over the sensor or the flag is still activated.

deactivated. A sheet of paper may still be over the sensor.

deactivated.

picked from the source.

pick a sheet of paper.

8E xx 11 The autocompensator DC motor takes too long to ramp up.

Diagnostic Information 2-9

Envelope Feeder Sub Error Codes

Status byte 1 contains the most valuable information to help isolate a feed problem with the envelope feeder and is the only byte contained in the following table.

Status Byte 1

00 There was no envelope feeder error reported.

10 Printer failed POST - Homing of Envelope feeder

11 Printer failed POST - Halted Envelope Feeder

21 The envelope feeder failed to feed, envelope jam.

30 The D.C. motor failed to reach operating speed.

32 The motor stalled.

36 The motor failed to stop.

Explanation

Duplex Unit Sub Error Codes

Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the duplex option and is the only byte contained in the following table.

Status Byte 4

00 No duplex error. No problem was reported to the engine by the

Explanation

duplex system card.

01 The leading edge of the sheet of paper never arrived at the input

sensor.

02 The duplex option system board never received media notification

from the printer.

03 The trailing edge of the sheet of paper never cleared the input

sensor.

2-10 4059 Service Manual

Status Byte 4

Explanation

04 The leading edge of the sheet of paper never arrived at the exit

05 The duplex logic thinks a sheet of paper is feeding to the duplex

06 The exit sensor detected a sheet of paper too early.

07 The sheet of paper’s trailing edge did not clear the exit sensor in

08 The feed motor experienced a complete motor stall.

0E The D.C. motor is under speed. The motor never reached the

13 There is paper left in the duplex option. Paper was sensed during

15 There is paper left in the duplex option. Paper was sensed during

18 The D.C. motor experienced an acceleration error.

3D There is paper left in the duplex option. Paper was sensed during

sensor. Note: This error is the most common due to the long length of the paper path between the input sensor and the exit sensor.

unit due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send a sheet of paper to the duplex unit.

the desired length of time.

correct operating speed.

the homing operation during POST.

the DC motor diagnostic test during POST.

IR clear during POST.

Diagnostic Information 2-11

User Status Messages

User Status Message Status Action

Ready The printer is ready to

receive and process data.

Ready/Hex The printer is ready and

HEX Trace is active, which is known as HEX Trace Ready.

Busy The printer is busy

receiving or processing data, or printing data.

Note: The printer indicator light blinks while the printer is processing data.

Press Menu> or <Menu to take the printer out of Ready and enter all the Menus except the TESTS MENU (Busy State).

Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy State). Press Select for the values. Press Menu> until Reset Printer is on the second line of the display. Press Select to Reset the printer.

Press Stop to take the printer out of Busy. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready.

Flushing Buffer The printer is flushing

corrupted print data and the current print job is being discarded.

2-12 4059 Service Manual

No button actions are possible while this message is displayed.

User Status Message Status Action

Printing Menu Settings The printer is processing

or printing a list of current settings menus because Print Menu Settings is selected from the menu.

Printing Directory List A directory of the flash

and disk contents is processing or printing because Print Directory is selected from the menu.

Press Stop to take the printer out of Ready. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the printer paper path. Press Go to return to Ready after the page prints. Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy State). Press Select for the values. Press Menu> until Reset Printer is on the second line of the display. Press Select to reset the printer.

Press Stop to take the printer out of Ready. The Not Ready message is displayed. No more data is processed, but the printer processes all paper currently in the paper path. Press Go to return to Ready after the page prints. Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy Stat). Press Select for the values. Press Menu> until Reset Printer is on the second line of the display. Press Select to reset the printer.

Diagnostic Information 2-13

User Status Message Status Action

Restoring Factory Defaults

Performing Self Tests The printer is running

Not Ready (Press Go)

Resetting Printer The printer is deleting

The printer is restoring factory defaults.

the normal series of start-up tests after it is powered On. When the tests are complete, the printer returns to Ready.

The printer is in the Not Ready State, which means it is not ready to receive or process data. This message displays when Menu> or <Menu is pressed during a print job.

any print jobs in process and restoring all settings to user defaults.

No button actions are possible while this message is displayed.

Press Go to take the printer out of the Not Ready state. Press Menu> or <Menu to take the printer out of Ready and enter the TESTS MENU (Busy State). Press Menu> until Reset Printer is on the second line of the display. Press Select to reset the printer.

No button actions are possible while this message is displayed.

Formatting Flash (Do Not Power Off)

Program Flash (Do Not Power Off)

Formatting Disk The disk is being

The flash memory is being formatted.

The flash memory is being programmed, which means fonts or macros are being written to flash memory.

formatted.

2-14 4059 Service Manual

No button actions are possible while this message is displayed.

Do not perform any button actions while this message is displayed.

No button actions are possible while this message is displayed.

User Status Message Status Action

Programming Disk (Do Not Power Off)

Menus Disabled The printer menus have

Activating Menu Changes

The disk is being programmed, which means fonts or macros are being written to disk.

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 message for one second and then returns to the Ready message.

The printer is reset to activate a printer setting changed in the menus.

No button actions are possible while this message is displayed.

Note: If information is written to flash memory and to disk at the same time, the Program Flash message is displayed.

No button actions are possible while this message is displayed.

Diagnostic Information 2-15

User Error Messages

User Error Message Explanation

200 Paper Jam Remove Cartridge

201 Paper Jam Remove Cartridge

202 Paper Jam Open Rear Door

230 Paper Jam Check Duplex

24X Paper Jam Check Tray X

250 Paper Jam Check MP Feeder

Paper is jammed at the printer Input Sensor. Open the printer’s upper front door and remove the print cartridge to access the paper jam area.

Paper is jammed between the printer’s input and exit sensors. Open the printer’s upper front door and remove the print cartridge to access the jam area.

Paper is jammed at the printer exit sensor. Open the printer rear door to access the jam area.

The paper is most likely jammed in the Duplex Unit. Remove the duplex front cover to access the jam area. If the paper is jammed in the rear of the duplex, then replace the duplex front cover and open the duplex rear door. If the paper is not jammed in the duplex unit, then it may be jammed in the rear of the printer. Open the printer rear door to access the jam.

Paper is jammed around Tray X (X=tray 1 thru 5). Try opening Tray X. If the tray is difficult to remove, then you may have to remove the tray above or below tray X to remove the jammed pages.

Paper is jammed in the multipurpose feeder.

260 Paper Jam Check Envelope Feeder

27X Paper Jam Check Output Bin X

Insert Cartridge or Close Door

2-16 4059 Service Manual

Paper is jammed in the envelope feeder.

Paper is jammed in output bin X (X=1 thru 3). Open the rear door of Output Bin X to access the jammed pages.

This message displays when the printer’s front door is open or the print cartridge is missing. If this message cannot be cleared go to “Cover Open Service Check”.

User Error Message Explanation

31 Defective Print Cartridge

32 Unsupported Print Cartridge

Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, they are not reprinted once a good print cartridge is inserted.

Note: This error indicates the printer was able to read the cartridge ID, but the ID did not pass the verification test. To pass the verification test, the ID read from the print cartridge must match the ID from the last “good” print cartridge or the same ID must be read from the print cartridge twice. The last “good” print cartridge ID is stored in NVRAM.

Error 32 is displayed when the top cover is closed and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, then they are not reprinted once a good print cartridge is inserted. This error message also displays on a model 3455 printer if the smart cartridge or smart cartridge hardware is not operating correctly. Try another model 3455 print cartridge. If this does not fix the problem, go to “Smart Cartridge Service Check” on page 2-102.

34 Short Paper The printer determines the paper length is too

short to print the formatted data. This occurs when the printer does not know the actual paper size loaded in the tray. For auto-size sensing trays, this error occurs if the paper stop is in the incorrect position. Make sure the Paper Size setting is correct for the size paper that is being used.

Diagnostic Information 2-17

User Error Message Explanation

36 Resolution Reduced The resolution of the page has been reduced

from 600 dpi to 300 dpi in order to prevent a Memory Full error. This message can only occur if the Resolution Reduction setting is turned on.

Note: 1200 dpi pages are not resolution reduced. If a 1200 dpi job runs out of memory, a Memory Full error is displayed.

37 Insufficient Collation Memory

38 Memory Full This message is displayed when the printer

39 Complex Page This message is displayed when the page is too

51 Defective Flash This message is displayed when the printer

52 Flash Full This message is displayed when there is not

53 Unformatted Flash This message is displayed when the printer

This message is displayed when the printer memory used to store pages is too full to collate the print job.

memory used to store pages is full.

complex to print.

detects a defective flash. This error may occur at power on, or during flash format and write operations. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the problem is resolved.

enough free space in the flash memory to hold the resources that have been requested to be written to flash.

detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted.

54 Standard Serial Error This error is displayed when a serial error

54 Serial Option X Error This error is displayed when a serial error

(framing or parity) is detected on the standard serial port. This usually indicates the serial port is not set up correctly.

(framing or parity) is detected on the optional serial port. This usually indicates the optional serial port is not set up correctly.

2-18 4059 Service Manual

User Error Message Explanation

56 Standard Serial Disabled

56 Parallel Port Disabled This error is displayed when data is sent to the

58 Too Many Trays Attached

58 Too Many Bins Attached

58 Too Many Disks Installed

61 Defective Disk This error code is displayed when the printer

This error is displayed when data is sent to the printer across the standard serial port, but the port has been disabled.

printer across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset.

This error code is displayed when too many input trays are attached to the printer.

This error code is displayed when too many optional output bins are attached to the printer.

This error is displayed when too many disks are attached to the printer.

detects a defective disk. This error may occur at power on or during disk format and write operations. The following actions may be taken while this message is displayed: Press Go to clear the message. The disk is marked defective and normal printer operations continue. Disk operations are not allowed with a defective disk. The Format Disk menu is not shown.

62 Disk Full This error code is displayed when there is not

enough free space on the disk to hold the resources that have been requested to be written to the disk. This message displays for both resource and PostScript Disk operators when the disk is full.

63 Unformatted Disk This error code displays when the printer detects

an unformatted disk at power on. Press Go to clear the message. The disk is marked as bad and normal operation continues. Disk operations are not allowed until the disk is formatted.

Diagnostic Information 2-19

User Error Message Explanation

80 Scheduled Maintenance

81 Engine Code CRC Failure

88 Toner Low This error displays when toner low occurs and the

The operator panel displays this message at each 250K page count interval. It is necessary to replace the fuser assembly, transfer roller, compensator pick-rolls and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit. For more information, go to “Scheduled Maintenance (2420/2450/2455/

3455)” on page 6-2.

This error displays when the microcode to be programmed in the engine flash code module has failed a CRC check. Press Go to clear the message. The microcode data is discarded and must be re-transmitted from the host computer.

toner low alarm is activated. Press Go to clear this message.

User Line 2 Messages

If none of the conditions exist that are listed in the following table, line 2 is blank. If any of the messages in the table are displayed the following actions can be taken:

Press Menu> or <Menu to take the printer offline and access the Ready Menu group.

Note: The Menu buttons are not active if Menu Lockout is turned on.

Press Stop to take the printer offline. The Not Ready message is displayed. No more data is processed from the host computer. Press the Go button to return the printer to the Ready state.

2-20 4059 Service Manual

User Message Explanation

Toner Low If the toner cartridge is low, then “Toner Low”

Tray X Missing If any of the input trays are missing, then “Tray X

Tray X Empty If any of the input trays are empty, then “Tray X

Tray X Low If any of the input trays are low, then “Tray X Low”

displays. The Toner Low condition clears whenever the upper front door is opened, and Toner Low displays again if the condition exists after the upper front door is closed.

Missing” displays (where X designates which Tray (1 through 5) is missing. If multiple trays are missing, they are prioritized in this order: Tray 1,

2..., then tray 5. Tray X Missing status clears whenever Tray X is reinserted.

Empty” displays where X designates which tray (Tray 1 through 5) is empty. If multiple trays are empty, then they are prioritized in this order: Tray 5, Tray 4,...Tray 1.

Note: Tray X Empty status clears whenever Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays. Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder.

displays where X designates which tray (1 through 5) displays. If multiple trays are low, they are prioritized in the following order: Tray 5,4,3,2,1.

Note: Tray X Low clears whenever Tray X goes empty, or Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays.

Note: The printer cannot detect when the envelope feeder or multipurpose feeder are low.

Diagnostic Information 2-21

User Line 2 Link Messages

If the printer is locked on a particular link, the link indication displays. If the printer is ready to process any link, none display. The link messages are listed in the following table.

User Message Explanation

Parallel Standard Parallel Port, if available.

Serial Standard Serial Port, if available.

Serial X Serial Port, where X=1,2,3, is attached to PCI

Network X Network card X, X=1,2,3, is attached to PCI

LocalTalk X LocalTalk Card X,X=1,2,3, is attached to PCI

Infrared Standard Infrared port, if available.

Infrared X Infrared Port X, X=1,2,3, is attached to PCI

connector X.

Check Device Connection Messages

The messages in the following table display when the printer looses communications with one of the following devices.

User Status Message Explanation

Check Output Bin X Connection

Check Env Feeder Connection

Check Tray X Connection

Check Output Bin X (X=1,2,or 3).

Check Envelope Feeder Option Connection.

Check Tray X (X=1,2,3,4 or 5).

Check Duplex Connection

2-22 4059 Service Manual

Check Duplex Option Connection.

The messages in the following table can occur in two ways. The specified device could have been removed from the printer, for instance to clear a paper jam. Otherwise, the device can still be attached to the printer, but is experiencing a communications problem, not fully connected, or having a hardware failure.

• If the device is temporarily removed or not connected properly,

then reattach it. When the option is recognized, the printer automatically clears the error and continues.

• If the option is experiencing a hardware problem, turn the printer

off and back on. If the error occurs again, turn the printer off, remove the option and call for service.

User Status Message Explanation

Turn Printer OFF to Enable Option

Insert Duplex Front Cover

Close Duplex Rear Door This message displays when the duplex rear door

This message displays when a printer option, Input Tray, Output Bin or Envelope Feeder, has been attached while the printer is powered On. In order to use the option, the printer must first be powered off and back on again. Data loss results if print jobs are active when the printer is power cycled. If a print job is active, then remove the option and finish the job. The printer automatically clears the message once the option is removed. Once the job is complete, turn off the printer and attach the option again.

This message displays when the duplex front access cover is not installed.

is open.

Diagnostic Information 2-23

Power-On Self Test (POST)

When you turn the printer On, it performs a Power-On Self Test. Check for correct POST functioning of the base printer by observing the following:

1. The LED comes on.

2. The operator panel displays one and a half row of pels, then clears.

3. Diamonds scroll across the display, then clear.

4. “Performing Self Test” appears on the display.

– The 2000 sheet high capacity option elevator tray moves to

the uppermost position if installed. – The duplex option is checked if installed. – The output expander option exit rollers turn if installed.

5. “Busy” appears on the display.

6. The fuser lamp turns on. The fuser takes longer to warm up from a cold start than a warm start.

7. The main fan turns on.

8. The main drive motor turns on.

9. The developer drive assembly drives the developer shaft in the toner cartridge.

10. The exit rollers turn.

11. The operator panel LED starts blinking.

12. Models 2420, 2450 2455 and 3455 only - The auxiliary fan turns on and continues to run until the printer is powered off.

13. “Ready” appears on the display.

2-24 4059 Service Manual

Symptom Tables

Symptom Table - Base Printer

Symptom Action

Auxiliary Fan (2420/2450/2455/

3455) fails to run or is noisy.

Dead Machine Go to the “Dead Machine Service

Operator Panel - One or more buttons do not work.

Operator Panel - Display is blank. Printer sounds 5 beeps.

Operator Panel - Display is blank. Printer does not emit 5 beeps.

Operator Panel continuously displays all diamonds - 5 beeps and does not complete POST.

Paperfeed problems - Base printer or Integrated 250 Paper Tr ay

Paper jams at exit of Redrive Assembly - No Duplex Option installed.

Paper jams at exit of Redrive Assembly - Duplex Option installed

Go to the “Auxiliary Fan Service Check” on page 2-47.

Check” on page 2-32.

Go to the “Operator Panel Buttons Service Check” on page 2-74.

Go to the “Operator Panel Service Check” on page 2-74.

Replace the operator panel assembly.

Go to the “Operator Panel Service Check” on page 2-74.

Go to the “Paper Feed Service Check” on page 2-86.

Go to the “Duplex Option Service Check” on page 2-35.

Fuser Solenoid (Models 1620/1650/2420/2450/

3455)fails to operate.

Print quality - Black page Go to “Print Quality - All Black Page”

Print quality - Blank page Go to “Print Quality - Blank Page” on

Print quality - Light print Go to “Print Quality - Light Print” on

Go to the “Fuser Envelope Conditioner Solenoid Service Check” on page 2-51.

on page 2-92.

page 2-92.

page 2-101.

Diagnostic Information 2-25

Symptom Action

Print quality - Background Go to “Print Quality - Background”

on page 2-96.

Print quality - Residual image Go to “Print Quality - Residual

Print quality - Skew Go to the “Paper Feed Service

Print quality - Banding Go to “Print Quality - Banding” on

Print quality - Random marks Go to “Print Quality - Random

Print quality - Toner on backside of printed page

Print quality - Vertical black bands on edge of copy

Unable to clear a “32-Unsupported Print Cartridge” User Error Message

Image” on page 2-100.

Check” on page 2-86.

page 2-99.

Marks” on page 2-94.

Go to “Print Quality - Toner on backside of printed page” on page 2-102.

Go to “Print Quality - Black bands on outer edges of the page” on page 2-99.

Go to “Smart Cartridge Service Check” on page 2-102

Symptom Table - High Capacity Feeder Option (2000 Sheet)

Symptom Action

The printer does not recognize the high capacity feeder option installed.

Paper feed problem with the high capacity feeder option.

2-26 4059 Service Manual

Go to the “High Capacity Feeder Input Tray Service Check” on page 2-61.

Go to the“High Capacity Feeder Input Tray Service Check” on page 2-61.

Symptom Table: Paper Tray Options

Symptom Action

Paper feed problem with 250 Sheet Paper Tray Option.

Paper feed problem with 500 Sheet Paper Tray Option.

Paper feed problem with 500/500 sheet paper tray option.

Media fails to pass thru from the lower attached Paper Tray option to the next higher mounted option.

Go to the “Input Tray(s) Option Service Check” on page 2-58.

Symptom Table - Duplex

Symptom Action

Paper feed problem with Duplex Go to the “Duplex Option Service

Paper jams at Paper Removal Tr ay

Paper skews in the Duplex Option Go to the “Duplex Option Service

Paper fails to pass from lower option thru the Duplex Option.

Check” on page 2-35.

Go to the “Duplex Option Service Check” on page 2-35.

Check” on page 2-35.

Go to the “Duplex Option Service Check” on page 2-35.

Symptom Table - Envelope Feeder Option

Symptom Action

Envelopes do not feed from the envelope feeder.

Envelopes do not feed properly into base printer.

Go to the “Envelope Feeder Option Service Check” on page 2-39.

Diagnostic Information 2-27

Symptom Table - Output Expander

Symptom Action

Printer does not display Output Bin Full

Paper does not feed all the way into the output tray.

Go to the “Output Bin Sensor Standard Tray Service Check” on page 2-78.

Go to the “Toner Sensor Service Check” on page 2-104.

Service Checks

Note: Anytime the engine board is replaced, the Configuration ID must be reset in NVRAM on the new engine board. Go to “Setting Configuration ID” on page 3-20.

Review the following information before performing any service checks.

• Paperfeed Problems (especially paper jams): Go to “Viewing

the Error Log” on page 3-8 and check the printer error log for indications of repetitive entries that help to isolate a problem to a particular area of the printer or option.

• Paperfeed Problems with error message: Use the “Sub Error

Codes For 9XX and 2XX Error Codes” on page 2-7 to help diagnose the problem.

• Print Quality Problems: Go to “Print Quality Test Pages” on

page 3-23 and print a test page to help diagnose problems before changing any settings or working on the printer.

• Use the resident diagnostics test provided to help isolate a

problem before taking the machine apart or removing any options.

2-28 4059 Service Manual

Charge Roll Service Check

Service Tip: Close and evenly spaced repetitive marks 47.19 mm (1.86 inch) apart or spots on the page can be caused by a damaged or contaminated charge roll.

To remove the charge roll:

1. Wrap a piece of plain white paper around the charge roll to prevent contamination or damage.

2. Carefully remove the roll by pressing outward and to the right on the charge roll link arm and remove the charge roll from the right side charge roll bearing.

3. Remove the charge roll from the left side charge roll bearing and remove the roll from the printer. Leave the paper wrapped around the charge roll until it is reinstalled.

FRU Action

1 Charge Roll Assembly Check the charge roll for correct

2 Left Side Charge Roll Link Check the left side charge roll link

installation, toner buildup, marks, cuts or other signs of contamination or damage. Replace as necessary.

assembly for correct assembly operation. Check for damage to the arm or bearing assembly.

Diagnostic Information 2-29

FRU Action

3 Right Side Charge Roll Link Check the right side charge roll link

assembly for correct assembly operation. If incorrect, replace the charge roll link assembly with the charge roll link assembly kit. If correct, check the right charge roll link assembly bearing for signs of wear or contamination. Excessive contamination could cause intermittent charging of the charge roll. If incorrect, replace the link assembly. Check for continuity of the right link assembly from the bearing to the charge roll high voltage contact on the right side frame. If incorrect, replace the link assembly.

Note: The screw that attaches the charge roll lead to the contact must be secure.

2-30 4059 Service Manual

Cover Open Switch/Cable Service Check

FRU Action

1 Toner Cartridge Check the toner cartridge to make

sure it is correctly installed and that the right and left hand cartridge tracks are not loose or broken. Check to make sure the cover open switch activation tab on the toner cartridge is not broken and that the tab correctly activates the cover open switch spring.

2 Cover Open Switch/Cable

Assembly

Check the cover open switch for proper mechanical operation. If incorrect, repair as necessary. Disconnect the cover open switch cable from J4 at the engine board and measure the voltage at J4-3. It measures approximately +5 V dc. If the voltage is incorrect, replace the engine board. If the voltage is correct, check the voltage at J4-1. If the voltage measures greater than +1.0 V dc, replace the engine board. If the voltage is correct, check the continuity between J4-1 and J4-3 on the cable. If no change in continuity occurs as the switch is activated, replace the cover open switch/cable assembly. If the continuity changes as the switch is activated, replace the engine board.

Note: It is easier to check the voltages on J4 with the controller board removed.

Diagnostic Information 2-31

Dead Machine Service Check

Note: Remove any paper handling options before servicing the printer for a dead machine condition. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemblies.

Service Tip: When removing the LVPS from the printer observe the following:

1. The LVPS uses a self docking connector that mates with another connector mounted on the left side frame assembly. Some force may be required to pull the LVPS loose from the connector.

2. Gently remove the LVPS supply using caution not to damage the printed circuit board. Pull the LVPS out far enough to reach the fuser lamp cable.

3. The fuser lamp cable uses a locking type of connector system. Unlock the fuser lamp cable connector, disconnect the cable and remove the LVPS from the printer.

FRU Action

1 Line Voltage Check the AC line voltage. If the line

voltage is incorrect, inform the customer.

2 AC Line Cord Check the line cord for any signs of

3 +5 V dc at any Option

Connector

4 +5 V dc at the controller

board test point

damage. If correct, check the continuity of the line cord and replace if necessary.

Check for +5 V dc on any of the option connectors. The easiest to access is the envelope feeder connector located behind the lower front door. If +5 V dc is present at any of the connectors, go to step 9. If +5 V dc is not present, go to step 4.

Check for +5 V dc at the +5 V dc test pad located on the controller board. If correct, go to step 9.

2-32 4059 Service Manual

FRU Action

5 +5 V dc at the engine board

Tes t Po int

6 LVPS Fuse F1 Remove the LVPS from the printer

7 LVPS Fuse F1 - Continues

to blow after LVPS installed in the printer.

8 LVPS Remove the LVPS from the machine:

Check for +5 V dc at the +5 V dc test point on the engine board. If correct, replace the engine board. If incorrect, go to step 6.

and check fuse F1. Replace the fuse if the fuse is blown.

Replace fuse F1 if necessary. Turn the LVPS on/off switch Off and connect the AC line cord and turn the LVPS On.

CAUTION: Before checking fuse F1 turn the LVPS Off and disconnect the AC line cord. Check fuse F1. If the fuse is blown, replace the LVPS.

CAUTION: Before making any measurements on the LVPS output connector, observe all necessary safety precautions before applying AC power. Measure the voltage on LVPS output connector CN3. The voltage measures +5 V dc. If incorrect, replace the LVPS.

Diagnostic Information 2-33

FRU Action

9 Engine Board Turn the printer off and disconnect

all the cables from the engine board. Check for +5 V dc at the engine board test point. If incorrect, replace the FRUs in the following order:

engine board

interconnect board

If correct, turn the printer off and reconnect one cable at a time until you find the defective 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 supply down to 0 V dc.

Service Tip: Check the engine board for burn marks or other damage, especially R20,R21, R22 and R23 located next to the upper left engine board mounting screw. If this screw is overtightened it might deform the engine board shield and cause it to short out these resistors.

2-34 4059 Service Manual

Duplex Option Service Check

The printer does not recognize the Duplex Option is attached. The printer does not recognize tray options below the duplex option are installed.

FRU Action

1 Fuse F1 on Duplex Option

System Board

2 Autoconnect Cables/

Connectors

If fuse F1 is blown, replace the fuse. If fuse F1 continues to blow, check the stepper motor for a short between the motor case and pins J3-1 through J3-4. If no problem is found, check the D.C. servo motor pins J1-1 and J1-2 to the motor housing for a short. If a short is found, replace the motor assembly. If no short is found, replace the system board.

Check the autoconnect cables for damage to the cables or the pins in the connectors. If damaged, replace the cable(s). If no damage is found, check to make sure the cables are connected to J9, J10, J11 and J12 on the duplex system board. If no problem is found, replace the duplex system board.

Diagnostic Information 2-35

POST fails, 230 Paper Jam, Check Duplex message displays.

FRU Action

1 Duplex D.C. Servo Drive

Motor

2 Input Sensor, Input Sensor

Flag

3 Paper Exit Sensor and Flag Check the duplex exit sensor for

Check the D.C. servo motor cables for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage. If no problem is found, replace the FRUs in the following order:

D.C. motor assembly

duplex option system board

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 the FRUs in the following order:

input sensor assembly

duplex option system board

correct installation and free movement of the sensor flag. Check to make sure the sensor cable is connected to J8 on the system board. If no problem is found, replace the FRUs in the following order:

2-36 4059 Service Manual

exit sensor assembly

duplex option system board

230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way out of the redrive.

FRU Action

1 Duplex Stepper Motor Check the stepper motor cable for

cuts or pinched wiring. Check the routing of the motor leads along the left side of the bottom tray. Check for correct installation of the motor cable connector at J3 on the system board. Check 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 J3-2 (Stpmtr A+). The resistance measures approximately 10 ohms. The resistance between J3-3 (Stpmtr B-) to J3-4 (Stpmtr B+) measures approximately 10 ohms. If the resistance is incorrect, replace the stepper motor. Check for shorts between windings on pins J3-1 to J3-2 and pins J3-3 to J3-4. If a short is found, replace the stepper motor assembly. If no short is found, replace the duplex system board.

Diagnostic Information 2-37

POST fails with Close Duplex Rear Door displayed when Duplex Rear Door is closed.

FRU Action

1 Rear Door Switch

(Not installed on some duplex units)

Check the rear door for correct installation and operation. Check to ensure the cable or connector is not damaged and is properly connected at J6 on the duplex system board. The rear door switch can be checked by measuring the continuity between J6-1 and J6-2 on the cable connector while actuating the rear door switch. If there is no continuity, replace the rear door switch assembly. If there is continuity, replace the duplex option system board.

POST fails with Insert Duplex Front Cover message displayed.

FRU Action

1 Front Cover Switch

(Not installed on some duplex units)

Check the switch for correct installation and that the jam removal tray actuates the switch. Check to make sure the switch cable is connected to J7 on the system board. If no problem is found, check the continuity between J7-1 and J7-2 on the cable connector while actuating the front cover switch. If there is no continuity, replace the front cover switch assembly. If there is continuity, replace the duplex option system board.

2-38 4059 Service Manual

Envelope Feeder Option Service Check

Service Tip: Check the envelope feeder paper path for any debris, pieces of envelope and so on. If any other options are installed make sure they are operating normally. If only the envelope feeder is failing to operate correctly, continue with this service check, otherwise go to the Interconnect Card Service Check.

Service Tip: The envelope feeder option receives its +5 V dc operating voltage from the +24 V dc bulk at J1-7. If +24 V dc is not present at J1-7, tray 1 is the only tray option that is recognized.

Note: If 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 attached input option.

FRU Action

1 Envelope Feeder Check to make sure the envelope

2 Front Autoconnect on

Printer

feeder is correctly installed and mated to the autoconnect at the front of the printer.

Check the connector for signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Remove the envelope feeder option and check the voltages at the autoconnect on the front of the printer. If incorrect, check the interconnect board. If correct, reinstall the envelope option and continue with step 3.

Diagnostic Information 2-39

FRU Action

3 Autoconnect on the

Envelope Option

Check the connector for any signs of damage to the connector or contacts. If you find damage, replace the damaged cable/connector assembly. Disconnect the autoconnect cable at J1 on the envelope system board and measure the following voltages:

J1-3 measures +5 V dc J1-5 measures +5 V dc J1-7 measures +24 V dc

If any of the voltages are incorrect, replace the autoconnect cable/connector. If the voltages are correct, replace the envelope system board.

2-40 4059 Service Manual

Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete.

FRU Action

1 Pass through Sensor Check for any debris, pieces of

envelope and so on over the pass thru sensor. Check for correct installation of the pass thru sensor flag. Make sure the sensor cable is attached to the envelope system board. Perform an envelope feeder sensor test to check both the sensor and sensor flag.

Note: It may be necessary to use a small tool to actuate 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 any signs of damage or binds. If incorrect, replace the flag. If the flag is operating correctly, check the voltage at J3-3. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, check the voltage at J3-2. The voltage changes from 0 to +5 V dc when the flag is moved in and out of the sensor. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the envelope system board.

Diagnostic Information 2-41

Operator panel displays 260 Paper Jam after attempted feed but before envelopes are put in the hopper OR the operator panel continues to display "Load Envelopes" after envelopes are placed in the hopper.

Service Tip: The kick rolls rotate during the attempted feed cycles.

FRU Action

1 Envelope Out Hopper

Sensor Flag

2 Envelope Out Hopper Input

Sensor

Check the envelope out sensor flag for damage, correct installation and operation. If incorrect, repair or replace the flag.

Check the sensor to make sure it is installed correctly and the sensor cable is properly connected to the envelope system board. If correct, perform the Envelope Feed Sensor Test to check both the sensor and flag. If the test fails, remove any envelopes in the hopper, turn the printer off and disconnect J3 from the system board. Turn the printer on and check the voltage at J3-3 on the system board. The voltage measures approximately +5 V dc. If incorrect, replace the envelope system board. If correct, replace the input sensor assembly.

2-42 4059 Service Manual

990 Service Error, Envelopes fail to feed from the hopper.

FRU Action

1 D.C. Feed Motor Assembly Check the motor and motor cable for

2 Envelope Feeder System

Board

any signs of loose wires or poor connections. Check to make sure the motor cable is connected to the envelope system board.

Check the voltage on J4-1. The voltage measures approximately +24 V dc. If incorrect, replace the envelope system board, if correct, measure the voltage at J4-6. The voltage measures approximately +5 V dc. If incorrect, disconnect J4 and measure the voltage again. If incorrect, replace the envelope feeder system board. If correct, replace the D.C. motor assembly.

260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls ARE NOT rotating.

FRU Action

1 Main Drive Belt Check the belt for correct installation

and for signs of damage. Replace as necessary.

2 Gears Check all the gears for correct

installation and for signs of damage. Repair or replace parts as necessary.

3 Clutch Latch Assembly Check the clutch latch assembly to

make sure it moves freely.

4 Master Cam Gear Master/

Kick Gear

Check the master cam gear and master/kick gear to make sure they rotate together. If not, then the tenons on the master kick gear may be sheared off. If incorrect, replace the master kick gear.

Diagnostic Information 2-43

260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls ARE rotating.

Check the deflector gap adjustment before continuing this service check.

FRU Action

1 Deflector Gap Adjustment Check the deflector gap adjustment.

The adjustment may be too narrow.

2 Weight Assembly Check the weight assembly to make

sure it moves up and down freely without any binds. Also check to make sure the weight assembly rests on all the rear kick rollers when the hopper is empty. Replace the weight assembly if it is damaged or does not operate properly.

3 Envelope Edge Guide Check the envelope edge guide to

make sure it is not warped or set too close to the envelopes in the hopper. Replace the edge guide if it is damaged or does not operate properly.

2-44 4059 Service Manual

260 Paper Jam displays, envelope stops in feeder paper path.

FRU Action

1 Kick Rolls/Feed Rolls/Drive

Rolls

2 Deflector Gap Adjustment Check the deflector gap adjustment.

Check all the rolls for any signs of oil, grease or other contamination. If you find a problem, clean or replace parts as required.

The adjustment may be too narrow.

Envelope Feeder multifeeds or may not display a 260 Paper Jam message.

FRU Action

1 Envelopes Check the envelopes being used in

2 Deflector Check the deflector gap adjustment.

3 Restraint Roll Bias Spring Check for a missing, broken or

the feeder. Check for signs of the envelopes being stuck together or signs of glue. Check to make sure the flaps are not interleaved.

The adjustment may be too wide.

incorrectly installed restraint roll bias spring. If incorrect, reinstall or replace the spring.

260 Paper Jam displays. An envelope stopped in the paper path of the feeder and an envelope also stopped in the base printer paper path.

FRU Action

1 Latch Lever Check to make sure the tip of the

latch lever is centered in the opening in the floor of the paper path. The latch lever may not be detented on the latch.

Diagnostic Information 2-45

Erase Lamp Service Check

Error code 928 may be displayed when the printer detects that the erase lamp assembly, cable or engine board is defective.

Note: If the erase lamp assembly is defective, both the erase lamp and lens are replaced as a kit.

Make the following checks when a 928 service error displays.

FRU Action

1 Cable, Front Harness Check the connection of the front

2 Engine Board Remove the controller board and

harness to connector J10 on the engine board for correct installation. If incorrect, repair as necessary. Check the front harness to erase lamp assembly for correct installation. If incorrect, repair as necessary.

toner cartridge from the machine. Ground pin J10-15. The erase lamps turn on. The lamps can be observed through the front of the machine with the cover open and print cartridge removed. If the lamps do not turn on, measure the voltage on J10-14. The voltage reads approximately +24 V dc. If incorrect, replace the engine board. If correct, check the voltage at J10-15. The voltage reads between +15 V dc to +20 V dc. If incorrect, check the continuity of the erase lamp lines in the main harness. If incorrect, replace the cable harness. If correct, replace the erase lamp assembly.

2-46 4059 Service Manual

Fan Service Check

Auxiliary Fan Service Check

The auxiliary fan is in models 2420, 2450, 2455 and 3455.

Fan does not run or is noisy.

FRU Action

1 Fan Assembly Check the fan for proper installation

and for excessive noise. If incorrect, replace the fan and cable assembly.

2 Engine Board Check to make sure the auxiliary fan

cable is seated on connector J7 on the engine board. If correct, check for +24 V dc on J7-1 on the engine board. If incorrect, replace the engine board. If correct, replace the fan assembly.

Note: When the printer is in warmup the voltage at J7-1 measures approximately +12 V dc. When the printer is running, the voltage measures approximately +24 V dc.

Main Fan Service Check

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

FRU Action

1 Main Fan Manually spin the fan and check that

it rotates freely. Check the cable connection to the engine board, J1 for correct installation.

2 Main Fan to Engine Board

Cable

Check the continuity of the cable. If incorrect, replace the cable.

Diagnostic Information 2-47

FRU Action

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, replace the engine board.

4 Error Code 927

(Fan not running)

Check the voltage at J1-3 on the engine board. The voltages are as follows:

+22 V dc to +24 V dc (printer and fan running)

+12 V dc to +15 V dc (printer not running - fan running about half speed).

If incorrect, replace the engine board. If this does not fix the problem, replace the main fan.

Fuser Service Check

Cold Fuser Service Check

Error codes 920, 921, and 922 may display for a cold fuser failure. A 920 error caused by low line voltage can sometimes be cleared by turning the machine off and then on again. A 925 service error indicates the wrong fuser lamp is installed in the printer and does not match the one stored in the printer code.

Service Tip: Set the Fuser Temperature to NORMAL before starting this service check.

FRU Action

1 Fuser Lamp (Incorrect

Lamp/925 Service Error)

2-48 4059 Service Manual

Install the correct voltage and wattage lamp or fuser assembly.

FRU Action

2 Fuser Lamp Remove the controller board. Run

the Diagnostic Print Test and observe the lamp through the left side frame. If the lamp doesn’t come on, unplug the printer and check the continuity between the two pins on the fuser lamp cable going to the fuser assembly. If you do not measure continuity, remove the fuser assembly and check the continuity of the lamp. If incorrect, replace the lamp. If correct, replace the fuser cover assembly.

3 LVPS and AC Fuser Lamp

Cable

4 Fuser Top Cover Assembly

(Thermal Fuse/Thermistor Assembly)

Turn the printer off. Disconnect the fuser lamp connector at the fuser assembly. Turn the printer on and check across the pins on LVPS end of the cable for line voltage. If incorrect, turn the printer off and disconnect the power cord and check the continuity of the AC fuser lamp cable. If incorrect, replace the cable. If correct, replace the LVPS.

Disconnect the thermistor cable from the fuser board at J2. The resistance is as follows:

HOT - J2-1 - J2-2 = 2.5K ohms

COLD = 150K ohms to 260K ohms

Diagnostic Information 2-49

Hot Fuser Service Check

Error codes 923 and 924 may display for a hot fuser failure.

CAUTION: The fuser may be hot, use caution before removing or servicing.

FRU Action

1Fuser Cover Assembly

(Assembly includes Thermistor and Thermal Fuses.)

2 Engine Board Error code 924 indicates the engine

Check for damage to the thermistor assembly. Check the resistance of the themistor:

HOT - J2-1 to J2-2 = 2.5K ohms

COLD =150K ohms to 260K ohms

Check the continuity from each pin of J2 to ground. If there is continuity, replace the fuser cover assembly

board detects an open circuit in the thermistor circuit for the fuser assembly. The voltage on J2-6 on the engine board measures approximately +5 V dc. If incorrect, replace the engine board. If correct, check the continuity of the DC fuser cable connected between J2 on the engine board and J1 on the fuser control board. In there is no continuity, replace the cable. If there is continuity, check the voltage on J2-2 on the fuser control board. It measures approximately +5 V dc. If incorrect, replace the fuser control board.

3 Fuser Hot Roll

Backup Roll Bearings

2-50 4059 Service Manual

Examine the fuser assembly for signs of overheating or damage. Check the hot roll and backup roll for signs of excessive toner, label glue, labels or other contaminants. If any are found, repair as necessary or replace the fuser assembly.

Fuser Envelope Conditioner Solenoid Service Check

The fuser solenoid is in models 3455, 2455, 2450, 2420, 1855, 1650, 1625 and 1620 and the World Trade printer model 2450.

Service Tip: Try changing the envelope enhance level setting. A different setting may correct the problem.

Note: The level I fuser board uses +42 V dc which is derived from the LVPS via the interconnect board (J1) and the envelope conditioner cable. The solenoid is controlled by logic located on the engine board. The level II fuser board does not use the +42 V dc and receives control for the solenoid from logic located on the engine board. A level II 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 the engine board, damage can result to the fuser board.

Engine Board Jumper Configurations

Refer to the “Fuser Board” on page 5-11, “Level 1 Engine Board” on page 5-9 and “Level 2 Engine Board” on page 5-10 to identify the level boards installed in your printer.

1. A level I fuser board and a level I engine board require a envelope conditioner cable and no jumpers on the engine board.

2. A level I fuser board and level II engine board require jumpers at locations JP1-2 to JP1-3 and JP2-2 to JP2-3 on the engine board.

3. A level II fuser board and level II engine board require jumpers at locations JP1-1 to JP1-2 and JP2-1 to JP2-2 on the engine board.

Diagnostic Information 2-51

Configuration 1

A level 1 fuser board and level 1 engine board are installed in configuration 1.

Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3.

FRU Action

1 Fuser Envelope Conditioner

Solenoid

2 Fuser Control Board The solenoid receives power from the

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, check the resistance of the solenoid between J4-1 and J4-2. The resistance measures between 5 ohms and 10 ohms. If incorrect, replace the solenoid assembly.

fuser control board. The fuser control board receives +42Vdc from the LVPS via the interconnect board and envelope conditioner cable. Check for approximately +42 V dc at the +42 V dc test point on the fuser control board. If the voltage is correct, replace the fuser control board.

2-52 4059 Service Manual

FRU Action

3 LVPS

Interconnect Board

4 Fuser DC Cable (Engine

Board to Fuser Board Cable) Engine Board

If the +42 V dc test point does not measure approximately +42 V dc, check the continuity of the cable connected between J3 on the fuser control and J1 on the interconnect board. If the cable does not measure continuity, replace the cable. If the cable measures continuity, check the voltage at CN3-18 on the LVPS. The voltage measures approximately +42 V dc. If the voltage is correct, replace the interconnect board assembly. If the voltage is incorrect, replace the LVPS.

Check for continuity of the DC fuser cable that is attached between J2 on the engine board and J1 on the fuser control board. If the cable does not measure continuity, replace the cable. If the cable measures continuity, replace the engine board.

Diagnostic Information 2-53

Configuration 2

A level I fuser board and level II engine board are installed in configuration 2.

Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3.

FRU Action

1 Engine Board Jumpers Check to make sure a jumper is

installed between JP1-2 and JP1-3 and also between JP2-2 and JP2-3 on the engine board. Note: If the jumpers are not in the correct position on the engine board, damage can result to the fuser board.

2 Fuser Envelope Conditioner

Solenoid

3 Fuser Control Board The solenoid receives power from the

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, check the resistance of the solenoid between J4-1 and J4-2. The resistance measures between 5 ohms and 10 ohms. If the resistance is incorrect, replace the solenoid assembly.

fuser control board. The fuser control board receives +42Vdc from the LVPS via the interconnect board and envelope conditioner cable. Check for approximately +42 V dc at the +42 V dc test point on the fuser control board, If the voltage is incorrect, replace the fuser control board.

2-54 4059 Service Manual

FRU Action

4 LVPS Interconnect Board

Envelope Conditioner Cable

5 Fuser DC Cable (Engine

board to Fuser Board cable) Engine Board

Check the +42 V dc test point on the fuser control board. If the voltage is incorrect, check the continuity of the envelope conditioner cable. If the cable does not measure continuity, replace the cable. If the cable measures continuity, check the voltage at J1-2 on the interconnect board. The voltage measures approximately +42 V dc. If incorrect, check the voltage at CN3-18 on the LVPS. It measures approximately +42 V dc. If incorrect, replace the LVPS. If correct, replace the interconnect board assembly.

Diagnostic Information 2-55

Configuration 3

A level II fuser board and level II engine board without the solenoid cable is installed in configuration 3.

Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section “Fuser Solenoid Adjustment” on page 4-3.

FRU Action

1 Engine Board Jumpers Check to make sure a jumper is

installed between JP1-1 and JP1-2 and also between JP2-1 and JP2-2 on the engine board.

2 Fuser Envelope Conditioner

Solenoid Fuser Control Board

3 Fuser Cable Check the continuity of the fuser

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, disconnect the DC fuser cable from J1 on the fuser control board and check the resistance of the solenoid between J1-2 and J1-4 on connector J1. The resistance measures between 5 ohms and 10 ohms. If incorrect, disconnect the solenoid from J4 and check the resistance of the solenoid between J4-1 and J4-2. If incorrect, replace the solenoid assembly. If correct, replace the fuser control board.

cable. If the cable does not measure continuity, replace the cable.

2-56 4059 Service Manual

FRU Action

4 Engine Board Check the +42 V dc test point on the

engine board. Go to “Engine Board” on page 5-4 in the locations section to find the +42 V dc test 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 Interconnect Board Check the voltage at CN3-18 on the

LVPS. It measures approximately +42 V dc. If incorrect, replace the LVPS. If correct, replace the interconnect board.

Input Sensor Service Check

Service Tip: Run the base sensor test. Check the input sensor for proper operation. The display changes from open to closed as the sensor flag is manually moved in and out of the sensor.

Service Tip: Run a Diagnostic Print Test in the continuous mode with the controller board removed. A defective input sensor or circuit causes the first copy to exit only partially through the fuser assembly.

FRU Action

1 Input Sensor Flag Check the input sensor flag for

damage and proper operation. If a problem is found, repair as necessary.

2 Engine Board Check for approximately +5 V dc at

J10-10 on the engine board. If incorrect, replace the engine board.

3 Input Sensor Cable Check the continuity of the input

sensor cable. If incorrect, replace the cable. If correct, replace the input sensor assembly.

Diagnostic Information 2-57

Input Tray(s) Option Service Check

250 Sheet, 500 Sheet and 500/500 Sheet Input Tray Option

Service Tip: Try all the other input paper sources to make sure they are properly feeding paper.

For 990 Error Code- Service Tray X, X= displays the number of the tray that has a problem or needs service.

FRU Action

1 Tray X option System Board

or Compensator Assembly or Autoconnect Cable

Check the autoconect cables and connectors for any signs of damage. Replace if necessary. Check the cables for continuity. If incorrect, replace the compensator assembly cable. If the cables, connectors and connections are good, replace the FRUs in the following order:

autocompensator assembly option

system board

2-58 4059 Service Manual

24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (The printer displays the value of X for the paper tray where the error occurs. Example: 241 is a Paper Jam Tray 1)

FRU Action

1 Pass Thru Sensor and Flag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller

The tray x option system board did not detect a piece of paper actuating the pass thru sensor. Remove any jammed sheets of paper from the printer and check the pass thru sensor and flag for proper operation by running the appropriate Tray Sensor Test from the diagnostics menu. If the test fails, check the sensor for correct installation and the flag for proper operation. Also check the sensor cable to make sure it is correctly connected to the option system board. If incorrect, replace the tray x option pass thru sensor assembly.

Check these parts for signs of broken or damaged parts, contamination on the drive rollers or wear plate and wear or damage to the drive shaft bearings. Check the drive roll assembly and skewed backup roller for signs of wear, slick spots, material buildup, and oil or grease on the rollers. Also check for proper operation of the paper aligning assembly. Repair or replace parts as necessary.

Diagnostic Information 2-59

Tray X Low message displays when Tray X is full or has adequate paper in the tray.

FRU Action

1 Paper Low Sensor

Assembly Paper Low Sensor Flag Tray X Option System Board

Run the Tray X Sensor Test and check the sensor for proper operation. If incorrect, check the following:

Paper low sensor flag for smooth and correct operation.

Paper low sensor for correct installation on the autocompensator housing.

Paper low sensor cable for signs of cuts, pinched wiring or other damage especially at connector J5 on the system board.

If no problem is found, replace the paper low sensor assembly. If this does not correct the problem, replace the option system board.

Tray X Empty message displays when Tray X has paper in the tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for

2 Paper Out Sensor (On

Option System Board)

correct operation and installation. If correct, replace the option system board. (The paper out sensor is mounted on the system board).

2-60 4059 Service Manual

Printer does not recognize Tray X is installed.

FRU Action

1 Autoconect Cables

Tray X System Board

Check the autoconnect from the printer or option above tray x. Check for signs of cuts, pinched wiring or damage to the contacts in the connector. Check the autoconnect cable(s) for correct installation at the tray x system board. If correct, check the continuity of the autoconnect cable(s). If correct, replace the tray x system board. If incorrect, replace the cable.

Paper from Tray X does not reach the Pass Thru Sensor.

Service Tip: Check the media in tray x to make sure it is within specifications. Some types of labels, foil material and slick papers can cause misfeeds and slippage of the rollers.

FRU Action

1 Autocompensator

Assembly

Check the autocompensator pick arm rollers for any sign of glazing, toner or other buildup. Clean or replace as necessary.

High Capacity Feeder Input Tray Service Check

Note: Voltage measurements in the high capacity feeder input tray service checks must be made with the high capacity feeder attached to the base printer to obtain accurate results.

Service Tip: Be sure the paper size switch is set to the correct paper size setting and the rear paper guides are in the correct locations for the size of paper installed in the high capacity feeder tray.

Service Tip: Check the other paper sources to be sure they are operating correctly.

Diagnostic Information 2-61

The base printer does not recognize that the high capacity input tray is installed.

FRU Action

1 High Capacity Feeder

Autoconnect Mechanical Check

2 Base Printer or option

mounted above

3 14 Pin HCIT Flex Cable Check the 14 pin flexible cable to be

Check the high capacity feeder input tray autoconnect to make sure it is mounted correctly and is not pushed down into the frame assembly or damaged. Be sure the high capacity feeder input tray autoconnect is properly connected to the high capacity feeder tray option board assembly.

Check the option or base printer autoconnect for signs of damage. Repair the high capacity option autoconnect as necessary.

sure it is installed correctly and properly seated in the connectors on both boards. Check the cable for damage. Repair or replace as necessary.

2-62 4059 Service Manual

FRU Action

5 High Capacity Feeder

Option Control Board

Check the voltage on J8-1 (green). The voltage measures +24 V dc. If incorrect, check the autoconnect system for any problems. +24 V dc must come from the base printer through the autoconnect system to the high capacity input for the high capacity feeder to be recognized. If the voltage is correct, check the voltages at J11-3(red) and J114(red). The voltages measure +24 V dc. If correct, replace the high capacity feeder option system board. If incorrect, disconnect J8 from the system board and measure the voltages again. If incorrect, check the LVPS cable and the A.C. internal wiring from the input appliance receptacle. If incorrect, replace as necessary. If correct, replace the LVPS. If the voltages are correct, check the stepper motor for shorts from the motor housing to each pin on the motor connector. If you find a short between any pin and the motor housing, replace the motor assembly. If no shorts are found, replace the high capacity feeder option control board.

Check the voltage at J9-1 (light blue). The voltage measures approximately +24 V dc. If incorrect, disconnect the cable at J9 and check the voltage again. If the voltage continues to be incorrect, replace the high capacity feeder option system board. If the voltage measures correctly, check the cable. If the cable is damaged, replace as necessary. If no problem is found with the cable, replace the high capacity feeder option control board.

Diagnostic Information 2-63

24X Paper Jam message displays, Paper jammed over the Pass Thru Sensor. (X=The printer displays the value of X for the paper tray where the error occurs. Example: 242 is a Paper Jam Tray 2)

FRU Action

1 Pass Thru Sensor and Flag

Assembly

2 Power Takeoff Shaft and

Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller

2-64 4059 Service Manual

Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray.

FRU Action

1 Paper Low Switch

Paper Low Switch Cable High Capacity Feeder Input System Board

Run the sensor diagnostics for tray X (X=the number that represents the high capacity input tray). If the test fails, disconnect the paper low switch cable from J3 on the high capacity system board. Short pins 1 and 2 together while observing the sensor test on the display. If the display does not change, replace the high capacity feeder system board. If the display changes check the continuity of the switch. If incorrect, replace the switch. If correct, replace the switch cable.

Tray X empty message displays when there is paper in the high capacity feeder input tray.

FRU Action

1 Paper Out Sensor Flag Check the paper out sensor flag for

2 Paper Out Sensor

(On Option System Board)

correct operation and installation. If correct, replace the high capacity feeder system board. (The paper out sensor is mounted on the high capacity feeder system board).

Tray X Empty Message displays when Tray X has paper in the tray.

FRU Action

1 Paper Out Sensor Flag Check the flag for correct operation

and installation.

2 Paper Out Sensor (Located

on the High Capacity Feeder Tray Option Board)

Run the Tray X sensor diagnostic. If incorrect, replace the high capacity feeder tray option board.

Diagnostic Information 2-65

The elevator tray fails to stop at the correct position and continues to drive into the bottom frame.

FRU Action

1 Lower Limit Switch

Lower Limit Switch Cable

2 High Capacity Feeder

Control Board

Check continuity of the lower limit 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.

Disconnect the lower limit switch cable and check the voltage at J2-1 (orange). The voltage measures approximately +5 V dc. If incorrect, replace the high capacity feeder option control board.

The elevator tray down button does not operate. The tray moves to the upper position.

Service Tip: Open the high capacity feeder option front door and check the black rubber bumper attached to the door switch spring. Be sure the rubber button is centered and not touching the sides of the hole or the switch will not function properly.

FRU Action

1 Lower Limit Switch

Lower Limit Switch Cable High Capacity Feeder Control Board

2-66 4059 Service Manual

Check the lower limit switch to make sure it is not closed (normally open). If incorrect, replace the switch. Check the lower limit switch cable for a short between pins 1 and 2. If incorrect, replace the cable. If correct, replace the high capacity feeder option control board.

Paper from the high capacity feeder input tray does not reach the pass thru sensor.

Service Tip: Check to be sure the paper in tray is within specifications.

FRU Action

1 Autocompensator

Assembly

2 Wear Strips Check the wear strips for glazing or

Check the autocompensator pick arm rollers for sign of glazing, toner or other buildup. Replace as necessary.

contamination. Replace as required. It is advisable to replace all four wear strips at the same time.

Diagnostic Information 2-67

The elevator tray does not move up or down. The printer recognizes that the option is installed.

FRU Action

1 Stepper Motor

High Capacity Feeder Option Control Board Stepper Motor Extension Cable

Be sure the motor cable is correctly installed at J1 on the high capacity feeder system 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 motor housing. If a problem is found, replace the motor. Measure the resistance between the following pins on the motor cable connector:

Pins 1 (orange) and 3 (green) Pins 2 (yellow) and 4 (white)

They measure between 10 and 15 ohms. If incorrect, replace the motor assembly. If correct, replace the high capacity feeder control board.

2-68 4059 Service Manual

The elevator moves in one direction only.

FRU Action

1 Stepper Motor

High Capacity Feeder Option Control Board

Check the voltages at J1 on the high capacity system board. The voltage measures as follows:

static (motor connected)

J1-1 (Orange) +24 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) approximately +12 V dc

If any of the voltages are incorrect, disconnect the motor and measure the resistance between pin J1-1 to J1-3 and J12 and J1-4. The resistance measures between 10 and 15 ohms. If incorrect, replace the motor. If correct, replace the high capacity feeder control board.

Diagnostic Information 2-69

Paper size switch not selecting paper size that is selected.

FRU Action

1 Paper Size Switch

High Capacity Feeder Option Control Board

Check for continuity between the common pin (J5-1) and the pin of the paper size selected.

J5-1 (Black): Common Lead J5-2 (Blue)B5 J5-3 (Green) Executive J5-4 (Yellow) A4 J5-5 (Orange) Letter J5-6 (Red) Legal J5-7 (Brown) A5

If any position does not measure continuity when selected, replace the paper size switch assembly. If the switch assembly is operating correctly, replace the high capacity feeder option control board.

24X Paper Jam Check Tray X Message displays when Tray X is empty. No Tray X Message displays.

FRU Action

1 High Capacity Feeder

Option Control Board

Check the voltages on the board at J4-1(red) and J4-3 (blue). The voltages measure approximately +5 V dc. If incorrect, disconnect J4 from the board and measure the voltages again. If incorrect, replace the high capacity feeder option control board.

2 Elevator Top Optical

Sensor Cable Elevator Top Optical Sensor

2-70 4059 Service Manual

Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.

Tray X Empty message displays. Tray does not respond to loading paper. No response from the front door switch.

FRU Action

1 High Capacity Feeder

Option Control Board

2 Elevator Top Optical

Sensor Cable Elevator Top Optical Sensor

Check the voltage on the board at J4-2 (green). The voltage measures approximately +5 V dc. If incorrect, disconnect the cable at J4 and check the voltage again. If incorrect, replace the high capacity feeder option control board.

Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.

Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate paper in the tray.

FRU Action

1 Paper Low Switch

Paper Low Switch Cable High Capacity Feeder Option Control Board

Run the sensor diagnostics for tray X (X=the number that represents the high capacity input tray). If the test fails, check the voltage at J3-1 (grey). The voltage measures approximately +24 V dc. If incorrect, disconnect the paper low switch cable from J3 and measure the voltage again on J3-1. If incorrect, replace the high capacity feeder option control board. If correct, check the cable for a short between pins 1 and 2 on the cable. If incorrect, replace the cable. If correct, check the switch for a bent or deformed actuator lever or defective switch. If incorrect, replace the switch.

Diagnostic Information 2-71

Excessive Noise or Vibration

FRU Action

1 Motor Plate Assembly Be sure the motor plate assembly

2 Motor Drive Belt Check the belt to be sure it is not too

3 Lead Screw Bearings If the bearings are worn or defective

4 Idler Pulley Be sure the idler pulley is not

screws are tight. Be sure the motor mounting screws are tight.

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.

the lead screw may “wobble”. Be sure the bearings and leadscrew are operating properly with no binds.

binding, worn or broken.

2-72 4059 Service Manual

Lexmark Optra S Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Notices and Safety Information

Laser Notices

Safety Information

Preface

1. General Information

Options

Maintenance Approach

Tools Required For Service

Acronyms

2. Diagnostic Information

Start

Service Error Codes

User Status Messages

User Error Messages

Power-On Self Test (POST)

Symptom Tables

Service Checks

Charge Roll Service Check

Cover Open Switch/Cable Service Check

Dead Machine Service Check

Duplex Option Service Check

Envelope Feeder Option Service Check

Erase Lamp Service Check

Fan Service Check

Fuser Service Check

Fuser Envelope Conditioner Solenoid Service Check

Input Sensor Service Check

Input Tray(s) Option Service Check

High Capacity Feeder Input Tray Service Check