4059 SM

Optra S
4059-XXX
Table of Contents Start Diagnostics Safety and Notices Trademarks Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Edition: March 24, 2006

The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. A form for readers comments is provided at the back of this publication. If the form has been removed, comments may be addressed to Lexmark International, Inc., D22A/035-3, 740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Copyright Lexmark International, Inc. 1998, 2004 All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550. P/N 12G0139
Contents
Notices and Safety Information. . . . . . . . . . . . . . . . . . . . . 1-ix
Laser Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-ix Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xvii
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-xxii
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-4 1-5 1-5 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 . . . . . . . . . . . . . . . . . . . Serial Port Service Check . . . . . . . . . . . . . . . . . . . . . . . Toner Sensor Service Check. . . . . . . . . . . . . . . . . . . . . Transfer Roll Service Check . . . . . . . . . . . . . . . . . . . . .
2-102 2-104 2-104 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
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner Paper Deflector Assembly . . . . . . . . . . . . . . . . . . . Integrated Tray Compensator Assembly . . . . . . . . . . . . . Integrated Tray Compensator Pick Roll Assembly . . . . . Interconnect Board Assembly . . . . . . . . . . . . . . . . . . . . . Left Side Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage Power Supply . . . . . . . . . . . . . . . . . . . . . . . Main Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multipurpose Tray/Lower Deflector Assembly . . . . . . . . . Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel Cable/Cover Open Switch Assembly . . . Optional 250/500 Paper Tray Assembly . . . . . . . . . . . . . Outer EMC Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Alignment Assembly . . . . . . . . . . . . . . . . . . . . . . . Paper Input Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Size Sensing Board. . . . . . . . . . . . . . . . . . . . . . . . Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Redrive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Side Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smart Cartridge Contacts . . . . . . . . . . . . . . . . . . . . . . . . Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Paper Deflector Assembly . . . . . . . . . . . . . . . . . . Upper Front Cover Hinge Assembly . . . . . . . . . . . . . . . . Upper Front Cover Interlock Switch Assembly . . . . . . . .
4-35 4-36 4-37 4-38 4-39 4-41 4-43 4-44 4-45 4-46 4-48 4-49 4-50 4-51 4-52 4-53 4-54 4-54 4-55 4-56 4-57 4-58 4-59 4-60 4-60 4-61 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scheduled Maintenance (2420/2450/2455/3455) . . . . . . . . . . 6-1 6-1 6-1 6-2
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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 LASER DE CLASSE 1 TO IEC 825
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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 erfllt gem amtlicher Besttigung der USA die Anforderungen der Bestimmung DHHS (Department of Health and Human Services) 21 CFR Teil J fr Laserprodukte der Klasse I (1). In anderen Lndern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International Electrotechnical Commission) 825 gem amtlicher Besttigung erfllt. Laserprodukte der Klasse I gelten als unschdlich. 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 Lnge 770-795 Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, da im Normalbetrieb, bei der Wartung durch den Benutzer oder bei ordnungsgemer Wartung durch den Kundendienst Laserbestrahlung, die die Klasse I bersteigen wrde, Menschen keinesfalls erreicht.
Avis relatif lutilisation de laser

Pour les Etats-Unis : cette imprimante est certifie conforme aux provisions DHHS 21 CFR alina J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante rpond aux normes IEC 825 relatives aux produits laser de Classe I.
Notices and Safety Information xi
Les produits laser de Classe I sont considrs comme des produits non dangereux. Cette imprimante est quipe dun laser de Classe IIIb (3b) (arsniure de gallium dune puissance nominale de 5 milliwatts) mettant sur des longueurs donde comprises entre 770 et 795 nanomtres. Limprimante et son systme laser sont conus pour impossible, dans des conditions normales dutilisation, dentretien par lutilisateur ou de rvision, lexposition des rayonnements laser suprieurs des rayonnements de Classe I .
Avvertenze sui prodotti laser

Questa stampante certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo J per i prodotti laser di classe 1 ed certificata negli altri Paesi come prodotto laser di classe 1 conforme ai requisiti della norma CEI 825. I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe IIIb (3b) allarseniuro di gallio della potenza di 5mW che opera sulla lunghezza donda compresa tra 770 e 795 nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non ricevano radiazioni laser superiori al livello della classe 1.
Avisos sobre el lser

Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos lser de Clase I (1) establecidos en el subcaptulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los dems pases, rene todas las condiciones expuestas en la norma IEC 825 para productos lser de Clase I (1). Los productos lser de Clase I no se consideran peligrosos. La impresora contiene en su interior un lser de Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a 795 nanmetros. El sistema lser y la impresora estn diseados de forma que ninguna persona pueda verse afectada por ningn tipo de radiacin lser superior al nivel de
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la Clase I durante su uso normal, el mantenimiento realizado por el usuario o cualquier otra situacin de servicio tcnico.
Declarao sobre Laser

A impressora est certificada nos E.U.A. em conformidade com os requisitos da regulamentao DHHS 21 CFR Subcaptulo J para a Classe I (1) de produtos laser. Em outros locais, est certificada como um produto laser da Classe I, em conformidade com os requisitos da norma IEC 825. Os produtos laser da Classe I no so considerados perigosos. Internamente, a impressora contm um produto laser da Classe IIIb (3b), designado laser de arseneto de potssio, de 5 milliwatts ,operando numa faixa de comprimento de onda entre 770 e 795 nanmetros. O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiao laser superior a um nvel de Classe I durante a operao normal, a manuteno feita pelo utilizador ou condies de assistncia 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 p blgelngdeomrdet 770-795 nanometer. Lasersystemet og printeren er udformet sledes, at mennesker aldrig udsttes for en laserstrling over Klasse I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
Huomautus laserlaitteesta
Tm kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -mrityksen mukainen ja muualla luokan I laserlaitteiden IEC 825 -mrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia kyttjlle. Kirjoittimessa on sisinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometri. Laserjrjestelm ja kirjoitin on suunniteltu siten, ett kyttj ei altistu luokan I mrityksi voimakkaammalle steilylle kirjoittimen normaalin toiminnan, kyttjn tekemien huoltotoimien tai muiden huoltotoimien yhteydess.
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina nkymttmlle lasersteilylle. l katso steeseen. VARNING! Osynlig laserstrlning nr denna del r ppnad och sprren r urkopplad. Betrakta ej strlen.
Laser-notis
Denna skrivare r i USA certifierad att motsvara kraven i DHHS 21 CFR, underparagraf J fr laserprodukter av Klass I (1). I andra lnder uppfyller skrivaren kraven fr laserprodukter av Klass I enligt kraven i IEC 825.
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Laserprodukter i Klass I anses ej hlsovdliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som bestr av en laserenhet av gallium-arsenid p 5 milliwatt som arbetar i vglngdsomrdet 770795 nanometer. Lasersystemet och skrivaren r utformade s att det aldrig finns risk fr att ngon person utstts fr laserstrlning ver Klass I-niv vid normal anvndning, underhll som utfrs av anvndaren eller annan freskriven servicetgrd.
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 betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som bestr av en gallium-arsenlaserenhet som avgir strling i blgelengdeomrdet 770-795 nanometer. Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstrling ut over klasse I-niv under vanlig bruk, vedlikehold som utfres av brukeren, eller foreskrevne serviceoperasjoner.
Avs sobre el Lser

Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes lser de classe I (1), i segons ha estat certificat en altres llocs, s un producte lser de classe I que compleix els requisits dIEC 825. Els productes lser de classe I no es consideren perillosos. Aquesta impressora cont un lser de classe IIIb (3b) darsenir de gal.li, nominalment de 5 mil.liwats, i funciona a la regi de longitud dona de 770-795 nanmetres. El sistema lser i la impressora han sigut concebuts de manera que mai hi hagi exposici a la radiaci lser per sobre dun nivell de classe I durant una operaci normal, durant les tasques de manteniment dusuari ni durant els serveis que satisfacin les condicions prescrites.
Notices and Safety Information xv
Japanese Laser Notice
Chinese Laser Notice
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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 Scurit
Ce produit a t conu, test et approuv pour respecter les normes strictes de scurit globale lors de l'utilisation de composants Lexmark spcifiques. Les caractristiques de Notices and Safety Information xvii
scurit de certains lments ne sont pas toujours videntes. Lexmark ne peut tre tenu responsable de l'utilisation d'autres pices de rechange. Les consignes d'entretien et de rparation de ce produit s'adressent uniquement un personnel de maintenance qualifi. Le dmontage et l'entretien de ce produit pouvant prsenter certains risques lectriques, le personnel d'entretien qualifi devra prendre toutes les prcautions ncessaires.
Norme di sicurezza
Il prodotto stato progettato, testato e approvato in conformit a severi standard di sicurezza e per lutilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non responsabile per lutilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona pi elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.
Sicherheitshinweise
Dieses Produkt und die zugehrigen Komponenten wurden entworfen und getestet, um beim Einsatz die weltweit gltigen Sicherheitsanforderungen zu erfllen. 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 fr dieses Produkt bernommen. Die Wartungsinformationen fr dieses Produkt sind ausschlielich fr die Verwendung durch einen Wartungsfachmann bestimmt. Whrend des Auseinandernehmens und der Wartung des Gerts besteht ein zustzliches Risiko eines elektrischen Schlags und krperlicher Verletzung. Das zustndige
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Fachpersonal sollte entsprechende Vorsichtsmanahmen treffen.
Pautas de Seguridad
Este producto se ha diseado, verificado y aprobado para cumplir los ms estrictos estndares de seguridad global usando los componentes especficos de Lexmark. Puede que las caractersticas de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La informacin sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga elctrica y de daos personales durante el desmontaje y la reparacin de la mquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.
Informaes de Segurana
Este produto foi concebido, testado e aprovado para satisfazer os padres globais de segurana na utilizao de componentes especficos da Lexmark. As funes de segurana de alguns dos componentes podem no ser sempre bvias. A Lexmark no responsvel pela utilizao de outros componentes de substituio. As informaes de segurana relativas a este produto destinam-se a profissionais destes servios e no devem ser utilizadas por outras pessoas. Risco de choques elctricos e ferimentos graves durante a desmontagem e manuteno deste produto. Os profissionais destes servios devem estar avisados deste facto e tomar os cuidados necessrios.
Notices and Safety Information xix
Informaci de Seguretat
Aquest producte est dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililitzaci de components especfics de Lexmark. Les caracterstiques de seguretat d'algunes peces pot ser que no sempre siguin bvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informaci pel manteniment daquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui. El risc de xoc elctric i de danys personals pot augmentar durant el procs de desmuntatge i de servei daquest producte. El personal professional ha destar-ne assabentat i prendre les mesures convenients.
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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.
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1. General Information
The Optra S Laser Printers are letter quality page printers designed to attach to IBM-compatible PCs 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)
Options
The following options are available. Some options are not available in every country. Contact your point of purchase for options available in your country. Memory options of 4MB, 8MB, 16MB and 32MB Flash memory options of 4MB and 8MB Integrated network options Token-Ring Ethernet Tri-Port IR Adapter IPDS SCS USB/Parallel Port 250 and 500-sheet paper trays of A5, letter, and legal size. 250 Sheet Special Media Tray Assembly 500/500-sheet dual trays (Models 2450, 2455 and 3455) 2000 Sheet High Capacity Feeder Envelope feeder Duplex option Hard Disk - 1.4 GB (Models 1250, 1620, 1650, 2420 and 2450) Hard Disk - 2.1 GB (Models 1255, 1625, 1855, 2455 and 3455) Forms Hard Disk - 2.1 GB Infrared Adapter Kiosk Adapter Output Expander (Models 1650, 1855, 2450, 2455 and 3455)
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
Acronyms
CSU DRAM EDO EP EPROM ESD FRU GB HVPS LASER LCD LED LVPS MROM NVRAM OEM PC POST RIP ROM SIMM SRAM UPR V ac V dc Customer Setup Dynamic Random Access Memory Enhanced Data Out Electrophotographic Process Erasable, Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Giga Byte High Voltage Power Supply Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode Low Voltage Power Supply Masked Read Only Memory Nonvolatile Random Access Memory Original Equipment Manufacturer Photoconductor Power-On Self Test Raster Imaging Processor Read Only Memory Single In-Line Memory Module Static Random Access Memory Used Parts Return Volts alternating current Volts direct current
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 900 RIP Software 901 Engine Flash Action Contact the next support level or call Lexmark.. This error indicates that the flash which the engine board code is programmed into is bad. Replace the engine board. These errors indicate an unrecoverable engine software error. Replace the engine board.
902 General Engine Software 903 Paperport Link Driver Error 904 Interface Violation by the controller software 905 Interface Violation by Paperport Device 906 ControllerEngine Link Driver Error
Error Code 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 920 Fuser Error
Action 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.
Indicates a problem in the transfer roll area. Go to the Transfer Roll Service Check on page 2-105. Indicates that the fuser is below temperature when printing. Go to the Cold Fuser Service Check on page 2-48. Indicates that the fuser is below standby temperature when the printer is idle. Go to the Cold Fuser Service Check on page 2-48. Fuser failed to reach standby temperature. Go to the Cold Fuser Service Check on page 2-48. Fuser is too hot during printing or when printer is idle. Go to the Hot Fuser Service Check on page 2-50. An open circuit has been detected in the Fuser Thermistor Circuit. Go to the Hot Fuser Service Check on page 2-50. Wrong fuser lamp installed. Check the fuser lamp for the correct type of lamp that should be installed. Indicates a printer fan stalled. Go to the Fan Service Check on page 2-47. Indicates that the engine has detected that either the erase lamp assembly is missing or disconnected. Go to the Erase Lamp Service Check on page 2-46.
921 Fuser Error
922 Fuser Error 923 Fuser Error 924 Fuser Error
925 Fuser Error 927 Fan Stalled 928 Erase Lamps
Error Code 929 Toner Sensor
Action 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. 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.
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
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.
Error Code 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 ID
Action Replace the controller board. Replace the controller board. Indicates that the controller code and FONT ROM are incompatible. Replace the controller board. Replace the controller board.
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. Indicates a problem with the Configuration ID. This error occurs because the engine received a configuration ID from the controller software which is not valid for the level of engine code existing in the printer. Setting the configuration ID correctly should fix this error. The ID can be set via the NPA data stream or operator panel. Note: This error is not generated at POR to allow the servicer a method of resetting the configuration ID. However, setting the configuration ID is the only operation that the servicer can perform. See Setting Configuration ID on page 3-20.
960 RAM Memory Error 961 RAM in Slot 1 is Bad.
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.
Error Code 962 RAM in Slot 2 is Bad. 964 Emulation Error 965 Emulation Error
Action 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. The engine protocol violation detected by the specified device. Communications error detected by the specified device. Invalid command received by the specified device. Invalid command parameter received by the specified 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).
975 - 979 Network Card X
980 <device> Comm 981 <device> 982 <device> Comm 983 <device> 984 <device>
Error Code 990 <device>
Action 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 1 DU DU XX XX Byte 5 Byte 2 XX XX Byte 6 Byte 3 XX XX Byte 7 Byte 4 XX XX Byte 8
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
Explanation The input sensor is still covered by the first sheet of paper through the printer and the second sheet is ready to arrive at the sensor. Video information has not started on the page at the input sensor within two inches after activating the input sensor flag. The media takes too long to complete a pass through the input sensor. This can occur when a sheet of paper is in the machine during POST and the input sensor flag has tripped the input sensor. This error is generated whenever media is seen at the input sensor before the sensor flag activates the input sensor. A paper jam is detected by the tray you are trying to feed from. A paper jam is detected by a smart option and an error message displays. Paper Tray 5 pass thru sensor is not activated by a sheet of paper. Paper Tray 4 pass thru sensor is not activated by a sheet of paper. Paper Tray 3 pass thru sensor is not activated by a sheet of paper. Paper Tray 2 pass thru sensor is not activated by a sheet of paper. Paper Tray 5 pass thru sensor is not activated and never deactivated. A sheet of paper may still be over the sensor or the flag is still activated.
84 xx 01 84 xx 02 84 xx 04
84 xx 05 84 xx 06 84 xx 07 84 xx 08 84 xx 09 84 xx 0A 84 xx 0B 84 xx 0C
Status Bytes 1, 2,3 84 xx 0D
Explanation Paper Tray 4 pass thru sensor is not activated and never deactivated. A sheet of paper may still be over the sensor or the flag is still activated. Paper Tray 3 pass thru sensor is not activated and never deactivated. A sheet of paper may still be over the sensor or the flag is still activated. Paper Tray 2 pass thru sensor is not activated and never deactivated. A sheet of paper may still be over the sensor. The paper activated the input sensor too soon. The paper activated the input sensor too soon. The envelope feeder pass thru sensor is activated and never deactivated. The envelope feeder pass thru sensor is not activated. The paper fed too early from Tray 1. The smart option did not pick the paper. The smart option did not pick the paper. The input sensor is not activated even though the paper is picked from the source. The autocompensator DC motor stalls when attempting to pick a sheet of paper. The autocompensator DC motor takes too long to ramp up.
84 xx 0E
84 xx 0F 84 xx 11 84 xx 13 84 xx 1D 84 xx 1E 84 xx 1F 84 xx 21 84 xx 22 8E xx 02 8E xx 0B 8E xx 11
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 10 11 21 30 32 36
Explanation There was no envelope feeder error reported. Printer failed POST - Homing of Envelope feeder Printer failed POST - Halted Envelope Feeder The envelope feeder failed to feed, envelope jam. The D.C. motor failed to reach operating speed. The motor stalled. The motor failed to stop.
Duplex Unit Sub Error Codes Status byte 4 contains the most valuable information to help isolate a failing part or assembly in the duplex option and is the only byte contained in the following table.
Status Byte 4 00 01 02 03
Explanation No duplex error. No problem was reported to the engine by the duplex system card. The leading edge of the sheet of paper never arrived at the input sensor. The duplex option system board never received media notification from the printer. The trailing edge of the sheet of paper never cleared the input sensor.
Status Byte 4 04
Explanation The leading edge of the sheet of paper never arrived at the exit sensor. Note: This error is the most common due to the long length of the paper path between the input sensor and the exit sensor. The duplex logic thinks a sheet of paper is feeding to the duplex unit due to a sensor malfunction in the paper path when in fact the printer has not sent a command to send a sheet of paper to the duplex unit. The exit sensor detected a sheet of paper too early. The sheet of papers trailing edge did not clear the exit sensor in the desired length of time. The feed motor experienced a complete motor stall. The D.C. motor is under speed. The motor never reached the correct operating speed. There is paper left in the duplex option. Paper was sensed during the homing operation during POST. There is paper left in the duplex option. Paper was sensed during the DC motor diagnostic test during POST. The D.C. motor experienced an acceleration error. There is paper left in the duplex option. Paper was sensed during IR clear during POST.
05
06 07 08 0E 13 15 18 3D
User Status Messages

User Status Message Ready Status The printer is ready to receive and process data. Action 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. No button actions are possible while this message is displayed.
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.
Flushing Buffer
The printer is flushing corrupted print data and the current print job is being discarded.
User Status Message Printing Menu Settings
Status The printer is processing or printing a list of current settings menus because Print Menu Settings is selected from the menu.
Action 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.
Printing Directory List
A directory of the flash and disk contents is processing or printing because Print Directory is selected from the menu.
User Status Message Restoring Factory Defaults Performing Self Tests
Status The printer is restoring factory defaults. The printer is running the normal series of start-up tests after it is powered On. When the tests are complete, the printer returns to Ready. The printer is in the Not Ready State, which means it is not ready to receive or process data. This message displays when Menu> or <Menu is pressed during a print job.
Action No button actions are possible while this message is displayed. No button actions are possible while this message is displayed.
Not Ready (Press Go)
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. 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.
Resetting Printer
The printer is deleting any print jobs in process and restoring all settings to user defaults. The flash memory is being formatted. The flash memory is being programmed, which means fonts or macros are being written to flash memory. The disk is being formatted.
Formatting Flash (Do Not Power Off) Program Flash (Do Not Power Off)
Formatting Disk
User Status Message Programming Disk (Do Not Power Off)
Status The disk is being programmed, which means fonts or macros are being written to disk.
Action No button actions are possible while this message is displayed. Note: If information is written to flash memory and to disk at the same time, the Program Flash message is displayed.
Menus Disabled
The printer menus have been disabled. This occurs when Menu> or <Menu is pressed while the printer is Ready and Menu Lockout is active. The printer display shows this 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.
Activating Menu Changes
No button actions are possible while this message is displayed.
User Error Messages

User Error Message 200 Paper Jam Remove Cartridge 201 Paper Jam Remove Cartridge Explanation Paper is jammed at the printer Input Sensor. Open the printers upper front door and remove the print cartridge to access the paper jam area. Paper is jammed between the printers input and exit sensors. Open the printers 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. 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 printers front door is open or the print cartridge is missing. If this message cannot be cleared go to Cover Open Service Check.
202 Paper Jam Open Rear Door 230 Paper Jam Check Duplex
24X Paper Jam Check Tray X
250 Paper Jam Check MP Feeder 260 Paper Jam Check Envelope Feeder 27X Paper Jam Check Output Bin X Insert Cartridge or Close Door
User Error Message 31 Defective Print Cartridge
Explanation Error code 31 is displayed when the top front cover is closed and a defective print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is defective. Depending on the setting of the Machine Class ID the printer may be allowed to print pages during this 10-20 second interval. If pages are allowed to print, they are not reprinted once a good print cartridge is inserted. Note: This error indicates the printer was able to read the cartridge ID, but the ID did not pass the verification test. To pass the verification test, the ID read from the print cartridge must match the ID from the last good print cartridge or the same ID must be read from the print cartridge twice. The last good print cartridge ID is stored in NVRAM.
32 Unsupported Print Cartridge
Error 32 is displayed when the top cover is closed and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of 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. 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.
34 Short Paper
User Error Message 36 Resolution Reduced
Explanation 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 39 Complex Page 51 Defective Flash
This message is displayed when the printer memory used to store pages is too full to collate the print job. This message is displayed when the printer memory used to store pages is full. This message is displayed when the page is too complex to print. This message is displayed when the printer detects a defective flash. This error may occur at power on, or during flash format and write operations. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the problem is resolved. This message is displayed when there is not enough free space in the flash memory to hold the resources that have been requested to be written to flash. This message is displayed when the printer detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted. This error is displayed when a serial error (framing or parity) is detected on the standard serial port. This usually indicates the serial port is not set up correctly. This error is displayed when a serial error (framing or parity) is detected on the optional serial port. This usually indicates the optional serial port is not set up correctly.
52 Flash Full
53 Unformatted Flash
54 Standard Serial Error
54 Serial Option X Error
User Error Message 56 Standard Serial Disabled 56 Parallel Port Disabled
Explanation This error is displayed when data is sent to the printer across the standard serial port, but the port has been disabled. This error is displayed when data is sent to the printer across the parallel port, but the parallel port has been disabled. Once this message is displayed, reporting of further errors is suppressed until the menus are entered, or the printer is reset. This error code is displayed when too many input trays are attached to the printer. 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. This error code is displayed when the printer detects a defective disk. This error may occur at power on or during disk format and write operations. The following actions may be taken while this message is displayed: Press Go to clear the message. The disk is marked defective and normal printer operations continue. Disk operations are not allowed with a defective disk. The Format Disk menu is not shown. This error code is displayed when there is not enough free space on the disk to hold the resources that have been requested to be written to the disk. This message displays for both resource and PostScript Disk operators when the disk is full. 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.
58 Too Many Trays Attached 58 Too Many Bins Attached 58 Too Many Disks Installed 61 Defective Disk
62 Disk Full
63 Unformatted Disk
User Error Message 80 Scheduled Maintenance
Explanation 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. This error displays when toner low occurs and the toner low alarm is activated. Press Go to clear this message.
81 Engine Code CRC Failure
88 Toner Low
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.
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User Message Toner Low Explanation If the toner cartridge is low, then Toner Low displays. The Toner Low condition clears whenever the upper front door is opened, and Toner Low displays again if the condition exists after the upper front door is closed. If any of the input trays are missing, then Tray X Missing displays (where X designates which Tray (1 through 5) is missing. If multiple trays are missing, they are prioritized in this order: Tray 1, 2..., then tray 5. Tray X Missing status clears whenever Tray X is reinserted. If any of the input trays are empty, then Tray X Empty displays where X designates which tray (Tray 1 through 5) is empty. If multiple trays are empty, then they are prioritized in this order: Tray 5, Tray 4,...Tray 1. Note: Tray X Empty status clears whenever Tray X is removed. When Tray X is reinserted, it is examined and the appropriate status, if any, displays. Also note that Empty status is not displayed for the Envelope Feeder or Multipurpose Feeder. Tray X Low If any of the input trays are low, then Tray X Low displays where X designates which tray (1 through 5) displays. 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.
Tray X Missing
Tray X Empty
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 Parallel Serial Serial X Network X LocalTalk X Infrared Infrared X Explanation Standard Parallel Port, if available. Standard Serial Port, if available. Serial Port, where X=1,2,3, is attached to PCI connector X. Network card X, X=1,2,3, is attached to PCI connector X. LocalTalk Card X,X=1,2,3, is attached to PCI connector X. Standard Infrared port, if available. 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 Check Output Bin X Connection Check Env Feeder Connection Check Tray X Connection Check Duplex Connection Explanation 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 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.
Explanation 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. This message displays when the duplex rear door is open.
User Status Message Turn Printer OFF to Enable Option
Insert Duplex Front Cover Close Duplex Rear Door
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.
Symptom Tables
Symptom Table - Base Printer
Symptom Auxiliary Fan (2420/2450/2455/ 3455) fails to run or is noisy. Dead Machine 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 Tray Paper jams at exit of Redrive Assembly - No Duplex Option installed. Paper jams at exit of Redrive Assembly - Duplex Option installed Fuser Solenoid (Models 1620/1650/2420/2450/ 3455)fails to operate. Print quality - Black page Print quality - Blank page Print quality - Light print Action Go to the Auxiliary Fan Service Check on page 2-47. Go to the Dead Machine Service 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 Paper Feed Service Check on page 2-86. Go to the Duplex Option Service Check on page 2-35. Go to the Fuser Envelope Conditioner Solenoid Service Check on page 2-51. Go to Print Quality - All Black Page on page 2-92. Go to Print Quality - Blank Page on page 2-92. Go to Print Quality - Light Print on page 2-101.
Symptom Print quality - Background Print quality - Residual image Print quality - Skew Print quality - Banding Print quality - Random marks 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
Action Go to Print Quality - Background on page 2-96. Go to Print Quality - Residual Image on page 2-100. Go to the Paper Feed Service Check on page 2-86. Go to Print Quality - Banding on page 2-99. Go to Print Quality - Random 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 The printer does not recognize the high capacity feeder option installed. Paper feed problem with the high capacity feeder option. Action Go to the High Capacity Feeder Input Tray Service Check on page 2-61. Go to theHigh Capacity Feeder Input Tray Service Check on page 2-61.
Symptom Table: Paper Tray Options

Symptom 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. Action Go to the Input Tray(s) Option Service Check on page 2-58. Go to the Input Tray(s) Option Service Check on page 2-58. Go to the Input Tray(s) Option Service Check on page 2-58. Go to the Input Tray(s) Option Service Check on page 2-58.
Symptom Table - Duplex

Symptom Paper feed problem with Duplex Paper jams at Paper Removal Tray Paper skews in the Duplex Option Paper fails to pass from lower option thru the Duplex Option. Action Go to the Duplex Option Service Check on page 2-35. Go to the Duplex Option Service Check on page 2-35. Go to the Duplex Option Service Check on page 2-35. Go to the Duplex Option Service Check on page 2-35.
Symptom Table - Envelope Feeder Option

Symptom Envelopes do not feed from the envelope feeder. Envelopes do not feed properly into base printer. Action Go to the Envelope Feeder Option Service Check on page 2-39. Go to the Envelope Feeder Option Service Check on page 2-39.
Symptom Table - Output Expander

Symptom Printer does not display Output Bin Full Paper does not feed all the way into the output tray. Action 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.
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 1 Charge Roll Assembly Action Check the charge roll for correct installation, toner buildup, marks, cuts or other signs of contamination or damage. Replace as necessary. Check the left side charge roll link assembly for correct assembly operation. Check for damage to the arm or bearing assembly.
Left Side Charge Roll Link
FRU 3 Right Side Charge Roll Link
Action 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.
Cover Open Switch/Cable Service Check

FRU 1 Toner Cartridge Action 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. 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.
Cover Open Switch/Cable Assembly
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 1 Line Voltage
Action Check the AC line voltage. If the line voltage is incorrect, inform the customer. Check the line cord for any signs of 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.
AC Line Cord
+5 V dc at any Option Connector
+5 V dc at the controller board test point
FRU 5 +5 V dc at the engine board Test Point
Action 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. Remove the LVPS from the printer 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.
LVPS Fuse F1
LVPS Fuse F1 - Continues to blow after LVPS installed in the printer.
LVPS
Remove the LVPS from the machine: CAUTION: Before making any measurements on the LVPS output connector, observe all necessary safety precautions before applying AC power. Measure the voltage on LVPS output connector CN3. The voltage measures +5 V dc. If incorrect, replace the LVPS.
FRU 9 Engine Board
Action 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.
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 1 Fuse F1 on Duplex Option System Board Action 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.
Autoconnect Cables/ Connectors
POST fails, 230 Paper Jam, Check Duplex message displays.

FRU 1 Duplex D.C. Servo Drive Motor Action 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 2 Input Sensor, Input Sensor Flag Run the Duplex Sensor Test from the diagnostics menu. If the test fails, check the input sensor cable at J5 on the system board for correct installation. If no problem is found, replace the FRUs in the following order: input sensor assembly duplex option system board 3 Paper Exit Sensor and Flag Check the duplex exit sensor for correct installation and free movement of the sensor flag. Check to make sure the sensor cable is connected to J8 on the system board. If no problem is found, replace the FRUs in the following order: exit sensor assembly duplex option system board
230 Paper Jam - Check Duplex message displays. The page is not duplexed and only exits half way out of the redrive.
FRU 1 Duplex Stepper Motor Action 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.
POST fails with Close Duplex Rear Door displayed when Duplex Rear Door is closed.
FRU 1 Rear Door Switch (Not installed on some duplex units) Action 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 1 Front Cover Switch (Not installed on some duplex units) Action 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.
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 1 Envelope Feeder Action Check to make sure the envelope 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.
Front Autoconnect on Printer
FRU 3 Autoconnect on the Envelope Option
Action 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.
Operator panel displays 260 Paper Jam immediately when envelope feed is requested - POST incomplete.
FRU 1 Pass through Sensor Action 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.
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 1 Envelope Out Hopper Sensor Flag Action 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.
Envelope Out Hopper Input Sensor
990 Service Error, Envelopes fail to feed from the hopper.

FRU 1 D.C. Feed Motor Assembly Action Check the motor and motor cable for any signs of loose wires or poor connections. Check to make sure the motor cable is connected to the envelope system board. 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.
Envelope Feeder System Board
260 Paper Jam displays, unable to clear and envelopes fail to feed from the hopper. Kick rolls ARE NOT rotating.
FRU 1 Main Drive Belt Action Check the belt for correct installation and for signs of damage. Replace as necessary. Check all the gears for correct installation and for signs of damage. Repair or replace parts as necessary. Check the clutch latch assembly to make sure it moves freely. 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.
Gears
3 4
Clutch Latch Assembly Master Cam Gear Master/ Kick Gear
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 1 2 Deflector Gap Adjustment Weight Assembly Action Check the deflector gap adjustment. The adjustment may be too narrow. Check the weight assembly to make sure it moves up and down freely without any binds. Also check to make sure the weight assembly rests on all the rear kick rollers when the hopper is empty. Replace the weight assembly if it is damaged or does not operate properly. Check the envelope edge guide to make sure it is not warped or set too close to the envelopes in the hopper. Replace the edge guide if it is damaged or does not operate properly.
Envelope Edge Guide
260 Paper Jam displays, envelope stops in feeder paper path.

FRU 1 Kick Rolls/Feed Rolls/Drive Rolls Action Check all the rolls for any signs of oil, grease or other contamination. If you find a problem, clean or replace parts as required. Check the deflector gap adjustment. The adjustment may be too narrow.
Deflector Gap Adjustment
Envelope Feeder multifeeds or may not display a 260 Paper Jam message.
FRU 1 Envelopes Action Check the envelopes being used in the feeder. Check for signs of the envelopes being stuck together or signs of glue. Check to make sure the flaps are not interleaved. Check the deflector gap adjustment. The adjustment may be too wide. Check for a missing, broken or incorrectly installed restraint roll bias spring. If incorrect, reinstall or replace the spring.
2 3
Deflector Restraint Roll Bias 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 1 Latch Lever Action 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.
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 1 Cable, Front Harness
Action Check the connection of the front harness to connector J10 on the engine board for correct installation. If incorrect, repair as necessary. Check the front harness to erase lamp assembly for correct installation. If incorrect, repair as necessary. Remove the controller board and toner cartridge from the machine. Ground pin J10-15. The erase lamps turn on. The lamps can be observed through the front of the machine with the cover open and print cartridge removed. If the lamps do not turn on, measure the voltage on J10-14. The voltage reads approximately +24 V 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.
Engine Board
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 1 Fan Assembly Action Check the fan for proper installation and for excessive noise. If incorrect, replace the fan and cable assembly. 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.
Engine Board
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 1 Main Fan
Action Manually spin the fan and check that it rotates freely. Check the cable connection to the engine board, J1 for correct installation. Check the continuity of the cable. If incorrect, replace the cable.
Main Fan to Engine Board Cable
FRU 3 Error Code 927 (Fan runs)
Action 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. 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.
Error Code 927 (Fan not running)
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 1 Fuser Lamp (Incorrect Lamp/925 Service Error)
Action Install the correct voltage and wattage lamp or fuser assembly.
FRU 2 Fuser Lamp
Action Remove the controller board. Run the Diagnostic Print Test and observe the lamp through the left side frame. If the lamp doesnt 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. 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
LVPS and AC Fuser Lamp Cable
Fuser Top Cover Assembly (Thermal Fuse/Thermistor Assembly)
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 1 Fuser Cover Assembly (Assembly includes Thermistor and Thermal Fuses.) Action 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 2 Engine Board Error code 924 indicates the engine board detects an open circuit in the thermistor circuit for the fuser assembly. The voltage on J2-6 on the engine board measures approximately +5 V dc. If incorrect, replace the engine board. If correct, check the continuity of the DC fuser cable connected between J2 on the engine board and J1 on the fuser control board. In there is no continuity, replace the cable. If there is continuity, check the voltage on J2-2 on the fuser control board. It measures approximately +5 V dc. If incorrect, replace the fuser control board. 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 Hot Roll Backup Roll Bearings
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.
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 1 Fuser Envelope Conditioner Solenoid Action 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. The solenoid receives power from the fuser control board. The fuser control board receives +42Vdc from the LVPS via the interconnect board and envelope conditioner cable. Check for approximately +42 V dc at the +42 V dc test point on the fuser control board. If the voltage is correct, replace the fuser control board.
Fuser Control Board
FRU 3 LVPS Interconnect Board
Action 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.
Fuser DC Cable (Engine Board to Fuser Board Cable) Engine Board
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 1 Engine Board Jumpers Action 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. 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. The solenoid receives power from the fuser control board. The fuser control board receives +42Vdc from the LVPS via the interconnect board and envelope conditioner cable. Check for approximately +42 V dc at the +42 V dc test point on the fuser control board, If the voltage is incorrect, replace the fuser control board.
Fuser Envelope Conditioner Solenoid
Fuser Control Board
FRU 4 LVPS Interconnect Board Envelope Conditioner Cable
Action 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. 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.
Fuser DC Cable (Engine board to Fuser Board cable) Engine Board
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 1 Engine Board Jumpers Action 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. 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. Check the continuity of the fuser cable. If the cable does not measure continuity, replace the cable.
Fuser Envelope Conditioner Solenoid Fuser Control Board
Fuser Cable
FRU 4 Engine Board
Action 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. 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.
LVPS 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 1 Input Sensor Flag
Action Check the input sensor flag for damage and proper operation. If a problem is found, repair as necessary. Check for approximately +5 V dc at J10-10 on the engine board. If incorrect, replace the engine board. Check the continuity of the input sensor cable. If incorrect, replace the cable. If correct, replace the input sensor assembly.
Engine Board
Input Sensor Cable
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 1 Tray X option System Board or Compensator Assembly or Autoconnect Cable
Action 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
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 1 Pass Thru Sensor and Flag Assembly Action 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.
Power Takeoff Shaft and Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller
Tray X Low message displays when Tray X is full or has adequate paper in the tray.
FRU 1 Paper Low Sensor Assembly Paper Low Sensor Flag Tray X Option System Board Action 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 1 2 Paper Out Sensor Flag Paper Out Sensor (On Option System Board) Action Check the paper out sensor flag for correct operation and installation. If correct, replace the option system board. (The paper out sensor is mounted on the system board).
Printer does not recognize Tray X is installed.

FRU 1 Autoconect Cables Tray X System Board Action 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 1 Autocompensator Assembly Action 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.
The base printer does not recognize that the high capacity input tray is installed.
FRU 1 High Capacity Feeder Autoconnect Mechanical Check Action 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. Check the 14 pin flexible cable to be sure it is installed correctly and properly seated in the connectors on both boards. Check the cable for damage. Repair or replace as necessary.
Base Printer or option mounted above
14 Pin HCIT Flex Cable
FRU 5 High Capacity Feeder Option Control Board
Action 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.
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 1 Pass Thru Sensor and Flag Assembly Action 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.
Power Takeoff Shaft and Spring, Bevel Gear, Feedroll Gear, Drive Roll Assembly, Wear Plate, Drive Shaft Bearings and Skewed Backup Roller
Tray X Paper Low Message displays when Tray X is full or has adequate Paper in the tray.
FRU 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder Input System Board Action 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 1 2 Paper Out Sensor Flag Paper Out Sensor (On Option System Board) Action Check the paper out sensor flag for correct operation and installation. If correct, replace the high capacity feeder system board. (The paper out sensor is mounted on the high capacity feeder system board).
Tray X Empty Message displays when Tray X has paper in the tray.
FRU 1 2 Paper Out Sensor Flag Paper Out Sensor (Located on the High Capacity Feeder Tray Option Board) Action Check the flag for correct operation and installation. Run the Tray X sensor diagnostic. If incorrect, replace the high capacity feeder tray option board.
The elevator tray fails to stop at the correct position and continues to drive into the bottom frame.
FRU 1 Lower Limit Switch Lower Limit Switch Cable Action 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.
High Capacity Feeder 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 1 Lower Limit Switch Lower Limit Switch Cable High Capacity Feeder Control Board
Action 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 1 Autocompensator Assembly Action Check the autocompensator pick arm rollers for sign of glazing, toner or other buildup. Replace as necessary. Check the wear strips for glazing or contamination. Replace as required. It is advisable to replace all four wear strips at the same time.
Wear Strips
The elevator tray does not move up or down. The printer recognizes that the option is installed.
FRU 1 Stepper Motor High Capacity Feeder Option Control Board Stepper Motor Extension Cable Action 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.
The elevator moves in one direction only.

FRU 1 Stepper Motor High Capacity Feeder Option Control Board Action 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.
Paper size switch not selecting paper size that is selected.

FRU 1 Paper Size Switch High Capacity Feeder Option Control Board Action 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 1 High Capacity Feeder Option Control Board Action 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. Check the continuity of the sensor cable. If incorrect, replace the cable. If correct, replace the top optical sensor assembly.
Elevator Top Optical Sensor Cable Elevator Top Optical Sensor
Tray X Empty message displays. Tray does not respond to loading paper. No response from the front door switch.
FRU 1 High Capacity Feeder Option Control Board Action 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.
Elevator Top Optical Sensor Cable Elevator Top Optical Sensor
Tray X Paper Low Message displays when the high capacity feeder input tray is full or has adequate paper in the tray.
FRU 1 Paper Low Switch Paper Low Switch Cable High Capacity Feeder Option Control Board Action 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.
Excessive Noise or Vibration

FRU 1 Motor Plate Assembly Action Be sure the motor plate assembly screws are tight. Be sure the motor mounting screws are tight. Check the belt to be sure it is not too tight. The motor can be adjusted while the motor is running for minimum belt noise and optimum performance. Note: If the belt is too tight a high pitch noise results. 3 Lead Screw Bearings If the bearings are worn or defective the lead screw may wobble. Be sure the bearings and leadscrew are operating properly with no binds. Be sure the idler pulley is not binding, worn or broken.
Motor Drive Belt
Idler Pulley
Main Drive Service Check

Service Tip: Excessive gear or main drive assembly noise is usually caused by a defective motor assembly or engine board. Service Tip: If there are equally spaced horizontal lines across the page, go to Print Quality - Evenly spaced horizontal lines or marks on page 2-95. CAUTION: Whenever the gearbox assembly is removed from the machine it must be handled very carefully. Do not allow any of the gears to come in contact with any metal or other hard surface to avoid gear damage. It is also very important not to let any dirt, paper, staples or other material come intact with the grease in the gearbox assembly.
FRU 1 Main Drive Assembly (Excessive noise or vibration) Action Remove the controller board and run a Diagnostic Print Test in the continuous mode. Check the main drive assembly for any excessive noise or vibration. Determine if the noise is in the main drive, toner cartridge, fuser or main drive gearbox. Look for any loose or worn parts in the developer drive assembly, main drive gearbox or fuser. Repair as necessary. A service error code 936 - Transport Motor may be displayed. Check the voltage at J12-6 on the engine board. It measures approximately +5 V dc when the motor is not running and goes to 0 V dc when the motor is running. If incorrect, replace the engine board. If this does not fix the problem, replace the main drive motor. Check the continuity of the main drive motor cable. If incorrect, replace the cable.
Main Drive Motor Assembly (Excessive noise, gears ratcheting and so on)
Main Drive Motor Cable
FRU 4 Motor does not turn, no gear error code 936 or User message 201 Paper Jam displays.
Action Check the voltages at J12 on the engine board. Pin number and voltage: J12-1 = +24 V dc J12-4 = +5 V dc (static) 0 V dc (when main drive motor running) J12-5 = + 5 V dc (static) 0 V dc (when main drive motor running) J12-6 = +5 V dc (static) +2.5 V dc (when main drive motor running) J12-7 = +5 V dc (static) 0 V dc (when main drive motor running) J12-8 = +5 V dc (static) +5 V dc (when main drive motor running) J12-11 = + 5 V dc (static) 0 V dc (when main drive motor running) If the voltage is incorrect, replace the FRUs in the following order: main drive motor assembly engine board
Operator Panel Service Check

Operator Panel Buttons Service Check Note: Before continuing with this service check do the Button Test on page 3-9 in the diagnostic aids chapter. The operator panel cable is a individual cable on some printers and a combination cable assembly with the cover switch cable on later models.
FRU 1 Operator Panel Assembly Action If any button fails the Button Test, replace the operator panel assembly.
FRU 2 Engine Board (No buttons work)
Action Check the voltage at J11-5. The voltage measures approximately +5 V dc with the controller board removed. If incorrect, replace the engine board. If correct, check the continuity of the operator panel cable. If incorrect, replace the cable. If correct, replace the operator panel assembly.
Operator Panel Display Service Check SERVICE TIP: The printer has detected a problem with the engine board, operator panel cable or operator panel assembly if POST does not complete and the printer emits 5 beeps and stops in a continuous pattern until the printer is turned off. The operator panel cable is a individual cable on some printers and a combination cable assembly with the cover switch cable on later models. Note: If the operator panel is operating properly except for a PEL or a few PELS missing or broken, run the LCD Test on page 3-9 from the hardware tests before continuing with this diagnostic service check.
FRU 1 Operator Panel Cable Action Check for proper installation of the cable at the engine board (J11) and at the operator panel. Check the continuity of the operator panel cable. If incorrect, replace the cable. Check the voltage at J11-2 on the engine board. It measures approximately +5 V dc. If incorrect, replace the engine board. If correct, replace the operator panel assembly. Check for ground between J13-4 and ground. If correct, replace the operator panel assembly. If incorrect, replace the engine board.
Operator Panel Display blank, 5 beeps, LED Off
Operator Panel Display blank, 5 beeps, LED On
FRU 4 Operator Panel all diamonds, No Beeps
Action Check to make sure a SIMM is not plugged in backwards. This condition causes the printer to fail POST displaying all diamonds on the operator panel with no beeps Check the voltage at Pin J11-1 and J11-3. The voltage measures approximately +5 V dc. If incorrect, replace the FRUs in the following order: operator panel assembly engine board
Operator Panel all diamonds, 5 Beeps
Options Service Check

Service Tip: When you have a problem with any of the options installed in the options slots on the interconnect board on a 2450 or 1650 (the 1250 has only one slot), switch the non operating option to one of the other option slots to isolate the failure. Flash Memory Option(s) Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Check to make sure that the Memory SIMM is installed correctly and is not broken or damaged. If the Memory SIMM is correctly installed not broken or damaged then run the Flash Test on page 3-3. If the test fails, replace the FLASH SIMM. If the problem continues, replace the controller board. DRAM Memory Option(s) This service check is the same as the flash memory option service check with the following exception: Run the DRAM Memory Test on page 3-10 from the menu if the DRAM Memory SIMM is correctly installed and not broken or damaged. If the test fails, replace the DRAM SIMM. If the problem continues, replace the controller board.
Hard Disk Option Service Tip: The Optra S printers support one hard disk option. Check to make sure only one hard disk option is installed.
1.4 GB - 1250/1620/1650/2420/2450 2.1 GB - 1255/1625/1855/2455/3455
Check to make sure the fixed disk and the fixed disk board are correctly installed. Run the Quick Disk Test on page 3-2 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk. Note: The Quick Disk Test is a non-destructive test and indicates Pass or Fail. If the test fails, replace the hard disk. If a problem still exists, replace the hard disk board. The Disk Test/Clean on page 3-2 is used to help restore the disk if the disk contains bad data and is unusable. This test is divided into a cleaning and a verifying or testing section. Note: This can be a very lengthy test depending on the disk size. This test leaves the hard disk unformatted. The servicer or user must reformat the disk using the Format Disk Menu operation. This is a destructive type of test. All the data on the disk is destroyed and should not be performed on a known good disk. Network Card Option Error Code 976 - Network Card X (X=Network card 1, 2, or 3) A 976 error code indicates an unrecoverable software error in network card x. Verify that network card x is correctly installed in the socket on the interconnect board and is properly grounded. If you find no problem, contact your next level of support before replacing the network card. Error Code 977 - Network Card X A 977 error displays when the RIP software detects that a network card is installed in slot x on the interconnect board but cannot establish communications with the network card. If you are servicing a 1650, 1855, 2420, 2450 or 2455 and the network card works in another slot, replace the interconnect board.
Output Bin Sensor Standard Tray Service Check

Service Tip: If the output bin standard tray fills up and the bin full sensor fails to post the message "Remove Paper Standard Bin", enter the Diagnostic Mode, select Output Bin Tests, select Sensor Tests and select Standard Bin. Check the sensor and flag for proper operation. If you find no problem with the sensor and flag, continue with the service check. Service Tip: Check to make sure the correct flag is installed. The Output Bin Sensor is a normally closed sensor with the sensor flag down. Therefore, unless the flag is in the up position or out of the sensor slot, a Remove Paper Standard Bin message is not displayed.
FRU 1 Engine Board Printer fails to display Remove Paper Standard Bin message. Output Bin Sensor Test fails Action Check the voltage at J6-3. It measures +5 V dc when the flag is in the sensor and 0 V dc when the flag is out of the sensor. If the voltage does not change, replace the sensor cable assembly. If this does not fix the problem, replace the engine board. Check to make sure the correct flag is installed. Check the flag for damage or improper operation. If incorrect, replace the flag. Note: A broken or improper operating sensor flag causes a Remove Paper Standard Bin message to display before POST completes and cannot be cleared.
Output Bin Sensor Flag
Output Expander Service Check

There are two levels of the 500 Sheet Output Expander Option.
Level 1 is equipped with a stepper motor/mechanical linkage assembly. Level 2 is equipped with a DC servo motor and a new mechanical linkage assembly and has fewer mechanical components.
Service Tip: The majority of the mechanical components can be observed during operation by removing the left, right and system board covers. The output expander functions without the covers installed. Note: Make sure the option is correctly installed before attempting to service the unit. Problems with excessive static electricity buildup.
FRU 1 Output Expander Control Board Cover
Action Check the output expander control board cover to make sure the ESD brush ground lead is firmly attached to the output expander frame. Also check to make sure the ESD brush is not loose.
Printer does not recognize one or more output expander options as being installed. Service Tip: If more than a single output expander option is installed, check each one to see if the printer recognizes any single option as being installed. If the printer recognizes any of the output expander options then the base printer autoconnect system is operating correctly and the problem is in the unrecognized expander option.
FRU 1 Output Expander Option
Action Make sure the output expander option is the only option that is not recognized by the base printer. If the output expander is the only option not recognized by the printer, continue with step 2. If not, check the autoconnects of the options not recognized and the interconnect board and cable connections. Check the autoconnects for damage, especially the connector pins. Remove the left and right side covers. Remove the front control board cover. Check the cables at J1A, J1B, J2A and J2B on the control board to make sure they are attached securely and correctly. Remove the output expander and check the voltages on the output bin autoconnect located on the top left rear of the printer. Go to Autoconnect - Top on page 5-21. If the voltages are correct, reinstall the output expander unit and check the voltages at J1A and J1B on the connector. If correct, replace the output expander control board. If incorrect, replace the output expander assembly mechanical linkage.
Output Expander Assembly Mechanical Linkage
202 Paper Jam Open Rear Door Message displays. A sheet of paper is jammed prior to the pass through sensor flag. 202 Paper Jam Open Rear Door Message displays. A sheet of paper feeds out to the standard bin even though bin x is selected. Paper exits half way out of the redrive. Service Tip: For this type of problem check the sub error codes. They can help isolate the problem. 202 Paper Jam messages can also occur prior to the output expander pass thru sensor.
FRU 1 Output Expander Drive Belt Drive Pulley Drive Belt Idler Pulley Belt Tension Spring Action Check to ensure the output expander drive belt is correctly installed on the drive pulley and belt idler pulley. Check the belt tension spring to make sure it is not loose or broken. Repair as necessary. If the DC motor is functioning properly check the gears, clutch and other linkage parts for correct operation and any signs of wear, broken gear teeth or damaged parts. If incorrect, replace the mechanical linkage/DC motor assembly.
Mechanical Linkage DC Motor Assembly Level 2
FRU 3 Stepper Motor Level 1
Action Check the stepper motor connector to ensure it is correctly installed at J4 on the output expander option board. Go to Output Expander Control Board - Level 1 Stepper Motor on page 5-22. If correct, disconnect J4 from the option board and check the resistance of the stepper motor at J4: J4-1 to J4-2: Approximately 10 ohms J4-3 to J4-4: Approximately 10 ohms. Also check each winding for shorts between J4-1 thru J4-4 and the motor housing. If you find a problem, replace the stepper motor. If you do not find a problem, replace the output expander mechanical linkage assembly.
FRU 4 Output Expander Control Board Level 1
Action Check the voltages at connector J4. Go to Output Expander Control Board - Level 1 Stepper Motor on page 5-22. Printer idle J4-1 +21 V dc to +24 V dc J4-2 +21 V dc to +24 V dc J4-3 +21 V dc to +24 V dc J4-4 +21 V dc to +24 V dc Printer Feeding Paper J4-1 Approximately +16 V J4-2 Approximately +16 V J4-3 Approximately +16 V J4-4 Approximately +16 V dc dc dc dc
The voltage drops to approximately +16 V dc as the output expander bin stepper motor turns on and a sheet of paper is fed through the redrive into the output expander assembly. If any of the voltages fail to change, replace the output expander option board. If that does not correct the problem, replace the output expander mechanical linkage assembly.
Remove Paper - Output Bin X is displayed, POST Incomplete, Unable to clear the message.
FRU 1 Dual Output Bin Sensor Flag Action Check the flag for correct operation, binding, broken parts or interference from the sensor cable, If incorrect, repair as necessary.
271 Paper Jam - Check Bin X. POST Incomplete

FRU 1 Pass Thru Sensor and Flag Assembly Control Board Action Check the sensor flag for proper operation. If correct, check to make sure the pass thru sensor cable is correctly connected to J3 on the control board. Disconnect the pass thru sensor cable from J3 on the control board and check the voltage at J3-3. The voltage measures approximately +5 V dc. If incorrect, replace the control board. If correct, check the voltage at J3-2. The voltage measures approximately 0 V dc. If incorrect, replace the sensor assembly. If this does not fix the problem, replace the control board.
271 Paper Jam - Check Bin X, POST Complete, First Sheet of paper feeds into Output Bin X. Note: Before performing the following checks run the Output Bin X Sensor Test and check for the failing sensor. Sensor Test: NF = Near Full (Upper part of sensor assembly) F = Full (Lower Part of sensor assembly) P = Pass Thru Sensor
990 Service - BIN X

FRU 1 D.C. Motor Mechanical Linkage Assembly (Level 2) Action Check the DC motor cable connector to be sure it is correctly installed at J4 on the output expander option board. Go to Output Expander Control Board Level 2 DC Motor on page 5-24. If correct, disconnect J4 from the option board and check the resistance of the motor on the cable connector: J4-1 to J4-2: measures between 115 and 135 ohms. Also check J4-1 and J4-2 to the motor case for shorts. If either the resistance is incorrect or a short is found, replace the motor/ mechanical linkage assembly. Note: If the DC motor is shorted, it may also be necessary to replace the control board. Disconnect the motor cable J4 and check the voltages at J4 on the board. Go to Output Expander Control Board - Level 2 DC Motor on page 5-24. Note: Use caution not to short to adjacent pins on the connector. J4-1 (Motor Idle) +24 V dc J4-2 (Motor Idle) +24 V dc J4-5 (Motor Idle) +5 V dc J4-6 (Motor Idle) +5 V dc If any of the voltages are incorrect, replace the control board. If the voltages are correct, replace the DC motor/mechanical linkage assembly.
Output Expander Control Board (Level 2)
No indication that Bin X is Full OR No indication that Bin X is Near Full Note: The NF or Near Full sensor will only be displayed on models that support an Output Expander that has a Dual Sensor installed.
FRU 1 Dual Output Bin X Sensor Assembly Control Board Action Check for correct installation of the sensor cable at J5 on the control board. If either the Bin Full (F) or Bin Near Full (NF) fail the sensor test then check the voltage at J5-3 and J5-4. The voltage measures approximately +5 V dc. If the voltage is incorrect, replace the control board. If correct, replace the sensor assembly.
Paper Feed Service Check

If you have a 936 Transport Motor Error go to the Main Drive Service Check on page 2-73.
FRU 1 Alignment Assembly Action Check to ensure the alignment assembly is correctly attached to the left side frame and the mounting screws are tight. Check the alignment assembly for any signs of worn rollers, contaminated rollers or binds. Replace the alignment assembly if any problem is found. Check the inner paper deflector for correct installation. If the deflector is bowed or not fitting correctly, replace the deflector.
Inner Deflector
Autocompensator fails to feed paper. Failures occur randomly throughout the stack of paper.
FRU 1 2 Pass Through Sensor Autocompensator Assembly Action Check the pass through sensor for correct installation and operation. The autocompensator pick roll shaft assembly is not providing enough torque if the pick rollers are not picking the paper correctly. Replace the autocompensator assembly. Check the wear strips for excessive wear, scratches or rough spots. Replace the wear strips if a problem is found.
Wear Strips in Tray X problem is found.
Paper feed failures occur only near the top of the stack of paper. The most common cause of this problem is paper curl. Remove the paper from tray x and check for the natural curvature in the paper. Reinstall the paper in the correct manner. If the problem persists, it may be necessary to reduce the stack height. Replace both pick rolls if the paper appears to be flat in the tray but the there is still a problem. Failures occur mainly near the bottom of the stack of paper. The autocompensator pick arm may not be coming down far enough to allow the pick rolls to properly contact the paper. Also the autocompensator motor may be failing. If this problems continues, replace the autocompensator assembly.
Double Feeding Paper Note: If double feeding paper occurs mostly from the bottom of the stack, check for missing or damaged restraint pads in the tray.
FRU 1 Paper Action Paper is usually the primary cause of a double feeding paper problem. Flex the paper before placing the paper in the tray. Edge welded paper is the most common cause of double feeding. Loading the paper in the tray in different locations and directions and using rough paper and short grain paper also causes double feeding. Make sure the counterbalance spring is not missing, loose or broken at the top of the autocompensator arm assembly. If you find a problem, replace the autocompensator assembly.
Autocompensator
Multipurpose Tray Paper fails to feed from the multipurpose tray. The pick roll should make one complete revolution and stop with the flat side down. If the pick roll turns but does not pick paper, check the roll for signs of wear, oil or grease on the surface of the pick roll or slick spots. If you find a problem, replace the pick roll assembly. Check to ensure the media that is being fed through the multipurpose tray assembly meets recommended paper specifications.
Parallel Port Service Check

Run the Parallel Wrap Test on page 3-11. Note: The Parallel Wrap Test is designed to check the parallel port hardware by using a wrap plug (P/N 1319128) and invoking the Parallel Diagnostic Test. This test helps isolate the printer from the parallel cable and host. The test provides failure information on the display for approximately 3 seconds. If the test indicates that a problem is detected, replace the controller board.
Printhead Service Check

The printhead assembly does not contain any service replaceable parts or components. If service error code 930 displays, the wrong printhead is installed in the printer.
Service Error Code 1 Error Code 931 No first HYSNC Signal Error Code 932 Lost HYSNC Explanation These errors usually indicate a failure in the HYSNC signal to the printhead. Check the continuity of the cables connected to J3 and J8 on the engine board. If incorrect, replace the defective cable. The voltage at J8-4 measures approximately +5 V dc. If incorrect, replace the engine board. The voltage at J3-7 measures approximately +24 V dc. If incorrect, replace the engine board. If correct, replace the printhead assembly.
Service Error Code 2 Error Code 934 Mirror Motor Lost Lock Error Code 935 Mirror Motor unable to reach operating speed
Explanation These error codes indicate a problem with the mirror motor circuit in the printhead assembly or the mirror motor cable to the engine board cable or engine board assembly. Check the continuity of the mirror motor cable connected to J3 on the engine board. If incorrect, replace the cable. The voltage at J3-7 measures approximately +24 V dc. If incorrect, replace the engine board. If correct, replace the FRUs in the following order: engine board printhead assembly
Print Quality Service Check

Service Tip: Before troubleshooting any print quality problems do the following:
Install another print cartridge if available before proceeding with the service checks. Use Tray 1 to test for print quality of the base printer.
Select the following menu settings as indicated. Be sure and note the original settings so you can return the printer to the original customer printer setup.
Print Resolution: Set to 300 dpi (print quality problems should be checked at different resolution settings). Print Darkness: Set to NORMAL. Toner Saver: Set to OFF. PQET: Set to OFF. Fuser Temperature: Set to NORMAL.
An incorrect printer driver for the installed software can cause problems. Incorrect characters could print and the copy may not fit the page correctly. Measure all voltages from the connector to printer ground. All voltages measured during the print cycle are measured with the controller board removed while running the print test.
Print Quality - All Black Page Service Tip: An all black page is generally caused by a problem in the high voltage system or an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum.
FRU 1 High Voltage Contacts
Action Check the high voltage contacts on the right side frame to ensure they fit securely and are not pitted, contaminated or damaged. If incorrect, replace the contact with one from the HV contact kit. Screws are included to attach the contacts to the right side frame in the HV contact kit.
HVPS
Check the voltages on J10-1 thru J10-8. If incorrect, replace the engine board. Check the continuity of the HVPS cable. If incorrect, replace the cable assembly. If correct, replace the engine board.
HVPS Cable (Part of Front Harness Cable) Engine Board
Print Quality - Blank Page
FRU 1 Print Cartridge
Action Check the print cartridge for any signs of damage, especially the PC drum contact on the cartridge.
FRU 2 High Voltage Contact
Action Check the PC drum contact on the right side frame for damage, PC drum contact wear or contamination. If the contact is bent or damaged, replace the contact. Note: Inspect the HVPS PC drum contact on the board for any signs of damage or contamination.
HVPS
Check the fuse on the HVPS. If open, replace the HVPS. Check the voltages at J10 on the engine board. Measure the following voltages from connector J10 to printer ground: Printer Idle J10-5 measures +24 V dc Printer Printing J10-5 measures +24 V dc In the voltages at J10-5 are incorrect, replace the engine board.
Front Cable Harness HVPS Section
Check the front cable harness at J10 on the engine board and at CN1 on the HVPS to make sure the harness is connected properly. If connected properly, check the continuity of the cable harness. If there is no continuity, replace the front cable harness. Generally a 93x service error is posted if the printhead assembly fails and the printer does not give a blank copy symptom. The printhead used in the printer does not have a mechanical shutter as previous laser printers. The printer is interlocked through the front top cover interlock switch.
Printhead Assembly
Print Quality - Random Marks Service Tip: The primary cause of random marks is due to loose material moving around inside the printer and attaching to the photoconductor, charge roll or transfer roll.
Symptom 1 Random Marks
Action Check the print cartridge for any signs of loose or foreign material that might be on the photoconductor. Check the transfer roll and charge roll for any pieces of material that are stuck to the rolls.
Print Quality - Blurred or Fuzzy Print Blurred of fuzzy print is usually caused by a problem in the main drive gearbox assembly, alignment assembly, any feed roller or in the transfer roll bearings or transfer roll. Check the gearbox assembly for correct operation. Check the transfer roll for binds or a contaminated shaft or bearings. Blurred print can also be caused by incorrect feeding from one of the input paper sources, paper trays, duplex or envelope feeder. Check the high voltage contacts to ensure they are not bent, corroded or damaged. Replace as necessary.
Print Quality - Evenly spaced horizontal lines or marks

FRU 1 Lines spaced 3.19 mm (.126 inch) apart Lines spaced 22.32 mm (.882 inch) apart Lines spaced 28.7 mm (1.130 inch) apart Lines spaced 47.83 mm (1.883 inch) apart Lines spaced 63.77 mm (2.511 inch) apart 3 Lines spaced 38.26 mm (1.506 inch) apart This can be caused by defective gear(s) in the main drive gearbox. Replace the FRUs in the following order: main drive gearbox reference edge 4 Lines spaced 44.64 mm (1.757 inch) apart Replace the FRUs in the following order: developer drive assembly main drive gearbox assembly 5 Lines spaced 47.19 mm (1.858 inch) apart Replace the FRUs in the following order: toner cartridge charge roll developer drive assembly 6 Lines spaced 49.16 mm (1.935 inch) apart Replace the toner cartridge. Action This can be caused by the motor pinion gear on the main drive motor. Replace the main drive motor. This can be caused by a defective gear in the main drive gearbox assembly. Replace the main drive gearbox assembly.
FRU 7 Lines spaced 49.74 mm (1.958 inch) apart
Action Replace the FRUs in the following order: redrive assembly fuser assembly
8 9 10
Lines spaced 51.02 mm (2.009 inch) apart Lines spaced 52.23 mm (2.056 inch) apart Lines spaced 76.53 mm (3.013 inch) apart
Replace the transfer roll. Replace the redrive assembly. Replace the FRUs in the following order: alignment assembly main drive gearbox assembly
11
Lines spaced 95.66 mm (3.766 inch) apart
Replace the FRUs in the following order: toner cartridge main drive gearbox assembly
12 13
Lines spaced 99.49 mm (3.917 inch) apart Lines spaced 114.79 mm (4.519 inch) apart
Replace the redrive assembly. Replace the alignment assembly.
Print Quality - Background Service Tip: Some background problems can be caused by rough papers or non-Lexmark toner cartridges. If the rough paper mode is on, turn it off and run the print test. Some slick or coated papers may also cause background. Some problems occur with printers that run a large amount of graphics in a humid environment. The customer may try to improve the print quality by increasing the transfer setting.
FRU 1 Erase Lamp/Lens Assembly
Action Check the erase lamp lens for any signs of toner, paper dust or other types of contamination. Clean the lens with a soft dry cloth if necessary. If unable to clean the contamination off the lens, replace the lens and lamp assembly. Check the erase lamp assembly. Use the same procedure as outlined in the Erase Lamp Service Check on page 2-46. The printhead on the Optra S printers cannot be cleaned. Try another printhead if all other attempts fail to correct a background problem. Check the high voltage contact from the HVPS to the transfer roll. Check the transfer arm assembly right side bearing for any signs of contamination, pitting or a loose cable to the bearing. If any problems are found, replace the defective part. Check the transfer roll shaft for any signs of contamination, wear or pitting on the ends of the shaft that go into the bearings. If a problem is found, clean the ends of the shaft or replace the transfer roll assembly. Check the high voltage contacts on the right side frame to ensure they are clean and not bent, deformed, or pitted. If incorrect, replace the contact.
Printhead
Transfer Roll Assembly
High Voltage Contacts
FRU 5 Engine Board HVPS Connector
Action Check the following voltages at J10 on the engine board. Measure the voltages from J10 to printer ground. Printer Idle J10-1 approximately 0 V dc J10-2 approximately 4 V dc J10-4 approximately 0 V dc Printer Printing J10-1 varies 0 V dc to +5 V dc J10-2 varies 0 V dc to +4 V dc J10-4 varies 0 V dc to +1.9 V dc If J10-1 voltage is incorrect, check the continuity of the front harness cable (J10-1 line). If there is no continuity, replace the harness cable. If there is continuity, replace the HVPS. If this does not correct the problem, replace the engine board. If J10-2 voltage is incorrect or if the voltage remains at 0 V dc, check the continuity of the front harness cable (J10-2 line). If there is no continuity, replace the harness cable. If there is continuity, replace the HVPS. If this does not correct the problem, replace the engine board. If J10-4 voltage is incorrect, check the front harness cable (J10-3 line). If there is not continuity, replace the harness cable. If correct, replace the engine board. if this does not correct the problem, replace the HVPS.
Print Quality - Banding Service Tip: Banding is difficult to detect except on a page with a uniform gray or a large amount of graphics printed on the page. Banding is primarily due to a variation in the speed of the paper as it feeds thru the printer, especially in the development and transfer process. Inspect the alignment assembly, main drive assembly and all other paper feed components for signs of wear, dirt, binds, or damage, especially the drive gears. Banding appears as light or dark horizontal lines on a uniformly gray page. Banding on model 3455 can also be caused by a defective charge roll brush contact or HVPS. Check the charge roll contact for any signs of damage and for proper connection to the HVPS and print cartridge. Print Quality - Black bands on outer edges of the page This print quality problem appears as vertical black bands on one or both sides of the copy and can be wide, narrow, light or dark.
FRU 1 Charge Roll Counterbalance Springs
Action If the problem is just on one side of the page, check the charge roll counterbalance spring on that side. You can check to see if enough force is being applied to the charge roll by applying a slight downward pressure with your finger to the charge roll link arm that the spring is attached to while you run a print test sample. See if the problem changes or goes away. If this fixes or changes the problem, then check the springs and charge roll link arm assemblies for binds or defective parts. Replace as necessary.
FRU 2 Charge Roll Assembly Charge Roll Link Arm
Action Check the charge roll for any signs of toner buildup or other contamination on the outer edges that correspond to the bands on the page. Check the charge links and arms for proper operation, binds or incorrectly mounted counterbalance springs. Repair or replace as necessary. Check the following voltages at J10-8 on the engine board: Printer Idle J10-8 measures 0 V dc Printer Printing Test Page J10-8 voltage changes from 0 V dc to +4 V dc If the voltage does not vary, check the continuity of line J10-8 in the front cable harness. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If this does not correct the problem, replace the engine board. Turn the printer Off and check the resistance between J10-7 and printer ground. The resistance measures approximately 0 ohms. If incorrect, make sure the engine board is mounted correctly and securely grounded. If correct, replace the engine board.
HVPS
Print Quality - Residual Image Service Tip: Install a new print cartridge if available before doing this service check. Residual image can be caused by the photoconductor, cleaning blade and other parts inside the print cartridge. Residual image on model 3455 can also be caused by the charge brush contact.
FRU 1 Erase Lamp Assembly
Action Check the erase lamp lens assembly for any signs of paper dust, toner buildup or any other contamination. Clean with a soft cloth or replace the lens and lamp assembly which are provided together in a kit. If the lens is clean then check the erase lamp assembly for failed erase lamps. If defective, replace the erase lamp assembly. Check the fuser assembly for signs of toner contamination. The hot roll especially might cause toner to be retained and deposited on the page.
Fuser Assembly
Print Quality - Light Print
FRU 1 Transfer Roll
Action Check the right end of the transfer roll shaft for signs of wear or contamination. If incorrect, replace the transfer roll. Check the right side transfer roll arm assembly bearing for any signs of wear or contamination. Also check to ensure the transfer cable is firmly attached to the bearing. If incorrect, replace the right side transfer arm assembly. Check the connection of the transfer roll assembly cable to the transformer on the HVPS board. Check the continuity of the cable from the bearing to the spade terminal on the cable. If incorrect, replace the right side transfer arm assembly. If correct, replace the HVPS.
Right Side Transfer Roll Arm Assembly
Print Quality - Toner on backside of printed page Service Tip: This is generally caused by loose toner in the machine in the paper path being carried through the printer on the backside of the paper.
FRU 1 Fuser Assembly Action Toner is being carried out on the backside of the media. This problem is generally caused by a toner buildup on the fuser hotroll or backup roll. Check the fuser hotroll and backup roll for any noticeable buildup of toner. Repair as necessary. Check the transfer roll for any signs of toner buildup or loose toner around the area of the transfer plate assembly. Clean the area and run another copy. If the problem continues, replace the FRUs in the following order: HVPS engine board
Transfer Roll Transfer Plate Assembly
Smart Cartridge Service Check

Note: If you are unable to clear a 32-Unsupported Cartridge User Error Message, make sure an Optra Se print cartridge is correctly installed in the printer. The cartridge is easily identified by the smart chip located on the top right side of the cartridge. Install another Optra Se cartridge before attempting to troubleshoot the printer. Check to make sure the smart cable is properly connected to J21 on the engine board. Check the print cartridge for any signs of damage or improper installation of the smart chip. Also check to make sure there is proper contact between the smart chip and the smart cartridge contacts.
Service Tip: An intermittent 32-Unsupported Cartridge User Error Message can be caused by poor contact between the smart cartridge contacts in the upper front cover and the smart chip. Also check for proper seating of the smart cartridge cable to the engine board.
FRU 1 Smart Cartridge Contact Smart Cartridge Ground Contact Action Check both contacts to make sure they are properly installed and the two contacts are not touching each other. Check both contacts for any signs of being bent, worn or broken. If incorrect replace both contacts. Check to make sure that the smart cartridge cover is properly snapped into place and is not damaged or broken. Replace as necessary. Check the plunger for correct installation and any signs of being damaged or broken. Correct any problem found or replace the plunger as necessary. Check the voltage on the smart cartridge contact. The voltage measures approximately +5 V dc when not writing data to the engine board. If data is being written, the voltage measures approximately +12 V dc. If incorrect, disconnect the cable from J21 on the engine board and check the voltage on J21-1. The voltage measures approximately +5 V dc. If incorrect, replace the engine board. If correct, replace the smart cartridge cable.
Smart Cartridge Cover
Smart Cartridge Plunger
Smart Cartridge Cable Engine Board
Serial Port Service Check

Run the Serial Wrap Test on page 3-12. Note: The Serial Wrap Test is designed to check the serial port hardware by using a wrap plug (P/N 1329048) and invoking the Serial Post Diagnostic Test. The test helps isolate the printer from the serial cable and host. The test provides failure information on the display for approximately three seconds. If the test indicates a problem, replace the controller board.
Toner Sensor Service Check

Service Tip: Check the print darkness MENU setting before checking the toner sensor. This service check is intended to be used when a 929 Service Error displays.
FRU 1 Developer Drive Assembly Action Incorrect operation of the developer drive assembly can cause the printer to display a 929 error code (Toner Sensor). Check the developer drive assembly for correct installation, any sign of worn, loose or broken parts. Check the toner sensor assembly cable to make sure it is properly seated into the toner sensor. If correct at both the sensor and engine board (J10), check the continuity of the cable. If incorrect, replace the cable.
Toner Sensor Cable
FRU 3 Toner Sensor
Action The toner sensor cable is part of the front harness and part of connector J10 on the engine board. Check the voltage at J1-011. It reads approximately +5 V dc. If incorrect, replace the engine board. If correct, check the voltage at J10-12. It reads approximately +5 V dc with the controller board removed from the printer. If incorrect, replace the engine board. If correct, replace the toner sensor assembly. A bad ground connection between J10-13 on the engine board and pin 3 on the toner sensor results in a 929 service error.
Transfer Roll Service Check

Service Tip: The transfer roll is 17.0 mm (.669 inch) diameter. Any print quality problems such as lines that are spaced 17 mm apart indicate you should check the transfer roll for damage, toner or foreign material buildup. Service Tip: The transfer roll assembly is part of the Maintenance Kit for models 2450, 2455 and 3455 printers and is replaced when a '80 Scheduled Maintenance message displays. Ask the customer if they have replaced the transfer roll recently. CAUTION: Make sure the printer is powered Off before making any checks on the transfer roll or associated parts for personal safety and to prevent damage to the printer.
FRU 1 Transfer Roll Assembly
Action Check the transfer roll for any signs of toner buildup, surface damage to the roll, oil or other contaminants on the surface of the roll. Replace the transfer roll as necessary.
FRU 2 Left Transfer Arm Assembly
Action Check the left transfer roll arm assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, check to ensure the arm is not broken and will lock into the EP frame correctly. Check the left transfer arm assembly spring for proper operation. Check the right transfer arm assembly to make sure it is fastened and locked in the down position. If the arm is not locked down, check to make sure the arm is not broken and will lock into the EP frame correctly. Check the right transfer arm assembly spring for proper operation. For any background problems, check to ensure the contact to the HVPS board is correct and that there is approximately 0 ohms resistance between the transfer roll shaft and the HVPS contact. If correct, go to Print Quality - Background on page 2-96 Check the voltage at J10-3. The voltage changes from +24 V dc with the printer idle to 0 V dc when the printer runs the print test. If the voltage is incorrect, check the continuity of line J10-3 in the front cable harness to the HVPS. If there is no continuity, replace the cable harness. If there is continuity, replace the HVPS. If the problem continues, replace the engine board.
Right Transfer Arm Assembly
HVPS - 917 Error Code
3. Diagnostic Aids
This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostic Mode.
Diagnostic Mode
To enter the Diagnostic Mode: 1. 2. 3. 4. Turn the printer off. Press and hold the Go and Return buttons. Turn the printer on. Release the buttons when "Performing Self Test" displays on the operator panel.
The tests display on the operator panel in the order shown:
Print Registration Print Tests Hardware Tests Duplex Tests (If installed) Input Tray Tests Output Bin Tests Base Sensor Tests Printer Setup Error Log EP Factory Defaults
Exiting the Diagnostics Mode

Select Exit Diagnostics to exit the Diagnostics Mode and return to normal mode.
Diagnostic Aids 3-1
Device Tests
Quick Disk Test
This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk. To run the Quick Disk Test: 1. Select the Quick Disk Test from the Device Tests menu. The power indicator blinks while the test is in progress. Quick Disk Test/Test Passed message displays if the test passes and the power indicator turns on solid. Quick Disk Test/Test Failed message displays if the test failed and the power indicator turns on solid. 2. Press Go, Return, or Stop to return to the Device Tests menu.
Disk Test/Clean
WARNING: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approximately 1 1/2 hours depending on the disk size. To run the Disk Test/Clean Test: 1. Select Disk Test/Clean from the Device Tests menu. "Files will be lost/Go or Stop?" message displays to warn the user that all contents on the disk will be lost. 2. To exit the test immediately and return to the Device Tests menu, press Return/Stop. To continue with the test, press Go. If go is selected, "Disk Test/Clean/BAD:000000 00%" message displays. The screen updates periodically indicating the percentage of test completed and the number of bad blocks found. 3. The power indicator blinks during the test. The test can be canceled anytime during the test by pressing Return/Stop. Once the test is complete, the power indicator turns on solid and a message displays.
xxxx Bad Blocks/yyyyyy Usable message displays if fewer than 2000 bad blocks are detected. xxxx indicates the number of bad blocks and yyyyyy indicates the number of usable blocks. xxxx Bad Blocks/Replace Disk message displays if more than 2000 bad blocks are detected. The disk cannot be recovered because too many bad blocks exist on the disk. 4. Press Go or Return/Stop to return to the Device Tests menu.
Flash Test
This test causes the file system to write and read data on the flash to test the flash. WARNING: This test destroys all data on the flash because the flash is reformatted at the end of the test. To run the Flash Test: 1. Select Flash Test from the Device Tests menu. The power indicator blinks while the test is running. Flash Test/Test Passed message displays if the test passes and the power indicator turns on solid. Flash Test/Test Failed message displays if the test fails and the power indicator turns on solid. 2. Press Go or Return/Stop to return to the Device Tests menu.
Disabling Download Emulations

Error Code 964: Download Emulation CRC Failure. Checksum failure detected in the emulation header or emulation file. Error Code 965: Download Emulation Outdated. Time stamps indicate the download emulation and RIP code are incompatible. To help resolve Download Emulation problems the following steps are necessary to instruct the printer to POR without activating any download emulations. To Disable the Download Emulation: 1. Turn the printer off. 2. Press and hold the Go and Menu buttons. Diagnostic Aids 3-3
3. Turn the printer On and release the buttons once Performing Self Test displays. Once the printer is idle, the emulation can be downloaded again. 4. Program the download emulation into the code overlay SIMM again. 5. If these steps do not resolve the problem, replace the code overlay SIMM and download the emulation again.
Duplex Tests
Duplex Quick Test
This test is used to verify that the Duplex Option Top Margin is set correctly. This test prints a duplexed version of the Quick Test Page that can be used to adjust the Top Margin for the backside of the duplexed page. You can run one duplexed page (Single) or continue printing duplexed pages (Continues) until Return/Stop is pressed. The paper you choose to print the page on should be either Letter or A4. To run the Duplex Quick Test: 1. Select Duplex Quick Test from the menu. 2. Select Single or Continuous. The single Duplex Quick test cannot be canceled. The printer attempts to print the Quick Test Page from the default paper source. If the default paper source only supports envelopes, then the page is printed from Tray 1. Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet. If adjustment is necessary the Top Margin Offset must be adjusted first. The range of the adjustment is -25 to +25. The Duplex Top Margin Offset range is -20 to +20. Adjustment of this setting lets you shift up or down the position of the Top Margin. Changing this parameter by 1 unit moves the margin
1/100 inch. A positive offset moves the text down the page and widens the top margin while a negative offset moves the text up the page and narrows the top margin. 3. Press Return/Stop to exit the test. Check the Top Margin Offset of the base printer.
Duplex Sensor Test

This test is used to determine whether or not the Duplex sensors and switches are working correctly. Select Sensor Test from the Duplex Tests menu. Manually actuate each of the duplex sensors. When the sensor/ switch is closed, CL (closed) displays, when the sensor/switch is open, OP (Open) displays. Duplex input sensor Duplex exit sensor Duplex front cover switch (not installed on all duplex options) Duplex rear door switch (not installed on all duplex options) Press Return/Stop to exit the test.
Duplex Motor Test

This test lets you test the duplex units paper feed drive system, and verify that the power and velocity values are acceptable. To run the Duplex Motor Test: 1. Select Motor Test from the Duplex Tests menu. The duplex motor test continues to run until the printer is powered off. The power indicator blinks while the test is running. The duplexer runs the motor at a high speed and then a low speed and takes an average of the power required for each speed. After all the information is computed, the motor turns off.
Diagnostic Aids 3-5
The following appears on the printer display: DUPLEX MOTOR AA BB CC DD EE FF To pass the test the following results must display: AA = 00 BB = in the range of 20 through 3F inclusively (hex) CC = in the range of 3A through 5D inclusively (hex) DD = in the range of 11 through 1F inclusively (hex) Ignore bytes EE and FF. If the test fails, remove the drive belt from the duplex D.C. motor and run the motor test again. For the duplex D.C. motor to pass the test the following results must display: AA = 00 BB = in the range of 29 through 3E inclusively (hex) CC = in the range of 35 through 51 inclusively (hex) DD = in the range of 0C through 13 inclusively (hex) For the duplex drive system to pass the test the following results must display: AA = 00 BB = in the range of 29 through 3F inclusively (hex) CC = in the range of 3A through 5D inclusively (hex) DD = in the range of 11 through 1F inclusively (hex) 2. Press Return/Stop to exit the test.
Duplex Feed 1 Test

This test feeds a blank sheet of paper to the duplex paper stop position 1. To run the Duplex Feed 1 Test: 1. Select Duplex Feed 1 from the Duplex Test menu. The power indicator blinks while the paper is feeding. "Duplex Feed 1/Feeding" message displays while the paper is feeding through the printer. Duplex Feed 1/Clear Paper message displays when the paper reaches paper stop position 1 and the power indicator turns on solid.
Duplex Feed 2 Test

This test feeds a blank sheet of paper to the duplex paper stop position 2. To run the Duplex Feed 2 Test: 1. Select Duplex Feed 2 from the Duplex Test menu. The power indicator blinks while the paper is feeding. "Duplex Feed 2/Feeding" message displays while the paper is feeding through the printer. Duplex Feed 2/Clear Paper message displays when the paper reaches the duplex paper stop position 2 and the power indicator turns on solid.
Diagnostic Aids 3-7
Error Log
Viewing the Error Log
The error log is helpful to the servicer by providing a history of printer errors. The error log contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in consecutive positions in the log are entered. All 2xx and 9xx error messages are stored in the error log. To view the Error Log: 1. Select Display Log from the Error Log menu. The Error log displays on 3 screens as only 4 entries display at a time. 2. To move to the next screen press Menu> to move forward or <Menu to move backward. 3. Press Return/Stop to exit the Error Log.
Clearing the Error Log

To clear the Error Log: 1. Select Clear Log from the Error Log menu. 2. Select "YES" to clear the Error Log or "NO" to exit the Clear Log menu. If "YES" is selected, the Empty Error Log displays on the screen. 3. Press Return/Stop to exit the Clear Log menu.
Hardware Tests
The following Hardware Tests can be selected from this menu: LCD Test Button Test DRAM Memory Test ROM Memory Test Parallel Wrap (if available) Serial Wrap (if available) Serial 1 Wrap (if available) Serial 3 Wrap (if available)
LCD Test
To run the LCD Test: 1. Select LCD Test from the Diagnostic menu. The LCD test continually executes the LCD display test. 2. Press Return/Stop to cancel the test.
Button Test
To run the Button Test: 1. Select Button Test from the Diagnostic menu. With no buttons pressed several OP (Open) appear on the display. 2. Press each button one at a time and a CL (Closed) displays in place of an OP. The proper operation of each button can be checked. 3. Press Return/Stop to cancel the test.
Diagnostic Aids 3-9
DRAM Memory Test

The purpose of this test is to check the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Memory Test: 1. Select DRAM Memory Test from the menu. The power indicator blinks indicating the test is in progress. 2. Press Return/Stop to exit the test. P:###### represents the number of times the memory test has passed and finished successfully. Initially 000000 displays with the maximum pass count being 999,999. F:##### represents the of time the memory test has failed and finished with errors. Initially 00000 displays with the maximum fail count being 99,999. Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is turned on solid, and the final results display. If the test fails, the message DRAM Error, displays for approximately 3 seconds and the failure count increases by 1.
ROM Memory Test

The ROM Memory Test is used to check the validity of the RIP code and fonts. To run the ROM Memory Test: 1. Select ROM Memory Test from the menu. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is in process. The test runs continuously. 2. Press Return/Stop to exit the test.
Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following messages displays for approximately 3 seconds: ROM Checksum Error ROM Burst Read Error Once the maximum pass count or fail count is reached, the test stops with the power indicator on solid. The final results display on the screen.
Parallel Wrap Test

This test is used with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested. To run the Parallel Wrap Test: 1. Disconnect the parallel interface cable and install the wrap plug (P/N 1319128). 2. Select the Parallel Wrap Test from the menu. The power indicator blinks indicating the test is in progress. The test runs continuously until canceled. Each time the test finishes, the screen updates. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following messages displays for approximately 3 seconds: Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fail Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error
Diagnostic Aids 3-11
DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum count is reached the test stops. The power indicator goes on solid and the final results display. Press Return/Stop to exit the test.
Serial Wrap Test

This test is used to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. To run the Serial Wrap Test: 1. Disconnect the serial interface cable and install the wrap plug. 2. Select the appropriate Serial Wrap Test from the menu: Serial Wrap, Serial 1 Wrap, Serial 2 Wrap or Serial 3 Wrap. P & F represent the same numbers for DRAM. The power indicator blinks indicating the test is running. 3. This test runs continuously unless canceled by pressing Return/ Stop.
Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, one of the following failure messages displays for approximately 3 seconds and the Fail Count increases by 1: Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum count is reached the test stops. The power indicator goes on solid and the final results display. Press Return/Stop to exit the test.
Input Tray Tests

Input Tray Feed Test
This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder. The paper is placed in the output bin. To run the Input Tray Feed Test: 1. Select Input Tray Feed Test from the menu. 2. Select the input source from the sources displayed on the Feeds Test menu. All installed sources are listed. 3. Select either Single (feeds one sheet of media from the selected source) or Continuous (continues feeding media from the selected source until Return/Stop is pressed). 4. Press Return/Stop to exit test.
Input Tray Sensor Test

This test is used to determine if the input tray sensors are working correctly. To run the Input Tray Sensor Test: 1. Select the Sensor Test from the Input Tray Test menu. "Input Tray/Empty=OP/Pass=OP" message displays. EM = Input Tray Empty Sensor LO = Input Tray Paper Low Sensor P = Input Tray Pass Thru Sensor 2. Once this message displays, the servicer can manually actuate each sensor. The tray empty sensor can be actuated by hand, however a sheet of paper can be used to cover the pass through sensor. When the sensor is closed, CL displays, when the sensor is open, OP displays. 3. Press Return/Stop to exit the test.
The multipurpose tray and the envelope feeder do not have a paper low sensor. The multipurpose tray does not have a pass thru sensor.
Output Bin Test - Standard Bin

This test is used to verify if the standard bin sensor is working correctly. To run the Standard Bin Sensor Test: 1. Select Output Bin Tests from the Diagnostic Menu. 2. Select Output Bin Tests - Sensor Tests. 3. Select Sensor Tests - Standard Bin. Standard Bin/Full=CL message displays. Manually actuate the bin sensor by moving the flag in and out of the sensor. The display indicates OP (open) when the flag is out of the sensor and CL (closed) when the flag is in the sensor. 4. Press Return/Stop to exit the test.
Output Bin Feed Test

Note: If the Configure Bins printer setting is link rather than mailbox, the printer selects its own internal bin linking regardless of which output bin is selected for the feed test This test is to verify that media can be fed to a specific output bin. No information is printed on the media because the printhead is not turned on during this test. To run the Output Bin Feed Test: 1. Select Feed Test from the Output Bin Test menu. 2. Select the output bin you want the paper to exit into. All output bins installed on the printer are shown on the feed test menu. 3. Select either Single (one sheet of media feeds to the selected output bin) or Continuous (media continues feeding to the selected output bin) until Return/Stop is pressed. 4. Press Return/Stop to exit the test.
Output Bin Sensor Test

This test is used to verify if the output bin sensors are working correctly. To run the Output Bin Sensor Test: 1. Select Sensor Test from the Output Bin Test menu. "Output Bin/Full=OP/Input=OP" message displays. Full = Output Bins Full Sensor Pass = Output Bins Pass Thru Sensor 2. Once the message displays, the servicer can manually actuate each of the output bin sensors. The bin full sensor can be actuated by hand, however a sheet of paper can be used to cover the bin's pass thru sensor. When the sensor is closed CL displays, and when the sensor is open OP displays. 3. Press Return/Stop to exit the test.
Output Bin X Sensor Test

Note: Some output expanders have a single output bin sensor installed while others have a dual sensor assembly. Both versions have a single pass thru sensor. This test is used to verify if the Output Bin X sensors are working correctly. To run the Output Bin X Sensor tests: 1. Select Output Bin tests from the menu. 2. Select Output Bin tests - Sensor Tests. 3. Select Sensor Tests - Output Bin X. Output Expander with Single Sensor The following is displayed: Output Bin X Full=OP P=OP Full=Bin Full Sensor P=Pass Thru Sensor
Output Expander with Dual Sensor: The following is displayed: Output Bin X P=OP F=OP NF=CL P = Pass Thru Sensor F = BIN FULL Sensor (lower part of dual sensor) NF = Near Full Sensor (upper part of dual sensor) Once the message displays, the servicer can manually actuate each of the output bin sensors. The bin full sensor can also be actuated by hand. Use a sheet of paper to cover the bin's pass thru sensor. When the sensor is closed CL displays, and when the sensor is open OP displays. 4. Press Return/Stop to exit the test.
Base Sensor Test

This test is used to determine if the sensors located inside the printer are working correctly. The following sensors can be checked: Toner Optical Sensor Input Sensor Output Sensor (Fuser Exit) Narrow Media Sensor Front Door Sensor (Upper Front Cover) To run the Base Sensor Test: 1. Select the Base Sensor Test. The operator panel displays OP for open and CL for closed. 2. Manually toggle the sensors by hand to verify that each sensor switches from open to closed.
Print Registration
The print registration range is as follows: Bottom Margin: -20 to +20 Top Margin: -25 to +25 Left Margin: -25 to +25 Right Margin: -10 to +10 To set Print Registration: 1. Select Registration from the Diagnostic menu. 2. The Top margin sign/value pair blinks. This indicates it is the margin value being changed. 3. To select the margin value to be changed press Select until the margin value pair you want to change is blinking. 4. To change the margin value press either Menu> or <Menu. When the value you want is displayed, press Select to save the value. 5. To exit the Registration menu, press Return. To verify the margin values are correct you must print the "Quick Test Page" from the registration screen. Press Go to print the test page. While printing the Quick Test Page the Quick Test Printing message displays. Once the Quick Test Page completes printing, the Registration screen displays again. The "Quick Test Page" should be printed on letter or A4 paper.
Printer Setup
Setting the Page Count
This lets the servicer change the page count from the diagnostic menu. This is used whenever the engine board is replaced because this board contains the printer's NVRAM Memory where the page count is stored. To set the Page Count: 1. Select Page Count from the diagnostic menu. The current page count displays. The leftmost digit blinks, indicating it is the first digit to be changed. 2. Press either Menu> or <Menu until the value you want displays. 3. Press Select to move to the next digit, press Menu> or <Menu until the value you want displays. Continue with each digit until you set the page count. You can skip any digit by pressing Select. 4. Press Select to save the new page count in NVRAM. 5. Press Return/Stop to exit the diagnostic menu.
Viewing the Permanent Page Count

The Permanent Page Count can only be viewed and cannot be changed. To view the Permanent Page Count: 1. Select Permanent Page Count from the menu. 2. Press Return/Stop to exit the diagnostic menu.
Maintenance Page Count (2420/2450/2455/3455)

This counter is reset by the servicer after a 80 Scheduled Maintenance message displays (250K copies) and a maintenance kit is installed. To view the Maintenance Page Count: 1. Select Maintenance Count Value from the diagnostic menu. 2. Press Return to go to the previous menu. To reset the Maintenance Page Count to zero: 1. Select Reset Maintenance Count. Pressing Select causes the maintenance page counter to reset to zero. Reset Maintenance Count Saved displays momentarily. When the reset operation is complete, the menu returns to the Printer Setup Reset Maintenance Count screen.
Setting Configuration ID
The configuration ID is used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The Configuration ID is originally set at the factory when the printer is manufactured, however it requires resetting whenever you replace the engine board and can be set on the operator panel. However the Configuration ID is the only diagnostic function displayed until a valid ID is entered. To set the Configuration ID: 1. Select Configuration ID from the Printer Setup menu. The current ID displays on the screen. The Configuration ID is on a label located inside the printer. The label is attached to the top front cover hinge assembly and is visible when the top front cover is open. The leftmost digit blinks indicating that it is the first digit to be changed. 2. To change the value, press either Menu> or <Menu until the value you want is reached. Press Select to move to the next digit, or press Select again to skip a digit. Change each digit as required. When the last digit is changed, press Select to validate the Configuration ID. If the ID is invalid then "INVALID
ID" message displays on Line 2 before the ID redisplays. You have to reenter the Configuration ID until a valid ID is verified. If the ID is valid then the ID is saved in NVRAM and the printer automatically PORs to activate the new setting. Note: When the printer PORs it does so in the normal mode.
Restore EP Factory Defaults

To restore each of the printer settings contained in the EP Setup menu to their factory default value select Restore from the menu. To exit the menu without restoring the settings to the factory default values, select Do Not Restore. Sometimes this is used to help correct print quality problems. Fuser Temperature This adjustment can be used to help solve some customer problems with paper curl on low grade papers and or problems with letter heads on some types of media. The fuser temperature can be adjusted as follows:
NORMAL LOWER LOWEST
Warm Up Time You can change the amount of time the printer warms up before allowing pages to print by changing this setting from 0 to 5. The factory sets the warm up at 0 or no warm up time. This time period allows the backup roll to heat up and helps reduce curl in some environments. Transfer The transfer can be adjusted as follows:
LOW MEDIUM HIGH
Print Contrast The print contrast setting controls the developer voltage offset. The print contrast can be adjusted as follows:
LOW MEDIUM HIGH
Charge Roll The charge roll can be adjusted as follows:
LOW MEDIUM HIGH
Print Tests
The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. Each of the installed options is listed in the following order in the menu: Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) Multipurpose Feeder (if installed) Envelope Feeder (if installed) For each input source selected you have the following choice:
Single (prints the Print Test Page once) Continuous (continue printing the Print Test Page until Return or Stop is pressed).
The contents of the Print Test Page varies depending on the media installed in the selected input source. Note: The Print Test Page always prints on one side of the paper, regardless of the duplex setting or the presence of a duplex option. To run the Print Test Page: 1. Select Print Tests from the Diagnostic menu. 2. Select the media source. 3. Select Single or Continuous. If single is selected no buttons are active during printing. If continuous is selected, Return or Stop can be selected to cancel the test. Check each Test Page from each source to assist in Print Quality and Paper Feed problems.
Print Quality Test Pages

The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled. The print quality test consists of three pages. Page one contains a mixture of graphics and text. Pages two and three only contain graphics. If duplex is turned On, the pages are duplexed, otherwise the pages are printed on one side. The Print Quality Test pages must always be printed on letter, legal or A4 paper. To run the Print Quality Test Pages: 1. 2. 3. 4. 5. Turn the printer off. Press and hold Select and Return. Turn on the printer. Release the buttons once Performing the Self Test displays. The printer performs its normal POR cycle then print one copy of the Print Quality Test pages. If you want more than one copy, perform these steps again.
The following is printed on page 1.
Diagnostic EP Setup: fuser temperature, warm up time, transfer, print contrast and charge roll settings. Contents of the Diagnostic Error Log. Printer configuration information: printer serial number, controller code level, engine code level, operator panel code level, smart option code levels, font versions, and so on. Values for the Quality Menu settings used to print the pages.
Printing Menu Settings Page

Note: This test page must be printed on letter, legal or A4 paper. To print the Menu Settings Page: 1. Select the TESTS MENU. 2. Select Print Menus from the TESTS MENU. The page contains the following information:
A list of all the printer settings contained in the control panel menus and their values. A list of the installed options and features such as RAM memory SIMMs, optional input paper trays, envelope feeder, duplexer, output bins, flash or disk. Printer information such as serial number, page count, installed RAM, engine code level, RIP code level, envelope feeder code level, tray 1-5 code levels, output bin 1-3 code levels, control panel code levels, font ROM version and SRAM availability.
Autocompensator Operation
The autocompensator is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore no special trays are needed for card stock or labels. The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm. This movement produces a downward force at the pick rolls. The friction between the pick roll and the paper produces a frictional locking condition. If the paper is physically held and not allowed to feed, then the motor stalls. Slippage between the roll and the paper is theoretically impossible. When the motor is energized the pick rolls are driven down into the stack increasing the normal force and drive force until the bending strength of the paper is overcome and the paper bends and moves up the dam. Once this critical threshold is achieved the normal force remains at a level just high enough to reliably feed the paper. Rather than having a fixed spring force for feeding all weights of paper like the D-roll, this device has its own mechanical logic for producing only enough pick energy to feed a single sheet of paper regardless of its stiffness. High normal force is one of the most significant contributors to double feeding paper. The pick arm is counter balanced by an extension spring located on the pick arm to reduce weight in the rest state. This spring is factory set to exert no more than ten to fifteen grams on the stack. This is as light as can be realistically set and always guarantee there is some force to start the autocompensating phenomena. This spring is not to be considered an adjustment for feeding problems unless it is obvious that the pick arm cannot fall all the way down to the bottom of the tray or has come loose.
Poor gear efficiency can cause the arm to generate higher normal forces. If the pick assembly is noisy, replacement may be required. The arm must pivot freely through its full range of motion. On 500 sheet trays there are wrap springs located on the pivot arbors of the arm. These springs aid to prevent the arm from bouncing. If the arm appears to be binding or sticky near the bottom of the tray these springs may be the problem. Reducing the tension on the counterbalance spring may be used as a temporary fix to get additional weight at bottom, until the pick assembly can be replaced. However, the counterbalance spring is not to be considered an adjustment for feeding problems.
Autoconnect System, Paper Tray Options, Envelope Feeder and Output Expander Operations
Electrical
Autoconnect Cabling and Connectors The printer options make electrical connection automatically or autoconnects requiring no external cables when the option is mechanically installed under the printer. Communication between the option and the base printer stops when you remove an option located above or below the printer. The printer no longer recognizes the option and deletes associated messages. Each installed option below the base printer provides an electrical autoconnect to the option attached below it. The output expander option attached above the base printer provides power to the option above it. We do not recommend to attach or Hot Plug any options with the base printer power turned On.
Duplex Option The duplex option interface is a six pin autoconnector that provides a +24 V dc, +24 V dc return, serial interface transmit signal, serial interface receive signal and two ground pins. The duplex option receives the +24 V dc from the base printer for the duplex motors and also converts the voltage to +5 V dc for duplex electronics. Duplex chassis grounding is provided from the printer to the duplex option through a ground spring attached to the frame and base of the printer. The ground connection is automatically made when the option is installed below the printer. The paper input sensor is located in the rear of the duplex unit under the input paper guide. The rear cover open switch is located on the rear cover assembly. The paper exit sensor is located on the left frame assembly. The jam removal tray open switch is located at the end of the left frame assembly. There are no switches in the level 2 duplex option. Option Microcode The options are Smart Options or options that have a system board. The option system board has a microprocessor that controls the option mechanism. A software architecture is provided that controls the option and communicates information such as paper path status, sensor or switch status, motor status and so on to the base printer.
Fuser Operation
The fuser in the Optra S printers is made up of two primary assemblies. The first assembly is the top fuser cover which contains the thermistor/cable, thermal fuse, cable assembly, left and right lamp brackets and cover. This is a complete assembly and the parts cannot be individually replaced as in previous Lexmark laser printers. The thermal fuse protects the fuser assembly from overheating or problems with the fuser lamp by opening the ac circuit to the lamp. The thermistor assembly is designed to keep the temperature of the fuser hot roll within a predetermined temperature by being in contact with the fuser hot roll and changes resistance as the temperature of Diagnostic Aids 3-27
the hot roll increases. The thermistor resistance changes from approximately 150K ohms to approximately 260K ohms as the temperature of the fuser hot roll increases. The thermistor is connected to the fuser control board connector J2-1 and J2-2 and from J2 to J1-2 and J1-3 on the fuser control board to J2-6 and J2-7 on the engine board. J2-6 (TEMPIN+) and J2-7 (TEMPIN-) are connected to module PLCC U9. U9 monitors the change in thermistor resistance and sends a signal (HEATON) from J20-A25 through the interconnect board to CN3-9 on the LVPS to signal the triac to turn the fuser lamp On or Off to maintain the correct fuser temperature. The voltage drop across the thermistor is proportional to the fuser temperature and varies from approximately 2.0 V dc (cold) to 2.3 V dc (warm during idle) to approximately 2.7 V dc during continuous printing. These voltages are assuming the fuser temperature is set to normal. The HEATON signal from CN3-9 varies from 0 V dc (lamp On) to +5 V dc (lamp Off) and is connected to the cathode of an Opto triac to control the fuser lamp. The second part of the assembly is the fuser frame which contains the hot roll, backup roll, and associated parts as well as the paper exit guide assembly, narrow media sensor, fuser control board (which has the exit sensor mounted on the board) and the envelope conditioner solenoid on the model 2420, 2450, 2455, 3455, 1620, 1625, 1650 and 1855. The model 2420, 2450 and 2455 printer fuser temperature is 200.8 degrees C while printing at 600 dpi and 163.9 degrees C while printing at 1200 dpi. The model 1620, 1625 and 1650 printer fuser temperature is 185.5 degrees C while printing at 600 dpi and 145.5 degrees C while printing at 1200 dpi. The model 1250 and 1255 printer fuser temperature is 206.9 degrees C while printing at 600 dpi and 151.5 degrees C while printing at 1200 dpi. The model 3455 printer fuser temperature is 270 degrees C while printing at 600 dpi and 170 degrees C while printing at 1200 dpi.
Paper Feed Jams

Paper Jams - Base Printer
Error Message 200 - Paper Jam - Remove Cartridge This message indicates that paper is jammed at the printer input sensor. This condition can be caused by the paper jamming prior to activating the input sensor flag, the sensor not detecting paper over the sensor or paper arriving at the sensor too late. Error Message 201 - Paper Jam - Remove Cartridge This message indicates the paper is jammed between the printers input and exit sensors. This condition can be caused by the paper exiting the input sensor too late or jamming in the fuser assembly prior to activating the exit sensor flag in time or not at all. Error Message 202 - Paper Jam - Open Rear Door This message indicates the paper is jammed at the printer exit sensor. This can be caused by the paper arriving at the sensor too late, the paper is jammed in the fuser assembly or is jammed exiting the fuser assembly in the redrive assembly or the exit sensor flag is not operating correctly.
Paper Jams - Options

Error Message 230 Paper Jam - Check Duplex The paper is most likely jammed in the duplex unit, however the paper can also be jammed in the redrive at the input to the duplex option. The redrive assembly may not be correctly installed or locked in position or the duplex link is bent and not aligned properly to allow paper to feed correctly into the duplex option. Error Message 24x (x=Tray 1 through 5) Paper Jam Check Tray x. The paper has not cleared the pass through sensor or reached the pass through sensor of the option above tray x.
Error Message 250 - Paper Jam - Check MP Feeder The paper is jammed in the multipurpose feeder and has not reached the base machine input sensor or has not reached the input sensor in time. Error Message 260 Paper Jam - Check Envelope Feeder An envelope is jammed in the envelope feeder or has not reached the base machine input sensor. Error Message 27x Paper Jam - Check Bin x. Paper is jammed in output bin x (X=bin 1 thru 3). Generally this message appears when the paper has not cleared the exit sensor in time, has jammed in the redrive assembly or has not fed into the output bin selected.
4. Repair Information
WARNING: Read the following before handling electronic parts.
Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards:
Keep the ESD-sensitive part in its original shipping container (a special ESD bag) until you are ready to install the part into the machine. Make the least-possible movements with your body to prevent an increase of static electricity from clothing fibers, carpets, and furniture. Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges any static electricity in your body to the machine. Hold the ESD-sensitive part by its edge connector shroud (cover); do not touch its pins. If you are removing a pluggable module, use the correct tool. Do not place the ESD-sensitive part on the machine cover or on a metal table; if you need to put down the ESD-sensitive part for any reason, first put it into its special bag. Machine covers and metal tables are electrical grounds. They increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.) Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers when you are not working on the machine, and do not put unprotected ESDsensitive parts on a table. If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case). Be extra careful in working with ESD-sensitive parts when coldweather heating is used because low humidity increases static electricity.
Repair Information 4-1
Adjustment Procedures
Duplex Motor Drive Belts
Do the duplex motor belt and drive belt adjustment whenever you remove or replace the duplex motor or loosen the motor or drive belt idler pulley. Service Tip: Excessive belt tension can result in stalling the duplex motor. Too little belt tension can result in belt slippage. To do the duplex drive belt adjustment: 1. Do the removal procedure Duplex Front Cover Door on page 4-21 to access the drive belt idler pulley. 2. Loosen the idler pulley mounting screw and position the idler to provide 3 mm (.5 mm) drive belt deflection. 3. Tighten the idler pulley mounting screw being careful to maintain the adjustment. 4. Reassemble the duplex unit. To do the duplex motor belt adjustment: 1. Do the removal procedure Duplex Motor on page 4-22 to access the motor mounting screws but do not remove the motor. 2. Loosen the screw in the elongated adjustment slot and position the motor to provide 3 mm (.5 mm) motor belt deflection. 3. Tighten both mounting screws being careful to maintain the adjustment. 4. Reassemble the duplex unit.
Fuser Solenoid Adjustment

Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature.
Printer Model 2420/2450/2455 1620/1625/1650/1855 3455 Solenoid Air Gap 4.4 mm (.170 inch) 3.9 mm (.153 inch) 4.8 mm (.153 inch)
Gap Adjustment
The gap adjustment allows you to increase the minimum gap between sheets of paper as they are fed through the printer. This adjustment does not reduce the printer's overall performance such as pages per minute but can help in reducing the amount of curl of some printed media thus improving media stacking in the output bin. Enter the Diagnostic Mode Select EP SETUP from the Diagnostic Menu. Select GAP ADJUST The range of the GAP adjustment is 0 to 255. Adjust the gap setting by using the Menu < > button to select the value. If GAP=0 displays, it indicates a factory setting to minimum gap. Select a value and run several copies of the media that displays a curl problem. It may take several tries before improvement is noticed. Note: This setting has no effect when printing in duplex mode. 1. 2. 3. 4.
Printhead Assembly Adjustment

Do the printhead assembly adjustment whenever you remove or replace the printhead assembly or loosen the mounting screws. Install the new printhead with the three mounting screws centered in the slots in the printhead frame assembly. Leave the screws loose enough to allow the printhead assembly to move from side to side within the slots. It is necessary to perform a registration adjustment before locking down the three printhead mounting screws. To perform the registration adjustment: 1. Turn the printer off. 2. Press and hold: Return and Go. 3. Turn the printer On and release the buttons when Performing Self Test" displays. 4. Select Registration from the menu. 5. Select Quick Test Page. The test page should only be printed on letter or A4 paper from Tray 1. The Quick Test Page consists of alignment diamonds, horizontal lines that can be used for skew adjustment, page count setting, printer serial number code levels and print registration settings. 6. Check the Quick Test Page for any sign of skew by checking the diamonds at the top left and top right of the test page for equal distance from the top of the page. If any adjustment is necessary, adjust the left or right printhead mounting screws and check the skew again by running another Quick Test Page. This procedure may take two or three attempts before you get satisfactory results. 7. When you have the correct adjustment, gently tighten the printhead mounting screws being careful not to move the printhead assembly.
Paper Alignment Assembly Adjustment

Do the alignment assembly adjustment whenever you replace the alignment assembly. Always print a copy of the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw. When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far enough to remove the old assembly and install the new one. If you are replacing the alignment assembly go to step a. If you are only adjusting the reference adjustment screw go to step b. a. Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings should be within the range specified in Print Registration on page 3-18. Do the reference adjustment if you are sure the margins are set correctly. 1. Loosen the locknut on the inside rear of the alignment assembly. 2. Remove the two screws holding the alignment assembly to the left side frame. 3. Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer. It is not necessary to completely remove the screw. 4. Install the new alignment assembly. Turn the reference screw clockwise with a 7 mm nut driver until it touches the back of the reference plate and tighten the nut with a 5.5 mm wrench. The reference adjustment screw can be adjusted without loosening the nut. Turn the screw clockwise a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want.
b. Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings should be within the range specified in Print Registration on page 3-18. The reference screw can be adjusted without loosening the locknut. Turn the screw a few turns and print a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting the screw as you check the results of each adjustment on a new test page until you obtain the results you want.
Screw Identification Table

The following table contains screw types, locations, and quantities necessary to service the printer. Each screw callout in the removal procedure graphic displays the screw reference number listed in the table. Pay careful attention to each screw type location when doing removals. You must install the correct screw type in each location during reassembly.
Reference Number
Screw Type M3.5x8 mm Thread Cutting
Location right side frame to center pan toner level sensor charge roll main drive gearbox EP module to left and right side frame developer drive assembly left side cover gap to left frame stacker duct to frame cartridge hold down assembly MPT deflector fuser to frame interconnect board shield ground engine board shield to frame laser cover
Purpose attach mounting mounting mounting attach mounting attach mounting mounting mounting mounting attach attach mounting
Qty 1 1 1 3 9 2 2 2 2 2 2 2 1 5
Reference Number
Screw Type M3.5x8 mm Thread Cutting
Location spring controller board integrated tray ITC board left side cover stacker support to right side frame
Purpose mounting mounting (front) mounting mounting attach attach mounting mounting attach attach mounting attach mounting
Qty 1 2 2 5 2 1 2 2 3 2 2 6 5
M3.5x12 mm Thread Cutting
engine board shield to left frame paper alignment assembly toner cartridge guide track left side frame to center pan right side frame to center pan deflector
M3x5 mm Taptite
INA cover (2 screws per cover) interconnect board
Reference Number
Screw Type M3x6 mm Taptite
Location outer shield inner redrive deflector interconnect board to center pan engine board (bottom holes) controller board to interconnect board ground controller board to inner shield fuser ground wire controller board (back) engine board to interconnect shield ground fuser ground wire lower stacker duct ground cables to ground (center pan - front) cross brace to right stacker duct cable clip (main drive gearbox, BTM) fuser screw door restraint
Purpose mounting mounting mounting mounting attach
Qty 6 2 2 2 2
mounting mounting mounting attach
2 1 2 1
mounting mounting attach attach mounting mounting mounting
1 1 1 1 2 7 1
Reference Number
Screw Type M3x8 mm Taptite
Location LVPS auto compensator hanger bracket
Purpose mounting mounting
Qty 2 1
M3x12 mm Taptite
HVPS board
mounting
M3x28 mm Taptite
developer drive ground (bottom hole)
attach
M3.5x8 mm Plastite Thread Forming
upper front cover left side cover autocompensator
mounting mounting mounting
5 3 3
Reference Number
Screw Type M3.5x10 mm Plastite Thread Forming
Location right side cover left side cover left side frame to pan
Purpose mounting mounting attach
Qty 3 3 1
M3.5x12 mm Plastite Thread Forming
left side cover
mounting
M3x6 mm SEMS Machine Screw with washer
fuser board
mounting
M3.5x12 mm Plastite Thread Forming with washer
printhead to EP frame
mounting
Removal Procedures
CAUTION: Remove power from the printer before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer. Use the hand grips on the side of the printer. Make sure your fingers are not under the printer when you lift or set the printer down. Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.
Covers
Left Door Release the two left door latches (A) and remove the door
Left Cover 1. Remove the left door. 2. Remove the five mounting screws (A).
3. Raise the upper front cover. 4. Remove the three mounting screws (B), the print cartridge and remove the left cover.
Right Cover 1. Raise the upper front cover. 2. Release the cover latch (A) and remove the right cover mounting screw (B).
3. Remove the redrive assembly. 4. Remove the right side cover mounting screws (B) and (C). 5. Remove the right side cover.
Upper Front Cover 1. Raise the upper front cover. 2. Remove the five upper front cover mounting screws (A) and remove the cover.
Laser Assembly Cover 1. 2. 3. 4. 5. 6. Remove the left door. Remove the left cover. Remove the right cover. Remove the rear paper deflector. Press the fuser wiper cover latch and remove the cover. Remove the paper full sensor flag assembly from the mounting bracket. 7. Remove the five screws (A) mounting the laser assembly cover and remove the cover.
Center Pan Assembly

1. Remove the left and right side frames. 2. Remove the pan assembly.
Controller Board
1. Remove the inner EMC shield. 2. Remove the controller board mounting screws (A). 3. Remove the two controller board parallel port mounting screws (B). 4. Remove the serial port mounting screws if present. 5. Remove the controller board.
Developer Drive Assembly

1. Remove the inner EMC shield. 2. Remove the three developer drive assembly mounting screws (A). 3. Remove the developer drive assembly. Note: Be sure the developer drive assembly wheel aligns with the hub on the main drive assembly when reinstalling the assembly.
Duplex Board
1. Lift the base printer from the duplex assembly. 2. Remove the four duplex board cover mounting screws. 3. Gently disconnect the cables from the duplex board. Use caution to avoid damage to the cables and connectors. 4. Remove the two duplex board mounting screws and remove the duplex board.
Duplex Front Cover Assembly

1. Lift the base printer from the duplex assembly. 2. Remove the four duplex board cover mounting screws and disconnect the duplex cover door switch cable at connector J6. 3. Position the duplex assembly on its side. 4. Gently release the three front cover assembly latches from the bottom of the duplex assembly. 5. Remove the duplex front cover assembly.
Duplex Front Cover Door

1. Remove the duplex front cover assembly. 2. Holding the front of the assembly away from you, open the cover door and gently pry the left side door pivot from the mounting. 3. Move the cover door to the left to clear the right door pivot from the mounting and remove the duplex front cover door.
Duplex Front Cover Door Switch

1. Remove the duplex front cover assembly. 2. Remove the four duplex board cover screws and disconnect the cover door switch cable at connector J6. 3. Loosen the cover door switch mounting screw and remove the switch. Note: Be sure the cover door switch is properly positioned in the mounting slots when reinstalling to allow the duplex cover door actuator arm to operate the switch.
Duplex Motor
1. Remove the duplex front cover door. 2. Gently disconnect the cables from the duplex board. Use caution to avoid damage to the cables and connectors. 3. Remove the four mounting screws from the left and right return guides and remove the guides. 4. Remove the four mounting screws on the right side of the duplex frame assembly. 5. Position the duplex assembly on its side. 6. Gently release the center drive deflector assembly latch from the bottom front left side of the duplex assembly. 7. Remove the center drive deflector assembly and the frame assembly from the duplexer. 8. Remove the two duplex motor mounting screws and remove the motor. Note: Pay attention to cable routing to avoid pinching or cutting wires during reassembly. Ensure cables are securely placed into the cable retaining tabs. Do the adjustment Duplex Motor Drive Belts on page 4-2 whenever you remove or replace the duplex motor.
Engine Board
Remove the inner EMC shield. Disconnect all cables from the engine board. Remove the four engine board mounting screws (A). Remove the engine board cage mounting screw (B) from the main drive motor assembly. 5. Remove the engine board. Note: Anytime the engine board is replaced, the Configuration ID must be reset in NVRAM on the new engine board. Go to Setting Configuration ID on page 3-20. 1. 2. 3. 4.
EP Frame Assembly
1. Remove the left and right side frames. 2. Remove the EP frame assembly.
Fans
Auxiliary Fan (Models 2420/2450/2455/3455) Remove the right cover. Remove the inner EMC shield. Remove the fuser wiper cover. Disconnect the auxiliary fan cable from the engine board at connector J7. 5. Note the routing of the auxiliary fan cable (A) and remove the fan (B). 1. 2. 3. 4.
Main Fan 1. Remove the top rear cover. 2. Remove the inner EMC shield. 3. Note the routing of the main fan cable (A) and disconnect the cable from the engine board at connector J1. 4. Release the four latches (B) and remove the fan from the left side frame.
Caution: Be sure the fuser assembly has cooled before working on any of the fuser FRUs. Note: You must replace cable ties (B) if removed during the fuser removals. The cable ties prevent the fuser wiring from obstructing the paper path through the fuser assembly.
Fuser
1. Remove the redrive assembly. 2. Remove the two fuser mounting screws (A). 3. Remove the fuser ground wire and remove the fuser assembly.
Fuser Board
1. 2. 3. 4. Remove the fuser assembly. Disconnect the cables (A) from the fuser board. Remove the fuser board mounting screw (B). Release the fuser board from the standoff tab (C) and lift the fuser board from the fuser assembly.
Fuser Cover
1. Remove the fuser assembly. 2. Note the thermistor cable routing and disconnect the cable from the fuser board. 3. Disconnect the thermal fuse cable from the left and right lamp brackets (A). 4. Loosen the left and right lamp bracket mounting screws (B) and remove the thermal fuse cable from the bracket. 5. Remove the left and right fuser cover mounting screws (C) and lift the cover from the fuser assembly.
Fuser Detack Fingers

1. 2. 3. 4. Remove the fuser assembly. Remove the fuser cover assembly. Remove the fuser detack housing assembly. Gently pry the detack finger and spring (A) from the housing assembly.
Fuser Detack Housing Assembly

1. 2. 3. 4. Remove the fuser assembly. Remove the fuser cover assembly. Remove the fuser lamp. Gently apply outward pressure on the left and right fuser side frames (B) to release the detack housing assembly.
Fuser Transfer Plate

1. 2. 3. 4. Remove the upper paper deflector. Remove the fuser transfer roll. Remove the inner paper deflector. Lift the left side of the fuser transfer plate (A) and move the plate to the left to clear the right side from its mounting. 5. Remove the fuser transfer plate.
Fuser Envelope Conditioner Solenoid

The fuser solenoid is in all the models except 1250 and 1255. 1. Remove the fuser assembly. 2. Remove the solenoid mounting screw (A). 3. Disconnect the solenoid link (B). 4. Remove the solenoid from the fuser assembly. Note: Do the Fuser Solenoid Adjustment on page 4-3 whenever you replace the fuser solenoid.
Fuser Exit Flag Assembly

1. Remove the fuser assembly. 2. Remove the fuser exit flag assembly.
Fuser Exit Roll Assembly

1. Remove the fuser assembly. 2. Press the exit shaft bushing retaining tabs and slide the left and right bushings (A) toward the inside of the fuser assembly. 3. Remove the exit roll assembly from the slots in the side frame. Note: Be sure the fuser idler gear (B) is in place and the bushing alignment tab is rotated to the correct position in the side frame slot as you snap each bushing in place when reinstalling the exit roll assembly.
Fuser Lamp
1. Remove the fuser assembly. 2. Caution: Hold the left lamp bracket and carefully remove the two mounting screws. There is pressure against the other end of the lamp therefore care must be used when removing the lamp from the fuser. Grip the lamp by the ceramic end piece and remove it from the fuser assembly. Be careful not to touch the glass as skin oils and acids can reduce the life of the lamp. 3. Remove the fuser lamp. Note: Be sure to position the left lamp mounting bracket around the fuser lower exit guide mounting pin when reinstalling the lamp. The fuser lamp FRU is color coded. The left and right fuser lamp bracket access holes let you view the end of the lamp. Use the following table to identify and install the correct lamp.
Description Fuser Lamp 115V 750W Fuser Lamp 115V 500W Fuser Lamp 220V 750W Fuser Lamp 220V 500W Fuser Lamp 100V 750W Fuser Lamp 100V 500W Color Code Red White Orange Black Purple Yellow
Fuser Lower Exit Guide Assembly

1. 2. 3. 4. 5. Remove the fuser assembly. Remove the fuser cover assembly. Remove the fuser detack housing assembly. Remove the fuser flag assembly. Gently apply outward pressure on the left and right fuser side frames to release the lower exit guide assembly.
High Voltage Power Supply

1. Remove the inner paper deflector. 2. Remove the toner sensor cable from the retainer (A) on the front of the HVPS. 3. Remove the right side cover. 4. Disconnect the JVPS cable from the HVPS at connector (C). 5. Disconnect the transfer roll cable from the HVPS board. Note: Use caution when disconnecting the cable from the transformer on the HVPS. The cable and connector can be easily damaged. 6. Remove the HVPS mounting screw (B). 7. Slide the HVPS to the left to release the mounting tab and remove the HVPS.
Inner EMC Shield

1. 2. 3. 4. 5. Remove the left door. Remove outer EMC shield. Remove all option boards from the connector board slots. Remove the inner EMC shield mounting screws (A). Remove the inner EMC shield.
Inner Paper Deflector Assembly

1. 2. 3. 4. 5. Remove the paper tray. Remove the upper deflector assembly. Place the printer on its side. Remove the lower deflector assembly. Gently pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer and remove the deflector.
Integrated Tray Compensator Assembly

1. 2. 3. 4. 5. 6. Remove the paper tray. Remove the left door. Remove the inner EMC shield. Disconnect the compensator motor cable from the engine board at connector J18. Place the printer on its side. Locate the integrated tray compensator assembly (E) on the bottom of the printer and disconnect the compensator arm bias spring (A) from the frame. Disconnect the compensator sensor cable (B) from the assembly. Remove the compensator assembly mounting screw (C). Remove the integrated tray compensator assembly.
7. 8. 9.
Integrated Tray Compensator Pick Roll Assembly

1. Remove the paper tray. 2. Place the printer on its side. 3. Locate the compensator assembly on the bottom of the printer and pull the compensator arm away from the printer. 4. Unsnap the pick roll assembly (D) from its mounting and remove.
Interconnect Board Assembly

1. 2. 3. 4. 5. Remove the inner EMC shield. Remove the engine board and shield. Remove the LVPS. Disconnect all cables from the interconnect board. Remove the interconnect board assembly mounting screws (A).
6. Place the printer on its back and remove the two mounting screws (A). 7. Remove the interconnect board assembly.
Left Side Frame

1. Remove the main drive assembly. 2. Remove the left side frame mounting screws (A).
3. Place the printer on its back and remove the four left side frame mounting screws (A). 4. Remove the left side frame.
Low Voltage Power Supply

1. Remove the right cover. 2. Remove the two LVPS mounting screws (A) from the rear of the bottom pan. 3. Pull the LVPS assembly from the right side of the printer. Initial resistance is felt as the automate plug disconnects. 4. Press the release latch on the fuser lamp cable connector and disconnect from the LVPS. 5. Remove the LVPS.
Main Drive Assembly

Remove the inner EMC shield. Remove the developer drive assembly. Remove the transfer shaft (A) through the bottom of the printer. Remove all cables from the cable clamps (B) on the main drive assembly. 5. Remove the three main drive assembly mounting screws (C). 6. Remove the link (D) from the rear of the main drive assembly. 7. Disconnect the cable from the main drive motor. 8. Remove the main drive assembly. Note: Do not remove the screws (E) on the main drive assembly. Be sure the main drive assembly gear shaft aligns with the hub on the left side frame when reinstalling the main drive assembly. 1. 2. 3. 4.
Main Drive Motor

1. Remove the main drive assembly. 2. Remove the three main drive motor mounting screws (A). 3. Remove the main drive motor.
Multipurpose Tray/Lower Deflector Assembly

1. Open the multipurpose tray to a position that let the left and right tray hinge slots (A) align with the rectangular mounting posts (B). Pull upward on each tray hinge to remove the tray from the two mounting posts. Be careful not to break the hinges or lose the O-ring from the left mounting post.
2. Remove the upper deflector. 3. Remove the paper out sensor. (1250, 1620,1650 and 2420) 4. Remove the screws (A) mounting the multipurpose tray/lower deflector assembly. 5. Remove the multipurpose tray/lower deflector assembly.
Operator Panel
1. Remove the upper front cover. 2. Gently press the three operator panel lens cover retaining tabs (A) and remove the lens cover. The button membrane is free to remove from the assembly. 3. Disconnect the operator panel cable and remove the operator panel board.
Operator Panel Cable/Cover Open Switch Assembly

Note: Pay careful attention to the cable routing through the printer before you remove the operator panel cable/cover open switch assembly. 1. Remove the left door, left cover, upper front cover, outer EMC shield and inner EMC shield. 2. Disconnect the operator panel/cover open switch cable from the engine board. 3. Release the cables from the three cable retainers. 4. Cut and remove the wire tie on the upper front cover hinge pivot arm. 5. Remove the operator panel and cover open switch bracket. Pull the cables through the rectangular hole in the hinge pivot arm. Note: If a large snap-on torroid is present on the old cable, remove the torroid before pulling the cables through the hinge pivot arm. 6. Plug the new operator panel cable into the operator panel and snap the new cover open switch cable into the bracket assembly. Note: If you remove a large snap-on torroid from the old cable, you must break the small torroid from the new cable assembly and replace it with the snap-on torroid. Be careful not to damage the cable. 7. Route the cables and torroid through the rectangular window in the cover hinge pivot arm. 8. Snap the operator panel and the cover open switch bracket assembly into the upper front cover. 9. Twist the cables together and attach to the cover hinge pivot arm with a wire tie. Be sure the torroid is on the opposite end of the cables near the engine board connectors. 10. Route the cables through the printer and down the inside of the engine board shield. 11. Plug the cables into the engine board connectors.
Optional 250/500 Paper Tray Assembly

Note: Remove the printer and other paper feed options to access the failing optional paper tray assembly. Paper Tray Compensator Assembly 1. Remove the printer and other paper feed options. 2. Disconnect the compensator assembly bias spring from the tray frame. 3. Disconnect the compensator assembly motor cable. 4. Remove the three compensator assembly mounting screws and remove the compensator assembly. Paper Tray Frame Assembly 1. Remove the compensator assembly. 2. Release the paper pass through sensor from its retaining tabs. 3. Release the frame assembly from the front and rear retaining tabs and remove the paper tray frame assembly. Paper Tray Board 1. Remove the paper tray frame assembly. 2. Disconnect all cables from the paper tray board. 3. Remove the three paper tray board mounting screws and remove the board. Note: Reinstall with the paper out sensor flag positioned in the sensor slot on the paper tray board. Paper Tray Paper Out Sensor Flag 1. Remove the paper tray frame assembly. 2. Remove the paper tray board. 3. Remove the paper out sensor flag. Paper Size Spring Comb 1. Remove the paper tray board. 2. Remove the paper size spring comb mounting screw and remove the spring comb.
Outer EMC Shield

1. Remove the left door. 2. Loosen the six outer EMC shield mounting screws (A) and remove the shield.
Paper Alignment Assembly

1. 2. 3. 4. 5. Remove the upper paper deflector assembly. Remove the inner paper deflector assembly. Release the input paper sensor from its mounting and remove. Remove the left door. Remove the two paper alignment assembly mounting screws (A) located inside the printer.
6. Locate the paper alignment assembly reference adjustment screw (B) through the left frame and remove the screw. 7. Remove the paper alignment assembly. Note: Do the Paper Alignment Assembly Adjustment on page 4-5 when you reinstall the assembly.
Paper Input Sensor

1. Remove the inner paper deflector assembly. 2. Disconnect the paper input sensor cable from the input sensor. 3. Release the input paper sensor from its mounting and remove.
Paper Size Sensing Board

1. Disconnect the paper size sensing board cable from the board. 2. Remove the two paper size sensing board mounting screws (A). 3. Remove the paper size sensing board.
Pick Roll
1. Remove the upper paper deflector. 2. Release the pick roll retaining tab and slide the pick roll off the shaft.
Printhead
1. Remove the laser assembly cover. 2. Disconnect the printhead cables (A) from the printhead assembly. 3. Remove the three printhead mounting screws (B) and remove the printhead. Note: Do the Printhead Assembly Adjustment on page 4-4 whenever you remove or replace the printhead assembly or loosen the mounting screws.
Redrive Assembly
1. Open the redrive door assembly, remove the restraint strap mounting screw and remove the door assembly. 2. Remove the redrive exit cover. 3. Remove the two redrive assembly mounting screws (A). 4. Release the two redrive assembly mounting latches (B) and remove the redrive assembly.
Right Side Frame

1. 2. 3. 4. 5. Remove the right side cover. Remove the LVPS. Remove the multipurpose tray assembly. Remove the auxiliary fan assembly. Disconnect the auto compensator arm bias spring from the right side frame. 6. Remove the toner sensor mounting screw (A), disconnect the sensor cable and remove the toner sensor. 7. Remove the right side frame mounting screws (B) and remove the right side frame.
Smart Cartridge Contacts

1. 2. 3. 4. Remove the upper front cover. Release tab (A) and remove the contact cover. Remove the contact plunger (B). Remove the two screws (C) and remove the contacts (D).
Toner Sensor
1. Remove the right side cover. 2. Remove the toner sensor mounting screw (A). Disconnect the toner sensor cable and remove the toner sensor.
Transfer Roll Assembly

1. Open the upper front cover and remove the print cartridge. 2. Pivot the transfer roll assembly toward the front of the printer. 3. Unsnap the transfer roll assembly from the left and right pivot arms and remove the transfer roll assembly.
Upper Paper Deflector Assembly

1. Open the multipurpose tray and remove the tray from the two mounting posts. Be careful not to lose the O-ring on the right mounting post. 2. Gently release the upper deflector assembly latch from its mounting on the right side frame and slide to the right. 3. Remove the upper deflector assembly.
Upper Front Cover Hinge Assembly

1. Remove the upper front cover. 2. Remove the laser assembly cover. 3. Remove the C-clips (A) from the upper front cover hinge assembly left and right hinge pins and remove the pins. Note the pin orientation and the C-clip location on the inside of each hinge. 4. Detach the two springs (B) from the upper front cover hinges. 5. Disconnect the operator panel cable from the operator panel assembly. 6. Raise the upper front cover hinge assembly to a position that lets you lift the left pivot arm from the mounting bracket (C). 7. Lift the left pivot arm from the bracket and move the upper cover hinge assembly toward the left to clear the right upper cover pivot arm from the mounting bracket. 8. Remove the upper front cover hinge assembly.
Upper Front Cover Interlock Switch Assembly

1. 2. 3. 4. Remove the upper front cover. Remove the operator panel. Remove the inner EMC shield. Press the retaining tabs (A) and remove the interlock switch assembly. 5. Note the routing of the interlock switch assembly cable and disconnect the cable at connector J4 on the engine board.
5. Connector Locations
Low Voltage Power Supply
Connector CN3 Interconnect Board Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Signal +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc +24 V dc Heat on +5 V dc +5 V dc Ground Ground Ground Ground +24 V dc ZC Out* +42 V dc
Connector Locations 5-1
High Voltage Power Supply

Connector CN1 Engine Board Pin No. 1 2 3 4 5 6 7 8 Signal Developer PWM +24 V dc Return Charge PWM +24 V dc IN TX PWM TX Enable TX CUR PWM SVRO OUT
Engine Board
Connector J1 Main Fan Pin No. 1 2 3 J2 Fuser Board 1 2 3 4 5 6 7 8 J3 Printhead (Mirror Motor) 1 2 3 4 5 6 7 J4 Cover Closed Switch 1 2 3 Signal Fan Stall Ground Fan On Exit Sns* Thump B +5 V dc Thump A Ground Hrtherm Thermgnd Narrow Media +24 V dc Return +24 V dc Return ReFREQ LOCKn Start* +24 V dc Return +24 V dc Cover Closed Ground +5 V dc
Connector J5 Printhead
Pin No. 1 2 3 4 5 6 7 8 9 10
Signal LENA* Ground LAOJ* Ground LASERPWM +5 V dc Ground Video* Ground Ground Ground Ground Opt2 Opt1 +5 V dc CRFANONn Ground Ground HSYNC* Ground +5 V dc FISENSEn Ground
J6 Output Level Sensor
1 2 3 4 5
J7 Auxiliary Fan (Model 2420/2450/2455/ 3455) J8 Printhead HYSNC
1 2 1 2 3 4
J9 Fuser Inductor Sense WT 2450 Only
1 2
Connector J10 Erase/Toner Sensor/Input Sensor
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Signal AT Servo Servo OutT TXENABLE Transfer +24 V dc Charge Ground Developer Ground In Sns* +5 V dc CTSENSE* Ground +24 V dc ERASEPWM* I2COTA +5 V dc PCLKP Ground FPIRQ
J11 Operator Panel
1 2 3 4 5
Connector J12 BLDC Motor
Pin No. 1 2 3 4 5 6 7 8 9 10 11
Signal +24 V dc +24 V dc Return +24 V dc Return Motor3 Motor4 Dir Motor1 +5 V dc Motor2 Ground Motor0 RXD Ground +5 V dc Ground Ground RXD Ground +5 V dc Ground Ground
J13 Autoconnect
1 2 3 4 5
J14 Autoconnect
1 2 3 4 5
Connector J15 Integrated Paper Tray
Pin No. 1 2 3 4 5 6 7 8 9 10
Signal +5 V dc PSIZE2 Ground PSIZE1 +24 V dc Ground POUT +5 V dc Paper Low +5 V dc (Not used) MPT Pick +24 V dc +24 V dc N/A Ground Ground N/A +5 V dc Ground POSENSE +5 V dc N/A Scart Scart Ground
J16 Staging Motor J17 MPT Pick
x 1 2
J18 Auto Compensator
1 2 3 4 5 6
J19 MPT Paper Out
1 2 3
J20 Interconnect Board J21 Smart Cartridge (Model 3455 only)
N/A 1 2
Level 1 Engine Board
Level 2 Engine Board
Fuser Board Level 1

Connector J1 Engine Board Pin No. 1 2 3 4 5 6 7 8 J2 Thermistor 1 2 J3 Thumper 1 2 J4 Thumper Solenoid 1 2 J5 Narrow Media Sensor 1 2 3 Signal NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* ThermGnd HRTherm Ground +42V dc ThumpB ThumpA +5 V dc Nar Media Ground
Level 2
Connector J1 Engine Board Pin No. 1 2 3 4 5 6 7 8 J2 Thermistor 1 2 J3 J4 Thumper Solenoid NA 1 2 J5 Narrow Media Sensor 1 2 3 Signal NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* ThermGnd HRTherm Not Used ThumpB ThumpA +5 V dc Nar Media Ground
Interconnect Board
Connector J1 Fuser Solenoid (Model1620/1625/ 1650/1855/2420/2450/ 2455) J2 LVPS Pin No. 1 2 1 2 3 4 5 6 7 8 9 10 J3 LVPS 1 2 3 4 5 6 7 8 J4 Autoconnect Top (Model1620/1625/ 1650/1855/2420/2450/ 2455) 1 2 3 4 Signal +42 V dc Ground +42 V dc Heaton Xeroxing +24 V dc +24 V dc +24 V dc Ground Ground Ground Ground Ground Ground Ground Ground +5 V dc +5 V dc +5 V dc +5 V dc +24 V dc Ground +5 V dc Fused Ground
Connector J5 Autoconnect BTM/FNT J6 Engine Board J7 Controller Board J8 ID-1
Pin No. 1 2 1 1 1 2
Signal +24 V dc Ground N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
J9 ID-2
3 4
J10 ID-3
5 6
J11 INA 1 (1250/1255) J12 INA 2 (1620/1625/1650/ 1855/2420) J13 INA 3 (2450/2455/3455)
1 1
N/A
Models 1250 and 1255
Models 1620, 1625, 1650, 1855, 2420, 2450, 2455 and 3455
Models 1650, 1855, and 2420 do not have connector J13. Models 1620 and 1625 have a jumper on J10 between the center pin and pin 5. Model 1855 has a jumper on J8 between the center pin and pin 2, on J9 between the center pin and pin 4 and on J10 between the center pin and pin 5. Models 2420, 2450 and 2455 have a jumper on J8 between the center pin and pin 2 and a jumper on J9 between the center pin and pin 3. Model 3455 has a jumper on J8 between the center pin and pin 1 and on J9 between the center pin and pin 1.
Envelope Option Board

Connector J1 Pin No. 1 2 3 4 5 6 7 J2 1 2 3 J3 1 2 3 J4 1 2 3 4 Signal N/A Ground Tx (EOC) Ground Rx (EOC) +24 V dc Return +24 V dc Ground Paper Present +5 V dc Ground Paper Present +5 V dc Motor - Phase BMotor - Phase AMotor - Phase B+ Motor - Phase A+
Duplex Option Board

Note: Duplex connectors J10 and J11 are interchangeable. No problem results if the connectors are switched.
Connector J1 Motor Pin No. 1 2 J2 DC Motor Sensor/Encoder Board 1 2 3 J3 Stepper Motor 1 2 3 4 J4 Fan 1 2 J5 Paper Input Sensor 1 2 3 J6 Rear Cover Open Switch (Level 2 does not use) J7 Jam Removal Tray Open Switch (Level 2 does not use) J8 Paper Exit Sensor 1 2 1 2 1 2 3 Signal Motor Motor + +5 V dc Sensor Tach + Ground STPMOTA STPMOTA + STPMOTB STPMOTB + +24 V dc Fan On +5 V dc Sensor Input + Ground Top Cover Open + Ground Front Drawer Open + Ground +5 V dc Sensor Exit + Ground
Connector J9 Autoconnect, Option Below
Pin No. 1 2 3 4
Signal Ground PrtxDout Ground PrtRxd +24 V dc Ground +24 V dc Ground N/A Ground PrtxDin Ground PrtRxD
J10 Autoconnect, Option Below J11 Printer Autoconnect J12 Printer Autoconnect
1 2 1 2 1 2 3 4 5
Level 1 Duplex Option Board
Level 2 Duplex Option Board
Autoconnect - Top
Connector Top Autoconnect Pin No. 1 2 3 4 5 6 7 8 Signal 0 V dc +5 V dc 0 V dc 0 V dc 0 V dc +5 V dc 0 V dc +24 V dc
Output Expander Control Board - Level 1 Stepper Motor

Connector J1A Autoconnect Pin No. 1 2 3 J1B 1 2 3 4 5 J2A Autoconnect 1 2 3 J2B 1 2 3 4 J3 Pass Thru Sensor 1 2 3 J4 Stepper Motor 1 2 3 4 Signal +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground N/C +24 V dc Ground +5 V dc prtxdout Ground prtrxd Ground Ground Paper Present RVsnsr Phase BPhase B+ Phase APhase A+
Connector J5 Bin Full Sensor Single Sensor
Pin No. 1 2 3 4 5
Signal Ground N/C +5 V dc N/C RVsnsr
Output Expander Control Board - Level 2 DC Motor
Connector J1A Autoconnect
Pin No. 1 2 3
Signal +24 V dc Ground +5 V dc Prtxdin Ground prtrxd Ground N/C +24 V dc Ground +5 V dc prtxdout Ground prtrxd Ground Ground Paper Present RVsnsr
J1B
1 2 3 4 5
J2A Autoconnect
1 2 3
J2B
1 2 3 4
J3 Pass Thru Sensor
1 2 3
Connector J4 DC Motor
Pin No. 1 2 3 4 5 6
Signal mtrout1 mtrout2 Ground Ground tach + +5 V dc Ground Ground binful binful RVsnsr
J5 Bin Full/Near Full Dual Sensor
1 2 3 4 5
6. Preventive Maintenance
This chapter describes procedures for printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance.
Safety Inspection Guide

The purpose of this inspection guide is to aid you in identifying unsafe conditions. If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you correct the hazard. Check the following items:
Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover Possible safety exposure from any non-Lexmark attachments
Lubrication Specifications
Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure. Some unauthorized lubricants may chemically attack polycarbonate parts. Use IBM no. 10 oil, P/N 1280443 (Approved equivalents: Mobil DTE27, Shell Tellus 100, Fuchs Renolin MR30), IBM no. 23 grease (Approved equivalent Shell Darina 1), and grease, P/N 99A0394 to lubricate appropriate areas of the machine.
Preventive Maintenance 6-1
Scheduled Maintenance (2420/2450/2455/3455)

The operator panel displays the message 80 Scheduled Maintenance at each 250K page count interval. It is necessary to replace the fuser assembly, transfer roller, compensator pick-rolls and charge roll at this interval to maintain the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part numbers: 99A0290 - 100V/750W 2450 99A0500 - 115V/750W 2420/2450/2455 99A0503 - 220V/750W 2420/2450/2455 99A0823 - 115V/750W 3455 99A0824 - 220V/750W 3455 After replacing the kit, the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance message. Refer to Maintenance Page Count (2420/2450/2455/3455) on page 3-20.
7. Parts Catalog How To Use This Parts Catalog

SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description. AR: (As Required) in the Units column indicates that the quantity is not the same for all machines. CC: (Color Code) in the Description column indicates the part is identified by a color marking on the part. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. PP: (Parts Packet) in the Description column indicates the part is contained in a parts packet. INDENTURE: The indenture is marked by a series of dots located before the parts description. The indenture indicates the relationship of a part to the next higher assembly. For example: INDENTURE RELATIONSHIP OF PARTS (No dot) MAIN ASSEMBLY (One dot) o Detail parts of a main assembly (One dot) o Subassembly of the main assembly (Two dot) o o Detail part of a one-dot subassembly (Two dot) o o Subassembly of a one-dot subassembly
The Optra S laser printer is available in eleven models. The model designations are as follows: 1250 (4059-121) 1255 (4059-125) 1620 (4059-162) 1625 (4059-165) 1650 (4059-160) 1855 (4059-185) 2420 (4059-242) 2450 (4059-240) 2455 (4059-245) 1855-C01 (4059-185) 3455 (4059-345) The parts catalog uses the four digit model number to identify model specific FRUs.
Parts Catalog 7-1
Assembly 1: Covers
AsmIndex 1-1 1-2 1-2 1-3 1-4 NS 1-5 1-5 1-6 1-7 1-8 1-8 1-8A 1-9 NS 1-10 NS 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11 1-11
Part Number 99A0553 99A0463 99A0464 99A0016 99A0004 99A0011 99A0012 99A0008 99A0007 99A0023 99A0020 99A0022 99A0021 99A0917 99A0458 99A0630 99A0631 99A0632 99A0633 99A0634 99A0535 99A0536 99A0537 99A0538 99A0539 99A0540 99A0541
Units 1 1 1 1 1 3 1 1 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Description Support, Paper Spacer, Front 2450/2455/3455 Spacer, Front 1620/1650/2420/1250/1255/1855/1625 Cover, Fuser Wick Assembly Spring, Latch Screw, Right Side Cvr Mtg PP 99A0263 Cover, RIght Side 1250/1620/1650/2420/1855/1625 Cover, Right Side 2450/2455/3455 Hinge, Upper Front Cover Label, TLI/ID/Serial No. - Blank Cover Assembly, Lower Front 1250/1255/1620/1625/1650/1855/2420 Cover Assembly, Lower Front 2450/2455/3455 Cap, MPT 2450/2455/3455 O-Ring, Lower Front Door Screw, Upper Front Cvr Mtg PP 99A0263 Kit, Upper Front Cover with Labels Labels, Upper Front Cover Bezel, Operator Panel, English Bezel, Operator Panel, France Bezel, Operator Panel, Italy Bezel, Operator Panel, Germany Bezel, Operator Panel, Spain Bezel, Operator Panel, Denmark Bezel, Operator Panel, Netherlands Bezel, Operator Panel, Norway Bezel, Operator Panel, Sweden Bezel, Operator Panel, Brazil/Portugal Bezel, Operator Panel, Finland Bezel, Operator Panel, Japan
Parts Catalog 7-3
Assembly 1: Covers (continued)
AsmIndex 1-12 1-13 1-13 NS 1-14 1-14 1-14 1-15 1-16 1-17 NS NS NS 1-18 1-19 1-20 1-21 1-22 1-23 1-24 1-25 1-26 NS
Part Number 99A0001 99A0009 99A0010 99A0017 99A0019 99A0018 99A0296 99A0003 99A0013 99A0552 99A0573 99A0550 99A0031 99A0036 99A0814 99A0816 99A0815 99A0817 99A0834 99A0577
Units 1 1 1 5 1 1 1 1 1 1 6 1 2 1 1 1 2 1 1 2 1 1 1
Description Operator Panel Assembly Cover, Left Side 1250/1255/1620/1650/2420/1855/1625 Cover, Left Side 2450/2455/3455 Screw, Left Side Cvr Mtg PP 99A0263 Door, Left Panel 1650/1855/2420 Door, Left Panel 1250/1255/1620/1625 Door, Left Panel 2450/2455/3455 Switch, Cover Open w/Operator Panel Cable Assembly Latch, Upper Cover Cover, Laser Assembly Screw, Laser Cover PP 99A0263 Cover Assembly, Redrive Cap Nut, Front Spacer Mounting 2450/2455/3455 Shield, ESD Cover Open Bracket, Cover Open Switch Spring, Cover Open Switch Screws, Contact Mounting PP 99A0263 Cable, Smart Cartridge 3455 Contact, Smart Cartridge Ground 3455 Contact, Smart Cartridge 3455 Cover, Smart Cartridge Contact 3455 Plunger, Overstress Smart Cartridge 3455 Cable Tie
Parts Catalog 7-5
Assembly 2: Frame
AsmIndex 2-1 2-2 2-2 2-3 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-11 2-12 2-12 2-13 2-14 2-15 2-16
Part Number 99A0425 99A0463 99A0464 99A0033 99A0034 99A0867 99A0551 99A0114 99A0113 99A0045 99A0039 99A0058 99A0558 99A0828 99A0904 99A0561 99A0111 99A0043 99A0049
Units 1 1 1 1 1 1 1 1 1 2 2 4 1 1 1 1 1 1 1 1 3 1 1 4 5
Description Support, Cross Brace Spacer, Front 2450/2455/3455 Spacer, Front 1250/1255/1620/1650/2420/1855/1625 Duct, Left Stacker 2450/2455/3455 Duct, Left Stacker 1250/1620/1650/2420/1855/1625 Duct, Main Body Support, Left Lower Stacker Duct, LVPS Left Side Pan, Drip ITC Latch, Cartridge Assembly Roller, Developer Support Pad, Machine Mounting Transfer Plate Assembly Transfer Plate Assembly 3455 Plate Assembly, Stacker Ground 2450/2455/3455 Support, Right Stacker 1250/1255/1620/1650/2420/1855/1625 Right Sideframe Track, Cartridge Guide RH Fan, Auxiliary 2420/2450/3455 Contact Kit PP 99A0585 o Contact, Doctor Blade/TAR/Developer Roll o Contact, PC Drum o Contact, Charge Roll o Block, Contact Mounting o Screw, Contact Mounting Contact, Charge Brush 3455 Sensor, Toner Cartridge Level Tray Bias Arm Assembly Spring, Tray Bias Pan, Center Assembly
2-16A 2-17 2-18 2-19 2-20
99A0805 99A0466 99A0026 99A0028 99A0038
1 1 1 1 1
Parts Catalog 7-7
Assembly 2: Frame (continued)
AsmIndex 2-21 2-22 2-23 2-24 2-25 2-26 2-26 2-27 2-28 2-29 2-30 2-30 2-31 2-32 2-33 2-34 2-35 NS 2-36 2-36 2-37 2-37 2-37 NS 2-38 2-39
Part Number 99A0056 99A0055 99A0042 99A0053 99A0063 99A0046 99A0804 99A0549 99A0029 99A0128 99A0189 99A0037 99A0899 99A0044 99A0567 99A0555 99A0556 99A0030 99A0803 99A0377 99A0378 99A0794 99A0499 99A0062 99A0138
Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 17 1 1 1 1 1 1 1 1
Description Deflector, Upper PF Deflector, Inner Frame, EP Module Sensor, Input Spring, PA Out Activate Cover, Gap 1620/1625/1650/1855/2420/2450/2455 Cover, Gap 3455 Shield, ESD Assembly with label Left Side Frame Board, Input Tray (ITC) Frame Extension 1650/2420/1855 Frame Extension 2450/2455/3455 Pan, Motor Drip Track, Cartridge Guide LH Link, Gear Release Bracket, Counterbalance Hinge Spring Spring, Counterbalance Screw PP 99A0263 Fan, Main Fan, Main 3455 Flag Kit, Standard Bin Level 1650/1855/2420 Flag Kit, Standard Bin Level 2450/2455/3455 Flag, Standard Bin Level 1855-C01 Flap, 250 Paper Output Bin 1855-C01 Bracket, Level Sensor 1650/2420/2450/3455 Sensor, Standard Bin Level 1620/1625/1650/1855/2420/2450/2455/3455
Parts Catalog 7-9
Assembly 3: Printhead
AsmIndex 3-1 3-1 3-1 3-1 NS
Part Number 99A0065 99A0398 99A0066 99A0829
Units 1 1 1 1 3
Description Printhead Assembly, 1620/1625/1650/1250/1255 Printhead Assembly, 1855 Printhead Assembly, 2420/2450/2455 Printhead Assembly, 3455 Screw, Printhead Mounting PP 99A0263
Parts Catalog 7-11
Assembly 4: Paper Feed (Autocompensator)
AsmIndex 4-1 4-2 4-3 NS
Part Number 99A0060 99A0067 99A0070
Units 1 1 2 1
Description Sensor, Paper Out Internal Tray Pick Arm Assembly (250) Pick Rolls Screw, Hanger PP 99A0263
Parts Catalog 7-13
Assembly 5: Paper Feed - Multipurpose Unit
AsmIndex 5-1 5-2 5-3 5-4 5-5
Part Number 99A0075 99A0071 99A0076 99A0081 99A0083
Units 1 1 1 1 1
Description Screw, Socket Set M4X5 mm 1250/1255/1650/1620/2420/1855/1625 Arm Assembly, MPT 1620/1650/1250/1255/2420/1855/1625 Pick Roll Assembly 1250/1255/1620/1650/2420/1855/1625 Spring Assembly, Separator 1620/1650/1250/1255/2420/1855/1625 MPT Pad Assembly Kit o Restraint Pad o MPT Pad Assembly 1250/1255/1620/1650/2420/1855/1625 Deflector Assembly, MPT 1620/1650/1250/1255/2420/1855/1625 Deflector, Lower Screw, Lower Deflector Mounting 8 mm PP 99A0263 2450 Screw, Lower Deflector Mounting 12mm PP 99A0263 1250/1255/1620/1650/2420/1855/1625 O-Ring, Lower Front Door Flag, MPT Paper Out 1250/1255/1650/1620/2420/1855/1625 Plate Assembly, MPT 1620/1650/1250/1255/2420/1855/1625 Sensor, MPT Paper Out 1250/1255/1620/1650/2420/1855/1625 Screw, Damper 1620/1650/1250/1255/2420/1855/1625 Screw, Frame Mounting PP 99A0263 1620/1650/1250/1255/2420/1855/1625 Clip, Pick Roll Shaft PP 99A0267 Solenoid, MPT (Frame) 1620/1650/1250/1255/2420/1855/1625 Bushing, Pick Roll Shaft 1250/1255/1620/1650/2420/1855/1625
5-6 5-7 5-8 5-8
99A0077 99A0080
1 1 2 2
5-9 5-10 5-11 5-12 5-13 5-14
99A0021 99A0084 99A0082 99A0078 99A0073
1 1 1 1 2 1
NS 5-15 5-16 99A0072 99A0074
2 1 2
Parts Catalog 7-15
Assembly 6: Paper Feed - Alignment
AsmIndex 6-1 6-2 6-3 6-4 6-5 NS NS
Part Number 99A0089 99A0492 99A0566 99A0559 99A0565 99A0490
Units 1 1 1 1 1 1 2
Description Alignment Assembly Paper Feed Screw, Paper Reference Adjustment Nut Lever, Bellcrank Release Washer, Reference Adjustment Clip, Reference Ground Screw, Alignment Asm Mtg PP 99A0263
Parts Catalog 7-17
Assembly 7: Paper Feed - Output
AsmIndex 7-1 7-1 7-1 7-2 7-2 NS NS NS NS NS
Part Number 99A0090 99A0091 99A0502 99A0109 99A0110 99A0104 99A0107 99A0891 99A0921
Units 1 1 1 1 1 1 1 2 1 1
Description Deflector Assembly, Inner 500 2450/2455 Deflector Assembly, Inner 250 1620/1650/1250/1255/2420/1855/1625 Deflector Assembly, Inner 250 1855-C01 Deflector Assembly Outer 500 2450/2455 Deflector Assembly Outer 250 1620/1650/1250/1255/2420/1855/1625 Spring, Upper Diverter Separator, Upper Screw, SEMS-Duplex Path PP 99A0263 Deflector Assembly, Inner 500 3455 Restraint, Door Hinge
Parts Catalog 7-19
Assembly 8: Integrated Paper Tray - 250 Sheet
AsmIndex 8-1 8-1 8-2 8-3 8-4 8-5 8-6 8-7 8-8 8-9 8-10 8-11 8-12 NS NS NS NS
Part Number 99A0115 99A0504 99A0894 99A0120 99A0892 99A0119 99A0123 99A0461 99A0121 99A0126 99A0124 99A0127 99A0893 99A0452 99A0501
Units 1 1 1 2 1 4 1 1 1 4 1 1 1 2 1 1 1
Description Tray, Integrated 250 Sheet Tray, Integrated 250 Sheet 1855-C01 Latch, Back Restraint Restraint Pad Restraint, Side 250 Sheet Tray Wear Strips Indicator Assembly, Paper Size Label, Tray Number Clip, 250 Tray Wear Finger, Autosize Plate, Snap-In Slider, Autosize 250 Restraint, Back 250 Sheet Tray Screw, Deflector Mounting PP 99A0263 Washer, Latch Mounting Screw, Latch Mounting PP 99A0263 Strip Assembly, Paper Tray Insert 1855-C01
Parts Catalog 7-21
Assembly 9: Main Drive
AsmIndex 9-1 9-1 9-1 9-2 9-3 9-4 NS NS NS
Units 1 1 1 1 1 1 4 3
Description Gearbox, w/Motor 2420/2450/2455 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 Gearbox, w/Motor 3455 Shaft, Power Takeoff Spring, Power Takeoff Shaft Gear, Bevel Screw, Gearbox Mounting PP 99A0263 Screw, Motor Mounting PP 99A0263 Clip, Cable
99A0260
Parts Catalog 7-23
Assembly 10: Developer Drive
AsmIndex 10-1 10-2 10-3 10-4 10-5
Part Number 99A0135 99A0564 99A0136
Units 1 1 1 1 2
Description Developer Drive Assembly Coupler, Gear #55 Shaft, Developer Drive Screw, Developer Drive Ground PP 99A0263 Screw, Developer Drive Mtg PP 99A0263
Parts Catalog 7-25
Assembly 11: Fuser
AsmIndex 11-1 11-1 11-1 11-1 11-1 11-1 11-1 11-1 11-1 11-1 11-1 11-2 11-2 11-3
Part Number 99A0589 99A0580 99A0591 99A0586 99A0587 99A0588 99A0524 99A0525 99A0526 99A0592 99A0593 99A0146 99A0725 99A0918
Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Description Fuser Assembly w/100V 750W Lamp 2420/2450/2455 Fuser Assembly w/115V 750W Lamp 2420/2450/2455 Fuser Assembly w/220V 750W Lamp 2420/2450/2455 Fuser Assembly w/100V 500W Lamp 1620/1650/1855/1625 Fuser Assembly w/115V 500W Lamp 1620/1650/1855/1625 Fuser Assembly w/220V 500W Lamp 1620/1650/1855/1625 Fuser Assembly w/100V 500W Lamp 1250/1255 Fuser Assembly w/115V 500W Lamp 1250/1255 Fuser Assembly w/220V 500W Lamp 1250/1255 Fuser Assembly w/115V 750W Lamp 3455 Fuser Assembly w/220V 750W Lamp 3455 Wiper Assembly, Dry Wiper Assembly, Wet Cover, Fuser Assembly with Thermistor, Thermal Fuse, and LH & RH Fuser Lamp Contact Assemblies Screw, Contact Assembly PP 99A0263 Exit Roll Assembly Detack Assembly 1250/1255/1620/16251650/ 1855/2420/2450/2455 Detack Assembly 3455 Hot Roll Assembly 1250/1255 Hot Roll Assembly 1620/1650/1855 Hot Roll Assembly 2420/2450/2455 Hot Roll Assembly 3455 Retainer, Backup Roll Bearing
11-4 11-5 11-6 11-6 11-7 11-7 11-7 11-7 11-8 99A0147 99A0156 99A0833 99A0562 99A0563 99A0149 99A0832 99A0144
4 1 1 1 1 1 1 1 2
Parts Catalog 7-27
Assembly 11: Fuser (continued)
AsmIndex 11-9 11-9 NS 11-10 11-11 11-12 11-13 11-14 11-15 11-16 11-17 11-17 11-17 11-18 11-19 11-20 11-21 11-22 11-23 11-23 11-23 11-23 11-24 11-24 11-25 11-25 11-26 11-27 11-28
Part Number 99A0158 99A0160 99A0159 99A0173
Units 1 1 2 1 1 1
Description Backup Roll, CBM 30 mm 2420/2450/3455 Backup Roll, CBM 22 mm 1620/1650/1250/1255/1855/1625 Spacer, Backup Roll 1620/ 1650/1250/1255/1855 Solenoid Assembly, Envelope Conditioner 1620/1625/1650/1855/2420/2450/2455/3455 Screw, Solenoid Mounting PP 99A0263 Screw, Board Cover Mounting PP 99A0263 Cover, Fuser Board 1620/1650/2420/2450/2455/1855/1625 Wire, Ground Screw, Ground Wire PP 99A0263 Clamp, DC Fuser Cable Board Assembly, Fuser w/o Driver 1250/1255 Board Assembly, Fuser w/Driver 1620/1650/2420/2450/2455/1855/1625 Board Assembly, Fuser 3455 Clamp, AC Fuser Cable Screw, Fuser Cover Assembly PP 99A0263 Retainer, Hot Roll Bearing Bearing, Hot Roll Bushing, Hot Roll Bellcrank, Backup Roll 1250/1255 Bellcrank, Backup Roll 1620/1650/1855/1625 Bellcrank, Backup Roll 2420/2450/2455 Bellcrank, Backup Roll 3455 Guide, Fuser Entry 1620/1650/2420/2450/2455/1855/1625/3455 Guide, Fuser Entry 1250/1255 Spring, Backup Roll Bellcrank 1250/1255 Spring, Backup Roll Bellcrank 1620/1650/2420/2450/2455/1855/1625/3455 Retainer, Backup Roll Bellcrank PP 99A0267 Gear, Hot Roll Gear, Idler
99A0557 99A0547 99A0196 99A0170 99A0171 99A0826 99A0546 99A0142 99A0143 99A0150 99A0163 99A0162 99A0161 99A0890 99A0164 99A0713 99A0412 99A0410
1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 1 1 1 2 2 2
99A0157 99A0148
1 1
Parts Catalog 7-29
Assembly 11: Fuser (continued)
AsmIndex 11-29 11-30 11-31 11-32 11-33 11-34 11-35 11-36 11-36 11-36 11-36 11-36 11-36 NS NS NS
Part Number 99A0297 99A0169 99A0172 99A0166 99A0897 99A0167 99A0140 99A0141 99A0177 99A0178 99A0175 99A0176
Units 1 1 1 1 2 2 1 1 1 1 1 1 1 7
Description Link, Solenoid 1620/1650/2420/2450/1855/1625/2455/3455 Sensor, Narrow Media Flag, Exit Sensor Guide Assembly, Lower Exit w/Narrow Media Sensor Spring, Redrive Idler Roller, Redrive Idler Tie, Wire PP 99A0577 Lamp, 115V 750W CC Red 2420/2450/2455/3455 Lamp, 115V 500W CC White 1250/1255/1620/1625/1650/1855 Lamp, 100V 500W CC Yellow 1250/1255/1620/1625/1650/1855 Lamp, 100V 750W CC Purple 2420/2450/2455 Lamp, 220V 750W CC Orange 2420/2450/2455/3455 Lamp, 220V 500W CC Black 1250/1255/1620/1650/2455 Screw, Hanger PP 99A0263 2450/1250 Clip, Fuse Mounting Standoff, Fuser Control Board
99A0145 99A0919
3 2
Parts Catalog 7-31
Assembly 12: Transfer
AsmIndex 12-1 12-1 12-2 12-3 12-4
Units 1 1 1 1 1
Description Transfer Roll Assembly Transfer Roll Assembly 1855-C01 PRC Arm, Transfer Roll Assembly Right Spring, Transfer Roll Right Erase Lamp Assembly Kit o Lamp, Erase Assembly o Lens, Erase Lamp Shaft, Transfer Pivot Spring, Transfer Roll Left Arm, Transfer Roll Left Retainer, Pivot Shaft PP 99A0267
12-5 12-6 12-7 NS
99A0185 99A0181 99A0354
1 1 1 1
Parts Catalog 7-33
Assembly 13: Charging
AsmIndex 13-1 13-2 13-3 NS
Part Number 99A0512 99A0513 99A0929
Units 1 1 1 1
Description Link Assembly, Charge Left Kit Link Assembly, Charge Right Kit Roll Assembly, Charge Screw, Charge Roll PP 99A0263
Parts Catalog 7-35
Assembly 14: Electronics
AsmIndex 14-1 14-1 14-1 14-1 14-1 14-2
Part Number 99A0900 99A0901 99A0902 99A0903 99A0946 1342514
Units 1 1 1 1 1 1
Description Engine Board Assembly with laser cable 1250/1255 Engine Board Assembly with laser cable 1620/1625/1650 Engine Board Assembly with laser cable 1855/1855-C01 Engine Board Assembly with laser cable 2420/2450/2455 Engine Board Assembly with jumpers 3455 Power Cord Set, 8 ft. - U.S., Canada (LV), Nicaragua, Venezuela, Peru (LV), Bolivia, Colombia, Costa Rica, Ecuador, El Salvador, Guatemala, Honduras, Mexico, Panama Europe, 6 ft. Power Cord Set, 6 ft. - Argentina (HV), Paraguay (HV), Uruguay (HV), APG (LV) Power Cord Set, 8 ft. - U.K., Ireland Power Cord Set, 6 ft. - Israel Power Cord Set, 6 ft. - Switzerland Power Cord Set, 6 ft. - South Africa Power Cord Set, 8 ft. - Chile (HV) Power Cord Set, 8 ft. - Denmark Power Cord Set, 6 ft. - Italy Power Cord Set, 8 ft. - Peru (HV) Power Cord Set, 8 ft. straight 1855-C01 Power Cord Set, 6 ft. straight 1855-C01 Power Cord Set, 8 ft. right angle 1855-C01 Power Cord Set, 6 ft. right angle 1855-C01 Fuse, 110 V ac LVPS Fuse, 220 V ac LVPS, 110 V ac 2420/2450/2455/3455 LVPS, 110 V ac 1620/1650/1625/1855 LVPS, 110 V ac 1250/1255 LVPS, 220 V ac 2420/2450/2455/3455 LVPS, 220 V ac 1620/1650/1855/1625 LVPS, 220 V ac 1250/1255
14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-2 14-3 14-3 14-4 14-4 14-4 14-4 14-4 14-4
1339538 1342536 1342537 1339539 1339540 1339541 1342534 1339543 1339542 1374067 99A0471 99A0493 99A0496 99A0497 99A0215 99A0205 99A0214 99A0216 99A0218 99A0199 99A0201 99A0203
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Parts Catalog 7-37
Assembly 14: Electronics (continued)
AsmIndex 14-5 14-6 14-7 14-7 14-8
Part Number
Units 1 1
Description Screw, HVPS Mounting PP 99A0263 Screw, Engine Bd Mounting Top PP 99A0263 High Voltage Power Supply High Voltage Power Supply 3455 Interconnect Board Assembly 2450/2455/3455 o 3 Slot Interconnect Board Assembly 1650/1855/2420 o 2 Slot Interconnect Board Assembly 1250/1255/1620/1625 o 1 Slot Screw, Int Board Mounting PP 99A0263 Screw, Int Board Shield Ground PP 99A0263 Screw, Int Shield Mounting PP 99A0263 Screw, Int Shield Mounting PP 99A0263 Screw, Controller Bd Mounting Front PP 99A0263 Screw, Parallel Connector Mounting Screw, Controller Bd Mounting Back PP 99A0263 Controller Board Assembly 1250/1620 Controller Board Assembly 1255 Controller Board Assembly 1625 Controller Board Assembly 1650/2420 Controller Board Assembly 1855 Controller Board Assembly 2450 Controller Board Assembly 2455 Controller Board Assembly 3455 Screw, Engine Bd Mtg Bottom PP 99A0263 Screw, Engine Bd Mtg Front PP 99A0263 Screw, Engine Bd Mtg Top PP 99A0263 Cable, Deflector Clip, EMC Six Finger
99A0220 99A0827 99A0376
1 1 1
14-8
99A0930
14-8
99A0960
14-9 14-9 14-9 14-9 14-10 14-11 14-12 14-13 14-13 14-13 14-13 14-13 14-13 14-13 14-13 14-14 14-14 14-14 NS NS 99A0575 99A0346 99A0187 99A0840 99A0841 99A0183 99A0842 99A0139 99A0844 99A0845 99A0426
2 1 2 3 2 2 2 1 1 1 1 1 1 1 1 2 2 2 1 1
Parts Catalog 7-39
AsmIndex 14-15 NS 14-16 14-16 14-16 14-17 14-18 14-18 14-18 14-19 14-19 14-19 NS NS NS NS NS NS 14-20 14-20 14-21 NS NS NS NS NS NS
Part Number 99A0236 99A0408
Units 1 1 6 4 2
Description Cover, INA Blank Cover, INA Flat (Blank) Screw, INA Cover Mounting PP 99A0263 2450 Screw, INA Cover Mounting PP 99A0263 Screw, INA Cover Mounting PP 99A0263 Engine Board Shield Assembly Shield, Inner Assembly 1250/1620/1625 o Cover, INA Blank Shield, Inner Assembly 1650/2420/1855 o Cover, INA Blank Shield, Inner Assembly 2450/2455/3455 o Cover, INA Blank Shield, Outer 1250/1255/1620/1625 Shield, Outer 1650/2420/1855 Shield, Outer 2450/2455 Shield, Interconnect Board 2450/2455/3455 Shield, Interconnect Board 1625/1650/1855/2420 Shield, Interconnect Board 1250/1255 Shield, Interconnect Board Mylar 2450/2455/3455 Shield, Interconnect Board Mylar 1625/1650/1855/2420 Shield, Interconnect Board Mylar 1250/1255 Screw, Outer Shield Mounting PP 99A0263 Screw, Outer Shield Mounting PP 99A0263 2450 Screw, Eng/Controller Mtg Ground PP 99A0263 Screw, Eng/Int Shield Ground PP 99A0263 Screw, Controller/Int Ground PP 99A0263 Screw, Int/Pan Mounting PP 99A0263 Screw, Eng/Int Ground PP 99A0263 Clip, Cable Screw, Cable Clip PP 99A0263
99A0213 99A0239 99A0238 99A0235 99A0207 99A0206 99A0204 99A0224 99A0229 99A0230 99A0243 99A0244 99A0245
1 1 1 1 2 1 3 1 1 1 1 1 1 1 1 1 4 6 1 1 2 2 1
99A0260
1 2
Parts Catalog 7-41
AsmIndex 14-22 14-23 14-23 14-24 14-25 14-25 14-25 14-26 14-27 14-28 14-29
Part Number 99A0138 99A0030 99A0803 99A0255 99A0129 99A0130 99A0801 99A0256 99A0128 99A0254 99A0257
Units 1 1 1 1 1 1 1 1 1 1 1
Description Sensor, Standard Bin Level Fan, Main Fan, Main 3455 Cable, Main Drive Motor Gearbox, w/Motor 2450/2420/2455 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 Gearbox, w/Motor 3455 Cable, Integrated Tray Board, Input Tray (ITC) Cable, Auto Connect Bottom Cable, Auto Connect Top 1650/1855/2420/2450/2455/3455
Parts Catalog 7-43
AsmIndex 14-30 14-31 14-32 14-33 14-34 14-34A 14-34B
Part Number 99A0049 99A0466 99A0296 99A0001 99A0576 99A0815 99A0814
Units 1 1 1 1 1 2 1
Description Fan, Auxiliary 2450/2455/3455 Sensor, Toner Cartridge Level Switch, Cover Open w/Operator Panel Cable Assembly Operator Panel Assembly Cable, Front Harness Contacts, Smart Cartridge Cable, Smart Cartridge 3455
Parts Catalog 7-45
AsmIndex 14-35 14-35 14-35 14-35 14-36 14-37 14-37 14-37 14-38 14-39 14-40 14-40 14-40 14-41
Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Description Printhead Assembly, 1620/1625/1650/1250/1255 Printhead Assembly, 1855/1855-C01 Printhead Assembly, 2420/2450/2455 Printhead Assembly, 3455 Cable, Hysnc Cable, Laser Cable, Laser 3455 Cable, Laser 1855/1855-C01 Cable, Envelope Conditioner 1620/1625/1650/1855/2420/2450/2455 Solenoid Assembly, Envelope Conditioner 1620/1625/1650/1855/2420/2450/2455/3455 Board Assembly, Fuser w/o Driver 1250/1255 Board Assembly, Fuser with Driver 1620/1625/1650/1855/2420/2450/2455 Board Assembly, Fuser 3455 Cover, Fuser Assembly with Thermistor, Thermal Fuse and RH Fuser Lamp Contact Assembly Sensor, Narrow Media Cable, Fuser D.C. Cable, Fuser A.C. Cable, Mirror Motor
14-42 14-43 14-44 14-45
99A0169 99A0252 99A0258 99A0250
1 1 1 1
Parts Catalog 7-47
Assembly 15: 250 Sheet Tray
AsmIndex 15-1 15-2 15-3 NS 15-4 15-5 15-6 15-7 15-8 15-9 15-10 15-11 15-12 15-13 15-13B 15-14 15-15 15-16 NS 15-17 15-18 15-19 15-20 15-21 15-22 15-23 15-24 15-25 15-25 15-25A 15-26
Part Number 99A0287 99A0070 99A0438 99A0448 99A0266 99A0026 99A0419 99A0058 99A0288 99A0272 99A0275 99A0282 99A0451 99A0450 99A0276 99A0277 99A0278 99A0280 99A0274 99A0273 99A0279 99A0445 99A0281
Units 1 3 2 2 1 1 1 1 4 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 3
Description Pick Arm Assembly Screw, Auto Comp Mounting PP 99A0263 Roll Assembly, Pick Bearing, Drive Roll Arm, Paper Out 250 Base, 250 Option Tray Bias Arm Assembly Spring, Tray Bias Pad, Machine Mounting Sensor, Option Pass Thru Shaft, 250 Drive Spring, Power Takeoff Cable, 250 Tray Option Roller, Skewed Backup Retainer, Roller Roll Assembly, Drive 500 Dual Screw, Wear Plate Mounting PP 99A0263 Wear Plate, Pass Thru 250 Tray Bellcrank, Roller Release Bearing, Drive Shaft Low Gear, Feed Roll Gear, Bevel Bearing, Drive Shaft Stud Assembly, 250 Frame Cable, 250 Auto Connect Option Screw, Switch Activate Spring Mounting PP 99A0263 Screw, Option Board Mounting PP 99A0263 Board, Option Tray 1250/1620/1650/2420/2450 Board, Option Tray 1255/1625/1855/2455/3455 Jumper, 2-pin Spring, Switch Activate
99A0284 99A0397 99A0627 99A0063
1 1 1 1
Parts Catalog 7-49
Assembly 15: 250 Sheet Tray (continued)
AsmIndex 15-27 15-27 15-28 15-29 15-30 15-31 15-32 15-33 15-34 15-35 15-36 15-37 15-38 NS NS NS NS
Part Number 99A0115 99A0504 99A0119 99A0120 99A0123 99A0461 99A0121 99A0126 99A0124 99A0127 99A0894 99A0893 99A0892 99A0429 99A0286 99A0446 99A0501
Units 1 1 4 2 1 1 1 4 1 1 1 1 1 1 1 1 1
Description Tray Assembly, 250 Sheet Option Tray Assembly, 250 Sheet 1855-C01 Wear Strips Restraint Pad Indicator Assembly, Paper Size Label, Tray Number (2-5) Clip, 250 Tray Wear Finger, Autosize Plate, Snap-In Slider, Autosize 250 Latch, Back Restraint Restraint, Back 250 Sheet Tray Restraint, Side 250 Sheet Tray Label, Options Circle 1255/1625/1855/2455 Spring, Backup Roller Aligner Assembly, Paper Strip Assembly, Paper Tray Insert 1855-C01
Parts Catalog 7-51
Assembly 16: 500 Sheet Tray
AsmIndex 16-1 16-2 16-3 16-4 16-5 16-6 16-7 16-8 16-9 16-10 16-11 16-12 16-13 16-14 16-15 16-16 16-17 16-18 16-19 16-20 16-21 16-22 16-23 16-23 16-24 16-25 16-26 16-27 16-28 16-29 16-30
Part Number 99A0350 99A0405 99A0070 99A0298 99A0058 99A0419 99A0026 99A0288 99A0895 99A0292 99A0123 99A0461 99A0457 99A0126 99A0124 99A0418 99A0120 99A0289 99A0896 99A0894 99A0447 99A0284 99A0397 99A0275 99A0280 99A0446 99A0274 99A0063
Units 1 3 1 2 1 4 1 1 1 1 4 1 1 1 4 1 1 2 1 1 1 1 1 1 1 3 1 1 1 1 1
Description Sensor, Paper Low Screw, Auto Comp Mounting PP 99A0263 Pick Arm Assembly Pick Roll Assembly Base, 500 Bottom Pad, Base 500 Spring, Tray Bias Tray Bias Arm Assembly Sensor, Option Pass Thru Restraint, Side 500 Sheet Tray Wear Strips Indicator Assembly, Paper Size Label, Tray Number (2-5) Clip, 500 Tray Wear Finger, Autosize Plate, Snap-In Slider, Autosize 500 Restraint Pad Tray, 500 Sheet Restraint, Back 500 Sheet Tray Latch, Back Restraint Shaft, 500 Drive Board, Tray 1250/1620/1650/2420/2450 Board, Tray 1255/1625/1855/2455/3455 Spring, Power Takeoff Screw, Board Mounting PP 99A0263 Bearing, Drive Shaft Low Aligner Assembly, Paper Retainer, Aligner Assembly PP 99A0267 Gear, Feed Roll Spring, Switch Activate
Parts Catalog 7-53
Assembly 16: 500 Sheet Tray (continued)
AsmIndex 16-31 16-32 16-33 16-34 16-35 16-36 16-37 16-38 16-39 16-40 16-41 16-42 16-43 16-44 NS
Units 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1
Description Spring, Backup Roller Bellcrank, Roller Release Gear, Bevel Bearing, Drive Shaft Cable, 500 Auto Connect Top Stud Assembly, 500 Frame Cable, 500 Auto Connect Bottom Bearing, Drive Roll Wear Plate, Pass Thru Screw, Wear Plate Mounting PP 99A0263 Roller, Skewed Backup Retainer, Roller Roll Assembly, Drive 500 Arm, Paper Out 500 Label, Options Circle 1255/1625/1855/2455
Parts Catalog 7-55
Assembly 17: 500/500 Dual Tray
AsmIndex 17-1 17-2 17-3 17-4 17-5 17-5 17-6 17-7 17-8 17-9 17-10 17-11 17-12 17-13 17-14 17-15 17-16 17-17 17-18 17-19 17-20 17-21 17-22 17-23 17-24 17-25 17-26 17-27 17-28 17-29 17-30
Part Number 99A0350 99A0405 99A0070 99A0293 99A0298 99A0514 99A0026 99A0419 99A0058 99A0288 99A0895 99A0292 99A0123 99A0461 99A0457 99A0126 99A0124 99A0418 99A0120 99A0289 99A0896 99A0894 99A0569 99A0277 99A0276 99A0450 99A0451 99A0438 99A0447
Units 1 3 1 2 1 1 2 1 1 4 1 1 4 1 1 1 4 1 1 2 1 1 1 1 1 2 1 1 1 2 1
Description Sensor, Paper Low Screw, Auto Comp Mounting PP 99A0263 Pick Arm Assembly Pick Roll Assembly Base, 500 Top Base, 500 Bottom Screw, Dual 500 Mounting Tray Bias Arm Assembly Spring, Tray Bias Pad, Base 500 Sensor, Option Pass Thru Restraint, Side 500 Sheet Tray Wear Strips Indicator Assembly, Paper Size Label, Tray Number (2-5) Clip, 500 Tray Wear Finger, Autosize Plate, Snap-In Slider, Autosize 500 Restraint Pad Tray, 500 Sheet Restraint, Back 500 Sheet Tray Latch, Back Restraint Cable Assembly Dual Tray Auto Connect Wear Plate, Pass Thru 500 Tray Screw, Wear Plate Mounting PP 99A0263 Roll Assembly, Drive 500 Dual Retainer, Roller Roller, Skewed Backup Bearing, Drive Roll Shaft, 500 Drive
Parts Catalog 7-57
Assembly 17: 500/500 Dual Tray (continued)
AsmIndex 17-31 17-32 17-33 17-34 17-35 17-36 17-37 17-38 17-39 17-40 17-41 17-42 17-43 17-44 17-45 17-46 17-47 17-47 17-48 17-49 NS
Part Number 99A0275 99A0280 99A0446 99A0300 99A0898 99A0274 99A0286 99A0472 99A0278 99A0273 99A0063 99A0279 99A0281 99A0444 99A0443 99A0284 99A0397
Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3
Description Spring, Power Takeoff Bearing, Drive Shaft Low Aligner Assembly, Paper Retainer, Aligner Assembly PP 99A0267 Board, Tray (Bottom) Cable, 500 Tray Board to Board Power Gear, Feed Roll Spring, Backup Roller Cable Assembly, 500/500 Dual Bellcrank, Roller Release Gear, Bevel Spring, Switch Activate Bearing, Drive Shaft Cable, 500 Auto Connect Top Stud Assembly, 500 Frame Arm, Paper Out 500 Board, Tray (Top) 1250/1620/1650/2420/2450 Board, Tray (Top) 1255/1625/1855/2455/3455 Screw, Board Mounting PP 99A0263 Nut, Dual 500 Mounting Label, Options Circle 1255/1625/1855/2455
99A0460 99A0429
2 1
Parts Catalog 7-59
Assembly 18: Duplex
AsmIndex 18-1 18-2 18-3 18-4 18-5 18-6 18-7 18-8 18-9 18-10 18-11 18-12 18-13 18-14 18-15 18-16 18-17 18-18 18-19 NS NS NS NS
Units 1 1 1 4 4 2 2 1 1 1 1 1 1 2
Description Cover, System Board Main Frame Assembly Idler Assembly, Belt Tension Spring, Aligner Guide Assembly, Paper Spring, Chassis Ground Screw, Motor Mount 3 mm PP 99A0413 Belt, Motor 114 Gear Pulley, Main Drive 96/54 Gear Motor Assembly Cable, D.C. Motor Tach Cam Follower Assembly Kit PP 99A0299 Actuator Assembly, Deflector Screw, Actuator Assembly Mounting PP 99A0413 Guide, Return RH Upper Screw, Upper Return Guide Mounting PP 99A0413 Guide, Return RH Lower Tray Assembly, Jam Removal Switch Assembly, Front Cover Roll, Debuckle Shaft, Debuckle Retainer 6 mm - Backup Roll PP 99A0404 Screw, M3x6L:G Supradrive PP 99A0413
99A0339
1 2
99A0340 99A0345 99A0261 99A0432 99A0428
1 1 1 1 1 2 2
Parts Catalog 7-61
Assembly 18: Duplex (continued)
AsmIndex 18-20 18-21 18-22 18-23 18-24 18-25 18-26 18-27 18-28 18-29 18-30 18-31 18-32 18-33 18-34 18-35 18-36 18-37 18-38 18-38 NS 18-39 18-40
Part Number
Units 1
Description Screw, Tray Open Switch Mounting PP 99A0413 Sensor, Exit - Optical Guide, LH Lower Guide, Return LH Upper Screw, LH Upper Return Guide Mounting PP 99A0413 Base Assembly, w/Tray Bias Shaft, Duplex Drive Spring, Duplex Shaft Gear, Pass Thru Idler Bearing, Drive Shaft Low Cable, Auto Connect Bottom Gear, Pass Thru Drive Roll Cable, Auto Connect Top Screw, Main Frame Assembly Mounting PP 99A0413 Gear, Duplex Bevel Pan, System Board Drip Bearing, Drive Shaft Fuse, .8A SB Board, System Level 1 Board, System Level 2 Kit, Duplex Option Card Jumper Screw, System Board Mounting PP 99A0413 Screw, System Board Cover PP 99A0413
99A0341 99A0342 99A0343
1 1 1 2
99A0306 99A0316 99A0315 99A0325 99A0280 99A0311 99A0274 99A0310
1 1 1 1 1 1 1 1 4
99A0317 99A0434 99A0279 99A0191 99A0403 99A0916 99A0956
1 1 1 1 1 1 1 2 4
Parts Catalog 7-63
Assembly 18: Duplex (continued)
AsmIndex 18-41 18-42 NS 18-43 18-44 18-45 18-46 18-47 18-48 18-49 18-50 18-51 18-52
Part Number 99A0305 99A0303 99A0435 99A0338 99A0332 99A0307 99A0335 99A0334 99A0327 99A0330
Units 1 1 1 1 1 1 1 2 2 1 3 1 1 2 2 2
Description Top Cover Assembly, Movable Top Cover Assembly, Fixed Retainer, 6 mm Top Cover PP 99A0404 Guide, Lower Entry Guide Assembly, Paper Decurl Guide, Center Drive Upper Air Plenum Spring, Decurl Shaft Bushing Frame, Outer Screw, Outer Frame PP 99A0413 Guide Assembly, Center Drive Fan Mounting Kit PP 99A0269 o Screw, Fan Mounting M4x30 o Washer, Fan - M4 o Nut, Fan - M4 Fan, Cooling Duplex Retainer, 5 mm Main Drive PP 99A0404 Main Drive Assembly Sensor, Input Optical Spring, Decurl Shaft Switch Assembly, Top Cover Open Retainer, 6 mm Drive Roll PP 99A0404 Shaft Assembly, Drive Shaft Assembly, Decurl Screw, Tensioner PP 99A0413 Retainer, 6 mm Clutch Roll PP 99A0404 Feet, Duplex Base Label, Options Circle 1255/1625/1855/2455
18-53 18-54 18-55 18-56 18-57 18-58 18-59 18-60 18-61 NS NS NS NS
99A0308 99A0337 99A0319 99A0433 99A0304 99A0336 99A0333
1 2 1 1 1 1 4 1 1 1 2
99A0058 99A0429
4 1
Parts Catalog 7-65
Assembly 19: Output Expander
AsmIndex 19-1 19-2 19-3 19-4 19-5 19-6 19-6 19-6 19-7 19-8 19-9 19-10 19-11 19-12 19-13
Part Number 99A0107 99A0104 99A0369 99A0052
Units 1 1 1 1 11
Description Diverter, Upper Also order 99A0104 Spring, Upper Diverter Shaft Assembly, Exit Also order PP 99A0572 Shaft Assembly, Lower Exit Also order PP 99A0572 Screw, PP 99A0263 Board, Output Expander Level 1 1650/2420/2450 Board, Output Expander Level 2 1855/2455/1650/2420/2450 Board, Output Expander DC motor Level 3 1650/1855/2420/2450/2455/3455 Cover, Front Control Board with ESD Brush Tray, Output Expander Spring, Diverter Diverter, Actuator Arm Spring, Output Tray Bracket, Attach Output Expander Assembly, Mechanical Linkage Level 1 1650/1855/2420/2450/2455 Output Expander Assembly, Mechanical Linkage Level 2 1855/2455/3455 Cover, Left Side Spring, Diverter Spring, Sector Bias Latch, Output Tray Shaft Bearing PP 99A0572 Sensor, Bin Full Level 1 1650/2420/2450 Sensor, Dual Bin Full Level 2 1855/2455/3455 Flag Kit, Output Paper Level Level Sensor Bracket Level 1 1650/2420/2450 Level Sensor Bracket Level 2 1855/2455/3455
99A0347 99A0406 99A0915 99A0571 99A0483 99A0924 99A0925 99A0482 99A0366 99A0480
1 1 1 1 1 1 1 1 2 1
19-13 19-14 19-15 19-16 19-17 19-18 19-19 19-19 19-20 19-21 19-21
99A0914 99A0372 99A0415 99A0416 99A0481 99A0350 99A0414 99A0378 99A0062 99A0409
1 1 2 1 1 2 1 1 1 1 1
Parts Catalog 7-67
Assembly 19: Output Expander (continued)
AsmIndex 19-22 19-23 19-24 19-25 19-26 19-27 19-28 19-29 19-30
Part Number 99A0374 99A0368 99A0363 99A0371 99A0361 99A0362 99A0364 99A0351 99A0370
Units 1 1 3 1 1 1 1 1 1
Description Door Assembly, Rear Access Shaft Assembly, Lower Also order PP 99A0572 Pulley, Drive Cover, Right Side Belt, 160 Gear Arm Assembly, Belt Idler Spring, Belt Tensioner Sensor, Output Expander Pass Thru Shaft Assembly, Middle Level 1 1650/1855/2420/2450/2455 Also order PP 99A0572 Shaft Assembly, Middle 40T Level 2 3455 Also order PP 99A0572 Frame Assembly, Output Expander Level 2 3455 Label, Options Circle 1855/2455/3455
19-30 19-31 NS
99A0913 99A0912 99A0429
1 1 1
Parts Catalog 7-69
Assembly 20: Envelope Feeder
AsmIndex 20-1 20-2 20-3 20-4 20-5 20-5A 20-6 20-7 20-8 20-9 20-9 NS NS NS NS NS NS
Units 1 1 1 1 1 1 1 7 1 1 1 6
Description Paper Weight Assembly Guide, Edge Cover, Top Clutch, Restraint/Gear Cover, Right Side Base Assembly Support, Slide Out Roller, Support Motor, Stepper D.C. Board Assembly, Electronic Control Board Assembly, Electronic Control 1855/2455/3455 Screw, Top/Motor/Board Belt, Gear Drive Bracket, Stack Limiter Spring, Restraint Roll Shaft Spring, Latch Return Flag, Envelope Out Sensor
99A0484 99A0491 99A0400 99A0489 99A0487
1 1 1 1 1
Parts Catalog 7-71
Assembly 20: Envelope Feeder (continued)
AsmIndex 20-11
Part Number
Units 1 1 1 1 3 2 1 1 1 1 1
Description Gear Kit, PP 99A0271 o Gear, Feed o Gear, Master Cam o Gear, Drive Roll Shaft o Gear, Master/Feed Kick o Gear, Drive Idler o Gear, Comp Drive/Clutch o Gear, Kick Roll Connect o Gear, Kick CNCT Idler o Gear, Feed Shaft Right o Gear, Drive Idler Rear Cover, Left Side Switch, Envelope Out Sensor, Envelope Pass Thru Retainer, 4 mm PP 99A0404 Retainer, Clip 5 mm Shaft PP 99A0404 Retainer, 6 mm PP 99A0404 Retainer, 7 mm Shaft PP 99A0404 Shaft, Drive Pressure Roller Cable, Auto Connect Front Spring, Cam Clutch Label, Options Circle 1255/1625/1855/2455 Label, Envelope Orientation Icon 1255/1625/1855/2455 Deflector Guide
20-12 20-13 20-14 NS NS NS NS NS NS NS NS NS NS
99A0381 99A0388 99A0485
1 1 1 1 3 2 3
99A0384 99A0385 99A0494 99A0429 99A0427 99A0469
1 1 1 1 1 1
Parts Catalog 7-73
Assembly 21: High Capacity Feeder
AsmIndex 21-1 21-2 NS NS 21-3 21-4 21-5 21-6 21-7 21-7A 21-8 21-9 21-10 21-11 21-12 21-13 21-14 21-15 21-16 21-17 NS 21-18 21-19 21-20 21-21 21-22 21-23
Part Number 99A0660
Units 1 3 6 6
Description Frame, Printer Support Frame 2 Screw, Printer Support 2 Frame Mounting PP 99A0675 Washer, Printer Support Frame 2 Star PP 99A0677 Nut, Printer Support Frame 2, 8-32 Hex PP 99A0676 Clamp, Feed Frame Screws, Feed Frame Clamp PP 99A0675 Bearing, Nyliner Leadscrew Top Cover, Side Deflector Assembly Front Strip, Wear Transfer Lead Screw Assembly Label, Tray Option Numbers Screw, Deflector Mounting 8-18 x 7/8 inch PP 99A0675 Bearing, Leadscrew Bottom Magnet, Door Frame Assembly Tray Assembly, Elevator Card Assembly, 2000 Option Control Nut, 6-32 Hinge Mounting PP 99A0676 Washer, Hinge Mounting Flat PP 99A0677 Cable, Optical Sensor Washer, Hinge Mounting Star PP 99A0677 Door Assembly, Front Hinge, Door Kit, Door Switch Spring and Bumper Washer, Door Switch Spring Mounting PP 99A0677 Screw, Card Assembly Mounting PP 99A0675
99A0698 99A0691 99A0656 99A0680 99A0681 99A0662 99A0461
2 4 2 1 1 4 2 1 3
99A0716 99A0658 99A0650 99A0661 99A0671
1 2 1 1 1 4 4
99A0690 99A0655 99A0657 99A0948
1 4 1 2 1 1 4
Parts Catalog 7-75
Assembly 21: High Capacity Feeder (continued)
AsmIndex 21-24 21-25 21-26 21-26 21-27 21-28 21-28 21-29 21-30 21-31 21-32 21-33 21-34 21-35 21-36 21-37 21-38 21-39 21-40 21-41 21-41A 21-42 21-43 21-44 21-45 21-46 21-47 21-48 21-49
Part Number
Units 1 4
Description Nut, Door Switch Spring Mounting PP 99A0676 Washer, Card Assembly Mounting PP 99A0677 Guide, Rear Paper with thumb screws Use with 99A0696 Guide, Rear Paper with retainer arm Use with 99A0219 Screw, Top Frame Mounting PP 99A0675 Frame Assembly, Top with labels Frame Assembly, Top with labels Screw, Top Frame Clamp Mounting PP 99A0675 Washer, Top Frame Clamp PP 99A0677 Clamp, Top Frame Mounting Nut, Base Mounting PP 99A0676 Washer, Base Mounting PP 99A0677 Screw, Base Mounting PP 99A0675 Pulley, Idler Spacer, Motor Mounting Cable, PS Internal Wiring Switch, Lower Limit Microswitch Nut, 2-56 Lower Limit Switch Mounting PP 99A0676 Motor Assembly Washer, Motor Plate Mounting PP 99A0677 Washer, Power Supply Ground PP 99A0677 Belt, Drive Nut, Power Supply Ground PP 99A0676 Screw, Motor Plate Mounting PP 99A0675 Connector, Appliance Inlet with Tye Wrap Cord, AC External Jumper Nut, Power Supply Cover PP 99A0676 Cover, Power Supply Screw, Power Supply Board Mounting PP 99A0675
99A0686 99A0188
3 3 6
99A0696 99A0219
1 1 2 2
99A0719
1 2 2 2
99A0663 99A0697 99A0699 99A0653
1 4 1 1 2
99A0665
1 4 2
99A0664
1 2 4
99A0669 99A0670 99A0714
1 1 2 1 2
Parts Catalog 7-77
AsmIndex 21-50 21-51 21-52 NS NS NS 21-53 21-54 21-55 21-56 21-57 NS NS NS 21-58 21-59
Units 2 1 1 1 1 1 1 2
Description Washer, Power Supply Board PP 99A0677 Power Supply Board Cable, Low Voltage Power Supply Cable, HCIT-TOC Power Cable, HCIT Power Passthru Cable, HCIT-14Pin Flex Bushing Nut, 2-56 Paper Low Switch Mounting PP 99A0676 Switch, Paper Low Sensor Assembly, Paper Out/Upper Limit Screw, Printer Support 1 Frame Mounting PP 99A0675 Washer, Printer Support Frame 1 Star PP 99A0677 Nut, Printer Support Frame 1 8-32 Hex PP 99A0676 Screw, Door to Door Frame Mounting PP 99A0675 Frame, Printer Support 1 Parts Kit, Paper Size Switch Assembly including cable, switch, lockwasher, nut and knob Washer, Sensor Bracket Mounting PP 99A0677 Screw, Sensor Bracket Mounting PP 99A0675
99A0654 99A0651
1 1 3 6 6 10
99A0659 99A0695
1 1
21-60 21-61
2 2
Parts Catalog 7-79
AsmIndex 21-62 21-63 21-64 21-65 21-66 21-67 21-68 21-69 21-70 NS 21-71 21-72 21-73 21-74 21-75 21-76 21-77 21-78 21-79 21-79 21-80 NS NS
Units 1 1 1 2 1 1 1 2
Description Cable, 250 Auto Connect Bearing, Drive Shaft Gear, Bevel Screw, Frame Mounting PP 99A0263 Roll Assembly, Drive 250 Option Roll, Skew Backup Retainer, Roller PP 99A0267 Screw, Wear Plate Mounting PP 99A0675 Plate Wear, Pass Thru Spring, Backup Roller Stud Assembly, 250 Frame Bearing, Drive Shaft Low Spring, Power Takeoff Shaft, 250 Drive Aligner Assembly, Paper Retainer, Aligner Assembly PP 99A0267 Gear, Feed Roll Bellcrank, Roller Release Card Assembly, 2000 Tray Option Card Assembly, 2000 Tray Option 1255/1625/1855/2455/3455 Screw, 2000 Tray Option Card Mounting PP 99A0263 Foot, Stabilizer PP 99A0672 Mounting Feet PP 99A0687
99A0277 99A0286 99A0445 99A0280 99A0275 99A0272 99A0446 99A0274 99A0278 99A0688 99A0401
1 1 1 1 1 1 1 1 1 1 1 1 3 4 4
Parts Catalog 7-81
AsmIndex 21-81 21-82 21-83 21-84 21-85 21-86 21-87 21-88 21-89 21-90 21-91 NS NS
Part Number
Units 3
Description Screw, Auto Comp Assembly Mounting PP 99A0263 Arm Assembly, Pick 2000 Roll Assembly, Pick Base, 2000 Option Screw, Deflector Mounting PP 99A0263 Deflector, Base Sensor, Pass Thru Label, Tray Option Numbers Washer, Bracket 250 Frame Retention Mounting PP 99A0677 Screw, Bracket 250 Frame Retention Mounting PP 99A0263 Bracket, 250 Frame Retention Arm, Paper Out 250 Sheet Label, Options Circle 1255/1625/1855/2455
99A0674 99A0070 99A0692 99A0678 99A0288 99A0461
1 2 1 1 1 1 1 4 4
99A0679 99A0448 99A0429
2 1 1
Parts Catalog 7-83
Assembly 22: Kiosk - Vertical Paper Adapter
AsmIndex 22-1 22-2 22-3 22-4 22-5 22-6 22-7 22-7B 22-8 22-9 22-10 22-11 22-12 22-13 22-14 22-15 22-16 22-17 22-18 22-19
Part Number 99A0231 99A0112 99A0197 99A0209
Units 1 1 1 12 1 16 7 3
Description Bail, Support Mounting, Frame Assembly Shaft, Drive Rear Retainer PP 99A0240 Arm Assembly, Pivot Screws PP 99A0234 Parts, Pulley PP 99A0208 Gear, Idler PP 99A0237 Tray Assembly, Backup Roller Spring, Backup Roller Roller, Backup Tray Assembly, Drive Roller Frame Assembly, Right Side Cover, Right Belt, 160G Guide, Paper Exit Shaft Assembly, Drive Roller Frame Assembly, Left Side Cover, Backup Tray Tray, Backup Roller
99A0079 99A0087 99A0086 99A0116 99A0125 99A0232 99A0217 99A0226 99A0122 99A0137 99A0088 99A0085
1 6 6 1 1 1 2 1 2 1 1 1
Parts Catalog 7-85
Assembly 23: Kiosk - Horizontal Paper Adapter
AsmIndex 23-1 23-2 23-3 23-4 23-5 23-6 23-7 23-7B 23-8 23-9 23-10 23-11 23-12 23-13 23-14 23-15 23-16 23-17 23-18
Part Number 99A0231 99A0112 99A0197 99A0209
Units 1 1 1 12 1 15 7 3
Description Bail, Support Mounting, Frame Assembly Shaft, Drive Rear Retainer PP 99A0240 Arm Assembly, Pivot Screws PP 99A0234 Parts, Pulley PP 99A0208 Gear, Idler PP 99A0237 Tray Assembly, Backup Roller Spring, Backup Roller Roller, Backup Tray Assembly, Drive Roller Frame Assembly, Right Side Cover, Right Belt, 160G Shaft Assembly, Drive Roller Frame Assembly, Left Side Cover, Backup Tray Tray, Backup Roller
99A0079 99A0087 99A0086 99A0905 99A0907 99A0232 99A0217 99A0122 99A0906 99A0088 99A0085
1 6 6 1 1 1 2 2 1 1 1
Parts Catalog 7-87
Assembly 24: Options

AsmIndex 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 Part Number 1328589 99A0517 99A0518 99A0519 99A0520 99A0724 99A0726 99A0521 99A0522 99A0523 99A0873 99A0420 99A0421 99A0422 99A0560 99A0424 99A0515 99A0459 99A0516 99A0628 99A0871 99A0629 13A0296 13A0297 99A0545 13A0298 99A0467 99A0923 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description 2MB DRAM SIMM 4MB DRAM SIMM 8MB DRAM SIMM 16MB DRAM SIMM 32MB DRAM SIMM 64MB EDO DRAM SIMM DBCS SIMM, Japan 1MB Flash SIMM 2MB Flash SIMM 4MB Flash SIMM SIMM, Bar Code 3455 Token-Ring Card 10/100 Ethernet Card 10Base2/10BaseT Card with T-connector Omni Bus INA Card IR Adapter Hard Disk, w/o Control Board 1250/1620/1650/2420/2450 Hard Disk, w/o Control Board 2.1GB 1255/1625/1855/2455/3455 Board, Hard Disk Control SIMM, IPDS Board 1250/1620/1650/2420/2450 SIMM, IPDS Board 1255/1625/1855/2455/3455 Adapter Card, SES for SCS Cable, Twinax Cable, Coax Adapter, Serial Cable, Serial Board, Parallel Port Adapter Board, USB/Parallel Port
Assembly 24: Options (continued)

AsmIndex 24 24 24 24 24 24 24 24 24 24 Part Number 99A0911 99A0910 99A0909 99A0863 99A0864 99A0865 99A0799 99A0417 99A0920 99A0945 Units 1 1 1 1 1 1 1 1 1 1 Description Tray Assembly, 250 Special Media Cartridge, 4059 Shipping (2) Cartridge, 4059 Shipping (1) Hopper, Integrated Label/Letter Hopper, Integrated Label/Letter Stacker Hopper, Legal Label Stacker Drive, Forms HD 2.1GB Kit, Cap/Stack Bails 250 Kit, Cap/Stack Bails 500 Kit, Paper Stacking Arm
Parts Catalog 7-89
Assembly 25: Miscellaneous

AsmIndex 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 Part Number 99A0263 99A0585 99A0267 99A0268 99A0269 99A0299 99A0271 99A0404 99A0413 99A0572 99A0577 99A0675 99A0676 99A0677 99A0083 99A0512 99A0513 99A0186 99A0702 99A0703 99A0704 99A0705 99A0706 99A0707 99A0710 99A0711 99A0712 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 1 Description Parts Packet, Screws Parts Packet, Contact Kit Parts Packet, Retainers Parts Packet, Springs Paper Feed Parts Packet, Duplex Option Fan Mounting Parts Packet, Duplex Option Cam Follower Assembly Parts Packet, Envelope Option Gears Parts Packet, Retainers Envelope Option Parts Packet, Screws Duplex Parts Packet, 500 Sheet Feeder Option Shaft Bearings Parts Packet, Cable Ties (10 each) Parts Packet, Screws High Capacity Feeder Parts Packet, Nuts High Capacity Feeder Parts Packet, Washers High Capacity Feeder Parts Kit, Multipurpose Tray Parts Kit, Charge Roll Link Asm, Left Side Parts Kit, Charge Roll Link Asm, Right Side Parts Kit, Erase Lamp/Lens Printer Stand Caster, Non Locking Printer Stand Caster, Locking Printer Stand Grommet, Wire Printer Stand Lock, Cam Printer Stand Storage Shelf Printer Stand Door Assembly, Cabinet Printer Stand Filler, Rear Top Piece Printer Stand Table Assembly, Large Printer Stand Table Assembly, Small
Assembly 25:Miscellaneous (continued)

AsmIndex 25 25 25 25 25 25 25 25 Part Number 99A0208 99A0234 99A0265 99A0295 99A0248 99A0301 99A0394 99A0462 Units 1 1 1 1 1 1 1 1 Description Parts Packet, Pulley - Kiosk Parts Packet, Screws - Kiosk Packaging, Short Packaging, Tall with 500/500 Option Tray Packaging, 500/500 Dual Option Tray Assembly Packaging, w/o 500/500 Option Tray Grease Packet, Nyogel 744 Grease Packet, IBM 23
Parts Catalog 7-91
Index
A
Acronyms 6 Adjustment Procedures 2 Duplex Motor Drive Belts 2 Fuser Solenoid 3 Gap Adjustment 3 Paper Alignment Assembly 5 Printhead Assembly 4 Autoconnect 21 Error Log 8 Clearing the Error Log 8 Viewing the Error Log 8 Hardware Tests 9 Button Test 9 DRAM Memory Test 10 LCD Test 9 Parallel Wrap Test 11 ROM Memory Test 10 Serial Wrap Test 12 Input Tray Tests 14 Input Tray Feed Test 14 Paper Feed Tests Base Sensor Test 17 Input Tray Sensor Test 14 Output Bin Feed Test 15 Output Bin Sensor Test 16 Output Bin Test - Standard Bin
B
Base Sensor Test Button Test 9
17
C
Connector Locations Autoconnect 21 Duplex Option Board 19 Engine Board 4 Envelope Option Board 17 Fuser Board 11 High Voltage Power Supply 3 Interconnect Board 14 LVPS 1 Output Expander Control BoardLevel 1 Stepper Motor 22 Output Expander Control BoardLevel 2 DC Motor 24
15
Output Bin X Sensor Test 16 Print Registration 18 Print Tests 22 Printer Setup 19 Maintenance Page Count (2420/ 2450/2455/3455) 20 Restore EP Factory Defaults 21 Setting Configuration ID 20 Setting the Page Count 19 Viewing the Permanent Page Count 19 Diagnostic Mode 1 Disabling Download Emulations 3 Disk Test/Clean 2 DRAM Memory Test 10 Duplex Option Board Connectors 19 Duplex Tests 4
D
Diagnostic Aids 1 Device Tests 2 Disk Test/Clean 2 Flash Test 3 Quick Disk Test 2 Diagnostic Mode 1 Duplex Tests 4 Duplex Feed 1 Test 7 Duplex Feed 2 Test 7 Duplex Motor Test 5 Duplex Quick Test 4 Duplex Sensor Test 5
E
Engine Board Connectors 4 Envelope Option Board Connectors
17
Index I-1
Error Codes Service Error Codes 2 User Error Messages 16 Error Log 8 ESD-Sensitive Parts 1
O
Output Bin Feed Test 15 Output Bin Sensor Test 16 Output Bin Test - Standard Bin 15 Output Bin X Sensor Test 16 Output Expander Control Board-Level 1 Stepper Motor 22 Output Expander Control Board-Level 2 DC Motor 24
F
Flash Test 3 Fuser Board 11
G
Gap Adjustment
P
3
Parallel Wrap Test 11 Parts Catalog 1 Charging 34 Covers 2 Developer Drive 24 Duplex 60 Electronics 36 Envelope Feeder 70 Frame 6 Fuser 26 High Capacity Feeder 74 Integrated Paper Tray - 250 Sheet
H
Hardware Tests 9 HVPS Connectors 3
I
Input Tray Feed Test 14 Input Tray Sensor Test 14 Interconnect Board Connectors
14
L
Laser Notices ix LCD Test 9 Lubrication Specifications LVPS Connectors 1
20
Kiosk - Horizontal Paper Adapter
Kiosk - Vertical Paper Adapter 84 Main Drive 22 M Miscellaneous 90 Options 88 Maintenance Approach 5 Output Expander 66 Maintenance Page Count (2420/2450/ Paper Feed 2455/3455) 20 Alignment 16 Maintenance, Preventive 1 Autocompensator 12 Maintenance, Scheduled (Model 2420/ Multipurpose Unit 14 2450/2455/3455) 2 Output 18 Messages Printhead 10 Check Device Connection Messages Transfer 32 22 250 Sheet Tray 48 Service Error Codes 2 500 Sheet Tray 52 User Error Messages 16 500/500 Dual Tray 56 User Line 2 Link Messages 22 Power-On Self Test (POST) 24 User Line 2 Messages 20 Preventive Maintenance 1 User Status Messages 12
86
Q
Quick Disk Test
I-2 4059 Service Manual
R
Removal Procedures 12 Removals Center Pan Assembly 18 Controller Board 19 Covers 12 Developer Drive Assembly 20 Duplex Board 21 Duplex Front Cover Assembly 21 Duplex Front Cover Door 21 Duplex Front Cover Door Switch
21
Duplex Motor 22 Engine Board 23 EP Frame Assembly 23 Fans 24 Fuser 26 Fuser Board 27 Fuser Cover 28 Fuser Detack Fingers 29 Fuser Detack Housing Assembly
Switch Assembly 49 Optional Paper Tray Assembly 50 Outer EMC Shield 51 Paper Alignment Assembly 52 Paper Input Sensor 53 Paper Size Sensing Board 54 Pick Roll 54 Printhead 55 Redrive Assembly 56 Right Side Frame 57 Smart Cartridge Contacts 58 Toner Sensor 59 Transfer Roll Assembly 60 Upper Front Cover Hinge Assembly
61
Upper Front Cover Interlock Switch Assembly 62 Upper Paper Deflector Assembly
60
Restore EP Factory Defaults ROM Memory Test 10
21
29
Fuser Envelope Solenoid 31 Fuser Exit Flag Assembly 31 Fuser Exit Roll Assembly 32 Fuser Lamp 33 Fuser Lower Exit Guide Assembly
S
Safety Information xvii Safety Inspection Guide 1 Scheduled Maintenance (2420/2450/ 2455/3455) 2 Screw Identification Table 7 Serial Wrap Test 12 Service Checks Charge Roll 29 Cover Open Switch/Cable 31 Dead Machine 32 Duplex Option 35 Envelope Feeder Option 39 Erase Lamp 46 Fan 47 Fuser 48 Fuser Solenoid 51 High Capacity Feeder Input Tray
33
Fuser Transfer Plate 30 HVPS 34 Inner EMC Shield 35 Inner Paper Deflector Assembly
36
Integrated Tray Compensator Assembly 37 Integrated Tray Compensator Pick Roll Assembly 38 Interconnect Board Assembly 39 Left Side Frame 41 LVPS 43 Main Drive Assembly 44 Main Drive Motor 45 Multipurpose Tray/Lower Deflector Assembly 46 Operator Panel 48 Operator Panel Cable/Cover Open
61
Input Sensor 57 Input Tray(s) Option 58 Main Drive 73 Operator Panel 74 Options 76
Index I-3
Output Bin Sensor 78 Output Expander 79 Paper Feed 86 Parallel Port 89 Print Quality 91 Printhead 89 Serial Port 104 Smart Cartridge 102 Toner Sensor 104 Transfer Roll 105 Setting Configuration ID 20 Setting the Page Count 19 Status Messages 12 Symptom Tables 25 Base Printer 25 Duplex 27 Envelope Feeder Option 27 High Capacity Feeder Option 26 Output Expander Option 28 Paper Tray Options 27
U
Unique Tools 5 User Line 2 Link Messages 22 User Line 2 Messages 20 User Status Messages 12
V
Viewing the Permanent Page Count
19
I-4 4059 Service Manual

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Table of Contents Start Diagnostics Safety and Notices Trademarks Index

Edition: March 24, 2006

Copyright Lexmark International, Inc. 1998, 2004 All rights reserved.

2-102 2-104 2-104 2-105

iv 4059 Service Manual

vi 4059 Service Manual

viii 4059 Service Manual

Notices and Safety Information Laser Notices

Laser Advisory Label

Notices and Safety Information ix

Class 1 Laser Statement Label

x 4059 Service Manual

Avis relatif lutilisation de laser

Notices and Safety Information xi

Avvertenze sui prodotti laser

Avisos sobre el lser

xii 4059 Service Manual

Declarao sobre Laser

Notices and Safety Information xiii

xiv 4059 Service Manual

Avs sobre el Lser

Notices and Safety Information xv

Japanese Laser Notice

Chinese Laser Notice

xvi 4059 Service Manual

Korean Laser Notice

xviii 4059 Service Manual

Fachpersonal sollte entsprechende Vorsichtsmanahmen treffen.

Notices and Safety Information xix

xx 4059 Service Manual

Chinese Safety Information

Korean Safety Information

Notices and Safety Information xxi

xxii 4059 Service Manual

General Information 1-1

1-2 4059 Service Manual

General Information 1-3

1-4 4059 Service Manual

Tools Required For Service

General Information 1-5

1-6 4059 Service Manual

2. Diagnostic Information Start

Diagnostic Information 2-1

Service Error Codes

2-2 4059 Service Manual

921 Fuser Error

922 Fuser Error 923 Fuser Error 924 Fuser Error

925 Fuser Error 927 Fan Stalled 928 Erase Lamps

Diagnostic Information 2-3

Error Code 929 Toner Sensor

2-4 4059 Service Manual

Replace the controller board.

960 RAM Memory Error 961 RAM in Slot 1 is Bad.

Diagnostic Information 2-5

975 - 979 Network Card X

2-6 4059 Service Manual

Error Code 990 <device>