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Optra
TM
S
4059-XXX
• TableofContents
• StartDiagnostics
• SafetyandNotices
• Trademarks
• Index
LexmarkandOptraaretrademarksof
LexmarkInternational,Inc.,registered
intheUnitedStatesand/orother
countries.
4059-XXX
FirstEdition: September 2002
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. Publications are not stocked at the
address given below; requests for publications should be made to your point of
purchase.
Comments may be addressed to Lexmark International, Inc., D22A/035-3,
740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may use
or distribute any of the information you supply in any way it believes appropriate
without incurring any obligation to you.
Lexmark and Optra are trademarks of Lexmark International, Inc., registered in
the United States and/or other countries.
©CopyrightLexmarkInternational,Inc.1998, 2002
All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software
clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark
International, Inc., Lexington, KY 40550.
4059-XXX
Contents
Notices and Safety Information
.......................ix
LaserNotices....................................... ix
SafetyInformation.................................. xvii
Preface
............................................. xxii
General Information
...................................
1-1
Options .......................................... 1-4
Maintenance Approach . . . ........................... 1-5
Tools Required For Service ........................... 1-5
Acronyms......................................... 1-6
Diagnostic Information
.................................
2-1
Start............................................. 2-1
ServiceErrorCodes.............................. 2-2
User Status Messages . .......................... 2-12
User Error Messages . . .......................... 2-16
Power-OnSelfTest(POST)....................... 2-24
SymptomTables................................ 2-25
ServiceChecks................................... 2-28
ChargeRollServiceCheck ....................... 2-29
CoverOpenSwitch/CableServiceCheck ............ 2-31
DeadMachineServiceCheck ..................... 2-32
DuplexOptionServiceCheck...................... 2-35
Envelope Feeder Option Service Check ............. 2-39
EraseLampServiceCheck ....................... 2-46
FanServiceCheck.............................. 2-47
FuserServiceCheck ............................ 2-48
Fuser Envelope Conditioner Solenoid Service Check . . . 2-51
Input Sensor Service Check ....................... 2-57
Input Tray(s) Option Service Check ................. 2-58
High Capacity Feeder Input Tray Service Check ....... 2-61
MainDriveServiceCheck ........................ 2-73
Operator Panel Service Check ..................... 2-74
OptionsServiceCheck........................... 2-76
OutputBinSensorStandardTrayServiceCheck ...... 2-78
Output Expander Service Check . . ................. 2-79
Paper Feed Service Check........................ 2-86
ParallelPortServiceCheck....................... 2-89
Printhead Service Check ......................... 2-89
PrintQualityServiceCheck....................... 2-91
Contents
iii
4059-XXX
SmartCartridgeServiceCheck................... 2-102
SerialPortServiceCheck....................... 2-104
TonerSensorServiceCheck..................... 2-104
TransferRollServiceCheck ..................... 2-105
Diagnostic Aids
......................................
3-1
Diagnostic Mode . .................................. 3-1
DeviceTests...................................... 3-2
QuickDiskTest................................. 3-2
DiskTest/Clean................................. 3-2
FlashTest ..................................... 3-3
DisablingDownloadEmulations .................... 3-3
DuplexTests...................................... 3-4
DuplexQuickTest............................... 3-4
DuplexSensorTest.............................. 3-5
DuplexMotorTest............................... 3-5
DuplexFeed1Test.............................. 3-7
DuplexFeed2Test.............................. 3-7
ErrorLog......................................... 3-8
ViewingtheErrorLog ............................ 3-8
ClearingtheErrorLog............................ 3-8
HardwareTests.................................... 3-9
LCDTest...................................... 3-9
ButtonTest .................................... 3-9
DRAMMemoryTest ............................ 3-10
ROMMemoryTest ............................. 3-10
ParallelWrapTest.............................. 3-11
SerialWrapTest ............................... 3-12
Input Tray Tests . ................................. 3-14
Input Tray Feed Test ............................ 3-14
Input Tray Sensor Test . . ........................ 3-14
OutputBinTest-StandardBin.................... 3-15
OutputBinFeedTest............................ 3-15
OutputBinSensorTest.......................... 3-16
OutputBinXSensorTest ........................ 3-16
BaseSensorTest .............................. 3-17
PrintRegistration ................................. 3-18
PrinterSetup..................................... 3-19
SettingthePageCount.......................... 3-19
Viewing the Permanent Page Count . ............... 3-19
Maintenance Page Count (2420/2450/2455/3455) ..... 3-20
SettingConfigurationID.......................... 3-20
RestoreEPFactoryDefaults...................... 3-21
iv
4059 Service Manual
4059-XXX
PrintTests....................................... 3-22
PrintQualityTestPages.......................... 3-23
PrintingMenuSettingsPage ...................... 3-24
AutocompensatorOperation......................... 3-25
Autoconnect System, Paper Tray Options, Envelope Feeder and
OutputExpanderOperations......................... 3-26
FuserOperation................................... 3-27
Paper Feed Jams ................................. 3-29
Repair Information
....................................
4-1
HandlingESD-SensitiveParts......................... 4-1
AdjustmentProcedures.............................. 4-2
DuplexMotorDriveBelts.......................... 4-2
Fuser Solenoid Adjustment ........................ 4-3
GapAdjustment................................. 4-3
Printhead Assembly Adjustment. . . .................. 4-4
Paper Alignment Assembly Adjustment ............... 4-5
Screw Identification Table . ........................... 4-7
RemovalProcedures............................... 4-12
Covers ....................................... 4-12
CenterPanAssembly............................ 4-18
ControllerBoard................................ 4-19
DeveloperDriveAssembly........................ 4-20
DuplexBoard.................................. 4-21
DuplexFrontCoverAssembly..................... 4-21
DuplexFrontCoverDoor......................... 4-21
DuplexFrontCoverDoorSwitch ................... 4-21
DuplexMotor .................................. 4-22
EngineBoard.................................. 4-23
EPFrameAssembly............................. 4-23
Fans......................................... 4-24
Fuser ........................................ 4-26
FuserBoard................................... 4-27
FuserCover................................... 4-28
Fuser Detack Fingers . . .......................... 4-29
FuserDetackHousingAssembly................... 4-29
FuserTransferPlate............................. 4-30
Fuser Envelope Conditioner Solenoid ............... 4-31
FuserExitFlagAssembly......................... 4-31
FuserExitRollAssembly......................... 4-32
FuserLamp ................................... 4-33
FuserLowerExitGuideAssembly.................. 4-33
High Voltage Power Supply ....................... 4-34
Contents
v
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