Lexmark Optra S Service Manual
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- Lexmark Optra S | Service Manual - Page 1
OptraTM S 4059-XXX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. - Lexmark Optra S | Service Manual - Page 2
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 All rights reserved. UNITED STATES GOVERNMENT RESTRICTED - Lexmark Optra S | Service Manual - Page 3
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 - Lexmark Optra S | Service Manual - Page 4
Smart Cartridge Service Check 2-102 Serial Port Service Check 2-104 Toner Sensor Service Check 2-104 Transfer Roll Service Check 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 - Lexmark Optra S | Service Manual - Page 5
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 - Lexmark Optra S | Service Manual - Page 6
4-55 Redrive Assembly 4-56 Right Side Frame 4-57 Smart Cartridge Contacts 4-58 Toner Sensor 4-59 Transfer Roll Assembly 4-60 5-24 Preventive Maintenance 6-1 Safety Inspection Guide 6-1 Lubrication Specifications 6-1 Scheduled Maintenance (2420/2450/2455/3455 6-2 vi 4059 Service Manual - Lexmark Optra S | Service Manual - Page 7
4059-XXX 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 - - Lexmark Optra S | Service Manual - Page 8
4059-XXX Notices and Safety Information Laser Notices The following laser notice labels may be affixed to this printer as shown: Laser Advisory Label ix 4059 Service Manual - Lexmark Optra S | Service Manual - Page 9
4059-XXX Class 1 Laser Statement Label CLASS 1 LASER PRODUCT LASER KLASSE 1 LUOKAN 1 LASERLAITE APPAREIL À LASER DE CLASSE 1 TO IEC 825 Notices and Safety Information x - Lexmark Optra S | Service Manual - Page 10
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 répond aux normes IEC 825 relatives aux produits laser de Classe I. xi 4059 Service Manual - Lexmark Optra S | Service Manual - Page 11
4059-XXX Les produits laser de Classe I sont considérés comme des produits non dangereux. Cette imprimante est équipée d'un laser de Classe IIIb (3b) (arséniure de gallium d'une puissance nominale de 5 milliwatts) émettant sur des longueurs d'onde comprises entre 770 et 795 nanomètres. L'imprimante - Lexmark Optra S | Service Manual - Page 12
condições de assistência prescritas. Laserinformatie De printer voldoet aan de eisen die gesteld worden aan klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van klasse IIIb ( 795 nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal - Lexmark Optra S | Service Manual - Page 13
4059-XXX Lasermeddelelse Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 825. Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bø - Lexmark Optra S | Service Manual - Page 14
ver Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan föreskriven serviceåtgärd. Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for usuari ni durant els serveis que satisfacin les condicions prescrites. xv 4059 Service Manual - Lexmark Optra S | Service Manual - Page 15
4059-XXX Japanese Laser Notice Chinese Laser Notice Notices and Safety Information xvi - Lexmark Optra S | Service Manual - Page 16
service personnel should understand this and take necessary precautions. Consignes de Sécurité • Ce produit a été conçu, testé et approuvé pour respecter les normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de xvii 4059 Service Manual - Lexmark Optra S | Service Manual - Page 17
Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung - Lexmark Optra S | Service Manual - Page 18
de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras os devem estar avisados deste facto e tomar os cuidados necessários. xix 4059 Service Manual - Lexmark Optra S | Service Manual - Page 19
les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d'aquest - Lexmark Optra S | Service Manual - Page 20
4059-XXX Chinese Safety Information Korean Safety Information Ozone Information This product does not produce measurable amounts of ozone gas. xxi 4059 Service Manual - Lexmark Optra S | Service Manual - Page 21
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 - Lexmark Optra S | Service Manual - Page 22
4059-XXX 1. General Information The Optra™ S Laser Printers are letter quality page printers designed to attach to IBM-compatible PC's and to most computer networks. The printer is available in eleven models. Optra S Model 1250 (4059-121) 1255 (4059-125) 1-1 4059 Service Manual - Lexmark Optra S | Service Manual - Page 23
4059-XXX Optra S Models 1620 (4059-162) 1625 (4059-165) 1650 (4059-160) 1855 (4059-185) 1855 (4059-C01) General Information 1-2 - Lexmark Optra S | Service Manual - Page 24
4059-XXX Optra S Models 2420 (4059-242) 2450 (4059-240) 2455 (4059-245) 3455 (4059-345) 1-3 4059 Service Manual - Lexmark Optra S | Service Manual - Page 25
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) General - Lexmark Optra S | Service Manual - Page 26
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 - Lexmark Optra S | Service Manual - Page 27
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 28
printer. Service error codes are indicated by a three digit error code. If a service error code is displayed, go to the "Service 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 - Lexmark Optra S | Service Manual - Page 29
4059-XXX Service Error Codes Service Error Codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover error. Replace the engine board. 903 Paperport Link Driver Error 904 Interface Violation by the controller software 905 Interface - Lexmark Optra S | Service Manual - Page 30
Tray 1 paper feed problem has been detected. Go to the "Input Tray(s) Option Service Check" on page 2-58 Roll Indicates a problem in the transfer roll area. Go to the "Transfer Roll Service Check" on page 927 Fan Stalled Indicates a printer fan stalled. Go to the "Fan Service Check" on page 2-47. - Lexmark Optra S | Service Manual - Page 31
properly, the developer drive assembly is not operating properly or the print cartridge is defective. Go to the "Remove Paper - Output Bin X is . 931-935 Printhead Error These errors represent a problem with the printhead. Go to the "Printhead Service Check" on page 2-89. 931 - Printhead: - Lexmark Optra S | Service Manual - Page 32
Check each board for correct installation and secure ground. If no problem is found, replace the FRUs in the following order: controller 939 error code. Contact your next level for software support. 941 Controller Code CRC Replace the controller board. 941 engine board. 2-5 4059 Service Manual - Lexmark Optra S | Service Manual - Page 33
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 If this does not fix the 2 is Bad. problem, replace the controller board. 964 Emulation Error 965 - Lexmark Optra S | Service Manual - Page 34
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 Byte 2 Byte 3 Byte 4 DU XX XX XX XX DU XX XX XX XX Byte 5 Byte 6 Byte 7 Byte 8 2-7 4059 Service Manual - Lexmark Optra S | Service Manual - Page 35
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 Explanation 84 xx 00 - Lexmark Optra S | Service Manual - Page 36
autocompensator DC motor stalls when attempting to pick a sheet of paper. 8E xx 11 The autocompensator DC motor takes too long to ramp up. 2-9 4059 Service Manual - Lexmark Optra S | Service Manual - Page 37
Explanation There was no envelope feeder error reported. Printer failed POST - Homing of Envelope feeder Printer failed POST - Halted Envelope Feeder The envelope 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 - Lexmark Optra S | Service Manual - Page 38
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 the duplex option. Paper was sensed during IR clear during POST. 2-11 4059 Service Manual - Lexmark Optra S | Service Manual - Page 39
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. The printer is flushing corrupted print data and the current print job is being discarded. No button actions are possible - Lexmark Optra S | Service Manual - Page 40
Go to return to Ready after the page prints. Press Menu> or until Reset Printer is on the second line of the display. Press Select to reset the printer. 2-13 4059 Service Manual - Lexmark Optra S | Service Manual - Page 41
the normal series of start-up tests after it is powered On. When the tests are complete, the printer returns to Ready. No button actions are possible while this message is displayed. The printer is in the Not Ready State, which means it is not ready to receive or process data. This - Lexmark Optra S | Service Manual - Page 42
this message for one second and then returns to the Ready message. No button actions are possible while this message is displayed. The printer is reset to No button actions are activate a printer setting possible while this changed in the menus. message is displayed. 2-15 4059 Service Manual - Lexmark Optra S | Service Manual - Page 43
thru 3). Open the rear door of Output Bin X to access the jammed pages. Insert Cartridge or Close Door This message displays when the printer's front door is open or the print cartridge is missing. If this message cannot be cleared go to "Cover Open Service Check". Diagnostic Information 2-16 - Lexmark Optra S | Service Manual - Page 44
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 - Lexmark Optra S | Service Manual - Page 45
too complex to print. 51 Defective Flash This message is displayed when the printer detects a defective flash. This error may occur at power on, or and normal operation continues. Flash operations are not allowed until the problem is resolved. 52 Flash Full This message is displayed when there - Lexmark Optra S | Service Manual - Page 46
the printer across printer is reset. 58 printer. 58 Too Many Bins Attached This error code is displayed when too many optional output bins are attached to the printer printer. 61 Defective Disk This error code is displayed when the printer and normal printer operations the printer detects - Lexmark Optra S | Service Manual - Page 47
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, the following actions can be taken: Press Menu> or - Lexmark Optra S | Service Manual - Page 48
Tray X Missing Tray X Empty Tray X Low Explanation If the toner cartridge is low, then "Toner Low" displays. The Toner Low condition clears the appropriate status, if any, displays. Note: The printer cannot detect when the envelope feeder or multipurpose feeder are low. 2-21 4059 Service Manual - Lexmark Optra S | Service Manual - Page 49
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 - Lexmark Optra S | Service Manual - Page 50
the error and continues. • If the option is experiencing a hardware problem, turn the printer off and back on. If the error occurs again, turn the printer off, remove the option and call for service. User Status Message Explanation Turn Printer OFF to Enable Option This message displays when - Lexmark Optra S | Service Manual - Page 51
On Self Test. Check for correct POST functioning of the base printer by observing the following: 1. The LED comes on. 2. 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. - Lexmark Optra S | Service Manual - Page 52
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 - Lexmark Optra S | Service Manual - Page 53
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 - Lexmark Optra S | Service Manual - Page 54
feed problem with 250 Sheet Paper Tray Option. Paper feed problem with 500 Sheet Paper Tray Option. Paper feed problem with 500 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. 2-27 4059 Service Manual - Lexmark Optra S | Service Manual - Page 55
. 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 - Lexmark Optra S | Service Manual - Page 56
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 2 Left . Check for damage to the arm or bearing assembly. 2-29 4059 Service Manual - Lexmark Optra S | Service Manual - Page 57
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 58
Open Switch/Cable Service Check FRU 1 Toner Cartridge 2 Cover Open Switch/Cable Assembly Action Check the toner cartridge to make sure it is correctly installed and that the right and left hand cartridge tracks are not the voltages on J4 with the controller board removed. 2-31 4059 Service Manual - Lexmark Optra S | Service Manual - Page 59
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 - Lexmark Optra S | Service Manual - Page 60
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 . The voltage measures +5 V dc. If incorrect, replace the LVPS. 2-33 4059 Service Manual - Lexmark Optra S | Service Manual - Page 61
. 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 - Lexmark Optra S | Service Manual - Page 62
4059-XXX 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 and J12 on the duplex system board. If no problem is found, replace the duplex system board. 2-35 4059 Service Manual - Lexmark Optra S | Service Manual - Page 63
Check the D.C. servo motor cables for signs of cuts or other damage. Check the D.C. servo motor sensor cable connector for pin damage. If no problem is found, replace the FRUs in the following order: D.C. motor assembly duplex option system board Run the Duplex Sensor Test from the diagnostics menu - Lexmark Optra S | Service Manual - Page 64
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. 2-37 4059 Service Manual - Lexmark Optra S | Service Manual - Page 65
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 - Lexmark Optra S | Service Manual - Page 66
Service Check Service with this service check, otherwise go to the Interconnect Card Service Check. Service Tip: The page 2-7. Printer does not recognize the envelope feeder as an attached at the front of the printer. Check the connector for signs the front of the printer. If incorrect, check the interconnect - Lexmark Optra S | Service Manual - Page 67
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 68
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. 2-41 4059 Service Manual - Lexmark Optra S | Service Manual - Page 69
to display "Load Envelopes" after envelopes are placed in the hopper. Service Tip: The kick rolls rotate during the attempted feed cycles. FRU , 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 - Lexmark Optra S | Service Manual - Page 70
4059-XXX 990 Service Error, Envelopes fail to feed from the hopper. FRU 1 D.C. Feed Motor Assembly 2 Envelope Feeder System Board Action Check the motor and motor not, then the tenons on the master kick gear may be sheared off. If incorrect, replace the master kick gear. 2-43 4059 Service Manual - Lexmark Optra S | Service Manual - Page 71
to feed from the hopper. Kick rolls ARE rotating. Check the deflector gap adjustment before continuing this service check. FRU 1 Deflector Gap Adjustment 2 Weight Assembly 3 Envelope Edge Guide Action Check the deflector gap adjustment. The adjustment may be too narrow. Check the weight assembly - Lexmark Optra S | Service Manual - Page 72
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 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 - Lexmark Optra S | Service Manual - Page 73
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 with the cover open and print cartridge removed. If the lamps do not - Lexmark Optra S | Service Manual - Page 74
printer is in warmup the voltage at J7-1 measures approximately +12 V dc. When the printer is running, the voltage measures approximately +24 V dc. Main Fan Service printer is powered on unless the printer is in the Power Saver mode. FRU 1 Main Fan 2 Main Fan to Engine Board Cable Action Manually - Lexmark Optra S | Service Manual - Page 75
and fan running) +12 V dc to +15 V dc (printer not running - fan running about half speed). If incorrect, replace the engine board. If this does not fix the problem, replace the main fan. Fuser Service Check Cold Fuser Service Check Error codes 920, 921, and 922 may display for a cold fuser failure - Lexmark Optra S | Service Manual - Page 76
Print Test and observe the lamp through the left side frame. If the lamp doesn't come on, unplug the printer and check the continuity between the two pins on the fuser lamp cable going to the fuser assembly. If : HOT - J2-1 - J2-2 = 2.5K ohms COLD = 150K ohms to 260K ohms 2-49 4059 Service Manual - Lexmark Optra S | Service Manual - Page 77
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.) 2 Engine Board 3 Fuser Hot Roll Backup Roll Bearings Action Check for damage to - Lexmark Optra S | Service Manual - Page 78
, 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 JP1-2 and JP2-1 to JP2-2 on the engine board. 2-51 4059 Service Manual - Lexmark Optra S | Service Manual - Page 79
4059-XXX Configuration 1 A level 1 fuser board and level 1 engine board are installed in configuration 1. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section "Fuser Solenoid Adjustment" on page 4-3. FRU Action 1 Fuser Envelope Conditioner Solenoid - Lexmark Optra S | Service Manual - Page 80
the fuser control board. If the cable does not measure continuity, replace the cable. If the cable measures continuity, replace the engine board. 2-53 4059 Service Manual - Lexmark Optra S | Service Manual - Page 81
4059-XXX Configuration 2 A level I fuser board and level II engine board are installed in configuration 2. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section "Fuser Solenoid Adjustment" on page 4-3. FRU Action 1 Engine Board Jumpers Check to - Lexmark Optra S | Service Manual - Page 82
the fuser control board. If the cable does not measure continuity, replace the cable. If the cable measures continuity, replace the engine board. 2-55 4059 Service Manual - Lexmark Optra S | Service Manual - Page 83
4059-XXX Configuration 3 A level II fuser board and level II engine board without the solenoid cable is installed in configuration 3. Note: Check the fuser envelope conditioner solenoid adjustment as described in the adjustment section "Fuser Solenoid Adjustment" on page 4-3. FRU Action 1 Engine - Lexmark Optra S | Service Manual - Page 84
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 Cable 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 - Lexmark Optra S | Service Manual - Page 85
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 - Lexmark Optra S | Service Manual - Page 86
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 aligning assembly. Repair or replace parts as necessary. 2-59 4059 Service Manual - Lexmark Optra S | Service Manual - Page 87
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 - Lexmark Optra S | Service Manual - Page 88
printer Thru Sensor. Service Tip: Check the 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 - Lexmark Optra S | Service Manual - Page 89
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 - Lexmark Optra S | Service Manual - Page 90
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 necessary. If no problem is found with the cable, replace the high capacity feeder option control board. 2-63 4059 Service Manual - Lexmark Optra S | Service Manual - Page 91
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 - Lexmark Optra S | Service Manual - Page 92
Check the flag for correct operation and installation. Run the Tray X sensor diagnostic. If incorrect, replace the high capacity feeder tray option board. 2-65 4059 Service Manual - Lexmark Optra S | Service Manual - Page 93
. If incorrect, replace the high capacity feeder option control board. The elevator tray down button does not operate. The tray moves to the upper position. Service Tip: Open the high capacity feeder option front door and check the black rubber bumper attached to the door switch spring. Be sure the - Lexmark Optra S | Service Manual - Page 94
4059-XXX 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 2 . It is advisable to replace all four wear strips at the same time. 2-67 4059 Service Manual - Lexmark Optra S | Service Manual - Page 95
tray does not move up or down. The printer recognizes that the option is installed. FRU 1 . 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 - Lexmark Optra S | Service Manual - Page 96
J1-4. The resistance measures between 10 and 15 ohms. If incorrect, replace the motor. If correct, replace the high capacity feeder control board. 2-69 4059 Service Manual - Lexmark Optra S | Service Manual - Page 97
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 98
incorrect, replace the cable. If correct, check the switch for a bent or deformed actuator lever or defective switch. If incorrect, replace the switch. 2-71 4059 Service Manual - Lexmark Optra S | Service Manual - Page 99
4059-XXX Excessive Noise or Vibration FRU 1 Motor Plate Assembly 2 Motor Drive Belt 3 Lead Screw Bearings 4 Idler Pulley 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 - Lexmark Optra S | Service Manual - Page 100
motor assembly or engine board. Service Tip: If there are noise is in the main drive, toner cartridge, fuser or main drive gearbox. Look gearbox or fuser. Repair as necessary. A service error code 936 - Transport Motor may be does not fix the problem, replace the main drive motor. Check the continuity - Lexmark Optra S | Service Manual - Page 101
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 - Lexmark Optra S | Service Manual - Page 102
. 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 operator panel assembly. If incorrect, replace the engine board. 2-75 4059 Service Manual - Lexmark Optra S | Service Manual - Page 103
following order: operator panel assembly engine board Options Service Check Service Tip: When you have a problem with any of the options installed in the 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 - Lexmark Optra S | Service Manual - Page 104
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 . If the test fails, replace the hard disk. If a problem still exists, replace the hard disk board. The "Disk Test/Clean - Lexmark Optra S | Service Manual - Page 105
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 - Lexmark Optra S | Service Manual - Page 106
, 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. 2-79 4059 Service Manual - Lexmark Optra S | Service Manual - Page 107
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 - Lexmark Optra S | Service Manual - Page 108
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 incorrect, replace the mechanical linkage/DC motor assembly. 2-81 4059 Service Manual - Lexmark Optra S | Service Manual - Page 109
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. Diagnostic Information 2-82 - Lexmark Optra S | Service Manual - Page 110
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 not correct the problem, replace the output expander mechanical linkage assembly. 2-83 4059 Service Manual - Lexmark Optra S | Service Manual - Page 111
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 - Lexmark Optra S | Service Manual - Page 112
4059-XXX 990 Service - BIN X FRU 1 D.C. Motor Mechanical Linkage Assembly (Level 2) 2 Output Expander Control Board (Level 2) Action Check the DC motor cable , replace the control board. If the voltages are correct, replace the DC motor/mechanical linkage assembly. 2-85 4059 Service Manual - Lexmark Optra S | Service Manual - Page 113
Near Full sensor will only be displayed on models that support an Output Expander that has a Dual Sensor installed. FRU Paper Feed Service Check If you have a 936 Transport Motor Error go to the "Main Drive Service Check" Replace the alignment assembly if any problem is found. Check the inner paper - Lexmark Optra S | Service Manual - Page 114
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 motor may be failing. If this problems continues, replace the autocompensator assembly. 2-87 4059 Service Manual - Lexmark Optra S | Service Manual - Page 115
, check for missing or damaged restraint pads in the tray. FRU 1 Paper 2 Autocompensator 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 - Lexmark Optra S | Service Manual - Page 116
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 printhead assembly. 2-89 4059 Service Manual - Lexmark Optra S | Service Manual - Page 117
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 118
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 119
-XXX 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 If correct, replace the engine board. FRU 1 Print Cartridge Action Check the print cartridge for any signs of damage, especially the PC drum contact on the - Lexmark Optra S | Service Manual - Page 120
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. 2-93 4059 Service Manual - Lexmark Optra S | Service Manual - Page 121
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 122
gearbox reference edge Replace the FRUs in the following order: developer drive assembly main drive gearbox assembly Replace the FRUs in the following order: toner cartridge charge roll developer drive assembly Replace the toner cartridge. 2-95 4059 Service Manual - Lexmark Optra S | Service Manual - Page 123
- 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 - Lexmark Optra S | Service Manual - Page 124
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 to the bearing. If any problems are found, replace the defective part into the bearings. If a problem is found, clean the ends of - Lexmark Optra S | Service Manual - Page 125
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 is continuity, replace the HVPS. If this does not correct the problem, replace the engine board. If J10-2 voltage is incorrect or if - Lexmark Optra S | Service Manual - Page 126
. 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 - Lexmark Optra S | Service Manual - Page 127
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. Print Quality - Residual Image Service Tip: Install a new print cartridge if available before - Lexmark Optra S | Service Manual - Page 128
the bearing to the spade terminal on the cable. If incorrect, replace the right side transfer arm assembly. If correct, replace the HVPS. 2-101 4059 Service Manual - Lexmark Optra S | Service Manual - Page 129
. If the problem continues, replace the FRUs in the following order: HVPS engine board 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 - Lexmark Optra S | Service Manual - Page 130
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 incorrect, replace the engine board. If correct, replace the smart cartridge cable. 2-103 4059 Service Manual - Lexmark Optra S | Service Manual - Page 131
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 - Lexmark Optra S | Service Manual - Page 132
from the printer. If incorrect service error. Transfer Roll Service Check Service Tip: The transfer roll is 17.0 mm (.669 inch) diameter. Any print quality problems Service Tip: The transfer roll assembly is part of the Maintenance Kit for models 2450, 2455 and 3455 printers printer is the printer. - Lexmark Optra S | Service Manual - Page 133
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 - Lexmark Optra S | Service Manual - Page 134
printer failures and verify repairs have corrected the problem. To run the printer diagnostic tests described in this chapter, you must put the printer • Input Tray Tests • Output Bin Tests • Base Sensor Tests • Printer Setup • Error Log • EP Factory Defaults Exiting the Diagnostics Mode Select Exit - Lexmark Optra S | Service Manual - Page 135
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 136
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. 3-3 4059 Service Manual - Lexmark Optra S | Service Manual - Page 137
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 The printer attempts to print the Quick Test Page from the default paper source. If the default paper source only supports envelopes - Lexmark Optra S | Service Manual - Page 138
Check the Top Margin Offset of the base printer. Duplex Sensor Test This test is used Select Sensor Test from the Duplex Tests menu. Manually actuate each of the duplex sensors. When the . The duplex motor test continues to run until the printer is powered off. - The power indicator blinks while the - Lexmark Optra S | Service Manual - Page 139
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 140
Duplex Feed 1/Feeding" message displays while the paper is feeding through the printer. - "Duplex Feed 1/Clear Paper" message displays when the paper Duplex Feed 2/Feeding" message displays while the paper is feeding through the printer. - "Duplex Feed 2/Clear Paper" message displays when the paper - Lexmark Optra S | Service Manual - Page 141
4059-XXX 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 ( - Lexmark Optra S | Service Manual - Page 142
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. 3-9 4059 Service Manual - Lexmark Optra S | Service Manual - Page 143
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 144
Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error 3-11 4059 Service Manual - Lexmark Optra S | Service Manual - Page 145
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 146
is reached the test stops. The power indicator goes on solid and the final results display. Press Return/Stop to exit the test. 3-13 4059 Service Manual - Lexmark Optra S | Service Manual - Page 147
lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of paper feeds through the printer as 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 - Lexmark Optra S | Service Manual - Page 148
Bin. - "Standard Bin/Full=CL" message displays. Manually actuate the bin sensor by moving the flag in and the "Configure Bins" printer setting is link rather than mailbox, the printer selects its own internal exit into. All output bins installed on the printer are shown on the feed test menu. 3. - Lexmark Optra S | Service Manual - Page 149
"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 - Lexmark Optra S | Service Manual - Page 150
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 test is used to determine if the sensors located inside the printer are working correctly. The following sensors can be checked: Toner - Lexmark Optra S | Service Manual - Page 151
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 152
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 menu. 2. Press Return/Stop to exit the diagnostic menu. 3-19 4059 Service Manual - Lexmark Optra S | Service Manual - Page 153
Page Count (2420/2450/2455/3455) This counter is reset by the servicer after a "80 Scheduled Maintenance" message displays (250K copies) and . When the reset operation is complete, the menu returns to the Printer Setup Reset Maintenance Count screen. Setting Configuration ID The configuration ID is - Lexmark Optra S | Service Manual - Page 154
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 transfer can be adjusted as follows: • LOW • MEDIUM • HIGH 3-21 4059 Service Manual - Lexmark Optra S | Service Manual - Page 155
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 - Lexmark Optra S | Service Manual - Page 156
and hold Select and Return. 3. Turn on the printer. 4. Release the buttons once Performing the Self Test displays. 5. 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. 3-23 4059 Service Manual - Lexmark Optra S | Service Manual - Page 157
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 - Lexmark Optra S | Service Manual - Page 158
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. 3-25 - Lexmark Optra S | Service Manual - Page 159
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 - Lexmark Optra S | Service Manual - Page 160
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 - Lexmark Optra S | Service Manual - Page 161
roll, backup roll, and associated parts as well as the paper exit guide assembly, narrow media sensor, fuser control board (which has the exit 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 - Lexmark Optra S | Service Manual - Page 162
arriving at the sensor too late. Error Message 201 - Paper Jam - Remove Cartridge This message indicates the paper is jammed between the printer's input and exit sensors. This condition can be caused by the paper exiting the pass through sensor of the option above tray x. 3-29 4059 Service Manual - Lexmark Optra S | Service Manual - Page 163
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 164
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 heating is used because low humidity increases static electricity. 4-1 4059 Service Manual - Lexmark Optra S | Service Manual - Page 165
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 - Lexmark Optra S | Service Manual - Page 166
fuser solenoid while installed in the printer. Adjust the screw on the solenoid stator and the solenoid armature. Printer Model 2420/2450/2455 1620/1625/1650/1855 3455 Solenoid Air Gap several copies of the media that displays a curl problem. It may take several tries before improvement is noticed - Lexmark Optra S | Service Manual - Page 167
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 - Lexmark Optra S | Service Manual - Page 168
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 on a new test page until you obtain the results you want. 4-5 4059 Service Manual - Lexmark Optra S | Service Manual - Page 169
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 170
table contains screw types, locations, and quantities necessary to service the printer. Each screw callout in the removal procedure graphic displays the gap to left attach 2 frame stacker duct to frame mounting 2 cartridge hold down assembly mounting 2 MPT deflector mounting 2 fuser to - Lexmark Optra S | Service Manual - Page 171
tray ITC board mounting 2 left side cover mounting 5 stacker support to right attach 2 side frame M3.5x12 mm engine board shield to attach 1 Thread Cutting left frame paper alignment assembly mounting 2 toner cartridge guide track mounting 2 left side frame to center attach 3 pan - Lexmark Optra S | Service Manual - Page 172
attach 1 (center pan - front) cross brace to right stacker duct attach 1 cable clip (main drive gearbox, BTM) mounting 2 fuser screw mounting 7 door restraint mounting 1 4-9 4059 Service Manual - Lexmark Optra S | Service Manual - Page 173
4059-XXX Reference Number Screw Type M3x8 mm Taptite Location LVPS auto compensator hanger bracket Purpose Qty mounting 2 mounting 1 M3x12 mm Taptite HVPS board mounting 1 M3x28 mm developer drive ground attach 1 Taptite (bottom hole) M3.5x8 mm upper front cover Plastite Thread - Lexmark Optra S | Service Manual - Page 174
1 M3x6 mm SEMS Machine Screw with washer fuser board mounting 1 M3.5x12 mm Plastite Thread Forming with washer printhead to EP frame mounting 3 4-11 4059 Service Manual - Lexmark Optra S | Service Manual - Page 175
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 - Lexmark Optra S | Service Manual - Page 176
4059-XXX Left Cover 1. Remove the left door. 2. Remove the five mounting screws (A). 4-13 4059 Service Manual - Lexmark Optra S | Service Manual - Page 177
4059-XXX 3. Raise the upper front cover. 4. Remove the three mounting screws (B), the print cartridge and remove the left cover. Repair Information 4-14 - Lexmark Optra S | Service Manual - Page 178
4059-XXX Right Cover 1. Raise the upper front cover. 2. Release the cover latch (A) and remove the right cover mounting screw (B). 4-15 4059 Service Manual - Lexmark Optra S | Service Manual - Page 179
4059-XXX 3. Remove the redrive assembly. 4. Remove the right side cover mounting screws (B) and (C). 5. Remove the right side cover. Repair Information 4-16 - Lexmark Optra S | Service Manual - Page 180
4059-XXX Upper Front Cover 1. Raise the upper front cover. 2. Remove the five upper front cover mounting screws (A) and remove the cover. 4-17 4059 Service Manual - Lexmark Optra S | Service Manual - Page 181
4059-XXX Laser Assembly Cover 1. Remove the left door. 2. Remove the left cover. 3. Remove the right cover. 4. Remove the rear paper deflector. 5. Press the fuser wiper cover latch and remove the cover. 6. Remove the paper full sensor flag assembly from the mounting bracket. 7. Remove the five - Lexmark Optra S | Service Manual - Page 182
4059-XXX 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. 4-19 4059 Service Manual - Lexmark Optra S | Service Manual - Page 183
4059-XXX 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. - Lexmark Optra S | Service Manual - Page 184
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 the duplex cover door actuator arm to operate the switch. 4-21 4059 Service Manual - Lexmark Optra S | Service Manual - Page 185
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 - Lexmark Optra S | Service Manual - Page 186
. Go to "Setting Configuration ID" on page 3-20. EP Frame Assembly 1. Remove the left and right side frames. 2. Remove the EP frame assembly. 4-23 4059 Service Manual - Lexmark Optra S | Service Manual - Page 187
4059-XXX Fans Auxiliary Fan (Models 2420/2450/2455/3455) 1. Remove the right cover. 2. Remove the inner EMC shield. 3. Remove the fuser wiper cover. 4. Disconnect the auxiliary fan cable from the engine board at connector J7. 5. Note the routing of the auxiliary fan cable (A) and remove the fan (B). - Lexmark Optra S | Service Manual - Page 188
4059-XXX 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. 4-25 4059 Service Manual - Lexmark Optra S | Service Manual - Page 189
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 190
4059-XXX Fuser Board 1. Remove the fuser assembly. 2. Disconnect the cables (A) from the fuser board. 3. Remove the fuser board mounting screw (B). 4. Release the fuser board from the standoff tab (C) and lift the fuser board from the fuser assembly. 4-27 4059 Service Manual - Lexmark Optra S | Service Manual - Page 191
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 192
assembly. 3. Remove the fuser lamp. 4. Gently apply outward pressure on the left and right fuser side frames (B) to release the detack housing assembly. 4-29 4059 Service Manual - Lexmark Optra S | Service Manual - Page 193
4059-XXX Fuser Transfer Plate 1. Remove the upper paper deflector. 2. Remove the fuser transfer roll. 3. Remove the inner paper deflector. 4. Lift the left side of the fuser transfer plate (A) and move the plate to the left to clear the right side from its mounting. 5. Remove the fuser transfer - Lexmark Optra S | Service Manual - Page 194
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. 4-31 4059 Service Manual - Lexmark Optra S | Service Manual - Page 195
4059-XXX 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) - Lexmark Optra S | Service Manual - Page 196
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 left and right fuser side frames to release the lower exit guide assembly. 4-33 4059 Service Manual - Lexmark Optra S | Service Manual - Page 197
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 198
4059-XXX Inner EMC Shield 1. Remove the left door. 2. Remove outer EMC shield. 3. Remove all option boards from the connector board slots. 4. Remove the inner EMC shield mounting screws (A). 5. Remove the inner EMC shield. 4-35 4059 Service Manual - Lexmark Optra S | Service Manual - Page 199
the paper tray. 2. Remove the upper deflector assembly. 3. Place the printer on its side. 4. Remove the lower deflector assembly. 5. Gently pry the inner paper deflector from the left and right mounting posts (A) located on the bottom of the printer and remove the deflector. Repair Information 4-36 - Lexmark Optra S | Service Manual - Page 200
(E) on the bottom of the printer and disconnect the compensator arm bias spring (A) from the frame. 7. Disconnect the compensator sensor cable (B) from the assembly. 8. Remove the compensator assembly mounting screw (C). 9. Remove the integrated tray compensator assembly. 4-37 4059 Service Manual - Lexmark Optra S | Service Manual - Page 201
XXX 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. Repair - Lexmark Optra S | Service Manual - Page 202
4059-XXX Interconnect Board Assembly 1. Remove the inner EMC shield. 2. Remove the engine board and shield. 3. Remove the LVPS. 4. Disconnect all cables from the interconnect board. 5. Remove the interconnect board assembly mounting screws (A). 4-39 4059 Service Manual - Lexmark Optra S | Service Manual - Page 203
4059-XXX 6. Place the printer on its back and remove the two mounting screws (A). 7. Remove the interconnect board assembly. Repair Information 4-40 - Lexmark Optra S | Service Manual - Page 204
4059-XXX Left Side Frame 1. Remove the main drive assembly. 2. Remove the left side frame mounting screws (A). 4-41 4059 Service Manual - Lexmark Optra S | Service Manual - Page 205
4059-XXX 3. Place the printer on its back and remove the four left side frame mounting screws (A). 4. Remove the left side frame. Repair Information 4-42 - Lexmark Optra S | Service Manual - Page 206
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 - Lexmark Optra S | Service Manual - Page 207
Drive Assembly 1. Remove the inner EMC shield. 2. Remove the developer drive assembly. 3. Remove the transfer shaft (A) through the bottom of the printer. 4. 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 - Lexmark Optra S | Service Manual - Page 208
4059-XXX Main Drive Motor 1. Remove the main drive assembly. 2. Remove the three main drive motor mounting screws (A). 3. Remove the main drive motor. 4-45 4059 Service Manual - Lexmark Optra S | Service Manual - Page 209
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 210
4059-XXX 2. Remove the upper deflector. 3. Remove the paper out sensor. (1250, 1620,1650 and 2420) 4. Remove the screws (A) mounting the multipurpose tray/lower deflector assembly. 5. Remove the multipurpose tray/lower deflector assembly. 4-47 4059 Service Manual - Lexmark Optra S | Service Manual - Page 211
4059-XXX 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. Repair - Lexmark Optra S | Service Manual - Page 212
Assembly Note: Pay careful attention to the cable routing through the printer before you remove the operator panel cable/cover open switch assembly. 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 - Lexmark Optra S | Service Manual - Page 213
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 - Lexmark Optra S | Service Manual - Page 214
4059-XXX Outer EMC Shield 1. Remove the left door. 2. Loosen the six outer EMC shield mounting screws (A) and remove the shield. 4-51 4059 Service Manual - Lexmark Optra S | Service Manual - Page 215
. 3. Release the input paper sensor from its mounting and remove. 4. Remove the left door. 5. Remove the two paper alignment assembly mounting screws (A) located inside the printer. Repair Information 4-52 - Lexmark Optra S | Service Manual - Page 216
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. 4-53 4059 Service Manual - Lexmark Optra S | Service Manual - Page 217
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 218
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. 4-55 4059 Service Manual - Lexmark Optra S | Service Manual - Page 219
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 220
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. 4-57 4059 Service Manual - Lexmark Optra S | Service Manual - Page 221
4059-XXX Smart Cartridge Contacts 1. Remove the upper front cover. 2. Release tab (A) and remove the contact cover. 3. Remove the contact plunger (B). 4. Remove the two screws (C) and remove the contacts (D). Repair Information 4-58 - Lexmark Optra S | Service Manual - Page 222
4059-XXX Toner Sensor 1. Remove the right side cover. 2. Remove the toner sensor mounting screw (A). Disconnect the toner sensor cable and remove the toner sensor. 4-59 4059 Service Manual - Lexmark Optra S | Service Manual - Page 223
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 224
assembly toward the left to clear the right upper cover pivot arm from the mounting bracket. 8. Remove the upper front cover hinge assembly. 4-61 4059 Service Manual - Lexmark Optra S | Service Manual - Page 225
4059-XXX Upper Front Cover Interlock Switch Assembly 1. Remove the upper front cover. 2. Remove the operator panel. 3. Remove the inner EMC shield. 4. Press the retaining tabs (A) and remove the interlock switch assembly. 5. Note the routing of the interlock switch assembly cable and disconnect the - Lexmark Optra S | Service Manual - Page 226
+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 5-1 4059 Service Manual - Lexmark Optra S | Service Manual - Page 227
4059-XXX Connector Locations 5-2 - Lexmark Optra S | Service Manual - Page 228
4059-XXX 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 5-3 4059 Service Manual - Lexmark Optra S | Service Manual - Page 229
4059-XXX Engine Board Connector Pin No. J1 Main Fan 1 2 3 J2 Fuser Board 1 2 3 4 5 6 7 8 J3 Printhead (Mirror 1 Motor) 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 + - Lexmark Optra S | Service Manual - Page 230
2 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 5-5 4059 Service Manual - Lexmark Optra S | Service Manual - Page 231
4059-XXX Connector J10 Erase/Toner Sensor/Input Sensor J11 Operator Panel Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 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 - Lexmark Optra S | Service Manual - Page 232
+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 5-7 4059 Service Manual - Lexmark Optra S | Service Manual - Page 233
7 8 9 10 J16 Staging Motor x J17 MPT Pick 1 2 J18 Auto Compensator 1 2 3 4 5 6 J19 MPT Paper Out 1 2 3 J20 Interconnect Board N/A J21 Smart Cartridge 1 (Model 3455 only) 2 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 - Lexmark Optra S | Service Manual - Page 234
4059-XXX Level 1 Engine Board 5-9 4059 Service Manual - Lexmark Optra S | Service Manual - Page 235
4059-XXX Level 2 Engine Board Connector Locations 5-10 - Lexmark Optra S | Service Manual - Page 236
8 ExitSns* J2 Thermistor J3 Thumper 1 ThermGnd 2 HRTherm 1 Ground 2 J4 Thumper Solenoid 1 2 J5 Narrow Media 1 Sensor 2 3 +42V dc ThumpB ThumpA +5 V dc Nar Media Ground 5-11 4059 Service Manual - Lexmark Optra S | Service Manual - Page 237
4059-XXX Level 2 Connector Pin No. Signal J1 Engine Board 1 2 3 4 5 6 7 8 J2 Thermistor 1 2 J3 NA J4 Thumper Solenoid 1 2 J5 Narrow Media 1 Sensor 2 3 NarMedia ThermGnd HRTherm Ground ThumpA +5 V dc ThumpB ExitSns* ThermGnd HRTherm Not Used ThumpB ThumpA +5 V dc Nar Media - Lexmark Optra S | Service Manual - Page 238
4059-XXX 5-13 4059 Service Manual - Lexmark Optra S | Service Manual - Page 239
/ 1650/1855/2420/2450/ 2455) J2 LVPS J3 LVPS J4 Autoconnect Top (Model1620/1625/ 1650/1855/2420/2450/ 2455) Pin No. 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 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 - Lexmark Optra S | Service Manual - Page 240
BTM/FNT J6 Engine Board J7 Controller Board J8 ID-1 J9 ID-2 J10 ID-3 J11 INA 1 (1250/1255) J12 INA 2 (1620/1625/1650/ 1855/2420) J13 INA 3 (2450/2455/3455) Pin No. 1 2 1 1 1 2 3 4 5 6 1 1 1 Models 1250 and 1255 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 N/A 5-15 4059 - Lexmark Optra S | Service Manual - Page 241
, 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 - Lexmark Optra S | Service Manual - Page 242
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+ 5-17 4059 Service Manual - Lexmark Optra S | Service Manual - Page 243
4059-XXX Connector Locations 5-18 - Lexmark Optra S | Service Manual - Page 244
XXX Duplex Option Board Note: Duplex connectors J10 and J11 are interchangeable. No problem results if the connectors are switched. Connector J1 Motor J2 DC Motor Sensor dc Sensor Input + Ground Top Cover Open + Ground Front Drawer Open + Ground +5 V dc Sensor Exit + Ground 5-19 4059 Service Manual - Lexmark Optra S | Service Manual - Page 245
4059-XXX Connector J9 Autoconnect, Option Below J10 Autoconnect, Option Below J11 Printer Autoconnect J12 Printer Autoconnect Pin No. 1 2 3 4 1 2 1 2 1 2 3 4 5 Signal Ground PrtxDout Ground PrtRxd +24 V dc Ground +24 V dc Ground N/A Ground PrtxDin Ground PrtRxD Level 1 Duplex Option Board - Lexmark Optra S | Service Manual - Page 246
4059-XXX 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 5-21 4059 Service Manual - Lexmark Optra S | Service Manual - Page 247
4059-XXX Output Expander Control Board - Level 1 Stepper Motor Connector J1A Autoconnect J1B J2A Autoconnect J2B J3 Pass Thru Sensor J4 Stepper Motor Pin No. 1 2 3 1 2 3 4 5 1 2 3 1 2 3 4 1 2 3 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 - Lexmark Optra S | Service Manual - Page 248
4059-XXX Connector J5 Bin Full Sensor Single Sensor Pin No. 1 2 3 4 5 Signal Ground N/C +5 V dc N/C RVsnsr 5-23 4059 Service Manual - Lexmark Optra S | Service Manual - Page 249
4059-XXX Output Expander Control Board - Level 2 DC Motor Connector J1A Autoconnect J1B J2A Autoconnect J2B J3 Pass Thru Sensor Pin No. 1 2 3 1 2 3 4 5 1 2 3 1 2 3 4 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 - Lexmark Optra S | Service Manual - Page 250
4059-XXX Connector J4 DC Motor J5 Bin Full/Near Full Dual Sensor Pin No. 1 2 3 4 5 6 1 2 3 4 5 Signal mtrout1 mtrout2 Ground Ground tach + +5 V dc Ground Ground binful binful RVsnsr 5-25 4059 Service Manual - Lexmark Optra S | Service Manual - Page 251
printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance. Safety Inspection Guide The purpose of this inspection guide • Possible safety exposure from any non-Lexmark attachments Lubrication Specifications Lubricate only when parts - Lexmark Optra S | Service Manual - Page 252
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 to "Maintenance Page Count (2420/2450/2455/3455)" on page 3-20. 6-2 4059 Service Manual - Lexmark Optra S | Service Manual - Page 253
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 - Lexmark Optra S | Service Manual - Page 254
4059-XXX Assembly 1: Covers 7-2 4059 Service Manual - Lexmark Optra S | Service Manual - Page 255
Description 1 Support, Paper 1 Spacer, Front 2450/2455/3455 1 Spacer, Front 1620/1650/2420/1250/1255/1855/1625 1 Cover, Label, TLI/ID/Serial No. - Blank 1 Cover Assembly, Lower Front 1250/1255/1620/1625/1650/1855/2420 1 Cover Assembly, Lower Front 2450/2455/3455 1 Cap, MPT 2450/2455 - Lexmark Optra S | Service Manual - Page 256
4059-XXX Assembly 1: Covers (continued) 7-4 4059 Service Manual - Lexmark Optra S | Service Manual - Page 257
Panel Assembly 1 Cover, Left Side 1250/1255/1620/1650/2420/1855/1625 1 Cover, Left Side 2450/2455/3455 5 Screw, Left Side Cartridge 3455 1 Contact, Smart Cartridge Ground 3455 2 Contact, Smart Cartridge 3455 1 Cover, Smart Cartridge Contact 3455 1 Plunger, Overstress Smart Cartridge - Lexmark Optra S | Service Manual - Page 258
4059-XXX Assembly 2: Frame 7-6 4059 Service Manual - Lexmark Optra S | Service Manual - Page 259
Plate Assembly 1 Transfer Plate Assembly 3455 1 Plate Assembly, Stacker Ground 2450/2455/3455 1 Support, Right Stacker 1250/1255/1620/1650/2420/1855/1625 1 Right Sideframe 1 Track, Cartridge Guide RH 1 Fan, Auxiliary 2420/2450/3455 1 Contact Kit PP 99A0585 3 o Contact, Doctor Blade - Lexmark Optra S | Service Manual - Page 260
4059-XXX Assembly 2: Frame (continued) 7-8 4059 Service Manual - Lexmark Optra S | Service Manual - Page 261
Activate 1 Cover, Gap 1620/1625/1650/1855/2420/2450/2455 1 Cover, Gap 3455 1 Shield, ESD Assembly with label 1 Left Side Frame 1 Board, Input Tray (ITC) 1 Frame Extension 1650/2420/1855 1 Frame Extension 2450/2455/3455 1 Pan, Motor Drip 1 Track, Cartridge Guide LH 1 Link, Gear - Lexmark Optra S | Service Manual - Page 262
4059-XXX Assembly 3: Printhead 7-10 4059 Service Manual - Lexmark Optra S | Service Manual - Page 263
4059-XXX AsmIndex 3-1 Part Number 99A0065 3-1 99A0398 3-1 99A0066 3-1 99A0829 NS Units Description 1 Printhead Assembly, 1620/1625/1650/1250/1255 1 Printhead Assembly, 1855 1 Printhead Assembly, 2420/2450/2455 1 Printhead Assembly, 3455 3 Screw, Printhead Mounting PP 99A0263 Parts - Lexmark Optra S | Service Manual - Page 264
4059-XXX Assembly 4: Paper Feed (Autocompensator) 7-12 4059 Service Manual - Lexmark Optra S | Service Manual - Page 265
4059-XXX AsmIndex 4-1 4-2 4-3 NS Part Number 99A0060 99A0067 99A0070 Units Description 1 Sensor, Paper Out Internal Tray 1 Pick Arm Assembly (250) 2 Pick Rolls 1 Screw, Hanger PP 99A0263 Parts Catalog 7-13 - Lexmark Optra S | Service Manual - Page 266
4059-XXX Assembly 5: Paper Feed - Multipurpose Unit 7-14 4059 Service Manual - Lexmark Optra S | Service Manual - Page 267
1 MPT Pad Assembly Kit o Restraint Pad o MPT Pad Assembly 1250/1255/1620/1650/2420/1855/1625 1 Deflector Assembly, MPT 1620/1650/1250/1255/2420/1855/1625 1 Deflector, Lower 2 Screw, Lower Deflector Mounting 8 mm PP 99A0263 2450 2 Screw, Lower Deflector Mounting 12mm PP 99A0263 1250 - Lexmark Optra S | Service Manual - Page 268
4059-XXX Assembly 6: Paper Feed - Alignment 7-16 4059 Service Manual - Lexmark Optra S | Service Manual - Page 269
4059-XXX AsmIndex 6-1 6-2 6-3 6-4 6-5 NS NS Part Number 99A0089 99A0492 99A0566 99A0559 99A0565 99A0490 Units Description 1 Alignment Assembly Paper Feed 1 Screw, Paper Reference Adjustment 1 Nut 1 Lever, Bellcrank Release 1 Washer, Reference Adjustment 1 Clip, Reference Ground 2 - Lexmark Optra S | Service Manual - Page 270
4059-XXX Assembly 7: Paper Feed - Output 7-18 4059 Service Manual - Lexmark Optra S | Service Manual - Page 271
99A0891 NS 99A0921 Units Description 1 Deflector Assembly, Inner 500 2450/2455 1 Deflector Assembly, Inner 250 1620/1650/1250/1255/2420/1855/1625 1 Deflector Assembly, Inner 250 1855-C01 1 Deflector Assembly Outer 500 2450/2455 1 Deflector Assembly Outer 250 1620/1650/1250/1255/2420 - Lexmark Optra S | Service Manual - Page 272
4059-XXX Assembly 8: Integrated Paper Tray - 250 Sheet 7-20 4059 Service Manual - Lexmark Optra S | Service Manual - Page 273
4059-XXX 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 Description 1 Tray, Integrated 250 Sheet 1 Tray, Integrated 250 Sheet - Lexmark Optra S | Service Manual - Page 274
4059-XXX Assembly 9: Main Drive 7-22 4059 Service Manual - Lexmark Optra S | Service Manual - Page 275
9-4 99A0954 NS NS NS 99A0260 Units Description 1 Gearbox, w/Motor 2420/2450/2455 1 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 1 Gearbox, w/Motor 3455 1 Shaft, Power Takeoff 1 Spring, Power Takeoff Shaft 1 Gear, Bevel 4 Screw, Gearbox Mounting PP 99A0263 3 Screw, Motor - Lexmark Optra S | Service Manual - Page 276
4059-XXX Assembly 10: Developer Drive 7-24 4059 Service Manual - Lexmark Optra S | Service Manual - Page 277
4059-XXX AsmIndex 10-1 10-2 10-3 10-4 10-5 Part Number 99A0135 99A0136 99A0564 Units Description 1 Developer Drive Assembly 1 Shaft, Developer Drive 1 Coupler, Gear #55 1 Screw, Developer Drive Ground PP 99A0263 2 Screw, Developer Drive Mtg PP 99A0263 Parts Catalog 7-25 - Lexmark Optra S | Service Manual - Page 278
4059-XXX Assembly 11: Fuser 7-26 4059 Service Manual - Lexmark Optra S | Service Manual - Page 279
w/220V 750W Lamp 2420/2450/2455 1 Fuser Assembly w/100V 500W Lamp 1620/1650/1855/1625 1 Fuser Assembly w/115V 500W Lamp 1620/1650/1855/1625 1 Fuser Assembly w/220V 500W Lamp 1620/1650/1855/1625 1 Fuser Assembly w/100V 500W Lamp 1250/1255 1 Fuser Assembly w/115V 500W Lamp 1250/1255 - Lexmark Optra S | Service Manual - Page 280
4059-XXX Assembly 11: Fuser (continued) 7-28 4059 Service Manual - Lexmark Optra S | Service Manual - Page 281
1 Board Assembly, Fuser w/o Driver 1250/1255 1 Board Assembly, Fuser w/Driver 1620/1650/2420/2450/2455/1855/1625 1 Board Assembly, Fuser 3455 1625 2 Bellcrank, Backup Roll 2420/2450/2455 1 Bellcrank, Backup Roll 3455 1 Guide, Fuser Entry 1620/1650/2420/2450/2455/1855/1625/3455 1 Guide - Lexmark Optra S | Service Manual - Page 282
4059-XXX Assembly 11: Fuser (continued) 7-30 4059 Service Manual - Lexmark Optra S | Service Manual - Page 283
11-36 99A0176 NS NS 99A0145 NS 99A0919 Units Description 1 Link, Solenoid 1620/1650/2420/2450/1855/1625/2455/3455 1 Sensor, Narrow Media 1 Flag, Exit Sensor 1 Guide Assembly, Lower Exit w/Narrow Media Sensor 2 Spring, Redrive Idler 2 Roller, Redrive Idler 1 Tie, Wire PP 99A0577 - Lexmark Optra S | Service Manual - Page 284
4059-XXX Assembly 12: Transfer 7-32 4059 Service Manual - Lexmark Optra S | Service Manual - Page 285
4059-XXX AsmIndex 12-1 12-1 12-2 12-3 12-4 Part Number 99A0179 99A0498 99A0349 99A0184 99A0186 12-5 12-6 12-7 NS 99A0185 99A0181 99A0354 Units Description 1 Transfer Roll Assembly 1 Transfer Roll Assembly 1855-C01 PRC 1 Arm, Transfer Roll Assembly Right 1 Spring, Transfer Roll Right 1 - Lexmark Optra S | Service Manual - Page 286
4059-XXX Assembly 13: Charging 7-34 4059 Service Manual - Lexmark Optra S | Service Manual - Page 287
AsmIndex 13-1 13-2 13-3 NS Part Number 99A0512 99A0513 99A1033 Units Description 1 Link Assembly, Charge Left Kit 1 Link Assembly, Charge Right Kit 1 Roll Assembly, Charge 1 Screw, Charge Roll PP 99A0263 Parts Catalog 7-35 - Lexmark Optra S | Service Manual - Page 288
4059-XXX Assembly 14: Electronics 7-36 4059 Service Manual - Lexmark Optra S | Service Manual - Page 289
99A0218 99A0199 99A0201 99A0203 Units Description 1 Engine Board Assembly with laser cable 1250/1255 1 Engine Board Assembly with laser cable 1620/1625/1650 1 Engine Board Assembly with laser cable 1855/1855-C01 1 Engine Board Assembly with laser cable 2420/2450/2455 1 Engine Board - Lexmark Optra S | Service Manual - Page 290
4059-XXX Assembly 14: Electronics (continued) 7-38 4059 Service Manual - Lexmark Optra S | Service Manual - Page 291
1 Interconnect Board Assembly 2450/2455/3455 o 3 Slot 1 Interconnect Board Assembly 1650/1855/2420 o 2 Slot 1 Interconnect Board Assembly 1250/1255/1620/1625 o 1 Slot 2 Screw, Int Board Mounting PP 99A0263 1 Screw, Int Board Shield Ground PP 99A0263 2 Screw, Int Shield Mounting PP - Lexmark Optra S | Service Manual - Page 292
4059-XXX Assembly 14: Electronics (continued) 7-40 4059 Service Manual - Lexmark Optra S | Service Manual - Page 293
Screw, INA Cover Mounting PP 99A0263 2 Screw, INA Cover Mounting PP 99A0263 1 Engine Board Shield Assembly 1 Shield, Inner Assembly 1250/1620/1625 1 o Cover, INA Blank 1 Shield, Inner Assembly 1650/2420/1855 2 o Cover, INA Blank 1 Shield, Inner Assembly 2450/2455/3455 3 o Cover, INA - Lexmark Optra S | Service Manual - Page 294
4059-XXX Assembly 14: Electronics (continued) 7-42 4059 Service Manual - Lexmark Optra S | Service Manual - Page 295
Fan, Main 1 Fan, Main 3455 1 Cable, Main Drive Motor 1 Gearbox, w/Motor 2450/2420/2455 1 Gearbox, w/Motor 1620/1650/1250/1255/1855/1625 1 Gearbox, w/Motor 3455 1 Cable, Integrated Tray 1 Board, Input Tray (ITC) 1 Cable, Auto Connect Bottom 1 Cable, Auto Connect Top 1650/1855/2420 - Lexmark Optra S | Service Manual - Page 296
4059-XXX Assembly 14: Electronics (continued) 7-44 4059 Service Manual - Lexmark Optra S | Service Manual - Page 297
99A0049 99A0466 99A0296 14-33 14-34 14-34A 14-34B 99A0001 99A0576 99A0815 99A0814 Units Description 1 Fan, Auxiliary 2450/2455/3455 1 Sensor, Toner Cartridge Level 1 Switch, Cover Open w/Operator Panel Cable Assembly 1 Operator Panel Assembly 1 Cable, Front Harness 2 Contacts, Smart - Lexmark Optra S | Service Manual - Page 298
4059-XXX Assembly 14: Electronics (continued) 7-46 4059 Service Manual - Lexmark Optra S | Service Manual - Page 299
/1855/2420/2450/2455 1 Solenoid Assembly, Envelope Conditioner 1620/1625/1650/1855/2420/2450/2455/3455 1 Board Assembly, Fuser w/o Driver 1250/1255 1 Board Assembly, Fuser with Driver 1620/1625/1650/1855/2420/2450/2455 1 Board Assembly, Fuser 3455 1 Cover, Fuser Assembly with Thermistor - Lexmark Optra S | Service Manual - Page 300
4059-XXX Assembly 15: 250 Sheet Tray 7-48 4059 Service Manual - Lexmark Optra S | Service Manual - Page 301
1 Screw, Switch Activate Spring Mounting PP 99A0263 3 Screw, Option Board Mounting PP 99A0263 1 Board, Option Tray 1250/1620/1650/2420/2450 1 Board, Option Tray 1255/1625/1855/2455/3455 1 Jumper, 2-pin 1 Spring, Switch Activate Parts Catalog 7-49 - Lexmark Optra S | Service Manual - Page 302
4059-XXX Assembly 15: 250 Sheet Tray (continued) 7-50 4059 Service Manual - Lexmark Optra S | Service Manual - Page 303
, Snap-In 1 Slider, Autosize 250 1 Latch, Back Restraint 1 Restraint, Back 250 Sheet Tray 1 Restraint, Side 250 Sheet Tray 1 Label, Options Circle 1255/1625/1855/2455 1 Spring, Backup Roller 1 Aligner Assembly, Paper 1 Strip Assembly, Paper Tray Insert 1855-C01 Parts Catalog 7-51 - Lexmark Optra S | Service Manual - Page 304
4059-XXX Assembly 16: 500 Sheet Tray 7-52 4059 Service Manual - Lexmark Optra S | Service Manual - Page 305
, Back 500 Sheet Tray 1 Latch, Back Restraint 1 Shaft, 500 Drive 1 Board, Tray 1250/1620/1650/2420/2450 1 Board, Tray 1255/1625/1855/2455/3455 1 Spring, Power Takeoff 3 Screw, Board Mounting PP 99A0263 1 Bearing, Drive Shaft Low 1 Aligner Assembly, Paper 1 Retainer, Aligner - Lexmark Optra S | Service Manual - Page 306
4059-XXX Assembly 16: 500 Sheet Tray (continued) 7-54 4059 Service Manual - Lexmark Optra S | Service Manual - Page 307
, Pass Thru 2 Screw, Wear Plate Mounting PP 99A0263 1 Roller, Skewed Backup 1 Retainer, Roller 1 Roll Assembly, Drive 500 1 Arm, Paper Out 500 1 Label, Options Circle 1255/1625/1855/2455 Parts Catalog 7-55 - Lexmark Optra S | Service Manual - Page 308
4059-XXX Assembly 17: 500/500 Dual Tray 7-56 4059 Service Manual - Lexmark Optra S | Service Manual - Page 309
4059-XXX 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 - Lexmark Optra S | Service Manual - Page 310
4059-XXX Assembly 17: 500/500 Dual Tray (continued) 7-58 4059 Service Manual - Lexmark Optra S | Service Manual - Page 311
1 Cable, 500 Auto Connect Top 1 Stud Assembly, 500 Frame 1 Arm, Paper Out 500 1 Board, Tray (Top) 1250/1620/1650/2420/2450 1 Board, Tray (Top) 1255/1625/1855/2455/3455 3 Screw, Board Mounting PP 99A0263 2 Nut, Dual 500 Mounting 1 Label, Options Circle 1255 - Lexmark Optra S | Service Manual - Page 312
4059-XXX Assembly 18: Duplex 7-60 4059 Service Manual - Lexmark Optra S | Service Manual - Page 313
99A0340 99A0345 99A0261 99A0432 99A0428 Units Description 1 Cover, System Board 1 Main Frame Assembly 1 Idler Assembly, Belt Tension 4 Spring, Aligner 4 Guide Assembly, Paper 2 Spring, Chassis Ground 2 Screw, Motor Mount 3 mm PP 99A0413 1 Belt, Motor 114 Gear 1 Pulley, Main Drive - Lexmark Optra S | Service Manual - Page 314
4059-XXX Assembly 18: Duplex (continued) 7-62 4059 Service Manual - Lexmark Optra S | Service Manual - Page 315
99A0916 99A0956 Units Description 1 Screw, Tray Open Switch Mounting PP 99A413 1 Sensor, Exit - Optical 1 Guide, LH Lower 1 Guide, Return LH Upper 2 Screw, LH Upper Return Guide Mounting PP 99A0413 1 Base Assembly, w/Tray Bias 1 Shaft, Duplex Drive 1 Spring, Duplex Shaft 1 Gear - Lexmark Optra S | Service Manual - Page 316
4059-XXX Assembly 18: Duplex (continued) 7-64 4059 Service Manual - Lexmark Optra S | Service Manual - Page 317
Assembly, Fixed 1 Retainer, 6 mm Top Cover PP 99A0404 1 Guide, Lower Entry 1 Guide Assembly, Paper Decurl 1 Guide, Center Drive Upper 1 Air Plenum 2 Spring, Decurl Shaft 2 mm Clutch Roll PP 99A0404 4 Feet, Duplex Base 1 Label, Options Circle 1255/1625/1855/2455 Parts Catalog 7-65 - Lexmark Optra S | Service Manual - Page 318
4059-XXX Assembly 19: Output Expander 7-66 4059 Service Manual - Lexmark Optra S | Service Manual - Page 319
4059-XXX AsmIndex 19-1 Part Number 99A0107 19-2 19-3 99A0104 99A0369 19-4 99A0052 19-5 19-6 99A0347 19-6 99A0406 19-6 99A0915 19-7 19-8 19-9 19-10 19-11 19-12 19-13 99A0571 99A0483 99A0924 99A0925 99A0482 99A0366 99A0480 19-13 99A0914 19-14 19-15 19-16 19-17 19-18 19-19 19-19 19-20 - Lexmark Optra S | Service Manual - Page 320
4059-XXX Assembly 19: Output Expander (continued) 7-68 4059 Service Manual - Lexmark Optra S | Service Manual - Page 321
4059-XXX AsmIndex 19-21 19-21 19-22 Part Number 99A0062 99A0409 99A0914 19-22 99A0374 19-23 99A0368 19-24 19-25 19-26 19-27 19-28 19-29 19-30 99A0363 99A0371 99A0361 99A0362 99A0364 99A0351 99A0370 19-30 99A0913 19-31 99A0912 NS 99A0429 Units Description 1 Level Sensor Bracket Level 1 - Lexmark Optra S | Service Manual - Page 322
4059-XXX Assembly 20: Envelope Feeder 7-70 4059 Service Manual - Lexmark Optra S | Service Manual - Page 323
NS 99A0489 NS 99A0487 Units Description 1 Paper Weight Assembly 1 Guide, Edge 1 Cover, Top 1 Clutch, Restraint/Gear 1 Cover, Right Side 1 Base Assembly 1 Support, Slide Out 7 Roller, Support 1 Motor, Stepper D.C. 1 Board Assembly, Electronic Control 1 Board Assembly - Lexmark Optra S | Service Manual - Page 324
4059-XXX Assembly 20: Envelope Feeder (continued) 7-72 4059 Service Manual - Lexmark Optra S | Service Manual - Page 325
2 Retainer, 6 mm PP 99A0404 3 Retainer, 7 mm Shaft PP 99A0404 1 Shaft, Drive Pressure Roller 1 Cable, Auto Connect Front 1 Spring, Cam Clutch 1 Label, Options Circle 1255/1625/1855/2455 1 Label, Envelope Orientation Icon 1255/1625/1855/2455 1 Deflector Guide Parts Catalog 7-73 - Lexmark Optra S | Service Manual - Page 326
4059-XXX Assembly 21: High Capacity Feeder 7-74 4059 Service Manual - Lexmark Optra S | Service Manual - Page 327
99A0671 99A0690 99A0655 99A0657 99A0948 21-23 Units Description 1 Frame, Printer Support Frame 2 3 Screw, Printer Support 2 Frame Mounting PP 99A0675 6 Washer, Printer Support Frame 2 Star PP 99A0677 6 Nut, Printer Support Frame 2, 8-32 Hex PP 99A0676 2 Clamp, Feed Frame 4 Screws - Lexmark Optra S | Service Manual - Page 328
4059-XXX Assembly 21: High Capacity Feeder (continued) 7-76 4059 Service Manual - Lexmark Optra S | Service Manual - Page 329
99A0714 Units Description 1 Nut, Door Switch Spring Mounting PP 99A0676 4 Washer, Card Assembly Mounting PP 99A0677 3 Guide, Rear Paper with thumb screws Use with 99A0696 3 Guide, Rear Paper with retainer arm Use with 99A0219 6 Screw, Top Frame Mounting PP 99A0675 1 Frame Assembly - Lexmark Optra S | Service Manual - Page 330
4059-XXX Assembly 21: High Capacity Feeder (continued) 7-78 4059 Service Manual - Lexmark Optra S | Service Manual - Page 331
Mounting PP 99A0676 1 Switch, Paper Low 1 Sensor Assembly, Paper Out/Upper Limit 3 Screw, Printer Support 1 Frame Mounting PP 99A0675 6 Washer, Printer Support Frame 1 Star PP 99A0677 6 Nut, Printer Support Frame 1 8-32 Hex PP 99A0676 10 Screw, Door to Door Frame Mounting PP 99A0675 - Lexmark Optra S | Service Manual - Page 332
4059-XXX Assembly 21: High Capacity Feeder (continued) 7-80 4059 Service Manual - Lexmark Optra S | Service Manual - Page 333
Assembly PP 99A0267 1 Gear, Feed Roll 1 Bellcrank, Roller Release 1 Card Assembly, 2000 Tray Option 1 Card Assembly, 2000 Tray Option 1255/1625/1855/2455/3455 3 Screw, 2000 Tray Option Card Mounting PP 99A0263 4 Foot, Stabilizer PP 99A0672 4 Mounting Feet PP 99A0687 Parts Catalog - Lexmark Optra S | Service Manual - Page 334
4059-XXX Assembly 21: High Capacity Feeder (continued) 7-82 4059 Service Manual - Lexmark Optra S | Service Manual - Page 335
Retention Mounting PP 99A0677 4 Screw, Bracket 250 Frame Retention Mounting PP 99A0263 2 Bracket, 250 Frame Retention 1 Arm, Paper Out 250 Sheet 1 Label, Options Circle 1255/1625/1855/2455 Parts Catalog 7-83 - Lexmark Optra S | Service Manual - Page 336
4059-XXX Assembly 22: Kiosk - Vertical Paper Adapter 7-84 4059 Service Manual - Lexmark Optra S | Service Manual - Page 337
99A0217 99A0226 99A0122 99A0137 99A0088 99A0085 Units Description 1 Bail, Support 1 Mounting, Frame Assembly 1 Shaft, Drive Rear 12 Roller 1 Frame Assembly, Right Side 1 Cover, Right 2 Belt, 160G 1 Guide, Paper Exit 2 Shaft Assembly, Drive Roller 1 Frame Assembly, Left Side 1 - Lexmark Optra S | Service Manual - Page 338
4059-XXX Assembly 23: Kiosk - Horizontal Paper Adapter 7-86 4059 Service Manual - Lexmark Optra S | Service Manual - Page 339
Number 99A0231 99A0112 99A0197 99A0209 99A0079 99A0087 99A0086 99A0905 99A0907 99A0232 99A0217 99A0122 99A0906 99A0088 99A0085 Units Description 1 Bail, Support 1 Mounting, Frame Assembly 1 Shaft, Drive Rear 12 Retainer PP 99A0240 1 Arm Assembly, Pivot 15 Screws PP 99A0234 7 Parts - Lexmark Optra S | Service Manual - Page 340
1250/1620/1650/2420/2450 1 Hard Disk, w/o Control Board 2.1GB 1255/1625/1855/2455/3455 1 Board, Hard Disk Control 1 SIMM, IPDS Board 1250/ 1620/1650/2420/2450 1 SIMM, IPDS Board 1255/1625/1855/2455/3455 1 Adapter Card, SES for SCS 1 Cable, Twinax 1 Cable - Lexmark Optra S | Service Manual - Page 341
99A0909 99A0863 99A0864 99A0865 99A0799 99A0417 99A0920 99A0945 Units Description 1 Tray Assembly, 250 Special Media 1 Cartridge, 4059 Shipping (2) 1 Cartridge, 4059 Shipping (1) 1 Hopper, Integrated Label/Letter 1 Hopper, Integrated Label/Letter Stacker 1 Hopper, Legal Label Stacker - Lexmark Optra S | Service Manual - Page 342
Caster, Locking 1 Printer Stand Grommet, Wire 2 Printer Stand Lock, Cam 1 Printer Stand Storage Shelf 1 Printer Stand Door Assembly, Cabinet 1 Printer Stand Filler, Rear Top Piece 1 Printer Stand Table Assembly, Large 1 Printer Stand Table Assembly, Small 7-90 4059 Service Manual - Lexmark Optra S | Service Manual - Page 343
4059-XXX Assembly 25:Miscellaneous (continued) AsmIndex 25 25 25 25 25 Part Number 99A0208 99A0234 99A0265 99A0295 99A0248 25 99A0301 25 99A0394 25 99A0462 Units Description 1 Parts Packet, Pulley - Kiosk 1 Parts Packet, Screws - Kiosk 1 Packaging, Short 1 Packaging, Tall with 500/ - Lexmark Optra S | Service Manual - Page 344
3-15 Output Bin Sensor Test 3-16 Output Bin Test - Standard Bin 3-15 Output Bin X Sensor Test 3-16 Print Registration 3-18 Print Tests 3-22 Printer Setup 3-19 Maintenance Page Count (2420/ 2450/2455/3455) 3-20 Restore EP Factory Defaults 3-21 Setting Configuration ID 3-20 Setting the Page Count 3-19 - Lexmark Optra S | Service Manual - Page 345
/2450/ 2455/3455) 3-20 Maintenance, Preventive 6-1 Maintenance, Scheduled (Model 2420/ 2450/2455/3455) 6-2 Messages Check Device Connection Messages 2-22 Service Error Codes 2-2 User Error Messages 2-16 User Line 2 Link Messages 2-22 User Line 2 Messages 2-20 User Status Messages 2-12 P Parallel - Lexmark Optra S | Service Manual - Page 346
4-56 Right Side Frame 4-57 Smart Cartridge Contacts 4-58 Toner Sensor 4-59 Transfer Guide Assembly Scheduled Maintenance (2420/2450/ 4-33 2455/3455) 6-2 Fuser Transfer Plate 4-30 Screw Identification Table 4-7 HVPS 4-34 Serial Wrap Test 3-12 Inner EMC Shield 4-35 Service Service Manual - Lexmark Optra S | Service Manual - Page 347
Port 2-89 Print Quality 2-91 Printhead 2-89 Serial Port 2-104 Smart Cartridge 2-102 Toner Sensor 2-104 Transfer Roll 2-105 Setting Configuration ID 3-20 the Page Count 3-19 Status Messages 2-12 Symptom Tables 2-25 Base Printer 2-25 Duplex 2-27 Envelope Feeder Option 2-27 High Capacity Feeder Option
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4059-XXX
Optra
TM
S
Lexmark and Optra are trademarks of
Lexmark International, Inc., registered
in the United States and/or other
countries.
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