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1. 40 Warm up LE A0 Maintenance Kit Count 41 Memory CEET 41 Operator Panel Tests 41 Button Tester Re te me etes 41 ECD Re Mr etie dais 42 Page Count sees ere HERE TERRE 42 PaperiFeed TEE 42 Permanent Page Count 43 Print Contrast Transfer on plus machines 43 Print Fregistrationi c uci dre et tetto d pg 43 Print Test Pages tsar e E SU 43 Print ein Rea a etae D oae etie ets 44 PrntTest EE 44 NN VE 44 IEEE 45 Quick Disk daim nent ete ee Rede tiq 45 QUICK Lee ne sel Sea ate e ERA 45 SIM 46 Network Connections and Checks 47 Wrap RE 47 CAN Informator e terr tenet Re rette 48 Serial Interface Option 10 48 Function Switch Setting sss 48 Repair InformallOIn uunc raa ane en Eege 53 Handling ESD sensitive Parts 53 Adjustments tete tope Deas 54 Envelope Restraint Spring On The Envelope Feeder 54 Paper Restraint Spring On The 100 sheet Auxiliary Feeder edades caet 54 Envelope Feeder Magnet And 100 sheet Auxiliary Feeder Magnet seen 55 Fuser Drive Gear Backlash sse 56 F ser Solenoid ere e rre ER ate edes 58 Paper Feed Magnet RENE 59 Optional Paper Feed Maonet 60 Printhead Skew L
2. 108 Service Manual System Board Connectors 10R 12R 12C 12L Connector Name Ji DRAM SIMM J2 DRAM SIMM J3 ROM SIMM flash memory option J4 ROM SIMM printer microcode J5 Printhead Mirror Motor Printhead Fan J6 Laser Printhead Hsync J7 Operator Pane Output Bin Sensor J8 DC to DC Convertor J9 DC to DC Convertor J10 INA Power Card J11 LVPS J12 Envelope Feeder Magnet J13 INA Card J14 Serial J15 Parallel Port J16 Font Card J17 500 Sheet Option J18 Duplex J19 Fuser J20 HVPS Flex Includes input and toner sensors and erase lamps on transfer roller J21 Paper Drive Motor J22 Paper Pick Magnet Connector Locations 109 System Board Connectors 16L Mirror Laser Op Pan
3. 26 Paper Feed Base Printer 26 Paper Feed Duplex Unit 27 Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder 28 irm ERES 28 Paper Size Sensing Problem sss 29 Regularly Spaced Marks sse 30 Residual Imagerie rtp Le ed ts 30 Random Marks 5 gets e t RR er uet P ee RE RR 31 Skew all edes ete etre tee e esi rts 31 Skew top and bottom only 31 Stalled diamonds on 31 Vertical Void or Streak 32 Diagnostic c a on ieri oua Eel Sa Een DUE SERT E aln 33 Diagnostics Mode 33 Grouped Diagnostic 5 34 Alphabetical List of Diagnostic Aids 35 Auto Clean nel aa a er nat 35 Auto Clean Delay sse nnns 35 Auto Clean Frequency nnns 35 POP AUS eege deed feeit era ceti 36 Developed Image Test 36 Disk Re EE 36 Duplex Feed 1 Test 37 Duplex Feed 2 Testament 38 Envelope Enhance 39 Envelope Print Test 39 Error Log plus machines only 39 xi Service Manual Fuser Temperature And Warm Up 40 Fuser Temperature
4. 108 System Board Connectors 18 110 System Board Connectors 10 112 edet ee Eeer 114 Mirror Motor Cable Fan Cable 115 Operator Panel Output Bin Sensor Cable Handle Mounted Outbin 116 Operator Panel Output Bin Sensor Cable Redrive Mounted Outbin Sensor 117 Printer Ground Straps sse 119 Preventive Maintenance 121 Safety Inspection Guide sss 121 Lubrication Specifications 121 Printhead Window Cleaning Procedure 124 Cleaning The Transfer Roller 124 Scheduled Mechanical Maintenance 125 Parts Galtalog ae ee erectos 127 How To Use This Parts Catalog 127 Assembly 1 128 Assembly 2 Lower Frame seen 132 Assembly 3 Upper 136 Assembly 4 Printhead 140 Assembly 5 Paper 142 Assembly 6 Paper Feed Alignment Gears 146 Assembly 7 Paper Feed Drive 148 Assembly 8 Standard Paper Tray 200 sheet 150 Assembly 9 Paper T
5. 88 Paper Feed Rollers 89 Paper Size Switch Removal 90 Printhead Removal 91 System Board Removal sse 92 System Cable Removal sss 94 Fuser Sensor Cable 94 Torquer Motor Removal DP 94 Toner Sensor Removal sss 95 Transfer Roll Housing Removal eene 96 Upper Frame Removal E 97 Zif Connector Removal 98 Duplex Option Top Cover And Table Cover Remowval 99 Duplex Option Exit Card And Cover Remowval 100 Duplex Option Bottom Cover And Entry Sensor Card Removal 100 Duplex Option System Card And Motor Removal 102 xiii Service Manual Connector 103 Major Assembly Locations 103 erm EL 104 RIP Board Installation 105 HVP S reed WA a er decreta ene esa ed a et 106 Transfer Roller HOUSING 106 System Cable 107 System Board Connectors 10 12 121
6. xi General Information 1 Models Covered in this 1 IBN Models eec EE done 1 Lexmark Model EE 2 OPTIONS MEM ED 2 Maintenance Approach 3 un ima tem ep vel ined 4 Unique Tools Required For 4 Diagnostic Information sn 5 4039 Diagnostics Failures With Error Codes 5 Power On Self Test POST 11 Symptom Table 12 Banding o Leader edet eere Uc ee AA Le La 13 leegen DEER 13 Black Page eene te Rte dae 15 Blank Page tdeo ber Pre RR 16 Blurred or Fuzzy Print ss 17 Dead Machlne CE eres en 17 Duplex en ent ge eevee no dt ed ee 18 Fand EMON trt minime Morte vase th 19 FUSER Theory ei te ade gees 20 Fuser 920 921 or 922 20 Fuser 923 Ett ee 21 Honeycomb e ete eer a te e eene 21 Horizontal Void or Streak 22 LAN Problems 5 2 cire aa A Den ten nt 23 Bt LI d EE 23 Network Card 977 Errors 24 Network Wrap Tests 24 Output Bin Sensor sistere cete nr d 24 Operator Panel Problem 25 Paper Feed Problem 500 Sheet Second
7. J15 112 Service Manual J11 System Board 10 Connector Name Ji N A J2 DRAM SIMM J3 Option SIMM flash memory option J4 ROM SIMM printer microcode J5 Printhead Mirror Motor Fan J6 Printhead Hsync Laser J7 Operator Panel J8 N A J9 N A J10 N A J11 LVPS J12 Envelope Feeder Magnet J13 INA Hard Disk J14 HVPS J15 Parallel Port J16 N A J17 Second Paper Tray Option J18 Duplex J19 Exit amp Paper Size Sensor Fuser Solenoid J20 Input amp Toner Sensor Board Erase Lamps J21 Drive Motor J22 Torquer Motor Tray 1 pick Connector Locations 113 The printhead cable connector for 10 10R 12R 12L and 12C is J6 The printhead cable connector for 16L is J4 Printhead Cables 6 2 2 Oe 220 NE SN H sync Connector Pin 1 Mirror Motor Laser Connector Connector Fan Connector 114 Service Manual Printhead Cable Pin Laser Hsync 1 1 2 2 3 3 4 4 5 6 6 5 7 4 8 3 9 2 10 1 Mirror Motor Cable Fan Cable The mirror motor cable connector for the 10 10R 12R 12L and 12C is J5 The mirror motor cable connector for 16L is J3 Pin
8. Form tabs D away from the power supply to create clearance for tabs A to move downward Release the top latches A Release the side latches B Release the bottom latches C Repair Information 85 Operator Panel Removal 1 2 3 Remove the top cover Disconnect the operator panel cable Remove the operator panel mounting screws from the inside of the top cover Option Card Removal 1 Remove all external trays Open the top cover Open the right cover Remove the outer EMC shield Remove cable and mounting screws as required Pop the card off the plastic standoffs 86 Service Manual Exit Sensor Removal 1 2 8 4 e Remove the front cover Disconnect the fuser sensor cable Disconnect the thermistor cable Disconnect the fuser solenoid cable This cable is not present in all models Release the latches A Pull the sensor down to remove it Repair Information 87 Paper Feed Magnet Assembly Removal 1 Cr GNM 9 Remove the print cartridge Remove the right cover Remove the system board Remove the inner EMC shield Locate the paper feed magnet mounting screw B visible through the right side frame A Remove the mounting screw B Remove the paper feed magnet assembly from the rear slip the connector under the right frame 88 Service Manual Paper Feed Rollers Removal Note
9. 1 2 3 4 Set the paper exit lever to use the front exit Print the test page As soon as the leading edge of the paper is visible coming out the front exit slot turn off the printer Remove the print cartridge and look at the image on the photoconductor Disk Test Clean This is a two hour test that should be performed only on a disk that contains bad data and is therefore unusable This test destroys all data on the disk by doing a multi pass write read on every block of the disk Bad blocks are flagged and removed from use If over 2000 bad blocks are found the test stops and the display indicates the disk must be replaced 36 Service Manual message describing test progress is displayed during the test Io c e Enter Diagnostics mode Select Device Test Select Disk Test Clean Select CONTINUE to start the test or CANCEL to return to Diagnostics mode main menu Select CANCEL to interrupt the test Press Return to return to Diagnostics mode main menu Duplex Feed 1 Test This test checks for slipping paper problems It verifies that the paper is entering the duplex unit far enough for the trailing edge to clear the selector fingers before the paper reverses direction 1 2 3 4 Enter Diagnostics mode Select Duplex Tests Select Duplex Feed 1 Select Tray 1 or Tray 2 Note Paper feeds all the way into the duplex unit and stop 5 6 T The message CLEAR
10. 24VDC Make the following voltage checks while printing and again while idling If the voltages are not correct replace the system board 10R 12R 12C 16L Voltage while Voltage while 12L Printing Idling J20 1 to J20 4 17 1 to J17 4 Less than 21 26VDC 1VDC J20 2 to J20 4 J17 2to J17 4 Greater than Less than 1VDC 0 5VDC 10P Voltage while Voltage while Printing Idling J14 1 toJ14 4 Less than OVDC 5VDC J14 2 to J14 4 Less than OVDC 5VDC Diagnostic Information 15 Inspect the printhead shutter for proper operation and make sure the actuator on top of the cartridge is present and extends into the printhead shroud when the printer top cover is closed A failed printhead will cause a 931 Service error rather than blank output Check the continuity of the HVPS cable The HVPS and transfer roll contacts should be clean and spring back when pressed Make sure the transfer roll contact under the left bearing is making contact with the HVPS Make the following voltage checks while running the print test continuously and again while idling 10R 12R 12C 16L Voltage while Voltage while 12L Printing Idling J20 1 to J20 4 J17 1 t0 J17 4 Less than 21 26VDC 1VDC J20 2 to J20 4 J17 2toJ17 4 Greater than Less than 1VDC 5VDC J20 3 to J20 4 J17 3toJ17 4 The meter Less than should fluctu 5VDC ate slightly between each page J20 8 to J20 4
11. Fuser Input Guide Removal 1 Remove the fuser input guide B by lifting the rear end of the guide and unsnapping both sides from the fuser Lift the fuser input guide upward at both sides near the fuser and slide the guide toward the rear of the machine to release Lift the guide out of the machine Clean the fuser input guide before installing it 74 Service Manual Repair Information 75 Fuser Lamp Removal CAUTION THE TEMPERATURE OF THE HOT ROLLER IS 150 2230 302 2446 F USE EXTREME CAUTION WHEN REMOVING THIS UNIT BEFORE YOU SERVICE THIS UNIT ALLOW THE MACHINE TO COOL FOR 5 MINUTES Note The fuser lamp is a glass heater Do not touch the lamp with your hands skin oils and acids can reduce the life of the heater lamp Use a soft cloth to handle the heater lamp at all times if the lamp is to be reinserted 1 Remove the fuser 2 Remove the right lamp bracket A 3 Carefully pull the lamp B out to the right using a soft cloth if the lamp is to be reinserted IN 76 Service Manual Fuser Solenoid Removal Remove the fuser 1 2 Remove the two mounting screws A holding the solenoid housing to the fuser housing 3 Disengage the solenoid bracket from the plunger Note When a new solenoid assembly is installed the fuser solenoid must be adjusted Repair Information 77 Fuser Thermistor Removal 1 e Disconnect the thermistor cable connector A from the exit senso
12. Printhead 10P Printhead 10R 12R 12C 12L 16L Printhead Shroud Assembly Cable Fan Mirror Motor Cable hsync Laser Cable Tie Pin Parts Packet Spring Parts Packet Screw Printhead Mtg Parts Packet Screw Hex Headed Parts Packet Pointer Parts Packet Retainer Parts Packet Parts Catalog 141 Assembly 5 Paper Feed 142 Service Manual Part Number 1039101 1183597 1381670 1381636 1383430 1039102 1408859 1383315 1328385 1328314 1039170 1328648 1328317 1039175 1042211 1328192 1328193 1039058 1328172 1042205 1328168 1042206 1328169 1042207 1328173 1381073 1328323 1328322 1328321 1383313 1381015 1183244 1 D Description Outer Deflector Upper Deflector Inner Deflector with Roller Input Sensor Board 10 Input Sensor Board 10R 12R 12C 12L 16L Lower Deflector 10R 12R 12L 16L Lower Deflector 10P 12C Flag Input Sensor Parts Packet Right Rail Asm With Gears 10R 12R 12C 12L 16L Right Rail Asm Without Gears Machine Pad 10R 12R 12C 10P Toner Shield Left Frame Tray Frame Spring Belt Redrive 10R 12R 12C 10P Belt Redrive 12L 16L Belt Auxiliary 12L 16L Shaft Asm Lower Redrive 10R 10P Shaft Asm Lower Redrive 12R 12L 12C 16L Deflector Redrive 10R 10P 12R 12C Deflector Redrive 12L 16L Shaft Asm Upper Redrive Shaft Asm Auxiliary Shaft 12L 16L Shaft Asm Middle Redrive 10R 10P Shaft Asm Middle Redrive 12R 12C 12L 16L Toner Sens
13. 20 4 J17 3toJ17 4 The meter Less than should fluctu 5VDC ate slightly between each page J20 8 to J20 4 J17 8toJ17 4 Less than 21 26VDC 1VDC Voltage 10P Voltage while Printing while Idling J14 1to J14 4 Less than 5VDC OVDC J14 2 to J14 4 Less than 5VDC OVDC J14 3to J14 4 The meter should OVDC fluctuate slightly between each page J14 8 to J14 4 1VDC 6VDC If any voltages are not correct replace the system board Note Contrast on the Diagnostics menu changed to Transfer on 4039 plus machines does not adjust the print contrast but changes the transfer algorithm slightly Users who run large jobs with very dense graphics in high humidity environments may get some print quality improvement from changing this setting users with more normal jobs will see no difference Make sure the HVPS contacts to the transfer roll housing are in good condition 14 Service Manual Black Page Black output is usually caused by an incorrect high voltage in the printing process resulting in toner development on the entire photoconductor drum Check the condition of each HVPS contact and make sure they spring back when pressed Check the continuity of the HVPS cable Make sure the following voltages are correct if they are not replace the system board 10P 10RA2R 12C 16L Voltage 12L J14 5toJ14 4 J20 5to J20 4 J17 5toJ17 4 24VDC J14 6 toJ14 4 J20 610 J20 4 J17 6toJ17 4
14. On Off 1 200 Off On Off Off 2 400 Off Off On Off 4 800 Off Off Off Off 9 600 default On On On Off 19 200 Off Off Off On 38 400 RS 422 only Switch 5 Data Bits Switch 5 selects the number of data bits 7 or 8 in each data frame 5 DATA BITS Off 8 On 7 Switch 6 and 7 Parity Switches 6 and 7 select the interface parity 6 7 Parity Off Off No Off On Ignore On Off Odd On On Even Note When setting the Ignore for parity the printer ignores the received parity and transmits using Even parity For all other parity settings the transmitted parity matches the received parity Diagnostic Aids 49 50 Switch 8 Buffer Size Switch 8 allows the adapter buffer size to be limited to minimize the amount of data in the buffer at any time 8 Buffer Size Off Normal On Minimum Switch 9 Protocol Switch 9 selects the type of protocol 9 Protocol Off DTR pacing RS232 only On XON XOFF Switch 10 Print Test Switch 10 selects the print test for the serial interface card This tests the connection between the serial interface unit and the printer The printout contains the serial interface unit code level and switch settings and the printer character set Note For the serial print test to work Advanced Status found under the PARALLEL SETUP menu must be set to
15. Replace all paper feed drive rollers at the same time Remove the lower frame Disconnect the system cable from the input sensor Remove the screws A and the outer deflector Remove the screws B and the toner shield E Separate the side frames Pull the guides C out of the side frames Use a flat blade tool to snap the gears and rollers D off the shaft N O1 bah Left Rear View Repair Information 89 Paper Size Switch Removal 1 Open the top cover Remove the print cartridge Remove the paper tray Open the right side cover Remove the front cover Remove the two screws A Unplug the cable B from the switch connector C Rotate the switch about 90 and pull it out of the printer B 7 i ET 90 Service Manual Printhead Removal IMPORTANT The printhead is ESD sensitive It is not serviceable and should be replaced as a unit Dg D gt Turn the printer off Remove the print cartridge Remove the right and top covers Remove the exit redrive and its belt Remove the air plenum Remove the screws A and the pointer if present Cut and discard the printhead cable clamp Disconnect the connectors B Remove the printhead and the printhe
16. rperlicher Verletzung existiert w hrend des Auseinandernehmens und der Wartung des Ger ts Fachpersonal sollte im vollen Verst ndnis der Lage entsprechende VorsichtsmaBnahmen ergreifen Ersatzteile m ssen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen da Sicherheitsvorkehrungen nicht immer offensichtlich sind Consignes de S curit Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Les normes de s curit de certaines pi ces n tant pas toujours explicites les pi ces de rechange doivent tre identiques ou conformes aux caract ristiques des pi ces d origine Notices and Safety Information vii Norme di sicurezza Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell assistenza autorizzato Durante lo smontaggio e il manutenzionamento di questo prodotto possibile il rischio accresciuto di scosse elettriche e danni personali Il personale di assistenza autorizzato consapevole di ci deve adottare le precauzioni necessarie E possibile che le funzioni di sicurezza di alcuni elementi non siano cosi ovvie quindi i pezzi di ricambio devono avere caratteristiche identiche o equivalenti a quelle dei
17. 1383586 1 Grease damping 1 oz 5 9900692 1 Grease IBM 23 2 1280443 1 Oil IBM 10 4 oz 1381035 1 Duplex Gears parts packet 1381048 1 Duplex Flags parts packet 1381963 1 Twinax serial debug cable 1381964 1 Coax serial debug cable Parts Catalog 173 174 Service Manual Index A abbreviations 4 auto clean 35 auto clean delay 35 auto clean frequency 35 background 13 banding 13 black page 15 blank page 16 blurred or fuzzy print 17 button test 41 connector locations 103 covers assembly 128 removal 64 D dead machine 17 defaults 36 developed image test 36 diagnostic aids alphabetical 35 grouped 34 diagnostics mode 33 disk test clean 36 drive motor removal 70 D roll assembly removal 69 duplex feed 1 test 37 duplex feed 2 test 38 duplex option assembly 168 bottom cover entry sensor card removal 100 exit card and cover removal 100 problems 18 system card and motor removal 102 top cover table cover removal 99 E electronics assembly 162 envelope enhance 39 envelope print test 39 Envelope and 100 sheet auxiliary feeder assembly 170 Envelope feeder adjustments envelope restraint spring 54 magnet 55 errorcodes 5 error log 39 ESD sensitive parts 53 exit sensor removal 87 F fan cable locations 115 927 error 19 fan redrive removal 72 frame lower frame assembly 132 lower frame assembly removal 83 upper frame assembly 136 upper frame removal 97 fu
18. PAPER appears on the display Slide the tray extension all the way out until it stops Push a small screwdriver through the lower end of one of the ventilation slots and through the sheet of paper fed in under the slot Open the cover and remove the sheet of paper Measure the distance from the mark on the paper to the trailing edge of the paper If the mark or hole is more than 95 mm from the trailing edge there is a paper slipping problem with the duplex unit paper feed Diagnostic Aids 37 Duplex Feed 2 Test This test verifies that paper feeds through the duplex unit properly and tests the stop point of the page as it feeds back over the top of the duplex paper tray Seco ence Enter Diagnostics mode Select Duplex Tests Select Duplex Feed 2 Select Tray 1 or Tray 2 Note Paper feeds all the way into the duplex unit and then feed out and stop on top of the paper tray 5 6 T 11 The message CLEAR PAPER appears on the display Open the printer top cover If you are doing the test with legal size paper open the top cover of the duplex unit Carefully remove the duplex unit from the printer without disturbing the position of the paper on the top of the duplex tray Do not disconnect the duplex cable from the printer Without changing the position of the page hold it to the top of the paper tray and remove the paper tray Measure from the leading edge of the page to the leading edge of the
19. Service Manual If the thermal fuse has blown the fuser and the fuser wiper will be damaged Before replacing the fuser and the fuser wiper check the voltage at 10P J11 16 10R 12R 12C 12L J11 3 16L J18 16 as you POR again It should stay at 0 until the 922 Error is displayed and then go to 24VDC 10P 5VDC if it does not replace the system board the fuser and the fuser wiper Next measure the voltage to the fuser lamp during a POR it should be line voltage until the 922 Error is displayed if it is not replace the LVPS the fuser and the fuser wiper If the voltage to the fuser lamp is the not the same as the line voltage replace the LVPS If the lamp fuser power cable thermal fuse thermistor and lamp voltage are OK check 10P J11 16 10R 12R 12C 12L J11 3 16L J18 16 to see if the system board is sending the correct signal to the TRIAC At POR this signal should go to 24VDC 10P 5VDC and then immediately drop to OVDC until the fuser is warm if it does not replace the system board If the signal is OK replace the LVPS Fuser 923 Error Check the connection and continuity of the cable from the fuser exit sensor board to system board 10P 10R 12R 12C 12L J19 16L J16 Check the thermistor condition and connection Check the thermistor resistance at system board 10P 10R 12R 12C 12L J19 5 to J19 6 16L J16 5 to J16 6 It should be from 100K Ohms to 260K Ohms when cold it may be as low as 2 3K Ohms when hot but inc
20. Services Department Westthorpe Marlow Bucks SL7 3RQ Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you Copyright Lexmark International Inc 1996 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington Ky 40550 Notices and Safety Information References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property rights may be used instead Evaluation and verification of operation in conjunction with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Electronic Emission Notices Consult the following list for any emission that may apply in your country Federal Communications
21. as 977 Enter Diagnostics mode Select Error Log Select CLEAR and then CONTINUE to clear the error log Press Return to return to Diagnostics mode main menu DO Le Diagnostic Aids 39 Fuser Temperature And Warm Up Time These settings allow adjustment of the fuser to correct problems with paper curl or melting letterheads Paper curl in which the top and bottom of the page curl toward the printed side hot paper curl can be corrected by reducing the fuser temperature Reduce the setting from Normal to No Boost if necessary reduce the setting further to Low Temperature Verify that the toner is being adequately fused to the paper at the new temperature setting Paper curl in which the edges of the paper curl toward the printed side cold paper curl can corrected by increasing the fuser warm up time Use the lowest setting that corrects the problem Setting 0 is the factory default and is the shortest warm up time Setting 5 increases warm up time by 90 seconds lower settings increase the time proportionately less Settings other than 0 may reduce throughput Use the or key to change the number and then select save Melting letterheads may be prevented by reducing the fuser temperature as described above for paper curl Fuser Temperature 1 Enter Diagnostics mode 2 Select Fuser Temperature 3 Select Normal No Boost Or Low Temperature 4 Press Return to return to the Diagnostics mode
22. been requested to be written to disk 6 Service Manual Error Code Action 63 Unformatted or Defective Disk The printer will ignore a disk it senses as defective Run the Quick Disk Test If the test fails the disk is defective or the data on track1 is bad If the Quick Disk Test passes but the disk does not work run the Disk Test Clean 2 hr test Replace the disk if instructed by the operator panel 7X Network Card Codes These user codes are documented in various network card user manuals See Network Wrap Tests on page 24 80 Scheduled Maintenance Printer has reached 200 000 prints 12C 100 000 prints without maintenance count reset 88 Toner Low Toner sensor detects low toner 90X Software Error Unrecoverable software error If one of these errors appeared during POST or while the printer was idle not printing or receiving data or while trying to print one of the internal test pages replace the system board If the error appeared while sending a job from the host to the printer turn the printer off then turn it on and try again If the error appears again call the next level service support for assistance 917 Transfer Roll Error Cannot start servo operation Verify correct cable connections from the Engine board to the HVPS Make sure there is continuity between the transfer roller and its contact on the HVPS replace the transfer roll if the continuity
23. checklist If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover e Possible safety exposure from any non Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts Use IBM no 10 oil PN 1280443 approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 to lubricate the areas of contact between e Gear no 2 and its stud on the side plate e Gear no 3 and its stud on the motor bracket e Gear no 4 and its thrust washer e Gear no 4 and its stud on the motor bracket e Gear no 5 and its stud on the motor bracket Preventive Maintenance 121 e Gear no 6 and its stud on the motor bracket e Gear no 6 and its thrust washer e Gear no 7 and its stud on the rail e Gear no 7 and its thrust washer e Gear no 8 and its stud on the rail e Gear no 8 and its thrust washer Gear no 9 and its stud on the rail The metering roller shaft and its bushings on the rail assembly The main metering backup r
24. housing Remove the D roll Disconnect the system cable from the input sensor board Note Use care the flag can be damaged while removing the sensor Release latch B and pull the sensor down and forward to get it out of its mounting Disconnect the toner sensor cable from the board Remove the sensor board 82 Service Manual Lower Frame Assembly Removal 1 em 10 11 Remove the right front and left covers Remove the LVPS and the rod for the on off switch Remove gear cover and the fuser input guide A Remove the transfer roll housing Disconnect the cable from the HVPS Remove the system board and the inner EMC shield Disengage the upper frame cables from the guide in the paper feed side frame Remove the screws B Remove the fuser cover Unplug the fuser wires C and push them below the HVPS Unplug the paper size switch cable 12 Lift the lower frame assembly straight up to separate it from the paper feed assembly Repair Information 83 LVPS Removal 1 Disconnect the power cord 2 Remove all external feed trays 3 Remove the left and right side covers 4 10P and 16L remove the system board and the inner EMC shield e Remove the left and right LVPS mounting screws Disconnect the fuser connector A 7 Liftthe supply up and then toward the right side frame to disconnect the On Off switch linkage D 84 Service Manual LVPS Cover Removal 1
25. most noticeable on fine dot or horizontal line patterns such as the second page of Print Test 2 or Print Test 3 Inspect the gear train and the paperfeed rollers for wear damage dirt or binds Background Areas that are supposed to stay blank are getting small amounts of toner deposited on them Clean the erase lamps and the printhead window Run the diagnostic Paper Feed Test and verify that all the erase lamps turn on If not verify that there is 24VDC on pin 10R 12R 12L 12C J20 16 16L J17 16 10 J20 1 and between 15 and 20VDC on pin 15 pin 2 on 10P Shorting pin 15 pin 2 on 10P to ground should turn on all the erase lamps Check the erase lamp cable continuity Replace the transfer roll housing if the voltage and the cable are good Inspect the contacts on the HVPS make sure each spring loaded contact returns when pressed and released Rough Paper mode can cause background on some papers if Rough Paper mode is on turn it off and run the print test again Printing on coated paper or using refilled print cartridges can also cause background Run the print test in continuous mode and check the following voltages then stop the test and check the voltages again Diagnostic Information 13 10R 12R 12C 16L Voltage while Voltage while 12L Printing Idling J20 1 to J20 4 17 1 toJ17 4 Less than 21 26VDC 1VDC J20 2 to J20 4 J17 2toJ17 4 Greater than Less than 1VDC 5VDC J20 3 to
26. serial port 7 Select Single or Continuous 8 Select CANCEL to stop continuous A PASSED message indicates the printer connection to the printer cable connector is good A FAILED message indicates a defective system board Note Ignore the number displayed after a failure is displayed 9 Press Return to return to the Diagnostics mode main menu 10 Turn the printer off then remove the wrap plug from the interface connector Diagnostic Aids 47 LAN Information The printer may be connected to one of the following LAN types Token Ring Ethernet 10BaseT Ethernet 10Base2 LocalTalk The Network external connectors are pictured below The printer test page also indicates to which type of LAN the printer is connected ove 0000 o O O O OO Ring Ethernet 10Base2 Ethernet 10BaseT LocalTalk Serial Interface Option 10P The serial interface unit switch settings determine how the printer receives data from the computer or terminal Set the switches according to your particular equipment requirements The serial interface has 12 function switches Function Switch Setting Switches 1 to 4 Speed Switches 1 through 4 define the serial interface speed in bits per second bps 1 2 3 4 SPEED BPS On On Off Off 150 On Off On Off 300 On Off Off Off 600 48 Service Manual 1 2 3 4 SPEED BPS Off On
27. through the right frame Torquer Motor Removal 10 1 2 3 4 5 Remove the lower frame assembly from the base Remove the D roll Remove the D roll shaft gear assembly taking care not to lose the two bushings Remove the two screws and remove the torquer motor and adapter Unsnap the adapter from the motor Note When reinstalling align the timing marks on the torquer motor gear and D roll gear 94 Service Manual Toner Sensor Removal 1 Remove the fuser input guide A 2 Remove the transfer roll housing 3 Lift the input sensor board far enough to disconnect the cable B 4 Remove the end of the bellcrank spring Lift the sensor to unsnap it 6 Work the cable out of the frame and remove the sensor e Repair Information 95 Transfer Roll Housing Removal 1 2 3 Remove the print cartridge Remove the fuser input guide Grasp the housing and pull toward the front of the machine to disconnect the housing from the mounting studs visible through openings B in the inner deflector Lift the transfer roll housing far enough to disconnect the system cable Lift the transfer roll housing out of the machine To replace the transfer roll housing perform the removal procedure in reverse order After replacing the Transfer Roll Housing open the top cover power the machine off then on to ensure the erase lamps flash off and on 96 Service Manual Upper Frame Removal Unplug
28. 12C o Shaft o Bellcrank o Roll o Thrust Washer Kit Prealigner and Metering Rollers Gear Idler Prealigner Spring Prealigner and Metering Bellcranks Parts Packet Bellcrank Prealigner 10P 10R 12R 12L 16L o Shaft o Roll o Bellcrank o Thrust washer Bellcrank Prealigner 12C Anchor Repair Kit Metering Anchor Repair Kit Prealigner Parts Catalog 147 Assembly 7 Paper Feed Drive 148 Service Manual EN 12 13 14 15 16 Part Number 1328311 1408705 1328279 1126832 1328385 1328314 1328313 1328454 1408482 1383315 1383316 1383433 1383318 1383318 1408259 1383318 1383318 1383318 1383314 1383316 1383314 1383314 1383315 1383318 1383315 1039170 1381306 1408243 1381663 Description D Roller Asm 10R 12R 12L 16L D Roller Asm 10P 12C Washer Thrust Clip D roll Rail Assembly Right With gears 10R 12R 12C 12L 16L Rail Assembly Right W O gears Shield D Roll Shaft D Roll with Gear 11 10R 12R 12C 12L 16L Shaft D Roll with Gear 11 10P Bushing Parts Packet Spring Gear Advance Parts Packet 10R 12R 12C 12L 16L Clutch Magnet Asm 10R 12R 12C 12L 16L Gear No 14 Sheet Feed Parts Packet Gear No 9 Parts Packet 10R 12R 12C 12L 16L Gear No 9 10P Gear No 7 Parts Packet Gear No 8 Parts Packet Gear No 10 Parts Packet Screw Clutch Mag Mtg Parts Packet 10R 12R 12C 12L 16L Spring Magnet Arm Parts Packet 10R 1
29. 250 Ohms If paper is not feeding correctly check the magnet adjustment Paper Feed Base Printer Run the print test or the diagnostic paper feed test and carefully examine the area of the problem If paper is not feeding make sure the paper is in the tray correctly and is not damaged or stuck together Make sure the D roll is in good condition and rotates when the magnet is picked With the 500 sheet trays make sure the tension wheel is set high enough to give good contact between the D roll and the paper stack 10R 12R 12C 12L 16L Make sure the pick magnet is being energized The pick magnet should have a resistance of 100 to 250 Ohms The voltage at 10R 12R 12C 12L J22 2 16L J19 2 should be 34V between picks and drop to about 30VDC it actually drops to zero but most meters will not react quickly enough briefly during the pick listen for the noise of the solenoid at the same time the voltage changes The magnet can be tested by shorting pin 2 to ground and listening for it to pick 10P The 10P has a torquer motor to activate the D roll It is connected at J22 of the system board the voltage check is the same as the 10R 12R 12C 12L 16L The resistance of the motor is 88 Ohms The motor can be tested by shorting pin 2 to ground and listening for it to pick If paper feeds but stops undamaged in the paper path there may be a sensor problem Run the diagnostic test for the input and exit sensors replace as necessary Check th
30. 2R 12C 12L 16L Washer Parts Packet 10R 12R 12C 12L 16L Washer Thrust Parts Packet Bushing Gear 10 Parts Packet Gear 13 Parts Packet Clip Parts Packet Machine Pad Torquer Motor 10P Adapter Torquer Motor 10P Screw Torquer Parts Packet Parts Catalog 149 Assembly 8 Standard Paper Tray 200 sheet 150 Service Manual Part Number 1183260 1183276 1183367 1058272 1183376 1183266 1183275 1183163 1408567 1183329 1183330 1039562 1058486 Description Paper Tray Assembly 11 in 200 sheet Paper Tray Assembly 14 in 200 sheet Heavy Duty Paper Tray Assembly 11 in 200 sheet Heavy Duty Paper Tray Assembly 14 in 200 sheet Paper Tray Assembly A5 11 in Cover 14 in Cover Paper Stop Corner Buckler Liner 11 in Liner 14 in Adjustable Guide Universal Paper Tray Adapter Parts Catalog 151 Assembly 9 Paper Tray 500 Sheet 152 Service Manual Part Number 1195837 1195831 1183801 1183804 1183357 1183359 1039582 1408851 1408882 1183262 1183298 1183266 1183275 1195835 1383385 1424558 1383385 1383390 1383390 1039597 1383385 Description Paper Tray Assembly 11 in Paper Tray Assembly 14 in Bottom Cover 11 in Bottom Cover 14 in Base 11 in Base 14 in Paper Guide Slide 11 in Slide 14 in Paper Stop Slider Paper Stop Cover 11 in Cover 14 in Pivot Plate with label Retaine
31. 4 1326041 1326042 1326043 1381025 1326113 1038708 1326064 1381033 1381582 1381034 1381035 1381048 Description Top Cover Asm with fan Duplex System Card Bottom Cover Exit Sensor Cover Exit Sensor Asm Bellcrank Table Cover Floor Paper Stop Slide Gear Block Frame Asm Input Sensor Card Duplex System Cable Cable Stepper Motor Cable Sensor Paper Feed Motor DC Switch Asm Cover Open Belt Paper Tray Belt Paper Drive Tray Asm 300 w Top Cover 12L 16L Tray Asm 130 w Top Cover 10R 12R 10P Top Cover Paper Tray Gear Parts Pack Flag Parts Pack 4 Parts Catalog 169 Assembly 16 Envelope 100 Sheet Auxiliary Feeder 170 Service Manual s Description Index Number 16 1183151 Envelope Feeder 1183966 1 100 Sheet Auxiliary Feeder 1 1183226 1 Weight Assembly 2 1622529 1 Screw 3 1039615 1 Spring 4 1383944 1 Magnet Assembly 5 1622303 1 Washer 6 1622536 1 Screw Mtg 7 1183587 1 Cover Right 8 1183155 1 Guide Large 8A 1183160 1 Latch Guide 9 1328459 1 Guide Small 10 1183273 1 Spring Override Lever 100 Sheet Auxiliary Feeder Only NS 1383934 1 Roller Pack Envelope Feeder Only NS 1383935 1 Roller Pack 100 Sheet Auxiliary Feeder Only Parts Catalog 171 Assembly 17 Options Part Units Description Index Number 17 2 1328586 1 1MB Flash SIMM 3 1328585 1 2 Flash SIMM 4 1376461 1 4MB Flash SIMM 5 132858
32. 508 1328482 1328189 Description Manual Feed Tray with guide Screw Deflector Spring Mtg Parts Packet 1383314 Cover Duplex mtg slot Screw Deflector Switch Mtg plate Parts Packet 1383314 Front Exit Door Parts Catalog 131 Assembly 2 Lower Frame 132 Service Manual Part Number 1381120 1381001 1381046 1381047 1381121 1381002 1381049 1381122 1381003 1381623 1325614 1329515 1408672 1328503 1328441 1623642 1623642 1328244 1624875 1328243 1039391 1329013 1383316 1383314 1039271 1383314 1622347 1329144 1328245 1408645 Units D Description Lower Frame Assembly 10R 12R 12L 12C 16L 10P Lower Frame Assembly 16L below serial number 11 09885 U S amp 11 10915 W T Motor Brkt and Gear Asm 10R Motor Brkt and Gear Asm 12R 12L 12C Motor Brkt and Gear Asm 16L Motor Brkt and Gear Asm 16L below serial number 11 09885 U S amp 11 10915 W T Bracket and Gear Asm 10R W O motor Bracket and Gear Asm 12R 12L 12C 16L W O motor Bracket and Gear Asm W O motor 16L below serial number 11 09885 U S amp 11 10915 W T Motor Brkt and Gear Asm 10P includes Gear 6 Plate Asm Gear Box Mtg 10R Plate Asm Gear Box Mtg 12R 12L 12C 16L Plate Gear Box Mtg 10P Screw Motor Brkt Mtg All except 10P Clip Ground Motor Mtg All except 10P Mtg Screw motor All except 10P Mtg Screw Gear Asm
33. 9 1 2MB DRAM SIMM 6 1321882 1 4MB DRAM SIMM 7 1321883 1 8MB DRAM SIMM 8 13A0339 1 4MB DIMM 9 13A0340 1 8MB DIMM 10 1 Option Cards 5 1381050 1 o INA LocalTalk 1402209 1 o INA Ethernet 10Base2 low memory 1402207 1 o INA Token Ring low memory z 1402208 1 o INA Ethernet 10BaseT low memory 1402219 1 o INA Ethernet 10Base2 high memory 1402217 1 o INA Token Ring high memory 1402218 1 INA Ethernet 10BaseT high memory 13A0294 1 o INA SCS 13A0295 1 o INA IPDS 13A0296 1 9 pin to Twinax cable SCS or IPDS 13A0297 1 9 pin to BNC cable SCS or IPDS 13A0298 1 9 pin to 9 pin set up cable 1328563 1 o Screw INA ground 9 1325231 1 Font Card Adapter 10R 12R 12L 12 C 10 1329037 1 Font Cartridge Adapter 16L 11 1381096 1 DC to DC Network Power 12 1329498 1 Hard Disk 40 16L 1425267 1 Hard Disk 40MB 10 13 1363110 1 Serial Adapter 10 172 Service Manual Assembly 18 Miscellaneous elle M Units Description 1319128 1 Parallel Wrap Plug 1329048 1 Serial Wrap Plug 1383313 1 Cables Jumpers parts packet 1383314 1 Fasteners parts packet 1383315 1 Clips parts packet 1383316 1 Springs parts packet 1383317 1 Gears 1 6 parts packet 1383318 1 Gears 7 14 parts packet 1381145 1 Metering and Prealigner rolls parts packet 1383385 1 Paper Tray parts packet 1383390 1 Paper Tray parts packet 1329301 1 Grease 20 1384076 1 Grease conductive 1 oz
34. All except 10P Gear No 6 All except 10P Mtg Screw Gear 6 All except 10P Gear No 2 Detent Box Right Cartridge Latch Spring Parts Packet Washer Parts Packet Shaft Gear 2 Nut Gear 2 PP Lockwasher Gear 2 Left Cartridge Latch Gear Train Cover All except 10P Gear Train Cover 10P Parts Catalog 133 Assembly 2 Lower Frame Continued 134 Service Manual ue Units Description 2 17 1383314 4 Nut Motor Bracket Parts Packet 17A 1383314 2 Screw Motor Bracket Parts Packet 10P 18 1328428 1 LH Bracket Duplex 19 1328427 1 RH Bracket Duplex NS 1383314 1 Screw Duplex Bracket Parts Packet 20 1039476 1 Grommet Printhead Cable 21 1328181 1 Bracket cover pivot 22 1325282 1 Cable Clamp 23 1408721 1 Guide Cable 10 NS 1383314 1 Screw Cable Clamp Parts Packet Parts Catalog 135 Assembly 3 Upper Frame 136 Service Manual Asm Index 3 1 Part Number 1325196 1381045 1383314 1325103 1328218 1328215 1402284 1383315 1039693 1383315 1328220 1039692 1383998 1424481 1328222 1325022 1383315 1383316 1383315 1383314 1383314 1383314 1328307 1325049 1328217 1328308 1325108 1383313 1381004 1383316 1383315 1383314 ND a Description Cover Hinge Asm 10R 12R 12C 10P does not include the load box Cover Hinge Asm 12L 16L does not include the load box Screw Cover Hinge Parts Packet Upper Plate Asm 10
35. Attach a 50 Ohm BNC terminator cap to each end of the T connector The customer may be able to provide this cap There is no wrap test for Token Ring with Unshielded Twisted Pair cable or for Ethernet 10Base T POR the printer If the printer completes POR successfully the printer network card and the port to the LAN are working correctly If the customer still has a problem printing see page 22 Output Bin Sensor Examine the bin area for obstructions or damage Run the diagnostic sensor test For handle mounted sensor The voltage at sensor card J2 3 pin 1 is the bottom pin should be 5VDC and the voltage at J2 4 should be 12L 10 to 14VDC 16L 22 to 26VDC If these are incorrect and the cable has continuity replace the system board The voltage between J2 1 and J2 2 should be 5VDC when the light beam is not blocked and near zero when it is blocked the voltage takes 15 to 25 seconds to change to the low level 24 Service Manual For redrive mounted sensor make sure the plastic bails and guide are in good condition and that they guide the sensor flag out of and into the sensor as paper passes into the bin On the sensor the voltage from pin 2 to pin 3 pin 1 is the bottom pin should change from 0 to 5VDC as the sensor is blocked and unblocked Pin 1 should always measure 5VDC Replace the sensor the sensor card on machines with latch mounted sensor or the sensor cable as necessary Operator Pan
36. B to eliminate the skew Moving the pointer toward the left raises the left adjustment point on the printout 5 Tighten the screws and verify the adjustment D Skew Adjustment Points 62 Service Manual Print Registration Adjustment Use Print Test 1 or the Quick Test to evaluate print registration Adjust the registration so the tips of the diamonds are at the top and bottom edges of the page and the printout is centered left to right Verify that the to Top Margin is correct before adjusting the Bottom Margin 1 2 3 10 11 12 Enter Diagnostics mode Select Print Registration Select one of the following Left Margin Top Margin or Bottom Margin The value of the margin you selected is shown Left Margin This margin can be set between 23 and 23 Changing the number by one moves the margin 1 75 inches Moving the number in a positive direction moves the margin toward the right and negative moves the margin to the left Top Margin This margin can be set between 20 and 20 Changing the number by one moves the margin by 1 75 inches Moving the number in a positive direction moves the margin down the page and widens the top margin Moving the number in a negative direction moves the text up the page and narrows the top margin Bottom Margin This margin can be set between 7 and 7 Moving the number in a positive direction moves the margin down and narrows the bottom margin Moving t
37. Commission FCC Statement This printer has been tested and found to comply with the limits for a Class B digital device pursuant to Part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radio or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult your point of purchase or service representative for additional suggestions Notices and Safety Information iii The manufacturer is not responsible for any radio or television interference caused by using other than recommended cables or by unauthorized changes or modifications to this equipment Unauthorized changes or modifications could void the user s authority to operate the equipment Note To comply with FCC reg
38. Feed Duplex Unit Paper Feed Duplex Unit Service Check Paper Feed Problem 500 sheet Second Tray Paper Feed Problem 500 sheet Second Tray Service Check Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Service Check Automatic Paper Size Sensing Problem Automatic Paper Size Sensing Problem Service Check LAN Problems LAN Service Check Blank Page Blank Page Service Check Black Page Random Marks Black Page Service Check Random Marks Service Check Regularly Spaced Marks Regularly Spaced Marks Service Check Skew all edges Skew Service Check Skew top and bottom only Light Print Fuzzy or Blurred Print Residual Image Honeycomb Background Horizontal Void or Streak 12 Service Manual Skew top and bottom Service Check Light Print Service Check Fuzzy Blurred Print Service Check Residual Service Check Honeycomb Service Check Background Service Check Horizontal Service Check Symptom Action or Service Check Vertical Void or Streak Vertical Service Check Banding Banding Service Check Banding Banding appears as light and dark horizontal lines on a page that is supposed to be uniformly gray It is due to variation in the speed of the paper as it moves from roll to roll during development or transfer It is undetectable when printing text and is
39. J17 8toJ17 4 Less than 21 26VDC 1VDC 16 Service Manual 10 Voltage while Voltage while Printing Idling J14 1 to J14 4 Less than 5VDC OVDC J14 2 to J14 4 Less than 5VDC OVDC J14 3 to J14 4 The meter should OVDC fluctuate slightly between each page J14 8 to J14 4 1VDC 6VDC If the voltages are not correct replace the system board Blurred or Fuzzy Print This can be caused by a damaged gear train or by paper slippage in the feed roll or transfer roll Also see Banding on page 13 Inspect the HVPS contacts make sure each spring loaded contact returns when pressed and released Inspect the transfer roll housing contacts for damage or contamination Check the gear train for damage binds or wear When using the 100 sheet auxiliary feeder some blurring may occur at the point where the feeder s friction rollers release the paper Dead Machine Possible causes no voltage reaching the printer LVPS failure blown LVPS fuse failure of the On Off switch or switch linkage or a shorted electrical component Check for the indicated voltages at the LVPS connection to the system board If no voltages are present remove the LVPS cover and check fuse F1 and the power switch before replacing the LVPS Diagnostic Information 17 If some voltages are present but all are not correct disconnect all cables except the LVPS from the system board POR and verify that the LVPS voltages are c
40. Motor Fan 1 1 2 2 3 3 4 4 5 5 6 2 1 Connector Locations 115 Operator Panel Output Bin Sensor Cable Handle Mounted Outbin Sensor Op Panel Cable Connector Pin 1 To System Board 116 Service Manual Operator Panel Output Bin Sensor Cable Redrive Mounted Outbin Sensor Op Panel Cable Pin 1 Connector The cable connector for 10 10R 12R 12L 12C is J7 The cable connector for 16L is J5 Connector Locations 117 Pin Op Panel Sensor 1 1 2 2 3 3 4 4 5 5 6 1 7 2 8 3 9 4 No connection on machines with redrive mounted output bin sensor 118 Service Manual Printer Ground Straps S Operator Panel lt to Upper Frame Load Box Shaft to Upper Frame HVPS to Frame Toner Shield to Static Brush to Lower Frame Lower Frame Connector Locations 119 Load Box Shaft to Upper Frame Toner Shield to Lower Frame 120 Service Manual Preventive Maintenance This chapter describes procedures for printer preventive maintenance Following these recommendations can help prevent problems and maintain optimum performance Safety Inspection Guide The purpose of this inspection guide is to aid you in identifying unsafe conditions Use good judgment to identify possible safety conditions not covered by this inspection guide Refer to the safety reminders for a general
41. Off To run the serial interface test print 1 Turn the printer power off 2 Setserial interface Switch 10 On 3 Turn the printer power on If the printer does not generate a printout there is a problem with the serial interface card or its connection to the printer Check the switch settings and ensure that the serial interface unit is correctly installed When the test is complete reset Switch 10 to Off 10 Print Test Off Normal Mode On Test mode Service Manual Switch 11 Polarity for RS 422 Serial Interface Switch 11 is used to reverse the polarity of the receive and transmit data line for the RS 422 serial interface 11 Mode Off Normal On Reverse Switch 12 Interface Switch 12 sets the serial interface in either RS 232C or RS 422 mode 12 Mode Off RS 232C On RS 422 Diagnostic Aids 51 52 Service Manual Repair Information This chapter explains how to make adjustments to the printer and how to remove defective FRUs Handling ESD sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts follow the instructions below in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to instal
42. R 12R 12C 10P Upper Plate Asm 12L 16L Cartridge Load Box 10R 12R 12C 12L 16L Cartridge Load Box 10P Right Cam Button Parts Packet Right Bellcrank Left Cam Button Parts Packet Spring Bellcrank Left Bellcrank Fan Asm Pad Acoustic Fan Plenum Asm 12R 12L 12C 16L Plenum Asm 10R 10P Retainer Parts Packet Spring Parts Packet Retainer Parts Packet Screw Parts Packet Washer Parts Packet Screw Plenum Mtg Parts Packet Grip Handle Handle Latch 10R 12R 12C 10P Handle Latch 12L 16L Sleeve Spring Handle Ground Strap Parts Packet Output Bin Sensor Assembly handle mounted 12L 16L Retainer E Clip Parts Packet Pivot Handle Parts Packet Screw Parts Packet Parts Catalog 137 Assembly 3 Upper Frame continued 138 Service Manual Part Number 1381099 1381134 1381095 1383314 1325138 1325067 1328467 nmm m N Description Cable Output Bin Operator Panel 12L handle mounted sensor Cable Output Bin Operator Panel 16L handle mounted sensor Cable Operator Panel 12C 12R 10R 10P Screw Shaft Mtg Parts Packet Spring Redrive 10R 12R 12C 10P Spring Plenum 10R 10P Spring Plenum 12R 12L 12C 16L Parts Catalog 139 Assembly 4 Printhead 140 Service Manual Part Number 1381624 1381005 1328431 1325017 1325018 1038199 1383315 1383316 1383314 1383314 1383314 1383315 1 E mm Description
43. V Power Supply 100V 10R 12R 12L 12C LV Power Supply 110V 10P LV Power Supply 220V 10P Fuse LVPS SB 12A 110V 16L 10P Fuse LVPS 6 3A 220V 16L 10P Fuse LVPS SB 10A 110V 10R 12R 12L 12C Fuse LVPS 4A 220V 10R 12R 12L 12C Power Cord Set U S Canada Mexico Central and South America Saudi Arabia LV Peru Power Cord Set Germany France Spain Norway Finland the Netherlands Austria Belgium Brazil Greece Luxembourg Portugal Sweden Turkey Indonesia Saudi Arabia HV Power Cord Set S Africa Power Cord Set Switzerland Power Cord Set Chile Italy Power Cord Set Denmark Power Cord Set New Zealand Australia Argentina Paraguay Power Cord Set Israel Power Cord Set UK Malaysia Singapore Rod on off Support Rod on off HV Power Supply 10R 12R 12C 12L 16L HV Power Supply 10P Cable HV Power Supply 10P System Board 10R System Board 12R 12L System Board 12C System Board 16L System Board 10P Cable Erase Lamps Input Sensor Board 10P Parts Catalog 163 Assembly 13 Electronics Continued 164 Service Manual Part Number 1328291 1321882 1328589 1325436 1325434 1328337 1419453 1328338 1325106 1328988 1383314 1328969 1325489 1328281 1328280 1195319 1383315 1383315 1383314 1383314 1383513 1039456 1381513 1381484 1381509 1381628 1376388 1376389 1376390 1325197 1328644 1328647 1381097 1 D D D D ND A A a n Description Cable HVPS Input Sensor B
44. ad shroud Pry off the grip rings holding the printhead to the shroud Note After replacing the printhead perform the printhead skew adjustment Repair Information 91 System Board Removal 1 e 6 T 8 Check the page count and write it down so you can set the new system board Turn the printer off Remove the right cover Remove the outer EMC shield by pressing down on the two bottom tabs slide the shield forward then down 10P has no outer EMC shield Disconnect all the external connectors from the system board and remove the option cards Remove the system board mounting hardware A Release the system board standoff Remove screw B and remove the system board Note If system board is being replaced remove the ROM SIMM and all options for installation on the new system board 92 Service Manual Repair Information 93 System Cable Removal 1 Turn the printer off Remove the right cover Remove the transfer roll housing Remove the fuser input guide Disconnect the system cable connections Remove the cable through the top of the machine Fuser Sensor Cable Removal o NO WL Turn the printer off Remove the system board Remove the inner EMC shield Disconnect the cable from the exit sensor board Remove the front cover Remove the front exit deflector switch Disconnect the cable from the paper sensor assembly Remove the cable
45. amine the paper path in the duplex unit and in the fuser exit area for paper or other obstructions Make sure the duplex unit is positioned correctly on the printer and that the gear at the bottom of the duplex unit meshes with the gear on the top of the paper tray Check that the paper is fed with no skew or binds from the duplexer into the metal channel at the right edge of the tray cover The tray roller should move the paper forward when the tray gear is turned but allow the paper to be pulled by the D roll when it picks Make sure the belt to the duplex DC motor is in place Make 18 Service Manual sure the duplex table cover floor is correctly snapped in place at its front and rear and that the gear block assembly is correctly snapped into the bottom cover Run duplex diagnostics tests 1 and 2 to make sure there is no slippage in the paper path Make sure the flags of the duplex unit input and exit sensors move freely While the 23 is displayed press and hold the Return button while pressing the second button from the top and note the 7th and 8th digits from the left If they are 01 or 03 there is a problem with the duplex input sensor signal Remove the duplex top cover and table cover Measure the voltage on JP6 3 of the duplex system board it should fluctuate from 0 to 5VDC as you toggle the sensor flag Check the sensor cable continuity If the sensor and the cable are good replace the duplex system card If the 7th and 8th
46. bly Two dot o o Subassembly of a one dot subassembly Parts Catalog 127 Assembly 1 Covers 128 Service Manu 1 1 1325311 1 Top Cover 10R 12R 12C 10P 1 1328204 1 Top Cover 121 161 NS 1329607 1 Kit Stacker Spring 16L 1A 1381017 1 Panel Asm 1B 1328207 1 Door Top Cover 121 161 NS 1328453 1 Screw Operator Panel 2 1325135 1 Front Logo 10R 2 1325136 1 Front Logo 12R 2 1325137 1 Front Logo 12L 2 1325952 1 Front Logo 12 2 1328511 1 Front Logo 16L 2 1419451 1 Front Logo 10 2 1375923 1 Front Logo 10R plus 2 1375925 1 Front Logo 12R plus 2 1375992 1 Front Logo 12 plus 2 1375927 1 Front Logo 12L plus 2 1377417 1 Front Logo 16L plus 3 1325115 1 Right Cover Asm 10R 12R 12L 12C 3 1328208 1 Right Cover Asm 10P 16L 4 1328210 1 Door Right Cover NS 1328329 1 ad Door Right Cover 10R 12R 12L 12C 5 1328186 1 Front Cover Asm 6 1195318 1 On Off Switch Lever 7 1329070 1 Output Deflector 8 1328473 1 Output Deflector Lever 9 1 Spring Deflector Lever Parts Packet 1383316 10 1058249 1 Spring On Off Actuator 11 1183599 1 Spring Front Cover Deflector 12 1328185 1 Left Cover 14 1325026 1 Paper Stop Asm 10R 12R 12C 10P 14 1328509 1 Paper Stop Asm 12L 16L 15 1183536 1 Front Exit Slide 16 1183538 1 Tray Front Exit with slide Parts Catalog 129 Assembly 1 Covers Continued Service Manual 130 Asm Index 1 17 NS NS NS Part Number 1328
47. bly and tighten the screws Remove the gear retaining plate from the assembly and install the motor in the printer 70 Service Manual lt lt Repair Information 71 Fan Redrive Removal 1 Open the top cover Remove the print cartridge Remove the top cover Remove the lower redrive shaft by disengaging the right end to the rear of the machine Disconnect the long redrive belt A and slip it off the lower shaft Remove the redrive assembly screws D Remove the plenum assembly and screws B Unplug the fan cable The fan C can now be removed from the plenum assembly PORN No 72 Service Manual Repair Information 7 Fuser Removal Note The heater lamp is fragile and may be damaged if you are not careful when you remove or replace the fuser unit CAUTION THE TEMPERATURE OF THE HOT ROLLER IS 150 2230 302 446 F USE EXTREME CAUTION WHEN REMOVING THIS UNIT BEFORE YOU SERVICE THIS UNIT ALLOW THE MACHINE TO COOL FOR 5 MINUTES 1 2 e o 1097 RE Unplug the power cord Remove the printer cartridge Disconnect the exit sensor cable from the fuser through the opening for the paper output Unsnap the front cover from the right side frame Remove the fuser cover Disconnect the power wires A from the left side of the fuser Remove the fuser input guide Completely loosen the four fuser mounting screws Lift the fuser out of the machine
48. ck is tested 1 Enter Diagnostics mode 2 Select Quick Disk Test 8 The display indicates Test Passed or Test Failed 4 Press Return to return to Diagnostics mode main menu Quick Test The Quick Test is activated by pressing Ready from any screen while in Diagnostics mode plus machines only as well as being an entry under Print Registration It provides a simple page alignment pattern that prints faster than the other print tests Diagnostic Aids 45 Sensor Test 1 Enter Diagnostics mode 2 Select Sensor Test 3 Select one of the following sensor tests Toner Low Output Bin Input Exit Cover Open Note The Output Bin sensor can have up to a 15 second delay in changing to open 4 When the sensor is blocked Open is displayed Otherwise Closed is displayed 5 Press Return to return to the Diagnostics mode main menu 46 Service Manual Network Connections Checks Wrap Tests The Wrap Tests check the circuits used to communicate with the host computer To run the Wrap Test 1 Turn the printer off 2 Disconnect the interface cable 3 Install the wrap plug in one of the interface cable connectors Note Install the parallel wrap plug part no 1319128 for the parallel test or install the 25 pin serial wrap plug part no 1329048 for the serial test 4 Enter Diagnostics mode 5 Select Wrap Test 6 Select Parallel for the parallel port or Serial for the 25 pin
49. d Lamp 220V 12R 12L Fuser and Lamp 220V 12C Fuser and Lamp 110V 16L Fuser and Lamp 220V 16L Fuser and Lamp 110V 10P Fuser and Lamp 220V 10P Fuser and Lamp Low Pressure 110V 10R Fuser and Lamp Low Pressure 220V 10R Screw Fuser Asm Parts Packet Fuser Wiper Assembly supply item 10R 12R 12C 12L 16L Fuser Wiper Assembly supply item 10P Fuser Cover 10R 10P Fuser Cover 12R 12L 12C 16L Spring Redrive Exit Screw Parts Packet Fuser Lamp 110V 10R 12R 12L Install lamp with color coded end away from gear Fuser Lamp 110V 12C 10P Install lamp with color coded end away from gear Fuser Lamp 220V 10R 12R 12L Install lamp with color coded end away from gear Fuser Lamp 220V 12C 10P Install lamp with color coded end away from gear Fuser Lamp 110V 16L Install lamp with color coded end away from gear Fuser Lamp 220V 16L Install lamp with color coded end away from gear Parts Catalog 159 Assembly 12 Fuser Continued 160 Service Manual Asm Part Index Number Description 12 8A 1381086 1 8 1381076 1 8 1381146 1 8 1383322 1 Hot Roll Assembly 10R Hot Roll Assembly 12R 12L 16L Hot Roll Assembly 12C Hot Roll Asm 10P NS 1039305 1 Backup Roll 10R 12R 12L 16L NS 1329928 1 Backup Roll 10 9 1381012 1 Thermistor Sensor Asm 10R 12R 12C 12L 16L 9 1381637 1 Thermistor Sensor Asm 10 10 1328458 1 Redrive Idle Arm Asm 12R 12L 12C 16L 10 1376367 1 Redriv
50. der 28 500 sheet second tray 26 paper feed test 42 paper size sensing problem 29 switch removal 90 paper tray 500 sheet assembly 152 standard 200 sheet assembly 150 parts catalog 127 how to use the catalog 127 permanent page count 43 power on self test POST 11 preventive maintenance 121 print contrast 43 print registration adjustments 63 print test page 43 print test 1 44 printtest 2 44 printtest3 45 printer ground strap locations 119 printhead assembly 140 cable locations 114 diagnosis 28 removal 91 skew adjustments 61 62 printhead window cleaning procedure 124 Q quick disk test 45 quick test 45 R random marks 31 regularly spaced marks 30 removals 64 repair information 53 residual image 30 S safety inspection guide 121 scheduled mechanical maintenance 125 sensortest 46 serial interface option 48 skew all edges 31 top and bottom only 31 stalled diamonds on display 31 symptom table 12 system board connector locations 108 110 112 removal 92 system cable locations 107 removal 94 test page 43 toner sensor removal 95 tools required 4 torquer motor removal 94 transfer roller assembly 166 cleaning 124 removal 68 transfer roller housing locations 106 removal 96 transfer test 43 177 U upper frame assembly 136 removal 97 V vertical void or streak 31 warm up time 40 wrap tests 47 2 Zif connector removal 98 Numeric 100 sheet auxiliary feeder paper r
51. digits are 04 there is an exit sensor problem Remove the duplex top cover and table cover Remove the paper tray so you can reach the sensor Measure the voltage on JP6 8 of the duplex board it should fluctuate from 0 to 5VDC as you toggle the sensor Check the sensor cable continuity If the sensor and the cable are good replace the duplex system card Fan 927 Error The fan should run continuously when the printer is powered up unless the printer is in Power Saver mode Check that the fan rotates freely when spun manually and that the cable connections to the fan are OK The voltage at 10P 10R 12R 12C 12L J5 6 16L J3 6 should be approximately 24VDC when the top cover is up Short pin 6 to ground to test the fan if the fan does not run check the continuity of the fan cable before replacing the fan A bad fan can pull down the 24 line even if it runs check that 10P 10R 12R 12C 12L J5 7 16L J3 7 has between 21 and 26VDC when the fan is running if it does not replace the system board Diagnostic Information 19 Fuser Theory The fuser lamp operates off line voltage from the LVPS The thermistor is in contact with the fuser hot roll The system board reads the thermistor resistance and toggles a TRIAC in the LVPS which cycles the lamp on and off to maintain the proper hot roll temperature Inside the fuser shroud there is a thermal fuse which is in series with the lamp if the TRIAC fails and leaves the lamp on continuou
52. duplex To run Print Test 1 moo me Enter Diagnostics mode Select Print Test 1 Select Single or Continuous Select CANCEL to stop continuous print Press Return to return to the main Diagnostics menu Print Test 2 Print Test 2 generates two printouts a page similar to the test page and a fine dot pattern which can be used to evaluate banding or other print quality problems Print Test 2 duplexes if the duplex option is installed To run Print Test 2 GR Co e c Enter Diagnostics mode Select Print Test 2 Select Single or Continuous Select Cancel to stop continuous print Press Return to return to the main Diagnostics menu 44 Service Manual Print Test 3 This test generates 2 printouts a solid black page and a dot pattern that can be used to evaluate print quality Enter Diagnostics mode Select Print Test 3 Select Single or Continuous Select CANCEL to stop continuous print Press Return to return to Diagnostics mode main menu SH E ces Quick Disk Test This is a one minute test which performs a non destructive write read on one block per track on the disk It tests the printer to disk communications and the disk hardware and circuitry but does only incidental testing of the disk surface itself The Quick Disk Test does not destroy data on the disk existing data is read and stored prior to the testing of each track and then re written after the tra
53. e Service Manual Lexmark LaserPrinter 4039 1XX e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK Second Edition June 1996 The following paragraph does not apply to the United Kingdom or any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions of the publication Improvements or changes in the products or the programs described in this publication may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase A form for reader s comments is provided at the back of this publication If the form has been removed comments may be addressed to Lexmark International Inc Department D22A 035 3 740 New Circle Road NW Lexington Kentucky 40550 U S A In the United Kingdom and Eire send to Lexmark International Ltd Marketing and
54. e see Fuser Temperature And Warm Up Time on page 40 If paper is jamming at the front exit verify that the front exit deflector switch is functioning by disconnecting 10P 10R 12R 12C 12L J19 16L J16 and checking the resistance from pin 1 to pin 2 as you operate the switch Also see 23 Paper Jams on page 18 Diagnostic Information 27 Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Check for the following paper or envelope jammed in the feed path missing hold down weight adjustable guide out of position feeder cable loose disconnected or plugged in the wrong connector feeder incorrectly installed worn or damaged rollers or gears warped or damaged envelopes being used envelopes being improperly installed envelope flaps must rest against the paper edge guide envelopes other than 20 or 24 pound being used in the envelope feeder paper other than 20 or 24 pound being used in the 100 sheet auxiliary feeder envelopes being interleaved with paper Run the diagnostics Envelope Feed test and make sure the feed magnet is being energized If not check the resistance of the magnet at 10P 10R 12R 12L 12C J12 1 to J12 2 16L J9 1 to J9 2 on the feeder cable the resistance should be from 105 Ohms to 155 Ohms If the magnet is good reconnect the cable and monitor the voltage between the two pins of the connector while running the Envelope Feed test if the voltage does not increase momentarily as the magne
55. e Idle Arm Asm 10R 10P 11 1381687 1 Paper Exit Bd Asm 12 1383315 Flag Parts Packet 13 1039481 Fuser Power Cable n 14 1381537 15 1381155 15A 1039328 15A 1328134 16 1039311 17 1381018 18 1383314 1 Cable Fuser Front Cover Exit Sensor Thermal Fuse Asm Clips Thermal Fuse 10R 10P Clips Thermal Fuse 12R 12L 16L Bail Handle Fuser Solenoid Asm 12R 12L 16L Screw Fuser Solenoid Mtg Parts Packet 1 pop 19 1039251 1 Gear No 1 Hot Roll 10R 10P 19 1328124 1 Gear No 1 Hot Roll 12R 12L 12C 16L 20 1383317 1 Gear 18T Redrive Parts Packet 21 1383316 1 Spring Redrive Idler Parts Packet 22 1328437 1 Contact Asm Right Lamp 23 1328438 1 Contact Asm Left Lamp 24 1383314 1 25 1039316 1 26 1039317 1 Screw Mtg Parts Packet Detack Fingers Detack Finger springs Parts Catalog 161 Assembly 13 Electronics 162 Service Manual Asm Part Index Number 13 1 1383974 1 1383975 1 1381014 1 1381039 1 1383981 1 1381643 1 1381644 NS 1328463 NS 1328464 NS 1035151 NS 1051604 3 1342514 3 1342530 3 1342532 3 1342533 3 1342534 3 1342535 3 1342536 3 1342537 3 1342543 4 1039467 4A 1058266 5 1381390 5 1381645 5A 1381653 6 1381515 6 1381517 6 1381504 6 1381519 6 1381578 NS 1408063 Description LV Power Supply 110V 10R 12R 12L 12C LV Power Supply 220V 10R 12R 12L 12C LV Power Supply 110V 16L LV Power Supply 220V 16L L
56. e continuity of the cable before replacing the sensor The input sensor signal is on 10P 26 Service Manual J20 6 10R 12R 12C 12L J20 11 16L 217 11 the output sensor signal is on 10P 10R 12R 12C 12L J19 8 16L J16 8 The voltage should be OVDC when there is no paper in the sensor and 5VDC when paper is present If paper is jamming clean the paper path of obstructions or repair any damaged parts Very thin or thick paper labels transparencies or card stock will have a higher jam rate than regular xerographic paper Check the condition of the paper in the tray and verify that the tray is installed correctly If paper is curling badly enough to cause a problem feeding or stacking see Fuser Temperature And Warm Up Time on page 40 Paper Feed Duplex Unit Check that all gears and belts are working correctly both in the duplex unit and on the tray top cover and that the gear on the tray top cover engages the gear on the duplexer If paper is jamming in the table cover area make sure the table cover is properly installed Run diagnostics Duplex Test 1 to make sure the paper is feeding far enough into the duplex unit before reversing Examine the condition of all rollers If paper is stopping or jamming as it is fed back across the top of the paper tray run diagnostics Duplex Test 2 to make sure there is no slippage in the paper path Make sure the paper tray top cover is not damaged Cold paper curl can also cause jams her
57. e printer on it performs a Power On Self Test Check for correct POST functioning by observing the following 1 112 rows of pels appear on the display and then clear 2 Diamonds fill the display and then clear 3 The fuser lamp and the fan turn on Performing Self Test appears on the display Note The printer may be idle for up to 60 seconds as the fuser warms to operating temperature Printer idle time is shorter if the fuser is already warm Note If the duplexer is installed the duplex drive motor turns on for about 5 seconds just before the ready screen appears 4 The ready screen appears on the display Note Diagnostics menu appears if you are in diagnostic mode 5 The drive motor and the mirror motor start to run The fan starts to run at high speed 6 The drive motor runs for approximately 10 seconds The fan runs at high speed then switches to low speed If the printer completes all these steps and no error messages are displayed the printer has successfully completed the POST Diagnostic Information 11 Symptom Table Symptom Action or Service Check Dead Machine Dead Machine Service Check Repeats pattern of five beeps and a pause Operator Panel Service Check Machine Hangs Displaying Diamonds Machine Hangs Displaying Diamonds Service Check Operator Panel Operator Panel Service Check Paper Feed Base Printer Paper Feed Base Printer Service Check Paper
58. ear 8 NES Redrive Gear Gear 9 on shaft on motor bracket Redrive ldler Gear 11 molded on D roll shaft Optional tray drive Gear 13 Gear 4 Gear 12 Motor pin Gear 3 KS RN SET 2 Right Rail Mounted on sideframe 104 Service Manual HVPS Print Cartridge Contacts Cover Interlock Transfer Roll Contacts Connector Locations 105 Transfer Roller Housing Transfer Roll Paper Guide Erase Lamp Window Transfer roller housing for 10 has no paper guide 106 Service Manual System Cable Pin 1 Input and Toner Sensors Pin 1 Transfer Roll System Board 10R 12R 12C 12L J20 161 J17 Connector Locations 107 System Board Connectors 10R 12R 12L JT J2 o L J3 J4 J16 o 5 o J18 J5 J6 J7 coca J8 J9 ca J13 J14 Jt Ji2 J15 J17 J21 J22
59. een the two shafts and the grounding spring e Use grease p n 1383586 to lubricate B on the duplex unit Preventive Maintenance 123 Printhead Window Cleaning Procedure Do not use cleaning fluids on the printhead window Do not use a bare cotton swab The swab deposits lint on the window Note The printhead window is a coated glass Do not push too hard and scratch or break the glass 1 Remove the print cartridge 2 Fold a lint free cloth over a cotton swab Swab Lint Free Cloth 3 Open the shutter 4 Insert the swab and cloth combination in the printhead window slot then slide it left to right several times Move the swab to a clean spot on the cloth and repeat the cleaning procedure Do this procedure several times to make sure the window is clean Cleaning The Transfer Roller Power off the printer Power on and let it complete POST Do this two to three times 124 Service Manual Scheduled Mechanical Maintenance The operator panel will display the message 80 Scheduled Maintenance at each 200K 100K for 12C page count interval It is necessary to replace the fuser assembly transfer roller d roll and lower redrive shaft assembly at this interval to maintain the print quality and reliability of the printer These items are available as individual FRUs They are also available as a maintenance Kit through the dealer options ordering channel After replacing the kit the maintenance count must be r
60. el Output Bin Font Card 17 1 10 1 9 ll Dep a g J3 J4 J5 DRAM mw J7 ES Je Envelope uplex Feeder z J2 JT2 i Resch L L a J12 5 i parallel n 5 F Serial ROM SUM J14 590 Sheet Option o 1 11 J16 J18 J19 p UE Ke S 16 1 1 4 14 1 1 16 Me 1 2 Paper Fuser VPS Paper Drive Flex Pick Motor Magnet 110 Service Manual System Board 16L Connector Name Ji DRAM SIMM J2 DRAM SIMM J3 Mirror Motor Printhead Fan J4 Laser Printhead Hsync J5 Operator Pane Output Bin Sensor J6 Duplex J7 Font Card J8 Hard Disk Option J9 Envelope Feeder Magnet J10 ROM SIMM Printer microcode J11 ROM SIMM flash memory option J12 INA Card J13 Parallel and Serial Port J14 500 Sheet Option J16 Paper Drive Motor J16 Fuser J17 HVPS Flex Includes input and toner sensors and erase lamps on transfer roller J18 LVPS J19 Paper Pick Magnet Connector Locations 111 System Board Connectors 10 J2 J5 J3 J4 J18 J7 J12
61. el Problem Possible causes failed LCD or operator panel card cable or connector problem or system board problem Replace the operator panel if POR stops with 11 2 rows of pels displayed Run the diagnostic tests for the LCD and for the buttons If only some buttons or pels work replace the operator panel If the operator panel is blank check for 5 at pin 1 of the in line connector under the top cover and replace the operator panel if the voltage is good Check for 5VDC at 10P 10R 12R 12C 12L J7 1 16L J5 1 on the system board and replace the cable if the voltage is good If the voltage at the system board is incorrect check that the LVPS is providing the correct voltages and replace the LVPS if its output voltages are wrong On models 10R 12R 12C 12L a DC DC convertor changes 34VDC at J9 1 into 5VDC 12VDC and 12VDC Check for 5VDC at J8 1 and for 34VDC at J9 1 and at J11 4 Replace the DC DC convertor the system board or the LVPS depending on where the voltage is incorrect Diagnostic Information 25 Paper Feed Problem 500 Sheet Second Tray Remove the module and inspect the tray the module D roll bias spring the gear train and the paper feed magnet spring Make sure the gear train is meshing with the drive gear at the bottom of the printer Look for other mechanical problems or damage Make sure the cable connector is in good condition The resistance of the paper feed magnet should be 100 Ohms to
62. els and card Stock 16ppm PostScript Level 1 emulation output bin sensing input output capacity 500 500 10R with PostScript Level 2 emulation and service error log RPQ only 12R with PostScript Level 2 emulation and service error log 12C with PostScript Level 2 emulation and service error log RPQ only 12L with PostScript Level 2 emulation and service error log 16L with PostScript Level 2 emulation and service error log General Information 1 Lexmark Model 4039 10 plus Called 10P in this manual and on the serial number plate 10ppm PostScript Level 2 emulation no serial port torquer motor rather than paper pick solenoid and service error log Options The following options are available Some options are not compatible with all printer models Some options are not available in every country Contact your point of purchase for options available in your country Memory upgrade options of 2MB 4MB and 8MB Flash memory options of 1MB 2MB and 4MB Intergated network options Token Ring option Ethernet option Apple Talk option 200 and 500 sheet paper trays of A5 letter and legal size 500 sheet second drawer withe letter size paper tray Envelope feeder 100 sheet auxiliary Duplex option Font cards Font cards adapter 40 MB Hard Disk Serial adapter 2 Service Manual Maintenance Approach The diagnostic information in this manual will lead you to the correct field replaceable unit FRU or pa
63. er as well as general environmental and safety instructions Diagnostic Information contains error code table symptom table and service checks used to isolate failing field replaceable units FRUS Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components and test points on the printer Preventive Maintenance contains safety inspection guidelines lubrication specifications and maintenance information to prevent problems and maintain optimum performance Parts Catalog contains illustrations and part numbers for individual FRUs Preface ix X Service Manual Table of Contents Notices and Safety Information iii Electronic Emission Notices iii Federal Communications Commission FCC Statement iii Industry Canada Compliance iv The United Kingdom Telecommunications Act 1984 iv European Community EC Electromagnetic Compatibility Directives ER V German Statement of Acoustic Emtssions V BR lei E Ecc tente ce edes vi Safety Information ia ee eat Ree bete ns vii Ozone Information iii viii Preface iiec cei eimi ix Table of Gontent
64. eset to zero to clear the 80 Scheduled Maintenance message Preventive Maintenance 125 126 Service Manual Parts Catalog How To Use This Parts Catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are broken down on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description AR As Required in the Units column indicates that the quantity is not the same for all machines NP Non Procurable in the Units column indicates that the part is non procurable and that the individual parts or the next higher assembly should be ordered NR Not Recommended in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted availability NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration INDENTURE The indenture is marked by a series of dots located before the parts description The indenture indicates the relationship of a part to the next higher assembly For example INDENTURE RELATIONSHIP OF PARTS No dot MAIN ASSEMBLY One dot o Detail parts of a main assembly One dot o Subassembly of the main assembly Two dot o o Detail part of a one dot subassem
65. estraint spring adjustment 54 178 Service Manual 4039 Printer Readers Service Manual P N 1419488 Comment 6 96 Form You may use this form to communicate your comments about this publication with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you 1 Did you find the book well organized YesO No 3 2 Was the content of the book accurate and complete Yes No O 3 Was the book easy to use Yes No O 4 What can we do to improve the book 5 What is your job title Questions or comments about supplies service applica tions and so on will slow response time considerably Please refer those questions or comments to your authorized dealer or point of purchase Note Please direct all requests for copies of publications to your point of purchase Publications are not stocked at the location to which this form is addressed NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape eur Buoy mc
66. etwork Card Network card ROS FLASH failure Replace the Network Card 973 Network Card Network card EEPROM NVRAM failure Replace the Network Card 974 Network Card Network card Network interface error Replace the Network Card 976 Network Card Network card software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a software or microcode incompatibility problem Do Not replace the card Contact your next level of support Diagnostic Information 9 Error Code Action 977 Network Card Network card is installed but is not communicating with the system board See Network Card 977 Errors on page 24 978 Network Card General network card hardware error Replace the Network Card 979 Network Card General network card software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a software or microcode incompatibility problem Do Not replace the card Contact your next level of support 990 Duplex Option Duplex error See Duplex on page 18 991 Duplex System Card Failure 993 Duplex Comm Failure 10 Service Manual Duplex system card failure Replace the duplex system card Communications between the duplex unit and the printer have failed See Duplex on page 18 Power On Self Test POST When you turn th
67. evel 1 61 Printhead Skew Level 2 62 xii Print Registration Adjustment 63 REMOVAIS i oe EE Ee dh eve aei ac epe pal Pede ea 64 COV FS Limit insiste annee M 64 Right Cover Removal 64 Front Cover Removal 64 Left Cover Removal ss 66 TOP Cover Removal ert Re C Reyes 66 Transfer Roll Removal nnen 68 D roll Assembly Removal eese 69 Drive Motor Removal 70 Fan Redrive 72 Fuser Removal day ee Reine EAS IRR 74 Fuser Input Guide Removal sse 74 Fuser Lamp Removal 76 Fuser Solenoid Removal rtt tentent 77 Fuser Thermistor Hemoval nnn 78 HVPS Reriovali 2 ettet reete eee ete er rt der 80 Input Sensor Removal 82 Lower Frame Assembly Removal sene 83 LVPS Removal sis 84 LVPS Cover Removal 85 Operator Panel Removal 86 Removal ren tn nr eren 86 Exit Sensor Removal enne 87 Paper Feed Magnet Assembly
68. ftover image down the page is probably the result of failed erase lamps not discharging the photoconductor or of a failed cleaner inside the print cartridge It can also be caused by a failed fuser hot roll retaining toner and redepositing it on the page Check that the erase lamp voltage at 10P J20 1 10R 12R 12C 12L J20 16 16L J17 16 is 24VDC and that the cable has continuity To test the erase lamps jumper 10P J20 2 10R 12R 12C 12L J20 15 16L J17 15 to ground 30 Service Manual Random Marks Random marks are nearly always due to a mechanical problem or due to foreign matter loose in the printer or in the print cartridge Inspect and clean the inside of the printer carefully and correct any problems found Skew all edges If the test print frame is parallel to all edges of the page but the margins are not all the same width see Print Registration Adjustment on page 63 If the test print frame is not parallel to the left and right edges of the paper the paper has skewed in the paper path Check the paper path for obstructions Make sure the paper in the tray is loaded properly and is undamaged Check the prealigner drive and auxiliary rollers springs and backup rollers for dirt wear or damage refer to the parts catalog for repair kits for broken bellcrank spring attachment hooks on the sideframe Make sure all the bellcrank assemblies pivot freely Check the gear train for damage or binds Skew top and bott
69. gear in one direction to check for backlash To adjust backlash Loosen the nut on the idler stud Move the idler stud downward in its slot Insert a 0 95 mm 037 feeler gage between the gear shoulders from the front of the machine You may need to use an angled or very small feeler gauge With the nut snug but not tight tap the idler upward until the gage is snug between the gear shoulders Tighten the locking nut Check the clearance again tightening may have altered the adjustment Be sure the fuser gear can be rotated slightly when gear 2 is held still 56 Service Manual 0 95 0 15 037 006 Idler Gear Fuser Gear Right Side Plate Repair Information 57 Fuser Solenoid Note The fuser solenoid must be mounted on the fuser for this adjustment and should be at room temperature 1 Loosen screw A 2 Remove the rubber washer 3 Rotate shaft B eccentric to obtain 4 2 mm 0 2 mm 0 165 in 0 008 in air gap 4 Tighten screw A 5 Replace the rubber washer Screw Shaft B 2 PEN 58 Service Manual Paper Feed Magnet 1 2 Remove the system board The magnet is accessed through the holes in the right frame With the armature latched on the cam step check for 0 60 mm 0 07 mm 0 024 in 0 003 in between the foam pad and the magnet pole piece If adjustment is required continue Keep the armature latched and loosen the magnet mounting screw A I
70. h memory for function requested To verify that the printer recognizes all the installed memory go to the user menus and print the Print Menus test page Make sure the memory shown on the printout matches the installed memory 38 Memory Full 39 Complex Page Memory used to store pages is full To verify that the printer recognizes all the installed memory go to the user menus and print the Print Menus test page Make sure the memory shown on the printout matches the installed memory Page too complex to print To verify that the printer recognizes all the installed memory go to the user menus and print the Print Menus test page Make sure the memory shown on the printout matches the installed memory 43 Font Card Not Supported 44 Defective Font Card 47 Font Card Removed While Printing Font card format not supported by printer Defective font card installed in font slot Printer needs data on removed card 52 Flash Full Not enough flash memory for data requested to be stored 53 Unformatted or Defective Flash 54 Serial Error Flash problem at POR or while attempting to write Framing or parity error on serial 58 Duplex Not Attached Duplex is electrically connected but no longer mechanically attached and printer top cover is closed 59 Duplex Cover Open Top cover of duplex unit is sensed open 62 Disk Full Not enough disk space for data that has
71. he latch located above the flat part of the D roll 7 Pushthe latch down away from the shaft and slide the D roll to the left off the shaft Note There is no positive detent when replacing the D roll Make certain the roll is in place by pulling toward the left without pushing the latch Note Later machines do not have a latch Remove the D roll by pulling it firmly to the left The D roll without a latch is intended to be installed only once if it is removed for any reason it should be replaced with a new one The new D roll may take considerable force to install Repair Information 69 Drive Motor Removal NOORWN 8 9 Unplug the power cord Remove the system board Remove the system board inner EMC shield Remove the fuser input guide A Remove the transfer housing assembly Remove the gear cover by releasing the rear latch and lifting up Remove screw C and the grounding clip this clip is not present on all machines Remove the motor mounting nuts B and screws Work the motor out of the machine 10P Do not remove the motor from the gear bracket assembly they are not available separately Installing the motor If the motor has been removed from the gear bracket assembly you must use the gear retaining plate as a tem plate to be sure the motor pinion is correctly positioned to gear 4 Install the gear retaining plate to the gear bracket assembly and tighten the nuts Install the motor to the assem
72. he laws of the Member States relating to electromagnetic compatibility COB PIMA CHIC BO Im S A Zo Sa CHERE cog m IE LL E 7 LOL TONER 5c SE RERA gt German Statement of Acoustic Emissions declaration of conformity with the requirements of the Directive has been signed by the Director of Manufacturing and Technical Support Lexmark International Ltd Boigny France This product satisfies the Class B limits of EN 55022 Notices and Safety Information V Trademarks Lexmark is a trademark of Lexmark International Inc The following terms denoted by a double asterisk in this publication are trademarks or registered trademarks of the following companies AppleTalk Apple Computer Inc IBM International Business Machines Corporation LocalTalk Apple Computer Inc PCL Hewlett Packard Company PostScript Adobe Systems Incorporated AppleTalk and LocalTalk are trademarks of Apple Computer Inc registered in the United States and other countries PCL is a registered trademark of the Hewlett Packard Company PCL 5 is Hewlett Packard Company s designation of a set of printer commands language and functions included in its printer products This printer is designed and manufactured by Lexmark International Inc to be compatible with the PCL 5 language Th
73. he number in a negative direction moves the text up the page and leaves a wider bottom margin Select to move the number in a positive direction Select to move the number in a negative direction Select Print Test 1 or Quick Test to check your settings Select Tray 1 or Tray 2 Select Single or Continuous 13 14 Select SAVE to save your settings when they are correct Press Return to return to the Diagnostics menu Repair Information 63 Removals When there is artwork to support a procedure it follows the text Covers Right Cover Removal 1 aR OD Turn the printer off Remove all external trays Open the top cover Swing the cover open Remove the E clip from the rear pivot pin and lift the cover off the rear pivot pin Front Cover Removal PPPN Unplug the power cord Remove the paper tray Open the top cover Open the right cover Remove the Duplex mounting slot covers Release the latches B You can reach the lower latches through the paper tray opening Pull the front cover forward then move the cover to the right to separate the on off switch linkage D Disconnect the ground strap from the frame on the left side Remove the front exit deflector switch 64 Service Manual Repair Information 65 Left Cover Removal 1 Unplug the power cord Open the top cover and remove the print cartridge Remove the front cover Locate the latch A and push
74. he resistance is not infinite The resistance from 10P 10R 12R 12L 12C J19 3 to J19 4 16L J16 1 to J16 2 varies with the paper size With the tray installed if the readings do not match the following within 596 replace the paper size sensor A5 1 4 K Ohms tray 1 only B5 2 0 K Ohms 10 5 3 0 K Ohms 11 4 7 Ohms A4 8 0 K Ohms 18 or 14 17 8 K Ohms legal tray If the problem is with the 500 sheet option the resistance from 10P 10R 12R 12L 12C J17 3 to J17 4 16L J14 3 to J14 4 should be infinite with no tray installed or with the tray installed should match the table Diagnostic Information 29 Regularly Spaced Marks This is caused by a defect on one of the rolls or gears in the print process The damaged part can be determined by the spacing of the marks according to the following table Find and replace the damaged part Component Print Defect Spacing on Page PC Drum part of print cartridge 125 7 mm Transfer Roll 53 1 mm Fuser Hot Roll10P 12R 12C 12L 16L 78 9 79 2 mm Fuser Hot Roll 10R 64 7 mm Fuser Backup Roll 69 1 mm Charge Roll part of print cartridge 37 1 37 7 mm Developer Roll part of print cartridge 40 0 mm Prealigner Feed Roller 68 5 mm Auxiliary Feed Roller 68 5 mm Spacings other than the ones listed could be caused by damage or a bind in the gear train Residual Image Residual image the walking of a le
75. he transfer roll voltage to light medium or dark low medium or high on plus machines but seldom produces a visible difference in print darkness This setting may be useful in environmental extremes to prevent toner from being deposited in white areas next to large black areas 1 Enter Diagnostics mode 2 Select Print Contrast 3 Select Light Medium or Dark Low Medium or High on plus machines 4 Press Return to return to the Diagnostics mode main menu Print Registration See Print Registration Adjustment on page 63 Print Test Page You can run the Print Test even if the printer is not attached to a computer Use this test to check print and graphics quality and the version numbers of printer microcode The first page of this test feeds from tray 1 Following pages continue to feed from this tray unless you change the paper source To run the Print Test 1 Turn the printer on 2 Select MENUS 3 Select TESTS MENU Diagnostic Aids 43 Select Print Test 5 Select either Single or Continuous depending if you want one page or continuous test pages 6 Select Stop when you want the continuous test to end Print Tests All of the print tests can be run in the Single or Continuous mode To stop continuous printing select CANCEL Print Test 1 Print Test 1 generates one print out similar to the test page This test uses paper from tray 1 only Print Test 1 will not
76. is correct If there is no continuity make sure the HVPS contact returns to its upward limit when depressed and make sure the left bearing of the transfer roll is making proper contact Diagnostic Information 7 Error Code Action 918 Transfer Roll Error Servo Failure Verify correct cable connections from the Engine board to the HVPS Make sure there is continuity between the transfer roller and its contact on the HVPS replace the transfer roll if the continuity is correct If there is no continuity make sure the HVPS contact returns to its upward limit when depressed and make sure the left bearing of the transfer roll is making proper contact 920 Fuser Error Fuser is below temperature while printing See Fuser 920 921 or 922 Error on page 20 921 Fuser Error Fuser is below standby temperature when idle See Fuser 920 921 or 922 Error on page 20 922 Fuser Error Fuser failed to reach standby temperature See Fuser 920 921 or 922 Error on page 20 923 Fuser Error 927 Fan Stalled Fuser is too hot while printing or when idle See Fuser 923 Error on page 21 See Fan 927 Error on page 19 931 Printhead Error No first hsync See Printhead on page 28 932 Printhead Error Lost hsync See Printhead on page 28 934 Printhead Error Lost lock condition See Printhead on page 28 935 Printhead Error Mirror motor unable to reach opera
77. is means the printer recognizes PCL 5 commands used in various applications programs and that the printer emulates the functions corresponding to the command s PostScript is a registered trademark of Adobe Systems Incorporated PostScript is Adobe Systems designation of a set of printer commands language and functions included in its software products This printer is designed and manufactured by Lexmark International Inc to be compatible with the PostScript Level 2 language This means the printer recognizes PostScript Level 2 commands used in the various application programs and that the printer emulates the functions corresponding to the commands Vi Service Manual Safety Information The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions The safety features of some parts may not always be obvious Therefore replacement parts must have the identical or equivalent characteristics as the original parts Sicherheitshinweise Die Wartungsinformationen f r dieses Produkt wurden zur Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen ben tzt werden Zus tzliches Risiko eines elektrischen Schlags und k
78. l the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and fur niture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not work ing on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair Information 53 Adjustments Envelope Restraint Spring On The Envelope Feeder 1 Loosen the mounting screw A 2 Position the
79. main menu Warm up Time 1 Enter Diagnostics mode 2 Select Warm Up Time 3 Select a setting of 0 through 5 Use the or key to change the number 0 is the shortest fuser warm up factory setting 5 is the longest fuser warm up 4 Press Return to return to the Diagnostics main menu 40 Service Manual Maintenance Kit Count This non displayed counter must be reset after the maintenance kit is replaced to prevent the 80 Scheduled Maintenance message from displaying when the machine is turned on poo c Enter Diagnostics mode Select Maintenance Count Select RESET to set the count back to 0 Press Return to return to the Diagnostics mode main menu Memory Test DW OY Ur Ro toire Enter Diagnostics mode Select Memory Test Select either DRAM or ROM Select Single or Continuous The display indicates PASSED or FAILED Select CANCEL to stop continuous memory test Press Return to return to Diagnostics mode Operator Panel Tests The following tests check for proper functioning of the operator panel buttons and display LCD Button Test To test the operator panel buttons 1 2 3 Enter Diagnostics mode Select Button Test Press each button Closed is displayed until the button is released Then Open is displayed Press Return to return to the Diagnostics mode main menu Diagnostic Aids 41 LCD Test To test the operator panel display Enter Diag
80. minimizes the toner accumulating on the fuser cleaner Enter Diagnostics mode Select Auto Clean Select On or Off Press Return to return to Diagnostics mode main menu Pa mic Auto Clean Delay This can be set from 1 to 60 seconds with a default of 1 Auto Clean Delay does not appear on the menu unless Auto Clean is on Enter Diagnostics mode Select Auto Clean Delay Select 4 or to display the delay desired Select SAVE Press Return to return to Diagnostics mode main menu ense oor mecs Auto Clean Frequency This can be set from 10 to 255 pages with a default of 50 Auto Clean Delay does not appear on the menu unless Auto Clean is on Enter Diagnostics mode Select Auto Clean Frequency Select 4 or to display the frequency desired Select SAVE Press Return to return to Diagnostics mode main menu Ou Eo Tos Diagnostic Aids 35 Defaults Allows setting the following defaults to U S or Non U S values U S NON U S Letter size paper A4 paper 10 envelopes DL envelopes Symbol Set Roman 8 Symbol Set PC 850 BORIS Enter Diagnostics mode Select Defaults Select U S or Non U S Press Return to return to Diagnostics mode main menu Developed Image Test Use the Developed Image Test to isolate print quality problems You might have to practice this procedure several times to get the timing correct To run the Developed Image Test
81. nostics mode Select LCD Test Select Single or Continuous The display goes through a continuous sequence of turning pels on and off Press Return to stop continuous LCD test 6 Press Return to return to the Diagnostics mode main menu Roos Tor e Page Count To view or set the page count 1 Enter Diagnostics mode 2 Select Page Count 3 Choose any number between 0000000 and 9999999 by Selecting NEXT to move the cursor under each digit Then select OR to select the number you want in each digit 4 Select SAVE to save the page count displayed Paper Feed Test This test allows you to observe the drive gear train and feed paper through the printer to check for broken gear teeth watch the paper path or check the erase lamps Note You may want to remove the gear cover before starting this test so you can observe the motor gears Enter Diagnostics mode Select Paper Feed Select Tray 1 Tray 2 or Manual Select Single or Continuous Select CANCEL to stop continuous mode Press Return to return to Diagnostics mode main menu ON Pe Cos Ne 42 Service Manual Permanent Page Count The permanent page count can be displayed only It cannot be modified or reset by the customer or servicer 1 Enter Diagnostics mode 2 Select Permanent Page Count 3 Press Return to return to Diagnostics mode main menu Print Contrast Transfer on plus machines This setting changes t
82. nsert feeler gage Rotate the magnet against the feeler gage Tighten the mounting screw The gage should pass between the foam pad and the magnet pole piece with moderate resistance Repair Information 59 Optional Paper Feed Magnet 1 With the armature latched on the cam step check for 0 60 mm 0 07 mm between the foam pad and the magnet pole piece If adjustment is required continue Keep the armature latched and loosen the magnet mounting screw A Note The flat side of the D roll is down when the feed is latched 3 4 5 6 Insert feeler gage Rotate the magnet against the feeler gage Tighten the mounting screw The gage should pass between the foam pad and the magnet pole piece with moderate resistance Lx 22 60 Service Manual Printhead Skew Level 1 1 Loosen the mounting screws A 2 Pivot the printhead around the shoulder screw B until the skew marks on the printout are parallel to the top edge of the paper Use Print Test 1 or Quick Test to check this Rotating the printhead clockwise will lower the left skew adjustment point on the test print 3 Tighten the screws 4 Install the top cover and print another page to verify the adjustment Skew Adjustment Points gt Repair Information 61 Printhead Skew Level 2 Remove the top cover Loosen the screws Run Print Test 1 or the Quick Test on the Diagnostics Menu Move the pointer
83. oard 10R 12R 12C 12L 16L DRAM SIMM 4MB 12R 12L DRAM SIMM 2MB 10R 10P Inner EMC Shield 10R 12R 12L 12C Outer EMC Shield 10R 12R 12L 12C Inner EMC Shield 16L Inner EMC Shield 10P Outer EMC Shield 16L Guide Font Card 10R 12R 12L 12C Guide Font Card 16L Washer Parts Packet Nut Card Mtg Standoff Card Gnd 10R 12R 12L 12C Standoff Internal Threads Standoff Card Gnd 16L External Threads Standoff INA or DC to DC plastic Standoff Sys Bd plastic Parts Packet Standoff Sys Bd plastic Parts Packet Screw HVPS Mtg Parts Packet Screw LVPS Mtg Parts Packet Switch On Off Switch Pivot ROM SIMM 10R ROM SIMM 12R 12L 12C ROM SIMM 16L ROM SIMM 10P ROM SIMM 10R 4039 plus ROM SIMM 12R 12L 4039 plus ROM SIMM 16L 4039 plus Serial cable 10R 12R 12L 12C Serial cable 16L Screw serial cable DC to DC convertor 10R 12R 12L 12C Parts Catalog 165 Assembly 14 Transfer Roll 166 Service Manual Part Number 1381008 1381007 1381652 1328356 Description Roll Asm Transfer Housing Transfer 10R 12R 12C 12L 16L Housing Transfer 10P sawtooth not present on 10 o Rear Lens Asm Erase Front Lens Asm Erase o Contact Transfer Roll o Lamp Asm Erase Cover Clip Bearing Parts Catalog 167 Assembly 15 Duplex Option 168 Service Manual Part Number 1381019 1381006 1381020 1326137 1381021 1408906 1408905 1326001 1381023 138102
84. oller and its stud and thrust washer e The D roller shaft and its bushings on the rail assembly e The auxiliary metering roller and its stud on the rail including the snap in groove and the snap ridges in the roller hole e Gear no 14 and its stud on the rail e Gear no 13 and its stud on the rail The auxiliary paper feed idler and its stud on the rail e The prealigner drive idler and its stud on the rail e The prealigner drive roller and its stud on the rail The prealigner backup roller and its shaft and thrust washer e fixed center idler gear in the 500 sheet base and its shaft e The idler gear in the 500 sheet base and its shaft Use IBM no 23 grease approved equivalent Shell Darina 1 to lubricate e Front pivot latch studs e Gear no 8 teeth at gear no 7 contact points e Gear no 9 teeth at gear no 11 contact points e Gear no 9 teeth at gear no 8 and gear 10 contact points e Cover Hinge Spring tips e Cartridge ramps at top center of both sides frames e Latch handle tips e Area of contact between fuser release bail and roll e All release arms areas of contact of fuser solenoid lever Use grease p n 1329301 to lubricate gear nos 2 3 4 5 6 and 12 Use all the grease in the packet Apply part of the grease rotate the gears and apply the rest The teeth of gears 3 4 and 5 should be completely coated 122 Service Manual Use grease p n 1384076 to lubricate e A Areas of contact betw
85. om only If the test print frame is parallel to the left and right edges of the paper but not parallel to the top and bottom the printhead skew needs to be adjusted See Printhead Skew Level 1 on page 61 and Printhead Skew Level 2 on page 62 Stalled diamonds on display Check the continuity of the cable from 10P 10R 12R 12C 12L J7 16L J5 on the system board to the operator panel Next reseat the ROM and memory SIMMs and POR This condition can also occur on models 10R 12R 12L 12C if a network card is installed without the accompanying DC power card Diagnostic Information 31 If the problem is still present replace one at a time the 1 ROM SIMM 2 System board Vertical Void or Streak Do a developed image test to determine if the defect is occurring before or after the transfer process If you see the defect on the photoconductor check the operation of the printhead shutter and clean the printhead window with a lint free cloth folded over a cotton swab do not use a bare swab and do not use any cleaning fluids or water on the printhead window Inspect the HVPS contacts If the image on the photoconductor is good inspect the fuser rolls and transfer roll Make sure the left transfer roll bearing is contacting the contact from the HVPS Make sure the HVPS contacts are clean and spring back when pressed 32 Service Manual Diagnostic Aids Diagnostics Mode To run some of the printer diagnostic tests de
86. on 4039 Diagnostics Failures With Error Codes Two digit codes are messages for the 4039 user but if they recur frequently or at inappropriate times they may be symptomatic of a service problem On plus models refer to the diagnostics error log for the last six errors or paper jam codes Error Code Action 20 Paper Jam The input sensor was not unmade in time See Paper Feed Base Printer on page 26 21 Paper Jam The exit sensor was not made in time after the input sensor was made See Paper Feed Base Printer on page 26 22 Paper Jam The exit sensor was not unmade in time See Paper Feed Base Printer on page 26 23 Paper Jam Jam at the duplex unit Paper is either not leaving the duplex entry sensor in time or not making or unmaking the duplex exit sensor in time See Duplex on page 18 24 Short Paper The defined paper size is too short to print data as formatted 25 Incorrect Manual Feed Paper fed manually while motor is running and previous page in path 27 Change Envelope Paper 28 Load Envelope Paper Envelopes paper loaded are wrong size Input sensor not made after pick attempt Tray is empty or printer is requesting a manual feed 29 Output Bin Full The output bin sensor has not been unmade 30 Top Cover Open or Print Cartridge Missing Diagnostic Information 5 Error Code Action 87 Insufficient Memory Not enoug
87. or Shaft 12L 16L Roller backup 12L 16L Spring backup 12L 16L Jumper Ground Parts Packet Paper Size Sensor Asm Arm Tray Frame Parts Catalog 143 Assembly 5 Paper Feed Continued 144 Service Manual Part Number 1328452 1328450 1381617 1381618 1328381 1383314 1183245 1383314 1328298 1328167 1381527 1042230 1325515 1383314 1328345 1381298 1376284 1381567 Description Deflector Paper 10R 12R 12C 12L 16L 10P Spring Shaft Grd 12L 16L Kit Anti Squeak Bearing 10P 10R 12R 12C Kit Anti Squeak Bearing 12L 16L Outer Redrive Shield 12L 16L Screw Backup Spring Mtg Parts Packet Spring Arm Tray Bias Screw Redrive Mtg Parts Packet Guide Fuser Input Redrive Assembly 12L 16L With Handle Mounted Bin Sensor Redrive Assembly 12L 16L With Redrive Mounted Bin Sensor Redrive Assembly 10R 10P Redrive Assembly 12R 12C Screw Parts Packet Spring Bias Transfer Housing Output Bin Sensor 12L 16L redrive mounted sensor Cable Output Bin Op Panel 12L 16L redrive mounted sensor Kit Bail Minibail and Guide 12L 16L redrive mounted sensor Parts Catalog 145 Assembly 6 Paper Feed Alignment Gears W RE j e Left Dear View 146 Service Manual Part Number 1328383 1409238 1381145 1039278 1383316 1328384 1402336 1383580 1383908 Description Bellcrank Metering 10P 10R 12R 12L 16L Bellcrank Metering
88. orrect Turn the power back off and one at a time reconnect the system board cables powering on in between each connection and checking the voltages The connection which causes the voltages to be wrong indicates which component is bad Repair or replace the failing component or cable as necessary Duplex The duplexer should home the front shafts should turn and the input deflector should move immediately when you install the duplexer with the printer already powered on or when you POR the printer with the duplexer installed This means the duplexer has completed its internal tests and is ready to communicate with the printer If the duplexer does not home it is either damaged or is not receiving 34VDC from the printer To check the connection from the printer system board to the duplex system board remove the duplex top cover and table cover Disconnect the duplex cable from the printer system board From left to right 10P top to bottom the voltages on the printer system board connector pins should be 0 34VDC 0 5VDC 0 and 5VDC With the cable connected these voltages should also be at duplex system board JP4 1 through JP4 6 If you do not find a cable or voltage problem replace the duplex system board A 933 error indicates that communication between the printer and duplexer had been established but has been lost Check the cable as above if the error persists replace the duplex system board 23 Paper Jams Ex
89. paper stack in the tray This measurement should be 75 mm or less If it is larger than 75 mm there is a drive problem in the duplex unit or in the tray top cover Select CONTINUE 12 Perform the test several times to verify that the measurement is accurate Press Return to return to Diagnostics mode main menu 38 Service Manual Envelope Use this procedure to set the fuser solenoid power level to low medium or high Increase the level to reduce envelope wrinkling or decrease the level to reduce solenoid noise Enter Diagnostics mode Select Envelope Enhance Select Low Medium or High Press Return to return to Diagnostics mode main menu Toc Envelope Print Test Note Printing only occurs on the first envelope The envelope feeds from the automatic envelope feeder if present If there is no auto matic feeder present the printer uses manual envelope Enter Diagnostics mode Select Envelope Print Select Single or Continuous Select CANCEL to stop continuous envelope feed Press Return to return to the Diagnostics mode main menu Or Mc Error Log plus machines only The error log records the last 6 2X Paper Jam or 9XX Service errors In a full log position 6 is the oldest error If more than 6 errors are received the oldest error is discarded If the same error occurs consecutively it is recorded only once All 97X Network Card errors are logged
90. pezzi originali Pautas de Seguridad La informaci n sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario Existen mayores riesgos de descargas el ctricas y da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado comprende esto y toma las precauciones necesarias Los dispositivos de seguridad de algunas partes quiz no siempre puedan ser reconocidas a simple vista Por lo tanto las partes de reemplazo deben poseer caracter sticas id nticas o equivalentes a las partes originales Sikkerhedsoplysninger Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik pa professionelt servicepersonale og b r derfor ikke benyttes af andre Risikoen for elektrisk st d ges under demontering og service af dette produkt hvorfor der ber tages de n dvendige forholdsregler Sikkerhedsforanstaltningerne er ikke altid lige apenbare for alle reservedele Der bor derfor kun anvendes originale reservedele eller reservedele med samme egenskaber som de oprindelige Ozone Information This product does not produce measurable amounts of ozone gas viii Service Manual Preface This manual is divided into the following chapters General Information contains a general description of the printer and the maintenance approach used to repair it Special tools and test equipment are listed in this chapt
91. r Parts Packet Spring Assembly Setscrew Parts Packet Thumb Wheel Gear Parts Packet Wheel Parts Packet Detent Spring Screw Parts Packet Parts Catalog 153 Assembly 10 Base for Paper Drawer 500 Sheet 154 Service Manual Part Number 1328194 1039558 1328197 1039170 1328674 Description Housing Roll Plate Assembly Gear Pad Machine Clip Ground Parts Catalog 155 Assembly 11 Optional Paper Drawer 500 Sheet 156 Service Manual Part Number 1183342 1328630 1039170 1039596 1383316 1039603 1039540 1383925 1383385 1383385 1383385 1381622 1383316 1039558 1183299 1383314 Description Base Assembly Deflector Feet Bellcrank Assembly Spring Bellcrank Parts Packet Drive Roller D Roller Tire Paper Feed Magnet Washer Parts Packet Screw Parts Packet Spring Parts Packet Drive Assembly D Roller Bias Spring Parts Packet Roller Switch Assembly Screws Parts Packet Parts Catalog 157 Assembly 12 Fuser 158 Service Manual Part Number 1381082 1381083 1381521 1381084 1381085 1381522 1381010 1381038 1381626 1381627 1381679 1381678 1383314 1380785 1382287 1039315 1328132 1038717 1383314 1383311 1381523 1383324 1381524 1381011 1381037 Description Fuser and Lamp 110V 10R Fuser and Lamp 110V 12R 12L Fuser and Lamp 110V 12C Fuser and Lamp 220V 10R Fuser an
92. r card Remove the fuser cover and wiper Remove the tape holding the thermistor cable to the shroud Squeeze the thermistor bracket tabs B and remove the thermistor from the shroud Remove the thermistor cable from the guide clips on the right of the fuser to remove the thermistor 78 Service Manual Repair Information 79 HVPS Removal Cx vesc OOo mE OT uso t Unplug the power cord Remove the left cover Remove the fuser input guide Remove the transfer roll housing Remove the fuser cover Disconnect the cable from the HVPS connector Remove the power switch rod Remove the ground screw B Remove the mounting screws C Pull the ground strap through the hole D The power supply is held in place by two latches on the left side To release the latches e Push one latch E in and raise one of the studs F to release the latch e Push the other latch E in and raise the other stud F to release the latch Lift the power supply until the studs F align with the large openings then move the power supply to the right to release it from the frame Move the front of the power supply to the right to clear the fuser power wires Tilt the front of the power supply up and lift it out of the machine 80 Service Manual Repair Information 81 Input Sensor Removal 1 2 8 4 Remove the fuser input guide A Remove the transfer roll
93. ray 500 5 152 Assembly 10 Base for Paper Drawer 500 Sheet 154 Assembly 11 Optional Paper Drawer 500 Sheet 156 Assembly 12 Fuser sssssssseeene nne 158 Assembly 13 Electronics 162 Assembly 14 Transfer Roll 166 Assembly 15 Duplex 168 xiv Assembly 16 Envelope and 100 Sheet Auxiliary Feeder te ee e es Assembly 17 Options ssssssseeeeenne Assembly 18 XV Service Manual General Information The 4039 is a family of 600 dpi Laserprinters designed to attach to IBM compatible PC s and to most types of computer networks The printer has PostScript and PCL emulation standard Models Covered in this Manual There are no voltage or pinout differences between the regular models and the plus models For example a voltage callout for the 16L also applies to the 16L plus IBM Models 4039 10R 4039 12R 4039 12L 4039 12C 4039 16L 4039 10R plus 4039 12R plus 4039 12C plus 4039 12L plus 4039 16L plus 10ppm PostScript Level 1 emulation input output capacity 200 250 12ppm PostScript Level 1 emulation input output capacity 200 250 12ppm PostScript Level 1 emulation output bin sensing input output capacity 500 500 Similar to 12R designed for printing lab
94. rease quickly as the fuser cools Honeycomb Areas of the page are covered with faint 6 mm circles This print defect is usually caused by the print cartridge If it is not the problem verify that the tab on the transfer roll housing is touching the contact on the HVPS the transfer roll housing should have continuity to ground Make sure the HVPS ground lead to the side frame is in place and making good contact Diagnostic Information 21 Horizontal Void or Streak This is usually due to the cartridge not being installed correctly Check the printhead area for obstructions and check the mechanical workings of the print cartridge and printhead shutter If nothing is found go to Blank Page and follow those instructions 22 Service Manual LAN Problems You cannot find a printer or network problem but jobs still do not print If the network card checks out successfully the problem may be with the hardware or software outside of the network card Below are some suggestions to the customer for checking hardware and software for possible problems Refer the customer to the LaserPrinter Network Printer Utility Guide to find the problem e Make sure that the desired network protocol is enabled from the printer operator panel e Verify proper print queue and printer driver configuration e Verify that the adapter port has been associated e Verify correct installation of software utility e Single route broadcast not supported acros
95. rt Use the error code charts symptom index service checks and diagnostic aids to determine the symptom and repair the failure See Diagnostic Information starting on page 5 This printer can be serviced without being connected to a host After you complete the repair perform tests as needed to verify the repair General Information 3 Abbreviations ASIC CSU DRAM EEPROM EP ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR VAC VDC Application Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Electrically Erasable Programmable Read Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Local Area Network Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power On Reset Power On Self Test Print Quality Enhancement Technology Raster Image Processor Read Only Storage Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current Unique Tools Required For Service Wrap Plug Parallel P N 1319128 Wrap Plug Serial P N 1329048 Twinax serial debug cable P N 1381963 Coax serial debug cable P N 1381964 4 Service Manual Diagnostic Informati
96. s network bridge if bridge is used Server problem check print server installation and configuration using the appropriate system guide to operations Light Print Light print is frequently caused by a worn out print cartridge Clean the transfer roll by powering on and off two or three times leaving the printer on for about two minutes each time Other causes are the same as for Blank Page Make sure Print Darkness on the customer menu is set to Normal or Dark 10P Increasing the diagnostics mode Print Contrast setting will darken print further PostScript emulation output may appear lighter than PCL output or a test print this is not a defect Verify on the Print Test that the print is too light before performing service Diagnostic Information 23 Network Card 977 Errors All network card errors are recorded as 977 in the error log If there are 977 errors in the log POR several times and take the appropriate action for the displayed error code If the displayed error is 977 verify that the network card is installed and grounded correctly Remove the network card and check for 5VDC at pin B24 of 10P 10R 12R 12C 12L J13 16L J12 If the voltage is incorrect replace the system board if there is 5VDC replace the network card Network Wrap Tests Token Ring with Shielded Twisted Pair Cable Disconnect the LAN cable from the electrical outlet leaving it connected to the printer network card Ethernet 10Base 2
97. scribed in this chapter you must put the printer in Diagnostics mode To enter Diagnostics mode 1 Turn the printer off 2 Press and hold the Ready and Return buttons Then turn the printer on The printer performs the Power On Self Test 3 Release the buttons when Performing Self Test is displayed 4 You can exit Diagnostics mode without a POR by selecting Reset Printer Diagnostic Aids 33 Grouped Diagnostic Aids Print Tests Operator Panel Tests Print Test Page Button Test Developed Image Test LCD Test Print Tests Duplex Tests Registration Tests Duplex Feed 1 Duplex Feed 2 Print Registration Quick Test Paper Feed Tests Page Counts Envelope Print Test Page Count Paper Feed Test Maintenance Kit Count Permanent Page Count Printer Setup Tests Device Tests Envelope Enhance Quick Disk Test Print Contrast Transfer Disk Test Clean Fuser Temperature Warm up Time Hardware Connection Checks Defaults LAN Information Memory Tests Wrap Tests Sensor Test Serial Interface Option Auto Clean Auto Clean Frequency Auto Clean Delay Error Log 34 Service Manual Alphabetical List of Diagnostic Aids Auto Clean Auto Clean needs to be turned on if there is an unacceptable amount of toner being deposited on the back of the page When Auto Clean is on after printing the number of pages specified in Auto Clean Frequency the printer pauses the number of seconds specified in Auto Clean Delay This pause
98. ser assembly 158 drive gear backlash adjustment 56 input guide removal 74 lamp removal 76 175 removal 74 solenoid adjustment 58 solenoid removal 77 thermistor removal 78 920 921 or 922 error 20 923 error 21 fuser temperature 40 fuser theory 20 fuser sensor cable removal 94 G gear train locations 104 H honeycomb 21 horizontal void or streak 22 HVPS locations 105 input sensor removal 82 L LAN information 48 problems 23 LCD test 42 light print 23 lower frame assembly 132 assembly removal 83 lubrication specifications 121 LVPS cover removal 85 removal 84 maintenance approach 3 maintenance kit count 41 176 Service Manual major assembly locations 103 memory test 41 mirror motor cable locations 115 N network connections and checks 47 wrap tests 24 network card 977 errors 24 operator panel problems 25 removal 86 operator panel output bin sensor cable handle mounted outbin sensor 116 redrive mounted outbin sensor 117 option card removal 86 optional paper feed magnet adjustments 60 options assembly 172 available 2 output bin sensor 24 P page count 42 paper drawer base assembly 500 sheet 154 optional 500 sheet assembly 156 paper feed alignment gears assembly 146 assembly 142 drive assembly 148 magnet adjustments 59 magnet assembly removal 88 rollers removal 89 paper feed problem base printer 26 duplex unit 27 Envelope feeder 28 100 sheet auxiliary fee
99. sly the fuse melts and shuts off power to the lamp The thermistor output voltage is proportional to the fuser temperature and is on 10P 10R 12R 12C 12L J19 6 16L J16 6 The voltage will cycle from approximately 2 0 to 2 3VDC as the lamp goes on and off during idle and will be around 2 7VDC during continuous printing when the Fuser Temperature is set to Normal In Power Saver mode the lamp is left off until a job is printed The system board signal to the LVPS TRIAC is on 10P J11 16 10R 12R 12C 12L J11 3 16L J18 16 The voltage is OVDC when the lamp is to be on and 24 10 5 when the lamp is to be off The lamp can be tested by briefly connecting this pin to ground Fuser 920 921 or 922 Error A 922 error during a POR caused by low line voltage can usually be cleared by doing another POR If the fuser lamp is lighting very dimly check for a 220V lamp installed in a 110V machine Check all the connectors to the exit sensor card and the lamp power connections at the left end of the fuser Make sure the thermistor is making contact with the hot roll Check the continuity of the lamp the thermal fuse and the fuser power cable Check the thermistor resistance at 10P 10R 12R 12C 12L J19 5 to J19 6 16L J16 5 to J16 6 it should be from 100K Ohms to 260K Ohms when cold it may be as low as 2 3K Ohms when hot but increases quickly as the fuser cools There should be no connection from either pin to ground 20
100. sor card cable 3 Depress the exit sensor flag actuator B and lift out the exit sensor card Duplex Option Bottom Cover And Entry Sensor Card Removal 1 Release the two latches A on the frame assembly and lift it out of the bottom cover 2 Pry up on the sensor card at B so it will clear the mounting stud and pull it out of the frame assembly Note When re installing the sensor lift up the flags so they will clear the sensor and not be damaged 100 Service Manual Repair Information 101 Duplex Option System Card And Motor Removal 1 Disconnect all cables 2 Release latches A and lift the system board out 3 Remove the two motor mounting screws 4 Liftthe motor out of the frame assembly Note The remaining FRU is the Gearblock Assembly When you replace this FRU see Lubrication Specifications on page 121 Note Reinstall the motor so the belt is not tight but will not jump teeth on the timing pulley 102 Service Manual Connector Locations This chapter shows the locations of major printer assemblies gears connectors and ground straps Major Assembly Locations Upper Frame Print Cartridge Operator Panel Fan Exit Redrive Low Voltage Print Head Power Supply High Voltage Power Supply System Board Toner Sensor Input Sensor Paper Feed Connector Locations 103 Gear Train A Se Aux Feeder Gear 14 drive G
101. spring B so it clears the separator roller by 1 9 0 2 mm 0 075 0 008 in 3 Tighten the mounting screw D A N IF 1 9 0 2 mm 0 075 0 008 Rear View Paper Restraint Spring On The 100 sheet Auxiliary Feeder 1 Loosen the mounting screw 2 Position the spring B so it clears the separator roller by 1 9 0 2 mm 0 040 0 008 in 3 Tighten the mounting screw B A A pn iv L d 1 A _v 1 9 0 2 mm 0 075 0 008 Rear View 54 Service Manual Envelope Feeder Magnet And 100 sheet Auxiliary Feeder Magnet 1 Hold the armature A in the closed coil active position 2 Loosen the mounting screw B and rotate the magnet assembly so the armature clears the clutch gear by 0 30 0 20 mm 0 012 0 008 in 3 Tighten the screw 4 Checkthe adjustment on both sides of the gear 0 30 0 20 mm 0 012 0 008 in Repair Information 55 Fuser Drive Gear Backlash Fuser drive gear backlash is adjusted so that when gear 2 is held still there is a slight amount of backlash in the fuser gear Print quality can be affected if the gears are too tight 18 2 3 Remove the fuser cover Locate gear 2 It is the white adjustable gear mounted to the side frame below the fuser gear Rotate the adjustable
102. t is picked replace the system board Check the adjustment of the feeder magnet If paper is being bent or double fed check the adjustment of the feeder restraint spring Printhead Note The printhead is a sealed unit It contains no parts that can replaced or serviced Verify the continuity of the fan mirror motor cable and the hsync cable Verify the presence of the following voltages 24VDC at 10P 10R 12R 12C 12L J5 1 16L J3 1 5VDC at 10P 10R 12R 12C 12L J6 5 16L J4 5 5 at 10P 10R 12R 12C 12L J6 1 16L J4 1 If these voltages are not correct replace the system board Verify 5VDC at pin 5 on the fan mirror motor cable at the mirror motor board If the voltage is correct replace the printhead if the voltage is bad and the cable is OK replace the system board 28 Service Manual Paper Size Sensing Problem The printed area does not fit on the page or the paper size cannot be changed from the operator panel Make sure that paper trays for the 4019 4028 or 4029 are not being used in the 4039 printer Make sure the paper tray and its stops are undamaged Make sure the cable to the paper size switch is connected correctly Disconnect 10P 10R 12R 12C 12L J19 16L J16 from the system board before making the following measurements With the tray removed make sure there is no continuity from 10P 10R 12R 12L 12C J19 3 to J19 4 16L J16 3 to J16 4 on the cable replace the paper size switch if t
103. the end to the rear to release it Push the top of the cover to the left Remove the cover by sliding it to the rear of the machine Top Cover Removal 1 Remove the top cover screws C 2 Liftthe rear of the cover first then the front and lift the cover off 3 Restthe cover on the machine and disconnect the operator panel cable and the ground wire 66 Service Manual Repair Information 67 Transfer Roll Removal 1 Unplug the power cord 2 Remove the print cartridge 3 Remove the bearing cover from the left side of the transfer roll Note Do not touch the transfer roll surface Support the left bearing cover from the front with your left hand e Use a small screwdriver to push the rear latch forward and release the bearing cover This exposes the bearing on the end of the transfer roll 4 Grasp the bearing on the end of the transfer roll Lift slightly and move it to the left until the right end of the transfer roll shaft slides out of the right side bearing 5 Remove the transfer roll 6 Liftthe right bearing straight up and out of the machine 68 Service Manual D roll Assembly Removal 1 Unplug the power cord 2 Remove the paper tray Note The following 3 steps are not necessary but may make it easier to see the parts 3 Remove the print cartridge 4 Remove the fuser input guide 5 Remove the transfer roll housing assembly 6 Move your finger down off the end of the shaft to t
104. the power cord Remove the print cartridge Remove the right left and top covers Remove the system board Remove the inner EMC shield Remove the load box latches A Release the latches B Pivot the upper frame to the rear to release the spring tension Unsnap the plastic insert D holding the upper frame cables in the right side frame 10 Remove the screws C 11 Remove the upper frame cables through the side frame 12 Lift the upper frame off the machine mom boah Repair Information 97 Zif Connector Removal 1 Slide the cable clamp A to the open position 2 Note how the contact surfaces of the cable are positioned as you pull the cable B out of the connector Clamp 98 Service Manual Duplex Option Top Cover And Table Cover Removal 1 Open the top cover by pulling up at A and pivoting 90 2 Prythe top cover from the bottom cover at B and lay the top cover on its side To disconnect the fan leads the table cover has to be removed Release latches C on the paper table cover and lift up Release latch D and lift the paper table cover out of the frame assembly 3 4 lt d 0 RUE SN RS Repair Information 99 Duplex Option Exit Card And Cover Removal 1 Pry up on tabs after the tabs are released lift up on the cover rotate the cover out and slide it to the right to completely remove it 2 Disconnect the exit sen
105. ting speed See Printhead on page 28 941 System Board ROM SIMM failed CRC code data or font data Run the diagnostic Memory Test for ROM Replace the SIMM if the test fails or the problem recurs after POR replace the system board if the SIMM does not fix the problem 944 System Board RIP processor failure Replace the System board 945 System Board ASIC 1 failure Replace the system board 8 Service Manual Error Code Action 946 System Board ASIC 2 failure Replace the system board 947 System Board Engine ASIC RAM failure Replace the System board 948 System Board Engine ASIC electronics failure Replace the system board 950 System Board 952 System Board SRAM failure Replace the system board Unable to zero PQET SRAM Replace the system board 953 System Board 960 Memory Error 961 Memory Error 970 Network Card NVRAM failure Replace the system board Bad or missing DRAM in the base DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM If test fails or the problem recurs after POR replace the DRAM SIMM Bad DRAM in the optional DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM If test fails or the problem recurs after POR replace the DRAM SIMM Network card processor failure Replace the Network Card 971 Network Card Network card RAM failure Replace the Network Card 972 N
106. ulations on electromagnetic interfer ence for a Class B computing device the printer cable must be shielded To assure compliance with FCC regulations for a Class B computing device use a properly shielded and grounded IBM cable Part numbers for the various interface cables are part number 1525612 for parallel interface and part number 8509386 for serial interface Use of a substitute cable not properly shielded and grounded may result in violation of FCC regulations Industry Canada Compliance Statement This digital apparatus does not exceed the Class B limits for radio noise emissions from digital apparatus as set out in the interference causing equipment standard entitled Digital Apparatus ICES 003 of Industry Canada Avis de conformit aux normes d Industrie Canada Cet appareil num rique respecte les limites de bruits radio lectriques applicables aux appareils num riques de Classe B prescrites dans la norme sur le mat riel brouilleur Appareils num riques NMB 003 dict e par Industrie Canada The United Kingdom Telecommunications Act 1984 This apparatus is approved under the approval number NS G 1234 J 100008 for the indirect connections to the public telecommunications systems in the United Kingdom iV Service Manual European Community Electromagnetic Compatibility Directive This product is in conformity with the protection requirements of EC Council directive 89 336 EEC on the approximation of t

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