LaserPrinter 4039 Series 4039-1XX • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries.
4039-1XX 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.
4039-1XX Table of Contents Notices and Safety Information.............................................. ix Electronic Emission Notices............................................................. ix Federal Communications Commission (FCC) Statement ............ ix Industry Canada Compliance Statement ...................................... x The United Kingdom Telecommunications Act 1984 .................... x European Community (EC) Electromagnetic Compatibility Directive ..................................
039-1XX Symptom Table ...............................................................................12 Banding .......................................................................................13 Background .................................................................................13 Black Page ..................................................................................15 Blank Page ..................................................................................
4039-1XX Diagnostic Aids....................................................................... 32 Diagnostics Mode............................................................................ 32 Grouped Diagnostic Aids ................................................................ 33 Alphabetical List of Diagnostic Aids ................................................ 34 Auto Clean .................................................................................. 34 Auto Clean Delay .....................
4039-1XX Network Connections and Checks ..................................................46 Wrap Tests ..................................................................................46 LAN Information ..........................................................................47 Serial Interface Option, 10P ........................................................47 Function Switch Setting........................................................47 Repair Information.........................................
4039-1XX Removals (continued) Operator Panel Removal............................................................. 84 Option Card Removal.................................................................. 84 Exit Sensor Removal................................................................... 85 Paper Feed Magnet Assembly Removal..................................... 86 Paper Feed Rollers Removal ...................................................... 87 Paper Size Switch Removal...............................
4039-1XX Preventive Maintenance....................................................... 119 Safety Inspection Guide ............................................................119 Lubrication Specifications..........................................................120 Printhead Window Cleaning Procedure ....................................122 Cleaning The Transfer Roller ....................................................122 Scheduled Mechanical Maintenance.........................................
4039-1XX 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.
4039-1XX 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 regulations on electromagnetic interference, for a Class B computing device, the printer cable must be shielded.
4039-1XX European Community (EC) Electromagnetic Compatibility Directive This product is in conformity with the protection requirements of EC Council directive 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility. German Statement of Acoustic Emissions A 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.
4039-1XX 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.
4039-1XX 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, è possibile il rischio accresciuto di scosse elettriche e danni personali. Il personale di assistenza autorizzato, consapevole di ciò, deve adottare le precauzioni necessarie.
4039-1XX 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 chapter, 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).
4039-1XX 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.
4039-1XX 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.
4039-1XX Maintenance Approach The diagnostic information in this manual will lead you to the correct field replaceable unit (FRU) or part. 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.
4039-1XX 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 ReadOnly 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
4039-1XX Diagnostic Information 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 25.
4039-1XX Error/Code Action 37 Insufficient Memory Not enough 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 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.
4039-1XX 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 23.
4039-1XX 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.
4039-1XX 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 SRAM failure. Replace the system board. 952 System Board Unable to zero PQET SRAM. Replace the system board. 953 System Board NVRAM failure. Replace the system board. 960 Memory Error Bad or missing DRAM in the base DRAM slot.
4039-1XX 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 23. 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.
4039-1XX Power-On Self Test (POST) When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning by observing the following: 1. 1½ 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.
4039-1XX Symptom Table Symptom Action or Service Check Dead Machine Dead Machine Service Check Repeats pattern of five beeps and a pause.
4039-1XX 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 most noticeable on fine dot or horizontal line patterns such as the second page of Print Test 2 or Print Test 3.
4039-1XX 10R/12R/12C/ 12L 16L J20-1 to J20-4 J17-1 to J17-4 J20-2 to J20-4 J17-2 to J17-4 J20-3 to J20-4 J17-3 to J17-4 J20-8 to J20-4 J17-8 to J17-4 Voltage while Printing Voltage while Idling Less than 1VDC Greater than 1VDC The meter should fluctuate slightly between each page. Less than 1VDC +21-26VDC Less than 5VDC Less than 5VDC +21-26VDC .
4039-1XX 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.
4039-1XX Blank Page 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.
4039-1XX . 10P J14-1 to J14-4 J14-2 to J14-4 J14-3 to J14-4 J14-8 to J14-4 Voltage while Printing Voltage while Idling Less than 5VDC Less than 5VDC The meter should fluctuate slightly between each page. 1VDC 0VDC 0VDC 0VDC 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.
4039-1XX 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 correct. 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.
4039-1XX 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.
4039-1XX 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 continuously, the fuse melts and shuts off power to the lamp.
4039-1XX 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.
4039-1XX 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. 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.
4039-1XX 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. 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.
4039-1XX 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).
4039-1XX 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. 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.
39-1XX 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 the continuity of the cable before replacing the sensor. The input sensor signal is on (10P) J20-6 (10R/12R/12C/12L) J20-11 (16L) J17-11; the output sensor signal is on (10P/10R/12R/12C/12L) J19-8 (16L) J16-8. The voltage should be 0VDC when there is no paper in the sensor and +5VDC when paper is present.
4039-1XX 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
4039-1XX 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.
4039-1XX 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.
4039-1XX 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 61.
4039-1XX 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.
4039-1XX Diagnostic Aids Diagnostics Mode To run some of the printer diagnostic tests described 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].
4039-1XX Grouped Diagnostic Aids Print Tests Operator Panel Tests Print Test Page Developed Image Test Print Tests Button Test LCD Test Registration Tests Duplex Tests Duplex Feed 1 Duplex Feed 2 Print Registration Quick Test Paper Feed Tests Page Counts Envelope Print Test Paper Feed Test Page Count Maintenance Kit Count Permanent Page Count Printer Setup Tests Device Tests Envelope Enhance Print Contrast (Transfer) Fuser Temperature/Warm-up Time Quick Disk Test Disk Test/Clean Hardware Con
4039-1XX 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 minimizes the toner accumulating on the fuser cleaner. 1. 2. 3. 4. Enter Diagnostics mode. Select [Auto Clean]. Select [On] or [Off].
4039-1XX 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 1. 2. 3. 4. 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.
4039-1XX A message describing test progress is displayed during the test. 1. 2. 3. 4. 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. 5. Select [CANCEL] to interrupt the test. 6. Press Return to return to Diagnostics mode main menu. Duplex Feed 1 Test This test checks for slipping paper problems.
4039-1XX 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. 1. Enter Diagnostics mode. 2. Select [Duplex Tests]. 3. Select [Duplex Feed 2]. 4. 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. The message [CLEAR PAPER] appears on the display. 6. Open the printer top cover. 7.
4039-1XX Envelope Enhance 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. 1. 2. 3. 4. Enter Diagnostics mode. Select [Envelope Enhance]. Select [Low], [Medium], or [High]. Press Return to return to Diagnostics mode main menu. Envelope Print Test Note: Printing only occurs on the first envelope. The envelope feeds from the automatic envelope feeder if present.
4039-1XX 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.
4039-1XX 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. 1. 2. 3. 4. 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 1. 2. 3. 4. 5. 6. 7. Enter Diagnostics mode. Select [Memory Test]. Select either [DRAM] or [ROM].
4039-1XX LCD Test To test the operator panel display: 1. 2. 3. 4. Enter Diagnostics mode Select [LCD Test]. Select [Single] or [Continuous]. The display goes through a continuous sequence of turning pels on and off. 5. Press Return to stop continuous LCD test. 6. Press Return to return to the Diagnostics mode main menu. Page Count To view or set the page count: 1. Enter Diagnostics mode. 2. Select [Page Count]. 3.
4039-1XX 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 the transfer roll voltage to light, medium, or dark (low, medium, or high on “plus” machines), but seldom produces a visible difference in print darkness.
4039-1XX 4. Select [Print Test Page]. 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 duplex. To run Print Test 1: 1. 2. 3. 4. 5.
4039-1XX Print Test 3 This test generates 2 printouts: a solid black page, and a dot pattern that can be used to evaluate print quality. 1. 2. 3. 4. 5. 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. Quick Disk Test This is a one minute test which performs a non-destructive write/ read on one block per track on the disk.
4039-1XX 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.
4039-1XX Network Connections and 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.
4039-1XX 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. 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.
4039-1XX 1 2 3 4 SPEED (BPS) Off On 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.
4039-1XX 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.
4039-1XX 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.
4039-1XX 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).
4039-1XX Adjustments Envelope Restraint Spring On The Envelope+ Feeder 1. Loosen the mounting screw [A]. 2. Position the spring [B] so it clears the separator roller by 1.9 ±0.2 mm (0.075 ±0.008 in.). 3. Tighten the mounting screw. Paper Restraint Spring On The 100-sheet Auxiliary Feeder 1. Loosen the mounting screw [A]. 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.
4039-1XX 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. Check the adjustment on both sides of the gear.
4039-1XX 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. 1. Remove the fuser cover. 2. Locate gear #2. It is the white adjustable gear mounted to the side frame below the fuser gear. 3. Rotate the adjustable gear in one direction to check for backlash. To adjust backlash: 1. Loosen the nut on the idler stud. 2.
4039-1XX Repair Information 55
4039-1XX 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.
4039-1XX Paper Feed Magnet 1. Remove the system board. The magnet is accessed through the holes in the right frame. 2. 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: 3. Keep the armature latched and loosen the magnet mounting screw [A]. 4. Insert feeler gage. 5. Rotate the magnet against the feeler gage. 6. Tighten the mounting screw. 7.
4039-1XX 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: 2. 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.
4039-1XX 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.
4039-1XX Printhead Skew - Level 2 1. 2. 3. 4. Remove the top cover. Loosen the screws [A]. Run Print Test 1 or the Quick Test on the Diagnostics Menu. Move the pointer [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.
4039-1XX 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. Enter Diagnostics mode. 2. Select [Print Registration]. 3. Select one of the following: [Left Margin], [Top Margin], or [Bottom Margin]. 4.
4039-1XX Removals When there is artwork to support a procedure, it follows the text. Covers Right Cover Removal 1. 2. 3. 4. 5. 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 1. 2. 3. 4. 5. 6. 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].
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4039-1XX Left Cover Removal 1. 2. 3. 4. 5. 6. Unplug the power cord. Open the top cover and remove the print cartridge. Remove the front cover. Locate the latch [A] and push 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. Lift the rear of the cover first, then the front, and lift the cover off. 3.
4039-1XX Repair Information 65
4039-1XX 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. • 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.
4039-1XX 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. 4. 5. 6. Remove the print cartridge. Remove the fuser input guide. Remove the transfer roll housing assembly. Move your finger down off the end of the shaft to the latch located above the flat part of the D-roll. 7. Push the latch down (away from the shaft) and slide the D-roll to the left, off the shaft.
4039-1XX Drive Motor Removal 1. 2. 3. 4. 5. 6. 7. 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). 8. Remove the motor mounting nuts [B] and screws. 9. Work the motor out of the machine.
4039-1XX Repair Information 69
4039-1XX Fan/Redrive Removal 1. 2. 3. 4. 5. 6. 7. 8. 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.
4039-1XX D B A C Repair Information 71
4039-1XX 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 °-230 ° C (302 °- 446 ° F). USE EXTREME CAUTION WHEN REMOVING THIS UNIT. BEFORE YOU SERVICE THIS UNIT, ALLOW THE MACHINE TO COOL FOR 5 MINUTES. 1. Unplug the power cord. 2. Remove the printer cartridge. 3. Disconnect the exit sensor cable from the fuser through the opening for the paper output. 4.
4039-1XX Repair Information 73
4039-1XX Fuser Lamp Removal CAUTION: THE TEMPERATURE OF THE HOT ROLLER IS 150 °-230 ° C (302 °-446 ° 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.
4039-1XX Fuser Solenoid Removal 1. Remove the fuser. 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.
4039-1XX Fuser Thermistor Removal 1. Disconnect the thermistor cable connector [A] from the exit sensor card. 2. Remove the fuser cover and wiper. 3. Remove the tape holding the thermistor cable to the shroud. 4. Squeeze the thermistor bracket tabs [B] and remove the thermistor from the shroud. 5. Remove the thermistor cable from the guide clips on the right of the fuser to remove the thermistor.
4039-1XX B A Repair Information 77
4039-1XX HVPS Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 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.
4039-1XX .
4039-1XX Input Sensor Removal 1. 2. 3. 4. Remove the fuser input guide [A]. Remove the transfer roll 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. 5. Release latch [B] and pull the sensor down and forward to get it out of its mounting. 6. Disconnect the toner sensor cable from the board. 7. Remove the sensor board.
4039-1XX Lower Frame Assembly Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 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.
4039-1XX LVPS Removal 1. 2. 3. 4. Disconnect the power cord. Remove all external feed trays. Remove the left and right side covers. (10P and 16L) remove the system board and the inner EMC shield. 5. Remove the left and right LVPS mounting screws. 6. Disconnect the fuser connector [A]. 7. Lift the supply up and then toward the right side frame to disconnect the On/Off switch linkage.
4039-1XX LVPS Cover Removal 1. Form tabs [D] away from the power supply to create clearance for tabs [A] to move downward. 2. Release the top latches [A]. 3. Release the side latches [B]. 4. Release the bottom latches [C].
4039-1XX Operator Panel Removal 1. Remove the top cover. 2. Disconnect the operator panel cable. 3. Remove the operator panel mounting screws from the inside of the top cover. Option Card Removal 1. 2. 3. 4. 5. 6. 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.
4039-1XX Exit Sensor Removal 1. 2. 3. 4. 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. 5. Release the latches [A]. 6. Pull the sensor down to remove it.
4039-1XX Paper Feed Magnet Assembly Removal 1. 2. 3. 4. 5. 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]). 6. Remove the mounting screw [B]. 7. Remove the paper feed magnet assembly from the rear (slip the connector under the right frame).
4039-1XX Paper Feed Rollers Removal Note: Replace all paper feed drive rollers at the same time. 1. 2. 3. 4. 5. 6. 7. 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.
4039-1XX Paper Size Switch Removal 1. 2. 3. 4. 5. 6. 7. 8. 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.
4039-1XX Printhead Removal IMPORTANT: The printhead is ESD-sensitive. It is not serviceable and should be replaced as a unit. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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 printhead shroud.
4039-1XX System Board Removal 1. Check the page count and write it down so you can set the new system board. 2. Turn the printer off. 3. Remove the right cover. 4. 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). 5. Disconnect all the external connectors from the system board and remove the option cards. 6. Remove the system board mounting hardware [A]. 7. Release the system board standoff. 8. Remove screw [B].
4039-1XX Repair Information 91
4039-1XX System Cable Removal 1. 2. 3. 4. 5. 6. 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 1. 2. 3. 4. 5. 6. 7. 8. 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.
4039-1XX 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. 5. Lift the sensor to unsnap it. 6. Work the cable out of the frame and remove the sensor.
4039-1XX Transfer Roll Housing Removal 1. Remove the print cartridge. 2. Remove the fuser input guide. 3. 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. 4. Lift the transfer roll housing far enough to disconnect the system cable. 5. Lift the transfer roll housing out of the machine. 6. To replace the transfer roll housing, perform the removal procedure in reverse order.
4039-1XX Upper Frame Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. Unplug 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.
4039-1XX Zif Connector Removal 1. Slide the cable clamp [A] to the open position. 2. Note how the contact surfaces [C] of the cable are positioned as you pull the cable [B] out of the connector.
4039-1XX Duplex Option Top Cover And Table Cover Removal 1. Open the top cover by pulling up at [A] and pivoting 90 °. 2. Pry the top cover from the bottom cover at [B] and lay the top cover on its side. 3. To disconnect the fan leads, the table cover has to be removed. 4. 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.
4039-1XX Duplex Option Exit Card And Cover Removal 1. Pry up on tabs [A], 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 sensor 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.
4039-1XX Repair Information 99
4039-1XX Duplex Option System Card And Motor Removal 1. 2. 3. 4. Disconnect all cables. Release latches [A] and lift the system board out. Remove the two motor mounting screws [B]. Lift the motor out of the frame assembly. Note: The remaining FRU is the Gearblock Assembly. When you replace this FRU see “Lubrication Specifications” on page 120”. Note: Reinstall the motor so the belt is not tight but will not jump teeth on the timing pulley.
4039-1XX Connector Locations This chapter shows the locations of major printer assemblies, gears, connectors, and ground straps.
4039-1XX Gear Train 102 Service Manual
4039-1XX HVPS Connector Locations 103
4039-1XX Transfer Roller Housing Paper Guide* * Transfer roller housing for 10P has no paper guide 104 Service Manual
4039-1XX System Cable Pin 1 Input and Toner Sensors Pin 1 Pin 1 Transfer Roll HVPS System Board (10R/12R/12C/12L) J20 (16L) J17 Pin 1 Connector Locations 105
4039-1XX System Board Connectors 10R/12R/12L 106 Service Manual
4039-1XX System Board Connectors 10R/12R/12C/12L Connector Name J1 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 Fle
4039-1XX System Board Connectors 16L 108 Service Manual
4039-1XX System Board 16L Connector Name J1 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
4039-1XX System Board Connectors 10P J21 J14 110 Service Manual J11
4039-1XX System Board 10P Connector Name J1 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 &Paper Size Sensor/Fuser Solenoid J20 Input & Toner Sensor Board/Erase Lamps J21 Drive Motor J22 Torque
4039-1XX Printhead Cables The printhead cable connector for 10P, 10R, 12R, 12L,and 12C is J6. The printhead cable connector for 16L is J4.
4039-1XX 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 10P, 10R, 12R, 12L, and 12C is J5. The mirror motor cable connector for 16L is J3.
4039-1XX Operator Panel/Output Bin Sensor Cable — Handle-Mounted Outbin Sensor 114 Service Manual
4039-1XX Operator Panel/Output Bin Sensor Cable — Redrive-Mounted Outbin Sensor Pin 1 Op Panel Cable Connector Pin 1 The cable connector for 10P, 10R, 12R, 12L, 12C is J7. The cable connector for 16L is J5.
4039-1XX Pin Op Panel 1 1 2 2 3 3 4 4 5 5 Sensor 6 1 7 2 8 3 9 4* * No connection on machines with redrive-mounted output bin sensor.
4039-1XX Printer Ground Straps Operator Panel to Upper Frame Load Box Shaft to Upper Frame Outer Deflector to Lower Frame HVPS to Frame Static Brush to Lower Frame Toner Shield to Lower Frame Connector Locations 117
4039-1XX Toner Shield to Lower Frame 118 Service Manual Load Box Shaft to Upper Frame
4039-1XX 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 checklist.
4039-1XX 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: • • • • • • • • • • • • • • • • • • • • • • • • Gear no. 2 and its stud on the side plate Gear no.
4039-1XX • • • • • • • • • Front pivot latch studs Gear no. 8 teeth at gear no. 7 contact points Gear no. 9 teeth at gear no. 11 contact points Gear no. 9 teeth at gear no. 8 and gear no. 10 contact points Cover Hinge Spring tips Cartridge “ramps” at top center of both sides frames Latch handle tips Area of contact between fuser release bail and roll 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.
4039-1XX 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. 3. Open the shutter. 4. Insert the swab and cloth combination in the printhead window slot, then slide it left to right several times.
4039-1XX 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.
4039-1XX 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.
4039-1XX Assembly 1: Covers 14 1 1B 2 1A 17 12 10 7 6 5 4 27 9 15 11 8 3 16 Parts Catalog 125
4039-1XX AsmIndex Part Number Units Description 1-1 1325311 1 Top Cover 10R/12R/12C/10P -1 1328204 1 Top Cover 12L/16L NS 1329607 1 Kit, Stacker Spring 16L -1A 1381017 1 Operator Panel Asm -1B 1328207 1 Door, Top Cover 12L/16L 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, 12C -2 1328511 1 Front Logo, 16L -2 1419451 1 Front Logo, 10P -2 1375923 1 Front Lo
4039-1XX Assembly 1: Covers (Continued) 14 1 1B 2 1A 17 12 10 7 6 5 4 27 9 15 11 8 3 16 Parts Catalog 127
4039-1XX AsmIndex Part Number 1-17 1328508 NS NS 1328482 NS -27 1328189 128 Service Manual Units Description 1 Manual Feed Tray with guide 1 Screw (Deflector Spring Mtg.) Parts Packet 1383314 1 Cover, Duplex mtg. slot 1 Screw (Deflector Switch Mtg.
4039-1XX Assembly 2: Lower Frame 1 7 14 4A 15 4 2 10 5 1 20 9 22 7 8 1 6 18 11 19 23 13 12 9 3 17 Parts Catalog 129
4039-1XX AsmIndex Part Number Units Description 2-1 1381120 1 Lower Frame Assembly 10R/12R/12L/12C/16L/ 10P -1 1381001 1 Lower Frame Assembly (16L below serial number 11-09885 U.S. & 11-10915 W.T.) -2 1381046 1 Motor, Brkt. and Gear Asm. 10R -2 1381047 1 Motor, Brkt. and Gear Asm. 12R/12L/12C -2 1381121 1 Motor, Brkt. and Gear Asm. 16L -2 1381002 1 Motor, Brkt. and Gear Asm. (16L below serial number 11-09885 U.S. & 11-10915 W.T.) -2 1381049 1 Bracket and Gear Asm.
4039-1XX Assembly 2: Lower Frame (Continued) 1 7 14 4A 15 4 2 10 5 1 20 9 22 7 8 1 6 18 11 19 23 13 12 9 3 17 Parts Catalog 131
4039-1XX AsmIndex 2-17 -17A Part Number Units Description 1383314 4 Nut, Motor Bracket Parts Packet 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, 10P NS 1383314 1 Screw, Cable Clamp Parts Packet 132 Service Manual
4039-1XX Assembly 3: Upper Frame 1A 1 22 17 18 23 19 23 3 20 28 23 29 8 23 26 14 25 7 11 2 12 16 21 24 28 6 12 24 4 11 5 10 30 Parts Catalog 133
4039-1XX AsmIndex Part Number Units Description 3-1 1325196 1 Cover Hinge Asm 10R/12R/12C/10P (does not include the load box) -1 1381045 1 Cover Hinge Asm 12L/16L (does not include the load box) -1A 1383314 1 Screw, Cover Hinge Parts Packet -2 1325103 1 Upper Plate Asm 10R/12R/12C/10P -2 1328218 1 Upper Plate Asm 12L/16L -3 1328215 1 Cartridge Load Box 10R/12R/12C/12L/16L -3 1402284 1 Cartridge Load Box, 10P -4 1383315 1 Right Cam Button, Parts Packet -5 1039693 1 Righ
4039-1XX Assembly 3: Upper Frame (continued) 1A 1 22 17 18 23 19 23 3 20 28 23 29 8 23 26 14 25 7 11 2 12 16 21 24 28 6 12 24 4 11 5 10 30 Parts Catalog 135
4039-1XX AsmIndex Part Number Units Description 3-26 1381099 1 Cable, Output Bin/Operator Panel 12L(handle mounted sensor) -26 1381134 1 Cable, Output Bin/Operator Panel 16L(handle mounted sensor) -26 1381095 1 Cable, Operator Panel 12C/12R/10R/10P -28 1383314 2 Screw, Shaft Mtg.
4039-1XX Assembly 4: Printhead 8 8A 8B 1 9 2 4 7 3 System Board 6 Parts Catalog 137
4039-1XX AsmIndex Part Number Units Description 4-1 1381624 1 Printhead 10P -1 1381005 1 Printhead 10R/12R/12C/12L/16L -2 1328431 1 Printhead Shroud Assembly -3 1325017 1 Cable, Fan/Mirror Motor -4 1325018 1 Cable, hsync/Laser NS 1038199 1 Cable, Tie -6 1383315 1 Pin, Parts Packet -7 1383316 1 Spring, Parts Packet -8 1383314 2 Screw, Printhead Mtg.
4039-1XX Assembly 5: Paper Feed 31 37 16 38 36 34 18 29 28 13 15 2 26 23 12 1 35 17 21 20 14 6 22 4 3 33 19 35 5 34 11 35 39 23 10 8 30 7 25 23 8 9 24 8 Parts Catalog 139
4039-1XX AsmIndex Part Number Units Description 5-1 1039101 1 Outer Deflector -2 1183597 1 Upper Deflector -3 1381670 1 Inner Deflector with Roller -4 1381636 1 Input Sensor Board 10P -4 1383430 1 Input Sensor Board 10R/12R/12C/12L/16L -5 1039102 1 Lower Deflector 10R/12R/12L/16L -5 1408859 1 Lower Deflector 10P/12C -6 1383315 1 Flag, Input Sensor, Parts Packet -7 1328385 1 Right Rail Asm (With Gears) 10R/12R/12C/ 12L/16L -7 1328314 1 Right Rail Asm (Without Gears)
4039-1XX Assembly 5: Paper Feed (Continued) 31 37 16 38 36 34 18 29 28 13 15 2 26 23 12 1 35 17 21 20 14 6 22 4 3 33 19 35 5 34 11 35 39 23 10 8 30 7 25 23 8 9 24 8 Parts Catalog 141
4039-1XX AsmIndex Part Number Units Description 5-27 1328452 1 Deflector, Paper 10R/12R/12C/12L/16L/10P NS 1328450 1 Spring, Shaft Grd. 12L/16L -28 1381617 1 Kit, Anti-Squeak Bearing 10P/10R/12R/12C -28 1381618 1 Kit, Anti-Squeak Bearing 12L/16L -29 1328381 1 Outer Redrive Shield 12L/16L NS 1383314 1 Screw Backup Spring Mtg., Parts Packet -30 1183245 1 Spring, Arm Tray Bias -31 1383314 1 Screw, Redrive Mtg.
4039-1XX Assembly 6: Paper Feed Alignment Gears Parts Catalog 143
4039-1XX AsmIndex Part Number Units Description 6-1 1328383 1 Bellcrank, Metering 10P/10R/12R/12L/16L -1 1409238 1 Bellcrank, Metering 12C - 1 o Shaft - 1 o Bellcrank - 1 o Roll - 1 o Thrust Washer -2 1381145 1 Kit, Prealigner and Metering Rollers -3 1039278 1 Gear, Idler, Prealigner -4 1383316 1 Spring, Prealigner and Metering Bellcranks, Parts Packet -5 1328384 1 Bellcrank, Prealigner 10P/10R/12R/12L/16L 1 o Shaft - 1 o Roll - 1 o Bellcrank -5 1402336 1 o
4039-1XX Assembly 7: Paper Feed Drive 5 1 23 8 6 19 24 9 16 3 19 14 2 17 10 15 25 20 7 11 18 21 4 7 13 12 22 18 21 8 Parts Catalog 145
4039-1XX AsmIndex Part Number Units Description 7-1 1328311 1 D-Roller Asm 10R/12R/12L/16L -1 1408705 1 D-Roller Asm, 10P/12C -2 1328279 1 Washer, Thrust -3 1126832 1 Clip, D-roll -4 1328385 1 Rail Assembly, Right (With gears)10R/12R/ 12C/12L/16L -4 1328314 1 Rail Assembly, Right (W/O gears) -5 1328313 1 Shield, D-Roll -6 1328454 1 Shaft, D-Roll with Gear 11, 10R/12R/12C/12L/ 16L -6 1408482 1 Shaft, D-Roll with Gear 11, 10P -7 1383315 1 Bushing, Parts Packet -8 1
4039-1XX Assembly 8: Standard Paper Tray (200 sheet) 1 3 2 4 6 5 Parts Catalog 147
4039-1XX AsmIndex Part Number Units Description 8- 1183260 1 Paper Tray Assembly, 11 in. (200-sheet) - 1183276 1 Paper Tray Assembly, 14 in. (200-sheet) - 1183367 1 Heavy Duty Paper Tray Assembly, 11 in. (200sheet) - 1058272 1 Heavy Duty Paper Tray Assembly, 14 in. (200sheet) - 1183376 1 Paper Tray Assembly, A5 -1 1183266 1 11 in. Cover -1 1183275 1 14 in. Cover -2 1183163 1 Paper Stop -3 1408567 1 Corner Buckler -4 1183329 1 Liner, 11 in.
4039-1XX Assembly 9: Paper Tray (500-Sheet) 5A Parts Catalog 149
4039-1XX AsmIndex Part Number Units Description 9- 1195837 1 Paper Tray Assembly, 11 in. - 1195831 1 Paper Tray Assembly. 14 in. -1 1183801 1 Bottom Cover 11 in. -1 1183804 1 Bottom Cover 14 in. -2 1183357 1 Base 11 in. -2 1183359 1 Base 14 in. -3 1039582 1 Paper Guide -4 1408851 1 Slide 11 in. -4 1408882 1 Slide 14 in. -5 1183262 1 Paper Stop -5A 1183298 1 Slider, Paper Stop -6 1183266 1 Cover 11 in. -6 1183275 1 Cover 14 in.
4039-1XX Assembly 10: Base for Paper Drawer (500-Sheet) 2 3 1 4 4 Parts Catalog 151
4039-1XX AsmIndex Part Number 10-1 1328194 1 Housing -2 1039558 1 Roll -3 1328197 1 Plate Assembly, Gear -4 1039170 1 Pad, Machine NS 1328674 1 Clip, Ground 152 Service Manual Units Description
4039-1XX Assembly 11: Optional Paper Drawer (500-Sheet) 12 5 6 4 7 8 13 10 11 9 2 14 1 3 16 3 Parts Catalog 153
4039-1XX AsmIndex Part Number 11-1 1183342 1 Base Assembly -2 1328630 1 Deflector -3 1039170 1 Feet -4 1039596 1 Bellcrank Assembly Units Description -5 1383316 1 Spring, Bellcrank, Parts Packet -6 1039603 1 Drive Roller -7 1039540 1 D-Roller Tire -8 1383925 1 Paper Feed Magnet -9 1383385 1 Washer, Parts Packet -10 1383385 1 Screw, Parts Packet -11 1383385 1 Spring, Parts Packet -12 1381622 1 Drive Assembly -13 1383316 1 D-Roller Bias Spring, Parts Pack
4039-1XX Assembly 12: Fuser 7 3 7 13 4 2 8 23 1 15 2 15A 8A 9 26 16 6 19 25 22 12 11 24 10 20 21 14 17 18 Parts Catalog 155
4039-1XX AsmIndex Part Number 12-1 1381082 1 Fuser and Lamp 110V 10R -1 1381083 1 Fuser and Lamp 110V 12R/12L -1 1381521 1 Fuser and Lamp 110V 12C -1 1381084 1 Fuser and Lamp 220V 10R -1 1381085 1 Fuser and Lamp 220V 12R/12L -1 1381522 1 Fuser and Lamp 220V 12C -1 1381010 1 Fuser and Lamp 110V 16L -1 1381038 1 Fuser and Lamp 220V 16L -1 1381626 1 Fuser and Lamp 110V 10P -1 1381627 1 Fuser and Lamp 220V 10P -1 1381679 1 Fuser and Lamp, Low Pressure 110V 10R -1 1
4039-1XX Assembly 12: Fuser (Continued) 7 3 7 13 4 2 8 23 1 15 2 15A 8A 9 26 16 6 19 25 22 12 11 24 10 20 21 14 17 18 Parts Catalog 157
4039-1XX AsmIndex Part Number Units Description 12-8A 1381086 1 Hot Roll Assembly 10R -8A 1381076 1 Hot Roll Assembly 12R/12L/16L -8A 1381146 1 Hot Roll Assembly 12C -8A 1383322 1 Hot Roll Asm, 10P NS 1039305 1 Backup Roll 10R/12R/12L/16L NS 1329928 1 Backup Roll, 10P -9 1381012 1 Thermistor Sensor Asm 10R/12R/12C/12L/16L -9 1381637 1 Thermistor Sensor Asm, 10P -10 1328458 1 Redrive Idle Arm Asm, 12R,12L,12C,16L -10 1376367 1 Redrive Idle Arm Asm, 10R/10P -11 138
4039-1XX Assembly 13: Electronics 4A 3 4 18 1 5 5A 21 11 23 9 18 22 6 13 7 Parts Catalog 159
4039-1XX AsmIndex Part Number Units Description 13-1 1383974 1 LV Power Supply 110V 10R/12R/12L/12C -1 1383975 1 LV Power Supply 220V 10R/12R/12L/12C -1 1381014 1 LV Power Supply 110V 16L -1 1381039 1 LV Power Supply 220V 16L -1 1383981 1 LV Power Supply 100V 10R/12R/12L/12C -1 1381643 1 LV Power Supply 110V, 10P -1 1381644 1 LV Power Supply 220V, 10P NS 1328463 1 Fuse, LVPS SB 12A 110V 16L/10P NS 1328464 1 Fuse, LVPS 6.
4039-1XX Assembly 13: Electronics (Continued) 4A 3 4 18 1 5 5A 21 11 23 9 18 22 6 13 7 Parts Catalog 161
4039-1XX AsmIndex Part Number Units Description 13-7 1328291 1 Cable, HVPS/Input Sensor Board 10R/12R/ 12C/12L/16L -9 1321882 1 DRAM SIMM 4MB 12R/12L -9 1328589 1 DRAM SIMM 2MB 10R/10P -11 1325436 1 Inner EMC Shield 10R/12R/12L/12C NS 1325434 1 Outer EMC Shield 10R/12R/12L/12C -11 1328337 1 Inner EMC Shield 16L -11 1419453 1 Inner EMC Shield 10P NS 1328338 1 Outer EMC Shield 16L -13 1325106 1 Guide, Font Card 10R/12R/12L/12C -13 1328988 1 Guide, Font Card 16L NS
4039-1XX Assembly 14: Transfer Roll Parts Catalog 163
4039-1XX AsmIndex Part Number 14-1 1381008 1 Roll Asm, Transfer -2 1381007 1 Housing, Transfer 10R/12R/12C/12L/16L -2 1381652 1 Housing, Transfer 10P (“sawtooth” not present on 10P) 1 o Rear Lens Asm, Erase 1 o Front Lens Asm, Erase 1 o Contact, Transfer Roll 1 o Lamp Asm, Erase 1 Cover, Clip Bearing -3 1328356 164 Service Manual Units Description
4039-1XX Assembly 15: Duplex Option 4 3 5 7 6 2 15 10 12 13 17 14 11 1 8 16 19 18 Parts Catalog 165
4039-1XX AsmIndex Part Number Units Description 15-1 1381019 1 Top Cover Asm (with fan) -2 1381006 1 Duplex System Card -3 1381020 1 Bottom Cover -4 1326137 1 Exit Sensor Cover -5 1381021 1 Exit Sensor Asm -6 1408906 1 Bellcrank -7 1408905 1 Table Cover (Floor) -8 1326001 1 Paper Stop/Slide -9 1381023 1 Gear Block Frame Asm -10 1381024 1 Input Sensor Card -11 1326041 1 Duplex System Cable -12 1326042 1 Cable, Stepper Motor -13 1326043 1 Cable, Sensor -
4039-1XX Assembly 16: Envelope+ and 100-Sheet Auxiliary Feeder Parts Catalog 167
4039-1XX AsmIndex Part Number Units Description 16- 1183151 1 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 Rolle
4039-1XX Assembly 17: Options AsmIndex Part Number Units Description 17-2 1328586 1 1MB Flash SIMM -3 1328585 1 2MB Flash SIMM -4 1376461 1 4MB Flash SIMM -5 1328589 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 1 Option Cards - 1381050 1 o INA-LocalTalk - 1402209 1 o INA-Ethernet 10Base2, low memory - 1402207 1 o INA-Token Ring, low memory - 1402208 1 o INA-Ethernet 10BaseT, low memory
4039-1XX Assembly 18: Miscellaneous AsmIndex Part Number 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 pa
4039-1XX Index Numerics 100-sheet auxiliary feeder paper restraint spring adjustment 52 A abbreviations 4 auto clean 34 auto clean delay 34 auto clean frequency 34 D-roll assembly removal 67 duplex feed 1 test 36 duplex feed 2 test 37 duplex option assembly 165 bottom cover/entry sensor card removal 98 exit card and cover removal 98 problems 18 system card and motor removal 100 top cover/table cover removal 97 B background 13 banding 13 black page 15 blank page 16 blurred or fuzzy print 17 button test 4
4039-1XX frame lower frame assembly 129 lower frame assembly removal 81 upper frame assembly 133 upper frame removal 95 fuser 920,921, or 922 error 20 923 error 21 assembly 155 drive gear backlash adjustment 54 input guide removal 72 lamp removal 74 removal 72 solenoid adjustment 56 solenoid removal 75 thermistor removal 76 fuser temperature 39 fuser theory 20 fuser/sensor cable removal 92 G lower frame assembly 129 assembly removal 81 lubrication specifications 120 LVPS cover removal 83 removal 82 M mai
4039-1XX P page count 41 paper drawer base assembly, 500-sheet 151 optional (500-sheet) assembly 153 paper feed alignment gears assembly 143 assembly 139 drive assembly 145 magnet adjustments 57 magnet assembly removal 86 rollers removal 87 paper feed problem 100-sheet auxiliary feeder 27 500-sheet second tray 25 base printer 25 duplex unit 26 Envelope+ feeder 27 paper feed test 41 paper size sensing problem 28 switch removal 88 paper tray (500-sheet) assembly 149 standard (200 sheet) assembly 147 parts ca
4039-1XX T test page 42 toner sensor removal 93 tools required 4 torquer motor removal 92 transfer roller assembly 163 cleaning 122 removal 66 transfer roller housing locations 104 removal 94 transfer test 42 U upper frame assembly 133 removal 95 V vertical void or streak 30 W warm-up time 39 wrap tests 46 Z Zif connector removal 96 174 Service Manual
