LaserPrinter 4039 Series
• Table of Contents
• Start Diagnostics
• Start Diagnostics
• Safety and Notices
• Trademarks
4039-1XX
•Index
• Main 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. 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; requ ests for publications should be made to your point of purchase.
Comments may be addressed to Lexmark International, Inc., Department D22A/035-3,
740 New Circle Road NW, Lexington, Kentucky 40550, U .S .A. Le xmark ma y use or di stribute
any of the information you supply in any way it believes appropriate without incurring any
obligation to you.
Lexmark is a trademark of Lexmark International, Inc, registered in the United States and/or
other countries.
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. This means the printer recognizes PCL 5
commands used in various applications programs, and that the printer emulates the
functions corresponding to the commands.
Other trademarks are the property of their respective owners.
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.
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....................................................................................... xi
German Statement of Acoustic Emissions................................... xi
Safety Information............................................................................xii
Ozone Information...........................................................................xiii
Preface.................................................................................... xiv
General Information.................................................................. 1
Models Covered in this Manual.....................................................1
IBM Models............................................................................1
Lexmark Model ......................................................................2
Options..........................................................................................2
Maintenance Approach.................................................................3
Abbreviations ................................................................................4
Unique Tools Required For Service..............................................4
Diagnostic Information............................................................. 5
4039 Diagnostics: Failures With Error Codes ...................................5
Power-On Self Test (POST)............................................................11
Table of Contents iii
4039-1XX
Symptom Table ...............................................................................12
Banding.......................................................................................13
Background.................................................................................13
Black Page..................................................................................15
Blank Page..................................................................................16
Blurred or Fuzzy Print..................................................................17
Dead Machine.............................................................................17
Duplex.........................................................................................18
Fan (927 Error)............................................................................19
Fuser Theory...............................................................................20
Fuser: 920, 921, or 922 Error......................................................20
Fuser: 923 Error..........................................................................21
Honeycomb.................................................................................21
Horizontal Void or Streak ............................................................22
LAN Problems.............................................................................22
Light Print....................................................................................22
Network Card 977 Errors.............................................................23
Network Wrap Tests....................................................................23
Output Bin Sensor.......................................................................23
Operator Panel Problem..............................................................24
Paper Feed Problem, 500-Sheet Second Tray...........................25
Paper Feed, Base Printer............................................................25
Paper Feed, Duplex Unit.............................................................26
Paper Feed Problem, Envelope+ Feeder/
100-Sheet Auxiliary Feeder.........................................................27
Printhead.....................................................................................27
Paper Size Sensing Problem ......................................................28
Regularly Spaced Marks.............................................................29
Residual Image ...........................................................................29
Random Marks............................................................................30
Skew, all edges...........................................................................30
Skew, top and bottom only..........................................................30
Stalled (diamonds on display).....................................................30
Vertical Void or Streak.................................................................31
iv Service Manual
4039-1XX
Diagnostic Aids....................................................................... 32
Diagnostics Mode............................................................................32
Grouped Diagnostic Aids ................................................................33
Alphabetical List of Diagnostic Aids................................................34
Auto Clean ..................................................................................34
Auto Clean Delay........................................................................34
Auto Clean Frequency ................................................................34
Defaults.......................................................................................35
Developed Image Test................................................................35
Disk Test/Clean...........................................................................35
Duplex Feed 1 Test.....................................................................36
Duplex Feed 2 Test.....................................................................37
Envelope Enhance......................................................................38
Envelope Print Test.....................................................................38
Error Log (“plus” machines only).................................................38
Fuser Temperature And Warm-Up Time.....................................39
Fuser Temperature..............................................................39
Warm-up Time.....................................................................39
Maintenance Kit Count................................................................40
Memory Test...............................................................................40
Operator Panel Tests..................................................................40
Button Test...........................................................................40
LCD Test..............................................................................41
Page Count.................................................................................41
Paper Feed Test .........................................................................41
Permanent Page Count...............................................................42
Print Contrast (Transfer on “plus” machines)..............................42
Print Registration.........................................................................42
Print Test Page ...........................................................................42
Print Tests...................................................................................43
Print Test 1...........................................................................43
Print Test 2...........................................................................43
Print Test 3...........................................................................44
Quick Disk Test...........................................................................44
Quick Test...................................................................................44
Sensor Test.................................................................................45
Table of Contents v
4039-1XX
Network Connections and Checks ..................................................46
Wrap Tests..................................................................................46
LAN Information ..........................................................................47
Serial Interface Option, 10P........................................................47
Function Switch Setting........................................................47
Repair Information.................................................................. 51
Handling ESD-sensitive Parts.....................................................51
Adjustments.....................................................................................52
Envelope Restraint Spring On The Envelope+ Feeder...............52
Paper Restraint Spring On The 100-sheet
Auxiliary Feeder ..........................................................................52
Envelope Feeder Magnet And 100-sheet
Auxiliary Feeder Magnet .............................................................53
Fuser Drive Gear Backlash.........................................................54
Fuser Solenoid............................................................................56
Paper Feed Magnet.....................................................................57
Optional Paper Feed Magnet......................................................58
Printhead Skew - Level 1 ............................................................59
Printhead Skew - Level 2 ............................................................60
Print Registration Adjustment......................................................61
Removals ........................................................................................62
Covers.........................................................................................62
Right Cover Removal..................................................................62
Front Cover Removal..................................................................62
Left Cover Removal.....................................................................64
Top Cover Removal ....................................................................64
Transfer Roll Removal.................................................................66
D-roll Assembly Removal............................................................67
Drive Motor Removal...................................................................68
Fan/Redrive Removal..................................................................70
Fuser Removal............................................................................72
Fuser Input Guide Removal ........................................................72
Fuser Lamp Removal..................................................................74
Fuser Solenoid Removal.............................................................75
Fuser Thermistor Removal..........................................................76
HVPS Removal ...........................................................................78
Input Sensor Removal.................................................................80
Lower Frame Assembly Removal ...............................................81
LVPS Removal............................................................................82
LVPS Cover Removal .................................................................83
vi Service Manual
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........................................................88
Printhead Removal......................................................................89
System Board Removal ..............................................................90
System Cable Removal...............................................................92
Fuser/Sensor Cable Removal.....................................................92
Torquer Motor Removal (10P) ....................................................92
Toner Sensor Removal...............................................................93
Transfer Roll Housing Removal..................................................94
Upper Frame Removal................................................................95
Zif Connector Removal ...............................................................96
Duplex Option Top Cover And Table Cover Removal ................97
Duplex Option Exit Card And Cover Removal ............................98
Duplex Option Bottom Cover And
Entry Sensor Card Removal .......................................................98
Duplex Option System Card And Motor Removal.....................100
Connector Locations............................................................ 101
Major Assembly Locations........................................................101
Gear Train.................................................................................102
HVPS ........................................................................................103
Transfer Roller Housing............................................................104
System Cable............................................................................105
System Board Connectors 10R/12R/12L..................................106
System Board Connectors 16L.................................................108
System Board Connectors 10P.................................................110
Printhead Cables.......................................................................112
Mirror Motor Cable/Fan Cable...................................................113
Operator Panel/Output Bin Sensor Cable —
Handle-Mounted Outbin Sensor................................................114
Operator Panel/Output Bin Sensor Cable —
Redrive-Mounted Outbin Sensor...............................................115
Printer Ground Straps...............................................................117
Table of Contents vii
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.........................................123
Parts Catalog......................................................................... 124
How To Use This Parts Catalog................................................124
Assembly 1: Covers ...........................................................125
Assembly 2: Lower Frame .................................................129
Assembly 3: Upper Frame .................................................133
Assembly 4: Printhead .......................................................137
Assembly 5: Paper Feed....................................................139
Assembly 6: Paper Feed Alignment Gears........................143
Assembly 7: Paper Feed Drive ..........................................145
Assembly 8: Standard Paper Tray (200 sheet)..................147
Assembly 9: Paper Tray (500-Sheet).................................149
Assembly 10: Base for Paper Drawer (500-Sheet)............151
Assembly 11: Optional Paper Drawer (500-Sheet)............153
Assembly 12: Fuser ...........................................................155
Assembly 13: Electronics...................................................159
Assembly 14: Transfer Roll................................................163
Assembly 15: Duplex Option..............................................165
Assembly 16: Envelope+ and 100-Sheet
Auxiliary Feeder............................................................167
Assembly 17: Options ........................................................169
Assembly 18: Miscellaneous..............................................170
Index ...................................................................................... 171
viii Service Manual
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 av ailable 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 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:
Reorient or relocate the receiving antenna.
•
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from
that to which the receiver is connected.
Consult your point of purchase or service representative for
•
additional suggestions.
Notices and Safety Information ix
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:
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.
To comply with FCC regulations on electromagnetic interfer-
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 interferencecausing equipment standard entitled: “Digital Apparatus”, ICES-003
of Industry Canada.
Avis de conformité aux normes d’Industrie Canada
Cet appareil numérique respecte les limites de bruits
radioélectriques applicables aux appareils numériques de Classe B
prescrites dans la norme sur le matériel brouilleur : “Appareils
numériques”, NMB-003 édictée par Industrie Canada.
The United Kingdom Telecommunications Act 1984
This apparatus is approved under the approval number NS/G/1234/
J/100003 for the indirect connections to the public
telecommunications systems in the United Kingdom.
x Service Manual
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.
This product satisfies the Class B limits of EN 55022.
Notices and Safety Information xi
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.
Therefore, replacement parts must have the identical or
equivalent characteristics as the original parts.
Sicherheitshinweise
•
Die Wartungsinformationen für dieses Produkt wurden zur
Verwendung durch einen Wartungsfachmann entwickelt und
sollten nicht von anderen benützt werden.
Zusätzliches Risiko eines elektrischen Schlags und körperlicher
•
Verletzung existiert während des Auseinandernehmens und der
Wartung des Geräts. Fachpersonal sollte im vollen Verständnis
der Lage entsprechende Vorsichtsmaßnahmen ergreifen.
• Ersatzteile müssen gleiche oder gleichwertige Merkmale wie die
Originalteile aufweisen, da Sicherheitsvorkehrungen nicht immer
offensichtlich sind.
Consignes de Sécurité
•
Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement à un personnel de maintenance
qualifié.
Le démontage et l'entretien de ce produit pouvant présenter
•
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.
• Les normes de sécurité de certaines pièces n'étant pas toujours
explicites, les pièces de rechange doivent être identiques ou
conformes aux caractéristiques des pièces d'origine.
xii Service Manual
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.
È possibile che le funzioni di sicurezza di alcuni elementi non
•
siano così ovvie, quindi, i pezzi di ricambio devono avere
caratteristiche identiche o equivalenti a quelle dei pezzi originali.
Pautas de Seguridad
•
La información 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 eléctricas y daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado comprende esto y toma las
precauciones necesarias.
Los dispositivos de seguridad de algunas partes quizá no
•
siempre puedan ser reconocidas a simple vista. Por lo tanto, las
partes de reemplazo deben poseer características idénticas o
equivalentes a las partes originales.
Sikkerhedsoplysninger
•
Oplysningerne om vedligeholdelse af dette produkt er forberedt
med henblik på professionelt servicepersonale, og bør derfor
ikke benyttes af andre.
Risikoen for elektrisk stø d ø ges under demontering og service af
•
dette produkt, hvorfor der bør tages de nødvendige
forholdsregler.
Sikkerhedsforanstaltningerne er ikke altid lige åpenbare for alle
•
reservedele. Der bør 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.
Notices and Safety Information xiii
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).
“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.
xiv Service Manual
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.
IBM Models
4039-10R 10ppm PostScript Level 1 emulation, input/output
capacity 200/250
4039-12R 12ppm PostScript Level 1 emulation, input/output
capacity 200/250
4039-12L 12ppm PostScript Level 1 emulation, output bin
sensing, input/output capacity 500/500
4039-12C Similar to 12R, designed for printing labels and card
stock
4039-16L 16ppm PostScript Level 1 emulation, output bin
sensing, input/output capacity 500/500
4039-10R plus 10R with PostScript Level 2 emulation and service
error log (RPQ only)
4039-12R plus 12R with PostScript Level 2 emulation and service
error log
4039-12C plus 12C with PostScript Level 2 emulation and service
error log (RPQ only)
4039-12L plus 12L with PostScript Level 2 emulation and service
error log
4039-16L plus 16L with PostScript Level 2 emulation and service
error log
General Information 1
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 av ailab le in
every country . Contact y our point of purchase f or options av ailabl e 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
AppleTalk 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
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
See
the symptom and repair the failure.
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.
“Diagnostic Information”
General Information 3
4039-1XX
Abbreviations
ASIC Application-Specific Integrated Circuit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EEPROM Electrically Erasable Programmable Read-
Only Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LAN Local Area Network
LASER Light Amplification by Stimulated Emission
of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PICS Problem Isolation Charts
PIXEL Picture Element
POR Power-On Reset
POST Power-On Self Test
PQET Print Quality Enhancement Technology
RIP Raster Image Processor
ROS Read-Only Storage
SRAM Static Random Access Memory
UPR Used Parts Replacement
VAC Volts alternating current
VDC 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
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
21 Paper Jam The exit sensor was not made in time
22 Paper Jam The exit sensor was not unmade in time.
23 Paper Jam Jam at the duplex unit. Paper is either
24 Short Paper The defined paper size is too short to
25 Incorrect Manual Feed Paper fed manually while motor is
27 Change Envelope/Paper Envelopes/paper loaded are wrong size.
28 Load Envelope/Paper Input sensor not made after pick
29 Output Bin Full The output bin sensor has not been
See
time.
page 25.
after the input sensor was made.
“Paper Feed, Base Printer” on page 25.
See
page 25.
not leaving the duplex entry sensor in
time or not making or unmaking the
duplex exit sensor in time.
on page 18.
print data as formatted.
running and previous page in path.
attempt. Tray is empty or printer is
requesting a manual feed.
unmade.
“Paper F eed, Base Printer” on
“Paper Feed, Base Printer” on
See
“Duplex”
See
30 Top Cover Open or Print Cartridge
Missing
Diagnostic Information 5
4039-1XX
Error/Code Action
37 Insufficient Memory Not enough memory for function
38 Memory Full Memory used to store pages is full.To
39 Complex Page Page too complex to print.To verify that
43 Font Card Not Supported Font card format not supported by
44 Defective Font Card Defective font card installed in font slot.
47 Font Card Removed While Printing Printer needs data on removed card.
52 Flash Full Not enough flash memory for data
53 Unformatted or Defective Flash Flash problem at POR or while
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.
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.
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.
printer.
requested to be stored.
attempting to write.
54 Serial Error Framing or parity error on serial.
58 Duplex Not Attached Duplex is electrically connected but no
59 Duplex Cover Open Top cover of duplex unit is sensed open.
62 Disk Full Not enough disk space for data that has
longer mechanically attached, and
printer top cover is closed.
been requested to be written to disk.
6 Service Manual
4039-1XX
Error/Code Action
63 Unformatted or Defective Disk The printer will ignore a disk it senses as
7X Network Card Codes These user codes are documented in
80 Scheduled Maintenance Printer has reached 200,000 prints
88 Toner Low Toner sensor detects low toner.
90X Software Error Unrecoverable software error. If one of
917 Transfer Roll Error Cannot start servo operation. Verify
defective. Run the Quic k Disk Test. If the
test fails, the dis k is def ectiv e 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.
various network card user manuals.
“Network Wrap Tests” on page 23.
(12C=100,000 prints) without
maintenance count reset.
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.
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.
See
Diagnostic Information 7
4039-1XX
Error/Code Action
918 Transfer Roll Error Servo Failure. Verify correct cable
920 Fuser Error Fuser is below temperature while
921 Fuser Error Fuser is below standby temperature
922 Fuser Error Fuser failed to reach standby
923 Fuser Error Fuser is too hot while printing or when
927 Fan Stalled
931 Printhead Error No first hsync.
932 Printhead Error Lost hsync.
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.
See
printing.
Error” on page 20.
when idle.
Error” on page 20.
temperature.
922 Error” on page 20.
idle.
See
“Fan (927 Error)” on page 19.
page 27.
“Fuser: 920, 921, or 922
See
“Fuser: 920, 921, or 922
See
“Fuser: 920, 921, or
See
“Fuser: 923 Error” on page 21.
See
“Printhead” on
See
“Printhead” on page 27.
934 Printhead Error Lost lock condition.
935 Printhead Error Mirror motor unable to reach operating
941 System Board ROM SIMM failed CRC; code data or
944 System Board RIP processor failure. Replace the
945 System Board ASIC 1 failure. Replace the system
page 27.
See
speed.
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.
system board.
board.
See
“Printhead” on
“Printhead” on page 27.
8 Service Manual
4039-1XX
Error/Code Action
946 System Board ASIC 2 failure. Replace the system
947 System Board Engine ASIC RAM failure. Replace the
948 System Board Engine ASIC electronics failure. Replace
950 System Board SRAM failure. Replace the system
952 System Board Unable to zero PQET SRAM. Replace
953 System Board NVRAM failure. Replace the system
960 Memory Error Bad or missing DRAM in the base
961 Memory Error Bad DRAM in the optional DRAM slot.
970 Network Card Network card processor failure. Replace
board.
system board.
the system board.
board.
the system board.
board.
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.
Reseat the DRAM and run the
diagnostic Memory Test for DRAM. If
test fails or the problem recurs after
POR, replace the DRAM SIMM.
the Network Card.
971 Network Card Network card RAM failure. Replace the
972 Network Card Network card ROS/FLASH failure.
973 Network Card Network card EEPROM/NVRAM failure.
974 Network Card Network card/Network interface error.
976 Network Card Network card software error. Verify that
Network Card.
Replace the Network Card.
Replace the Network Card.
Replace the Network Card.
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
4039-1XX
Error/Code Action
977 Network Card Network card is installed but is not
978 Network Card General network card hardware error.
979 Network Card General network card software error.
990 Duplex Option Duplex error.
991 Duplex System Card Failure Duplex system card failure. Replace the
993 Duplex Comm. Failure Communications between the duplex
communicating with the system board.
See
“Network Card 977 Errors” on
page 23.
Replace the Network Card.
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.
See
“Duplex” on page 18.
duplex system card.
See
unit and the printer have failed.
“Duplex” on page 18.
10 Service Manual
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:
warms to operating temperature. Printer idle time is shorter if the
fuser is already warm.
Note:
for about 5 seconds just before the ready screen appears.
4. The ready screen appears on the display.
Note:
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 f an 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.
The printer may be idle for up to 60 seconds as the fuser
If the duplexer is installed, the duple x drive motor turns on
Diagnostics menu appears if you are in diagnostic mode.
Diagnostic Information 11
4039-1XX
Symptom Table
Symptom Action or Service Check
Dead Machine Dead Machine Service Check
Repeats pattern of five beeps and a
pause.
Machine Hangs Displaying Diamonds Machine Hangs Displaying Diamonds
Operator Panel Operator Panel Service Check
Paper Feed, Base Printer Paper Feed, Base Printer Service Check
Paper Feed, Duplex Unit Paper Feed, Duplex Unit Service Check
Paper Feed Pro blem, 500-sheet
Second Tray
Paper Feed Problem, Envelope+
Feeder/100-Sheet Auxiliary Feeder
Automatic Paper Size Sensing Problem Automatic Paper Size Sensing Problem
LAN Problems LAN Service Check
Blank Page Blank Page Service Check
Black Page Black Page Service Check
Random Marks Random Marks Service Check
Regularly Spaced Marks Regularly Spaced Marks Service Check
Skew, all edges Skew Service Check
Operator Panel Service Check
Service Check
Paper Fee d Problem, 500 -sheet Second
Tray Service Check
Paper Feed Problem, Envelope+
Feeder/100-Sheet Auxiliary Feeder
Service Check
Service Check
Skew, top and bottom only Skew, top and bottom Service Check
Light Print Light Print Service Check
Fuzzy or Blurred Print Fuzzy Blurred Print Service Check
Residual Image Residual Service Check
Honeycomb Honeycomb Service Check
Background Background Service Check
Horizontal Void or Streak Horizontal Service Check
12 Service Manual
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 dev elopment or transf er.
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 T est 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 (10P) 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
4039-1XX
10R/12R/12C/
12L
16L
Voltage while
Printing
J20-1 to J20-4 J17-1 to J17-4 Less than
1VDC
J20-2 to J20-4 J17-2 to J17-4 Greater than
1VDC
J20-3 to J20-4 J17-3 to J17-4 The meter
should fluctuate slightly
between
each page.
J20-8 to J20-4 J17-8 to J17-4 Less than
1VDC
.
10P Voltage while Printing
Voltage
while Idling
J14-1 to J14-4 Less than 5VDC 0VDC
J14-2 to J14-4 Less than 5VDC 0VDC
J14-3 to J14-4 The meter should
0VDC
fluctuate slightly
between each page.
Voltage while
Idling
+21-26VDC
Less than
5VDC
Less than
5VDC
+21-26VDC
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
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.
10P
10R/12R/12C/
12L
16L Voltage
J14-5 to J14-4 J20-5 to J20-4 J17-5 to J17-4 +24VDC
J14-6 to J14-4 J20-6 to J20-4 J17-6 to J17-4 +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/
12L
16L
J20-1 to J20-4 J17-1 to J17-4 Less than
Voltage while
Printing
Voltage while
Idling
21-26VDC
1VDC
J20-2 to J20-4 J17-2 to J17-4 Greater than
1VDC
10P
Voltage while
Printing
J14-1 to J14-4 Less than
Voltage while
Idling
0VDC
Less than
0.5VDC
5VDC
J14-2 to J14-4 Less than
0VDC
5VDC
Diagnostic Information 15
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.
Make the following voltage checks while running the print test
continuously and again while idling.
10R/12R/12C/
12L
16L
Voltage while
Printing
J20-1 to J20-4 J17-1 to J17-4 Less than
1VDC
J20-2 to J20-4 J17-2 to J17-4 Greater than
1VDC
J20-3 to J20-4 J17-3 to J17-4 The meter
should fluctuate slightly
between
each page.
J20-8 to J20-4 J17-8 to J17-4 Less than
1VDC
Voltage while
Idling
+21-26VDC
Less than
5VDC
Less than
5VDC
+21-26VDC
16 Service Manual
4039-1XX
.
10P
Voltage while
Printing
Voltage while
Idling
J14-1 to J14-4 Less than 5VDC 0VDC
J14-2 to J14-4 Less than 5VDC 0VDC
J14-3 to J14-4 The meter should
0VDC
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
see
the feed roll or transfer roll. Also
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 ma y occur
at the point where the feeder’s friction rollers release the paper.
“Banding” on page 13.
Dead Machine
Possib le causes: no voltage reaching the printer, LVPS failure, b lown
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
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.
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. F rom 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
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
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
indicates that communication between the printer and
: Examine the paper path in the duplex unit and in
18 Service Manual
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
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 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.
is displayed, press and hold the Return button while
23
Fan (927 Error)
The fan should run continuously when the printer is powered up,
unless the printer is in Power Sa ver mode . Check that the f an 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 +24V 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
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.
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 0VDC when
the lamp is to be on and +24VDC (10P: +5VDC) 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 pow er
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 Service Manual
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. 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 0VDC until the fuser is warm; if it does
not, replace the system board. If the signal is OK, replace the L VPS .
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 increase 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
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. 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.
• Make sure that the desired network protocol is enabled from the
printer operator panel.
• Verify proper print queue and printer driver configuration
• Verify that the adapter port has been associated
• Verify correct installation of software utility
• Single route broadcast not supported across 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.
22 Service Manual
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. 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:
LAN cable from the electrical outlet, leaving it connected to the
printer network card.
Ethernet 10Base-2:
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,
page 22.
Attach a 50 Ohm BNC terminator cap to each
Disconnect the
see
“LAN Problems” on
Output Bin Sensor
Examine the bin area for obstructions or damage. Run the
diagnostic sensor test.
Diagnostic Information 23
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 b loc k ed (the voltage tak es 15 to 25
seconds to change to the low level).
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 latchmounted sensor), or the sensor cable as necessary.
Operator Panel 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 1½ 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 +5VDC 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.
24 Service Manual
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. 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 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 500sheet 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.
Diagnostic Information 25
4039-1XX
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.
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 tra y and v erify that the
tray is installed correctly.
If paper is curling badly enough to cause a problem feeding or
see
stacking,
“Fuser Temperature And Warm-Up Time” on page 39.
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
see
damaged. Cold paper curl can also cause jams here;
Temperature And Warm-Up Time” on page 39.
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.
see
Also
“23 Paper Jams” on page 18
“Fuser
26 Service Manual
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 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 F eed test; if the voltage does not increase momentarily as
the magnet 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:
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, +5VDC 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.
The printhead is a sealed unit. It contains no parts that can
Diagnostic Information 27
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 f or 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 the 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 5% 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 K Ohms
A4 8.0 K Ohms
13” 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.
28 Service Manual
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) 37.1-37.7 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 leftover 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.
Diagnostic Information 29
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
see
margins are not all the same width
Adjustment” on page 61.
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.
“Print Registration
Skew, top and bottom 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
See
needs to be adjusted.
and “Printhead Skew - Level 2” on page 60.
“Printhead Skew - Level 1” on page 59
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.
30 Service Manual
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. 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.
Diagnostic Information 31
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].
Diagnostic Aids 32
4039-1XX
Grouped Diagnostic Aids
Print Tests Operator Panel Tests
Print Test Page Button Test
Developed Image Test LCD Test
Print Tests
Duplex Tests
Registration Tests
Print Registration
Quick Test
Paper Feed Tests Page Counts
Envelope Print Test Page Count
Paper Feed Test Maintenance Kit Count
Printer Setup Tests Device Tests
Envelope Enhance Quick Disk Test
Print Contrast (Transfer) Disk Test/Clean
Fuser Temperature/Warm-up Time
Duplex Feed 1
Duplex Feed 2
Permanent Page Count
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
Diagnostic Aids 33
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. Enter Diagnostics mode.
2. Select [Auto Clean].
3. Select [On] or [Off].
4. Press Return to return to Diagnostics mode main menu.
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.
1. Enter Diagnostics mode.
2. Select [Auto Clean Delay].
3. Select [+] or [-] to display the delay desired.
4. Select [SAVE].
5. Press Return to return to Diagnostics mode main menu.
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.
1. Enter Diagnostics mode.
2. Select [Auto Clean Frequency].
3. Select [+] or [-] to display the frequency desired.
4. Select [SAVE].
5. Press Return to return to Diagnostics mode main menu.
34 Service Manual
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. Enter Diagnostics mode.
2. Select [Defaults].
3. Select [U.S.] or [Non U.S.].
4. 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:
1. Set the paper exit lever to use the front exit.
2. Print the test page.
3. As soon as the leading edge of the paper is visible coming out
the front exit slot, turn off the printer.
4. 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 b locks are flagged and remov ed
from use. If over 2000 bad blocks are found the test stops and the
display indicates the disk must be replaced.
Diagnostic Aids 35
4039-1XX
A message describing test progress is displayed during the test.
1. Enter Diagnostics mode.
2. Select [Device Test]
3. Select [Disk Test/Clean].
4. 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. 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. Enter Diagnostics mode.
2. Select [Duplex Tests].
3. Select [Duplex Feed 1].
4. Select [Tray 1], or [Tray 2].
Note:
Paper feeds all the way into the duplex unit and stop.
5. The message [CLEAR PAPER] appears on the display.
6. Slide the tray extension all the way out until it stops.
7. 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.
8. Open the cover and remove the sheet of paper.
9. 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.
36 Service Manual
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:
and stop on top of the paper tray.
5. The message [CLEAR PAPER] appears on the display.
6. Open the printer top cover.
7. If you are doing the test with legal size paper, open the top cov er
8. Carefully remove the duplex unit from the printer without
9. Without changing the position of the page, hold it to the top of
10. Measure from the leading edge of the page to the leading edge
11. Select [CONTINUE].
12. Perform the test several times to verify that the measurement is
13. Press Return to return to Diagnostics mode main menu.
Paper feeds all the w ay into the duplex unit and then f eed out
of the duplex unit.
disturbing the position of the paper on the top of the duplex tray.
Do not disconnect the duplex cable from the printer.
the paper tray and remove the paper tray.
of the 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.
accurate.
Diagnostic Aids 37
4039-1XX
Envelope Enhance
Use this procedure to set the fuser solenoid power level to low,
medium, or high. Increase the level to reduce en velope wrinkling, or
decrease the level to reduce solenoid noise.
1. Enter Diagnostics mode.
2. Select [Envelope Enhance].
3. Select [Low], [Medium], or [High].
4. Press Return to return to Diagnostics mode main menu.
Envelope Print Test
Note:
from the automatic envelope feeder if present. If there is no automatic feeder present, the printer uses manual envelope.
1. Enter Diagnostics mode.
2. Select [Envelope Print].
3. Select [Single] or [Continuous].
4. Select [CANCEL] to stop continuous envelope feed.
5. Press Return to return to the Diagnostics mode main menu.
Printing only occurs on the first envelope. The env elope feeds
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 as 977.
1. Enter Diagnostics mode.
2. Select [Error Log].
3. Select [CLEAR] and then [CONTINUE] to clear the error log.
4. Press Return to return to Diagnostics mode main menu.
38 Service Manual
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. V erify 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 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.
Diagnostic Aids 39
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. Enter Diagnostics mode.
2. Select [Maintenance Count].
3. Select [RESET] to set the count back to “0”.
4. Press Return to return to the Diagnostics mode main menu.
Memory Test
1. Enter Diagnostics mode.
2. Select [Memory Test].
3. Select either [DRAM] or [ROM].
4. Select [Single] or [Continuous].
5. The display indicates [PASSED], or [FAILED].
6. Select [CANCEL] to stop continuous memory test.
7. Press Return to return to Diagnostics mode.
Operator Panel Tests
The following tests chec k for proper functioning of the operator panel
buttons and display (LCD).
Button Test
To test the operator panel buttons:
1. Enter Diagnostics mode.
2. Select [Button Test].
3. Press each button. [Closed] is displayed until the button is
released. Then [Open] is displayed.
4. Press Return to return to the Diagnostics mode main menu.
40 Service Manual
4039-1XX
LCD Test
To test the operator panel display:
1. Enter Diagnostics mode
2. Select [LCD Test].
3. Select [Single] or [Continuous].
4. 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. 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:
test so you can observe the motor gears.
1. Enter Diagnostics mode.
2. Select [Paper Feed].
3. Select [Tray 1], [Tray 2], or [Manual].
4. Select [Single] or [Continuous].
5. Select [CANCEL] to stop continuous mode.
6. Press Return to return to Diagnostics mode main menu.
You may want to remove the gear cover before starting this
Diagnostic Aids 41
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. 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 61.
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].
42 Service Manual
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. Enter Diagnostics mode.
2. Select [Print Test 1].
3. Select [Single] or [Continuous].
4. Select [CANCEL] to stop continuous print.
5. 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:
1. Enter Diagnostics mode.
2. Select [Print Test 2].
3. Select [Single] or [Continuous].
4. Select [Cancel] to stop continuous print.
5. Press Return to return to the main Diagnostics menu.
Diagnostic Aids 43
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. Enter Diagnostics mode.
2. Select [Print Test 3].
3. Select [Single] or [Continuous].
4. Select [CANCEL] to stop continuous print.
5. 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. 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 rewritten after the track is tested.
1. Enter Diagnostics mode.
2. Select [Quick Disk Test].
3. 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.
44 Service Manual
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:
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.
The Output Bin sensor can have up to a 15 second delay
Diagnostic Aids 45
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:
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
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:
9. Press Return to return to the Diagnostics mode main menu.
10. T urn the printer off, then remov e the wrap plug from the interf ace
Install the parallel wrap plug part no. 1319128 for the parallel
serial port.
Ignore the number displayed after a failure is displayed.
connector.
46 Service Manual
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.
The serial interface has 12 function switches.
Function Switch Setting
Switches 1 to 4 — Speed:
interface speed in bits per second (bps).
1234SPEED (BPS)
On On Off Off 150
On Off On Off 300
On Off Off Off 600
Switches 1 through 4 define the serial
Diagnostic Aids 47
4039-1XX
1234SPEED (BPS)
OffOnOnOff1,200
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.
5DATA 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.
48 Service Manual
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:
9Protocol
Off DTR pacing (RS232 only)
On XON/XOFF
Switch 10 - Print Test:
Switch 9 selects the type of protocol.
Switch 10 selects the print test for the serial
interface card. This tests the connection between the serial interf ace
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 [Off].
To run the serial interface test print:
1. Turn the printer power off.
2. Set serial 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. Chec k the s witch
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
Diagnostic Aids 49
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.
12 Mode
Off RS-232C
On RS-422
50 Service Manual
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). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic boards:
• Keep the ESD-sensitive part in its original shipping container (a
special “ESD bag”) until you are ready to install the part into the
machine.
• Make the least-possible mov ements with your body to pre vent an
increase of static electricity from clothing fibers, carpets, and furniture.
• Put the ESD wrist strap on your wrist. Connect the wrist band to
the system ground point. This discharges any static electricity in
your body to the machine.
Hold the ESD-sensitive part by its edge connector shroud
•
(cover); do not touch its pins. If you are removing a pluggable
module, use the correct tool.
Do not place the ESD-sensitive part on the machine cover or on
•
a metal table; if you need to put down the ESD-sensitive part for
any reason, first put it into its special bag.
Machine covers and metal tables are electrical grounds. They
•
increase the risk of damage because they make a discharge
path from your body through the ESD-sensitive part. (Large
metal objects can be discharge paths without being grounded.)
• Prevent ESD-sensitive parts from being accidentally touched by
other personnel. Install machine covers when you are not working on the machine, and do not put unprotected 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 51
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.
52 Service Manual
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.
Repair Information 53
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 f or bac klash.
To adjust backlash:
1. Loosen the nut on the idler stud.
2. Move the idler stud downward in its slot.
3. 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.
4. With the nut snug but not tight, tap the idler upward until the
gage is snug between the gear shoulders.
5. Tighten the locking nut.
6. 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.
54 Service Manual
4039-1XX
Repair Information 55
4039-1XX
Fuser Solenoid
Note:
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
4. Tighten screw [A].
5. Replace the rubber washer.
The fuser solenoid must be mounted on the fuser for this
(0.165 in.± 0.008 in.) air gap.
56 Service Manual
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. The gage should pass between the foam pad and the magnet
pole piece with moderate resistance.
Repair Information 57
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:
3. Insert feeler gage.
4. Rotate the magnet against the feeler gage.
5. Tighten the mounting screw.
6. The gage should pass between the foam pad and the magnet
The flat side of the D-roll is down when the feed is latched.
pole piece with moderate resistance.
58 Service Manual
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.
B
Skew Adjustment Points
A
Repair Information 59
4039-1XX
Printhead Skew - Level 2
1. Remove the top cover.
2. Loosen the screws [A].
3. Run Print Test 1 or the Quick Test on the Diagnostics Menu.
4. 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.
A
B
60 Service Manual
Skew Adjustment Points
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. The value of the margin you selected is shown.
5.
Left Margin:
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.
6.
Top Margin:
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.
7.
Bottom Margin:
Moving the number in a positive direction moves the margin
down and narrows the bottom margin. Moving the number in a
negative direction moves the te xt up the page and leav es a wider
bottom margin.
8. Select [+] to move the number in a positive direction.
9. Select [-] to move the number in a negative direction.
10. Select [Print Test 1], or [Quick Test] to check your settings.
11. Select [Tray 1], or [Tray 2].
12. Select [Single], or [Continuous].
13. Select [SAVE] to save your settings when they are correct.
14. Press Return to return to the Diagnostics menu.
This margin can be set between -23 and +23.
This margin can be set between -20 and +20.
This margin can be set between -7 and +7.
Repair Information 61
4039-1XX
Removals
When there is artwork to support a procedure, it follows the text.
Covers
Right Cover Removal
1. Turn the printer off.
2. Remove all external trays.
3. Open the top cover.
4. Swing the cover open.
5. Remove the E-clip from the rear piv ot pin and lift the cover off the
rear pivot pin.
Front Cover Removal
1. Unplug the power cord.
2. Remove the paper tray.
3. Open the top cover.
4. Open the right cover.
5. Remove the Duplex mounting slot covers.
6. Release the latches [B]. You can reach the lower latches through
the paper tray opening.
7. Pull the front cover forward, then move the cover to the right to
separate the on/off switch linkage [D].
8. Disconnect the ground strap from the frame on the left side.
9. Remove the front exit deflector switch.
62 Service Manual
4039-1XX
Repair Information 63
4039-1XX
Left Cover Removal
1. Unplug the power cord.
2. Open the top cover and remove the print cartridge.
3. Remove the front cover.
4. Locate the latch [A] and push the end to the rear to release it.
5. Push the top of the cover to the left.
6. 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. Rest the cover on the machine and disconnect the operator
panel cable and the ground wire.
64 Service Manual
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. 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. Lift the right bearing straight up and out of the machine.
66 Service Manual
4039-1XX
D-roll Assembly Removal
1. Unplug the power cord.
2. Remove the paper tray.
Note:
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 the latch
7. Push the latch down (away from the shaft) and slide the D-roll to
Note:
certain the roll is in place by pulling toward the left without pushing
the latch.
Note:
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.
The following 3 steps are not necessary, but may make it
located above the flat part of the D-roll.
the left, off the shaft.
There is no positive detent when replacing the D-roll. Make
Later machines do not have a latch. Remove the D-roll by
Repair Information 67
4039-1XX
Drive Motor Removal
1. Unplug the power cord.
2. Remove the system board.
3. Remove the system board inner EMC shield.
4. Remove the fuser input guide [A].
5. Remove the transfer housing assembly.
6. Remove the gear cover by releasing the rear latch and lifting up.
7. Remove scre w [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.
10P: Do not remove the motor from the gear bracket assemb ly; the y
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 template 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 assembly and tighten the
screws. Remove the gear retaining plate from the assembly and
install the motor in the printer.
68 Service Manual
4039-1XX
Repair Information 69
4039-1XX
Fan/Redrive Removal
1. Open the top cover.
2. Remove the print cartridge.
3. Remove the top cover.
4. Remove the lower redrive shaft by disengaging the right end to
the rear of the machine.
5. Disconnect the long redrive belt [A] and slip it off the lower shaft.
6. Remove the redrive assembly screws [D].
7. Remove the plenum assembly and screws [B].
8. Unplug the fan cable. The fan [C] can now be removed from the
plenum assembly.
70 Service Manual
4039-1XX
D
B
A
C
Repair Information 71
4039-1XX
Fuser Removal
Note:
careful when you remove or replace the fuser unit.
CAUTION:
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
4. Unsnap the front cover from the right side frame.
5. Remove the fuser cover.
6. Disconnect the power wires [A] from the left side of the fuser.
7. Remove the fuser input guide.
8. Completely loosen the four fuser mounting screws.
9. Lift the fuser out of the machine.
The heater lamp is fragile and may be damaged if you are not
THE TEMPERATURE OF THE HOT ROLLER IS
opening for the paper output.
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.
2. Lift the fuser input guide upward at both sides near the fuser and
slide the guide toward the rear of the machine to release.
3. Lift the guide out of the machine.
4. Clean the fuser input guide before installing it.
72 Service Manual
4039-1XX
Repair Information 73
4039-1XX
Fuser Lamp Removal
CAUTION:
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:
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.
THE TEMPERATURE OF THE HOT ROLLER IS
The fuser lamp is a glass heater. Do not touch the lamp with
74 Service Manual
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:
solenoid must be adjusted.
When a new solenoid assembly is installed, the fuser
A
Repair Information 75
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.
76 Service Manual
4039-1XX
B
A
Repair Information 77
4039-1XX
HVPS Removal
1. Unplug the power cord.
2. Remove the left cover
3. Remove the fuser input guide.
4. Remove the transfer roll housing.
5. Remove the fuser cover.
6. Disconnect the cable from the HVPS connector.
7. Remove the power switch rod.
8. Remove the ground screw [B].
9. Remove the mounting screws [C].
10. Pull the ground strap through the hole [D].
11. The power supply is held in place by two latches on the left side.
To release the latches:
Push one latch [E] in and raise one of the studs [F] to release
•
the latch.
• Push the other latch [
release the latch.
12. 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.
13. Move the front of the power supply to the right (to clear the fuser
power wires).
14. Tilt the front of the power supply up and lift it out of the machine
] in and raise the other stud [F] to
E
78 Service Manual
4039-1XX
.
C
F
D
F
E
B
Repair Information 79
4039-1XX
Input Sensor Removal
1. Remove the fuser input guide [A].
2. Remove the transfer roll housing.
3. Remove the D-roll.
4. Disconnect the system cable from the input sensor board.
Note:
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.
Use care, the flag can be damaged while removing the
A
B
80 Service Manual
4039-1XX
Lower Frame Assembly Removal
1. Remove the right, front, and left covers
2. Remove the LVPS and the rod for the on/off switch.
3. Remove gear cover and the fuser input guide [A].
4. Remove the transfer roll housing.
5. Disconnect the cable from the HVPS.
6. Remove the system board and the inner EMC shield.
7. Disengage the upper frame cables from the guide in the paper
feed side frame.
8. Remove the screws [B].
9. Remove the fuser cover.
10. Unplug the fuser wires [C] and push them below the HVPS.
11. Unplug the paper size switch cable.
12. Lift the lower frame assembly straight up to separate it from the
paper feed assembly.
Repair Information 81
4039-1XX
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.
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.
82 Service Manual
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].
Repair Information 83
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. Remove all external trays.
2. Open the top cover.
3. Open the right cover.
4. Remove the outer EMC shield.
5. Remove cable and mounting screws as required.
6. Pop the card off the plastic standoffs.
84 Service Manual
4039-1XX
Exit Sensor Removal
1. Remove the front cover.
2. Disconnect the fuser/sensor cable.
3. Disconnect the thermistor cable.
4. 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.
Repair Information 85
4039-1XX
Paper Feed Magnet Assembly Removal
1. Remove the print cartridge.
2. Remove the right cover.
3. Remove the system board.
4. Remove the inner EMC shield.
5. 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 f eed magnet assembly from the rear (slip the
connector under the right frame).
A
B
B
86 Service Manual
Loading...