LaserPrinter 4039 Series
4039-1XX
•Table of Contents
•Start Diagnostics
•Safety and Notices
•Trademarks
•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; requests 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. Lexmark may use or distribute 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.
ãCopyright 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
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property rights may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s responsibility.
Consult the following list for any emission that may apply in your country.
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: To comply with FCC regulations on electromagnetic interference, 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.
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.
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.
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.
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
•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.
•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.
•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
•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.
•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.
•Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik på professionelt servicepersonale, og bør derfor ikke benyttes af andre.
•Risikoen for elektrisk stød øges 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.
This product does not produce measurable amounts of ozone gas.
Notices and Safety Information xiii
4039-1XX
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
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.
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
The following options are available. Some options are not compatible with all printer models. Some options are not available in every country. Contact your point of purchase for options available in your country.
Memory upgrade options of 2MB, 4MB and 8MB.
Flash memory options of 1MB, 2MB and 4MB
Intergated network options
Token-Ring option
Ethernet option
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
The diagnostic information in this manual will lead you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. See “Diagnostic Information” starting on page 5. This printer can be serviced without being connected to a host.
After you complete the repair, perform tests as needed to verify the repair.
General Information 3
4039-1XX
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 |
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
Two-digit codes are messages for the 4039 user, but if they recur frequently or at inappropriate times they may be symptomatic of a service problem. On “plus” models, refer to the diagnostics error log for the last six errors or paper jam codes.
Error/Code |
Action |
|
|
|
|
20 |
Paper Jam |
The input sensor was not unmade in |
|
|
time. See “Paper Feed, Base Printer” on |
|
|
page 25. |
|
|
|
21 |
Paper Jam |
The exit sensor was not made in time |
|
|
after the input sensor was made. See |
|
|
“Paper Feed, Base Printer” on page 25. |
|
|
|
22 |
Paper Jam |
The exit sensor was not unmade in time. |
|
|
See “Paper Feed, Base Printer” on |
|
|
page 25. |
|
|
|
23 |
Paper Jam |
Jam at the duplex unit. Paper is either |
|
|
not leaving the duplex entry sensor in |
|
|
time or not making or unmaking the |
|
|
duplex exit sensor in time. See “Duplex” |
|
|
on page 18. |
|
|
|
24 |
Short Paper |
The defined paper size is too short to |
|
|
print data as formatted. |
|
|
|
25 |
Incorrect Manual Feed |
Paper fed manually while motor is |
|
|
running and previous page in path. |
|
|
|
27 |
Change Envelope/Paper |
Envelopes/paper loaded are wrong size. |
|
|
|
28 |
Load Envelope/Paper |
Input sensor not made after pick |
|
|
attempt. Tray is empty or printer is |
|
|
requesting a manual feed. |
|
|
|
29 |
Output Bin Full |
The output bin sensor has not been |
|
|
unmade. |
|
|
|
30 |
Top Cover Open or Print Cartridge |
|
Missing |
|
|
|
|
|
Diagnostic Information 5
4039-1XX
Error/Code |
Action |
|
|
|
|
37 |
Insufficient Memory |
Not enough memory for function |
|
|
requested.To verify that the printer |
|
|
recognizes all the installed memory, go |
|
|
to the user menus and print the “Print |
|
|
Menus” test page. Make sure the |
|
|
memory shown on the printout matches |
|
|
the installed memory. |
|
|
|
38 |
Memory Full |
Memory used to store pages is full.To |
|
|
verify that the printer recognizes all the |
|
|
installed memory, go to the user menus |
|
|
and print the “Print Menus” test page. |
|
|
Make sure the memory shown on the |
|
|
printout matches the installed memory. |
|
|
|
39 |
Complex Page |
Page too complex to print.To verify that |
|
|
the printer recognizes all the installed |
|
|
memory, go to the user menus and print |
|
|
the “Print Menus” test page. Make sure |
|
|
the memory shown on the printout |
|
|
matches the installed memory. |
|
|
|
43 |
Font Card Not Supported |
Font card format not supported by |
|
|
printer. |
|
|
|
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 |
|
|
requested to be stored. |
|
|
|
53 |
Unformatted or Defective Flash |
Flash problem at POR or while |
|
|
attempting to write. |
|
|
|
54 |
Serial Error |
Framing or parity error on serial. |
|
|
|
58 |
Duplex Not Attached |
Duplex is electrically connected but no |
|
|
longer mechanically attached, and |
|
|
printer top cover is closed. |
|
|
|
59 |
Duplex Cover Open |
Top cover of duplex unit is sensed open. |
|
|
|
62 |
Disk Full |
Not enough disk space for data that has |
|
|
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 |
|
defective. Run the Quick Disk Test. If the |
|
test fails, the disk is defective or the data |
|
on track1 is bad. If the Quick Disk Test |
|
passes but the disk does not work, run |
|
the Disk Test/Clean (2 hr. test). Replace |
|
the disk if instructed by the operator |
|
panel. |
|
|
7X Network Card Codes |
These user codes are documented in |
|
various network card user manuals. See |
|
“Network Wrap Tests” on page 23. |
|
|
80 Scheduled Maintenance |
Printer has reached 200,000 prints |
|
(12C=100,000 prints) without |
|
maintenance count reset. |
|
|
88 Toner Low |
Toner sensor detects low toner. |
|
|
90X Software Error |
Unrecoverable software error. If one of |
|
these errors appeared during POST, or |
|
while the printer was idle (not printing or |
|
receiving data), or while trying to print |
|
one of the internal test pages, replace |
|
the system board. If the error appeared |
|
while sending a job from the host to the |
|
printer, turn the printer off, then turn it on |
|
and try again. If the error appears again, |
|
call the next level service support for |
|
assistance. |
|
|
917 Transfer Roll Error |
Cannot start servo operation. Verify |
|
correct cable connections from the |
|
Engine board to the HVPS. Make sure |
|
there is continuity between the transfer |
|
roller and its contact on the HVPS; |
|
replace the transfer roll if the continuity |
|
is correct. If there is no continuity, make |
|
sure the HVPS contact returns to its |
|
upward limit when depressed, and make |
|
sure the left bearing of the transfer roll is |
|
making proper contact. |
|
|
Diagnostic Information 7
4039-1XX
Error/Code |
Action |
|
|
|
|
918 |
Transfer Roll Error |
Servo Failure. Verify correct cable |
|
|
connections from the Engine board to |
|
|
the HVPS. Make sure there is continuity |
|
|
between the transfer roller and its |
|
|
contact on the HVPS; replace the |
|
|
transfer roll if the continuity is correct. If |
|
|
there is no continuity, make sure the |
|
|
HVPS contact returns to its upward limit |
|
|
when depressed, and make sure the left |
|
|
bearing of the transfer roll is making |
|
|
proper contact. |
|
|
|
920 |
Fuser Error |
Fuser is below temperature while |
|
|
printing. See “Fuser: 920, 921, or 922 |
|
|
Error” on page 20. |
|
|
|
921 |
Fuser Error |
Fuser is below standby temperature |
|
|
when idle. See “Fuser: 920, 921, or 922 |
|
|
Error” on page 20. |
|
|
|
922 |
Fuser Error |
Fuser failed to reach standby |
|
|
temperature. See “Fuser: 920, 921, or |
|
|
922 Error” on page 20. |
|
|
|
923 |
Fuser Error |
Fuser is too hot while printing or when |
|
|
idle. See “Fuser: 923 Error” on page 21. |
|
|
|
927 |
Fan Stalled |
See “Fan (927 Error)” on page 19. |
|
|
|
931 |
Printhead Error |
No first hsync. See “Printhead” on |
|
|
page 27. |
|
|
|
932 |
Printhead Error |
Lost hsync. See “Printhead” on page 27. |
|
|
|
934 |
Printhead Error |
Lost lock condition. See “Printhead” on |
|
|
page 27. |
|
|
|
935 |
Printhead Error |
Mirror motor unable to reach operating |
|
|
speed. See “Printhead” on page 27. |
|
|
|
941 |
System Board |
ROM SIMM failed CRC; code data or |
|
|
font data. Run the diagnostic Memory |
|
|
Test for ROM. Replace the SIMM if the |
|
|
test fails or the problem recurs after |
|
|
POR; replace the system board if the |
|
|
SIMM does not fix the problem. |
|
|
|
944 |
System Board |
RIP processor failure. Replace the |
|
|
system board. |
|
|
|
945 |
System Board |
ASIC 1 failure. Replace the system |
|
|
board. |
|
|
|
8 Service Manual
4039-1XX
Error/Code |
Action |
|
|
|
|
946 |
System Board |
ASIC 2 failure. Replace the system |
|
|
board. |
|
|
|
947 |
System Board |
Engine ASIC RAM failure. Replace the |
|
|
system board. |
|
|
|
948 |
System Board |
Engine ASIC electronics failure. Replace |
|
|
the system board. |
|
|
|
950 |
System Board |
SRAM failure. Replace the system |
|
|
board. |
|
|
|
952 |
System Board |
Unable to zero PQET SRAM. Replace |
|
|
the system board. |
|
|
|
953 |
System Board |
NVRAM failure. Replace the system |
|
|
board. |
|
|
|
960 |
Memory Error |
Bad or missing DRAM in the base |
|
|
DRAM slot. Reseat the DRAM and run |
|
|
the diagnostic Memory Test for DRAM. If |
|
|
test fails or the problem recurs after |
|
|
POR, replace the DRAM SIMM. |
|
|
|
961 |
Memory Error |
Bad DRAM in the optional DRAM slot. |
|
|
Reseat the DRAM and run the |
|
|
diagnostic Memory Test for DRAM. If |
|
|
test fails or the problem recurs after |
|
|
POR, replace the DRAM SIMM. |
|
|
|
970 |
Network Card |
Network card processor failure. Replace |
|
|
the Network Card. |
|
|
|
971 |
Network Card |
Network card RAM failure. Replace the |
|
|
Network Card. |
|
|
|
972 |
Network Card |
Network card ROS/FLASH failure. |
|
|
Replace the Network Card. |
|
|
|
973 |
Network Card |
Network card EEPROM/NVRAM failure. |
|
|
Replace the Network Card. |
|
|
|
974 |
Network Card |
Network card/Network interface error. |
|
|
Replace the Network Card. |
|
|
|
976 |
Network Card |
Network card software error. Verify that |
|
|
the network card is installed and |
|
|
grounded correctly. If this error returns |
|
|
after a POR, there is a software or |
|
|
microcode incompatibility problem. Do |
|
|
Not replace the card. Contact your next |
|
|
level of support. |
|
|
|
Diagnostic Information 9
4039-1XX
Error/Code |
Action |
|
|
|
|
977 |
Network Card |
Network card is installed but is not |
|
|
communicating with the system board. |
|
|
See “Network Card 977 Errors” on |
|
|
page 23. |
|
|
|
978 |
Network Card |
General network card hardware error. |
|
|
Replace the Network Card. |
|
|
|
979 |
Network Card |
General network card software error. |
|
|
Verify that the network card is installed |
|
|
and grounded correctly. If this error |
|
|
returns after a POR, there is a software |
|
|
or microcode incompatibility problem. |
|
|
Do Not replace the card. Contact your |
|
|
next level of support. |
|
|
|
990 |
Duplex Option |
Duplex error. See “Duplex” on page 18. |
|
|
|
991 |
Duplex System Card Failure |
Duplex system card failure. Replace the |
|
|
duplex system card. |
|
|
|
993 |
Duplex Comm. Failure |
Communications between the duplex |
|
|
unit and the printer have failed. See |
|
|
“Duplex” on page 18. |
|
|
|
10 Service Manual
4039-1XX
When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning by observing the following:
1.1½ rows of pels appear on the display and then clear.
2.Diamonds fill the display and then clear.
3.The fuser lamp and the fan turn on. [Performing Self Test] appears on the display.
Note: The printer may be idle for up to 60 seconds as the fuser warms to operating temperature. Printer idle time is shorter if the fuser is already warm.
Note: If the duplexer is installed, the duplex drive motor turns on for about 5 seconds just before the ready screen appears.
4.The ready screen appears on the display.
Note: Diagnostics menu appears if you are in diagnostic mode.
5.The drive motor and the mirror motor start to run. The fan starts to run at high speed.
6.The drive motor runs for approximately 10 seconds. The fan runs at high speed, then switches to low speed.
If the printer completes all these steps and no error messages are displayed, the printer has successfully completed the POST.
Diagnostic Information 11
4039-1XX
Symptom |
Action or Service Check |
|
|
Dead Machine |
Dead Machine Service Check |
|
|
Repeats pattern of five beeps and a |
Operator Panel Service Check |
pause. |
|
|
|
Machine Hangs Displaying Diamonds |
Machine Hangs Displaying Diamonds |
|
Service Check |
|
|
Operator Panel |
Operator Panel Service Check |
|
|
Paper Feed, Base Printer |
Paper Feed, Base Printer Service Check |
|
|
Paper Feed, Duplex Unit |
Paper Feed, Duplex Unit Service Check |
|
|
Paper Feed Problem, 500-sheet |
Paper Feed Problem, 500-sheet Second |
Second Tray |
Tray Service Check |
|
|
Paper Feed Problem, Envelope+ |
Paper Feed Problem, Envelope+ |
Feeder/100-Sheet Auxiliary Feeder |
Feeder/100-Sheet Auxiliary Feeder |
|
Service Check |
|
|
Automatic Paper Size Sensing Problem |
Automatic Paper Size Sensing Problem |
|
Service Check |
|
|
LAN Problems |
LAN Service Check |
|
|
Blank Page |
Blank Page Service Check |
|
|
Black Page |
Black Page Service Check |
|
|
Random Marks |
Random Marks Service Check |
|
|
Regularly Spaced Marks |
Regularly Spaced Marks Service Check |
|
|
Skew, all edges |
Skew 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 development or transfer. It is undetectable when printing text and is most noticeable on fine dot or horizontal line patterns such as the second page of Print Test 2 or Print Test 3. Inspect the gear train and the paperfeed rollers for wear, damage, dirt, or binds.
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/ |
16L |
|
Voltage while |
Voltage while |
|||
12L |
|
Printing |
|
Idling |
|||
|
|
|
|||||
|
|
|
|
|
|
|
|
J20-1 to J20-4 |
J17-1 to J17-4 |
|
Less than |
+21-26VDC |
|||
|
|
|
1VDC |
|
|
|
|
J20-2 to J20-4 |
J17-2 to J17-4 |
|
Greater than |
Less than |
|||
|
|
|
1VDC |
|
5VDC |
||
J20-3 to J20-4 |
J17-3 to J17-4 |
|
The meter |
Less than |
|||
|
|
|
should fluctu- |
5VDC |
|||
|
|
|
ate slightly |
|
|
||
|
|
|
between |
|
|
||
|
|
|
each page. |
|
|
||
J20-8 to J20-4 |
J17-8 to J17-4 |
|
Less than |
+21-26VDC |
|||
|
|
|
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. |
|
|
|
|
||
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 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/ |
16L |
Voltage |
|
12L |
||||
|
|
|
||
|
|
|
|
|
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/ |
16L |
Voltage while |
Voltage while |
|
12L |
Printing |
Idling |
||
|
J20-1 to J20-4 |
J17-1 to J17-4 |
Less than |
21-26VDC |
|
|
1VDC |
|
J20-2 to J20-4 |
J17-2 to J17-4 |
Greater than |
Less than |
|
|
1VDC |
0.5VDC |
|
|
|
|
|
|
|
|
10P |
Voltage while |
Voltage while |
|
Printing |
Idling |
|
|
|
|
||
|
|
|
|
J14-1 to J14-4 |
Less than |
0VDC |
|
|
5VDC |
|
|
J14-2 to J14-4 |
Less than |
0VDC |
|
|
5VDC |
|
|
|
|
|
|
Diagnostic Information 15
4039-1XX
Inspect the printhead shutter for proper operation and make sure the actuator on top of the cartridge is present and extends into the printhead shroud when the printer top cover is closed. A failed printhead will cause a 931 Service error rather than blank output.
Check the continuity of the HVPS cable. The HVPS and transfer roll contacts should be clean and spring back when pressed. Make sure the transfer roll contact under the left bearing is making contact with the HVPS.
Make the following voltage checks while running the print test continuously and again while idling.
10R/12R/12C/ |
16L |
Voltage while |
Voltage while |
|
12L |
Printing |
Idling |
||
|
||||
|
|
|
|
|
J20-1 to J20-4 |
J17-1 to J17-4 |
Less than |
+21-26VDC |
|
|
|
1VDC |
|
|
J20-2 to J20-4 |
J17-2 to J17-4 |
Greater than |
Less than |
|
|
|
1VDC |
5VDC |
|
J20-3 to J20-4 |
J17-3 to J17-4 |
The meter |
Less than |
|
|
|
should fluctu- |
5VDC |
|
|
|
ate slightly |
|
|
|
|
between |
|
|
|
|
each page. |
|
|
J20-8 to J20-4 |
J17-8 to J17-4 |
Less than |
+21-26VDC |
|
|
|
1VDC |
|
|
|
|
|
|
16 Service Manual