Lexmark 4039 Service Manual
LaserPrinter 4039 Series
• Table of Contents
• Start Diagnostics
• Start Diagnostics
• Safety and Notices
• Trademarks
4039-1XX
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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
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