Lexmark 4039-16L plus, 4039-12L plus, 4039-12C plus, 4039-12R plus, 4039-10R plus Service Manual

Lexmark LaserPrinter

4039-1XX

•Table of Contents

•Start Diagnostics

•Safety and Notices

•Trademarks

• Index

• Manuals Menu

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

Second Edition (June 1996)

The following paragraph does not apply to the United Kingdom or any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions of the publication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase.

A form for reader’s comments is provided at the back of this publication. If the form has been removed, comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. In the United Kingdom and Eire, send to Lexmark International Ltd., Marketing and Services Department, Westthorpe, Marlow Bucks SL7 3RQ. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

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.

Notices and Safety Information

References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property rights may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s responsibility.

Electronic Emission Notices

Consult the following list for any emission that may apply in your country.

Federal Communications 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 iii

The manufacturer is not responsible for any radio or television interference caused by using other than recommended cables or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the user’s authority to operate the equipment.

Note: To comply with FCC 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.

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.

iv Service Manual

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 v

Trademarks

Lexmark is a trademark of Lexmark International, Inc.

The following terms, denoted by a double asterisk (**) in this publication, are trademarks or registered trademarks of the following companies.

AppleTalk	Apple Computer, Inc.
IBM	International Business Machines
	Corporation
LocalTalk	Apple Computer, Inc.
PCL	Hewlett-Packard Company
PostScript	Adobe Systems Incorporated

AppleTalk and LocalTalk are trademarks of Apple Computer, Inc. registered in the United States and other countries.

PCL is a registered trademark of the Hewlett-Packard Company. PCL 5 is Hewlett-Packard Company’s designation of a set of printer commands (language) and functions included in its printer products. This printer is designed and manufactured by Lexmark International, Inc., to be compatible with the PCL 5 language. This means the printer recognizes PCL 5 commands used in various applications programs, and that the printer emulates the functions corresponding to the commands.

PostScript is a registered trademark of Adobe Systems Incorporated. PostScript is Adobe Systems’ designation of a set of printer commands (language) and functions included in its software products. This printer is designed and manufactured by Lexmark International, Inc., to be compatible with the PostScript Level 2 language. This means the printer recognizes PostScript Level 2 commands used in the various application programs, and that the printer emulates the functions corresponding to the commands.

vi Service Manual

Safety Information

•The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.

•There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

•The safety features of some parts may not always be obvious. Therefore, replacement parts must have the identical or equivalent characteristics as the original parts.

Sicherheitshinweise

•Die Wartungsinformationen 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.

Notices and Safety Information vii

Norme di sicurezza

•Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell'assistenza autorizzato.

•Durante lo smontaggio e il manutenzionamento di questo prodotto, 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 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.

Ozone Information

This product does not produce measurable amounts of ozone gas.

viii Service Manual

Preface

This manual is divided into the following chapters:

•“General Information” contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this 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.

Preface ix

x Service Manual

Table of Contents
Notices and Safety Information..............................................	iii
Electronic Emission Notices..............................................................	iii
Federal Communications Commission (FCC) Statement .............	iii
Industry Canada Compliance Statement .....................................	iv
The United Kingdom Telecommunications Act 1984 ...................	iv
European Community (EC) Electromagnetic Compatibility
Directive ........................................................................................	v
German Statement of Acoustic Emissions....................................	v
Trademarks ......................................................................................	vi
Safety Information ............................................................................	vii
Ozone Information...........................................................................	viii
Preface......................................................................................	ix
Table of Contents ....................................................................	xi
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
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

x

Fuser Theory ...............................................................................	20
Fuser: 920, 921, or 922 Error ......................................................	20
Fuser: 923 Error ..........................................................................	21
Honeycomb .................................................................................	21
Horizontal Void or Streak ............................................................	22
LAN Problems .............................................................................	23
Light Print ....................................................................................	23
Network Card 977 Errors.............................................................	24
Network Wrap Tests....................................................................	24
Output Bin Sensor .......................................................................	24
Operator Panel Problem..............................................................	25
Paper Feed Problem, 500-Sheet Second Tray ...........................	26
Paper Feed, Base Printer............................................................	26
Paper Feed, Duplex Unit .............................................................	27
Paper Feed Problem, Envelope+ Feeder/
100-Sheet Auxiliary Feeder.........................................................	28
Printhead .....................................................................................	28
Paper Size Sensing Problem ......................................................	29
Regularly Spaced Marks .............................................................	30
Residual Image ...........................................................................	30
Random Marks ............................................................................	31
Skew, all edges ...........................................................................	31
Skew, top and bottom only ..........................................................	31
Stalled (diamonds on display) .....................................................	31
Vertical Void or Streak.................................................................	32
Diagnostic Aids.......................................................................	33
Diagnostics Mode............................................................................	33
Grouped Diagnostic Aids.................................................................	34
Alphabetical List of Diagnostic Aids ................................................	35
Auto Clean...................................................................................	35
Auto Clean Delay ........................................................................	35
Auto Clean Frequency.................................................................	35
Defaults .......................................................................................	36
Developed Image Test ................................................................	36
Disk Test/Clean ...........................................................................	36
Duplex Feed 1 Test .....................................................................	37
Duplex Feed 2 Test .....................................................................	38
Envelope Enhance ......................................................................	39
Envelope Print Test .....................................................................	39
Error Log (“plus” machines only) .................................................	39

xi Service Manual

Fuser Temperature And Warm-Up Time.....................................	40
Fuser Temperature ..............................................................	40
Warm-up Time .....................................................................	40
Maintenance Kit Count................................................................	41
Memory Test ...............................................................................	41
Operator Panel Tests ..................................................................	41
Button Test...........................................................................	41
LCD Test..............................................................................	42
Page Count .................................................................................	42
Paper Feed Test .........................................................................	42
Permanent Page Count...............................................................	43
Print Contrast (Transfer on “plus” machines) ..............................	43
Print Registration.........................................................................	43
Print Test Page ...........................................................................	43
Print Tests ...................................................................................	44
Print Test 1...........................................................................	44
Print Test 2...........................................................................	44
Print Test 3...........................................................................	45
Quick Disk Test ...........................................................................	45
Quick Test ...................................................................................	45
Sensor Test.................................................................................	46
Network Connections and Checks ..................................................	47
Wrap Tests..................................................................................	47
LAN Information ..........................................................................	48
Serial Interface Option, 10P ........................................................	48
Function Switch Setting .......................................................	48
Repair Information..................................................................	53
Handling ESD-sensitive Parts .....................................................	53
Adjustments ....................................................................................	54
Envelope Restraint Spring On The Envelope+ Feeder...............	54
Paper Restraint Spring On The 100-sheet
Auxiliary Feeder ..........................................................................	54
Envelope Feeder Magnet And 100-sheet
Auxiliary Feeder Magnet .............................................................	55
Fuser Drive Gear Backlash .........................................................	56
Fuser Solenoid ............................................................................	58
Paper Feed Magnet ....................................................................	59
Optional Paper Feed Magnet ......................................................	60
Printhead Skew - Level 1 ............................................................	61
Printhead Skew - Level 2 ............................................................	62

xii

Print Registration Adjustment......................................................	63
Removals ........................................................................................	64
Covers .........................................................................................	64
Right Cover Removal ..................................................................	64
Front Cover Removal ..................................................................	64
Left Cover Removal.....................................................................	66
Top Cover Removal ....................................................................	66
Transfer Roll Removal.................................................................	68
D-roll Assembly Removal ............................................................	69
Drive Motor Removal...................................................................	70
Fan/Redrive Removal..................................................................	72
Fuser Removal ............................................................................	74
Fuser Input Guide Removal ........................................................	74
Fuser Lamp Removal ..................................................................	76
Fuser Solenoid Removal .............................................................	77
Fuser Thermistor Removal..........................................................	78
HVPS Removal ...........................................................................	80
Input Sensor Removal.................................................................	82
Lower Frame Assembly Removal ...............................................	83
LVPS Removal ............................................................................	84
LVPS Cover Removal .................................................................	85
Operator Panel Removal.............................................................	86
Option Card Removal..................................................................	86
Exit Sensor Removal...................................................................	87
Paper Feed Magnet Assembly Removal.....................................	88
Paper Feed Rollers Removal ......................................................	89
Paper Size Switch Removal ........................................................	90
Printhead Removal......................................................................	91
System Board Removal...............................................................	92
System Cable Removal...............................................................	94
Fuser/Sensor Cable Removal .....................................................	94
Torquer Motor Removal (10P).....................................................	94
Toner Sensor Removal ...............................................................	95
Transfer Roll Housing Removal ..................................................	96
Upper Frame Removal ................................................................	97
Zif Connector Removal................................................................	98
Duplex Option Top Cover And Table Cover Removal.................	99
Duplex Option Exit Card And Cover Removal...........................	100
Duplex Option Bottom Cover And
Entry Sensor Card Removal......................................................	100
Duplex Option System Card And Motor Removal .....................	102

xiii Service Manual

Connector Locations............................................................	103
Major Assembly Locations ........................................................	103
Gear Train .................................................................................	104
RIP Board Installation Hardware...............................................	105
HVPS ........................................................................................	106
Transfer Roller Housing ............................................................	106
System Cable............................................................................	107
System Board Connectors 10R/12R/12L ..................................	108
System Board Connectors 16L .................................................	110
System Board Connectors 10P.................................................	112
Printhead Cables.......................................................................	114
Mirror Motor Cable/Fan Cable...................................................	115
Operator Panel/Output Bin Sensor Cable —
Handle-Mounted Outbin Sensor................................................	116
Operator Panel/Output Bin Sensor Cable —
Redrive-Mounted Outbin Sensor...............................................	117
Printer Ground Straps ...............................................................	119
Preventive Maintenance.......................................................	121
Safety Inspection Guide ............................................................	121
Lubrication Specifications .........................................................	121
Printhead Window Cleaning Procedure ....................................	124
Cleaning The Transfer Roller ....................................................	124
Scheduled Mechanical Maintenance ........................................	125
Parts Catalog.........................................................................	127
How To Use This Parts Catalog................................................	127
Assembly 1: Covers ...........................................................	128
Assembly 2: Lower Frame .................................................	132
Assembly 3: Upper Frame .................................................	136
Assembly 4: Printhead .......................................................	140
Assembly 5: Paper Feed....................................................	142
Assembly 6: Paper Feed Alignment Gears........................	146
Assembly 7: Paper Feed Drive ..........................................	148
Assembly 8: Standard Paper Tray (200 sheet)..................	150
Assembly 9: Paper Tray (500-Sheet).................................	152
Assembly 10: Base for Paper Drawer (500-Sheet)............	154
Assembly 11: Optional Paper Drawer (500-Sheet)............	156
Assembly 12: Fuser ...........................................................	158
Assembly 13: Electronics...................................................	162
Assembly 14: Transfer Roll................................................	166
Assembly 15: Duplex Option..............................................	168

xiv

Assembly 16: Envelope+ and 100-Sheet
Auxiliary Feeder ............................................................	170
Assembly 17: Options ........................................................	172
Assembly 18: Miscellaneous..............................................	173
Index ......................................................................................	175

xv Service Manual

General Information

The 4039 is a family of 600 dpi Laserprinters designed to attach to IBM**-compatible PC’s and to most types of computer networks. The printer has PostScript** and PCL** emulation standard.

Models Covered in this Manual

There are no voltage or pinout differences between the regular models and the plus models. For example, a voltage callout for the 16L also applies to the 16L plus.

IBM Models

4039-10R 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

Lexmark Model

4039-10 plus (Called 10P in this manual and on the serial number plate) 10ppm, PostScript Level 2 emulation, no serial port, torquer motor rather than paper pick solenoid, and service error log

Options

The following options are available. Some options are not compatible with all printer models. Some options are not available in every country. Contact your point of purchase for options available in your country.

Memory upgrade options of 2MB, 4MB and 8MB.

Flash memory options of 1MB, 2MB and 4MB

Intergated network options

Token-Ring option

Ethernet option

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

Maintenance Approach

The diagnostic information in this manual will lead you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. See “Diagnostic Information” starting on page 5. This printer can be serviced without being connected to a host.

After you complete the repair, perform tests as needed to verify the repair.

General Information 3

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

Diagnostic Information

4039 Diagnostics: Failures With Error Codes

Two-digit codes are messages for the 4039 user, but if they recur frequently or at inappropriate times they may be symptomatic of a service problem. On “plus” models, refer to the diagnostics error log for the last six errors or paper jam codes.

Error/Code		Action
20	Paper Jam	The input sensor was not unmade in
		time. See “Paper Feed, Base Printer” on
		page 26.
21	Paper Jam	The exit sensor was not made in time
		after the input sensor was made. See
		“Paper Feed, Base Printer” on page 26.
22	Paper Jam	The exit sensor was not unmade in time.
		See “Paper Feed, Base Printer” on
		page 26.
23	Paper Jam	Jam at the duplex unit. Paper is either
		not leaving the duplex entry sensor in
		time or not making or unmaking the
		duplex exit sensor in time. See “Duplex”
		on page 18.
24	Short Paper	The defined paper size is too short to
		print data as formatted.
25	Incorrect Manual Feed	Paper fed manually while motor is
		running and previous page in path.
27	Change Envelope/Paper	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

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

Error/Code	Action
63 Unformatted or Defective Disk	The printer will ignore a disk it senses as
	defective. Run the Quick Disk Test. If the
	test fails, the disk is defective or the data
	on track1 is bad. If the Quick Disk Test
	passes but the disk does not work, run
	the Disk Test/Clean (2 hr. test). Replace
	the disk if instructed by the operator
	panel.
7X Network Card Codes	These user codes are documented in
	various network card user manuals. See
	“Network Wrap Tests” on page 24.
80 Scheduled Maintenance	Printer has reached 200,000 prints
	(12C=100,000 prints) without
	maintenance count reset.
88 Toner Low	Toner sensor detects low toner.
90X Software Error	Unrecoverable software error. If one of
	these errors appeared during POST, or
	while the printer was idle (not printing or
	receiving data), or while trying to print
	one of the internal test pages, replace
	the system board. If the error appeared
	while sending a job from the host to the
	printer, turn the printer off, then turn it on
	and try again. If the error appears again,
	call the next level service support for
	assistance.
917 Transfer Roll Error	Cannot start servo operation. Verify
	correct cable connections from the
	Engine board to the HVPS. Make sure
	there is continuity between the transfer
	roller and its contact on the HVPS;
	replace the transfer roll if the continuity
	is correct. If there is no continuity, make
	sure the HVPS contact returns to its
	upward limit when depressed, and make
	sure the left bearing of the transfer roll is
	making proper contact.

Diagnostic Information 7

Error/Code		Action
918	Transfer Roll Error	Servo Failure. Verify correct cable
		connections from the Engine board to
		the HVPS. Make sure there is continuity
		between the transfer roller and its
		contact on the HVPS; replace the
		transfer roll if the continuity is correct. If
		there is no continuity, make sure the
		HVPS contact returns to its upward limit
		when depressed, and make sure the left
		bearing of the transfer roll is making
		proper contact.
920	Fuser Error	Fuser is below temperature while
		printing. See “Fuser: 920, 921, or 922
		Error” on page 20.
921	Fuser Error	Fuser is below standby temperature
		when idle. See “Fuser: 920, 921, or 922
		Error” on page 20.
922	Fuser Error	Fuser failed to reach standby
		temperature. See “Fuser: 920, 921, or
		922 Error” on page 20.
923	Fuser Error	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 28.
932	Printhead Error	Lost hsync. See “Printhead” on page 28.
934	Printhead Error	Lost lock condition. See “Printhead” on
		page 28.
935	Printhead Error	Mirror motor unable to reach operating
		speed. See “Printhead” on page 28.
941	System Board	ROM SIMM failed CRC; code data or
		font data. Run the diagnostic Memory
		Test for ROM. Replace the SIMM if the
		test fails or the problem recurs after
		POR; replace the system board if the
		SIMM does not fix the problem.
944	System Board	RIP processor failure. Replace the
		system board.
945	System Board	ASIC 1 failure. Replace the system
		board.

8 Service Manual

Error/Code		Action
946	System Board	ASIC 2 failure. Replace the system
		board.
947	System Board	Engine ASIC RAM failure. Replace the
		system board.
948	System Board	Engine ASIC electronics failure. Replace
		the system board.
950	System Board	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

Error/Code		Action
977	Network Card	Network card is installed but is not
		communicating with the system board.
		See “Network Card 977 Errors” on
		page 24.
978	Network Card	General network card hardware error.
		Replace the Network Card.
979	Network Card	General network card software error.
		Verify that the network card is installed
		and grounded correctly. If this error
		returns after a POR, there is a software
		or microcode incompatibility problem.
		Do Not replace the card. Contact your
		next level of support.
990	Duplex Option	Duplex error. See “Duplex” on page 18.
991	Duplex System Card Failure	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

Power-On Self Test (POST)

When you turn the printer on, it performs a Power-On Self Test. Check for correct POST functioning by observing the following:

1.1½ rows of pels appear on the display and then clear.

2.Diamonds fill the display and then clear.

3.The fuser lamp and the fan turn on. [Performing Self Test] appears on the display.

Note: The printer may be idle for up to 60 seconds as the fuser warms to operating temperature. Printer idle time is shorter if the fuser is already warm.

Note: If the duplexer is installed, the duplex drive motor turns on for about 5 seconds just before the ready screen appears.

4.The ready screen appears on the display.

Note: Diagnostics menu appears if you are in diagnostic mode.

5.The drive motor and the mirror motor start to run. The fan starts to run at high speed.

6.The drive motor runs for approximately 10 seconds. The fan runs at high speed, then switches to low speed.

If the printer completes all these steps and no error messages are displayed, the printer has successfully completed the POST.

Diagnostic Information 11

Symptom Table

Symptom	Action or Service Check
Dead Machine	Dead Machine Service Check
Repeats pattern of five beeps and a	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

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.

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

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