Lexmark 4039-1XX Service Manual Download Page 1

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4039-1XX

Lexmark LaserPrinter

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

• Table of Contents

• Index

• Safety and Notices

• Trademarks

• Start Diagnostics

• Manuals Menu

Summary of Contents for 4039-1XX

Page 1: ...er Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Star...

Page 2: ...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 rem...

Page 3: ...r 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 inter...

Page 4: ...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...

Page 5: ...e 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...

Page 6: ...ommands 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 r...

Page 7: ...ten nicht von anderen ben tzt werden Zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung existiert w hrend des Auseinandernehmens und der Wartung des Ger ts Fachpersonal sollte...

Page 8: ...mayores riesgos de descargas el ctricas y da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado comprende esto y toma las precauciones necesarias Los dispositivo...

Page 9: ...solate 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...

Page 10: ...x Service Manual...

Page 11: ...oustic 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 Option...

Page 12: ...eder 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...

Page 13: ...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 H...

Page 14: ...l 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...

Page 15: ...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 U...

Page 16: ...xv Service Manual Assembly 16 Envelope and 100 Sheet Auxiliary Feeder 170 Assembly 17 Options 172 Assembly 18 Miscellaneous 173 Index 175...

Page 17: ...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 prin...

Page 18: ...er 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...

Page 19: ...ble 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 print...

Page 20: ...charge 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 Diod...

Page 21: ...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 i...

Page 22: ...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 Defec...

Page 23: ...able 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...

Page 24: ...ser 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 92...

Page 25: ...d 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...

Page 26: ...y 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 o...

Page 27: ...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 appea...

Page 28: ...Feeder 100 Sheet Auxiliary Feeder Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder Service Check Automatic Paper Size Sensing Problem Automatic Paper Size Sensing Problem Service Check LA...

Page 29: ...l 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 sh...

Page 30: ...Make sure the HVPS contacts to the transfer roll housing are in good condition 10R 12R 12C 12L 16L Voltage while Printing Voltage while Idling J20 1 to J20 4 J17 1 to J17 4 Less than 1VDC 21 26VDC J20...

Page 31: ...he system board Make the following voltage checks while printing and again while idling If the voltages are not correct replace the system board 10P 10R 12R 12C 12L 16L Voltage J14 5 to J14 4 J20 5 to...

Page 32: ...hould 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 co...

Page 33: ...ry feeder some blurring may occur at the point where the feeder s friction rollers release the paper Dead Machine Possible causes no voltage reaching the printer LVPS failure blown LVPS fuse failure o...

Page 34: ...uplex top cover and table cover Disconnect the duplex cable from the printer system board From left to right 10P top to bottom the voltages on the printer system board connector pins should be 0 34VDC...

Page 35: ...duplex system card If the 7th and 8th digits are 04 there is an exit sensor problem Remove the duplex top cover and table cover Remove the paper tray so you can reach the sensor Measure the voltage on...

Page 36: ...is left off until a job is printed The system board signal to the LVPS TRIAC is on 10P J11 16 10R 12R 12C 12L J11 3 16L J18 16 The voltage is 0VDC when the lamp is to be on and 24VDC 10P 5VDC when the...

Page 37: ...the correct signal to the TRIAC At POR this signal should go to 24VDC 10P 5VDC and then immediately drop to 0VDC until the fuser is warm if it does not replace the system board If the signal is OK rep...

Page 38: ...is usually due to the cartridge not being installed correctly Check the printhead area for obstructions and check the mechanical workings of the print cartridge and printhead shutter If nothing is fou...

Page 39: ...d Verify correct installation of software utility Single route broadcast not supported across network bridge if bridge is used Server problem check print server installation and configuration using th...

Page 40: ...NC terminator cap to each end of the T connector The customer may be able to provide this cap There is no wrap test for Token Ring with Unshielded Twisted Pair cable or for Ethernet 10Base T POR the p...

Page 41: ...POR stops with 1 rows of pels displayed Run the diagnostic tests for the LCD and for the buttons If only some buttons or pels work replace the operator panel If the operator panel is blank check for 5...

Page 42: ...gh to give good contact between the D roll and the paper stack 10R 12R 12C 12L 16L Make sure the pick magnet is being energized The pick magnet should have a resistance of 100 to 250 Ohms The voltage...

Page 43: ...both in the duplex unit and on the tray top cover and that the gear on the tray top cover engages the gear on the duplexer If paper is jamming in the table cover area make sure the table cover is prop...

Page 44: ...2 on the feeder cable the resistance should be from 105 Ohms to 155 Ohms If the magnet is good reconnect the cable and monitor the voltage between the two pins of the connector while running the Envel...

Page 45: ...e sure there is no continuity from 10P 10R 12R 12L 12C J19 3 to J19 4 16L J16 3 to J16 4 on the cable replace the paper size switch if the resistance is not infinite The resistance from 10P 10R 12R 12...

Page 46: ...iled cleaner inside the print cartridge It can also be caused by a failed fuser hot roll retaining toner and redepositing it on the page Check that the erase lamp voltage at 10P J20 1 10R 12R 12C 12L...

Page 47: ...prealigner drive and auxiliary rollers springs and backup rollers for dirt wear or damage refer to the parts catalog for repair kits for broken bellcrank spring attachment hooks on the sideframe Make...

Page 48: ...heck the operation of the printhead shutter and clean the printhead window with a lint free cloth folded over a cotton swab do not use a bare swab and do not use any cleaning fluids or water on the pr...

Page 49: ...ut the printer in Diagnostics mode To enter Diagnostics mode 1 Turn the printer off 2 Press and hold the Ready and Return buttons Then turn the printer on The printer performs the Power On Self Test 3...

Page 50: ...est Paper Feed Tests Page Counts Envelope Print Test Page Count Paper Feed Test Maintenance Kit Count Permanent Page Count Printer Setup Tests Device Tests Envelope Enhance Quick Disk Test Print Contr...

Page 51: ...4 Press Return to return to Diagnostics mode main menu Auto Clean Delay This can be set from 1 to 60 seconds with a default of 1 Auto Clean Delay does not appear on the menu unless Auto Clean is on 1...

Page 52: ...he test page 3 As soon as the leading edge of the paper is visible coming out the front exit slot turn off the printer 4 Remove the print cartridge and look at the image on the photoconductor Disk Tes...

Page 53: ...tor fingers before the paper reverses direction 1 Enter Diagnostics mode 2 Select Duplex Tests 3 Select Duplex Feed 1 4 Select Tray 1 or Tray 2 Note Paper feeds all the way into the duplex unit and st...

Page 54: ...e paper open the top cover of the duplex unit 8 Carefully remove the duplex unit from the printer without disturbing the position of the paper on the top of the duplex tray Do not disconnect the duple...

Page 55: ...eder present the printer uses manual envelope 1 Enter Diagnostics mode 2 Select Envelope Print 3 Select Single or Continuous 4 Select CANCEL to stop continuous envelope feed 5 Press Return to return t...

Page 56: ...est setting that corrects the problem Setting 0 is the factory default and is the shortest warm up time Setting 5 increases warm up time by 90 seconds lower settings increase the time proportionately...

Page 57: ...iagnostics mode 2 Select Memory Test 3 Select either DRAM or ROM 4 Select Single or Continuous 5 The display indicates PASSED or FAILED 6 Select CANCEL to stop continuous memory test 7 Press Return to...

Page 58: ...by Selecting NEXT to move the cursor under each digit Then select OR to select the number you want in each digit 4 Select SAVE to save the page count displayed Paper Feed Test This test allows you to...

Page 59: ...s to prevent toner from being deposited in white areas next to large black areas 1 Enter Diagnostics mode 2 Select Print Contrast 3 Select Light Medium or Dark Low Medium or High on plus machines 4 Pr...

Page 60: ...t 1 will not duplex To run Print Test 1 1 Enter Diagnostics mode 2 Select Print Test 1 3 Select Single or Continuous 4 Select CANCEL to stop continuous print 5 Press Return to return to the main Diagn...

Page 61: ...s and the disk hardware and circuitry but does only incidental testing of the disk surface itself The Quick Disk Test does not destroy data on the disk existing data is read and stored prior to the te...

Page 62: ...of the following sensor tests Toner Low Output Bin Input Exit Cover Open Note The Output Bin sensor can have up to a 15 second delay in changing to open 4 When the sensor is blocked Open is displayed...

Page 63: ...rial wrap plug part no 1329048 for the serial test 4 Enter Diagnostics mode 5 Select Wrap Test 6 Select Parallel for the parallel port or Serial for the 25 pin serial port 7 Select Single or Continuou...

Page 64: ...ter is connected Serial Interface Option 10P The serial interface unit switch settings determine how the printer receives data from the computer or terminal Set the switches according to your particul...

Page 65: ...parity the printer ignores the received parity and transmits using Even parity For all other parity settings the transmitted parity matches the received parity Off On On Off 1 200 Off On Off Off 2 400...

Page 66: ...nter character set Note For the serial print test to work Advanced Status found under the PARALLEL SETUP menu must be set to Off To run the serial interface test print 1 Turn the printer power off 2 S...

Page 67: ...ce Switch 11 is used to reverse the polarity of the receive and transmit data line for the RS 422 serial interface Switch 12 Interface Switch 12 sets the serial interface in either RS 232C or RS 422 m...

Page 68: ...52 Service Manual...

Page 69: ...static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not p...

Page 70: ...ition the spring B so it clears the separator roller by 1 9 0 2 mm 0 075 0 008 in 3 Tighten the mounting screw Paper Restraint Spring On The 100 sheet Auxiliary Feeder 1 Loosen the mounting screw A 2...

Page 71: ...eeder Magnet 1 Hold the armature A in the closed coil active position 2 Loosen the mounting screw B and rotate the magnet assembly so the armature clears the clutch gear by 0 30 0 20 mm 0 012 0 008 in...

Page 72: ...ble gear in one direction to check for backlash To adjust backlash 1 Loosen the nut on the idler stud 2 Move the idler stud downward in its slot 3 Insert a 0 95 mm 037 feeler gage between the gear sho...

Page 73: ...Repair Information 57...

Page 74: ...oid must be mounted on the fuser for this adjustment and should be at room temperature 1 Loosen screw A 2 Remove the rubber washer 3 Rotate shaft B eccentric to obtain 4 2 mm 0 2 mm 0 165 in 0 008 in...

Page 75: ...for 0 60 mm 0 07 mm 0 024 in 0 003 in between the foam pad and the magnet pole piece If adjustment is required continue 3 Keep the armature latched and loosen the magnet mounting screw A 4 Insert feel...

Page 76: ...ce If adjustment is required continue 2 Keep the armature latched and loosen the magnet mounting screw A Note The flat side of the D roll is down when the feed is latched 3 Insert feeler gage 4 Rotate...

Page 77: ...the skew marks on the printout are parallel to the top edge of the paper Use Print Test 1 or Quick Test to check this Rotating the printhead clockwise will lower the left skew adjustment point on the...

Page 78: ...he screws A 3 Run Print Test 1 or the Quick Test on the Diagnostics Menu 4 Move the pointer B to eliminate the skew Moving the pointer toward the left raises the left adjustment point on the printout...

Page 79: ...he margin to the left 6 Top Margin This margin can be set between 20 and 20 Changing the number by one moves the margin by 1 75 inches Moving the number in a positive direction moves the margin down t...

Page 80: ...ver off the rear pivot pin Front Cover Removal 1 Unplug the power cord 2 Remove the paper tray 3 Open the top cover 4 Open the right cover 5 Remove the Duplex mounting slot covers 6 Release the latche...

Page 81: ...Repair Information 65...

Page 82: ...and push the end to the rear to release it 5 Push the top of the cover to the left 6 Remove the cover by sliding it to the rear of the machine Top Cover Removal 1 Remove the top cover screws C 2 Lift...

Page 83: ...Repair Information 67...

Page 84: ...rom the front with your left hand Use a small screwdriver to push the rear latch forward and release the bearing cover This exposes the bearing on the end of the transfer roll 4 Grasp the bearing on t...

Page 85: ...ed above the flat part of the D roll 7 Push the latch down away from the shaft and slide the D roll to the left off the shaft Note There is no positive detent when replacing the D roll Make certain th...

Page 86: ...ing nuts B and screws 9 Work the motor out of the machine 10P Do not remove the motor from the gear bracket assembly they are not available separately Installing the motor If the motor has been remove...

Page 87: ...Repair Information 71...

Page 88: ...Remove the lower redrive shaft by disengaging the right end to the rear of the machine 5 Disconnect the long redrive belt A and slip it off the lower shaft 6 Remove the redrive assembly screws D 7 Rem...

Page 89: ...Repair Information 73 D B C A...

Page 90: ...he opening for the paper output 4 Unsnap the front cover from the right side frame 5 Remove the fuser cover 6 Disconnect the power wires A from the left side of the fuser 7 Remove the fuser input guid...

Page 91: ...Repair Information 75...

Page 92: ...TO COOL FOR 5 MINUTES Note The fuser lamp is a glass heater Do not touch the lamp with your hands skin oils and acids can reduce the life of the heater lamp Use a soft cloth to handle the heater lamp...

Page 93: ...al 1 Remove the fuser 2 Remove the two mounting screws A holding the solenoid housing to the fuser housing 3 Disengage the solenoid bracket from the plunger Note When a new solenoid assembly is instal...

Page 94: ...exit sensor card 2 Remove the fuser cover and wiper 3 Remove the tape holding the thermistor cable to the shroud 4 Squeeze the thermistor bracket tabs B and remove the thermistor from the shroud 5 Re...

Page 95: ...Repair Information 79 B A...

Page 96: ...e hole D 11 The power supply is held in place by two latches on the left side To release the latches Push one latch E in and raise one of the studs F to release the latch Push the other latch E in and...

Page 97: ...Repair Information 81 F E B F D C...

Page 98: ...3 Remove the D roll 4 Disconnect the system cable from the input sensor board Note Use care the flag can be damaged while removing the sensor 5 Release latch B and pull the sensor down and forward to...

Page 99: ...r roll housing 5 Disconnect the cable from the HVPS 6 Remove the system board and the inner EMC shield 7 Disengage the upper frame cables from the guide in the paper feed side frame 8 Remove the screw...

Page 100: ...ays 3 Remove the left and right side covers 4 10P and 16L remove the system board and the inner EMC shield 5 Remove the left and right LVPS mounting screws 6 Disconnect the fuser connector A 7 Lift th...

Page 101: ...formation 85 LVPS Cover Removal 1 Form tabs D away from the power supply to create clearance for tabs A to move downward 2 Release the top latches A 3 Release the side latches B 4 Release the bottom l...

Page 102: ...l cable 3 Remove the operator panel mounting screws from the inside of the top cover Option Card Removal 1 Remove all external trays 2 Open the top cover 3 Open the right cover 4 Remove the outer EMC...

Page 103: ...oval 1 Remove the front cover 2 Disconnect the fuser sensor cable 3 Disconnect the thermistor cable 4 Disconnect the fuser solenoid cable This cable is not present in all models 5 Release the latches...

Page 104: ...the right cover 3 Remove the system board 4 Remove the inner EMC shield 5 Locate the paper feed magnet mounting screw B visible through the right side frame A 6 Remove the mounting screw B 7 Remove t...

Page 105: ...1 Remove the lower frame 2 Disconnect the system cable from the input sensor 3 Remove the screws A and the outer deflector 4 Remove the screws B and the toner shield E 5 Separate the side frames 6 Pul...

Page 106: ...e top cover 2 Remove the print cartridge 3 Remove the paper tray 4 Open the right side cover 5 Remove the front cover 6 Remove the two screws A 7 Unplug the cable B from the switch connector C 8 Rotat...

Page 107: ...e the right and top covers 4 Remove the exit redrive and its belt 5 Remove the air plenum 6 Remove the screws A and the pointer if present 7 Cut and discard the printhead cable clamp 8 Disconnect the...

Page 108: ...he two bottom tabs slide the shield forward then down 10P has no outer EMC shield 5 Disconnect all the external connectors from the system board and remove the option cards 6 Remove the system board m...

Page 109: ...Repair Information 93...

Page 110: ...the cable from the exit sensor board 5 Remove the front cover 6 Remove the front exit deflector switch 7 Disconnect the cable from the paper sensor assembly 8 Remove the cable through the right frame...

Page 111: ...fuser input guide A 2 Remove the transfer roll housing 3 Lift the input sensor board far enough to disconnect the cable B 4 Remove the end of the bellcrank spring 5 Lift the sensor to unsnap it 6 Wor...

Page 112: ...ting studs visible through openings B in the inner deflector 4 Lift the transfer roll housing far enough to disconnect the system cable 5 Lift the transfer roll housing out of the machine 6 To replace...

Page 113: ...d 5 Remove the inner EMC shield 6 Remove the load box latches A 7 Release the latches B 8 Pivot the upper frame to the rear to release the spring tension 9 Unsnap the plastic insert D holding the uppe...

Page 114: ...98 Service Manual Zif Connector Removal 1 Slide the cable clamp A to the open position 2 Note how the contact surfaces C of the cable are positioned as you pull the cable B out of the connector...

Page 115: ...at A and pivoting 90 2 Pry the top cover from the bottom cover at B and lay the top cover on its side 3 To disconnect the fan leads the table cover has to be removed 4 Release latches C on the paper...

Page 116: ...cable 3 Depress the exit sensor flag actuator B and lift out the exit sensor card Duplex Option Bottom Cover And Entry Sensor Card Removal 1 Release the two latches A on the frame assembly and lift i...

Page 117: ...Repair Information 101...

Page 118: ...system board out 3 Remove the two motor mounting screws B 4 Lift the motor out of the frame assembly Note The remaining FRU is the Gearblock Assembly When you replace this FRU see Lubrication Specifi...

Page 119: ...semblies gears connectors and ground straps Major Assembly Locations Low Voltage Power Supply Output Sensor Paper Tray Operator Panel Fan Exit Redrive Print Head High Voltage Power Supply Fuser LowerF...

Page 120: ...104 Service Manual Gear Train...

Page 121: ...Connector Locations 105 HVPS...

Page 122: ...106 Service Manual Transfer Roller Housing Paper Guide Transfer roller housing for 10P has no paper guide...

Page 123: ...Connector Locations 107 System Cable System Board 10R 12R 12C 12L J20 16L J17 Pin 1 Pin 1 HVPS Input and Toner Sensors Pin 1 Transfer Roll Pin 1...

Page 124: ...108 Service Manual System Board Connectors 10R 12R 12L...

Page 125: ...inthead Fan J6 Laser Printhead Hsync J7 Operator Pane Output Bin Sensor J8 DC to DC Convertor J9 DC to DC Convertor J10 INA Power Card J11 LVPS J12 Envelope Feeder Magnet J13 INA Card J14 Serial J15 P...

Page 126: ...110 Service Manual System Board Connectors 16L...

Page 127: ...tput Bin Sensor J6 Duplex J7 Font Card J8 Hard Disk Option J9 Envelope Feeder Magnet J10 ROM SIMM Printer microcode J11 ROM SIMM flash memory option J12 INA Card J13 Parallel and Serial Port J14 500 S...

Page 128: ...112 Service Manual System Board Connectors 10P J21 J14 J11...

Page 129: ...nthead Mirror Motor Fan J6 Printhead Hsync Laser J7 Operator Panel J8 N A J9 N A J10 N A J11 LVPS J12 Envelope Feeder Magnet J13 INA Hard Disk J14 HVPS J15 Parallel Port J16 N A J17 Second Paper Tray...

Page 130: ...114 Service Manual Printhead Cables The printhead cable connector for 10P 10R 12R 12L and 12C is J6 The printhead cable connector for 16L is J4 Connector...

Page 131: ...Fan Cable The mirror motor cable connector for the 10P 10R 12R 12L and 12C is J5 The mirror motor cable connector for 16L is J3 Printhead Cable Pin Laser Hsync 1 1 2 2 3 3 4 4 5 6 6 5 7 4 8 3 9 2 10 1...

Page 132: ...116 Service Manual Operator Panel Output Bin Sensor Cable Handle Mounted Outbin Sensor...

Page 133: ...or Locations 117 Operator Panel Output Bin Sensor Cable Redrive Mounted Outbin Sensor The cable connector for 10P 10R 12R 12L 12C is J7 The cable connector for 16L is J5 Op Panel Cable Connector Pin 1...

Page 134: ...118 Service Manual No connection on machines with redrive mounted output bin sensor Pin Op Panel Sensor 1 1 2 2 3 3 4 4 5 5 6 1 7 2 8 3 9 4...

Page 135: ...nector Locations 119 Printer Ground Straps Outer Deflector to Lower Frame HVPS to Frame Operator Panel to Upper Frame Toner Shield to Lower Frame Load Box Shaft to Upper Frame Static Brush to Lower Fr...

Page 136: ...120 Service Manual Toner Shield to Lower Frame Load Box Shaft to Upper Frame...

Page 137: ...or altered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety e...

Page 138: ...e idler and its stud on the rail The prealigner drive roller and its stud on the rail The prealigner backup roller and its shaft and thrust washer The fixed center idler gear in the 500 sheet base and...

Page 139: ...Preventive Maintenance 123 Use grease p n 1384076 to lubricate A Areas of contact between the two shafts and the grounding spring Use grease p n 1383586 to lubricate B on the duplex unit A B...

Page 140: ...glass 1 Remove the print cartridge 2 Fold a lint free cloth over a cotton swab 3 Open the shutter 4 Insert the swab and cloth combination in the printhead window slot then slide it left to right sever...

Page 141: ...the fuser assembly transfer roller d roll and lower redrive shaft assembly at this interval to maintain the print quality and reliability of the printer These items are available as individual FRUs T...

Page 142: ...126 Service Manual...

Page 143: ...ecommended in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indi...

Page 144: ...128 Service Manual Assembly 1 Covers 1 14 2 1A 12 1B 17 10 4 3 16 15 11 9 8 27 5 6 7...

Page 145: ...lus 2 1375992 1 Front Logo 12C plus 2 1375927 1 Front Logo 12L plus 2 1377417 1 Front Logo 16L plus 3 1325115 1 Right Cover Asm 10R 12R 12L 12C 3 1328208 1 Right Cover Asm 10P 16L 4 1328210 1 Door Rig...

Page 146: ...130 Service Manual Assembly 1 Covers Continued 1 14 2 1A 12 1B 17 10 4 3 16 15 11 9 8 27 5 6 7...

Page 147: ...r Units Description 1 17 1328508 1 Manual Feed Tray with guide NS 1 Screw Deflector Spring Mtg Parts Packet 1383314 NS 1328482 1 Cover Duplex mtg slot NS 1 Screw Deflector Switch Mtg plate Parts Packe...

Page 148: ...132 Service Manual Assembly 2 Lower Frame 7 1 14 1 20 22 3 19 6 11 1 18 2 15 13 12 8 9 9 7 23 17 5 10 4 4A...

Page 149: ...10915 W T 2 1381623 1 Motor Brkt and Gear Asm 10P includes Gear 6 3 1325614 1 Plate Asm Gear Box Mtg 10R 3 1329515 1 Plate Asm Gear Box Mtg 12R 12L 12C 16L 3 1408672 1 Plate Gear Box Mtg 10P 4 1328503...

Page 150: ...134 Service Manual Assembly 2 Lower Frame Continued 7 1 14 1 20 22 3 19 6 11 1 18 2 15 13 12 8 9 9 7 23 17 5 10 4 4A...

Page 151: ...2 Screw Motor Bracket Parts Packet 10P 18 1328428 1 LH Bracket Duplex 19 1328427 1 RH Bracket Duplex NS 1383314 1 Screw Duplex Bracket Parts Packet 20 1039476 1 Grommet Printhead Cable 21 1328181 1 Br...

Page 152: ...136 Service Manual Assembly 3 Upper Frame 1 1A 3 26 14 28 12 4 5 11 24 6 10 30 16 12 2 11 7 8 29 28 20 23 19 23 23 23 18 17 22 21 25 24...

Page 153: ...ing Bellcrank 8 1039692 1 Left Bellcrank 9 1383998 1 Fan Asm NS 1424481 1 Pad Acoustic Fan 10 1328222 1 Plenum Asm 12R 12L 12C 16L 10 1325022 1 Plenum Asm 10R 10P 11 1383315 1 Retainer Parts Packet 12...

Page 154: ...138 Service Manual Assembly 3 Upper Frame continued 1 1A 3 26 14 28 12 4 5 11 24 6 10 30 16 12 2 11 7 8 29 28 20 23 19 23 23 23 18 17 22 21 25 24...

Page 155: ...handle mounted sensor 26 1381134 1 Cable Output Bin Operator Panel 16L handle mounted sensor 26 1381095 1 Cable Operator Panel 12C 12R 10R 10P 28 1383314 2 Screw Shaft Mtg Parts Packet 29 1325138 1 S...

Page 156: ...140 Service Manual Assembly 4 Printhead System Board 9 2 7 6 4 3 1 8B 8A 8...

Page 157: ...31 1 Printhead Shroud Assembly 3 1325017 1 Cable Fan Mirror Motor 4 1325018 1 Cable hsync Laser NS 1038199 1 Cable Tie 6 1383315 1 Pin Parts Packet 7 1383316 1 Spring Parts Packet 8 1383314 2 Screw Pr...

Page 158: ...142 Service Manual Assembly 5 Paper Feed...

Page 159: ...t Frame 11 1039175 1 Tray Frame Spring 12 1042211 1 Belt Redrive 10R 12R 12C 10P 12 1328192 1 Belt Redrive 12L 16L 13 1328193 1 Belt Auxiliary 12L 16L 14 1039058 1 Shaft Asm Lower Redrive 10R 10P 14 1...

Page 160: ...144 Service Manual Assembly 5 Paper Feed Continued...

Page 161: ...ias 31 1383314 1 Screw Redrive Mtg Parts Packet 33 1328298 1 Guide Fuser Input 34 1328167 1 Redrive Assembly 12L 16L With Handle Mounted Bin Sensor 34 1381527 1 Redrive Assembly 12L 16L With Redrive M...

Page 162: ...146 Service Manual Assembly 6 Paper Feed Alignment Gears...

Page 163: ...hrust Washer 2 1381145 1 Kit Prealigner and Metering Rollers 3 1039278 1 Gear Idler Prealigner 4 1383316 1 Spring Prealigner and Metering Bellcranks Parts Packet 5 1328384 1 Bellcrank Prealigner 10P 1...

Page 164: ...148 Service Manual Assembly 7 Paper Feed Drive 1 5 3 2 20 7 4 22 7 13 12 18 21 8 21 18 11 10 14 19 25 24 23 8 19 6 9 17 15 16...

Page 165: ...gnet Asm 10R 12R 12C 12L 16L 10 1383318 1 Gear No 14 Sheet Feed Parts Packet 11 1383318 1 Gear No 9 Parts Packet 10R 12R 12C 12L 16L 11 1408259 1 Gear No 9 10P 12 1383318 1 Gear No 7 Parts Packet 13 1...

Page 166: ...150 Service Manual Assembly 8 Standard Paper Tray 200 sheet 1 5 2 3 4 6...

Page 167: ...67 1 Heavy Duty Paper Tray Assembly 11 in 200 sheet 1058272 1 Heavy Duty Paper Tray Assembly 14 in 200 sheet 1183376 1 Paper Tray Assembly A5 1 1183266 1 11 in Cover 1 1183275 1 14 in Cover 2 1183163...

Page 168: ...152 Service Manual Assembly 9 Paper Tray 500 Sheet 5A...

Page 169: ...3 1039582 1 Paper Guide 4 1408851 1 Slide 11 in 4 1408882 1 Slide 14 in 5 1183262 1 Paper Stop 5A 1183298 1 Slider Paper Stop 6 1183266 1 Cover 11 in 6 1183275 1 Cover 14 in 7 1195835 1 Pivot Plate wi...

Page 170: ...154 Service Manual Assembly 10 Base for Paper Drawer 500 Sheet...

Page 171: ...Parts Catalog 155 Asm Index Part Number Units Description 10 1 1328194 1 Housing 2 1039558 1 Roll 3 1328197 1 Plate Assembly Gear 4 1039170 1 Pad Machine NS 1328674 1 Clip Ground...

Page 172: ...156 Service Manual Assembly 11 Optional Paper Drawer 500 Sheet...

Page 173: ...1 Spring Bellcrank Parts Packet 6 1039603 1 Drive Roller 7 1039540 1 D Roller Tire 8 1383925 1 Paper Feed Magnet 9 1383385 1 Washer Parts Packet 10 1383385 1 Screw Parts Packet 11 1383385 1 Spring Par...

Page 174: ...158 Service Manual Assembly 12 Fuser 13 7 3 4 8 7 1 2 23 15 15A 2 8A 9 19 22 24 20 10 21 18 17 14 11 12 25 6 16 26...

Page 175: ...cket 3 1380785 1 Fuser Wiper Assembly supply item 10R 12R 12C 12L 16L 3 1382287 1 Fuser Wiper Assembly supply item 10P 4 1039315 1 Fuser Cover 10R 10P 4 1328132 1 Fuser Cover 12R 12L 12C 16L 6 1038717...

Page 176: ...160 Service Manual Assembly 12 Fuser Continued 13 7 3 4 8 7 1 2 23 15 15A 2 8A 9 19 22 24 20 10 21 18 17 14 11 12 25 6 16 26...

Page 177: ...1383315 1 Flag Parts Packet 13 1039481 1 Fuser Power Cable 14 1381537 1 Cable Fuser Front Cover Exit Sensor 15 1381155 1 Thermal Fuse Asm 15A 1039328 2 Clips Thermal Fuse 10R 10P 15A 1328134 2 Clips T...

Page 178: ...162 Service Manual Assembly 13 Electronics...

Page 179: ...0 1 Power Cord Set Germany France Spain Norway Finland the Netherlands Austria Belgium Brazil Greece Luxembourg Portugal Sweden Turkey Indonesia Saudi Arabia HV 3 1342532 1 Power Cord Set S Africa 3 1...

Page 180: ...164 Service Manual Assembly 13 Electronics Continued...

Page 181: ...2R 12L 12C NS 1328281 2 Standoff Internal Threads NS 1328280 4 Standoff Card Gnd 16L External Threads NS 1195319 2 Standoff INA or DC to DC plastic NS 1383315 2 Standoff Sys Bd plastic Parts Packet NS...

Page 182: ...166 Service Manual Assembly 14 Transfer Roll...

Page 183: ...1381008 1 Roll Asm Transfer 2 1381007 1 Housing Transfer 10R 12R 12C 12L 16L 2 1381652 1 Housing Transfer 10P sawtooth not present on 10P 1 o Rear Lens Asm Erase 1 o Front Lens Asm Erase 1 o Contact T...

Page 184: ...168 Service Manual Assembly 15 Duplex Option...

Page 185: ...op Slide 9 1381023 1 Gear Block Frame Asm 10 1381024 1 Input Sensor Card 11 1326041 1 Duplex System Cable 12 1326042 1 Cable Stepper Motor 13 1326043 1 Cable Sensor 14 1381025 1 Paper Feed Motor DC 15...

Page 186: ...170 Service Manual Assembly 16 Envelope and 100 Sheet Auxiliary Feeder...

Page 187: ...1 Screw 3 1039615 1 Spring 4 1383944 1 Magnet Assembly 5 1622303 1 Washer 6 1622536 1 Screw Mtg 7 1183587 1 Cover Right 8 1183155 1 Guide Large 8A 1183160 1 Latch Guide 9 1328459 1 Guide Small 10 1183...

Page 188: ...memory 1402208 1 o INA Ethernet 10BaseT low memory 1402219 1 o INA Ethernet 10Base2 high memory 1402217 1 o INA Token Ring high memory 1402218 1 o INA Ethernet 10BaseT high memory 13A0294 1 o INA SCS...

Page 189: ...ket 1383317 1 Gears 1 6 parts packet 1383318 1 Gears 7 14 parts packet 1381145 1 Metering and Prealigner rolls parts packet 1383385 1 Paper Tray parts packet 1383390 1 Paper Tray parts packet 1329301...

Page 190: ...174 Service Manual...

Page 191: ...ly 168 bottom cover entry sensor card removal 100 exit card and cover removal 100 problems 18 system card and motor removal 102 top cover table cover removal 99 E electronics assembly 162 envelope enh...

Page 192: ...l 85 removal 84 M maintenance approach 3 maintenance kit count 41 major assembly locations 103 memory test 41 mirror motor cable locations 115 N network connections and checks 47 wrap tests 24 network...

Page 193: ...p locations 119 printhead assembly 140 cable locations 114 diagnosis 28 removal 91 skew adjustments 61 62 printhead window cleaning procedure 124 Q quick disk test 45 quick test 45 R random marks 31 r...

Page 194: ...ice Manual U upper frame assembly 136 removal 97 V vertical void or streak 31 W warm up time 40 wrap tests 47 Z Zif connector removal 98 Numeric 100 sheet auxiliary feeder paper restraint spring adjus...

Page 195: ...e Yes No 3 Was the book easy to use Yes No 4 What can we do to improve the book ______________________________________________ ______________________________________________ 5 What is your job title _...

Page 196: ...Along Line POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape BUSINESS...

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