Lexmark 4039 - B/W Laser Printer Service Manual Download Page 6

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Service Manual

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

Removals ........................................................................................62

Summary of Contents for 4039 - B/W Laser Printer

Page 1: ... 4039 Series Lexmark is a trademark 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 Start Diagnostics ...

Page 2: ...ute 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 ...

Page 3: ...s 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 Wit...

Page 4: ...ms 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 ...

Page 5: ...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 Pr...

Page 6: ...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 Fus...

Page 7: ...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 Sy...

Page 8: ...r 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 Assemb...

Page 9: ...rinter 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 inte...

Page 10: ...386 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 interference causing equipment standard entitled Digital Apparatus ICES 003 of Industry Canada Avis de confor...

Page 11: ...rective 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 ...

Page 12: ...ht 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 offensi...

Page 13: ...suario 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 ...

Page 14: ... 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 ins...

Page 15: ...9 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 R...

Page 16: ... 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 t...

Page 17: ...placeable 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 ...

Page 18: ...ic 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 Se...

Page 19: ... Base Printer on page 25 22 Paper Jam The exit sensor was not unmade in time See Paper Feed Base Printer on page 25 23 Paper Jam Jam at the duplex unit Paper is either not leaving the duplex entry sensor in time or not making or unmaking the duplex exit sensor in time See Duplex on page 18 24 Short Paper The defined paper size is too short to print data as formatted 25 Incorrect Manual Feed Paper ...

Page 20: ...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 st...

Page 21: ...coverable 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 ...

Page 22: ...ror Fuser failed to reach standby temperature See Fuser 920 921 or 922 Error on page 20 923 Fuser Error Fuser is too hot while printing or when idle See Fuser 923 Error on page 21 927 Fan Stalled See Fan 927 Error on page 19 931 Printhead Error No first hsync See Printhead on page 27 932 Printhead Error Lost hsync See Printhead on page 27 934 Printhead Error Lost lock condition See Printhead on pa...

Page 23: ...or 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 Netw...

Page 24: ... 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 bet...

Page 25: ...ms 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...

Page 26: ...lope 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 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 ...

Page 27: ...hat 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 spr...

Page 28: ...rence 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 2 to J20 4 J17 2 to J17 4 Greater than 1VDC Less than 5VDC J20 3 to J20 4 J17 3 to J17 4 The meter should fluctu ate slightly between each page Less than 5VDC J20 8 to J20 4 J17 8 to J17 4 Less...

Page 29: ...lace the 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 J20 4 J17 5 to J17 4 24VDC J14 6 to J14 4 J20 6 to J20 4 J17 6 to J17 4 24VDC 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 26V...

Page 30: ...cts 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 Voltage while Idling J20 1 to J20 4 J17 1 to J17 4 Less than 1VDC 21 26VDC J20 2 to J20 4 J17 2 to J17 4 Greater than ...

Page 31: ...xiliary 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 of the On Off switch or switch linkage or a shorted electrical component Check for the indicated voltages at the LVPS connection to the system board If no voltages are present remove the LVPS cove...

Page 32: ... the duplex 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 0 5VDC 0 and 5VDC With the cable connected these voltages should also be at duplex system board JP4 1 through JP4 6 If you do not find a cable or voltage problem replace the duplex system board...

Page 33: ...e the duplex system card If the 7th and 8th digits are 04 there is an exit sensor problem Remove the duplex top cover and table cover Remove the paper tray so you can reach the sensor Measure the voltage on JP6 8 of the duplex board it should fluctuate from 0 to 5VDC as you toggle the sensor Check the sensor cable continuity If the sensor and the cable are good replace the duplex system card Fan 9...

Page 34: ... lamp is left off until a job is printed The system board signal to the LVPS TRIAC is on 10P J11 16 10R 12R 12C 12L J11 3 16L J18 16 The voltage is 0VDC when the lamp is to be on and 24VDC 10P 5VDC when the lamp is to be off The lamp can be tested by briefly connecting this pin to ground Fuser 920 921 or 922 Error A 922 error during a POR caused by low line voltage can usually be cleared by doing ...

Page 35: ...nding the correct signal to the TRIAC At POR this signal should go to 24VDC 10P 5VDC and then immediately drop to 0VDC until the fuser is warm if it does not replace the system board If the signal is OK replace the LVPS Fuser 923 Error Check the connection and continuity of the cable from the fuser exit sensor board to system board 10P 10R 12R 12C 12L J19 16L J16 Check the thermistor condition and...

Page 36: ...ter Utility Guide to find the problem Make sure that the desired network protocol is enabled from the printer operator panel Verify proper print queue and printer driver configuration Verify that the adapter port has been associated Verify correct installation of software utility Single route broadcast not supported across network bridge if bridge is used Server problem check print server installa...

Page 37: ...16L J12 If the voltage is incorrect replace the system board if there is 5VDC replace the network card Network Wrap Tests Token Ring with Shielded Twisted Pair Cable Disconnect the LAN cable from the electrical outlet leaving it connected to the printer network card Ethernet 10Base 2 Attach a 50 Ohm BNC terminator cap to each end of the T connector The customer may be able to provide this cap Ther...

Page 38: ...5VDC as the sensor is blocked and unblocked Pin 1 should always measure 5VDC Replace the sensor the sensor card on machines with latch mounted sensor or the sensor cable as necessary Operator Panel Problem Possible causes failed LCD or operator panel card cable or connector problem or system board problem Replace the operator panel if POR stops with 1 rows of pels displayed Run the diagnostic test...

Page 39: ...roblem If paper is not feeding make sure the paper is in the tray correctly and is not damaged or stuck together Make sure the D roll is in good condition and rotates when the magnet is picked With the 500 sheet trays make sure the tension wheel is set high enough to give good contact between the D roll and the paper stack 10R 12R 12C 12L 16L Make sure the pick magnet is being energized The pick m...

Page 40: ...ng see Fuser Temperature And Warm Up Time on page 39 Paper Feed Duplex Unit Check that all gears and belts are working correctly both in the duplex unit and on the tray top cover and that the gear on the tray top cover engages the gear on the duplexer If paper is jamming in the table cover area make sure the table cover is properly installed Run diagnostics Duplex Test 1 to make sure the paper is ...

Page 41: ... 1 to J9 2 on the feeder cable the resistance should be from 105 Ohms to 155 Ohms If the magnet is good reconnect the cable and monitor the voltage between the two pins of the connector while running the Envelope Feed test if the voltage does not increase momentarily as the magnet is picked replace the system board Check the adjustment of the feeder magnet If paper is being bent or double fed chec...

Page 42: ...ake sure there is no continuity from 10P 10R 12R 12L 12C J19 3 to J19 4 16L J16 3 to J16 4 on the cable replace the paper size switch if the resistance is not infinite The resistance from 10P 10R 12R 12L 12C J19 3 to J19 4 16L J16 1 to J16 2 varies with the paper size With the tray installed if the readings do not match the following within 5 replace the paper size sensor If the problem is with th...

Page 43: ...r of a failed cleaner inside the print cartridge It can also be caused by a failed fuser hot roll retaining toner and redepositing it on the page Check that the erase lamp voltage at 10P J20 1 10R 12R 12C 12L J20 16 16L J17 16 is 24VDC and that the cable has continuity To test the erase lamps jumper 10P J20 2 10R 12R 12C 12L J20 15 16L J17 15 to ground Component Print Defect Spacing on Page PC Dru...

Page 44: ...e prealigner drive and auxiliary rollers springs and backup rollers for dirt wear or damage refer to the parts catalog for repair kits for broken bellcrank spring attachment hooks on the sideframe Make sure all the bellcrank assemblies pivot freely Check the gear train for damage or binds Skew top and bottom only If the test print frame is parallel to the left and right edges of the paper but not ...

Page 45: ...onductor check the operation of the printhead shutter and clean the printhead window with a lint free cloth folded over a cotton swab do not use a bare swab and do not use any cleaning fluids or water on the printhead window Inspect the HVPS contacts If the image on the photoconductor is good inspect the fuser rolls and transfer roll Make sure the left transfer roll bearing is contacting the conta...

Page 46: ...ust put the printer in Diagnostics mode To enter Diagnostics mode 1 Turn the printer off 2 Press and hold the Ready and Return buttons Then turn the printer on The printer performs the Power On Self Test 3 Release the buttons when Performing Self Test is displayed 4 You can exit Diagnostics mode without a POR by selecting Reset Printer ...

Page 47: ...uick Test 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 Contrast Transfer Disk Test Clean Fuser Temperature Warm up Time Hardware Connection Checks Defaults LAN Information Memory Tests Wrap Tests Sensor Test Serial Interface Option Auto Clean Auto Clean ...

Page 48: ... Off 4 Press Return to return to Diagnostics mode main menu Auto Clean Delay This can be set from 1 to 60 seconds with a default of 1 Auto Clean Delay does not appear on the menu unless Auto Clean is on 1 Enter Diagnostics mode 2 Select Auto Clean Delay 3 Select or to display the delay desired 4 Select SAVE 5 Press Return to return to Diagnostics mode main menu Auto Clean Frequency This can be set...

Page 49: ...rint the test page 3 As soon as the leading edge of the paper is visible coming out the front exit slot turn off the printer 4 Remove the print cartridge and look at the image on the photoconductor Disk Test Clean This is a two hour test that should be performed only on a disk that contains bad data and is therefore unusable This test destroys all data on the disk by doing a multi pass write read ...

Page 50: ...selector fingers before the paper reverses direction 1 Enter Diagnostics mode 2 Select Duplex Tests 3 Select Duplex Feed 1 4 Select Tray 1 or Tray 2 Note Paper feeds all the way into the duplex unit and stop 5 The message CLEAR PAPER appears on the display 6 Slide the tray extension all the way out until it stops 7 Push a small screwdriver through the lower end of one of the ventilation slots and ...

Page 51: ...al size 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 duplex cable from the printer 9 Without changing the position of the page hold it to the top of the paper tray and remove the paper tray 10 Measure from the leading edge of the page to the leading ed...

Page 52: ...ic feeder present the printer uses manual envelope 1 Enter Diagnostics mode 2 Select Envelope Print 3 Select Single or Continuous 4 Select CANCEL to stop continuous envelope feed 5 Press Return to return to the Diagnostics mode main menu Error Log plus machines only The error log records the last 6 2X Paper Jam or 9XX Service errors In a full log position 6 is the oldest error If more than 6 error...

Page 53: ...he lowest setting that corrects the problem Setting 0 is the factory default and is the shortest warm up time Setting 5 increases warm up time by 90 seconds lower settings increase the time proportionately less Settings other than 0 may reduce throughput Use the or key to change the number and then select save Melting letterheads may be prevented by reducing the fuser temperature as described abov...

Page 54: ...ter Diagnostics mode 2 Select Memory Test 3 Select either DRAM or ROM 4 Select Single or Continuous 5 The display indicates PASSED or FAILED 6 Select CANCEL to stop continuous memory test 7 Press Return to return to Diagnostics mode Operator Panel Tests The following tests check for proper functioning of the operator panel buttons and display LCD Button Test To test the operator panel buttons 1 En...

Page 55: ...99999 by Selecting NEXT to move the cursor under each digit Then select OR to select the number you want in each digit 4 Select SAVE to save the page count displayed Paper Feed Test This test allows you to observe the drive gear train and feed paper through the printer to check for broken gear teeth watch the paper path or check the erase lamps Note You may want to remove the gear cover before sta...

Page 56: ...tremes to prevent toner from being deposited in white areas next to large black areas 1 Enter Diagnostics mode 2 Select Print Contrast 3 Select Light Medium or Dark Low Medium or High on plus machines 4 Press Return to return to the Diagnostics mode main menu Print Registration See Print Registration Adjustment on page 61 Print Test Page You can run the Print Test even if the printer is not attach...

Page 57: ...nt Test 1 will not duplex To run Print Test 1 1 Enter Diagnostics mode 2 Select Print Test 1 3 Select Single or Continuous 4 Select CANCEL to stop continuous print 5 Press Return to return to the main Diagnostics menu Print Test 2 Print Test 2 generates two printouts a page similar to the test page and a fine dot pattern which can be used to evaluate banding or other print quality problems Print T...

Page 58: ...ations and the disk hardware and circuitry but does only incidental testing of the disk surface itself The Quick Disk Test does not destroy data on the disk existing data is read and stored prior to the testing of each track and then re written after the track is tested 1 Enter Diagnostics mode 2 Select Quick Disk Test 3 The display indicates Test Passed or Test Failed 4 Press Return to return to ...

Page 59: ...t one 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 Otherwise Closed is displayed 5 Press Return to return to the Diagnostics mode main menu ...

Page 60: ...in serial wrap plug part no 1329048 for the serial test 4 Enter Diagnostics mode 5 Select Wrap Test 6 Select Parallel for the parallel port or Serial for the 25 pin serial port 7 Select Single or Continuous 8 Select CANCEL to stop continuous A PASSED message indicates the printer connection to the printer cable connector is good A FAILED message indicates a defective system board Note Ignore the n...

Page 61: ...e printer is connected Serial Interface Option 10P The serial interface unit switch settings determine how the printer receives data from the computer or terminal Set the switches according to your particular equipment requirements The serial interface has 12 function switches Function Switch Setting Switches 1 to 4 Speed Switches 1 through 4 define the serial interface speed in bits per second bp...

Page 62: ... for parity the printer ignores the received parity and transmits using Even parity For all other parity settings the transmitted parity matches the received parity Off On On Off 1 200 Off On Off Off 2 400 Off Off On Off 4 800 Off Off Off Off 9 600 default On On On Off 19 200 Off Off Off On 38 400 RS 422 only 5 DATA BITS Off 8 On 7 6 7 Parity Off Off No Off On Ignore On Off Odd On On Even 1 2 3 4 ...

Page 63: ...he printer character set Note For the serial print test to work Advanced Status found under the PARALLEL SETUP menu must be set to Off To run the serial interface test print 1 Turn the printer power off 2 Set serial interface Switch 10 On 3 Turn the printer power on If the printer does not generate a printout there is a problem with the serial interface card or its connection to the printer Check ...

Page 64: ...terface 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 mode 11 Mode Off Normal On Reverse 12 Mode Off RS 232C On RS 422 ...

Page 65: ...s any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tabl...

Page 66: ... 2 Position the spring B so it clears the separator roller by 1 9 0 2 mm 0 075 0 008 in 3 Tighten the mounting screw Paper Restraint Spring On The 100 sheet Auxiliary Feeder 1 Loosen the mounting screw A 2 Position the spring B so it clears the separator roller by 1 9 0 2 mm 0 040 0 008 in 3 Tighten the mounting screw ...

Page 67: ...iary Feeder Magnet 1 Hold the armature A in the closed coil active position 2 Loosen the mounting screw B and rotate the magnet assembly so the armature clears the clutch gear by 0 30 0 20 mm 0 012 0 008 in 3 Tighten the screw 4 Check the adjustment on both sides of the gear ...

Page 68: ...justable 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 shoulders from the front of the machine You may need to use an angled or very small feeler gauge 4 With the nut snug but not tight tap the idler upward until the gage is snug between the gear should...

Page 69: ...Repair Information 55 4039 1XX ...

Page 70: ...solenoid 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 air gap 4 Tighten screw A 5 Replace the rubber washer ...

Page 71: ...check for 0 60 mm 0 07 mm 0 024 in 0 003 in between the foam pad and the magnet pole piece If adjustment is required continue 3 Keep the armature latched and loosen the magnet mounting screw A 4 Insert feeler gage 5 Rotate the magnet against the feeler gage 6 Tighten the mounting screw 7 The gage should pass between the foam pad and the magnet pole piece with moderate resistance ...

Page 72: ...e piece 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 the magnet against the feeler gage 5 Tighten the mounting screw 6 The gage should pass between the foam pad and the magnet pole piece with moderate resistance ...

Page 73: ...until the skew marks on the printout are parallel to the top edge of the paper Use Print Test 1 or Quick Test to check this Rotating the printhead clockwise will lower the left skew adjustment point on the test print 3 Tighten the screws 4 Install the top cover and print another page to verify the adjustment B A Skew Adjustment Points ...

Page 74: ...osen the screws A 3 Run Print Test 1 or the Quick Test on the Diagnostics Menu 4 Move the pointer B to eliminate the skew Moving the pointer toward the left raises the left adjustment point on the printout 5 Tighten the screws and verify the adjustment B A Skew Adjustment Points ...

Page 75: ...ves the 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 the page and widens the top margin Moving the number in a negative direction moves the text up the page and narrows the top margin 7 Bottom Margin This margin can be set between 7 and 7 Moving the...

Page 76: ...he cover off the rear pivot pin Front Cover Removal 1 Unplug the power cord 2 Remove the paper tray 3 Open the top cover 4 Open the right cover 5 Remove the Duplex mounting slot covers 6 Release the latches B You can reach the lower latches through the paper tray opening 7 Pull the front cover forward then move the cover to the right to separate the on off switch linkage D 8 Disconnect the ground ...

Page 77: ...Repair Information 63 4039 1XX ...

Page 78: ...tch A and push the end to the rear to release it 5 Push the top of the cover to the left 6 Remove the cover by sliding it to the rear of the machine Top Cover Removal 1 Remove the top cover screws C 2 Lift the rear of the cover first then the front and lift the cover off 3 Rest the cover on the machine and disconnect the operator panel cable and the ground wire ...

Page 79: ...Repair Information 65 4039 1XX ...

Page 80: ...ver from the front with your left hand Use a small screwdriver to push the rear latch forward and release the bearing cover This exposes the bearing on the end of the transfer roll 4 Grasp the bearing on the end of the transfer roll Lift slightly and move it to the left until the right end of the transfer roll shaft slides out of the right side bearing 5 Remove the transfer roll 6 Lift the right b...

Page 81: ...located 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 the roll is in place by pulling toward the left without pushing the latch Note Later machines do not have a latch Remove the D roll by pulling it firmly to the left The D roll without a latch is in...

Page 82: ... mounting 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 removed from the gear bracket assembly you must use the gear retaining plate as a tem plate to be sure the motor pinion is correctly positioned to gear 4 Install the gear retaining plate to the gear b...

Page 83: ...Repair Information 69 4039 1XX ...

Page 84: ...er 4 Remove the lower redrive shaft by disengaging the right end to the rear of the machine 5 Disconnect the long redrive belt A and slip it off the lower shaft 6 Remove the redrive assembly screws D 7 Remove the plenum assembly and screws B 8 Unplug the fan cable The fan C can now be removed from the plenum assembly ...

Page 85: ...Repair Information 71 4039 1XX D B C A ...

Page 86: ...ough the 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 guide 8 Completely loosen the four fuser mounting screws 9 Lift the fuser out of the machine Fuser Input Guide Removal 1 Remove the fuser input guide B by lifting the rear end of the guide and unsna...

Page 87: ...Repair Information 73 4039 1XX ...

Page 88: ...HINE 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 at all times if the lamp is to be reinserted 1 Remove the fuser 2 Remove the right lamp bracket A 3 Carefully pull the lamp B out to the right using a soft cloth if the lamp is to be reinserted ...

Page 89: ... Removal 1 Remove the fuser 2 Remove the two mounting screws A holding the solenoid housing to the fuser housing 3 Disengage the solenoid bracket from the plunger Note When a new solenoid assembly is installed the fuser solenoid must be adjusted A ...

Page 90: ...m the exit sensor card 2 Remove the fuser cover and wiper 3 Remove the tape holding the thermistor cable to the shroud 4 Squeeze the thermistor bracket tabs B and remove the thermistor from the shroud 5 Remove the thermistor cable from the guide clips on the right of the fuser to remove the thermistor ...

Page 91: ...Repair Information 77 4039 1XX B A ...

Page 92: ...ugh the hole D 11 The power supply is held in place by two latches on the left side To release the latches Push one latch E in and raise one of the studs F to release the latch Push the other latch E in and raise the other stud F to release the latch 12 Lift the power supply until the studs F align with the large openings then move the power supply to the right to release it from the frame 13 Move...

Page 93: ...Repair Information 79 4039 1XX F E B F D C ...

Page 94: ...sing 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 get it out of its mounting 6 Disconnect the toner sensor cable from the board 7 Remove the sensor board B A ...

Page 95: ...ansfer roll housing 5 Disconnect the cable from the HVPS 6 Remove the system board and the inner EMC shield 7 Disengage the upper frame cables from the guide in the paper feed side frame 8 Remove the screws B 9 Remove the fuser cover 10 Unplug the fuser wires C and push them below the HVPS 11 Unplug the paper size switch cable 12 Lift the lower frame assembly straight up to separate it from the pa...

Page 96: ...ed trays 3 Remove the left and right side covers 4 10P and 16L remove the system board and the inner EMC shield 5 Remove the left and right LVPS mounting screws 6 Disconnect the fuser connector A 7 Lift the supply up and then toward the right side frame to disconnect the On Off switch linkage ...

Page 97: ...mation 83 4039 1XX LVPS Cover Removal 1 Form tabs D away from the power supply to create clearance for tabs A to move downward 2 Release the top latches A 3 Release the side latches B 4 Release the bottom latches C ...

Page 98: ... panel cable 3 Remove the operator panel mounting screws from the inside of the top cover Option Card Removal 1 Remove all external trays 2 Open the top cover 3 Open the right cover 4 Remove the outer EMC shield 5 Remove cable and mounting screws as required 6 Pop the card off the plastic standoffs ...

Page 99: ...r Removal 1 Remove the front cover 2 Disconnect the fuser sensor cable 3 Disconnect the thermistor cable 4 Disconnect the fuser solenoid cable This cable is not present in all models 5 Release the latches A 6 Pull the sensor down to remove it ...

Page 100: ...emove the right cover 3 Remove the system board 4 Remove the inner EMC shield 5 Locate the paper feed magnet mounting screw B visible through the right side frame A 6 Remove the mounting screw B 7 Remove the paper feed magnet assembly from the rear slip the connector under the right frame B B A ...

Page 101: ... time 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 Pull the guides C out of the side frames 7 Use a flat blade tool to snap the gears and rollers D off the shaft ...

Page 102: ...pen the 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 Rotate the switch about 90 and pull it out of the printer ...

Page 103: ...Remove 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 connectors B 9 Remove the printhead and the printhead shroud 10 Pry off the grip rings holding the printhead to the shroud Note After replacing the printhead perform the printhead skew adjustment...

Page 104: ... on the 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 mounting hardware A 7 Release the system board standoff 8 Remove screw B and remove the system board Note If system board is being replaced remove the ROM SIMM and all options for installation on ...

Page 105: ...Repair Information 91 4039 1XX ...

Page 106: ...nnect 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 Torquer Motor Removal 10P 1 Remove the lower frame assembly from the base 2 Remove the D roll 3 Remove the D roll shaft gear assembly taking care not to lose the two bushings 4 Remove the two sc...

Page 107: ...ve the 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 Work the cable out of the frame and remove the sensor B A ...

Page 108: ...e mounting 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 the transfer roll housing perform the removal procedure in reverse order After replacing the Transfer Roll Housing open the top cover power the machine off then on to ensure the erase lamps fla...

Page 109: ...m board 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 upper frame cables in the right side frame 10 Remove the screws C 11 Remove the upper frame cables through the side frame 12 Lift the upper frame off the machine ...

Page 110: ...96 Service Manual 4039 1XX 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 111: ...ng up 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 table cover and lift up Release latch D and lift the paper table cover out of the frame assembly A C D B ...

Page 112: ... card 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 it out of the bottom cover 2 Pry up on the sensor card at B so it will clear the mounting stud and pull it out of the frame assembly Note When re installing the sensor lift up the flags so they wi...

Page 113: ...Repair Information 99 4039 1XX ...

Page 114: ...ft the 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 Specifications on page 120 Note Reinstall the motor so the belt is not tight but will not jump teeth on the timing pulley A B ...

Page 115: ...er assemblies 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 LowerFrame Upper Frame Print Cartridge Transfer Roll System Board Toner Sensor Input Sensor Paper Feed ...

Page 116: ...102 Service Manual 4039 1XX Gear Train ...

Page 117: ...Connector Locations 103 4039 1XX HVPS ...

Page 118: ...104 Service Manual 4039 1XX Transfer Roller Housing Paper Guide Transfer roller housing for 10P has no paper guide ...

Page 119: ...Connector Locations 105 4039 1XX 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 120: ...106 Service Manual 4039 1XX System Board Connectors 10R 12R 12L ...

Page 121: ...tor Printhead 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 Parallel Port J16 Font Card J17 500 Sheet Option J18 Duplex J19 Fuser J20 HVPS Flex Includes input and toner sensors and erase lamps on transfer roller J21 Paper Drive Motor J22 Paper Pick Magnet...

Page 122: ...108 Service Manual 4039 1XX System Board Connectors 16L ...

Page 123: ...ne Output 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 Sheet Option J16 Paper Drive Motor J16 Fuser J17 HVPS Flex Includes input and toner sensors and erase lamps on transfer roller J18 LVPS J19 Paper Pick Magnet ...

Page 124: ...110 Service Manual 4039 1XX System Board Connectors 10P J21 J14 J11 ...

Page 125: ...J5 Printhead 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 Option J18 Duplex J19 Exit Paper Size Sensor Fuser Solenoid J20 Input Toner Sensor Board Erase Lamps J21 Drive Motor J22 Torquer Motor Tray 1 pick ...

Page 126: ...112 Service Manual 4039 1XX 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 127: ...Cable 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 Pin Motor Fan 1 1 2 2 3 3 4 4 5 5 6 2 7 1 ...

Page 128: ...114 Service Manual 4039 1XX Operator Panel Output Bin Sensor Cable Handle Mounted Outbin Sensor ...

Page 129: ...Locations 115 4039 1XX 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 Pin 1 ...

Page 130: ...116 Service Manual 4039 1XX 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 131: ...or Locations 117 4039 1XX 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 Frame ...

Page 132: ...118 Service Manual 4039 1XX Toner Shield to Lower Frame Load Box Shaft to Upper Frame ...

Page 133: ...ent to identify possible safety conditions not covered by this inspection guide Refer to the safety reminders for a general checklist If any unsafe conditions exist find out how serious the hazard could be and if you can continue before you correct the hazard Check the following items Damaged missing or altered parts especially in the area of the On Off switch and the power supply Damaged missing ...

Page 134: ...he rail Gear no 7 and its thrust washer Gear no 8 and its stud on the rail Gear no 8 and its thrust washer Gear no 9 and its stud on the rail The metering roller shaft and its bushings on the rail assembly The main metering backup roller and its stud and thrust washer The D roller shaft and its bushings on the rail assembly The auxiliary metering roller and its stud on the rail including the snap ...

Page 135: ...le tips Area of contact between fuser release bail and roll All release arms areas of contact of fuser solenoid lever Use grease p n 1329301 to lubricate gear nos 2 3 4 5 6 and 12 Use all the grease in the packet Apply part of the grease rotate the gears and apply the rest The teeth of gears 3 4 and 5 should be completely coated Use grease p n 1384076 to lubricate A Areas of contact between the tw...

Page 136: ...k the 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 several times Move the swab to a clean spot on the cloth and repeat the cleaning procedure Do this procedure several times to make sure the window is clean Cleaning The Transfer Roller Power off the ...

Page 137: ...place 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 They are also available as a maintenance Kit through the dealer options ordering channel After replacing the kit the maintenance count must be reset to zero to clear the 80 Scheduled Maintenance m...

Page 138: ... Not Recommended 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 indicates that the part has a restricted availability NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration INDENTURE The indenture is ma...

Page 139: ...Parts Catalog 125 4039 1XX Assembly 1 Covers 1 14 2 1A 12 1B 17 10 4 3 16 15 11 9 8 27 5 6 7 ...

Page 140: ... 12R plus 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 Right Cover NS 1328329 1 Label Door Right Cover 10R 12R 12L 12C 16L 5 1328186 1 Front Cover Asm 6 1195318 1 On Off Switch Lever 7 1329070 1 Output Deflector 8 1328473 1 Output Deflector Lever 9 1 S...

Page 141: ...Parts Catalog 127 4039 1XX Assembly 1 Covers Continued 1 14 2 1A 12 1B 17 10 4 3 16 15 11 9 8 27 5 6 7 ...

Page 142: ... Number 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 Packet 1383314 27 1328189 1 Front Exit Door ...

Page 143: ...Parts Catalog 129 4039 1XX 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 144: ... S 11 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 1 Screw Motor Brkt Mtg All except 10P 4A 1328441 1 Clip Ground Motor Mtg All except 10P NS 1623642 1 Mtg Screw motor All except 10P NS 1623642 1 Mtg Screw Gear Asm All except 10P 5 1328244 1 Ge...

Page 145: ...Parts Catalog 131 4039 1XX 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 146: ...83314 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 Bracket cover pivot 22 1325282 1 Cable Clamp 23 1408721 1 Guide Cable 10P NS 1383314 1 Screw Cable Clamp Parts Packet ...

Page 147: ...Parts Catalog 133 4039 1XX 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 148: ... 1 Spring 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 1383316 1 Spring Parts Packet NS 1383315 1 Retainer Parts Packet 14 1383314 1 Screw Parts Packet NS 1383314 1 Washer Parts Packet 16 1383314 1 Screw Plenum Mtg Parts Packet 17 1328307 1 Grip Ha...

Page 149: ...Parts Catalog 135 4039 1XX 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 150: ...el 12L 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 Spring Redrive 10R 12R 12C 10P 30 1325067 2 Spring Plenum 10R 10P 30 1328467 2 Spring Plenum 12R 12L 12C 16L ...

Page 151: ...Parts Catalog 137 4039 1XX Assembly 4 Printhead System Board 9 2 7 6 4 3 1 8B 8A 8 ...

Page 152: ... 1328431 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 Printhead Mtg Parts Packet 8A 1383314 1 Screw Hex Headed Parts Packet 8B 1383314 1 Pointer Parts Packet 9 1383315 1 Retainer Parts Packet ...

Page 153: ...Parts Catalog 139 4039 1XX Assembly 5 Paper Feed 34 38 16 37 31 36 29 15 21 20 22 14 13 17 2 12 33 4 1 23 26 6 3 18 35 34 35 5 19 24 23 8 8 9 8 25 30 10 23 11 39 28 35 7 ...

Page 154: ... 1 Left 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 1328172 1 Shaft Asm Lower Redrive 12R 12L 12C 16L 15 1042205 1 Deflector Redrive 10R 10P 12R 12C 15 1328168 1 Deflector Redrive 12L 16L 16 1042206 1 Shaft Asm Upper Redrive 17 1328169 1 Shaft Asm...

Page 155: ...Parts Catalog 141 4039 1XX Assembly 5 Paper Feed Continued 34 38 16 37 31 36 29 15 21 20 22 14 13 17 2 12 33 4 1 23 26 6 3 18 35 34 35 5 19 24 23 8 8 9 8 25 30 10 23 11 39 28 35 7 ...

Page 156: ...Tray Bias 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 Mounted Bin Sensor 34 1042230 1 Redrive Assembly 10R 10P 34 1325515 1 Redrive Assembly 12R 12C 35 1383314 1 Screw Parts Packet NS 1328345 1 Spring Bias Transfer Housing 36 1381298 1 Output Bin Se...

Page 157: ...Parts Catalog 143 4039 1XX Assembly 6 Paper Feed Alignment Gears ...

Page 158: ... 1 o Thrust 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 10R 12R 12L 16L 1 o Shaft 1 o Roll 1 o Bellcrank 1 o Thrust washer 5 1402336 1 Bellcrank Prealigner 12C NS 1383580 1 Anchor Repair Kit Metering NS 1383908 1 Anchor Repair Kit Prealigner ...

Page 159: ...Parts Catalog 145 4039 1XX 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 160: ...tch Magnet 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 1383318 1 Gear No 8 Parts Packet 14 1383318 1 Gear No 10 Parts Packet 15 1383314 1 Screw Clutch Mag Mtg Parts Packet 10R 12R 12C 12L 16L 16 1383316 1 Spring Magnet Arm Parts Packet 10R 12R 12C 12...

Page 161: ...Parts Catalog 147 4039 1XX Assembly 8 Standard Paper Tray 200 sheet 1 5 2 3 4 6 ...

Page 162: ... 1183367 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 1 Paper Stop 3 1408567 1 Corner Buckler 4 1183329 1 Liner 11 in 4 1183330 1 Liner 14 in 5 1039562 1 Adjustable Guide 6 1058486 1 Universal Paper Tray Adapter ...

Page 163: ...Parts Catalog 149 4039 1XX Assembly 9 Paper Tray 500 Sheet 5A ...

Page 164: ...14 in 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 with label 8 1383385 1 Retainer Parts Packet 10 1424558 1 Spring Assembly 11 1383385 1 Setscrew Parts Packet 12 1383390 1 Thumb Wheel Gear Parts Packet 13 1383390 1 Wheel Parts Packet 14 1039597 1...

Page 165: ...Parts Catalog 151 4039 1XX Assembly 10 Base for Paper Drawer 500 Sheet 4 4 2 1 3 ...

Page 166: ...152 Service Manual 4039 1XX 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 167: ...Parts Catalog 153 4039 1XX Assembly 11 Optional Paper Drawer 500 Sheet 1 12 5 6 7 13 11 9 8 4 10 2 14 3 16 3 ...

Page 168: ...83316 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 Parts Packet 12 1381622 1 Drive Assembly 13 1383316 1 D Roller Bias Spring Parts Packet 14 1039558 1 Roller 15 1183299 1 Switch Assembly 16 1383314 1 Screws Parts Packet ...

Page 169: ...Parts Catalog 155 4039 1XX 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 170: ...rts Packet 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 1 Spring Redrive Exit 7 1383314 1 Screw Parts Packet 8 1383311 1 Fuser Lamp 110V 10R 12R 12L Install lamp with color coded end away from gear 8 1381523 1 Fuser Lamp 110V 12C 10P Install lamp wi...

Page 171: ...Parts Catalog 157 4039 1XX 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 172: ...sm 12 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 Thermal Fuse 12R 12L 16L 16 1039311 1 Bail Handle 17 1381018 1 Fuser Solenoid Asm 12R 12L 16L 18 1383314 1 Screw Fuser Solenoid Mtg Parts Packet 19 1039251 1 Gear No 1 Hot Roll 10R 10P 19 1328124...

Page 173: ...Parts Catalog 159 4039 1XX Assembly 13 Electronics 5A 7 13 6 9 11 5 4A 4 3 18 1 18 23 21 22 ...

Page 174: ...1342530 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 1342533 1 Power Cord Set Switzerland 3 1342534 1 Power Cord Set Chile Italy 3 1342535 1 Power Cord Set Denmark 3 1342536 1 Power Cord Set New Zealand Australia Argentina Paraguay 3 1342537 1 Powe...

Page 175: ...Parts Catalog 161 4039 1XX Assembly 13 Electronics Continued 5A 7 13 6 9 11 5 4A 4 3 18 1 18 23 21 22 ...

Page 176: ... 10R 12R 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 1383315 2 Standoff Sys Bd plastic Parts Packet NS 1383314 1 Screw HVPS Mtg Parts Packet 18 1383314 1 Screw LVPS Mtg Parts Packet 19 1383513 1 Switch On Off 20 1039456 1 Switch Pivot 21 1381513 ...

Page 177: ...Parts Catalog 163 4039 1XX Assembly 14 Transfer Roll ...

Page 178: ... 14 1 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 Transfer Roll 1 o Lamp Asm Erase 3 1328356 1 Cover Clip Bearing ...

Page 179: ...Parts Catalog 165 4039 1XX Assembly 15 Duplex Option 3 7 2 12 13 14 8 19 16 1 18 11 17 10 15 6 5 4 ...

Page 180: ...per Stop 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 1326113 1 Switch Asm Cover Open 16 1038708 1 Belt Paper Tray 17 1326064 1 Belt Paper Drive 18 1381033 1 Tray Asm 300 w Top Cover 12L 16L 18 1381582 1 Tray Asm 130 w Top Cover 10R 12R 10P 19 138...

Page 181: ...Parts Catalog 167 4039 1XX Assembly 16 Envelope and 100 Sheet Auxiliary Feeder ...

Page 182: ...22529 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 1183273 1 Spring Override Lever 100 Sheet Auxiliary Feeder Only NS 1383934 1 Roller Pack Envelope Feeder Only NS 1383935 1 Roller Pack 100 Sheet Auxiliary Feeder Only ...

Page 183: ...g low 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 13A0295 1 o INA IPDS 13A0296 1 o 9 pin to Twinax cable SCS or IPDS 13A0297 1 o 9 pin to BNC cable SCS or IPDS 13A0298 1 o 9 pin to 9 pin set up cable 1328563 1 o Screw INA ground 9 1325231 1 Fon...

Page 184: ...ts packet 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 1 Grease 2g 1384076 1 Grease conductive 1 oz 1383586 1 Grease damping 1 oz 9900692 1 Grease IBM 23 1280443 1 Oil IBM 10 4 oz 1381035 1 Duplex Gears parts packet 1381048 1 Duplex Flags parts pack...

Page 185: ...ostics mode 32 disk test clean 35 drive motor removal 68 D roll assembly removal 67 duplex feed 1 test 36 duplex feed 2 test 37 duplex option assembly 165 bottom cover entry sensor card removal 98 exit card and cover removal 98 problems 18 system card and motor removal 100 top cover table cover removal 97 E electronics assembly 159 envelope enhance 38 envelope print test 38 Envelope and 100 sheet ...

Page 186: ... HVPS locations 103 I input sensor removal 80 L LAN information 47 problems 22 LCD test 41 light print 22 lower frame assembly 129 assembly removal 81 lubrication specifications 120 LVPS cover removal 83 removal 82 M maintenance approach 3 maintenance kit count 40 major assembly locations 101 memory test 40 mirror motor cable locations 113 N network connections and checks 46 wrap tests 23 network ...

Page 187: ...ount 42 power on self test POST 11 preventive maintenance 119 print contrast 42 print registration adjustments 61 print test 1 43 print test 2 43 print test 3 44 print test page 42 printer ground strap locations 117 printhead assembly 137 cable locations 112 diagnosis 27 removal 89 skew adjustments 59 60 printhead window cleaning procedure 122 Q quick disk test 44 quick test 44 R random marks 30 r...

Page 188: ...uired 4 torquer motor removal 92 transfer roller assembly 163 cleaning 122 removal 66 transfer roller housing locations 104 removal 94 transfer test 42 U upper frame assembly 133 removal 95 V vertical void or streak 30 W warm up time 39 wrap tests 46 Z Zif connector removal 96 ...

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Lexmark 4039 - B/W Laser Printer, Service Manual

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