Lexmark 4039-1XX manual

4039-1XX LaserPrinter 4039 Series Le xmark is a trademark of Lexmark International, In c., registered in the United States and/or other countr ies. • T able of Contents •I n d e x • Safety and Notices • T rademarks • Star t Diagnostics • Manuals Menu • Star t Diagnostics[...]

Second Edition (June 1996) The following paragraph does not apply to the United Kingdo m or any countr y where such provisions are inconsistent with local law: LEXMARK INTERNA TIONAL, INC. PR O VIDES THIS PUBLICA TION “AS IS” WITHOUT W ARRANTY OF ANY KIND , EITHER EXPRESS OR IMPLIED , INCLUDING, B UT NO T LIMITED TO , THE IMPLIED W ARRANTIES OF[...]

T able of Contents iii 4039-1XX T ab le of Contents Notices and Safety Information .............................................. ix Electronic Emission Notices ............................................................. ix Federal Communications Commission (FCC) Statement ............ ix Industry Canada Compliance Statement .....................[...]

iv Service Manual 4039-1XX Symptom Table ............................................................................... 12 Banding ....................................................................................... 13 Background ................................................................................. 13 Black Page ....................[...]

T able of Contents v 4039-1XX Diagnostic Aids ....................................................................... 32 Diagnostics Mode ............................................................................ 32 Grouped Diagnostic Aids ................................................................ 33 Alphabetical List of Diagnostic Aids ...[...]

vi Service Manual 4039-1XX Network Connections and Checks .................................................. 46 Wrap Tests ...................................... ............................................ 46 LAN Information .......................................................................... 47 Serial Interface Option, 10P .................[...]

T able of Contents vii 4039-1XX Removals (continued) Operator Panel Removal ............................................................. 84 Option Card Removal................... ............................................... 84 Exit Sensor Removal................................................................... 85 Paper Feed Magnet Assembly Re[...]

viii Service Manual 4039-1XX Preventive Maintenance ....................................................... 119 Safety Inspection Guide ............................................................ 119 Lubrication Specifications .......................................................... 120 Printhead Window Cleaning Procedure .......................[...]

Notices and Safety Information ix 4039-1XX No tices and Safety Inf ormation Ref erences in this publication to products, progr ams, or serv ices do not imply that the manuf acturer intends to make these av ailable in all countries in which it operates. Any ref erence to a product, program, or ser vice is not intended to state or imply that only tha[...]

x Service Manual 4039-1XX The manuf acturer is not responsible f or any radio or tele vision interf erence caused by using other than recommended cab les or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the user’ s authority to operate the equipment. Note: T o comply with FCC regulati[...]

Notices and Safety Information xi 4039-1XX European Comm unity (EC) Electromagnetic Compatibility Directive This product is in conformity with the protection requirements of EC Council directiv e 89/336/EEC on the approximation of the la ws of the Member States relating to electromagnetic compatibility . German Statement of Acoustic Emissions A dec[...]

xii Service Manual 4039-1XX Safety Inf ormation • The maintenance inf or mation for this product has been prepared f or use by a prof essional ser vice person and is not intended to be used by others. • There ma y be an increased risk of electr ic shock and personal injur y during disassembly and servicing of this product. Prof essional ser vic[...]

Notices and Safety Information xiii 4039-1XX Norme di sicurezza • Le inf o rmazioni r iguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell'assis tenza autorizzato. • Durante lo smontaggio e il manutenzionamento di questo prodotto , è possibile il r ischio accresciuto di scosse elettr iche e danni perso[...]

xiv Service Manual 4039-1XX Preface This manual is divided into the f ollowing chapters: • “General Inf or mation” contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter , as well as general en vironmental and saf ety instructions. • “Diagno[...]

General Information 1 4039-1XX General Inf o rmation The 4039 is a f a mily of 600 dpi Laser printers designed to attach to IBM-compatible PC’ s and to most types of computer netw or ks. The printer has P ostScript and PCL emulation standard. Models Co vered in this Manual There are no voltage or pinout diff erences between the regular models and[...]

2 Service Manual 4039-1XX Lexmark Model 4039-10 plus (Called 10P in this manual and on the serial number plate) 10ppm, P ostScript Lev el 2 emulation, no serial por t, torquer motor rather than paper pick solenoid, and ser vice error log Options The f ollowing options are a vailab le. Some options are not compatible with all printer models. Some op[...]

General Information 3 4039-1XX Maintenance Approac h The diagnostic inf ormation in this manual will lead y ou to the correct field replaceable unit (FR U) or par t. Use the error code char ts, symptom index, service checks , and diagnostic aids to deter mine the symptom and repair the failure . See “Diagnostic Inf or mation” star ting on page [...]

4 Service Manual 4039-1XX Abbreviations Unique T ools Required For Service Wrap Plug (P arallel), P/N 1319128 Wrap Plug (Serial), P/N 1329048 T winax/serial debug cab le, P/N 1381963 Coax/serial debug cable , P/N 1381964 ASIC Application-Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memor y EEPROM Electrically Erasable P[...]

Diagnostic Information 5 4039-1XX Diagnostic Inf ormation 4039 Diagnostics: F ailures With Error Codes T wo-digit codes are messages f or the 4039 user , but if they recur frequently or at inappropriate times they may be symptomatic of a ser vice problem. On “plus” models , ref er to the diagnos tics error log f or the last six errors or paper [...]

6 Service Manual 4039-1XX 37 Insufficien t Memor y Not enough memor y for function requested.T o verify that the printer recognizes all the ins talled memor y , go to the user menus and print the “Print Menus” test page. Make sure t he memor y shown on the printout m atches the installed memor y . 38 Memor y Full Memor y used to s tore pages is[...]

Diagnostic Information 7 4039-1XX 63 Unforma tted or Defectiv e Dis k The print er will ignore a disk it senses as defe ctive. Run the Quic k Disk T est. If the test f ails, th e disk is def ect ive or the data on track1 is bad. If t he Quick Disk T est passes but the disk does not wor k, run the Disk T est/Cle an (2 hr . test). Replace the disk if[...]

8 Service Manual 4039-1XX 918 T ransf er Roll Error Ser vo F ailure. V erify correct cable connections from the Engine board t o the HVPS . Mak e sure there is continui ty between the tr ansf er roller and its contact on the HVPS; replace the transf er roll if the continuity is correct . If there is no co ntinuity , m ake sure the HVPS contact retu[...]

Diagnostic Information 9 4039-1XX 946 System Board ASIC 2 f a ilure. Repl ace the system board. 947 System Board Engine ASIC RA M failure. Replace the system board. 948 System Board E ngine ASIC elect ronics failure. Replace the system board . 950 System Board SRAM failure. Replace the system board. 952 System Board Unable to zero PQET SRAM. Replac[...]

10 Service Manual 4039-1XX 977 Network Card Networ k card is insta lled but is not communic ating with the system board. See “Network Card 97 7 Errors” on page 23. 978 Network Card General networ k card hard ware error . Replace the Networ k Card. 979 Network Card General networ k card software error. V erify t hat the networ k card is ins tall[...]

Diagnostic Information 11 4039-1XX P ower -On Self T est (POST) When you turn the printer on, it performs a P ower-On Self T est. Check f or correct POST functioning b y obser ving the f ollowing: 1. 1½ rows of pels appear on the displa y and then clear . 2. Diamonds fill the displa y and then clear . 3. The fuser lamp and the fan turn on. [P erfo[...]

12 Service Manual 4039-1XX Symptom T ab le Symptom Action or Service Check Dead Machine Dead Machin e Ser vice Check Repeats patte rn of five beeps and a pause. Operator Panel Service Che ck Machine Hangs Displaying Diamonds Machine Hangs Displaying Diamonds Ser vice Check Operator Panel Operator P an el Ser vice Check P aper Feed, Base Printer P a[...]

Diagnostic Information 13 4039-1XX Banding Banding appears as light and dark hor izontal lines on a page that is supposed to be unif or mly gra y . It is due to variation in the speed of the paper as it mov es from roll to roll during dev elopment or transf er . It is undetectable when printing text and is most noticeab le on fine dot or horizontal[...]

14 Service Manual 4039-1XX . If any v oltages are not correct replace the system board. Note: “Contrast” on the Diagnostics menu (changed to “T ransf er” on 4039 plus machines) does not adjust the print contrast but changes the transf er algor ithm slightly . Users who run large jobs with very dens e graphics in high humidity environments m[...]

Diagnostic Information 15 4039-1XX Blac k P age Black output is usually caused b y an incorrect high v oltage in the printing process, resulting in toner dev elopment on the entire photoconductor drum. Check the condition of each HVPS contact and make sure the y spr ing back when pressed. Check the continuity of the HVPS cable . Make sure the f oll[...]

16 Service Manual 4039-1XX Blank P age Inspect the printhead shutter for proper operation and mak e sure the actuator on top of the car tr idge is present and e xtends into the printhead shroud when the pr inter top cov er is closed. A failed printhead will cause a 931 Ser vice error rather than blank output. Check the contin uity of the HVPS cable[...]

Diagnostic Information 17 4039-1XX . If the voltages are not correct replace the system board. Blurred or Fuzzy Print This can be caused by a damaged gear train or b y paper slippage in the f eed roll or transf er roll. Also see “Banding” on page 13. Inspect the HVPS contacts; make sure each spring-loaded contact returns when pressed and releas[...]

18 Service Manual 4039-1XX If some voltages are present, b ut all a re not correct, disconnect all cables e xcept the L VPS from the system board. POR and verify that the L VPS v oltages are correct. T ur n the power bac k off and, one at a time, reconnect the system board cab les, powering on in between each connection and checking the v oltages. [...]

Diagnostic Information 19 4039-1XX sure the duple x tab le co v er (floor) is correctly snapped in place at its front and rear and that the gear bloc k assemb ly is correctly snapped into the bottom cov er . Run duplex diagnostics tests #1 and #2 to make sure there is no slippage in the paper path. Mak e sure the flags of the duple x unit input and[...]

20 Service Manual 4039-1XX Fuser Theory The fuser lamp operates off line v oltage from the L VPS. The ther mistor is in contact with the fuser hot roll. The system board reads the ther mistor resistance and toggles a TRIAC in the L VPS which cycles the lamp on and off to maintain the proper hot roll temperature. Inside the fuser shroud there is a t[...]

Diagnostic Information 21 4039-1XX If the ther mal fuse has blo w n, the fuser and the fuser wiper will be damaged. Before replacing the fuser and the fuser wiper , chec k the voltage at (10P) J11-16 (10R/12R/12C/12L) J11-3 (16L)J18-16 as you POR again. It should sta y at 0 until the 922 Error is display ed and then go to +24VDC(10P: +5VDC); if it [...]

22 Service Manual 4039-1XX Horizontal V oid or Streak This is usually due to the car tr idge not being installed correctly . Check the printhead area f or obstr uctions, and chec k the mechanical workings of the print car tridge and pr inthead shutter . If nothing is found go to “Blank P age” and f ollow those instructions. LAN Pr oblems Y ou c[...]

Diagnostic Information 23 4039-1XX P ostScript emulation output may appear lighter than PCL output or a test pr int; this is not a def ect. V erify on the Print T e st that the pr int is too light before perf or ming ser vice. Network Car d 977 Error s All network card errors are recorded as 977 in the error log. If there are 977 errors in the log,[...]

24 Service Manual 4039-1XX F or handle-mounted sensor : The voltage at sensor card J2-3 (pin 1 is the bottom pin) should be +5VDC , and the voltage at J2-4 should be (12L) 10 to 14VDC (16L) 22 to 26VDC . If these are incorrect and the cable has contin uity , replace the system board. The voltage between J2-1 and J2-2 should be +5VDC when the light [...]

Diagnostic Information 25 4039-1XX On models 10R/12R/12C/12L, a DC-DC conv er tor changes +34VDC at J9-1 into +5VDC , +12VDC , and -12VDC . Check f or +5VDC at J8-1 and f or +34VDC at J9-1 and at J11-4. Replace the DC-DC conv er tor , the system board, or the L VPS depending on where the v oltage is incorrect. P a per Feed Problem, 500-Sheet Second[...]

26 Service Manual 4039-1XX If paper feeds b ut stops undamaged in the paper path there may be a sensor problem. Run the diagnostic test f or the input and exit sensors replace as necessar y . Check the continuity of the cab le bef ore replacing the sensor . The input sensor signal is on (10P) J20-6 (10R/12R/12C/12L) J20-11 (16L) J17-11; the output [...]

Diagnostic Information 27 4039-1XX P a per Feed Problem, En velope+ Feeder/ 100-Sheet A uxiliar y Feeder Check f or the follo wing: paper or env elope jammed in the feed path; missing hold-down weight; adjustab le guide out of position; feeder cable loose , disconnected, or plugged in the wrong connector ; f eeder incorrectly installed; wor n or da[...]

28 Service Manual 4039-1XX P a per Siz e Sensing Problem (The printed area does not fit on the page, or the paper size cannot be changed from the operator panel.) Make sure that paper tr a ys f or the 4019, 4028, or 4029 are not being used in the 4039 printer . Make sure the paper tr a y and its stops are undamaged. Make sure the cable to the paper[...]

Diagnostic Information 29 4039-1XX Regularly Spaced Marks This is caused by a def ect on one of the rolls or gears in the pr int process. The damaged part can be deter mined by the spacing of the marks according to the follo wing table . Find and replace the damaged par t. Spacings other than the ones listed could be caused b y damage or a bind in [...]

30 Service Manual 4039-1XX Random Marks Random marks are near ly alwa ys due to a mechanical problem or due to f oreign matter loose in the printer or in the pr int car tridge. Inspect and clean the inside of the printer carefully and correct any problems f ound. Skew , all edges If the test print frame is parallel to all edges of the page but the [...]

Diagnostic Information 31 4039-1XX If the problem is still present, replace one at a time the: 1. R OM SIMM 2. System board V ert ical V oid or Streak Do a de v eloped image test to deter mine if the def ect is occurr ing bef ore or after the transf er process. If you see the def ect on the photoconductor , check the operation of the printhead shut[...]

Diagnostic Aids 32 4039-1XX Diagnostic Aids Diagnostics Mode T o r un some of the pr inter diagnostic tests described in this chapter , you m ust put the printer in Diagnostics mode. T o enter Diagnostics mode: 1. T ur n the pr inter off . 2. Press and hold the Ready and Retur n buttons . Then tur n the printer on. The pr inter perf or ms the P owe[...]

Diagnostic Aids 33 4039-1XX Grouped Dia gnostic Aids Print T ests Operator P anel T ests Print T est P age Button T est De v eloped Image T est LCD T est Print T ests Duplex T ests Registration T ests Duple x F eed 1 Duple x F eed 2 Print Registration Quic k T est P aper Feed T ests P age Counts Env elope Pr int T est P age Count P aper Feed T est [...]

34 Service Manual 4039-1XX Alphabetical List of Diagnostic Aids Au t o C l e a n A uto Clean needs to be tur ned on if there is an unacceptable amount of toner being deposited on the back of the page. When A uto Clean is on, after printing the number of pages specified in A uto Clean F requency , the pr inter pauses the number of seconds specified [...]

Diagnostic Aids 35 4039-1XX Defaults Allows setting the f ollowing def aults to U.S . or Non U.S . values . 1. Enter Diagnostics mode. 2. Select [Defaults]. 3. Select [U .S.] or [Non U .S.]. 4. Press Retur n to retur n to Diagnostics mode main menu. Developed Ima ge T est Use the De veloped Image T est to isolate print quality problems. Y ou might [...]

36 Service Manual 4039-1XX A message describing test progress is display ed dur ing the test. 1. Enter Diagnostics mode. 2. Select [De vice T est] 3. Select [Disk T est/Clean]. 4. Select [CONTINUE] to star t the test, or [CANCEL] to retur n to Diagnostics mode main menu. 5. Select [CANCEL] to interrupt the test. 6. Press Return to retur n to Diagno[...]

Diagnostic Aids 37 4039-1XX Duplex Feed 2 T est This test verifies that paper f eeds through the duple x un it properly and tests the stop point of the page as it feeds bac k over the top of the duplex paper tr ay . 1. Enter Diagnostics mode. 2. Select [Duplex T e sts]. 3. Select [Duple x F eed 2]. 4. Select [T ray 1] or [T ra y 2]. Note: P aper f [...]

38 Service Manual 4039-1XX En velope Enhance Use this procedure to set the fuser solenoid power le v el to low , medium, or high. Increase the lev el to reduce env elope wr inkling, or decrease the lev el to reduce solenoid noise. 1. Enter Diagnostics mode. 2. Select [Env elope Enhance]. 3. Select [Low], [Medium], or [High]. 4. Press Return to retu[...]

Diagnostic Aids 39 4039-1XX Fuser T emperature And W arm-Up Time These settings allow adjustment of the fuser to correct problems with paper curl or melting letterheads. P aper cur l in which the top and bottom of the page cur l tow ard the printed side (hot paper cur l) can be corrected by reducing the fuser temperature. Reduce the setting from No[...]

40 Service Manual 4039-1XX Maintenance Ki t Count This non-display ed coun ter must be reset after the maintenance kit is replaced to pre vent the [80 Scheduled Maintenance] message from displa ying when the machine is tur ned on. 1. Enter Diagnostics mode. 2. Select [Maintenance Count]. 3. Select [RESET] to set the count back to “0”. 4. Press [...]

Diagnostic Aids 41 4039-1XX LCD T est T o test the ope rator panel displa y: 1. Enter Diagnostics mode 2. Select [LCD T est]. 3. Select [Single] or [Continuous]. 4. The displa y goes through a continuous sequence of turning pels on and off . 5. Press Retur n to stop continuous LCD test. 6. Press Retur n to retur n to the Diagnostics mode main menu.[...]

42 Service Manual 4039-1XX P e rmanent P age Count The permanent pa ge count can be displa yed only . It cannot be modified or reset by the customer or ser vicer . 1. Enter Diagnostics mode. 2. Select [P er manent P age Count]. 3. Press Return to retur n to Diagnostics mode main menu. Print Contrast (T ransfer on “plus” machines) This setting c[...]

Diagnostic Aids 43 4039-1XX 4. Select [Print T est P age]. 5. Select either [Single] or [Continuous] depending if y ou want one page or continuous test pages . 6. Select [Stop] when you w ant the continuous test to end. Print T ests All of the print tests can be run in the [Single] or [Continuous] mode. T o stop continuous pr inting select [CANCEL][...]

44 Service Manual 4039-1XX Print T est 3 This test generates 2 printouts: a solid blac k page , and a dot pattern that can be used to ev aluate prin t quality . 1. Enter Diagnostics mode. 2. Select [Print T est 3]. 3. Select [Single] or [Continuous]. 4. Select [CANCEL] to stop continuous print. 5. Press Return to retur n to Diagnostics mode main me[...]

Diagnostic Aids 45 4039-1XX Sensor T est 1. Enter Diagnostics mode. 2. Select [Sensor T e st]. 3. Select one of the f ollowing sensor tests . • T oner Low • Output Bin • Input • Exit • Cov er Open Note: The Output Bin sensor can hav e up to a 15 second delay in changing to open. 4. When the sensor is bloc ked [Open] is displa yed. Otherwi[...]

46 Service Manual 4039-1XX Netw ork Connections and Chec ks Wrap T ests The Wrap T ests check the circuits used to communicate with the host computer . T o r un the Wrap T est: 1. T ur n the pr inter off . 2. Disconnect the interf ace cable. 3. Install the wrap plug in one of the interf ace cable connectors. Note: Install the parallel wrap plug par[...]

Diagnostic Aids 47 4039-1XX LAN Inf ormation The printer may be connected to one of the f ollowing LAN types: T oken-Ring Ethernet 10BaseT Ethernet 10Base2 LocalT alk The Network external connectors are pictured below . The printer test page also indicates to which type of LAN the printer is connected. Serial Interface Option, 10P The serial interf[...]

48 Service Manual 4039-1XX Switch 5 – Data Bits: Switch 5 selects the number of data bits (7 or 8) in each data frame. Switch 6 and 7 – P a rity: Switches 6 and 7 select the interface parity . Note: When setting the “Ignore” f or parity , the pr inter ignores the receiv ed parity and transmits using Even parity . For all other parity settin[...]

Diagnostic Aids 49 4039-1XX Switch 8 – Buffer Size: Switch 8 allows the adapter b uffer size to be limited, to minimize the amount of data in the buff er at any time. Switch 9 – Pr otocol: Switch 9 selects the type of protocol. Swi tch 10 - P rin t T est: Switch 10 selects the print test f or the serial interf ace card. This tests the connectio[...]

50 Service Manual 4039-1XX Switch 11 – P olarity for RS-422 Serial Interface: Switch 11 is used to rev erse the polar ity of the receiv e and transmit data line f or 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 Rev erse 12 Mode Off RS-232C On RS-4[...]

Repair Information 51 4039-1XX Repair Inf ormation This chapter e xplains how to make adjustments to the printer and how to remo ve def ective FR Us. Handling ESD-sensitive P ar ts Many electronic products use par ts that are known to be sensitiv e to electrostatic discharge (ESD). T o prev ent damage to ESD-sensitive par ts, f ollow the instructio[...]

52 Service Manual 4039-1XX Adjustments En velope Restraint Spring On The En velope+ Feeder 1. Loosen the mounting screw [ A ]. 2. P osition 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 . P a per Restraint Spring On The 100-sheet A uxiliary Feeder 1. Loosen the mounting screw [[...]

Repair Information 53 4039-1XX En velope Feeder Magnet And 100-sheet A uxiliary Feeder Magnet 1. Hold the armature [ A ] in th e closed (coil activ e) 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 adjust[...]

54 Service Manual 4039-1XX Fuser Drive Gear Bac klash Fuser drive gear backlash is adjusted so that when gear #2 is held still, there is a slight amount of backlash in the fuser gear . Print quality can be affected if the gears are too tight. 1. Remov e the fuser cov er . 2. Locate gear #2. It is the white adjustable gear mounted to the side frame [...]

Repair Information 55 4039-1XX[...]

56 Service Manual 4039-1XX Fuser Solenoid Note: The fuser solenoid must be mounted on the fuser f or this adjustment and should be at room temperature. 1. Loosen screw [ A ]. 2. Remov e 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 wash[...]

Repair Information 57 4039-1XX P a per Feed Magnet 1. Remov e the system board. The magnet is accessed through the holes in the right frame. 2. With the armature latched on the cam step check f or 0.60 mm ± 0.07 mm (0.024 in ± 0.003 in.) between the f oam pad and the magnet pole piece. If adjustment is required, continue: 3. K eep the ar mature l[...]

58 Service Manual 4039-1XX Optional P a per Feed Magnet 1. With the armature latched on the cam step check for 0.60 mm ± 0.07 mm between the f oam pad and the magnet pole piece. If adjustment is required, continue: 2. K eep the ar mature latched and loosen the magnet mounting screw [ A ]. Note: The flat side of the D-roll is down when the f eed is[...]

Repair Information 59 4039-1XX Printhead Skew - Level 1 1. Loosen the mounting screws [ A ]. 2. Pivot the printhead around the shoulder screw [ B ] until the sk ew marks on the pr intout are parallel to the top edge of the paper . Use Print T est 1 or Quick T es t to check this . Rotating the printhead clockwise will lo wer the left ske w adjustmen[...]

60 Service Manual 4039-1XX Printhead Skew - Level 2 1. Remov e the top cov er . 2. Loosen the screws [ A ]. 3. Run Print T est 1 or the Quick T es t on the Diagnostics Menu. 4. Mov e the pointer [ B ] to eliminate the skew . Mo ving the pointer toward the left r aises the left adjustment point on the pr intout. 5. Tighten the screws , and verify th[...]

Repair Information 61 4039-1XX Print Registration Adjustment Use Print T est 1 or the Quick T est to e valuate print registration. Adjust the registration so the tips of the diamonds are at the top and bottom edges of the page and the pr intout is centered left to right. V er ify that the to T o p Margin is correct bef ore adjusting the Bottom Marg[...]

62 Service Manual 4039-1XX Remo vals When there is ar twork to suppor t a procedure, it f ollows the te xt. Co vers Right Cover Remo val 1. T ur n the pr inter off . 2. Remov e all external tra ys. 3. Open the top cov er . 4. Swing the cov er open. 5. Remov e the E-clip from the rear pivot pin and lift the co ver off the rear pivot pin. Fr ont Cove[...]

Repair Information 63 4039-1XX[...]

64 Service Manual 4039-1XX Left Co ver Remov al 1. Unplug the pow er cord. 2. Open the top cov er and remov e the print car t ridge. 3. Remov e the front cov er . 4. Locate the latch [ A ] and push the end to the rear to release it. 5. Push the top of the cov er to the left. 6. Remov e the cov er by sliding it to the rear of the machine . T op Cove[...]

Repair Information 65 4039-1XX[...]

66 Service Manual 4039-1XX T ransfer Roll Remo val 1. Unplug the pow er cord. 2. Remov e the prin t car tridge. 3. Remov e the bearing cover from the left side of the tr ansf er roll: Note: Do not touch the transf er roll surface. • Suppor t the left bear ing cov er from the front with your left hand. • Use a small screwdriver to push the rear [...]

Repair Information 67 4039-1XX D-r o ll Assemb ly Remo v al 1. Unplug the power cord. 2. Remov e the paper tray . Note: The f ollowing 3 steps are not necessary , but ma y make it easier to see the par ts. 3. Remov e the pr int car tr idge. 4. Remov e the fuser input guide. 5. Remov e the transfer roll housing assemb ly . 6. Mov e your finger down [...]

68 Service Manual 4039-1XX Drive Motor Remo val 1. Unplug the pow er cord. 2. Remov e the system board. 3. Remov e the system board inner EMC shield. 4. Remov e the fuser input guide [ A ]. 5. Remov e the transf er housing assembly . 6. Remov e the gear cov er b y releasing the rear latch and lifting up . 7. Remov e scre w [ C ] and the grounding c[...]

Repair Information 69 4039-1XX[...]

70 Service Manual 4039-1XX F an/Redrive Remov al 1. Open the top cov er . 2. Remov e the prin t car tridge. 3. Remov e the top cov er . 4. Remov e the lower redrive shaft b y 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. Remov e the redrive assembly scre ws [ D ].[...]

Repair Information 71 4039-1XX D B C A[...]

72 Service Manual 4039-1XX Fuser Remo v al Note: The heater lamp is fragile and ma y be damaged if you are not careful when you remo v e or replace the fuser unit. CA UTION: THE TEMPERA TURE OF THE HO T ROLLER IS 150 ° -230 ° C (302 ° - 446 ° F). USE EXTREME CA UTION WHEN REMO VING THIS UNIT . BEFORE Y OU SER VICE THIS UNIT , ALLO W THE MA CHIN[...]

Repair Information 73 4039-1XX[...]

74 Service Manual 4039-1XX Fuser Lamp Remo v al CA UTION: THE TEMPERA TURE OF THE HO T ROLLER IS 150 ° -230 ° C (302 ° -446 ° F). USE EXTREME CA UTION WHEN REMO VING THIS UNIT . BEFORE Y OU SER VICE THIS UNIT , ALLO W THE MA CHINE T O COOL FOR 5 MINUTES. Note: The fuser lamp is a glass heater . Do not touch the lamp with your hands; skin oils a[...]

Repair Information 75 4039-1XX Fuser Solenoid Remo val 1. Remov e the fuser . 2. Remov e the two mounting screws [ A ] holding the solenoid housing to the fuser housing. 3. Disengage the solenoid brac ket from the plunger . Note: When a new solenoid assemb ly is installed, the fuser solenoid must be adjusted. A[...]

76 Service Manual 4039-1XX Fuser Thermistor Remo val 1. Disconnect the thermistor cable connector [ A ] from the e xit sensor card. 2. Remov e the fuser cov er and wiper . 3. Remov e the tape holding the ther mistor cable to the shroud. 4. Squeeze the thermistor brack et tabs [ B ] and remov e the ther mistor from the shroud. 5. Remov e the ther mi[...]

Repair Information 77 4039-1XX B A[...]

78 Service Manual 4039-1XX HVPS Remo v al 1. Unplug the pow er cord. 2. Remov e the left cov er 3. Remov e the fuser input guide. 4. Remov e the transf er roll housing. 5. Remov e the fuser cov er . 6. Disconnect the cab le from the HVPS connector . 7. Remov e the power s witch rod. 8. Remov e the ground screw [ B ]. 9. Remov e the mounting screws [...]

Repair Information 79 4039-1XX . F E B F D C[...]

80 Service Manual 4039-1XX Input Sensor Remo v al 1. Remov e the fuser input guide [ A ]. 2. Remov e the transf er roll housing. 3. Remov e the D-roll. 4. Disconnect the system cable from the input sensor board. Note: Use care, the flag can be damaged while remo ving the sensor . 5. Release latch [ B ] and pull the sensor down and f orward to get i[...]

Repair Information 81 4039-1XX Lower Frame Assemb ly Remov al 1. Remov e the r ight, front, and left cov ers 2. Remov e the L VPS and the rod for the on/off s witch. 3. Remov e gear cov er and the fuser input guide [ A ]. 4. Remov e the transfer roll housing. 5. Disconnect the cable from the HVPS . 6. Remov e the system board and the inner EMC shie[...]

82 Service Manual 4039-1XX L VPS Remov al 1. Disconnect the pow er cord. 2. Remov e all external feed tr ays. 3. Remov e the left and r ight side cov ers. 4. (10P and 16L) remov e the system board and the inner EMC shield. 5. Remov e the left and r ight L VPS mounting screws. 6. Disconnect the fuser connector [ A ]. 7. Lift the supply up and then t[...]

Repair Information 83 4039-1XX L VPS Cover Remo val 1. F or m tabs [ D ] awa y from the power supply to create clear ance f or tabs [ A ] to move do wnward. 2. Release the top latches [ A ]. 3. Release the side latches [ B ]. 4. Release the bottom latches [ C ].[...]

84 Service Manual 4039-1XX Operator P anel Remov al 1. Remov e the top cov er . 2. Disconnect the operator panel cab l e. 3. Remov e the operator panel mounting screws from the inside of the top cov er . Option Car d Remov al 1. Remov e all external tra ys. 2. Open the top cov er . 3. Open the right cov er . 4. Remov e the outer EMC shield. 5. Remo[...]

Repair Information 85 4039-1XX Exit Sensor Remo val 1. Remov e the front cov er . 2. Disconnect the fuser/sensor cable . 3. Disconnect the ther mistor cable . 4. Disconnect the fuser solenoid cable . This cab le is not present in all models. 5. Release the latches [ A ]. 6. Pull the sensor down to remo ve it.[...]

86 Service Manual 4039-1XX P a per Feed Magnet Assembl y Removal 1. Remov e the prin t car tridge. 2. Remov e the righ t cov er . 3. Remov e the system board. 4. Remov e the inner EMC shield. 5. Locate the paper f ee d magnet mounting screw [ B ] (visible through the right side frame [ A ]). 6. Remov e the mounting screw [ B ]. 7. Remov e the paper[...]

Repair Information 87 4039-1XX P aper Feed Rollers Remo val Note: Replace all paper f eed drive rollers at the same time. 1. Remov e the lower frame . 2. Disconnect the system cable from the input sensor . 3. Remov e the screws [ A ] and the outer deflector . 4. Remov e the screws [ B ] and the toner shield [ E ]. 5. Separate the side frames . 6. P[...]

88 Service Manual 4039-1XX P a per Siz e Switch Remo val 1. Open the top cov er . 2. Remov e the prin t car tridge. 3. Remov e the paper tra y . 4. Open the right side cov er . 5. Remov e the front cov er . 6. Remov e the two screws [ A ]. 7. Unplug the cable [ B ] from the s witch connector [ C ]. 8. Rotate the s witch about 90 ° and pull it out [...]

Repair Information 89 4039-1XX Printhead Remov al IMPORT ANT : The pr inthead is ESD-sensitive. It is not serviceable and should be replaced as a unit. 1. T ur n the pr inter off . 2. Remov e the pr int car tr idge. 3. Remov e the r ight and top cov ers. 4. Remov e the exit redrive and its belt. 5. Remov e the air plenum. 6. Remov e the screws [ A [...]

90 Service Manual 4039-1XX System Board Remo val 1. Chec k the page count and write it down so you can set the ne w system board. 2. T ur n the pr inter off . 3. Remov e the righ t cov er . 4. Remov e the outer EMC shield by pressing down on the tw o bottom tabs, slide the shield f orward, then down (10P has no outer EMC shield). 5. Disconnect all [...]

Repair Information 91 4039-1XX[...]

92 Service Manual 4039-1XX System Cable Remo val 1. T ur n the pr inter off . 2. Remov e the righ t cov er . 3. Remov e the transf er roll housing. 4. Remov e the fuser input guide. 5. Disconnect the system cable connections . 6. Remov e the cable through the top of the machine. Fuser/Sensor Cable Remo val 1. T ur n the pr inter off . 2. Remov e th[...]

Repair Information 93 4039-1XX T oner Sensor Remov al 1. Remov e the fuser input guide [ A ] 2. Remov e the transfer roll housing. 3. Lift the input sensor board f ar enough to disconnect the cable [ B ]. 4. Remov e the end of the bellcrank spring. 5. Lift the sensor to unsnap it. 6. W ork the cable out of the frame and remo ve the sensor . B A[...]

94 Service Manual 4039-1XX T ransfer Roll Housing Remo val 1. Remov e the prin t car tridge. 2. Remov e the fuser input guide. 3. Grasp the housing and pull to ward the front of the machine to disconnect the housing from the mounting studs, visible through openings [ B ] in the inner deflector . 4. Lift the transf er roll housing f ar enough to dis[...]

Repair Information 95 4039-1XX Upper Frame Remo val 1. Unplug the power cord. 2. Remov e the pr int car tr idge. 3. Remov e the r ight, left, and top cov ers. 4. Remov e the system board. 5. Remov e the inner EMC shield. 6. Remov e the load box latches [ A ]. 7. Release the latches [ B ]. 8. Pivot the upper fr ame to the rear to rele ase the spring[...]

96 Service Manual 4039-1XX Zif Connector Remo val 1. Slide the cable clamp [ A ] to the open position. 2. Note how the contact surf aces [ C ] of the cab le are positioned as you pull the cab le [ B ] out of the connector .[...]

Repair Information 97 4039-1XX Duplex Option T op Cover And T able Co ver Remov al 1. Open the top cov er by pulling up at [ A ] and piv oting 90 ° . 2. Pr y the top cov er from the bottom cover at [ B ] and la y the top cov er on its side. 3. T o disconnect the fan leads , the table co ver has to be remov ed. 4. Release latches [ C ] on the paper[...]

98 Service Manual 4039-1XX Duplex Option Exit Car d And Cover Remo val 1. Pry up on tabs [ A ], after the tabs are released, lift up on the cov er , rotate the cov er out, and slide it to the r ight to completely remov e it. 2. Disconnect the e xit sensor card cable. 3. Depress the e xit sensor flag ac tuator [ B ] and lift out the e xit sensor car[...]

Repair Information 99 4039-1XX[...]

100 Service Manual 4039-1XX Duplex Option System Car d And Motor Remov al 1. Disconnect all cables . 2. Release latches [ A ] and lift the system board out. 3. Remov e the two motor mounting screws [ B ]. 4. Lift the motor out of the frame assembly . Note: The remaining FR U is the Gearblock Assemb ly . When you replace this FR U see “Lubrication[...]

Connector Locations 101 4039-1XX Connector Locations This chapter shows the locations of major printer assemblies, gears, connectors, and gr ound straps . Major Assembl y Locations Low V oltage Power Supply Output Sensor Paper T ray Operator Panel Fan Exit Redrive Print Head High V oltage Power Supply Fuser LowerFrame Upper Frame Print Cartridge T [...]

102 Service Manual 4039-1XX Gear T rain[...]

Connector Locations 103 4039-1XX HVPS[...]

104 Service Manual 4039-1XX T ransfer Roller Housing Paper Guide* * T ransfer roller housing for 10P has no paper guide[...]

Connector Locations 105 4039-1XX System Cable System Board (10R/12R/12C/12L) J20 (16L) J17 Pin 1 Pin 1 HVPS Input and T oner Sensors Pin 1 T ransfer Roll Pin 1[...]

106 Service Manual 4039-1XX System Board Connector s 10R/12R/12L[...]

Connector Locations 107 4039-1XX System Board Connectors 10R/12R/12C/12L Connector Name J1 DRAM SIMM J2 DRAM SIMM J3 ROM SIMM (flash memor y opt ion ) J4 R OM SIMM (printer mic rocode) J5 Printhead Mirror Motor(Printhead)/ F an J6 Laser (Pr in the ad)/ Hsync J7 Operator Pane/Output Bin Sensor J8 DC to DC Conv er tor J9 DC to DC Conv er tor J10 INA [...]

108 Service Manual 4039-1XX System Board Connector s 16L[...]

Connector Locations 109 4039-1XX System Board 16L Connector Name J1 DRAM SIMM J2 DRAM SIMM J3 Mirror Motor(Printhead)/ F an J4 Laser (Pr in the ad)/ Hsync J5 Operator Pane/Output Bin Sensor J6 Duplex J7 Font Card J8 Hard Disk Opti on J9 Env e lope Feeder Magnet J10 ROM SIMM (Printer microcode) J11 ROM SIMM (flash me mor y option) J12 INA Card J13 P[...]

110 Service Manual 4039-1XX System Board Connector s 10P J21 J14 J1 1[...]

Connector Locations 111 4039-1XX System Board 10P Connector Name J1 N/A J2 DRAM SIMM J3 Option SIMM (flash memor y option) J4 R OM SIMM (printer mic rocode) J5 Printhead Mirror Motor/F an J6 Printhead Hsync/Laser J7 Operator Panel J8 N/A J9 N/A J10 N/A J11 L VPS J12 En velope F eeder Magnet J13 INA/Hard Disk J14 HVPS J15 Par allel Port J16 N/A J17 [...]

112 Service Manual 4039-1XX Printhead Cables The printhead cable connector f or 10P , 10R, 12R, 12L,and 12C is J6. The printhead cable connector for 16L is J4. Connector[...]

Connector Locations 113 4039-1XX Mirror Motor Cab le/Fan Cab le The mirror motor cable connector f or the 10P , 10R, 12R, 12L, and 12C is J5. The mirror motor cable connector f or 16L is J3. Printhead Cable Pin Laser Hsy nc 11 22 33 44 56 65 74 83 92 10 1 Pin Motor Fan 11 22 33 44 55 62 71[...]

114 Service Manual 4039-1XX Operator P anel/Output Bin Sensor C able — Handle-Mounted Outbin Sensor[...]

Connector Locations 115 4039-1XX Operator P anel/Output Bin Sensor C able — Redrive-Mounted Outbin Sensor The cable connector f or 10P , 10R, 12R, 12L, 12C is J7. The cab le connector f or 16L is J5. Op Panel Cable Connector Pin 1 Pin 1[...]

116 Service Manual 4039-1XX * No connection on machines with redrive-mounted output bin sensor . Pin Op Panel Sensor 11 22 33 44 55 61 72 83 94 *[...]

Connector Locations 117 4039-1XX Printer Ground Straps Outer Deflector to Lower Frame HVPS to Frame Operator Panel to Upper Frame T oner Shield to Lower Frame Load Box Shaft to Upper Frame Static Brush to Lower Frame[...]

118 Service Manual 4039-1XX T oner Shield to Lower Frame Load Box Shaft to Upper Frame[...]

Preventive Maintenance 119 4039-1XX Preventive Maintenance This chapter describes procedures for printer pre ventiv e maintenance. F ollowing these recommendations can help pre vent problems and maintain optim um perf or mance. Safety Inspection Guide The pur pose of this inspection guide is to aid you in identifying unsaf e conditions. Use good ju[...]

120 Service Manual 4039-1XX Lubrication Specifications Lubricate only when par ts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature f ailure. Some unauthorized lubricants ma y chemically attack polycarbonate par ts. Use IBM no .10 oil PN 1280443 (approv ed equivalents: Mobil DTE27,[...]

Preventive Maintenance 121 4039-1XX • F ront pivot latch studs • Gear no . 8 teeth at gear no. 7 contact points • Gear no . 9 teeth at gear no. 11 contact points • Gear no . 9 teeth at gear no. 8 and gear no . 10 contact points • Cov er Hinge Spr ing tips • Car tridge “ramps” at top center of both sides frames • Latch handle tips [...]

122 Service Manual 4039-1XX Printhead Window Cleaning Pr ocedure Do not use cleaning fluids on the printhead window . Do not use a bare cotton sw ab. The s wab deposits lint on the window . Note: The printhead window is a coated glass. Do not push too hard and scratch or break the glass. 1. Remov e the prin t car tridge. 2. F old a lint free cloth [...]

Preventive Maintenance 123 4039-1XX Scheduled Mechanical Maintenance The operator panel will displa y the message “80 Sch eduled Maintenance” at each 200K (100K for 12C) page count interval. It is necessar y to replace the fuser assembly , transf er roller, d-roll, and lower redriv e shaft assembly at this inter val to maintain the print qualit[...]

Parts Catalog 124 4039-1XX P ar ts Catalog How T o Use This Pa r ts Catalog • SIMILAR ASSEMBLIES: If two assemb lies contain a majority of identical par ts, the y are broken do wn on the same list. Common par ts are shown by one inde x number . P ar ts peculiar to one or the other of the assemblies are listed separ ately and identified by descrip[...]

Parts Catalog 125 4039-1XX Assembl y 1: Cover s 1 14 2 1A 12 1B 17 10 4 3 16 15 11 9 8 27 5 6 7[...]

126 Service Manual 4039-1XX Asm- Index Par t Number Units Description 1-1 13253 11 1 T op Cov er 10R/12R/1 2C/10P -1 1328204 1 T op Cov er 1 2L/16L NS 1329607 1 Kit, Stacker Spring 16L -1A 1381017 1 Operator Panel Asm -1B 1328207 1 Door , T op Cover 12L/16L NS 1328453 1 Screw , Operator Panel -2 1325135 1 Front Logo , 10R -2 1325136 1 Front Logo , [...]

Parts Catalog 127 4039-1XX Assembl y 1: Cover s (Continued) 1 14 2 1A 12 1B 17 10 4 3 16 15 11 9 8 27 5 6 7[...]

128 Service Manual 4039-1XX Asm- Index Par t Number Units Description 1-17 1328508 1 Manual Feed T ra y with guide NS 1 Screw (Deflector Spring Mtg.) P ar ts P ack et 1383314 NS 1328482 1 Cover , Duplex mtg. slot NS 1 Screw (Deflector Switch M t g. plate) P ar ts P acket 1383314 -27 1328189 1 F ro nt Exit Door[...]

Parts Catalog 129 4039-1XX Assembl y 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[...]

130 Service Manual 4039-1XX Asm- Index Par t Number Units Description 2-1 138 1120 1 Lo wer F rame As sembly 10R/12R/12L/12C/16L/ 10P -1 1381001 1 Lower F rame Assembly (16L bel ow serial number 11-09885 U .S. & 11-109 15 W .T .) -2 1381046 1 Motor , Brkt. and Ge ar Asm. 10R -2 1381047 1 Motor , Brkt. and Ge ar Asm. 12R/12L/12C -2 1381121 1 Mot[...]

Parts Catalog 131 4039-1XX Assembl y 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[...]

132 Service Manual 4039-1XX Asm- Index Par t Number Units Description 2-17 1383314 4 Nut, Motor Bracket P ar ts Pack et -17A 1383314 2 Screw , Mo tor Brack et P ar ts Pac ket, 10P -18 1328428 1 LH Bracket, Duplex -19 1328427 1 RH Bracket, Duple x NS 1383314 1 Screw , Dupl ex Brac ket P ar ts Pack et -20 1039476 1 Grommet, Printhead Cable -21 132818[...]

Parts Catalog 133 4039-1XX Assembl y 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[...]

134 Service Manual 4039-1XX Asm- Index Par t Number Units Description 3-1 132 5196 1 Cov er Hinge Asm 10R/12R/12C/10P (does not include the load bo x) -1 1381045 1 Cover Hinge Asm 12L/16L (does not include the load bo x) -1A 1383314 1 Screw , Cov er Hinge P ar ts P acket -2 1325103 1 Upper Pla te Asm 10R/12R/1 2C/10P -2 1328218 1 Upper Plate Asm 12[...]

Parts Catalog 135 4039-1XX Assembl y 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[...]

136 Service Manual 4039-1XX Asm- Index Par t Number Units Description 3-26 1381099 1 Cable, Output Bin/Operator Panel 12L(handle mounted sensor) -26 1381134 1 Cable , Output Bin/Operator P anel 16L(handle mounted sensor) -26 1381095 1 Cable, Operator P anel 12C/12R/10R/10P -28 1383314 2 Screw , Shaft Mtg., P a r ts P a c ket -29 1325138 1 Sprin g, [...]

Parts Catalog 137 4039-1XX Assembl y 4: Printhead System Board 9 2 7 6 4 3 1 8B 8A 8[...]

138 Service Manual 4039-1XX Asm- Index Par t Number Units Description 4-1 138 1624 1 Print head 10P -1 1381005 1 Pr inthead 10R/12R/1 2C/12L/16L -2 1328431 1 Pr inthead Shroud As sembly -3 1325017 1 Cable, F an/Mirro r Motor -4 1325018 1 Cable, hsync/Laser NS 1038199 1 Cable, Tie -6 1383315 1 Pin, Par ts P ack et -7 1383316 1 Spr ing, P ar ts P ack[...]

Parts Catalog 139 4039-1XX Assembl y 5: P aper 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[...]

140 Service Manual 4039-1XX Asm- Index Par t Number Units Description 5-1 103 9101 1 Outer Deflector -2 1183597 1 Upper Deflect or -3 1381670 1 Inne r Deflector with Roller -4 1381636 1 Input Se nsor Board 10P -4 1383430 1 Input Se nsor Board 10R/12R/ 12C/12L/16L -5 1039102 1 Lower Deflector 10R/ 12R/12L/16L -5 1408859 1 Lower Deflector 10P/12 C -6[...]

Parts Catalog 141 4039-1XX Assembl y 5: P aper 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[...]

142 Service Manual 4039-1XX Asm- Index Par t Number Units Description 5-27 1328452 1 Deflector, P aper 10R/12 R/12C/12L/16L/10 P NS 1328450 1 Spring, Shaft Grd. 12L/16L -28 1381617 1 Kit, Anti-Sque ak Bearing 1 0P/10R/12R/12C -28 1381618 1 Kit, Anti-Sque ak Bearing 1 2L/16L -29 1328381 1 Outer Redr ive Shield 12L/16L NS 1383314 1 Screw Backup Sprin[...]

Parts Catalog 143 4039-1XX Assembl y 6: P aper Feed Alignment Gears[...]

144 Service Manual 4039-1XX Asm- Index Par t Number Units Description 6-1 132 8383 1 Bellcrank, Meterin g 10P/10R/12R/12L/16 L -1 1409238 1 Bell crank, Meter ing 12C - 1 o Shaft - 1 o Bellcrank -1 o R o l l - 1 o Thrust Wa sher -2 1381145 1 Kit, P realigner and Meter ing Rollers -3 1039278 1 Gear, Idler , Prealigne r -4 1383316 1 Spr ing, Prealigne[...]

Parts Catalog 145 4039-1XX Assembl y 7: P aper 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[...]

146 Service Manual 4039-1XX Asm- Index Par t Number Units Description 7-1 132 83 11 1 D-Roller Asm 10R/12 R/12 L/1 6L -1 1408705 1 D-Roller Asm, 10P/12C -2 1328279 1 Washer , Thr ust -3 1126832 1 Clip, D-roll -4 1328385 1 Rail Ass embly , Right (With gears)10R/12R/ 12C/12L/16L -4 1328314 1 Rail Ass embly , Right (W/O ge ars) -5 1328313 1 Shield, D-[...]

Parts Catalog 147 4039-1XX Assembl y 8: Standard P aper T ra y (200 sheet) 1 5 2 3 4 6[...]

148 Service Manual 4039-1XX Asm- Index Par t Number Units Description 8- 118 3260 1 P ap er T ray Assembly , 11 in. (200-she et) - 1183276 1 Paper T ra y Assembly , 14 in. (200-sheet) - 1183367 1 He avy Duty P aper T ray Assemb ly , 11 in. (200- sheet) - 1058272 1 He avy Duty P aper T ray Assemb ly , 14 in. (200- sheet) - 1183376 1 Paper T ra y Ass[...]

Parts Catalog 149 4039-1XX Assembl y 9: P aper T r a y (500-Sheet) 5A[...]

150 Service Manual 4039-1XX Asm- Index Par t Number Units Description 9- 119 5837 1 P ap er T ray Assembly , 11 in. - 1195831 1 Paper T ra y Assembly . 14 in. -1 1183801 1 Bottom Cover 11 in. -1 1183804 1 Bottom Cover 14 in. -2 1183357 1 Base 11 in. -2 1183359 1 Base 14 in. -3 1039582 1 Paper Guide -4 1408851 1 Slide 1 1 in. -4 1408882 1 Slide 1 4 [...]

Parts Catalog 151 4039-1XX Assembl y 10: Base for P aper Drawer (500-Sheet) 4 4 2 1 3[...]

152 Service Manual 4039-1XX Asm- Index Par t Number Units Description 10-1 1328194 1 Ho using -2 1039558 1 Roll -3 1328197 1 Plate Assembly , Gear -4 1039170 1 P ad, Machine NS 1328674 1 Clip, Ground[...]

Parts Catalog 153 4039-1XX Assembl y 11: Optional P aper Drawer (500-Sheet) 1 12 5 6 7 13 11 9 8 4 10 2 14 3 16 3[...]

154 Service Manual 4039-1XX Asm- Index Par t Number Units Description 11-1 1183342 1 Base Asse mbly -2 1328630 1 Defle ctor -3 1039170 1 Feet -4 1039596 1 Bellcrank As sembly -5 1383316 1 Sprin g, Bellcrank, Parts Pack et -6 1039603 1 Drive Roller -7 1039540 1 D-Roller Tire -8 1383925 1 P aper Feed Magnet -9 1383385 1 Washer , Parts Pack et -10 138[...]

Parts Catalog 155 4039-1XX Assembl y 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[...]

156 Service Manual 4039-1XX Asm- Index Par t Number Units Description 12-1 1381082 1 Fuser and Lamp 110V 10R -1 1381083 1 Fuser and Lamp 110V 12R/12L -1 1381521 1 Fuser and Lamp 110V 12C -1 1381084 1 Fuser and Lamp 220V 10R -1 1381085 1 Fuser and Lamp 220V 12R/12L -1 1381522 1 Fuser and Lamp 220V 12C -1 1381010 1 Fuser and Lamp 110V 16L -1 1381038 [...]

Parts Catalog 157 4039-1XX Assembl y 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[...]

158 Service Manual 4039-1XX Asm- Index Par t Number Units Description 12-8A 1381086 1 Hot Roll Asse mbly 10R -8A 1381076 1 Hot Roll Assembly 12R/12 L/16L -8A 1381146 1 Hot Roll Assembly 12C -8A 1383322 1 Hot Roll Asm, 10P NS 1039305 1 Backup Roll 10R/12R/12 L/16L NS 1329928 1 Backup Roll, 10P -9 1381012 1 Ther mistor Sensor Asm 10R/12R/12C/12L/16L [...]

Parts Catalog 159 4039-1XX Assembl y 13: Electronics 5A 7 13 6 9 11 5 4A 4 3 18 1 18 23 21 22[...]

160 Service Manual 4039-1XX Asm- Index Par t Number Units Description 13-1 1383974 1 L V Po wer Supply 110V 10R/12 R/12L/12C -1 1383975 1 L V Po wer Supply 220V 10R/12 R/12L/12C -1 1381014 1 L V Po wer Supply 110V 16L -1 1381039 1 L V Po wer Supply 220V 16L -1 1383981 1 L V Po wer Supply 100V 10R/12R/12 L/12C -1 1381643 1 L V Po wer Supply 110V , 1[...]

Parts Catalog 161 4039-1XX Assembl y 13: Electronics (Contin ued) 5A 7 13 6 9 11 5 4A 4 3 18 1 18 23 21 22[...]

162 Service Manual 4039-1XX Asm- Index Par t Number Units Description 13-7 1328291 1 C able, HVPS/Input Sensor Board 10R/12R/ 12C/12L/16L -9 1321882 1 DRAM SIMM 4MB 12R/12L -9 1328589 1 DRAM SIMM 2MB 10R/10P -11 1325436 1 Inne r EMC Shield 10R/12 R/12L/12C NS 1325434 1 Outer EMC Shield 1 0R/12R/12L/12C -11 1328337 1 Inne r EMC Shield 16L -11 141945[...]

Parts Catalog 163 4039-1XX Assembl y 14: T ransfer Roll[...]

164 Service Manual 4039-1XX Asm- Index Par t Number Units Description 14-1 1381008 1 Roll Asm , T ransfer -2 1381007 1 Housing, T ransfer 10R/12R/12C/ 12L/16L -2 1381652 1 Housing, T ransf e r 10P (“sawtooth” not present on 10P) 1 o Rear Lens Asm, Erase 1 o Front Lens Asm, Erase 1 o Contact, T ransf er Roll 1 o Lamp Asm, Erase -3 1328356 1 Cove[...]

Parts Catalog 165 4039-1XX Assembl y 15: Duplex Option 3 7 2 12 13 14 8 19 16 1 18 11 17 10 15 6 5 4[...]

166 Service Manual 4039-1XX Asm- Index Par t Number Units Description 15-1 1381019 1 T op Cover Asm (with fan) -2 1381006 1 Duplex System Card -3 1381020 1 Bottom Cover -4 1326137 1 Exit Sensor Cover -5 1381021 1 Exit Sensor Asm -6 1408906 1 Bell crank -7 1408905 1 T able Cov er (Floor) -8 1326001 1 P aper Stop/Slide -9 1381023 1 Gear Block F rame [...]

Parts Catalog 167 4039-1XX Assembl y 16: En velope+ and 100-Sheet A uxiliary Feeder[...]

168 Service Manual 4039-1XX Asm- Index Par t Number Units Description 16- 118 3151 1 Env elope+ Feeder - 1183966 1 100-Sheet Auxiliar y Feeder -1 1183226 1 Weight Assembly -2 1622529 1 Screw -3 1039615 1 Spr ing -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[...]

Parts Catalog 169 4039-1XX Assembl y 17: Options Asm- Index Par t Number Units Description 17-2 1328586 1 1MB Flash SIMM -3 1328585 1 2MB Flash SIMM -4 1376461 1 4MB Flash SIMM -5 1328589 1 2MB DRAM SIMM -6 1321882 1 4MB DRAM SIMM -7 1321883 1 8MB DRAM SIMM -8 13A0339 1 4MB DIMM -9 13A0340 1 8MB DIMM -10 1 Option Cards - 1381050 1 o INA-LocalT alk [...]

170 Service Manual 4039-1XX Assembl y 18: Miscellaneous Asm- Index Par t Number Units Description - 131 9128 1 P arallel Wrap Plug - 132 9048 1 Serial Wrap Plu g - 138 3313 1 Cables/J umpers par ts packet - 138 33 14 1 Fasteners par ts packet - 138 3315 1 Clips par ts packet - 138 3316 1 Springs pa r ts packet - 138 33 17 1 Gears (1-6) par t s pack[...]

Index 171 4039-1XX Inde x Numerics 100-sheet auxiliary feeder paper restraint spring adjustment 52 A abbreviations 4 auto clean 34 auto clean delay 34 auto clean frequency 34 B background 13 banding 13 black page 15 blank page 16 blurred or fuzzy print 17 button test 40 C connector locations 101 covers assembly 125 removal 62 D dead machine 17 defa[...]

172 Service Manual 4039-1XX frame lower frame assembly 129 lower frame assembly removal 81 upper frame assembly 133 upper frame removal 95 fuser 920,921, or 922 error 20 923 error 21 assembly 155 drive gear backlash adjustment 54 input guide removal 72 lamp removal 74 removal 72 solenoid adjustment 56 solenoid removal 75 thermistor removal 76 fuser[...]

Index 173 4039-1XX P page count 41 paper drawer base assembly, 500-sheet 151 optional (500-sheet) assembly 153 paper feed alignment gears assembly 143 assembly 139 drive assembly 145 magnet adjustments 57 magnet assembly removal 86 rollers removal 87 paper feed problem 100-sheet auxiliary feeder 27 500-sheet second tray 25 base printer 25 duplex un[...]

174 Service Manual 4039-1XX T test page 42 toner sensor removal 93 tools required 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[...]