Lexmark 4039-1XX Bedienungsanleitung

4039-1XX

LaserPrinter 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

Second Edition (June 1996)

The following paragraph does not apply to the United Kingdom or any country where such

provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES

THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS

OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not

allow disclaimer of express or implied warranties in certain transactions, therefore, this

statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are

periodically made to the information herein; these changes will be incorporated in later

editions of the publication. Improvements or changes in the products or the programs

described in this publication may be made at any time. Publications are not stocked at the

address given below; requests for publications should be made to your point of purchase.

Comments may be addressed to Lexmark International, Inc., Department D22A/035-3,

740 New Circle Road NW, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute

any of the information you supply in any way it believes appropriate without incurring any

obligation to you.

Lexmark is a trademark of Lexmark International, Inc, registered in the United States and/or

other countries.

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

States and other countries.

PCL is a registered trademark of the Hewlett-Packard Company. PCL 5 is Hewlett-Packard

Company’s designation of a set of printer commands (language) and functions included in its

printer products. This printer is designed and manufactured by Lexmark International, Inc., to

be compatible with the PCL 5 language. This means the printer recognizes PCL 5

commands used in various applications programs, and that the printer emulates the

functions corresponding to the commands.

Other trademarks are the property of their respective owners.

 Copyright Lexmark International, Inc. 1996

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,

duplication or disclosure by the Government is subject to restrictions as set forth in

subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at

DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,

Lexington, Ky 40550.

4039-1XX

Table of Contents iii

4039-1XX

Table of Contents

Notices and Safety Information.............................................. ix

Electronic Emission Notices............................................................. ix

Federal Communications Commission (FCC) Statement............ ix

Industry Canada Compliance Statement ......................................x

The United Kingdom Telecommunications Act 1984....................x

European Community (EC) Electromagnetic Compatibility

Directive....................................................................................... xi

German Statement of Acoustic Emissions................................... xi

Safety Information............................................................................xii

Ozone Information...........................................................................xiii

Preface.................................................................................... xiv

General Information.................................................................. 1

Models Covered in this Manual.....................................................1

IBM Models............................................................................1

Lexmark Model ......................................................................2

Options..........................................................................................2

Maintenance Approach.................................................................3

Abbreviations ................................................................................4

Unique Tools Required For Service..............................................4

Diagnostic Information............................................................. 5

4039 Diagnostics: Failures With Error Codes ...................................5

Power-On Self Test (POST)............................................................11

iv Service Manual

4039-1XX

Symptom Table ...............................................................................12

Banding.......................................................................................13

Background.................................................................................13

Black Page..................................................................................15

Blank Page..................................................................................16

Blurred or Fuzzy Print..................................................................17

Dead Machine.............................................................................17

Duplex.........................................................................................18

Fan (927 Error)............................................................................19

Fuser Theory...............................................................................20

Fuser: 920, 921, or 922 Error......................................................20

Fuser: 923 Error..........................................................................21

Honeycomb.................................................................................21

Horizontal Void or Streak ............................................................22

LAN Problems.............................................................................22

Light Print....................................................................................22

Network Card 977 Errors.............................................................23

Network Wrap Tests....................................................................23

Output Bin Sensor.......................................................................23

Operator Panel Problem..............................................................24

Paper Feed Problem, 500-Sheet Second Tray...........................25

Paper Feed, Base Printer............................................................25

Paper Feed, Duplex Unit.............................................................26

Paper Feed Problem, Envelope+ Feeder/

100-Sheet Auxiliary Feeder.........................................................27

Printhead.....................................................................................27

Paper Size Sensing Problem ......................................................28

Regularly Spaced Marks.............................................................29

Residual Image ...........................................................................29

Random Marks............................................................................30

Skew, all edges...........................................................................30

Skew, top and bottom only..........................................................30

Stalled (diamonds on display).....................................................30

Vertical Void or Streak.................................................................31

Table of Contents v

4039-1XX

Diagnostic Aids....................................................................... 32

Diagnostics Mode............................................................................32

Grouped Diagnostic Aids ................................................................33

Alphabetical List of Diagnostic Aids................................................34

Auto Clean ..................................................................................34

Auto Clean Delay........................................................................34

Auto Clean Frequency ................................................................34

Defaults.......................................................................................35

Developed Image Test................................................................35

Disk Test/Clean...........................................................................35

Duplex Feed 1 Test.....................................................................36

Duplex Feed 2 Test.....................................................................37

Envelope Enhance......................................................................38

Envelope Print Test.....................................................................38

Error Log (“plus” machines only).................................................38

Fuser Temperature And Warm-Up Time.....................................39

Fuser Temperature..............................................................39

Warm-up Time.....................................................................39

Maintenance Kit Count................................................................40

Memory Test...............................................................................40

Operator Panel Tests..................................................................40

Button Test...........................................................................40

LCD Test..............................................................................41

Page Count.................................................................................41

Paper Feed Test .........................................................................41

Permanent Page Count...............................................................42

Print Contrast (Transfer on “plus” machines)..............................42

Print Registration.........................................................................42

Print Test Page ...........................................................................42

Print Tests...................................................................................43

Print Test 1...........................................................................43

Print Test 2...........................................................................43

Print Test 3...........................................................................44

Quick Disk Test...........................................................................44

Quick Test...................................................................................44

Sensor Test.................................................................................45

vi 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

Envelope Restraint Spring On The Envelope+ Feeder...............52

Paper Restraint Spring On The 100-sheet

Auxiliary Feeder ..........................................................................52

Envelope Feeder Magnet And 100-sheet

Auxiliary Feeder Magnet .............................................................53

Fuser Drive Gear Backlash.........................................................54

Fuser Solenoid............................................................................56

Paper Feed Magnet.....................................................................57

Optional Paper Feed Magnet......................................................58

Printhead Skew - Level 1 ............................................................59

Printhead Skew - Level 2 ............................................................60

Print Registration Adjustment......................................................61

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

Covers.........................................................................................62

Right Cover Removal..................................................................62

Front Cover Removal..................................................................62

Left Cover Removal.....................................................................64

Top Cover Removal ....................................................................64

Transfer Roll Removal.................................................................66

D-roll Assembly Removal............................................................67

Drive Motor Removal...................................................................68

Fan/Redrive Removal..................................................................70

Fuser Removal............................................................................72

Fuser Input Guide Removal ........................................................72

Fuser Lamp Removal..................................................................74

Fuser Solenoid Removal.............................................................75

Fuser Thermistor Removal..........................................................76

HVPS Removal ...........................................................................78

Input Sensor Removal.................................................................80

Lower Frame Assembly Removal ...............................................81

LVPS Removal............................................................................82

LVPS Cover Removal .................................................................83

Table of Contents vii

4039-1XX

Removals (continued)

Operator Panel Removal.............................................................84

Option Card Removal..................................................................84

Exit Sensor Removal...................................................................85

Paper Feed Magnet Assembly Removal.....................................86

Paper Feed Rollers Removal......................................................87

Paper Size Switch Removal........................................................88

Printhead Removal......................................................................89

System Board Removal ..............................................................90

System Cable Removal...............................................................92

Fuser/Sensor Cable Removal.....................................................92

Torquer Motor Removal (10P) ....................................................92

Toner Sensor Removal...............................................................93

Transfer Roll Housing Removal..................................................94

Upper Frame Removal................................................................95

Zif Connector Removal ...............................................................96

Duplex Option Top Cover And Table Cover Removal ................97

Duplex Option Exit Card And Cover Removal ............................98

Duplex Option Bottom Cover And

Entry Sensor Card Removal .......................................................98

Duplex Option System Card And Motor Removal.....................100

Connector Locations............................................................ 101

Major Assembly Locations........................................................101

Gear Train.................................................................................102

HVPS ........................................................................................103

Transfer Roller Housing............................................................104

System Cable............................................................................105

System Board Connectors 10R/12R/12L..................................106

System Board Connectors 16L.................................................108

System Board Connectors 10P.................................................110

Printhead Cables.......................................................................112

Mirror Motor Cable/Fan Cable...................................................113

Operator Panel/Output Bin Sensor Cable —

Handle-Mounted Outbin Sensor................................................114

Operator Panel/Output Bin Sensor Cable —

Redrive-Mounted Outbin Sensor...............................................115

Printer Ground Straps...............................................................117

viii Service Manual

4039-1XX

Preventive Maintenance....................................................... 119

Safety Inspection Guide............................................................119

Lubrication Specifications..........................................................120

Printhead Window Cleaning Procedure ....................................122

Cleaning The Transfer Roller....................................................122

Scheduled Mechanical Maintenance.........................................123

Parts Catalog......................................................................... 124

How To Use This Parts Catalog................................................124

Assembly 1: Covers ...........................................................125

Assembly 2: Lower Frame .................................................129

Assembly 3: Upper Frame .................................................133

Assembly 4: Printhead .......................................................137

Assembly 5: Paper Feed....................................................139

Assembly 6: Paper Feed Alignment Gears........................143

Assembly 7: Paper Feed Drive ..........................................145

Assembly 8: Standard Paper Tray (200 sheet)..................147

Assembly 9: Paper Tray (500-Sheet).................................149

Assembly 10: Base for Paper Drawer (500-Sheet)............151

Assembly 11: Optional Paper Drawer (500-Sheet)............153

Assembly 12: Fuser ...........................................................155

Assembly 13: Electronics...................................................159

Assembly 14: Transfer Roll................................................163

Assembly 15: Duplex Option..............................................165

Assembly 16: Envelope+ and 100-Sheet

Auxiliary Feeder............................................................167

Assembly 17: Options ........................................................169

Assembly 18: Miscellaneous..............................................170

Index ...................................................................................... 171

Notices and Safety Information ix

4039-1XX

Notices and Safety Information

References in this publication to products, programs, or services do

not imply that the manufacturer intends to make these available in all

countries in which it operates. Any reference to a product, program,

or service is not intended to state or imply that only that product,

program, or service may be used. Any functionally equivalent

product, program, or service that does not infringe any existing

intellectual property rights may be used instead. Evaluation and

verification of operation in conjunction with other products,

programs, or services, except those expressly designated by the

manufacturer, are the user’s responsibility.

Electronic Emission Notices

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

country.

Federal Communications Commission (FCC) Statement

This printer has been tested and found to comply with the limits for a

Class B digital device, pursuant to Part 15 of the FCC Rules. These

limits are designed to provide reasonable protection against harmful

interference in a residential installation. This equipment generates,

uses, and can radiate radio frequency energy and, if not installed

and used in accordance with the instructions, may cause harmful

interference to radio communications. However, there is no

guarantee that interference will not occur in a particular installation.

If this equipment does cause harmful interference to radio or

television reception, which can be determined by turning the

equipment off and on, the user is encouraged to try to correct the

interference by one or more of the following measures:

•Reorient or relocate the receiving antenna.

•Increase the separation between the equipment and receiver.

•Connect the equipment into an outlet on a circuit different from

that to which the receiver is connected.

•Consult your point of purchase or service representative for

additional suggestions.

xService Manual

4039-1XX

The manufacturer is not responsible for any radio or television

interference caused by using other than recommended cables or by

unauthorized changes or modifications to this equipment.

Unauthorized changes or modifications could void the user’s

authority to operate the equipment.

Note: To comply with FCC regulations on electromagnetic interfer-

ence, for a Class B computing device, the printer cable must be

shielded.

To assure compliance with FCC regulations for a Class B computing

device, use a properly shielded and grounded IBM cable. Part

numbers for the various interface cables are: part number 1525612

for parallel interface, and part number 8509386 for serial interface.

Use of a substitute cable not properly shielded and grounded may

result in violation of FCC regulations.

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 conformité aux normes d’Industrie Canada

Cet appareil numérique respecte les limites de bruits

radioélectriques applicables aux appareils numériques de Classe B

prescrites dans la norme sur le matériel brouilleur : “Appareils

numériques”, NMB-003 édictée par Industrie Canada.

The United Kingdom Telecommunications Act 1984

This apparatus is approved under the approval number NS/G/1234/

J/100003 for the indirect connections to the public

telecommunications systems in the United Kingdom.

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