Lexmark 4039-1XX 168

168 Service Manual

4039-1XX

Asm-

Index Part

Number Units Description

16- 1183151 1 Envelope+ Feeder

- 1183966 1 100-Sheet Auxiliary Feeder

-1 1183226 1 Weight Assembly

-2 1622529 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)

Contents

Main Second Edition (June 1996) Copyright Lexmark International, Inc. 1996 All rights reserved. Table of Contents Notices and Safety Information.............................................. ix Diagnostic Information............................................................. 5 iv Diagnostic Aids....................................................................... 32 vi Repair Information.................................................................. 51 Connector Locations............................................................ 101 viii Preventive Maintenance....................................................... 119 Index ...................................................................................... 171 Parts Catalog......................................................................... 124 Notices and Safety Information Electronic Emission Notices Federal Communications Commission (FCC) Statement x Industry Canada Compliance Statement Avis de conformit aux normes dIndustrie Canada The United Kingdom Telecommunications Act 1984 Page Safety Information Ozone Information Preface General Information Models Covered in this Manual 2 Options Page 4 Abbreviations Unique Tools Required For Service Diagnostic Information 5 Diagnostic Information 4039 Diagnostics: Failures With Error Codes 6 Diagnostic Information 7 8 Diagnostic Information 9 10 Power-On Self Test (POST) 12 Symptom Table Symptom Action or Service Check Banding Background 14 Black Page 16 Blank Page Blurred or Fuzzy Print Dead Machine 18 Duplex Fan (927 Error) 20 Fuser Theory Fuser: 920, 921, or 922 Error Fuser: 923 Error Honeycomb Page Network Card 977 Errors Network Wrap Tests Output Bin Sensor 24 Operator Panel Problem Paper Feed Problem, 500-Sheet Second Tray Paper Feed, Base Printer 26 Paper Feed, Duplex Unit Paper Feed Problem, Envelope+ Feeder/ 100-Sheet Auxiliary Feeder Printhead 28 Paper Size Sensing Problem Regularly Spaced Marks Residual Image 30 Random Marks Skew, all edges Skew, top and bottom only Stalled (diamonds on display) Vertical Void or Streak Diagnostic Aids Diagnostics Mode Grouped Diagnostic Aids 34 Alphabetical List of Diagnostic Aids Auto Clean Auto Clean Delay Auto Clean Frequency Defaults Developed Image Test Disk Test/Clean 36 Duplex Feed 1 Test Duplex Feed 2 Test 38 Envelope Enhance Envelope Print Test Error Log (plus machines only) Fuser Temperature And Warm-Up Time 40 Maintenance Kit Count Memory Test Operator Panel Tests Page Count Paper Feed Test 42 Permanent Page Count Print Contrast (Transfer on plus machines) Print Registration Print Test Page Print Tests 44 Quick Disk Test Quick Test Page 46 Network Connections and Checks Wrap Tests LAN Information Serial Interface Option, 10P 48 Page 50 Repair Information Adjustments Page 54 Fuser Drive Gear Backlash Page Page Paper Feed Magnet 58 Optional Paper Feed Magnet Printhead Skew - Level 1 BA Page Print Registration Adjustment 62 Removals Covers Right Cover Removal Front Cover Removal Page Page Page Page D-roll Assembly Removal 68 Drive Motor Removal Page Page Page 72 Fuser Removal Fuser Input Guide Removal Page 74 Fuser Lamp Removal A Page Page 78 HVPS Removal Page 80 Input Sensor Removal B A Lower Frame Assembly Removal Page Page Page Page 86 Paper Feed Magnet Assembly Removal Page Page Printhead Removal 90 System Board Removal Page 92 System Cable Removal Fuser/Sensor Cable Removal Torquer Motor Removal (10P) Page 94 Transfer Roll Housing Removal Upper Frame Removal Page Page Page Page 100 Duplex Option System Card And Motor Removal B A Connector Locations 101 Connector Locations This chapter shows the locations of major printer assemblies, gears, connectors, and ground straps. Major Assembly Locations Page Page Page Page Page Connector Locations 107 System Board Connectors 10R/12R/12C/12L Page Connector Locations 109 System Board 16L Page Connector Locations 111 System Board 10P Page Connector Locations 113 Mirror Motor Cable/Fan Cable Printhead Cable Pin Laser Hsync Page Page 116 Connector Locations 117 Printer Ground Straps Page Preventive Maintenance Page Page Page Page Parts Catalog Parts Catalog 125 Assembly 1: Covers 126 Parts Catalog 127 Assembly 1: Covers (Continued) 128 5 10 4A 4 130 5 10 4A 4 132 Page 134 Page 136 Page 138 Parts Catalog 139 Assembly 5: Paper Feed 140 Parts Catalog 141 Assembly 5: Paper Feed (Continued) 142 Page 144 Parts Catalog 145 Assembly 7: Paper Feed Drive 146 Page 148 Page 150 Page 152 Page 154 Parts Catalog 155 Assembly 12: Fuser 156 Parts Catalog 157 Assembly 12: Fuser (Continued) 158 Page 160 Page 162 Page 164 Page 166 Page 168 Parts Catalog 169 Assembly 17: Options 170 Assembly 18: Miscellaneous Index Numerics A B C 172 G H I L P Q R S 174 T U V W