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Lexmark X83 Scan/Print/Copy

4403-001

· Table of Contents · Start Diagnostics · Safety and Notices · Trademarks · Index

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

4403-001
Edition: June 2001 The following paragraph does not apply to 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. Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at [email protected]. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners. © Copyright Lexmark International, Inc. 2001. All rights reserved. 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.

U.S.A. P/N: 12G3797

Japanese P/N:

4403-001

Table of Contents
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scanner Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2 1-3 1-5 1-6

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-1 POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Carrier Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 CCD Module Assembly Service Check . . . . . . . . . . . . . . . . . . . . 2-8 Gear Train Assembly Service Check . . . . . . . . . . . . . . . . . . . . . . 2-9 Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . . . 2-10 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Paper Path Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Scan/Copy Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-17 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Test Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

iii

4403-001 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 Scanner Lid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 Rear Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 Top Housing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-4 Paper Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4 CCD Module Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-5 Gear Train Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Access Cover Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .4-6 Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Access Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Left Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 Middle Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9 Print Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 ASF Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 System Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12 Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 Encoder Strip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 Maintenance Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 Belt/Idler Pulley Assembly (Print Engine) Removal. . . . . . . . . . .4-14 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Assembly 2: Paper Feed, Frame and Carrier Transport . . . . . . . . . .7-6 Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1

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Safety Information
· This product is designed, tested and approved to meet strict
global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

· ·

Consignes de Sécurité
· Ce produit a été conçu, testé et approuvé pour respecter les
normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

· ·

Safety Information v

4403-001

Norme di sicurezza
· Il prodotto è stato progettato, testato e approvato in conformità a
severi standard di sicurezza e per l'utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l'utilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

· ·

Sicherheitshinweise
· Dieses Produkt und die zugehörigen Komponenten wurden
entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

· ·

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4403-001

Pautas de Seguridad
· Este producto se ha diseñado, verificado y aprobado para
cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

· ·

Informações de Segurança
· Este produto foi concebido, testado e aprovado para satisfazer
os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

· ·

Safety Information vii

4403-001

Informació de Seguretat
· Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informació pel manteniment d'aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d'aquest producte. El personal professional ha d'estar-ne assabentat i prendre les mesures convenients.

· ·

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Safety Information ix

4403-001

Preface
This manual and contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General Information 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 environmental and safety instructions. 2. Diagnostic Information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs). 3. Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems. 4. Repair Information provides instructions for making printer adjustments and removing and installing FRUs. 5. Connector Locations uses illustrations to identify the connector locations and test points on the printer. 6. Preventive Maintenance contains the lubrication specifications and recommendations to prevent problems. 7. Parts Catalog contains illustrations and part numbers for individual FRUs.

x Service Manual

4403-001

1. General Information
The Lexmark X83 machine is an electro-mechanical scanner, printer, and copier that creates characters and graphics by composing programmed patterns of ink dots using a printhead and liquid ink. The printhead uses small heater plates and nozzles to control ink flow and the formation of characters on the print media. The printhead assembly and ink supply are combined into a singleunit, print cartridge available as a customer replaceable supply item. Dual printheads provide color and true black printing without changing printheads. The number and size of inkjets or nozzles, in the printhead, determines the overall quality and capability of the printer. The black cartridge has a total of 208 nozzles and installs on the right. The color cartridge has a total of 192 nozzles and installs on the left. The printer is capable of printing in two directions from either cartridge.

Power Consumption
· · · ·
<6 Watts - power off and power to the printer 8 Watts - Idle Mode (power on - not printing) 21 Watts - Printing (average) 31 Watts - Printing (peak)

General Information 1-1

4403-001

Scanner Specifications
Scanner Type Scan Modes Flatbed, CCD True Color: 48 Bit Internal (68.7 Billion Colors) 24 Bit External (16.7 Million Colors) Gray Mode: 12 Bits Internal (4,096 Shades of Gray) 8 Bits External (256 Shades of Gray) Text/Line Art: 1 Bit Per Pixel Scan Method Scan Area Scan Resolution Resolution/Quality (Applicable when operating via standalone mode) One Pass Scanning 8.5 X 11.7 inches 216 X 292 mm Optical: 600 dpi (H) X 1200 dpi (V) Interpolated: 19,200 X 19,200 Selectable via Op-Panel High / Photo - 600 X 600 dpi Scan 1200 X 1200 dpi Print (by interpolation) Normal - 300 X 300 dpi Scan 600 X 600 dpi Print (by interpolation) Draft / Quick - 300 X 300 dpi Scan 300 X 600 dpi Print (by interpolation)

1-2 Service Manual

4403-001

Operator Panel

General Information 1-3

4403-001

Press this button: Number of Copies Lighter/Darker Reduce/Enlarge Paper Type < or > Menu Select Quality Color Copy Black Copy Scan To Scan Cancel Power

When you want to: Select the number of copies. Make the document lighter or darker than the original. Make the document smaller or larger than the original. Select glossy, photo, transparency, or plain paper type. Scroll through menu sub-categories. Change settings using the menus. Choose the displayed selection. Choose photo, quick, or normal copy setting. Make a color copy. Make a black and white copy. Select a scan destination, such as To copy, To and email, To an application, To a file, or To fax. Press the scan button after selecting a Scan To destination. Cancel a scan, print, or copy job, or return to a menu category from a menu sub-category. Turn the printer on or off.

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4403-001

Maintenance Approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. After you complete the repair, perform tests as needed to verify the repair.

General Information 1-5

4403-001

Abbreviations
B/M CCD EOF ESD FPC FRU HVPS LCD LVPS OEM V ac V dc ZIF Bill of Material Charged Coupled Device End of Form Electrostatic Discharge Flat Printhead Cable Field Replaceable Unit High Voltage Power Supply Liquid Crystal Display Low Voltage Power Supply Original Equipment Manufacturer Volts alternating current Volts direct current Zero Insertion Force

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2. Diagnostic Information
Start
Use the symptom tables, service checks, and diagnostic aids in chapter three, to determine the printer failure.

Power-On Self Test (POST) Sequence
Press the power button to turn machine on.

· "X83 by Lexmark" appears in the LCD. · The Photo, Normal, and Quick indicator lights turn on. · The Charge Couple Device (CCD) moves to the left, then · · · · ·
returns to the right. The paper feed motor runs then stops. The carrier moves to the left then returns to the right stopping at the maintenance station. The Photo and Quick lights turn off. Normal light stays on. The message below is displayed on the LCD.

If your printer completes POST with no errors, go to the "Symptom Tables" on page 2-3, locate the symptom and take the indicated action. If your printer does not complete POST, locate the symptom in the following table and take the indicated action.

Diagnostic Information 2-1

4403-001

POST Symptom Table
Symptom No Photo, Normal, or Quick lights and no motors run. Paper feed gears do not turn Carrier does not move Carrier slams side frame CCD does not move CCD lamp does not turn on LCD displays "Unlock Scanner" Action Go to the "Power Service Check" on page 2-14. If okay, go to the "Operator Panel Problems" on page 2-3.

Go to the "Paper Feed Service Check" on page 2-11.

Go to the "Carrier Transport Service Check" on page 2-6. Go to the "Carrier Transport Service Check" on page 2-6. Go to the "Gear Train Assembly Service Check" on page 2-9. Go to the "CCD Module Assembly Service Check" on page 2-8. Go to the "CCD Module Assembly Service Check" on page 2-8.

2-2 Service Manual

4403-001

Symptom Tables
Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems
Symptom · · · · No carrier movement Slow carrier movement Carrier stops Carrier slams side frame Action Go to the "Carrier Transport Service Check" on page 2-6.

Maintenance Station Problems
Symptom Maintenance station: · Fails to cap the printheads · Fails to clean the printheads Action Go to the "Maintenance Station Service Check" on page 2-10.

Operator Panel Problems
Symptom · Buttons do not work · LCD does not display Action Check operator panel cable connection at J8 on the system board. Then run the "Power-On Self Test (POST) Sequence" on page 2-1. If the LED buttons or any lights fail, check connection J8. If the problem remains, replace the operator panel assembly. Go to the "Operator Panel Removal" on page 4-4.

If the problem still exists, replace the system board. Go to the "System Board Removal" on page 4-12.

Diagnostic Information 2-3

4403-001 Printer Communication Table
Symptom · Not able to print Test Page Action Check the USB cable and system board cable connections. If okay, replace system board. Go to the "System Board Removal" on page 4-12.

Scanner Problems
Symptom · CCD does not move · Lamp does not light · The operator panel displays "Unlock Scanner" · Scanned images are: faded, or colors are dull, blurry or fuzzy. Images are slanted or crooked and the strait lines in the image appear to be jagged or uneven. · Blank copies Action Go to the "CCD Module Assembly Service Check" on page 2-8. Go to the "Gear Train Assembly Service Check" on page 2-9. Go to the "Scan/Copy Quality Service Check" on page 2-17.

2-4 Service Manual

4403-001 Paper Feed Problems
Symptom · Fails to pick paper · Picks more than one sheet of paper · Picks paper but fails to feed · Paper jams · Paper fails to exit · Noisy paper feed Envelopes fail to feed Paper skews Action Go to the "Paper Feed Service Check" on page 2-11.

Go to the "Paper Feed Service Check" on page 2-11. Go to the "Paper Path Service Check" on page 2-13.

Power Problems
Symptom No power in machine, motors do not operate Action Go to the "Power Service Check" on page 2-14.

Print Quality Problems
Symptom · · · · · · · · Voids in characters Light print Prints off the page Fuzzy print Carrier moves but no print Printhead dries prematurely Colors print incorrectly Vertical alignment off Action Go to the "Print Quality Service Check" on page 2-15.

· Ink smearing · Vertical streaks on paper · Print lines crowded

Go to the "Paper Feed Service Check" on page 2-11.

Diagnostic Information 2-5

4403-001

Service Checks
Carrier Transport Service Check
FRU 1 System Board Carrier Transport Motor Action Check the transport carrier motor connector J6. If connected, check for approximately 30 volts on pins 1 and 2 or at the wire connections located on the rear of the transport carrier motor. If voltage is incorrect, replace the system board. If voltage is correct, check the motor for shorts. Check the motor for binds, or loose motor pulley. A noisy or chattering motor or a motor that fails to turn can be caused by:

2

Carrier Transport Motor

· An open or short in the motor. · An open or short in the motor driver
on the system board.

· A bind in the carrier transport
mechanism.
With the carrier transport motor cable (J6) disconnected from the system board, check for 0 to 10 ohms between the following pins on the motor: J6-1 and J6-2 If the readings are incorrect, replace the print engine. Go to the "Print Engine Removal" on page 4-11. 3 Carrier Guide Rod Clean the carrier rod. Note: Lubricate the rod and the carrier rod bearing surfaces with grease P/N 99A0394.

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FRU 4 Encoder Strip Carrier with PCB Assembly Action Check the encoder strip for proper installation. Also, check it for wear, dirt and grease. Be sure all printhead connectors are fully seated. Check the cables for damage. If the encoder strip and all connections are okay, but the carrier still slams the side frame, replace the print engine. Go to the "Print Engine Removal" on page 4-11. 5 Carrier Transport Belt Idler Pulley Parts Carrier Frame Check for worn, loose or broken parts. Check for obstructions blocking carrier movement. Check the carrier belt idler pulley mounting screw. Loosen the screw and allow the tension spring to take up any slack in the belt. Tighten the screw. If the pulley mounting bracket has reached the stop, replace the belt. Go to the "Belt/Idler Pulley Assembly (Print Engine) Removal" on page 4-14. Lubricate carrier to carrier frame engagement with grease P/N 99A0394. 6 Printhead Carrier Assembly Disconnect the printer and check the carrier printhead connector (J5). If the connection is good, remove the printhead carrier and check the cable connection to the home sensor board. If the problem remains, replace the system board. Go to the "System Board Removal" on page 4-12. A problem with the maintenance station can cause carrier movement problems at the right margin. Go to the "Maintenance Station Removal" on page 4-13. If the carrier does not move toward the cartridge load position when the access cover is opened, verify that power is on. If the carrier still does not move, check connector J10 pin 1 for approximately 4 volts, with the cover closed. If the voltage is correct, replace the sensor. Go to the "Access Cover Sensor Removal" on page 4-6. If the voltage is incorrect, replace the system board. Go to the "System Board Removal" on page 4-12.

7

Maintenance Station

8

Access Cover Sensor

Diagnostic Information 2-7

4403-001

CCD Module Assembly Service Check
The CCD (charged coupled device) Module will not move during POST Test. The CCD lamp does not come on when CCD module assembly moves and the Photo, Normal, Quick lights stay on. The CCD LCD displays "Unlock Scanner."

FRU 1 CCD Module Assembly

Action If CCD module will not move, go to the "Gear Train Assembly Service Check" on page 2-9. If lamp does not come on as CCD module assembly is scanning or moving, check connector (JP3) on the system board. If connected and the lamp still does not work, replace the CCD module assembly. If the lamp does not correct the problem after the CCD replacement, replace the system board. Go to "System Board Removal" on page 4-12 for more information. To unlock scanner, press the red lever down. The lever is located by the USB plug on the rear of the machine. Note: Unlock scanner before use.

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Gear Train Assembly Service Check
CCD will not move or scan.
FRU 1 Gear Train Assembly Action Disconnect J7 and check the reading at pin 1 and 3 for approximately 225.5 ohms. If the reading is incorrect, replace the gear train assembly. Go to the "Gear Train Assembly Removal" on page 4-6. If the reading is correct, check at pins 1 through 6 for approximately 29 volts, with the machine turned on. If the voltage is incorrect, replace the system board. Go to the "System Board Removal" on page 4-12. Note: Ensure scanner is unlocked. 2 Scanner Belt Check the belt for proper installation. If the belt is damaged, replace. Go to the "Belt/Idler Pulley Assembly (Print Engine) Removal" on page 4-14. Note: If not properly installed, the belt will slip.

Diagnostic Information 2-9

4403-001

Maintenance Station Service Check
The maintenance station has three functions: 1. Wipes the printhead nozzles to clean them of dirt. 2. Provides a place for printheads to fire all nozzles, keeping them clear prior to printing. 3. Seals the printhead when it is not being used to prevent the nozzles from drying.

FRU 1 Maintenance Station Assembly

Action As the carrier moves to the right over the maintenance station, a slot on the bottom of the carrier engages a tab on the sled of the maintenance station causing the cap to rise and seal the printhead. Carrier movement to the left uncaps the printhead. The wiper cleans the printhead nozzles as the carrier leaves the maintenance station. The wiper cleans the printhead only when the carrier is moving to the left. There should be no wiping action of the printhead nozzles when the carrier is moving to the right. After the cleaning operation is complete, a tab on the maintenance station engages a tab on the carrier, causing the wiper to lower. Check the maintenance station for worn or broken parts. Replace if needed. Go to the "Maintenance Station Removal" on page 4-13. Worn wipers cause degraded print quality just after a maintenance cleaning. Check for loose or worn wipers. Worn caps cause the printhead nozzles to dry and clog. Check for loose or worn caps.

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Paper Feed Service Check
If your machine does not have paper jam problems, continue with the service check. If your machine does have a paper jam problem, examine it for the following before you begin the service check:

· · · ·

Check the entire paper path for obstructions. Be sure there is not too much paper in the sheet feeder. Be sure the correct type of paper is being used. Check for static in the paper.

FRU 1 System Board

Action Run the "Power-On Self Test (POST) Sequence" on page 2-1. Replace parts as needed. To check the paper feed motor, disconnect the paper feed connector J5 and check for approximately 5 ohms between pins 3 and 4. If the reading is incorrect, replace the print engine. Go to the "Print Engine Removal" on page 4-11. If the reading is correct, replace the system board. Go to the "System Board Removal" on page 4-12.

Diagnostic Information 2-11

4403-001
FRU 2 Paper Feed Motor Action A noisy or chattering motor or a motor that fails to turn, can be caused by: · An open or short in the motor · An open or short in the motor driver on the system board · A bind in the paper feed mechanism With the paper feed motor cable J5 disconnected from the system board, check for approximately 5 ohms between the following pins on the motor: Pin 3 to Pin 4 If the readings are incorrect, replace the print engine. Go to the "Print Engine Removal" on page 4-11. Although the paper feeds in a forward direction only, the paper feed motor turns in two directions. If the paper feed motor turns in one direction only, replace the system board. Go to the "System Board Removal" on page 4-12. Binds in the paper feed motor or gear train can cause intermittent false paper jam errors. Remove the paper feed motor and check the shaft for binds. Also check for a loose or worn motor gear. 3 4 Auto Sheet Feeder Assembly Mid Frame Assembly Check the pick roller for wear. Check the following for wear: · Small Feed rollers · Large Feed roller · Exit roller · Star rollers If the mid frame assembly needs to be replaced, go to the "Print Engine Removal" on page 4-11 and replace print engine. 5 End-of-Forms Flag and Spring Check for binds or damage.

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Paper Path Service Check
Examine the machine for the following before you begin this service check:

· Check the entire paper path for obstructions. · Be sure the correct type of paper is being used. · Be sure the printer is installed on a flat surface.
FRU 1 2 3 4 Large and Small Feed Rollers Small Feed Roller Springs Auto Sheet Feeder Assembly Mid Frame Asm Action Check for wear and binds. Check for damage. Check the pick roller for wear. Check the following for wear: · Exit roller · Star rollers 5 End-of-Forms Flag Check for binds or damage.

Diagnostic Information 2-13

4403-001

Power Service Check
FRU 1 External Power Supply Printhead Cable Paper Feed Motor Carrier Transport Motor Operator Panel Action Plug the external power supply into an outlet. Check for + 30 V dc. If voltage is incorrect, replace the power supply. Unplug the printer. Disconnect the printhead cable and plug in the printer. Look for a symptom change. Check the failing part for shorts and replace as necessary. Repeat this procedure for the carrier transport motor, paper feed motor, and operator panel. 3 System Board If the symptom has not changed, replace the system board. Go to the "System Board Removal" on page 4-12.

2

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4403-001

Print Quality Service Check
FRU / Function 1 2 Printhead Cartridge Color Printhead Cartridge Cross Contamination Action Be sure the machine contains good print cartridges. Cross contamination of color inks results in incorrect colors printed, as when green prints for yellow, (when yellow and blue are mixed in the printhead cartridge). This problem resolves quickly as the printhead cartridge is used. If cross contamination occurs, check the following: · The maintenance station wiper for damage. · The printhead nozzle plate was resealed with tape. 3 Printhead Carrier Assembly Reseat the printhead cable in the system board and check the following parts for wear or damage: · Printhead Cartridge Latch · Latch Spring · Carrier 4 System Board Printhead Carrier Assembly Perform the "Test Page" on page 3-1. Look for a break in the diagonal line of the nozzle test pattern. A broken line indicates one or more print nozzles are not working. Run the test again to verify the failure. Check the gold-plated contacts on the end of the printhead carrier cable for dirt, wear and damage. Use only a clean dry cloth to clean the contacts. If the symptom remains, replace the system board. Go to the "System Board Removal" on page 4-12. 5 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station. Go to the "Maintenance Station Removal" on page 4-13, and then return to this check.

Diagnostic Information 2-15

4403-001
FRU / Function 6 Paper Feed Action Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: · Correct type of paper is being used. Also check the paper for curl or wrinkles. · Feed rollers for wear, dirt, or looseness. · Gears for wear or binds. · Paper path for obstructions. 7 Carrier Transport Blurred print and voids can be caused by problems in the carrier transport area. Check the following: · Carrier transport belt for wear. · Carrier guide rod for wear or dirt. If dirty, clean and lubricate. · Carrier to carrier frame engagement should be lubricated with grease P/N 99A0394. · Idler pulley parts for wear, damage, or looseness. 8 Alignment Uneven vertical lines can be adjusted by performing the printhead alignment adjustments. The user is directed, through the Printer Control program, to perform the printhead alignment adjustments, when replacing a printhead cartridge.

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Scan/Copy Quality Service Check
FRU / Function 1 Scanned images are: faded, or colors are dull, blurry or fuzzy. Images are slanted or crooked and the strait lines in the image appear to be jagged or uneven. Blank copies. Action Check the lighter/darker settings to see if it is correct. There are two ways to make the adjustment: · From the operator panel · From the Lexmark Scan and Copy program. Check to see if there is any dust, deris on the glass. This may cause a poor image. Check the press plate on the scan lid for any dust or debris. If blank copies found, make sure that the original document is facing down on the scanner bed. Check the print cartridges to see if they need to be cleaned or replaced. Check the paper type and copy quality settings on the operator panel or Lexmark Scan and Copy Control program.

2

Diagnostic Information 2-17

4403-001

2-18 Service Manual

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3. Diagnostic Aids
Test Page
This test prints the test page. To run a complete test page of black and color patterns, be sure the printhead cartridges are in good condition. To enter the test: 1. Turn the printer on. 2. Open the access cover. 3. Install a known good black print cartridge in the right side of the carrier and a good color print cartridge in the left side. 4. Close the access cover. 5. Install paper in the sheet feeder. 6. Press the Menu button. 7. Press arrow to maintenance. 8. Press Select. 9. Press arrow to self test. 10. Press the Select button and test will run. The printer prints four lines of black and color printhead cartridge nozzle purge patterns followed by a black and color nozzle test pattern. The purge pattern is used to clear all printhead nozzles. The nozzle test pattern prints all nozzles on a diagonal line. There should be no breaks in the nozzle test pattern. A break in the pattern indicates one or more nozzles are not working. If a print quality problem exists, see "Print Quality Service Check" on page 2-15.

Diagnostic Aids 3-1

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3-2 Service Manual

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4. Repair Information
This chapter explains how to make adjustments to the printer and how to remove defective parts. Note: Read the following before handling electronic parts.

Handling ESD-Sensitive Parts
Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing system board:

· · · · · ·

· · ·

Keep the ESD-sensitive part in its original shipping container (a special "ESD bag") until you are ready to install the part into the machine. Make the least-possible movements with your body to prevent an increase of static electricity from clothing fibers, carpets, and furniture. Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges 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 tables are electrical grounds. They increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.) Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table. If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case). Be extra careful in working with ESD-sensitive parts when cold weather heating is used because low humidity increases static electricity.

Repair Information 4-1

4403-001

Adjustments
The user is directed, in the Printer Control program, to perform the printhead alignment adjustments after replacing a print cartridge.

Removal Procedures
The following procedures are arranged according to the name of the printer part discussed. CAUTION: Unplug the power cord before removing any parts.

Releasing Plastic Latches
Many of the parts are held in place with plastic latches. The latches break easily; release them carefully. To remove such parts, press the hook end of the latch away from the part to which it is latched.

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4403-001

Scanner Lid Assembly Removal
1. Open the lid. 2. Lift and remove.

Rear Cover Removal
1. Remove two screws [A] from the rear cover. 2. Depress two latches [B] on the bottom of the rear cover. 3. Lift the rear cover and remove.

Repair Information 4-3

4403-001

Operator Panel Removal
1. 2. 3. 4. 5. Remove the scanner lid. Remove the rear cover. Disconnect the operator panel cable from the system board. Depress two latches on the left side of the operator panel. Lift the operator panel and remove.

Top Housing Assembly Removal
1. 2. 3. 4. 5. 6. 7. Remove the scanner lid. Remove the rear cover. Disconnect the operator panel cable from the system board. Remove the operator panel. Remove two screws from the top housing. Lift the right side of the housing. Remove the top housing assembly.

Paper Support Removal
1. Open the paper support. 2. Depress the paper support at the hinge. 3. Remove the paper support.

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4403-001

CCD Module Assembly Removal
1. 2. 3. 4. 5. 6. 7. Remove the rear cover. Disconnect the CCD cable from the system board. Remove the top housing assembly. Depress the shaft retainer [A]. Lift and remove the shaft. Remove the belt from pulleys. Lift and remove the CCD module.

Repair Information 4-5

4403-001

Gear Train Assembly Removal
1. Remove the CCD module assembly. 2. Disconnect the gear train assembly cable from the system board. 3. Remove two screws [A]. 4. Lift and remove the gear train assembly.

Access Cover Sensor Removal
1. Remove the top housing assembly. 2. Disconnect the access cover sensor cable (J10) from the system board. 3. Remove the sensor screw. 4. Remove the sensor. Note routing of cables.

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Right Cover Removal
1. Remove the rear cover. 2. Depress two latches [A]. 3. Remove the right cover.

Access Cover Removal
1. 2. 3. 4. Remove the rear cover. Remove the right cover. Depress the access cover hinge. Remove the access cover.

Repair Information 4-7

4403-001

Left Cover Removal
1. Remove the rear cover. 2. Depress two latches [A]. 3. Remove the left cover.

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Middle Frame Removal
1. 2. 3. 4. Remove the scanner lid assembly. Remove the rear cover. Remove the top housing assembly. Disconnect the operator panel and CCD cables from the system board. 5. Remove left and right covers. 6. Remove the operator panel assembly. 7. Remove the two screws [A].

Repair Information 4-9

4403-001 8. Depress the two clips [B] and slide the middle frame forward to remove.

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4403-001

Print Engine Removal
1. 2. 3. 4. 5. 6. 7. Remove the rear cover. Remove the top housing assembly. Remove the left cover. Remove the right cover. Remove the middle frame. Move carrier to the center. Remove three screws [B].

8. Slide the print engine forward and remove.

Repair Information 4-11

4403-001

ASF Module Removal
1. Remove the print engine. 2. Remove three screws [A]. 3. Remove the ASF module.

System Board Removal
1. Remove the print engine. 2. Remove the ASF module. 3. Disconnect the transport and paper feed motor cables from the system board. 4. Remove the four screws. 5. Remove the system board. WARNING: When removing the system board, use care not to damage the EOF flag.

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Carrier Removal
Remove the rear cover. Remove the top housing assembly. Remove the left and right covers. Disconnect the carrier cable from the system board. Loosen the set screw on the carrier belt tensioner. Depress the belt tensioner and remove the belt from the transport carrier motor gear. 7. Remove both retainer clips from the carrier shaft. 8. Remove the shaft and carrier. Note: ­ Keep dirt and grease off the encoder strip. ­ Observe orientation of the encoder strip to the sensor, located on the rear of the carrier. ­ Be careful not to damage the encoder strip when reinstalling in the carrier. 1. 2. 3. 4. 5. 6.

Encoder Strip Removal
1. Remove the carrier assembly. 2. Depress the encoder strip clip. 3. Remove the encoder strip.

Maintenance Station Removal
1. Remove the middle frame assembly. 2. Remove the print engine. 3. Depress the two clips [A].

Repair Information 4-13

4403-001 4. Remove the maintenance station.

Belt/Idler Pulley Assembly (Print Engine) Removal
1. 2. 3. 4. 5. 6. Remove the middle frame. Slide the carrier to the left. Loosen the belt tensioner adjuster screw. Depress the belt tensioner and remove the belt from the pulley. Depress the latch. Slide the belt tensioner to the right and remove.

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5. Connector Locations

Units J4 J5 J6 J7 J8 J10 PS1 JP3

Description Printhead Cable Paper Feed Motor Carrier Transport Motor Scanner Motor Operator Panel Cover Sensor End-of-Forms Sensor CCD Module

Connector Locations 5-1

4403-001

5-2 Service Manual

4403-001

6. Preventive Maintenance
This chapter contains the lubrication specifications. Follow these recommendations to prevent problems and maintain optimum performance.

Lubrication Specifications
Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease P/N 99A0394 to lubricate the following:

· · · ·

All gear mounting studs. The left and right ends of the large feed roller at the side frames. The carrier to carrier frame engagement. The carrier guide rod, and carrier guide rod bearings.

WARNING: Keep grease from coming into contact with any electrical components, may cause printer damage or failure. Do not lubricate the scanner rod or bearing after replacing.

Preventive Maintenance 6-1

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6-2 Service Manual

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7. Parts Catalog
How to Use This Parts Catalog

· SIMILAR ASSEMBLIES: If two assemblies contain a majority of
identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. PP: in the parts description column indicates the part is available in the listed parts packet. NA: Not available as a FRU.

· · ·

Parts Catalog 7-1

4403-001

Assembly 1: Covers

7-2 Service Manual

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Assembly 1: Covers
AsmIndex 1­1 ­2 ­3 ­4 ­5 ­6 ­7 NS NS Part Number 12G6141 12G6140 12G6138 12G6135 12G6133 12G6139 12G6134 12G6156 7366857 Units 1 1 1 1 1 1 1 4 1 Description Cover Assembly, Rear Felt Pad Assembly Base Assembly Cover, Right Cover, Access with Latch Paper Exit Tray Cover, Left Screws (Parts Packet) Plain package B/M includes: Carton, Cushion Set, and Sealing Tape

Parts Catalog 7-3

4403-001

Assembly 1 (cont.): Covers

7-4 Service Manual

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Assembly 1 (cont.): Covers
Assembly 1: Covers
AsmIndex 1­1 ­2 ­3 ­4 ­5 Part Number 12G6129 12G6136 12G6126 12G6122 12G6150 Units 1 1 1 1 1 Description Scanner Lid Assembly Paper Support ASF Top Housing Assembly Middle Frame Assembly Belt, Scanner

Parts Catalog 7-5

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Assembly 2: Paper Feed, Frame and Carrier Transport

7-6 Service Manual

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Assembly 2: Paper Feed, Frame and Carrier Transport
AsmIndex 2­1 ­2 ­3 ­4 ­5 ­6 NS Part Number 12G6121 12G6120 12G6151 12G6123 12G6149 12G6154 12G6153 Units 1 1 1 1 1 1 1 Description ASF Module Printing Engine Encoder Strip with Clip Idler Pulley Assembly Belt, Carrier Maintenance Station Assembly EOF Flag with Spring

Parts Catalog 7-7

4403-001

Assembly 3: Electronics

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Assembly 3: Electronics

3­1 NS NS ­2 ­3 NS ­4 ­4 ­5 ­6 NS NS

12G6177 12G6124 12G6176 12G6125 12G6130 12G6131 12G6159 12G6159 12G6137 12G6128 12G6157 12G6158

1 1 1 1 1 1 1 1 1 1 1 1

CCD Module Assembly with Cable CCD Module Assembly Cable, CCD Gear Train Assembly Operator Panel Assembly Operator Panel Overlays Board, System Board, System Model 2 Sensor, Access Cover Power Supply (LV) 100­127 Power Supply (HV) 220­240 Power Supply ­ Japan 100V

Parts Catalog 7-9

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7-10 Service Manual

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Index
A
Abbreviations 1-6 Adjustments 4-2

O
Operator Panel 1-3

B
Black Copy button 1-4 Button Black Copy 1-4 Cancel 1-4 Color Copy 1-4 Lighter/Darker 1-4 Menu 1-4 Number of Copies 1-4 Paper Type 1-4 Power 1-4 Quality 1-4 Reduce/Enlarge 1-4 Scan 1-4 Scan To 1-4 Select 1-4

P
Paper Type button 1-4 Parts Catalog Carrier Transport 7-6 Covers 7-2 Electronics 7-8 Frame 7-6 Paper Feed 7-6 Plastic Latches 4-2 Power button 1-4 Power Consumption 1-1 Power-On Self Test Sequence 2-1 Symptom Table 2-2 Problems Carrier Transport 2-3 Maintenance Station 2-3 Operator Panel 2-3 Paper Feed 2-5 Power 2-5 Print Quality 2-5 Printer Communication 2-4 Scanner 2-4

C
Cancel button 1-4 Color Copy button 1-4 Connector Locations 5-1

E
ESD-Sensitive Parts 4-1

Q
Quality button 1-4

L
Lighter/Darker button 1-4 Lubrication Specifications 6-1

M
Maintenance Approach 1-5 Menu button 1-4

N
Number of Copies button 1-4

Index X-1

4403-001

R
Reduce/Enlarge button 1-4 Removals Access Cover 4-7 Access Cover Sensor 4-6 ASF Module 4-12 Belt/Idler Pulley Assembly 4-14 Carrier 4-13 CCD Module Assembly 4-5 Encoder Strip 4-13 Gear Train Assembly 4-6 Left Cover 4-8 Maintenance Station 4-13 Middle Frame 4-9 Operator Panel 4-4 Paper Support 4-4 Print Engine 4-11 Rear Cover 4-3 Right Cover 4-7 Scanner Lid Assembly 4-3 System Board 4-12 Top Housing Assembly 4-4

T
Table of Contents iii Test Page 3-1

Part Numbers
12G6120 12G6121 12G6122 12G6123 12G6124 12G6125 12G6126 12G6128 12G6129 12G6130 12G6131 12G6133 12G6134 12G6135 12G6136 12G6137 12G6138 12G6139 12G6140 12G6141 12G6149 12G6150 12G6151 12G6153 12G6154 12G6156 12G6157 12G6158 12G6159 12G6176 12G6177 7366857 7-7 7-7 7-5 7-7 7-9 7-9 7-5 7-9 7-5 7-9 7-9 7-3 7-3 7-3 7-5 7-9 7-3 7-3 7-3 7-3 7-7 7-5 7-7 7-7 7-7 7-3 7-9 7-9 7-9 7-9 7-9 7-3

S
Safety Information v Scan button 1-4 Scan To button 1-4 Select button 1-4 Service Checks Carrier Transport 2-6 CCD Module Assembly 2-8 Gear Train Assembly 2-9 Maintenance Station 2-10 Paper Feed 2-11 Paper Path 2-13 Power 2-14 Print Quality 2-15 Scan/Copy Quality 2-17 Specifications Scanner 1-2 Start 2-1 Symptom Table (POST) 2-2 Symptom Tables 2-3

X-2 Service Manual