Lexmark X5100 Series All-In-One 4407 Service Manual
Contents
1. Safety Information The safety of this product is based on testing and approvals of the original design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized 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 S curit La s curit de ce produit repose sur des tests et des agr ations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Safety Information V 4407 XXX Norme di sicurezza Lasicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici Il produttore non responsabile per la sicurezza in caso di sostituzione non autorizzat2. gt Lexmark X5100 Series All In One 4407 XXX Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK 4407 XXX Edition February 2003 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 ServicelnfoAndTraining Lexmark com 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
3. 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 2003 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense U S A P N 12G9219 Japanese P N 12G9220 4407 XXX Table of Contents Safety Information V Pref CO uiseku auus ERG aua bed een deena danses x General Information 1 1 Power GoBSumplioti as ss as ce we DF Pra E We hansrvesets 1 1 Scanner Specificato sssusa ess sme dade aawndeeeeana od 1 2 parar Panel seas ipu echa ein 1 3 Maintenance APOMOACh ssssusesesere zkeseeu red REX Rar wane 1 5 Abbrevialans ss 1 6 Diagnostic Information 2 1 PLA asda bi Pad Ti a Di DD 2 1 Power On Self Test POST Sequence 2 1 POST Syriptom Table cascas din dicas gas da de 2 2 Symptom Tables assume pa kx Ex Rink xx ORAE RR Re n cien 2 3 SANV CHECKS urn 2 6 Carrier Transport Service Check au aaa 2 6 CCD Module Assembly Service Check 2 8 Maintenance Station Service Check 2 9 Paper Feed Service Check isasazouececzecearecea da 2 10 Paper Path Service Ch
4. Press the Options button and go to the cartridge menu Press arrow to self test Press the Select button and the test runs es ONO BR 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 13 Diagnostic Aids 3 1 4407 XXX 3 2 Service Manual 4407 XXX 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 E
5. da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informac es de Seguranca A seguran a deste produto baseia se em testes e aprovac es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunranga no caso de uso de pecas de substitui o nao autorizadas As informac es de seguran a relativas a este produto destinam se a profissionais destes servicos e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servicos devem estar avisados deste facto e tomar os cuidados necess rios Safety Information vii 4407 XXX Informaci de Seguretat La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les q estions de Seguretat si s utilitzen peces de recanvi no autoritzades Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui Elrisc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients a orl A o EANES
6. pins on the motor Pin 1 to Pin 2 Pin 3 to Pin 4 If the readings are incorrect replace the print engine Go to the Print Engine on page 4 9 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 on page 4 15 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 Check the pick roller for wear 4 End of Forms Flag and Spring Check for binds or damage Diagnostic Information 2 11 4407 XXX 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 Action 1 Large and Small Feed Rollers Check for wear and binds 2 Small Feed Roller Springs 3 Auto Sheet Feeder Assembly Check for damage Check the pick roller for wear 4 Mid Frame Asm Check the following for wear Exit roller Star rollers 5 End of Forms Flag Check for binds or damage Power Service Check FRU Action 1 External Power Supply Plug the external power supply into a
7. tension spring to take up any slack in the belt Tighten the screw If the pulley mounting bracket has reached the stop replace the carrier assembly Go to the Carrier Assembly on page 4 10 Lubricate carrier to carrier frame engagement with grease P N 99A0394 Maintenance Station Scanner Assembly Sensor A problem with the maintenance station can cause carrier movement problems at the right margin Go to the Maintenance Station on page 4 12 If the carrier does not move toward the cartridge load position when the scanner assembly is opened verify that power is on Check connector JP12 for approximately 28 volts on pins 1 and 2 If the voltage is correct replace the system board If voltage is incorrect replace the printing engine Go to the System Board on page 4 15 Diagnostic Information 2 7 4407 XXX CCD Module Assembly Service Check The CCD charge coupled device Module does not move during POST Test The CCD lamp does not come on The CCD LCD displays Unlock Scanner Clear Paper Jam FRU Action 1 CCD Module Assembly If lamp does not come on as CCD module assembly is scanning or moving check connector JP4 on the system board If connected and the lamp still does not work replace the scanner module assembly If the problem still persists replace the system board Go to System Board on page 4 15 for more information To unlock scanne
8. 2 Remove scanner module assembly 3 Remove mid frame cover 4 Remove the print engine Repair Information 4 13 4407 XXX 5 Remove four screws A 4 14 Service Manual 4407 XXX 7 Depress tension spring C 8 Lift up and remove ASF module System Board Remove scanner lid assembly Remove scanner module assembly Remove mid frame cover Remove the print engine Remove the ASF module Disconnect all cables from the system board on Bun Repair Information 4 15 4407 XXX 7 Remove three screws A A 8 Remove the system board 4 16 Service Manual 4407 XXX 5 Connector Locations Units Description JP3 Scanner Motor JP4 CCD Scanner JP6 Operator Panel JP7 Carrier JP8 Carrier JP10 Paper Feed Motor JP11 Media Sensor JP12 Carrier Transport Motor JP13 USB JP14 Power Supply Terminals PS1 EOF Sensor PS2 Scanner Housing Sensor Connector Locations 5 1 4407 XXX 5 2 Service Manual 4407 XXX 6 Preventive Maintenance This chapter contains the lubrication specifications Follow these recommendations to prevent problems and maintain optimum performance Lubrication Specifications Lubricat
9. 3 Operator Panel 2 3 Paper Feed 2 5 Power 2 5 Print Quality 2 5 Printer Communication 2 4 Scanner 2 4 Q Quality button 1 4 R Reduce Enlarge button 1 4 Removals ASF Module 4 13 Carrier Assembly 4 10 Maintenance Station 4 12 Mid Frame Cover 4 6 Print Engine 4 9 Rear Cover 4 8 Scanner Lid Assembly 4 3 Scanner Module Assembly 4 3 Scanner Support 4 6 System Board 4 15 Index X 1 4407 XXX 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 Maintenance Station 2 9 Paper Feed 2 10 Paper Path 2 12 Power 2 12 Print Quality 2 13 Scan Copy Quality 2 15 Specifications Scanner 1 2 Start 2 1 Symptom Table POST 2 2 Symptom Tables 2 3 T Table of Contents iii TestPage 3 1 Part Numbers 13D0303 7 5 13D0400 7 5 13D0401 7 5 13D0402 7 5 56P1480 7 5 56P1481 7 5 56P1482 7 5 56P1483 7 3 56P1484 7 3 56P1485 7 3 56P1486 7 3 56P1487 7 3 56P1488 7 5 56P1489 7 5 56P1490 7 5 56P1491 7 3 7370714 7 3 X 2 Service Manual
10. A S EST Wa HSE Az ta sol Sa AUT Le To Wal TES soc SPAS AE alou CFM CHet HAS XX RSU i El ce E 480 88 RA sia Sur ME Mala EX 202 AME 40 28 H MEME ASE gar E NES HAS ule ziv A73 848 BALE AAS ele Silo ARH ME duia JIER o AIS SASH He ft d AXIS HG ES SAIS viil Service Manual 4407 XXX ZERM o AT da B9 AE TP OR AUX GE eb AR FA DLE JB MAN RERE RP AE AEN MR BSE MAR SANGRE SHE SIRs A BAL RE s AL BT NES HE AR BUD BE ES T5 DE TA ie ASM Re We a RA HRK MARSH TESRANE For Safety Information ix 4407 XXX Preface This manual 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 Diagnostic Information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUS Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the connector locations and test points on the printer Preventive Maintenance contains the lubricatio
11. SD 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 4407 XXX 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 po
12. Service Check on page 2 15 2 4 Service Manual 4407 XXX Paper Feed Problems Symptom Action Fails to pick paper Go to the Paper Feed Service Picks more than one sheet of Check on page 2 10 paper Picks paper but fails to feed Paper jams Paper fails to exit Noisy paper feed Envelopes fail to feed Go to the Paper Feed Service Check on page 2 10 Paper skews Go to the Paper Path Service Check on page 2 12 Power Problems Symptom Action No power in machine motors do Go to the Power Service Check not operate on page 2 12 Print Quality Problems Symptom Action Voids in characters Go to the Print Quality Service Light print Check on page 2 13 Prints off the page Fuzzy print Carrier moves but no print Printhead dries prematurely Colors print incorrectly Vertical alignment off Ink smearing Go to the Paper Feed Service Vertical streaks on paper Check on page 2 10 Print lines crowded Diagnostic Information 2 5 4407 XXX Service Checks Carrier Transport Service Check FRU Action 1 System Board Carrier Transport Motor Check the carrier transport motor connector JP12 If connected check for approximately 30 volts on pins 1 and 2 or at the wire connections located on the rear of the carrier transport motor If voltage is incorrect replace the system board If v
13. Set and Sealing Tape Parts Catalog 7 3 4407 XXX Assembly 2 Print Engine and Carrier Transport 7 4 Service Manual 4407 XXX Assembly 2 Print Engine and Carrier Transport E MES Units Description 2 1 56P1481 1 ASF Module 2 56P1489 1 Board System 3 56P1480 1 Print Engine 4 56P1488 1 Encoder Strip 5 56P1482 1 Carrier w Cable Assembly 6 56P1490 1 Maintenance Station Assembly 7 13D0400 1 Power Supply LV 100 127V NS 13D0401 1 Power Supply HV 220 240V NS 13D0402 1 Power Supply Japan 100V NS 13D0303 1 Power Supply Brazil 110 127V Parts Catalog 7 5 4407 XXX 7 6 Service Manual 4407 XXX Index A Abbreviations 1 6 Adjustments 4 2 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 C Cancel button 1 4 Color Copy button 1 4 Connector Locations 5 1 E ESD Sensitive Parts 4 1 L Lighter Darker button 1 4 Lubrication Specifications 6 1 Maintenance Approach 1 5 Menu button 1 4 N Number of Copies button 1 4 O Operator Panel 1 3 P Paper Type button 1 4 Parts Catalog Carrier Transport 7 4 Covers 7 2 Print Engine 7 4 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
14. a delle parti e 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 pi elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen vi Service Manual 4407 XXX Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del disefio original y componentes espec ficos EI fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas Lainformaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de
15. e 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 4407 XXX 6 2 Service Manual 4407 XXX 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 Parts Catalog 7 1 4407 XXX Assembly 1 Covers 7 2 Service Manual 4407 XXX Assembly 1 Covers Asm Part Index Number Units Description 1 1 56P1485 1 Scanner Lid Assembly 2 56P1483 1 Scanning Module Assembly 2 56P1484 1 Scanning Module Assembly Japan 3 56P1486 1 Cable Cover 4 56P1487 1 Scanner Support NS 56P1491 1 Operator Panel Overlays NS 7370714 1 Plain Package B M includes Carton Cushion
16. eck ss aus xa Rank e mx CR a 2 12 Power Service Check da same cease E A RR RR RR e ada 2 13 Print Quality Service Check iassuooe xaxa n RR xx xm ss 2 14 Scan Copy Quality Service Check 2 16 Diagnostie AIS 6 6555 65 6005 en a E ss tees 3 1 Test P ge scies ima masses asas ad sean sax ds 3 1 Repair Information 2222 usan hah haha 4 1 Handling ESD Sensilive Pans s s rk ne sre 4 1 AG JOBS yasni 4 2 Removal PRECES usse ses hmi pass pads LES RR EAE 4 2 Releasing Plastic Laiches cases ren 4 2 Scanner Lid Assembly esses o RR aaa deus 4 3 Scanner Module Assembly 4 3 Scanner SURPON sek Gora Sax ee 4 6 Mid Frame GOVEl uus nx eee aa a cage atom a aie mega OR RC Ri a 4 6 Rear COVEN an 4 8 PU BID ss x ces dar POS wan E Sues xw RSEN OU EE uS SM RES 4 9 parer ASSeImblyu sees xeu Dr pipi erc acsip dur e ip 4 10 4407 XXX Maintenance SIMON sa dieu acid stum dieses uere i v 4 12 ASP MOU aaa rin 4 13 System Board s ses isassantissesnsasemshe drag es EE x 4 15 Connector Locations 2x s Rat Rx xn EE RR X KON RR 5 1 Preventive Maintenance 6 1 Lubricatiori SDectieallolis s uu viu ea 6 1 Parts Catalog a 22 00 a aE ROGROE AGE RENE RAE E 7 1 Assembly 1 COVES acer sa ed se ex mE SERE ME SE was 7 2 Assembly 2 Print Engine and Carrier Transport 7 4 INAEX xax ERO Ex Ra kx KE xa cR TER RASE RO ENS X 1 iV Service Manual 4407 XXX
17. elow is displayed on the LCD THp y 100 Normal Quality 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 4407 XXX POST Symptom Table Symptom Action No power light No motors run Paper feed gears do not turn Go to the Power Service Check on page 2 12 If okay go to the Operator Panel Problems on page 2 3 Go to the Paper Feed Service Check on page 2 10 Carrier does not move Go to the Carrier Transport Service Check on page 2 6 Carrier slams side frame Go to the Carrier Transport Service Check on page 2 6 CCD lamp does Go to the CCD Module Assembly Service Check on not turn on page 2 8 LCD displays Go to the CCD Module Assembly Service Check on Unlock Scanner page 2 8 Clear Paper Jam 2 2 Service Manual 4407 XXX Symptom Tables Locate the symptom in the following tables and take the appropriate action Carrier Transport Problems Symptom Action No carrier movement Go to the Carrier Transport Slow carrier movement Service Check on page 2 6 Carrier stops Carrier slams side frame Maintenance Station Problems Symptom Action Maintenance station G
18. 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 on page 4 15 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station Go to the Maintenance Station on page 4 12 and then return to this check Diagnostic Information 2 13 4407 XXX FRU Function Action 6 Paper Feed 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 Encoder strip for dirt or grease 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 replac
19. ews A frm Es 4 8 Service Manual 4407 XXX 5 Lift the left side and then the right side 6 Remove the rear cover Print Engine 1 2 3 4 Remove scanner lid assembly Remove scanner module assembly Remove mid frame cover Remove two screws A Repair Information 4 9 4407 XXX 5 Disconnect the power supply connector B 6 Slide print engine forward lift and remove Carrier Assembly Remove scanner lid assembly Remove scanner module assembly Remove mid frame cover Remove the print engine 8 D 4 10 Service Manual 4407 XXX 5 Loosen the belt tensioner screw A lad 6 Depress the belt tensioner B 7 Remove belt from carrier motor gear C 8 Remove clips D from left and right side D C B D 9 Disconnect carrier cable from system board Repair Information 4 11 4407 XXX 10 Remove carrier shaft 11 Depress clip E and disconnect encoder strip Note routing of encoder strip and belt E 12 Disconnect the carrier cables Note the routing of the carrier cables 13 Lift and remove carrier Maintenance Station Remove scanner lid assembly Remove scanner module assembly Remove mid frame cover Remove the print engine Rogo mw oz 4 12 Service Manual 4407 XXX 5 Depress clips A on the rear of the maintenance station 6 Pull maintenance station forward and remove ASF Module 1 Remove scanner lid assembly
20. gnostic Information 2 9 4407 XXX 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 Action 1 System Board 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 JP10 and check for approximately 5 ohms between the following pins Pin 1 to Pin 2 Pin 3 to Pin 4 If the reading is incorrect replace the print engine Go to the Print Engine on page 4 9 If the reading is correct check for approximately 28 volts on pin 1 If voltage is incorrect replace the system board Go to the System Board on page 4 15 2 10 Service Manual 4407 XXX FRU Action 2 Paper Feed Motor 3 Auto Sheet Feeder Assembly 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 JP10 disconnected from the system board check for approximately 5 ohms between the following
21. illion 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 One Pass Scanning Scan Area 8 5 X 11 7 inches 216 X 292 mm Scan Resolution Optical 600 dpi H X 2400 dpi V Interpolated 19 200 X 19 200 1 2 Service Manual 4407 XXX Operator Panel Options Photos O Photo Stop o Power Number of Copies Reduce Enlarge Copy Quantity Black Copy Photo Copy Start Scan Start Fax 0006000 General Information 1 3 4407 XXX Press this button When you want to Number of Select the number of copies Copies Lighter Darker Make the document lighter or darker than the original Reduce Enlarge Make the document smaller or larger than the original Paper Type Select glossy photo transparency or plain paper type or Scroll through menu sub categories Menu Change settings using the menus Select Choose the displayed selection Quality Choose photo quick or normal copy setting Color Copy Make a color copy Black Copy Make a black and white copy Scan To Select a scan destination such as To copy To an e mail To an application To a file or To fax Scan Press the scan button after selecting a Scan To destination Cancel Cancel a scan print o
22. ing a printhead cartridge 2 14 Service Manual 4407 XXX Scan Copy Quality Service Check FRU Function Action 1 Scanned images Check the lighter darker settings to see if it is are faded or correct There are two ways to make the colors are dull adjustment blurry or fuzzy Images are From the operator panel slanted or From the Lexmark Scan and Copy program crooked and the strait lines in the Check to see if there is any dust or debris on the image appear to glass This may cause a poor image be jagged or uneven Check the press plate on the scan lid for any dust or debris 2 Blank copies 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 Diagnostic Information 2 15 4407 XXX 2 16 Service Manual 4407 XXX 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 Lift the scanner assembly Install a known good black print cartridge in the left carrier and a good color print cartridge in the right Close the access cover Install paper in the sheet feeder
23. n outlet Check for 30 V dc If voltage is incorrect replace the power supply 2 Printhead Cable Paper Feed Motor Carrier Transport Motor Operator Panel System Board Unplug the printer Check all connections for correct seating If the symptom has not changed replace the system board Go to the System Board on page 4 15 2 12 Service Manual 4407 XXX Print Quality Service Check FRU Function Action Printhead Cartridge Color Printhead Cartridge Cross Contamination Printhead Carrier Assembly 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 Reseat the printhead cable in the system board and check the following parts for wear or damage Printhead Cartridge Latch Latch Spring Carrier 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
24. n specifications and recommendations to prevent problems Parts Catalog contains illustrations and part numbers for individual FRUs X Service Manual 4407 XXX 1 General Information The Lexmark X5150 4407 XXX machine features 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 single unit 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 640 nozzles and installs on the right The color cartridge has a total of 480 nozzles and installs on the left The printer is capable of printing in two directions from either cartridge Power Consumption 0 6 Watts Power Off 9 Watts Idle Mode power on not printing 23 Watts Printing average e 21 Watts Continuous Copying average 18 Watts Continuous Scanning average General Information 1 1 4407 XXX Scanner Specifications Scanner Type Flatbed CCD Scan Modes True Color 48 Bit Internal 68 7 B
25. o to the Maintenance Station Service Check on page 2 9 Fails to cap the printheads Fails to clean the printheads Operator Panel Problems Symptom Action Buttons do not work Check operator panel cable LCD does not display connection at JP6 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 JP6 If the problem remains replace the scanner module assembly Go to the Scanner Module Assembly on page 4 3 If the problem still exists replace the system board Go to the System Board on page 4 15 Diagnostic Information 2 3 4407 XXX Printer Communication Table Symptom Action Not able to print Test Page Check the USB cable and system board cable connections If okay replace system board Go to the System Board on page 4 15 Scanner Problems Symptom Action CCD does not move Lamp does not light Go to the CCD Module Assembly Service Check on page 2 8 The operator panel displays Unlock Scanner Clear Paper Jam 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 Press the Power button Turn off the printer Press the red lever to unlock scanner and try again Go to the Scan Copy Quality
26. oltage is correct check the motor for shorts 2 Carrier Transport Motor 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 An open or short in the motor An open or short in the motor driver on the system board e A bind in the carrier transport mechanism With the carrier transport motor cable JP12 disconnected from the system board check for 0 to 10 ohms between the following pins on the motor JP12 1 and JP12 2 If the readings are incorrect replace the print engine Go to the Print Engine on page 4 9 3 Carrier Guide Rod Clean the carrier rod Note Lubricate the rod and the carrier rod bearing surfaces with grease P N 99A0394 2 6 Service Manual 4407 XXX FRU Action Encoder Strip Carrier Assembly Check the encoder strip for proper installation Also check it for wear dirt and grease Be sure all printhead connectors and carrier cables 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 system board Go to the System Board on page 4 15 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
27. r press the red lever Note Unlock scanner before use 2 8 Service Manual 4407 XXX 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 Action 1 Maintenance Station Assembly As the carrier moves to the left 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 right 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 atab 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 on page 4 12 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 Dia
28. r copy job or return to a menu category from a menu sub category Power Turn the printer on or off 1 4 Service Manual 4407 XXX 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 4407 XXX Abbreviations B M Bill of Material CCD Charge Coupled Device EOF End of Form ESD Electrostatic Discharge FPC Flat Printhead Cable FRU Field Replaceable Unit HVPS High Voltage Power Supply LCD Liquid Crystal Display LVPS Low Voltage Power Supply OEM Original Equipment Manufacturer V ac Volts alternating current V dc Volts direct current ZIF Zero Insertion Force 1 6 Service Manual 4407 XXX 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 The Power indicator light turns on The Charge Coupled Device CCD lamp turns on and the scanner moves to the left then returns to the right The paper feed motor runs then stops The carrier moves to the right then returns to the left stopping at the maintenance station Power light stays on The message b
29. wer 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 Never apply excessive force when releasing the hook 4 2 Service Manual 4407 XXX Scanner Lid Assembly 1 Open the lid 2 Lift and remove Scanner Module Assembly 1 Lift and open scanner module 2 Depress guide on one side and loosen and then depress guide on the other side Repair Information 4 3 4407 XXX 3 Remove cable cover 4 Disconnect cables ARERR EE 4 4 Service Manual 4407 XXX 5 Lift and remove scanner module Repair Information 4 5 4407 XXX Scanner Support 1 Lift the scanner module assembly 2 Insert screwdriver and depress tab A on either side 3 Remove scanner support Mid Frame Cover 1 Remove scanner lid assembly 2 Remove scanner module assembly 4 6 Service Manual 4407 XXX 3 Remove two screws A from the top of the mid frame dm A 4 Remove two screws B from the rear 5 Lift left rear mid frame Repair Information 4 7 4407 XXX 6 Depress tabs on front of mid frame C 7 Lift the front left tab 8 Remove the mid frame cover Rear Cover Remove scanner lid assembly Remove scanner module assembly Remove mid frame cover Remove two scr
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