Lexmark 4097-00X Printer User Manual
Contents
1. 2 7 Paper Feed Service Check assaz dam a de dada 2 8 Paper Path Service Check u ans dann 2 10 Power Semice Check ess ruines ea 211 Print Quality Service 2 12 Diagnostic Aids een 3 1 Test Page Eu us a Taha dee bm ni 3 1 Repair Information Loco co com ask 4 1 Handling ESB Sensilivo Parts an an SSD 4 1 AUUSIMENIE spp ui oran 4 2 Removal Procedures usa 4 2 Releasing Plastic Latches 4 2 Connector Locations oo oo o o mw ooo oooooWooooowooo oo 5 1 Preventive Maintenance 6 1 Lubrication Specifications amam m sinia Rosa aa 6 1 Parts Catalog mo oo oo mo oo inian a 7 1 Niet a 1 1 4097 00X Preface This manual 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 illustra2. 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 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 bidirectional alignment The user is directed through the Printer Control program to perform the bidirectional printing alignment when replacing a print cartridge 9 Mid Frame Banding or uneven print on photo quality images Brackets Be sure the printer contains the mid frame brackets If not order a new mid frame and install the mid frame brackets which are included in the FRU Diagnostic Information 2 13 4097 00X 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 print cartridges are in good condition Install a black print cartridge
3. Service Manual Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries 4097 00X First Edition June 1998 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 D22 035 3 740 New Circle Road N W Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you 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 and Lexmark with diamond design are trademarks of Le
4. Voltage Power Supply OEM Original Equipment Manufacturer Vac Volts alternating current Vdc Volts direct current ZIF Zero Insertion Force 1 2 Service Manual 4097 00X 2 Diagnostic Information Start Use the indicator light table the symptom tables service checks and diagnostic aids in chapter 3 to determine the printer failure Indicator Light Table Indicator Light Indicates Power light on Machine is on flashes on and off Power light on and busy light Paper out flashes two times Power light on and busy light Paper jam Power light and busy light flash Go to the Carrier Transport Service Check on page 2 5 Both lights on at the same time Printer is busy or printing Diagnostic Information 2 1 4097 00X Power On Self Test POST Sequence Turn the printer on and check for a correct POST operation by observing the following 1 The power light comes on 2 The carrier moves over the maintenance station two times and seals the printheads 3 The paper feed gears turn 4 All motors stop and the power light stays on 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 POST Symptom Table Symptom Action No power light and no motors
5. ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires viii Service Manual 4097 00X Norme di sicurezza e Il prodotto stato progettato testato approvato in conformit a severi standard di sicurezza per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark responsabile per l utilizzo di parti di ricambio di altri produttori e Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato e 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 e Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen 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 f r dieses Produkt bernommen e Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt e W
6. pessoas Risco de choques el ctricos e ferimentos graves durante desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios X Service Manual 4097 00X Informaci de Seguretat e Aquest producte est dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi e La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e El risc 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 Safety Information Xi 4097 00X ro Ha a At og AZA tet RA ASME AE AHA ler SSH Hl MEE ASS Maut BASS SASHA So AS AH SAS HHG SAE OS 40 HELICH AS HA ASAE 0 AWS Beer Et AXE Sale APRE PAGUE LHES ARE MEHN REEK KP LCR ECN MARANA CMS UGA PIME HRM BY TR DE TA ie ASW RSE DI RE a BE RA d HRK MARSH TESRANE I xii Service Manual 4097 00X 1 General Information The Lexmark 3200 Color J
7. run Paper feed gears do not turn Go to the Power Service Check on page 2 11 Go to the Paper Feed Service Check on page 2 8 Carrier does not move Go to the Carrier Transport Service Check on page 2 5 Carrier slams side frame Go to the Carrier Transport Service Check on page 2 5 No busy light Replace the operator panel or the system board 2 2 Service Manual 4097 00X Symptom Tables Locate the symptom in the following tables and take the appropriate action Carrier Transport Problems Symptom Action No carrier movement e Slow carrier movement e Carrier stops Carrier slams side frame Go to the Carrier Transport Service Check on page 2 5 Maintenance Station Problems Symptom Action Maintenance station Fails to cap the printheads Fails to clean the printheads Operator Panel Problems Go to the Maintenance Station Service Check on page 2 7 Symptom Action Paper feed or power buttons do not operate Busy or paper feed lights do not come on Replace the operator panel or the system board Diagnostic Information 2 3 4097 00X Paper Feed Problems Symptom Action 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 Go to the Paper Feed S
8. R ASSEMBLIES If two assemblies contain a majority of identical parts they are broken down 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 e NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration e PP in the parts descriptions column indicates the part is available in the listed parts packet Parts Catalog 7 1 4097 00X Assembly 1 Covers 7 2 Service Manual 4097 00X Rs LA Units Description 1 1 17D0561 1 Cover Rear Asm 001 1 17D0562 1 Cover Rear Asm 002 2 17D0590 2 Screws PP 3 17D0550 1 Base Asm 001 3 17D0551 1 Base Asm 002 4 17D0560 1 Buttons and Lens Asm Operator Panel 5 17D0554 1 Cover Access 001 5 17D0555 1 Cover Access 002 6 17D0552 1 Cover Front 001 6 17D0553 1 Cover Front 002 7 17D0557 1 Tray Exit Asm 001 7 17D0558 1 Tray Exit Asm 002 8 17D0590 4 Feet Machine PP NS 7350160 1 Package Plain B M Includes Carton Cushion Set Sealing Tape Parts Catalog 7 3 4097 00X Assembly 2 Paper Feed Carrier Transport 7 4 Service Manual 4097 00X eae u Units Description 2 1 17D0566 1 Roller Small Feed Asm 2 17D0589 1 Lever EOF Asm 3 17D0565 1 Roller Large Feed with Gear Asm 4 17D0564 1 Roller Star Asm Mid Frame with Brackeis 5 17D0569 1 Roller Exit Asm wi
9. and binds 2 Small Feed Roller Springs Check for damage 3 Auto Sheet Feeder Check the pick rollers for wear 4 Mid Frame Asm Check the following for wear e Exit roller Star rollers 5 End of Forms Flag Check for binds or damage 2 10 Service Manual 4097 00X Power Service Check FRU Action External Power Supply Plug the external power supply into an outlet Check for 30 V de If you do not have correct voltage replace the external power supply Power Connector Disconnect the external power supply and disconnect the J5 power connector from the system board If continuity is incorrect replace the power connector Printhead Cable Carrier Home Sensor Parallel Cable Paper Feed Motor Carrier Transport Motor Operator Panel Unplug the printer Disconnect one of the printhead cables 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 home sensor parallel cable carrier transport motor paper feed motor and operator panel System Board If the symptom has not changed replace the system board Diagnostic Information 2 11 4097 00X Print Quality Service Check FRU Function Action 1 Print Cartridge Be sure the machine contains good print cartridges 2 Color Print Cartridge Cross Contaminat
10. aused by 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 disconnected from the system board check for zero to ten 0 10 ohms between the following pins on the motor J4 1 and J4 2 J4 3 and J4 4 If the readings are incorrect replace the motor 3 Carrier Guide Rod Clean the carrier rod Note Lubricate the rod and the carrier rod bearing surfaces with grease P N 99A0394 4 Carrier Transport Check for worn loose or broken parts Check for Belt obstructions blocking carrier movement Idler Pulley Parts Carrier Frame Carrier to carrier frame engagement should be lubricated with grease P N 99A0394 Diagnostic Information 2 5 4097 00X FRU Action 5 Printhead Cable Home Sensor Disconnect the printer and check the carrier printhead connector J1 If the connection is good remove the printhead carrier and rod without disconnecting the printhead cables Insert a piece of paper into the sensor Plug in the printer and check for 5 V dc at connection C located on the rear of the sensor The voitage drops when paper is removed If voltage does not change when paper is removed replace the home position sensor If the problem remains replace the system board 6 Maintenance Station A problem with the maintenance station can cause carrier moveme
11. e 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 4097 00X Adjustments The user is directed in the Printer Control program to perform the bidirectional alignment adjustments after replacing a pri
12. e system board check for approximately 10 ohms between the following pins on the motor Pin1toPin2 Pin3toPin4 If the readings are incorrect replace the motor 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 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 loose or worn motor gear 3 Drive Train Check for binds in the gear train and paper feed Assembly mechanism by removing the paper feed motor and rotating the large gear by hand If you notice a bind replace the drive train assembly Check the feed clutch inside the large feed gear 4 Auto Sheet Check the pick rollers for wear Feeder 5 Mid Frame Asm Check the following for wear Exit roller Star rollers 6 End of Forms Check for binds or damage If binds are found Flag and Spring replace the small feed roll bracket assembly Diagnostic Information 2 9 4097 00X Paper Path Service Check Examine the machine for the following before you begin this service check e Check the entire paper path for obstructions e Be sure the correct type of paper is being used e Be sure the printer is installed on a flat surface FRU Action 1 Large and Small Feed Rollers Check for wear
13. e the star roller assembly Do not reinstall the old star roller assembly Operator Panel Assembly Removal 1 2 3 4 5 Remove the front cover Remove the carrier frame Disconnect the operator panel cable from the system board Note the routing of the cable Remove the operator panel screw from the carrier frame Remove the operator panel Paper Feed Motor Removal D Remove the front cover Remove the carrier frame Disconnect the paper feed motor from the system board Remove the two screws mounting the paper feed motor to the gear plate assembly and remove the motor Note the routing of all cables Paper Guide Removal Slide the paper guide to the center of the printer lift up and remove 4 6 Service Manual 4097 00X Power Connector Removal 1 2 4 Remove the front cover Remove the carrier frame Disconnect the power connector from the system board Note the routing of all cables Remove the screw from the power connector and remove the power connector Printhead Carrier Cable Rod Removal ABON Remove the front cover Remove the carrier frame Disconnect the printhead carrier cables from the system board Remove the shaft retainers from the ends of the carrier rod Lift up on the right side of the carrier rod and slide it out the right side of the machine Note The carrier is attached to the carrier belt between two raised tabs on the belt Be su
14. er frame and remove the small feed roller assemblies Slide the EOF flag to the right and remove Note the positioning of the tension spring System Board Removal a A Remove the front cover Remove the carrier frame Disconnect all connectors from the system board Remove the four system board screws from the system board Note when removing the system board be careful not to damage the end of form EOF flag Remove the system board 4 8 Service Manual 4097 00X 5 Connector Locations J1 Printhead Cable 1 J2 Printhead Cable 2 J3 Paper Feed Motor J4 Carrier Transport Motor J5 Power Connector J6 Parallel Port J7 Operator Panel S1 EOF Sensor 52 Access Door Sensor Connector Locations 5 1 4097 00X 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 replaced or as needed not on scheduled basis Use grease P N 99A0394 to lubricate the following e All gear mounting studs e The left and right ends of the large feed roller at the side frames The carrier to carrier frame engagement e The carrier guide rod and carrier guide rod bearings Preventive Maintenance 6 1 4097 00X 7 Paris Catalog How to Use This Parts Catalog e SIMILA
15. ervice Check on page 2 8 Envelopes fail to feed Go to the Paper Feed Service Check on page 2 8 Paper skews Go to the Paper Path Service Check on page 2 10 Power Problems Symptom Action No power in machine motors do not operate Go to the Power Service Check on page 2 11 Print Quality Problems Symptom Action Voids in characters Light print Prints off the page Fuzzy print Carrier moves but no print Printhead drys prematurely Colors print incorrectly Vertical alignment off Go to the Print Quality Service Check on page 2 12 Ink smearing Vertical streaks on paper Print lines crowded Go to the Paper Feed Service Check on page 2 8 2 4 Service Manual 4097 00X Service Checks Carrier Transport Service Check FRU Action 1 System Board Unplug the printer and disconnect the carrier transport motor connector J4 from the system board Plug in the printer and check for approximately 12 V dc between J4 1 and ground If the voltage is incorrect replace the system board If the voltage is correct check for carrier transport motor pins shorted to the housing If a short is detected replace the carrier transport motor 2 Carrier Transport Check the motor for binds or loose motor pulley Motor A noisy or chattering motor or a motor that fails to turn can be c
16. etprinter is a personal near laser quality inkjet printer The printer contains single unit customer replaceable supply items Dual printheads provide color and true black printing without changing printheads 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 e lt 8 Watts power off and power to the printer e 8 Watts Idle Mode power on not printing 15 Watts Printing average e 25 Watts Printing peak Operator Panel Buttons Lights Left Button Power On Off Left Light Steady Power On Flashing Printer Error Right Button Paper Feed clears a paper jam or loads paper when there is a paper out condition Right Light Steady Busy Flashing Paper Out Jam General Information 1 1 4097 00X 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 Begin with Indicator Light Table on page 2 1 After you complete the repair perform tests as needed to verify the repair Abbreviations ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LVPS Low
17. he front cover Remove the carrier frame Disconnect the carrier transport motor connector from the system board Remove the belt from the carrier transport motor pulley Unlatch the right side of the sheet feeder and unhook the carrier transport motor cable Remove the two screws securing the carrier transport motor to the carrier frame and remove the motor Note the routing of the motor cable Exit Roller Assembly Removal E 2 3 Remove the front cover Unlatch and remove the exit roller bushing from the left side of the gear plate Note of the position of the spring located on the end of the exit roller shaft Remove the spring and lift the exit roller out of the machine Front Cover Removal 1 2 3 Remove the two cover mounting screws from the upper rear corners of the of the rear cover When reassembling do not overtighten these screws as they will damage the plastic threads Lift up on the two cover latches located on each side of the base cover Pull the front cover forward and remove Gear Plate Assembly Station Removal WN Remove the front cover Remove the carrier frame Remove the large feed roller Disconnect the paper feed motor and the power connector from the system board Note the routing of all cables Remove the two gear plate assembly screws from the carrier frame and remove the gear plate 4 4 Service Manual 4097 00X Gutter Pad Maintenance S
18. 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 Safety Information ix 4097 00X Pautas de Seguridad Este producto se ha disefiado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio e La informaci n sobre el mantenimiento de este producto esta dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la maquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem n o ser sempre bvias A Lexmark n o respons vel pela utiliza o de outros componentes de substitui o e As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras
19. in the right side of the printhead cradle and a color printhead cartridge in the left side To enter the test 1 Turn the printer on 2 Be sure there is paper in the sheet feeder 3 Press the power and paper feed buttons at the same time and hold for approximately five seconds until the test starts The test will run until the power button is depressed The first three lines are color print cartridge nozzle purge patterns The next line is a black print cartridge nozzle purge pattern These test patterns are used to verify all print cartridge nozzles are working properly There should be no breaks in the test patterns 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 12 Diagnostic Aids 3 1 4097 00X 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 paris 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 logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machin
20. ion Cross contamination of color inks results in incorrect colors printed as when green prints for yellow when yellow and blue are mixed in the print cartridge This problem resolves quickly as the print 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 4 System Board Printhead Cable Rubber Backer Reseat the printhead cables in the system board and check the following parts for wear or damage Print Cartridge Latch Latch Spring Carrier Run the Test Page on page 3 1 A void in the print indicates one or more print nozzles are not working Run the test again to verify the failure Be sure the printhead cables are connected properly Remove the print cartridges and 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 A worn rubber backer results in poor contact between the printhead carrier cable and the print cartridge Check the rubber backer for wear If the symptom remains replace the system board 5 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station Perform the Maintenance Station Service Check on page 2 7 then return to this check 2 12 Service Manual 4097 00X
21. nt 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 paris Releasing Plastic Latches Many of the parts are held in place with plastic latches The latches break easily release them carefully To remove such paris 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 4097 00X Access Cover Removal 1 Open the access cover 2 Push the mounting tabs toward the center of the machine 3 Remove the access cover Buttons Lenses Removal 1 Remove the front cover 2 Depress the button clips and remove the buttons 3 Lift and remove the lenses Carrier Belt Idler Pulley Removal 1 Remove the front cover 2 Remove the printhead carrier without disconnecting the system board cables 3 Remove the carrier belt 4 Depress the latch on the idler pulley slide it to the left and remove Carrier Frame Assembly Base Removal 1 Remove the front cover 2 Remove the six screws that secure the carrier frame to the base assembly 3 Remove the paper guide 4 Tilt the lower part of the carrier frame up and remove the carrier frame Note Be sure the parallel cable clips are not trapped inside the cover Repair Information 4 3 4097 00X Carrier Transport Motor Removal 1 2 3 Remove t
22. nt problems at the right margin Go to the Maintenance Station Service Check on page 2 7 7 Access Cover Sensor 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 the actuator arm for binds If the arm is working correctly replace the system board 2 6 Service Manual 4097 00X Maintenance Station Service Check The maintenance station has two functions 1 Cleans the printhead nozzles during the print operation 2 Seals the printhead when it is not being used to prevent the nozzles from drying FRU Action 1 Maintenance As the carrier moves to the right over the Station Assembly 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 2 Wiper Worn wipers cause degraded print
23. quality just after a maintenance cleaning Check for loose or worn wipers 3 Cap Worn caps cause the printhead nozzles to dry and clog Check for loose or worn caps Diagnostic Information 2 7 4097 00X 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 e 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 e Check for static in the paper FRU Action 1 System Board Unplug the printer and disconnect the paperfeed motor J3 from the system board Plug the printer in and check for approximately 9 12 V dc between J3 1 and ground and J3 2 and ground on the system board If the voltage is not present check for motor pins shorted to the motor housing If you find a shorted pin replace the motor If you still have a failure after replacing the motor replace the system board 2 8 Service Manual 4097 00X FRU Action 2 Paper Feed Motor 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 disconnected from th
24. r Panel 4 6 Paper Feed Motor 4 6 Index 1 1 4097 00X Paper Guide 4 6 Power Connector 4 7 Printhead Cable 4 7 Rear Cover 4 8 Sheet Feeder 4 8 Small Feed Rollers 4 8 Star Roller 4 6 System Board 4 8 Wipers amp Caps 4 5 Repair Information 4 1 5 Safety Information vi Service Checks Carrier Transport 2 5 Envelope Feed 2 7 Maintenance Station 2 7 Paper Feed 2 8 Power 2 11 Start 2 1 Symptom Table POST 2 2 Symptom Tables 2 1 2 3 T Tests Test Page 3 1 1 2 Service Manual
25. re to note this location when reinstalling the carrier 6 7 8 9 10 11 12 13 Remove the carrier belt from the rear of the carrier Remove the carrier Depress and remove the printhead carrier cable retainer latch located on the carrier frame Remove the carrier cable and latch Remove the home sensor screw from the rear of the carrier Remove the printhead cable retainer clip screw from the rear of the carrier Depress the two clips on the top of the cradle assembly and remove the front of the cradle assembly Remove the carrier cable and note the routing of the cable and home sensor Note If there is any glue on the carrier rod retainer clips reinstall only one clip when replacing the carrier rod Repair Information 4 7 4097 00X Rear Cover Removal 1 2 Open the rear cover Push the mounting tabs toward the center of the machine and remove the rear cover Sheet Feeder Removal 1 2 4 5 Remove the front cover Remove the carrier frame Remove the two screws that hold the sheet feeder to the carrier frame Remove the screw from the gear plate Depress the sheet feeder latch from the carrier frame and remove the sheet feeder Small Feed Rollers EOF Removal D Remove the front cover Remove the carrier frame Remove the sheet feeder Facing the rear of the machine remove the small feed rollers Unhook the four small feed roller springs from the carri
26. t II Bracket Left amp Right with Screws Parts Catalog 7 11 4097 00X Assembly 6 Maintenance Station 7 12 Service Manual 4097 00X Asm Part Index Number Units Description 7 1 17D0586 1 Maintenance Station 2 17D0587 1 Wipers and Caps 3 17D0556 1 Gutter Pad Parts Catalog 7 13 4097 00X Index A Abbreviations 1 2 Adjustments 4 2 Aids 3 1 Assemblies 1 Covers 7 2 2 Carrier Transport 7 4 2 Paper Feed 7 4 3 Electronics 7 6 4 Carrier 7 8 5 Carrier Transport 7 10 6 Maintenance Station 7 12 Connector Locations 5 1 D Diagnostic Aids 3 1 E ESD Sensitive Parts 4 1 G General Information 1 1 Indicator Light Table 2 1 L Lubrication Specifications 6 1 Maintenance Approach 1 2 P Parts Carrier 7 8 Carrier Transport 7 4 7 10 Covers 7 2 Electronics 7 6 Maintenance Station 7 12 Paper Feed 7 4 Plastic Latches 4 2 POST Sequence 2 2 Symptom Table 2 2 Power Consumption 1 1 Preventive Maintenance 6 1 Problems Carrier Transport 2 3 Maintenance Station 2 3 Paper Feed 2 4 Power 2 4 Print Quality 2 4 R Removals Access Cover 4 3 Base Asm 4 3 Buttons Lenses 4 3 Carrier 4 7 Carrier Belt 4 3 Carrier Frame 4 3 Carrier Rod 4 7 Carrier Transport Motor 4 4 EOF Flag 4 8 Exit Roller 4 4 Front Cover 4 4 Gear Plate 4 4 Gutter Pad 4 5 Idler Pulley 4 3 Large Feed Roller 4 5 Maintenance Station 4 5 Mid Frame Assembly 4 6 Operato
27. tation Removal 1 2 3 6 7 8 Remove the front cover Remove the carrier frame Remove the two screws from the rear of the maintenance station Depress the two clips on the rear of the carrier frame and remove the maintenance station Remove the spring and actuator lever from the front of the maintenance station Lift and remove the wiper assembly Remove the cap assembly Remove the felt gutter pad Note If any glue is present on the maintenance station during removal replace the entire maintenance station Large Feed Roller Removal Remove the front cover Remove the carrier frame Remove the exit roller Remove the small feed roller assemblies Remove the EOF flag Remove the mid frame Remove the bushings at the ends of the large feed roller and remove the roller Maintenance Wiper and Cap Removal 1 2 Remove the front cover Push the carrier to the left away from the maintenance station 3 Gently pull the cap and wiper off their mountings Repair Information 4 5 4097 00X Mid Frame Star Roller Assembly Removal D OG I Remove the front cover Remove the carrier frame Remove the exit roller Remove the small feed roller assemblies Remove the EOF flag Depress the latches located on the rear of the mid frame and remove the mid frame and star roller assembly Note If any glue is present on the star roller assembly during removal replac
28. th Gear 6 17D0568 1 Plate Gear Asm without Motor 7 17D0567 1 Motor Paper Feed Asm with Gear 8 17D0584 1 Sheet Feeder Asm 001 8 17D0585 1 Sheet Feeder Asm 002 9 17D0573 12 Bearings Large Feed Roller Parts Catalog 7 5 4097 00X Assembly 3 Electronics 7 6 Service Manual 4097 00X AE a Units Description 3 1 17D0570 1 System Board 2 17D0590 4 Screws PP 3 17D0559 1 Operator Panel Power Connector 4 17D0574 1 Actuator Assembly NS 17D0575 1 Power Supply External LV 100 Japan NS 17D0576 1 Power Supply External LV 120 NS 17D0577 1 Power Supply External HV 220 Parts Catalog 7 7 4097 00X Assembly 4 Carrier 7 8 Service Manual 4097 00X Asm Part Index Number Units Description 4 1 17D0578 1 Carrier Assembly Complete 2 17D0580 1 Rod Carrier Guide 3 17D0579 1 Printhead Rubber Backers 4 17D0581 1 Cartridge Interlock Keys 5 17D0572 1 Printhead Home Sensor Cable Parts Catalog 7 9 4097 00X Assembly 5 Carrier Transport 7 10 Service Manual 4097 00X ae ee Units Description 5 1 17D0590 11 Screws PP 1 17D0590 1 Spring PP 2 17D0582 1 Motor Carrier Transport with Gear 3 17D0590 2 Retainers Carrier Guide Rod PP 4 17D0583 1 Belt Carrier 5 17D0580 1 Rod Carrier Guide 6 17D0588 1 Pulley Idler Asm 7 17D0563 1 Frame Carrier 8 17D0564 1 Roller Star Asm Mid Frame 9 17D0710 1 Accessory Packe
29. tions to identify the connector locations and test points on the printer Preventive Maintenance contains the lubrication specifications and recommendations to prevent problems Parts Catalog contains illustrations and part numbers for individual FRUs Preface vii 4097 00X Safety Information e 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 paris e 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 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 e Ce produit a t con u test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de l utilisation d autres pi ces de rechange e Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi e Le d montage et l entretien de
30. xmark International Inc registered in the United States and or other countries Color Jetprinter is a trademark of Lexmark International Inc Other trademarks are the property of their respective owners O Copyright Lexmark International Inc 1998 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 4097 00X Table of Contents diga Safety 22 2 4 General Information 1 1 Power CONSUMPTION dd asser 1 1 Operator Panel susanne 1 1 Maintenance Approach 2254 en 1 2 ABDFEVIALIONS aaa een 1 2 Diagnostic Information 2 1 Sal acaba dd do Da ad 2 1 Indicator Light ee some metan sra ada 2 1 Power On Self Test POST Sequence 2 2 POST Symptom Table daa na sa oem 2 2 Symptom Tape es 2 3 Service Checks passas do a t 2 5 Carrier Transport Service 2 5 Maintenance Station Service Check
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