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1100 Color Jetprinter Service Manual
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1000 Color JetprinterTM 1100 Color Jetprinter
4096-00X
· Table of Contents · Start Diagnostics · Safety and Notices · Trademarks · Index · Manuals Menu
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
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First Edition (May, 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. A form for reader's comments is provided at the back of this publication. If the form has been removed, 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 Optra are trademarks of Lexmark 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. © Copyright Lexmark International, Inc. 1997, 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.
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Table of Contents
Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-1 Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Carrier Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Envelope Feed Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . . . . 2-7 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Paper Path Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base and Sheet Feed Assembly Removal. . . . . . . . . . . . . . . . . . Carrier Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carrier Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . Carrier Transport Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . Drive Train Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . End-of-Form Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Large Feed Roll Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Station Assembly Removal. . . . . . . . . . . . . . . . . . . Mid-Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . 4-1 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-4 4-4 4-5 4-5 4-5 4-6 4-6 4-6
iii
4096-00X Small Feed Roll Assembly Removal . . . . . . . . . . . . . . . . . . . . . . .4-6 System Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 System Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Assembly 2: Paper Feed / Carrier Transport / Maintenance . . . . . . .7-4 Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6 Assembly 4: Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 Assembly 5: Sheet Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
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Notices and Safety Information
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.
· ·
Notices and Safety Information v
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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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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.
· ·
Notices and Safety Information vii
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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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Notices and Safety Information ix
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1. General Information
The Lexmark 1000 Color JetprinterTM and 1100 Color Jetprinter are personal, near laser-quality inkjet printers. The print cartridge is a single-unit customer replaceable supply item. A single printhead provides three colors and composite black printing. The printer also supports a black print cartridge and provides 600 X 600 dpi edge definition for professional quality text image and graphics printing.
Printer Lexmark 1000 Color Jetprinter Lexmark 1100 Color Jetprinter
Model 001 002 003 004
Color Gray Black Gray Black
Paper Support / Exit Tray No No Yes Yes
Power Consumption
· · · ·
Less than 3 Watts - power off and power to the printer 9 Watts - Idle Mode (power on - not printing) 12 Watts - Printing (average) 20 Watts - Printing (peak)
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 "Start" on page 2-1. The user is directed, in the Printer Control program, to perform the bidirectional alignment adjustments after replacing a print cartridge. General Information 1-1
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Abbreviations
EOF ESD FRU HVPS LVPS NVRAM OEM POST V ac V dc ZIF End-of-Form Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Power-On Self Test Volts alternating current Volts direct current Zero Insertion Force
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2. Diagnostic Information
Start
Power-On Self Test (POST) Sequence
When you turn the printer on it performs a POST. Turn your machine on and check for a correct POST operation by observing the following: 1. The carrier moves. 2. The paper feed gears turn. 3. After 30 seconds the carrier moves over the maintenance station and caps the printhead. 4. All motors stop. If your machine does not complete POST, use the symptom tables and service checks in chapter 2 to determine the failing part.
Diagnostic Information 2-1
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Symptom Tables
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 2-5.
Maintenance Station Problems
Symptom Maintenance station: · Fails to cap the printhead · Fails to clean the printhead Action Go to the "Maintenance Station Service Check" on page 2-7.
Paper Feed Button Problems
Symptom Paper feed button does not operate. Action Replace the system board.
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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 2-8.
Go to the "Envelope Feed Service Check" on page 2-6. Go to the "Paper Feed Service Check" on page 2-8.
Power Problems
Symptom · No power in machine · No motors operating Action Go to the "Power Service Check" on page 2-11.
Print Quality Problems
Symptom · · · · · · · · 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 Action Go to the "Print Quality Service Check" on page 2-12.
· Ink smearing · Vertical streaks on paper · Print lines crowded
Go to the "Print Quality Service Check" on page 2-12.
Diagnostic Information 2-3
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POST Symptom Table
Symptom No power and the motors do not run Paper feed gears do not turn Carrier doesn't move Carrier slams side frame Action Go to the "Power Service Check" on page 2-11.
Go to the "Paper Feed Service Check" on page 2-8.
Go to the "Carrier Transport Service Check" on page 2-5. Go to the "Carrier Transport Service Check" on page 2-5.
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Service Checks
Carrier Transport Service Check
FRU 1 System Board Action Check the motor for binds, or loose motor pulley. Turn the printer off and disconnect N6 from the system board. Check for motor pins shorted to the motor housing. If you find a pin shorted to the housing, replace the motor. If the failure remains, replace the system board. 2 Carrier Transport 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 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: N6-1 and N6-2 N6-3 and N6-4 If the readings are incorrect, replace the motor. 3 Carrier Guide Rod Clean the carrier rod. Note: Lubricate the carrier guide rod and the carrier rod bearing surface with grease P/N 1329301. 4 Carrier Transport Belt Idler Pulley Parts Carrier Frame Check for worn, loose or broken parts. Check for obstructions blocking carrier movement. Carrier to carrier frame engagement should be lubricated with grease P/N 1329301.
Diagnostic Information 2-5
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FRU 5 Home Position Sensor Action Be sure the carrier returns to the home position after turning the printer on. If the carrier moves half way, or if there is an abnormal sound, turn the printer off and disconnect N3 from the system board. Turn the printer on and check for 5 V dc between N3-4 and N3-2 on the system board. If the voltage is present, replace the home position sensor. If the voltage is not present, replace the system board. A problem with the maintenance station can cause carrier movement problems at the right margin. Go to the "Maintenance Station Service Check" on page 2-7.
6
Maintenance Station
Envelope Feed Service Check
FRU 1 Envelope Guide Action Be sure the envelope guide has been turned to the envelope load position. Be sure the envelope guide is against the envelopes.
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Maintenance Station Service Check
The maintenance station has two functions:
· Cleans the printhead nozzles during the print operation. · 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. 2 Wiper A worn wiper causes degraded print quality just after a maintenance cleaning. Check for a loose or worn wiper. A worn cap causes the printhead nozzles to dry and clog. Check for a loose or worn cap.
3
Cap
Diagnostic Information 2-7
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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 Turn the printer on and verify the paper feed motor activates. Be sure the end-of-form sensor lever is in the down position. Turn the printer off and disconnect N7 from the system board. Check for motor pins shorted to the motor housing. If you find a shorted pin, replace the paper feed motor. If you still have a failure after replacing the paper feed motor, replace the system board. 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, or a bind in the paper feed mechanism. With the paper feed motor cable N7 disconnected from the system board, check for 80 ohms (±7 ohms) between the following pins on the motor: Pin 1 to Pin 2, Pin 1 to Pin 4 160 ohms (±7 ohms) between pins 2 and 4. If the readings are incorrect, replace the paper feed motor and drive train assembly. 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.
2
Paper Feed Motor
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FRU 3 Drive Train Assembly Action Check for binds in the gear train and paper feed 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 gear on the left side of the auto sheet feeder. Turn the clutch gear and check that it rotates freely in one direction and locks when turned in the opposite direction. Check the pick rollers for wear. Check the following for wear: · Friction wheels · Exit roller · Star rollers Check for binds or damage. If binds are found, replace the end-of-forms flag. Check the sensor for dirt. Be sure the sensor lever is in the down position. If the failure remains, replace the system board.
4 5
Auto Sheet Feeder Mid-Frame Asm Access Cover Asm
6 7
End-of-Forms Flag and Spring End-of-Forms Sensor
Diagnostic Information 2-9
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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 Mid-Frame Asm Access Cover Asm Action Check for wear and binds. Check for damage. Check the pick rollers for wear. Check the following for wear: · Friction wheels · Exit roller · Star rollers Check for binds or damage.
5
End-of-Forms Flag
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Power Service Check
FRU 1 Power Supply Action Disconnect N1 from the system board and check the following voltages on the power supply cable: · N1-1 to GND = +5 V dc · N1-3 to GND = +24 V dc If you do not have correct voltage, replace the power supply. Be sure to unplug the machine before you reconnect the power supply to the system board. 2 Printhead Cable Carrier Home Sensor Parallel Cable Turn off the printer. Disconnect one of the printhead cables and turn on 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 and parallel cable. 3 System Board If the symptom has not changed, replace the system board.
Diagnostic Information 2-11
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Print Quality Service Check
FRU / Function 1 2 Print Cartridge Color Print Cartridge Cross Contamination Action Be sure the machine contains a good print cartridge. 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 maintenance station wiper for damage. · The printhead nozzle plate was resealed with tape. 3 Printhead Carrier Assembly Reseat the printhead cables in the system board and check the following parts for wear or damage: · Print Cartridge Latch · Latch Spring · Carrier
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FRU / Function 4 System Board Printhead Cable Rubber Backer Action Execute the "Clean Print Nozzle" in "Cartridges" of the Printer Control Program. Look for a break in the diagonal line of the test pattern. A broken line indicates one or more print nozzles are not working. Run the test again to verify the failure. If there are even breaks in the diagonal line similar to the pattern shown below, ensure the printhead cables are connected properly. If the symptom remains, replace the system board.
If there is a single break or random breaks in the diagonal line check the following: · Check the gold-plated contacts, on the end of the cable that connect to the carrier, for dirt and wear. Use only a clean dry cloth to clean the contacts. Also check the cable for damage. You may need to remove the cable from the carrier to inspect it. · A worn rubber backer results in poor contact between the printhead cable and the print cartridge. Check the rubber backer for wear. 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. 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.
6
Paper Feed
Diagnostic Information 2-13
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FRU / Function 7 Carrier Transport Action 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. · Carrier to carrier frame engagement should be lubricated with grease P/N 1329301, as well as the carrier guide rod and bearing. · 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.
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3. Diagnostic Aids
There are no residence diagnostic aids associated with the 4096 printers.
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 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 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
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Adjustments
The user is directed, in the Printer Control program, to perform the bidirectional alignment adjustments after replacing a print cartridge.
Removal Procedures
The following procedures are arranged according to the name of the printer part discussed. 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.
Access Cover Removal
1. Open the access cover. 2. Press both left and right side of the hinges to the center of the machine. 3. Remove the access cover from the front cover.
Base and Sheet Feed Assembly Removal
1. Remove the front cover. 2. Remove the five screws that secure the carrier frame to the base assembly and power supply ground strap. 3. Disconnect the power supply connector at the system board and cut the wire clamp on the left side. 4. Remove the carrier frame from the base assembly and lift it off the base. 5. Remove the two screws that secure the power supply to the base assembly. 6. Remove the power supply.
4-2 Service Manual
4096-00X
Carrier Belt Removal
1. 2. 3. 4. 5. 6. Remove the front cover. Remove the retainer spring from the right side of the carrier rod. Slide the carrier rod to the right, out of the machine. Remove the carrier belt from the rear of the carrier. Remove the carrier belt from the carrier transport motor pulley. Remove the carrier belt.
Carrier Frame Assembly Removal
1. Remove the front cover. 2. Remove the five screws that secure the carrier frame to the base assembly and power supply ground strap. 3. Disconnect the power supply connector at the system board and cut the wire clamp on the left side. 4. Remove the carrier frame from the base assembly and lift it off the base. 5. Remove the two screws that secure the power supply to the base. 6. To replace the carrier frame, remove all associated parts from the old carrier frame and install them on the new carrier frame.
Carrier Transport Motor Removal
1. 2. 3. 4. Remove the front cover. Remove the carrier frame assembly. Disconnect the motor connector from the system board. Remove the two screws then remove the motor.
Repair Information 4-3
4096-00X
Drive Train Assembly Removal
Remove the front cover. Remove the carrier frame. Remove the base assembly. Remove the maintenance station assembly. Remove the printhead carrier assembly. Remove the large feed roll and mid-frame assembly. Disconnect the paper feed motor connector from the system board. 8. Remove the two screws securing the drive train to the carrier frame. 9. Push the drive train to the right and remove it from the carrier frame. Note: The paper feed motor is a part of the drive train assembly. 1. 2. 3. 4. 5. 6. 7.
End-of-Form Flag Removal
1. 2. 3. 4. Remove the front cover. Remove the carrier frame from the base assembly. Disconnect all cables from the system board. Remove the four screws securing the system board to the carrier frame and remove the system board. (Take care when removing the system board, not to damage the end-of-form flag). Remove the two center feed roller springs from the carrier frame. Unlatch the clip from the right side of the end-of-form flag. Remove the spring, while noting its position. Unlatch the left side and remove the end-of-form flag.
5. 6. 7. 8.
4-4 Service Manual
4096-00X
Front Cover Removal
1. Release the two hooks [A] in the illustration by using a screwdriver. 2. While pushing the left side edge of the front cover upward, release the hook [B]. Repeat this on the right side. 3. Slide the front cover forward and remove it from the rear cover.
Large Feed Roll Removal
1. 2. 3. 4. 5. Remove the front cover. Remove the carrier frame from the base assembly. Move the printhead carrier assembly to the left. Remove the maintenance station assembly. Turn and remove the retainers at both ends of the large feed roller. 6. Remove the mid-frame assembly. 7. Remove the large feed roller from the carrier frame.
Maintenance Station Assembly Removal
1. Remove the front cover. 2. Release the two hooks on the rear of the maintenance station. 3. Remove the maintenance station by sliding it forward.
Repair Information 4-5
4096-00X
Mid-Frame Assembly Removal
Remove the front cover. Remove the carrier frame from the base assembly. Move the printhead carrier assembly to the left. Remove the maintenance station assembly. Turn and remove the retainers at both ends of the large feed roller. 6. Remove the mid-frame assembly. 1. 2. 3. 4. 5.
Power Supply Removal
1. 2. 3. 4. Remove the front cover. Remove the carrier frame from the base assembly. Disconnect the power supply connector from the system board. Remove the screws that secure the power supply to the base assembly and remove the power supply.
Printhead Carrier Assembly Removal
1. Remove the front cover. 2. Disconnect the printhead cable from the system board. 3. Remove the retainer spring from the right end of the carrier guide rod. 4. Slide the carrier guide rod out the right side of the machine. 5. Remove the belt from the back of the carrier. 6. Lift the carrier out of the machine.
Small Feed Roll Assembly Removal
1. 2. 3. 4. Remove the front cover. Remove the carrier frame from the base assembly. Remove the four small feed roller springs from the carrier frame. Remove each of the small feed roll assemblies from the frame.
4-6 Service Manual
4096-00X
System Board Removal
1. Remove the front cover. 2. Remove the carrier frame from the base assembly. 3. Disconnect all cables from the system board. Remove the four screws securing the system board to the carrier frame and remove the system board, taking care not to damage the end-of-form flag. Note the routing of all cables.
Repair Information 4-7
4096-00X
4-8 Service Manual
4096-00X
5. Connector Locations
System Board Connectors
N1 N2 N3 N4 N6 N7 S1
Power Supply Parallel Port Printhead Cable 1 Printhead Cable 2 Carrier Transport Motor Paper Feed Motor Paper Feed Switch
Connector Locations 5-1
4096-00X
5-2 Service Manual
4096-00X
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 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.
Preventive Maintenance 6-1
4096-00X
6-2 Service Manual
4096-00X
7. Parts Catalog
How To Use This Parts Catalog
· SIMILAR 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. 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.
· ·
Parts Catalog 7-1
4096-00X
Assembly 1: Covers
7-2 Service Manual
4096-00X
AsmIndex 1 -1 -1 -1 -1 -2 -2 -2 -3 -3 -3 NS NS Part Number 11B5128 11B5129 17Z0177 17Z0176 11B5127 17Z0174 17Z0175 11B5125 17Z0170 17Z0171 11B5111 7349593
Units 1 1 1 1 1 1 1 1 1 1 1 1
Description Cover, Access Asm, Star Wheels (002) Cover, Access Asm, Star Wheels (001) Cover, Access Asm, Star Wheels (003) Cover, Access Asm, Star Wheels (004) Cover, Front Asm & Button (001, 002) Cover, Front Asm & Button (003) Cover, Front Asm & Button (004) Base Asm and Sheet Feed (001, 002) Base Asm and Sheet Feed (003) Base Asm and Sheet Feed (004) Support, Banner Paper Replaceable Package B/M - Includes: (Carton, Cushion Set, Sealing Tape) (001, 002) Replaceable Package B/M - Includes: (Carton, Cushion Set, Sealing Tape) (003, 004)
NS
7350132
1
Parts Catalog 7-3
4096-00X
Assembly 2: Paper Feed / Carrier Transport / Maintenance
7-4 Service Manual
4096-00X
AsmIndex 2 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -NS Part Number 11B5130 11B5142 11B5144 11B5136 11B5144 11B5135 11B5137 11B5144 11B5144 11B5134 11B5133 11B5143 11B5144
Units 1 1 1 1 1 1 1 1 1 1 1 1 6
Description Frame, Carrier Motor, Carrier Transport Assembly Screw, (PP) End-of-Form Flag and Spring Spring, Small Feed Roll Asm, (PP) Feed Roll Assembly, Small Drive Train Assembly with Paper Feed Motor Arm, Tensioner (PP) Belt, Carrier (PP) Feed Roll Assembly, Large with Gear Frame, Mid Assembly Maintenance Assembly Screw, (PP)
Parts Catalog 7-5
4096-00X
Assembly 3: Electronics
7-6 Service Manual
4096-00X
AsmIndex 3 -1 -2 -2 -2 -3 -3 -4 -5 Part Number 11B5130 11B5138 11B6044 17Z0180 11B5139 11B5140 11B5125 11B5141 11B5624 11B5622 11B5624 11B5624 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5623 11B5622 11B5141 11B5622 11B5622 11B5622 11B5626 11B5622 11B5625 11B5622 11B5622 11B5621
Units 1 1 1 1 1 1 1 1
Description Frame, Carrier System Board with ROM (LV) (001, 002) System Board with ROM (HV) (001, 002) System Board with ROM (LV & HV) (003, 004) Power Supply: 110V Power Supply: 220V Base Asm and Sheet Feed (001, 002) Power Cord, U.S. Power Cord, Austria Power Cord, Belgium Power Cord, Brazil Power Cord, Canada Power Cord, Chile Power Cord, Cyrillic Power Cord, Denmark Power Cord, East Turkey Power Cord, Europe Power Cord, Finland Power Cord, France Power Cord, Germany Power Cord, Greece Power Cord, Israel Power Cord, Italy Power Cord, Japan Power Cord, Mexico Power Cord, Netherlands Power Cord, Norway Power Cord, Peru Power Cord, Portugal Power Cord, South Africa Power Cord, Spain Power Cord, Sweden Power Cord, UK, Ireland
Parts Catalog 7-7
4096-00X
Assembly 4: Carrier
7-8 Service Manual
4096-00X
AsmIndex 4 -1 -2 -3 -4 Part Number 11B5131 11B5132 11B5130 11B5144
Units 1 1 1 1
Description Carrier Assembly, with Carrier Home Sensor Rod, Carrier Guide Frame, Carrier Spring, Carrier Guide Rod (PP)
Parts Catalog 7-9
4096-00X
Assembly 5: Sheet Feeder
7-10 Service Manual
4096-00X
AsmIndex 5 -1 -2 -2 -2 -3 -3 -3 -4 -4 Part Number 11B5130 11B5125 17Z0170 17Z0171 11B5126 17Z0172 17Z0173 17Z0178 17Z0179
Units 1 1 1 1 1 1 1 1 1
Description Frame, Carrier Base, Sheet Feeder Asm and Garage Assembly (001, 002) Base, Sheet Feeder Asm and Garage Assembly (003) Base, Sheet Feeder Asm and Garage Assembly (004) Support, Upper Paper (001, 002) Support, Upper Paper (003) Support, Upper Paper (004) Tray, Exit (003) Tray, Exit (004
Parts Catalog 7-11
4096-00X
7-12 Service Manual
4096-00X
Index
A
Abbreviations 1-2 Adjustments 4-2 Assemblies 2 Carrier Transport 7-4 2 Maintenance Station 7-4 2 Paper Feed 7-4 3 Electronics 7-6 4 Carrier 7-8 5 Sheet Feeder 7-10 Access Cover 4-2 Base Assembly 4-2 Carrier Belt Asm 4-3 Carrier Frame Asm 4-3 Carrier Transport Motor 4-3 Drive Train Assembly 4-4 End-of-Form Flag 4-4 Front Cover 4-5 Large Feed Roll 4-5 Maintenance Station 4-5 Mid-Frame Assembly 4-6 Power Supply 4-6 Printhead Carrier Asm 4-6 Sheet Feed Asm 4-2 Small Feed Roll Asm 4-6 System Board 4-7
C
Connectors System Board 5-1
E
ESD-Sensitive Parts 4-1
S
Safety Information v Service Checks Envelope Feed 2-6 Maintenance Station 2-6 Paper Feed 2-8 Paper Path 2-9 Power 2-10 Print Quality 2-11 Transport 2-5 Symptom Table (POST) 2-4 Symptom Tables 2-2
L
Lubrication Specifications 6-1
M
Maintenance Approach 1-1
P
Parts Catalog 7-1 Plastic Latches 4-2 POST Sequence 2-1 Symptom Table 2-4 Power Consumption 1-1 Problems Carrier Transport 2-2 Maintenance Station 2-2 Paper Feed 2-3 Paper Feed Button 2-2 Power 2-3 Print Quality 2-3
R
Removals
Index I-1
4096-00X
I-2 Service Manual
Lexmark 1000 / 1100 Color Jetprinter (4096-00X) Service Manual U.S. - P/N 17Z0168, Japan - 17Z0169 May, 1998
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