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Preventive Maintenance 6-1

6. Preventive Maintenance

This chapter contains 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.

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Summary of Contents for 3000 Color Jetprinter

Page 1: ...tprinter Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start Diagnostics Manuals Menu ...

Page 2: ...le Road N W Lexington Kentucky 40550 U S A In the United Kingdom and Eire send to Lexmark International Ltd Marketing and Services Department Westhorpe House Westhorpe Marlow Bucks SL7 3RQ Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you If your printer has broken or missing parts or if you are missing public...

Page 3: ... Check 2 8 2 10 Paper Path Service Check 2 10 Power Service Check 2 11 Print Quality Service Check 2 12 Diagnostic Aids 3 1 Print NVRAM Contents 3 2 NVRAM Defaults 3 3 Reset NVRAM to EMEA Defaults 3 3 Reset NVRAM to U S Defaults 3 3 Test Page 3 4 Repair Information 4 1 Handling ESD Sensitive Parts 4 1 Adjustments 4 2 Removal Procedures 4 2 Releasing Plastic Latches 4 2 Access Cover Removal 4 3 Bas...

Page 4: ...9 Rear Cover Removal 4 9 Sheet Feeder Removal 4 9 Small Feed Roll Assembly Removal 4 10 Small Feed Roll Bracket Assembly Removal 4 10 System Board Removal 4 11 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 8 Assembly 4...

Page 5: ...ble and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems 4 Repair Information provides instructions for making printer adjustments and removing and installing FRUs 5 Connector Locations uses illustrations to identify the connector locations and test points on the printer 6 Preventiv...

Page 6: ...his 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 u...

Page 7: ... 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 w...

Page 8: ...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 ...

Page 9: ... 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...

Page 10: ...x ...

Page 11: ...ge and graphics printing Operator Panel Power Consumption Less than 3 5 Watts power off and power to the printer 9 Watts Idle Mode power on not printing 12 Watts Printing average 20 Watts Printing peak Buttons Lights Left Button Power On Off Left Light Steady Power On Blinking Printer Error Right Button Paper Feed clears a paper jam or loads paper when there is a paper out condition Right Light St...

Page 12: ...om and repair the failure Begin with Error Indicator Table on page 1 After you complete the repair perform tests as needed to verify the repair Abbreviations EOF End of Forms ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LVPS Low Voltage Power Supply OEM Original Equipment Manufacturer V ac Volts alternating current V dc Volts direct current ZIF Zero Inserti...

Page 13: ... in chapter 3 to determine the printer failure Error Indicator Table Error Code Number of Power Light Flashes Action Blank 8 Replace the system board 64 65 7 Replace the system board 81 1 Go to the Carrier Transport Service Check on page 2 5 89 4 Go to the Carrier Transport Service Check on page 2 5 127 and up 10 Replace the system board ...

Page 14: ...er movement Carrier stops Carrier slams side frame Go to the Carrier Transport Service Check on page 2 5 Symptom Action Maintenance station Fails to cap the printheads Fails to clean the printheads Go to the Maintenance Station Service Check on page 2 7 Symptom Action Paper Feed and or Install print cartridge buttons do not operate Replace the system board Busy light does not come on Replace the s...

Page 15: ...ed Service Check on page 2 6 Paper skews Go to the Paper Path Service Check on page 2 10 Symptom Action No power in machine motors do not operate Go to the Power Service Check on page 2 11 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 Servic...

Page 16: ...h no errors go to the Error Indicator Table on page 2 1 locate the symptom and take the indicated action If your machine does not complete POST locate the symptom in the following table and take the indicated action POST Symptom Table Symptom Action No Power On light and no motors run Go to the Power Service Check on page 2 11 Power light but no busy light Replace the system board Paper feed gears...

Page 17: ...otor 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 CN2 1 and CN2 2 CN2 3 and CN2 4 If the readings are incorrect replace the...

Page 18: ...ion sensor If the voltage is not present replace the system board 6 Maintenance Station 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 FRU Action 1 Envelope Guide Be sure the envelope guide has been turned to the envelope load position Be sure the envelope guide is against the envelopes Perform ...

Page 19: ...r 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 car...

Page 20: ...the motor If you still have a failure after replacing the motor replace the system board 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 or a bind in the paper feed mechanism With the paper feed motor cable disconnected from the system board check for 60 ohms 15 ohms...

Page 21: ...eed clutch inside the large feed gear Remove the sheet feeder Turn the clutch gear and check that it rotates freely in one direction and locks when turned in the opposite direction 4 Auto Sheet Feeder Check the pick rollers for wear 5 Mid Frame Asm Check the friction wheels exit roller and star rollers for wear 6 End of Forms Flag and Spring Check for binds or damage If binds are found replace the...

Page 22: ...pe 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 Check for damage 3 Auto Sheet Feeder Check the pick rollers for wear 4 Mid Frame Asm Check the following for wear Friction wheels Exit roller Star rollers 5 End of Forms Flag Check for binds or damage ...

Page 23: ...e before you reconnect the power supply to the system board 2 Printhead Cable Carrier Home Sensor Parallel Cable Paper Feed Motor Carrier Transport Motor 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 transp...

Page 24: ...en 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 Maintenance station wiper for damage 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...

Page 25: ...e 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...

Page 26: ...y clean and lubricate Carrier to carrier frame engagement should be lubricated with grease P N 1329301 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 FRU Function Action...

Page 27: ...inter To begin the test hold the buttons until both the operator panel lights come on and then release the buttons after five seconds Some tests require the End of Form Flag to be out of the sensor To remove the End of Form Flag from the sensor 1 Open the sheet feeder 2 Place a sheet of paper in the paper path until the End of Form Flag is tripped To terminate the test turn the printer off ...

Page 28: ... diagnostic purposes To run the test 1 Place a sheet of paper in the sheet feeder far enough to push the End of Form flag out of the sensor 2 Load paper into the sheet feeder 3 With the printer off press and hold the Paper Feed button and turn the printer on The contents of NVRAM print ...

Page 29: ...ons to reset NVRAM to the EMEA factory defaults A sheet of paper feeds and verifies the defaults have been set by printing EMEA Reset NVRAM to U S Defaults This test resets the user defaults area of NVRAM to the U S factory defaults The page count and the error log do not change Note Factory defaults are initially set to U S To run the test 1 With the printer off press and hold the Install Print C...

Page 30: ...evel and date Line 2 Manufacturer name Line 3 Model name Line 4 U S or EMEA defaults Line 5 Page count followed by the last error Line 6 Motor type The next line is the black print cartridge nozzle pattern The next three lines are the purge pattern where all nozzles are printing This action cleans purges the nozzles Another nozzle test pattern follows These test patterns are used to verify all pri...

Page 31: ...und 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 cor rect 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 rea son first put it into its special bag Mac...

Page 32: ...rocedures The following procedures are arranged according to the name of the printer part discussed CAUTION Unplug the power cord before removing any parts Releasing Plastic Latches Many of the parts are held in place with plastic latches The latches break easily release them carefully To remove such parts press the hook end of the latch away from the part to which it is latched ...

Page 33: ...e the carrier frame to the base assembly 6 Remove the screw that secures the power supply frame to the carrier frame 7 Slide the machine off the base assembly Carrier Belt Removal 1 Remove the front cover 2 Remove the retainer spring from the left side of the carrier guide rod 3 Remove the screw from the right side of the carrier guide rod 4 Slide the carrier rod to the left out of the machine 5 R...

Page 34: ... feeder 4 Disconnect the power supply connector at the system board 5 Remove the two screws that secure the carrier frame to the base assembly 6 Remove the screw that secures the power supply frame to the carrier frame 7 Slide the carrier frame assembly off the base assembly 8 To replace the carrier frame remove all associated parts from the old carrier frame and install them on the new carrier fr...

Page 35: ...e two screws securing the carrier transport motor to the carrier frame and remove the motor Note the routing of the motor cable Drive Train Assembly Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the sheet feeder 4 Unplug the paper feed motor assembly Note the routing of the motor cable 5 Remove the two screws securing the drive train to the carrier frame 6 Push the drive train ...

Page 36: ...acket 11B5600 2 Slide the cover upward and off the machine To reassemble 1 Align the tabs on the front cover over the front edge of the base assembly 2 Rotate the front cover over the top edge of the rear cover and press in on both sides opposite the cover latches until they latch Gutter Pad Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the sheet feeder 4 Remove the base assemb...

Page 37: ...ly 11 Turn and remove the retainer at the right end of the large feed roller 12 Remove the large feed roller from the carrier frame Maintenance Station Assembly Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the base assembly 4 Depress the clip on the left and right side of the carrier frame that secures the maintenance station assembly and slide the assembly out of the machine ...

Page 38: ...ly and remove it from the carrier frame Paper Feed Motor Removal 1 Remove the front cover 2 Remove the rear cover 3 Disconnect the paper feed motor from the system board 4 Remove the two screws mounting the paper feed motor to the drive train assembly and remove the motor Power Supply Removal 1 Remove the front cover 2 Remove the rear cover 3 Disconnect the power supply connector from the system b...

Page 39: ...r out of the machine Rear Cover Removal 1 Remove the screws from the bottom assembly 2 Remove the front cover 3 Pry upward on the two rear cover latches 4 Work the tabs of the rear cover free from the base assembly 5 To reassemble place the cover over the tabs in the base assembly and press toward the front of the machine until the cover latches Be sure the parallel connector snaps do not get trap...

Page 40: ...o remove them from the small feed roll bracket Small Feed Roll Bracket Assembly Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the sheet feeder 4 Remove the system board 5 Remove the four small feed roller springs from the carrier frame 6 Push down on each of the small feed roll assemblies to remove them from the small feed roll bracket 7 Push the two locking tabs A to the rear ...

Page 41: ...d cables from the system board 4 Disconnect the other cables from the system board 5 Remove the three screws securing the system board to the carrier frame and remove the system board Note the routing of all the cables 6 Remove the system board being careful not to damage the End of Form flag 7 Set NVRAM to the proper country defaults See NVRAM Defaults on page 3 3 ...

Page 42: ...4 12 ...

Page 43: ...N3 Paper Feed Motor CN4 Printhead Cable 1 CN5 Printhead Cable 2 CN6 Printhead Cable 3 CN7 Printhead Cable 4 CN8 Parallel Port CN9 Power Supply PH1 EOF Sensor U14 Code Module SW1 Power Switch SW2 Paper Feed Switch SW3 Install Print Cartridge Switch LED1 Busy Light LED2 Power On Light ...

Page 44: ...5 2 ...

Page 45: ...in 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 ...

Page 46: ...6 2 ...

Page 47: ... 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 ...

Page 48: ...7 2 Assembly 1 Covers ...

Page 49: ...ssembly 2 11A5431 1 Felt Pad Ink Absorption 3 11B5742 1 Cover Front Assembly and Paper Scale 4 11B5743 1 Cover Rear Assembly 5 11B5744 1 Cover Access Assembly 6 11B5600 2 Front Cover Mounting Screws PP N S 7349474 1 Replaceable Package B M Includes Carton Cushion Set Sealing Tape ...

Page 50: ...7 4 Assembly 2 Paper Feed Carrier Transport Maintenance ...

Page 51: ...oll Assembly Small and Spring 7 11B5589 1 Mounting Bracket Small Feed Roll Assembly 8 11B5590 1 Drive Train Assembly 9 11B5738 1 Motor Paper Feed Assembly 10 11B5600 5 Screws Paper Feed Motor Mounting PP 11 11B5588 1 Arm Tensioner 12 11B5597 1 Belt Carrier 13 11B5600 1 Spring Large Feed Roll Dampening PP 14 11A5440 1 Feed Roll Assembly Large 15 11B5587 1 Frame Mid Assembly 16 11B5599 1 Maintenance...

Page 52: ...7 6 Assembly 2 Paper Feed Carrier Transport Maintenance ...

Page 53: ...n 2 18 11B5600 2 Screw PP 19 11B5600 1 Screw PP 20 11B5600 1 Screw PP 21 1367389 1 Cap and Wiper B M One of each 22 11B5595 1 Star Roller Asm 23 11B5600 2 Screw PP NS 11B5600 2 Bearings Large Feed Roll PP NS 11B5600 2 Screws Star Roller Assembly Mounting PP ...

Page 54: ...7 8 Assembly 3 Electronics ...

Page 55: ...talog 7 9 Asm Index Part Number Units Description 3 1 11B5745 1 System Board with ROM 2 11B5746 1 Power Supply 3 11B5600 3 Screws System Board PP 4 11B5600 2 Screws Base Asm PP NS 11B5602 1 Cable Parallel Port ...

Page 56: ...7 10 Assembly 3 Electronics Continued ...

Page 57: ...Power Cord Brazil LV Power Cord Brazil HV Power Cord Canada Power Cord Chile Power Cord Columbia Power Cord Costa Rica Power Cord Denmark Power Cord Ecuador Power Cord Egypt Power Cord El Salvador Power Cord Finland Power Cord France Power Cord Germany Power Cord Guatemala Power Cord Honduras Power Cord Israel Power Cord Italy Power Cord Japan Power Cord Mexico Power Cord Netherlands Power Cord Ni...

Page 58: ...7 12 Assembly 4 Carrier ...

Page 59: ...og 7 13 Asm Index Part Number Units Description 4 1 11B5596 1 Carrier Assembly 2 11B5585 1 Rod Carrier Guide 3 11B5584 1 Frame Carrier 4 11B5600 1 Screw Carrier Guide Rod PP 5 11B5600 1 Spring Carrier Guide Rod PP ...

Page 60: ...7 14 Assembly 5 Sheet Feeder ...

Page 61: ...Parts Catalog 7 15 Asm Index Part Number Units Description 5 1 11B5584 1 Frame Carrier 2 11B5600 2 Screws Sheet Feeder Mounting PP 3 11B5747 1 Sheet Feeder Asm 4 11B5743 1 Cover Rear Asm ...

Page 62: ...7 16 ...

Page 63: ...2 Operator Panel 2 2 Paper Feed 2 3 Power 2 3 Print Quality 2 3 R Removals Access Cover 4 3 Base Assembly 4 3 Carrier Belt 4 3 Carrier Frame 4 4 Carrier Home Sensor 4 4 Carrier Transport Motor 4 5 Drive Train Assembly 4 5 Front Cover 4 6 Gutter Pad 4 6 Large Feed Roll 4 7 Maintenance Station 4 7 Mid Frame Assembly 4 8 Paper Feed Motor 4 8 Power Supply 4 8 Printhead Carrier 4 9 Rear Cover 4 9 Relea...

Page 64: ...X 2 T Tests Print NVRAM Contents 3 2 Reset NVRAM Defaults EMEA 3 3 U S 3 3 Test Page 3 4 ...

Page 65: ... book well organized Yes No 2 Was the content of the book accurate and complete Yes No 3 Was the book easy to use Yes No 4 What can we do to improve the book 5 What is your job title Questions or comments about supplies service applications and so on will slow response time considerably Please refer those questions or comments to your authorized dealer or point of purchase Note Please direct all r...

Page 66: ...Cut Along Line POSTAGE WILL BE PAID BY ADDRESSEE Lexmark International Inc Department D22A Building 035 3 740 New Circle Road NW Lexington Ky 40550 Fold Here Tape Please Do Not Staple Tape BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY ...

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