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Service Manual

4400-001

Preface

This manual contains maintenance procedures for service
personnel. It is divided into the following chapters:

1. General Information contains a general description of the

printer and the maintenance approach used to repair it. Special
tools and test equipment are listed.

2. Diagnostic Information contains an error indicator table,

symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).

3. Diagnostic Aids contains tests and checks used to locate or

repeat symptoms of printer problems.

4. Repair Information provides instructions for making printer

adjustments and removing and installing FRUs.

5. Connector Locations uses illustrations to identify the

connector locations and test points on the printer.

6. Preventive Maintenance contains the lubrication specifications

and recommendations to prevent problems.

7. Parts Catalog contains illustrations and part numbers for

individual FRUs.

Содержание X63

Страница 1: ...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 L...

Страница 2: ...t New Circle Road Lexington Kentucky 40550 U S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate with...

Страница 3: ...7 CIS Assembly Service Check 2 9 Scanner Motor with Gear Assembly Service Check 2 10 Maintenance Station Service Check 2 11 Paper Feed Service Check 2 12 Paper Path Service Check 2 14 Power Service C...

Страница 4: ...13 Operator Panel Assembly Removal 4 15 Printer Unit Removal 4 16 ASF Assembly Removal 4 17 Maintenance Station Removal 4 19 Carrier Assembly with Belt Removal 4 20 System Board Removal 4 21 Mid Fram...

Страница 5: ...y and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t con u test et approuv pour respecter les normes...

Страница 6: ...ale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltwe...

Страница 7: ...reparaci n de la m quina 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 sati...

Страница 8: ...d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte est orientada exclusivament a professi...

Страница 9: ...Safety Information ix 4400 001...

Страница 10: ...bles 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 prov...

Страница 11: ...to a single unit Print cartridges are available as a customer replaceable supply item Dual printheads provide color and true black printing without changing printheads The number and size of inkjets o...

Страница 12: ...2400 dpi Addressable Mono 600 X 600 dpi 1200 X 2400 dpi Addressable Printing Width 203 mm Feeding Method Automatic 100 sheets of 20 lb cut sheets Max 10 mm Manual Tray No Emulation Host Based Printin...

Страница 13: ...acker Paper Stacker Paper Tray Bin Type without Manual Tray Modem Speed 14 4 Kbps Coding Method MH MR MMR Error Correction Mode LCD 2 lines of 16 characters each Scanning Resolution and Type Standard...

Страница 14: ...Tone Mode DRPD USA Yes Other Countries No Report and List TX RX Journal Yes Image TCR Yes Reduction of first page sent by Memory TX System Data Yes Telephone Number List Yes Self Test Yes Copy Multip...

Страница 15: ...205 4 mm Weight Packed Weight 5 6 Kg 8 0 Kg packed weight ASF Auto Sheet Feed B M Bill of Material CIS Contact Image Sensor EOF End of Form ESD Electrostatic Discharge FPC Flat Printhead Cable FRU Fi...

Страница 16: ...1 6 Service Manual 4400 001...

Страница 17: ...en stops 3 Carrier returns to the right 4 Powering Up Please Wait is displayed on the LCD 5 Ready ANS FAX the Date and Time display when POST is complete If your printer completes POST with no errors...

Страница 18: ...5 If okay go to the Operator Panel Problems on page 2 3 Paper feed gears do not turn Go to the Paper Feed Service Check on page 2 12 Carrier does not move Go to the Carrier Transport Service Check on...

Страница 19: ...intenance station Fails to cap the printheads Fails to clean the printheads Go to the Maintenance Station Service Check on page 2 11 Symptom Action Buttons do not work LCD does not display Check opera...

Страница 20: ...perator panel cable connector CN17 on the system board If okay go to the Scanner Motor with Gear Assembly Service Check on page 2 10 If the scanner motor is working correctly replace the operator pane...

Страница 21: ...Check on page 2 9 Scanned images are faded or colors are dull blurry or fuzzy Images are slanted or crooked and the straight lines in the image appear to be jagged or uneven Blank copies Go to the Sc...

Страница 22: ...Service Check on page 2 12 Paper skews Go to the Paper Path Service Check on page 2 14 Symptom Action No power in machine motors do not operate Go to the Power Service Check on page 2 15 Symptom Actio...

Страница 23: ...Check the motor for binds or loose motor pulley A noisy or chattering motor or a motor that fails to turn can be caused by An open or short in the motor An open or short in the motor driver on the sys...

Страница 24: ...r broken parts Check for obstructions blocking carrier movement If pulley assembly is damaged replace Lubricate carrier to carrier frame engagement with grease P N 99A0394 6 Maintenance Station A prob...

Страница 25: ...es not come on during the scanning process check connector CN13 on the system board If the connection is okay check for a voltage reading of approximately 4 volts from ground to CN13 2 pin If voltage...

Страница 26: ...es not come on during the scanning process check connector CN8 on the system board If the connection is okay check for voltage reading of approximately 28 volts at pins CN8 1 CN8 2 CN8 3 CN8 4 If volt...

Страница 27: ...l 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 carr...

Страница 28: ...e sure the correct type of paper is being used Check for static in the paper FRU Action 1 System Board Run the Power On Self Test POST Sequence on page 2 1 Replace parts as needed To check the paper f...

Страница 29: ...hough the paper feeds in a forward direction only the paper feed motor turns in two directions If the paper feed motor turns in one direction only replace the system board Go to the System Board Remov...

Страница 30: ...U Action 1 Large and Small Feed Rollers Check for wear and binds 2 Small Feed Roller Springs Check for damage or disconnected springs 3 Auto Sheet Feeder Assembly Check the pick roller for wear 4 Mid...

Страница 31: ...es Paper Feed Motor Carrier Transport Motor Operator Panel Unplug the printer Disconnect the printhead cables and plug in the printer Look for a symptom change Check the failing part for shorts and re...

Страница 32: ...rint the self test page To enter the self test page press the Setup button and then Menu button until Print Report is displayed Press Options button until Self Test is displayed Then press the Start b...

Страница 33: ...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...

Страница 34: ...trol Program Check to see if there is any dust or debris on the glass lens of the CIS This may cause a poor image 2 Blank copies If blank copies found make sure that the original document is facing do...

Страница 35: ...nd pause then the 3 second 2100 Hz fax response tone and a 1650 Hz 1850 Hz warbling handshaking tone from the called machine Check the connectors on the line interface board P1 and P2 If okay check co...

Страница 36: ...2 20 Service Manual 4400 001...

Страница 37: ...n motor starts to rotate when the document detect sensor has detected the leading edge of the document The roller feeds the first page of the document into the feeder The scan motor is stopped when th...

Страница 38: ...t a document is loaded and the document scan sensor detects the scan position of the document The scanner mechanism consists of components which feed scan and eject the documents that are to be copied...

Страница 39: ...st Self Test Maintenance Cartridge Clean Cartridge Align Scanner Init Paper Size Letter A4 Legal Letter Ringer Volume Off Low Medium High Medium Fax Print Letter Quality Draft Quality Letter Quality F...

Страница 40: ...Receive Log Speed Dial List Self Test Protocol Dump ASF Test System Data NVRAM Dump CIS Pattern Maintenance Cartridge Clean Program Download Message Confirm On Off Error On Error Remote RCV Code 0 9...

Страница 41: ...hading is displayed 4 After scanning shading waveform is printed 5 After shading waveform has printed press Stop 6 Turn Off system and turn On Aging Test Scanner Aging Scanner part aging Printer Aging...

Страница 42: ...ed to the PC when you are running this test If cable is not connected it may cause a fatal error Message Confirm A message confirmation report shows whether the transmission was successful or not and...

Страница 43: ...tup when Yes is displayed to turn on the Error Correction Mode Press Start or Setup when No is displayed to turn off the Error Correction Mode Auto Reduction When receiving a document as long or longe...

Страница 44: ...ine rings before answering an incoming call If you are using your machine as both a telephone and a fax machine we suggest you set the ring count to at least 4 to give you time to answer 1 Press Setup...

Страница 45: ...ch button Each pressed button displays a corresponding number or symbol in the LCD panel If any button fails replace the operator panel Modem Speed Default 14400 bps Select baud rate of 14400 12000 96...

Страница 46: ...TX Level displays 3 Enter a number from 1 through 15 on the keypad Set RX Level Default 43 dBm Reception level may be too low due cable losses If set to 43 dBm reception sensitivity will be between 0...

Страница 47: ...to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge do not touch its pins If you are removing a pluggable module use t...

Страница 48: ...Procedures The following procedures are arranged according to the name of the printer part discussed CAUTION Unplug the power cord before removing any parts Releasing Plastic Latches Many of the part...

Страница 49: ...st be replaced as close as possible to their original positions Before removing any component from the machine note the cable routing When servicing the machine 1 Check to verify that documents are no...

Страница 50: ...l 2 Push the bushing on both ends of the roller slightly inward then rotate it until it reaches the slot as shown Then lift the roller out Note Check the roller for any dirt If dirty wipe it off with...

Страница 51: ...Top Cover Assembly Removal 1 Open the operator panel and open the print cartridge compartment cover Remove the white roller assembly Remove the six screws as shown 2 Remove the three screws as shown a...

Страница 52: ...Assembly Exit Shaft Removal 1 Remove the top cover assembly See Top Cover Assembly Removal on page 4 5 2 Take out the rollers from the base assembly Note Clean the surface of the rollers with ethyl a...

Страница 53: ...emove the top cover assembly See Top Cover Assembly Removal on page 4 5 2 Remove the drive feed roller See Rollers Drive Feed Roller Assembly Exit Shaft Removal on page 4 6 3 Remove one screw securing...

Страница 54: ...over Remove one screw to release the CIS from the bracket Note Be careful not to lose the springs Note Check the glassy surface of the CIS for any stain or scratch If stained wipe off with ethyl alcoh...

Страница 55: ...er Motor with Gear Assembly Removal 1 Remove the top cover assembly See Top Cover Assembly Removal on page 4 5 2 Unplug the motor connector from the system board Make sure the harness is released from...

Страница 56: ...4 10 Service Manual 4400 001 3 Remove two screws as shown and remove the scan motor assembly 4 Remove the two screws securing the motor to the motor bracket...

Страница 57: ...1 4400 001 Power Supply Removal 1 Remove the top cover assembly See Top Cover Assembly Removal on page 4 5 2 Unplug the power supply connector from the system board Make sure the harness is released f...

Страница 58: ...4 12 Service Manual 4400 001 3 Remove one screw securing the ground wires to the bracket 4 Push down on the hooks on both ends and remove the power supply...

Страница 59: ...01 Line Interface Board Removal 1 Remove the top cover assembly See Top Cover Assembly Removal on page 4 5 2 Remove the one screw securing the ground wires to the bracket 3 Unplug the line interface c...

Страница 60: ...ice Manual 4400 001 4 Pull the snap as shown to unlock the line interface board from the system board Push up on the line interface board 5 Unplug all the connectors from the line interface board and...

Страница 61: ...mbly Removal on page 4 5 2 Disconnect the operator panel cable from the system board 3 Release harness from harness hook 4 Remove the two ground strap screws 5 Turn the tie stopper 90 degrees as shown...

Страница 62: ...y Removal on page 4 5 2 Remove the paper support extension 3 Release lower paper guide tabs 4 Release upper paper guide tab 5 Remove the paper guide 6 Remove the paper deflector 7 Remove three screws...

Страница 63: ...cover assembly See Top Cover Assembly Removal on page 4 5 2 Remove paper support extension 3 Release lower paper guide tabs 4 Release upper paper guide tab 5 Remove paper guide 6 Remove paper deflect...

Страница 64: ...4 18 Service Manual 4400 001 11 Remove ASF assembly...

Страница 65: ...Repair Information 4 19 4400 001 Maintenance Station Removal 1 Remove the printer unit 2 Remove one screw 3 Rease two tabs from the rear of the maintenance station and remove the maintenance station...

Страница 66: ...sconnect the carrier cables from the system board 3 Release tab on carrier cable guide 4 Release carrier cable guide from frame 5 Remove pulley stopper 6 Depress the belt tensioner and remove the belt...

Страница 67: ...1 System Board Removal 1 Remove the top cover assembly See Top Cover Assembly Removal on page 4 5 2 Remove two screws securing the system board 3 Unplug all connectors 4 Pull the sensor lever toward y...

Страница 68: ...rom friction roller assembly 6 Remove exit roller assembly 7 Release four springs on small feed roller assembly 8 Press down and remove each section of lower portion of small feed roller assembly 9 Re...

Страница 69: ...emove the printer unit See Printer Unit Removal on page 4 16 2 Remove the mid frame assembly See Mid Frame Assembly with Exit Rollers Removal on page 4 22 3 Remove the maintenance station 4 Remove the...

Страница 70: ...ly with Gears Removal 1 Remove the printer unit See Printer Unit Removal on page 4 16 2 Remove the large feed roller assembly See Large Feed Roller Assembly with Gear Removal on page 4 23 3 Remove the...

Страница 71: ...moval on page 4 5 2 Manually move the carrier to the center of the machine 3 Remove the idler pulley assembly spring cover retainer 4 Press the idler pulley and remove the belt from the carrier transp...

Страница 72: ...4 26 Service Manual 4400 001...

Страница 73: ...4400 001 5 Connector Locations System Board Units Description CN5 Carrier Motor CN8 Scanner Motor CN10 Power Supply CN11 Paper Feed Motor CN12 Door Switch CN13 CIS CN15 Line Interface Board CN16 Spea...

Страница 74: ...5 2 Service Manual 4400 001 Logic Card Units Description P1 System Board P2 Phone Lines...

Страница 75: ...Connector Locations 5 3 4400 001 Power Supply Units Description J5 System Board...

Страница 76: ...5 4 Service Manual 4400 001...

Страница 77: ...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...

Страница 78: ...6 2 Service Manual 4400 001...

Страница 79: ...ommon 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 t...

Страница 80: ...7 2 Service Manual 4400 001 Assembly 1 Main Assembly...

Страница 81: ...ort Paper Extension 2 12G6932 1 Guide Paper 3 12G6931 1 Deflector Paper 4 12G6935 1 Cover Top Assembly 5 12G6934 1 CIS White Roller Assembly 6 12G6936 1 Tray Paper Exit Assembly 7 12G6937 1 Tray Scan...

Страница 82: ...7 4 Service Manual 4400 001 Assembly 2 Base Unit...

Страница 83: ...wer Supply 6 12G6940 1 Base Assembly 7 12G6946 1 Motor Scanner with Gear Assembly 8 12G6947 1 Motor Carrier Assembly 9 12G6948 1 Shaft Exit 10 12G6941 1 Drive Feed Roller Assembly 11 12G6949 1 Strap O...

Страница 84: ...7 6 Service Manual 4400 001 Assembly 3 Engine...

Страница 85: ...12G6965 1 Spring Carrier Shaft Retainer 7 12G6956 1 Maintenance Station Assembly 8 12G6966 1 Bearing Feed Roller 9 12G6962 1 Feed Roller Large with Gear 10 12G6964 1 Frame Mid Assembly with Exit Rolle...

Страница 86: ...7 8 Service Manual 4400 001...

Страница 87: ...sport 2 3 Maintenance Station 2 3 Operator Panel 2 3 Paper Feed 2 6 Power 2 6 Print Quality 2 6 Printer Communication 2 5 Scanner 2 5 Program Download 3 6 R Remote RCV Code 3 7 Removal Procedures 4 2...

Страница 88: ...ment Sensors 3 2 Drive Feed Roller Assembly 3 1 Scanner 3 1 U User Mode 3 3 Part Numbers 12G6931 7 3 12G6932 7 3 12G6933 7 3 12G6934 7 3 12G6935 7 3 12G6936 7 3 12G6937 7 3 12G6938 7 3 12G6939 7 3 12G...

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