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4-14

Service Manual

4402-001

Maintenance Station Removal

1. Remove the middle frame assembly.

2. Remove the print engine.

3. Depress the two clips [A].

4. Remove the maintenance station.

Belt/Idler Pulley Assembly (Print Engine) Removal

1. Remove the middle frame.

2. Slide the carrier to the left.

3. Loosen the belt tensioner adjuster screw.

4. Depress the belt tensioner and remove the belt from the pulley.

5. Depress the latch.

6. Slide the belt tensioner to the right and remove.

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Содержание X73 4402-001

Страница 1: ...an Print Copy Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Index Safety and Notices Trademarks Start Diagnostics Table of Contents ...

Страница 2: ...2 2 740 West 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 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 Le...

Страница 3: ...POST Symptom Table 2 2 Symptom Tables 2 3 Service Checks 2 6 Carrier Transport Service Check 2 6 CCD Module Assembly Service Check 2 8 Gear Train Assembly Service Check 2 9 Maintenance Station Service Check 2 10 Paper Feed Service Check 2 11 Paper Path Service Check 2 13 Power Service Check 2 14 Print Quality Service Check 2 15 Scan Copy Quality Service Check 2 17 Diagnostic Aids 3 1 Test Page 3 1...

Страница 4: ...Right Cover Removal 4 7 Access Cover Removal 4 7 Left Cover Removal 4 8 Middle Frame Removal 4 9 Print Engine Removal 4 11 ASF Module Removal 4 12 System Board Removal 4 12 Carrier Removal 4 13 Encoder Strip Removal 4 13 Maintenance Station Removal 4 14 Belt Idler Pulley Assembly Print Engine Removal 4 14 Connector Locations 5 1 Preventive Maintenance 6 1 Lubrication Specifications 6 1 Parts Catal...

Страница 5: ...ervicing 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 respo...

Страница 6: ...rsonale 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...

Страница 7: ...aración 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 ...

Страница 8: ...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 h...

Страница 9: ...Safety Information ix 4402 001 ...

Страница 10: ...tic 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 scanner printer copier problems 4 Repair Information provides instructions for making printer adjustments and removing and installing FRUs 5 Connector Locations uses illustrations to...

Страница 11: ...t print cartridge available as a customer replaceable supply item Dual printheads provide color and true black printing without changing printheads The number and size of inkjets or nozzles in the printhead determines the overall quality and capability of the printer The black cartridge has a total of 208 nozzles and installs on the right The color cartridge has a total of 192 nozzles and installs...

Страница 12: ...l 68 7 Billion Colors 24 Bit External 16 7 Million Colors Gray Mode 12 Bits Internal 4 096 Shades of Gray 8 Bits External 256 Shades of Gray Text Line Art 1 Bit Per Pixel Scan Method One Pass Scanning Scan Area 8 5 X 11 7 inches 216 X 292 mm Scan Resolution Optical 600 dpi H X 1200 dpi V Interpolated 9600 X 9600 ...

Страница 13: ...y Make a black and white copy Scan Press the scan button after selecting a Scan To destination Scan To Select a scan destination such as To copy To and e mail To an application To a file or To fax Scan To E mail Scan an image or document and send with an e mail message Scan To Fax Scan an image or document and send as a fax Paper Feed Load or eject a sheet of paper from the printer Power Turn the ...

Страница 14: ...and repair the failure After you complete the repair perform tests as needed to verify the repair Abbreviations B M Bill of Material CCD Charged Coupled Device EOF End of Form ESD Electrostatic Discharge FPC Flat Printhead Cable 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 direc...

Страница 15: ... light turns on The paper feed motor runs then stops Status light stays on for a second and turns off The carrier moves to the left then returns to the right stopping at the maintenance station 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 sym...

Страница 16: ...page 2 3 Paper feed gears do not turn Go to the Paper Feed Service Check on page 2 11 Carrier does not move Go to the Carrier Transport Service Check on page 2 6 Carrier slams side frame Go to the Carrier Transport Service Check on page 2 6 CCD does not move Go to the Gear Train Assembly Service Check on page 2 9 CCD lamp does not turn on Go to the CCD Module Assembly Service Check on page 2 8 ...

Страница 17: ...e printheads Fails to clean the printheads Go to the Maintenance Station Service Check on page 2 10 Symptom Action Buttons do not work Power or status lights do not work Check operator panel cable connection at J6 on the system board Then run the Power On Self Test POST Sequence on page 2 1 If operator panel fails replace the operator panel assembly If the problem still exists replace the system b...

Страница 18: ...m Board Removal on page 4 12 Symptom Action CCD does not move Lamp does not light Go to the CCD Module Assembly Service Check on page 2 8 Go to the Gear Train Assembly Service 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 Scan Copy Quality Service C...

Страница 19: ...Feed Service Check on page 2 11 Paper skews Go to the Paper Path Service Check on page 2 13 Symptom Action No power in machine motors do not operate Go to the Power Service Check on page 2 14 Symptom Action Voids in characters Light print Prints off the page Fuzzy print Carrier moves but no print Printhead dries prematurely Colors print incorrectly Vertical alignment off Go to the Print Quality Se...

Страница 20: ...tor Check the motor for binds or loose motor pulley A noisy or chattering motor or a motor that fails to turn can be caused by An open or short in the motor An open or short in the motor driver on the system board A bind in the carrier transport mechanism With the carrier transport motor cable J4 disconnected from the system board check for 0 to 10 ohms between the following pins on the motor J4 1...

Страница 21: ...ne Removal on page 4 14 Lubricate carrier to carrier frame engagement with grease P N 99A0394 6 Printhead Carrier Assembly Disconnect the printer and check the carrier printhead connector J2 If the connection is good remove the printhead carrier and check the cable connection to the home sensor board If the problem remains replace the system board Go to the System Board Removal on page 4 12 7 Main...

Страница 22: ...d Lexmark Scan and Copy Control program is not opened the CCP lamp will not come on If lamp does not come on as CCD module assembly is scanning or moving check connector J7 on the system board If connected and the lamp still does not work replace the CCD module assembly If the lamp does not correct the problem after the CCD replacement replace the system board See System Board Removal on page 4 12...

Страница 23: ...Gear Train Assembly Removal on page 4 6 If the reading is correct check at pins 1 through 6 for approximately 28 volts with the machine turned on If the voltage is incorrect replace the system board Go to the System Board Removal on page 4 12 Note Ensure scanner is unlocked 2 Scanner Belt Check the belt for proper installation If the belt is damaged replace Go to the Belt Idler Pulley Assembly Pri...

Страница 24: ...he 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 engag...

Страница 25: ...ch paper in the sheet feeder Be sure the correct type of paper is being used Check for static in the paper FRU Action 1 System Board Run the Power On Self Test POST Sequence on page 2 1 Replace parts as needed To check the paper feed motor disconnect the paper feed connector J3 and check for approximately 5 ohms between pins 3 and 4 If the reading is incorrect replace the print engine Go to the Pr...

Страница 26: ... 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 Removal on page 4 12 Binds in the paper feed motor or gear train can cause intermittent false paper jam errors Remove the paper feed motor and check the shaft for binds Also check for a loose or worn motor gear 3 Auto Sheet Feede...

Страница 27: ... sure the correct type of paper is being used Be sure the printer is installed on a flat surface FRU Action 1 Large and Small Feed Rollers Check for wear and binds 2 Small Feed Roller Springs Check for damage 3 Auto Sheet Feeder Assembly Check the pick roller for wear 4 Mid Frame Asm Check the following for wear Exit roller Star rollers 5 End of Forms Flag Check for binds or damage ...

Страница 28: ...aper Feed Motor Carrier Transport Motor Operator Panel Unplug the printer Disconnect the printhead cable 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 transport motor paper feed motor and operator panel 3 System Board If the symptom has not changed replace the system board Go to the System Board Re...

Страница 29: ...the printhead cable in the system board and check the following parts for wear or damage Printhead Cartridge Latch Latch Spring Carrier 4 System Board Printhead Carrier Assembly Perform the Test Page on page 3 1 Look for a break in the diagonal line of the nozzle test pattern A broken line indicates one or more print nozzles are not working Run the test again to verify the failure Check the gold p...

Страница 30: ...oids 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 printhead alignment adjust...

Страница 31: ...re two ways to make the adjustment From the Lexmark Scan and Copy Control program Check to see if there is any dust debris on the glass This may cause a poor image Check the press plate on the scan lid for any dust or debris 2 Blank copies If there are blank copies make sure the original document is facing down on the scanner bed Check the print cartridges to see if they need to be cleaned or repl...

Страница 32: ...2 18 Service Manual 4402 001 ...

Страница 33: ...ton and releasing it 6 Paper feeds into the printer 7 The test page prints The test page consists of three color bars nozzle purge pattern black purge pattern black nozzle purge pattern and heater checks Note To stop test page press the power button again The test page prints three color bars nozzle purge pattern black purge pattern black nozzle purge pattern and heater checks The purge pattern is...

Страница 34: ...3 2 Service Manual 4402 001 ...

Страница 35: ...em 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...

Страница 36: ...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 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 ...

Страница 37: ...3 4402 001 Scanner Lid Assembly Removal 1 Open the lid 2 Lift and remove Rear Cover Removal 1 Remove two screws A from the rear cover 2 Depress two latches B on the bottom of the rear cover 3 Lift the rear cover and remove ...

Страница 38: ...ift the operator panel and remove Top Housing Assembly Removal 1 Remove the scanner lid 2 Remove the rear cover 3 Disconnect the operator panel cable from the system board 4 Remove the operator panel 5 Remove two screws from the top housing 6 Lift the right side of the housing 7 Remove the top housing assembly Paper Support Removal 1 Open the paper support 2 Depress the paper support at the hinge ...

Страница 39: ...ssembly Removal 1 Remove the rear cover 2 Disconnect the CCD cable from the system board 3 Remove the top housing assembly 4 Depress the shaft retainer A 5 Lift and remove the shaft 6 Remove the belt from pulleys 7 Lift and remove the CCD module ...

Страница 40: ...ar train assembly cable from the system board 3 Remove two screws A 4 Lift and remove the gear train assembly Access Cover Sensor Removal 1 Remove the top housing assembly 2 Disconnect the access cover sensor cable J9 from the system board 3 Remove the sensor screw B 4 Remove the sensor Note routing of cables ...

Страница 41: ...2 001 Right Cover Removal 1 Remove the rear cover 2 Depress two latches A 3 Remove the right cover Access Cover Removal 1 Remove the rear cover 2 Remove the right cover 3 Depress the access cover hinge 4 Remove the access cover ...

Страница 42: ...4 8 Service Manual 4402 001 Left Cover Removal 1 Remove the rear cover 2 Depress two latches A 3 Remove the left cover ...

Страница 43: ...1 Remove the scanner lid assembly 2 Remove the rear cover 3 Remove the top housing assembly 4 Disconnect the operator panel and CCD cables from the system board 5 Remove left and right covers 6 Remove the operator panel assembly 7 Remove the two screws A ...

Страница 44: ...4 10 Service Manual 4402 001 8 Depress the two clips B and slide the middle frame forward to remove ...

Страница 45: ...gine Removal 1 Remove the rear cover 2 Remove the top housing assembly 3 Remove the left cover 4 Remove the right cover 5 Remove the middle frame 6 Move carrier to the center 7 Remove three screws B 8 Slide the print engine forward and remove ...

Страница 46: ... 3 Remove the ASF module System Board Removal 1 Remove the print engine 2 Remove the ASF module 3 Disconnect the transport and paper feed motor cables from the system board 4 Remove the four screws 5 Remove the system board WARNING When removing the system board use care not to damage the EOF flag ...

Страница 47: ...ioner and remove the belt from the transport carrier motor gear 7 Remove both retainer clips from the carrier shaft 8 Remove the shaft and carrier Note Keep dirt and grease off of the encoder strip Obsesrve orientation of the encoder strip to the sensor located on the rear of the carrier Be careful not to damage the encoder strip when reinstalling the carrier Encoder Strip Removal 1 Remove the car...

Страница 48: ...e two clips A 4 Remove the maintenance station Belt Idler Pulley Assembly Print Engine Removal 1 Remove the middle frame 2 Slide the carrier to the left 3 Loosen the belt tensioner adjuster screw 4 Depress the belt tensioner and remove the belt from the pulley 5 Depress the latch 6 Slide the belt tensioner to the right and remove ...

Страница 49: ...ations 5 1 4402 001 5 Connector Locations Units Description J2 Printhead Cable J3 Paper Feed Motor J4 Carrier Transport Motor J5 Scanner Motor J6 Operator Panel J7 CCD Module J9 Cover Sensor PS1 End of Forms Sensor ...

Страница 50: ...5 2 Service Manual 4402 001 ...

Страница 51: ...eplaced or as needed not on a scheduled basis Use grease P N 99A0394 to lubricate the following All gear mounting studs The left and right ends of the large feed roller at the side frames The carrier to carrier frame engagement The carrier guide rod and carrier guide rod bearings WARNING Keep the grease from coming into contact with any electrical components may cause printer damage or failure Do ...

Страница 52: ...6 2 Service Manual 4402 001 ...

Страница 53: ...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 NA Not available as a FRU ...

Страница 54: ...7 2 Service Manual 4402 001 Assembly 1 Covers ...

Страница 55: ...12G6141 1 Cover Assembly Rear 2 12G6140 1 Felt Pad Assembly 3 12G6138 1 Base Assembly 4 12G6135 1 Cover Right 5 12G6133 1 Cover Access with Latch 6 12G6175 1 Paper Exit Tray 7 12G6134 1 Cover Left NS 12G6156 4 Screws PP NS 7366857 1 Plain package B M includes Carton Cushion Set Sealing Tape ...

Страница 56: ...7 4 Service Manual 4402 001 Assembly 1 cont Covers ...

Страница 57: ...mbly 1 cont Covers Assembly 1 Covers Asm Index Part Number Units Description 1 1 12G6171 1 Scanner Lid Assembly 2 12G6174 1 Paper Support ASF 3 12G6126 1 Top Housing Assembly 4 12G6122 1 Middle Frame Assembly 5 12G6150 1 Belt Scanner ...

Страница 58: ...7 6 Service Manual 4402 001 Assembly 2 Paper Feed Frame and Carrier Transport ...

Страница 59: ...ansport Asm Index Part Number Units Description 2 1 12G6121 1 ASF Module 2 12G6120 1 Printing Engine 3 12G6151 1 Encoder Strip with Clip 4 12G6123 1 Idler Pulley Assembly 5 12G6149 1 Belt Carrier 6 12G6154 1 Maintenance Station Assembly NS 12G6153 1 EOF Flag with Spring ...

Страница 60: ...7 8 Service Manual 4402 001 Assembly 3 Electronics ...

Страница 61: ...D Module Assembly NS 12G6176 1 CCD Cable 2 12G6125 1 Gear Train Assembly 3 12G6172 1 Operator Panel Assembly NS 12G6173 1 Operator Panel Overlays 4 12G6170 1 Board System 5 12G6137 1 Sensor Access Cover 6 12G6128 1 Power Supply LV 100 127 NS 12G6157 1 Power Supply HV 220 240 NS 12G6158 1 Power Supply Japan 100V ...

Страница 62: ...7 10 Service Manual 4402 001 ...

Страница 63: ...rame 7 6 Paper Feed 7 6 Plastic Latches 4 2 Power button 1 3 Power Consumption 1 1 1 3 Power On Self Test Sequence 2 1 Symptom Table 2 2 Problems Carrier Transport 2 3 Maintenance Station 2 3 Operator Panel 2 3 Paper Feed 2 5 Power 2 5 Print Quality 2 5 Scanner 2 4 R Removals Access Cover 4 7 Access Cover Sensor 4 6 ASF Module 4 12 Belt Idler Pulley Assembly 4 14 Carrier 4 13 CCD Module Assembly 4...

Страница 64: ...n 1 3 Specifications Scanner 1 2 Start 2 1 Symptom Table POST 2 2 Symptom Tables 2 3 T Test Page 3 1 Part Numbers 12G6120 7 7 12G6121 7 7 12G6122 7 5 12G6123 7 7 12G6124 7 9 12G6125 7 9 12G6126 7 5 12G6128 7 9 12G6133 7 3 12G6134 7 3 12G6135 7 3 12G6137 7 9 12G6138 7 3 12G6140 7 3 12G6141 7 3 12G6149 7 7 12G6150 7 5 12G6151 7 7 12G6153 7 7 12G6154 7 7 12G6156 7 3 12G6157 7 9 12G6158 7 9 12G6170 7 ...

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