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Lexmark 031 Printer User Manual

1. RE er Units Description 2 1 11B5130 1 Frame Carrier 2 11B5142 1 Motor Carrier Transport Assembly 3 11B5144 1 Screw PP 4 11B5136 1 End of Form Flag and Spring 5 1185144 1 Spring Small Feed Roll Asm PP 6 11B5135 1 Feed Roll Assembly Small 7 11B5137 1 Drive Train Assembly with Paper Feed Motor 8 11B5144 1 Arm Tensioner PP 9 11B5144 1 Belt Carrier PP 10 11B5134 1 Feed Roll Assembly Large with Gear 11 11B5133 1 Frame Mid Assembly 12 11B5143 1 Maintenance Assembly NS 11B5144 6 Screw PP Parts Catalog 7 5 4096 00X Assembly 3 Electronics 7 6 Service Manual 4096 00X Asm Part ARE Index Number Units Description 3 1 11B5130 1 Frame Carrier 2 11B5138 1 System Board with ROM LV 001 002 2 11B6044 1 System Board with ROM HV 001 002 2 1720180 1 System Board with ROM LV amp HV 003 004 3 11B5139 1 Power Supply 110V 3 11B5140 1 Power Supply 220V 4 11B5125 1 Base Asm and Sheet Feed 001 002 5 11B5141 1 Power Cord U S 11B5624 Power Cord Austria 11B5622 Power Cord Belgium 11B5624 Power Cord Brazil 11B5624 Power Cord Canada 11B5622 Power Cord Chile 11B5622 Power Cord Cyrillic 11B5622 Power Cord Denmark 11B5622 Power Cord East Turkey 11B5622 Power Cord Europe 11B5622 Power Cord Finland 11B5622 Power Cord France 11B5622 Power Cord Germany 11B5622 Power Cord Greece 11B5623 Power Cord Israel 11B5622 Power Cord Italy 11B5141 Power Cord
2. 2 6 Maintenance Station Service Check 2 7 Paper Feed Service Check au kate ERE xx EXE xn non 2 8 Paper Path Service Check 2 10 Power Service Check aaa 2 11 Print Quality Service Check ua 2 12 Diagnostic Alds 22 0666 suussauussuuasaumussuansagessuu 3 1 Repair Information ceaerensszuesimedsiteueieeeis EE dr 4 1 Handling ESD Sersilivo Pars coses dei cuir E nri px ha T Eg 4 1 POUSINSNS raras rara aaa 4 2 Removal ProSeQUres sans en 4 2 Releasing Plastic Latches csse eer RR Rm RR 4 2 Access Cover Removal 4222s eme danses esse 4 2 Base and Sheet Feed Assembly Removal 4 2 Carrier Bell Removalssesiseeassiosisemassositatasses 4 3 Carrier Frame Assembly Removal 4 3 Carrier Transport Motor Removal 4 3 Drive Train Assembly Removal 4 4 End or Form Flag Removal sea sens th ERE aan 4 4 Front Cover Bomoval saasssesmiseses edax on wedeawese 4 5 Large Feed Hell Removal 452i a 4 5 Maintenance Station Assembly Removal 4 5 Mid Frame Assembly Removal 4 6 Power Supply Removal 404 nera mmt nm s 4 6 Printhead Carrier Assembly Removal 4 6 4096 00X Small Feed Roll Assembly Removal 4 6 System Board Removal ss sas anne ana nn 4 7 Connector Locations 5 1 System Board Connectors ssiiar
3. Fails to cap the printhead Fails to clean the printhead Go to the Maintenance Station Service Check on page 2 7 Paper Feed Button Problems Symptom Action Paper feed button does not operate Replace the system board 2 2 Service Manual 4096 00X Paper Feed Problems Symptom Action Fails to pick paper Picks more than one sheet of paper Picks paper but fails to feed Paper jams Paper fails to exit Noisy paper feed ee o o Envelopes fail to feed Go to the Paper Feed Service Check on page 2 8 Go to the Envelope Feed Service Check on page 2 6 Paper skews Power Problems Go to the Paper Feed Service Check on page 2 8 Symptom Action No power in machine No motors operating Print Quality Problems 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 eee o o o o 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 4096 00X POST Symptom Table Symptom Action No power and Go to the Power Service Chec
4. 00X FRU Function Action 4 System Board Printhead Cable Rubber Backer 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 tI II EE 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 6 Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area Check the following Correct type of paper is being used Also check the paper for curl or wrinkles Feed
5. 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 4096 00X Table of Contents Notices and Safety Information V General Information 1 1 Power ConsumptllOI 22 88 sc eme a ae ie aa da 1 1 Maintenance Approach ss sacs mamans ange ae E xc n 1 1 AbbreviatlOnS ao a au a a d a uaa coh un 1 2 Diagnostic Information 2 1 cci ran cad A 2 1 Power On Self Test POST Sequence 2 1 ovimplom Tables aussi 2 2 POST Symptom Tans saei aa dies eds eripiat en 2 4 SOMOS CHECKS arras 2 5 Carrier Transport Service Check 2 5 Envelope Feed Service Check
6. Japan 11B5622 Power Cord Mexico 11B5622 Power Cord Netherlands 11B5622 Power Cord Norway 11B5626 Power Cord Peru 11B5622 Power Cord Portugal 11B5625 Power Cord South Africa 11B5622 Power Cord Spain 11B5622 Power Cord Sweden 11B5621 Power Cord UK Ireland Parts Catalog 7 7 4096 00X Assembly 4 Carrier 7 8 Service Manual 4096 00X dos Maney Units Description 4 1 11B5131 1 Carrier Assembly with Carrier Home Sensor 2 11B5132 1 Rod Carrier Guide 3 11B5130 1 Frame Carrier 4 11B5144 1 Spring Carrier Guide Rod PP Parts Catalog 7 9 4096 00X Assembly 5 Sheet Feeder 7 10 Service Manual 4096 00X pid Ne Units Description 5 1 11B5130 1 Frame Carrier 2 11B5125 1 Base Sheet Feeder Asm and Garage Assembly 001 002 2 1720170 1 Base Sheet Feeder Asm and Garage Assembly 003 2 1720171 1 Base Sheet Feeder Asm and Garage Assembly 004 3 11B5126 1 Support Upper Paper 001 002 3 1720172 1 Support Upper Paper 003 3 1720173 1 Support Upper Paper 004 4 1720178 1 Tray Exit 003 4 1720179 1 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 8 Electronics 7 6 4 Carrier 7 8 5 Sheet Feeder 7 10 C Connectors System Board 5 1 E ESD Sensitive Parts 4 1 L Lu
7. 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 4096 00X 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 1 2 Service Manual 4096 00X 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 2 3 4 The carrier moves The paper feed gears turn After 30 seconds the carrier moves over the maintenance station and caps the printhead 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 4096 00X Symptom Tables Carrier Transport Problems Symptom Action No carrier movement Slow carrier movement Carrier stops Carrier slams side frame Go to the Carrier Transport Ser vice Check on page 2 5 Maintenance Station Problems Symptom Action Maintenance station
8. power supply cable N1 1to 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 4096 00X Print Quality Service Check FRU Function Action 1 Print Cartridge Be sure the machine contains a good print cartridge 2 Color Print Cartridge Cross Contamination 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 2 12 Service Manual 4096
9. Lexmark n o respons vel pela utiliza o de outros componentes de substituic o As informa es de seguran a relativas a este produto destinam se a profissionais destes servicos e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servicos devem estar avisados deste facto e tomar os cuidados necess rios Notices and Safety Information vii 4096 00X Informaci de Seguretat Aquest producte est dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi e La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui e El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients viii Service Manual 4096 00X REG re 2 Jh of rh pem ro x ARP Ae ARP Lexmark JUE FPR RARE FRET WARE ALE EY RA DI RE HI BE AS GL APTA SERS EA Lexmark MAR ARF d BY EP BE EARS AEA TSE EDO RUE HA o ARP AE NE ECAA AR Sel A A E
10. RE ZUR BMS ARIS BDA P TE FORUM TU TEN ost al TO Dit r rlo SH Lexmark TA L49 ALSO SA GAS EO HS SA H ESSI en Lc a t o case SA masa exmark CE mal 32 algo ch st E non E E E 9 i E MES ASAL Sule AP AIA SAS WALL AME elm qdo ABU Me qua SHE Ol AAS SAS Best ut ZE ASES SAIS Notices and Safety Information ix 4096 00X X Service Manual 4096 00X 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 Paper Support Printer Model Color Exit Tray Lexmark 1000 Color 001 Gray No Jetprinter 002 Black No Lexmark 1100 Color 003 Gray Yes Jetprinter 004 Black 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
11. arrier 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 atab 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 3 Cap A worn cap causes the printhead nozzles to dry and clog Check for a loose or worn cap Diagnostic Information 2 7 4096 00X Paper Feed Service Check If your machine does not have paper jam problems continue with the service check If your machine does have a paper jam problem examine it for the following before you begin the service check Check the entire paper path for obstructions Besure there is not too much paper in the sheet feeder Besure the correct type of paper is being used Check for static in the paper FRU Action 1 System Board Turn the printer on and verify the paper feed motor activates Be sure the end of form sensor lever is in the down position Tur
12. brication 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 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 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 Index l 1 4096 00X l 2 Service Manual Reader Comment Lexmark 1000 1100 Color Jetprinter Form 4096 00X Service Manual U S P N 1720168 Japan 1720169 May 1998 You may use this form to communicate your comments about this publication with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you 1 Did you find the book well organized Yes O No O 2 Was the content of the book accurate and complete Yes I No O 3 Was the book easy to use Yes I No O 4 W
13. e 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 e PP inthe parts description column indicates the part is available in the listed parts packet Parts Catalog 7 1 4096 00X Assembly 1 Covers 4096 00X pid se Units Description 1 1 11B5128 1 Cover Access Asm Star Wheels 002 1 11B5129 1 Cover Access Asm Star Wheels 001 1 1720177 1 Cover Access Asm Star Wheels 003 1 1720176 1 Cover Access Asm Star Wheels 004 2 11B5127 1 Cover Front Asm amp Button 001 002 2 1720174 1 Cover Front Asm amp Button 003 2 1720175 1 Cover Front Asm amp Button 004 3 11B5125 1 Base Asm and Sheet Feed 001 002 3 1720170 1 Base Asm and Sheet Feed 003 3 1720171 1 Base Asm and Sheet Feed 004 NS 11B5111 1 Support Banner Paper NS 7349593 1 Replaceable Package B M Includes Carton Cushion Set Sealing Tape 001 002 NS 7350132 1 Replaceable Package B M Includes Carton Cushion Set Sealing Tape 003 004 Parts Catalog 7 3 4096 00X Assembly 2 Paper Feed Carrier Transport Maintenance 7 4 Service Manual 4096 00X
14. e b 1000 Color Jetprinter 1100 Color Jetprinter 4096 00X Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK 4096 00X 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
15. ed motor is a part of the drive train assembly End of Form Flag Removal Pon N 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 4 4 Service Manual 4096 00X Front Cover Removal 1 2 Release the two hooks A in the illustration by using a screwdriver While pushing the left side edge of the front cover upward release the hook B Repeat this on the right side Slide the front cover forward and remove it from the rear cover Large Feed Roll Removal c1 D 6 T 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 Remove the mid frame assembly Remove the large feed roller from the carrier frame Maintenance Station Assembly Removal 1 2 3 Remove the front cover Release the two hooks on the rear of the maintenance sta
16. hat can we do to improve the book 5 What is your job title Questions or comments about supplies service applications and so on slow response time considerably Please refer those questions or comments to your authorized dealer or point of purchase Note Please direct all requests for copies of publications to your point of purchase Publications are not stocked at the location to which this form is addressed NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 0353 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape eur Buoy m9
17. k on page 2 11 the motors do not run Paper feed Go to the Paper Feed Service Check on page 2 8 gears do not turn Carrier doesn t Go to the Carrier Transport Service Check on move page 2 5 Carrier slams Go to the Carrier Transport Service Check on side frame page 2 5 2 4 Service Manual 4096 00X Service Checks Carrier Transport Service Check FRU Action 1 System Board 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 A noisy or chattering motor or a motor that fails to Motor turn can be caused by An open or short in the motor An open or short in the motor driver on the System board Abind 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 N 6 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 Check for worn loose or broken parts Check for Belt obstructions blocking carrier movemen
18. k ne peut tre tenu responsable de l utilisation d autres pi ces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Notices and Safety Information V 4096 00X Norme di sicurezza e prodotto stato progettato testato e approvato in conformit 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 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 pi elevato Il personale 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 weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nich
19. n 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 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 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 8 Service Manual 4096 00X FRU Action Drive Train Check for binds in the gear train and paper feed Assembly mechanism by removing the paper feed motor and rotating the large gear by hand If you notice a bind replace the drive train assembly Check the feed clutch gear on
20. ng 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 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 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 dis charge 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 elect
21. oard 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 Power Supply N2 Parallel Port N3 Printhead Cable 1 N4 Printhead Cable 2 N6 Carrier Transport Motor N7 Paper Feed Motor S1 Paper Feed Switch 1 m O 0000 pg U i AN Ng Nu M UJ N 1 U UI U NN Di JL FA up LA PEUX El a 0 d 1 V 1 0000 Xm E Y N7 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 e 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 Us
22. ricity Repair Information 4 1 4096 00X 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 O O1 E ND Remove the front cover Remove the retainer spring from the right side of the carrier rod Slide the carrier rod to the right o
23. rollers for wear dirt or looseness Gears for wear or binds Paper path for obstructions Diagnostic Information 2 13 4096 00X FRU Function Action 7 Carrier Transport Blurred print and voids can be caused by problems in the carrier transport area Check the following Carrier transport belt for wear Carrier guide rod for wear or dirt Carrier to carrier frame engagement should be lubricated with grease P N 1329301 as well as the carrier guide rod and bearing ldler 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 2 14 Service Manual 4096 00X 3 Diagnostic Aids There are no residence diagnostic aids associated with the 4096 printers Diagnostic Aids 3 1 4096 00X 3 2 Service Manual 4096 00X 4 Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts Note Read the following before handling electronic 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 turni
24. sis aksa itira Ra sagesse 5 1 Preventive Maintenance 6 1 Lubrication Specilicatlons iuucs2aabcke qe erc ra deu pads uds 6 1 Parts Catalog u 20a sn rain 7 1 How To Use This Parts Catalog aan san ann 7 1 Assembly T Cover ei 7 2 Assembly 2 Paper Feed Carrier Transport Maintenance 7 4 ASSBHIDIy 3 EJlSEHONlEB asus 7 6 Assembly 4 Barmer aan 7 8 Assembly 5 Sheet Feeder sc u 2 uu au ss eR a 7 10 INDEX EE 0 AAA A 1 1 iv Service Manual 4096 00X 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 S curit Ce produit a t congu test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmar
25. t Idier Pulley Parts Carrier Frame Carrier to carrier frame engagement should be lubricated with grease P N 1329301 Diagnostic Information 2 5 4096 00X FRU Action 5 Home Position Sensor 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 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 Envelope Feed Service Check 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 2 6 Service Manual 4096 00X 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 Action 1 Maintenance As the carrier moves to the right over the Station Assembly maintenance station a slot on the bottom of the c
26. t von Lexmark sind wird von Lexmark keinerlei Verantwortung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen vi Service Manual 4096 00X Pautas de Seguridad Este producto se ha dise ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio Lainformaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informac es de Seguranca Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguranca na utilizac o de componentes espec ficos da Lexmark As fung es de seguran a de alguns dos componentes podem n o ser sempre bvias A
27. 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 Auto Sheet Check the pick rollers for wear Feeder Mid Frame Asm Access Cover Asm Check the following for wear Friction wheels Exit roller Star rollers End of Forms Flag and Spring Check for binds or damage If binds are found replace the end of forms flag End of Forms Sensor Check the sensor for dirt Be sure the sensor lever is in the down position If the failure remains replace the system board Diagnostic Information 2 9 4096 00X Paper Path Service Check Examine the machine for the following before you begin this service check Check the entire paper path for obstructions Besure the correct type of paper is being used e Besure the printer is installed on a flat surface FRU Action 1 Large and Small Check for wear and binds Feed Rollers 2 Small Feed Roller Check for damage Springs 3 Auto Sheet Check the pick rollers for wear Feeder 4 Mid Frame Asm Check the following for wear Access Cover Asm Friction wheels Exit roller Starrollers 5 End of Forms Check for binds or damage Flag 2 10 Service Manual 4096 00X Power Service Check FRU Action 1 Power Supply Disconnect N1 from the system board and check the following voltages on the
28. tion Remove the maintenance station by sliding it forward Repair Information 4 5 4096 00X Mid Frame Assembly Removal on D 6 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 Remove the mid frame assembly Power Supply Removal SONDE 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 e Remove the front cover Disconnect the printhead cable from the system board Remove the retainer spring from the right end of the carrier guide rod Slide the carrier guide rod out the right side of the machine Remove the belt from the back of the carrier Lift the carrier out of the machine Small Feed Roll Assembly Removal qom 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 b
29. ut 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 Remove the front cover Remove the five screws that secure the carrier frame to the base assembly and power supply ground strap Disconnect the power supply connector at the system board and cut the wire clamp on the left side Remove the carrier frame from the base assembly and lift it off the base Remove the two screws that secure the power supply to the base 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 moo mo 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 A O OT 0 TN 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 Remove the two screws securing the drive train to the carrier frame Push the drive train to the right and remove it from the carrier frame Note The paper fe

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