Lexmark All in One Printer 4402 001 User Manual

Lexmark X73 Scan/Print/Copy  
• Table of Contents  
• Start Diagnostics  
• Safety and Notices  
• Trademarks  
• Index  
Lexmark and Lexmark with diamond  
design are trademarks of Lexmark  
International, Inc., registered in the  
United States and/or other countries.  
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4402-001  
Table of Contents  
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v  
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x  
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1  
Scanner Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2  
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3  
Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4  
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4  
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1  
Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-1  
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  
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1  
Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1  
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2  
iii  
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4402-001  
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2  
Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2  
Scanner Lid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-3  
Rear Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3  
Operator Panel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4  
Top Housing Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-4  
Paper Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4  
CCD Module Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .4-5  
Gear Train Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6  
Access Cover Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .4-6  
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  
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1  
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1  
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1  
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1  
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2  
Assembly 2: Paper Feed, Frame and Carrier Transport . . . . . . . . . .7-6  
Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1  
iv Service Manual  
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4402-001  
Safety Information  
This product is designed, tested and approved to meet strict  
global safety standards with the use of specific Lexmark  
components. The safety features of some parts may not always  
be obvious. Lexmark is not responsible for the use of other  
replacement parts.  
The maintenance information for this product has been  
prepared for use by a professional service person and is not  
intended to be used by others.  
There may be an increased risk of electric shock and personal  
injury during disassembly and servicing of this product.  
Professional service personnel should understand this and take  
necessary precautions.  
Consignes de Sécurité  
Ce produit a été conçu, testé et approuvé pour respecter les  
normes strictes de sécurité globale lors de l'utilisation de  
composants Lexmark spécifiques. Les caractéristiques de  
sécurité de certains éléments ne sont pas toujours évidentes.  
Lexmark ne peut être tenu responsable de l'utilisation d'autres  
pièces de rechange.  
Les consignes d'entretien et de réparation de ce produit  
s'adressent uniquement à un personnel de maintenance  
qualifié.  
Le démontage et l'entretien de ce produit pouvant présenter  
certains risques électriques, le personnel d'entretien qualifié  
devra prendre toutes les précautions nécessaires.  
Safety Information v  
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4402-001  
Norme di sicurezza  
Il prodotto è stato progettato, testato e approvato in conformità a  
severi standard di sicurezza e per lutilizzo con componenti  
Lexmark specifici. Le caratteristiche di sicurezza di alcune parti  
non sempre sono di immediata comprensione. Lexmark non è  
responsabile per lutilizzo di parti di ricambio di altri produttori.  
Le informazioni riguardanti la manutenzione di questo prodotto  
sono indirizzate soltanto al personale di assistenza autorizzato.  
Durante lo smontaggio e la manutenzione di questo prodotto, il  
rischio di subire scosse elettriche e danni alla persona è più  
elevato. Il personale di assistenza autorizzato, deve, quindi,  
adottare le precauzioni necessarie.  
Sicherheitshinweise  
Dieses Produkt und die zugehörigen Komponenten wurden  
entworfen und getestet, um beim Einsatz die weltweit gültigen  
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten  
Funktionen der Bauteile und Optionen sind nicht immer  
offensichtlich. Sofern Teile eingesetzt werden, die nicht von  
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder  
Haftung für dieses Produkt übernommen.  
Die Wartungsinformationen für dieses Produkt sind  
ausschließlich für die Verwendung durch einen  
Wartungsfachmann bestimmt.  
Während des Auseinandernehmens und der Wartung des  
Geräts besteht ein zusätzliches Risiko eines elektrischen  
Schlags und körperlicher Verletzung. Das zuständige  
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen  
treffen.  
vi Service Manual  
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4402-001  
Pautas de Seguridad  
Este producto se ha diseñado, verificado y aprobado para  
cumplir los más estrictos estándares de seguridad global  
usando los componentes específicos de Lexmark. Puede que  
las características de seguridad de algunas piezas no sean  
siempre evidentes. Lexmark no se hace responsable del uso de  
otras piezas de recambio.  
La información sobre el mantenimiento de este producto está  
dirigida exclusivamente al personal cualificado de  
mantenimiento.  
Existe mayor riesgo de descarga eléctrica y de daños  
personales durante el desmontaje y la reparación de la  
máquina. El personal cualificado debe ser consciente de este  
peligro y tomar las precauciones necesarias.  
Informações de Segurança  
Este produto foi concebido, testado e aprovado para satisfazer  
os padrões globais de segurança na utilização de componentes  
específicos da Lexmark. As funções de segurança de alguns  
dos componentes podem não ser sempre óbvias. A Lexmark  
não é responsável pela utilização de outros componentes de  
substituição.  
As informações de segurança relativas a este produto  
destinam-se a profissionais destes serviços e não devem ser  
utilizadas por outras pessoas.  
Risco de choques eléctricos e ferimentos graves durante a  
desmontagem e manutenção deste produto. Os profissionais  
destes serviços devem estar avisados deste facto e tomar os  
cuidados necessários.  
Safety Information vii  
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4402-001  
Informació de Seguretat  
Aquest producte està dissenyat, comprovat i aprovat per tal  
d'acomplir les estrictes normes de seguretat globals amb la  
utililització de components específics de Lexmark. Les  
característiques de seguretat d'algunes peces pot ser que no  
sempre siguin òbvies. Lexmark no es responsabilitza de l'us  
d'altres peces de recanvi.  
La informació pel manteniment daquest 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 daquest producte.  
El personal professional ha destar-ne assabentat i prendre les  
mesures convenients.  
viii Service Manual  
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4402-001  
Safety Information ix  
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4402-001  
Preface  
This manual describes the Lexmark X73 Scan/Print/Copy (4402-  
001) and contains maintenance procedures for service personnel  
only. 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 in this chapter, as well as  
general environmental and safety instructions.  
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 scanner/printer/copier 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.  
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4402-001  
1. General Information  
The Lexmark X73 machine is an electro-mechanical scanner,  
printer, and copier that creates characters and graphics by  
composing programmed patterns of ink dots using a printhead and  
liquid ink. The printhead uses small heater plates and nozzles to  
control ink flow and the formation of characters on the print media.  
The printhead assembly and ink supply are combined into a single-  
unit, 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  
on the left. The printer is capable of printing in two directions from  
either cartridge.  
Power Consumption  
<6 Watts - power off and power to the printer  
8 Watts - Idle Mode (power on - not printing)  
21 Watts - Printing (average)  
31 Watts - Printing (peak)  
General Information 1-1  
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4402-001  
Scanner Specifications  
Scanner Type  
Scan Modes  
Flatbed, CCD  
True Color:  
48 Bit Internal (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  
Scan Area  
One Pass Scanning  
8.5 X 11.7 inches  
216 X 292 mm  
Scan Resolution  
Optical: 600 dpi (H) X 1200 dpi (V)  
Interpolated: 9600 X 9600  
1-2 Service Manual  
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4402-001  
Operator Panel  
Press this  
button:  
When you want to:  
Setup  
Adjust your copy and scan settings using the Scan &  
Copy Control Program on your computer.  
Color Copy  
Black Copy  
Scan  
Make a color copy.  
Make a black and white copy.  
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  
Paper Feed  
Power  
Scan an image or document and send as a fax.  
Load or eject a sheet of paper from the printer.  
Turn the printer on or off.  
General Information 1-3  
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4402-001  
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.  
After you complete the repair, perform tests as needed to verify the  
repair.  
Abbreviations  
B/M  
Bill of Material  
CCD  
EOF  
ESD  
FPC  
FRU  
HVPS  
LVPS  
OEM  
V ac  
V dc  
ZIF  
Charged Coupled Device  
End of Form  
Electrostatic Discharge  
Flat Printhead Cable  
Field Replaceable Unit  
High Voltage Power Supply  
Low Voltage Power Supply  
Original Equipment Manufacturer  
Volts alternating current  
Volts direct current  
Zero Insertion Force  
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4402-001  
2. Diagnostic Information  
Start  
Use the symptom tables, service checks, and diagnostic aids in  
chapter three, to determine the printer failure.  
Power-On Self Test (POST) Sequence  
Press the power button to turn machine on.  
Power 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  
Tableson page 2-3, locate the symptom and take the indicated  
action.  
If your printer does not complete POST, locate the symptom in the  
following table and take the indicated action.  
Diagnostic Information 2-1  
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4402-001  
POST Symptom Table  
Symptom  
Action  
No Power or  
Go to the Power Service Checkon page 2-14. If okay,  
Status lights and go to the Operator Panel Problemson page 2-3.  
no motors run.  
Paper feed  
gears do not  
turn  
Go to the Paper Feed Service Checkon page 2-11.  
Carrier does not Go to the Carrier Transport Service Checkon  
move  
page 2-6.  
Carrier slams  
side frame  
Go to the Carrier Transport Service Checkon  
page 2-6.  
CCD does not  
move  
Go to the Gear Train Assembly Service Checkon  
page 2-9.  
CCD lamp does Go to the CCD Module Assembly Service Checkon  
not turn on page 2-8.  
2-2 Service Manual  
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4402-001  
Symptom Tables  
Locate the symptom in the following tables and take the appropriate  
action.  
Carrier Transport Problems  
Symptom  
Action  
No carrier movement  
Slow carrier movement  
Carrier stops  
Go to the Carrier Transport  
Service Checkon page 2-6.  
Carrier slams side frame  
Maintenance Station Problems  
Symptom  
Action  
Maintenance station:  
Go to the Maintenance Station  
Service Checkon page 2-10.  
Fails to cap the printheads  
Fails to clean the printheads  
Operator Panel Problems  
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) Sequenceon  
page 2-1. If operator panel fails,  
replace the operator panel assembly.  
If the problem still exists, replace the  
system board. Go to the System  
Board Removalon page 4-12.  
Note: If any buttons or lights fail,  
check connection J6. If the problem  
remains, replace the operator panel  
assembly. Go to the Operator  
Panel Removalon page 4-4.  
Diagnostic Information 2-3  
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4402-001  
Printer Communication Table  
Symptom  
Action  
Not able to print Test Page  
Check the USB cable and system  
board cable connections. If okay,  
replace system board. Go to the  
System Board Removalon  
page 4-12.  
Scanner Problems  
Symptom  
Action  
CCD does not move  
Lamp does not light  
Go to the CCD Module Assembly  
Service Checkon page 2-8.  
Go to the Gear Train Assembly  
Service Checkon 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.  
Go to the Scan/Copy Quality  
Service Checkon page 2-17.  
Blank copies.  
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4402-001  
Paper Feed Problems  
Symptom  
Action  
Fails to pick paper  
Picks more than one sheet of  
paper  
Go to the Paper Feed Service  
Checkon page 2-11.  
Picks paper but fails to feed  
Paper jams  
Paper fails to exit  
Noisy paper feed  
Envelopes fail to feed  
Go to the Paper Feed Service  
Checkon page 2-11.  
Paper skews  
Go to the Paper Path Service  
Checkon page 2-13.  
Power Problems  
Symptom  
Action  
No power in machine, motors do  
not operate  
Go to the Power Service Check”  
on page 2-14.  
Print Quality Problems  
Symptom  
Action  
Voids in characters  
Light print  
Go to the Print Quality Service  
Checkon page 2-15.  
Prints off the page  
Fuzzy print  
Carrier moves but no print  
Printhead dries prematurely  
Colors print incorrectly  
Vertical alignment off  
Ink smearing  
Vertical streaks on paper  
Print lines crowded  
Go to the Paper Feed Service  
Checkon page 2-11.  
Diagnostic Information 2-5  
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4402-001  
Service Checks  
Carrier Transport Service Check  
FRU  
Action  
1
2
System Board  
Check the transport carrier motor connector J4. If  
connected, check for approximately 28 volts on  
pins 1 and 2 or at the wire connections located on  
the rear of the transport carrier motor. If voltage is  
incorrect, replace the system board. If voltage is  
correct, check the motor for shorts.  
Carrier Transport  
Motor  
Carrier Transport  
Motor  
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 and J4-2  
If the readings are incorrect, replace the print  
engine. Go to the Print Engine Removalon  
page 4-11.  
3
Carrier Guide Rod Clean the carrier rod.  
Note: Lubricate the rod and the carrier rod bearing  
surfaces with grease P/N 99A0394.  
2-6 Service Manual  
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4402-001  
FRU  
Action  
4
Encoder Strip  
Check the encoder strip for proper installation.  
Also, check it for wear, dirt and grease.  
Carrier with PCB  
Assembly  
Be sure all printhead connectors are fully seated.  
Check the cables for damage.  
If the encoder strip and all connections are okay,  
but the carrier still slams the side frame, replace  
the print engine. Go to the Print Engine  
Removalon page 4-11.  
5
Carrier Transport  
Belt  
Check for worn, loose or broken parts. Check for  
obstructions blocking carrier movement.  
Idler Pulley Parts  
Carrier Frame  
Check the carrier belt idler pulley mounting screw.  
Loosen the screw and allow the tension spring to  
take up any slack in the belt. Tighten the screw. If  
the pulley mounting bracket has reached the stop,  
replace the belt. Go to the Belt/Idler Pulley  
Assembly (Print Engine) Removalon  
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 Removalon page 4-12.  
7
8
Maintenance  
Station  
A problem with the maintenance station can cause  
carrier movement problems at the right margin. Go  
to the Maintenance Station Removalon  
page 4-14.  
Access Cover  
Sensor  
If the carrier does not move toward the cartridge  
load position when the access cover is opened,  
verify that power is on. If the carrier still does not  
move, check connector J9 pin 1 for approximately  
5 volts, with the cover closed. If the voltage is  
correct, replace the sensor. Go to the Access  
Cover Sensor Removalon page 4-6. If the  
voltage is incorrect, replace the system board. Go  
to the System Board Removalon page 4-12.  
Diagnostic Information 2-7  
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4402-001  
CCD Module Assembly Service Check  
The CCD (charged coupled device) Module will not move during  
POST Test.  
The CCD lamp does not come on when CCD module assembly  
moves.  
FRU  
Action  
1
CCD Module Assembly  
If CCD module will not move, go to  
the Gear Train Assembly Service  
Checkon page 2-9.  
Note: If the printer is not  
connected to the PC and  
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  
Removalon page 4-12 for more  
information.  
To unlock scanner, press the red  
lever down. The lever is located by  
the USB plug on the rear of the  
machine.  
Note: Unlock scanner before use.  
2-8 Service Manual  
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4402-001  
Gear Train Assembly Service Check  
CCD will not move or scan.  
FRU  
Action  
1
Gear Train Assembly  
Disconnect J5 and check the reading  
at pin 1 and 3 for approximately  
225.5 ohms. If the reading is  
incorrect, replace the gear train  
assembly. Go to the Gear Train  
Assembly Removalon 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 Removalon 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  
(Print Engine) Removalon  
page 4-14.  
Note: If not properly installed, the  
belt will slip.  
Diagnostic Information 2-9  
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4402-001  
Maintenance Station Service Check  
The maintenance station has three functions:  
1. Wipes the printhead nozzles to clean them of dirt.  
2. Provides a place for printheads to fire all nozzles, keeping them  
clear prior to printing.  
3. Seals the printhead when it is not being used to prevent the  
nozzles from drying.  
FRU  
Action  
1
Maintenance  
Station Assembly  
As the carrier moves to the right over the  
maintenance station, a slot on the bottom of the  
carrier engages a tab on the sled of the  
maintenance station causing the cap to rise and  
seal the printhead. Carrier movement to the left  
uncaps the printhead. The wiper cleans the  
printhead nozzles as the carrier leaves the  
maintenance station. The wiper cleans the  
printhead only when the carrier is moving to the  
left. There should be no wiping action of the  
printhead nozzles when the carrier is moving to  
the right. After the cleaning operation is complete,  
a tab on the maintenance station engages a tab on  
the carrier, causing the wiper to lower.  
Check the maintenance station for worn or broken  
parts. Replace if needed. Go to the Maintenance  
Station Removalon page 4-14.  
Worn wipers cause degraded print quality just after  
a maintenance cleaning. Check for loose or worn  
wipers.  
Worn caps cause the printhead nozzles to dry and  
clog. Check for loose or worn caps.  
2-10 Service Manual  
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4402-001  
Paper Feed Service Check  
If your machine does not have paper jam problems, continue with  
the service check. If your machine does have a paper jam problem,  
examine it for the following before you begin the service check:  
Check the entire paper path for obstructions.  
Be sure there is not too much paper in the sheet feeder.  
Be sure the correct type of paper is being used.  
Check for static in the paper.  
FRU  
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 Print Engine  
Removalon page 4-11. If the reading is correct,  
replace the system board. Go to the System  
Board Removalon page 4-12.  
Diagnostic Information 2-11  
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4402-001  
FRU  
Action  
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  
A bind in the paper feed mechanism  
With the paper feed motor cable J3 disconnected  
from the system board, check for approximately 5  
ohms between the following pins on the motor:  
Pin 3 to Pin 4  
If the readings are incorrect, replace the print  
engine. Go to the Print Engine Removalon  
page 4-11.  
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. Go to the System  
Board Removalon 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
4
Auto Sheet  
Feeder Assembly  
Check the pick roller for wear.  
Mid Frame  
Assembly  
Check the following for wear:  
Small Feed rollers  
Large Feed roller  
Exit roller  
Star rollers  
If any rollers need to be replaced, go to the Print  
Engine Removalon page 4-11 and replace the  
print engine.  
5
End-of-Forms  
Check for binds or damage.  
Flag and Spring  
2-12 Service Manual  
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4402-001  
Paper Path Service Check  
Examine the machine for the following before you begin this service  
check:  
Check the entire paper path for obstructions.  
Be sure the correct type of paper is being used.  
Be sure the printer is installed on a flat surface.  
FRU  
Action  
1
2
3
4
Large and Small  
Feed Rollers  
Check for wear and binds.  
Small Feed Roller  
Springs  
Check for damage.  
Auto Sheet  
Feeder Assembly  
Check the pick roller for wear.  
Check the following for wear:  
Mid Frame Asm  
Exit roller  
Star rollers  
5
End-of-Forms  
Flag  
Check for binds or damage.  
Diagnostic Information 2-13  
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4402-001  
Power Service Check  
FRU  
Action  
1
2
External Power  
Supply  
Plug the external power supply into an outlet.  
Check for + 30 V dc. If voltage is incorrect, replace  
the power supply.  
Printhead Cable  
Paper Feed Motor and plug in the printer. Look for a symptom  
Unplug the printer. Disconnect the printhead cable  
Carrier Transport  
Motor  
change. Check the failing part for shorts and  
replace as necessary.  
Operator Panel  
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  
Removalon page 4-12.  
2-14 Service Manual  
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4402-001  
Print Quality Service Check  
FRU / Function  
Action  
1
2
Printhead  
Cartridge  
Be sure the machine contains good print  
cartridges.  
Color Printhead  
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  
printhead cartridge). This problem resolves quickly  
as the printhead cartridge is used.  
If cross contamination occurs, check the following:  
The maintenance station wiper for damage.  
The printhead nozzle plate was resealed with  
tape.  
3
4
Printhead Carrier  
Assembly  
Reseat the printhead cable in the system board  
and check the following parts for wear or damage:  
Printhead Cartridge Latch  
Latch Spring  
Carrier  
System Board  
Printhead Carrier  
Assembly  
Perform the Test Pageon 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-plated contacts on the end of the  
printhead carrier cable for dirt, wear, and damage.  
Use only a clean dry cloth to clean the contacts.  
If the symptom remains, replace the system board.  
Go to the System Board Removalon  
page 4-12.  
5
Maintenance  
Station  
Intermittent nozzle failures can be caused by worn  
parts in the maintenance station. Go to the  
Maintenance Station Removalon page 4-14,  
and then return to this check.  
Diagnostic Information 2-15  
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4402-001  
FRU / Function  
Action  
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 rollers for wear, dirt, or looseness.  
Gears for wear or binds.  
Paper path for obstructions.  
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. 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 adjustments.  
The user is directed, through the Printer Control  
program, to perform the printhead alignment  
adjustments, when replacing a printhead cartridge.  
2-16 Service Manual  
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4402-001  
Scan/Copy Quality Service Check  
FRU / Function  
Action  
1
Scanned images  
are faded, or  
colors are dull,  
blurry or fuzzy.  
Images are  
Check the lighter/darker settings to see if it is  
correct. There are two ways to make the  
adjustment:  
From the Lexmark Scan and Copy Control  
program.  
slanted or  
crooked and the  
straight lines in  
the image appear  
to be jagged or  
uneven.  
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 replaced.  
Check the paper type and copy quality settings on  
the operator panel or Lexmark Scan and Copy  
Control program.  
Diagnostic Information 2-17  
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4402-001  
2-18 Service Manual  
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4402-001  
3. Diagnostic Aids  
Test Page  
This test prints the test page.  
To run a complete test page of black and color patterns, be sure the  
printhead cartridges are in good condition.  
To enter the test:  
1. Open the access cover.  
2. Install a known good black print cartridge in the right side of the  
carrier and a good color print cartridge in the left side.  
3. Close the access cover.  
4. Install paper in the sheet feeder.  
5. Press and hold the paper feed button while pressing the power  
button 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 used to clear all printhead nozzles. The nozzle test  
pattern prints all nozzles on a diagonal line. There should be no  
breaks in the nozzle test pattern. A break in the pattern indicates  
one or more nozzles are not working.  
If a print quality problem exists, see Print Quality Service Check”  
on page 2-15.  
Diagnostic Aids 3-1  
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4402-001  
3-2 Service Manual  
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4402-001  
4. Repair Information  
This chapter explains how to make adjustments to the printer and  
how to remove defective parts.  
Note: Read the following before handling electronic parts.  
Handling ESD-Sensitive Parts  
Many electronic products use parts that are known to be sensitive to  
electrostatic discharge (ESD). To prevent damage to ESD-sensitive  
parts, follow the instructions below in addition to all the usual  
precautions, such as turning off power before removing system  
board:  
Keep the ESD-sensitive part in its original shipping container (a special  
ESD bag) until you are ready to install the part into the machine.  
Make the least-possible movements with your body to prevent an  
increase of static electricity from clothing fibers, carpets, and furniture.  
Put the ESD wrist strap on your wrist. Connect the wrist band to the  
system ground point. This discharges any static electricity in your body  
to the machine.  
Hold the ESD-sensitive part by its edge connector shroud (cover); do  
not touch its pins. If you are removing a pluggable module, use the  
correct tool.  
Do not place the ESD-sensitive part on the machine cover or on a  
metal table; if you need to put down the ESD-sensitive part for any  
reason, first put it into its special bag.  
Machine covers and metal tables are electrical grounds. They increase  
the risk of damage because they make a discharge path from your  
body through the ESD-sensitive part. (Large metal objects can be  
discharge paths without being grounded.)  
Prevent ESD-sensitive parts from being accidentally touched by other  
personnel. Install machine covers when you are not working on the  
machine, and do not put unprotected ESD-sensitive parts on a table.  
If possible, keep all ESD-sensitive parts in a grounded metal cabinet  
(case).  
Be extra careful in working with ESD-sensitive parts when cold weather  
heating is used because low humidity increases static electricity.  
Repair Information 4-1  
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4402-001  
Adjustments  
The user is directed, in the Printer Control program, to perform the  
printhead alignment adjustments after replacing a print cartridge.  
Removal 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.  
4-2 Service Manual  
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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  
Repair Information 4-3  
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4402-001  
Operator Panel Removal  
1. Remove the scanner lid.  
2. Remove the rear cover.  
3. Disconnect the operator panel cable from the system board.  
4. Depress two latches on the left side of the operator panel.  
5. Lift 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.  
3. Remove the paper support.  
4-4 Service Manual  
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4402-001  
CCD Module Assembly 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.  
Repair Information 4-5  
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4402-001  
Gear Train Assembly Removal  
1. Remove the CCD module assembly.  
2. Disconnect the gear 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.  
4-6 Service Manual  
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4402-001  
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.  
Repair Information 4-7  
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4402-001  
Left Cover Removal  
1. Remove the rear cover.  
2. Depress two latches [A].  
3. Remove the left cover.  
4-8 Service Manual  
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4402-001  
Middle Frame Removal  
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].  
Repair Information 4-9  
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4402-001  
8. Depress the two clips [B] and slide the middle frame forward to  
remove.  
4-10 Service Manual  
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4402-001  
Print Engine 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.  
Repair Information 4-11  
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4402-001  
ASF Module Removal  
1. Remove the print engine.  
2. Remove three screws [A].  
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.  
4-12 Service Manual  
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4402-001  
Carrier Removal  
1. Remove the rear cover.  
2. Remove the top housing Assembly.  
3. Remove the left and right covers.  
4. Disconnect the carrier cable from the system board.  
5. Loosen the set screw on the carrier belt tensioner.  
6. Depress the belt tensioner 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 carrier assembly.  
2. Depress the encoder strip clip.  
3. Remove the encoder strip.  
Repair Information 4-13  
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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.  
4-14 Service Manual  
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4402-001  
5. Connector Locations  
Units  
Description  
J2  
J3  
J4  
Printhead Cable  
Paper Feed Motor  
Carrier Transport  
Motor  
J5  
J6  
Scanner Motor  
Operator Panel  
CCD Module  
J7  
J9  
Cover Sensor  
PS1  
End-of-Forms Sensor  
Connector Locations 5-1  
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4402-001  
5-2 Service Manual  
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4402-001  
6. Preventive Maintenance  
This chapter contains the lubrication specifications. Follow these  
recommendations to prevent problems and maintain optimum  
performance.  
Lubrication Specifications  
Lubricate only when parts are replaced or as needed, not on a  
scheduled basis. Use grease P/N 99A0394 to lubricate the following:  
All gear mounting studs.  
The left and right ends of the large feed roller at the side frames.  
The carrier to carrier frame engagement.  
The carrier guide rod, and carrier guide rod bearings.  
WARNING: Keep the grease from coming into contact with any  
electrical components, may cause printer damage or failure. Do not  
lubricate the scanner rod or bearing after replacing.  
Preventive Maintenance 6-1  
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4402-001  
6-2 Service Manual  
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4402-001  
7. Parts Catalog  
How to Use This Parts Catalog  
SIMILAR ASSEMBLIES: If two assemblies contain a majority of  
identical parts, they are shown on the same list. Common parts  
are shown by one index number. Parts peculiar to one or the  
other of the assemblies are listed separately and identified by  
description.  
NS: (Not Shown) in the Asm-Index column indicates that the  
part is procurable but is not pictured in the illustration.  
PP: in the parts description column indicates the part is  
available in the listed parts packet.  
NA: Not available as a FRU.  
Parts Catalog 7-1  
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4402-001  
Assembly 1: Covers  
7-2 Service Manual  
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4402-001  
Assembly 1: Covers  
Asm- Part  
Index Number  
Units Description  
11  
2  
12G6141  
12G6140  
12G6138  
12G6135  
12G6133  
12G6175  
12G6134  
12G6156  
7366857  
1
1
1
1
1
1
1
4
1
Cover Assembly, Rear  
Felt Pad Assembly  
Base Assembly  
Cover, Right  
3  
4  
5  
Cover, Access with Latch  
Paper Exit Tray  
Cover, Left  
6  
7  
NS  
NS  
Screws (PP)  
Plain package B/M includes: Carton, Cushion  
Set, Sealing Tape  
Parts Catalog 7-3  
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4402-001  
Assembly 1 (cont.): Covers  
7-4 Service Manual  
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4402-001  
Assembly 1 (cont.): Covers  
Assembly 1: Covers  
Asm- Part  
Units Description  
Index Number  
11  
2  
3  
4  
5  
12G6171  
12G6174  
12G6126  
12G6122  
12G6150  
1
1
1
1
1
Scanner Lid Assembly  
Paper Support ASF  
Top Housing Assembly  
Middle Frame Assembly  
Belt, Scanner  
Parts Catalog 7-5  
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4402-001  
Assembly 2: Paper Feed, Frame and Carrier  
Transport  
7-6 Service Manual  
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4402-001  
Assembly 2: Paper Feed, Frame and Carrier Transport  
Asm- Part  
Units Description  
Index Number  
21  
2  
12G6121  
12G6120  
12G6151  
12G6123  
12G6149  
12G6154  
12G6153  
1
1
1
1
1
1
1
ASF Module  
Printing Engine  
3  
Encoder Strip with Clip  
Idler Pulley Assembly  
Belt, Carrier  
4  
5  
6  
Maintenance Station Assembly  
EOF Flag with Spring  
NS  
Parts Catalog 7-7  
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4402-001  
Assembly 3: Electronics  
7-8 Service Manual  
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4402-001  
Assembly 3: Electronics  
31  
NS  
NS  
2  
12G6177  
12G6124  
12G6176  
12G6125  
12G6172  
12G6173  
12G6170  
12G6137  
12G6128  
12G6157  
12G6158  
1
1
1
1
1
1
1
1
1
1
1
CCD Module Assembly with Cable  
CCD Module Assembly  
CCD Cable  
Gear Train Assembly  
3  
Operator Panel Assembly  
Operator Panel Overlays  
Board, System  
NS  
4  
5  
Sensor, Access Cover  
Power Supply (LV) 100127  
Power Supply (HV) 220240  
Power Supply Japan 100V  
6  
NS  
NS  
Parts Catalog 7-9  
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4402-001  
7-10 Service Manual  
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4402-001  
Index  
Operator Panel 2-3  
Paper Feed 2-5  
A
Abbreviations 1-4  
Adjustments 4-2  
B
Black Copy button 1-3  
Button  
Black Copy 1-3  
Color Copy 1-3  
Paper Feed 1-3  
Power 1-3  
Scan 1-3  
Scan To 1-3  
Scanner 2-4  
Scan To E-mail 1-3  
Scan To Fax 1-3  
Setup 1-3  
R
Removals  
Access Cover 4-7  
Access Cover Sensor 4-6  
ASF Module 4-12  
C
Color Copy button 1-3  
Connector Locations 5-1  
Belt/Idler Pulley Assembly 4-14  
Carrier 4-13  
CCD Module Assembly 4-5  
Encoder Strip 4-13  
Gear Train Assembly 4-6  
E
ESD-Sensitive Parts 4-1  
L
Maintenance Station 4-14  
Middle Frame 4-9  
Lubrication Specifications 6-1  
M
Maintenance Approach 1-4  
O
Operator Panel 1-3  
Top Housing Assembly 4-4  
P
Paper Feed button 1-3  
Parts Catalog 7-1  
Carrier Transport 7-6  
Covers 7-2  
Electronics 7-8  
Frame 7-6  
Paper Feed 7-6  
I-1  
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4402-001  
S
Safety Information 1-v  
Scan button 1-3  
Scan To button 1-3  
Scan To E-mail button 1-3  
Scan To Fax button 1-3  
Service Checks  
Carrier Transport 2-6  
CCD Module Assembly 2-8  
Gear Train Assembly 2-9  
Paper Feed 2-11  
Paper Path 2-13  
12G6120 7-7  
12G6126 7-5  
12G6134 7-3  
12G6137 7-9  
12G6138 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 7-9  
12G6171 7-5  
12G6172 7-9  
12G6173 7-9  
12G6174 7-5  
12G6175 7-3  
12G6176 7-9  
12G6177 7-9  
7366857 7-3  
Power 2-14  
Print Quality 2-15  
Setup Button 1-3  
Specifications  
Scanner 1-2  
Start 2-1  
Symptom Table (POST) 2-2  
Symptom Tables 2-3  
T
Test Page 3-1  
I-2 Service Manual  
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