Lexmark 2030, Service Manual

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

Page 2: ... stocked at the address given below requests for publications should be made to your point of purchase Comments may be addressed to Lexmark International Inc Department D22A 035 3 740 New Circle Road 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 Lexmark is a trademark of Lexm...

Page 3: ...agnostic Aids 3 1 Test Page 3 1 Repair Information 4 1 Handling ESD Sensitive Parts 4 1 Adjustments 4 2 Removal Procedures 4 2 Releasing Plastic Latches 4 2 Access Cover Removal 4 3 Base Assembly Removal 4 3 Carrier Belt Removal 4 3 Carrier Frame Assembly Removal 4 4 Carrier Home Sensor Removal 4 4 Carrier Transport Motor Removal 4 5 DC DC Converter Removal 4 5 Drive Train Assembly Removal 4 5 Fro...

Page 4: ...l 4 11 Connector Locations 5 1 System Board Connectors 5 1 Preventive Maintenance 6 1 Lubrication Specifications 6 1 Parts Catalog 7 1 How to Use This Parts Catalog 7 1 Assembly 1 Covers 7 2 Assembly 2 Paper Feed Carrier Transport Maintenance 7 4 Assembly 2 Paper Feed Carrier Transport Maintenance 7 6 Assembly 3 Electronics 7 8 Assembly 4 Carrier 7 10 Assembly 5 Sheet Feeder 7 12 Index X 1 ...

Page 5: ...ing 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 indi vidual FRUs Safety Information The maintenance information for this product has been prepared for use by a profes...

Page 6: ...ntage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires Les normes de sécurité de certaines pièces n étant pas toujours explicites les pièces de rechange doivent être identiques ou conformes aux caractéristiques des pièces d origine Norme di sicurezza Le informazioni riguardanti la manutenz...

Page 7: ...rsonale og bør derfor ikke benyttes af andre Risikoen for elektrisk stød øges under demontering og service af dette produkt hvorfor der bør tages de nødvendige forholdsregler Sikkerhedsforanstaltningerne er ikke altid lige åpenbare for alle reservedele Der bør derfor kun anvendes originale reservedele eller reservedele med samme egenskaber som de oprindelige Informações de Segurança As informações...

Page 8: ...4091 001 viii Chinese Safety Information Korean Safety Information ...

Page 9: ...s lights or error indicators All printer errors are sent to the host PC The printer also contains no NVRAM on the system board Page count and printhead ink levels are stored in the PC Power Consumption Less than 3 5 Watts power off and power to the printer 7 5 Watts Idle Mode power on not printing 12 Watts Printing average 25 Watts Printing peak Maintenance Approach The diagnostic information in t...

Page 10: ...arallel Wrap Plug P N 1319128 ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LVPS Low Voltage Power Supply OEM Original Equipment Manufacturer V ac Volts alternating current V dc Volts direct current ZIF Zero Insertion Force ...

Page 11: ... the following tables and take the appropriate action Carrier Transport Problems Maintenance Station Problems Symptom Action No carrier movement Slow carrier movement Carrier stops Carrier slams side frame Go to the Carrier Transport Service Check on page 2 3 Symptom Action Maintenance station Fails to cap the printheads Fails to clean the printheads Go to the Maintenance Station Service Check on ...

Page 12: ...elope Feed Service Check on page 2 4 Paper skews Go to the Paper Path Service Check on page 2 8 Symptom Action No power in machine motors do not operate Go to the Power Service Check on page 2 9 Symptom Action Voids in characters Light print Prints off the page Fuzzy print Carrier moves but no print Printhead drys prematurely Colors print incorrectly Vertical alignment off Go to the on page 2 10 I...

Page 13: ...d A bind in the carrier transport mechanism With the carrier transport motor cable disconnected from the system board check for zero to ten 0 10 ohms between the following pins on the motor CN6 1 and CN6 2 CN6 3 and CN6 4 If the readings are incorrect replace the motor 3 Carrier Guide Rod Clean the carrier rod Note Lubricate the rod and the carrier rod bearing surfaces with grease P N 1329301 4 Ca...

Page 14: ...carrier movement problems at the right margin Go to the Maintenance Station Service Check on page 2 5 FRU Action 1 Envelope Guide Be sure the envelope guide has been turned to the envelope load position Be sure the envelope guide is against the envelopes Perform the Paper Feed Service Check on page 2 6 FRU Action ...

Page 15: ...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 t...

Page 16: ...er 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 Unplug the printer and disconnect CN7 from the system board Plug the printer in and check for a pulse of 24 V dc between CN7 1 and ground and CN7 2 and ground on the system board If the voltage is not present check for motor pins shorted to the motor housing If you find a ...

Page 17: ...ystem 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 3 Drive Train Assembly Check for binds in the gear train and paper feed mechanism by removing the paper feed motor and rotating the large gear by hand If you notice a bind replace the drive train asse...

Page 18: ...t 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 Check the pick rollers for wear 4 Mid Frame Asm Check the following for wear Friction wheels Exit roller Star rollers 5 End of Forms Flag Check for binds or damage ...

Page 19: ... CN8 4 to GND 5 V dc If you do not have correct voltage replace the DC DC Converter Be sure to unplug the machine before you reconnect the DC DC Converter to the system board 3 Printhead Cable Carrier Home Sensor Parallel Cable Paper feed motor Carrier transport motor Unplug the printer Disconnect one of the printhead cables and plug in the printer Look for a symptom change Check the failing part ...

Page 20: ...System Board Printhead Cable Rubber Backer Run the Test Page on page 3 1 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...

Page 21: ...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 1329301 Idler pulley parts for wear damage or ...

Page 22: ...owing lines Line 1 Code level and date Line 2 Manufacturer name Line 3 Model name Line 4 Motor type The next line is the black print cartridge nozzle pattern The next three lines are the purge pattern where all nozzles are printing This action cleans purges the nozzles Another nozzle test pattern follows These test patterns are used to verify all print cartridge nozzles are working There should be...

Page 23: ...m 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 ba...

Page 24: ...dures The following procedures are arranged according to the name of the printer part discussed CAUTION Unplug the power cord before removing any parts Releasing Plastic Latches Many of the parts are held in place with plastic latches The latches break easily release them carefully To remove such parts press the hook end of the latch away from the part to which it is latched ...

Page 25: ...cures the DC DC Converter frame to the carrier frame 7 Press down on the left side clip and slide the DC DC converter out of the base 8 Unlatch the carrier frame from the base assembly and lift it off the base 9 Slide the machine off the base assembly Carrier Belt Removal 1 Remove the front cover 2 Remove the retainer spring from the left side of the carrier rod 3 Remove the screw from the right s...

Page 26: ...e the two screws that secure the carrier frame to the base assembly 6 Remove the screw that secures the DC DC converter frame to the carrier frame 7 Press down on the left side clip and slide the DC DC converter out of the base 8 Unlatch the carrier frame from the base assembly and lift it off the base 9 Slide the carrier frame assembly off the base assembly 10 To replace the carrier frame remove ...

Page 27: ...erter Removal 1 Remove the front cover 2 Remove the rear cover 3 Disconnect the DC DC converter connector from the system board 4 Remove the screw that secures the DC DC converter to the carrier frame on the right side 5 Push down on the latch at the left rear of the DC DC converter and slide it off the base Drive Train Assembly Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the...

Page 28: ...acket 11B5600 2 Slide the cover upward and off the machine To reassemble 1 Align the tabs on the front cover over the front edge of the base assembly 2 Rotate the front cover over the top edge of the rear cover and press in on both sides opposite the cover latches until they latch Gutter Pad Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the sheet feeder 4 Remove the base assemb...

Page 29: ...sembly 11 Turn and remove the retainer at the right end of the large feed roller 12 Remove the large feed roller from the carrier frame Maintenance Station Assembly Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the base assembly 4 Depress the clip on the left and right side of the carrier frame that secures the maintenance station assembly and slide the assembly out of the mach...

Page 30: ...Remove the two screws mounting the paper feed motor to the drive train assembly and remove the motor 5 See the Note in the on page 2 10 Printhead Carrier Assembly Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the sheet feeder 4 Unlock the four printhead cable connectors and disconnect the printhead cable from the system board 5 Unlatch the cable retainer from the carrier frame ...

Page 31: ...Sheet Feeder Removal 1 Remove the front cover 2 Remove the rear cover 3 Remove the two sheet feeder mounting screws from the rear of the carrier frame 4 Unlatch the right sheet feeder latch from the front of the carrier frame Note For reassembly The cables are routed through tab slots in the sheet feeder 5 Remove the sheet feeder Small Feed Roll Assembly Removal 1 Remove the front cover 2 Remove t...

Page 32: ...he sheet feeder 4 Remove the system board 5 Remove the four small feed roller springs from the carrier frame 6 Push down on each of the small feed roll assemblies to remove them from the small feed roll bracket 7 Push the two locking tabs A to the rear to release the small feed roll assembly from the carrier frame ...

Page 33: ... disconnect the printhead cables from the system board 4 Disconnect the other cables from the system board 5 Remove the three screws securing the system board to the carrier frame and remove the system board Note the routing of all the cables 6 Remove the system board being careful not to damage the End of Form flag 7 See the Note in the on page 2 10 ...

Page 34: ...Connector Locations 5 1 4091 001 5 Connector Locations System Board Connectors ...

Page 35: ...tor Names CN1 Printhead Cable 1 CN2 Printhead Cable 2 CN3 Printhead Cable 3 CN4 Printhead Cable 4 CN5 Home Position Sensor CN6 Carrier Transport Motor CN7 Paper Feed Motor CN8 DC DC Converter CN9 Parallel Port PH1 EOF Sensor U13 Code Module JP1 Jumper ...

Page 36: ... maintain optimum performance Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use grease P N 1329301 to lubricate the following All gear mounting studs The left and right ends of the large feed roller at the side frames The carrier to carrier frame engagement The carrier guide rod and carrier guide rod bearings ...

Page 37: ... 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 descriptions column indicates the part is available in the listed parts packet ...

Page 38: ...7 2 4091 001 Assembly 1 Covers ...

Page 39: ...scription 1 1 11B5580 1 Base Assembly 2 11B5600 2 Front Cover Mounting Screws PP 3 11B5581 1 Cover Front Assembly 4 11B5582 1 Cover Rear Assembly 5 11B5583 1 Cover Access Assembly N S 7347859 1 Replaceable Package B M Includes Carton Cushion Set Sealing Tape ...

Page 40: ...7 4 4091 001 Assembly 2 Paper Feed Carrier Transport Maintenance ...

Page 41: ...B5601 1 Feed Roll Assembly Small 7 11B5589 1 Mounting Bracket Small Feed Roll Assembly 8 11B5590 1 Drive Train Assembly 9 11A5444 1 Motor Paper Feed Assembly 10 11B5600 5 Screws Paper Feed Motor Mounting PP 11 11B5588 1 Arm Tensioner 12 11B5597 1 Belt Carrier 13 11B5600 1 Spring Large Feed Roll Dampening PP 14 11A5440 1 Feed Roll Assembly Large 15 11B5587 1 Frame Mid Assembly 16 11B5599 1 Maintena...

Page 42: ...7 6 4091 001 Assembly 2 Paper Feed Carrier Transport Maintenance ...

Page 43: ...scription 2 18 11B5600 2 Screw PP 19 11B5600 1 Screw PP 20 11B5600 1 Screw PP 21 1367389 1 Cap and Wiper B M One of each 22 11B5595 1 Star Roller Asm 23 11B5600 2 Screw PP NS 11B5600 2 Bearings Large Feed Roll NS 11B5600 2 Screws Star Roller Assembly Mounting ...

Page 44: ...7 8 4091 001 Assembly 3 Electronics ...

Page 45: ...P 4 11B5592 1 External Power Supply Asm LV 5 11B5593 1 External Power Supply Asm HV 6 11B5600 2 Screws Base Asm PP NS 11B5602 1 Cable Parallel Port NS 11B6073 1 Power Cable United Kingdom NS 11B6074 1 Power Cable Europe NS 11B6075 1 Power Cable Israel NS 11B6076 1 Power Cable Australia New Zealand NS 11B6077 1 Power Cable South Africa NS 11B6078 1 Power Cable Peru ...

Page 46: ...7 10 4091 001 Assembly 4 Carrier ...

Page 47: ...11 4091 001 Asm Index Part Number Units Description 4 1 11B5596 1 Carrier Assembly 2 11B5585 1 Rod Carrier Guide 3 11B5584 1 Frame Carrier 4 11B5600 1 Screw Carrier Guide Rod PP 5 11B5600 1 Spring Carrier Guide Rod PP ...

Page 48: ...7 12 4091 001 Assembly 5 Sheet Feeder ...

Page 49: ...Parts Catalog 7 13 4091 001 Asm Index Part Number Units Description 5 1 11B5584 1 Frame Carrier 2 11B5600 2 Screws Sheet Feeder Mounting PP 3 11A5451 1 Sheet Feeder Asm 4 11B5582 1 Cover Rear Asm ...

Page 50: ... Paper Feed 2 2 Power 2 2 Print Quality 2 2 R Removals Access Cover 4 3 Base Assembly 4 3 Carrier Belt 4 3 Carrier Frame 4 4 Carrier Home Sensor 4 4 Carrier Transport Motor 4 5 DC DC Converter 4 5 Drive Train Assembly 4 5 Front Cover 4 6 Gutter Pad 4 6 Large Feed Roll 4 7 Maintenance Station 4 7 Mid Frame Assembly 4 8 Paper Feed Motor 4 8 Power Supply 4 5 Printhead Carrier 4 8 Rear Cover 4 9 Sheet...

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