Lexmark P122 Photo Jetprinter, Service Manual

Page 1: ...ith 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 Lexmark P122 Photo Jetprinter ...

Page 2: ... West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of purchase Lexmark a...

Page 3: ...ptom Table 2 1 Symptom Tables 2 2 Service Checks 2 5 First Print Line Service Check 2 5 Maintenance Station Service Check 2 6 LCD Assembly Display Service Check 2 7 Paper Feed Service Check 2 8 Paper Path Service Check 2 10 CompactFlash SmartMedia Service Check 2 11 Power Service Check 2 11 Print Quality Service Check 2 12 Transport Service Check 2 14 Diagnostic Aids 3 1 Paper Pick Assembly Operat...

Page 4: ...rier Belt Removal 4 12 LCD Card Removal 4 13 Paper Support Removal 4 14 Slide Guide Removal 4 15 USB DC Jack Board Removal 4 16 Connector Locations 5 1 Engine Board Connectors 5 1 LCD Board Connectors 5 3 USB PSB Power Board Connector 5 4 Preventive Maintenance 6 1 Lubrication Specifications 6 1 Parts Catalog 7 1 How to Use the Parts Catalog 7 1 Assembly 1 Covers 7 2 Assembly 2 Carrier Assembly 7 ...

Page 5: ...iagnostic Information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems 4 Repair Information provides instructions for making printer adjustments and removing and installing FRUs 5 Connector Locations uses illustrations to identify...

Page 6: ...rvicing 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 respon...

Page 7: ... 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 Lexm...

Page 8: ...ación 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 ut...

Page 9: ... d algunes peces pot ser que no sempre siguin òbvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informació pel manteniment d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ...

Page 10: ...x Service Manual 4102 P01 ...

Page 11: ...erator panel into the cover set and slots to support the compact flash and smart media Camera memory cards have been incorporated into the printer near the top of the access cover under the translucent cover Note that there is no exit tray and that there is a handle molded into the cover behind the translucent card slot cover to encourage portability Also note that the multi part fan shaped paper ...

Page 12: ...limited number of special characters Operator Panel Buttons Power On There is no power on button Print When pressed with images present and accessible to the photocontroller printing as selected is initiated If no selections have been made then all images will be printed using the current printer settings Note that a message indicating all photos will be printed will be displayed for several secon...

Page 13: ...be chosen The results of this selection vary depending on the location within the menu Menu Index Print Pressing this button will initiate printing of an index print The menu selection function was imbedded into the menu system Return Exit button Permits exit of a selection without saving the result Printer Errors The printer signals errors by displaying error messages in the display Display Messa...

Page 14: ... S A 120 127 V 60 Europe Middle East and Africa 220 240 V 50 Taiwan 110 V 60 Japan 100 V 50 60 230 V 50 Hz 120 V 60 Hz 100 V 60 Hz Power Supply connected to outlet but not to the machine 3 Watts 3 Watts 2 Watts Idle Power On 7 Watts 6 Watts 5 Watts Idle Power On with CompactFlash Card Insert 7 Watts 6 Watts 5 Watts Printing Average Power Consumption 16 Watts 15 Watts 15 Watts ...

Page 15: ...on page 2 1 This printer can be serviced without being connected to a host computer After you complete the repair perform tests as needed to verify the repair Abbreviations CSU Customer Setup EOF End of Forms ESD Electrostatic Discharge FRU Field Replaceable Unit HV High Voltage LCD Liquid Crystal Display LED Light Emitting Diode LV Low Voltage NVRAM Nonvolatile Random Access Memory OEM Original E...

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Page 17: ...tion and seals the printhead 4 Two rows of diamonds are displayed 5 The code level is displayed 6 The name is displayed 7 The date is displayed 8 Ready is displayed POST Symptom Table Symptom Action No motors run Go to the Power Service Check on page 2 11 Paper feed gears do not turn Go to the Paper Feed Service Check on page 2 8 Carrier does not move Carrier slams side frame Go to the Transport S...

Page 18: ...tion Printer not communicating with host computer Check the USB connection connector J601 If the connection is good replace the USB DC jack board Symptom Action Fails to cap the printhead Fails to clean the printhead Go to the Maintenance Station Service Check on page 2 6 Symptom Action Paper Feed button does not operate With the power on check for a voltage reading at connector J633 located on th...

Page 19: ...sh SmartMedia Service Check on page 2 11 Symptom Action Paper fails to stop at first print line Go to the First Print Line Service Check on page 2 5 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 Go to the Paper Feed Service Check on page 2 8 Paper skews Go to the Paper Path Service Check on page 2 10 Symptom Act...

Page 20: ... Prints off the page Fuzzy print Carrier moves but does not print Printhead drying prematurely Excessive ink flow Flooding Horizontal banding Go to the Print Quality Service Check on page 2 12 Ink smearing Vertical streaks on paper Print lines crowded Go to the Paper Feed Service Check on page 2 8 ...

Page 21: ... 1 End of Forms Flag Check the flag for binds or damage 2 End of Forms Sensor Check the sensor for dirt 3 System Board Perform the End of Forms EOF Sensor Test on page 3 4 to check the end of forms sensor on the system board 4 Paper Pick Assembly Check the paper pick assembly for binds wear or damage ...

Page 22: ... Carrier movement to the left will uncap 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...

Page 23: ... If the LCD assembly is blank and the printer completes POST check the system board cable connections Check for a voltage reading of approximately 4 V dc on pin 15 at connector J631 If the voltage is correct replace the LCD assembly If the voltage is incorrect replace the system board If all diamonds are displayed after the printer completes POST check the LCD assembly cable for continuity and rep...

Page 24: ... not to overfill the sheet feeder Be sure the correct type of paper is being used Check for static in the paper Parts FRUs Action 1 System Board Check for approximately 17 V dc pulse between paper feed connector J3F 4 and ground on the system board as the paper feed motor is running during the POST sequence If the voltage is incorrect replace the system board If correct check for motor pins shorte...

Page 25: ...aper feed motor is running If the voltage reading is incorrect replace the system board 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...

Page 26: ...g the paper Be sure the correct type of paper is being used Be sure the printer is installed on a flat surface Parts FRUs Action 1 Large and Small Feed Rollers Check for wear and binds 2 Small Feed Roller Springs Check for damage 3 Exit Roller Star Rollers Exit Drive Belt and Tensioner Check for wear and binds 4 Sheet Feeder Check the following for wear or damage Paper pick assembly All parts insi...

Page 27: ... to Print Quality Service Check on page 2 12 Run the CompactFlash Test on page 3 3 If the test fails replace the system board Run the DRAM Test on page 3 4 If the test fails replace the system board Parts FRUs Action 1 Power Supply Check voltage reading of 30 V dc with power supply connected to the USB DC jack board J601 9 to GND 30 V dc J601 10 to GND 30 V dc If incorrect voltage or no voltage re...

Page 28: ...n the print nozzles when you suspect the nozzles are clogged or if the characters are not printing completely When you clean the print nozzles a test line prints so you can see if the cleaning process was successful Use the operator panel to run the nozzle test and clean the cartridge 1 Press Return until Ready appears on the operator panel 2 Press the Arrow button until you see SETUP OPTIONS 3 Pr...

Page 29: ... to remove the cable from the carrier to inspect it 4 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station Perform the Maintenance Station Service Check on page 2 6 and then return to this check 5 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 bei...

Page 30: ...ts FRUs Action 1 Transport Motor Check the motor for binds or loose motor pulley Disconnect the transport motor J2C from the system board Check for approximately 7 ohms between pins 3 and 4 on the motor cable and for shorted motor pins If the reading is incorrect replace the engine frame assembly If the failure remains replace the system board 2 System Board Check connector J2C on the system board...

Page 31: ...movement Carrier to carrier frame engagement should be lubricated with grease P N 99A0394 6 Printhead Cable Be sure all connectors are fully seated Check the cables for damage 7 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 6 Parts FRUs Action ...

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Page 33: ...n between the pick roll and the paper produces a frictional locking condition The arm must pivot freely through its full range of motion If the pick assembly is noisy replace the automatic sheet feeder Diagnostic Mode To enter the Diagnostic Mode 1 Use Power button or unplug the power supply from the printer 2 Press and hold the arrow up button 3 Plug the power supply into the printer 4 Release th...

Page 34: ...d a processing percent begins counting up 5 Upon reaching 100 percent the printer goes into a reprogramming state where the display message is Reprogramming 6 When reprogramming is complete the new code level appears 7 Remove the camera card from the slot and continue printing LCD Test To run the LCD Test 1 Select LCD Test from the Diagnostic Menu The LCD test runs continually 2 Press Print to sto...

Page 35: ...t checks the connection between a SmartMedia camera card and the System Board It performs a write read and erase to the camera card To run the SmartMedia Test 1 Insert a camera card into the SmartMedia slot bottom slot 2 Select SmartMedia from the Diagnostic Menu 3 Press Print to return to the Diagnostic Menu Upon completion of the test a Pass or Fail message appears SmartMedia Write Protect Test ...

Page 36: ...ading position If this fails check all cable connections sensor switch lever and carrier transport motor If the switch is bad replace the system board If the transport motor is bad replace the engine frame assembly End of Forms EOF Sensor Test To run the test 1 Turn off printer 2 Insert a single sheet of paper into the sheet feeder to depress the EOF flag 3 Turn on printer Paper ejects from printe...

Page 37: ...arpets 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 printer 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 printer cover or on a metal table if...

Page 38: ...wing procedures are arranged according to the name of the printer part discussed Unplug the power cord before removing any parts Covers Access Cover Second Access Cover Removal 1 Open access cover and depress clip A on the left side 2 Remove the access cover ...

Page 39: ...Repair Information 4 3 4102 P01 3 Depress clip A on the left side of the second access cover 4 Remove the second access cover ...

Page 40: ...4 4 Service Manual 4102 P01 Top Cover Assembly Removal 1 Remove the four screws A from the bottom of the printer ...

Page 41: ...Repair Information 4 5 4102 P01 2 Lift the top cover up and unplug the cable at connector B J601 3 Remove the top cover assembly ...

Page 42: ...al 1 Remove the top cover 2 Remove the two screws A from the bottom of the back cover 3 Lift the back cover out and remove Bottom Cover Assembly Removal 1 Remove the top cover 2 Remove the engine frame assembly 3 Remove the bottom cover assembly ...

Page 43: ...Repair Information 4 7 4102 P01 Button Card Removal 1 Remove the top cover assembly 2 Remove the three button card mounting screws A 3 Disconnect cable B from the button card 4 Remove the button card ...

Page 44: ...8 Service Manual 4102 P01 Engine Board Removal 1 Remove the top cover 2 Remove the engine frame assembly 3 Disconnect all cables 4 Remove the four engine board mounting screws A 5 Remove the engine board ...

Page 45: ...Repair Information 4 9 4102 P01 Engine Frame Assembly Removal 1 Remove the top cover 2 Unplug the cable at connector A J601 ...

Page 46: ...0 Service Manual 4102 P01 3 Remove the four screws A from the bottom cover 4 Remove the engine frame assembly Exit Tray Removal 1 Remove the paper from the exit tray 2 Pull out on the exit tray and remove ...

Page 47: ...mbly Removal 1 Remove the top cover 2 Remove the engine frame assembly 3 Remove the left and right carrier rod clips A 4 Slide the rod to the left and remove 5 Remove the carrier cable from the retainer B 6 Remove the carrier belt 7 Remove the carrier ...

Page 48: ... Ink Carrier Belt Removal 1 Remove the top cover 2 Remove the ink carrier assembly 3 Loosen the belt tension pulley mounting screw A slide the pulley in the direction of the arrow and retighten the mounting screw 4 Remove the belt ...

Page 49: ...Repair Information 4 13 4102 P01 LCD Card Removal 1 Remove the top cover assembly 2 Remove the three LCD card mounting screws A 3 Disconnect cable B from the button card 4 Remove the LCD card ...

Page 50: ...4 14 Service Manual 4102 P01 Paper Support Removal 1 Remove the top cover 2 Remove the back cover 3 Remove the mounting screw A 4 Remove the paper support ...

Page 51: ...Repair Information 4 15 4102 P01 Slide Guide Removal 1 Remove the top cover 2 Gently lift up A to unsnap the autocompensator shaft 3 Slide the guide toward the left B to remove ...

Page 52: ...4 16 Service Manual 4102 P01 USB DC Jack Board Removal 1 Remove the top cover 2 Unplug the cable at connector B J601 3 Remove the jack board mounting screw A 4 Remove the board ...

Page 53: ...Connector Locations 5 1 4102 P01 5 Connector Locations Engine Board Connectors J2C Transport Carrier Motor J3F Paper Feed Motor J5 Carrier J303 Engine Board S1 EOF Sensor S3 Cover Switch ...

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Page 55: ...Connector Locations 5 3 4102 P01 LCD Board Connectors J631 Engine Board J632 LCD J633 Operator Panel ...

Page 56: ...5 4 Service Manual 4102 P01 USB PSB Power Board Connector J601 Engine Board J602 USB External Device J604 USB PC J605 Power ...

Page 57: ...ions 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 Both ends of the sheet feeder pick roll shaft at the side frames The carrier to carrier frame engagement The carrier guide shaft and carrier guide shaft bearings Both ends of t...

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Page 59: ... a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts pertaining to one of the other 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 shown in the illustration ...

Page 60: ...7 2 Service Manual 4102 P01 Assembly 1 Covers ...

Page 61: ...686 1 Paper Support Assembly 2 12G3678 1 Cover Back 3 12G3687 1 Cover Top Assembly with Buttons and Keys PCB 4 12G3680 1 Cover Bottom Assembly 5 12G3690 1 Tray Exit 6 12G3688 1 Guide Slide 7 12G3677 1 Label Need More Ink 8 12G3675 1 Cover Second Access 9 12G3676 1 Cover Access ...

Page 62: ...7 4 Service Manual 4102 P01 Assembly 2 Carrier Assembly ...

Page 63: ...Parts Catalog 7 5 4102 P01 Asm Index Part Number Units Description 2 1 12G3682 1 Ink Carrier Assembly ...

Page 64: ...7 6 Service Manual 4102 P01 Assembly 3 Electronics ...

Page 65: ...83 1 Operator Panel LCD Assembly 2 12G3685 1 Cable Engine Board 3 12G3679 1 Board USB DC Jack 4 12G1825 1 Power Supply External LV 100 V Japan 4 12G1826 1 Power Supply External LV 120 V U S A 4 12G1827 1 Power Supply External HV 220 V 5 12G3684 1 Engine Board Main PCB Assembly ...

Page 66: ...7 8 Service Manual 4102 P01 Assembly 4 Frame Assembly ...

Page 67: ...Parts Catalog 7 9 4102 P01 Asm Index Part Number Units Description 4 1 12G3681 1 Frame Assembly 2 12G3691 1 Belt Carrier ...

Page 68: ...7 10 Service Manual 4102 P01 Assembly 5 Miscellaneous Asm Index Part Number Units Description 5 12G3692 1 Parts Packet 5 7366233 1 Field Packaging B M ...

Page 69: ...rs 7 2 Electronics 7 6 Frame Assembly 7 8 POST 2 1 POST Symptom Table 2 1 Preventive Maintenance 6 1 Problems Carrier Transport 2 2 Communications 2 2 CompactFlash SmartMedia 2 3 Maintenance Station 2 2 Paper Feed 2 3 Paper Feed Button 2 2 Paper Status Light 2 2 Power 2 3 Print Quality 2 4 R Removals 4 2 Access Cover Second Acess Cover 4 2 Back Cover 4 6 Bottom Cover Assembly 4 6 Button Card 4 7 E...

Page 70: ...T 2 1 Symptom Tables 2 2 T Tests Access Cover Sensor 3 4 Button 3 2 Code Level 3 2 CompactFlash 3 3 DRAM 3 4 End of Forms EOF 3 4 LCD 3 2 SmartMedia 3 3 SmartMedia Write Protect 3 3 Part Numbers 12G1825 7 7 12G1826 7 7 12G1827 7 7 12G3675 7 3 12G3676 7 3 12G3677 7 3 12G3678 7 3 12G3679 7 7 12G3680 7 3 12G3681 7 9 12G3682 7 5 12G3683 7 7 12G3684 7 7 12G3685 7 7 12G3686 7 3 12G3687 7 3 12G3688 7 3 1...