Lexmark 1000 Color Jetprinter, Service Manual

Page 1: ...olor Jetprinter 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: ...ed 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 1 800 553 9727 In other countries contact your point of purchase Le...

Page 3: ... Service Check 2 10 Power Service Check 2 11 Print Quality Service Check 2 12 Diagnostic Aids 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 2 Base and Sheet Feed Assembly Removal 4 2 Carrier Belt Removal 4 3 Carrier Frame Assembly Removal 4 3 Carrier Transport Motor Removal 4 3 Drive Train Ass...

Page 4: ... 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 3 Electronics 7 6 Assembly 4 Carrier 7 8 Assembly 5 Sheet Feeder 7 10 Index I 1 ...

Page 5: ...ring 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 n...

Page 6: ...rsonale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark...

Page 7: ...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...

Page 8: ...d algunes peces pot ser que no sempre siguin òbvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informació pel manteniment d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional h...

Page 9: ...Notices and Safety Information ix 4096 00X ...

Page 10: ...x Service Manual 4096 00X ...

Page 11: ...n 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 Start on page 2 1 The user ...

Page 12: ...Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POST Power On Self Test V ac Volts alternating current V dc Volts direct current ZIF Zero Insertion Force ...

Page 13: ...r machine on and check for a correct POST operation by observing the following 1 The carrier moves 2 The paper feed gears turn 3 After 30 seconds the carrier moves over the maintenance station and caps the printhead 4 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 ...

Page 14: ...ier movement Slow carrier movement Carrier stops Carrier slams side frame Go to the Carrier Transport Ser vice Check on page 2 5 Symptom Action Maintenance station Fails to cap the printhead Fails to clean the printhead Go to the Maintenance Station Service Check on page 2 7 Symptom Action Paper feed button does not operate Replace the system board ...

Page 15: ...e Feed Service Check on page 2 6 Paper skews Go to the Paper Feed Service Check on page 2 8 Symptom Action No power in machine No motors operating 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 Go to the Print Quality Servi...

Page 16: ...s do not 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 doesn t move Go to the Carrier Transport Service Check on page 2 5 Carrier slams side frame Go to the Carrier Transport Service Check on page 2 5 ...

Page 17: ...n 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 disconnected from the system board check for zero to ten 0 10 ohms between the following pins on the motor N6 1 and N6 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 carrie...

Page 18: ...heck 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 FRU Action 1 Envelope Guide Be sure the envelope guide ...

Page 19: ...er 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 ca...

Page 20: ...ill 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 betwe...

Page 21: ...tch gear and check that it rotates freely in one direction and locks when turned in the opposite direction 4 Auto Sheet Feeder Check the pick rollers for wear 5 Mid Frame Asm Access Cover Asm Check the following for wear Friction wheels Exit roller Star rollers 6 End of Forms Flag and Spring Check for binds or damage If binds are found replace the end of forms flag 7 End of Forms Sensor Check the ...

Page 22: ...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 Access Cover Asm Check the following for wear Friction wheels Exit roller Star rollers 5 End of Forms Flag Check for binds or damage ...

Page 23: ...e 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 Syst...

Page 24: ...s 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 ...

Page 25: ...he 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 wo...

Page 26: ...rier to carrier frame engagement should be lubricated with grease P N 1329301 as well as the carrier guide rod and bearing Idler 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...

Page 27: ...Diagnostic Aids 3 1 4096 00X 3 Diagnostic Aids There are no residence diagnostic aids associated with the 4096 printers ...

Page 28: ...3 2 Service Manual 4096 00X ...

Page 29: ...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 30: ...s 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 g...

Page 31: ...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 6 To replace the carrier frame remove all associated parts from the old carrier fram...

Page 32: ...emove it from the carrier frame Note The paper feed motor is a part of the drive train assembly End of Form Flag Removal 1 Remove the front cover 2 Remove the carrier frame from the base assembly 3 Disconnect all cables from the system board 4 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...

Page 33: ...l Removal 1 Remove the front cover 2 Remove the carrier frame from the base assembly 3 Move the printhead carrier assembly to the left 4 Remove the maintenance station assembly 5 Turn and remove the retainers at both ends of the large feed roller 6 Remove the mid frame assembly 7 Remove the large feed roller from the carrier frame Maintenance Station Assembly Removal 1 Remove the front cover 2 Rel...

Page 34: ...board 4 Remove the screws that secure the power supply to the base assembly and remove the power supply Printhead Carrier Assembly Removal 1 Remove the front cover 2 Disconnect the printhead cable from the system board 3 Remove the retainer spring from the right end of the carrier guide rod 4 Slide the carrier guide rod out the right side of the machine 5 Remove the belt from the back of the carri...

Page 35: ...ver 2 Remove the carrier frame from the base assembly 3 Disconnect all cables from the system board 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 ...

Page 36: ...4 8 Service Manual 4096 00X ...

Page 37: ...Locations 5 1 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 ...

Page 38: ...5 2 Service Manual 4096 00X ...

Page 39: ... 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 ...

Page 40: ...6 2 Service Manual 4096 00X ...

Page 41: ...n 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 ...

Page 42: ...7 2 Service Manual 4096 00X Assembly 1 Covers ...

Page 43: ...2 11B5127 1 Cover Front Asm Button 001 002 2 17Z0174 1 Cover Front Asm Button 003 2 17Z0175 1 Cover Front Asm Button 004 3 11B5125 1 Base Asm and Sheet Feed 001 002 3 17Z0170 1 Base Asm and Sheet Feed 003 3 17Z0171 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 ...

Page 44: ...7 4 Service Manual 4096 00X Assembly 2 Paper Feed Carrier Transport Maintenance ...

Page 45: ...11B5136 1 End of Form Flag and Spring 5 11B5144 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 ...

Page 46: ...7 6 Service Manual 4096 00X Assembly 3 Electronics ...

Page 47: ...2 11B5622 11B5622 11B5622 11B5622 11B5623 11B5622 11B5141 11B5622 11B5622 11B5622 11B5626 11B5622 11B5625 11B5622 11B5622 11B5621 1 Power Cord U S Power Cord Austria Power Cord Belgium Power Cord Brazil Power Cord Canada Power Cord Chile Power Cord Cyrillic Power Cord Denmark Power Cord East Turkey Power Cord Europe Power Cord Finland Power Cord France Power Cord Germany Power Cord Greece Power Co...

Page 48: ...7 8 Service Manual 4096 00X Assembly 4 Carrier ...

Page 49: ...talog 7 9 4096 00X Asm Index Part Number 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 ...

Page 50: ...7 10 Service Manual 4096 00X Assembly 5 Sheet Feeder ...

Page 51: ... Feeder Asm and Garage Assembly 001 002 2 17Z0170 1 Base Sheet Feeder Asm and Garage Assembly 003 2 17Z0171 1 Base Sheet Feeder Asm and Garage Assembly 004 3 11B5126 1 Support Upper Paper 001 002 3 17Z0172 1 Support Upper Paper 003 3 17Z0173 1 Support Upper Paper 004 4 17Z0178 1 Tray Exit 003 4 17Z0179 1 Tray Exit 004 ...

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Page 53: ...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 S...

Page 54: ...I 2 Service Manual 4096 00X ...

Page 55: ... the book accurate and complete Yes No 3 Was the book easy to use Yes No 4 What 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 quest...

Page 56: ...t Along Line POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 035 3 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY ...