Lexmark 1200 Service Manual

Optra Color 1200

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

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•Index

• Manuals Menu

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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First Edition (October, 1998) The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED,INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22/035-3, 740 New Circle Road N.W., Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase.

Lexmark,FontVision, MarkVision, and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

Other trademarks are the property of their respective owners.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

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Contents

SafetyInformation.......................................ix

Safety Notice ...........................................ix

GeneralInformation....................................1-1

Maintenance Approach ................................1-1

Tools ..............................................1-1

Serial Number .......................................1-2

Abbreviations .......................................1-3

Standard Features ....................................1-4

Options.............................................1-5

Printer Supplies ......................................1-6

Cross Section of Printer ................................1-6

Operational Theory ......................................1-8

Electrophotographic Process ............................1-8

Photoconductor Drum ................................1-10

Electrical Charge Unit ................................1-10

Exposure Assembly ..................................1-11

Developer Assembly .................................1-11

Transfer Assembly ...................................1-12

Cleaning Assembly ..................................1-13

Paper Feed, Transfer, and Fusing .......................1-14

Print Modes ........................................1-26

Clearing Paper Jams ...................................1-27

Printing From the Multipurpose Feeder ...................1-28

DiagnosticInformation .................................2-1

Part Numbers........................................2-1

Adjustments and Procedures Following Parts Replacement....2-1

Start .................................................2-2

Initial Check .........................................2-2

Printer Messages .......................................2-3

Service Error Message Table............................2-4

Status Messages ....................................2-11

Attendance Messages ................................2-14

Symptom Table .....................................2-24

Service Checks .......................................2-28

Fuser Service Check .................................2-28

Color Print Unit Missing Service Check ...................2-29

Drive 1 DC Motor Service Check........................2-29

Drive 2 Stepper Motor Service Check ....................2-30

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Transport Belt/BUD Service Check.......................2-30

Optional Paper Feed Service Check......................2-31

Paper Jam Service Check..............................2-31

Paper Carrying Service Check ..........................2-33

Paper Exit FU/FD Service Check ........................2-35

Paper Low/Empty Tray 1, 2, 3 Service Check...............2-36

Paper Tray Missing/Size Service Check ...................2-36

Remove Paper Sensor Service Check ....................2-37

Power Supply Service Check ...........................2-37

Marks on Paper Service Check..........................2-38

Image Quality Troubleshooting ............................2-39

Print Quality Problems.................................2-39

Sensor Service Check ................................2-46

DiagnosticAids ........................................3-1

Power-On Self Test Sequence ...........................3-1

Using the Operator Panel ...............................3-2

Operator Panel Buttons.................................3-3

Printing the Menu Settings ..............................3-4

Operator Menu Disabled ...............................3-4

Menu Overview .......................................3-4

Diagnostic Mode ......................................3-6

Diagnostic Menu Group ................................3-6

Setting Printer top Margin ..............................3-10

Color Calibration of Printer .............................3-13

Print Tests ...........................................3-15

Input/Output Source Print Tests .........................3-15

Print Quality Pages ...................................3-16

LCD Hardware Test...................................3-17

Button Test .........................................3-17

DRAM Memory Test ..................................3-17

Std Parallel Wrap Test and Parallel X Wrap Test ...........3-18

Serial Wrap Tests ....................................3-19

Quick Disk Test .....................................3-20

Disk Test/Clean .....................................3-21

Setting the Page Count ...............................3-23

Viewing the Permanent Page Count .....................3-23

Viewing and Resetting the Drum Counters ................3-24

Calibrating the Transparency Sensor .....................3-24

Viewing the Error Log .................................3-25

Clearing the Error Log ................................3-26

US / Non-US ........................................3-27

Exiting Diagnostics Mode ..............................3-27

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Test Print 1.........................................3-28

Test Print 2.........................................3-29

RepairInformation.....................................4-1

Precautions for Disassembly and Cleaning ................4-1

Handling the Printed Circuit Boards with MOS ICs ...........4-1

Precautions for Handling the Drum Cartridge ...............4-2

Parts not to be touched ................................4-3

Adjustment Procedures ..................................4-3

Transfer Belt Tracking Adjustment .......................4-3

Thermistor Rank Adjustment ............................4-5

LED Head Light Quantity Adjustment .....................4-5

Top Margin for Color Mode .............................4-5

Top Margin for Black and White Mode ....................4-6

Overhead Projection Sheet Detection Sensor Adjustment .....4-6

Printhead Adjustments (X, Y, and Theta) ..................4-6

Removal Procedures ...................................4-10

LED Head Removal .................................4-10

Transfer Belt Unit Removal ............................4-11

Paper Remaining Sensor Removal ......................4-12

Belt Unit Drive Frame, BUD Motor, BUD Sensor Removal ....4-12

Engine Board (PG14 ENG BB) Removal..................4-14

Cover Removals.....................................4-15

Head Controller Board (P614 HDCONT) Removal ..........4-21

Operator Panel Removal ..............................4-22

MPF Removal ......................................4-23

Paper Feed Roller Removal ...........................4-24

MPF Roller .........................................4-25

FPadRemoval .....................................4-26

Registration Sensor Removal ..........................4-26

MPF Paper Empty Sensor Removal .....................4-27

Humidity Sensor Removal .............................4-27

Printer Controller (614 PRCONT) Removal ...............4-28

HVU1(U) Removal ..................................4-29

Drive 2 (U) and Face Up/Face Down (FUD) Solenoid Removal 4-29

Fuser Removal .....................................4-30

Fuser Thermostat, Fuse, and Thermistor Removals .........4-34

Fuser Press Roller Removal ...........................4-37

Fuser Pawl Removal .................................4-39

Fuser Heater Removal ...............................4-42

Fuser Heat Roller and Gear H, Gear 30 Removal ..........4-44

Heater Drive Board, 230 V Only ........................4-45

HVU 2 Removal ....................................4-46

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Power Supply Switch Removal .........................4-46

Power Supply Board (P614-MPS) Removal ................4-47

Size Sensor Board (P611-PSZ) Removal .................4-48

Toner Remaining Sensor, Drum Gear Sensor Removal.......4-48

Drive 1 Removal .....................................4-50

Drum Drive Gear Sensor (P614-DGS) Removal ............4-51

Registration Roller Removal ............................4-52

OHP Sensor Removal ................................4-57

Paper Exit Sensor Removal ............................4-59

Output Bin Full Sensor Removal ........................4-59

RIP Controller Card Removal ...........................4-61

Paper Face Up/Face Down (FUD) Delivery Sensor Removal . .4-61

Optional Paper Feeder Removal Procedures .................4-62

Outer Cover Removal .................................4-62

Size Sensor Board (P611-PSZ) Removal .................4-63

Drive Board (P614-2/3 DRIV) Removal ...................4-64

Paper Feed Motor 2 (PM42) Removal ....................4-64

Paper Feed Roller Removal ............................4-65

Paper Remaining Sensor Removal ......................4-66

Paper Feed Clutch, Solenoid, and Transfer Roller Removal . . .4-67

ConnectorLocations....................................5-1

Paper Handling .......................................5-1

Cross Section of Printer ................................5-2

Electronic Board Layout ................................5-4

Electrical Components .................................5-5

Sensors.............................................5-6

Power Supply Board (614-MPS-E) ........................5-7

High Voltage Unit 1 Board (614-HVU1).....................5-8

High Voltage Unit 2 Board (P614-HVU2) ...................5-9

Optional Paper Feed Controller Board (P614-2/3 DRIV) ......5-10

Printhead Controller Board (P614-HD CONT) ..............5-11

Printer Controller Board (P614-PRCONT) .................5-12

Size Sensor Board (P611-PSZ) .........................5-13

RIP Controller Card ..................................5-14

Preventive Maintenance .................................6-1

Maintenance Kit ......................................6-1

Periodic Maintenance ..................................6-2

Lubricants and Cleaners ...............................6-2

PartsCatalog ..........................................7-1

How to Use This Parts Catalog ............................7-1

Assembly 1: Covers ......................................7-2

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Assembly 2: Paper Exit...................................7-6

Assembly 3: Upper Unit ..................................7-8

Assembly 4: Base 1.....................................7-14

Assembly 5: Base 2.....................................7-18

Assembly 6: Feeder ....................................7-26

Assembly 7: Electrical...................................7-30

Assembly 8: I/F Controller................................7-36

Assembly 9: Fuser......................................7-38

Assembly 10: Cassette ..................................7-42

Assembly 11: Optional Feeder Base........................7-44

Assembly 12: Optional Feeder Paper Feed ..................7-50

Assembly 13: Optional Features...........................7-52

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Safety Information

Safety Notice

• 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 injur y during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

• 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 ix

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• Il prodotto è stato progettato, testato e approvato in

conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di par ti 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.

• 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.

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• 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.

• Existemayorriesgodedescargaeléctricaydedaños

personales durante el desmontaje y la reparación de la máquina. Elpersonal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

• 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 xi

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• 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 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 ha d’estar-ne assabentat i prendre les mesures convenients.

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Safety Information xiii

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1. General Information

Maintenance Approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure. You may find that the removals in the Repair Information chapter will help you identify parts.

After you complete the repair, perform tests as needed to verify the repair.

Tools

The removal and adjustment procedures described in this manual require the following tools and equipment:

• Magnetic tip Phillips screwdrivers, large and small

• Flat-blade screwdrivers

• Analog volt ohmmeter (a digital volt ohmmeter may also be

used)

• Needle nose pliers

• Tweezers, C-ring pliers

• Magnifier (10 times or equivalent)

• 6-angle wrench (1.5 mm).

When you make voltage readings, always use frame ground unless another ground is specified.

General Information 1-1

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Serial Number

Lower the multipur pose feeder and refer to the label on the right. The serial number is also listed on the menu settings page you can print from the Tests Menu.

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Abbreviations

ASIC Application-Specific Integrated Circuit CSU Customer Setup DRAM Dynamic Random Access Memory EEPROM Electrically Erasable Programmable Read-

Only Memory EP Electrophotographic Process ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LAN Local Area Network LASER Light Amplification by Stimulated Emission

of Radiation LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PICS Problem Isolation Charts PIXEL Picture Element POR Power-On R eset POST Power-On Self Test PQET Print Quality Enhancement Technology RIP Raster Image Processor ROS Read-Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement VAC Volts alternating current VDC Volts direct current

General Information 1-3

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Standard Features

Print method Dry electrophotographic process using LED printheads Print

addressability Maximum print

speed Fonts 1. 75 resident scalable fonts:

Paper input • 250-sheet tray

Paper output • Top output bin: 250 sheets (collated)

Paper sizes supported

Printer memory 32MB (two 16MB 50 ms EDO SIMMS)

600 dpi

• 12 ppm (letter and A4 paper) (Color)

• 12 ppm (Mono)

• PostScript Level 2 emulation: 39 Optra compatible plus 36 additional

• PCL emulation: 45 LaserJet compatible plus 30 additional

2. PCL bitmap fonts:

• LinePri nter

•POSTNETBarcode

3. FontVision

4. World class international font support:

• 77 symbol sets, including support for

• Canadian, French, Brazilian,

• Portuguese, Cyrillic, and Greek

• Multipurpose feeder

• Rear output bin: 100 sheets (uncollated)

A4, A5, JIS B4, JIS B5, A3, letter, legal, 11 x 17

Some printer models may ship with more memory.

font manager utility with 110 fonts

Flash memory 4MB (for permanent storage of fonts, logos, and forms) Interface Parallel (standard Centronics protocol that complies with

bidirectional IEEE 1284B)

Internalsolutions ports

Printer software MarkVision

• 2 ports for network adapters, tri-port adapters, or parallel port adapters

• 1 connector for hard disk

• 2 pairs of memory connectors

utility that lets you manage your printer from your computer. Supported in the following environments: Windows 95, Windows NT 4.0, Windows 3.1x, OS/2 Warp, Macintosh, UNIX.

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Options

Optional drawer Support unit and 250-sheet tray; up to two drawers may

be installed underneath the printer 250-sheet tray Replacement tray Memory • 32MB option (two 16MB memory cards)

• 64MB option (two 32MB memory cards)

• Maximum installed memory: 128MB

Hard disk option 2.5-inch hard disk to store fonts, forms, job statistics, and

Hard disk adapter ribbon cable

MarkNet S internal network adapters

Tri-port adapter Provides support for the following interfaces:

Parallel port adapter

Infrared adapter For use with the tri-port adapter; receives infrared beam

Serial interface adapter

Parallel cables High speed bidirectional 10-foot and 20-foot 1284-B

spooled jobs

For installing compatible Lexmark or third-party hard

disks

Adapters available to support the following topologies:

• Ethernet 10BaseT and 10Base2

• Ethernet 10/100BaseTX

• Token-Ring (connects the printer to a Token-Ring network via DB9 or RJ45)

• Serial RS-232C/RS-422A (which can also be configured to support a class 1 fax modem)

• High speed Infrared local connections

• LocalTalk network connection

Provides additional parallel port

from an IrDA-compatible workstation Converts the printer’s parallel port to a serial port

parallel cables; 9.8-foot 1284 A-C parallel cable

Serial cable 50-foot serial cable

General Information 1-5

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Printer Supplies

Toner cartridges Black, magenta, cyan, or yellow

cartridges

Photoconductors • Black photoconductor (with fuser

coating roll)

• Cyan, magenta, and yellow photoconductors (packaged together)

Transparencies A4 and letter size

6,500 pages each (5% coverage)

13,000 pages each

Cross Section of Printer

1 FuserRoller 18 Absorption Roller 2 PressRoller 19 Registration Upper Roller (Metal) 3 Heater 20 Registration Roller (Rubber) 4 FuserOil Roller 21 Registration Sensor 5 Paper Exit Sensor Lever 22 Registration Sensor Lever 6 Belt Drive Roller 23 MPF Roller 7 BeltThermistor 24 Feeder Friction Stop Pad 8 Transfer Belt 25 MPF Assembly 9 Transfer Sheet 26 Paper Carrying Roller 10 Cleaning Blade 27 Paper Noise-Cut Roller 11 Charging Roller 28 Pick-up Paper Feed Roller 12 Photoconductor Drum 29 Paper Remaining Detection

Lever

13 LED Printhead 30 Paper Remaining Detection

Sensors 14 DevelopmentRoller 31 Transport Belt Blade 15 DeveloperSupply Roller 32 Transport Belt Waste Bottle 16 DeveloperDoctor Blade 33 Belt Unit Drive Motor 17 DeveloperAgitator 34 Interface RIP Controller Card

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General Information 1-7

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Operational Theory

This printer makes a color image by overlapping each color toner in dot units and fusing them to the paper. The process is divided into two steps. The first step is the electrophotographic process which forms the image on the PC. The second step consists of Feeding, Transferring, Fusing which feeds the paper, transfers the image to the paper and fuses the toner.

Electrophotographic Process

As the photoconductor drum rotates it is electrically charged, the image is exposed to the PC drum, the image is developedwith toner, the image is transferred to the paper, and the PC drum is cleaned.

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General Information 1-9

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Photoconductor Drum

The photoconductor drum uses aluminum as the base material and a layer of organic photo conductor (OPC) on the surface. A characteristic of this layer is that only the part that the light shines on becomes conductive.

Electrical Charge Unit

The charge roller of the electrical charge unit evenly charges the surface of the drum. The static latent image forms on the photosensitive drum.

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Exposure Assembly

The exposure assembly uses an LED head to form an electrostatic image by emitting light onto the charged drum. The length of time the light is on is contained in non-volatile memory (EEPROM) in the printer controller because the light emitting time of each LED is different in every head. When the LED head is replaced, the light emitting time must be reset. If you replace the LED head, be sure to also replace the EEPROM.

Developer Assembly

The toner agitator stirs the toner in the cartridge.The toner supply roller provides toner to the development roller.The doctor blade is pressed to the development roller which is conductive rubber.

As the development roller rotates, toner feeds between the developer roller and the doctor blade. This friction charges the toner negatively. As the toner comes in contact with the photoconductor drum, it sticks to the electrostatic latent image.

General Information 1-11

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Transfer Assembly

Paper is held to the transfer belt electrostatically. The belt rotates at the same speed as the photoconductor drum. The absorption roller applies a positive charge to the paper. T he toner formed on the photoconductor drum transfers to the paper because of the positive charge from the transfer sheet under the transfer belt.

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Cleaning Assembly

The cleaning blade scrapes off the remaining toner on the photoconductor drum after the toner image has been transferred to the paper.

A rotating coil in the waste toner conveyance assembly conveys the scraped-off toner to the waste toner bag.

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Paper Feed, Transfer, and Fusing

Two drives perform the entire paper feed in this printer, drive 1 and drive 2. There is a separate motor in the second paper feeder to drive the paper feed.

Drive 1

Drive 1 consists of a brush-less dc motor and gear unit. Drive 1 carries paper from the paper feed unit to the registration unit and also drives the electrophotographic process. The motor starts running after it receives an ON signal from the printer controller.The motor then sends a synchronizing signal to the printer controller. When monochrome mode is selected, clutch 2 interrupts the electrophotographic process for color printing.

Do not disassemble the gears in drive 1 because the phase adjustment has been preset. Do not turn the PC when it is out of the machine as the gears will lose timing to work as a matched set.

Drive 2

Drive 2 consists of a hybrid stepping motor and gear assembly. It drives the fuser and exit assembly. There is no synchronizing signal for this motor.

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General Information 1-15

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Paper Cassette Feeder

The printer controller sends a signal to the paper feed solenoid which turns on and drives the paper feed roller connected to drive 1 by a spring clutch. The paper in the cassette is picked one sheet at a time.

Multipurpose Feeder

After it r eceives a signal from the printer controller,the MPF solenoid turns on and drives the MPF roller connected to drive 1 by a spring clutch. The paper in the multipurpose feeder is picked up one sheet at a time.

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+ 230 hidden pages