Lexmark 4090-001 User Manual

Color Jetprinter™ 2070

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4090-001

•Index

• Manuals Menu

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

4090-001

Third Edition (July, 1997)

The following paragraph doesnot apply to theUnited Kingdomor anycountry where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL,INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTYOF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimerof expressor implied warrantiesin 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 inlater editionsof thepublication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not 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 Lexmark International, Inc., registered in the United States

and/or other countries. Color Jetprinter is a trademark of Lexmark International, Inc. 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.

4090-001

Contents 1

Contents .............................................. iii

Preface ...............................................vi

SafetyInformation..................................... vi

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

Resolution and Print Speed ............................1-1

PowerConsumption..................................1-1

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

Abbreviations....................................1-2

UniqueToolsRequiredForService...................1-2

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

Start..............................................2-1

ErrorIndicatorTable...............................2-2

Power-On Self Test (POST) Sequence ................2-2

POSTSymptomTable.............................2-3

SymptomTables .................................2-4

ServiceChecks......................................2-6

EnvelopeFeedServiceCheck.......................2-6

FirstPrintLineServiceCheck.......................2-6

MaintenanceStationServiceCheck..................2-7

Paper Feed Service Check .........................2-8

Paper Path Service Check.........................2-10

ParallelPortServiceCheck........................2-11

PowerServiceCheck.............................2-11

PrintQualityServiceCheck........................2-12

TransportServiceCheck..........................2-14

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

EncoderSensorTest.................................3-2

InitializeErrorLog....................................3-3

Paper Sensor Test ...................................3-4

ParallelPortTest....................................3-5

PrintNVRAMContents................................3-6

TestPage..........................................3-7

iii

4090-001

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

Handling ESD-Sensitive Parts.......................... 4-1

Adjustments........................................ 4-2

RemovalProcedures................................. 4-2

ReleasingPlasticLatches.......................... 4-2

BaseAssemblyRemoval........................... 4-3

CarrierBeltRemoval.............................. 4-3

CarrierFrameAssemblyRemoval ................... 4-4

CarrierTransportMotorRemoval.................... 4-5

Code Module Removal . . .......................... 4-6

Edge Guide Asm and Paper Load Shaft Removal ....... 4-6

EncoderCardRemoval............................ 4-6

EncoderStripRemoval............................ 4-6

ExitDriveBeltRemoval............................ 4-7

ExitRollerRemoval............................... 4-7

FeedArmAssemblyRemoval....................... 4-7

FrontCoverRemoval ............................. 4-8

GutterPadRemoval.............................. 4-8

InsideIdlerGearsRemoval......................... 4-9

LargeFeedRollRemoval......................... 4-10

LargeOutsideGearRemoval...................... 4-11

LeftSideFrameAssemblyRemoval................. 4-12

Maintenance Station Assembly Removal ............. 4-13

Maintenance Wipers and Caps Removal ............. 4-13

Manual Insert Tray Removal ....................... 4-13

MidFrameAssemblyRemoval..................... 4-13

Paper Feed Motor Removal ....................... 4-14

Paper Guide and EOF Flag Assembly Removal . ....... 4-14

Paper Load Door Removal ........................ 4-16

Pick Roll Hub, Shaft and Envelope Bucklers Removal . . . 4-16

Power Supply Removal. . ......................... 4-16

Printhead Cable, Cradle & Paper Deflector Removal .... 4-17

Printhead Carrier Assembly Removal ................ 4-19

Printhead Rubber Backer Removal. . ................ 4-19

RearCoverRemoval............................. 4-20

RightSideFrameAssemblyRemoval................ 4-20

Small Feed Roll Shaft, Rollers & Paper Flap Removal . . . 4-21

StarRollerRemoval ............................. 4-21

SystemBoardRemoval........................... 4-21

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

SystemBoardConnectors............................. 5-2

EncoderCardConnector........................... 5-3

4090-001

PreventiveMaintenance ................................6-1

Lubrication Specifications. . ............................6-1

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

HowToUseThisPartsCatalog.........................7-1

Assembly1:Covers..................................7-2

Assembly2:Frames..................................7-4

Assembly 3: Paper Feed . . ............................7-6

Assembly4:Electronics...............................7-8

Assembly5:Carrier.................................7-12

Assembly6:CarrierTransport.........................7-14

Assembly 7: Sheet Feeder . ...........................7-16

Assembly 8: Maintenance Station ......................7-18

Index ..................................................1

4090-001

Preface 2

This manual 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 error indicator table, symptom table, 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. ConnectorLocations uses illustrations to identify theconnector 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.

Safety Information

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.

• The safety features of some parts may not always be

obvious. Therefore, replacement parts must have the identical or equivalent characteristics as the original parts.

4090-001

Sicherheitshinweise

• Die Wartungsinformationen für dieses Produkt wurden zur

Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen benützt werden.

• Zusätzliches Risiko eines elektrischen Schlags und

körperlicher Verletzung existiert während des Auseinandernehmens und der Wartung des Geräts. Fachpersonal sollte im vollen Verständnis der Lage entsprechende Vorsichtsmaßnahmen ergreifen.

• Ersatzteile müssen gleiche oder gleichwertige Merkmale wie

die Originalteile aufweisen,da Sicherheitsvorkehrungen nicht immer offensichtlich sind.

Consignes de Sécurité

• 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.

• 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 manutenzione di questo

prodotto sono indirizzate soltanto al personale dell'assistenza autorizzato.

• Durante lo smontaggio e il manutenzionamento di questo

prodotto, è possibile il rischio accresciuto di scosse elettriche e danni personali. Il personale di assistenza autorizzato, consapevole di ciò, deve adottare le precauzioni necessarie.

• È possibile che le funzioni di sicurezza dialcunielementinon

siano così ovvie, quindi, i pezzi di ricambio devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali.

Preface vii

4090-001

Pautas de Seguridad

• La información sobre el mantenimiento de este producto fue

escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario.

• Existen mayores riesgos de descargas eléctricas y daños

personales durante el desmontaje y la reparación de la máquina. El personal cualificado comprende esto y toma las precauciones necesarias.

• Los dispositivos de seguridad de algunas partes quizá no

siempre puedan ser reconocidas a simple vista. Por lo tanto, las partes de reemplazo deben poseer características idénticas o equivalentes a las partes originales.

Sikkerhedsoplysninger

• Oplysningerne om vedligeholdelse af dette produkt er

forberedt med henblik på professionelt servicepersonale, og bør derfor ikke benyttes af andre.

• Risikoen for elektrisk stød øges under demontering og

service af dette produkt, hvorfor der børtages 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 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.

• Os dispositivos de segurança de algumas peças poderão

não ser sempre suficientemente evidentes. Assim, as peças sobressalentes devem possuir características idênticas ou equivalentes às peças originais.

viii

4090-001

Chinese Safety Information

Korean Safety Information

Preface ix

4090-001

1. General Information

The Color JetprinterTM2070 (4090-001) printer is a personal, near laser-quality inkjet printer. The print cartridge contains single-unit customer-replaceable supply items. Dual printheads provide color and true black printing without changing printheads. The black cartridge has a total of 104 nozzles and installs on the left. The color cartridge has a total of 96 nozzles and installs on the right. The printer is capable of printing in two directions from either cartridge.

Resolution and Print Speed

Color Black

600 X 300 dpi 600 X 600 (using special paper)

167 cps - Letter Quality 300 cps - Draft

600 X 300 dpi 600 X 600 (using special paper)

230 cps - Letter Quality 300 cps - Draft

Power Consumption

Less than 2 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 this manual leads you to the correct field replaceable unit (FRU) or part. Use the error indicator charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. Begin with “Start” on page 2-1.

This printer can be serviced without being connected to a host computer. The user is directed, in the Printer Control program, to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge.

General Information 1-1

4090-001

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

Abbreviations

CE Customer Engineer CSU Customer Setup ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LED Light-Emitting Diode 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

Unique Tools Required For Service

Parallel Wrap Plug P/N 1319128

General Information 1-2

4090-001

2. Diagnostic Information

Use the error indicator table, symptom tables, service checks, and diagnostic aids to determine the failing part.

Start

Service error indications show as a series of flashes of the Power light. There is a pause between each series of flashes. If your printer has an error indication, locate the series of flashes in the ’Error

Indicator Table’ on page 2-2 and take the indicated action. Unplug

the printer to clear the error indicator. If an error indicator appears, go to the error indicator table and take

the indicated action for that error. The printer also logs the last occurring error. If you think it may have

an intermittent error, or the error indicator lights have been cleared, you can retrieve the error:

1. Run the ’Print NVRAM Contents’ on page 3-6. The last error appears at the bottom of the page.

2. Run ’Initialize Error Log’ on page 3-3 to clear the error (the error may not be the result of a current error).

3. Run the ’Test Page’ on page 3-7. If no error appears, go to

’Power-On Self Test (POST) Sequence’ on page 2-2.

Diagnostic Information 2-1

4090-001

Error Indicator Table

Number

Error Code

Power

Light

Flashes

Action

64 65

66 78

79 81 83 89

127 and up

9 1 8 4

Replace the Code Module and/or system board.

Replace the Code Module and/or system board. Go to the ’Transport Service Check’ on page 2-14. Replace the Code Module and/or system board. Go to the ’Transport Service Check’ on page 2-14. Replace the Code Module and/or system board.

Power-On Self Test (POST) Sequence

When you turn the printer on it performs a POST. Turn your printer on and check for a correct POST operation by observing the following:

1. The busy light comes on and goes off.

2. The power light comes on.

3. The carrier moves over the maintenance station and seals the printheads.

4. The paper feed gears turn.

5. All motors stop and the power light stays on.

If your printer completes POST with no errors, go to the ’Symptom

Tables’onpage2-4, locate the symptom and take the indicated

action.

Diagnostic Information 2-2

4090-001

If your pr inter does not complete POST, locate the symptom in the following table and take the indicated action.

POST Symptom Table

Symptom Action

No Powerlight and no motors run

Power light, but no busy light

Feeds paper Go to the ’First Print Line Service Check’ on page 2-6. Paper feed

gears do not turn

Carrier doesn’t move

Carrier slams side frame

Go to the ’Power Service Check’ on page 2-11.

Replace the system board.

Go to the ’Paper Feed Service Check’ on page 2-8.

Go to the ’Transport Service Check’ on page 2-14.

2-3

4090-001

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

• Carrier slams side frame

Go to the ’Transport Service Check’

on page 2-14.

Communications Problems

Symptom Action

Printer not communicating with host computer.

Go to the ’Parallel Port Service

Check’ on page 2-11.

Maintenance Station Problems

Symptom Action

• Fails to cap the printhead

• Fails to clean the printhead

Go to the ’Maintenance Station

ServiceCheck’onpage2-7.

Op Panel

Symptom Action

Paper feed button does not operate

Busy light does not come on Replace the system board.

Replace the system board.

Diagnostic Information 2-4

4090-001

Paper Feed Problems

Symptom Action

Paper fails to stop at first print line Go to the ’First Print Line Service

Check’ on page 2-6.

• 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

Envelopes fail to feed Go to the ’Envelope Feed Service

Paper skews Go to the ’Paper Path Service

Go to the ’Paper Feed Service

Check’ on page 2-8.

Check’ on page 2-6.

Check’ on page 2-10.

Power Problems

Symptom Action

No power in printer, no Power light, no motors

Go to the ’Power Service Check’ on

page 2-11.

Print Quality Problems

Symptom Action

• Voids in characters

• Light print

• Prints off the page

•Fuzzyprint

• Carrier moves but does not print

• Printhead drying prematurely

• Vertical alignment off

Go to the ’Print Quality Service

Check’ on page 2-12.

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

2-5

Go to the ’Paper Feed Service

Check’ on page 2-8.

4090-001

Service Checks

Envelope Feed Service Check

FRU Action

1 Envelope Guide Be sure the envelope guides have been turned

to the envelope load positions. Be sure the envelope guides are against the

envelopes. Perform the ’Paper Feed Service Check’ on

page 2-8.

First Print Line Service Check

FRU Action

1End-of-Forms

Flag

2End-of-Forms

Sensor

3 System Board Perform the ’PaperSensor Test’ on page 3-4 to

4 Feed Arm

Assembly

Check the flag for binds or damage.

Check the sensor for dirt.

check the end-of-forms sensor on the system board.

Check all parts of the feed arm assembly for binds, wear,or damage.

Diagnostic Information 2-6

4090-001

Maintenance Station Service Check

The maintenance station has two functions:

1. Cleans the printhead nozzles during the print operation.

2. Seals the printhead when it is not being used to prevent the nozzles from drying.

FRU Action

1 Maintenance

Station Assembly

2 Wiper A worn wiper causes degraded print quality just

3 Cap A worn cap causes the printhead nozzles to dry

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 caps to rise and seal the printheads. Carrier movement to the left will uncap the printheads. The wipers clean the printhead nozzles as the carrier leaves the maintenance station. The wipers clean the printheads 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 tabon the maintenancestation engages atab on the carrier, causing the wipers to lower.

Check the maintenance station for worn or broken parts.

after a maintenance cleaning. Check for loose or worn wiper.

and clog. Check for loose or worn cap.

2-7

4090-001

Paper Feed Service Check

If your printer does not have paper jam problems, continue with the service check. If your printer does have a paper jam problem, examine it for the following before you begin the ser vice 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 With J5 disconnected and power on, check for

+30 V dc between J5-1 and ground, and between J5-2 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 shorted pin, replace the motor. If you still havea failure after replacing the motor, replace the system board.

Diagnostic Information 2-8

4090-001

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 disconnected from the system board, check for 5 to 10 ohms between pin 1 and 4 on the motor cable.

If the reading is incorrect, replace the motor. Checkfor motorpins shorted to themotor housing. If you find a shorted pin, replace the motor.If the failure remains, 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 paperfeed motorand check the shaft forbinds. Also check for loose or worn motor gear.

3 Gears Check for binds in the gear train and paper feed

4 Feed Arm

Assembly

5 Paper Path Perform the ’Paper Path Service Check’ on page

mechanism by rotating the large feed roll byhand. If you notice a bind, isolate it by removing one of the small idler gears on the inside of the left side frame. Replace any worn or binding gears or rollers.

At the beginning of the paper feed operation, the paper feed motor reverses momentarily to allow the feed arm pawl to drop off the home position notch in the left side frame.If the pawl fails to drop off the notch, check the feed arm assembly for binds, and worn or broken parts.

2-10,startingatStep1.

2-9

4090-001

Paper Path Service Check

Examine the printer for the following before you begin this service check:

• Check the entire paper path for obstructions.

• Be sure the paper guides are not worn or broken and are posi-

tioned against the paper without binding or buckling the paper.

• Be sure the correct type of paper is being used.

• Be sure the printer is installed on a flat surface.

FRU Action

1 Large and Small

Feed Rollers

2 Small Feed Roller

Springs Paper Guide Paper Flap

3 Exit Rollers

Star Rollers Exit Drive Belt

4 Sheet Feeder Check the following for wear or damage:

5End-of-Forms

Flag & Spring

Check for wear and binds.

Check for damage.

Check for wear and binds.

• Pick Rollers

• Envelope Bucklers

• All parts inside the left and right edge guides. Check for binds or damage.

Diagnostic Information 2-10

4090-001

Parallel Port Service Check

FRU Action

1 Parallel Port Run a test page to be sure the printer can print.

Run the ’Parallel Port Test’ on page 3-5.Ifthetest fails, replace the system board.

Power Service Check

FRU Action

1 Power Supply Disconnect J3 from the system board and check

the following voltages on the power supply cable:

• J3-1toGND=+5Vdc

• J3-3 to GND = +30 V dc

• J3-5 to GND = +13.5 V dc

• J3-6toGND=+5Vdc

• J3-8toGND=+5Vdc

If you do not have correct voltage, replace the power supply. Be sure to unplug the printer before you reconnect the power supply to the system board.

3 Printhead Cable

Parallel Cable Encoder Card

4 System Board If the symptom has not changed, replace the

Turn off the printer. Disconnect one of the printhead cablesand turn on the printer.Look fora symptom change. Check the failing part for shorts and replace as necessary. Repeat this procedure for the parallel cable and the encoder card.

system board.

2-11

4090-001

Print Quality Service Check

FRU Action

1 Print Cartridge Be sure the printer contains good print cartridges. 2 Printhead Carrier

Assembly

3 System Board

Printhead Cable Rubber Backer

Reseat the printhead cables in the system board and check the following parts for wear or damage:

• Print Cartridge Latch

• Latch Spring

•Carrier

•Performthe’Test Page’on page 3-7. 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, replace the system board.

If there is a single break or random breaks in the diagonal line check the following:

• Check the gold-plated contacts, on the end of the 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 mayneedtoremovethecablefromthecarrier 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.

4 Maintenance

Station

Intermittent nozzle failures can be caused by worn parts in the maintenance station. Perform the

’Maintenance Station Service Check’ on page 2-7,

then return to this check.

Diagnostic Information 2-12

4090-001

FRU Action

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 being used. Also check the paper for curl or wrinkles.

• Feed rollers for wear,dirt, or looseness.

• Gearsforwearorbinds.

• Paper path for obstructions.

6 Transport Blurred printand voids canbe caused byproblems

in the transport area. Check the following:

• Transport belt for wear.

• Carrier guide rod for wear or dirt.

• Carrier to carrier frame engagement should be lubricated with grease P/N 1329301.

Do not lubricate the carrier guide rod or carrier bearing surfaces.

• Idler pulley parts for wear, damage, or looseness.

• Encoder strip for wear or dirt.

7 Alignment Uneven vertical lines can be adjusted by

performing the bidirectional alignment. The user is directed, through the Printer Control program, to perform thehead to head and bidirectional printing alignments, when replacing a print cartridge.

2-13

+ 54 hidden pages