Lexmark 4094 schematic

5000 and 5700 Color Jetprinter™

5770 Photo Jetprinter

• Table of Contents

• Start Diagnostics

• Safety and Notices

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• Trademarks

•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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Edition: October 2000

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 and Optra are trademarks 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.

©CopyrightLexmarkInternational,Inc.1998, 2000
All rights reserved.

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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Table of Contents

Preface................................................ix

SafetyInformation .......................................x

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

Models ...............................................1-1

Lights and Buttons (5770) ................................1-2

Operator Panel and Menu (5770) ...........................1-3

Resolution and Print Speed . . . ............................1-5

PowerConsumption.....................................1-5

Maintenance Approach ..................................1-5

Abbreviations ..........................................1-6

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

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

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

Power-On Self Test (POST) Sequence ...................2-3

Power-On Self Test (POST) Sequence (5770) ..............2-3

POSTSymptomTable ................................2-4

SymptomTables.....................................2-5

ServiceChecks ........................................2-8

FirstPrintLineServiceCheck...........................2-8

Maintenance Station Service Check . . . ...................2-9

Operator Panel Service Check (5770) . . ..................2-10

Operator Panel Display Service Check . ..................2-11

Paper Feed Service Check . ...........................2-12

Paper Path Service Check. . ...........................2-14

ParallelPortServiceCheck ...........................2-14

PhotoControllerServiceCheck ........................2-15

PowerServiceCheck ................................2-16

PrintQualityServiceCheck............................2-17

TransportServiceCheck..............................2-19

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

Paper Pick Assembly Operation ............................3-1

EndofForms(EOF)Test .................................3-5

TestPage.............................................3-6

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

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

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

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Removal Procedures . ....................................4-2

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

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

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

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

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

Covers(Complete)Removal.............................4-5

Cover(Center)Removal................................4-6

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

EncoderStripRemoval.................................4-7

EOFFlagAssemblyandHolderRemoval ..................4-7

ExitDriveBeltRemoval................................ 4-8

ExitRollerRemoval ...................................4-8

GearPlateRemoval...................................4-9

GutterPadRemoval...................................4-9

LargeFeedRollRemoval...............................4-9

Maintenance Station Assembly Removal . .................4-10

Maintenance Wipers and Caps Removal . .................4-10

Mid-FrameAssemblyRemoval .........................4-10

Paper Feed Motor Removal . . ..........................4-11

Paper Pick Assembly Removal .........................4-11

PhotoControllerAssemblyRemoval .....................4-11

Printhead Cable and Cradle Removal . . . .................4-12

Printhead Carrier Assembly Removal . . . .................4-13

Printhead Rubber Backer Removal ......................4-14

Sheet Feeder Removal ...............................4-15

SmallFeedRollerRemoval ............................4-15

StarRollerRemoval ..................................4-15

SystemBoardRemoval............................... 4-15

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

System Board Connectors (5000, 5700) ......................5-1

System Board Connectors (5770) .......................... 5-2

Photo Controller Board Connectors (5770) . . ................. 5-3

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

LubricationSpecifications .................................6-1

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

HowToUseThePartsCatalog ............................7-1

Covers ...............................................7-2

Frames ...............................................7-4

Paper Feed ............................................7-6

Electronics.............................................7-8

Carrier ..............................................7-10

CarrierTransport ......................................7-12

Sheet Feeder .........................................7-14

Maintenance Station ....................................7-16

PhotoController .......................................7-18

Index.................................................X-1

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vi Service Manual

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Preface

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 an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).

3. Diagnostic Aids contains tests a nd 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 the
connector locations and test points on the printer.

6. Preventive Maintenance contains the lubrication specifications
and recommendations to prevent problems.

7. Parts Catalog contains illustrations and part numbers for
individual FRUs.

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Safety Information

• 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

injury during 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 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.

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Norme di sicurezza

• Il prodotto è stato progettato,testato e approvatoin 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 parti 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.

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 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.

Safety Information ix

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Pautas de Seguridad

• 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.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y 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 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.

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Informació de Seguretat

• 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.

Safety Information xi

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1. General Information

The Lexmark 5000 Color JetprinterTMand Lexmark 5700 Color
Jetprinter are personal, near laser-quality inkjet printers. 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 208 nozzles
and the photo cartridge has a total of 192 nozzles. Either the black
or the photo cartridge is installed on the right. The color c artridge
has a total of 192 nozzles and installs on the left. The printer is
capable of pr inting in two directions.

The Lexmark Photo Jetprinter 5770 printer is a general purpose
printer that provides high quality text and photos. The 5770 can be
used without a computer to print photos or connected to a computer.
When connected to a computer the printer performs the same as a

5700.

Models

4094 - (S01, S02) 4093 - (S01, S02) 4093 - (S04)

General Information 1-1

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Lights and Buttons (5770)

The printer has two sets of lights and buttons:

• One set is located at the bottom left-hand corner of the printer,

on the operator panel.

• The other set is located at the top of the printer and includes the

Paper Status light and Paper Feed button.

Paper Status Light

Paper Feed Button

Operator Panel

1-2 Service Manual

Busy Light

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Operator Panel and Menu (5770)

Using the Operator Panel

The operator panel, on the front left side of the printer, has a 2-line
by 16-character liquid crystal display (LCD), five buttons and one
indicator light.

Operator
Panel
Display

Busy Light

Index

Select

Print

Cancel

Print All

Menu

Operator Panel Busy Light

On A camera card is installed and the printer is ready to print.
Off A camera card is not installed.
Blinking The printer is busy.

General Information 1-3

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Operator Panel Buttons

Menu Used to scroll through the Menus.
Select Used to select menu item - An asterisk (*) indicates an

item is selected.

Print Used to print a photo - Press and hold this button to

cancel print when the light is blinking.

Index Used to print an index page containing small images of all

photos on the camera card.

Print All Used to print all photos on the camera card.

Paper Status Light

Paper Feed Button

Paper Status Light (All Models)

Off Ready to print.
On Solid Printing or feeding media through the printer.
Blinking Out of paper or printer error

Paper Feed Button (All Models)

Clears a paper jam or loads paper when there is a paper out
condition.

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Resolution and Print Speed

600 X 300 Draft
600 X 600 Letter Quality
1200 X 1200 Ultra High Quality

3 page/minute Draft 8 page/minute Draft

600 X 300 Draft
600 X 600 Letter Quality
1200 X 1200 Ultra High Quality

Power Consumption

• Less than 10 Watts - power off and power to the printer

• Less than 10 Watts - Idle Mode (power on - not printing)

• Less than 15 Watts - Printing (average)

• Less than 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.

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

General Information 1-5

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Abbreviations

CSU Customer Setup
EOF End of Forms
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HV High Voltage
LED Light-Emitting Diode
LV Low Voltage
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
POST Power-On Self Test
V ac Volts alternating current
V dc Volts direct current

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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 Paper
Status 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. Run the “Test Page” on page 3-6.
If no error appears,go to “Power-OnSelf Test (POST) Sequence” on

page 2-3.

Diagnostic Information 2-1

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Error Indicator Table

2

3
4
5

6, 7

8

9, 10

12

14

81 Go to the “Transport Service Check” on page 2-18.
93 Replace the system board.

89 Go to the “Transport Service Check” on page 2-18.
90 Check the carrier for obstruction or binds. If no

obstruction or bind, replace the system board.

64-78 Replace the system board.

83 Replace the system board.
79 Replace the system board.
92 Replace the printhead. If problem remains, replace

the printhead cable.

95 The printer has received an invalid resolution setting

from the user’s application. Change the resolution in
the application and turn the printer off and on to reset
the condition. Refer to “Resolution and Print Speed”

on page 1-5.

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Power-On Self Test (POST) Sequence

Plug the printer in and check for a correct POST operation by
observing the following:

1. The Paper Status light comes on and goes off.

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

3. The paper feed gears turn.

4. All motors stop.

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

Tables,” on page 2-5, locate the symptom and take the indicated

action.
If your pr inter does not complete POST, locate the symptom in the

following table and take the indicated action.

Power-On Self Test (POST) Sequence (5770)

Plug the printer in and check for a correct post operation by
observing the following:

1. The Paper Status light comes on and goes off.

2. The operator panel Busy light comes on and then goes off.

3. The operator panel displays two rows of diamonds.

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

5. The paper feed gears turn.

6. All motors stop, and Ready appears in the display.

Diagnostic Information 2-3

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POST Symptom Table

No motors run Go to the “Power Service Check” on page 2-15.
Paper feed

gears do not
turn

Carrier does not
move

Carrier slams
side frame

No Paper Status
light

Blank Display
(5770)

All Diamonds
displayed after
POST (5770)

Display difficult
to read (5770)

Display OK,
Buttons do not
function (5770)

One or more
buttons do not
function (5770)

Go to the “Paper Feed Service Check” on page 2-11.

Go to the “Transport Service Check” on page 2-18.

Go to the “Transport Service Check” on page 2-18.

Replace the system board.

Go to the “Operator Panel Display Service Check (5770)”

on page 2-10.

Go to the “Operator Panel Display Service Check (5770)”

on page 2-10

Go to the “Operator Panel Display Service Check (5770)”

on page 2-10.

Go to the “Operator Panel Button Service Check (5770)”

on page 2-10.

Go to the “Operator Panel Button Service Check (5770)”

on page 2-10.

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Symptom Tables

Locate the symptom in the following tables and take the appropriate
action.

Carrier Transport Problems

• No carrier movement

• Slow carrier movement

• Carrier stops

• Carr ier slams side frame

Go to the “Transport Service Check”

on page 2-18.

Communications Problems

Printer not communicating with
host computer (All models except
5770

5770 Go to the “Parallel Port Service Check

Check the parallel port connection
(connector J7). If the connection is
good, replace the system board

(5770)” on page 2-13.

Maintenance Station Problems

• Fails to cap the printhead

• Fails to clean the printhead

Go to the “Maintenance Station

ServiceCheck”onpage2-9.

Paper Feed Button and Paper Status Light Problems

Paper Feed button does not
operate

Paper Status light does not comeonReplace the system board.

Replace the system board.

Diagnostic Information 2-5

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Photo Controller Problems (5770)

Prints from a PC but does not
print from a flash card.
Prints from a Flash Card but does
not print from a PC.

Go to the “Photo Controller Service

Check (5770)” on page 2-14.

Paper Feed Problems

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

Check” on page 2-8.

• 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

Paper skews Go to the “Paper Path Service Check”

Go to the “PaperFeedService Check”

on page 2-11.

on page 2-13.

Power Problems

No power in printer Go to the “Power Service Check” on

page 2-15.

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Print Quality Problems

• Voids in characters

• Light print

• Prints off the page

• Fuzzy print

• Carrier moves but does not print

• Printhead drying prematurely

• Vertical alignment off

• Excessive ink flow (Flooding)

• Horizontal banding

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

Go to the “Print Quality Service

Check” on page 2-16.

Go to the “PaperFeedService Check”

on page 2-11.

Diagnostic Information 2-7

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Service Checks

First Print Line Service Check

1End-of-Forms

Flag

2End-of-Forms

Sensor

3 System Board Perform the “End of Forms (EOF) Test” on

4 Paper Pick

Assembly

Check the flag for binds or damage.

Check the sensor for dirt.

page 3-5 to check the end-of-forms sensor on

the system board.
Check the paper pick assembly for binds,

wear, or damage.

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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.

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.Thereshouldbenowipingactionofthe
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 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.

Diagnostic Information 2-9

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Operator Panel Button Service Check (5770)

1 Operator Panel

Cable
Photo Controller

Board

2 Operator Panel

Assembly

3 Operator Panel

Assembly
Photo Controller

Board
System Board to

Photo Controller
Board Cable

System Board

If the operator panel display is OK, but the buttons
do not function, check the operator panel cable for
continuity and replace the cable if necessary.If the
symptom remains, replace the photo controller
board.

Run the “Button Test (5770)” on page 3-2.Ifanyof
the buttons fail, replace the operator panel
assembly.

Check all cables for proper connection. With
power applied to the printer, disconnect JP1 from
the photo controller board. Check for +5 V dc at
JP1-2 on the controller board. If correct, replace
the operator panel assembly.If incorrect, check for
+5 V dc at pins P1-28 and P1-29. If voltage is
correct, replace the photo controller board. If
incorrect, check for +5 V dc at pins J9-28 and
J9-29 on the system board. If correct, replace the
system board to photo controller board cable. If
the voltage at J9 is incorrect, replace the system
board.

Operator Panel Display Service Check (5770)

1 Operator Panel

Assembly
Operator Panel

Cable
Photo Controller

Board
System Board to

Photo Controller
Board Cable

2-10 Service Manual

If the operator panel is blank and the printer
completes POST, voltage is not getting to the
operator panel. Trace the +5 V dc line t o the
operator panel and replace the failing part. Trace
+5 V dc at pins JP1-2, P1-28 and P1-29 on the
photo controller board and pins J9-28 and J9-29
on the system board.

If all diamonds are displayed after the printer
completes POST, check the operator panel cable
for continuity and replace the cable if necessary. If
the symptom remains, replace the photo controller
board.

Run the “LCD Test (5770),” on page 3-2. If the test
does not show all PELS, replace the operator
panel assembly.

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Paper Feed Service Check

If your pr inter does not have paper jams, continue with the service
check. If your printer does have a paper jam problem, examine it for
the following before you begin the service 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.

1 System Board With (J6) disconnected and power on, check for

+30 V dc between (J6-1) 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
have a failure after replacing the motor, replace
the system board.

Diagnostic Information 2-11

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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.
Check for motor pins shorted to the motor
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 paper feed motor and check the shaft for
binds. Also check for loose or worn motor gear.

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

mechanism by rotating the large feed roll by hand.
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.

4 Paper Path Perform the “Paper Path Service Check” on

page 2-13, starting at Step 1.

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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

positioned 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.

1 Large and Small

Feed Rollers

2 Small Feed Roller

Springs

3ExitRoller

Star Rollers
Exit Drive Belt

4 Sheet Feeder Check the following for wear or damage:

5 End-of-Forms

Flag & Spring

Check for wear and binds.

Check for damage.

Check for wear and binds.

• Paper pick assembly

• All parts inside the left and right edge guides.

Check for binds or damage.

Parallel Port Service Check (5770)

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

Run the “Parallel Port Wrap Test(5770)” on

page 3-3

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Photo Controller Service Check (5770)

If the printer prints from a PC, but does not print from a Flash Card,
or the printer prints from a Flash Card but does not print from a PC,
continue with this service check.

1 Photo Controller

Board

2 System Board

System Board to
Photo Controller
Board Cable

Photo Controller
Board

Disconnect the photo controller assembly from the
printer by removing the photo controller cable from
the system board. Run a “Test Page”on page 3-6.
If the printer prints correctly, continue with this
service check. If the printer has a print quality
problem, go to the “Print Quality Service Check”

on page 2-16.

Run the “CompactFlash Test (5770)” on page 3-3
and the “SmartMedia Test (5770)” on page 3-3.
If either test fails, replace the photo controller
board.

Run the “Parallel Port Wrap Test (5770)” on

page 3-3. If the test fails, replace the photo

controller board.
Run the “DRAM Test (5770)” on page 3-4 and the

“SRAM Test (5770)” on page 3-4.Ifthetestfails,

replace the photo controller board.
Check the system board to photo controller board

cable connections.
Check for +5 V dc at pins P1-28 and P1-29 on the

photo controller board. If incorrect, check the
system board to photo controller board cable for
continuity and replace the cable if necessary.If the
symptoms remains, replace the photo controller
board.

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Power Service Check

1 Power Supply Disconnect the power connector from the system

board at (J4) and check the following voltages on
the power supply cable:

J4-3 to GND = +30 V dc
If you do not have correct voltage, replace the

power supply. Be sure to unplug the printer before
you reconnect the power connector (J4) to the
system board.

2 Printhead Cable

Parallel Cable
Encoder Card

3 Photo Controller

Board (5770)
Photo Controller

Operator Panel
(5770)

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

Unplug the printer. Disconnect one of the
printhead cables and re-plug the printer. Look for a
symptom change. Check the failing part for shorts
and replace as necessary. Repeat this procedure
for the parallel cable and the encoder card.

Remove the camera card from the camera card
slot. Unplug the printer. Remove the photo
controller assembly and disconnect the photo
controller to system board cables. Re-plug the
printer and look for a symptom change and
replace the failing part.

Unplug the printer and re-plug the photo controller
cables. Disconnect the operator panel. Re-plug
the printer and look for a symptom change and
replace the failing part.

system board.

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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 CartridgeLatch

• Latch Spring

•Carrier

Perform the “Test Page” on page 3-6. Look for a
break in the diagonal line of the test pattern. A
brokenline indicates one or more print nozzles are
not working. Run the test again to verify the
failure.If there are evenbreaks in the diagonal line
similar to the pattern shown, replace the system
board.

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

Note: Unplug the printer before cleaning contacts.

• 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.

• Refer to the test page. The temperature valueis
in Celsius.

4 Maintenance

Station

2-16 Service Manual

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

“Maintenance Station Service Check” on
page 2-9, then return to this check.

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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.

• Paper for curl or wrinkles.

• Feed rollers for wear, dirt, or looseness.

• Gears for wear or binds.

• Paper path for obstructions.

6 Transport Blurred print and voids can be caused by

problems in the transport area. Check the
following:

• Transportbelt forwear and full engagement into
the carrier grip.

• Carrier guide rod for wear or dirt.

• Carrier to carrier frame engagement should be
lubricated with grease P/N 99A0394.
Lubricate the carrier guiderod andcarrier frame
on both sides where the two top bearing
surfaces ride on the frame.

• 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 the head to head and bidirectional printing
alignments, when replacing a print cartridge.

5770 - Printhead alignment is also performed at
the operator panel. The user is instructed to
perform alignment settings at the operator panel.
These settings are used to print photos from the
flash card or an external storage drive.

Diagnostic Information 2-17

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Transport Service Check

1 Transport Motor Check the motor for binds, or loose motor pulley.

Disconnect the transport motor (J5) from the
system board. Check for 8 to 18 ohms between
pins 1 and 2 on the motor cable. If the reading is
incorrect, replace the motor.

Check for motor pins shorted to the motor
housing. If you find a pin shorted to the housing,
replace the motor. If the failure remains, replace
the system board.

2 System Board Disconnect (J5) from the system board and check

for a pulse of 30 V dc between (J5-2) and ground
as the printer goes through POST.

3 Carrier Guide

Rod

4 Transport Belt

Idler Pulley Parts
Carrier Frame

5 Encoder Strip

Encoder Card

6 Printhead Cable

Printhead Cable
Guide Strip

Clean the carrier rod.
Note: Lubricate the rod and the carrier rod bearing

surface.
Check for worn, loose or broken parts. Check for

obstructions blocking carrier movement.
Carrier to carrier frame engagement should be

lubricated with grease P/N 99A0394.
Check the encoder strip for wear, dirt and grease.

Be sure all printhead connectors are fully seated.
Check the cables for damage.

Check the encoder card connection.
Be sure all connectors are fully seated. Check the

cables for damage.
Some early level machines may experience a

printhead cable popping noise. These machines
can be identified by checking for a printhead cable
relief hole in the carrier frame located above the
maintenance station. If no printhead cable relief
hole is present, install the printhead cable guide
and clip.

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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 2-9.

Diagnostic Information 2-19

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3. Diagnostic Aids

Paper Pick Assembly Operation

The paper pick assembly is a paper pick device that generates its
own normal force which is inherent in the fundamental design of the
pick arm. If light media is used, the paper pick assembly picks very
gently; if a heavy media is used, it picks very aggressively.

The spring pressure of the device is designed so the input torque
from the motor produces movement about the pivot of the arm
causing a downward force at the pick roll. The friction 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 paper pick assembly.

Diagnostic Mode (5770)

To enter the Diagnostic Mode:

1. Unplug the power supply from the printer.

2. Press and hold the Index and Print buttons.

3. Plug the power supply into the printer.

4. Release the buttons when Diagnostic Menu appears in the
Operator Panel Display.

Unplug the power supply from the printer to exit the Diagnostic
Mode.

The tests display on the operator panel in the order shown:

• Code Level

• LCD

• Button

• CompactFlash

• SmartMedia

• Parallel Port

• Controller Port

• DRAM

• SRAM

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Code Level (5770)

Displays the current code level on the Controller Board. Code
upgrades to the Photo Controller Board can be down loaded from
either camera card slot or through the parallel port such as an
external storage drive. Use the following procedure to upgrade the
code.

1. With power applied to the printer, insert the camera card
containing the newer code level in the proper slot.

2. The message “Upgrading Flash ROM” will appear on the
display and the busy light will blink.

3. Wait one minute. If the message “OK! Remove Card & Reset”
does not appear, unplug the printer.

4. Replug the printer. The message “Upgrading Flash ROM” will
appear once again.

5. Within a minute, the message “OK! Remove Card & Reset” will
appear.

6. Remove the camera card from the slot, unplug and replug the
printer.

LCD Test (5770)

To run the LCD Test:

1. Select LCD Test from the Diagnostic Menu. The LCD test runs
continually.

2. Press Cancel to stop the test.

Button Test (5770)

To run the Button Test:

1. Select Button Test from the Diagnostic Menu. With no buttons
pressed, OP (Open) appears several times on the display.

2. Press each button, one at a time, and a CL (Closed) appears in
place of the OP. This checks the proper operation of each of the
buttons.

3. Press Print and Print All together to stop the test.

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CompactFlash Test (5770)

The purpose of this test is to check the connection between a
CompactFlash camera card and the Photo Controller Board. This
test performs a write, read and erase to the camera card.

To run the CompactFlash Test:

1. Insert a camera card into the CompactFlash slot (top slot).

2. Select CompactFlash from the Diagnostic Menu.

3. Press Cancel to stop the test.

Upon completion of the test, a Pass or Fail message appears in the
display.

SmartMedia Test (5770)

The purpose of this test is to check the connection between a
SmartMedia camera card and the Photo Controller Board. This test
performs a write, read 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 Cancel to stop the test.

Upon completion of the test, a Pass or Fail message appears in the
display.

Parallel Port Wrap Test (5770)

This test performs a wrap around test between the printer parallel
port and the parallel port test connector.

To run the Parallel Port Test:

1. Install a parallel wrap plug (P/N 1319128) in the parallel port.

2. Select Parallel Port from the Diagnostic Menu.

3. Press Cancel to stop the test.

Upon completion of the test, a Pass or Fail message appears in the
display.

Diagnostic Aids 3-3

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Controller Port Test (5770)

This test is not used for servicing the printer.

DRAM Test (5770)

The purpose of this test is to check the validity of DRAM on the
Photo Controller Board. The test writes patterns of data to DRAM to
verify that each bit in memory can set and read correctly.

To run the DRAM Test:

1. Select DRAM Test from the Diagnostic Menu.

2. Press Cancel to stop the test.

Upon completion of the test, a Pass of Fail message appears in the
display.

SRAM Test (5770)

The purpose of this test is to check the validity of SRAM on the
Photo Controller Board. The test writes patterns of data to SRAM to
verify that each bit in memory can set and read correctly.

To run the SRAM Test:

1. Select SRAM Test from the Diagnostic Menu.

2. Press Cancel to stop the Test.

Upon completion of the test, a Pass or Fail message appears in the
display.

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End of Forms (EOF) Test

This test checks the EOF sensor on the system board.
During the test, the Busy light remains on and shows the EOF

sensor status as follows:

• On - paper is in sensor

• Off - paper is not in sensor

To run the test:

1. Remove all paper and turn the printer on.

2. Insert a single sheet of paper into the sheet feeder until the EOF
flag activates and the Busy light comes on. The paper feeds
momentarily.

3. Press the Paper Feed button and the paper ejects as the Busy
light turns off.

4. If the preceding steps fail to occur, the sensor is bad. Replace
the system board.

Diagnostic Aids 3-5

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Test Page

This test prints the test page.
To run a complete test page of black and color patterns, be sure the

print cartridges are in good condition. Install a blackprint cartridge in
the right side of the printhead cradle and a color print cartridge in the
left side.

To enter the test:

1. Unplug the printer.

2. Ensure the manual paper slot is empty.

3. To start the test, press and hold the Paper Feed button while
plugging the printer in. Release the button when the printer
completes POST.

The test page contains the following:

• Code level and date

• Current Celsius temperature

• Nozzle test pattern for both cartridges

• Purge test for both cartridges

• Text (printer model)

• Paper test results

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4. Repair Information

This chapter explains how to make adjustments to the printer and
how to remove defective parts.

Note: Read the following before handling electronic parts. When
working on the printer, always unplug the printer from the electrical
outlet. High voltage is present in the power supply as long as it is
plugged into the electrical outlet.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to
electrostatic discharge (ESD). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic boards:

• Keep the ESD-sensitive part in its original shipping container

(a special “ESD bag”) until you are ready to install the part into the printer.

• Make the least-possible movements with your body to prevent an increase

of static electricity from clothing fibers, carpets, 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 you need to put down the ESD-sensitive part for any reason, first
put it into its special bag.

• Printer covers and metal tables are electrical grounds. They increase the

risk of damage because they make a discharge path from your body
through the ESD-sensitive part. (Large metal objects can be discharge
paths without being grounded.)

• Prevent ESD-sensitive parts from being accidentally touched by other

personnel. Install printer covers when you are not working on the printer,
and do not put unprotected ESD-sensitive parts on a table.

• If possible, keep all ESD-sensitive parts in a grounded metal cabinet

(case).

• Be careful in working with ESD-sensitive parts when cold weather heating

is used because low humidity increases static electricity.

Repair Information 4-1

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Adjustments

The user is directed, in the Printer Control program, to perform the
head to head and bidirectional alignment adjustments after replacing
a print cartridge.

Removal Procedures

The following procedures are arranged according to the name of the
printer part discussed. Unplug the power cord before removing any
parts.

Releasing Plastic Latches

Many of the parts are held in place with plastic latches. The latches
break easily; release them carefully.To remove such parts, press the
hook end of the latch away from the part to which it is latched.

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Base Assembly Removal

1. Remove the four screws from the left and right exit tray bases
and remove the bases. During reassembly, do not overtighten
the screws, as this may strip the plastic.

2. Remove the accent cover.

3. Remove the three screws from the left and right covers.

4. Remove the center cover.

5. Disconnect the power connector at the system board.

6. Remove the three screws securing the carrier frame to the base
cover.

7. Slide the printer off the base cover.

Carrier Belt Removal

1. Remove the four screws from the left and right exit tray bases
and remove the bases. During reassembly, do not overtighten
the screws, as this may strip the plastic.

2. Remove the accent cover.

3. Remove the three screws from the left and right covers.

4. Remove the center cover.

5. Remove the printhead carrier assembly.

6. Push the idler pulley to the right to release the tension on the
belt and remove the belt.

Note: When reinstalling the carrier belt, place the carrier at the
center position between the tabs on either end of the belt.

Repair Information 4-3

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Carrier Frame Assembly Removal

1. Remove all covers, refer to “Covers (Complete) Removal” on

page 4-5.

2. Disconnect the power connector at the system board.

3. Remove the sheet feeder assembly.

4. Remove the three screws securing the carrier frame to the base
cover. During reassembly, do not overtighten the screws, as this
may strip the plastic.

5. Slide the printer off the base cover.

Carrier Transport Motor Removal

1. Remove all covers (except the left and base covers), refer to

“Covers (Complete) Removal” on page 4-5.

2. Disconnect the transport motor connector from the system
board.

3. Remove the belt from the transport motor pulley.

4. Remove the two screws securing the transport motor to the
carrier frame and remove the motor. Note the routing of the
motor cable. During reassembly, do not overtighten the screws,
as this may strip the plastic.

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Covers (Complete) Removal

1. Open the access door and remove the accent cover.

2. Remove one screw from the left cover and two screws from the
right cover.

3. Lay the machine on its back and remove the four screws from
the left and right tray bases.

4. Remove the tray bases and the exit tray.

5. Unlatch the right cover from the base, slide it to the right and
remove the right cover.

6. Remove the center cover.

7. Unlatch the left cover from the base, slide it to the left and
remove the left cover.

Repair Information 4-5

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Cover (Center) Removal

1. Remove the two screws from the right exittray base and remove
the base. During reassembly, do not overtighten the screws, as
this may strip the plastic.

2. Open the access door and lift the top edge of the accent cover
pulling forward to remove.

3. Remove the two screws from the right cover and press and
unlatch the cover from the bottom.

4. Remove the right cover by sliding it to the right.

5. Remove the screw that secures the center cover and remove
the center cover.

Encoder Card Removal

1. Remove all covers (except the base), refer to “Covers

(Complete) Removal” on page 4-5.

2. Remove the printhead carrier assembly.

3. Disconnect the printhead cable from the encoder card.

4. Remove the screw from the encoder card and remove the card.

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Encoder Strip Removal

1. Remove all covers (except the base), refer to “Covers

(Complete) Removal” on page 4-5.

2. Remove the printhead carrier assembly.

3. Gently release the tension on the encoder strip by flexing the
encoder strip tensioner and remove the encoder strip.

Note: When reinstalling the encoder str ip, make sure the ends of
the strip are centered in their mounting notches and the strip does
not bind in the encoder card on the carrier.

Install the strip with the graphic on the left side as follows:

• Arrow Up

− “F” Down

EOF Flag Assembly and Holder Removal

1. Remove all covers, refer to “Covers (Complete) Removal,” on

page 4-5.

2. Remove the carrier frame assembly.

3. Remove the encoder strip.

4. Remove the system board.

5. Remove the sheet feeder assembly.

6. Remove the four small feed roll springs.

7. Push the locking tabs [A] to the rear and pull the holder down
and out of the carrier frame.

Repair Information 4-7

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Exit Drive Belt Removal

1. Remove all covers, refer to “Covers (Complete) Removal,” on

page 4-5.

2. Remove the carrier frame assembly.

3. Remove the two screws from the star roller assembly and
remove the assembly. Do not overtighten the screws, as this
may strip the plastic.

4. Remove the printhead carrier assembly.

5. Remove the maintenance station.

6. Unhook the springs from the small feed rollers.

7. Remove the small feedrollers by unlatching them from the feed
roller holder.

8. Remove the mid-frame assembly by pushing it forward from the
rear and out of the machine.

9. Remove the right large feed roller bushing.

10. Remove the large feed roller.

11. Remove the exit roller assembly.

12. Replace the exit drive belt.

Exit Roller Removal

1. Open the access door.

2. Remove the two screws from the star roller assembly and
remove the assembly. Do not overtighten the screws, as this
may strip the plastic.

3. Unlatch the right side of the exit roller and remove the exit drive
belt from the exit roller pulley.

4. Remove the exit roller.

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Gear Plate Removal

1. Remove all covers, refer to “Covers (Complete) Removal,” on

page 4-5.

2. Unplug the power connector.

3. Remove the frame from the base and remove the carrier.

4. Remove the maintenance station assembly.

5. Remove the mid-frame assembly.

6. Unplug the paper feed motor.

7. Remove the two screws from the gear plate and remove the
gear plate. During reassembly, do not overtighten the screws,
as this may strip the plastic.

Gutter Pad Removal

1. Open the access door and remove the accent cover.

2. Remove the right exit tray base.

3. Remove the accent cover.

4. Remove the right cover.

5. Remove the maintenance station.

6. Remove the gutter pad.

Large Feed Roll Removal

1. Remove all covers, refer to “Covers (Complete) Removal” on

page 4-5.

2. Remove the carrier frame assembly from the base.

3. Remove the printhead carrier assembly.

4. Remove the maintenance station.

5. Remove the mid-frame assembly.

6. Remove the large feed roller.

Repair Information 4-9

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Maintenance Station Assembly Removal

1. Open the access cover.

2. Remove the accent cover.

3. Remove the right exit tray base.

4. Remove the right cover.

5. Unlatch the two clips at the rear of the maintenance station and
slide the assembly forward, out of the printer.

Maintenance Wipers and Caps Removal

1. Open the access cover.

2. Push the carrier to the left away from the maintenance station.

3. Remove the accent cover.

4. Remove the right exit tray base.

5. Remove the right cover.

6. Remove the wipers and caps.

Note: Be sure the wipers are completely seated.

Mid-Frame Assembly Removal

1. Remove all covers, refer to “Covers (Complete) Removal” on

page 4-5.

2. Remove the carrier frame assembly.

3. Remove the two screws from the star roller assembly and
remove the assembly. During reassembly, do not overtighten
the screws, as this may strip the plastic.

4. Remove the printhead carrier assembly.

5. Remove the maintenance station assembly.

6. Unhook the springs from the small feed rollers.

7. Remove the small feedrollers by unlatching them from the feed
roller holder.

8. Remove the m id-frame assembly.

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Paper Feed Motor Removal

1. Remove the accent cover.

2. Remove the screws from the left and right covers. During
reassembly, do not overtighten the screws, as this may strip the
plastic.

3. Remove the right and left exit tray bases.

4. Remove the left, right and center covers.

5. Disconnect the paper feed motor connector from the system
board.

6. Remove the gear plate assembly.

7. Remove the two screws securing the paper feed motor and
remove the motor. Note the routing of the motor cable.

Paper Pick Assembly Removal

1. Remove all covers (except the base), refer to “Covers

(Complete) Removal” on page 4-5.

2. Remove the left and right bezel from the sheet feeder.

3. Remove the C-clip from the right side of the pick roll shaft.

4. Pull the pick roll shaft out to the left and removethe paper pick
assembly. Note the orientation of the paper pick assembly
spring.

Photo Controller Assembly Removal (5770)

1. Remove the two rear screws securing the photo controller base
to the printer base.

2. Remove the screw securing the photo controller to the center
cover.

3. Unlatch the latch securing the photo controller cover to the rear
of the printer base.

4. Slide the photo controller assembly to the left off the printer
base.

Note: When replacing the photo controller board, the printing
alignments will be reset to factory defaults. The user should be
instructed to perform the “Align Cartridge” procedure to
optimize photo printing.

Repair Information 4-11

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Printhead Cable and Cradle Removal

1. Remove the accent, right and center covers.

2. Remove the printhead carrier assembly.

3. Disconnect the printhead cablefrom the encoder card. Note the
routing of the cable under the retaining clip on the carrier.

4. Separate the cradle from the printhead carrier assembly by
pushing out the cradle latches [A].

5. Feed the folded end of the printhead cable through the opening
in the carrier assembly and remove the cable.

Note: Use the illustration to assemblethe carrier parts in the correct
sequence.

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Printhead Carrier Assembly Removal

1. Remove all covers (except the base), refer to “Covers

(Complete) Removal” on page 4-5.

2. Unlock the three printhead cable connectors and disconnect the
printhead cable from the system board.

3. Remove the spring clips from the ends of the carrier guide rod
and move the carrier to the left.

4. Remove the carrier guide rod by sliding it to the left.

5. Remove the carrier assembly by lifting upward, taking care to
clear the encoder strip before pulling the carrier assembly out.

6. Disconnect the carrier belt.

7. When installing the belt, connect the carrier between the two
raised markers on the belt.

Repair Information 4-13

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Printhead Rubber Backer Removal

1. Remove all covers, refer to “Covers (Complete) Removal” on

page 4-5.

2. Remove the printhead carrier assembly.

3. Separate the cradle from the printhead carrier assembly by
pushing out the cradle latches [A].

4. Remove the rubber backer and paper deflector from under the
printhead carrier cable.

Note: Use the illustration to assemblethe carrier parts in the correct
sequence.

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Sheet Feeder Removal

1. Remove all covers (except the base), refer to “Covers

(Complete) Removal” on page 4-5.

2. Remove the three screws that secure the sheet feeder to the
carrier frame.During reassembly, do not overtighten the screws,
as this may strip the plastic.

3. Remove the sheet feeder assembly.

Note: Take note of the routing of all cables.

Small Feed Roller Removal

1. Remove all covers, refer to “Covers (Complete) Removal” on

page 4-5.

2. Remove the sheet feeder assembly.

3. Unhook the small feed roller springs and remove the rollers by
pushing them down at the rear.

Star Roller Removal

1. Open the access door.

2. Remove the two screws from the star roller assembly and
remove the assembly. During reassembly, do not overtighten
the screws, as this may strip the plastic.

System Board Removal

1. Remove all covers (except the base), refer to “Covers

(Complete) Removal” on page 4-5.

2. Unlock the three printhead cable connectors and disconnect the
printhead cables from the system board.

3. Disconnect the other cables from the system board.

4. Remove the three screws securing the system board to the
carrier frame and remove the system board. Note the routing of
the paper feed motor cable. Pull the EOF flag out of the sensor
while removing the system board. During reassembly, do not
overtighten the screws, as this may strip the plastic.

Repair Information 4-15

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5. Connector Locations

System Board Connectors (5000, 5700)

J1 Printhead

Cable 1

J2

J3

J4

J5

J7
SW1

S1

Printhead
Cable 2

Printhead
Cable 3

Power
Connector

Transpor t
Motor

Parallel Port
Paper Feed

Switch
EOF Sensor

Connector Locations 5-1

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System Board Connectors (5770)

J1 Printhead

Cable 1

J2 Printhead

Cable 2

J3 Printhead

Cable 3

J4 Power

Connector

J5 Transport

Motor

J6 Paper Feed

Motor

J9 Photo

Controller
Cable

J10 Photo

Controller
Cable Shield

SW1 Paper Feed

Switch

S1 EOF Sensor

5-2 Service Manual

4093/4094

Photo Controller Board Connectors (5770)

J1 Parallel Port
J2 CompactFlash Card
JP1 Operator Panel
JP2 SmartMedia Card
P1 Photo Controller to

System Board

Connector Locations 5-3

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5-4 Service Manual

4093/4094

6. Preventive Maintenance

This chapter contains the lubrication specifications. Follow these
recommendations to prevent problems and 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 feedroller 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 the exit roller shaft.

Preventive Maintenance 6-1

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6-2 Service Manual

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7. Parts Catalog

How To Use The Parts Catalog

• SIMILAR ASSEMBLIES: If two assemblies contain a majority of

identical parts, they are shown on 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 shown in the illustration.

• PP: in the Description column indicates the part is available in

the listed parts packet.

Parts Catalog 7-1

4093/4094

Assembly 1: Covers

7-2 Service Manual

4093/4094

Assembly 1: Covers

Asm­Index

1 -1 13A3842 1 Cover, Front Access

10 17A0100 1 Exit Tray Asm (4093-S01,S04)
10 17A0101 1 Exit Tray Asm (4093-S02)
11 13A3857 1 Gutter Pad
NS 7349594 1 Plain Package B/M (5000-5700)includes:

NS 7350305 1 Plain Package B/M (5770) includes:

NS 12G0149 1 Packet of 20 Feet

Part
Number

1 13A3843 1 Cover, Front Access

2 13A3846 1 Cover, Accent (4094-S01)
2 13A3848 1 Cover, Accent (4093-S01)
2 13A3849 1 Cover, Accent (4093-S02)
2 13A3847 1 Cover, Accent (4094-S02)
3 17A0138 3 Screws, PP
4 13A3852 1 Cover, Right

4 13A3853 1 Cover, Right

5 13A3844 1 Cover, Left

5 13A3845 1 Cover, Left

6 13A3856 1 Lens (LED) & Power Button
7 13A3854 1 Cover, Center

7 13A3855 1 Cover, Center

8 13A3840 1 Base Asm includes Feet, Gutter Pad

8 13A3841 1 Base Asm includes Feet, Gutter Pad

9 13A3861 1 Exit Tray Base (L & R) (4093-S01,S04)
9 13A3862 1 Exit Tray Base (L & R) (4093-S02)

Units Description

(4093-S01,S04)(4094-S01)

(4093-S02) (4094-S02)

(4093-S01,S04) (4094-S01)

(4093-S02) (4094-S02)

(4093-S01,S04) (4094-S01)

(4093-S02) (4094-S02)

(4093-S01,S04)(4094-S01)

(4093-S02) (4094-S02)

(4093-S01,S04) (4094-S01)

(4093-S02) (4094-S02)

(Carton, Cushion Set, Sealing Tape)

(Carton, Cushion Set, Sealing Tape)

Parts Catalog 7-3

4093/4094

Assembly 2: Frames

7-4 Service Manual

4093/4094

Assembly 2: Frames

Asm­Index

2-1 17A0132 1 Sheet Feeder Asm

1 17A0133 1 Sheet Feeder Asm

2 17A0138 3 Screws, PP
3 12G0249 1 Washers, (packet of 10) ASF Right

NS 17A0493 5 Printhead Cable Guide Strip & Clip
NS 17A0748 5 Pulley Cuff & Printhead Cable Pad

Part
Number

Units Description

(4093-S01,S04) (4094-S01)

(4093-S02) (4094-S02)

Mounting Screw (PP)

Parts Catalog 7-5

4093/4094

Assembly 3: Paper Feed

7-6 Service Manual

4093/4094

Assembly 3: Paper Feed

Asm­Index

3-1 17A0132 1 Sheet Feeder Asm

Part
Number

1 17A0133 1 Sheet Feeder Asm

2 17A0106 1 Small Feed Roll Asm w/Holder & Flag
3 17A0104 1 Mid Frame
4 17A0138 2 Bushing, Large Feed Roll (PP)
5 17A0108 1 Large Feed Roll Asm
6 17A0111 1 Exit Roller and Pulley B/M
7 17A0138 2 Screw,Paper Feed Motor (PP)
8 17A0107 1 Star Roller Crossbar Asm
9 17A0136 1 Maintenance Station Asm

10 13A3840 1 Base Asm, IncludesFeet& Gutter Pad

10 13A3841 1 Base Asm, IncludesFeet& Gutter Pad

11 17A0112 1 Exit Drive Belt
12 17A0109 1 PaperFeedMotor Asmwith IdlerGear
13 17A0110 1 Gears Plate Asm without Motor

Units Description

(4093-S01,S04) (4094-S01)

(4093-S02)(4094-S02)

(4093-S01,S04) (4094-S01)

(4093-S02) (4094-S02)

Parts Catalog 7-7

4093/4094

Assembly 4: Electronics

7-8 Service Manual

4093/4094

Assembly 4: Electronics

Asm­Index

4-1 13A4494 1 .5mm to 1 mm conversionkit for4093

NS 11B6073 1 Power Cable (United Kingdom)
NS 11B6074 1 Power Cable (Europe)
NS 11B6075 1 Power Cable (Israel)
NS 11B6076 1 Power Cable (Australia /New Zealand)
NS 11B6077 1 Power Cable (South Africa)
NS 17A0119 1 Cover, System Board

Part
Number

1 13A4497 1 .5mm to 1 mm conversion kit for the

1 17A0116 1 System Board - See Notice below

1 17A0118 1 System Board - See Notice below

2 17A0120 1 Power Connector
3 13A3593 1 Power Supply, External 100 V

3 13A3594 1 Power Supply, External 120-127 V

3 13A3595 1 Power Supply, External 220-240 V

Units Description

(Contains Carrier Asm and System
Board)

4094 (Contains Carrier Asm and
System Board)

1mmwidth(4093-S01, S02)

1mmwidth(4094-S01, S02)

(4093-S01, S02) (4094-S01, S02)

(4093-S01, S02) (4094-S01, S02)

(4093-S01, S02) (4094-S01, S02)

Cable Notice

Check the printhead cable connectors to determine the correct
system board replacement.

• .5 mm width

.5 mm cable with 0.625 inch (16 mm) width at connectors
(J1, J2, J3)

• 1mmwidth

1 mm cable with 1.25 inch (32 mm) width at connectors
(J1, J2, J3)

Parts Catalog 7-9

4093/4094

Assembly 5: Carrier

7-10 Service Manual

4093/4094

Assembly 5: Carrier

Asm­Index

5-1 17A0139 1 Printhead Carrier Asm - see “Cable

Part
Number

1 17A0140 1 Printhead Carrier Asm - see “Cable

3 17A0126 1 Encoder Card Asm w/ Thermistor

3 17A0127 1 Encoder Card Asm w/ Thermistor

4 17A0138 1 Screw, Encoder Card Mount (PP)
5 17A0138 2 Bearing, Carrier (PP)
6 17A0125 1 Carrier Guide Rod
7 17A0138 2 Retainers, Shaft (PP)
8 17A0128 1 Printhead Cartridge Interlock Key B/M

NS 13A3860 1 Garage Asm

Units Description

Notice” on page 7-9

1mmwidth(4093-S01, S02, S04)

Notice” on page 7-9

1mmwidth(4094-S01, S02)

(4093-S01, S02, S04)

(4094-S01, S02)

Parts Catalog 7-11

4093/4094

Assembly 6: Carrier Transport

7-12 Service Manual

4093/4094

Assembly 6: Carrier Transport

Asm­Index

6-1 17A0129 1 Motor, Carrier Transport Asm &

Part
Number

2 17A0130 1 Carrier Belt
3 17A0131 1 Encoder Strip
4 17A0138 1 Idler Pulley Tension Asm (PP)
5 17A0138 2 Screw,Carrier Transport Motor (PP)
6 12G0164 5 Retainer, Encoder Strip (5 in

Units Description

Pulley (DC)

packet)

Parts Catalog 7-13

4093/4094

Assembly 7: Sheet Feeder

7-14 Service Manual

4093/4094

Assembly 7: Sheet Feeder

Asm­Index

7-1 17A0132 1 Sheet Feeder Asm

Part
Number

1 17A0133 1 Sheet Feeder Asm

2 17A0102 1 Support, Paper

2 17A0103 1 Support, Paper

3 17A0134 1 Paper Pick Assembly
4 17A0135 1 Belt, Sheet Feeder Drive

Units Description

(4093-S01,S04) (4094-S01)

(4093-S02) (4094-S02)

(4093-S01,S04) (4094-S01)

(4093-S02) (4094-S02)

Parts Catalog 7-15

4093/4094

Assembly 8: Maintenance Station

7-16 Service Manual

4093/4094

Assembly 8: Maintenance Station

Asm­Index

8-1 17A0136 1 Maintenance Station Asm

2, 3 17A0137 1 Wiper and Cap B/M (one of each)

Part
Number

Units Description

Parts Catalog 7-17

4093/4094

Assembly 9: Photo Controller

7-18 Service Manual

4093/4094

Assembly 9: Photo Controller

Asm­Index

9-1 12G0142 1 Board, Photo Controller

Part
Number

2 12G0145 1 Cables,Operator Paneland System

3 14R0172 1 PowerSupply, External 100 V
3 14R0173 1 Power Supply, External 120-127 V
3 14R0174 1 Power Supply, External 220-240 V
4 12G0146 1 Cover, Accent
5 12G0141 1 Board, System
6 12G0143 1 Covers, Photo Controller
7 12G0144 1 Panel, Operator
8 17A0120 1 Power Connector

Units Description

Board and a System Board Cable

Shield.

Parts Catalog 7-19

4093/4094

7-20 Service Manual

4093/4094

Index

A

Abbreviations 1-6
Adjustments 4-2
arallel 2-13
Assemblies

1 Covers 7-2
2Frames7-4
3 Paper Feed 7-6
4 Electronics 7-8
5 Carrier 7-10
6 Carrier Transport 7-12
7 Sheet Feeder 7-14
8 Maintenance Station 7-16
9 Photo Controller 7-18

C

Connectors

Photo Controller (5770) 5-3
System Board (5000, 5700) 5-1
System Board (5770) 5-2

D

Diagnostic Aids

End of Forms Test 3-5
Paper Pick Assembly 3-1
Test Page 3-6

E

Error Indicator Table 2-2
ESD-Sensitive Parts 4-1

L

Lubrication Specifications 6-1

M

Maintenance Approach 1-5
Models 1-1

P

Parallel 2-13
Plastic Latches 4-2

POST

POST Symptom Table 2-4
Sequence 2-3

Sequence (5770) 2-3
Power Consumption 1-5
Problems

Carrier Transport 2-5

Communications 2-5

Maintenance Station 2-5

Paper Feed 2-6

Paper Feed Button 2-5

Paper Status Light 2-5

Power 2-6

Print Quality 2-7

R

Removal 4-5
Removals

Base Assembly 4-3

Carrier Belt 4-3

Carrier Frame 4-4

Carrier Transport Motor 4-4

Center Cover 4-6

Covers (Complete) 4-5

Encoder Card 4-6

Encoder Strip 4-7

EOF Flag Asm 4-7

Exit Drive Belt 4-8

Exit Roller 4-8

Gear Plate 4-9

Gutter Pad 4-9

Large Feed Roll 4-9

Maintenance Caps 4-10

Maintenance Station 4-10

Maintenance Wipers 4-10

Mid-Frame Assembly 4-9

Paper Feed Motor 4-11

Paper Pick Assembly 4-11

Photo Controller Asm 4-11

Printhead Cable & Cradle 4-12

Printhead Carrier Asm 4-13

Printhead Rubber Backer 4-14

Sheet Feeder 4-15

, 4-10

Index I-21

4093/4094

Small Feed Roller 4-15
Star Roller 4-15
System Board 4-15

S

Safety Information viii
Service Checks

First Print Line 2-8
Maintenance Station 2-9
Paper Feed 2-11
Paper Path 2-13
Parallel Port (5770) 2-13
Power 2-15
Print Quality 2-16

Transport 2-18
Symptom Table (POST) 2-4
Symptom Tables 2-5

T

Tests

Button 3-2

Code Level 3-2

CompactFlash 3-3

Controller Port 3-4

DRAM 3-4

End of Forms (EOF) 3-5

LCD 3-2

Parallel Port (5770) 3-3

SmartMedia 3-3

SRAM 3-4

Test Page 3-6

Part Numbers

11B6073 7-9
11B6074 7-9
11B6075 7-9
11B6076 7-9
11B6077 7-9
12G0141 7-19
12G0142 7-19
12G0143 7-19
12G0144 7-19
12G0145 7-19
12G0146 7-19
12G0164 7-13
12G0249 7-5

13A3593 7-9
13A3594 7-9
13A3595 7-9
13A3840 7-3
13A3841 7-3
13A3842 7-3
13A3843 7-3
13A3844 7-3
13A3845 7-3
13A3846 7-3
13A3847 7-3
13A3848 7-3
13A3849 7-3
13A3852 7-3
13A3853 7-3
13A3854 7-3
13A3855 7-3
13A3856 7-3
13A3857 7-3
13A3860 7-11
13A3861 7-3
13A3862 7-3
13A4494 7-9
13A4497 7-9
14R0172 7-19
14R0173 7-19
14R0174 7-19
17A0100 7-3
17A0101 7-3
17A0102 7-15
17A0103 7-15
17A0104 7-7
17A0106 7-7
17A0107 7-7
17A0108 7-7
17A0109 7-7
17A0110 7-7
17A0111 7-7
17A0112 7-7
17A0116 7-9
17A0118 7-9
17A0119 7-9
17A0120 7-9
17A0125 7-11
17A0126 7-11
17A0127 7-11
17A0128 7-11

, 7-7
, 7-7

, 7-19

I-22 Service Manual

4093/4094

17A0129 7-13
17A0130 7-13
17A0131 7-13
17A0132 7-5
17A0133 7-5
17A0134 7-15
17A0135 7-15
17A0136 7-7
17A0137 7-17
17A0138 7-3
17A0139 7-11
17A0140 7-11
17A0493 7-5
17A0748 7-5
7349594 7-3

, 7-7, 7-15
, 7-7, 7-15

, 7-17
, 7-5, 7-7, 7-11, 7-13

Index I-23

4093/4094

I-24 Service Manual