Lexmark 4097 schematic

Lexmark 3200 Color Jetprinter

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

TM

4097-00X

•Index

• Manuals Menu

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

4097-00X

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

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

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. 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,
740New 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 addit ional c opies of public ations rel ated
to this product by calling 1-800-553-9727. In other countries, contact your point of
purchase.

Lexmark and Lexmark with diamond design 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.

© Copyright Lexmark International, Inc. 1998.
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 restricti ons as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

4097-00X

Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Power Consumption
Operator Panel
Maintenance Approach

Abbreviations

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start

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

Indicator Light Table
Power-On Self Test (POST) Sequence
POST Symptom Table
Symptom Tables

Service Checks

Carrier Transport Service Check
Maintenance Station Service Check
Paper Feed Service Check
Paper Path Service Check
Power Service Check
Print Quality Service Check

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Test Page

Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-Sensitive Parts
Adjustments
Removal Procedures

Releasing Plastic Latches

Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

Lubrication Specifications

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-1

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

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

. . . . . . . . . . . . . . . . . . . . 2-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

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

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

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

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

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

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

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

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

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

v

4097-00X

Preface

This manual is divided into the following chapters:

1.

General Information

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

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

3.

Diagnostic Aids

repeat symptoms of printer problems.

4.

Repair Information

adjustments and removing and installing FRUs.

5.

Connector Locations

connector locations and test points on the printer.

6.

Preventive Maintenance

and recommendations to prevent problems.

7.

Parts Catalog

individual FRUs.

contains illustrations and part numbers for

contains a general description of the

contains an error indicator table,

contains tests and checks used to locate or

provides instructions for making printer

uses illustrations to identify the

contains the lubrication specifications

Preface vii

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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 f eatures 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.

viii Service Manual

4097-00X

Norme di sicurezza

Il prodotto è stato progettato, testato e approvato in conf ormità 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

4097-00X

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. Le xmark 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.

x Service Manual

4097-00X

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

4097-00X

xii Service Manual

4097-00X

1. General Information

The Lexmark 3200 Color JetprinterTM is a personal, near laser­quality inkjet printer. The printer 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 installs on the right. The color cartridge
has a total of 192 nozzles and installs on the left. The printer is
capable of printing in two directions from either cartridge.

Power Consumption

<8 Watts - power off and power to the printer

•

8 Watts - Idle Mode (power on - not printing)

•

15 Watts - Printing (average)

•

25 Watts - Printing (peak)

•

Operator Panel

Buttons Lights

Left Button

• Power On/Off

Right Button

• P aper F eed - clears a paper jam
or loads paper when there is a
paper out condition.

Left Light

• Steady - Power On

• Flashing - Printer Error
Right Light

• Steady - Busy

• Flashing - Paper Out/Jam

General Information 1-1

4097-00X

Maintenance Approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FR U) or part. Use the symptom index, service
checks, and diagnostic aids to determine the symptom and repair
the failure. Begin with

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

“Indicator Light Table” on page 2-1

Abbreviations

ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LVPS Low Voltage Power Supply
OEM Original Equipment Manufacturer
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

.

1-2 Service Manual

4097-00X

2. Diagnostic Information

Start

Use the indicator light table, the symptom tables, service checks,
and diagnostic aids in chapter 3, to determine the printer failure.

Indicator Light Table

Indicator Light Indicates

Power light on Machine is on.
Power light on and busy light

flashes two times
Power light on and busy light

flashes on and off
Power light and busy light flash Go to the

Both lights on at the same time Printer is busy or printing.

Paper out.

Paper jam.

“Carrier T ransport Service

Check” on page 2-5

.

Diagnostic Information 2-1

4097-00X

Po wer-On Self Test (POST) Sequence

Turn the printer on and check for a correct POST operation by
observing the following:

1. The power light comes on.

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

3. The paper feed gears turn.

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

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

Tables” on page 2-3

, locate the symptom and take the indicated

“Symptom

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

following table and take the indicated action.

POST Symptom Table

Symptom Action

No power light
and no motors
run

Paper feed
gears do not
turn

Carrier does not
move

Carrier slams
side frame

No busy light Replace the operator panel, or the system board.

Go to the

Go to the

Go to the

page 2-5

Go to the

page 2-5

“Power Service Check” on page 2-11

“Paper Feed Service Check” on page 2-8

“Carrier Transport Service Check” on

.

“Carrier Transport Service Check” on

.

.

.

2-2 Service Manual

4097-00X

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

Service Check” on page 2-5

Maintenance Station Problems

Symptom Action

Maintenance station:

• Fails to cap the printheads

• Fails to clean the printheads

Go to the

Service Check” on page 2-7

Operator Panel Problems

Symptom Action

• Paper feed or po wer buttons do

not operate

• Busy or paper feed lights do not

come on

Replace the operator panel,or the
system board.

“Carrier Transport

.

“Maintenance Station

.

Diagnostic Information 2-3

4097-00X

ymp

ymp

Paper Feed Problems

Symptom Action

• 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

Paper skews Go to the

Go to the

Check” on page 2-8

Check” on page 2-8

Check” on page 2-10

Power Problems

tom Action

S

No power in machine, motors do
not operate

Go to the

on page 2-11

Print Quality Problems

tom Action

S

• Voids in characters

• Light print

• Prints off the page

• Fuzzy print

• Carrier moves but no print

• Printhead drys prematurely

• Colors print incorrectly

• Vertical alignment off

Go to the

Check” on page 2-12

“Paper Feed Service

.

“Paper Feed Service

.

“Paper Path Service

.

“Power Service Check”

.

“Print Quality Service

.

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

2-4 Service Manual

Go to the

Check” on page 2-8

“Paper Feed Service

.

4097-00X

Service Checks

Carrier Transport Service Check

FRU Action

1 System Board Unplug the printer and disconnect the carrier

2 Carrier Transport

Motor

transport motor connector (J4) from the system
board. Plug in the printer and check for
approximately 12 V dc between (J4-1) and ground.
If the voltage is incorrect, replace the system
board. If the voltage is correct, check for carrier
transport motor pins shorted to the housing. If a
short is detected, replace the carrier transport
motor.

Check the motor for binds, or loose motor pulley.
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 carrier transport mechanism.
With the carrier transport motor cable

disconnected from the system board, check for
zero to ten (0 - 10) ohms between the following
pins on the motor:

J4-1 and J4-2
J4-3 and J4-4

If the readings are incorrect, replace the motor.

3 Carrier Guide Rod Clean the carrier rod.

: Lubricate the rod and the carrier rod bearing

Note

surfaces with grease P/N 99A0394.

4 Carrier Transport

Belt
Idler Pulley Parts
Carrier Frame

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.

Diagnostic Information 2-5

4097-00X

FRU Action

5 Printhead Cable /

Home Sensor

6 Maintenance

Station

7 Access Cover

Sensor

Disconnect the printer and check the carrier
printhead connector (J1). If the connection is
good, remove the printhead carrier and rod,
without disconnecting the printhead cables. Insert
a piece of paper into the sensor. Plug in the printer
and check for 5 V dc at connection (C) located on
the rear of the sensor. The voltage drops when
paper is removed. If voltage does not change
when paper is removed, replace the home position
sensor. If the problem remains, replace the system
board.

A problem with the maintenance station can cause
carrier movement problems at the right margin. Go
to the

“Maintenance Station Service Check” on

page 2-7

If the carrier does not move toward the cartridge
load position when the access cover is opened,
verify that power is on. If the carrier still does not
move, check the actuator arm for binds. If the arm
is working correctly, replace the system board.

.

2-6 Service Manual

4097-00X

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 Worn wipers cause degraded print quality just after

3 Cap Worn caps cause the printhead nozzles to dry and

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 cap to rise and
seal the printhead. Carrier movement to the left
uncaps the printhead. The wiper cleans the
printhead nozzles as the carrier leaves the
maintenance station. The wiper cleans the
printhead only when the carrier is moving to the
left. There should be no wiping action of the
printhead nozzles when the carrier is moving to
the right. After the cleaning operation is complete,
a tab on the maintenance station engages a tab on
the carrier, causing the wiper to lower.

Check the maintenance station for worn or broken
parts.

a maintenance cleaning. Check for loose or worn
wipers.

clog. Check for loose or worn caps.

Diagnostic Information 2-7

4097-00X

Paper Feed Service Check

If your machine does not have paper jam problems, continue with
the service check. If your machine 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.

•

FRU Action

1 System Board Unplug the printer and disconnect the paperfeed

motor (J3) from the system board. Plug the printer
in and check for approximately 9 - 12 V dc
between (J3-1) and ground and (J3-2) 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 have a failure after replacing the motor,
replace the system board.

2-8 Service Manual

4097-00X

FRU Action

2 Paper Feed Motor A noisy or chattering motor or a motor that fails to

3 Drive Train

Assembly

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 approximately 10
ohms between the following pins on the motor:

Pin 1 to Pin 2 Pin 3 to Pin 4
If the readings are incorrect, replace the motor.
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.

Check for binds in the gear train and paper feed
mechanism by removing the paper feed motor and
rotating the large gear by hand. If you notice a
bind, replace the drive train assembly. Check the
feed clutch inside the large feed gear.

4 Auto Sheet

Feeder

5 Mid Frame Asm Check the following for wear:

6 End-of-Forms

Flag and Spring

Check the pick rollers for wear.

•Exit roller

• Star rollers

Check for binds or damage. If binds are found,
replace the small feed roll bracket assembly.

Diagnostic Information 2-9

4097-00X

Paper Path Service Chec k

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

Check the entire paper path for obstructions.

•

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

3 Auto Sheet

Feeder

4 Mid Frame Asm Check the following for wear:

5 End-of-Forms

Flag

Check for wear and binds.

Check for damage.

Check the pick rollers for wear.

•Exit roller

• Star rollers

Check for binds or damage.

2-10 Service Manual

4097-00X

Power Servi ce C heck

FRU Action

1 External Power

Supply

2 Power Connector Disconnect the external power supply and

3 Printhead Cable

Carrier Home
Sensor
Parallel Cable
Paper Feed Motor
Carrier Transport
Motor
Operator Panel

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

Plug the external power supply into an outlet.
Check for + 30 V dc. If you do not have correct
voltage, replace the external power supply.

disconnect the (J5) power connector from the
system board. If continuity is incorrect, replace the
power connector.

Unplug the printer. Disconnect one of the
printhead cables and plug in the printer. Look for a
symptom change. Check the failing part for shorts
and replace as necessary.

Repeat this procedure for the carrier home sensor,
parallel cable, carrier transport motor, paper feed
motor and operator panel.

system board.

Diagnostic Information 2-11

4097-00X

Print Quality Service Check

FRU / Function Action

1 Print Cartridge Be sure the machine contains good print

2 Color Print

Cartridge Cross
Contamination

3 Printhead Carrier

Assembly

4 System Board

Printhead Cable
Rubber Backer

cartridges.
Cross contamination of color inks results in

incorrect colors printed, as when green prints for
yellow, (when yellow and blue are mixed in the
print cartridge). This problem resolves quickly as
the print cartridge is used.

If cross contamination occurs, check the following:

• The maintenance station wiper for damage.

• The printhead nozzle plate was resealed with
tape.

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

• Print Cartridge Latch

• Latch Spring

•Carrier

Run the “Test Page” on page 3-1. A void in the
print indicates one or more print nozzles are not
working. Run the test again to verify the failure. Be
sure the printhead cables are connected properly.

Remove the print cartridges and check the gold­plated contacts on the end of the printhead carrier
cable for dirt, wear and damage. Use only a clean
dry cloth to clean the contacts.

5 Maintenance

Station

2-12 Service Manual

A worn rubber backer results in poor contact
between the printhead carrier cable and the print
cartridge. Check the rubber backer for wear.

If the symptom remains, replace the system board.
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.

4097-00X

FRU / Function Action

6 Paper Feed Ink smudging and smearing can be caused by

7 Carrier Transport Blurred print and voids can be caused by problems

8 Alignment Uneven vertical lines can be adjusted by

9Mid Frame

Brackets

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.

• Gears for wear or binds.

• Paper path for obstructions.

in the carrier transport area. Check the following:

• Carrier transport belt for wear.

• Carrier guide rod for wear or dirt. If dirty, clean
and lubricate.

• Carrier to carrier frame engagement should be
lubricated with grease P/N 99A0394.

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

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

Banding or uneven print on photo quality images.
Be sure the printer contains the mid frame

brackets. If not, order a new mid frame and install
the mid frame brackets which are included in the
FRU.

Diagnostic Information 2-13

4097-00X

3. Diagnostic Aids

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 black print cartridge in
the right side of the printhead cradle and a color printhead cartridge
in the left side.

To enter the test:

1. Turn the printer on

2. Be sure there is paper in the sheet feeder.

3. Press the power and paper feed buttons at the same time and
hold for approximately five seconds, until the test starts.

The test will run until the power button is depressed.
The first three lines are color print cartridge nozzle purge patterns.

The next line is a black print cartridge nozzle purge pattern.
These test patterns are used to verify all print cartridge nozzles are

working properly. There should be no breaks in the test patterns. A
break in the pattern indicates one or more nozzles are not working.

If a print quality problem exists, see

on page 2-12

.

“Print Quality Service Check”

Diagnostic Aids 3-1

4097-00X

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.

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 remo ving 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 machine.
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 machine.

Hold the ESD-sensitive part by its edge connector shroud (cover); do

•

not touch its pins. If you are removing a pluggable module, use the
correct tool.

Do not place the ESD-sensitive part on the machine cover or on a

•

metal table; if you need to put down the ESD-sensitive part for any
reason, first put it into its special bag.

Machine 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 machine covers when you are not working on the
machine, 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 extra careful in working with ESD-sensitive parts when cold weather

•

heating is used because low humidity increases static electricity.

Repair Information 4-1

4097-00X

Adjustments

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

Removal Procedures

The following procedures are arranged according to the name of the
printer part discussed.

CAUTION: 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.

4-2 Service Manual

4097-00X

Access Cover Removal

1. Open the access cover.

2. Push the mounting tabs toward the center of the machine.

3. Remove the access cover.

Buttons / Lenses Removal

1. Remove the front cover.

2. Depress the button clips and remove the buttons.

3. Lift and remove the lenses.

Carrier Belt / Idler Pulley Removal

1. Remove the front cover.

2. Remove the printhead carrier without disconnecting the system
board cables.

3. Remove the carrier belt.

4. Depress the latch on the idler pulley, slide it to the left and
remove.

Carrier Frame Assembly / Base Removal

1. Remove the front cover.

2. Remove the six screws that secure the carrier frame to the base
assembly.

3. Remove the paper guide.

4. Tilt the lower part of the carrier frame up and remove the carrier
frame.

Note:

cover.

Be sure the parallel cable clips are not trapped inside the

Repair Information 4-3

4097-00X

Carrier Transport Motor Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Disconnect the carrier transport motor connector from the
system board.

4. Remove the belt from the carrier transport motor pulley.

5. Unlatch the right side of the sheet feeder and unhook the carrier
transport motor cable.

6. Remove the two screws securing the carrier transport motor to
the carrier frame and remove the motor. Note the routing of the
motor cable.

Exit Roller Assembly Removal

1. Remove the front cover.

2. Unlatch and remove the exit roller bushing from the left side of
the gear plate. Note of the position of the spring located on the
end of the exit roller shaft.

3. Remove the spring and lift the exit roller out of the machine.

Front Cover Removal

1. Remove the two cover mounting screws from the upper rear
corners of the of the rear cover. When reassembling, do not
overtighten these screws as they will damage the plastic
threads.

2. Lift up on the two cover latches located on each side of the base
cover.

3. Pull the front cover forward and remove.

Gear Plate Assembly Station Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Remove the large feed roller.

4. Disconnect the paper feed motor and the power connector from
the system board. Note the routing of all cables.

5. Remove the two gear plate assembly screws from the carrier
frame and remove the gear plate.

4-4 Service Manual

4097-00X

Gutter Pad / Maintenance Station Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Remove the two screws from the rear of the maintenance
station.

4. Depress the two clips on the rear of the carrier frame and
remove the maintenance station.

5. Remove the spring and actuator lever from the front of the
maintenance station.

6. Lift and remove the wiper assembly.

7. Remove the cap assembly.

8. Remove the felt gutter pad.

Note:

removal, replace the entire maintenance station.

If any glue is present on the maintenance station during

Large Feed Roller Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Remove the exit roller.

4. Remove the small feed roller assemblies.

5. Remove the EOF flag.

6. Remove the mid frame.

7. Remove the bushings at the ends of the large feed roller and
remove the roller.

Maintenance Wiper and Cap Removal

1. Remove the front cover.

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

3. Gently pull the cap and wiper off their mountings.

Repair Information 4-5

4097-00X

Mid Frame / Star Roller Assembly Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Remove the exit roller.

4. Remove the small feed roller assemblies.

5. Remove the EOF flag.

6. Depress the latches located on the rear of the mid frame and
remove the mid frame and star roller assembly.

Note:

removal, replace the star roller assembly. Do not reinstall the old star
roller assembly.

If any glue is present on the star roller assembly during

Operator Panel Assembly Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Disconnect the operator panel cable from the system board.
Note the routing of the cable.

4. Remove the operator panel screw from the carrier frame.

5. Remove the operator panel.

Paper Feed Motor Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Disconnect the paper feed motor from the system board.

4. Remove the two screws mounting the paper feed motor to the
gear plate assembly and remove the motor. Note the routing of
all cables.

Paper Guide Remova l

Slide the paper guide to the center of the printer, lift up and remove.

4-6 Service Manual

4097-00X

Power Connector Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Disconnect the power connector from the system board. Note
the routing of all cables.

4. Remove the screw from the power connector and remove the
power connector.

Printhead Carrier / Cable / Rod Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Disconnect the printhead carrier cables from the system board.

4. Remove the shaft retainers from the ends of the carrier rod.

5. Lift up on the right side of the carrier rod and slide it out the right
side of the machine.

Note:

tabs on the belt. Be sure to note this location when reinstalling the
carrier.

10. Remove the home sensor screw from the rear of the carrier.

11. Remove the printhead cable retainer clip screw from the rear of

12. Depress the two clips on the top of the cradle assembly and

13. Remove the carrier cable and note the routing of the cable and

Note:

only one clip when replacing the carrier rod.

The carrier is attached to the carrier belt between two raised

6. Remove the carrier belt from the rear of the carrier.

7. Remove the carrier.

8. Depress and remove the printhead carrier cable retainer latch
located on the carrier frame.

9. Remove the carrier cable and latch.

the carrier.

remove the front of the cradle assembly.

home sensor.

If there is any glue on the carrier rod retainer clips, reinstall

Repair Information 4-7

4097-00X

Rear Cover Removal

1. Open the rear cover.

2. Push the mounting tabs toward the center of the machine and
remove the rear cover.

Sheet Feeder Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Remove the two scre ws that hold the sheet feeder to the carrier
frame.

4. Remove the screw from the gear plate.

5. Depress the sheet feeder latch from the carrier frame and
remove the sheet feeder.

Small Feed Rollers / EOF Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Remove the sheet feeder

4. Facing the rear of the machine, remove the small feed rollers.

5. Unhook the four small feed roller springs from the carrier frame
and remove the small feed roller assemblies.

6. Slide the EOF flag to the right and remove. Note the positioning
of the tension spring.

System Board Removal

1. Remove the front cover.

2. Remove the carrier frame.

3. Disconnect all connectors from the system board.

4. Remove the four system board screws from the system board.
Note when removing the system board, be careful not to
damage the end of form EOF flag.

5. Remove the system board.

4-8 Service Manual

4097-00X

5. Connector Locations

J1 Printhead Cable 1
J2 Printhead Cable 2
J3 Paper Feed Motor
J4 Carrier Transport

Motor
J5 Power Connector
J6 Parallel Port
J7 Operator Panel
S1 EOF Sensor
S2 Access Door Sensor

Connector Locations 5-1

4097-00X

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 feed roller at the side frames.

•

The carrier to carrier frame engagement.

•

The carrier guide rod, and carrier guide rod bearings.

•

Preventive Maintenance 6-1

4097-00X

7. Parts Catalog

How to Use This Parts Catalog

SIMILAR ASSEMBLIES: If two assemblies contain a majority of

•

identical parts, they are broken down 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 pictured in the illustration.
PP: in the parts descriptions column indicates the part is

•

available in the listed parts packet.

Parts Catalog 7-1

4097-00X

Assembly 1: Covers

7-2 Service Manual

4097-00X

Asm­Index

1 -1 17D0561 1 Cover, Rear Asm (001) 1 17D0562 1 Cover, Rear Asm (002) 2 17D0590 2 Screws, (PP) 3 17D0550 1 Base Asm (001) 3 17D0551 1 Base Asm (002) 4 17D0560 1 Buttons and Lens Asm (Operator Panel) 5 17D0554 1 Cover, Access (001) 5 17D0555 1 Cover, Access (002) 6 17D0552 1 Cover, Front (001) 6 17D0553 1 Cover, Front (002) 7 17D0557 1 Tray, Exit Asm (001) 7 17D0558 1 Tray, Exit Asm (002) 8 17D0590 4 Feet, Machine (PP) NS 7350160 1 Package, Plain B/M Includes:

Part
Number

Units Description

(Carton, Cushion Set, Sealing Tape)

Parts Catalog 7- 3

4097-00X

Assembly 2: P aper Feed / Carrier Transport

7-4 Service Manual

4097-00X

Asm­Index

2 -1 17D0566 1 Roller, Small Feed Asm 2 17D0589 1 Lever, EOF Asm 3 17D0565 1 Roller, Large Feed with Gear Asm 4 17D0564 1 Roller, Star Asm / Mid Frame with

5 17D0569 1 Roller, Exit Asm with Gear 6 17D0568 1 Plate, Gear Asm without Motor 7 17D0567 1 Motor, Paper Feed Asm with Gear 8 17D0584 1 Sheet Feeder Asm (001) 8 17D0585 1 Sheet Feeder Asm (002) 9 17D0573 12 Bearings, Large Feed Roller

Part
Number

Units Description

Brackets

Parts Catalog 7-5

4097-00X

Assembly 3: Electronics

7-6 Service Manual

4097-00X

Asm­Index

3 -1 17D0570 1 System Board 2 17D0590 4 Screws, (PP) 3 17D0559 1 Operator Panel / Power Connector 4 17D0574 1 Actuator Assembly NS 17D0575 1 Power Supply, External (LV) 100 Japan NS 17D0576 1 Power Supply, External (LV) 120 NS 17D0577 1 Power Supply, External (HV) 220

Part
Number

Units Description

Parts Catalog 7- 7

4097-00X

Assembly 4: Carrier

7-8 Service Manual

4097-00X

Asm­Index

4 -1 17D0578 1 Carrier Assembly (Complete) 2 17D0580 1 Rod, Carrier Guide 3 17D0579 1 Printhead Rubber Backers 4 17D0581 1 Cartridge Interlock Keys 5 17D0572 1 Printhead / Home Sensor Cable

Part
Number

Units Description

Parts Catalog 7-9

4097-00X

Assembly 5: Carrier Transpor t

Service Manual

7-10

4097-00X

Asm­Index

5 -1 17D0590 11 Screws, (PP)
1 17D0590 1 Spring (PP)
2 17D0582 1 Motor, Carrier Transport with Gear
3 17D0590 2 Retainers, Carrier Guide Rod (PP)
4 17D0583 1 Belt, Carrier
5 17D0580 1 Rod, Carrier Guide
6 17D0588 1 Pulley, Idler Asm
7 17D0563 1 Frame, Carrier
8 17D0564 1 Roller, Star Asm / Mid Frame
9 17D0710 1 Accessory Packet II (Bracket Left &

Part
Number

Units Description

Right with Screws)

Parts Catalog

7-11

4097-00X

Assembly 6: Maintenance Station

7-12 Service Manual

4097-00X

Asm­Index

7 -1 17D0586 1 Maintenance Station 2 17D0587 1 Wipers and Caps 3 17D0556 1 Gutter Pad

Part
Number

Units Description

Parts Catalog 7-13

4097-00X

Index

A

Abbreviations 1-2

3-1

4-2

7-2

7-4

7-4

7-6

7-8

7-10

7-12

Adjustments
Aids
Assemblies

1 Covers
2 Carrier Transport
2 Paper Feed
3 Electronics
4 Carrier
5 Carrier Transport
6 Maintenance Station

C

Connector Locations 5-1

D

Diagnostic Aids 3-1

E

ESD-Sensitive Parts 4-1

G

General Information 1-1

I

Indicator Light Table 2-1

L

Lubrication Specifications 6-1

M

Maintenance Approach 1-2

P

Parts

Carrier
Carrier Transport
Covers
Electronics
Maintenance Station

Paper Feed
Plastic Latches
POST

Sequence

Symptom Table
Power Consumption
Preventive Maintenance
Problems

Carrier Transport

Maintenance Station

Paper Feed

Power

Print Quality

7-8

7-4, 7-10

7-2

7-6

7-4

4-2

2-2

2-2

2-3

2-4

2-4

2-4

R

Removals

4-7

4-3

4-3

4-3

4-3

4-3

4-7

4-8

4-4

4-4
4-4
4-5

4-3

4-6

Access Cover
Base Asm
Buttons / Lenses
Carrier
Carrier Belt
Carrier Frame
Carrier Rod
Carrier Transport Motor
EOF Flag
Exit Roller
Front Cover
Gear Plate
Gutter Pad
Idler Pulley
Large Feed Roller
Maintenance Station
Mid Frame Assembly
Operator Panel
Paper Feed Motor

1-1

4-5

4-6

7-12

6-1

2-3

4-5

4-6

4-4

Index I-1

4097-00X

Paper Guide 4-6
Power Connector
Printhead Cable
Rear Cover
Sheet Feeder
Small Feed Rollers
Star Roller
System Board
Wipers & Caps

Repair Information

4-7

4-8

4-8

4-6

4-8

4-5

4-1

S

Safety Information vi
Service Checks

2-7

2-8

2-1, 2-3

Carrier Transport
Envelope Feed
Maintenance Station
Paper Feed

Power
Start
Symptom Table (POST)
Symptom Tables

2-11

2-1

T

Tests

Test Page

3-1

4-7

2-5

4-8

2-7

2-2

I-2 Service Manual