Lexmark 4300 Series Service Manual

October 31, 2006

Lexmark™ 4300 Series

Photo All-In-One

• Table of contents

• Start diagnostics

4421-XXX

• Safety and notices

• Trademarks

•Index

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

4421-XXX

Edition: October 31, 2006

he 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.

his 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 D22A/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation

o 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.

References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the user’s responsibility.

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

ll oher trademarks are the property of their respective owners.

2005 Lexmark International, Inc. ll rights reserved.

UNITED STATES GOVERNMENT RIGHTS

his software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense.

U.S.A. P/N 12G9470 Japanese P/N 12G9471

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Table of contents

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

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

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Scanner specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Navigating the control panel menus. . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

Power-On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . . . . 2-1

Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Catastrophic errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Non-catastrophic errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

POST symptom table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Carrier transport service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

CIS module assembly service check . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Maintenance station service check . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Paper feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Scan and copy quality service check . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Self Test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Releasing plastic latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Table of contents

iii

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Removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

General precautions on removals . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

ASF guide with spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Card reader access door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Control panel cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Scanner module assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Print engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Base assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Carrier assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

System board removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Maintenance station removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Rear cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19

Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

System board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers, scanner, and base. . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Assembly 2: Engine, carrier, and electronics . . . . . . . . . . . . . . . . . . . . . .7-6

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

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3

iv Service Manual

Safety information

• The safety of this product is based on testing and approvals of the

original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized 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

• La sécurité de ce produit repose sur des tests et des

agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.

• 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.

4421-XXX

Norme di sicurezza

• La sicurezza del prodotto si basa sui test e sull'approvazione del

progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti.

• 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.

Safety information v

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Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des

ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit 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.

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y aprobaciones del

diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.

• 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

• A segurança deste produto baseia-se em testes e aprovações do

modelo original e de componentes específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição não autorizadas.

• 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.

vi Service Manual

Informació de Seguretat

• La seguretat d'aquest producte es basa en l'avaluació i aprovació del

disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada

exclusivament a professionals i no està destinada a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar durant el

procés de desmuntatge i de servei d’aquest producte. El personal professional ha d’estar-ne assabentat i prendre les mesures convenients.

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Safety information vii

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viii Service Manual

Preface

This manual contains maintenance procedures for service personnel. It is divided into the following chapters:

1. General information contains a general description of the All-In-One

and the maintenance approach used to repair it. Special tools and test equipment are listed, 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 and checks used to locate or repeat

symptoms of All-In-One problems.

4. Repair information provides instructions for making All-In-One

adjustments and removing and installing FRUs.

5. Locations and connectors uses illustrations to identify the connector

locations and test points on the All-In-One.

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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Definitions

Note: A note provides additional information.

Warning: A warning identifies something that could damage the product

hardware or software.

CAUTION: A caution identifies something that could cause you harm.

Preface ix

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x Service Manual

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1. General information

The Lexmark™ 4300 Series (4421-XXX) Photo All-In-One features an electro-mechanical color scanner, printer, and copier that creates characters and graphics by composing programmed patterns of ink dots using a printhead and liquid ink. The printhead uses small heater plates and nozzles to control ink flow and the formation of characters on the print media. The printhead assembly and ink supply are combined into a single-unit print cartridge available as a customer replaceable supply item. Dual printheads provide color and true black printing without changing printheads. The number and size of inkjets or nozzles in the printhead determines the overall quality and capability of the printer. The black print cartridge has a total of 640 nozzles and installs on the left. The color cartridge has a total of 480 nozzles and installs on the right. The photo cartridge has a total of 480 nozzles and installs on the left. The All-In-One is capable of printing in two directions from either print cartridge.

General information 1-1

4421-XXX

Power consumption

• Printing – 14.1 watts

• Idle – 9.7 watts

• Sleep – 8.0 watts

Scanner specifications

Scanner Type Flatbed, CIS

Scan Modes True Color:

• 48 bit internal

• 24 bit external

Gray Mode:

• 16 bit internal

• 8 bit external

Text/Line Art:

• 1 bit per pixel

Scan Method One-pass scanning

Scan Area • 8.5 x 11.7 inches

• 215 x 297 mm

Scan Resolution • Horizontal: 1200 dpi

• Vertical: 2400 dpi

• Interpolated: 19,200 x 19,200

Resolution/Quality Select by setting print resolution in

printer driver and scan resolution in scanner setting in the AIO center when operating in host based mode.

Select resolution/quality from the operator panel when operating in standalone mode.

1-2 Service Manual

Control panel

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Buttons Functions

1 Power This button turns the All-In-One on and off.

2 Rotate This button rotates the image on the control panel

display 90 degrees for easier viewing of photos.

3 Page Preview This button allows you to preview an image before it

is printed, scanned, or copied.

Note: Multiple previews can be made before scanning.

In Photo Card mode, you can preview multiple pages. Use the arrow buttons to scroll through the photos.

4 Select • This button chooses a menu option.

• In Photo Card mode, this button selects or deselects a photo to be printed.

5Menu •Copy–Displays the Copy menu, or returns to the

default Copy menu screen.

• Scan–Displays the Scan menu, or returns to the default Scan menu screen.

• Photo–Displays the Photo menu, or returns to the default Photo menu screen.

General information 1-3

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Buttons Functions

6 Cancel • This button cancels a copy, scan, or print job.

• In Photo Card mode, this button deselects the preview photo selected.

Other helpful information about this button:

• When viewing a photo, you can cancel all photo selections. Press Cancel twice, and then follow the instructions on the control panel display.

• When copying, press Cancel twice to return to the default settings from a default mode screen.

7 Color Start This button starts a color copy, scan, or photo job,

8 Black Start This button starts a black-and-white copy, scan, or

depending on which mode is selected.

• Copy–Start a color copy.

• Scan–Start a color scan.

• Photo Card–Start a color print job.

photo job, depending on which mode is selected.

• Copy–Starts a black-and-white copy.

• Scan–Starts a black-and-white scan.

• Photo Card–Starts a black-and-white print job.

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4421-XXX

Buttons Functions

9 Up Arrow • This button allows you to scroll through menu

options.

• This button changes the selected area when cropping an image.

• In Photo Card mode, this button allows you to skip forward through the memory card to view every tenth picture on the control panel display.

• In Copy mode, this button changes the blank paper size.

Down Arrow • This button allows you to scroll through menu

options.

• This button changes the selected area when cropping an image.

• In Photo Card mode, this button allows you to skip backward through the memory card to view every tenth picture on the control panel display.

• In Copy mode, this button changes the blank paper size.

Right Arrow (+) • This button allows you to scroll through menu

Left Arrow (-) • This button allows you to scroll through menu

10 Resize In Copy mode:

options.

• This button changes the selected area when cropping an image.

• This button increases the number of copies.

• This button allows you to display the next picture on a memory card.

options.

• This button changes the selected area when cropping an image.

• This button decreases the number of copies.

• This button allows you to display the previous picture on a memory card.

— This button enlarges or reduces an image.

In Scan mode:

— This button does not function.

In Photo Card mode:

— This button sets the image size of photos. — While cropping, this button allows you to zoom

in or zoom out on a photo.

General information 1-5

4421-XXX

Buttons Functions

11 N u m b e r o f

Copies

12 Mode This button selects Copy, Scan, or Photo Card mode.

In Copy and Photo Card modes:

— This button specifies the number of copies to

print.

In Scan mode:

— This button does not function.

Navigating the control panel menus

1. Press Mode to select the Copy, Scan, or Photo Card mode.

2. Press Menu to open the menu structure of the selected mode.

3. Press Up and Down Arrows to scroll through the menus in the current

mode.

4. Press Left and Right Arrows to scroll through the options list of the

highlighted item.

5. Press Select to choose a setting.

Maintenance approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the symptom tables, error code tables, service checks, and diagnostic aids to determine the symptom and repair the failure.

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

Tools required for service

• Flat-blade screwdriver

• #1 Phillips screwdriver

• #2 Phillips screwdriver

• Spring hook

• Analog or digital multimeter

1-6 Service Manual

Acronyms

ADF Automatic Document Feeder ASF Automatic Sheet Feeder B/M Bill of Material CCD Charge Coupled Device CIS Contact Image Sensor DBCS Double Byte Character Set DPS Direct Print Service EOF End of Form ESD Electrostatic Discharge FFC Flexible Flat Cable FPC Flat Printhead Cable FRU Field Replaceable Unit HVPS High Voltage Power Supply LCD Liquid Crystal Display LED Light-Emitting Diode LVPS Low Voltage Power Supply MPF Multipurpose Feeder NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POR Power—On Reset POST Power-On Self Test ROM Read Only Memory SBCS Single Byte Character Set USB Universal Serial Bus V ac Volts alternating current V dc Volts direct current ZIF Zero Insertion Force

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General information 1-7

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1-8 Service Manual

2. Diagnostic information

Use the error code tables, POST symptom table, symptom tables, and service checks in this chapter to determine the All-In-One failure.

Start

Power-On Self Test (POST) sequence

Press the Power button to turn the All-In-One on.

1. The Power and Copy lights come on.

2. Lexmark 4300 Series appears on the LCD.

3. The Copy, Scan, and Photo Card lights go through a flashing sequence, and then the Copy light stays on.

4. The carrier moves off the maintenance station, and then returns.

5. The scanner (CIS) moves from the home position, and then returns.

Note: After the sequence above, the Power light, Copy light, and LCD remain on.

4421-XXX

If the All-In-One completes POST with no errors, go to “Symptom tables”

on page 2-7, locate the symptom, and take the appropriate action.

If the All-In-One does not complete POST, go to the “POST symptom

table” on page 2-6, locate the symptom, and take the appropriate action.

Diagnostic information

2-1

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Error codes

Catastrophic errors

In this state, the All-In-One is in an error mode such that operation cannot continue. These errors affect the entire All-In-One. The LCD is on and operating. An error message is displayed on the LCD. The All-In-One accepts data, but discards it and does not respond.

Catastrophic error list

Code Name Description Action

0000 NVRAM R/W There was an error

detected in reading or writing NVRAM.

0001 Memory

Failure

Unable to initialize memory

Unplug the All-In-One; wait a few seconds, then plug the All-In-One back in and turn the power on. If the error remains, clean the NVRAM by pressing the Up Arrow and Menu button simultaneously. The Self Test menu appears; select Clean NVRAM. If the error continues, replace the system board.

2-2 Service Manual

Code Name Description Action

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0002 Hardware

Failure

0003 ROM

Checksum Error

General hardware failure (unable to localize failure to a specific system)

Corrupted ROM Unplug the All-In-One;

wait a few seconds, then plug the All-In-One back in and turn the power on. If the error remains, clean the NVRAM by pressing the Up Arrow and Menu button simultaneously. The Self Test menu appears; select Clean NVRAM. If the error continues, replace the system board.

0200 Flash

Programming

Unable to program flash memory

Diagnostic information

2-3

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Non-catastrophic errors

In this state, an error has occurred, but the All-In-One can continue to operate. You may need to intervene using a button press, or the machine may time out and return to the Error! Reference source not found state, depending upon the error. The All-In-One will continue to accept and respond to data until its buffers are full. In general, the entire device is in the non-catastrophic error state, but only the logical device with the error changes its behavior.

Non-catastrophic error list

Code Name Description Action

1003 Paper

Calibrate Failure

1102 Incorrect

Printhead

1201 Print

Incomplete

The DC paper feed system fails to initialize or calibrate.

The printhead ID is not valid.

The print carrier stopped before all of the data was used.

Unplug the All-In-One; wait a few seconds, then plug the All-In-One back in and turn the power on. If the error remains, check for voltage (approximately 5 V dc) on pin 2 of J15. If okay, verify voltage at the Encoder card as well (same pin at Encoder card end). If there is no voltage at J15-pin 2, replace the system board. If there is no voltage at the Encoder card end, but voltage is okay at J15, replace the print engine.

Replace the print cartridge(s).

Resend the print job.

2-4 Service Manual

Code Name Description Action

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1202 Data Error Incorrect data has

been sent from the host computer to the printer.

1203 Printhead

Short

1204 Printhead

Programming

1205 Mono TSR

Error

1206 Color TSR

Error

Short test detected a short-circuit in the printhead.

The firmware is unable to program a pseudorandom printhead ID.

A problem is detected in the mono TSR circuit. The firmware cannot determine printhead temperature.

A problem is detected in the color TSR circuit. The firmware cannot determine printhead temperature.

Unplug the All-In-One; wait a few seconds, then plug the All-In-One back in and turn the power on. If the error remains, replace USB cable. If error continues, replace the system board.

Replace print cartridge(s).

1207 Paper System

Error

A paper system control failure was detected.

Clear the paper path. Unplug the All-In-One; wait a few seconds, then plug the All-In-One back in and turn the power on. If the error remains, clean the NVRAM by pressing the Up Arrow and Menu button simultaneously. The Self Test menu appears; select Clean NVRAM. If the error continues, replace the system board.

Diagnostic information

2-5

+ 53 hidden pages