Lexmark 7100 Series Service Manual

Edition: October 25, 2006
Lexmark™ 7100 Series AIO
• Table of Contents
• Start Diagnostics
4409-XXX
• Trademarks
•Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
4409-XXX
Edition: October 25, 2006
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 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 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 Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Other trademarks are the property of their respective owners.
© 2004 Lexmark International, Inc. All rights reserved.
UNITED STATES GOVERNMENT RIGHTS
This 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: 12G9424
Japanese P/N: 12G9425
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Table of contents

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Scanner specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power-On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . 2-1
POST symptom table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Carrier transport service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CCD module assembly service check . . . . . . . . . . . . . . . . . . . . . 2-8
Pictbridge service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Maintenance station service check . . . . . . . . . . . . . . . . . . . . . . 2-10
Paper feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Paper path service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Scan/copy quality service check . . . . . . . . . . . . . . . . . . . . . . . . 2-16
ADF module service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Catastrophic error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Non-catastrophic error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Test page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Releasing plastic latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Scanner assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
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Exit tray removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Print engine cover with left and right covers . . . . . . . . . . . . . . . . .4-6
Carrier removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Fax card removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Print engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Maintenance station removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Rear access door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
ADF module assembly removal . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Pictbridge card with cable removal . . . . . . . . . . . . . . . . . . . . . . .4-20
Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
System board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Fax card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
PictBridge card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly 2: Electronics and carrier transport . . . . . . . . . . . . . . . . . . . 6
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
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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.
Safety information v
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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.

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.
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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.
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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 ix
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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
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 and checks used to locate or
repeat symptoms of printer problems.
4. Repair information provides instructions for making printer
adjustments and removing and installing FRUs.
5. 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.

Definitions

CAUTION: A caution identifies something that might cause a
servicer harm.
Warning: A warning identifies something that might damage the
printer hardware or software.
Note: A note provides additional information.
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1. General information

The Lexmark™ 7100 Series (4409-XXX) All-In-One features an electro-mechanical color scanner, printer, copier, and fax 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 cartridge has a total of 640 nozzles and installs on the left. The color cartridge has a total of 480 nozzles installs on the right. The printer is capable of printing in two directions from either cartridge.
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Power consumption

Mode Description Power consumption
Printing All-in-One is generating hard
copy output
Copying All-in-One is generating hard
copy output from hard copy originals
Scanning All-in-One is scanning hard
copy documents
Ready All-in-One is turned on and
not printing, scanning, faxing or using Pictbridge, and is not in power-saver.
High Off All-in-One is plugged into a
wall outlet, but power switch is turned off
Power Saver All-in-One sitting idle and at
ready state, but LCD backlight is turned off.
18.76 Watts
18.53 Watts
15.63 Watts
11.79 Watts
6.22 Watts
6.66 Watts
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Scanner specifications

Scanner Type Flatbed, CCD
Scan Modes True Color:
Scan Method One Pass Scanning
Scan Area 8.5 X 11.7 inches
Scan Resolution Flatbed Scanning:
48 Bit Internal (68.7 billion colors) 24 Bit External (16.7 million colors)
Gray Mode:
16 Bit Internal (4,096 shades of gray) 8 Bit External (256 shades of gray)
Text/Line Art:
1 Bit Per Pixel
216 X 297 mm
-Optical or horizontal: 1200 ppi
-Vertical: 4800 ppi
- Interpolated: 19,200 x 19,200
- ADF horizontal: 600 ppi
- ADF vertical: 600 ppi
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Control panel

The control panel is designed to allow the user to access functions in an intuitive and swift manner. The panel is set up to function in one of three different modes: Scan, Copy, or Fax. The display offers different options depending upon which mode the machine is in. Increment and scroll operations are automatic when a button is held, and increments are accelerated the longer the button is held.
Buttons Functions
Number of Copies
Lighter/Darker Allows the user to select the darkness of the image to
Reduce/Enlarge Allows the user to make a copy smaller or larger than
This button changes the number of copies that are made in the copy mode. It has no action in the scan mode or fax mode. The settings range from 1 to 99 copies.
be faxed (in fax mode) or copied (in copy mode). It is disabled in scan mode. There are seven available darknesses, with the middle darkness setting being the default.
the original. The available settings are:
- 25% (default)
- 400%
- Custom%
- Fit to page
- 2x2 Poster
- 4x4 Poster The custom setting allows the user to enter any percentage from 25% to 400%.
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Buttons Functions
Left arrow < Right arrow>
Options Displays the first entry in the options menu. The
Select This button is used to choose the option currently
Quality Adjusts the quality of the document to be copied,
Color Initiates a stand-alone color copy/fax/scan job,
The standard operation of the left arrow button is to decrement any displayed count or decrement through a list on the LCD.
The standard operation of the right arrow button is to increment any displayed count or increment through a list on the LCD.
options menu is dependent on the copy/fax/scan mode.
displayed on the LCD. In addition:
• If the button is held down for three seconds while in copy or fax mode when no options are selected and no paper is loaded, it will load paper.
• If the button is held down for three seconds while in copy or fax mode when no menu options are selected and the paper is already loaded, it will eject the paper.
scanned or faxed. There are three quality settings:
- Quick print
- Normal (default)
- Best
depending upon which mode is selected at the time the button is pressed. This button is disabled during a print or PC copy job.
Black Initiates a stand-alone mono copy/fax/scan job,
depending upon which mode is selected at the time the button is pressed. This button is disabled during a print or PC copy job.
General information 1-5
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Buttons Functions
Mode This button has three mode LEDs: copy, fax and scan.
Repeated pressing of this button cycles the LEDs and the machine through copy/fax/scan modes:
Copy Mode: Enables the user to make mono or color copies. Upon entering this mode, the LCD shall display the current number of copies, the copy quality, and the reduce/enlarge percentage. To make a copy, enter the copy mode and press either Color or Mono to initiate the copy.
Fax Mode: This mode is used to transmit faxes. Upon entering this mode, the LCD shall prompt the user for a phone number to initiate a fax, and the display will show the current date and time. To initiate a fax, enter the fax mode, enter a phone number, and press either Color or Mono to initiate the fax.
Scan Mode: Scans an image to the host. Upon entering this mode, the LCD shall prompt the user for scan-to destination. To initiate a scan, enter the scan mode, select a scan destination, and press either Color or Mono to initiate the scan.
Stop/Clear Cancel a scan, print, or copy job, or return to a menu
category from a menu sub-category.
Power Turns the machine on or off.
Speed Dials There are five speed dial buttons. Pressing one of
these buttons causes the machine to instantly display the name and phone number associated with that quick dial button. Press either the Color or Mono button to initiate the fax to that number. The speed dial names and numbers can be programmed by using the control panel or the host software. Pressing one of the speed dial buttons while in the copy or scan mode will automatically switch to fax mode and display the first speed dial selection.
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Buttons Functions
Speed Dials (5—99)
Redial/Pause When pressing this button while the machine is in fax
This button gives access to additional speed dial numbers. Speed dials #5—#79 are single entry and speed dials #80—#99 are group entries. Single entries contain only one phone number. Group entries contain up to five different phone numbers. The speed dial names and numbers can be programmed by using either the control panel or the host software.
Pressing this button displays the speed dial #5 and upward name and phone number. You can cycle through the speed dial in multiple ways:
1. Repeated pressing of Speed Dials (5—99) button
2. Using the arrow keys
3. Using the keypad to type the two digit number Pressing the speed dials (5—99) button while in the copy or scan mode will automatically switch to fax mode and display speed dial selection #5.
mode, the machine will immediately dial the number that was last entered. The fax is sent using the current settings.
Pressing this button after you have already started entering a number inserts a “,” into the number. When the machine dials this number, the “,” results in a three second pause before sending the next number. This is useful if needing to wait for an outside line or waiting for prompts in an automated answering system.
If this button is pressed while in copy or scan mode, the machine will automatically switch to fax mode and initiate the proper response for redial/pause.
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Buttons Functions
Auto Answer Toggles the state of the auto answer function and the
auto answer LED.
If an incoming call is present and:
• Auto answer LED is off: The machine will display the manual mode answering message “Incoming Call Press 9 to answer” and answer the incoming call only if you enter the correct manual mode keypress.
• Auto answer LED is on: The machine will answer the incoming call after the expected number of rings. If you pick up the phone prior to the machine answering the call and fax tones are present on the line, it will detect these fax tones and immediately respond to the fax.

Maintenance approach

The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the symptom 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.
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Abbreviations

B/M Bill of Material CCD Charge Coupled Device EOF End of Form ESD Electrostatic Discharge FPC Flat Printhead Cable FRU Field Replaceable Unit HVPS High Voltage Power Supply LCD Liquid Crystal Display LVPS Low Voltage Power Supply OEM Original Equipment Manufacturer V ac Volts alternating current V dc Volts direct current ZIF Zero Insertion Force
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2. Diagnostic information

Start

Use the post symptom table, symptom tables, and service checks in this chapter to determine the printer failure.

Power-On Self Test (POST) sequence

Press the Power button to turn machine on.
The Copy, Scan, and Fax indicator lights turn on.
The Charge-Coupled Device (CCD) moves to the right and then
returns.
The Fax and Scan indicator lights turn off.
The Copy and Auto Answer indicator lights stay on.
The paper feed motor runs then stops.
The carrier moves and then returns to the maintenance station.
The following message is displayed on the LCD.
If your printer completes POST with no errors, go to the “Symptom
tables” on page 2-2, locate the symptom and take the appropriate
action.
If your printer does not complete POST, locate the symptom in the following table and take the appropriate action.
Diagnostic information 2-1
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POST symptom table

Symptom Action
No Power, Copy, Fax, or Scan lights, and no motors run.
Paper feed gears do not turn
Carrier does not move
Carrier slams side frame
CCD does not move
CCD lamp does not turn on
Go to the “Power service check” on page 2-14. If okay, go to the “Control panel problems” on page 2-3.
Go to the “Paper feed service check” on page 2-11.
Go to the “Carrier transport service check” on
page 2-6.
Go to the “Carrier transport service check” on
page 2-6.
Go to the “CCD module assembly service check” on
page 2-8.
Go to the “CCD module assembly service check” on
page 2-8.

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 “Carrier transport
service check” on page 2-6.
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Maintenance station problems
Symptom Action
Maintenance station:
• Fails to cap the printheads
• Fails to clean the printheads
Go to the “Maintenance station
service check” on page 2-10.
Control panel problems
Symptom Action
• Buttons do not work
• LCD does not display
Check control panel cable connection at J2 on the system board. Then run the “Power-On
Self Test (POST) sequence” on page 2-1.
If the LED buttons or any lights fail, check connection J2. If the problem remains, replace the scanner assembly. Go to the “Scanner
assembly removal” on page 4-3.
If the problem still exists, replace the system board. Go to the “System
board removal” on page 4-13.
Printer communication table
Symptom Action
Not able to print Test Page Check the USB cable and system
board cable connections. If okay, replace system board. Go to the
“System board removal” on page 4-13.
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Scanner problems
Symptom Action
• CCD does not move
• Lamp does not light
• Scanned images are faded, or colors are dull, blurry or fuzzy. Images are slanted or crooked and the straight lines in the image appear to be jagged or uneven.
• Blank copies
Go to the “CCD module assembly
service check” on page 2-8.
Go to the “Scan/copy quality
service check” on page 2-16.
ADF module problems
Symptom Action
Does not feed paper Go to the “ADF module service
check” on page 2-17.
CCD lamp does not light Go to the “CCD module assembly
service check” on page 2-8.
Pictbridge problems
Symptom Action
Camera does not communicate with printer
Check USB cable connection. Go to
“Pictbridge service check” on page 2-9.
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
Go to the “Paper feed service
check” on page 2-11.
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Symptom Action
Envelopes fail to feed Go to the “Paper feed service
check” on page 2-11.
Paper skews Go to the “Paper path service
check” on page 2-13.
Power problems
Symptom Action
No power in machine; motors do not operate
Go to the “Power service check”
on page 2-14.
Print quality problems
Symptom Action
• Voids in characters
• Light print
• Prints off the page
• Fuzzy print
• Carrier moves but no print
• Printhead dries prematurely
• Colors print incorrectly
• Vertical alignment off
• Ink smearing
• Vertical streaks on paper
• Print lines crowded
Go to the “Print quality service
check” on page 2-14.
Go to the “Paper feed service
check” on page 2-11.
Note: A failed media type detection sensor will give a “close rear
press Select” message. (A bad media detection sensor responses identically to one detecting that the rear door is open).
Diagnostic information 2-5
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