Lexmark P122 Photo Jetprinter Service Manual

Lexmark P122 Photo Jetprinter

• Table of Contents

• Start Diagnostics

4102-P01

• Safety and Notices

• Trademarks

•Index

• Manuals Menu

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

4102-P01

Edition: May 2001

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
[e-mail]. 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.

© Copyright Lexmark International, Inc. 2000.
All rights reserved.

UNITED STATES GOVERNMENT RESTRICTED RIGHTS

This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.

4102-P01

Table of Contents

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

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

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

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Panel and Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Using the Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operator Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Printer Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Resolution and Print Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Input Voltage Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

AC Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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

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

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

POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

First Print Line Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . . . . 2-6

LCD Assembly Display Service Check . . . . . . . . . . . . . . . . . . . . 2-7

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

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

CompactFlash/SmartMedia Service Check . . . . . . . . . . . . . . . . 2-11

Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

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

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

Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Code Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

LCD Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Button Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

CompactFlash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

SmartMedia Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

SmartMedia Write Protect Test . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

DRAM Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Access Cover Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

iii

4102-P01

End-of-Forms (EOF) Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . .3-4

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

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

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

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

Button Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Engine Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Engine Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . .4-9

Exit Tray Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Ink Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Ink Carrier Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

LCD Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Paper Support Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Slide Guide Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

USB/DC Jack Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

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

Engine Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

LCD Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

USB PSB/Power Board Connector . . . . . . . . . . . . . . . . . . . . . . . .5-4

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

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

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

How to Use the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Assembly 2: Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

Assembly 4: Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

Assembly 5: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

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

iv Service Manual

4102-P01

Preface

This manual describes the Personal Picture Maker 120 by Lexmark

(4102-P01) and 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.

Preface v

4102-P01

Safety Information

• This product is designed, tested and approved to meet strict

global safety standards with the use of specific Lexmark
components. The safety features of some parts may not always
be obvious. Lexmark is not responsible for the use of other
replacement parts.

• The maintenance information for this product has been

prepared for use by a professional service person and is not
intended to be used by others.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precautions.

Consignes de Sécurité

• Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécurité globale lors de l'utilisation de
composants Lexmark spécifiques. Les caractéristiques de
sécurité de certains éléments ne sont pas toujours évidentes.
Lexmark ne peut être tenu responsable de l'utilisation d'autres
pièces de rechange.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

vi Service Manual

4102-P01

Norme di sicurezza

• Il prodotto è stato progettato, testato e approvato in conformità a

severi standard di sicurezza e per l’utilizzo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune parti
non sempre sono di immediata comprensione. Lexmark non è
responsabile per l’utilizzo di parti di ricambio di altri produttori.

• Le informazioni riguardanti la manutenzione di questo prodotto

sono indirizzate soltanto al personale di assistenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto, il

rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise

• Dieses Produkt und die zugehörigen Komponenten wurden

entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder
Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinandernehmens und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

Safety Information vii

4102-P01

Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de Lexmark. Puede que
las características de seguridad de algunas piezas no sean
siempre evidentes. Lexmark no se hace responsable del uso de
otras piezas de recambio.

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Informações de Segurança

• Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes
específicos da Lexmark. As funções de segurança de alguns
dos componentes podem não ser sempre óbvias. A Lexmark
não é responsável pela utilização de outros componentes de
substituição.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

viii Service Manual

4102-P01

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 ix

4102-P01

x Service Manual

4102-P01

1. General Information

The Lexmark P122 Photo Jetprinter (4102-P01) is designed to be a

small personal inkjet printer specifically for standalone photographic

printing. It also supports printing from a personal computer using the

Windows 98 operating system. The photoprinter incorporates a new

photo control operator panel into the cover set and slots to support

the compact flash and smart media. Camera memory cards have

been incorporated into the printer near the top of the access cover

under the translucent cover. Note that there is no exit tray and that

there is a handle molded into the cover behind the translucent card

slot cover to encourage portability. Also note that the multi part fan

shaped paper support is hinged and can fold away into the covers.

Model

KODAK Personal Picture Maker 120 by Lexmark - 4102-P01

Operator Panel

.

Operator
Panel

General Information 1-1

4102-P01

Operator Panel and Menu

Using the Operator Panel

The operator panel has a 2-line by 16-character liquid crystal display
(LCD) and five buttons. This display will support upper and lower
case alphabetic, numeric, and a limited number of special
characters.

Operator Panel Buttons

Power On: There is no power on button.

Print: When pressed with images present and accessible to the

photocontroller, printing as selected is initiated. If no selections have
been made, then all images will be printed using the current printer
settings. Note that a message indicating, all photos will be printed,
will be displayed for several seconds to permit cancel of printing if
desired.

1-2 Service Manual

4102-P01

Cursor Left, and Right UP and Down buttons: These buttons are

used to permit navigation within a level of the menu structure,

allowing movement from one choice to another. Since the menu

choices are circular, movement in either direction can result in the

desired selection.

Select button: This button may be embossed with an * symbol that

can be used in the menu structure as shorthand for “select”.

Pressing this button causes the selection that is shown on the

second line of the display to be chosen. The results of this selection

vary depending on the location within the menu.

Menu (Index Print): Pressing this button will initiate printing of an

index print. The menu selection function was imbedded into the

menu system.

Return/Exit button: Permits exit of a selection without saving the

result.

Printer Errors

The printer signals errors by displaying error messages in the

display.

Display
Message

Carrier Stall Carrier Stall Carrier has stopped due to

Cartridge Error Cartridge Short

Paper Jam Paper Jam Paper Jam

Out of Paper Out of Paper Out of Paper

Error Type Description

maintenance, a jam in the paper
path or obstruction/failure of the
carrier drive.

Printer detects a short in the

Error

cartridge circuit.

General Information 1-3

4102-P01

Resolution and Print Speed

Color

1200 X 1200 Ultra High Quality

2 page/minute

Input Voltage Range

Supply Type Voltage Range HZ

U.S.A. 120 - 127 V 60

Europe, Middle
East, and Africa

Taiwan 110 V 60

Japan 100 V 50/60

220 - 240 V 50

AC Power Consumption

230 V / 50 Hz 120 V / 60 Hz 100 V / 60 Hz

Power Supply
connected to
outlet, but not
to the machine

Idle Power On 7 Watts 6 Watts 5 Watts

Idle Power On
with
CompactFlash
Card Insert

3 Watts 3 Watts 2 Watts

7 Watts 6 Watts 5 Watts

Printing
Average Power
Consumption

1-4 Service Manual

16 Watts 15 Watts 15 Watts

4102-P01

Maintenance Approach

The diagnostic information in this manual leads you to the correct

field replaceable unit (FRU) or part. Use the error indicator charts,

symptom index, service checks, and diagnostic aids to determine

the symptom and repair the failure. Begin with “Start” on page 2-1.

This printer can be serviced without being connected to a host

computer.

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

repair.

Abbreviations

CSU Customer Setup

EOF End of Forms

ESD Electrostatic Discharge

FRU Field Replaceable Unit

HV High Voltage

LCD Liquid Crystal Display

LED Light-Emitting Diode

LV Low Voltage

NVRAM Nonvolatile Random Access Memory

OEM Original Equipment Manufacturer

POST Power-On Self Test

V ac Volts alternating current

V dc Volts direct current

General Information 1-5

4102-P01

1-6 Service Manual

4102-P01

2. Diagnostic Information

Start

If no error appears, go to “Power-On-Self-Test (POST) Sequence”

on page 2-1.

Power-On-Self-Test (POST) Sequence

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

observing the following:

1. One row of squares are displayed.

2. The paper feed motor runs and the gears turn.

3. The carrier moves three times to the left. The carrier returns to
the maintenance station and seals the printhead.

4. Two rows of diamonds are displayed.

5. The code level is displayed.

6. The name is displayed.

7. The date is displayed

8. Ready is displayed.

POST Symptom Table

Symptom Action

No motors run Go to the “Power Service Check” on

page 2-11.

Paper feed gears do not turn Go to the “Paper Feed Service

Check” on page 2-8.

• Carrier does not move

• Carrier slams side frame

• Blank display

• All diamonds displayed after POST

• Display difficult to read

• Display OK, buttons do not function

• One or more buttons do not function

Go to the “Transport Service Check”

on page 2-14.

Go to the

Service Check” on page 2-7

“LCD Assembly Display

.

Diagnostic Information 2-1

4102-P01

Symptom Tables

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

Carrier Transport Problems

Symptom Action

• No carrier movement

• Slow carrier movement

• Carrier stops

• Carrier slams side frame

Go to the “Transport Service Check”

on page 2-14.

Communications Problems

Symptom Action

Printer not communicating with
host computer.

Check the USB connection (connector
J601). If the connection is good,
replace the USB/DC jack board.

Maintenance Station Problems

Symptom Action

• Fails to cap the printhead

• Fails to clean the printhead

Go to the “Maintenance Station

Service Check” on page 2-6.

Paper Feed Button and Paper Status Light Problems

Symptom Action

Paper Feed button does not
operate

2-2 Service Manual

With the power on, check for a voltage
reading at connector J633 located on
the LCD for approximately +3 V dc on
pins 1, 2, 3, 4, 6, and 7 to ground. If
the voltage is incorrect, replace the
system board. If the voltage is correct,
replace the top assembly
with buttons and the key PCB cover.

4102-P01

CompactFlash/SmartMedia Card Problems

Symptom Action

Prints from a PC but does not
print from a CompactFlash card.
Prints from a SmartMedia card
but does not print from a PC.

Go to the

SmartMedia Service Check” on
page 2-11

“CompactFlash/

.

Paper Feed Problems

Symptom Action

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

Check” on page 2-5.

• Fails to pick paper

• Picks more than one sheet of

paper

• Picks paper but fails to feed

• Paper jams

• Paper fails to exit

• Noisy paper feed

Paper skews Go to the “Paper Path Service Check”

Go to the “Paper Feed Service Check”

on page 2-8.

on page 2-10.

Power Problems

Symptom Action

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

page 2-11.

Diagnostic Information 2-3

4102-P01

Print Quality Problems

Symptom Action

• Voids in characters

• Light print

• Prints off the page

• Fuzzy print

• Carrier moves but does not print

• Printhead drying prematurely

• Excessive ink flow (Flooding)

• Horizontal banding

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

Go to the “Print Quality Service

Check” on page 2-12.

Go to the “Paper Feed Service Check”

on page 2-8.

2-4 Service Manual

4102-P01

Service Checks

First Print Line Service Check

Parts / FRUs Action

1End-of-Forms

Flag

2End-of-Forms

Sensor

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

4 Paper Pick

Assembly

Check the flag for binds or damage.

Check the sensor for dirt.

on page 3-4 to check the end-of-forms sensor

on the system board.

Check the paper pick assembly for binds,
wear, or damage.

Diagnostic Information 2-5