Lexmark WinWriter 150c Service Manual

WinWriter™150c

• Table of Contents

• Start Diagnostics

4077-001

• 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.

4077-001

Third Edition (July, 1997)

The followingparagraphdoesnot apply to the United Kingdom or 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 WarrantiesOf MerchantabilityOrFitness
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 ortypographicalerrors.Changesare

periodically made to the information herein; these changes will be incorporated in later
editions of the publication. Improvements or changes in the products or the programs
described in this publication may be made at any time. Publications are not stocked at the
address given below; requests for publications should be made to your point of purchase.

Reader comments may be addressed to Lexmark International, Inc., Department
D22A/035-3, 740 New Circle Road, 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.

Lexmark is a trademark of Lexmark International, Inc., registered in the United States
and/or other countries. WinWriter is a trademark of Lexmark International, Inc.

© Copyright Lexmark International, Inc. 1995, 1997. 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
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DFARS 252.227-7013 and in applicable FAR provisions:
Lexmark International, Inc., Lexington, KY 40550 USA.

4077-001

Contents 1

Preface ..............................................vi

SafetyInformation................................... vi

GeneralInformation ....................................1

PowerConsumption..................................1

Maintenance Approach................................1

Abbreviations....................................2

UniqueToolsRequiredForService...................2

DiagnosticInformation .................................3

Start..............................................3

ErrorIndicatorTable...............................4

Power-On-Self-Test (POST) Sequence................4

POSTSymptomTable.............................5

SymptomTables .................................6

CarrierTransportProblems.........................6

CommunicationsProblems .........................6

MaintenanceStationProblems ......................6

Paper Feed Problems . ............................7

PowerProblems..................................7

PrintQualityProblems.............................7

ServiceChecks......................................8

EnvelopeFeedServiceCheck.......................8

FirstPrintLineServiceCheck.......................8

MaintenanceStationServiceCheck ..................9

Paper Feed Service C heck ........................10

Paper Path Service Check.........................13

ParallelPortServiceCheck........................14

PowerServiceCheck.............................14

PrintQualityServiceCheck........................15

TransportServiceCheck..........................17

DiagnosticAids ......................................18

TestPage.........................................19

ParallelPortTest...................................20

EncoderSensorTest................................21

End-of-FormsSensorTest............................22

InitializeErrorLog...................................23

PrinterErrorLogRecovery............................24

iii

4077-001

RepairInformation ....................................25

Handling ESD-Sensitive Parts......................... 25

Adjustments....................................... 26

RemovalProcedures................................ 26

ReleasingPlasticLatches......................... 26

BaseAssemblyRemoval ......................... 27

CarrierBeltRemoval............................. 27

CarrierFrameAssemblyRemoval.................. 28

CarrierTransportMotorRemoval................... 29

Code Module Removal. . ......................... 30

Edge Guide Asm and Paper Load Shaft Removal ...... 30

EjectorsRemoval ............................... 30

EncoderCardRemoval........................... 30

EncoderStripRemoval........................... 31

FeedArmAssemblyRemoval...................... 31

FrontCoverRemoval ............................ 32

GutterPadRemoval............................. 32

InsideIdlerGearsRemoval........................ 33

LargeFeedRollRemoval......................... 34

LargeOutsideGearRemoval...................... 35

LeftSideFrameAssemblyRemoval................. 36

Maintenance Station Assembly Removal ............. 37

Maintenance Wipers and Caps Removal ............. 37

Manual Insert Tray Removal ....................... 37

MidFrameAssemblyRemoval..................... 37

Paper Feed Motor Removal ....................... 38

Paper Guide and EOF Flag Assembly Removal. ....... 38

Paper Load Door Removal ........................ 40

Pick Roll Hub, Shaft and Envelope Bucklers Removal . . . 40

Power Supply Removal. . ......................... 40

Printhead Cable, Cradle & Paper Deflector Removal .... 41

Printhead Carrier Assembly Removal ................ 43

Printhead Rubber Backer Removal. . ................ 44

RearCoverRemoval............................. 45

RightSideFrameAssemblyRemoval................ 45

Small Feed Roll Shaft, Rollers & Paper Flap Removal. . . 46

SystemBoardRemoval........................... 46

ConnectorLocations ..................................47

SystemBoardConnectors............................ 48

Encoder Card Connector............................. 49

PreventiveMaintenance ................................50

LubricationSpecifications............................ 50

iv

4077-001

PartsCatalog ........................................51

HowToUseThisPartsCatalog........................51

Assembly1:Covers..............................52

Assembly2:Frames..............................54

Assembly 3: Paper Feed ..........................56

Assembly4:Electronics...........................58

Assembly 4: Electronics (continued) .................60

Assembly5:Carrier..............................62

Assembly6:CarrierTransport......................64

Assembly 7: Sheet Feeder.........................66

Assembly8:MaintenanceStation...................68

Index ...............................................70

v

4077-001

Preface 2

This manual is divided into the following chapters:

1. General Information contains a general description of the
printer and the maintenance approach used to repair it. Special
tools and test equipment are listed in this chapter, as well as
general environmental and safety instructions.

2. Diagnostic Information contains error code table, symptom
table, 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. ConnectorLocations 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.

Safety Information

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.

• The safety features of some parts may not always be

obvious. Therefore, replacement parts must have the
identical or equivalent characteristics as the original parts.

vi

4077-001

Sicherheitshinweise

• Die Wartungsinformationen für dieses Produkt wurden zur

Verwendung durch einen Wartungsfachmann entwickelt und
sollten nicht von anderen benützt werden.

• Zusätzliches Risiko eines elektrischen Schlags und

körperlicher Verletzung existiert während des
Auseinandernehmens und der Wartung des Geräts.
Fachpersonal sollte im vollen Verständnis der Lage
entsprechende Vorsichtsmaßnahmen ergreifen.

• Ersatzteile müssen gleiche oder gleichwertige Merkmale wie

die Originalteile aufweisen, da Sicherheitsvorkehrungen nicht
immer offensichtlich sind.

Consignes de Sécurité

• 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.

• Les normes de sécurité de certaines pièces n'étant pas

toujours explicites, les pièces de rechange doivent être
identiques ou conformes aux caractéristiques des pièces
d'origine.

Norme di sicurezza

• Le informazioni riguardanti la manutenzione di questo

prodotto sono indirizzate soltanto al personale
dell'assistenza autorizzato.

• Durante lo smontaggio e il manutenzionamento di questo

prodotto, è possibile il rischio accresciuto di scosse elettriche
e danni personali. Il personale di assistenza autorizzato,
consapevole di ciò, deve adottare le precauzioni necessarie.

• È possibile che le funzioni di sicurezza di alcuni elementi non

siano così ovvie, quindi, i pezzi di ricambio devono avere
caratteristiche identiche o equivalenti a quelle dei pezzi
originali.

Preface vii

4077-001

Pautas de Seguridad

• La información sobre el mantenimiento de este producto fue

escrita para el personal de mantenimiento cualificado y no
para cualquier otro usuario.

• Existen mayores riesgos de descargas eléctricas y daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado comprende esto y toma las
precauciones necesarias.

• Los dispositivos de seguridad de algunas partes quizá no

siempre puedan ser reconocidas a simple vista. Por lo tanto,
las partes de reemplazo deben poseer características
idénticas o equivalentes a las partes originales.

Sikkerhedsoplysninger

• Oplysningerne om vedligeholdelse af dette produkt er

forberedt med henblik på professionelt servicepersonale, og
bør derfor ikke benyttes af andre.

• Risikoen for elektrisk stød øges under demontering og

service af dette produkt, hvorfor der bør tages de nødvendige
forholdsregler.

• Sikkerhedsforanstaltningerne er ikke altid lige åpenbare for

alle reservedele. Der bør derfor kun anvendes originale
reservedele eller reservedele med samme egenskaber som
de oprindelige.

Informações de Segurança

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devemser
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.

• Os dispositivos de segurança de algumas peças poderão

não ser sempre suficientemente evidentes. Assim, as peças
sobressalentes devem possuir características idênticas ou
equivalentes às peças originais.

viii

4077-001

Chinese Safety Information

Korean Safety Information

Preface ix

4077-001

General Information 8

The WinWriter™ 150c (4077-001) printer is a personal, near laser­quality inkjet printer. The print cartridge contains single-unit
customer-replaceable supply items. Dual printheads provide color
and true black printing without changing pr intheads. Print resolution
is 600 x 300 pels per inch. The printer can print at speeds of 167 cps
in Letter Quality mode and 300 cps in Draft mode. The black
cartridge is installed on the left and the color cartridge on the right.
The pri nt cartridges used in the WinWriter 150c are the same print
cartridges used in the ExecJet II and ExecJet IIc.

Power Consumption

Less than 2 Watts - power off and power to the printer

•

• 7.5 Watts - Idle Mode (power on - not printing)

• 12 Watts - Printing (average)

• 25 Watts - Printing (peak)

Maintenance Approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the error code charts,
symptom index, service checks, and diagnostic aids to determine
the symptom and repair the failure. Begin with “Start” on page 3.

This printer can be serviced without being connected to a host
computer.The user is directed, in the WinWriter 150c Printer Control
program, to perform the head to head and bidirectional alignment
adjustments after replacing a print cartridge.

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

General Information 1

4077-001

Abbreviations

CE Customer Engineer
CSU Customer Setup
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
POST Power-On Self Test
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

Unique Tools Required For Service

Parallel Wrap Plug P/N 1319128

General Information 2

4077-001

Diagnostic Information 9

Use the error indicator table, symptom tables, service checks, and
diagnostic aids in this chapter to determine the failing part.

Start

Service error indications show as a series of flashes of the Power
On light. There i s a pause between each series of flashes. If your
machine has an error indication, locate the series of flashes in the

“Error Indicator Table” on page 4 and take the indicated action.

Unplug the machine to clear the error indicator.
If an error indicator appears, go to the error indicator table and take

the indicated action for that error.
The printer also logs the last occurring error. If you think it may have

an intermittent error, or the error indicator lights have been cleared,
you can retrieve the error:

1. Run the “Printer Error Log Recovery” on page 24. The last error
appears as a series of flashes of the power on light.

2. Run “Initialize Error Log” on page 23 to clear the error (the error
may not be the result of a current error).

3. Run the “Test Page” on page 19. If no error appears, go to

“Power-On-Self-Test (POST) Sequence” on page 4.

If your machine does not have an error indicated, go to “Power-On-

Self-Test (POST) Sequence” on page 4.

Diagnostic Information 3

4077-001

Error Indicator Table

Number

Error
Code

of

Power

Light

Flashes

Action

64
65

66 ­78

83
79
81
89

127
and
up

7

6

8
9
1
4

10

Replace the Code Module and/or system board.

Replace the Code Module and/or system board.

Replace the Code Module and/or system board.
Replace the Code Module and/or system board.
Go to the “Transport Service Check” on page 17.
Go to the “Transport Service Check” on page 17.
Replace the Code Module and/or system board.

Power-On-Self-Test (POST) Sequence

When you turn the pr inter on it performs a POST. Turn your machine
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 and seals the
printheads.

3. The paper feed gears turn.

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

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

Tables” on page 6, locate the symptom and take the indicated

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

following table and take the indicated action.

Diagnostic Information 4

4077-001

POST Symptom Table

Symptom Action

No Power On
light and no
motors run

Feeds paper Go to the

Paperfeed gears
do not turn

Carrier doesn’t
move

Carrier slams
side frame

Go to the

page 8

Go to the

.

page 10

Go to the

Go to the

“Power Service Check” on page 14.

“First Print Line Service Check” on

“Paper Feed Service Check” on

.

“Transport Service Check” on page 17.

“Transport Service Check” on page 17.

5

4077-001

Symptom Tables

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

Carrier Transport Problems

Symptom Action

• N o carrier movement

• Slow carrier movement

• Carrier stops

• Carrier slams side frame

Go to the

Check” on page 17

Communications Problems

Symptom Action

Printer not communicating with
host computer.

Go to the

Check” on page 14

Maintenance Station Problems

Symptom Action

Maintenance station:

• Fails to cap the printhead

• Fails to clean the printhead

Go to the

Service Check” on page 9

“Transport Service

.

“Parallel Port Service

.

“Maintenance Station

.

Diagnostic Information 6

4077-001

Paper Feed Problems

Symptom Action

Paper fails to stop at first print line Go to the

Check” on page 8

• Fails to pick paper

• Picks more than one sheet of
paper

• Picks paper but fails to feed

• Paper jams

• Paper fails to exit

• Noisy paper feed

Envelopes fail to feed Go to the

Go to the

Check” on page 10

Check” on page 8

Paper skews Go to the

Check” on page 13

Power Problems

Symptom Action

“First Print Line Service

.

“Paper Feed Service

.

“EnvelopeFeed Service

.

“Paper Path Service

.

No power in machine, no Power
On light, no motors

Go to the

on page 14

Print Quality Problems

Symptom Action

• Voids in characters

•Lightprint

• Prints off the page

•Fuzzyprint

• Carrier moves but does not print

• Printhead drying prematurely

• Vertical alignment off

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

Go to the

Check” on page 15

Go to the

Check” on page 10

“Power Service Check”

.

“Print Quality Service

.

“Paper Feed Service

.

7

4077-001

Service Checks

Envelope Feed Service Check

FRU Action

1 Envelope Guide Be sure the envelope guides havebeen turned

to the envelope load positions.
Be sure the envelope guides are against the

envelopes.
Perform the

on page 10

“Paper Feed Service Check”

.

First Print Line Service Check

FRU Action

1End-of-Forms

Flag

2End-of-Forms

Sensor

3 System Board Perform the

4 Feed Arm

Assembly

Check the flag for binds or damage.

Check the sensor for dirt.

“End-of-Forms Sensor Test” on

page 22

the system board.
Check all parts of the feed arm assembly for

binds, wear, or damage.

to check the end-of-forms sensor on

Diagnostic Information 8

4077-001

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 A worn wiper causes degraded print quality just

3 Cap A worn cap causes the printhead nozzles to dry

As the carrier moves to the right over the
maintenance station, a slot on the bottom of the
carrier engages a tab on the sled of the
maintenance station causing the caps to rise and
seal the printheads. Carrier movement to the left
will uncap the printheads. The wipers clean the
printhead nozzles as the carrier leaves the
maintenance station. The wipers clean the
printheads only when the carrier is moving to the
left. 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 slot
on the carrier, causing the wipers to lower.
Check the maintenance station for worn or broken
parts.

after a maintenance cleaning. Check for loose or
worn wiper.

and clog. Check for loose or worn cap.

9

4077-001

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 With J5 disconnected and power on, check for +24

V dc between J5-3 and ground, and between J5-4
and ground on the system board. If the voltage is
not present, check for motor pins shorted to the
motor housing. If you find a shorted pin, replace
the motor. If you still have a failure after replacing
the motor, replace the system board.

Diagnostic Information 10

4077-001

FRU Action

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

turn, can be caused by:

• A n 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 100 ohms (±20
ohms) between the following pins on the motor:

Pin 1 to Pin 4
Pin 2 to Pin 4
Pin 3 to Pin 5
Pin 3 to Pin 6

If the readings are incorrect, replace the motor.
Checkformotor pins shorted to the motor housing.
If you find a shorted pin, replace the motor. If the
failure remains, replace the system board.
Although the paper feeds in a forward direction
only, the paper feed motor turns in two directions.
If the paper feed motor turns in one direction only,
replace the system board.
Binds in the paper feed motor or gear train can
cause intermittent false paper jam errors. Remove
the paper feed motor and check the shaft forbinds.
Also check for loose or worn motor gear.

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

mechanism by rotating the large feed roll by hand.
If you notice a bind, isolate it by removing one of
the small idler gears on the inside of the left side
frame. Replace any worn or binding gears or
rollers.

4 Feed Arm

Assembly

At the beginning of the paper feed operation, the
paper feed motor reverses momentarily to allow
the feed arm pawl to drop off the home position
notch in the left side frame. If the pawl fails to drop
off the notch, check the feed arm assembly for
binds, and worn or broken parts.

11

4077-001

FRU Action

5 Pick Roll Clutch

Spring
Right Side Frame

If your printer DOES have a spring and spacer,
remove both and replace the feed arm assembly
with the new style three gear feed arm assembly,
P/N 69G4398.

A

6 Sheet Feeder Check the following for wear or damage:

• Pick Rollers

• Envelope Bucklers

• All parts inside the left and right edge guides

7End-of-Forms

Flag Spring

8 Ejectors After the paper exits from the feed rollers, the

Check for binds or damage.

paper feed motor reverses causing the paper
ejectors to move the last sheet of paper into the
exit tray. If the ejectors do not move or restore,
check them for worn, loose, or broken parts. Be
sure the ejectors are connected to the large feed
roll shaft.

Diagnostic Information 12

4077-001

Paper Path Service Check

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

• Check the entire paper path for obstructions.

• Be sure the p aper guides are not worn or broken and are

positioned against the paper without binding or buckling the
paper.

• Be sure the correct type of paper is being used.

• Be sure the p rinter is installed on a flat surface.

FRU Action

1 Large and Small

Feed Rollers

2 Small Feed Roller

Springs
Paper Guide
Paper Flap

3 Sheet Feeder Check the following for wear or damage:

4 End-of-Forms

Flag

5 Ejectors After the paper exits from the feed rollers, the

Check for wear and binds.

Check for damage.

• Envelope Bucklers

• All parts inside the left and right edge guides.

Check for binds or damage.

paper feed motor reverses causing the paper
ejectors to move the last sheet of paper into the
exit tray. If the ejectors do not restore, check them
for worn, loose, or broken parts. Be sure the
ejectors are connected to the large feed roll shaft.

13

4077-001

Parallel Port Service Check

FRU Action

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

Run the
test fails, replace the system board.

“Parallel Port Test” on page 20.Ifthe

2 Communications

Jumper

If the parallel cable has been replaced and there is
still a communications problem, move the
communications jumper to pins 2 and 3.

Power Service Check

FRU Action

1 Power Supply Disconnect J11 from the system board and check

the following voltages on the power supply cable:

• J11-1 to GND = +5 V dc

• J11-3 to GND = +24 V dc
If you do not have correct voltage, replace the

power supply. Be sure to unplug the machine
before you reconnect the power supply to the
system board.

3 Printhead Cable

Parallel Cable
Encoder Card

Turn off the printer. Disconnect one of the
printhead cables and tur n on the printer. Look for a
symptom change. Check the failing part for shorts
and replace as necessary. Repeat this procedure
for the parallel cable and the encoder card.

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

system board.

Diagnostic Information 14

4077-001

Print Quality Service Check

FRU Action

1 Print Cartridge Be sure the machine contains good print

cartridges.

2 Printhead Carrier

Assembly

3SystemBoard

Printhead Cable
Rubber Backer

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

• Print Cartridge Latch

•LatchSpring

• Carrier

•Performthe
a break in the diagonal line of the test pattern. A
broken line indicates one or more print n ozzles
are not working. Run the test again to verify the
failure. If there are even breaks in the diagonal
line similar to the pattern shown below, replace
the system board.

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

• Check the gold-plated contacts, on the end of
the cable that connect to the carrier, for dirt and
wear. Use only a clean dry cloth to clean the
contacts. Also check the cable for damage. You
mayneedtoremovethecablefromthecarrierto
inspect it.

• A worn rubber backer results in poor contact
between the printhead cable and the print
cartri dge. Check the rubber backer for wear.

“Test Page” on page 19. Look for

4 Maintenance

Station

15

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

“Maintenance Station Service Check” on
page 9

, then return to this check.

4077-001

FRU Action

5 Paper Feed Ink smudging and smearing can be caused by

paper problems or problems in the paper feed
area.
Check the following:

• Correct type of paper is being used. Also check
the paper for curl or wrinkles.

• Feed rollers for wear, dirt, or looseness.

•Gearsforwearorbinds.

• Paper path for obstructions.

6 Transport Blurred print and voids can be caused by problems

in the transport area. Check the following:

• Transport belt for wear.

• Carrier guide rod for wear or dirt.

• Carrier to carrier frame engagement should be
lubricated with grease P/N 1329301. Do not
lubricate the carrier guide rod.

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

• Encoder strip for wear or dirt.

7 Uneven vertical lines can be adjusted by

performing the Bidirectional Alignment. The user is
directed, through the WinWriter 150c Printer
Control program, to perform the head to head and
bidirectional printing alignments, when replacing a
print cartridge.

Diagnostic Information 16

4077-001

Transport Service Check

FRU Action

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

Disconnect the transport motor (J6) from the
system board. Check for 8 to 18 ohms between
pins 2 and 3 on the motor cable. If the reading is
incorrect, replace the motor.

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

2 System Board Turn the printer off and disconnect J6 from the

system board. Turn the printer on and check for a
pulseof6to8VdcbetweenJ6-2andgroundand
between J6-3 and ground on the system board as
the machine goes through POST.

3 Carrier Guide Rod Clean the carrier rod.

Note: Do not lubricate the rod or the carrier rod
bearing surface.

4 Transport Belt

Idler Pulley Parts
Carrier Frame

5 Encoder Strip Check for wear and dirt.
6 Printhead Cable Be sure connector J4 is fully seated. Check the

7 Encoder Strip

Printhead Cable
Encoder Card
System Board

8 Maintenance

Station

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 1329301.

cable for damage.
Perform the

page 21

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 9

“Encoder Sensor Test” on

. If you cannot enter the test, replace the

.

17

4077-001

Diagnostic Aids 3

Use these diagnostic test procedures to verify a repair. There are
two ways to enter test procedures, each procedure will indicate
which one to use:

1. Press the on/off button five times allowing one second between
each press.

2. Turn the machine off, move the two pin jumper on connector J13,
then turn the machine on. The test begins when the power but­ton is pressed. Return the jumper to pins 2 and 3 after you com­plete testing.

J13

Diagnostic Aids 18

4077-001

Test Page

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

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

To enter the test press the on/off button five times allowing one
second between each press. Pages continue to print until you turn
off the power or unplug the printer.

The first line of this test page is the code level and code level date.
The next line is the black print cartridge nozzle pattern. The next
three lines are the purge pattern where all nozzles are printing. This
action cleans (purges) the nozzles. Another nozzle test pattern
follows. These patterns are then repeated for the color cartridge.

These test patterns are used to verify all print cartridge nozzles are
working. There should be no breaks in the diagonal line. A break in
the diagonal line indicates one or more nozzles are not working.

The next patterns to print are the vertical and horizontal alignment
test patterns used to align the black printhead to the color printhead.
The user performs this alignment after changing a print cartridge.

19

4077-001

Parallel Port Test

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

This test requires a parallel port wrap plug. Install the wrap plug in
the parallel port before you start the test. If the test is successful, the
power on light flashes. If the test is not successful, the power on light
remains off.

To run the test:

1. Turn the machine off and move the two pin jumper on connector
J13 to the pins shown below.

J13

2. Turn the machine on to start the test. Turn power off or unplug
the printer to stop the test.

3. Return the jumper to its original pin position after completing the
test.

Diagnostic Aids 20

4077-001

Encoder Sensor Test

This test disables the printer motors to allow you to manually move
the carrier to verify the encoder is working correctly.

To run the test:

1. Turn the machine off and move the two pin jumper on connector
J13 to the pin position shown below.

J13

2. Turn the machine on to start the test. Turn power off or unplug
the printer to stop the test.

3. Return the jumper to its original pin position after completing the
test.

The power on light flashes as the carrier is moved. If the power on
light does not flash, power off the printer and remove the carrier
assembly without unplugging the printhead cable.

Power on the printer and check for +5 V dc at pins 1, 2 and 3 of the
encoder card connector.

1. If voltage is not present, check the printhead cable for opens to
the encoder card. If the printhead cable is good, replace the
system board.

2. If voltage is present, check the sensor on the encoder card by
monitoring pin 3 of the encoder card connector as you pass a
piece of paper through the sensor. The voltage should go from
+5 V dc to 0 V dc. Turn the power off and back on to make this
check again. If the voltage at pin 3 does not change, replace the
encoder card. If the symptom remains, replace the printhead
cable.

21

4077-001

End-of-Forms Sensor Test

This test checks the end-of-forms sensor on the system board.
Check the end-of-forms sensor by either activating the end-of-forms

flag or by placing a piece of paper in the manual feed slot. The
power light goes on and off as you move the flag past the sensor. If
the test fails, replace the system board.

To run the test:

1. Turn the machine off and move the two pin jumper on connector
J13 to the pin position shown below.

J13

2. Turn the machine on to start the test. Turn power off or unplug
the printer to stop the test.

3. Return the jumper to its original pin position after completing the
test.

Diagnostic Aids 22

4077-001

Initialize Error Log

This test allows you to track new errors.
Use this procedure to reset the error log to zero. The error log is

especially helpful in diagnosing intermittent or difficult problems. To
start this procedure, the paper sensor must be open by placing a
piece of paper in the manual paper feed slot before you turn the
machine on. The test is complete when power is turned off.

To run the test:

1. Turn the machine off and move the two pin jumper on connector
J13 to the pin position shown below.

J13

2. Turn the machine on to start the test. Turn power off or unplug
the printer to stop the test.

3. Return the jumper to its original pin position after completing the
test.

23

4077-001

Printer Error Log Recovery

This test retrieves the last error from NVRAM.
To run the test:

1. Turn the machine off and move the two pin jumper on connector
J13 to the pin position shown below.

J13

2. Turn the machine on to start the test. Turn power off or unplug
the printer to stop the test.

3. Return the jumper to its original pin position after completing the
test.

The last error appears as a series of flashes of the power on light. If
the power on light does not flash, there are no errors.

Diagnostic Aids 24

4077-0014077-001

Repair Information 4

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 removing logic boards:

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

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

• Make the least-possible movementswith 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 electr ical 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 ESD­sensitive parts on a table.

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

cabinet (case).

Repair Information 25

4077-001

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

weather heating is used because low humidity increases static
electricity.

Adjustments

The user is directed, in the WinWriter 150c Printer Control program,
to perform the head to head and bidirectional alignment adjustments
after replacing a print cartridge.

Removal Procedures

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

Releasing Plastic Latches

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

Never apply excessive force

Hook

when releasing the hook.

Repair Information 26

4077-001

Base Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Disconnect the power supply connector at the system board.

4. Unlatch the two ejectors from the large feed roll shaft by pushing
down the ejectors where they grip the large feed roll shaft.

5. Remove the two screws securing the carrier frame to the base
cover.

6. Remove the ground straps from the carrier frame. Slide the
maintenance assembly out of the carrier frame.

7. Slide the machine off the base cover.

Note: when reinstalling the machine on the base assembly, be
sure to connect the ejectors to the large feed roll shaft.

Carrier Belt Removal

1. Remove the front cover.

2. Remove the carrier assembly.

3. Pushthe idler pulley to the right to release the tension on the belt
and remove the belt.

27

4077-001

Carrier Frame Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the base assembly.

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

5. Remove the four screws [A] securing the carrier frame to the left
and right side frames and remove the carrier frame assembly.

A

Repair Information 28

4077-001

Note: During reassembly:

1. Besure the small feed roll spring extensions [B] are in the groves
of the small feed roll arms.

2. Be sure the short extensions of the two paper flap springs are
trapped under the carrier frame [C].

B

Carrier Transport Motor Removal

1. Remove the front cover.

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

3. Remove the belt from the transport motor pulley.

C

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

29

4077-001

Code Module Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Gently pry the Code Module from the system board noting the
position of the notch in the module. The notch is down.

Edge Guide Asm and Paper Load Shaft Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the paper load door and manual insert tray.

4. Remove the pick roll hub, shaft and envelope bucklers.

5. Remove the two screws from the right side frame.

6. Work the paper load shaft out of the side frames.

7. Pull up the bottom of the edge guides to separate them from the
top of the back plate and remove the assembly from the frames.

Note: When reinstalling, be sure the edge guide springs are turned
to the inside to maintain spring tension on the guides.

Ejectors Removal

1. Remove the front cover.

2. Unlatch the ejectors from the large feed roll shaft by pushing
down the ejectors where they grip the large feed roll shaft.

3. To remove the ejectors, unlatch them by prying them forward.

Encoder Card Removal

1. Remove the front cover.

2. Remove the printhead carrier assembly.

3. Disconnect the printhead cable from the encoder card.

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

Repair Information 30

4077-001

Encoder Strip Removal

1. Remove the front cover.

2. Remove the carrier assembly.

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

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

Feed Arm Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the C-clip from the feed arm and remove the assembly.

31

4077-001

Front Cover Removal

1. Place a screwdriver in slot [A] and release the cover latches.

2. Slide the cover forward and off the machine.

A

A

To reassemble:

1. Slide the cover over the matching pieces on the bottom cover.

2. Press in both sides opposite the cover latches until they latch.

Gutter Pad Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the base assembly.

4. Scrape the old gutter pad off the base.

Repair Information 32

4077-001

Inside Idler Gears Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the printer from the base assembly.

4. Remove the paper feed motor.

5. Gently pry the two idler gears from the left side frame. Be careful
not to break the locking tabs [A].

33

4077-001

Large Feed Roll Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the carrier frame assembly.

4. Using a small screwdriver, break the four prongs off the
compound idler gear and remove the idler gear.

5. Remove the large feed roll from the mid frame by pulling it out of
the four mounting clips. Spread the right side frame and remove
the large feed roll.

Note: Install the compound idler gear after the machine is installed
inthebaseassembly.

Repair Information 34

4077-001

Large Outside Gear Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the paper load door and manual insert tray.

4. Remove the C-clip from the feed arm assembly and remove the
feed arm assembly.

5. Remove the C-clip from the left side of the pick roll shaft.

6. Pull the pick roll shaft out far enough to remove the large gear.

A

Note: Gently pull the feed arm guide [A] on the left side frame
forward, then remove the large gear.

35

4077-001

Left Side Frame Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the carrier frame assembly.

4. Remove the paper load door and manual insert tray.

5. Using a small screwdriver, break the four prongs off the
compound idler gear [A] and remove the idler gear.

6. Remove the two screws [B] securing the left side frame to the
back plate. Slide the left side frame off the back plate. Note the
relationship of the parts.

Note: Install a new compound idler gear [A] after the machine is
installed in the base assembly.

B

A

Repair Information 36

4077-001

Maintenance Station Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the screw from the maintenance station assembly and
slide the assembly forward, out of the machine.

Maintenance Wipers and Caps Removal

1. Remove the front cover.

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

3. Gently pull the caps and wipers off their mountings.

Note: When reinstalling the caps, be sure the cap is positioned with
the locking tabs to the left and right before pushing them down on
their mounting posts. Be sure the wipers are completely seated.

Manual Insert Tray Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the paper load door.

4. Spread the right side frame away from the manual insert tray
until the pins in the insert tray clear the frame.

5. Remove the manual insert tray from the left side frame.

Mid Frame Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the carrier frame assembly.

4. Remove the paper load door and manual insert tray.

5. Remove the small feed roll shaft.

6. Pull up the four clips securing the mid frame to the large feed roll
and work the mid frame out of both side frames.

37

4077-001

Paper Feed Motor Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the base assembly.

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

Paper Guide and EOF Flag Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the printhead carrier assembly.

4. Remove the carrier frame assembly.

5. Remove the system board.

6. Remove the encoder strip.

7. Remove the three small feed roll springs.

8. Push the locking tabs [A] to the rear and pull the paper guide
down and out of the carrier frame.

A

Repair Information 38

4077-001

Note: During reassembly:

1. Besure the small feed roll spring extensions [B] are in the groves
of the small feed roll arms.

2. Be sure the short extensions of the two paper flap springs are
trapped under the carrier frame [C].

B

C

39

4077-001

Paper Load Door Removal

Spread the left side frame where it joins the paper load door and
remove the door.

Pick Roll Hub, Shaft and Envelope Bucklers Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the paper load door and manual insert tray.

4. Slide the left paper guide to the right.

5. Remove the C-clip from the left side of the pick roll shaft.

6. Pull the pick roll shaft out to the left and remove the pick roll
shaft, hubs and envelope bucklers.

Note: During reassembly, be sure the pick roll hubs are in the slots
at the bottom of the paper guides and the rolls are c entered on the
pick pads.

Power Supply Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the base assembly.

4. Push down the latches and slide the power supply forward and
off the base assembly.

Repair Information 40

4077-001

Printhead Cable, Cradle & Paper Deflector Removal

1. Remove the front cover.

2. Remove the printhead carrier assembly.

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

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

Note: Some machines have a cradle with removable interlock keys.
Theinterlockkeyscanberemovedbypryingthekeylatchonthe
back of the cradle.

Rubber Backer

Interlock Keys

Cradle

Latch

A

Spring

Cable

Encoder Card

Carrier

Deflector

Cable

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

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

41

4077-001

Note: Be sure the cable is secured under the three retaining clips

[B] on the back of the carrier.

B

Repair Information 42

4077-001

Printhead Carrier Assembly Removal

1. Remove the front cover.

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

3. Remove the retainer from the right end of the carrier guide rod.

Note: Some machines may have a retainer spring in place of the
E-ring at the left end of the carrier rod.

4. Slide the carrier guide rod to the left, out of the machine.

5. Lift the carrier out of the machine.

43

4077-001

Printhead Rubber Backer Removal

1. Remove the front cover.

2. Remove the printhead carrier assembly.

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

Rubber Backer

Interlock Keys

Cradle

Latch

A

Spring

Cable

Encoder Card

Carrier

Deflector

Cable

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

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

Repair Information 44

4077-001

Rear Cover Removal

1. Remove the front cover.

2. Place a screwdriver in slot [A] and release the cover latches.

A

A

3. Slide the cover up and off the machine.

4. To reassemble, place the coverover the tabs in the bottom cover
and press down until the cover latches. Be sure the parallel
connector snaps do not get trapped behind the cover.

Right Side Frame Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the carrier frame assembly.

4. Remove the paper load door and manual insert tray.

5. Remove the two screws securing the right side frame to the back
plate. Slide the ri ght side frame off the back plate. Note the
relationship of the parts.

45

4077-001

Small Feed Roll Shaft, Rollers & Paper Flap Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the carrier frame assembly.

4. Spread the left and right side frames apart far enough to remove
the small feed roll shaft assembly.

System Board Removal

1. Remove the front cover.

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

3. Disconnect the other cables from the system board.

4. Gently release the tension on the encoder strip by flexing the
encoder strip tensioner and remove the encoder strip from the
left side only.

5. Remove the three screws securing the system board to the
carrier frame and remove the system board. Note the routing of
the paper feed motor cable.

Note: The head to head and bidirectional printing alignments will be
reset to factory defaults. The user, through the WinWriter 150c
Printer Control program, is directed to perform these alignments.
When reinstalling the system board, it is easier to insert the
printhead cables in the four connectors prior to installing the board.

Repair Information 46

4077-001

Connector Locations 6

The machine is shipped with the jumper pin settings in the following
static positions. Be sure to r eturn the jumpers to these pin positions
after testing.

Test Jumper J13

J13

Communications Jumper J12 pin 1 and 2.

J12

Connector Locations 47

4077-001

System Board Connectors

J11 J1

1

1

1

S1

J2

J3

1

1

J4

1

J6

1

1

J5J13

36

U56

U54

1

J9

SW1

1

J12

1

1

1

Connector Locations 48

4077-001

Connector Connector Names

J1 Printhead Cable 1
J2 Printhead Cable 2
J3 Printhead Cable 3
J4 Printhead Cable 4
J5 Paper Feed Motor
J6 Transport Motor
J9 Parallel Port
J11 Power Supply
J12 Communications Jumper
J13 Test Jumper
S1 EOF Sensor
SW1 Power Switch
U56 Code Module

Encoder Card Connector

PIN 1

49

4077-001

Preventive Maintenance 7

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 1329301 to lubricate the following:

• All gear mounting studs.

• The left and right ends of the large feed roller at the side frames.

• Both ends of the sheet feeder pick roll shaft at the side frames.

• The carrier to carrier frame engagement.

Do not lubricate the carrier guide rod, or carrier guide rod bearings.

Preventive Maintenance 50

4077-001

Parts Catalog 8

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 par t is

available in the listed parts packet.

Parts Catalog 51

4077-001

Assembly 1: Covers

3

2

4

1

Parts Catalog 52

4077-001

Asm­Index

Part
Number

1-1 69G411

5

-2 69G411
6

-3 69G411
8

-4 69G411
9

Units Description

1 Base Asm includes Exit Tray, Gutter Pad,

Feet

1 FrontCover Asm, Access Cover,Button &

LED Lens

1 Rear Cover

1 Gutter Pad

53

4077-001

Assembly 2: Frames

2

1

5

3

4

Parts Catalog 54

4077-001

Asm­Index

Part
Number

Units Description

2 -1 69G4120 1 Left Side Frame Sub-Asm without

Gears - Also order gears B/M
69G4127

-2 13A1279 1 Mid Frame

-3 69G4121 1 Right Side Frame

-4 69G4122 1 Carrier Frame

-5 69G4188 4 Screw, Frame Mounting (PP)

55

4077-001

Assembly 3: Paper Feed

10

5

8

7

2

6

1

4

3

9

Parts Catalog 56

4077-001

Asm­Index

Part
Number

Units Description

3 -1 70G3039 1 Paper Guide Asm includes EOF

Flag, Spring, 3 Small Feed Roll
Springs
On S/N prior to 11-AA000, also
order 13A1280

-2 69G4126 1 Small Feed Roll Shaft Roll B/M

and Paper Flap

-2 69G4382 1 Small Feed Roll B/M for

Rubber Large Feed Roll

-3 69G4129 1 Ejector Asm

-4 69G4124 1 Large Feed Roll Asm (includes

Small Compound Idler Gear)

-4 69G4380 1 Rubber Large Feed Roll

-5 69G4125 1 Paper Feed Motor, Motor Gear,

Toroid

-6 69G4127 1 Gears B/M

-7 69G4398 1 Feed Ar m Asm

-8 69G4188 2 C-Clip (PP)

-9 69G4188 3 Spring, Small Feed Roll (PP)

-10 69G4188 2 Screw, Paper Feed Motor
Mounting (PP)

57

4077-001

Assembly 4: Electronics

5

4

1

2

3

Parts Catalog 58

4077-001

Asm­Index

Part
Number

Units Description

4 -1 69G4132 1 System Board

-2 69G4133 1 Power Supply with Ground Plane,
Insulator, Cover

-2 69G4136 1 Power Supply, Korea

-3 1339526

1342514
1339520
1339520
1342514
1342514
1342534
1339526
1342534
1342514
1342514
1339525
1342514
1339519
1342514
1339520
1339520
1339520
1342514
1342514
1339521
1339524
70G0496
1342514
1339520
1342514
1339520
1342514
1342536
1342514
1339517
1339523
1339520
1339520
1339522
1339519
1342536
1342514

1PowerCord,U.S.

Power Cord, Argentina
Power Cord, Austria
Power Cord, Belgium
Power Cord, Bolivia
Power Cord, Brazil (LV)
Power Cord, Brazil (HV)
Power Cord, Canada
Power Cord, Chile
Power Cord, Columbia
Power Cord, Costa Rica
Power Cord, Denmark
Power Cord, Ecuador
Power Cord, Egypt
Power Cord, El Salvador
Power Cord, Finland
Power Cord, France
Power Cord, Germany
Power Cord, Guatemala
Power Cord, Honduras
Power Cord, Israel
Power Cord, Italy
Power Cord, Japan
Power Cord, Mexico
Power Cord, Netherlands
Power Cord, Nicaragua
Power Cord, Norway
Power Cord, Panama
Power Cord, Paraguay
Power Cord, Peru
Power Cord, Saudi Arabia
Power Cord, South A frica
Power Cord, Spain
Power Cord, Sweden
Power Cord, Switzerland
Power Cord, United Kingdom
Power Cord, Ur uguay
Power Cord, Venezuela

59

4077-001

Assembly 4: Electronics (continued)

4

5

1

2

3

Parts Catalog 60

4077-001

Asm­Index

Part
Number

Units Description

-4 69G4137 1 Code Module

-5 69G4188 5 Screw, System Board Mounting
(PP)

NS 69G4188 1 Screw, Ground Jumper Mounting

(PP)

NS 69G4188 2 Jumper, 2-Pin (PP)

61

4077-001

Assembly 5: Carrier

1

9

4

8

2

1

3

1

6

5

2

7

Parts Catalog 62

4077-001

Asm­Index

Part
Number

Units Description

5 -1 69G4154 1 Printhead Carrier Asm (includes

Carrier, Cradle, Deflector)

-2 69G4155 1 Printhead Cable (Folded)

-3 1367109 1 Rubber Backer

-4 69G4157 1 Carrier Guide Rod

-5 69G4156 1 Encoder Card Asm

-6 69G4188 1 Screw, Encoder Card Mounting

(PP)

-7 69G4188 1 Retainer Right, Carrier Guide Rod

(PP)

-8 69G4188 1 E-Ring, Carrier Guide Rod (PP)

Note: An E-Ring can be used in
place of a retainer spring on the
left end of the carrier guide rod.

-9 69G4153 1 Printhead Cartridge Interlock Key

B/M

63

4077-001

Assembly 6: Carrier Transport

4

2

1

6

3

5

Parts Catalog 64

4077-001

Asm­Index

Part
Number

Units Description

6 -1 69G4158 1 Carrier Transport Motor & Pulley

-2 69G4159 1 Carrier Belt

-3 69G4162 1 Encoder Strip

-3 69G4403 1 Encoder Strip
(Later Level - Slimmer)

-4 69G4163 1 Idler Pulley Tension Asm

-5 69G4188 2 Screw, Carrier Transport Motor
Mounting (PP)

-6 69G4188 1 Tensioner, Encoder Strip (PP)

65

4077-001

Assembly 7: Sheet Feeder

8

9

11

6

5

2

10

1

4

4

12

16

15

14

13

7

3

12

Parts Catalog 66

4077-001

Asm­Index

Part
Number

Units Description

7 -1 69G4166 1 Right Edge Guide & Width Adjust

Strip

-2 69G4167 1 Left Edge Guide

-3 69G4131 1 Upper Paper Support

-4 1367469 1 Pick Roll & Paper Load Shaft B/M

-5 1367463 2 Pick Roll Hub Asm

-6 1367019 1 Envelope Buckler B/M, Left & Right

-7 69G4169 1 Back Plate

-8 69G4164 1 Paper Load Door Asm

-9 69G4165 1 Manual Insert Tray

-10 69G4127 1 Gear, Paper Load (Gears B/M)

-11 69G4188 1 E-Ring (PP)

-12 69G4188 4 Screw, Side Frame (PP)

-13 69G4188 1 Spring, Left Paper Load (PP)

-14 69G4188 1 Spring, Right Paper Load (PP)

-15 69G4188 1 Spring, Pick Roll Clutch

-16 69G4188 1 Spacer

67

4077-001

Assembly 8: Maintenance Station

2

3

1

Parts Catalog 68

4077-001

Asm­Index

Part
number

Units Description

8 -1 69G4186 1 Maintenance Station Asm

-2 1367389 1 Wiper and Cap B/M (one of each)

-3 69G4188 1 Screw, Maintenance Station
Mounting (PP)

69

4077-001

Index 9

A

Abbreviations 2
Adjustments 26
Assemblies

1 Covers 52
2 Frames 54
3 Paper Feed 56
4 Electronics 58
5 Carrier 62
6 Carrier Transport 64
7 Sheet Feeder 66
8 Maintenance Station 68

C

Connector Locations 47
Connectors

System Board 48

D

Diagnostic Aids 18
Diagnostic Information 3

E

Error Indicator Table 4
ESD-Sensitive Parts 25

G

General Information 1

L

Lubrication Specifications 50

M

Maintenance Approach 1

P

Parts Catalog 51
Plastic Latches 26
POST

Sequence 4
Symptom Table 5

Power Consumption 1
Preventive Maintenance 50
Problems

Carrier Transport 6
Communications 6

Maintenance Station 6
Paper Feed 7
Power 7
Print Quality 7

R

Removals

Base Assembly 27
Carrier Belt 27
Carrier Frame 28
Carrier Transport Motor 29
Code Module 30
Edge Guide Asm 30
Ejectors 30
Encoder Card 30
Encoder Strip 31
Envelope Bucklers 40
EOF Flag Asm 38
Feed Arm Assembly 31
Front Cover 32
Gutter Pad Adhesive Pad 32
Inside idler Gears 33
Large Feed Roll 34
Large Outside Gear 35
Left Side Frame 36
Maintenance Station 37
Maintenance Wipers & Caps 37
Manual Insert Tray 37
Mid Frame Assembly 37
Paper Deflector 41
Paper Feed Motor 38
Paper Flap 46
Paper Guide 38
Paper Load Door 40
Paper Load Shaft 30
Pick Roll Hub 40
Pick Roll Shaft 40
Power Supply 40
Printhead Cable 41
Printhead Carrier 43
Printhead Cradle 41
Printhead Rubber Backer 44
Rear Cover 45
Right Side Frame 45
Small Feed Roll Shaft 46
Small Feed Rollers 46
System Board 46

Repair Information 25

S

Service Checks

Envelope Feed 8

70

4077-001

First Print Line 8
Maintenance Station 9
Paper Feed 10
Paper Path 13
Parallel Port 14
Power 14
Print Quality 15
Transport 17

Start 3
Symptom Table (POST) 5
Symptom Tables 6

T

Tests

Encoder Sensor 21
End-of-Forms 22
Initialize Error Log 23
Parallel Port 20
Printer Error Log Recovery 24
Test Page 19

Tools 2

71