LEXMARK X5100 Service Manual
Lexmark™ X5100 Series
• Table of Contents
•Start Diagnostics
• Safety and Notices
All-In-One
4407-XXX
• Trademarks
•Index
Lexmark and Lexmark with diamond
design are trade ma rks of Lexmark
International, Inc., registered in the
United States and/or ot her countries.
4407-XXX
Edition: March 24, 2006
The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERN ATIONAL, 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 all o w di sc la im er o f e x pres s o r i mpl i ed wa rr an tie s i n c ertai n t ra ns act ion s; t he refore, t hi s
statement may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the info rmation herein; these changes will be inco rporated 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 D2 2A/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 an y obligatio n
to yo u.
Lexmark is a trademark of Lexmark International, Inc., registered in the United States
and/or other countries.
Other trademarks are the propert y of their respec tive owners.
© 2003 Lexmark Inte rna t io nal , Inc.
All rights reserved.
UNITED STATES GOVERNMENT RIGHTS
This software and any accompanying documentation provided under this agreement are
commercial computer sof tware and documentation developed exclusively at pri vate
expense.
U.S.A. P/N: 12G9219
Japanese P/N: 12G9220
4407-XXX
Table of Contents
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Scanner Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-1
POST Symptom Tabl e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Carrier Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CCD Module Assembly Service Check . . . . . . . . . . . . . . . . . . . . 2-8
Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . . . . 2-9
Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -10
Paper Path Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -12
Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -13
Print Quality Service Che ck . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Scan/Copy Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-16
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Test Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Repair Informatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-S ensi tive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Scanner Lid Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Scanner Module Assemb ly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Scanner Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Mid-Frame Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Print Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
iii
4407-XXX
Maintenance Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
ASF Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
System Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Assembly 2: Print Engine and Carrier Transport . . . . . . . . . . . . . . . .7-4
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
iv Service Manual
4407-XXX
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 par ts.
• 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 precaut ions.
Consignes de Sécurité
• La sécurité de ce produit repose sur des tests et des
agréations por tant 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 électriqu es, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.
Safety Information v
4407-XXX
Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione
del progetto originale e dei componenti specifici. Il produttore
non è responsabile per la sicurezza in caso di sostituzione non
autorizzata delle parti.
• Le informazioni riguardanti la manutenzione di questo prodotto
sono indirizzate soltanto al personale di assistenza autorizzato.
• Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.
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 Auseinanderne hme ns und der Wartung des
Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständig e
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.
vi Service Manual
4407-XXX
Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y
aprobaciones del diseño original y component es esp ecíficos.
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 segur a n ça 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.
Safety Information vii
4407-XXX
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 in formaci ó 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 convenie n ts.
viii Service Manual
4407-XXX
Safe ty In formation ix
4407-XXX
Preface
This manual contains maintenance procedures for service
personnel. It is divided into the following chapters:
1. General Informati on 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. D iagnostic Information contains an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).
3. D iagnostic 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.
x Service Manual
4407-XXX
1. Gen e r a l Informat io n
The Lexmark™ X5150 (4407-XXX) machine features an electromechanical scanner, printer, and copier that creates characters and
graphics by composing programmed patterns of ink dots using a
printhead and liquid ink. The printhead uses small heater plates and
nozzles to control ink flow and the formation of characters on the
print media. The printhea d 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 cartridg e has a total of 640
nozzles and installs on the right. The color cartridge has a total of
480 nozzles and installs on the left. The printer is capable of printing
in two directions from either cartridge.
Power Cons umption
• 0.6 Watts - Power “Off”
• 9 Watts - Idle Mode (power on - not printing)
• 23 Watts - Printing (average)
• 21 Watts - Continuous Copying (average)
• 18 Watts - Continuous Scanning (average)
General Information 1-1
4407-XXX
Scanner Specif ications
Scanner Type Flatbed, CCD
Scan Modes T rue Color:
48 Bit Internal (68.7 Billion Color s)
24 Bit External (16.7 Million Col ors)
Gray Mode:
12 Bits Internal (4,096 Shades of
Gray)
8 Bits External (256 Shades of G ray)
Te xt/Line Art:
1 Bit Per Pixel
Scan Method One Pass Scanni ng
Scan Area 8.5 X 11.7 inches
216 X 292 mm
Scan Resolution Optical: 600 dpi (H) X 2400 dpi (V)
Interpolated: 19,200 X 19,200
1-2 Service Manual
4407-XXX
Operator Panel
Options
Select
Number
of Copies
+
Reduce/
Enlarge
Copy
Quantity
Start
Copy:
Photos:
Scan
To:
Fax:
Color
Copy
Photo
Options
-E-mail
-File
-Software
Stop/
Clear
Black
Copy
Photo
Copy
Start
Scan
Start
Fax
Power
General Information 1-3
4407-XXX
Press this
button:
Number of
Copies
Lighter/Darker Make the document lighter or darker than the original.
Reduce/Enlarge Make the document smaller or larger than the original .
Paper Type Select glossy, photo, transparency, or plain paper type.
- or + Scroll through menu sub-categories.
Menu Change settings using the menus.
Select Choose the displa yed selection.
Quality Choose photo , qui ck, or normal cop y setting.
Colo r Copy Make a color copy.
Black Copy Make a black and white copy.
Scan To Select a scan destina ti on, such as To copy, To an e-
Scan Press the scan button after selecting a Scan To
When you want to:
Select the number of cop ies.
mail, To an application, To a file, or To fax.
destination.
Cancel Cancel a scan, print, or copy job, or return to a menu
Power Turn the printer on or off.
category from a menu sub-category.
1-4 Service Manual
4407-XXX
Maintenance Approach
The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the symptom index, 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.
General Information 1-5
4407-XXX
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
1-6 Service Manual
4407-XXX
2. Diagnostic Information
Start
Use the symptom tables, service checks, and diagnostic aids in
chapter three, to determine the printer failure.
Power-On Self Test (POST) Sequence
Press the power button to turn machine on.
• The Power indicator light turns on.
• The Charge-Coupled Device (CCD) lamp turns on and the
scanner moves to the left, then returns to the right.
• The paper feed motor runs then stops.
• The carrier moves to the right then returns to the left stopping at
the maintenance station.
• Power light stays on.
• The message below is displayed on the LCD.
1
PY
Normal Quality
If your printer completes POST with no errors, go to the “Symptom
Tables” on page 2- 3, locate the symptom and take the indicated
action.
If your printer does not complete POST, locate the symptom in the
following table and take the indicated action.
1
Diagnostic Information 2-1
4407-XXX
POST Symp tom Table
Symptom Action
No power light
No motors run
Paper feed
gears do not
turn
Carrier does not
move
Carrier slam s
side frame
CCD lamp does
not tu rn on
LCD displays
“Unlock Scanner
Clear Paper
Jam”
Go to the “Power Service Check” on page 2-12. If ok ay,
go to the “Operator Panel Problems” on page 2-3.
Go to the “Paper Feed Service Check ” on page 2-10.
Go to the “Carrier Transport Service Chec k” on
page 2-6.
Go to the “Carrier Transport Service Chec k” 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.
2-2 Service Manual
4407-XXX
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 T ransport
Service Check” on page 2-6.
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 2-9.
Operator Panel Problems
Symptom Action
• Buttons do not work
• LCD does not display
Check operator panel cable
connection at JP6 on the system
board. Then run th e “Power- On Self
Test (POST) Sequence” on
page 2-1.
If the LED buttons or any lights fail,
check c onnection JP6 . If the prob lem
remains, replace the scanner
module assembly. Go to the
“Scanner Module Assembly” on
page 4-3.
If the pr oblem still exists, replace the
system board. Go to the “System
Board” on page 4-15.
Diagnostic Information 2-3
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