Lexmark X6100 Technical documentation

Lexmark™ X6100 Series All-In-One

• Table of Contents

• Start Diagnostics

• Safety and Notices

•Trademarks

4408-XXX

•Index

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

4408-XXX

Edition: March 24, 2006
The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore, this
statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at
[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.

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

Other trademarks are the property of their respective owners.

© 2003 Lexmark International, Inc.
All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

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

U.S.A. P/N: 12G9253

Japanese P/N: 12G9254

4408-XXX

Table of contents

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

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x

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

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

Machine types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

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

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

POST symptom table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Scan/Copy Quality service check. . . . . . . . . . . . . . . . . . . . . . . . 2-16

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

Test page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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

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

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

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4408-XXX

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

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

Print engine cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

ASF removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Base assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Carrier removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Fax card removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Maintenance station removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Midframe removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Print engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Scanner lid assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Scanner and ADF assembly removal . . . . . . . . . . . . . . . . . . . . .4-12

System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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: Paper feed, frame, and carrier transport . . . . . . . . . . . .7-6

Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

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

iv Service Manual

4408-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 parts.

• The maintenance information for this product has been

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

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

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

Consignes de Sécurité

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

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

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

s'adressent uniquement à un personnel de maintenance
qualifié.

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

certains risques électriques, le personne l d'en tr et ien qu alifié
devra prendre toutes les précautions nécessaires.

Safety information v

4408-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 Auseinandernehmens und der Wartung des

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

vi Service Manual

4408-XXX

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y

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

• La información sobre el mantenimiento de este producto está

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

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

Informações de Segurança

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

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

• As informações de segurança relativas a este produto

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

• Risco de choques eléctricos e ferimentos graves durante a

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

Safety information vii

4408-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 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.

viii Service Manual

4408-XXX

Safety information ix

4408-XXX

Preface

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

1. General information contains a general description of the
printer and the maintenance approach used to repair it. Spec ial
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. Part s cata lo g contains illustrations and part numbers for
individual FRUs.

Definitions

CAUTION: A caution identifies something that might cause a

servicer harm.

Warning: A warning identifies something that might damage the

printer hardware or software.

Note: A note provides additional information.

x Service Manual

4408-XXX

1. General information

The Lexmark™ X6170 4408-K01/AK1 and X6150 4408-K02/AK2
machines feature an electro-mechanical color scanner, printer,
copier, and fax that creates characters and graphics by composing
programmed patterns of ink dots using a printhead and liquid ink.
The printhead uses small heater plates and nozzles to control ink
flow and the formation of characters on the print media. The
printhead assembly and ink supply are combined into a single-unit,
print cartridge available as a customer replaceable supply item. Du al
printheads provide color and true black printing without changing
printheads. The number and size of inkjets or nozzles, in the
printhead, determines the overall quality and capability of the printer.
The black cartridge has a total of 208 nozzles and installs on the le ft.
The color cartridge has a total of 192 nozzles and installs on the
right. The printer is capable of printing in two directions from either
cartridge.

Power consumption

• 2.55 Watts - Sleep

• 3.107 Watts - Printing

• 6.64 Watts - Idle

Machine types

4408-K01/AK1 4408-K02/AK2

General information 1-1

4408-XXX

Scanner specifications

Scanner Type Flatbed, CCD
Scan Modes True Color:

Scan Method One Pass Scanning
Scan Area 8.5 X 11.7 inches

Scan Resolution Flatbed Scanning:

Resolution/Quality

(Applicable when operating via
standalone mode)

48 Bit Internal (68.7 billion colors)
24 Bit External (16.7 million colors)

Gray Mode:

12 Bit Internal (4,096 shades of
gray)
8 Bit External (256 shades of gray)

Text/L in e Art:

1 Bit Per Pixel

216 X 292 mm

-Optical: 1200 (H) x 4800 ppi (V)

-Interpolated: 19,200 x 19,200 ppi
ADF Scanning (4408-K01/AK1) only

-Optical: 600 (H) x 300 ppi (V)
Selectable via Contorl Panel

-Quick- 300 x 300 ppi Scan
600 x 300 dpi Print

-Normal- 300 x 600 ppi Scan
600 x 600 dpi Print

-Better- 600 x 600 ppi Scan
600 x 600 dpi Print

-Best- 600 x 600 ppi Scan
600 x 600 dpi Print

1-2 Service Manual

Notes:

1) Photo Mode = Best Mode

2) The number of printhead passes

will increase with the quality mode.

4408-XXX

Resolution/Quality

(Applicable when operating via
Host)

Selectable via All-In-One GUI for
Color/Gray

-Quick- 75 x 75 ppi Scan
600 x 300 dpi Print

-Normal- 150 x 150 ppi Scan
600 x 600 dpi Print

-Better- 200 x 200 ppi Scan
1200 x 1200 dpi Print

-Best- 300 x 300 ppi Scan
2400 x 1200 dpi Print

Selectable via All-In-One GUI for
Black Copy

-Quick- 150 x 150 ppi Scan
600 x 300 dpi Print

-Normal- 300 x 300 ppi Scan
600 x 600 dpi Print

-Better- 600 x 600 ppi Scan
1200 x 1200 dpi Print

-Best- 600 x 1200 ppi Scan
2400 x 1200 dpi Print

General information 1-3

4408-XXX

Control panel

Press: To:

Number of
Copies

Lighter/Darker Lighten or darken a copy.
Reduce/Enlarge Make the document smaller or larger.
Left arrow <

Right arrow>
Options Scroll through the list of menu headings.
Select Choose the displayed selection.
Quality Choose normal, better, best, or quick copy setting.
Color Copy Make a color copy.

Select the number of copies.

Scroll through menu sub-categories.

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4408-XXX

Press: T o:

Black Copy Make a black and white copy.
Scan Scan after selecting a Scan To destination.
Stop/Clear 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.

Maintenance approach

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the symptom ind ex, service
checks, and diagnostic aids to determine th e sym p tom an d re pa ir
the failure.

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

General information 1-5

4408-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

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4408-XXX

2. Diagnostic information

Start

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

Power-On Self Test (POST) sequence

Press the Power button to turn machine on.

• The Power, Copy, Scan, and Fax indicator lights turn on.

• The Charge-Coupled Device (CCD) moves to the right, and

then to the left.

• The paper feed motor runs then stops.

• The carrier moves and then returns to the maintenance station.

• The Power and Copy buttons stay on.

• The following message is displayed on the LCD.

1

PY

1

Normal

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.

Diagnostic information 2-1

4408-XXX

POST symptom table

Symptom Action

No Power, Copy ,
Fax, or Scan
lights and no
motors run.

Paper feed
gears do not
turn

Carrier does not
move

Carrier slams
side frame

CCD does not
move

CCD lamp does
not turn on

LCD displays
“Unlock
Scanner”

Go to the “Power service check” on page 2-13. If okay,
go to the “Control panel problems” on page 2-3.

Go to the “Paper Feed service check” on page 2-10.

Go to the “Carrier Transport service check” on

page 2-6.

Go to the “Carrier Transport service check” on

page 2-6.

Go to the “Maintenance Station service check” on

page 2-9.

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

4408-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 Transport

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.

Control panel problems

Symptom Action

• Buttons do not work

• LCD does not display

Check control panel cable
connection at J4 on the system
board. Then run the “Power-On

Self Test (POST) sequence” on
page 2-1.

If the LED buttons or any lights fail,
check connection J4. If the problem
remains, replace the scanner
assembly. Go to the “Scanner and

ADF assembly removal” on
page 4-12.

If the problem still exists, replace the
system board. Go to the “System

board removal” on page 4-15.

Diagnostic information 2-3

4408-XXX

Printer communication table

Symptom Action

• Not able to print Test Page Check the USB cable and system
board cable connections. If okay,
replace system board. Go to the

“System board removal” on
page 4-15.

Scanner problems

Symptom Action

• CCD does not move

• Lamp does not light

• Control panel displays “Unlock

Scanner”

• Scanned images are: faded, or

colors are dull, blurry or fuzzy.
Images are slanted or crooked
and the strait lines in the image
appear to be jagged or uneven.

• Blank copies

Go to the “CCD Module Assembly

service check” on page 2-8.

To unlock the scanner, press the
scanner lock located under the
scanner assembly.

Go to the “Scan/Copy Quality

service check” on page 2-16.

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4408-XXX

Paper feed problems

Symptom Action

• Fails to pick paper

• Picks more than one sheet of
paper

• Picks paper but fails to feed

• Paper jams

• Paper fails to exit

• Noisy paper feed

Envelopes fail to feed Go to the “Paper Feed service

Paper skews Go to the “Paper Path service

Go to the “Paper Feed service

check” on page 2-10.

check” on page 2-10.

check” on page 2-12.

Power problems

Symptom Action

No power in machine, motors do
not operate

Go to the “Power service chec k ”

on page 2-13.

Print quality problems

Symptom Action

• Voids in characters

• Light print

• Prints off the page

• Fuzzy print

• Carrier moves but no print

• Printhead dries prematurely

• Colors print incorrectly

• Vertical alignment off

Go to the “Print Quality service

check” on page 2-14.

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

Go to the “Paper Feed service

check” on page 2-10.

Diagnostic information 2-5

4408-XXX

Service checks

Carrier Transport service check

FRU Action

1 System Board

Carrier Transport
Motor

2 Carrier Transport

Motor

Check the transport carrier motor connector JP7. If
connected, check for approximately 30 volts on
pins 1 and 2 or at the wire connections located on
the rear of the transport carrier motor. If voltage is
incorrect, replace the system board. If voltage is
correct, check the motor for shorts. If motor needs
replacing, replace the print engine. Go to “Print

engine removal” on page 4-12.

Check the motor for binds, or loose motor pulley.
A noisy or chattering motor or a motor that fails to

turn can be caused by:

• An open or short in the motor.

• An open or short in the motor driver

on the system board.

• A bind in the carrier transport

mechanism.

With the carrier transport motor cable (JP7)
disconnected from the system board, check for 0
to 10 ohms between the following pins on the
motor:

JP7-1 and JP7-2

If the readings are incorrect, replace the print
engine. Go to the “Print engine removal” on

page 4-12.

3 Carrier Guide Rod Clean the carrier rod.

Note: Lubricate the rod and the carrier rod bearing
surfaces with grease P/N 99A0394.

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4408-XXX

FRU Action

4 Encoder Strip

Carrier Assembly

5 Carrier Transport

Belt
Idler Pulley Parts
Carrier Frame

6 Printhead Carrier

Assembly

Check the encoder strip for proper installation.
Also, check it for wear, dirt, and grease.

Be sure all printhead connectors are fully seated.
Check the cables for damage.

If the encoder strip and all connections are okay,
but the carrier still slams the side frame, replace
the print engine. Go to the “Print engine

removal” on page 4-12.

Check for worn, loose or broken parts. Check for
obstructions blocking carrier movement.

Check the carrier belt idler pulley mounting screw.
Loosen the screw and allow the tension spring to
take up any slack in the belt. Tighten the screw . If
the pulley mounting bracket has reached the stop,
replace the carrier assembly. Go to the “Loosen

carrier belt tensioner screw (A).” on page 4-6.

Lubricate carrier to carrier frame engagement with
grease P/N 99A0394.

Disconnect the printer and check the carrier
printhead connectors JP1 and JP2. If the
connections are good, remove the printhead
carrier and check the cable connection to the
home sensor board. If the problem remains,
replace the system board. Go to the “System

board removal” on page 4-15.

7 Maintenance

Station

A problem with the maintenance station can cause
carrier movement problems at the right margin. Go
to the “Maintenance station removal” on

page 4-9.

Diagnostic information 2-7

4408-XXX

CCD Module Assembly service check

The CCD (charge-coupled device) Module does not move during
POST Test.

The CCD lamp does not come on when CCD module assembly
moves.

The CCD LCD displays “Unlock Scanner.”

FRU Action

1 CCD Module Assembly If CCD module does not move, go to

the “Maintenance Station service

check” on page 2-9.

If lamp does not come on as CCD
module assembly is scanning or
moving, check connector (JP9) on
the system board. If connected and
the lamp still does not work, replace
the control panel scanner assembly.
If the problem persists, replace the
system board. Go to “System

board removal” on page 4-15 for

more information.

2-8 Service Manual

To unlock scanner, press the red
lever down.

Note: Unlock scanner before use.

4408-XXX

Maintenance Station service check

The maintenance station has three functions:

1. Wipes the printhead nozzles to clean them of dirt.

2. Provides a place for printheads to fire all nozzles, keeping them
clear prior to printing.

3. Seals the printhead when it is not being used to prevent the
nozzles from drying.

FRU Action

1 Maintenance

Station Assembly

As the carrier moves to the left over the
maintenance station, a slot on the bottom of the
carrier engages a tab on the sled of the
maintenance station causing the cap to rise and
seal the printhead. Carrier movement to the right
uncaps the printhead. The wiper cleans the
printhead nozzles as the carrier leaves the
maintenance station. The wiper cleans the
printhead 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 tab on
the carrier, causing the wiper to lower.

Check the maintenance station for worn or broken
parts. Replace if needed. Go to the “Maintenance

station removal” on page 4-9.

Worn wipers cause degraded print quality just after
a maintenance cleaning. Check for loose or worn
wipers.

Worn caps cause the printhead nozzles to dry and
clog. Check for loose or worn caps.

Diagnostic information 2-9

4408-XXX

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 Run the “Power-On Self Test (POST)

sequence” on page 2-1. Replace parts as

needed. To check the paper feed motor,
disconnect the paper feed connector JP5 and
check for approximately 5 ohms between pins:
1 and 2
3 and 4

2-10 Service Manual

If the reading is incorrect, replace the print engine.
Go to the “Print engine removal” on page 4-12.
If the reading is correct, replace the system board.
Go to the “System board removal” on

page 4-15.

4408-XXX

FRU Action

2 Paper Feed Motor A noisy or chatterin g motor or a mo tor that fails to

turn, can be caused by:

• An 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 JP5 disconnected
from the system board, check for approximately 5
ohms between the following pins on the motor:

1 and 2
3 and 4

If the readings are incorrect, replace the print
engine. Go to the “Print engine removal” on

page 4-12.

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. Go to the “System

board removal” on page 4-15.

3 Auto Sheet

Feeder Assembly

4 Mid Frame

Assembly

5 End-of-Forms

Flag and Spring

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 for binds.
Also check for a loose or worn motor gear.

Check the pick roller for wear.

Check the following for wear:

• Small Feed rollers

• La rge Feed roller

•Exit roller

• Star rollers

If the mid frame assembly needs to be replaced,
go to the “Print engine removal” on page 4-12
and replace print engine.

Check for binds or damage.

Diagnostic information 2-11

4408-XXX

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 correct type of paper is being used.

• Be sure the printer is installed on a flat surface.

FRU Action

1 Large and Small

Feed Rollers

2 Small Feed Roller

Springs

3 Auto Sheet

Feeder Assembly

4 Mid Frame Asm Check the following for wear:

5 End-of-Forms

Flag

Check for wear and binds.

Check for damage.

Check the pick roller for wear.

•Exit roller

• Star rollers

Check for binds or damage.

Note: If any of these items are damaged or defective, replace the
print engine. Go to “Print engine removal” on page 4-12.

2-12 Service Manual

4408-XXX

Power service check

FRU Action

1 External Power

Supply

2 Printhead Cable

Paper Feed Motor
Carrier Transport
Motor
Control Panel

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

Plug the external power supply into an outlet.
Check for + 30 V dc. If voltage is incorrect, replace
the power supply.

Unplug the printer. Check all connections and plug
in the printer. Look for a symptom change. Check
the failing part for shorts and replace as
necessary.

system board. Go to the “System board

removal” on page 4-15.

Diagnostic information 2-13

4408-XXX

Print Quality service check

FRU / Function Action

1 Printhead

Cartridge

2 Color Printhead

Cartridge Cross
Contamination

3 Printhead Carrier

Assembly

4 System Board

Printhead Carrier
Assembly

Be sure the machine contains good print
cartridges.

Cross contamination of color inks results in
incorrect colors printed, as when green prints for
yellow, (when yellow and blue are mixed in the
printhead cartridge). This problem resolves quickly
as the printhead cartridge is used.

If cross contamination occurs, check the following:

• The maintenance station wiper for damage.

• The printhead nozzle plate was resealed with
tape.

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

• Printhead Cartridge Latch

• Latch Spring

• Carrier

Perform the “Test page” on page 3-1. Look for a
break in the diagonal line of the nozzle test
pattern. A broken line indicates one or more print
nozzles are not working. Run the test again to
verify the failure.

Check the gold-plated contacts on the end of the
printhead carrier cable for dirt, wear and damage.
Use only a clean dry cloth to clean the contacts.

5 Maintenance

Station

2-14 Service Manual

If the symptom remains, replace the system board.
Go to the “System board removal” on

page 4-15.

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

“Maintenance station removal” on page 4-9,

and then return to this check.

4408-XXX

FRU / Function Action

6 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.

• Gears for wear or binds.

• Paper path for obstructions.

7 Carrier Transport Blurred print and voids can be caused by problems

in the carrier transport area. Check the following:

• Carrier transport belt for wear.

• Carrier guide rod for wear or dirt. If dirty, clean
and lubricate.

• Carrier to carrier frame engagement should be
lubricated with grease P/N 99A0394.

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

8 Alignment Uneven vertical lines can be adjusted by

performing the printhead alignment adjustments.
The user is directed, through the Lexmark Solution
Center to perform the printhead alignment
adjustments, when replacing a printhead cartridge.

Diagnostic information 2-15

4408-XXX

Scan/Copy Quality service check

FRU / Function Action

1 Scanned images

are: faded, or
colors are dull,
blurry or fuzzy.
Images are
slanted or
crooked and the
strait lines in the
image appear to
be jagged or
uneven.

2 Blank copies. If blank copies found, make sure that the original

Check the lighter/darker settings to see if it is
correct. There are two ways to make the
adjustment:

• From the control panel

• From the Lexmark Solution Center

Check to see if there is any dust, debris on the
glass. This may cause a poor image.

Check the press plate on the scan lid for any dust
or debris.

document is facing down on the scanner bed.
Check the print cartridges to see if they need to be

cleaned or replaced.
Check the paper type and copy quality settings on

the control panel or Lexmark Solution Center.

2-16 Service Manual

4408-XXX

3. Diagnostic aids

Test page

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

printhead cartridges are in good condition.
To enter the test:

1. Turn the printer on.

2. Lift the scanner unit.

3. Install a known good black print cartridge in the left side of the
carrier and a good color cartridge in the right.

4. Close the scanner unit.

5. Load paper in the paper support.

6. Press the Options button until “Maintenance” appears.

7. Press the right arrow to self test.

8. Press the Select button and the test runs.

The printer prints four lines of black and color printhead cartri dge
nozzle purge patterns followed by a black and color nozzle test
pattern. The purge pattern is used to clear all printhea d nozzles. The
nozzle test pattern prints all nozzles on a diagonal line. There should
be no breaks in the nozzle test pattern. A break in the pattern
indicates one or more nozzles are not working.

If a print quality problem exists, see “Print Quality service check”

on page 2-14.

Diagnostic aids 3-1

4408-XXX

3-2 Service Manual

4408-XXX

4. Repair information

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 system
board:

• 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 movements with 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 electrical 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 ESD-sensitive parts on a table.

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

(case).

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

heating is used because low humidity increases static electricity.

Repair information 4-1

4408-XXX

Adjustments

The user is directed, in the Lexmark Solution Center, to perform the
printhead alignment adjustments after replacing a print cartridge.

Removal procedures

The following procedures are arranged according to the na me of the
printer part discussed.

CAUTION: 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 re move such parts, press the
hook end of the latch away from the part to which it is latched.

4-2 Service Manual

4408-XXX

Print engine cover removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove print engine.

4. Remove four screws (A).

A

Repair information 4-3

4408-XXX

5. Depress six latches (B).

6. Remove print engine cover.

B

ASF removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove print engine.

4-4 Service Manual

4408-XXX

4. Disconnect media sensor (A).

5. Remove four screws (B) from ASF.

A

B

6. Remove ASF.

Base assembly removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove print engine.

4. Remove print engine cover from base assembly.

Repair information 4-5

4408-XXX

Carrier removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove midframe.

4. Remove print engine.

5. Disconnect carrier cables from system board.

6. Loosen carrier belt tensioner screw (A).

4-6 Service Manual

A

4408-XXX

7. Depress carrier belt tensioner (B).

8. Remove carrier belt from motor pulley (C).

9. Remove two retainer clips (D) from the carrier shaft.

B DD C

10. Remove shaft.

11. Lift and remove carrier.

Note: Position of encoder strip.

Fax card removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove print engine.

4. Remove exit tray.

Repair information 4-7

4408-XXX

5. Remove fax card cover (A).

6. Remove three fax card screws (B).

A

7. Remove fax card.

Note: Routing of all cables.

4-8 Service Manual

B

4408-XXX

Maintenance station removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove print engine.

4. Use a screwdriver to unlatch maintenance station (A).

A

Repair information 4-9

4408-XXX

5. Slide maintenance station forward and remove.

4-10 Service Manual

4408-XXX

Midframe removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove six screws (A) from midframe.

A

4. Use screwdriver to unlatch midframe.

Tabs

5. Remove midframe.

Repair information 4-11

4408-XXX

Print engine removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove midframe.

4. Move the carrier to the center of the printer.

5. Remove two screws (A) from print engine.

A

6. Disconnect cables from system board.

7. LIft and remove print engine.

Scanner lid assembly removal

1. Open the lid.

2. Lift and remove.

Scanner and ADF assembly removal

1. Remove scanner lid.

2. Lift scanner assembly.

4-12 Service Manual

4408-XXX

3. With screwdriver depress two clips (A) on cable cover and
remove.

A

4. Depress clip (B) on left side of scanner assembly.

5. Depress clip (C) on right side of scanner assembly.

B

Repair information 4-13

C

4408-XXX

6. Disconnect all cables (D) from system board.

D

7. Disconnect ground cable (E).

E

8. Lift and remove scanner and ADF assembly.

Note: Routing of all cables.
Note: Do not lubricate scanner rod or bearing after replacing.

4-14 Service Manual

4408-XXX

System board removal

1. Remove scanner lid.

2. Remove scanner assembly.

3. Remove print engine.

4. Remove ASF.

5. Disconnect all cables from system board.

6. Remove three screws (A) from system board.

7. Remove system board.

A

Repair information 4-15

4408-XXX

4-16 Service Manual

4408-XXX

5. Connector locations

1

1

JP3

JP5

1

JP4

1

J3

PS1

JP2

1

JP7

J4

JP9

J6

1

J2

1

J1

1

JP15

1

JP16

1

JP6

1

PS2

JP1

Units Description

J1 ADF Entry Sensor
J2 ADF Exit Sensor
J3 USB and Phone Jacks
J4 Control Panel
JP1 Carrier

Connector locations 5-1

4408-XXX

JP2 Carrier
JP3 Jumper
JP4 Power Supply Terminal
JP5 Paper Feed Motor
JP6 Media Sensor
JP7 Transport Carrier

Motor
JP9 CCD Module
JP15 ADF Paper Feed

Motor
JP16 CCD Module Scanner

Motor
PS2 Scanner Housing

Sensor
S1 EOF

Units Description

J1 USB and Phone Jacks
J4 Fax Speaker
JP2 USB

J3

JP2

J5

J1

J4

1

1

5-2 Service Manual

4408-XXX

6. Preventive maintenance

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 99A0394 to lubrica te the following:

• All gear mounting studs.

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

• The carrier to carrier frame engagement.

• The carrier guide rod, and carrier guide rod bearings.

Warning: Keep grease from coming into contact with any electrical

components, may cause printer damage or failure. Do not lubricate
the scanner rod or bearing after replacing.

Preventive maintenance 6-1

4408-XXX

6-2 Service Manual

4408-XXX

7. Parts catalog

How to use this parts catalog

• SIMILAR ASSEMBLIES: If two assemblies contain a majority of

identical parts, they are shown 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 description column indicates the part is

available in the listed parts packet.

• NA: Not available as a FRU.

Parts catalog 7-1

4408-XXX

Assembly 1: Covers

1

2

7-2 Service Manual

3

4

5

4408-XXX

Assembly 1: Covers

Asm­Index

Part
Number

1-1 56P1778 1 Paper support

2 56P1784 1 Midframe cover
3 56P1783 1 Engine cover
4 56P1786 1 Fax cover
5 56P1781 1 Base assembly

NS 7371533 1 Plain package B/M includes: carton, cushion

NS 7371538 1 Plain package B/M includes: carton, cushion

Units Description

set, and sealing tape (001)

set, and sealing tape (002)

Parts catalog 7-3

4408-XXX

Assembly 1 (cont.): Covers

6

1

5

7-4 Service Manual

2

3

4

4408-XXX

Assembly 1: (cont.) Covers

Asm­Index

Part
Number

1-1 56P1780 1 Scanner lid assembly (002)

2 56P1779 1 Scanner lid assembly (001)
3 56P1776 1 Control panel scanner assembly (001)
4 15K0153 1 Cover, control panel, English
5 56P1785 1 Scanner support

6 56P1775 1 ADF Module
NS 56P1777 1 Control panel scanner assembly (002)
NS 56P1789 1 Control panel scanner assebmly (AK1)
NS 56P1790 1 Control panel scanner assembly (AK2)
NS 15K0154 1 Cover, control panel, French
NS 15K0155 1 Cover, control panel, Germany
NS 15K0156 1 Cover, control panel, Spain
NS 15K0157 1 Cover, control panel, Italy
NS 15K0158 1 Cover, control panel, Dutch
NS 15K0159 1 Cover, control panel, Portuguese (Brazil)
NS 15K0160 1 Cover, control panel, Polish
NS 15K0161 1 Cover, control panel, Japanese
NS 15K0162 1 Cover, control panel, Simple Chinese
NS 15K0163 1 Cover, control panel, Traditional Chinese
NS 15K0164 1 Cover, control panel, Russian
NS 15K0167 1 Cover, control panel, Greek

Units Description

Parts catalog 7-5

4408-XXX

Assembly 2: Paper feed, frame, and carrier transport

1

7-6 Service Manual

4

2

3

4408-XXX

Assembly 2: Paper feed, frame, and carrier transport

Asm­Index

Part
Number

2-1 56P1774 1 ASF module

2 56P1770 1 Printing engine

3 56P1773 1 Carrier w/cable assembly

4 56P1788 1 Maintenance station assembly

Units Description

Parts catalog 7-7

4408-XXX

Assembly 3: Electronics

1

2

3

7-8 Service Manual

4408-XXX

Assembly 3: Electronics

Asm­Index

Part
Number

3-1 13D0400 1 Power supply (LV) 120 V

2 56P1771 1 Board, system (001)

3 56P1787 1 Fax card
NS 56P1772 1 Board, system (002)
NS 13D0401 1 Power supply (HV) 220 V
NS 13D0402 1 Power supply — Japan 100 V

Units Description

Parts catalog 7-9

4408-XXX

7-10 Service Manual

4408-XXX

Index

A

abbreviations 1-6
adjustments

2-15, 4-2

B

button

black copy 1-5
color copy 1-4
lighter/darker
number of copies 1-4
power 1-5
quality
reduce/enlarge 1-4
scan 1-5
select

1-4

1-4

1-4

C

carrier 2-6, 2-7
carrier transport 2-15
carrier transport motor cable 2-6
cartridge
CCD module assembly 2-8
connector locations 5-1
control panel

1-1

1-4

E

ESD-sensitive parts 4-1

G

general information 1-1

L

LCD 2-1, 2-3
lubrication specifications 6-1

M

machine types 1-1
maintenance approach

1-5

P

paper feed motor 2-11

paper jam
parts catalog

carrier transport
covers 7-2
electronics
frame 7-6
paper feed 7-6

plastic latches
POST sequence 2-1
POST symptom tables 2-2
power consumption
preventive maintenance 6-1
print quality 2-5
printer communication table
problems

carrier transport 2-3
control panel
maintenance station 2-3
paper feed 2-5
power
print quality 2-5
scanner 2-4

2-5

7-6

7-8

4-2

1-1

2-4

2-3

2-5

R

removals

4-4

ASF
base assembly 4-5
carrier 4-6
fax card
maintenance station 4-9
midframe 4-11
print engine
print engine cover 4-3
scanner and ADF assembly 4-12
scanner lid assembly
system board 4-15

4-7

4-12

4-12

S

safety information v
scanner assembly
scanner specifications 1-2
service checks 2-6

carrier transport

2-16

2-6

Index X-1

4408-00X

CCD module assembly 2-8
maintenance station 2-9
paper feed
paper path 2-12
power 2-13
print quality
scan/copy quality 2-16
system board 2-6

2-1

start
symptom tables 2-3

2-10

2-14

T

table of contents 1-iii
test page 3-1

Part Numbers

13D0400 7-9
13D0401
13D0402 7-9
15K0153 7-5
15K0154
15K0155 7-5
15K0156 7-5
15K0157
15K0158 7-5
15K0159
15K0160 7-5
15K0161 7-5
15K0162
15K0163 7-5
15K0164 7-5
15K0167
56P1770 7-7
56P1771 7-9
56P1772
56P1773 7-7
56P1774 7-7
56P1775
56P1776 7-5
56P1777 7-5
56P1778
56P1779 7-5
56P1780 7-5
56P1781
56P1783 7-3
56P1784 7-3

7-9

7-5

7-5
7-5

7-5

7-5

7-9

7-5

7-3

7-3

56P1785
56P1786 7-3
56P1787
56P1788 7-7
56P1789 7-5
56P1790
7371533 7-3
7371538 7-3

7-5
7-9

7-5

X-2 Service Manual