Table of Contents: 7000 Color Jetprinter™ 7200, 7200V Color Jetprinter
Table of Contents: 7000 Color Jetprinter™ 7200, 7200V Color Jetprinter
Table of Contents: 7000 Color Jetprinter™ 7200, 7200V Color Jetprinter
4092-00X
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Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
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First Edition (November 1997) 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/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.If your printer has broken or missing parts, or if you are missing publications, call 1-8004LEXBMP. In other countries, contact your point of purchase. You can obtain additional copies of publications related to this product by calling 1800-553-9727. Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries. Color Jetprinter is a trademark of Lexmark International, Inc. Other trademarks are the property of their respective owners. Copyright Lexmark International, Inc. 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 subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.
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Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Resolution and Print Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Unique Tools Required For Service . . . . . . . . . . . . . . . . 1-3 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Error Indicator Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Power-On Self Test (POST) Sequence. . . . . . . . . . . . . . 2-2 POST Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Envelope Feed Service Check . . . . . . . . . . . . . . . . . . . . 2-6 First Print Line Service Check . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance Station Service Check . . . . . . . . . . . . . . . . 2-7 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-8 Paper Path Service Check . . . . . . . . . . . . . . . . . . . . . . 2-10 Parallel Port Service Check. . . . . . . . . . . . . . . . . . . . . . 2-11 Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Print Quality Service Check. . . . . . . . . . . . . . . . . . . . . . 2-12 Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Encoder Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Initialize Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 End of Forms (EOF) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Parallel Port Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Print NVRAM Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Test Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Base Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Carrier Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Carrier Frame Assembly Removal . . . . . . . . . . . . . . . . . 4-4 Carrier Transport Motor Removal . . . . . . . . . . . . . . . . . . 4-5 iv
4092 Code Module Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Edge Guide Asm and Paper Load Shaft Removal . . . . . . 4-6 Encoder Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Encoder Strip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Exit Drive Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Exit Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Feed Arm Assembly Removal . . . . . . . . . . . . . . . . . . . . . 4-7 Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Gutter Pad Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Inside Idler Gears Removal . . . . . . . . . . . . . . . . . . . . . . . 4-9 Large Feed Roll Removal. . . . . . . . . . . . . . . . . . . . . . . . 4-10 Large Outside Gear Removal. . . . . . . . . . . . . . . . . . . . . 4-11 Left Side Frame Assembly Removal . . . . . . . . . . . . . . . 4-12 Maintenance Station Assembly Removal. . . . . . . . . . . . 4-13 Maintenance Wipers and Caps Removal . . . . . . . . . . . . 4-13 Manual Insert Tray Removal . . . . . . . . . . . . . . . . . . . . . 4-13 Mid Frame Assembly Removal . . . . . . . . . . . . . . . . . . . 4-13 Paper Feed Motor Removal . . . . . . . . . . . . . . . . . . . . . . 4-14 Paper Guide and EOF Flag Assembly Removal . . . . . . 4-14 Paper Load Door Removal. . . . . . . . . . . . . . . . . . . . . . . 4-16 Pick Roll Shaft, Hub and Envelope Bucklers Removal . 4-16 Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Printhead Cable, Cradle & Paper Deflector Removal . . 4-17 Printhead Carrier Assembly Removal . . . . . . . . . . . . . . 4-19 Printhead Rubber Backer Removal . . . . . . . . . . . . . . . . 4-19 Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Right Side Frame Assembly Removal . . . . . . . . . . . . . . 4-20 Small Feed Roll Shaft, Rollers & Paper Flap Removal . 4-21 Star Roller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 System Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 System Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Encoder Card Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 How To Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . 7-1 Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Assembly 2: Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Assembly 3: Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Assembly 4: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Assembly 5: Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Assembly 6: Carrier Transport . . . . . . . . . . . . . . . . . . . . . . . 7-14 v
4092 Assembly 7: Sheet Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Assembly 8: Maintenance Station . . . . . . . . . . . . . . . . . . . . 7-18 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1
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Preface
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 indicator 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. 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.
Safety Information
This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.
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Consignes de Scurit
Ce produit a t conu, test et approuv pour respecter les normes strictes de scurit globale lors de l'utilisation de composants Lexmark spcifiques. Les caractristiques de scurit de certains lments ne sont pas toujours videntes. Lexmark ne peut tre tenu responsable de l'utilisation d'autres pices de rechange. Les consignes d'entretien et de rparation de ce produit s'adressent uniquement un personnel de maintenance qualifi. Le dmontage et l'entretien de ce produit pouvant prsenter certains risques lectriques, le personnel d'entretien qualifi devra prendre toutes les prcautions ncessaires.
Norme di sicurezza
Il prodotto stato progettato, testato e approvato in conformit a severi standard di sicurezza e per lutilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non responsabile per lutilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona pi elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.
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Sicherheitshinweise
Dieses Produkt und die zugehrigen Komponenten wurden entworfen und getestet, um beim Einsatz die weltweit gltigen Sicherheitsanforderungen zu erfllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung fr dieses Produkt bernommen. Die Wartungsinformationen fr dieses Produkt sind ausschlielich fr die Verwendung durch einen Wartungsfachmann bestimmt. Whrend des Auseinandernehmens und der Wartung des Gerts besteht ein zustzliches Risiko eines elektrischen Schlags und krperlicher Verletzung. Das zustndige Fachpersonal sollte entsprechende Vorsichtsmanahmen treffen.
Pautas de Seguridad
Este producto se ha diseado, verificado y aprobado para cumplir los ms estrictos estndares de seguridad global usando los componentes especficos de Lexmark. Puede que las caractersticas de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La informacin sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga elctrica y de daos personales durante el desmontaje y la reparacin de la mquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.
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Informaes de Segurana
Este produto foi concebido, testado e aprovado para satisfazer os padres globais de segurana na utilizao de componentes especficos da Lexmark. As funes de segurana de alguns dos componentes podem no ser sempre bvias. A Lexmark no responsvel pela utilizao de outros componentes de substituio. As informaes de segurana relativas a este produto destinamse a profissionais destes servios e no devem ser utilizadas por outras pessoas. Risco de choques elctricos e ferimentos graves durante a desmontagem e manuteno deste produto. Os profissionais destes servios devem estar avisados deste facto e tomar os cuidados necessrios.
Informaci de Seguretat
Aquest producte est dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililitzaci de components especfics de Lexmark. Les caracterstiques de seguretat d'algunes peces pot ser que no sempre siguin bvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informaci pel manteniment daquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui. El risc de xoc elctric i de danys personals pot augmentar durant el procs de desmuntatge i de servei daquest producte. El personal professional ha destar-ne assabentat i prendre les mesures convenients.
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1. General Information
The Lexmark Color JetprinterTM Series 7000, 7200 & 7200V (Machine Type 4092) printers are personal, near laser-quality inkjet printers. The print cartridges contain single-unit customerreplaceable supply items. Dual printheads provide color and true black printing without changing printheads. The black cartridge has a total of 208 nozzles and installs on the left. The color cartridge has a total of 192 nozzles and installs on the right. These printers are capable of printing in two directions from either cartridge.
Operator Panel
Lights Left Light Steady - Power On Blinking - Printer Error Right Light Steady - Busy Blinking - Paper Out/Jam Alternating Blinking Lights: Printheads are in the load position or printheads are installed incorrectly.
Right Button - Paper Feed Clears a paper jam or loads paper when there is a paper out condition.
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Power Consumption
Less than 5 Watts - power off and power to the printer 10 Watts - Idle Mode (power on - not printing) 30 Watts - Printing (average) 40 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 indicator charts, symptom index, service checks, and diagnostic aids to determine the symptom and repair the failure. Begin with Start on page 2-1. This printer can be serviced without being connected to a host computer. The user is directed, in the 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.
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Abbreviations
CE CSU EOF ESD FRU HVPS LED LVPS NVRAM OEM POST V ac V dc ZIF Customer Engineer Customer Setup End of Forms Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Light-Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Power-On Self Test Volts alternating current Volts direct current Zero Insertion Force
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2. Diagnostic Information
Use the error indicator table, symptom tables, service checks, and diagnostic aids to determine the failing part.
Start
Service error indications show as a series of flashes of the Power light. There is a pause between each series of flashes. If your printer has an error indication, locate the series of flashes in the Error Indicator Table on page 2-2 and take the indicated action. Unplug the printer 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 Print NVRAM Contents on page 3-6. The last error appears at the bottom of the page. 2. Run Initialize Error Log on page 3-3 to clear the error (the error may not be the result of a current error). 3. Run the Test Page on page 3-7. If no error appears, go to Power-On Self Test (POST) Sequence on page 2-2.
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Error Code
Action
64 65 66 78 79 81 83 89 90 92 93 127 and up
7 6 9 2 8 4 5 12 3 10
Replace the code module and/or system board and printhead cable. Replace the code module and/or system board and printhead cable. Replace the Code Module and/or system board. Go to the Transport Service Check on page 2-15. Replace the code module and/or system board. Go to the Transport Service Check on page 2-15. Check the carrier and/or replace the system board. Go to the Power Service Check on page 2-11. Replace the code module and/or system board. Replace the Code Module and/or system board.
2-2
4092 If your printer completes POST with no errors, go to the Symptom Tables on page 2-4, 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.
Go to the First Print Line Service Check on page 2-6. Go to the Paper Feed Service Check on page 2-8.
Go to the Transport Service Check on page 2-15. Go to the Transport Service Check on page 2-15.
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Symptom Tables
Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems
Symptom No carrier movement Slow carrier movement Carrier stops Carrier slams side frame Action Go to the Transport Service Check on page 2-15.
Communications Problems
Symptom Printer not communicating with host computer Action Go to the Parallel Port Service Check on page 2-11.
2-4
Go to the Envelope Feed Service Check on page 2-6. Go to the Paper Path Service Check on page 2-10.
Power Problems
Symptom No power in printer, no Power light, no motors Action Go to the Power Service Check on page 2-11.
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Service Checks
Envelope Feed Service Check
FRU 1 Envelope Guide Action Be sure the envelope guides have been turned to the envelope load positions. Be sure the envelope guides are against the envelopes. Perform the Paper Feed Service Check on page 2-8.
2-6
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Cap
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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.
Action With J5 disconnected and power on, check for +30 V dc between J5-1 and ground, and between J5-3 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.
2-8
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FRU 2 Paper Feed Motor Action 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 paper feed mechanism With the paper feed motor cable disconnected from the system board, check for 5 to 10 ohms between pin 1 and 4 on the motor cable. If the reading is incorrect, replace the motor. Check for motor 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 for binds. 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. 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. Perform the Paper Path Service Check on page 2-10, starting at Step 1.
Paper Path
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Check the entire paper path for obstructions. Be sure the paper 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 printer is installed on a flat surface.
Action Check for wear and binds. Check for damage.
FRU 1 2 Large and Small Feed Rollers Small Feed Roller Springs Paper Guide Paper Flap Exit Roller Star Rollers Exit Drive Belt Sheet Feeder
Check the following for wear or damage: Pick Rollers Envelope Bucklers All parts inside the left and right edge guides.
2-10
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2-12
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FRU 3 System Board Printhead Cable Rubber Backer Thermal Sensor Action Perform the Test Page on page 3-7. Look for a break in the diagonal line of the test pattern. A broken line indicates one or more print nozzles 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 may need to remove the cable from the carrier to inspect it. A worn rubber backer results in poor contact between the printhead cable and the print cartridge. Check the rubber backer for wear. Refer to the test page. The temperature value in Celsius, or the message Thermal Sensor Not Installed is printed. If the thermal sensor is not installed or malfunctioning, and the printer is operating in a warm environment > 104F (40C), excessive ink may flow from the cartridge. Be sure the thermal sensor is connected to J7 on the system board. If the thermal sensor is connected and a Thermal Sensor Not Installed message prints, replace the thermal sensor. Note: Printing slows to prevent overheating and excessive ink flow, when the temperature is above the normal operating range, or when printing complex graphics. The normal operating temperature range is 60 F to 90 F (16 C to 32 C). 4 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station. Perform the Maintenance Station Service Check on page 2-7, then return to this check.
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FRU 5 Paper Feed Action Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: 6 Transport Correct type of paper is being used. Paper for curl or wrinkles. Feed rollers for wear, dirt, or looseness. Gears for wear or binds. Paper path for obstructions.
Blurred print and voids can be caused by problems in the transport area. Check the following: Transport belt for wear and full engagement into the carrier grip. Carrier guide rod for wear or dirt. Carrier to carrier frame engagement should be lubricated with grease P/N 1329301. Lubricate the carrier guide rod and carrier frame on both sides where the two top bearing surfaces ride on the frame. Idler pulley parts for wear, damage, or looseness. Encoder strip for wear or dirt.
Alignment
Uneven vertical lines can be adjusted by performing the bidirectional alignment. The user is directed, through the Printer Control program, to perform the head to head and bidirectional printing alignments, when replacing a print cartridge.
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2-16
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3. Diagnostic Aids
Use these diagnostic test procedures to verify a repair. There are two ways to enter test procedures, each procedure will indicate the method to use: Procedure 1:
Press and hold the Paper Feed button while turning the printer on. Release the button when the printer completes POST.
Procedure 2:
Turn the printer off. Use a two pin jumper on connector J6. Turn the printer on. The test begins when the Power Button is pressed.
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2. Ensure the manual paper slot is empty. 3. Press and hold the Paper Feed button while turning the printer on and continue to hold until the Busy Light begins to flash.
Manually moving the carrier to the left causes the Power Light to flash. Manually moving the carrier to the right, causes the Busy Light to remain on. If the test fails 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. See Connector Locations on page 5-1. 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.
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2. Place a sheet of paper in the manual feed far enough to activate the EOF (End of Forms) sensor. 3. Press the Power Button. When the Power Light begins to flash, the Error Log clear is complete. (This may take several seconds). To stop the test, turn power off or unplug the printer.
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To run the test: 1. Turn the printer off and place a two pin jumper on connector J6 as shown below. (Pins 3 & 4).
2. To start the test, press and hold the Paper Feed button while turning the printer on. Hold the button until the Power Light blinks rapidly. Turn power off or unplug the printer to stop the test.
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To run the test: 1. Turn the printer off. 2. Attach the wrap plug to the parallel port. 3. Place a two pin jumper on pins (1 & 2) of test connector J6. 4. Turn the printer on. If the lights blink alternately, the test is failing. If the Busy Light stays on and the Power Light blinks, the test is working properly. If the Busy Light blinks intermittently, an intermittent failure is occurring.
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3-6
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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 black print cartridge in the left side of the printhead cradle and a color print cartridge in the right side. To enter the test: 1. Turn the printer off. 2. Ensure the manual paper slot is empty. 3. To start the test, press and hold the Paper Feed button while turning the printer on. Release the button when the printer completes POST. The test page contains the following:
Code level and date Current printhead temperature in Celsius (read by the thermal sensor board) Nozzle test pattern for both cartridges Purge test for both cartridges Text (printer model) Paper test result (for manufacturing purposes only)
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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. When working on the printer, always unplug the printer from the wall outlet. High voltage is present in the power supply as long as it is plugged into the wall outlet.
Keep the ESD-sensitive part in its original shipping container (a special ESD bag) until you are ready to install the part into the printer. 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 printer. 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 printer 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. Printer 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 printer covers when you are not working on the printer, 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.
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Adjustments
The user is directed, in the 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.
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4-3
4092
4092 Note: During reassembly: 1. Be sure the small feed roll spring extensions [B] are in the grooves 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]. 3. Be sure the tab from the paper guide does not deflect the small feedroll shaft downward. The shaft should be forward of the tab.
4-5
4092
Note: When reinstalling, be sure the edge guide springs are turned to the inside to maintain spring tension on the guides.
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4-7
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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.
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4-9
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Note: Install the compound idler gear and retainer clip after the printer is installed in the base assembly.
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Note: Gently pull the feed arm guide [A] on the left side frame forward, then remove the large gear.
4-11
4092
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4092
4092 Note: During reassembly: 1. Be sure the small feed roll spring extensions [B] are in the grooves 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]. 3. Be sure the tab from the paper guide does not deflect the small feedroll shaft downward. The shaft should be forward of the tab.
4-15
4092
Note: During reassembly, be sure the pick roll hubs are in the slots at the bottom of the paper guides and the rolls are centered on the pick pads.
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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.
4-17
4092 Note: Be sure the cable is secured under the three retaining clips [B] on the back of the carrier.
4092
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.
4-19
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3. Slide the cover up and off the printer. 4. To reassemble, place the cover over 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.
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4-21
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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 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. The carrier guide rod, and carrier guide rod bearings. Both ends of the exit roller shaft.
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 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. The carrier guide rod, and carrier guide rod bearings. Both ends of the exit roller shaft.
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Assembly 1: Covers
7-2
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AsmIndex 1 -1 1 1A 1A 2 Part Number 17B0150 17B0151 13A1234 13A1452 13B0201
Units 1 1 1 1 1
Description Base Asm includes Feet, Gutter Pad (4092-001, 003, 006) Base Asm includes Feet, Gutter Pad (4092-002, 004, 005) Exit Tray and Extender (4092-001, 003, 006) Exit Tray and Extender (4092-002, 004, 005) Front Cover Asm, Access Cover with Door Latch, Buttons & LED Lens (4092-001, 006) Front Cover Asm, Access Cover with Door Latch, Buttons & LED Lens (4092-002) Front Cover Asm, Access Cover with Door Latch, Buttons & LED Lens (4092-003) Front Cover Asm, Access Cover with Door Latch, Buttons & LED Lens (4092-004) Front Cover Asm, Access Cover with Door Latch, Buttons & LED Lens (4092-005) Front Access Door with Latch (4092-001, 006) Front Access Door with Latch (4092-002) Front Access Door with Latch (4092-003) Front Access Door with Latch (4092-004, 005) Rear Cover (4092-001, 003, 006) Rear Cover (4092-002, 004, 005)
13B0403
17B0152
17B0153
17B0165
2A 2A 2A 2A 3 3
1 1 1 1 1 1
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7-4
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AsmIndex 1-4 4 5 6 7 8 9 10 11 NS NS NS NS NS NS NS Part Number 17B0158 69G4119 13B0203 13B0239 13B0239 17B0166 17B0164 17B0163 17B0161 17B0162 13A1257 7347806 13A3554 17B0159 17B0156 17B0167
Units 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1
Description Gutter Pad (Large) Gutter Pad (Small) Lens (LED) & Power Button Screw (PP) Screw (PP) Cover, Video Card Cable, Video Ground Cable, Video Flex Board, Video Cable, Video (Coax) Office Organizer Plain Package B/M includes: (Carton, Cushion Set, Sealing Tape) Garage with Sticker (4092-003, 004) Need More Ink Label (4092-003, 004) Snappy Sticker Ex2 Inside Sticker (4092-003, 004)
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Assembly 2: Frames
7-6
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AsmIndex 2 -1 1 2 3 3 4 Part Number 13B0411 13B0412 13B0272 13A1236 13A1446 13B0204
Units 1 1 1 1 1 1
Description Left Side Frame (4092-001, 003, 006) Left Side Frame (4092-002, 004, 005) Mid Frame Right Side Frame (4092-001, 003, 006) Right Side Frame (4092-002, 004, 005) Carrier Frame
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7-8
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AsmIndex 3 -1 2 3 4 5 5A 6 7 8 9 10 11 12 NS Part Number 13B0205 13A1280 13B0212 13B0275 13B0276 13B0239 13B0271 69G4398 13B0239 13B0239 13B0239 13B0223 70G0579 13B0239
Units 1 1 1 1 1 1 1 1 1 3 2 1 1 1
Description Paper Guide Asm includes EOF Flag & Spring Small Feed Roll Shaft Roll B/M and Paper Flap Star Roller Asm Large Feed Roll Asm (includes Small Compound Idler Gear) Paper Feed Motor, Motor Gear, Toroid Warning Label, Motor (PP) Gears B/M Feed Arm Asm C-Clip (PP) Spring, Small Feed Roll (PP) Screw, Paper Feed Motor Mounting (PP) Exit Roller Exit Drive Belt Gear Retainer (PP)
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Assembly 4: Electronics
7-10
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AsmIndex 4 -1 1 Part Number 13B0070 17B0160
Units 1 1
Description System Board, W/O Code Module System Board, W/O Code Module (4092-005)
2 3
13B0214 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
1 1
Power Supply (Universal) with Ground Plane, Insulator, Cover Power Cord, 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 Africa Power Cord, Spain Power Cord, Sweden Power Cord, Switzerland Power Cord, United Kingdom Power Cord, Uruguay Power Cord, Venezuela
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7-12
AsmIndex 4-4 4 5 6 7 NS
Units 1 1 5 1 1 1
Description Code Module (4092-001, 002, 003, 004, 006) Code Module (4092-005) Screw, System Board Mounting, Frame Mounting (PP) Thermal Sensor Board w/ Cable Screw, Thermal Sensor Mounting (PP) Jumper, 2-Pin (PP)
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Assembly 5: Carrier
7-14
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AsmIndex 5 -1 2 3 4 5 6 7 8 9 Part Number 13B0237 13B0222 13B0238 13B0217 69G4156 13B0239 13B0221 13B0239 17B0168
Units 1 1 1 1 1 1 1 2 2
Description Printhead Carrier B/M Printhead Cable (Folded) Rubber Backer Carrier Guide Rod Encoder Card Asm Screw, Encoder Card Mounting (PP) Printhead Cartridge Interlock Key B/M Screw, Carrier Guide Rod (PP) Washer, Lock (Packet of 50)
4092
7-16
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AsmIndex 6 -1 2 3 4 5 6 Part Number 13B0219 13B0215 69G4403 17B0157 13B0239 13B0239
Units 1 1 1 1 2 1
Description Carrier Transport Motor & Pulley Carrier Belt Encoder Strip Idler Pulley Tension Asm Screw, Carrier Transport Motor Mounting (PP) Tensioner, Encoder Strip (PP)
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7-18
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AsmIndex 7 -1 1 2 2 3 3 4 5 6 7 7 8 8 9 9 10 11 12 13 14 Part Number 13A1227 13A1442 13A1228 13A1443 69G4131 13A1451 13A1229 1367463 1367019 69G4169 13A1448 13A1226 13A1440 69G4165 13A1447 13B0239 13B0239 13B0239 13B0239 13B0271
Units 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 4 1 1 1
Description Right Edge Guide & Width Adjust Strip (4092-001, 003, 006) Right Edge Guide & Width Adjust Strip (4092-002, 004, 005) Left Edge Guide (4092-001, 003, 006) Left Edge Guide (4092-002, 004, 005) Upper Paper Support (4092-001, 003, 006) Upper Paper Support (4092-002, 004, 005) Pick Roll & Paper Load Shaft B/M Pick Roll Hub Asm Envelope Buckler B/M, Left & Right Back Plate (4092-001, 003, 006) Back Plate (4092-002, 004, 005) Paper Load Door (4092-001, 003, 006) Paper Load Door (4092-002, 004, 005) Manual Insert Tray (4092-001, 003, 006) Manual Insert Tray (4092-002, 004, 005) E-Ring (PP) Screw, Side Frame (PP) Spring, Left Paper Load (PP) Spring, Right Paper Load (PP) Gear, Paper Load (Gears B/M)
4092
7-20
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AsmIndex 8 -1 2 3 Part number 13B0160 70G0590 13B0239
Units 1 1 2
Description Maintenance Station Asm Wiper and Cap B/M (one of each) Screw, Maintenance Station Mounting (PP)
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Index
A
Abbreviations 1-3 Adjustments 4-2 Assemblies
1 Covers 7-2 2 Frames 7-6 3 Paper Feed 7-8 4 Electronics 7-10 5 Carrier 7-14 6 Carrier Transport 7-16 7 Sheet Feeder 7-18 8 Maintenance Station 7-20
3
Communications 2-4 Maintenance Station 2-4 Operator Panel 2-4 Paper Feed 2-5 Power 2-5 Print Quality 2-5
R
Removal Procedures 4-2 Removals
Base Assembly 4-3 Carrier Belt 4-3 Carrier Frame 4-4 Carrier Transport Motor 4-5 Code Module 4-6 Edge Guide Asm 4-6 Encoder Card 4-6 Encoder Strip 4-6 Envelope Bucklers 4-16 EOF Flag Asm 4-14 Exit Drive Belt 4-7 Exit Roller 4-7 Feed Arm Assembly 4-7 Front Cover 4-8 Gutter Pad 4-8 Inside Idler Gears 4-9 Large Feed Roll 4-10 Large Outside Gear 4-11 Left Side Frame 4-12 Maintenance Caps 4-13 Maintenance Station 4-13 Maintenance Wipers 4-13 Manual Insert Tray 4-13 Mid Frame Assembly 4-13 Paper Deflector 4-17 Paper Feed Motor 4-14 Paper Flap 4-21 Paper Guide 4-14 Paper Load Door 4-16 Paper Load Shaft 4-6 Pick Roll Hub 4-16 Pick Roll Shaft 4-16 Power Supply 4-16 Printhead Cable 4-17 Printhead Carrier 4-19 Printhead Cradle 4-17 Printhead Rubber Backer 4-19 Rear Cover 4-20 Right Side Frame 4-20 Small Feed Roll Shaft 4-21 Small Feed Rollers 4-21 Star Roller 4-21 System Board 4-21
C
Connector Locations 5-1 Connectors
Encoder Card System Board
5-2 5-1
D
Diagnostic Aids 3-1 Diagnostic Information 2-1
E
Error Indicator Table 2-2 ESD-Sensitive Parts 4-1
G
General Information 1-1
L
Lubrication Specifications 6-1
M
Maintenance Approach 1-2
P
Parts Catalog 7-1 Plastic Latches 4-2 POST
Sequence 2-2 Symptom Table
2-3
2-4
X-1
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Video Board
4-22
S
Service Checks
Envelope Feed 2-6 First Print Line 2-6 Maintenance Station Paper Feed 2-8 Paper Path 2-10 Parallel Port 2-11 Power 2-11 Print Quality 2-12 Transport 2-15 Video 2-16
2-7
T
Tests
Encoder Sensor 3-2 Initialize Error Log 3-3 Parallel Port 3-5 Print NVRAM Contents Test Page 3-7
3-6
Tools 1-3
X-2