Lexmark X6100 Series All-In-One

4408-XXX

Table of Contents Start Diagnostics Safety and Notices Trademarks Index

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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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 [email protected]. 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

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Table of contents
Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machine types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scanner specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-2 1-4 1-5 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

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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 Scurit
La scurit de ce produit repose sur des tests et des
agrations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilit concernant la scurit en cas d'utilisation de pices de rechange non agres. 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.

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Norme di sicurezza
La sicurezza del prodotto si basa sui test e sull'approvazione
del progetto originale e dei componenti specifici. Il produttore non 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 pi elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

Sicherheitshinweise
Die Sicherheit dieses Produkts basiert auf Tests und
Zulassungen des ursprnglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung fr die Sicherheit 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.

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Pautas de Seguridad
La seguridad de este producto se basa en pruebas y
aprobaciones del diseo original y componentes especficos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. 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.

Informaes de Segurana
A segurana deste produto baseia-se em testes e aprovaes
do modelo original e de componentes especficos. O fabricante no responsvel pela segunrana, no caso de uso de peas de substituio no autorizadas. As informaes de segurana relativas a este produto destinam-se 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.

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Informaci de Seguretat
La seguretat d'aquest producte es basa en l'avaluaci i
aprovaci del disseny original i els components especfics. El fabricant no es fa responsable de les qestions de seguretat si s'utilitzen peces de recanvi no autoritzades. 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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Safety information ix

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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. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions. 2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs). 3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems. 4. Repair information provides instructions for making printer adjustments and removing and installing FRUs. 5. Connector locations uses illustrations to identify the connector locations and test points on the printer. 6. Preventive maintenance contains the lubrication specifications and recommendations to prevent problems. 7. Parts catalog contains illustrations and part numbers for individual FRUs.

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.

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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. 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 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. 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

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Scanner specifications
Scanner Type Scan Modes Flatbed, CCD True Color: 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/Line Art: 1 Bit Per Pixel Scan Method Scan Area Scan Resolution One Pass Scanning 8.5 X 11.7 inches 216 X 292 mm Flatbed Scanning: -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) Resolution/Quality (Applicable when operating via standalone mode) Selectable via Contorl Panel -Quick300 x 300 ppi Scan 600 x 300 dpi Print -Normal300 x 600 ppi Scan 600 x 600 dpi Print -Better600 x 600 ppi Scan 600 x 600 dpi Print -Best600 x 600 ppi Scan 600 x 600 dpi Print Notes: 1) Photo Mode = Best Mode 2) The number of printhead passes will increase with the quality mode.

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Resolution/Quality (Applicable when operating via Host) Selectable via All-In-One GUI for Color/Gray -Quick75 x 75 ppi Scan 600 x 300 dpi Print -Normal150 x 150 ppi Scan 600 x 600 dpi Print -Better200 x 200 ppi Scan 1200 x 1200 dpi Print -Best300 x 300 ppi Scan 2400 x 1200 dpi Print Selectable via All-In-One GUI for Black Copy -Quick150 x 150 ppi Scan 600 x 300 dpi Print -Normal300 x 300 ppi Scan 600 x 600 dpi Print -Better600 x 600 ppi Scan 1200 x 1200 dpi Print -Best600 x 1200 ppi Scan 2400 x 1200 dpi Print

General information 1-3

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Control panel

Press: Number of Copies Lighter/Darker Reduce/Enlarge Left arrow < Right arrow> Options Select Quality Color Copy

To: Select the number of copies. Lighten or darken a copy. Make the document smaller or larger. Scroll through menu sub-categories. Scroll through the list of menu headings. Choose the displayed selection. Choose normal, better, best, or quick copy setting. Make a color copy.

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Press: Black Copy Scan Stop/Clear Power To: Make a black and white copy. Scan after selecting a Scan To destination. Cancel a scan, print, or copy job, or return to a menu category from a menu sub-category. Turn the printer on or off.

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

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Abbreviations
B/M CCD EOF ESD FPC FRU HVPS LCD LVPS OEM V ac V dc ZIF Bill of Material Charge Coupled Device End of Form Electrostatic Discharge Flat Printhead Cable Field Replaceable Unit High Voltage Power Supply Liquid Crystal Display Low Voltage Power Supply Original Equipment Manufacturer Volts alternating current Volts direct current Zero Insertion Force

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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.

Normal

PY

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

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POST symptom table

Symptom 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 Action 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.

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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 Carrier Transport service check on page 2-6.

Maintenance station problems

Symptom Maintenance station: Fails to cap the printheads Fails to clean the printheads Action Go to the Maintenance Station service check on page 2-9.

Control panel problems

Symptom Buttons do not work LCD does not display Action 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 Not able to print Test Page Action 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 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 Action 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 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 Paper skews Action Go to the Paper Feed service check on page 2-10.

Go to the Paper Feed service check on page 2-10. Go to the Paper Path service check on page 2-12.

Power problems
Symptom No power in machine, motors do not operate Action Go to the Power service check on page 2-13.

Print quality problems

Symptom 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 Action 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

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Service checks
Carrier Transport service check
FRU 1 System Board Carrier Transport Motor Action 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:

Carrier Transport Motor

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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FRU 4 Encoder Strip Carrier Assembly 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. 5 Carrier Transport Belt Idler Pulley Parts Carrier Frame 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. 6 Printhead Carrier Assembly 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. 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. Action Check the encoder strip for proper installation. Also, check it for wear, dirt, and grease.

Maintenance Station

Diagnostic information 2-7

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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 1 CCD Module Assembly

Action 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. To unlock scanner, press the red lever down. Note: Unlock scanner before use.

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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 1 Maintenance Station Assembly

Action 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

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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 1 System Board

Action 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 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.

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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 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. 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. 3 4 Auto Sheet Feeder Assembly Mid Frame Assembly Check the pick roller for wear. Check the following for wear: Small Feed rollers Large 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. 5 End-of-Forms Flag and Spring Check for binds or damage.

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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 1 2 3 4 Large and Small Feed Rollers Small Feed Roller Springs Auto Sheet Feeder Assembly Mid Frame Asm Action Check for wear and binds. Check for damage. Check the pick roller for wear. Check the following for wear: Exit roller Star rollers 5 End-of-Forms Flag 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.

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Power service check

FRU 1 External Power Supply Printhead Cable Paper Feed Motor Carrier Transport Motor Control Panel System Board Action 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. If the symptom has not changed, replace the system board. Go to the System board removal on page 4-15.

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Print Quality service check

FRU / Function 1 2 Printhead Cartridge Color Printhead Cartridge Cross Contamination Action 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. 3 Printhead Carrier Assembly Reseat the printhead cables in the system board and check the following parts for wear or damage: Printhead Cartridge Latch Latch Spring Carrier 4 System Board Printhead Carrier Assembly 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. If the symptom remains, replace the system board. Go to the System board removal on page 4-15. 5 Maintenance Station 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.

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4408-XXX
FRU / Function 6 Paper Feed Action 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 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. Blank copies. Action 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. If blank copies found, make sure that the original 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.

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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 cartridge nozzle purge patterns followed by a black and color nozzle test pattern. The purge pattern is used to clear all printhead 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

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3-2 Service Manual

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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.

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 name 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 remove such parts, press the hook end of the latch away from the part to which it is latched.

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Print engine cover removal

1. 2. 3. 4. Remove scanner lid. Remove scanner assembly. Remove print engine. Remove four screws (A).

Repair information 4-3

4408-XXX 5. Depress six latches (B).

B
6. Remove print engine cover.

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).

A
5. Remove four screws (B) from ASF.

B
6. Remove ASF.

Base assembly removal

1. 2. 3. 4. Remove scanner lid. Remove scanner assembly. Remove print engine. Remove print engine cover from base assembly.

Repair information 4-5

4408-XXX

Carrier removal
1. 2. 3. 4. 5. 6. Remove scanner lid. Remove scanner assembly. Remove midframe. Remove print engine. Disconnect carrier cables from system board. Loosen carrier belt tensioner screw (A).

4-6 Service Manual

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.

10. Remove shaft. 11. Lift and remove carrier. Note: Position of encoder strip.

Fax card removal

1. 2. 3. 4. Remove scanner lid. Remove scanner assembly. Remove print engine. Remove exit tray.

Repair information 4-7

4408-XXX 5. Remove fax card cover (A).

A
6. Remove three fax card screws (B).

B
7. Remove fax card. Note: Routing of all cables.

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Maintenance station removal

1. 2. 3. 4. Remove scanner lid. Remove scanner assembly. Remove print engine. Use a screwdriver to unlatch maintenance station (A).

Repair information 4-9

4408-XXX 5. Slide maintenance station forward and remove.

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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. 2. 3. 4. 5. Remove scanner lid. Remove scanner assembly. Remove midframe. Move the carrier to the center of the printer. 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.

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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.

Repair information 4-13

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.

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4408-XXX

System board removal

1. 2. 3. 4. 5. 6. Remove scanner lid. Remove scanner assembly. Remove print engine. Remove ASF. Disconnect all cables from system board. Remove three screws (A) from system board.

A
7. Remove system board.

Repair information 4-15

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5. Connector locations
J4

1 JP3 JP5 1 1 JP4 1

J3

JP9 J6 1 J2 1 J1 1 JP15 1 JP16 1 JP6 1 PS2

JP2
Units J1 J2 J3 J4 JP1 Description ADF Entry Sensor ADF Exit Sensor USB and Phone Jacks Control Panel Carrier

PS1
1 JP7

JP1

Connector locations 5-1

4408-XXX
JP2 JP3 JP4 JP5 JP6 JP7 JP9 JP15 JP16 PS2 S1 Carrier Jumper Power Supply Terminal Paper Feed Motor Media Sensor Transport Carrier Motor CCD Module ADF Paper Feed Motor CCD Module Scanner Motor Scanner Housing Sensor EOF

J5 JP2 J3 J1

J4 1

Units J1 J4 JP2

Description USB and Phone Jacks Fax Speaker USB

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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 99A0394 to lubricate 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

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6-2 Service Manual

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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

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Assembly 1: Covers
1

3 4

7-2 Service Manual

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Assembly 1: Covers
AsmIndex 1-1 2 3 4 5 NS NS Part Number 56P1778 56P1784 56P1783 56P1786 56P1781 7371533 7371538 Units 1 1 1 1 1 1 1 Description Paper support Midframe cover Engine cover Fax cover Base assembly Plain package B/M includes: carton, cushion set, and sealing tape (001) Plain package B/M includes: carton, cushion set, and sealing tape (002)

Parts catalog 7-3

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Assembly 1 (cont.): Covers

2 3 5

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Assembly 1: (cont.) Covers

AsmIndex 1-1 2 3 4 5 6 NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS Part Number 56P1780 56P1779 56P1776 15K0153 56P1785 56P1775 56P1777 56P1789 56P1790 15K0154 15K0155 15K0156 15K0157 15K0158 15K0159 15K0160 15K0161 15K0162 15K0163 15K0164 15K0167 Units 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Description Scanner lid assembly (002) Scanner lid assembly (001) Control panel scanner assembly (001) Cover, control panel, English Scanner support ADF Module Control panel scanner assembly (002) Control panel scanner assebmly (AK1) Control panel scanner assembly (AK2) Cover, control panel, French Cover, control panel, Germany Cover, control panel, Spain Cover, control panel, Italy Cover, control panel, Dutch Cover, control panel, Portuguese (Brazil) Cover, control panel, Polish Cover, control panel, Japanese Cover, control panel, Simple Chinese Cover, control panel, Traditional Chinese Cover, control panel, Russian Cover, control panel, Greek

Parts catalog 7-5

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Assembly 2: Paper feed, frame, and carrier transport

1

4 2

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Assembly 2: Paper feed, frame, and carrier transport

AsmIndex 2-1 2 3 4 Part Number 56P1774 56P1770 56P1773 56P1788 Units 1 1 1 1 Description ASF module Printing engine Carrier w/cable assembly Maintenance station assembly

Parts catalog 7-7

4408-XXX

Assembly 3: Electronics

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Assembly 3: Electronics
AsmIndex 3-1 2 3 NS NS NS Part Number 13D0400 56P1771 56P1787 56P1772 13D0401 13D0402 Units 1 1 1 1 1 1 Description Power supply (LV) 120 V Board, system (001) Fax card Board, system (002) Power supply (HV) 220 V Power supply Japan 100 V

Parts catalog 7-9

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Index
A
abbreviations 1-6 adjustments 2-15, 4-2 paper jam 2-5 parts catalog carrier transport 7-6 covers 7-2 electronics 7-8 frame 7-6 paper feed 7-6 plastic latches 4-2 POST sequence 2-1 POST symptom tables 2-2 power consumption 1-1 preventive maintenance 6-1 print quality 2-5 printer communication table 2-4 problems carrier transport 2-3 control panel 2-3 maintenance station 2-3 paper feed 2-5 power 2-5 print quality 2-5 scanner 2-4

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

C
carrier 2-6, 2-7 carrier transport 2-15 carrier transport motor cable 2-6 cartridge 1-1 CCD module assembly 2-8 connector locations 5-1 control panel 1-4

R
removals ASF 4-4 base assembly 4-5 carrier 4-6 fax card 4-7 maintenance station 4-9 midframe 4-11 print engine 4-12 print engine cover 4-3 scanner and ADF assembly 4-12 scanner lid assembly 4-12 system board 4-15

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

S
safety information v scanner assembly 2-16 scanner specifications 1-2 service checks 2-6 carrier transport 2-6

P
paper feed motor 2-11

Index X-1

4408-00X
CCD module assembly 2-8 maintenance station 2-9 paper feed 2-10 paper path 2-12 power 2-13 print quality 2-14 scan/copy quality 2-16 system board 2-6 start 2-1 symptom tables 2-3 56P1785 56P1786 56P1787 56P1788 56P1789 56P1790 7371533 7371538 7-5 7-3 7-9 7-7 7-5 7-5 7-3 7-3

T
table of contents 1-iii test page 3-1

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

X-2 Service Manual