000 Color Jetprinter™ 1100 Color Jetprinter 4096-00X • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
4096-00X First Edition (May, 1998) 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.
4096-00X Table of Contents Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
096-00X Small Feed Roll Assembly Removal . . . . . . . . . . . . . . . . . . . . . . .4-6 System Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 System Board Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication Specifications . . . . . . . . . . . . . . . .
4096-00X Notices and Safety Information 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.
4096-00X Norme di sicurezza • Il prodotto è stato progettato, testato e approvato in conformità a • • severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
4096-00X Pautas de Seguridad • Este producto se ha diseñado, verificado y aprobado para • • cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento.
4096-00X Informació de Seguretat • Aquest producte està dissenyat, comprovat i aprovat per tal • • d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.
4096-00X Notices and Safety Information ix
4096-00X x Service Manual
4096-00X 1. General Information The Lexmark 1000 Color JetprinterTM and 1100 Color Jetprinter are personal, near laser-quality inkjet printers. The print cartridge is a single-unit customer replaceable supply item. A single printhead provides three colors and composite black printing. The printer also supports a black print cartridge and provides 600 X 600 dpi edge definition for professional quality text image and graphics printing.
4096-00X Abbreviations EOF ESD FRU HVPS LVPS NVRAM OEM POST V ac V dc ZIF End-of-Form Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Power-On Self Test Volts alternating current Volts direct current Zero Insertion Force 1-2 Service Manual
4096-00X 2. Diagnostic Information Start Power-On Self Test (POST) Sequence When you turn the printer on it performs a POST. Turn your machine on and check for a correct POST operation by observing the following: 1. The carrier moves. 2. The paper feed gears turn. 3. After 30 seconds the carrier moves over the maintenance station and caps the printhead. 4. All motors stop. If your machine does not complete POST, use the symptom tables and service checks in chapter 2 to determine the failing part.
4096-00X Symptom Tables Carrier Transport Problems Symptom Action • • • • Go to the “Carrier Transport Service Check” on page 2-5. No carrier movement Slow carrier movement Carrier stops Carrier slams side frame Maintenance Station Problems Symptom Action Maintenance station: Go to the “Maintenance Station Service Check” on page 2-7. • Fails to cap the printhead • Fails to clean the printhead Paper Feed Button Problems Symptom Action Paper feed button does not operate.
4096-00X 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 Go to the “Paper Feed Service Check” on page 2-8. Envelopes fail to feed Go to the “Envelope Feed Service Check” on page 2-6. Paper skews Go to the “Paper Feed Service Check” on page 2-8. Power Problems Symptom Action • No power in machine • No motors operating Go to the “Power Service Check” on page 2-11.
4096-00X POST Symptom Table Symptom Action No power and the motors do not run Go to the “Power Service Check” on page 2-11. Paper feed gears do not turn Go to the “Paper Feed Service Check” on page 2-8. Carrier doesn’t move Go to the “Carrier Transport Service Check” on page 2-5. Carrier slams side frame Go to the “Carrier Transport Service Check” on page 2-5.
4096-00X Service Checks Carrier Transport Service Check 1 FRU Action System Board Check the motor for binds, or loose motor pulley. Turn the printer off and disconnect N6 from the system board. Check for motor pins shorted to the motor housing. If you find a pin shorted to the housing, replace the motor. If the failure remains, replace the system board. 2 Carrier Transport Motor A noisy or chattering motor or a motor that fails to turn can be caused by: • An open or short in the motor.
4096-00X FRU Action 5 Home Position Sensor Be sure the carrier returns to the home position after turning the printer on. If the carrier moves half way, or if there is an abnormal sound, turn the printer off and disconnect N3 from the system board. Turn the printer on and check for 5 V dc between N3-4 and N3-2 on the system board. If the voltage is present, replace the home position sensor. If the voltage is not present, replace the system board.
4096-00X Maintenance Station Service Check The maintenance station has two functions: • Cleans the printhead nozzles during the print operation. • Seals the printhead when it is not being used to prevent the nozzles from drying. 1 FRU Action Maintenance Station Assembly As the carrier moves to the right over the maintenance station, a slot on the bottom of the carrier engages a tab on the sled of the maintenance station causing the cap to rise and seal the printhead.
4096-00X 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.
4096-00X FRU Action 3 Drive Train Assembly Check for binds in the gear train and paper feed mechanism by removing the paper feed motor and rotating the large gear by hand. If you notice a bind, replace the drive train assembly. Check the feed clutch gear on the left side of the auto sheet feeder. Turn the clutch gear and check that it rotates freely in one direction and locks when turned in the opposite direction. 4 Auto Sheet Feeder Check the pick rollers for wear.
4096-00X 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 Check for wear and binds. 2 Small Feed Roller Springs Check for damage. 3 Auto Sheet Feeder Check the pick rollers for wear.
4096-00X Power Service Check 1 FRU Action Power Supply Disconnect N1 from the system board and check the following voltages on the power supply cable: • N1-1 to GND = +5 V dc • N1-3 to GND = +24 V dc If you do not have correct voltage, replace the power supply. Be sure to unplug the machine before you reconnect the power supply to the system board. 2 Printhead Cable Carrier Home Sensor Parallel Cable Turn off the printer. Disconnect one of the printhead cables and turn on the printer.
4096-00X Print Quality Service Check FRU / Function Action 1 Print Cartridge Be sure the machine contains a good print cartridge. 2 Color Print Cartridge Cross Contamination Cross contamination of color inks results in incorrect colors printed, as when green prints for yellow, (when yellow and blue are mixed in the print cartridge). This problem resolves quickly as the print cartridge is used. If cross contamination occurs, check: • The maintenance station wiper for damage.
4096-00X 4 FRU / Function Action System Board Execute the “Clean Print Nozzle” in “Cartridges” of the Printer Control Program. 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, ensure the printhead cables are connected properly. If the symptom remains, replace the system board.
4096-00X 7 FRU / Function Action 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. • Carrier to carrier frame engagement should be lubricated with grease P/N 1329301, as well as the carrier guide rod and bearing. • Idler pulley parts for wear, damage, or looseness.
4096-00X 3. Diagnostic Aids There are no residence diagnostic aids associated with the 4096 printers.
4096-00X 3-2 Service Manual
4096-00X 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).
4096-00X Adjustments The user is directed, in the Printer Control program, to perform the bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. Unplug the power cord before removing any parts. Releasing Plastic Latches Many of the parts are held in place with plastic latches. The latches break easily; release them carefully.
4096-00X Carrier Belt Removal 1. 2. 3. 4. 5. 6. Remove the front cover. Remove the retainer spring from the right side of the carrier rod. Slide the carrier rod to the right, out of the machine. Remove the carrier belt from the rear of the carrier. Remove the carrier belt from the carrier transport motor pulley. Remove the carrier belt. Carrier Frame Assembly Removal 1. Remove the front cover. 2. Remove the five screws that secure the carrier frame to the base assembly and power supply ground strap. 3.
4096-00X Drive Train Assembly Removal 1. 2. 3. 4. 5. 6. 7. Remove the front cover. Remove the carrier frame. Remove the base assembly. Remove the maintenance station assembly. Remove the printhead carrier assembly. Remove the large feed roll and mid-frame assembly. Disconnect the paper feed motor connector from the system board. 8. Remove the two screws securing the drive train to the carrier frame. 9. Push the drive train to the right and remove it from the carrier frame.
4096-00X Front Cover Removal 1. Release the two hooks [A] in the illustration by using a screwdriver. 2. While pushing the left side edge of the front cover upward, release the hook [B]. Repeat this on the right side. 3. Slide the front cover forward and remove it from the rear cover. Large Feed Roll Removal 1. 2. 3. 4. 5. Remove the front cover. Remove the carrier frame from the base assembly. Move the printhead carrier assembly to the left. Remove the maintenance station assembly.
4096-00X Mid-Frame Assembly Removal 1. 2. 3. 4. 5. Remove the front cover. Remove the carrier frame from the base assembly. Move the printhead carrier assembly to the left. Remove the maintenance station assembly. Turn and remove the retainers at both ends of the large feed roller. 6. Remove the mid-frame assembly. Power Supply Removal 1. 2. 3. 4. Remove the front cover. Remove the carrier frame from the base assembly. Disconnect the power supply connector from the system board.
4096-00X System Board Removal 1. Remove the front cover. 2. Remove the carrier frame from the base assembly. 3. Disconnect all cables from the system board. Remove the four screws securing the system board to the carrier frame and remove the system board, taking care not to damage the end-of-form flag. Note the routing of all cables.
4096-00X 4-8 Service Manual
4096-00X 5.
4096-00X 5-2 Service Manual
4096-00X 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.
96-00X 6-2 Service Manual
4096-00X 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of • • identical parts, they are broken down on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration.
4096-00X Assembly 1: Covers 7-2 Service Manual
4096-00X AsmIndex Part Number Units 1 -1 11B5128 1 Cover, Access Asm, Star Wheels (002) -1 11B5129 1 Cover, Access Asm, Star Wheels (001) -1 17Z0177 1 Cover, Access Asm, Star Wheels (003) -1 17Z0176 1 Cover, Access Asm, Star Wheels (004) -2 11B5127 1 Cover, Front Asm & Button (001, 002) -2 17Z0174 1 Cover, Front Asm & Button (003) -2 17Z0175 1 Cover, Front Asm & Button (004) -3 11B5125 1 Base Asm and Sheet Feed (001, 002) -3 17Z0170 1 Base Asm and Sheet Feed (003) -3
4096-00X Assembly 2: Paper Feed / Carrier Transport / Maintenance 7-4 Service Manual
4096-00X AsmIndex Part Number Units 2 -1 11B5130 1 Frame, Carrier -2 11B5142 1 Motor, Carrier Transport Assembly -3 11B5144 1 Screw, (PP) -4 11B5136 1 End-of-Form Flag and Spring -5 11B5144 1 Spring, Small Feed Roll Asm, (PP) -6 11B5135 1 Feed Roll Assembly, Small -7 11B5137 1 Drive Train Assembly with Paper Feed Motor -8 11B5144 1 Arm, Tensioner (PP) -9 11B5144 1 Belt, Carrier (PP) -10 11B5134 1 Feed Roll Assembly, Large with Gear -11 11B5133 1 Frame, Mid Assem
4096-00X Assembly 3: Electronics 7-6 Service Manual
4096-00X AsmIndex Part Number Units 3 -1 11B5130 1 Frame, Carrier -2 11B5138 1 System Board with ROM (LV) (001, 002) -2 11B6044 1 System Board with ROM (HV) (001, 002) -2 17Z0180 1 System Board with ROM (LV & HV) (003, 004) -3 11B5139 1 Power Supply: 110V -3 11B5140 1 Power Supply: 220V -4 11B5125 1 Base Asm and Sheet Feed (001, 002) -5 11B5141 11B5624 11B5622 11B5624 11B5624 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5622 11B5623 11B5622 11B5141 11B56
4096-00X Assembly 4: Carrier 7-8 Service Manual
4096-00X AsmIndex Part Number Units 4 -1 11B5131 1 Carrier Assembly, with Carrier Home Sensor -2 11B5132 1 Rod, Carrier Guide -3 11B5130 1 Frame, Carrier -4 11B5144 1 Spring, Carrier Guide Rod (PP) Description Parts Catalog 7-9
4096-00X Assembly 5: Sheet Feeder 7-10 Service Manual
4096-00X AsmIndex Part Number Units 5 -1 11B5130 1 Frame, Carrier -2 11B5125 1 Base, Sheet Feeder Asm and Garage Assembly (001, 002) -2 17Z0170 1 Base, Sheet Feeder Asm and Garage Assembly (003) -2 17Z0171 1 Base, Sheet Feeder Asm and Garage Assembly (004) -3 11B5126 1 Support, Upper Paper (001, 002) -3 17Z0172 1 Support, Upper Paper (003) -3 17Z0173 1 Support, Upper Paper (004) -4 17Z0178 1 Tray, Exit (003) -4 17Z0179 1 Tray, Exit (004 Description Parts Catalog 7-11
4096-00X 7-12 Service Manual
4096-00X Index A Access Cover 4-2 Base Assembly 4-2 Carrier Belt Asm 4-3 Carrier Frame Asm 4-3 Carrier Transport Motor 4-3 Drive Train Assembly 4-4 End-of-Form Flag 4-4 Front Cover 4-5 Large Feed Roll 4-5 Maintenance Station 4-5 Mid-Frame Assembly 4-6 Power Supply 4-6 Printhead Carrier Asm 4-6 Sheet Feed Asm 4-2 Small Feed Roll Asm 4-6 System Board 4-7 Abbreviations 1-2 Adjustments 4-2 Assemblies 2 Carrier Transport 7-4 2 Maintenance Station 7-4 2 Paper Feed 7-4 3 Electronics 7-6 4 Carrier 7-8 5 Sheet Fe
4096-00X I-2 Service Manual
Lexmark 1000 / 1100 Color Jetprinter (4096-00X) Service Manual U.S. - P/N 17Z0168, Japan - 17Z0169 May, 1998 Reader Comment Form You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you. 1. Did you find the book well organized? No Yes 2. Was the content of the book accurate and complete? No Yes 3.
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