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Lexmark 7100 Series Service Manual

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See also: User Manual , Installation Manual
Edition: October 25, 2006
Lexmark™ 7100 Series AIO
4409-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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Summary of Contents for Lexmark 7100 Series

  • Page 1 Edition: October 25, 2006 Lexmark™ 7100 Series AIO 4409-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.
  • Page 2 You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    4409-XXX Table of contents Safety information........v Preface .
  • Page 4 4408-XXX Exit tray removal ........4-5 Print engine cover with left and right covers .

  • Page 5: Safety Information

    4409-XXX Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 6 4409-XXX Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
  • Page 7 4409-XXX Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
  • Page 8 4409-XXX Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 9 4409-XXX Safety information...

  • Page 10: Preface

    4409-XXX Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

  • Page 11: General Information

    4409-XXX 1. General information The Lexmark™ 7100 Series (4409-XXX) All-In-One features 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.

  • Page 12: Power Consumption

    4409-XXX Power consumption Mode Description Power consumption Printing All-in-One is generating hard 18.76 Watts copy output Copying All-in-One is generating hard 18.53 Watts copy output from hard copy originals Scanning All-in-One is scanning hard 15.63 Watts copy documents Ready All-in-One is turned on and 11.79 Watts not printing, scanning, faxing or using Pictbridge, and is...

  • Page 13: Scanner Specifications

    4409-XXX Scanner specifications Scanner Type Flatbed, CCD Scan Modes True Color: 48 Bit Internal (68.7 billion colors) 24 Bit External (16.7 million colors) Gray Mode: 16 Bit Internal (4,096 shades of gray) 8 Bit External (256 shades of gray) Text/Line Art: 1 Bit Per Pixel Scan Method One Pass Scanning...

  • Page 14: Control Panel

    4409-XXX Control panel The control panel is designed to allow the user to access functions in an intuitive and swift manner. The panel is set up to function in one of three different modes: Scan, Copy, or Fax. The display offers different options depending upon which mode the machine is in.
  • Page 15 4409-XXX Buttons Functions Left arrow < The standard operation of the left arrow button is to Right arrow> decrement any displayed count or decrement through a list on the LCD. The standard operation of the right arrow button is to increment any displayed count or increment through a list on the LCD.
  • Page 16 4409-XXX Buttons Functions Mode This button has three mode LEDs: copy, fax and scan. Repeated pressing of this button cycles the LEDs and the machine through copy/fax/scan modes: Copy Mode: Enables the user to make mono or color copies. Upon entering this mode, the LCD shall display the current number of copies, the copy quality, and the reduce/enlarge percentage.
  • Page 17 4409-XXX Buttons Functions Speed Dials This button gives access to additional speed dial (5—99) numbers. Speed dials #5—#79 are single entry and speed dials #80—#99 are group entries. Single entries contain only one phone number. Group entries contain up to five different phone numbers. The speed dial names and numbers can be programmed by using either the control panel or the host software.

  • Page 18: Maintenance Approach

    4409-XXX Buttons Functions Auto Answer Toggles the state of the auto answer function and the auto answer LED. If an incoming call is present and: • Auto answer LED is off: The machine will display the manual mode answering message “Incoming Call Press 9 to answer”...

  • Page 19: Abbreviations

    4409-XXX Abbreviations Bill of Material Charge Coupled Device End of Form Electrostatic Discharge Flat Printhead Cable Field Replaceable Unit HVPS High Voltage Power Supply Liquid Crystal Display LVPS Low Voltage Power Supply Original Equipment Manufacturer V ac Volts alternating current V dc Volts direct current Zero Insertion Force...
  • Page 20 4409-XXX 1-10 Service Manual...

  • Page 21: Diagnostic Information

    4409-XXX 2. Diagnostic information Start Use the post symptom table, symptom tables, and service checks in this chapter to determine the printer failure. Power-On Self Test (POST) sequence Press the Power button to turn machine on. • The Copy, Scan, and Fax indicator lights turn on. •...

  • Page 22: Post Symptom Table

    4409-XXX POST symptom table Symptom Action No Power, Copy, Go to the “Power service check” on page 2-14. If okay, Fax, or Scan go to the “Control panel problems” on page 2-3. lights, and no motors run. Paper feed Go to the “Paper feed service check”...

  • Page 23: Test Page

    4409-XXX Maintenance station problems Symptom Action Maintenance station: Go to the “Maintenance station service check” on page 2-10. • Fails to cap the printheads • Fails to clean the printheads Control panel problems Symptom Action • Buttons do not work Check control panel cable •...

  • Page 24: Scanner Problems

    4409-XXX Scanner problems Symptom Action • CCD does not move Go to the “CCD module assembly • Lamp does not light service check” on page 2-8. • Scanned images are faded, or Go to the “Scan/copy quality service check” on page 2-16.
  • Page 25 4409-XXX Symptom Action Envelopes fail to feed Go to the “Paper feed service check” on page 2-11. Paper skews Go to the “Paper path service check” on page 2-13. Power problems Symptom Action “Power service check” No power in machine; motors do Go to the not operate on page...

  • Page 26: Service Checks

    4409-XXX Service checks Carrier transport service check Action System Board Check the transport carrier motor connector J5. If connected, check for approximately 30 volts on Carrier Transport pins 1 and 2 or at the wire connections located on Motor the rear of the transport carrier motor. If voltage is incorrect, replace the system board.
  • Page 27 4409-XXX Action Encoder Strip Check the encoder strip for proper installation. Also, check it for wear, dirt, and grease. 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.

  • Page 28: Ccd Module Assembly Service Check

    4409-XXX CCD module assembly service check The CCD (charge-coupled device) Module does not move during POST Test. The CCD lamp does not come on when CCD module assembly moves. Action CCD Module Assembly If CCD module does not move check that the belt is still on the CCD module and that it does not bind.

  • Page 29: Pictbridge Service Check

    4409-XXX Pictbridge service check Action Pictbridge Card To check Pictbridge port, use a standard USB cable to connect the Pictbridge port (USB type “A”) on the front of the machine into the USB device port (USB type “B”) on the back of the machine (the USB device port is the port that is normally connected to a host PC).

  • Page 30: Maintenance Station Service Check

    4409-XXX Maintenance station service check The maintenance station has three functions: 1. Wipes the printhead nozzles to clean them of dirt. 2. Provides a place for printheads to fire all nozzles, keeping them clear prior to printing. 3. Seals the printhead when it is not being used to prevent the nozzles from drying.

  • Page 31: Paper Feed Service Check

    4409-XXX Paper feed service check If your machine does not have paper jam problems, continue with the service check. If your machine does have a paper jam problem, examine it for the following before you begin the service check: • Check the entire paper path for obstructions.
  • Page 32 4409-XXX Action Paper Feed Motor 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 •...

  • Page 33: Paper Path Service Check

    4409-XXX Action End-of-Forms Check for binds or damage. Flag and Spring 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. •...

  • Page 34: Power Service Check

    4409-XXX Power service check Action External Power Plug the external power supply into an outlet. Supply Check for + 30 V dc. If voltage is incorrect, replace the power supply. Printhead Cable Unplug the printer. Check all connections and plug Paper Feed Motor in the printer.
  • Page 35 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. The alignment can also be performed from the control panel by selecting the Maintenance Option, then Align Cartridges.

  • Page 36: Scan/Copy Quality Service Check

    Check the print cartridges to see if they need to be cleaned or replaced. Check the paper type and copy quality settings on the control panel or Lexmark Solution Center. 2-16 Service Manual...

  • Page 37: Adf Module Service Check

    ADF input tray. Check the print cartridges to see if they need to be cleaned or replaced. Check the paper type and copy quality settings on the control panel or Lexmark Solution Center. 2-17 Diagnostic information...

  • Page 38: Error Codes

    4409-XXX Error codes Catastrophic error In this state, the All-In-One is in an error mode such that operation cannot continue. These errors affect the entire All-In-One. The LCD is on and operating. An error message is displayed on the LCD. The All-In-One accepts data, but discards it and does not respond.
  • Page 39 4409-XXX Code Name Description Action 0002 Hardware General hardware Unplug the All-In-One; Failure failure (unable to wait a few seconds, localize failure to a then plug the specific system) All-In-One back in and turn the power on. If the error remains, clean the NVRAM by pressing the Down button and Menu...

  • Page 40: Non-Catastrophic Error

    4409-XXX Non-catastrophic error In this state, an error has occurred, but the All-In-One can continue to operate. You may need to intervene using a button press, or the machine may time out and return to the Error! Reference source not found state, depending upon the error. The All-In-One will continue to accept and respond to data until its buffers are full.
  • Page 41 4409-XXX Code Name Description Action 1101 Paper Out The All-In-One is out of Load paper and press paper. Select. (LCD should display instructions on how to recover.) 1102 Incorrect Printhead ID is not Replace the print Printhead valid. cartridge(s). 1103 Missing Printhead is missing.
  • Page 42 4409-XXX Code Name Description Action 1204 Printhead Unable to program Replace print Programming pseudo-random cartridge(s). printhead ID. 1205 Mono TSR Problem is detected in Replace print Error mono TSR circuit. cartridge(s). Cannot determine printhead temperature. 1206 Color Problem in color TSR Replace print circuit;...
  • Page 43 4409-XXX Code Name Description Action 2200 Scan Carrier The scan carrier has Unplug the All-In-One; Stall stalled. wait a few seconds, then plug the All-In-One back in and turn the power on. If error remains, check all connections to the scanner.
  • Page 44 4409-XXX 2-24 Service Manual...

  • Page 45: Diagnostic Aids

    4409-XXX 3. Diagnostic aids Test page This test prints the test page. To run a complete test page of black and color patterns, be sure the printhead cartridges are in good condition. To enter the test: 1. Turn the printer on. 2.
  • Page 46 4409-XXX 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. Service Manual...

  • Page 47: Repair Information

    4409-XXX 4. Repair information This chapter explains how to make adjustments and remove defective parts from the printer. 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).

  • Page 48: Adjustments

    4409-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.

  • Page 49: Scanner Assembly Removal

    4409-XXX Scanner assembly removal 1. Lift and remove scanner lid. 2. Remove three screws (A) from the rear cover. 3. Remove rear cover. 4. Disconnect all cables (B) from the system board. 5. Unscrew and disconnect ground cable (C). Repair information...
  • Page 50 4409-XXX 6. Lift scanner assembly and depress two scanner supports (D). 7. Remove two screws (E) and remove two retainers. 8. Lift and remove scanner assembly. Note: Routing of all cables and orientation of scanner support springs. Service Manual...

  • Page 51: Exit Tray Removal

    4409-XXX Exit tray removal 1. Raise scanner assembly. 2. Depress left tab (A) toward the center and remove exit tray. Repair information...

  • Page 52: Print Engine Cover With Left And Right Covers

    4409-XXX Print engine cover with left and right covers 1. Remove scanner assembly. 2. Depress left tab (A) toward the center and remove exit tray. Service Manual...
  • Page 53 4409-XXX 3. Remove ten screws (A). 4. Remove the left side cover. 5. Remove right cover. Repair information...
  • Page 54 4409-XXX 6. Disconnect the Pictbridge cable (B) from the system board. 7. Remove six screws (C) from the scanner supports. Service Manual...
  • Page 55 4409-XXX 8. Remove scanner supports. Note orientation of scanner support springs. 9. Release cover tabs (D). 10.Lift and remove print engine cover. Repair information...

  • Page 56: Carrier Removal

    4409-XXX Carrier removal 1. Remove scanner assembly. 2. Remove print engine cover with left and right covers. 3. Disconnect carrier cables from the system board. 4. Remove carrier shaft retainer clips (A). 4-10 Service Manual...
  • Page 57 4409-XXX 5. Disconnect and remove the encoder strip (B). 6. Remove carrier shaft through the left side. 7. Depress the belt tensioner (C) and remove the belt. 8. Remove carrier. 4-11 Repair information...

  • Page 58: Fax Card Removal

    4409-XXX Fax card removal 1. Remove scanner lid. 2. Remove scanner assembly. 3. Disconnect cable from fax card. 4. Remove four screws (A) and remove fax card. Note: Alignment of J4 connector to system board. 4-12 Service Manual...

  • Page 59: System Board Removal

    4409-XXX System board removal 1. Remove scanner lid. 2. Remove scanner assembly. 3. Remove fax card. 4. Disconnect all cables from system board. 5. Remove five screws (A) from the system board. 6. Remove system board. 4-13 Repair information...

  • Page 60: Print Engine Removal

    4409-XXX Print engine removal 1. Remove eight screws (A) from the print engine. 2. Remove speaker cable from the carrier frame and note routing of cable. 4-14 Service Manual...
  • Page 61 4409-XXX 3. Lift and remove print engine. Note: Orientation of autocompensation shaft (B) into gear. 4-15 Repair information...

  • Page 62: Maintenance Station Removal

    4409-XXX Maintenance station removal 1. Remove scanner assembly. 2. Remove print engine cover with left and right covers. 3. Remove print engine. 4. Depress two clips (A). 5. Slide maintenance station forward and remove. 4-16 Service Manual...

  • Page 63: Rear Access Door Removal

    4409-XXX Rear access door removal 1. Remove rear cover. 2. Disconnect media sensor (J3)(A). 3. Open rear access door. 4. Depress hinges (B) and remove access door. 4-17 Repair information...

  • Page 64: Adf Module Assembly Removal

    4409-XXX ADF module assembly removal 1. Lift scanner lid. 2. Lift ADF. 3. Depress two clips (A) and remove end cover. 4-18 Service Manual...
  • Page 65 4409-XXX 4. Disconnect three cables (B) and ground strap screw (C). 5. Remove screw (D) and retainer. 6. Lift and remove ADF. 4-19 Repair information...

  • Page 66: Pictbridge Card With Cable Removal

    4409-XXX Pictbridge card with cable removal 1. Remove scanner lid and rear cover. 2. Raise the scanner assembly and depress two supports. 3. Rotate scanner assembly to open fully upright. 4. Remove two screws (A) from right cover. 5. Remove right cover. 6.

  • Page 67: Connector Locations

    4409-XXX 5. Connector locations System board Units Description Voltage (Approximate) Ohms Pictbridge Pin 1 – 5 V Control Panel Media Sensor Transport Carrier Pins 1 and 2 – 30 V Between Pins 1 Motor and 2 – 21.5 ohms Paper feed Motor Pins 1 and 2 –...
  • Page 68 4409-XXX Service Manual...

  • Page 69: Fax Card

    4409-XXX Fax card Units Description Speaker PictBridge card Voltage Units Description (approximately) Con2 Pictbridge Pin 1 – 5 Volts Connector locations...
  • Page 70 4409-XXX Service Manual...

  • Page 71: Preventive Maintenance

    4409-XXX 6. Preventive maintenance This chapter contains the lubrication specifications. Follow these recommendations to prevent problems and maintain optimum performance. Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease P/N 99A0394 to lubricate the following: •...
  • Page 72 4409-XXX Service Manual...

  • Page 73: Parts Catalog

    4409-XXX 7. Parts catalog How to use this parts catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 74: Assembly 1: Covers

    4409-XXX Assembly 1: Covers Service Manual...
  • Page 75 4409-XXX Assembly 1: Covers Asm- Part Units Description Index Number 56P3010 Cover, left 56P3009 Engine cover 56P3011 Cover, right 56P3012 Cover, rear 56P3017 Door, rear access with sensor 56P3008 Base, printer 56P3007 Exit tray 7373898 Plain package B/M includes: carton, cushion set, and sealing tape Parts catalog...
  • Page 76 4409-XXX Assembly 1 (cont.): Covers Service Manual...
  • Page 77 4409-XXX Assembly 1: (cont.) Covers Asm- Part Units Description Index Number 56P3006 Scanner lid assembly 56P3004 Control panel scanner assembly (K01)(EK1) 56P3005 Control panel scanner assembly (AK1) 56P3019 Cover, control panel English 56P3020 Cover, control panel French 56P3021 Cover, control panel Germany 56P3022 Cover, control panel Spain 56P3023...

  • Page 78: Assembly 2: Electronics And Carrier Transport

    4409-XXX Assembly 2: Electronics and carrier transport Service Manual...
  • Page 79 4409-XXX Assembly 2: Electronics and carrier transport Asm- Part Units Description Index Number 56P3001 Board, system 56P3013 Fax card (USA) 56P3014 Fax card (EMEA/APG only) 56P3000 Print engine 56P3015 Card, PictBridge 56P3002 Carrier w/cable belt assembly 56P3016 Maintenance station assembly 21H0330 Power supply 32 watt universal 11B6501...
  • Page 80 4409-XXX Service Manual...
  • Page 81 4409-XXX Index abbreviations handling ESD-sensitive parts adjustments 2-15 button lubrication specifications black copy color copy lighter/darker maintenance approach number of copies power quality paper feed motor 2-12 reduce/enlarge paper jam select parts catalog covers plastic latches carrier POST sequence carrier transport 2-15 POST symptom tables carrier transport motor cable...
  • Page 82 4409-XXX service checks 56P3002 ADF module 2-17 56P3003 carrier transport 56P3004 CCD module assembly 56P3005 maintenance station 2-10 56P3006 paper feed 2-11 56P3007 paper path 2-13 56P3008 power 2-14 56P3009 print quality 2-14 56P3010 scan/copy quality 2-16 56P3011 system board 56P3012 start 56P3013...

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