Page 1 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Main Menu 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.
Page 2 Comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road NW, 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.
Page 3: Table Of Contents
4079-00X Contents Notices and Safety Information ......vii Safety Information........vii Preface .
Page 4 4079-00X Print Quality Service Check..... . 2-43 Purge Unit Service Check ..... . . 2-45 RAM (Memory) Service Check .
Page 5 4079-00X Carriage Card, Carriage Card Holder Cover Removal. . 4-12 Carriage Encoder And Paper Width Sensor Removal . . 4-15 Carriage Frame Removal ......4-19 Carriage Ribbon Cables Removal .
Page 6 4079-00X Carriage and Printhead ......7-12 Base ........7-14 Purge Unit .
Page 7: Notices And 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.
Page 8 Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. 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 für dieses Produkt übernommen.
Page 9 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. •...
Page 10 4079-00X Chinese Safety Information Korean Safety Information Service Manual...
Page 11: Preface
4079-00X Preface This service manual is designed to be used by printer repair technicians during servicer training and when repairing a failing printer. The technician should first understand the failing symptom. Then begin at “Start” (page 2-1) in this service manual and follow the steps to diagnose and fix the failure.
Page 12: General Information
4079-00X 1. General Information This chapter introduces and describes the Lexmark™ Color Jetrinter™ 4079 plus, the tools needed to repair it, and the customer switch settings that control the features of the printer. Description The Color Jetprinter is a tabletop four-color inkjet printer for draft or letter quality applications in an attended PC attach environment.
Page 13: Ink Cartridges
4079-00X Ink Cartridges Each ink cartridge contains 30 grams of liquid ink, and is rated for as much as 700 pages of text. Each color cartridge is physically coded to fit in its own color slot. Also, the ink cartridge has an electronic label which is sensed by the cartridge sensor.
Page 14: Printer Emulation
4079-00X • Grease • Cleaning tissue • Magnifier Refer to the parts catalog for part numbers of special tools. When taking voltage readings, always use frame ground unless another ground is specified. When you use the syringe, clip the end of the tip so it will fit over the small tube connectors and into the ink joints.
Page 15: Operator Panel
4079-00X Operator Panel You can access various printing functions and options using the printer’s operator panel. Indicators There are several indicators in the operator panel that show the sta- tus of the machine. Display This 2-line liquid crystal display (LCD) shows the printer’s status, menu items and error messages.
Page 16 4079-00X Buttons Five buttons on the operator panel control the printer. There are two operations for each button, depending on the state of the printer and whether Alt is pressed. 1. Menu and Menu - Press Menu to display the menu system, whether the printer is Ready or Not-Ready.
Page 17: Printhead Capping
4079-00X If the Ready light is off, pressing Start/Stop turns on the Ready light and the printer is ready to receive information. When Alt + Reset is pressed, the printer returns to its power-on sta- tus. 5. Print Buffer and Alt Print Buffer prints the contents of the print buffer, if any.
Page 18: Abbreviations
4079-00X If the head is positioned too close to thick paper, envelopes, or densely inked graphics, the ink could be smeared. In general, keep the head position as close as possible to the paper. Also, be sure that quality coated paper is being used for best print quality.
Page 19: Diagnostic Information
4079-00X 2. Diagnostic Information Start When the covers are removed, you will get a Cover Open error code. To prevent this, tape the cover open interlock arm in the closed posi- tion on the operator panel. All voltages in the service checks are positive unless otherwise noted.
Page 20: Error Code Table
4079-00X 2. If the printer has power but does not complete POST, with Ready on the display, go to the “Operator Panel Service Check” on page 2-31. 3. Run Test Print A. To enter Controller Diagnostics, press and hold Menu and Print Buffer while turning on the printer. After the POST is complete, the first item in the Controller Diagnostics menu is displayed.
Page 21: Logged Error Code
4079-00X Logged Error Code If no error code number is displayed, you can enter Controller Diag- nostics mode and check for Last Error code number. See “Controller Diagnostics” on page 3-9. Code No Of Beeps Or Symptom Action Or Failing Fru 1 Beep - ROM error Logic board.
Page 22 4079-00X Code No Of Beeps Or Symptom Action Or Failing Fru 7 Beeps “Logic Board And Related Cables Service Check” on page 2-29. none No Beeps - Operator panel “Operator Panel Service Check” does not work correctly (but- on page 2-31.
Page 23 4079-00X Code No Of Beeps Or Symptom Action Or Failing Fru 10 Beeps - ROM error Logic board. If you replace the logic board, go to the “Service Adjustment Mode” on page 4-4 and perform the print position adjustment, and the direction off- set adjustment.
Page 24 4079-00X Code No Of Beeps Or Symptom Action Or Failing Fru 10 Beeps - Magenta head “Head Temp/Heat Pulse Service temperature detection error Check” on page 2-20. 10 Beeps - Cyan head tem- “Head Temp/Heat Pulse Service perature detection error Check”...
Page 25 4079-00X Code No Of Beeps Or Symptom Action Or Failing Fru 10 Beeps - Magenta head “Ink Sensor Service Check” on ink sensor error page 2-26. 10 Beeps - Cyan head ink “Ink Sensor Service Check” on sensor error page 2-26.
Page 26: Operator Codes And Symptom Table
4079-00X Code No Of Beeps Or Symptom Action Or Failing Fru Incorrect checksum Controller board EPROM (J6), (EPROM) RAM (J5 or J8) 8 Beeps - communications “Undetermined Problem Service error Check” on page 2-47. Operator Codes And Symptom Table The following code numbers are operator instructions and mes- sages.
Page 27 4079-00X Code Beeps - Symptom Action Or Fru Paper loaded is incorrect Change paper size loaded. size; correct size indicated on second line of display. Paper tray empty or paper Load paper tray. If error persists, did not feed; POST com- go to “Check Paper Service pletes, tries to feed paper...
Page 28 4079-00X Code Beeps - Symptom Action Or Fru Serial error (framing or par- Press Start/Stop to continue. ity) detected; possibly the Once the serial error has been serial link is set up incor- displayed, serial error reporting is rectly. suppressed until interface param- eters are changed or printer is powered off.
Page 29 4079-00X Code Beeps - Symptom Action Or Fru none Blurring or smudging of print Printhead position lever too low. Wrong type of media. Wrong print mode selected see “Printing Mode” on page 3-4. none Smeared print, poor quality Printhead position lever in wrong position see “Adjusting The Print- head Position Lever”...
Page 30: Service Checks
4079-00X Service Checks Carriage Drive Service Check Conditions That Could Cause This Symptom Explanation Symptom You have an error code or • Carriage motor a failing carriage drive • Logic board motor. Action • Carriage Check the carriage drive motor winding resistance. Drive Motor Connector pins 5 and 6 are one phase;...
Page 31: Carriage Motor Drive Data Service Check
• Linear encoder/paper width sensor • Carriage board • Logic board Be sure the printer is not installed in an unusually hot or cold envi- ronment. See the Lexmark Color Jetprinter 4079 Plus User’s Refer- ence for installation standards. Action Belt and Idler Proper belt tension is required for good escapement.
Page 32: Carriage Position Service Check
4079-00X Carriage Position Service Check Conditions That Could Cause This Symptom Explanation Symptom You have an error code • Carriage lock indicating a carriage motor • Carriage drive path obstructed or carriage linear encoder/ • Carriage belt or idler paper width sensor error. •...
Page 33: Check Paper Service Check
4079-00X Action Logic Board If the characters are printed in their correct position and you still receive an error code, replace the logic board. If you replace the logic board, go to the “Ser- vice Adjustment Mode” on page 4-4 and perform the print position adjustment, and the direction offset adjustment.
Page 34 4079-00X Action Paper Out Check the paper sensor signal at CNPE pin 1 on the Photo Sensor right connector card, with the card plugged in. Paper Out Photo Sensor Cable You can manually feed paper to check this signal. Push the paper lift spring clutch plate (Asm.20-10) to the right, and turn the rear ejector roller (Asm.
Page 35: Cover Open Service Check
4079-00X Cover Open Service Check Conditions That Could Cause This Symptom Explanation Symptom The Cover Open mes- • Inner cover not closed correctly sage is displayed with the • Operator panel inner cover closed. • Logic board Action Inner Cover The inner cover actuates the operator panel cover interlock lever.
Page 36: Hard Disk Service Check
4079-00X Hard Disk Service Check Action Hard Disk Inter- Be sure the hard disk interface card is correctly face Card installed and not damaged. Hard Disk Enter the Controller Diagnostic Menu Select Disk Menu and run the Quick Disk Test. If you get a failure, replace the hard disk.
Page 37 4079-00X Action Purge Assem- Be sure all the ink lines are connected. With the purge assembly removed and laying on its • Left Connec- side, check the voltage on the contact straps. The tor Cable voltage should be +5 V dc with the contacts open. •...
Page 38: Head Heater Service Check
4079-00X Head Heater Service Check Conditions That Could Cause This Symptom Explanation Symptom You have a head heater • Carriage board error code. • Logic board • Printhead • Carriage cables Action Printhead Use the codes in the“Error Code Table” on page 2-2 to identify the printhead you think may be failing.
Page 39 4079-00X Action • Printhead Use the codes in the“Error Code Table” on page 2-2 • Carriage to identify the printhead you think may be failing. Be Board sure the printhead is seated properly and the head cover is fully closed. Check the voltage to the printhead as read by the analog switch IC2 on the carriage board.Check the resistance and voltage between each pin and frame...
Page 40: Host Print Service Check
4079-00X If the problem is not corrected, replace the logic board. Be sure to go to the “Service Adjustment Mode” on page 4-4 and perform the print position adjustment, and the direction offset adjustment. Host Print Service Check Conditions That Could Cause This Symptom Explanation Symptom The printer does not com-...
Page 41 4079-00X Keep the assembly on a level plane while servicing with the black cartridge end slightly elevated. Cover any open ink lines with absor- bent cloth, secured with a rubber band, when possible. Action Ink Cartridge The error code should indicate which cartridge is suspected.
Page 42: Ink Flow Service Check
4079-00X Ink Flow Service Check Conditions That Could Cause This Symptom Explanation Symptom You have no ink flow, with • Ink Cartridge Supply Lines no error code displayed. • Carriage supply and waste lines • Purge waste lines • Ink cartridge waste lines •...
Page 43 4079-00X Action Carriage Ink Be sure the carriage ink supply assembly waste Supply Assem- lines fill when the purge motor completes its cycle. • Ink Cartridge The purge unit discharges ink back to the ink car- Assembly tridge through the waste line in the ink return unit. Waste Lines Be sure the waste lines are not blocked.
Page 44: Ink Sensor Service Check
4079-00X Ink Sensor Service Check Conditions That Could Cause This Symptom Explanation Symptom You have problems with • Ink cartridge ink sensing. The sensor • Ink sensor may indicate no ink when • Ink sensor cable a good cartridge is •...
Page 45 4079-00X Action Ink Sensor Check the ink sensor by checking for 5 V dc between the pins designated for each cartridge sen- sor on the CNINK connector as you push the sensor down and up. Cyan = pins 1 - 2 Magenta = pins 3 - 4 Yellow = pins 5 - 6 Black = pins 7 - 8...
Page 46 4079-00X Action • Sensor Cable Check the sensor cable continuity, matching pins on • Logic Board CNINK at the left connector card with wires to the ink sensor units. If the continuity is not correct, replace the sensor cable. If the continuity is correct, replace the logic board. If you replace the logic board, go to the “Service Adjustment Mode”...
Page 47: Logic Board And Related Cables Service Check
4079-00X Logic Board And Related Cables Service Check Conditions That Could Cause This Symptom Explanation Symptom You have problems with • System cables the logic board or cables. • Carriage board • Logic board Action • Brown Car- Follow these steps if 5 beeps are sounded, checking riage Cable 2 the error after each action: •...
Page 48 4079-00X Action • Brown Car- Follow these steps if 6 beeps are sounded, checking riage Cable 1 the error after each action: • White Rib- bon Cable 1 1. Check for correct connection of the brown car- • Carriage riage cable 1 to the carriage board and the right Board connector card.
Page 49: Operator Panel Service Check
4079-00X Operator Panel Service Check Conditions That Could Cause This Symptom Explanation Symptom Nothing appears on the • Power supply display, buttons or LEDs • Operator panel fail, but the printer starts • Logic board POST. • Controller board Action Power Supply 1.
Page 50: Paperfeed Electrical Service Check
4079-00X Action • Controller Turn off the printer. Board • Operator Install the controller board and connect the power Panel supply connector. Press and hold MENU and Print Buffer and turn on the printer to clear the controller diagnostic mode. Check operation of buttons, LEDs, and LCD, see “Controller Diagnostics”...
Page 51 4079-00X Error Code Appears Go To When paper is in the printer beyond the start position of Test Step 5 Print A, or above the ejector rollers, but not beyond the platen. Action • Paper Out Remove any paper that may be in the machine. Sensor •...
Page 52 4079-00X Action • Platen Check the platen for bits of paper, paper dust, or ink. • Linear Clean the platen with a wet paper towel if necessary. Encoder/ Paper Width When the carriage moves to pick up paper, the Sensor paper width sensor detects the black surface of the platen and the white surface of the paper to deter- mine the width of the paper.
Page 53 4079-00X Action • Timing Slit Be sure the carriage is unobstructed and moves • White Ribbon freely. • Brown Rib- Be sure the printer is not picking up vibrations from • Carriage the environment. Move the printer to a different loca- Board tion if necessary.
Page 54: Paperfeed Mechanical Service Check
4079-00X Paperfeed Mechanical Service Check Conditions That Could Cause This Symptom Explanation Symptom Paper indexing or feeding • Foreign object in path problem; you may see an • Paper dust or ink on rollers error code. • Paperfeed motor, gear train •...
Page 55 4079-00X Action • Pinch Roller Be sure the paper moves through the paperfeed • Paperfeed pinch rollers onto the platen. If it does not, replace Roller the following FRUs in sequence. Check printer oper- ation after each replacement. 1. Pinch Roller Assembly or related parts (Asm. 17- 2.
Page 56: Paperfeed Motor Service Check
4079-00X Paperfeed Motor Service Check Conditions That Could Cause This Symptom Explanation Symptom No paperfeed roller rota- • Paperfeed motor tion during POST or while • Logic board printing Test Print A. Action Paperfeed Watch the paperfeed motor and gears as you turn Motor Cable on the printer.
Page 57: Power Supply Service Check
4079-00X Action Paperfeed Check the paperfeed motor winding resistance at Motor the motor connector. The pins are numbered 14 - 9, with 14 at the top of the connector. Check the resis- tance on four phases, each of which should have approximately 70 Ohms resistance.
Page 58 4079-00X Action Fuse Check the primary fuse at the power supply. If it is bad, replace it and check the machine again. Power Supply Turn the machine off and remove the controller board and the card cover. Leave connector CNPOW plugged into the logic board and unplug the power supply connector from the controller board.
Page 59: Print Escapement Service Check
4079-00X Action • Controller Leave the controller board removed and the power Card supply disconnected. Go to the, “Service Adjustment • EPROM Con- Mode” on page 4-4 and follow the procedure to enter troller Card the Service Adjustment Mode with the controller •...
Page 60 4079-00X Be sure there is no obstruction in the carriage drive path and that the print timing slit is not dirty, broken, or bent. Use a cleancloth to clean the timing slit. If the drive path is obstructed, clear the obstruction, then run POST to check the printer.
Page 61: Print Quality Service Check
4079-00X Print Quality Service Check Conditions That Could Cause This Symptom Explanation Symptom Print quality problems, • Clogged ink lines missing dots, colors, or ink • Printhead smearing. Possible ink • Cartridge present sensor supply problem. You are in this service check because the print sample nozzle check indicates some nozzles may be blocked.
Page 62 4079-00X Action Ink Flow and 1. Be sure the ink line connectors are not loose, dis- Supply Lines connected, or defective. 2. Be sure the carriage is not catching on the ink lines. Reposition the ink lines as necessary. 3. Perform a Long Cleaning, observing the carriage supply lines, subtank ink levels, and carriage waste lines.
Page 63: Purge Unit Service Check
4079-00X Purge Unit Service Check Conditions That Could Cause This Symptom Explanation Symptom You are here after using • Purge motor the Head Cap Position • Purge sensor cable Service Check, or • Left connector card cable because you suspect the •...
Page 64: Ram (Memory) Service Check
4079-00X RAM (Memory) Service Check Conditions That Could Cause This Symptom Explanation Symptom Data is missing from your • RAM SIMM J5 or J8 (4079-001 only) print job, additional data • Logic Board (4079-002 only) appears, or error code 960. Action SIMM The printer requires 4 MB of RAM to complete...
Page 65: Undetermined Problem Service Check
4079-00X Undetermined Problem Service Check You have been directed to this service check because you cannot find an error code or symptom in “Start” on page 2-1 or the “Error Code Table” on page 2-2 or because more information is needed on the symptom or error code than the Error Code/Symptom Index can provide.
Page 66: Diagnostic Aids
4079-00X 3. Diagnostic Aids Testing The Printer Diagnostic Aids are divided into two types of functions: Controller Diagnostics, and Service Adjustment Mode. In addition, some test prints can be run from the operator mode. The tests are provided for printer testing and diagnostics. The printer does not need to be attached to a host system to use the tests.
Page 67: Operator Test Functions
4079-00X Operator Test Functions When the printer is turned on, it goes through a check-out routine and indicates any failure by an error code number in the display. Some of these codes are correctable by the operator, others can only be repaired by a trained service person. The error codes are listed in the “Error Code Table”...
Page 68: Test Print A
4079-00X Test Print A Test Print A prints a sample of machine settings and lines of color in varying densities, and also drives the printer extensively. The printer completes the test on one sheet of 215.9 by 279.4 mm (8-1/2 by 11-inch) paper, then returns to the menu mode. After you complete any repairs, run the print sample several times to ensure that the printer is operating correctly.
Page 69: Printhead Cleaning Procedures
4079-00X After the nozzle check is printed, the printer returns to the menu mode. In this example, some of the nozzles are clogged, resulting in a void in the print. You would run the head clean procedure, then run the print sample again.
Page 70 4079-00X Bold Black Prints bolder black than Quality mode. Use when darker black is needed. High Quality Use for printing graphics or colors on paper other than the recommended coated paper, and when ink starts to run together seriously. Requires longer print time than Quality mode. Draft mode, for fast printing.
Page 71 4079-00X Follow this chart to choose the correct print mode. Diagnostic Aids...
Page 72: Power-On Self Test (Post)
4079-00X Power-on Self Test (Post) When the printer power is turned on, the following sequence of events takes place. You may have to watch carefully to see all that is happening during POST, but generally a completed POST indicates that there were no failures during the sequence. 1.
Page 73 4079-00X 26. Purge unit suctions ink from printheads and pumps ink out through waste ink lines. 27. Head capping mechanism is lowered, allowing the carriage to return to normal position. 28. Purge motor stops running. 29. Carriage moves about one-fourth of the way to the right. 30.
Page 74: Controller Diagnostics
4079-00X Controller Diagnostics This mode is used by service persons to isolate failing FRUs and make adjustments to the printed page. To enter Controller Diagnostics, press and hold Menu and Print Buffer while turning on the printer. After the POST is complete, the first item in the Controller Diagnostics menu is displayed.
Page 75: Paper Load Test
4079-00X Paper Load Test Select Paper Load Test from the menu to start the continuous paper load test. A sheet of paper is loaded into the printer, a line is printed across the top of the page, and the page is ejected. The test is repeated until you press the Menu button.
Page 76: Ram Test
4079-00X RAM Test Select RAM Test from the menu to verify the DRAM on the controller board. The display shows the amount of memory in each SIMM, or shows a failure of the SIMM in either slot 1 or slot 2. Last Error Select Last Error to display the last error stored in memory.
Page 77: Defaults
4079-00X Defaults Use this option whenever the controller board is replaced to make sure the national defaults are set correctly. The only value currently affected is paper size, which is different for non-U.S. users. Service Adjustment Mode In Service Adjustment Mode, adjustments can be made to the offset of the color ink jets relative to each other, and several cleaning modes can be entered.
Page 78: Repair Information
4079-00X 4. Repair Information This chapter contains adjustments and removal procedures. When- ever parts are replaced, make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed. Lubrication Requirements Use Grease (part 1321875) on the following parts as needed: •...
Page 79: Adjustments
4079-00X • 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);...
Page 80 4079-00X Follow this procedure to adjust the head gap: 1. Center the carriage (see “Printhead Uncapping and Carriage Centering” on page 4-9. 2. Unplug the power cord from the AC outlet. 3. Remove the paper guide, top cover, and inner cover. 4.
Page 81: Service Adjustment Mode
4079-00X 8. Hold the gauge on the recessed portion of the platen, left side. 9. Using the carriage belt, move the carriage over the feeler gauge. 10.Adjust the head gap so that the carriage does not touch the feeler gauge as it passes over. Turn the head gap adjustment one click at a time until the carriage clears the feeler gauge with the least possible clearance.
Page 82 4079-00X If Black Offset is not seen as a menu item, you may not have entered Service Adjustment mode. Turn off the printer, wait a few seconds, and try the procedure once more. To enter Service Adjustment mode with the control board removed. 1.
Page 83: Print Position Adjustment
4079-00X Cleaning Cleaning A - normal clean Cleaning B - long clean Cleaning C - fills new tubing, using approxi- mately 4 grams of each color ink Cleaning D - flushes the tubes thoroughly, using 4.5 grams of each color ink Center Head Centers the carriage and upcaps the heads Note: Turn power off when the carrier...
Page 84 4079-00X 4. Circle the print portion that shows the best offset values, using the magnifier to view the test print, if necessary. The best selec- tion is when the two colors appear closest to being one line. Note: Do not adjust the black offset value. It is used as a standard, and the other nozzles are adjusted to it.
Page 85 4079-00X 5. Adjust the offset values for the cyan, magenta, and yellow noz- zles. The values circled on Test Print C result in the best print quality. For example, yellow value might be +1, magenta -1, and blue 0. a. Press Select to turn off the Ready indicator (press Print Buffer if you need to exit from any submenu).
Page 86: Service Information
4079-00X Service Information Releasing Plastic Latches Many of the parts are held in place with plastic latches. To remove such parts, press the hook end of the latch away from the part to which it is latched. Warning: Never use excessive force to release the latches. they are easily broken.
Page 87: Manual Carriage Centering (No Power)
4079-00X The printheads are now uncapped. The carriage can now be moved as needed for servicing. The printheads should not be left uncapped overnight. Manual Carriage Centering (No Power) If the printheads were manually capped, reverse the procedure in “Manual Printhead Capping (Disabled Machine)” before attempting to move the carriage.
Page 88: Manual Printhead Capping (Disabled Machine)
4079-00X Manual Printhead Capping (Disabled Machine) If there is no power to the machine and the printheads must be capped, follow this procedure. Remove the screw from the hole marked Stock in the base and insert it in the hole marked Clamp. As the screw is tightened, the capping mechanism is raised and the printheads are capped.
Page 89: Carriage Card, Carriage Card Holder Cover Removal
4079-00X Carriage Card, Carriage Card Holder Cover Removal 1. Remove the covers. 2. Center the carriage (see “Printhead Uncapping and Carriage Centering” on page 4-9). 3. Remove the printhead cover and the printheads. 4. Remove the carriage card holder cover: Carefully push the small latches (1) on both sides.
Page 90 4079-00X 6. While flexing the carriage card holder latches (A), lift out the carriage card holder and card. 7. Remove the carriage card (Asm. 9-8) from the holder by flexing both sides of the holder outward and pulling the card from its mounting groove.
Page 91 4079-00X Installation Notes: When you install the carriage card, first make sure the card is seated in the front of the card holder (1), then rotate the card backward until it locks in place behind the guides (2), only one of which is shown. When replacing the printhead cover: 1.
Page 92: Carriage Encoder And Paper Width Sensor Removal
4079-00X 3. Squeeze both side latches and push the cover all the way into position. If the head cover is not in position, it can cause a bumping noise during print operation. 4. Push down on the carriage cardholder cover to engage the printheads.
Page 93 4079-00X 7. Remove the white encoder holder by pushing both side latches (B) toward the center, while lifting up and removing the encoder holder. 8. Place a small screwdriver behind the paper width sensor (A) and push it out while releasing the latch (B). 9.
Page 94 4079-00X Encoder Cable Handling When replacing the encoder unit, bend the flexible cable at the spec- ified position. 4-17...
Page 95 4079-00X Installation Note: When installing the carriage card, first make sure the card is seated in the front of the card holder (1), then rotate the card backward until it locks in place behind the guides (2), only one of which is shown. 4-18 Repair Information...
Page 96: Carriage Frame Removal
4079-00X Carriage Frame Removal The carriage frame (with the carriage and carriage drive installed) can be tilted away from the printer to allow servicing of other parts without removing the carriage or disconnecting the ink tubes. 1. Remove the covers. 2.
Page 97: Carriage Ribbon Cables Removal
4079-00X 8. Release the latches (2), one near each end of the carriage frame, and lift off the carriage frame. 9. Lay the frame upside down at the front or left side of the printer. In this position, the carriage motor should be on top, which will prevent the drainage of ink if the printheads are removed.
Page 98: Carriage Cable Handling
4079-00X 7. Release three latches (1) from the front side of the carriage frame and remove the ink tube guide from the carriage frame. Note how the cables are folded and routed through this guide. Carriage Cable Handling When installing the carriage cable, install the cable on the ink tube guide, and bend it at the specified position.
Page 99 4079-00X Carriage cable 19 pin Carriage cable 20 pin 4-22 Repair Information...
Page 100: Carriage Shaft, Belt, And Ink Supply Removals
4079-00X Carriage Shaft, Belt, And Ink Supply Removals It is normally not necessary to remove the carriage except to replace the carriage belt, or to replace the carriage and ink supply assembly. Warning: If possible, move the printer to a suitable service area, and cover the table with the drop cloth before servicing ink tubes or the purge unit.
Page 101 4079-00X 6. Remove the carriage shaft: a. Push the latch on the left end of the shaft and remove the shaft stopper. Be careful not to use excessive force. b. Push latch on the right end of the shaft to release the car- riage shaft.
Page 102 4079-00X 7. Remove the carriage belt from the carriage drive motor pulley by loosening the idler pulley mounting screw and pushing the pulley to the right. 8. Carriage Belt removal: If you are replacing the carriage belt, carefully turn the carriage over and disconnect the carriage belt clamp.
Page 103 4079-00X 10.Disconnect the ink lines from the carriage to the ink cartridge assembly (2) and hook the drain joint holder in the holes pro- vided on the carriage frame. 11.Remove the carriage card holder cover. 12.Disconnect the two carriage ribbon cables and slide the cables out of the carriage.
Page 104: Controller Board And Logic Board Removal
4079-00X 3. Perform printhead cleaning until all ink lines and subtanks are filled. When replacing the carriage shaft: 1. Remove the carriage shaft guide from the bottom of the car- riage. 2. Insert the carriage shaft into the carriage (the notched end must be to the left side).
Page 105: Cover Removals
4079-00X b. Pull the cover down and outward. 5. Remove the controller board bracket (3 screws). 6. Remove the screws from the logic board and pull the board out part way. 7. Disconnect the ribbon cables and connectors. 8. Pull out the logic board. Note that the front of the board is held by metal grounding clips.
Page 106 4079-00X 2. Remove the printed paper guide by pulling it up and out of the machine. 3. Remove the front cover and the inner cover. 4. Remove the two cover screws (1). 5. Remove the top cover (2), lifting rear to front. The front of the cover is held by plastic hooks.
Page 107: Hard Disk Removal
4079-00X Electronic Modules Memory SIMMS and the control card EPROM plug into the controller board and lock into place. Release the latches as shown to remove the modules. When installing a module, make sure the latches click into place. Hard Disk Removal 1.
Page 108: Ink Cartridge Assembly Removal
4079-00X Ink Cartridge Assembly Removal 1. Remove the covers. 2. Be sure the paper lifting plate is in its raised position: a. Move the spring plate (1) to the right. It is accessible at the right end of the carriage frame under the carriage shaft.
Page 109 4079-00X 4. Disconnect the purge ink waste tubes from the side frame. Wrap the end of the tubes in cleaning cloth, secured with a rub- ber band, to prevent ink spillage. 5. Disconnect the carriage ink supply joint from the side frame and hook it to the top of the carriage frame, as shown below.
Page 110 4079-00X 7. Use a flat-blade screwdriver to release the left latch while lifting the unit slightly. The bottom of the unit is set into two offset posts attached to the bottom pan. 8. Release the right latch as you lift the unit, and slide the unit out of the machine.
Page 111: Inner Cover Spur Unit Removal
4079-00X Inner Cover Spur Unit Removal 1. Remove the inner cover. 2. Insert a screwdriver under the spur unit and spread the latches to the sides as shown. Be careful not to use excessive force on the plastic latches. 4-34 Repair Information...
Page 112: Lower Frame Removal
4079-00X Lower Frame Removal If it is necessary to remove the white ribbon cables or the motor cables, follow this procedure. Make sure the following parts are removed: Operator panel, operator panel base, controller board, power supply. 1. Remove the covers. 2.
Page 113: Operator Panel Removal
4079-00X Operator Panel Removal 1. Remove the covers. 2. Remove the operator panel base and operator panel assembly by pulling latch and lifting the assembly. Lay the assembly on its right side. 3. Disconnect the operator panel cable from the right connector card.
Page 114: Paperfeed And Eject Rollers Removal
4079-00X 5. Lift the operator panel upward. Paperfeed And Eject Rollers Removal 1. Remove the covers. 2. Center the carriage. 3. Remove the operator panel. 4. Remove the carriage frame. 5. Remove the purge unit, leaving the ink tubes connected. 6.
Page 115 4079-00X 9. Squeeze the latch (1) while pushing the roller to the left (2).. 10.Using a thin screwdriver, raise the latch on the shaft and pull the shaft to the right. 11.Remove the eject roller (below) in the same way as the paper- feed roller.
Page 116: Paperfeed Motor Removal
4079-00X Paperfeed Motor Removal 1. Remove the covers. 2. Disconnect the paperfeed motor cable. 3. Loosen two screws (1) on opposite corners of the paperfeed motor and remove the motor. Do not loosen the other two screws. Paper Sensor Removal 1.
Page 117 4079-00X 3. Remove the mounting screw to release the paper sensor holder. 4. Squeeze the latches (A) on the bottom of the sensor holder, at the same end as the connector. 5. Remove the sensor from the holder. Installation Notes: When replacing the paper sensor, first put the hook on the sensor holder into the metal frame, then align the sen- sor and insert the screw.
Page 118: Pickup Roller, Paper Lifting Plate Removal
4079-00X Pickup Roller, Paper Lifting Plate Removal 1. Remove the covers. 2. Center the carriage. 3. Remove the operator panel. 4. Remove the carriage frame. 5. Remove the pinch roller base unit. 6. Remove the E-ring (1) from the pickup roller shaft. This shaft has a three-latch bearing.
Page 119: Pinch Roller Base Unit Removal
4079-00X 10.Raise the paper lifting plate and remove it. Installation Notes: When installing the pickup roller shaft, line up the holes in the pinch roller base unit with the pins on the side frames. Attach the tension springs using needle-nose pliers. Pinch Roller Base Unit Removal 1.
Page 120 4079-00X 5. Using needle-nose pliers, release the springs on each side of the pinch roller base unit. 6. Carefully pull the two guide arms on the pinch roller base unit away from the pickup roller, lift the unit off and set it aside. Be careful not to bend the pressure plate.
Page 121: Platen Removal
4079-00X Platen Removal 1. Remove the covers. 2. Center the carriage. 3. Remove the operator panel. 4. Remove the carriage frame. 5. Remove the purge unit part way, without removing the ink tubes. 6. Remove the pinch roller base unit. 7.
Page 122: Power Supply Removal
4079-00X Power Supply Removal 1. Remove the covers. 2. Disconnect power supply connector from controller board J4. 3. Remove controller board mounting screws. 4. Lift controller board out of machine. 5. Remove two power supply mounting screws at front of power supply.
Page 123: Printhead, Printhead Cover Removal
4079-00X 7. Remove the end plate by loosening the screw and sliding the plate off. This will reveal the 3.15A fuse. Installation Notes: When replacing the power supply, remember to hook up the power switch arm and replace the end plate. Printhead, Printhead Cover Removal 1.
Page 124: Print Timing Slit Removal
4079-00X 4. Squeeze both sides of the printhead cover (1) and pull it down- ward (2). Note the hook and latch on each side. 5. Pull out the four printheads and lay them aside in a safe place where the ink will not stain anything. Note the location of each color, so they can be returned to the same positions.
Page 125 4079-00X 3. Push the leaf spring (1) and unhook the left end of the print tim- ing slit (2). 4. Unhook the right end of the timing slit (3). 5. Draw the print timing slit through the carriage and out of the machine.
Page 126: Purge Unit Removal
4079-00X Purge Unit Removal Warning: If possible, move the printer to a suitable service area, and cover the table with the drop cloth before servicing ink tubes or the purge unit. 1. Remove the covers. 2. Center the carriage. 3. Disconnect the purge unit cable from the left connector card at CNPG and release the wires from the wiring saddles.
Page 127: Separation Sheet Removal
4079-00X The purge unit can now be lifted out of the printer. Separation Sheet Removal 1. Remove the covers. 2. Remove the carriage frame. 3. Remove the pinch roller base unit. 4. Remove the pickup roller. 5. Remove the separation sheet by pushing a screwdriver in at each end.
Page 128: Connector Locations
4079-00X 5. Connector Locations The following pages show the location of specific test points and major parts of the printer. Illustrations of the paper path and the ink supply system are also included. Carriage Card Connector Locations 5-1...
Page 129: Right Connector Card
4079-00X Right Connector Card Left Connector Card Connector Locations...
Page 130: Control Card 4079 - 001
4079-00X Control Card 4079 - 001...
Page 131: Control Card 4079 - 002
4079-00X Control Card 4079 - 002 Connector Locations...
Page 132: Logic Card
4079-00X Logic Card...
Page 133: Ink Supply Diagram
4079-00X Ink Supply Diagram The ink diagram illustrates the ink flow for a single color ink. Each color ink has the same ink flow pattern. • The ink cartridge supplies the ink to the sensor lines and also Connector Locations...
Page 134: Paper Path
4079-00X absorbs waste ink in a separate chamber. • The pump (located in the purge assembly) draws ink from the ink cartridge, through the ink, through the supply lines and into the subtank. • Ink feeds into the printhead from the subtank. •...
Page 135: Preventive Maintenance
Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply. • Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover. • Possible safety exposure from any non-Lexmark attachments. Preventive Maintenance 6-1...
Page 136: Lubrication Specifications
4079-00X Lubrication Specifications Use Grease (part 1321875) on the following parts as needed: • All shaft holders • The shaft hole of eject roller, pickup roller, and paperfeed roller on the right frame. • The gears on the right frame. •...
Page 137: Parts Catalog
4079-00X 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.
Page 138: Covers
4079-00X Assembly 1: Covers...
Page 139 4079-00X Asm- Part Description Index Number Units 1321701 Support, Paper 1321703 Guide, Printed Paper, 4079-001 1373324 Guide, Printed Paper, 4079-002 1321704 Cover, Front, 4079-001 1373325 Cover, Front, 4079-002 1321707 Label, Serial Number Parts Catalog...
Page 140: Covers (Cont.)
4079-00X Assembly 2: Covers (Cont.)
Page 141 4079-00X Asm- Part Description Index Number Units 1321708 Top Cover (with logo),4079-001 1373326 Top Cover (with Logo) 4079-002 1321709 Plate, Upper Cover, 4079-001 1373366 Plate, Upper Cover, 4079-002 1321710 Coupler 1321711 Cover, Ink Cartridge (also order refs. 5 and 6), 4079-001 1373368 Cover, Ink Cartridge (also order refs.
Page 142: Inner Cover
4079-00X Assembly 3: Inner Cover...
Page 143 4079-00X Asm- Part Description Index Number Units 1321717 Spur Unit Assembly 1321716 Cover, Inner (Access Cover), 4079-001 1373359 Cover, Inner (Access Cover), 4079-002 Parts Catalog...
Page 144: Printer Electronics
4079-00X Assembly 4: Printer Electronics...
Page 145 4079-00X Asm- Part Description Index Number Units 1321719 Logic Board, 4079-001 1373371 Logic Board, 4079-002 1321825 Controller Board, 4079-001 (does not include EPROM Controller Card or Mem- ory SIMM) 1373373 Controller Board (does not include EPROM Controller Card, memory is on the board), 4079-002 1321880 EPROM, Control Card, 4079-001...
Page 146: Power Supply And Control Panel
4079-00X Assembly 5: Power Supply and Control Panel 7-10...
Page 147 4079-00X Asm- Part Description Index Number Units 1321884 Power Supply, 120 V 1321885 Power Supply, 220 V • 1321726 Fuse, 125 V 3.15 A • 1321727 Fuse, 250 V 2.0 A • 1321858 Screw • 1321863 Screw 1321729 Base, Control Panel 1321832 Plate, Grounding (also in PP 1321820) 1321728...
Page 148: Carriage And Printhead
4079-00X Assembly 6: Carriage and Printhead 7-12...
Page 149 4079-00X Asm- Part Description Index Number Units 1321731 Printhead 1321833 Clip, Head Cover Stabilizer 1321834 Clip, Head Cover Stabilizer 1321730 Cover, Printhead 1321732 Cable, Connector Card Left 1321863 Screw 7-13 Parts Catalog...
Page 150: Base
4079-00X Assembly 7: Base 7-14...
Page 151 4079-00X Asm- Part Description Index Number Units 1321733 Guide, Ribbon Cable 1321734 Ribbon Cable 1321735 Motor Cable 1321736 Holder, Logic Card, 4079-001 1373336 Holder. Logic Card, 4079-002 1321836 Plate, Grounding (also in PP 1321820) 1321737 Arm, Power Switch Actuating 1321738 Switch, Power, 4079-001 1373330 Switch, Power, 4079-002...
Page 152: Purge Unit
4079-00X Assembly 8: Purge Unit 7-16...
Page 153 4079-00X Asm- Part Description Index Number Units 1321743 Purge Unit Assembly 1321745 Motor, Purge Unit • 1321746 Gear, Worm 1321744 Purge Maintenance Kit • Spring • Spring • 1321837 Ink Absorber • Spring • Spring 1321747 Sensor and Cable 1321857 Screw 1321865 Cover, Purge Unit Hose...
Page 154: Print Timing Encoder
4079-00X Assembly 9: Print Timing Encoder 7-18...
Page 155 4079-00X Asm- Part Description Index Number Units 1321752 Cable, Carriage (inc. re 11-3) 1321754 Linear Encoder/Paper Width Sensor 1321838 Holder, Encoder 1321878 Cover, Sensor 1321749 Slit, Print Timing 1321750 Cover, Carriage Card Holder 1321751 Holder, Carriage Card 1321753 Card, Carriage 7-19 Parts Catalog...
Page 156: Carriage Ink Supply
4079-00X Assembly 10: Carriage Ink Supply 7-20...
Page 157 4079-00X Asm- Part Description Index Number Units 10-1 1321888 Carriage Ink Supply Assembly • 1321756 Joint, Supply • 1321757 Joint, Pump • 1321839 Shaft, Head Gap Adjustment • 1321840 Clamp, Head Gap Adjustment • 1321759 Lever, Head Gap Adjustment, 4079-001 •...
Page 158: Carriage Drive
4079-00X Assembly 11: Carriage Drive 7-22...
Page 159 4079-00X Asm- Part Description Index Number Units 11-1 1321764 Shaft, Carriage 1321762 Holder, Joint 1321761 Guide, Ink Tube 1321765 Cable, Ground 1321760 Motor, Carriage Drive 1321763 Stopper 1321863 Screw 1321819 Screw 7-23 Parts Catalog...
Page 160: Carriage Drive Frame
4079-00X Assembly 12: Carriage Drive Frame 7-24...
Page 161 4079-00X Asm- Part Description Index Number Units 12-1 1321766 Guide, Carriage 1321772 Label, Carriage Instructions 1321842 Spring 1321863 Screw 1321770 Idler Assembly, Carriage Belt 1321769 Plate, Right Frame 1321767 Lever, Carriage Lock, 4079-001 1373332 Lever, Carriage Lock, 4079-002 1321773 Frame, Carriage 1321774 Belt Assembly, Carriage 1321843...
Page 162: Ink Supply Unit
4079-00X Assembly 13: Ink Supply Unit 7-26...
Page 163 4079-00X Asm- Part Description Index Number Units 13-1 1321775 Ink Cartridge Assembly, Includes Assem- bly 14 • 1321776 Sensor Cable Unit • 1321777 Ink Sensor Assembly, Complete • 1321779 Ink Supply Hose Kit, Complete 7-27 Parts Catalog...
Page 164: Ink Return Unit
4079-00X Assembly 14: Ink Return Unit 7-28...
Page 165 4079-00X Asm- Part Description Index Number Units 14-1 1321775 Ink Cartridge Assembly, Includes Assem- bly 13 • 1321780 Holder, Drain Tube • 1321781 Drain Tube Assembly • 1321782 Base, Ink Compartment (also order index 5) • 1321783 Ink Absorber 7-29 Parts Catalog...
Page 166: Ink Cartridge Interlock
4079-00X Assembly 15: Ink Cartridge Interlock 7-30...
Page 167 4079-00X Asm- Part Description Index Number Units 15-1 1321784 Spring, Leaf 1321844 Plate, Lock 1321845 Spring 1321846 Needle Protector 7-31 Parts Catalog...
Page 168: Sheetfeed Entry
4079-00X Assembly 16: Sheetfeed Entry 7-32...
Page 169 4079-00X Asm- Part Description Index Number Units 16-1 1321795 Pickup Roller Assembly • 1321818 E-Clip (also order index 9) • 1321855 • 1321821 Spring 1321789 Card, Right Connector 1321786 Plate, Paper Lifting Assembly, 4079-001 1373333 Plate, Paper Lifting Assembly, 4079-002 •...
Page 170: Sheetfeed Pinch Roller
4079-00X Assembly 17: Sheetfeed Pinch Roller 7-34...
Page 171 4079-00X Asm- Part Description Index Number Units 17-1 1321791 Pinch Roller Base • 1321794 Plate, Pressure • 1321792 Arm, Base • 1321793 Pinch Roller Assembly • 1321868 Spring 7-35 Parts Catalog...
Page 172: Paperfeed/Ejector Roller
4079-00X Assembly 18: Paperfeed/Ejector Roller 7-36...
Page 173 4079-00X Asm- Part Description Index Number Units 18-1 1321798 Platen 1321799 Roller, Eject (also order ref. 7) 1321802 Roller, Paperfeed (also order ref. 6, may need E-Clip below) 1321887 E-Clip (used on left side of Paperfeed Roller) 1321801 Cover, Dust, 4079-001 1373367 Cover, Dust, 4079-002 1321819...
Page 174: Sheetfeed Separation
4079-00X Assembly 19: Sheetfeed Separation 7-38...
Page 175 4079-00X Asm- Part Description Index Number Units 19-1 1321805 Sheetfeed Separation Assembly 1321869 Spring 1321850 Arm, Paper Sensor 1321806 Paper Out Photo Sensor 1321819 Screw 1321851 Holder, Paper Sensor 1321804 Base, Sheetfeed Separation 7-39 Parts Catalog...
Page 176: Paperfeed Frame
4079-00X Assembly 20: Paperfeed Frame 7-40...
Page 177 4079-00X Asm- Part Description Index Number Units 20-1 1321862 Screw 1321809 Frame, Center 1321807 Cable, Paper Sensor 1321852 Clamp 1321808 Motor, Paperfeed 1321856 Screw 1321853 Plate Assembly, Ground 1321812 Frame, Right, 4079-001 1373338 Frame, Right, 4079-002 • Plate • Spring, Ground Plate •...
Page 178: Tools
4079-00X Assembly 21: Tools 7-42...
Page 179 4079-00X Asm- Part Description Index Number Units 21-1 1749245 Gauge, Feeler, mm 1477752 Syringe, Ink 1321875 Grease 1280055 Drop Cloth 2108930 Cleaning Cloth 1319128 Wrap Plug 452642 Magnifier 7-43 Parts Catalog...
Page 180: Hard Disk And Options
4079-00X Assembly 22: Hard Disk and Options 7-44...
Page 181 4079-00X Asm- Part Description Index Number Units 22-1 1373404 Hard Disk 40 MB, includes interface card, 4079-002 only 1364876 8 MB, DRAM SIMM 1364875 16 MB, DRAM SIMM, 4079-002 1364874 32 MB, DRAM SIMM, 4079-002 7-45 Parts Catalog...
Page 182: Index
4079-00X Index manual print head capping 4-11 menu system 3-1 abbreviations 1-7 models available 1-1 adjustments 4-2 operating temperatures 1-2 carriage cable handling 4-21 operator codes and messages 2-8 carriage card 5-1 operator panel 1-4 carriage centering 4-9 operator test functions 3-2 coated paper 1-1 connector locations 5-1 control card 5-3...
Page 183 4079-00X operator panel 2-31 paper feed electrical 2-32 releasing plastic latches 4-9 paper feed mechanical 2-36 removal procedures 4-11 paperfeed motor 2-38 removals power supply 2-39 carriage belt 4-23 print escapement 2-41 carriage card 4-12 print quality 2-43 carriage card holder cover 4-12 purge unit 2-45 carriage encoder 4-15 undetermined problem 2-47...

Lexmark Jetprinter 4079-00 series Service Manual

Notices and Safety Information

General Information

Diagnostic Information

4079-00X

Diagnostic Aids

Repair Information

4079-00X

Connector Locations

Preventive Maintenance

Parts Catalog

4079-00X

Index

Quick Links

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Summary of Contents for Lexmark Jetprinter 4079-00 series

Table of Contents