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Lexmark 7000 Color Jetprinter Course Information

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Download this manual See also: Service Manual, Manual
Course Information
Introduction
Course Information
Service Training
Introduction
This service training module, along with the product
specific service manual, can be used as an outline for
training on current Lexmark personal or desktop
printers.
Cross references to the service manual for new
products are placed at selected points throughout the
module lessons. The cross references let you view
parts, theory of operation, adjustments, and so on, at
the click of your mouse. When you have finished,
simply use your right mouse button to return to the
service training lesson.
The lessons in this course will be updated as
necessary to include new technology, or unique printer
mechanisms that may require specialty training.
Use the Tools pull down menu, Find and Match Whole
Word Only to locate a specific subject.
For example: 7000 Color Jetprinter
SERVICE TRAINING MENU
SERVICE MANUAL MENU
HELP

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Summary of Contents for Lexmark 7000 Color Jetprinter

  • Page 1 Introduction Introduction This service training module, along with the product specific service manual, can be used as an outline for training on current Lexmark personal or desktop Course Information printers. Cross references to the service manual for new products are placed at selected points throughout the module lessons.
  • Page 2 Course Information HELP Lesson Outline Lesson Outline This course is divided into the following lessons: • Covers, Drive, and Component Location • Paper Path • Print Process • Electronics • Diagnostics • Service Tips • Course Exam SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 3 Course Information HELP Lesson Objectives Lesson Objectives Upon completion of these lessons, along with your prior knowledge and appropriate documentation, you will be able to: • Locate and identify all major components. • List the motors used in the printer and describe their function.
  • Page 4 Prerequisite • Ability to follow non-complex procedures (written and graphic) to isolate product problems. Lexmark service training courses are developed • Use of special tools and instructions (written and assuming the student has these entry level skills: graphic) in the adjustment of electro-mechanical devices such as diskette drives and printers.
  • Page 5 Refer to the service manual “Table of Contents” for you may order books and other material from location of connectors and pin numbers. Lexmark. To order material - call 1 - 800 - 553 - 9727 (U.S.) SERVICE TRAINING MENU...
  • Page 6 • Windows 95 or Windows NT. you have a training machine available for the • 16 MB of RAM (24 for Windows NT). product for which you want to receive Lexmark certification. • Color palette supporting at least 256 colors.

  • Page 7: Special Tools

    Course Information HELP Special Tools Special Tools Refer to the service manual for special tools, equipment, and so on. SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 8 You may need to schedule more time if you are a first time user of Lexmark service training, or this is your first service training course. Experience personnel may use the following outline for scheduling training time: •...
  • Page 9 Lexmark service training course in the product • Have completed the color printing lessons and category for which you want to receive Lexmark understand how printers place color on paper. certification. If you met all of these conditions and want to skip...
  • Page 10 The color print cartridge contain three colors of ink: cyan, magenta and yellow. Lexmark inkjet printers provide high quality text and graphic printing. Lexmark printers can print on envelopes, single sheet paper labels, 3 x 5 index cards, and transparencies.
  • Page 11 New Products New Products This is Lexmark’s new 7000 Color Jetprinter (Machine Type 4092). The 7000 Color Jetprinter is a personal, near laser-quality inkjet printer. Dual printheads provide color and true black printing without changing printheads. The black print cartridge has a total of 208 nozzles.
  • Page 12 It is highly recommended, but not required, that you have a training machine available for the product for which you want to receive Lexmark certification. Removing the machine covers at this time is necessary to locate and identify sub assemblies called out in this lesson.
  • Page 13 Printer 4077. Be sure to use the appropriate service manual for your printer. For example, if you are training on the Lexmark Color jet printer machine type 4077, you must use the 4077 Service Manual. In this case, there are different models of the 4077 color printer.
  • Page 14 Covers, Drive, and Component Location HELP Covers Removing an inkjet printer cover may be as simple as prying gently on two plastic latches. Insert a small screwdriver into slot A on both sides of the printer and gently press just enough to release the cover latch.
  • Page 15 Covers, Drive, and Component Location HELP Covers Release the rear cover latches in the same manner and slide the cover off the machine. SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 16 Motor The purpose of the paper feed motor is to feed paper from the automatic sheet feed through the printer's paper path. Note: All Lexmark inkjet printers use a stepper motor for feeding paper. SERVICE TRAINING MENU SERVICE MANUAL MENU...
  • Page 17 Covers, Drive, and Component Location HELP Drive and Component Location In this illustration, we have separated the frame and carrier transport assembly from the base assembly to aid in parts identification. You can also see the location of the paper feed motor and the carrier transport motor.
  • Page 18 As the carrier transport motor turns, it moves the carrier left or right using the carrier belt. Some Lexmark inkjet printers, for example, 2050, 150c and 2070 use a DC motor and an encoder strip with an encoder board. As the carrier moves laterally, the...
  • Page 19 Covers, Drive, and Component Location HELP Drive and Component Location Lexmark inkjet printers use either a mechanical maintenance station or a motor driven assembly to wipe and cap the printhead. The maintenance station has two functions: • It seals the printhead nozzles using caps to protect the nozzles from damage or drying between print jobs.
  • Page 20 Covers, Drive, and Component Location HELP Drive and Component Location Clean Action As the carrier moves to the left, the printhead nozzles are uncapped and wipers clean the nozzles. • The wipers clean the printhead nozzles only when the carrier moves to the left. •...
  • Page 21 Covers, Drive, and Component Location HELP Drive and Component Location In addition to the paper feed and carrier transport motor, the 4076 II and 4076 IIc inkjet printers use a third motor (DC) to drive and cap the printhead and raise the wiper.
  • Page 22 Covers, Drive, and Component Location HELP Drive and Component Location The 4076 DC motor is mounted to the rear of the drive assembly as illustrated. As the DC motor turns, it provides lifting motion through a worm and drive gear combination inside the drive assembly.
  • Page 23 Covers, Drive, and Component Location HELP Drive and Component Location Lexmark’s personal inkjet printers have one system board and one power supply. Go to your service manual and locate the removals section. Follow the cover removal steps for your printer machine type and model.
  • Page 24 Covers, Drive, and Component Location HELP Summary Summary At this point, you should know how to remove the covers from your printer. You should also be able to locate the following: • Paper Feed Motor • Carrier Transport Motor • Maintenance Station Assembly •...

  • Page 25: Paper Path

    Lexmark inkjet printers typically use one paper feed motor to feed paper from the sheet feeder to the exit tray. The paper path on the majority of Lexmark inkjet Paper Path printers is short. In many instances, the trailing edge of...

  • Page 26: Theory Of Operation

    Paper Path HELP Theory of Operation Theory of Operation The remaining parts in the paper feed mechanism are: • Feed Arm Assembly The paper feed mechanism contains more than half • Paper Feed Gears the parts in the printer. The parts involved in the •...
  • Page 27 9. Small Feed Roller 10. Large Feed Roller 11. Exit Roller 12. Star Rollers The components illustrated in this frame are used in the Lexmark 2050 Color Jetprinter (Machine Type 4077, Model 201). SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 28 Paper Path HELP Theory of Operation When a paper feed command is sent to the printer, the paper feed motor receives stepping pulses (+24 V dc or +30 V dc, depending upon model) from the system board. The motor turns in a reverse direction momentarily to let the feed arm assembly drop from a home (latched) position.
  • Page 29 Paper Path HELP Theory of Operation As paper feeds from the sheet feed, the corner bucklers cause the top sheet of paper to bow or “buckle” slightly. The paper pick rollers continue to feed the top sheet of paper from the sheet feed assembly. This buckling action results in only the top sheet of paper being removed from underneath the buckler.
  • Page 30 Paper Path HELP Theory of Operation The paper feed arm assembly remains engaged until the paper reaches the end-of-forms flag, or paper sensor. A signal is sent to the system board causing the paper feed motor to change direction and stop (This direction change causes the feed arm assembly to restore to the home position).
  • Page 31 Paper Path HELP Theory of Operation As the printing continues, or an end of page command is received, the paper enters the paper exit rollers (11) and star rollers (12). Note: The star rollers are small stainless steel spikes designed to feed the paper without leaving marks or tracking any remaining wet ink.
  • Page 32 After printing is completed, the paper is driven out of the printer by the exit (11) and star rollers (12). Let’s look at some other paper feed mechanisms commonly used in Lexmark color inkjet printers such as the 4078-001 and 4091-001. SERVICE TRAINING MENU...
  • Page 33 Paper Path HELP Theory of Operation Depicted are the major parts used to feed paper through the printer. The parts are: 1. Sheet Feed Assembly and Paper Guides 2. Pick Rollers 3. Paper Feed Motor, Drive Train 4. Small Feed Roll Assembly 5.
  • Page 34 Paper Path HELP Theory of Operation When a paper feed command is sent to the 4078-001 printer, the paper feed motor receives +24 V dc from the system board. The motor rotates in the pick direction causing the clutch pawl, mounted in the large feed gear, to engage the ratchet in the pick roll drive gear.
  • Page 35 Note: This style sheet feed assembly is designed to feed paper using only one corner buckler. There is no manual feed tray like the Lexmark 2050, but paper can be fed through the auto sheet feeder manually with the sheet feeder load arm in the load position.
  • Page 36 (5) and the large feed roll (6). We have shown you two major types of paper feed assemblies used to feed paper through Lexmark inkjet printers. Your printer may contain identical components or some combination of the two designs.
  • Page 37 Color Printing Module for an overview of how inkjet printers place color on paper. While in the Color Printing Module, look for the new Lexmark Photo Print Cartridge information. The Photo Print Cartridge enhances the quality of digital photographic output.

  • Page 38: Print Cartridges

    Print Process HELP Print Cartridges Print Cartridges The Lexmark inkjet print cartridge is a printhead and ink supply combined into one unit. The color cartridge contains three colors of ink (cyan, magenta, and yellow). The monochrome cartridge contains black ink.
  • Page 39 Print Process HELP Print Cartridges Most Lexmark inkjet printers can hold two print cartridges; a monochrome and a color cartridge. The color cartridge installs on the right. Some color inkjet printers can hold only one print cartridge at a time and the user must swap print...
  • Page 40 Printers with two printheads require head to head print alignment adjustments in addition to bidirectional alignment adjustments. Most Lexmark inkjet printers can print a Test Page. The Test Page can be used to verify that all print cartridge nozzles are working. There should be no breaks in the diagonal line.
  • Page 41 Print Cartridges With the exception of the 4076 II and 4076 IIc, all The printer logic receives and translates the electronic Lexmark inkjet printers have bidirectional data stream into carrier returns, line spacing, communications capabilities between the host PC characters, or graphics as instructed.
  • Page 42 Print Process HELP Print Cartridges Printers capable of printing at 300 x 300 dpi (dots per inch) means that each square inch of paper can be divided into 90,000 (300 x 300) picture elements (pels). The machine logic determines whether to print or not to print each of the 90,000 pels, or dots, that make up the final printed output.
  • Page 43 Print Process HELP Print Cartridges Dependent upon printhead size and other factors such If the text is Courier size 20, machine logic determines as fonts selected, the print cartridge may or may not that the top half of the character prints first. print a complete character at one time.
  • Page 44 Print Process HELP Print Cartridges After a line of text prints, the paper then indexes Let's take a closer look at the print cartridge to see why allowing the lower half of the characters on that same this type of pattern is necessary. line to be printed as shown.
  • Page 45 Print Process HELP Print Cartridges The print cartridge is made up of an ink supply, printhead nozzles and electrical contacts. The printhead nozzles and electrical contacts should not be touched as oil from your hands can damage the surface. Always try a known good print cartridge when attempting to resolve a print quality problem.
  • Page 46 The color printhead has 48 nozzles arranged in three sets (cyan, magenta, yellow) of 16 nozzles for each color. Some Lexmark color inkjet printers such as the 2070 (4090-001) use a different printhead that contains 96 nozzles (color) and 104 (monochrome). The 4079 inkjet printhead has 64 nozzles.
  • Page 47 Print Process HELP Print Cartridges Each nozzle has a heating element and two parallel plates between which ink is always present. One of the plates has an opening, or gap, through which an ink drop is ejected when this nozzle is required.
  • Page 48 Print Process HELP Print Cartridges The data stream received by the printer is interpreted by the machine logic. The logic then controls the overall print operation, including paper movement and the printing of characters. Signals making up characters or graphics are sent from the system board to the appropriate nozzles, depending upon the character, or graphic, to be printed.
  • Page 49 Print Process HELP Print Cartridges Note: The physical size of the printhead and printhead nozzles limits the amount of ink coverage at any given time. Therefore, it is necessary to move in increments for characters larger than the printhead. When a signal is sent to a selected nozzle, heat is generated by the heating element.
  • Page 50 Print Process HELP Print Cartridges The liquid surrounding the heating element vaporizes instantly causing a vapor bubble to form. SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 51 Print Process HELP Print Cartridges As the vapor bubble expands, it generates a pressure wave, or shock wave, which forces a droplet of ink out of the nozzle. The machine logic sends signals to the appropriate nozzles and the required character prints. The printer logic keeps tract of the maximum number of nozzle fires that can occur before running out of ink.
  • Page 52 Print Process HELP Print Cartridges After a drop of ink is forced out of the nozzle, the heater is turned off. When the heater is turned off, the vapor bubble cools and condenses back to liquid. SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 53 Print Process HELP Print Cartridges The negative pressure produced by the contracting vapor bubble draws ink back into the nozzle. The nozzle is now ready to produce the next drop of ink when signaled. SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 54 Print Process HELP Print Cartridges When the number of nozzle fires equals the maximum number of nozzle fires for a new cartridge, the operator is prompted through the control program that the cartridge is empty. If a used print cartridge is reinstalled, the control program cannot determine one used cartridge from another.
  • Page 55 Print Process HELP Summary Summary • You have seen how the printer prints by using heat to force ink out of selected nozzles. • A signal is sent by the printer logic to the heating element of a selected nozzle. •...

  • Page 56: Power Distribution

    10% of the rated voltage. Electronics Refer to the appropriate service manual for your product. Lexmark’s inkjet printers have one system board and one power supply. This lesson provides a brief overview of these two components. SERVICE TRAINING MENU...

  • Page 57: System Board

    Electronics HELP System Board System Board The system board is sometimes unique to each model. Use the service manual part number section to order the correct replacement part. The system board controls the paper feed motor, the printhead, and carrier movement. It also serves as an interface between the host PC and the printer.
  • Page 58 Electronics HELP Power Supply Power Supply The power supply transforms ac line voltage into dc voltage. The dc voltage is then supplied to the main printer board. Some common dc output voltages are: • +5 V dc • +24 V dc •...

  • Page 59: External Power Supply

    Electronics HELP External Power Supply External Power Supply Some printers use an external power supply with an internal dc converter. The dc converter power output can be checked with a meter by disconnecting the power supply connector from the system board. Be sure to unplug the printer's external power supply before reconnecting to the system board.
  • Page 60 Diagnostics HELP Introduction Introduction Diagnostics begins by understanding the customer’s problem. Diagnostics Attempting to repair hardware only becomes more difficult once you start removing or replacing parts without understanding what it is you are attempting to resolve. This is especially true while working in the customer’s environment.
  • Page 61 Diagnostics HELP Environment Environment Some customers have unique requirements for their hardware that exceeds its design limitation. Experienced service personnel know how quickly a customer can become dissatisfied with a superior product simply because the wrong kind of paper is used.
  • Page 62 Diagnostics HELP Supplies Supplies The wrong kind of ink (inkjet printers), toner (laser printers), or ribbon (dot matrix printers), may be the cause of print quality problems. Incorrect software setup or machine configuration may cause unexpected results. Once you understand the customer’s problem, isolate the cause as quickly as possible.
  • Page 63 Let’s look at Lexmark’s latest method of helping you to quickly identify and correct most hardware problems. SERVICE TRAINING MENU SERVICE MANUAL MENU...
  • Page 64 These tables and service checks are designed to provide a quick solution regardless of the printer type. Lexmark service manuals recommend you begin by locating the diagnostic section in your ink jet, dot matrix or laser printer service manual. The Diagnostic section begins with a Start section.

  • Page 65: Error Indications

    Diagnostics HELP Error Indications Error Indications Inkjet printers may flash a series of lights to indicate and error. If your machine has an error indication, locate and match the series of flashes with the number of flashes listed in the Error Indicator Table. In this illustration, we are using an inkjet Error Indicator Table.

  • Page 66: Service Checks

    Diagnostics HELP Service Checks Service Checks Laser printers may post an error message or service check in the operator display panel. In this illustration, the service check lists steps to follow to determine if the motor is defective. The recommended approach is to start with the first item listed and proceed down the list checking each component.

  • Page 67: Post Symptom Table

    Diagnostics HELP POST Symptom Table POST Symptom Table Dot matrix printers may beep, blink LEDs, or display a error indication number to indicate a problem. If your dot matrix printer appears “dead” with no power on light and no motor movement, go to the Power Service Check.
  • Page 68 Diagnostics HELP Test Test The course exam does contain questions relating to diagnostics. Therefore, you are expected to use the If you have a machine available, review the diagnostic service manual to answer technical questions. information section at this time and perform diagnostic test and service checks as listed.
  • Page 69 Diagnostics HELP Adjustments Adjustments Review the adjustment section and make adjustments, if any, as listed. Review the preventive maintenance specifications section in the service manual, if applicable. Always follow the preventive maintenance guidelines as listed to ensure customer satisfaction and reliable machine operation.
  • Page 70 Course Summary HELP Now that you have completed these lessons, you should be able to: • Remove the covers, locate and identify all major components. Course Summary • Describe the print process. • Explain how an image is placed on paper. •...
  • Page 71 The Service Tips section contains information that may be advantageous to you. After reviewing Service Tips, go to the service training menu, click the Course Exam button, and select the printer exam for which you want to receive Lexmark certification. SERVICE TRAINING MENU SERVICE MANUAL MENU...
  • Page 72 Service Tips HELP Bidirectional Bidirectional Some Lexmark printers are capable of sending information back to the computer across the parallel interface. These printers support two communication Service Tips modes which allow status messages to be sent back to the computer.
  • Page 73 If the printer received the print job and appropriate • Use a high quality shielded cable (we recommend commands in this mode but does not respond, check Lexmark P/N 1329605 10 ft) for correct printer setup, that is., Automatic Emulation/ Mode Switching, Language, port, and so on.
  • Page 74 Service Tips HELP Transparencies Transparencies • Be careful not to touch the printed surface until the ink is dry. • Use only transparencies approved for inkjet • Do not stack multiple transparencies until dry applications. (remove them as they exit the printer). •...
  • Page 75 Service Tips HELP Power Supply Power Supply Always unplug the printer from the wall outlet when connecting the power supply into the system board to prevent damage to the system board. SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...
  • Page 76 Service Tips HELP Unplugging an inkjet printer Unplugging an inkjet printer To properly cap the ink cartridges and prevent the printhead nozzles from drying, be sure to wait for the carrier to stop moving before unplugging the printer. If the customer is using a power bar or power strip, allow the carrier time to move to the maintenance station before turning the printer off.
  • Page 77 Service Tips HELP Copying DOS Files Copying DOS Files The old “standard” method of copying a file from DOS to verify the printer is working correctly and capable of receiving the IBM Personal Printer Data Stream (PPDS), or ASCII data stream, should only be used on printers capable of receiving ASCII data.

  • Page 78: Hex Trace

    If the printer is not responding to the commands as sent, the resolution may be something as simple as checking the printer emulation mode. Your Lexmark Technical Support Center is available to help you interpret the Hex Trace print should you need assistance with a Lexmark product.
  • Page 79 Service Tips HELP Latches Latches Many of the parts are held in place with plastic latches. Avoid excessive force to release the latch. To remove such parts, press the hook end of the latch away from the part to which it latches. SERVICE TRAINING MENU SERVICE MANUAL MENU Service Training...

  • Page 80: Test Page

    Service Tips HELP Test Page Test Page If your printer has test page capability, run a test page to check the printer paper feed mechanisms and print quality. The test page is helpful when diagnosing printer problems since it can be run without the need to attach the printer to a PC.
  • Page 81 Service Tips HELP Labels Labels • Do not use label sheets with a slick backing material. • Be sure the adhesive does not come in contact with any part of the printer. • Use full label sheets. Partially used sheets (with areas exposed by missing labels) can cause labels to peel off during printing and can damage the printer.
  • Page 82 Service Tips HELP Envelope Skew Envelope Skew • If loading envelopes in the manual feeder, make sure the right edge of the envelope is against the • Make sure the envelope guides have been turned raised edge beside the envelope symbol of the to the envelope load position.
  • Page 83 HELP System Board Damage System Board Damage Lexmark inkjet printers use either a small dc motor or a stepper motor to move the carrier assembly. Note: Before moving the carrier assembly by hand, check to see which motor type is being used.

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