Lexmark 5000 Service Manual
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Lexmark 5000 Service Manual

Lexmark 5000 Service Manual

Color jetprinter photo jetprinter 4093/4094
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5000 and 5700 Color Jetprinter™
5770 Photo Jetprinter
4093/4094
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
• Manuals Menu
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark 5000

  • Page 1 5000 and 5700 Color Jetprinter™ 5770 Photo Jetprinter 4093/4094 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the...
  • Page 2 Comments may be addressed to Lexmark International, Inc., Department D22/035-3, 740 New Circle Road N.W., 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 4093/4094 Table of Contents Preface ..........ix Safety Information .
  • Page 4 Connector Locations ........5-1 System Board Connectors (5000, 5700) ..... .5-1 System Board Connectors (5770) .
  • Page 5 4093/4094 Parts Catalog ......... 7-1 How To Use The Parts Catalog .
  • Page 6 4093/4094 Service Manual...

  • Page 7: Preventive Maintenance

    4093/4094 Preface This manual 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 8: 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 9 Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.
  • Page 10 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
  • Page 11 Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. • La informació pel manteniment d’aquest producte està...
  • Page 12 4093/4094 4093/4094 Service Manual...

  • Page 13: General Information

    192 nozzles and installs on the left. The printer is capable of printing in two directions. The Lexmark Photo Jetprinter 5770 printer is a general purpose printer that provides high quality text and photos. The 5770 can be used without a computer to print photos or connected to a computer.

  • Page 14: Lights And Buttons (5770)

    4093/4094 Lights and Buttons (5770) The printer has two sets of lights and buttons: • One set is located at the bottom left-hand corner of the printer, on the operator panel. • The other set is located at the top of the printer and includes the Paper Status light and Paper Feed button.

  • Page 15: Operator Panel And Menu (5770)

    4093/4094 Operator Panel and Menu (5770) Using the Operator Panel The operator panel, on the front left side of the printer, has a 2-line by 16-character liquid crystal display (LCD), five buttons and one indicator light. Operator Panel Display Busy Light Select Menu Print...
  • Page 16 4093/4094 Operator Panel Buttons Menu Used to scroll through the Menus. Select Used to select menu item - An asterisk (*) indicates an item is selected. Print Used to print a photo - Press and hold this button to cancel print when the light is blinking. Index Used to print an index page containing small images of all photos on the camera card.

  • Page 17: Resolution And Print Speed

    4093/4094 Resolution and Print Speed 600 X 300 Draft 600 X 300 Draft 600 X 600 Letter Quality 600 X 600 Letter Quality 1200 X 1200 Ultra High Quality 1200 X 1200 Ultra High Quality 3 page/minute Draft 8 page/minute Draft Power Consumption •...

  • Page 18: Abbreviations

    4093/4094 Abbreviations Customer Setup End of Forms Electrostatic Discharge Field Replaceable Unit High Voltage Light-Emitting Diode Low Voltage NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer POST Power-On Self Test V ac Volts alternating current V dc Volts direct current Service Manual...

  • Page 19: Diagnostic Information

    4093/4094 2. Diagnostic Information Use the error indicator table, symptom tables, service checks, and diagnostic aids to determine the failing part. Start Service error indications show as a series of flashes of the Paper Status light. There is a pause between each series of flashes. If your printer has an error indication, locate the series of flashes in the “Error Indicator Table”...

  • Page 20: Error Indicator Table

    4093/4094 Error Indicator Table Go to the “Transport Service Check” on page 2-18. Replace the system board. Go to the “Transport Service Check” on page 2-18. Check the carrier for obstruction or binds. If no obstruction or bind, replace the system board. 6, 7 64-78 Replace the system board.

  • Page 21: Power-On Self Test (Post) Sequence

    4093/4094 Power-On Self Test (POST) Sequence Plug the printer in and check for a correct POST operation by observing the following: 1. The Paper Status light comes on and goes off. 2. The carrier moves over the maintenance station and seals the printheads.

  • Page 22: Post Symptom Table

    4093/4094 POST Symptom Table No motors run Go to the “Power Service Check” on page 2-15. Paper feed Go to the “Paper Feed Service Check” on page 2-11. gears do not turn Carrier does not Go to the “Transport Service Check” on page 2-18.

  • Page 23: Symptom Tables

    4093/4094 Symptom Tables Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems • No carrier movement Go to the “Transport Service Check” • Slow carrier movement on page 2-18. • Carrier stops • Carrier slams side frame Communications Problems Printer not communicating with Check the parallel port connection...
  • Page 24 4093/4094 Photo Controller Problems (5770) Prints from a PC but does not Go to the “Photo Controller Service print from a flash card. Check (5770)” on page 2-14. Prints from a Flash Card but does not print from a PC. Paper Feed Problems Paper fails to stop at first print line Go to the...
  • Page 25 4093/4094 Print Quality Problems • Voids in characters Go to the “Print Quality Service • Light print Check” on page 2-16. • Prints off the page • Fuzzy print • Carrier moves but does not print • Printhead drying prematurely •...

  • Page 26: Service Checks

    4093/4094 Service Checks First Print Line Service Check End-of-Forms Check the flag for binds or damage. Flag End-of-Forms Check the sensor for dirt. Sensor System Board Perform the “End of Forms (EOF) Test” on page 3-5 to check the end-of-forms sensor on the system board.

  • Page 27: Maintenance Station Service Check

    4093/4094 Maintenance Station Service Check The maintenance station has two functions: 1. Cleans the printhead nozzles during the print operation. 2. Seals the printhead when it is not being used to prevent the nozzles from drying. Maintenance As the carrier moves to the right over the Station Assembly maintenance station, a slot on the bottom of the carrier engages a tab on the sled of the...

  • Page 28: Operator Panel Display Service Check

    4093/4094 Operator Panel Button Service Check (5770) Operator Panel If the operator panel display is OK, but the buttons Cable do not function, check the operator panel cable for continuity and replace the cable if necessary. If the Photo Controller symptom remains, replace the photo controller Board board.

  • Page 29: Paper Feed Service Check

    4093/4094 Paper Feed Service Check If your printer does not have paper jams, continue with the service check. If your printer 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 30: Paper Path Service Check

    4093/4094 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 31: Parallel Port Service Check

    4093/4094 Paper Path Service Check Examine the printer for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the paper guides are not worn or broken and are positioned against the paper without binding or buckling the paper.

  • Page 32: Photo Controller Service Check

    4093/4094 Photo Controller Service Check (5770) If the printer prints from a PC, but does not print from a Flash Card, or the printer prints from a Flash Card but does not print from a PC, continue with this service check. Photo Controller Disconnect the photo controller assembly from the Board...

  • Page 33: Power Service Check

    4093/4094 Power Service Check Power Supply Disconnect the power connector from the system board at (J4) and check the following voltages on the power supply cable: J4-3 to GND = +30 V dc If you do not have correct voltage, replace the power supply.

  • Page 34: Print Quality Service Check

    4093/4094 Print Quality Service Check Action Print Cartridge Be sure the printer contains good print cartridges. Printhead Carrier Reseat the printhead cables in the system board Assembly and check the following parts for wear or damage: • Print Cartridge Latch •...
  • Page 35 4093/4094 Action Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: • Correct type of paper is being used. • Paper for curl or wrinkles. • Feed rollers for wear, dirt, or looseness. •...

  • Page 36: Transport Service Check

    4093/4094 Transport Service Check Transport Motor Check the motor for binds, or loose motor pulley. Disconnect the transport motor (J5) from the system board. Check for 8 to 18 ohms between pins 1 and 2 on the motor cable. If the reading is incorrect, replace the motor.
  • Page 37 4093/4094 Maintenance A problem with the maintenance station can cause Station carrier movement problems at the right margin. Go to the “Maintenance Station Service Check” on page 2-9. 2-19 Diagnostic Information...
  • Page 38 4093/4094 2-20 Service Manual...

  • Page 39: Diagnostic Aids

    4093/4094 3. Diagnostic Aids Paper Pick Assembly Operation The paper pick assembly is a paper pick device that generates its own normal force which is inherent in the fundamental design of the pick arm. If light media is used, the paper pick assembly picks very gently;...
  • Page 40 4093/4094 Code Level (5770) Displays the current code level on the Controller Board. Code upgrades to the Photo Controller Board can be down loaded from either camera card slot or through the parallel port such as an external storage drive. Use the following procedure to upgrade the code.
  • Page 41 4093/4094 CompactFlash Test (5770) The purpose of this test is to check the connection between a CompactFlash camera card and the Photo Controller Board. This test performs a write, read and erase to the camera card. To run the CompactFlash Test: 1.
  • Page 42 4093/4094 Controller Port Test (5770) This test is not used for servicing the printer. DRAM Test (5770) The purpose of this test is to check the validity of DRAM on the Photo Controller Board. The test writes patterns of data to DRAM to verify that each bit in memory can set and read correctly.

  • Page 43: End Of Forms (Eof)Test

    4093/4094 End of Forms (EOF) Test This test checks the EOF sensor on the system board. During the test, the Busy light remains on and shows the EOF sensor status as follows: • On - paper is in sensor • Off - paper is not in sensor To run the test: 1.

  • Page 44: Test Page

    4093/4094 Test Page This test prints the test page. To run a complete test page of black and color patterns, be sure the print cartridges are in good condition. Install a black print cartridge in the right side of the printhead cradle and a color print cartridge in the left side.

  • Page 45: Repair Information

    4093/4094 4. Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. Note: Read the following before handling electronic parts. When working on the printer, always unplug the printer from the electrical outlet.

  • Page 46: Adjustments

    4093/4094 Adjustments The user is directed, in the Printer Control program, to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. Unplug the power cord before removing any parts.

  • Page 47: Base Assembly Removal

    4093/4094 Base Assembly Removal 1. Remove the four screws from the left and right exit tray bases and remove the bases. During reassembly, do not overtighten the screws, as this may strip the plastic. 2. Remove the accent cover. 3. Remove the three screws from the left and right covers. 4.

  • Page 48: Carrier Frame Assembly Removal

    4093/4094 Carrier Frame Assembly Removal 1. Remove all covers, refer to “Covers (Complete) Removal” on page 4-5. 2. Disconnect the power connector at the system board. 3. Remove the sheet feeder assembly. 4. Remove the three screws securing the carrier frame to the base cover.

  • Page 49: Covers (Complete) Removal

    4093/4094 Covers (Complete) Removal 1. Open the access door and remove the accent cover. 2. Remove one screw from the left cover and two screws from the right cover. 3. Lay the machine on its back and remove the four screws from the left and right tray bases.

  • Page 50: Cover (Center) Removal

    4093/4094 Cover (Center) Removal 1. Remove the two screws from the right exit tray base and remove the base. During reassembly, do not overtighten the screws, as this may strip the plastic. 2. Open the access door and lift the top edge of the accent cover pulling forward to remove.

  • Page 51: Encoder Strip Removal

    4093/4094 Encoder Strip Removal 1. Remove all covers (except the base), refer to “Covers (Complete) Removal” on page 4-5. 2. Remove the printhead carrier assembly. 3. Gently release the tension on the encoder strip by flexing the encoder strip tensioner and remove the encoder strip. Note: When reinstalling the encoder strip, make sure the ends of the strip are centered in their mounting notches and the strip does not bind in the encoder card on the carrier.

  • Page 52: Exit Drive Belt Removal

    4093/4094 Exit Drive Belt Removal 1. Remove all covers, refer to “Covers (Complete) Removal,” on page 4-5. 2. Remove the carrier frame assembly. 3. Remove the two screws from the star roller assembly and remove the assembly. Do not overtighten the screws, as this may strip the plastic.

  • Page 53: Gear Plate Removal

    4093/4094 Gear Plate Removal 1. Remove all covers, refer to “Covers (Complete) Removal,” on page 4-5. 2. Unplug the power connector. 3. Remove the frame from the base and remove the carrier. 4. Remove the maintenance station assembly. 5. Remove the mid-frame assembly. 6.

  • Page 54: Maintenance Station Assembly Removal

    4093/4094 Maintenance Station Assembly Removal 1. Open the access cover. 2. Remove the accent cover. 3. Remove the right exit tray base. 4. Remove the right cover. 5. Unlatch the two clips at the rear of the maintenance station and slide the assembly forward, out of the printer.

  • Page 55: Paper Feed Motor Removal

    4093/4094 Paper Feed Motor Removal 1. Remove the accent cover. 2. Remove the screws from the left and right covers. During reassembly, do not overtighten the screws, as this may strip the plastic. 3. Remove the right and left exit tray bases. 4.

  • Page 56: Printhead Cable And Cradle Removal

    4093/4094 Printhead Cable and Cradle Removal 1. Remove the accent, right and center covers. 2. Remove the printhead carrier assembly. 3. Disconnect the printhead cable from the encoder card. Note the routing of the cable under the retaining clip on the carrier. 4.

  • Page 57: Printhead Carrier Assembly Removal

    4093/4094 Printhead Carrier Assembly Removal 1. Remove all covers (except the base), refer to “Covers (Complete) Removal” on page 4-5. 2. Unlock the three printhead cable connectors and disconnect the printhead cable from the system board. 3. Remove the spring clips from the ends of the carrier guide rod and move the carrier to the left.

  • Page 58: Printhead Rubber Backer Removal

    4093/4094 Printhead Rubber Backer Removal 1. Remove all covers, refer to “Covers (Complete) Removal” on page 4-5. 2. Remove the printhead carrier assembly. 3. Separate the cradle from the printhead carrier assembly by pushing out the cradle latches [A]. 4. Remove the rubber backer and paper deflector from under the printhead carrier cable.

  • Page 59: Sheet Feeder Removal

    4093/4094 Sheet Feeder Removal 1. Remove all covers (except the base), refer to “Covers (Complete) Removal” on page 4-5. 2. Remove the three screws that secure the sheet feeder to the carrier frame. During reassembly, do not overtighten the screws, as this may strip the plastic.
  • Page 60 4093/4094 4-16 Service Manual...

  • Page 61: Connector Locations

    4093/4094 5. Connector Locations System Board Connectors (5000, 5700) Printhead Cable 1 Printhead Cable 2 Printhead Cable 3 Power Connector Transport Motor Parallel Port Paper Feed Switch EOF Sensor Connector Locations...

  • Page 62: System Board Connectors (5770)

    4093/4094 System Board Connectors (5770) Printhead Cable 1 Printhead Cable 2 Printhead Cable 3 Power Connector Transport Motor Paper Feed Motor Photo Controller Cable Photo Controller Cable Shield Paper Feed Switch EOF Sensor Service Manual...

  • Page 63: Photo Controller Board Connectors (5770)

    4093/4094 Photo Controller Board Connectors (5770) Parallel Port CompactFlash Card Operator Panel SmartMedia Card Photo Controller to System Board Connector Locations...
  • Page 64 4093/4094 Service Manual...

  • Page 65: Lubrication Specifications

    4093/4094 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 66 4093/4094 Service Manual...

  • Page 67: Parts Catalog

    4093/4094 7. Parts Catalog How To Use The 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 68: Covers

    4093/4094 Assembly 1: Covers Service Manual...
  • Page 69 17A0100 Exit Tray Asm (4093-S01,S04) 17A0101 Exit Tray Asm (4093-S02) 13A3857 Gutter Pad 7349594 Plain Package B/M (5000-5700)includes: (Carton, Cushion Set, Sealing Tape) 7350305 Plain Package B/M (5770) includes: (Carton, Cushion Set, Sealing Tape) 12G0149 Packet of 20 Feet Parts Catalog...

  • Page 70: Frames

    4093/4094 Assembly 2: Frames Service Manual...
  • Page 71 4093/4094 Assembly 2: Frames Asm- Part Units Description Index Number 17A0132 Sheet Feeder Asm (4093-S01,S04) (4094-S01) 17A0133 Sheet Feeder Asm (4093-S02) (4094-S02) 17A0138 Screws, PP 12G0249 Washers, (packet of 10) ASF Right Mounting Screw (PP) 17A0493 Printhead Cable Guide Strip & Clip 17A0748 Pulley Cuff &...

  • Page 72: Paper Feed

    4093/4094 Assembly 3: Paper Feed Service Manual...
  • Page 73 4093/4094 Assembly 3: Paper Feed Asm- Part Units Description Index Number 17A0132 Sheet Feeder Asm (4093-S01,S04) (4094-S01) 17A0133 Sheet Feeder Asm (4093-S02)(4094-S02) 17A0106 Small Feed Roll Asm w/Holder & Flag 17A0104 Mid Frame 17A0138 Bushing, Large Feed Roll (PP) 17A0108 Large Feed Roll Asm 17A0111 Exit Roller and Pulley B/M...

  • Page 74: Electronics

    4093/4094 Assembly 4: Electronics Service Manual...
  • Page 75 4093/4094 Assembly 4: Electronics Asm- Part Units Description Index Number 13A4494 .5mm to 1 mm conversion kit for 4093 (Contains Carrier Asm and System Board) 13A4497 .5mm to 1 mm conversion kit for the 4094 (Contains Carrier Asm and System Board) 17A0116 System Board - See Notice below 1 mm width (4093-S01, S02)

  • Page 76: Carrier

    4093/4094 Assembly 5: Carrier 7-10 Service Manual...
  • Page 77 4093/4094 Assembly 5: Carrier Asm- Part Units Description Index Number 17A0139 Printhead Carrier Asm - see “Cable Notice” on page 7-9 1 mm width (4093-S01, S02, S04) 17A0140 Printhead Carrier Asm - see “Cable Notice” on page 7-9 1 mm width (4094-S01, S02) 17A0126 Encoder Card Asm w/ Thermistor (4093-S01, S02, S04)

  • Page 78: Carrier Transport

    4093/4094 Assembly 6: Carrier Transport 7-12 Service Manual...
  • Page 79 4093/4094 Assembly 6: Carrier Transport Asm- Part Units Description Index Number 17A0129 Motor, Carrier Transport Asm & Pulley (DC) 17A0130 Carrier Belt 17A0131 Encoder Strip 17A0138 Idler Pulley Tension Asm (PP) 17A0138 Screw, Carrier Transport Motor (PP) 12G0164 Retainer, Encoder Strip (5 in packet) 7-13 Parts Catalog...

  • Page 80: Sheet Feeder

    4093/4094 Assembly 7: Sheet Feeder 7-14 Service Manual...
  • Page 81 4093/4094 Assembly 7: Sheet Feeder Asm- Part Units Description Index Number 17A0132 Sheet Feeder Asm (4093-S01,S04) (4094-S01) 17A0133 Sheet Feeder Asm (4093-S02) (4094-S02) 17A0102 Support, Paper (4093-S01,S04) (4094-S01) 17A0103 Support, Paper (4093-S02) (4094-S02) 17A0134 Paper Pick Assembly 17A0135 Belt, Sheet Feeder Drive 7-15 Parts Catalog...

  • Page 82: Maintenance Station

    4093/4094 Assembly 8: Maintenance Station 7-16 Service Manual...
  • Page 83 4093/4094 Assembly 8: Maintenance Station Asm- Part Units Description Index Number 17A0136 Maintenance Station Asm 2, 3 17A0137 Wiper and Cap B/M (one of each) 7-17 Parts Catalog...

  • Page 84: Photo Controller

    4093/4094 Assembly 9: Photo Controller 7-18 Service Manual...
  • Page 85 4093/4094 Assembly 9: Photo Controller Asm- Part Units Description Index Number 12G0142 Board, Photo Controller 12G0145 Cables, Operator Panel and System Board and a System Board Cable Shield. 14R0172 Power Supply, External 100 V 14R0173 Power Supply, External 120-127 V 14R0174 Power Supply, External 220-240 V 12G0146...
  • Page 86 4093/4094 7-20 Service Manual...
  • Page 87 7-16 Print Quality 9 Photo Controller 7-18 Removal Connectors Removals Photo Controller (5770) Base Assembly System Board (5000, 5700) Carrier Belt System Board (5770) Carrier Frame Carrier Transport Motor Center Cover Diagnostic Aids Covers (Complete) End of Forms Test Encoder Card...
  • Page 88 4093/4094 Small Feed Roller 4-15 13A3593 Star Roller 4-15 13A3594 System Board 4-15 13A3595 13A3840 13A3841 13A3842 Safety Information viii 13A3843 Service Checks 13A3844 First Print Line 13A3845 Maintenance Station 13A3846 Paper Feed 2-11 13A3847 Paper Path 2-13 13A3848 Parallel Port (5770) 2-13 13A3849 Power...
  • Page 89 4093/4094 17A0129 7-13 17A0130 7-13 17A0131 7-13 17A0132 7-15 17A0133 7-15 17A0134 7-15 17A0135 7-15 17A0136 7-17 17A0137 7-17 17A0138 7-11 7-13 17A0139 7-11 17A0140 7-11 17A0493 17A0748 7349594 I-23 Index...
  • Page 90 4093/4094 I-24 Service Manual...

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