Lexmark WinWriter 100 Service Manual
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Lexmark WinWriter 100 Service Manual

Lexmark WinWriter 100 Service Manual

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WinWriter™ 100
4076-001
• 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 WinWriter 100

  • Page 1 WinWriter™ 100 4076-001 • 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.
  • Page 2 RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Greenwich, CT 06836.

  • Page 3: Table Of Contents

    4076-0WJ Contents Notices and Safety Information ......vi Electronic Emission Notices ......vi Federal Communications Commission (FCC) Statement .
  • Page 4 4076-0WJ Service Checks ........8 Envelope Feed Service Check .
  • Page 5 4076-0WJ Repair Information, Removal Procedures (continued) Paper Ejectors Removal......32 Paper Feed Motor Removal ......32 Paper Guide Removal .

  • Page 6: Notices And Safety Information

    4076-0WJ Notices and Safety Information References in this publication to products, programs, or services do not imply that the manufacturer intends to make these avail- able in all countries in which it operates. Any reference to a prod- uct, program, or service is not intended to state or imply that only that product, program, or service may be used.

  • Page 7: Canadian Department Of Communications Compliance

    4076-0WJ • Consult your point of purchase or service representative for additional suggestions. The manufacturer is not responsible for any radio or television interference caused by using other than recommended cables or by unauthorized changes or modifications to this equipment. Unauthorized changes or modifications could void the user’s authority to operate the equipment.

  • Page 8: Japanese Vcci Notice

    Member States relating to electromagnetic compatibil- ity. Germany A declaration of conformity with the requirements of the Directive has been signed by the Director of Manufacturing and Technical Support, Lexmark International, Ltd., Boigny, France. This product satisfies the Class B limits of EN 55022. viii...

  • Page 9: Trademarks

    4076-0WJ Trademarks Lexmark is a trademark of Lexmark International, Inc. The following terms, denoted by an asterisk (*) in this publication, are trademarks or registered trademarks of the International Business Machines Corporation in the United States and/or other countries, and are used under license:...

  • Page 10: Safety Information

    4076-0WJ Safety Information • The maintenance information for this product has been pre- pared for use by a professional service person and is not intended to be used by others. • There may be an increased risk of electric shock and per- sonal injury during disassembly and servicing of this prod- uct.

  • Page 11: Norme Di Sicurezza

    4076-0WJ Norme Di Sicurezza • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell’assistenza autorizzato. • Durante lo smontaggio e il manutenzionamento di questo prodotto, e possibile il rischio accresciuto di scosse elettriche e danni personali. Il personale di assistenza autorizzato, consapevole di cio, deve adottare le precauzioni necessarie.

  • Page 12: General Information

    4076-0WJ General Information The WinWriter 100 4076 OWJ is a general purpose high-quality ink jet printer with a customer-replaceable print cartridge containing the ink and the print head. With a total of 56 nozzles in the print head it can print at speeds of 167 cps in Letter Quality mode and 300 cps in Draft mode.

  • Page 13: Abbreviations

    4076-0WJ Abbreviations Customer Engineer Central Processing Unit Customer Setup DRAM Dynamic Random Access Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply LASER Light Amplification by Stimulated Emission of Radiation Liquid Crystal Display Light-Emitting Diode LVPS Low Voltage Power Supply Maintenance Analysis Procedures NVRAM...

  • Page 14: Diagnostic Information

    4076-0WJ Diagnostic Information Use the error code charts, symptom index, service checks, and diagnostic aids in this chapter to determine the failing part in a mal- functioning printer. Start Service error indications show up as a series of flashes of the Power On light.

  • Page 15: Error Indicator Table

    4076-0WJ Error Indicator Table Number of Error Power Light Action Code Flashes Replace the Code Module and/or system board 66 to Replace the Code Modules and/or system board Replace the Code Module and/or system board Replace the Code Module and/or the system board Go to the “Maintenance Station Service...

  • Page 16: Power-On-Self-Test (Post) Sequence

    4076-0WJ Power-on-self-test (POST) Sequence When you turn the printer on it performs a POST. Turn your machine on and check for a correct POST operation by observing the follow- ing: 1. The power light comes on. 2. The paper feed gears turn. 3.

  • Page 17: Symptom Tables

    4076-0WJ Symptom Tables Locate your symptom in the following tables and take the appropri- ate action. Carrier Transport Problems SYMPTOM ACTION • No carrier movement Go to the “Transport Service Check” • Slow carrier movement on page • Carrier stops Communications Problem SYMPTOM ACTION...

  • Page 18: Paper Feed Problems

    4076-0WJ Paper Feed Problems SYMPTOM ACTION Paper fails to stop at first print Go to the “First Print Line Service line Check” on page • Fails to pick paper Go to the “Paper Feed Service • Picks more than one sheet of Check”...

  • Page 19: Service Checks

    4076-0WJ Service Checks Envelope Feed Service Check FRU OR PROCEDURE ACTION Envelope Loading Be sure the envelope guides have been turned to the envelope load positions Be sure the envelope guides are against the envelopes Go to and perform the “Paper Feed Service Check”...

  • Page 20: Maintenance Station Service Check

    4076-0WJ Maintenance Station Service Check The maintenance station has two functions: 1. Cleans the print head nozzles during the print operation. 2. Seals the print head when it is not being used to prevent the noz- zles from drying. FRU OR PROCEDURE ACTION Maintenance Drive Assem- Disconnect J4 from the system board.

  • Page 21: Operator Panel Service Check

    4076-0WJ Operator Panel Service Check FRU OR PROCEDURE ACTION Power Supply Disconnect J11 from the system board and check the following volt- ages on the power supply cable: J11-1 to GND = +5V dc J11-3 to GND = +24 V dc If you do not have correct voltage, replace the power supply.
  • Page 22 4076-0WJ FRU OR PROCEDURE ACTION System Board With J5 disconnected and power on, check for +24 V dc between J5-3 and ground, and between J5-4 and ground on the system board. If the voltage is not present, check for motor pins shorted to the motor hous- ing.
  • Page 23 4076-0WJ FRU OR PROCEDURE ACTION Gears Check for binds in the gear train and paper feed mechanism. To do this, rotate the largest gear by hand. If you notice a bind isolate it by removing the small idler gear on the outside of the right side plate.

  • Page 24: Paper Path Service Check

    4076-0WJ Paper Path Service Check Examine the machine for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the paper guides are not worn or broken and are posi- tioned against the paper without binding or buckling the paper. •...

  • Page 25: Parallel Port Service Check

    4076-0WJ Parallel Port Service Check FRU OR PROCEDURE ACTION Parallel Port Run a test page to be sure the printer can print. Run the“Parallel Port Test” on page 19. If the test fails, replace the system board. Power Service Check FRU OR PROCEDURE ACTION Power Supply...

  • Page 26: Print Quality Service Check

    4076-0WJ Print Quality Service Check FRU OR PROCEDURE ACTION Print Cartridge Be sure the machine has a known good print cartridge. Print Head Carrier Assembly Reseat the print head cable in the system board and check the following parts for wear or damage: Print Cartridge Latch Latch Spring Carrier...
  • Page 27 4076-0WJ FRU OR PROCEDURE ACTION Maintenance Station Intermittent nozzle failures can be caused by worn parts in the mainte- nance station. Go to and perform the “Maintenance Station Service Check” on page 9, then return to this check. Paper Feed Ink smudging and smearing can be caused by paper problems or prob- lems in the paper feed area.

  • Page 28: Transport Service Check

    4076-0WJ Transport Service Check FRU OR PROCEDURE ACTION Transport Motor Check the motor for binds, or loose motor pulley. Disconnect the transport motor (J6) from the system board. Check for 8 to 18 ohms between pins 1 and 2 on the motor cable.

  • Page 29: Diagnostic Aids

    4076-0WJ Diagnostic Aids Use these diagnostic test procedures to verify a repair. The test pro- cedures are entered by first turning the machine off, moving the two- pin jumper on connector J12, then turning the machine on. J12 is accessed through the door opening on the right side of the machine. The test begins when the power button is pressed.

  • Page 30: Parallel Port Test

    4076-0WJ The numbers across the bottom of the page are used in manufactur- ing. The last number on this line is the last occurring error code. This number coincides with the flashing power on light and indicates the type of error indication. Additional pages print the same as the first page without the purge pattern.

  • Page 31: Initialize Error Log

    4076-0WJ Initialize Error Log Use this procedure to reset the error log to zero. The paper sensor must be open to perform this function. To do this, place a piece of paper in the manual paper feed slot before you turn the machine on. Resetting the error log allows you to track new errors.

  • Page 32: Repair Information

    4076-0WJ Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. WARNING: Read the following before handling electronic parts. Handling ESD-sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).

  • Page 33: Adjustments

    4076-0WJ • Be extra careful in working with ESD-sensitive parts when cold- weather heating is used because low humidity increases static electricity. Adjustments Bi-directional Alignment Adjustment The bi-directional alignment can be checked by printing a test page. The adjustment is correct when the vertical bars appear straight. To adjust the bi-directional alignment: 1.

  • Page 34: Removal Procedures

    4076-0WJ Removal Procedures The following procedures are arranged in alphabetical order accord- ing to the name of the printer part discussed. When there is artwork to support a procedure, it follows the text. 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.

  • Page 35: Auto Sheet Feed (Asf) Removal

    4076-0WJ Auto Sheet Feed (ASF) Removal 1. Remove the top cover. 2. Push in the two latches [A] that secure the auto sheet feed to the side frame, then lift up the auto sheet feed to remove it from the machine.

  • Page 36: Asf Right And Left Edge Guide Assemblies Removal

    4076-0WJ ASF Right And Left Edge Guide Assemblies Removal 1. Remove the auto sheet feed. 2. Remove the manual insert tray by prying one of the side frames away from it. 3. Remove the inside C-clip from the pick roller shaft and pull the shaft out to the right.

  • Page 37: Carrier Transport Belt Removal

    4076-0WJ Carrier Transport Belt Removal 1. Remove the top cover. 2. Move the carrier in line with the opening in the carrier transport motor frame. 3. Reach through the opening and pull the belt from the carrier. 4. Remove the belt from the carrier transport motor pulley. 5.

  • Page 38: Carrier Transport Motor Frame Removal

    4076-0WJ Carrier Transport Motor Frame Removal 1. Remove the top cover. 2. Disconnect J6 from the system board. 3. Move the carrier in line with the opening in the carrier transport motor frame. 4. Reach through the opening and pull the belt from the carrier. 5.

  • Page 39: Encoder Strip Removal

    4076-0WJ Encoder Strip Removal 1. Remove the top cover. 2. Move the carrier in line with the opening on the carrier transport motor frame. 3. Reach through the opening and pull the belt from the carrier. 4. Rotate the carrier guide rod top-to-rear to unlock the rod latches. Gently push the carrier guide rod latches at each end of the rod to the rear and lift up the rod until the sensor on the carrier clears the encoder strip.

  • Page 40: Feed Arm Assembly Removal

    4076-0WJ Feed Arm Assembly Removal 1. Remove the top cover. 2. Remove the auto sheet feed. 3. Remove the C-clip from the center of the large gear and remove the feed arm assembly. Inside Idler Gears Removal 1. Remove the top cover. 2.

  • Page 41: Maintenance Drive And Rocker Assemblies Removal

    4076-0WJ 9. Rotate the carrier guide rod top-to-rear to unlock the rod latches. Gently push the carrier guide rod latches, at each end of the rod, to the rear and lift up the rod until the sensor on the carrier clears the encoder strip.

  • Page 42: Middle Frame Removal

    4076-0WJ Middle Frame Removal 1. Remove the top cover. 2. Remove the print cartridge. 3. Remove the auto sheet feed. 4. Disconnect the print head cables from the system board. 5. Disconnect J4, J5, and J6 from the system board. 6.

  • Page 43: Paper Ejectors Removal

    4076-0WJ Paper Ejectors Removal 1. Remove the top cover. 2. Pivot the paper ejector pusher toward the front then pull it to remove the paper ejector from the shaft. 3. Unsnap the paper ejectors from the middle frame. Paper Feed Motor Removal 1.

  • Page 44: Paper Release Lever Removal

    4076-0WJ Paper Release Lever Removal 1. Remove the top cover. 2. Pull the paper release lever forward. 3. Place a screw driver into the slot [A] of the paper release lever. Push the screw driver down to release the latch, then remove the lever.

  • Page 45: Print Head Cable Removal

    4076-0WJ Print Head Cable Removal 1. Remove the top cover. 2. Remove the print cartridge. 3. Remove the carrier. 4. Remove the cable clip [A] from the left side of the carrier. 5. Remove the pointer from the front of the carrier. 6.

  • Page 46: Right Side Frame Removal

    4076-0WJ Right Side Frame Removal 1. Remove the top cover. 2. Remove the print cartridge. 3. Remove the auto sheet feed. 4. Disconnect the print head cables from the system board. 5. Disconnect connectors J4, J5, and J6 from the system board. 6.

  • Page 47: Rubber Backer Removal

    4076-0WJ To install the right side frame onto the middle frame, align the right side frame latch with the latching surface on the mid frame before you align the roller shafts and carrier guide. It may be easier to do this with the machine on its left side.

  • Page 48: System Board Removal

    4076-0WJ System Board Removal 1. Remove the top cover. 2. Disconnect the print head cables from the system board. 3. Disconnect connectors J4, J5, and J6 from the system board. Remove the machine from the base. To do this, push the frame latches out as you lift the machine from the base.

  • Page 49: Top Cover Removal

    4076-0WJ Top Cover Removal 1. Unplug the power cord and the interface cable from the back of the printer. 2. Unlatch the auto sheet feed left cover by pushing it up from the bottom, then slide it off the machine. 3.

  • Page 50: Connector Locations

    4076-0WJ Connector Locations This chapter shows the locations of major printer assemblies, con- nectors, and ground straps. System Board Connectors .CE/TP Connector Locations...
  • Page 51 4076-0WJ Connector Connector Names Print Head Cable Print Head Cable Maintenance Motor Paper Feed Motor Transport Motor Parallel Port Operator Panel Power Supply Test Jumper Code Module Connector Locations...

  • Page 52: Preventive Maintenance

    4076-0WJ Preventive Maintenance This chapter contains the lubrication specifications. Following these recommendations can help prevent problems and maintain optimum performance. Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use no. 23 grease to lubricate the following: •...

  • Page 53: Parts Catalog

    4076-0WJ Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a major- ity 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 sep- arately and identified by description.

  • Page 54: Assembly 1: Covers

    4076-0WJ Assembly 1: Covers...
  • Page 55 4076-0WJ Asm- Part Units Description Index Number 1367099 Top Cover 1367487 Access Cover Asm 1367486 Font Card Door 1367479 Rear Cover 1367493 Left Output Guide 1374401 Logo Screw, Parts Packet 1367169 Washer, Parts Packet 1367169 1374409 Microsoft at Work Label...

  • Page 56: Assembly 2: Frames

    4076-0WJ Assembly 2: Frames...
  • Page 57 4076-0WJ Asm- Part Units Description Index Number 1367489 Base Asm 1367209 Left Side Frame 1367219 Middle Frame Asm 1367229 Right Side Frame 1367309 Carrier Transport Motor Frame 1367199 Exit Tray Asm 1367079 Carrier Guide...

  • Page 58: Assembly 3: Paper Feed

    4076-0WJ Assembly 3: Paper Feed...
  • Page 59 4076-0WJ ASm- Part Units Description Index Number 1367179 Paper Release Lever Bushing, Parts Packet1367169 1367339 Paper Guide 1367279 Small Feed Roller Asm 1367289 Exit Roller Asm 1367266 Ejector B/M Spring, Parts Packet1367169 1367049 End of Forms Flag 1367269 Large Feed Roller Asm...

  • Page 60: Assembly 3: Paper Feed (Cont.)

    4076-0WJ Assembly 3: Paper Feed (Cont.)
  • Page 61 4076-0WJ Asm- Part Units Description Index Number 3-10 1367239 Paper Feed Motor Asm 1367249 Gears B/M 1367259 Feed Arm Asm C-Clip, Parts Packet 1367169 Screw, Parts Packet 1367169...

  • Page 62: Assembly 4: Electronics

    4076-0WJ Assembly 4: Electronics...
  • Page 63 4076-0WJ Asm- Part Units Description Index Number 1374402 System Board, (No Code Module) Screw, Parts Packet 1367169 1367189 Power Supply Screw, Parts Packet 1367169 Screw, Parts Packet 1367169 Screw, Parts Packet 1367169 1430317 Power Cord, US 1342536 Power Cord, Argentina 1339520 Power Cord, Austria 1339520...

  • Page 64: Assembly 4: Electronics (Cont.)

    4076-0WJ Assembly 4: Electronics (Cont.)
  • Page 65 4076-0WJ Asm- Part Units Description Index Number 1342514 Power Cord, Peru 1339520 Power Cord, Portugal 1339523 Power Cord, South Africa 1339520 Power Cord, Spain 1339520 Power Cord, Sweden 1339522 Power Cord, Switzerland 1339520 Power Cord, Turkey 1339519 Power Cord, United Kingdom 1342536 Power Cord, Uruguay 1342514...

  • Page 66: Assembly 4 Electronics (Cont.)

    4076-0WJ Assembly 4 Electronics (Cont.)
  • Page 67 4076-0WJ Asm- Part Units Description Index Number 1374403 Operator Panel Card 1374404 Operator Panel Cable Screw, Parts Packet 1367169 1374408 Power Button 1374406 Op Panel Cover...

  • Page 68: Assembly 5: Carrier

    4076-0WJ Assembly 5: Carrier...
  • Page 69 4076-0WJ Asm- Part Units Description Index Number 1367299 Print Head Carrier Asm 1367149 Cable, Print Head Screw, Parts Packet 1367169 1367109 Rubber Backer 1367089 Guide Rod, Carrier Clip, Parts Packet 1367169 1374338 Toroid, Non-Western Hemisphere...

  • Page 70: Assembly 6: Carrier Transport

    4076-0WJ Assembly 6: Carrier Transport...
  • Page 71 4076-0WJ Asm- Part Units Description Index Number 1367319 Motor Asm Screw, Parts Packet 1367169 1367359 Belt 1367379 Encoder Strip 1367349 Star Roller Asm Spring, Parts Packet 1367169 1367329 Idler Pulley B/M...

  • Page 72: Assembly 7: Auto Sheet Feed

    4076-0WJ Assembly 7: Auto Sheet Feed...
  • Page 73 4076-0WJ Asm- Part Units Description Index Number 1367497 Right Edge Guide and Width Adjust Strip 1367498 Left Edge Guide Asm 1367439 Upper Paper Support 1367469 Pick Roll and Paper Load Shaft B/M 1367463 Pick Roll Hub Asm 1367449 Left Side Cover 1367459 Right Side Cover 1367029...

  • Page 74: Assembly 8: Maintenance Station

    4076-0WJ Assembly 8: Maintenance Station...
  • Page 75 4076-0WJ Asm- Part Units Description Index number 1367369 Rocker Asm 1367399 Drive Asm 1367389 Wiper and Cap B/M Screw, Parts Packet 1367169...

  • Page 76: Index

    4076-0WJ Index Removal Carrier Transport Motor Abbreviatimons Removal Adjustments Carrier Transport Problems ASF Envelope Buckler And Pick Code Module Removal Roller Hub Removal Communications Problem ASF Paper Load Lever Removal Connector Locations ASF Right And Left Edge Guide Assemblies Removal Diagnostic Information Assembly 1 Covers...
  • Page 77 4076-0WJ Large Feed Roller Assembly Removal Procedures Removal Left Side Frame Removal Lubrication Specifications Service Checks Start Symptom Tables Maintenance Approach Maintenance Drive And Rocker Assemblies Removal Unique Tools Maintenance Station Problems Maintenance Station Service Check Operator Panel Problems Operator Panel Removal Operator Panel Service Check Outside Idler Gears Removal Paper Feed Problems...

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