Lexmark X63 Service Manual
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Lexmark X63 Service Manual

Lexmark X63 Service Manual

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Lexmark X63
All-In-One
4400-001
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark X63

  • Page 1 Lexmark X63 All-In-One 4400-001 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    4400-001 Table of Contents Safety Information........v Preface .
  • Page 4 4400-001 Releasing Plastic Latches ......4-2 Removals ......... . .4-3 General Precautions on Removals.

  • Page 5: 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 6 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 7 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 8 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 9 4400-001 Safety Information...

  • Page 10: Preface

    4400-001 Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed. 2.

  • Page 11: General Information

    4400-001 1. General Information The Lexmark™ X63 All-In-One is a letter quality print, fax, copy and scan machine. The printhead uses small heater plates and nozzles to control ink flow and the formation of characters on the print media. The printhead assembly and ink supply are combined into a single unit.

  • Page 12: Specifications

    4400-001 Specifications Printer Engine Technology Thermal Inkjet 2-pin and printhead swapping type Speed Color 6 ppm at Draft Mode Mono 12 ppm at Draft Mode Resolution Color 600 X 600 dpi (1200 X 2400 dpi Addressable) Mono 600 X 600 dpi (1200 X 2400 dpi Addressable) Printing Width 203 mm...

  • Page 13: Facsimile

    4400-001 Facsimile General Compatibility ITU-G3 Scan Method Scan Width Maximum 216 mm, Effective 210 mm Scan Resolution 300 X 300 dpi Scan Speed 7 seconds Feeding Method Sheet-Feed 20 sheets of 20 pound Guide Document Input Guide Stacker Document Output Stacker/Paper Stacker Paper Tray Bin Type (without Manual Tray)
  • Page 14 4400-001 Telephone Speed Dial 70 locations Chain Dial On-Hook Dial Yes, 1-Key Last Number Redial Yes, 1-Key Auto Redial Hold and Mute Pause Yes, use Redial Key Ringer Volume S/W Option Setting (4 steps) Tone/Pulse Select Only Tone Mode DRPD USA: Yes, Other Countries: No Report and TX/RX Journal...

  • Page 15: Scanner

    4400-001 Scanner Compatibility TWAIN Technology Platen CIS Light Source for Color CIS RGB LEDs (Line Order Control) Power and Size Power Source 110V-240V / 50Hz-60Hz Dimensions 440.6 X 319.6 X 205.4 mm Weight (Packed Weight) 5.6 Kg (8.0 Kg packed weight) Abbreviations Auto Sheet Feed Bill of Material...
  • Page 16 4400-001 Service Manual...

  • Page 17: Diagnostic Information

    4400-001 2. Diagnostic Information Start Power-On Self Test (POST) Sequence 1. CIS light turns on then turns off. 2. Carrier moves to the left and the paper feed motor runs then stops. 3. Carrier returns to the right. 4. “Powering Up Please Wait” is displayed on the LCD. 5.

  • Page 18: Post Symptom Table

    4400-001 POST Symptom Table Symptom Action LCD or operator Go to the “Power Service Check” on page 2-15. If okay, panel buttons do go to the “Operator Panel Problems” on page 2-3. not work and no motors run Paper feed Go to the “Paper Feed Service Check”...

  • Page 19: Symptom Tables

    4400-001 Symptom Tables Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems Symptom Action • No carrier movement Go to the “Carrier Transport • Slow carrier movement Service Check” on page 2-7. • Carrier stops •...
  • Page 20 4400-001 Symptom Action Document scan sensor does not Check operator panel cable detect document connector CN17 on the system board. If okay, go to the “Scanner Motor with Gear Assembly Service Check” on page 2-10. If the scanner motor is working correctly, replace the operator panel assembly.
  • Page 21 4400-001 Printer Communication Table Symptom Action Not able to print Self Test Page Check the USB cable and system board cable connections. If okay, replace system board. Go to the “System Board Removal” on page 4-21. Scanner Problems Symptom Action Light does not turn on Go to the “CIS Assembly Service...
  • Page 22 4400-001 Paper Feed Problems Symptom Action • Fails to pick paper Go to the “Paper Feed Service • Picks more than one sheet of Check” on page 2-12. paper • Picks paper but fails to feed • Paper jams • Paper fails to exit •...

  • Page 23: Service Checks

    4400-001 Service Checks Carrier Transport Service Check Action System Board Check the carrier transport motor connector CN5. If connected, check for approximately 28 volts on Carrier Transport pins 1 and 2 or at the wire connections located on Motor the rear of the carrier transport motor. If voltage is incorrect, replace the system board.
  • Page 24 4400-001 Action Encoder Strip Check the encoder strip for proper installation. Also, check it for wear, dirt and grease. Replace if Carrier Assembly needed. with Belt Be sure all printhead connectors are fully seated. Check the cables for damage. If the encoder strip and all connections are okay, but the carrier still slams the side frame, replace the carrier assembly with belt.

  • Page 25: Cis Assembly Service Check

    4400-001 CIS Assembly Service Check The CIS lamp does not light when scanning is in process or during the (POST) sequence. Action CIS Assembly If light does not come on during the scanning process, check connector CN13 on the system board. If the connection is okay, check for a voltage reading of approximately 4 volts from ground to CN13-2 pin.

  • Page 26: Scanner Motor With Gear Assembly Service Check

    4400-001 Scanner Motor with Gear Assembly Service Check Motor will not run. Action Scanner Motor with Gear Check scanner motor for shorts. Assembly Disconnect connector CN8 from the system board and check for approximately 12.5 ohms between the following pins on the motor connector.

  • Page 27: Maintenance Station Service Check

    4400-001 Maintenance Station Service Check The maintenance station has three functions: 1. Wipes the printhead nozzles to clean them of dirt. 2. Provides a place for printheads to fire all nozzles, keeping them clear prior to printing. 3. Seals the printhead when it is not being used to prevent the nozzles from drying.

  • Page 28: Paper Feed Service Check

    4400-001 Paper Feed Service Check If your machine does not have paper jam problems, continue with the service check. If your machine does have a paper jam problem, examine it for the following before you begin the service check: • Check the entire paper path for obstructions.
  • Page 29 4400-001 Action Paper Feed Motor A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or short in the motor • An open or short in the motor driver on the system board •...

  • Page 30: Paper Path Service Check

    4400-001 Paper Path Service Check Examine the machine for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the correct type of paper is being used. • Be sure the printer is installed on a flat surface. Action Large and Small Check for wear and binds.

  • Page 31: Power Service Check

    4400-001 Power Service Check Action Power Supply Plug the machine into an outlet. Check for approximately 30 V dc at J5 pin 1. If voltage is incorrect, replace the power supply. Printhead Cables Unplug the printer. Disconnect the printhead Paper Feed Motor cables and plug in the printer.

  • Page 32: Print Quality Service Check

    4400-001 Print Quality Service Check FRU / Function Action Printhead Be sure the machine contains good print Cartridge cartridges. Color Printhead Cross contamination of color inks results in Cartridge Cross incorrect colors printed, as when green prints for Contamination yellow, (when yellow and blue are mixed in the printhead cartridge).
  • Page 33 4400-001 FRU / Function 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. Also check the paper for curl or wrinkles. •...

  • Page 34: Scan/Copy Quality Service Check

    4400-001 Scan/Copy Quality Service Check FRU / Function Action Scanned images Check the lighter/darker settings to see if it is are: faded, or correct. colors are dull, blurry or fuzzy. • From the operator panel Images are • From the Scan & Copy Control Program slanted or crooked and the straight lines in...

  • Page 35: Fax/Telephone Communication Service Check

    4400-001 Fax/Telephone Communication Service Check FRU / Function Action Line Interface No dial tone Board or System Board. Verify correct dialing method (tone or pulse). Are TEL and LINE connections reversed? Verify phone Cannot make number and availability of other fax machine. telephone connection to Before dialing, press the Speaker button so you...
  • Page 36 4400-001 2-20 Service Manual...

  • Page 37: Diagnostic Aids

    4400-001 3. Diagnostic Aids Theory of Mechanism Scanner Mechanism The scanner mechanism consists of components which feed, scan, and eject the documents that are to be copied or transmitted to a remote facsimile unit. These components and their functions are explained below.

  • Page 38: Contact Image Sensor (Cis)

    4400-001 Contact Image Sensor (CIS) The contact image sensor unit consist of LEDs, rod lens array, and a photo sensor. The LEDs illuminate the document to be scanned when the leading edge is detected by the document scan sensor. The LEDs turn off when the document exits the scanner mechanism. The LEDs illuminate the document to obtain an image from the document through the rod lens array, where the image is translated into voltage levels.
  • Page 39 4400-001 Setting up System in User Mode Setup Item Default Status Date Jan/01/01 Month - Day - Year Jan/01/01 Time 12:00:00P Hour - Minute - AM/PM 12:00 PM Print Report Fax Confirm Transmit Log Receive Log Speed Dial List Self Test Maintenance Cartridge Clean Cartridge Align...
  • Page 40 4400-001 Setting up System in Service Mode Setup Item Default Status CIS Test Red, Green and Blue maximum and minimum peak levels Aging Test Scanner Aging/ Printer Aging Print Report Fax Confirm Transmit Log Receive Log Speed Dial List Self Test Protocol Dump ASF Test System Data...
  • Page 41 4400-001 Setup Item Default Status ROM Test Modem Speed Item 14400/12000/9600/ 14400 bps (1-6) 7200/4800/2400 Set TX Level (1-15) Set RX Level (40-50) Pause Time (1-9) CIS Test The test adjusts the light of CIS. It is already set at CIS Test to get optimum quality.
  • Page 42 4400-001 Maintenance 1. Press Setup. 2. Press Menu until ‘Maintenance’ displays. 3. Press Options but ton to select, cartridge clean, cartridge align and scanner init. 4. Press Start after you select. Program Download 1. Press Setup. 2. Press Menu four times until ‘Program Download Press Start’ is displayed.
  • Page 43 4400-001 Remote RCV Code The remote receive code lets you initiate fax received from an extension phone plugged into the EXT jack. If you pick up the extension phone and hear fax tones, enter the remote receive code and the fax starts receiving. The password is preset to 9. 1.
  • Page 44 4400-001 Retry Interval 1. Press Setup. 2. Press Menu until ‘Retry Interval’ displays. 3. Enter the number of minutes (from 1 to 7) using the numbers on the keypad. Retry Count 1. Press Setup. 2. Press Menu until ‘Retry Count’ displays. 3.
  • Page 45 4400-001 Modem Test The modem sends various transmit signals on the telephone line. You can check the following: – FSK – Tones: 1100Hz, 1650Hz, 1850Hz, 2100Hz – G3 training: 14400, 12000, 9600, 7200, 4800, 2400 bps 1. Press Setup. 2. Press Menu until ‘Modem Test’ displays. DTMF Test This feature the user or tester verify that the phone keypad buttons are working correctly.
  • Page 46 4400-001 Set TX Level Default=12 dBm FCC requires that the transmission level be less than -9 dBm. From - 9 dBm to -15 dBm is acceptable. You can set the transmission level between 0 and -15 dBm in 1 dBm steps using the operator panel keypad.

  • Page 47: Repair Information

    4400-001 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. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).

  • Page 48: Adjustments

    4400-001 Adjustments The user is directed, in the Printer Control program, to perform the bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. CAUTION: Unplug the power cord before removing any parts. Releasing Plastic Latches Many of the parts are held in place with plastic latches.

  • Page 49: Removals

    4400-001 Removals General Precautions on Removals When you disassemble and reassemble components, use extreme caution. The close proximity of cables to moving parts makes proper routing a must. If components are removed or replaced, any cables disturbed must be replaced as close as possible to their original positions.

  • Page 50: Cis White Roller Assembly Removal

    4400-001 CIS White Roller Assembly Removal 1. Open the operator panel. 2. Push the bushing on both ends of the roller slightly inward, then rotate it until it reaches the slot as shown. Then lift the roller out. Note: Check the roller for any dirt. If dirty, wipe it off with soft cloth dampened with water.

  • Page 51: Top Cover Assembly Removal

    4400-001 Top Cover Assembly Removal 1. Open the operator panel and open the print cartridge compartment cover. Remove the white roller assembly. Remove the six screws as shown. 2. Remove the three screws as shown and remove the top cover assembly.

  • Page 52: Rollers (Drive Feed Roller Assembly, Exit Shaft) Removal

    4400-001 Rollers (Drive Feed Roller Assembly, Exit Shaft) Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Take out the rollers from the base assembly. Note: Clean the surface of the rollers with ethyl alcohol. After wiping them, you must dry them completely.

  • Page 53: Cis (Contact Image Sensor) Removal

    4400-001 CIS (Contact Image Sensor) Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Remove the drive feed roller. See “Rollers (Drive Feed Roller Assembly, Exit Shaft) Removal” on page 4-6. 3. Remove one screw securing the CIS assembly and unplug the CIS harness.
  • Page 54 4400-001 4. Turn the CIS assembly over. Remove one screw to release the CIS from the bracket Note: Be careful not to lose the springs. Note: Check the glassy surface of the CIS for any stain or scratch. If stained, wipe off with ethyl alcohol. If it is heavily stained or scratched, replace it.

  • Page 55: Scanner Motor With Gear Assembly Removal

    4400-001 Scanner Motor with Gear Assembly Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Unplug the motor connector from the system board. Make sure the harness is released from hooks securing the harness as shown.
  • Page 56 4400-001 3. Remove two screws as shown and remove the scan motor assembly. 4. Remove the two screws securing the motor to the motor bracket. 4-10 Service Manual...

  • Page 57: Power Supply Removal

    4400-001 Power Supply Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Unplug the power supply connector from the system board. Make sure the harness is released from the hook as shown. 4-11 Repair Information...
  • Page 58 4400-001 3. Remove one screw securing the ground wires to the bracket. 4. Push down on the hooks on both ends and remove the power supply. 4-12 Service Manual...

  • Page 59: Line Interface Board Removal

    4400-001 Line Interface Board Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Remove the one screw securing the ground wires to the bracket. 3. Unplug the line interface connector from the system board. 4-13 Repair Information...
  • Page 60 4400-001 4. Pull the snap as shown to unlock the line interface board from the system board. Push up on the line interface board. 5. Unplug all the connectors from the line interface board and remove it. 4-14 Service Manual...

  • Page 61: Operator Panel Assembly Removal

    4400-001 Operator Panel Assembly Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Disconnect the operator panel cable from the system board. 3. Release harness from harness hook. 4. Remove the two ground strap screws. 5.

  • Page 62: Printer Unit Removal

    4400-001 Printer Unit Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Remove the paper support extension. 3. Release lower paper guide tabs. 4. Release upper paper guide tab. 5. Remove the paper guide. 6.

  • Page 63: Asf Assembly Removal

    4400-001 8. Remove ground strap screw. Note: When you reassemble the unit, do not pinch or short the wire harness. ASF Assembly Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Remove paper support extension. 3.
  • Page 64 4400-001 11.Remove ASF assembly. 4-18 Service Manual...

  • Page 65: Maintenance Station Removal

    4400-001 Maintenance Station Removal 1. Remove the printer unit. 2. Remove one screw. 3. Rease two tabs from the rear of the maintenance station and remove the maintenance station.. 4-19 Repair Information...

  • Page 66: Carrier Assembly With Belt Removal

    4400-001 Carrier Assembly with Belt Removal 1. Remove the printer unit. See “Printer Unit Removal” on page 4-16. 2. Disconnect the carrier cables from the system board. 3. Release tab on carrier cable guide. 4. Release carrier cable guide from frame. 5.

  • Page 67: System Board Removal

    4400-001 System Board Removal 1. Remove the top cover assembly. See “Top Cover Assembly Removal” on page 4-5. 2. Remove two screws securing the system board. 3. Unplug all connectors. 4. Pull the sensor lever toward you and remove the system board. 4-21 Repair Information...

  • Page 68: Mid Frame Assembly With Exit Rollers Removal

    4400-001 Mid Frame Assembly with Exit Rollers Removal 1. Remove the top cover. 2. Remove the carrier assembly. 3. Remove the maintenance station. 4. Remove the encoder strip. 5. Remove two screws from friction roller assembly. 6. Remove exit roller assembly. 7.

  • Page 69: Large Feed Roller Assembly With Gear Removal

    4400-001 Large Feed Roller Assembly with Gear Removal 1. Remove the printer unit. See “Printer Unit Removal” on page 4-16. 2. Remove the mid frame assembly. See “Mid Frame Assembly with Exit Rollers Removal” on page 4-22. 3. Remove the maintenance station. 4.

  • Page 70: Paper Feed Motor Assembly With Gears Removal

    4400-001 Paper Feed Motor Assembly with Gears Removal 1. Remove the printer unit. See “Printer Unit Removal” on page 4-16. 2. Remove the large feed roller assembly. See “Large Feed Roller Assembly with Gear Removal” on page 4-23. 3. Remove the two screws and remove the paper feed motor assembly.

  • Page 71: Carrier Transport Motor Removal

    4400-001 Carrier Transport Motor Removal 1. Remove the top cover assembly. Go to the “Top Cover Assembly Removal” on page 4-5. 2. Manually move the carrier to the center of the machine. 3. Remove the idler pulley assembly spring cover retainer. 4.
  • Page 72 4400-001 4-26 Service Manual...

  • Page 73: Connector Locations

    4400-001 5. Connector Locations System Board Units Description Carrier Motor Scanner Motor CN10 Power Supply CN11 Paper Feed Motor CN12 Door Switch CN13 CN15 Line Interface Board CN16 Speaker CN17 Operator Panel Connector Locations...

  • Page 74: Logic Card

    4400-001 Logic Card Units Description System Board Phone Lines Service Manual...

  • Page 75: Power Supply

    4400-001 Power Supply Units Description System Board Connector Locations...
  • Page 76 4400-001 Service Manual...

  • Page 77: Preventive Maintenance

    4400-001 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 78 4400-001 Service Manual...

  • Page 79: Parts Catalog

    4400-001 7. Parts Catalog How to Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.
  • Page 80 4400-001 Assembly 1: Main Assembly Service Manual...
  • Page 81 4400-001 Assembly 1: Main Assembly Asm- Part Units Description Index Number 12G6933 Support, Paper Extension 12G6932 Guide, Paper 12G6931 Deflector, Paper 12G6935 Cover, Top Assembly 12G6934 CIS White Roller Assembly 12G6936 Tray, Paper Exit Assembly 12G6937 Tray, Scan Exit Assembly 12G6938 Screw Parts Packet 12G6939...
  • Page 82 4400-001 Assembly 2: Base Unit Service Manual...

  • Page 83: Index

    4400-001 Assembly 2: Base Unit Asm- Part Units Description Index Number 12G6972 Phone Line Cord 12G6954 Cable, Line Interface Board 12G6971 Power Line Cord 12G6951 Board, Line Interface 12G6952 Power Supply 12G6940 Base Assembly 12G6946 Motor, Scanner with Gear Assembly 12G6947 Motor, Carrier Assembly 12G6948...
  • Page 84 4400-001 Assembly 3: Engine Service Manual...
  • Page 85 4400-001 Assembly 3: Engine Asm- Part Units Description Index Number 12G6955 ASF Assembly 12G6961 Small Feed Roller Assembly with EOF and Springs 12G6970 System Board 12G6969 Main Frame Assembly with Encoder Clip 12G6959 Motor, Carrier Transport 12G6965 Spring, Carrier Shaft Retainer 12G6956 Maintenance Station Assembly 12G6966...
  • Page 86 4400-001 Service Manual...
  • Page 87 4400-001 Index Problems Carrier Transport Abbreviations Maintenance Station Adjustments Operator Panel Aging Test Paper Feed Answer On Rings Power Auto Reduction Print Quality Printer Communication Scanner CIS Test Program Download Connector Locations Remote RCV Code Diagnostic Aids Removal Procedures Diagnostic Information Removals DTMF Test ASF Assembly...
  • Page 88 4400-001 Maintenance Station 2-11 12G6946 Paper Feed 2-12 12G6947 Paper Path 2-14 12G6948 Power 2-15 12G6949 Print Quality 2-16 12G6950 Scan/Copy Quality 2-18 12G6951 Scanner Motor 2-10 12G6952 Service Mode 12G6953 Set RX Level 3-10 12G6954 Set TX Level 3-10 12G6955 Specifications 12G6956...

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