Lexmark X83 User manual

4403-XXX
Lexmark™ X83, X85 Scan/Print/Copy
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
• Table of Contents
•Index
• Safety and Notices
• Trademarks
• Start Diagnostics

Edition: October 2002
The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS
PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not allow disclaimer of express or implied warranties in certain transactions; therefore, this
statement may not apply to you.
This publication could include technical inaccuracies or typographical errors.Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.
Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at
[e-mail]. Lexmark may use or distribute any of the
information you supply in any way it believes appropriate without incurring any obligation
to you. 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 is a trademark of Lexmark International, Inc., registered in the United States
and/or other countries.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 2001, 2002.
All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
This software and documentation are provided with RESTRICTED 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.,
Lexington, KY 40550.
4403-XXX
U.S.A. P/N: 12G9186

iii
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Table of Contents
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Scanner Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-1
POST Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Carrier Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
CCD Module Assembly Service Check . . . . . . . . . . . . . . . . . . . . 2-8
Gear Train Assembly Service Check. . . . . . . . . . . . . . . . . . . . . . 2-9
Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . . . 2-10
Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Paper Path Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Print Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Scan/Copy Quality Service Check . . . . . . . . . . . . . . . . . . . . . . . 2-17
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Test Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Scanner Lid Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Top Housing Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Paper Support Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
CCD Module Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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Gear Train Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Access Cover Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Right Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Access Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Left Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Middle Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Print Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
ASF Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
System Board Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Encoder Strip Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Maintenance Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Belt/Idler Pulley Assembly (Print Engine) Removal. . . . . . . . . . .4-14
Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2
Assembly 2: Paper Feed, Frame and Carrier Transport . . . . . . . . . .7-6
Assembly 3: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1

Safety Information v
4403-XXX
Safety Information
•The safety of this product is based on testing and approvals of
the original design and specific components. The manufacturer
is not responsible for safety in the event of use of unauthorized
replacement parts.
•The maintenance information for this product has been
prepared 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 personal
injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precautions.
Consignes de Sécurité
•La sécuritéde ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des
composants particuliers. Le fabricant n'assume aucune
responsabilitéconcernant la sécuritéen cas d'utilisation de
pièces de rechange non agréées.
•Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement àun personnel de maintenance
qualifié.
•Le démontage et l'entretien de ce produit pouvant présenter
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

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4403-XXX
Norme di sicurezza
•La sicurezza del prodotto si basa sui test e sull'approvazione
del progetto originale e dei componenti specifici. Il produttore
non èresponsabile per la sicurezza in caso di sostituzione non
autorizzata delle parti.
•Le informazioni riguardanti la manutenzione di questo prodotto
sono indirizzate soltanto al personale di assistenza autorizzato.
•Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona èpiù
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.
Sicherheitshinweise
•Die Sicherheit dieses Produkts basiert auf Tests und
Zulassungen des ursprünglichen Modells und bestimmter
Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird
vom Hersteller keine Verantwortung oder Haftung für die
Sicherheit übernommen.
•Die Wartungsinformationen für dieses Produkt sind
ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
•Während des Auseinandernehmens und der Wartung des
Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

Safety Information vii
4403-XXX
Pautas de Seguridad
•La seguridad de este producto se basa en pruebas y
aprobaciones del diseño original y componentes específicos.
El fabricante no es responsable de la seguridad en caso de uso
de piezas de repuesto no autorizadas.
•La información sobre el mantenimiento de este producto está
dirigida exclusivamente al personal cualificado de
mantenimiento.
•Existe mayor riesgo de descarga eléctrica y de daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.
Informações de Segurança
•A segurança deste produto baseia-se em testes e aprovações
do modelo original e de componentes específicos. O fabricante
não éresponsável pela segunrança, no caso de uso de peças
de substituição não autorizadas.
•As informações de segurança relativas a este produto
destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.
•Risco de choques eléctricos e ferimentos graves durante a
desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

viii Service Manual
4403-XXX
Informacióde Seguretat
•La seguretat d'aquest producte es basa en l'avaluaciói
aprovaciódel disseny original i els components específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
•La informaciópel manteniment d’aquest producte està
orientada exclusivament a professionals i no estàdestinada
a ningúque no ho sigui.
•El risc de xoc elèctric i de danys personals pot augmentar
durant el procés de desmuntatge i de servei d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre
les mesures convenients.

Safety Information ix
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xService Manual
4403-XXX
Preface
This manual and 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 in this chapter, as well as
general environmental and safety instructions.
2. Diagnostic Information contains an error indicator table,
symptom tables, and service checks used to isolate failing field
replaceable units (FRUs).
3. Diagnostic Aids contains tests and checks used to locate or
repeat symptoms of printer problems.
4. Repair Information provides instructions for making printer
adjustments and removing and installing FRUs.
5. Connector Locations uses illustrations to identify the
connector locations and test points on the printer.
6. Preventive Maintenance contains the lubrication specifications
and recommendations to prevent problems.
7. Parts Catalog contains illustrations and part numbers for
individual FRUs.

General Information 1-1
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1. General Information
The Lexmark™X83 4403-001 and Lexmark X85 4403-K11
machines feature an electro-mechanical scanner, printer, and copier
that creates characters and graphics by composing programmed
patterns of ink dots using a printhead and liquid ink. 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, print cartridge
available as a customer replaceable supply item. Dual printheads
provide color and true black printing without changing printheads.
The number and size of inkjets or nozzles, in the printhead,
determines the overall quality and capability of the printer. The black
cartridge has a total of 208 nozzles and installs on the right. The
color cartridge has a total of 192 nozzles and installs on the left. The
printer is capable of printing in two directions from either cartridge.
Power Consumption
•<6 Watts - power off and power to the printer
•8 Watts - Idle Mode (power on - not printing)
•21 Watts - Printing (average)
•31 Watts - Printing (peak)

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Scanner Specifications
Scanner Type Flatbed, CCD
Scan Modes True Color:
48 Bit Internal (68.7 Billion Colors)
24 Bit External (16.7 Million Colors)
Gray Mode:
12 Bits Internal (4,096 Shades of
Gray)
8 Bits External (256 Shades of Gray)
Text/Line Art:
1 Bit Per Pixel
Scan Method One Pass Scanning
Scan Area 8.5 X 11.7 inches
216 X 292 mm
Scan Resolution Optical: 600 dpi (H) X 1200 dpi (V)
Interpolated: 19,200 X 19,200
Resolution/Quality
(Applicable when operating via
standalone mode)
Selectable via Op-Panel
High / Photo - 600 X 600 dpi Scan
1200 X 1200 dpi Print (by
interpolation)
Normal - 300 X 300 dpi Scan
600 X 600 dpi Print (by
interpolation)
Draft / Quick - 300 X 300 dpi Scan
300 X 600 dpi Print (by
interpolation)

General Information 1-3
4403-XXX
Operator Panel

1-4 Service Manual
4403-XXX
Press this
button: When you want to:
Number of
Copies Select the number of copies.
Lighter/Darker Make the document lighter or darker than the original.
Reduce/Enlarge Make the document smaller or larger than the original.
Paper Type Select glossy, photo, transparency, or plain paper type.
< or > Scroll through menu sub-categories.
Menu Change settings using the menus.
Select Choose the displayed selection.
Quality Choose photo, quick, or normal copy setting.
Color Copy Make a color copy.
Black Copy Make a black and white copy.
Scan To Select a scan destination, such as To copy, To an e-
mail, To an application, To a file, or To fax.
Scan Press the scan button after selecting a Scan To
destination.
Cancel Cancel a scan, print, or copy job, or return to a menu
category from a menu sub-category.
Power Turn the printer on or off.

General Information 1-5
4403-XXX
Maintenance Approach
The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the symptom index, service
checks, and diagnostic aids to determine the symptom and repair
the failure.
After you complete the repair, perform tests as needed to verify the
repair.

1-6 Service Manual
4403-XXX
Abbreviations
B/M Bill of Material
CCD Charged Coupled Device
EOF End of Form
ESD Electrostatic Discharge
FPC Flat Printhead Cable
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LCD Liquid Crystal Display
LVPS Low Voltage Power Supply
OEM Original Equipment Manufacturer
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

Diagnostic Information 2-1
4403-XXX
2. Diagnostic Information
Start
Use the symptom tables, service checks, and diagnostic aids in
chapter three, to determine the printer failure.
Power-On Self Test (POST) Sequence
Press the power button to turn machine on.
•The Photo, Normal, and Quick indicator lights turn on.
•The Charge Couple Device (CCD) moves to the left, then
returns to the right.
•The paper feed motor runs then stops.
•The carrier moves to the left then returns to the right stopping at
the maintenance station.
•The Photo and Quick lights turn off.
•Normal light stays on.
•The message below is displayed on the LCD.
If your printer completes POST with no errors, go to the “Symptom
Tables”on page 2-3, locate the symptom and take the indicated
action.
If your printer does not complete POST, locate the symptom in the
following table and take the indicated action.

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POST Symptom Table
Symptom Action
No Photo,
Normal, or
Quick lights and
no motors run.
Go to the “Power Service Check”on page 2-14. If okay,
go to the “Operator Panel Problems”on page 2-3.
Paper feed
gears do not
turn
Go to the “Paper Feed Service Check”on page 2-11.
Carrier does not
move Go to the “Carrier Transport Service Check”on page 2-6.
Carrier slams
side frame Go to the “Carrier Transport Service Check”on page 2-6.
CCD does not
move Go to the “Gear Train Assembly Service Check”on page 2-9.
CCD lamp does
not turn on Go to the “CCD Module Assembly Service Check”on page 2-8.
LCD displays
“Unlock
Scanner”
Go to the “CCD Module Assembly Service Check”on
page 2-8.

Diagnostic Information 2-3
4403-XXX
Symptom Tables
Locate the symptom in the following tables and take the appropriate
action.
Carrier Transport Problems
Maintenance Station Problems
Operator Panel Problems
Symptom Action
•No carrier movement
•Slow carrier movement
•Carrier stops
•Carrier slams side frame
Go to the “Carrier Transport
Service Check”on page 2-6.
Symptom Action
Maintenance station:
•Fails to cap the printheads
•Fails to clean the printheads
Go to the “Maintenance Station
Service Check”on page 2-10.
Symptom Action
•Buttons do not work
•LCD does not display Check operator panel cable connection at J8 on the system
board. Then run the “Power-On
Self Test (POST) Sequence”on
page 2-1.
If the LED buttons or any lights fail,
check connection J8. If the problem
remains, replace the operator panel
assembly. Go to the “Operator
Panel Removal”on page 4-4.
If the problem still exists, replace the
system board. Go to the “System
Board Removal”on page 4-12.

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Printer Communication Table
Scanner Problems
Symptom Action
•Not able to print Test Page Check the USB cable and system
board cable connections. If okay,
replace system board. Go to the
“System Board Removal”on
page 4-12.
Symptom Action
•CCD does not move
•Lamp does not light Go to the “CCD Module Assembly Service Check”on page 2-8.
•The operator panel displays
“Unlock Scanner”Go to the “Gear Train Assembly Service Check”on page 2-9.
•Scanned images are: faded, or
colors are dull, blurry or fuzzy.
Images are slanted or crooked
and the strait lines in the image
appear to be jagged or uneven.
•Blank copies
Go to the “Scan/Copy Quality
Service Check”on page 2-17.