Lexmark WinWriter 100 User manual

4076-001
WinWriter™ 100
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
• Manuals Menu

First Edition (August,1994)
THEFOLLOWINGPARAGRAPHDOESNOTAPPLYTOTHE
UNITED KINGDOM OR ANY COUNTRY WHERE SUCH PROVI-
SIONS 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 typo-
graphical errors. Changes are periodically made to the informa-
tion herein; these changes will be incorporated in later editions of
the publication. Improvements or changes in the products or the
programs described in this publication may be made at any time.
Publications are not stocked at the address given below; requests
for publications should be made to your point of purchase.
A form for reader’s comments is provided at the back of this publi-
cation. If the form has been removed, comments may be
addressed to Lexmark International, Inc., Department F95/035-3,
740 New Circle Road, Lexington, Kentucky 40511, U.S.A. Lex-
mark may use or distribute any of the information you supply in
any way it believes appropriate without incurring any obligation to
you.
(C) COPYRIGHT LEXMARK INTERNATIONAL, INC. 1993. 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., Greenwich, CT 06836.
4076-0WJ

iii
4076-0WJ
Contents 1
NoticesandSafetyInformation ............................vi
ElectronicEmissionNotices........................... vi
Federal Communications Commission (FCC) Statement . vi
Canadian Department Of Communications Compliance
Statement...................................... vii
The United Kingdom Telecommunications Act 1984 ..... vii
JapaneseVCCINotice............................viii
European Community (EC) Electromagnetic Compatibility
Directive.......................................viii
Germany.......................................viii
Trademarks........................................ ix
Preface........................................... ix
SafetyInformation....................................x
Sicherheitshinweise..................................x
Consignes De Securite................................x
NormeDiSicurezza................................. xi
Pautas De Seguridad ................................ xi
Sikkerhedsoplysninger ............................... xi
General Information .....................................1
PowerConsumption...............................1
MaintenanceApproach ............................1
Abbreviations....................................2
UniqueToolsRequiredForService...................2
DiagnosticInformation ...................................3
Start..............................................3
ErrorIndicatorTable...............................4
Power-on-self-test(POST)Sequence.................5
POSTSymptomTable. ............................5
SymptomTables .................................6
CarrierTransportProblems .....................6
CommunicationsProblem.......................6
Maintenance Station Problems ...................6
OperatorPanelProblems .......................6
PaperFeedProblems..........................7
PowerProblems ..............................7
PrintQualityProblems .........................7

iv
4076-0WJ
ServiceChecks..................................... 8
EnvelopeFeedServiceCheck ...................... 8
FirstPrintLineServiceCheck....................... 8
Maintenance Station Service Check . ................. 9
Operator Panel Service Check ..................... 10
Paper Feed Service Check ........................ 10
Paper Path Service Check ........................ 13
ParallelPortServiceCheck........................ 14
PowerServiceCheck ............................ 14
PrintQualityServiceCheck........................ 15
TransportServiceCheck.......................... 17
DiagnosticAids ........................................18
TestPage..................................... 18
ParallelPortTest................................ 19
EncoderSensorTest............................. 19
InitializeErrorLog............................... 20
Repair Information . . . ...................................21
HandlingESD-sensitiveParts...................... 21
Adjustments....................................... 22
Bi-directionalAlignmentAdjustment................. 22
RemovalProcedures................................ 23
ReleasingPlasticLatches......................... 23
Auto Sheet Feed (ASF) Removal . . . ................ 24
ASF Envelope Buckler And Pick Roller Hub Removal . . . 24
ASF Right And Left Edge Guide Assemblies Removal. . . 25
ASF Paper Load Lever Removal.................... 25
CarrierRemoval ................................ 25
CarrierTransportBeltRemoval..................... 26
CarrierGuideRemoval........................... 26
CarrierTransportMotorRemoval................... 26
CarrierTransportMotorFrameRemoval ............. 27
Code Module Removal . . ......................... 27
EncoderStripRemoval........................... 28
End-of-formsFlagRemoval........................ 28
ExitRollerAssemblyRemoval ..................... 28
FeedArmAssemblyRemoval...................... 29
InsideIdlerGearsRemoval........................ 29
LargeFeedRollerAssemblyRemoval............... 29
LeftSideFrameRemoval......................... 29
Maintenance Drive And Rocker Assemblies Removal . . . 30
MiddleFrameRemoval........................... 31
Operator Panel Removal. ......................... 31
OutsideIdlerGearsRemoval ...................... 31

v
4076-0WJ
Repair Information, Removal Procedures (continued)
Paper Ejectors Removal...........................32
Paper Feed Motor Removal........................32
Paper Guide Removal . ...........................32
Paper Release Lever Removal . . . ..................33
Power Supply Removal ...........................33
PrintHeadCableRemoval.........................34
RightSideFrameRemoval........................35
Rubber Backer Removal ..........................36
SmallFeedRollerAssemblyRemoval................36
StarRollerRemoval..............................36
SystemBoardRemoval...........................37
TopCoverRemoval..............................38
Connector Locations ...................................39
System Board Connectors .........................39
Preventive Maintenance .................................41
Lubrication Specifications..........................41
PartsCatalog .........................................42
HowToUseThisPartsCatalog.....................42
Assembly1:Covers ..........................43
Assembly2:Frames..........................45
Assembly3:PaperFeed ......................47
Assembly3:PaperFeed(Cont.) ................49
Assembly4:Electronics .......................51
Assembly4:Electronics(Cont.) .................53
Assembly4Electronics(Cont.)..................55
Assembly5:Carrier ..........................57
Assembly6:CarrierTransport ..................59
Assembly 7: Auto Sheet Feed ..................61
Assembly 8: Maintenance Station ...............63
Index................................................65

vi
4076-0WJ
Notices and Safety Information 2
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. Any functionally
equivalent product, program, or service that does not infringe any
existing intellectual property rights may be used instead. Evalua-
tion and verification of operation in conjunction with other prod-
ucts, programs, or services, except those expressly designated
by the manufacturer, are the user’s responsibility.
Electronic Emission Notices
Consult the following list for any emission notices that may apply
in your country.
Federal Communications Commission (FCC) Statement
This printer has been tested and found to comply with the limits
for a Class B digital device, pursuant to Part 15 of the FCC Rules.
These limits are designed to provide reasonable protection
against harmful interference in a residential installation. This
equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio communica-
tions. However, there is no guarantee that interference will not
occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be
determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of
the following measures:
•Reorient or relocate the receiving antenna.
•Increase the separation between the equipment and
receiver.
•Connect the equipment into an outlet on a circuit different
from that to which the receiver is connected.

vii
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.
NOTE: To comply with FCC regulations on electromagnetic inter-
ference, for a Class B computing device, the printer cable must be
shielded.
To assure compliance with FCC regulations for a Class B com-
puting device, use a properly shielded and grounded IBM cable.
Part numbers for the various interface cables are: part number
1525612 for parallel interface, and part number 8509386 for
serial interface. Use of a substitute cable not properly shielded
and grounded may result in violation of FCC regulations.
Canadian Department Of Communications Compliance
Statement
This equipment does not exceed Class B limits per radio noise
emissions for digital apparatus, set out in the Radio Interference
Regulation of the Canadian Department of Communications.
The United Kingdom Telecommunications Act 1984
This apparatus is approved under the approval number NS/G/
1234/J/100003 for the indirect connections to the public telecom-
munications systems in the United Kingdom.

viii
4076-0WJ
Japanese VCCI Notice
European Community (EC) Electromagnetic Compatibility
Directive
This product is in conformity with the protection requirements of
EC Council directive 89/336/EEC on the approximation of the
laws of the 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.

ix
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:
IBM
Except for archiving, Apple software shall not be copied onto
another disk or into memory unless as part of the execution of the
IBM Printer Utilities.
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.
2. “Diagnostic Information” contains error code table, symp-
tom table, 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. “Locations” uses illustrations to identify the major compo-
nents and test points on the printer.
6. “Parts Catalog” contains illustrations and part numbers for
individual FRUs.

x
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. Professional service personnel should understand this
and take necessary precautions.
•The safety features of some parts may not always be obvi-
ous. Therefore, replacement parts must have the identical
or equivalent characteristics as the original parts.
Sicherheitshinweise
•Die Wartungsinformationen fuer dieses Produkt wurden zur
Verwendung durch einen Wartungsfachmann entwickelt
und sollten nicht von anderen benuetzt werden.
•Zusaetzliches Risiko eines elektrischen Schlags und
koerperlicher Verletzung existiert waehrend des
Auseinandernehmens und der Wartung des Geraets.
Fachpersonal sollte im vollen Verstaendnis der Lage
entsprechende VorsichtsmaBnahmen ergreifen.
•Ersatzteile muessen gleiche oder gleichwertige Merkmale
wie die Originalteile aufweisen, da
Sicherheitsvorkehrungen nicht immer offensichtlich sind.
ConsignesDeSecurite
•Les consignes d’entretien et de reparation de ce produit
s’adressent uniquement a un personnel de maintenance
qualifie.
•Le demontage et l’entretien de ce produit pouvant presenter
certains risques electriques, le personnel d’entretien
qualifie devra prendre toutes les precau- tions necessaires.
•Les normes de securite de certaines pieces n’etant pas
toujours explicites, les pieces de rechange doivent etre
identiques ou conformes aux caracteristiques des pieces
d’origine.

xi
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.
•E possibile che le funzioni di sicurezza di alcuni elementi
non siano cosi ovvie, quindi, i pezzi di ricambio devono
avere caratteristiche identiche o equivalenti a quelle dei
pezzi originali.
Pautas De Seguridad
•La informacion sobre el mantenimiento de este producto
fue escrita para el personal de mantenimiento cualificado y
no para cualquier otro usuario.
•Existen mayores riesgos de descargas electricas y danos
personales durante el desmontaje y la reparacion de la
maquina. El personal cualificado comprende esto y toma
las precauciones necesarias.
•Los dispositivos de seguridad de algunas partes quiza no
siempre puedan ser reconocidas a simple vista. Por lo
tanto, las partes de reemplazo deben poseer
caracteristicas identicas o equivalentes a las partes
originales.
Sikkerhedsoplysninger
•Oplysningerne om vedligeholdelse af dette produkt er
forberedt med henblik pa professionelt servicepersonale,
og bor derfor ikke benyttes af andre.
•Risikoen for elektrisk stod oges under demontering og
service af dette produkt, hvorfor der bor tages de
nodvendige forholdsregler.
•Sikkerhedsforanstaltningerne er ikke altid lige apenbare for
alle reservedele. Der bor derfor kun anvendes originale
reservedele eller reservedele med samme egenskaber som
de oprindelige.

General Information 1
4076-0WJ
General Information 7
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. The printer prints in two directions with a resolution of
300 x 300 pels per inch in text and graphics. Print Quality Enhance-
ment Technology (PQET) smooths the edges. The printer can han-
dle a variety of paper sizes as well as envelopes and other media
using an integrated automatic sheet feeder and manual insert tray.
Power Consumption
•Less than 2 Watts - power off and power to the printer
•7.5 Watts - Idle Mode (power on - not printing)
•12 Watts - Printing (average)
•25 Watts - Printing (peak)
Maintenance Approach
The diagnostic information in this manual will lead you to the correct
field replaceable unit (FRU) or part. Use the error code charts,
symptom index, service checks, and diagnostic aids to determine
the symptom and repair the failure. Begin with “Start” on page 3.
This printer can be serviced without being connected to a host. How-
ever, a Personal Computer will be needed to adjust the bi-directional
alignment.
After you complete the repair, perform tests as needed to verify the
repair.

4076-0WJ
General Information 2
Abbreviations
Unique Tools Required For Service
Wrap Plug (Parallel) P/N = 1319128
CE Customer Engineer
CPU Central Processing Unit
CSU Customer Setup
DRAM Dynamic Random Access Memory
EP Electrophotographic Process
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LASER Light Amplification by Stimulated Emission
of Radiation
LCD Liquid Crystal Display
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
MAP Maintenance Analysis Procedures
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
PC Photoconductor
PCA Printed Circuit Assemblies
PICS Problem Isolation Charts
PIXEL Picture Element
POST Power-On Self Test
PQET Print Quality Enhancement Technology
PSO Printer Sharing Option
SRAM Static Random Access Memory
UPR Used Parts Replacement
V AC Volts alternating current
V DC Volts direct current
ZIF Zero Insertion Force

Diagnostic Information 3
4076-0WJ
Diagnostic Information 8
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. There is a pause between each series of flashes. If your
machine has an error indication, locate the series of flashes in the
following table and take the indicated action. Unplug the machine to
clear the error indicator.
If your machine does not have an error indicator, go to “Power-on-
self-test (POST) Sequence” on page 5. If an error indicator appears
while you are working on the machine, go to the error indicator table
and take the indicated action for that error.
The printer also logs the last occurring error. If you think you may
have an intermittent error, or the error indicator lights have been
cleared, you can retrieve the error from the Test Page printout:
1. Run the “Test Page” on page 18. The error is the last number to
print on the page in the lower right corner. Note the number.
2. Run “Initialize Error Log” on page 20 to clear the log (the number
may not be the result of a current error).
3. Run the Test Page again to verify a current error. If no error
prints, go to “Power-on-self-test (POST) Sequence” on page 5.

4076-0WJ
Diagnostic Information 4
Error Indicator Table
Error
Code
Number of
Power Light
Flashes Action
64
65 7 Replace the Code Module and/or system
board
66 to
78 6 Replace the Code Modules and/or system
board
No
Log 8 Replace the Code Module and/or system
board
79 9 Replace the Code Module and/or the system
board
80 2 Gotothe“Maintenance Station Service
Check” on page 9.
81 1 Gotothe“Transport Service Check” on
page 17.
85 3 Gotothe“Transport Service Check” on
page 17.
89 4 Gotothe“Transport Service Check” on
page 17.
90 5 Gotothe“Transport Service Check” on
page 17.
127
and
up
10 Go to the “Maintenance Station Service
Check” on page 9.

4076-0WJ
5
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. The carrier moves to the left and right at least one time.
4. The maintenance station cleans and caps the print head.
5. All motors stop and the power light stays on.
If your machine completes POST with no errors, go to the “Symptom
Tables”onpage6, locate your symptom and take the indicated
action.
If your machine does not complete POST locate your symptom in
the following table and take the indicated action
POST Symptom Table.
Symptom Action
No Power On light and no motors
run Go to the “Power Service
Check” on page 14.
Feeds paper Go to the “First Print Line
ServiceCheck”onpage8.
Paper feed gears do not turn Go to the “Paper Feed Service
Check” on page 10.
Carrier doesn’t move Go to the “Transport Service
Check” on page 17.
Maintenance station doesn’t move Go to the “Maintenance Station
ServiceCheck”onpage9.
The carrier moves then error 85
appears Replace the system board

4076-0WJ
Diagnostic Information 6
Symptom Tables
Locate your symptom in the following tables and take the appropri-
ate action.
Carrier Transport Problems
Communications Problem
Maintenance Station Problems
Operator Panel Problems
SYMPTOM ACTION
• No carrier movement
• Slow carrier movement
• Carrier stops
Go to the “Transport Service Check”
on page 17.
SYMPTOM ACTION
Printer not communicating with
host. Go to the “Parallel Port Service
Check” on page 14.
SYMPTOM ACTION
• Maintenance station doesn’t
move
• Fails to cap the print head
• Fails to clean the print head
Go to the “Maintenance Station Ser-
vice Check” on page 9.
SYMPTOM ACTION
• Panel light(s) not working
• Panel button(s) not working
• Power Light is the only light that
comes on
Go to the “Operator Panel Service
Check” on page 10.

4076-0WJ
7
Paper Feed Problems
Power Problems
Print Quality Problems
SYMPTOM ACTION
Paper fails to stop at first print
line Go to the “First Print Line Service
Check” on page 8.
• Fails to pick paper
• Picks more than one sheet of
paper
• Picks paper but fails to feed
• Paper jams
• Paper fails to exit
• Noisy paper feed
Go to the “Paper Feed Service
Check” on page 10.
Envelopes fail to feed Go to the “Envelope Feed Service
Check” on page 8.
Paper skews Go to the “Paper Path Service
Check” on page 13.
SYMPTOM ACTION
No power in machine, no Power
On light, no motors Go to the “Power Service Check” on
page 14.
SYMPTOM ACTION
• Voids in characters
•Lightprint
• Prints off the page
• Prints satellites
• Carrier moves but does not print
• Print head drying out prema-
turely
• Vertical alignment off
Go to the “Print Quality Service
Check” on page 15.
• Ink smearing
• Vertical streaks on paper
• Print lines crowded
Go to the “Paper Feed Service
Check” on page 10.

4076-0WJ
Diagnostic Information 8
Service Checks
Envelope Feed Service Check
First Print Line Service Check
FRU OR PROCEDURE ACTION
1 Envelope Loading Be sure the envelope guides have
been turned to the envelope load
positions
Besuretheenvelopeguidesare
against the envelopes
Go to and perform the “Paper Feed
Service Check” on page 10.
FRU OR PROCEDURE ACTION
1 End-of-Forms Flag Check the flag for binds or damage.
2 End-of-Forms Sensor Check the sensor for dirt.
3 System Board If the paper does not stop at the first
writing line, replace the system board.
4 Feed Arm Assembly Check all parts of the feed arm
assembly for binds, wear, or damage.
5 Operator Panel Go to the “Operator Panel Service
Check” on page 10.

4076-0WJ
9
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.
Note: if the failure remains, replace the system board.
FRU OR PROCEDURE ACTION
1 Maintenance Drive Assem-
bly Disconnect J4 from the system board. Check for 18 ohms (±4 ohms)
between pins 1 and 2 at the motor. If
the reading is incorrect, replace the
maintenance drive assembly,
Check for motor pins shorted to the
motor housing. If you find a shorted
pin, replace the maintenance drive
assembly. If the symptom remains,
replace the system board.
A bind in the drive assembly can pre-
vent the motor from turning. Check for
binds and loose or worn parts in the
drive assembly. Also check the motor
gear
2 System Board Turn the printer off and disconnect J4
from the system board. Turn the
machine on and check for a pulse of
15 V dc between J4-1 and ground on
the system board as the machine
goes through POST.
3 Maintenance Rocker
Assembly Check for binds or wear.
4 Wiper A worn wiper will cause degraded
print quality just after a maintenance
cleaning. Check for loose or worn
wiper.
5 Cap A worn cap will cause the print head
nozzles to dry and clog. Check for
loose or worn cap.