Lexmark WinWriter 150c User manual

4077-001
WinWriter™150c
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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Third Edition (July, 1997)
The following paragraph does not apply to the United Kingdom or any country where such
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Publication “As Is” Without Warranty Of Any Kind, Either Express Or Implied,
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This publication could include technical inaccuracies or typographical errors. Changes are
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© Copyright Lexmark International, Inc. 1995, 1997. All Rights Reserved.
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Lexmark International, Inc., Lexington, KY 40550 USA.
4077-001

4077-001
iii
Contents 1
Preface ..............................................vi
SafetyInformation................................... vi
GeneralInformation....................................1
PowerConsumption..................................1
Maintenance Approach................................1
Abbreviations....................................2
UniqueToolsRequiredForService...................2
DiagnosticInformation .................................3
Start..............................................3
ErrorIndicatorTable...............................4
Power-On-Self-Test (POST) Sequence................4
POSTSymptomTable.............................5
SymptomTables .................................6
CarrierTransportProblems.........................6
CommunicationsProblems .........................6
MaintenanceStationProblems ......................6
Paper Feed Problems . ............................7
PowerProblems..................................7
PrintQualityProblems.............................7
ServiceChecks......................................8
EnvelopeFeedServiceCheck.......................8
FirstPrintLineServiceCheck.......................8
MaintenanceStationServiceCheck ..................9
Paper Feed Service Check ........................10
Paper Path Service Check.........................13
ParallelPortServiceCheck........................14
PowerServiceCheck.............................14
PrintQualityServiceCheck........................15
TransportServiceCheck..........................17
DiagnosticAids ......................................18
TestPage.........................................19
ParallelPortTest...................................20
EncoderSensorTest................................21
End-of-FormsSensorTest............................22
InitializeErrorLog...................................23
PrinterErrorLogRecovery............................24

4077-001
iv
RepairInformation ....................................25
Handling ESD-Sensitive Parts......................... 25
Adjustments....................................... 26
RemovalProcedures................................ 26
ReleasingPlasticLatches......................... 26
BaseAssemblyRemoval ......................... 27
CarrierBeltRemoval............................. 27
CarrierFrameAssemblyRemoval .................. 28
CarrierTransportMotorRemoval................... 29
Code Module Removal. . ......................... 30
Edge Guide Asm and Paper Load Shaft Removal ...... 30
EjectorsRemoval............................... 30
EncoderCardRemoval........................... 30
EncoderStripRemoval........................... 31
FeedArmAssemblyRemoval...................... 31
FrontCoverRemoval............................ 32
GutterPadRemoval............................. 32
InsideIdlerGearsRemoval........................ 33
LargeFeedRollRemoval......................... 34
LargeOutsideGearRemoval...................... 35
LeftSideFrameAssemblyRemoval................. 36
Maintenance Station Assembly Removal ............. 37
Maintenance Wipers and Caps Removal ............. 37
Manual Insert Tray Removal....................... 37
MidFrameAssemblyRemoval..................... 37
Paper Feed Motor Removal ....................... 38
Paper Guide and EOF Flag Assembly Removal. ....... 38
Paper Load Door Removal ........................ 40
Pick Roll Hub, Shaft and Envelope Bucklers Removal . . . 40
Power Supply Removal. . ......................... 40
Printhead Cable, Cradle & Paper Deflector Removal .... 41
Printhead Carrier Assembly Removal................ 43
Printhead Rubber Backer Removal. . ................ 44
RearCoverRemoval............................. 45
RightSideFrameAssemblyRemoval................ 45
Small Feed Roll Shaft, Rollers & Paper Flap Removal. . . 46
SystemBoardRemoval........................... 46
ConnectorLocations ..................................47
SystemBoardConnectors............................ 48
Encoder Card Connector............................. 49
PreventiveMaintenance ................................50
LubricationSpecifications............................ 50

4077-001
v
PartsCatalog ........................................51
HowToUseThisPartsCatalog........................51
Assembly1:Covers..............................52
Assembly2:Frames..............................54
Assembly 3: Paper Feed ..........................56
Assembly4:Electronics...........................58
Assembly 4: Electronics (continued) .................60
Assembly5:Carrier..............................62
Assembly6:CarrierTransport......................64
Assembly 7: Sheet Feeder.........................66
Assembly8:MaintenanceStation...................68
Index ...............................................70

vi
4077-001
Preface 2
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, symptom
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. 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 indi-
vidual FRUs.
Safety Information
•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.
•The safety features of some parts may not always be
obvious. Therefore, replacement parts must have the
identical or equivalent characteristics as the original parts.

Preface vii
4077-001
Sicherheitshinweise
•Die Wartungsinformationen für dieses Produkt wurden zur
Verwendung durch einen Wartungsfachmann entwickelt und
sollten nicht von anderen benützt werden.
•Zusätzliches Risiko eines elektrischen Schlags und
körperlicher Verletzung existiert während des
Auseinandernehmens und der Wartung des Geräts.
Fachpersonal sollte im vollen Verständnis der Lage
entsprechende Vorsichtsmaßnahmen ergreifen.
•Ersatzteile müssen gleiche oder gleichwertige Merkmale wie
die Originalteile aufweisen, da Sicherheitsvorkehrungen nicht
immer offensichtlich sind.
Consignes de Sécurité
•Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement à un 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.
•Les normes de sécurité de certaines pièces n'étant pas
toujours explicites, les pièces de rechange doivent être
identiques ou conformes aux caractéristiques des pièces
d'origine.
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, è possibile il rischio accresciuto di scosse elettriche
e danni personali. Il personale di assistenza autorizzato,
consapevole di ciò, deve adottare le precauzioni necessarie.
•È possibile che le funzioni di sicurezza di alcuni elementi non
siano così ovvie, quindi, i pezzi di ricambio devono avere
caratteristiche identiche o equivalenti a quelle dei pezzi
originali.

viii
4077-001
Pautas de Seguridad
•La información 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 eléctricas y daños
personales durante el desmontaje y la reparación de la
máquina. El personal cualificado comprende esto y toma las
precauciones necesarias.
•Los dispositivos de seguridad de algunas partes quizá no
siempre puedan ser reconocidas a simple vista. Por lo tanto,
las partes de reemplazo deben poseer características
idénticas o equivalentes a las partes originales.
Sikkerhedsoplysninger
•Oplysningerne om vedligeholdelse af dette produkt er
forberedt med henblik på professionelt servicepersonale, og
bør derfor ikke benyttes af andre.
•Risikoen for elektrisk stød øges under demontering og
service af dette produkt, hvorfor der bør tages de nødvendige
forholdsregler.
•Sikkerhedsforanstaltningerne er ikke altid lige åpenbare for
alle reservedele. Der bør derfor kun anvendes originale
reservedele eller reservedele med samme egenskaber som
de oprindelige.
Informações de Segurança
•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.
•Os dispositivos de segurança de algumas peças poderão
não ser sempre suficientemente evidentes. Assim, as peças
sobressalentes devem possuir características idênticas ou
equivalentes às peças originais.

Preface ix
4077-001
Chinese Safety Information
Korean Safety Information

General Information 1
4077-001
General Information 8
The WinWriter™ 150c (4077-001) printer is a personal, near laser-
quality inkjet printer. The print cartridge contains single-unit
customer-replaceable supply items. Dual printheads provide color
and true black printing without changing printheads. Print resolution
is 600 x 300 pels per inch. The printer can print at speeds of 167 cps
in Letter Quality mode and 300 cps in Draft mode. The black
cartridge is installed on the left and the color cartridge on the right.
The print cartridges used in the WinWriter 150c are the same print
cartridges used in the ExecJet II and ExecJet IIc.
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 leads 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
computer. The user is directed, in the WinWriter 150c Printer Control
program, to perform the head to head and bidirectional alignment
adjustments after replacing a print cartridge.
After you complete the repair, perform tests as needed to verify the
repair.

General Information 2
4077-001
Abbreviations
Unique Tools Required For Service
Parallel Wrap Plug P/N 1319128
CE Customer Engineer
CSU Customer Setup
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LED Light-Emitting Diode
LVPS Low Voltage Power Supply
NVRAM Nonvolatile Random Access Memory
OEM Original Equipment Manufacturer
POST Power-On Self Test
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

Diagnostic Information 3
4077-001
Diagnostic Information 9
Use the error indicator table, symptom tables, service checks, and
diagnostic aids in this chapter to determine the failing part.
Start
Service error indications show 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
“Error Indicator Table” on page 4 and take the indicated action.
Unplug the machine to clear the error indicator.
If an error indicator appears, 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 it may have
an intermittent error, or the error indicator lights have been cleared,
you can retrieve the error:
1. Run the “Printer Error Log Recovery” on page 24. The last error
appears as a series of flashes of the power on light.
2. Run “Initialize Error Log” on page 23 to clear the error (the error
may not be the result of a current error).
3. Run the “Test Page” on page 19. If no error appears, go to
“Power-On-Self-Test (POST) Sequence” on page 4.
If your machine does not have an error indicated, go to “Power-On-
Self-Test (POST) Sequence” on page 4.

Diagnostic Information 4
4077-001
Error Indicator Table
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
following:
1. The power light comes on.
2. The carrier moves over the maintenance station and seals the
printheads.
3. The paper feed gears turn.
4. All motors stop and the power light stays on.
If your machine completes POST with no errors, go to the “Symptom
Tables” on page 6, locate the symptom and take the indicated
action.
If your machine does not complete POST, locate the symptom in the
following table and take the indicated action.
Error
Code
Number
of
Power
Light
Flashes
Action
64
65 7Replace the Code Module and/or system board.
66 -
78 6Replace the Code Module and/or system board.
83 8Replace the Code Module and/or system board.
79 9Replace the Code Module and/or system board.
81 1Go to the “Transport Service Check” on page 17.
89 4Go to the “Transport Service Check” on page 17.
127
and
up
10 Replace the Code Module and/or system board.

5
4077-001
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 Service Check” on
page 8.
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.
Carrier slams
side frame Go to the “Transport Service Check” on page 17.

Diagnostic Information 6
4077-001
Symptom Tables
Locate the symptom in the following tables and take the appropriate
action.
Carrier Transport Problems
Communications Problems
Maintenance Station Problems
Symptom Action
• No carrier movement
• Slow carrier movement
• Carrier stops
• Carrier slams side frame
Go to the “Transport Service
Check” on page 17.
Symptom Action
Printer not communicating with
host computer. Go to the “Parallel Port Service
Check” on page 14.
Symptom Action
Maintenance station:
• Fails to cap the printhead
• Fails to clean the printhead
Go to the “Maintenance Station
Service Check” on page 9.

7
4077-001
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
•Fuzzyprint
• Carrier moves but does not print
• Printhead drying prematurely
• 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.

Diagnostic Information 8
4077-001
Service Checks
Envelope Feed Service Check
First Print Line Service Check
FRU Action
1 Envelope Guide Be sure the envelope guides have been turned
to the envelope load positions.
Be sure the envelope guides are against the
envelopes.
Perform the “Paper Feed Service Check”
on page 10.
FRU Action
1End-of-Forms
Flag Check the flag for binds or damage.
2End-of-Forms
Sensor Check the sensor for dirt.
3 System Board Perform the “End-of-Forms Sensor Test” on
page 22 to check the end-of-forms sensor on
the system board.
4 Feed Arm
Assembly Check all parts of the feed arm assembly for binds, wear, or damage.

9
4077-001
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.
FRU Action
1 Maintenance
Station Assembly As the carrier moves to the right over the maintenance station, a slot on the bottom of the
carrier engages a tab on the sled of the
maintenance station causing the caps to rise and
seal the printheads. Carrier movement to the left
will uncap the printheads. The wipers clean the
printhead nozzles as the carrier leaves the
maintenance station. The wipers clean the
printheads only when the carrier is moving to the
left. There should be no wiping action of the
printhead nozzles when the carrier is moving to
the right. After the cleaning operation is complete,
a tab on the maintenance station engages a slot
on the carrier, causing the wipers to lower.
Check the maintenance station for worn or broken
parts.
2 Wiper A worn wiper causes degraded print quality just
after a maintenance cleaning. Check for loose or
worn wiper.
3 Cap A worn cap causes the printhead nozzles to dry
and clog. Check for loose or worn cap.

Diagnostic Information 10
4077-001
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.
•Be sure there is not too much paper in the sheet feeder.
•Be sure the correct type of paper is being used.
•Check for static in the paper.
FRU Action
1 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 housing. If you find a shorted pin, replace
the motor. If you still have a failure after replacing
the motor, replace the system board.

11
4077-001
2 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
• A bind in the paper feed mechanism
With the paper feed motor cable disconnected
from the system board, check for 100 ohms (±20
ohms) between the following pins on the motor:
Pin 1 to Pin 4
Pin 2 to Pin 4
Pin 3 to Pin 5
Pin 3 to Pin 6
If the readings are incorrect, replace the motor.
Check for motor pins shorted to the motor housing.
If you find a shorted pin, replace the motor. If the
failure remains, replace the system board.
Although the paper feeds in a forward direction
only, the paper feed motor turns in two directions.
If the paper feed motor turns in one direction only,
replace the system board.
Binds in the paper feed motor or gear train can
cause intermittent false paper jam errors. Remove
the paper feed motor and check the shaft for binds.
Also check for loose or worn motor gear.
3 Gears Check for binds in the gear train and paper feed
mechanism by rotating the large feed roll by hand.
If you notice a bind, isolate it by removing one of
the small idler gears on the inside of the left side
frame. Replace any worn or binding gears or
rollers.
4 Feed Arm
Assembly At the beginning of the paper feed operation, the paper feed motor reverses momentarily to allow
the feed arm pawl to drop off the home position
notch in the left side frame. If the pawl fails to drop
off the notch, check the feed arm assembly for
binds, and worn or broken parts.
FRU Action