Lexmark Pro900 Series Service Manual
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Lexmark Pro900 Series Service Manual

Machine type 4444-301, 4444-30e
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Lexmark Pro900 Series All-In-One
Machine Type 4444-30x, 4444-30E

Service Manual

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Summary of Contents for Lexmark Pro900 Series

  • Page 1: Service Manual

    Lexmark Pro900 Series All-In-One Machine Type 4444-30x, 4444-30E Service Manual...
  • Page 2 Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. All other trademarks are the property of their respective owners.

  • Page 3: Table Of Contents

    Lexmark Pro900 Series Table of contents Table of contents ............iii Safety information.
  • Page 4 Lexmark Pro900 Series Locations and connectors .............

  • Page 5: Safety Information

    Lexmark Pro900 Series 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.
  • Page 6 Lexmark Pro900 Series 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.
  • Page 7 Lexmark Pro900 Series Safety information...

  • Page 8: Preface

    Lexmark Pro900 Series Preface This manual contains maintenance procedures for service providers. 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. It includes printer specifications, special tools, and acronyms.

  • Page 9: General Information

    Lexmark Pro900 Series 1. General information The Lexmark™ Pro700 Series All-In-One (4444-301, 4444-30E) is a letter-quality print, copy, fax, and scan machine. It is a standalone color/mono copier. General information...

  • Page 10: Print Specifications

    Lexmark Pro900 Series Print specifications Print speed Quick print: 33 ppm mono / 30 ppm color Print functions/features Standalone photo printing: • Color or black (grayscale) photo printing • Photo Menu options pop up at card insert • Print all photos •...

  • Page 11: Scanner Specifications

    Lexmark Pro900 Series Scanner specifications Scanner type Flatbed CIS Scan modes True Color: • 48 bits internal • 24 bits external Gray Mode: • 16 bits internal • 8 bits external Text/Line Art: 1 bit per pixel Scan method One pass...

  • Page 12: Fax Specifications

    Lexmark Pro900 Series Fax specifications Fax type Standalone mono and color fax Paper size Send and receive legal, letter, and A4 Fax resolution Mono and color support initiated via operator panel: • Standard: 100 x 100 ppi • Fine: 200 x 200 ppi •...

  • Page 13: Copy Specifications

    Lexmark Pro900 Series Copy specifications Copy function Standalone only Standalone copy speed Quick copy: First copy: 8 ppm mono target, 3 ppm color Additional copies: 25 ppm mono, 21 ppm color Standalone copy specifications Mono copy: • Quick: 300 X 600 dpi print, 150 X 150 ppi scan •...
  • Page 14 Lexmark Pro900 Series Standalone media type Flatbed: • Letter • A4 • B5 • A5 • A6 • 3 x 5 in. • 4 x 6 in. • 4 x 8 in. • 5 x 7 in. • 10 x 15 cm •...

  • Page 15: Media Specifications

    Lexmark Pro900 Series Media specifications Input tray Paper capacities Plain Up to 150 sheets Envelopes Up to 10 envelopes Banner Up to 20 sheets Coated Up to 100 sheets Photo/glossy Up to 25 sheets Transparencies Up to 50 sheets Iron-on transfer...
  • Page 16 Lexmark Pro900 Series Media sizes (via driver) continued Automatic sheet feed (continued): • 5 x 7 in. • 13 x 18 cm • Custom size (width 3-8.5 in./height 5.0-17.0 in.) Envelopes: • 6 3/4 (3 5/8 x 6 1/2 in.) •...

  • Page 17: Understanding The Operator Panel

    Lexmark Pro900 Series Understanding the operator panel Using the operator panel The operator panel buttons allow you to copy, scan, fax, or print documents and photos. The operator panel features: • 4.3” touchscreen WQVGA display with screen saver • 2 wireless medallion LEDs (green and amber) •...
  • Page 18 Lexmark Pro900 Series Number Part LED/button Function Help Displays Help text and animation Home Returns to the home screen 1-10 General information...

  • Page 19: Maintenance Approach

    Lexmark Pro900 Series Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error codes, symptom tables, service checks, and diagnostic aids to determine the symptom and repair the failure.

  • Page 20: Diagnostic Information

    Lexmark Pro900 Series 2. Diagnostic information Power-On Self Test (POST) sequence Plug the All-In-One into an electrical outlet, and press the Power button. The All-In-One does a Power-On Self Test (POST) sequence. 1. The Power button, Copy button, and Color button lights come on.

  • Page 21: Error Code Table

    Lexmark Pro900 Series Error Code Table Error Name Description Action Code Print Carrier Stall The All-In-One carrier has Technical Support Center: stalled. Clear the carrier jam, and resend the print job. Service: “Carrier service checks” on page 2-12. 0101 Paper Out The All-In-One is out of paper.
  • Page 22 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 010B Printhead Error The printhead has an error. Reinstall the print tanks. If the error is still there, then replace the print tanks. Check the printhead contacts to be sure that they are clean.
  • Page 23 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 1100 Paper Jam There is paper jammed in the All-In-One. Clear the paper jam, and resend the print job. Service: Clear the paper jam, and resend the print job.
  • Page 24 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 1201 Print Incomplete The print carrier stopped before all of the data was used. Clear any carrier jams. Unplug the All-In- One from the wall outlet, wait a few seconds, then plus the All-In-One back in and turn the power on.
  • Page 25 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 1207 Paper System Error A paper system error control failure was detected. Clear the paper path. Unplug the All-In- One from the wall outlet; wait a few seconds, then plug the All-In-One back in and turn the power on.
  • Page 26 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 1212 Watchdog Error Indicates printer system was reset by Watchdog timer; Unplug the All-In-One from the wall outlet; Subsystem stall failure. wait a few seconds, then plug the All-In- One back in and turn the power on.
  • Page 27 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 1217 Printhead Temperature Error There is a problem determining temperature. Check and clean the contacts. If the problem persists, then replace the printhead. Service: Check and clean the contacts. If the problem persists, then replace the printhead.
  • Page 28 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 120A Undefined Error The microprocessor has encountered an abort or Unplug the All-In-One from the wall outlet; undefined instruction. wait a few seconds, then plug the All-In- One back in, and turn the power on. If the problem remains, then replace the All-In- One.
  • Page 29 Lexmark Pro900 Series Error Name Description Action Code Technical Support Center: 121A Loop Timeout Error Error detected that a while loop or similar loop timed out before Unplug the All-In-One from the wall outlet; the event it was waiting on wait a few seconds, then plug the All-In- finished.

  • Page 30: Service Checks

    Lexmark Pro900 Series Service checks System board service checks Symptom Action Dead machine Check the power supply connector J4, pin 1 for approximately 30 V dc. If voltage is incorrect, replace the power supply. If voltage is correct, check all other connectors on the system board.

  • Page 31: Carrier Service Checks

    Lexmark Pro900 Series Carrier service checks Symptom Action • The carrier slams • Check the encoder strip for proper installation. against the side • Check the carrier cable connectors J21, J22, and J23 on the system board. If frame. connectors are okay, replace the carrier assembly with belt and cables. See •...

  • Page 32: Diagnostic Aids

    Lexmark Pro900 Series 3. Diagnostic aids Test mode Test page This test prints the test page. To run a complete test page of black and color patterns, be sure the printhead tanks are in good condition. To enter the test: 1.

  • Page 33: Uninstall/Reinstall Instructions For Windows Users

    2. From your desktop, click Start > Programs > Lexmark Pro900 Series > Tools > Uninstall Lexmark Pro900 Series. 3. This message appears: “This program will uninstall the Lexmark Pro900 Series from your system. Do you wish to continue?” Click Yes.

  • Page 34: Repair Information

    Lexmark Pro900 Series 4. Repair information This chapter explains how to make adjustments to the All-In-One 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). To prevent damage to ESD-sensitive parts, follow the instructions below: •...

  • Page 35: Removal Procedures

    Lexmark Pro900 Series Removal procedures The following procedures are arranged according to the name of the All-In-One 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. The latches break easily; release them carefully. To remove such parts, press the hook end of the latch away from the part to which it is latched.

  • Page 36: Second Paper Tray Removal

    Lexmark Pro900 Series Second paper tray removal Remove the second exit tray from the printer, if installed. Service Manual...

  • Page 37: Duplex/Media Sensor Removal

    Lexmark Pro900 Series Duplex/media sensor removal 1. Press in on the tabs (A) to disconnect the duplex from the rear of the printer. 2. Remove the duplex. Repair information...

  • Page 38: Adf/Scanner Assembly Removal

    Lexmark Pro900 Series ADF/scanner assembly removal 1. Remove the two screws (A) from the rear of the printer. 2. Place the printer on its side, and remove the four screws (B) from the bottom of the printer. Service Manual...
  • Page 39 Lexmark Pro900 Series 3. Disconnect the right side cover from the printer. 4. Remove the right side cover. Repair information...
  • Page 40 Lexmark Pro900 Series 5. Disconnect the left side cover from the printer. Remove the left side cover. Service Manual...
  • Page 41 Lexmark Pro900 Series Remove the five screws (C) from the system board shield. Remove the system board shield. Disconnect the four ADF/scanner cables (D) from the system board. Note: Pay attention to the routing of all cables. Repair information...
  • Page 42 Lexmark Pro900 Series 10. Open the scanner, and press out on the tabs. 11. Lift the ADF/scanner assembly, and unroute the cables through the midframe. 12. Remove the ADF/scanner assembly. Service Manual...
  • Page 43 Lexmark Pro900 Series 13. Unroute the cables through the bottom of the ADF/scanner assembly. 14. Disconnect the spring (E) from the right side hinge of the ADF/scanner assembly, and remove. 4-10 Repair information...
  • Page 44 Lexmark Pro900 Series 15. Using a spring hook, unlatch the tab (F) from the right side of the ADF/scanner assembly. 16. Using a spring hook, unlatch the tab (G) from the left side of the ADF/scanner assembly. 4-11 Service Manual...
  • Page 45 Lexmark Pro900 Series 17. Disconnect the scanner lid, lift, and remove. 4-12 Repair information...

  • Page 46: Wick Removal

    Lexmark Pro900 Series Wick removal 1. Open the scanner, and press in on the tabs (E). 2. Dislodge the wick from the housing with a spring hook. 4-13 Service Manual...
  • Page 47 Lexmark Pro900 Series 3. Remove the wick from the housing. Note: When re-installing the wick, slide it in the housing. Make sure that it is properly positioned under the tabs (A). 4-14 Repair information...

  • Page 48: Midframe Removal

    Lexmark Pro900 Series Midframe removal 1. Remove the duplex. See “Duplex/media sensor removal” on page 4-4 2. Remove the ADF/scanner assembly. See “ADF/scanner assembly removal” on page 4-5. 3. Remove the INA card. See “INA card removal” on page 4-18.
  • Page 49 Lexmark Pro900 Series 6. Disconnect the three cables (C) from the system board. 7. Unsnap the midframe from the rear cover. 4-16 Repair information...
  • Page 50 Lexmark Pro900 Series 8. Unsnap the midframe from the right and left sides of the front cover. Lift the midframe, and remove. 4-17 Service Manual...

  • Page 51: Ina Card Removal

    Lexmark Pro900 Series INA card removal 1. Open the ADF/scanner assembly. 2. Remove the screw (A) from the INA card cover. 3. Remove the INA card cover, and remove the two screws (B). 4-18 Repair information...
  • Page 52 Lexmark Pro900 Series 4. Lift the INA card, and disconnect the cable (C). 5. Remove the INA card. 4-19 Service Manual...

  • Page 53: Pick Tire Removal

    Lexmark Pro900 Series Pick tire removal 1. Remove the paper tray. 2. Place the printer on its back. Note: Be careful to not mar the finish of the printer. 3. Release the latch (A). 4-20 Repair information...
  • Page 54 Lexmark Pro900 Series 4. Remove the tire. Reinstallation note: For correct reinstallation of the pick tire, be sure the tire is in the position shown in the picture below when placing it on the clip. Also be sure that the tire treads are pointing in the right direction.

  • Page 55: Operator Panel Removal

    Lexmark Pro900 Series Operator panel removal 1. Remove the ADF/scanner assembly. See “ADF/scanner assembly removal” on page 4-5. 2. Remove the midframe. See “Midframe removal” on page 4-15. 3. Unroute the operator panel cable through the slot (A). 4. Remove the two screws (B) from the operator panel.
  • Page 56 Lexmark Pro900 Series 5. Press the two clips (C), and disconnect the operator panel from the midframe. 6. Remove the operator panel. 4-23 Service Manual...

  • Page 57: Rfid Card Removal

    Lexmark Pro900 Series RFID card removal 1. Remove the ADF/scanner assembly. See “ADF/scanner assembly removal” on page 4-5. 2. Remove the midframe. See “Midframe removal” on page 4-15. 3. Remove the two screws (A), and disconnect the cable (B). 4. Remove the RFID card.

  • Page 58: System Board Removal

    Lexmark Pro900 Series System board removal CAUTION: POTENTIAL INJURY This device contains a lithium battery. There is a danger of explosion if a lithium battery is incorrectly replaced. Replace it only with the same or equivalent type of lithium battery.

  • Page 59: Fax Card Removal

    Lexmark Pro900 Series Fax card removal 1. Remove the ADF/scanner assembly. See “ADF/scanner assembly removal” on page 4-5. 2. midframe. See “Midframe removal” on page 4-15. 3. Remove the system board. See “System board removal” on page 4-25. 4. Remove the four screws (A) from the top of the back plate.
  • Page 60 Lexmark Pro900 Series 6. Disconnect the carrier cable clip, and remove the carrier cables. 7. Lift the system board plate, and disconnect the speaker wire (C) from the fax card. 4-27 Service Manual...
  • Page 61 Lexmark Pro900 Series 8. Remove the two screws (D) from the fax card. 9. Remove the fax card. 4-28 Repair information...

  • Page 62: Print Engine Removal

    Lexmark Pro900 Series Print engine removal 1. Remove the ADF/scanner assembly. See “ADF/scanner assembly removal” on page 4-5. 2. Remove the midframe. See “Midframe removal” on page 4-15. 3. RFID card. See “RFID card removal” on page 4-24. 4. Remove the two screws (A) from the front cover.
  • Page 63 Lexmark Pro900 Series 6. Remove the screw (B) from the bottom left side of the rear cover. Note: Be sure to remove the power supply before removing the rear cover. 7. Press down on the clip (C) to disconnect the rear cover from the right side of the print engine.
  • Page 64 Lexmark Pro900 Series 8. Use a flathead screw driver to release the clip (D) to disconnect the rear cover from the left side of the print engine. Unroute the cables from the top of the rear cover. 10. Remove the rear cover.
  • Page 65 Lexmark Pro900 Series The print engine remains. 4-32 Repair information...

  • Page 66: Carrier Assembly Removal

    Lexmark Pro900 Series Carrier assembly removal 1. Remove the duplex. See “Duplex/media sensor removal” on page 4-4. 2. Remove the ADF/scanner assembly. See “ADF/scanner assembly removal” on page 4-5. 3. Remove the midframe. See “Midframe removal” on page 4-15. “System board removal” on page 4-25.
  • Page 67 Lexmark Pro900 Series 8. Disconnect the clip (D) from the left side of the carrier assembly. 9. Disconnect the hose (E) from the purge pump. 4-34 Repair information...
  • Page 68 Lexmark Pro900 Series 10. Lift the purge pump, and remove. Note: Be sure to pay attention to the position of the encoder dial when reinstalling the purge pump. 11. Disconnect the belt (F). 12. Remove the carrier shaft through the right side of the carrier assembly frame.
  • Page 69 Lexmark Pro900 Series 13. Press on the clip (G), and remove the carrier cables. 14. Remove the clip from the carrier cables. 4-36 Repair information...
  • Page 70 Lexmark Pro900 Series 15. Remove the carrier assembly. 4-37 Service Manual...

  • Page 71: Encoder Dial Sensor Removal

    Lexmark Pro900 Series Encoder dial sensor removal 1. Remove the duplex. “Duplex/media sensor removal” on page 4-4. 2. Remove the ADF/scanner assembly. See “ADF/scanner assembly removal” on page 4-5. 3. Remove the midframe. See “Midframe removal” on page 4-15. “System board removal” on page 4-25.

  • Page 72: Locations And Connectors

    Lexmark Pro900 Series 5. Locations and connectors Locations Front view Number Part Function Automatic document feeder (ADF) • Loads original documents in the ADF tray • Recommended for scanning, copying, or faxing multiple-page documents ADF output tray Holds documents as they exit from the ADF...

  • Page 73: Rear View

    Lexmark Pro900 Series Rear view < LINE Number Part Function Scanner unit • Accesses the ink cartridges and printheads • Removes paper jams Printhead Installs, replaces, or removes ink cartridges Ethernet port Connects the printer to a computer, local network, an...

  • Page 74: System Board

    Lexmark Pro900 Series System board USB-backside Service Manual...

  • Page 75: System Board Connections

    Lexmark Pro900 Series System board connections Connector Description Pin number Value Paper pick motor 1 & 2 30 V Transport carrier motor 1 & 2 30 V Paper feed motor 1 & 2 30 V Power supply 30 V Scanner motor...

  • Page 76: Ina Card

    Lexmark Pro900 Series INA card INA card connections Connector Description Pin number Value INA card Service Manual...

  • Page 77: Rfid Card

    Lexmark Pro900 Series RFID card (under shield) RFID card connections Connector Description Pin number Value Locations and connectors...

  • Page 78: Fax Card

    Lexmark Pro900 Series Fax card Fax card connections Connector Description Pin number Value Speaker System board Service Manual...

  • Page 79: Preventive Maintenance

    Lexmark Pro900 Series 6. Preventive maintenance This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help prevent problems and maintain optimum performance. Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease to lubricate the following: •...
  • Page 80 Lexmark Pro900 Series Service Manual...

  • Page 81: Parts Catalog

    Lexmark Pro900 Series 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: Asm- Units/ Units/ Description Index mach • Asm-index: Identifies the assembly and the item in the diagram. For example, 2-1 indicates assembly 2 and item number 1.

  • Page 82: Assembly 1: Covers

    Lexmark Pro900 Series Assembly 1: Covers Service Manual...
  • Page 83 Lexmark Pro900 Series Assembly 1: Covers Asm- Index Units/mach Units/ FRU Description ADF input tray ADF cover Scanner lid assembly Module comp scanner assembly INA wireless card US/ROW INA wireless card EU/AS/J Midframe cover/operator panel Operator panel insert Operator panel overlay (English)

  • Page 84: Assembly 2: Electronics

    Lexmark Pro900 Series Assembly 2: Electronics Service Manual...
  • Page 85 Lexmark Pro900 Series Assembly 2: Electronics Asm- Index Units/mach Units/ FRU Description Module, duplex assembly Rear cover RFID card Fax card assembly Print engine assembly System board (Pro905) Right side cover Output extender Paper pick rollers Front cover Paper tray...

  • Page 86: Index

    Lexmark Pro900 Series Index 1-11 Acronyms Diagnostic aids Test mode Diagnostic information POST 2-11 Service checks 2-12 Carrier 2-11 CIS module assembly 2-11 System board Troubleshooting tables Error code table General information Copy specifications Media specifications Print specifications Scanner specifications...

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