Lexmark 4098-001 User Manual

Lexmark Z51 Color Jetprinter™

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4098-001

• Index

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

First Edition (March 1999) 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.

A form for reader’s comments is provided at the back of this publication. If the form has

4098-00X

Table of Contents

Preface.................................................v

SafetyInformation.......................................vi

GeneralInformation....................................1-1

Operator Panel .........................................1-1

Maintenance Approach ..................................1-2

Abbreviations ........................................1-2

DiagnosticInformation .................................2-1

Start .................................................2-1

Indicator Light Table...................................2-1

Error Indicator Table ..................................2-2

Power-On Self Test (POST) Sequence ....................2-4

POST Symptom Table.................................2-5

Symptom Tables .....................................2-6

Service Checks ........................................2-8

Carrier Transport Service Check .........................2-8

Maintenance Station Service Check .....................2-10

Paper Feed Service Check ............................2-11

Paper Path Service Check.............................2-13

Power Service Check.................................2-13

Print Quality Service Check ............................2-14

DiagnosticAids .......................................3-1

Auto Compensator Assembly Operation .....................3-1

Print Test Page .........................................3-2

End of Forms (EOF) Test .................................3-3

Encoder Sensor Test ....................................3-4

Clear NVRAM ..........................................3-5

Print NVRAM Contents ...................................3-6

Print Clean Page .......................................3-6

RepairInformation.....................................4-1

Handling ESD-Sensitive Parts .............................4-1

Adjustments ...........................................4-2

Removal Procedures ....................................4-2

Releasing Plastic Latches ..............................4-2

Auto Compensator Assembly Removal ....................4-3

Buttons / Lenses Removal ..............................4-3

Carrier Frame Assembly / Base Removal ..................4-3

iii

4098-00X

Carrier Transport Motor Removal .........................4-4

Encoder Sensor / Temperature Sensor Removal .............4-4

Encoder Strip Removal .................................4-4

Front Cover Removal ..................................4-5

Gear Plate Assembly Removal ...........................4-5

Gutter Pad / Maintenance Station Removal .................4-5

Maintenance Wipers and Caps Removal ...................4-5

Mid Frame / Large Feed Roller / Exit Roller Removal..........4-6

Operator Panel Removal................................4-6

Paper Feed Motor Removal .............................4-7

Power / Parallel / USB Board Removal.....................4-7

Printhead Cable and Cradle Removal......................4-8

Rear Cover Removal...................................4-8

Sheet Feeder Removal .................................4-9

Small Feed Rollers ....................................4-9

Small Feed Roller Holder / EOF Removal...................4-9

Star Wheel Roller Assembly Removal .....................4-9

System Board Removal................................4-10

ConnectorLocations....................................5-1

Connector Locations (cont.) ...............................5-2

Preventive Maintenance .................................6-1

Lubrication Specifications .................................6-1

PartsCatalog ..........................................7-1

How to Use This Parts Catalog .............................7-1

Assembly 1: Covers ......................................7-2

Assembly 2: Frames......................................7-4

Assembly 3: Paper Feed ..................................7-6

Assembly 4: Electronics .................................7-10

Assembly 5: Carrier .....................................7-12

Assembly 6: Carrier Transport .............................7-14

Assembly 7: Maintenance Station ..........................7-16

Index................................................ X-1

iv Service Manual

Preface

This manual describes the Lexmark Z51 Color Jetprinter (4098-001) 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.

Preface v

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.

• 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

• Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange.

• 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.

vi Service Manual

Norme di sicurezza

• Il prodotto è stato progettato,testato e approvatoin 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.

• 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 è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

Sicherheitshinweise

• Dieses Produkt und die zugehörigen Komponenten wurden

entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt 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

Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

cumplir los más estrictos estándares de seguridad global usando los componentes específicos de 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.

• 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

• Este produto foi concebido, testado e aprovado para satisfazer

os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição.

• 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

Informació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de 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

orientada exclusivament a professionals i no està destinada a ningú que 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

x Service Manual

4098-001

1. General Information

The Lexmark Z51 Color JetprinterTMis an electro-mechanical printer 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 n ozzles, 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.

Operator Panel

Buttons Lights

• Left Button - Power Power On/Off

Right Button - Paper Feed

• Clears a paper jam

• Loads paper when paper is out

Left Light

•On-PowerOn

• Flashing - Printer Error Right Light - Busy

•On-Busy

• Flashing - Paper Out/Jam

General Information 1-1

4098-001

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. Begin with “Indicator Light Table” on page 2-1.

After you complete the repair, perform tests as needed to verify the repair.

Abbreviations

EOF End of Forms ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LVPS Low Voltage Power Supply OEM Original Equipment Manufacturer V ac Volts alternating current V dc Volts direct current LIF Low Insertion Force USB Universal Serial Bus FPC Flat Printer Cable

1-2 Service Manual

4098-001

2. Diagnostic Information

Start

Service error indications are a series of Power light flashes. There is a pause between each series of flashes. If your printer has an error indicator, locate the series of flashes in the “Error Indicator Table”

on page 2-2. and take the indicated action. Unplug the printer to

clear the error indicator. 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“Print NVRAM Contents” on page 3-6 The last error appears at the bottom of the page.

2. To capture the next error in the error log, run “Clear NVRAM”

on page 3-5 to clear the error.

3. Run the “Print Test Page” on page 3-2.” If no error appears, go to “Power-On Self Test (POST) Sequence” on page 2-4.”

Indicator Light Table

Indicator Light Indicates

Power light on Machine is on. Power light on and busy light

flashes Power light and busy light flashes Go to the “Carrier Transport Service

Both lights on at the same time Printer is busy or printing. Power light flashes See “Error Indicator Table” on

Paper jam or paper out.

Check,”on page 2-8.

page 2-2

Diagnostic Information 2-1

4098-001

Error Indicator Table

Number of Power

Light

Flashes

Service Error (Logged)

281Carrier stall No carrier emitter

393Data error Incorrect data has

489Print

Error Name

incomplete

Error Description Action

signals received, carrier not moving

been sent from the host PC to the printer

Carrier stopped before print data all used

Goto“Carrier

Transport Service Check” on page 2-8.

Ensure the driver is installed correctly.

Check the system board and cable. If OK, check printhead cables. Replace as needed.

Check system board and cable. If OK, check printhead cables. Replace as needed.

664,66thru78Exception

765Address

2-2 Service Manual

Error

Illegal instruction from microprocessor

16/32 bit item on odd address boundary

Replace system board

Replace system board. See“System

Board Removal” on page 4-10.

4098-001

Number of Power

Light

Flashes

8 None NVRAM

979Error xxxxx Replace

11 91 Error xxxxx Replace

12 92 Short error Short test

Service Error (Logged)

Error Name

error

Error Description Action

Error detected in reading or writing NVRAM

detected short circuit in printhead

Replace system board. See “System

Board Removal,”on page 4-10.

system board. See “System

Board Removal” on page 4-10.”

system board Check and

replace printhead and cable as needed.IfOK, replace the system board.

13 94 Head

Select

15 96 USB error Error in USB

None 31,32,33 Watchdog No action

Install head ID and print command head ID do not match

hardwaredetected or invalid result occurred in USB code

Replace printheads.

Check system board cable. If OK, check system board and power/ parallel/USB board. Replace as needed.

Note: There are seven reserved error code power light flashes (5, 10, 14, and 16) that haveno code names. If any reserved codes are

received, unplug and re-plug the printer.

Diagnostic Information 2-3

4098-001

Power-On Self Test (POST) Sequence

Tur n the printer on and check for a correct POST operation by observing the following:

1. The power light come on.

2. The carrier moves to the left to wipe the printheads.

3. The carrier movesto the right over the maintenance station and seals the printheads.

4. The paper feed gears turn.

5. All motors stop and the power light stays on.

If your pr inter completes POST with no errors, go to the “Symptom

Tables” on page 2-6, locate the symptom and take the indicated

action. If your pr inter does not complete POST, locate the symptom in the

“POST Symptom Table” on page 2-5 and take the indicated

action.

2-4 Service Manual

4098-001

POST Symptom Table

Symptom Action

No power light and no motors run

Paper feed gears do not turn

Carrier does not move Go to the “Carrier Transport Service Check”

Carrierslamssideframe Gotothe“Carrier Transport Service Check”

No busy light Replace the operator panel, or the system

Go to the “Power Service Check” on

page 2-13.

Go to the “Paper Feed Service Check” on

page 2-11.

on page 2-8.

board.

Diagnostic Information 2-5

4098-001

Symptom Tables

Locate the symptom in the following tables and take the indicated action.

Carrier Transport Problems

Symptom Action

• No carrier movement

• Slow carrier movement

• Carrier stops

• Carrier slams side frame

• Carrier does not move to cartridge load position when opening access door

Go to the “Carrier Transport

Service Check” on page 2-8.

Maintenance Station Problems

Symptom Action

• Fails to cap the printheads

• Fails to clean the printheads

Go to the “Maintenance Station

Service Check” on page 2-10.

Operator Panel Problems

Symptom Action

• Power or Paper Feed buttons do not operate

• Power or Busy lights do not come on

Replace the operator panel, or the system board.

Printer Communication Table

Symptom Action

• Not able to print Test Page Check the USB cable and system

board cable connections. If OK, replace Power/Parallel/USB board

2-6 Service Manual

4098-001

Paper Feed Problems

Symptom Action

• 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

Paper skews Go to the “Paper Path Service

Go to the “Paper Feed Service

Check” on page 2-11.

Check,”on page 2 -13.

Power Problems

Symptom Action

No power in machine, motors do not operate and lights do not come on

Go to the “Power Service

Check,”on page 2 -13.

Print Quality Problems

Symptom Action

• Voids in characters

• Light print

• Prints off the page

• Blurred print

• Carrier moves, but no print

• Printhead dries prematurely

• Colors print incorrectly

• Vertical alignment off

Go to the “Print Quality Service

Check,”on page 2 -14.

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

Go to the “Paper Feed Service

Check” on page 2-11.

Diagnostic Information 2-7

4098-001

Service Checks

Carrier Transport Service Check

FRU Action

1 System Board Unplug the printer and disconnect the carrier

transport motor connector (J5) from the system board. Plug in the printer and check for approximately +30 V dc between (J5-1) and ground at the system board. If the voltage is incorrect, replace the system board. If the voltage is correct, check for carrier transport motor pins shorted to the housing. If a short is detected, replace the carrier transport motor.

2 Carrier Transport

Motor

3CarrierGuide

Shaft

4 Carrier Transport

Belt Idler Pulley Parts Carrier Frame

Check the motor for binds, or loose motor pulley. A noisy or chattering motor or a motor that fails to

turncanbecausedby:

• An open or short in the motor.

• An open or short in the motor driver on the system board.

• A bind in the carrier transport mechanism.

With the carrier transport motor cable disconnected from the system board, check for zero to ten (0 - 10) ohms between pins J5-1 and J5-2 on the motor. If the readings are incorrect, replace the motor.

Clean the carrier shaft. Lubricate the shaft and the carrier shaft bearing surfaces with grease (P/N 99A0394)

Check for worn, loose or broken parts. Check for obstructions blocking carrier movement. Lubricate the carrier to carrier frame engagement with grease (P/N 99A0394)

2-8 Service Manual

4098-001

FRU Action

5 Encoder Strip

Encoder Card Printhead Cable System Board

6 Maintenance

Station

7 Operator Panel

Operator Panel Cable System Board

Check the encoder strip for proper installation. Check the strip for wear, dirt and grease. Be sure the carrier cable is fully seated in connector J10 and the cable is seated in the encoder card. Check the cable for damage.

Perform the “Encoder Sensor Test” on

page 3-4. If you cannot enter the test, replace the

system board. A problem with the maintenance station can cause

carrier movement problems at the right margin. Go to the “Maintenance Station Service Check,”on

page 2-10.

If the carrier does not move when the access cover is opened, check the actuator arm for binds. If the arm is working correctly, check the operator panel cable is fully seated in J16 at the system board and in the operator panel. Check the continuity of the cable at pins 3 and 4. If the cable is good, replace the system board or operator panel.

Diagnostic Information 2-9

+ 49 hidden pages