Lexmark Z31 4099 Service Manual
Lexmark Z31 Color Jetprinter
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
™
4099
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
4099
First Edition (August 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 allowdisclaimerofexpressor 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 describedmay be
made at any time.
A form for reader’s comments is provided at the back of this publication. If the form has
been removed, comments may be addressed to Lexmark International, Inc., Department
D22/035-3, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may
use or distribute any of the information you supply in any way it believes appropriate
without incurringany 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.
Color Jetprinter is a trademark of Lexmark International,Inc.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 1999.
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
DFARS252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.
4099
Table of Contents
Preface.................................................v
SafetyInformation.......................................vi
GeneralInformation....................................1-1
Power Consumption .....................................1-1
Operator Panel .........................................1-2
Maintenance Approach ..................................1-3
Abbreviations ........................................1-3
DiagnosticInformation .................................2-1
Start .................................................2-1
Power-On Self Test (POST) Sequence ....................2-2
POST Symptom Table .................................2-2
Symptom Tables .....................................2-3
Service Checks ........................................2-5
Carrier Transport Service Check .........................2-5
Maintenance Station Service Check ......................2-7
Paper Feed Service Check .............................2-8
Paper Path Service Check.............................2-10
Power Service Check.................................2-11
Print Quality Service Check ............................2-12
DiagnosticAids .......................................3-1
Test Page .............................................3-1
RepairInformation.....................................4-1
Handling ESD-Sensitive Parts .............................4-1
Adjustments ...........................................4-2
Removal Procedures ....................................4-2
Releasing Plastic Latches ..............................4-2
Access Cover Removal ................................4-3
Front Cover Removal..................................4-3
Base Cover Assembly Removal..........................4-3
Ink Pad Removal .....................................4-3
Buttons and Lenses Removal ...........................4-3
Sheet Feeder Assembly Removal ........................4-4
Printhead Carrier Assembly Removal .....................4-5
Maintenance Station Removal ...........................4-5
End-of-Forms Flag Removal ............................4-6
Mid Frame / Star Roller Assembly Removal ................4-6
iii
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Large Feed Roller Assembly Removal .....................4-6
Gear Plate Assembly Removal ...........................4-7
Carrier Belt / Idler Pulley Removal ........................4-7
Power Connector Removal ..............................4-7
ConnectorLocations....................................5-1
Preventive Maintenance .................................6-1
Lubrication Specifications .................................6-1
PartsCatalog ..........................................7-1
Index.................................................I-1
iv Service Manual
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Preface
This manual describes the Lexmark Z31 Color Jetprinter™(4099)
and 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 containsthe lubrication specifications
and recommendations to prevent problems.
7. Parts Catalog contains illustrations and part numbers for
individual FRUs.
Preface v
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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
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Norme di sicurezza
• Ilprodotto è statoprogettato,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 elektr ischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.
Safety Information vii
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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 responsabledel 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 globaisde 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
4099
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
4099
x Service Manual
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1. General Information
The Lexmark Z31 Color Jetprinter (4099) is a personal, near laserquality inkjet printer. The printer contains single-unit customer
replaceable supply items. Dual printheads provide color and true
black printing without changing printheads. 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 car tridge.
Power Consumption
• <8 Watts - power off and power to the printer
• 8 Watts - Idle Mode (power on - not printing)
• 15 Watts - Printing (average)
• 25 Watts - Printing (peak)
General Information 1-1
4099
Operator Panel
Paper Feed button
Power button
Buttons Application
Turnstheprinteronoroff.
Power button
• Ejects paper from the printer.
• Advancesa sheet of paper into
the automatic sheet feeder when
the printer has run out of paper
during a print job.
Paper Feed button
1-2 Service Manual
4099
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.“Use the indicator light table, the symptom tables,
service checks, and diagnostic aids in chapter 3, to determine
the printer failure,” on page 2-1.
After you complete the repair, perform tests as needed to verify the
repair.
Abbreviations
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
ZIF Zero Insertion Force
FPC Flat Printhead Cable
General Information 1-3
4099
1-4 Service Manual
4099
2. Diagnostic Information
Start
Use the indicator light table, the symptom tables, service checks,
and diagnostic aids in chapter 3, to determine the printer failure.
Indicator Light Table
Indicator Light Indicates
Power light is On
Paper Feed light is Off
Both lights are On Machine is printing.
Power light is On
Paper Feed light is blinking
Power light is blinking
Machineisonandreadytoprint.
May be out of paper or have a paper
jam.
Paper Feed light blinks two times
Paper Feed light blinks three times
Go to the “Carrier Transport Service
Check” on page 2-5.
Go to the“Power Service Check” on
page 2-11.
Diagnostic Information 2-1
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Power-On Self Test (POST) Sequence
Turn the printer on and check for a correct POST operation by
observing the following:
1. The power light comes on.
2. The carrier movesoverthe maintenance stationthree times and
seals the printheads.
3. The paper feed gears turn.
4. All motors stop and the power light stays on.
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.
POST Symptom Table
Symptom Action
No power light
andnomotors
run
Paper feed
gears do not
turn
Carrier does not
move
Carrier slams
side frame
2-2 Service Manual
Go to the “Power Service Check” on page 2-11.
Go to the “Paper Feed Service Check” on page 2-8.
Go to the “Carrier Transport Service Check” on
page 2-5.
Go to the “Carrier Transport Service Check” on
page 2-5.
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Symptom Tables
Locate the symptom in the following tables and take the appropriate
action.
Carrier Transport Problems
Symptom Action
• No carrier movement
• Slow carrier movement
• Carrier stops
• Carrier slams side frame
Go to the “Carrier Transport
Service Check” on page 2-5.
Maintenance Station Problems
Symptom Action
Maintenance station:
• Fails to cap the printheads
• Fails to clean the printheads
Go to the “Maintenance Station
Service Check” on page 2-7.
Operator Panel Problems
Symptom Action
• Paper feed or power buttons do
not operate
• Power or paper feed lights do
not come on
Unplug the printer and disconnect
the operator panel connector (J3)
from the system board. Plug in the
printer and check for approximately
+ 5 V dc between pins:
J3-2 and Ground
J3-3 and Ground
J3-4 and Ground
J3-6 and Ground
If voltage is incorrect, replace the
system board. If voltage is correct
replace the operator panel.
Diagnostic Information 2-3
4099
Paper Feed Problems
Symptom Action
• Fails to pick paper
• Picks more than one sheet of
paper
• Pickspaper but fails to feed
• Paper jams
• Paper fails to exit
• Noisy paper feed
Envelopes fail to feed Go to the “Paper Feed Service
Paper skews Go to the “Paper Path Service
Go to the “Paper Feed Service
Check” on page 2-8.
Check” on page 2-8.
Check” on page 2-10.
Power Problems
Symptom Action
No power in machine, motors do
not operate
Go to the “Power Service Check”
on page 2-11.
Print Quality Problems
Symptom Action
• Voids in characters
• Light print
• Prints off the page
•Fuzzyprint
• Carrier moves but no print
• Printhead dries prematurely
• Colors print incorrectly
• Vertical alignment off
Go to the “Print Quality Service
Check” on page 2-12.
• Ink smearing
• Vertical streaks on paper
• Print lines crowded
2-4 Service Manual
Go to the “Paper Feed Service
Check” on page 2-8.
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Service Checks
Carrier Transport Service Check
FRU Action
1 System Board Unplug the printer and disconnect the carrier
transport motor connector (J8) from the system
board. Plug in the printer and check for
approximately 12 V dc between (J8-1) and ground
as the printer goes through POST.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
Check the motor for binds, or loose motor pulley.
A noisy or chatteringmotor 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 0
to 10 ohms between the following pins on the
motor:
J8-1 and J8-2
J8-3 and J8-4
If the readings are incorrect, replace the motor.
3 Carrier Guide Rod Clean the carrier rod.
Note: Lubricate the rodand thecarrierrod bearing
surfaces with grease P/N 99A0394.
Diagnostic Information 2-5
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