LEXMARK Z51 Service 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.
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
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.
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 TestPage 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
• Blurredprint
• 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
4098-001
Maintenance Station Service Check
The maintenance station has three functions:
1. Wipes the printhead nozzles to clear them of dirt.
2. Provides a place for the printheads to spit all nozzles keeping
them clear prior to printing.
3. Seals the printheads when not in use to prevent the nozzles
from dr ying.
FRU Action
1 Maintenance
Station Assembly
2 Wipers Worn wipers cause degraded print quality just after
3 Caps Worn caps cause the printhead nozzles to dry and
As the carrier moves to the right over the
maintenance station, a tab on the bottom of the
carrier engages a tab on the sled of the
maintenance station causing the caps to rise and
seal the printhead. Carrier movement to the left
uncaps 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 printheads are wiped, a tab on
the carrier engages a tab on the maintenance
station and wipers are lowered. The carrier will
then move to the right over the felt pad where they
will spit all nozzles.
Check the maintenance station for worn or broken
parts.
a printhead maintenance cleaning. Check forloose
or worn wipers.
clog. Check for loose or worn caps.
2-10 Service Manual
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