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Lexmark 4098-001 Service Manual

Color jetprinter
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Lexmark Z51 Color Jetprinter™
4098-001
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
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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Summary of Contents for Lexmark 4098-001

  • Page 1 Lexmark Z51 Color Jetprinter™ 4098-001 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 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.

  • Page 3: Table Of Contents

    4098-00X Table of Contents Preface ..........v Safety Information.
  • Page 4 4098-00X Carrier Transport Motor Removal ......4-4 Encoder Sensor / Temperature Sensor Removal ... . .4-4 Encoder Strip Removal .

  • Page 5: Preface

    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.

  • Page 6: 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. •...
  • Page 7 Il prodotto è stato progettato, testato e approvato in 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.
  • Page 8 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. •...
  • Page 9 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...
  • Page 10 Service Manual...

  • Page 11: General Information

    The number and size of inkjets or nozzles, 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.

  • Page 12: Maintenance Approach

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

  • Page 13: Diagnostic Information

    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.

  • Page 14: Error Indicator Table

    4098-001 Error Indicator Table Number Service of Power Error Light (Logged) Flashes 64,66 thru Service Manual Error Error Description Name Carrier stall No carrier emitter signals received, carrier not moving Data error Incorrect data has been sent from the host PC to the...
  • Page 15 4098-001 Number Service of Power Error Light (Logged) Flashes None None 31,32,33 Note: There are seven reserved error code power light flashes (5, 10, 14, and 16) that have no code names. If any reserved codes are received, unplug and re-plug the printer.

  • Page 16: Power-On Self Test (Post) Sequence

    4098-001 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 come on. 2. The carrier moves to the left to wipe the printheads. 3. The carrier moves to the right over the maintenance station and seals the printheads.

  • Page 17: Post Symptom Table

    4098-001 POST Symptom Table Symptom No power light and no motors run Paper feed gears do not turn Carrier does not move Carrier slams side frame No busy light Action Go to the “Power Service Check” on page 2-13. Go to the “Paper Feed Service Check”...

  • Page 18: Symptom Tables

    4098-001 Symptom Tables Locate the symptom in the following tables and take the indicated action. Carrier Transport Problems Symptom • No carrier movement • Slow carrier movement • Carrier stops • Carrier slams side frame • Carrier does not move to...
  • Page 19 4098-001 Paper Feed Problems Symptom • 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 Power Problems...

  • Page 20: Service Checks

    Action 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.
  • Page 21 4098-001 Encoder Strip Encoder Card Printhead Cable System Board Maintenance Station Operator Panel Operator Panel Cable System Board Action 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.

  • Page 22: Maintenance Station Service Check

    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 drying.

  • Page 23: Paper Feed Service Check

    4098-001 Paper Feed Service Check If your printer does not have paper jam problems, continue with the service check. If your printer does have a paper jam problems, examine it for the following before you begin the service check: •...
  • Page 24 4098-001 Paper Feed Motor Drive Train Assembly Sheet Feeder Mid Frame Asm 2-12 Service Manual Action A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or short in the motor •...

  • Page 25: Paper Path Service Check

    Feed Rollers End-of-Forms Flag / Spring System board Paper Path Service Check Examine the printer for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the paper guide is not worn/ broken and positioned against the paper without binding.

  • Page 26: Print Quality Service Check

    4098-001 Print Quality Service Check Print Cartridge Color Print Cartridge Cross Contamination Wiper Print Cartridge Printhead Carrier Assembly System Board Printhead Cable Rubber Backer Print Cartridge 2-14 Service Manual Action Be sure the machine contains good print cartridges. Cross contamination of color inks results in incorrect colors printed, as when green prints for yellow.
  • Page 27 4098-001 Encoder Card Maintenance Station Paper Feed Transport Alignment Action Refer to the “Test Page” again. The current Temperature is the ambient temperature at the encoder card in degrees celcius. Printing slows to prevent overheating. Overheating can cause excessive ink flow from the print cartridges. The normal operating range is from 16 to 32 degrees celcius.
  • Page 28 4098-001 2-16 Service Manual...

  • Page 29: Diagnostic Aids

    4098-001 3. Diagnostic Aids Auto Compensator Assembly Operation The auto compensator assembly is a paper pick device that generates its own normal force which is inherent in the fundamental design of the pick arm. If light media is used, the auto compensator assembly picks very gently;...

  • Page 30: Print Test Page

    4098-001 Print Test Page To Run: • Install known good Color and Black Print Cartridges • Hold down the Paper Feed button and Power On. • Continue to hold the Paper Feed button down until POST completes. What Prints: •...

  • Page 31: End Of Forms (Eof) Test

    The Busy Light will come on when the flag is removed from the sensor and will be off when the flag is in the sensor. • Unplug the printer power or press the Power button to end the test. •...

  • Page 32: Encoder Sensor Test

    4098-001 Encoder Sensor Test To start the Test: • Unplug power to the printer. • Remove the rear cover. • Place a 2 pin jumper on J13 • Hold down the Paper Feed button. • Plug power to the printer.

  • Page 33: Clear Nvram

    • Release the buttons when both the Power and Busy Lights turn • After approximately 20 seconds, the Power Light will flash. • Power off the printer to exit the test. • Remove the jumper from J14. What Happens: •...

  • Page 34: Print Nvram Contents

    4098-001 Print NVRAM Contents To Run: • Load paper in the auto sheet feeder. • Place a sheet of paper in the manual sheet feeder. • Hold down the Paper Feed button and Power On. • Continue to hold the Paper Feed button down until POST completes.

  • Page 35: Repair Information

    4098-001 4. Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. Note: 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).

  • Page 36: Adjustments

    4098-001 Adjustments The user is directed, in the Printer Control program, to perform the bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. CAUTION: Unplug the power cord before removing any parts.

  • Page 37: Auto Compensator Assembly Removal

    4098-001 Auto Compensator Assembly Removal 1. Remove all covers. 2. Remove the E-clip from right side of the auto compensator shaft. Note: For reinstalling purposes, note the position of the spring before removing. 3. Pull shaft out the left side and remove auto compensator.

  • Page 38: Carrier Transport Motor Removal

    4098-001 Carrier Transport Motor Removal 1. Remove all covers. 2. Remove the sheet feeder. 3. Disconnect (J5) the carrier transport motor connector {A}from the system board. 4. Remove the belt {B}from the carrier transport motor pulley. 5. Remove the two screws {C}securing the carrier transport motor to the carrier frame and remove the motor{D}.

  • Page 39: Front Cover Removal

    4098-001 Front Cover Removal 1. Remove rear cover. 2. Disconnect operator panel cable. 3. Insert screwdriver and release two latches located on the bottom of front cover. 4. Pull the front cover forward and remove. Gear Plate Assembly Removal 1. Remove all covers.

  • Page 40: Mid Frame / Large Feed Roller / Exit Roller Removal

    4098-001 Mid Frame / Large Feed Roller / Exit Roller Removal 1. Remove all covers. 2. Remove the sheet feeder. 3. Remove the printhead carrier and the maintenance station. Note: The carrier is attached to the belt at a raised tab. When reinstalling, be sure the belt tab and carrier are aligned.

  • Page 41: Paper Feed Motor Removal

    3. Remove the retainers from the ends of the carrier shaft. 4. Slide the shaft left and remove from the printer. 5. Disconnect printhead cables from the system board. Note: The carrier is attached to the belt at a raised tab. When reinstalling, be sure the belt tab and carrier are aligned.

  • Page 42: Printhead Cable And Cradle Removal

    4098-001 Printhead Cable and Cradle Removal 1. Remove all covers. 2. Remove the printhead carrier assembly. 3. Disconnect the printhead cable from the encoder card. Note the routing of the cable under the retaining clip on the carrier. 4. Separate the cradle from the printhead carrier assembly by pushing out the cradle latches {A}.

  • Page 43: Sheet Feeder Removal

    6. Slide holder down and remove holder and EOF flag. Star Wheel Roller Assembly Removal 1. Remove all covers. 2. Move printhead carrier to the center of the printer. 3. Remove two screws on each end of star wheel roller assembly. 4. Remove star wheel roller assembly.

  • Page 44: System Board Removal

    4098-001 System Board Removal 1. Remove all covers. 2. Remove the sheet feeder. 3. Disconnect all connectors from the system board. 4. Remove the two screws securing the system board to the carrier frame. Note: when removing the system board, be careful not to damage the EOF flag.

  • Page 45: Connector Locations

    4098-001 5. Connector Locations System Board Transport Motor Printhead Printhead Printhead Paper Feed Motor Test Jumper Test Jumper Operator Panel Connector Locations...

  • Page 46: Connector Locations (Cont.)

    The printer firmware will provide USB standard device ID information including a manufacturing name, Lexmark International, Inc., and product name. The communication path under USB will be bi-directional and asynchronous. Service Manual...

  • Page 47: Preventive Maintenance

    4098-001 6. Preventive Maintenance This chapter contains the lubrication specifications. Follow these recommendations to prevent problems and maintain optimum performance. Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease P/N 99A0394 to lubricate the following: •...
  • Page 48 4098-001 Service Manual...

  • Page 49: Parts Catalog

    4098-001 7. Parts Catalog How to Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 50: Assembly 1: Covers

    4098-001 Assembly 1: Covers Service Manual...
  • Page 51 4098-001 Assembly 1: Covers Asm- Part Index Number 14R0187 14R0156 14R0171 14R0192 14R0157 14R0192 14R0151 14R0145 14R0153 14R0154 14R0147 14R0149 7350234 14R0193 14R0194 Units Description Support, Paper Buttons and Lens Asm Card, Operator Panel Screw, Operator Panel Card Mount (PP)

  • Page 52: Assembly 2: Frames

    4098-001 Assembly 2: Frames Service Manual...
  • Page 53 4098-001 Assembly 2: Frames Asm- Part Index Number 14R0160 14R0159 Units Description Frame, Main Frame, Mid Parts Catalog...

  • Page 54: Assembly 3: Paper Feed

    4098-001 Assembly 3: Paper Feed Service Manual...
  • Page 55 4098-001 Assembly 3: Paper Feed Asm- Part Index Number 14R0189 14R0161 14R0192 14R0192 14R0192 14R0164 14R0165 14R0185 Units Description Auto Compensator Assembly Small Feed Roller Asm w/Holder & Flag Screws, Gear Plate Asm Mount (PP) Spring and C-Clip, Auto Compensator...
  • Page 56 4098-001 Assembly 3 (cont.): Paper Feed Service Manual...
  • Page 57 4098-001 Assembly 3 (cont.): Paper Feed Asm- Part Index Number 14R0159 14R0192 14R0163 14R0166 14R0192 14R0162 14R0190 14R0192 14R0145 14R0160 14R0167 Units Description Frame, Mid Bushing, Large Feed Roll (PP) Large Feed Roller Asm w/Gear & Pulley Exit Roller Asm...

  • Page 58: Assembly 4: Electronics

    4098-001 Assembly 4: Electronics 7-10 Service Manual...
  • Page 59 4098-001 Assembly 4: Electronics Asm- Part Index Number 14R0171 14R0170 14R0169 12G1812 12G1813 12G1814 14R0160 14R0145 14R0192 14R0192 14R0168 14R0195 11B6073 11B6074 11B6075 11B6076 11B6077 Units Description Card, Operator Panel Cable, System Board Board, Power / Parallel / USB Power Supply, External (LV) 100 V...

  • Page 60: Assembly 5: Carrier

    4098-001 Assembly 5: Carrier 7-12 Service Manual...
  • Page 61 4098-001 Assembly 5: Carrier Asm- Part Index Number 14R0175 14R0192 14R0179 17A0124 14R0176 14R0192 14R0192 17A0125 14R0180 Units Description Printhead Carrier Asm (complete) Screw, Encoder Card Mount (PP) Encoder Card Asm with Temperature Sensor Backer, Printhead Rubber Cable, Printhead Bearing, Carrier (PP)

  • Page 62: Assembly 6: Carrier Transport

    4098-001 Assembly 6: Carrier Transport 7-14 Service Manual...
  • Page 63 4098-001 Assembly 6: Carrier Transport Asm- Part Index Number 14R0181 14R0182 14R0183 14R0184 14R0192 14R0192 Units Description Carrier Transport Motor Asm and Pulley Belt, Carrier Encoder Strip Pulley, Idler Tension Screws, Carrier Transport Motor (PP) Retainer, Encoder Strip (PP) 7-15...

  • Page 64: Assembly 7: Maintenance Station

    4098-001 Assembly 7: Maintenance Station 7-16 Service Manual...

  • Page 65: Index

    4098-001 Assembly 7: Maintenance Station Asm- Part Index Number 14R0190 14R0191 14R0191 Units Description Maintenance Station Asm Caps, Maintenance (PP) Wipers, Maintenance (PP) 7-17 Parts Catalog...
  • Page 66 4098-001 7-18 Service Manual...
  • Page 67 4098-001 Index Abbreviations Adjustments Assemblies 1 Covers 2 Frames 3 Paper Feed 3 Paper Feed (cont.) 7-10 4 Electronics 7-12 5 Carrier 6 Carrier Transport 7 Maintenance Station Connector Locations Diagnostic Aids Auto Compensator Operation Encoder Test End of Forms Test...
  • Page 68 Exit Roller Front Cover Gear Plate Gutter Pad Large Feed Roller Maintenance Station Mid Frame Operator Panel Paper Feed Motor Printhead Cable & Cradle Rear Cover Sheet Feeder Small Feed Roller Holder Small Feed Rollers Star Wheel Roller Assembly 4-10 System Board Temperature Sensor Wipers &...
  • Page 69 U.S. P/N 12G0147 - Japan P/N 12G0148 March 1999 You may use this form to communicate your comments about this publication, with the understanding that Lexmark may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.
  • Page 70 UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO. 2659 LEXINGTON, KY POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 032-2 740 NEW CIRCLE ROAD NW LEXINGTON KY 40511 9954 | | | | | |...

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