Lexmark Z31 Color Jetprinter Service Manual Download Page 13

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General Information

1-3

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

Summary of Contents for Z31 Color Jetprinter

Page 1: ...r Jetprinter Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Index Safety and Notices Trademarks Start Diagnostics Table of Contents ...

Page 2: ...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 incurring any 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 ...

Page 3: ...r Feed Service Check 2 8 Paper Path Service Check 2 10 Power Service Check 2 11 Print Quality Service Check 2 12 Diagnostic Aids 3 1 Test Page 3 1 Repair Information 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 ...

Page 4: ...Roller Assembly Removal 4 6 Gear Plate Assembly Removal 4 7 Carrier Belt Idler Pulley Removal 4 7 Power Connector Removal 4 7 Connector Locations 5 1 Preventive Maintenance 6 1 Lubrication Specifications 6 1 Parts Catalog 7 1 Index I 1 ...

Page 5: ...or 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 poi...

Page 6: ...icing 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 responsa...

Page 7: ...ersonale 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 Lexmar...

Page 8: ...ión 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 util...

Page 9: ... 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...

Page 10: ...x Service Manual 4099 ...

Page 11: ... 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 cartridge Power Consumption 8 Watts power off and power to the printer 8 Watts Idle Mode power on not printing 15 Watts Printing av...

Page 12: ... Application Turns the printer on or off Ejects paper from the printer Advances a sheet of paper into the automatic sheet feeder when the printer has run out of paper during a print job Power button Paper Feed button Paper Feed button Power button ...

Page 13: ...or 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...

Page 14: ...1 4 Service Manual 4099 ...

Page 15: ...Indicator Light Indicates Power light is On Paper Feed light is Off Machine is on and ready to print Both lights are On Machine is printing Power light is On Paper Feed light is blinking May be out of paper or have a paper jam Power light is blinking 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 C...

Page 16: ... 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 and no motors run Go to the Power Service Check on page 2 11 Paper feed gears do not turn Go to the Paper Feed Service Check on page ...

Page 17: ...m Action Maintenance station Fails to cap the printheads Fails to clean the printheads Go to the Maintenance Station Service Check on page 2 7 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 J...

Page 18: ...ervice Check on page 2 8 Paper skews Go to the Paper Path Service Check on page 2 10 Symptom Action No power in machine motors do not operate Go to the Power Service Check on page 2 11 Symptom Action Voids in characters Light print Prints off the page Fuzzy print Carrier moves but no print Printhead dries prematurely Colors print incorrectly Vertical alignment off Go to the Print Quality Service C...

Page 19: ...t is detected replace the carrier transport motor 2 Carrier Transport Motor Check the motor for binds or loose motor pulley A noisy or chattering motor or a motor that fails to turn can be caused by 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 boar...

Page 20: ...bly Disconnect the printer and check the carrier printhead connector J5 If the connection is good remove the printhead carrier and check the cable connection to the home sensor board If the problem remains replace the system board 6 Maintenance Station A problem with the maintenance station can cause carrier movement problems at the right margin Go to the Maintenance Station Service Check on page ...

Page 21: ...n causing the cap to rise and seal the printhead Carrier movement to the left uncaps the printhead The wiper cleans the printhead nozzles as the carrier leaves the maintenance station The wiper cleans the printhead 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 cleaning operation is complete a ...

Page 22: ...Be sure the correct type of paper is being used Check for static in the paper FRU Action 1 System Board Unplug the printer and disconnect the paper feed motor J9 from the system board Plug the printer in and check for approximately 9 to12 V dc between J9 1 and ground and J9 2 and ground on the system board as the printer goes through POST If the voltage is not present check for motor pins shorted ...

Page 23: ...tor turns in two directions If the paper feed motor turns in one direction only replace the system board Binds in the paper feed motor or gear train can cause intermittent false paper jam errors Remove the paper feed motor and check the shaft for binds Also check for a loose or worn motor gear 3 Gear Plate Assembly Check for binds in the gear train and paper feed mechanism by removing the paper fe...

Page 24: ...the correct type of paper is being used Be sure the printer is installed on a flat surface FRU Action 1 Large and Small Feed Rollers Check for wear and binds 2 Small Feed Roller Springs Check for damage 3 Auto Sheet Feeder Assembly Check the pick roller for wear 4 Mid Frame Asm Check the following for wear Exit roller Star rollers 5 End of Forms Flag Check for binds or damage ...

Page 25: ... Home Sensor Parallel Cable Paper Feed Motor Carrier Transport Motor Operator Panel Unplug the printer Disconnect one of the printhead cables and plug in the printer Look for a symptom change Check the failing part for shorts and replace as necessary Repeat this procedure for the carrier home sensor parallel cable carrier transport motor paper feed motor and operator panel 4 System Board If the sy...

Page 26: ...rinthead Cartridge Latch Latch Spring Carrier 4 System Board Printhead Carrier Assembly Perform the Test Page on page 3 1 Look for a break in the diagonal line of the nozzle test pattern A broken line indicates one or more print nozzles are not working Run the test again to verify the failure If there are even breaks in the diagonal line similar to the pattern shown below replace the system board ...

Page 27: ... voids can be caused by problems in the carrier transport area Check the following Carrier transport belt for wear Carrier guide rod for wear or dirt If dirty clean and lubricate Carrier to carrier frame engagement should be lubricated with grease P N 99A0394 Idler pulley parts for wear damage or looseness 8 Alignment Uneven vertical lines can be adjusted by performing the printhead alignment adju...

Page 28: ...2 14 Service Manual 4099 ...

Page 29: ...er 6 Turn the printer off 7 Hold down the Paper Feed and Power buttons at the same time until both lights begin to flash 8 Release both buttons Test pages print until the Power button is pressed The printer prints four lines of black and color printhead cartridge nozzle purge patterns followed by a black and color nozzle test pattern The purge pattern is used to clear all printhead nozzles The noz...

Page 30: ...3 2 Service Manual 4099 ...

Page 31: ... ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag M...

Page 32: ...ocedures The following procedures are arranged according to the name of the printer 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 33: ...ver 3 Place the printer on its base Pull the cover forward and remove Base Cover Assembly Removal 1 Remove the front cover 2 Remove the four screws holding the carrier frame assembly to the rear of the base cover 3 Remove the two screws holding the front of the carrier frame assembly to the base cover 4 Lift the carrier frame assembly out of the base cover assembly Ink Pad Removal 1 Remove the fro...

Page 34: ...4 Remove the sheet feeder assembly mounting screw from the gear plate assembly 5 Remove the sheet feeder assembly from the carrier frame assembly System Board Removal 1 Remove the front cover 2 Remove the base cover assembly 3 Remove the sheet feeder assembly 4 Disconnect all connectors from the system board Note the cable routings 5 Remove the four mounting screws from the system board Warning Wh...

Page 35: ...ove the printhead carrier cable retainer latch located on the carrier frame Pull the printhead carrier cable through the hole in the carrier frame When reinstalling the cable retainer ensure the two retainer tabs are through the carrier frame before latching the two retainer latches Note Before installing the carrier belt loosen the carrier belt idler pulley mounting screw Tighten the screw after ...

Page 36: ...ies 5 Release the two latches located at the rear corners of the mid frame and raise the mid frame at the rear and out of the carrier frame Large Feed Roller Assembly Removal 1 Remove the front cover 2 Remove the base cover assembly 3 Remove the sheet feeder assembly 4 Remove the small feed roller assemblies 5 Remove the maintenance station assembly 6 Remove the bearing from the right end of the l...

Page 37: ...over 2 Remove the retainers from the ends of the carrier guide rod 3 Slide the carrier guide rod out the right side of the carrier frame Note The carrier is attached to the carrier belt between two raised tabs on the belt Be sure to note this location when reinstalling the printhead carrier assembly 4 Remove the carrier belt from the rear of the carrier Note Before installing the carrier belt loos...

Page 38: ...4 8 Service Manual 4099 ...

Page 39: ...r Locations Units Description J3 Operator Panel J4 Parallel Port J5 Printhead Cable 1 J6 Printhead Cable 2 J7 Printhead Cable 3 J8 Carrier Transport Motor J9 Paper Feed Motor J10 Power Connector PS1 Access Door Sensor PS2 End of Forms Sensor ...

Page 40: ...5 2 Service Manual 4099 ...

Page 41: ...aintain 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 All gear mounting studs The left and right ends of the large feed roller at the side frames The carrier to carrier frame engagement The carrier guide rod and carrier guide rod bearings ...

Page 42: ...6 2 Service Manual 4099 ...

Page 43: ...mmon parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP in the parts description column indicates the part is available in the listed parts packet NA Not available as a FRU ...

Page 44: ...7 2 Service Manual 4099 Assembly 1 Covers ...

Page 45: ...Part Number Units Description 1 1 12G0190 1 Base Cover with Feet Exit Tray and Banner Support 2 12G0193 1 Felt Ink Pad 3 12G0192 1 Access Cover 4 12G0191 1 Front Cover 5 12G0195 1 Power Button and Lens NS 7350512 1 Field Packaging B M ...

Page 46: ...7 4 Service Manual 4099 Assembly 2 Paper Feed ...

Page 47: ...P 2 12G0197 1 Carrier Transport Motor 3 12G0209 2 Retainer Carrier Guide Rod PP 4 12G0209 1 Carrier Belt Tensioner PP 5 12G0206 1 Carrier Belt 6 12G0209 2 Bushing Feed Roller PP 7 12G0196 1 Mid Frame with Star Rollers Large and Small Feed Rollers 8 12G0209 1 End of Forms Flag Spring PP ...

Page 48: ...7 6 Service Manual 4099 Assembly 2 Paper Feed Continued ...

Page 49: ...g 7 7 4099 Asm Index Part Number Units Description 2 1 12G0209 2 Screws PP 6 12G0209 2 Bushing Feed Roller PP 9 12G0199 1 Gear Plate Asm with Motor 10 12G0194 1 Power Connector with Cable Note Includes Op Panel Asm ...

Page 50: ...7 8 Service Manual 4099 Assembly 3 Electronics ...

Page 51: ... 12G1826 1 P S External LV 120 V 4 12G1827 1 P S External HV 220 V 4 12G1825 1 P S External LV 100 V Japan 5 11B6073 1 Power Cord United Kingdom Hong Kong Ireland 5 11B6074 1 Power Cord Europe Chile 5 11B6076 1 Power Cord Australia New Zealand Brazil 5 11B6077 1 Power Cord South Africa 5 11B6078 1 Power Cord Peru 5 11B6138 1 Power Cord China 6 42F1814 2 Parallel Port Cable Clip ...

Page 52: ...7 10 Service Manual 4099 Assembly 4 Carrier ...

Page 53: ...Parts Catalog 7 11 4099 Asm Index Part Number Units Description 4 1 12G0204 1 Printhead Carrier Asm with Cable and Sensor 2 12G0205 1 Carrier Guide Rod 3 12g1868 1 Holder FPC Flat Parallel Cable ...

Page 54: ...7 12 Service Manual 4099 Assembly 5 Automatic Sheet Feeder ...

Page 55: ...Parts Catalog 7 13 4099 Asm Index Part Number Units Description 5 1 12G0207 1 Automatic Sheet Feeder Asm 2 12G3619 1 Paper Support ...

Page 56: ...7 14 Service Manual 4099 Assembly 6 Maintenance Station ...

Page 57: ...Parts Catalog 7 15 4099 Asm Index Part Number Units Description 6 1 12G0208 1 Maintenance Station Assembly ...

Page 58: ...7 16 Service Manual 4099 ...

Page 59: ...ation Specifications 6 1 M Maintenance 2 7 Maintenance Approach 1 3 O Operator Panel 1 2 P Parts Automatic Sheet Feeder 7 12 Carrier 7 10 Catalog 7 1 Covers 7 2 Electronics 7 8 Maintenance Station 7 14 Paper Feed 7 4 7 6 Plastic Latches 4 2 Power Consumption 1 1 Power On Self Test Sequence 2 2 Symptom Table 2 2 Preventive Maintenance 6 1 Problems Carrier Transport 2 3 Maintenance Station 2 3 Opera...

Page 60: ...2 8 Paper Path 2 10 Power 2 11 Print Quality 2 12 Start 2 1 Symptom Table POST 2 2 Symptom Tables 2 3 T Tests Test Page 3 1 Part Numbers 11B6073 7 9 11B6074 7 9 11B6076 7 9 11B6077 7 9 11B6078 7 9 11B6138 7 9 12G0190 7 3 12G0191 7 3 12G0192 7 3 12G0193 7 3 12G0194 7 7 7 9 12G0195 7 3 12G0196 7 5 12G0197 7 5 12G0199 7 7 12G0200 7 9 12G0204 7 11 12G0205 7 11 12G0206 7 5 12G0207 7 13 12G0208 7 15 12G...

Page 61: ...es No 2 Was the content of the book accurate and complete Yes No 3 Was the book easy to use Yes No 4 What can we do to improve the book ______________________________________________ ______________________________________________ 5 What is your job title ______________________________________________ Questions or comments about supplies service applications and so on slow response time considerabl...

Page 62: ... Along Line POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 032 2 740 WEST NEW CIRCLE ROAD LEXINGTON KY 40511 9954 Fold Here Tape Please Do Not Staple Tape BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 2659 LEXINGTON KY ...

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