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1-2

Service Manual

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

Содержание Z51 Color Jetprinter

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

Страница 2: ...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 pr...

Страница 3: ...intenance 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 Diagnostic Aids 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 Repair Information 4 1 Handling ESD Sensitive Parts 4...

Страница 4: ...B 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 Connector Locations 5 1 Connector Locations cont 5 2 Preventive Maintenance 6 1 Lubrication Specifications 6 1 Parts Catalog 7 1 How to Use This Parts Catalog 7 1 A...

Страница 5: ... 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 conn...

Страница 6: ...ng 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...

Страница 7: ...onale 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 s...

Страница 8: ...n 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 utiliz...

Страница 9: ...lgunes 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...

Страница 10: ...x Service Manual ...

Страница 11: ...eplaceable supply item Dual printheads provide color and true black printing without changing printheads 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 The printer is capable of prin...

Страница 12: ... 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...

Страница 13: ...hts 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 ligh...

Страница 14: ...93 Data error Incorrect data has been sent from the host PC to the printer Check the system board and cable If OK check printhead cables Replace as needed 4 89 Print incomplete Carrier stopped before print data all used Check system board and cable If OK check printhead cables Replace as needed 6 64 66 thru 78 Exception Error Illegal instruction from microprocessor Replace system board 7 65 Addres...

Страница 15: ...n page 4 10 11 91 Error xxxxx Replace system board 12 92 Short error Short test detected short circuit in printhead Check and replace printhead and cable as needed If OK replace the system board 13 94 Head Select Install head ID and print command head ID do not match Replace printheads 15 96 USB error Error in USB hardware detected or invalid result occurred in USB code Check system board cable If...

Страница 16: ...eads 3 The carrier moves to 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 printer completes POST with no errors go to the Symptom Tables on page 2 6 locate the symptom and take the indicated action If your printer does not complete POST locate the symptom in the POST Symptom Table on page 2 5 and t...

Страница 17: ... Service Check on page 2 13 Paper feed gears do not turn Go to the Paper Feed Service Check on page 2 11 Carrier does not move Go to the Carrier Transport Service Check on page 2 8 Carrier slams side frame Go to the Carrier Transport Service Check on page 2 8 No busy light Replace the operator panel or the system board ...

Страница 18: ... does not move to cartridge load position when opening access door Go to the Carrier Transport Service Check on page 2 8 Symptom Action Fails to cap the printheads Fails to clean the printheads Go to the Maintenance Station Service Check on page 2 10 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 Symptom ...

Страница 19: ...the Paper Path Service Check on page 2 13 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 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 ...

Страница 20: ...e 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 board check for zero to ten 0 10 ohms between pins J5 1 and J5 2 on the motor If the readings are incorrect repla...

Страница 21: ...e 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 2 10 7 Operator Panel Operator Panel Cable System Board 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...

Страница 22: ...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 w...

Страница 23: ...tire paper path for obstructions Be sure there is not too much paper in the sheet feeder Be sure the correct type of paper is being used Check for static in the paper FRU Action 1 System Board With J12 disconnected and power on check for 30 V dc between J12 2 and ground at the system board If the voltage is not present check for motor pins shorted to the motor housing If you find a shorted pin rep...

Страница 24: ...ed motor or gear train can cause intermittent false paper jams Remove the paper feed motor and check the shaft for binds 3 Drive Train Assembly Check for binds in the gear train and paper feed mechanism by removing the paper feed motor and rotating the large gear by hand If you notice a bind replace the drive train assembly Also check the feed clutch inside the large feed gear 4 Sheet Feeder Check...

Страница 25: ...for binds Perform the End of Forms EOF Test on page 3 3 If the test fails replace the system board FRU Action 1 External Power Supply Plug the external power supply into an outlet Check for 30 V dc at the connector If voltage is incorrect replace the external power supply 2 Connector Board All Cables Operator Panel Encoder Card System Board Isolate for a shorted component by disconnecting the comp...

Страница 26: ...e Run the Print Clean Page on page 3 6 Look at the nozzle test pattern the diagonal line at the bottom of the page There should be no breaks in the diagonal lines Random breaks in the line indicate a problem with the print cartridge Run the Print Test Page on page 3 2 The test patterns at the bottom of the page are checking for opens in any of the lines to the printheads There should be black and ...

Страница 27: ...ion Perform the Maintenance Station Service Check on page 2 10 then return to this check 7 Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area Check the following Correct type of paper is being used Paper for curl or wrinkles Feed rollers for wear dirt or looseness Gears for wear or binds Paper path for obstructions 8 Transport Blurred print and ...

Страница 28: ...2 16 Service Manual 4098 001 ...

Страница 29: ...ia is used the auto compensator assembly picks very gently if a heavy media is used it picks very aggressively The spring pressure of the device is designed so the input torque from the motor causes downward force at the pick roll The friction between the pick roll and the paper produces a frictional locking condition The arm must pivot freely through its full range of motion If the pick assembly ...

Страница 30: ...ower On Continue to hold the Paper Feed button down until POST completes What Prints Code Level and Code Level Date Current Ambient Temperature in Degrees Celsius Manufacturer Information Paper Test Result Head Detect and Type Information Color and Black Nozzle Test Pattern 3 Printhead Purge Lines Nozzle Test Pattern Data Lines Test Pattern ...

Страница 31: ...ug power to the printer Release the buttons when the Power Light flashes approximately 5 seconds To Test Place a piece of paper in the manual feeder to activate the end of forms sensor 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 Remove the jumper from J13 ...

Страница 32: ... button when both Lights turn off approximately 5 seconds To Test Move the carrier by hand from right to left and left to right The Power Light will flash when the carrier is moved and will be off when the carrier is stationary The Busy Light will be off when the carrier is moved from right to left and on when the carrier is moved from left to right Unplug the printer to exit the test Remove the j...

Страница 33: ...paper sensor Open the access cover Hold down the Power and Paper Feed buttons Plug power to the printer Release the buttons when both the Power and Busy Lights turn on After approximately 20 seconds the Power Light will flash Power off the printer to exit the test Remove the jumper from J14 What Happens The following will be reset to zero Last Error Page Count Carrier Metric Drop Count Color and B...

Страница 34: ...ount Carrier Metric Total distance carrier traveled in 32 600th of an inch Dot Counts Cyan Magenta Yellow Primary and Secondary Black Thermal Sensor Y N Current Ambient Temperature in Degrees Celsius Left and Right Head ID Print Clean Page To Run Install known good Color and Black Print Cartridges Open the Access Cover Hold down the Paper Feed button and Power On Continue to hold the Paper Feed bu...

Страница 35: ... to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge 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 Machine co...

Страница 36: ...l Procedures 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 ...

Страница 37: ... 3 Pull shaft out the left side and remove auto compensator Buttons Lenses Removal 1 Remove all covers 2 Remove operator panel 3 Depress the button clips and remove the buttons 4 Lift and remove the lenses Carrier Frame Assembly Base Removal 1 Remove all covers 2 Remove the three screws that secure the carrier frame to the base assembly 3 Remove system board cable 4 Pull frame to the rear and remo...

Страница 38: ... the carrier transport motor to the carrier frame and remove the motor D Note the routing of the motor cable Encoder Sensor Temperature Sensor Removal 1 Remove all covers 2 Remove printhead carrier 3 Remove screw from the encoder sensor 4 Unplug cable and remove sensor Encoder Strip Removal 1 Remove all covers 2 Depress retainer clip on left side of encoder strip 3 Remove encoder strip Note The en...

Страница 39: ...ove the carrier frame 4 Remove mid frame and star roller assembly 5 Remove the two gear plate assembly screws from the carrier frame and remove the gear plate Gutter Pad Maintenance Station Removal 1 Remove all covers 2 Remove the carrier frame 3 Depress two plastic latches and remove the maintenance station 4 Remove the felt gutter pads Maintenance Wipers and Caps Removal 1 Remove all covers 2 Pu...

Страница 40: ...oller mounting screws Remove star wheel roller assembly 5 Remove the bushing from the right side of the large feed roller 6 Depress tabs A on each end of mid frame and remove large feed roller and mid frame 7 Apply pressure and remove the exit roller and belt 8 Remove mounting screws B and remove gear plate and paper feed motor assembly Operator Panel Removal 1 Remove all covers 2 Disconnect the o...

Страница 41: ...and disconnect two ground wires 4 Depress latches and slide the card out Printhead Carrier Assembly Shaft Removal 1 Remove all covers 2 Apply pressure to the idler pulley and remove the belt from the transport carrier motor 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 carrie...

Страница 42: ...he 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 Rear Cover Removal 1 Remove the two screws from rear cover 2 Insert screwdriver and depress two plastic latches and remove rear cover ...

Страница 43: ... roller 4 Press down on the friction roller assembly and remove Small Feed Roller Holder EOF Removal 1 Remove all covers 2 Remove sheet feeder assembly 3 Remove mid frame 4 Remove system board 5 Depress two tabs A on small feed roller holder 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 printe...

Страница 44: ...e 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 5 Remove the system board ...

Страница 45: ...Connector Locations 5 1 4098 001 5 Connector Locations J1 System Board J5 Transport Motor J6 Printhead J10 Printhead J11 Printhead J12 Paper Feed Motor J13 Test Jumper J14 Test Jumper J16 Operator Panel ...

Страница 46: ...sconnected or reconnected the change will be quickly detected and reflected in the operating system view of available ports 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 J1 Parallel J2 System Board J3 Power Supply J4 USB ...

Страница 47: ...intain 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 exit roller assembly at the mid frame The carrier to carrier frame engagement The carrier guide shaft and carrier guide shaft bearings ...

Страница 48: ...6 2 Service Manual 4098 001 ...

Страница 49: ...e 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 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 descriptions column indicates the part is available in the listed parts packet ...

Страница 50: ......

Страница 51: ...P 5 14R0157 1 Tray Banner Paper 6 14R0192 2 Screws Rear Cover Mount PP 7 14R0151 1 Cover Rear 8 14R0145 1 Base Cover with four feet and Gutter Pad 9 14R0153 1 Pads Gutter 10 14R0154 1 Tray Exit Asm 11 14R0147 1 Door Access and Need More Ink Label 12 14R0149 1 Cover Front with Label NS 7350234 1 Plain Package B M includes Carton Cushion Set Sealing Tape NS 14R0193 1 Label Need More Ink NS 14R0194 1...

Страница 52: ...7 4 Service Manual 4098 001 Assembly 2 Frames ...

Страница 53: ...Parts Catalog 7 5 4098 001 Assembly 2 Frames Asm Index Part Number Units Description 2 1 14R0160 1 Frame Main 2 14R0159 1 Frame Mid ...

Страница 54: ...7 6 Service Manual 4098 001 Assembly 3 Paper Feed ...

Страница 55: ...mbly 2 14R0161 1 Small Feed Roller Asm w Holder Flag 3 14R0192 1 Screws Gear Plate Asm Mount PP 3 14R0192 1 Spring and C Clip Auto Compensator Shaft PP 4 14R0192 1 Screws Paper Feed Motor Mount PP 5 14R0164 1 Paper Feed Motor Asm with Gear 6 14R0165 1 Gear Plate Asm without Motor 7 14R0185 1 ASF Asm without Auto Compensator ...

Страница 56: ...7 8 Service Manual 4098 001 Assembly 3 cont Paper Feed ...

Страница 57: ... PP 10 14R0163 1 Large Feed Roller Asm w Gear Pulley 11 14R0166 1 Exit Roller Asm 12 14R0192 2 Screws Star Roller Mount PP 13 14R0162 1 Star Roller Crossbar Asm 14 14R0190 1 Maintenance Station Asm 15 14R0192 1 Holder Printhead Cable Guide Clip PP 16 14R0145 1 Base Cover with four feet and Gutter Pad 17 14R0160 1 Frame Main 18 14R0167 1 Exit Drive Belt ...

Страница 58: ...7 10 Service Manual 4098 001 Assembly 4 Electronics ...

Страница 59: ...120 V U S A 4 12G1814 1 Power Supply External HV 220 V 5 14R0160 1 Frame Main 6 14R0145 1 Base Cover with four feet gutter pad 7 14R0192 1 Screws System Board Mount PP 7 14R0192 1 Ground Cables Power Parallel USB Board PP 8 14R0168 1 System Board 9 14R0195 1 Cable with Torroid Operator Panel NS 11B6073 1 Power Cable United Kingdom NS 11B6074 1 Power Cable Europe NS 11B6075 1 Power Cable Israel NS ...

Страница 60: ...7 12 Service Manual 4098 001 Assembly 5 Carrier ...

Страница 61: ...ad Carrier Asm complete 2 14R0192 1 Screw Encoder Card Mount PP 3 14R0179 1 Encoder Card Asm with Temperature Sensor 4 17A0124 2 Backer Printhead Rubber 5 14R0176 1 Cable Printhead 6 14R0192 2 Bearing Carrier PP 7 14R0192 2 Retainers Shaft PP 8 17A0125 1 Shaft Carrier 9 14R0180 2 Cartridge Interlock Keys B M ...

Страница 62: ...7 14 Service Manual 4098 001 Assembly 6 Carrier Transport ...

Страница 63: ...sm Index Part Number Units Description 6 1 14R0181 1 Carrier Transport Motor Asm and Pulley 2 14R0182 1 Belt Carrier 3 14R0183 1 Encoder Strip 4 14R0184 1 Pulley Idler Tension 5 14R0192 2 Screws Carrier Transport Motor PP 6 14R0192 1 Retainer Encoder Strip PP ...

Страница 64: ...7 16 Service Manual 4098 001 Assembly 7 Maintenance Station ...

Страница 65: ...Parts Catalog 7 17 4098 001 Assembly 7 Maintenance Station Asm Index Part Number Units Description 7 1 14R0190 1 Maintenance Station Asm 2 14R0191 1 Caps Maintenance PP 3 14R0191 1 Wipers Maintenance PP ...

Страница 66: ...7 18 Service Manual 4098 001 ...

Страница 67: ...ions 6 1 M Maintenance Approach 1 2 O Operator Panel Lights 1 1 P Parts Carrier 7 12 Carrier Transport 7 14 Covers 7 2 Electronics 7 10 Frames 7 4 Maintenance Station 7 16 Paper Feed 7 6 Paper Feed cont 7 8 Plastic Latches 4 2 POST Sequence 2 4 Symptom Table 2 5 Power Consumption 1 1 Preventive Maintenance 6 1 Problems Carrier Transport 2 6 Maintenance Station 2 6 Operator Panel 2 6 Paper Feed 2 7...

Страница 68: ... Quality 2 14 Start 2 1 Symptom Table POST 2 5 Symptom Tables 2 6 T Tests Encoder 3 4 End of Forms EOF 3 3 NVRAM Dump 3 5 Test Page 3 2 Part Numbers 11B6073 7 11 11B6074 7 11 11B6075 7 11 11B6076 7 11 11B6077 7 11 14R0145 7 3 7 9 7 11 14R0147 7 3 14R0149 7 3 14R0151 7 3 14R0153 7 3 14R0154 7 3 14R0156 7 3 14R0157 7 3 14R0159 7 5 7 9 14R0160 7 5 7 9 7 11 14R0161 7 7 14R0163 7 9 14R0164 7 7 14R0165 ...

Страница 69: ... 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 considerably Please refer those quest...

Страница 70: ...t Along Line POSTAGE WILL BE PAID BY ADDRESSEE LEXMARK INTERNATIONAL INC DEPARTMENT D22A BUILDING 032 2 740 NEW CIRCLE ROAD NW 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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