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Lexmark 4098-001 - page 1
4098-001 Lexmark Z51 Color Jetprinter™ Le xmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. • T able of Contents • Inde x • Safety and Notices • T rademarks • Star t Diagnostics ...
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Lexmark 4098-001 - page 2
First Edition (Mar ch 1999) The follo wing paragraph does not apply to an y country where such pro visions are inconsistent with local law : LEXMARK INTERNA TIONAL, INC. PR O VIDES THIS PUBLICA TION “AS IS” WITHOUT W ARRANTY OF ANY KIND , EITHER EXPRESS OR IMPLIED , INCLUDING, BUT NO T LIMITED TO , THE IMPLIED W ARRANTIES OF MERCHANT ABILITY OR ...
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Lexmark 4098-001 - page 3
iii 4098-00X Table of Contents P r e f a c e ................................................. v S a f e t yI n f o r m a t i o n ....................................... v i G e n e r a lI n f o r m a t i o n .................................... 1 - 1 Operator Panel ......................................... 1 - 1 Maintenance Approach .............. ...
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Lexmark 4098-001 - page 4
iv Ser vice Man ual 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 P ...
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Lexmark 4098-001 - page 5
Pref ace v Preface This manual describes the Lexmark Z51 Color Jetprinter (4098-001) and contains maintenance procedures f or ser vice personnel. It is divided into the f ollowing chapters: 1. General Information contains a gener al descr iption of the printer and the maintenance approach used to repair it. Special tools and test equipment are list ...
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Lexmark 4098-001 - page 6
vi Ser vice Man ual Safety Inf ormation • This product is designed, tested and approv ed to meet str ict global saf ety standards with the use of specific Le xmark components. The saf ety features of some parts may not alwa ys be obvious . Lexmark is not responsible f or the use of other replacement par ts. • The maintenance inf or mation f or ...
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Lexmark 4098-001 - page 7
Saf ety Inf or mation vii Norme di sicurezza • Il prodotto è stato progettato , testato e approv ato in conf or mità a se v eri standard di sicurezza e per l’utilizzo con componenti Le xmark specifici. Le caratteristiche di sicurezza di alcune par ti non sempre sono di immediata comprensione. Le xmark non è responsabile per l’utilizzo di p ...
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Lexmark 4098-001 - page 8
viii Ser vice Manual P autas de Seguridad • Este producto se ha diseñado , verificado y aprobado para cumplir los más estrictos estándares de segur idad global usando los componentes específicos de Le xmark. Puede que las características de seguridad de algunas piezas no sean siempre e videntes. Lexmark no se hace responsab le del uso de otr ...
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Lexmark 4098-001 - page 9
Saf ety Information ix Inf ormació de Seguretat • Aquest producte està disseny at, comprovat i apro vat per tal d'acomplir les estrictes nor mes 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 respon ...
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Lexmark 4098-001 - page 10
x Ser vice Man ual ...
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Lexmark 4098-001 - page 11
General Inf or mation 1-1 4098-001 1. General Inf ormation The Le xmark Z51 Color Jetpr inter TM is an electro-mechanical printer that creates characters and gr aphics by composing progr ammed patterns of ink dots using a pr inthead and liquid ink. The printhead uses small heater plates and nozzles to control ink flow and the f or mation of charact ...
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Lexmark 4098-001 - page 12
1-2 Ser vice Man ual 4098-001 Maintenance Appr oach The diagnostic inf or mation in this manual leads you to the correct field replaceable unit (FR U) or par t. Use the symptom inde x, ser vice checks , and diagnostic aids to deter mine the symptom and repair the f ailure. Begin with “Indicator Light T able” on pa g e 2-1 . After you complete t ...
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Lexmark 4098-001 - page 13
Diagnostic Inf or mation 2-1 4098-001 2. Diagnostic Inf ormation Star t Ser vice error indications are a series of P ower light flashes . There is a pause between each series of flashes. If y our printer has an error indicator , locate the series of flashes in the “Error Indicator T able” on page 2-2 . and take the indicated action. Unplug the ...
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Lexmark 4098-001 - page 14
2-2 Ser vice Man ual 4098-001 Error Indicator T able Number of Power Light Flashes Service Error (Logged) Error Name Error Description Action 28 1 Carrier stall No carrier emitter signals received, carrier not moving Go to “Carrier Tr a n s p o r t Service Check” on page 2-8 . Ensure the driver is installed correctly . 39 3 Data error Incorrect ...
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Lexmark 4098-001 - page 15
Diagnostic Inf or mation 2-3 4098-001 Note: There are se v en reser v ed error code power light flashes ( 5, 10, 14, and 16 ) that hav e no code names. If any reserved codes are receiv ed, unplug and re-plug the printer . 8 None NVRAM error Error detected in reading or writing NVRAM Replace system board. See “System Board Remov al,”on page 4-10 ...
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Lexmark 4098-001 - page 16
2-4 Ser vice Man ual 4098-001 P ower -On Self T est (POST) Sequence T ur n the printer on and check f or a correct POST operation by obser ving the f ollowing: 1. The p o wer light come on. 2. The carr ier mov es to the left to wipe the printheads. 3. The carr ier mov es to the r ight o ver the maintenance station and seals the printheads. 4. The p ...
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Lexmark 4098-001 - page 17
Diagnostic Inf or mation 2-5 4098-001 POST Symptom T able Symptom Action No power light and no motors run Go to the “P ower Service Check” on page 2-13 . P aper feed gears do not turn Go to the “Paper Feed Service Check” on page 2-11 . Carrier does not mov e Go to the “Carrier T ransport Service Check” on page 2-8 . C a r r i e rs l a m ...
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Lexmark 4098-001 - page 18
2-6 Ser vice Man ual 4098-001 Symptom Tables Locate the symptom in the f o llo wing tables and take the indicated action. Carrier T ranspor t Prob lems Maintenance Station Prob lems Operator P anel P r oblems Printer Communication T able Symptom Action • No carrier movement • Slow carrier mov ement • Carrier stops • Carrier slams side frame ...
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Lexmark 4098-001 - page 19
Diagnostic Inf or mation 2-7 4098-001 P aper F eed Pr oblems Pow e r P ro b l e m s Print Quality Prob lems Symptom Action • F ails to pick paper • Picks more than one sheet of paper • Picks paper b ut fails to f eed • P aper jams • P aper fails to e xit • Noisy paper feed Go to the “Paper Feed Service Check” on page 2-11 . P aper s ...
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Lexmark 4098-001 - page 20
2-8 Ser vice Man ual 4098-001 Service Checks Carrier T ranspor t Service Check FRU Action 1 System Board Unplug the printer and disconnect the carr ier transport motor connector (J5) from the system board. Plug in the printer and check f or appro ximately +30 V dc between (J5-1) and ground at the system board. If the v oltage is incorrect, replace ...
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Lexmark 4098-001 - page 21
Diagnostic Inf or mation 2-9 4098-001 5 Encoder Strip Encoder Card Printhead Cable System Board Check the encoder strip for proper installation. Check the strip f or wear , dir t and grease. Be sure the carrier cable is fully seated in connector J10 and the cable is seated in the encoder card. Chec k the cable f or damage. Pe r f o r m t h e “Enc ...
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Lexmark 4098-001 - page 22
2-10 Ser vice Manual 4098-001 Maintenance Station Service Check The maintenance station has three functions: 1. Wipes the pr inthead nozzles to clear them of dir t. 2. Provides a place for the printheads to spit all nozzles keeping them clear prior to pr inting. 3. Seals the pr intheads when not in use to pre vent the nozzles from dr ying. FRU Acti ...
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Lexmark 4098-001 - page 23
Diagnostic Inf or mation 2-11 4098-001 P aper Feed Ser vice Chec k If your printer does not ha ve paper jam problems , continue with the ser vice chec k. If your printer does hav e a paper jam problems, e xamine it for the f ollowing bef ore you begin the ser vice chec k: • Check the entire paper path f or obstructions. • Be sure there is not t ...
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Lexmark 4098-001 - page 24
2-12 Ser vice Manual 4098-001 2 P aper Feed Motor A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or shor t in the motor • An open or shor t in the motor driver on the system board • A bind in the paper f eed mechanism With the paper f eed motor cable disconnected from the system board, check f or 3 to 5 ...
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Lexmark 4098-001 - page 25
Diagnostic Inf or mation 2-13 4098-001 P aper Path Service Chec k Examine the printer for the f ollowing bef ore you begin this service check: • Check the entire paper path f or obstructions. • Be sure the paper guide is not worn/ broken and positioned against the paper without binding. • Be sure the correct type of paper is being used. • B ...
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Lexmark 4098-001 - page 26
2-14 Ser vice Manual 4098-001 Print Quality Service Check FRU Action 1 Print Car tridge Be sure the machine contains good print car tridges. 2C o l o r P r i n t Car tridge Cross Contamination Wiper Print Car tridge Cross contamination of color inks results in incorrect colors printed, as when green prints for yello w . T his prob lem resolves quic ...
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Lexmark 4098-001 - page 27
Diagnostic Inf or mation 2-15 4098-001 5 Encoder Card Refer to the “T est Page” again. The current T e mper ature is the ambient temperature at the encoder card in degrees celcius. Pr inting slows to pre vent o verheating. Overheating can cause e xcessive ink flow from the print car tridges. The normal operating range is from 16 to 32 degrees c ...
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Lexmark 4098-001 - page 28
2-16 Ser vice Manual 4098-001 ...
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Lexmark 4098-001 - page 29
Diagnostic Aids 3-1 4098-001 3. Diagnostic Aids A uto Compensator Assembly Operation The auto compensator assembly is a paper pic k device that generates its own normal f orce which is inherent in the fundamental design of the pick arm. If light media is used, the auto compensator assembly pic ks very gently; if a heavy media is used, it picks v er ...
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Lexmark 4098-001 - page 30
3-2 Ser vice Man ual 4098-001 Print T est Pa ge To R u n : • Install known good Color and Blac k Pr int Cartr idges • Hold down the P aper F eed button and P ower On. • Continue to hold the P aper F eed button do w n until POST completes. What Prints: • Code Le vel and Code Le vel Date. • Current Ambient T emperature in Degrees Celsius. ? ...
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Lexmark 4098-001 - page 31
Diagnostic Aids 3-3 4098-001 End of Forms (EOF) T est T o Star t the T est: • Unplug power to the printer . • Remov e the rear cove r . • P l a c ea2p i nj u m p e r o nJ 1 3 . • Hold down the P ow er and Paper F eed buttons . • Plug power to the printer . • Release the buttons when the P ow er Light flashes (appro ximately 5 seconds). ...
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Lexmark 4098-001 - page 32
3-4 Ser vice Man ual 4098-001 Encoder Sensor Test T o star t the T est: • Unplug powe r to the printer . • Remov e the rear cov er . • P l a c ea2p i nj u m p e r o nJ 1 3 • Hold down the P aper F eed button. • Plug power to the printer . • Release the button when both Lights turn off (appro ximately 5 seconds). T o T est: • Mov e the ...
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Lexmark 4098-001 - page 33
Diagnostic Aids 3-5 4098-001 Clear NVRAM T o Run: • Unplug power to the printer . • Remov e the rear cove r . • P l a c ea2p i nj u m p e r o nJ 1 4 • Place a sheet of paper in the manual sheet f eeder far enough to activ ate the paper sensor . • Open the access cov er . • Hold down the P ow er and Paper F eed buttons . • Plug power t ...
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Lexmark 4098-001 - page 34
3-6 Ser vice Man ual 4098-001 Print NVRAM Contents To R u n : • Load paper in the auto sheet f eeder . • Place a sheet of paper in the manual sheet f eeder . • Hold down the P aper F eed button and P ower On. • Continue to hold the P aper F eed button do w n until POST completes. What Prints: • NVRAM contents in hexadecimal f ormat. • C ...
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Lexmark 4098-001 - page 35
Repair Inf or mation 4-1 4098-001 4. Repair Inf ormation This chapter e xplains how to mak e adjustments to the pr inter and how to remo ve def ective par ts . Note: Read the f ollowing bef ore handling electronic par ts. Handling ESD-Sensitive P ar ts Many electronic products use parts that are known to be sensitiv e to electrostatic discharge (ES ...
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Lexmark 4098-001 - page 36
4-2 Ser vice Man ual 4098-001 Adjustments The user is directed, in the Printer Control program, to perf or m the bidirectional alignment adjustments after replacing a print car tr idge . Remo v al Pr ocedures The f ollowing procedures are arranged according to the name of the printer par t discussed. CA UTION: Unplug the power cor d before remo vin ...
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Lexmark 4098-001 - page 37
Repair Inf or mation 4-3 4098-001 Auto Compensator Assembl y Remov al 1. Remove all co vers. 2. Remove the E-clip from right side of the auto compensator shaft. Note: F or reinstalling pur poses, note the position of the spring bef ore removing. 3. Pull shaft out the l eft side and remo ve auto compensator . Buttons / Lenses Remov al 1. Remove all ...
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Lexmark 4098-001 - page 38
4-4 Ser vice Man ual 4098-001 Carrier T ranspor t Motor Remo val 1. Remove all co vers. 2. Remove the sheet f eeder . 3. Disconnect (J5) the carr ier transport motor connector {A} from the system board. 4. Remove the belt {B} from the carrier transpor t motor pulle y . 5. Remove the tw o screws {C} securing the carrier transpor t motor to the carri ...
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Lexmark 4098-001 - page 39
Repair Inf or mation 4-5 4098-001 Front Co ver Remov al 1. Remove rear co ver . 2. Disconnect operator panel cable. 3. Inser t screwdriver and release two latches located on the bottom of front cov er . 4. Pull the front cover f orward and remov e. Gear Plate Assembl y Remova l 1. Remove all co vers. 2. Remove the sheet f eeder . 3. Remove the carr ...
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Lexmark 4098-001 - page 40
4-6 Ser vice Man ual 4098-001 Mid Frame / Large Feed Roller / Exit Roller Remov al 1. Remove all co vers. 2. Remove the sheet f eeder . 3. Remove the printhead carrier and the maintenance station. Note: The carrier is attached to the b elt at a r aised tab . When reinstalling, be sure the belt tab and carrier are aligned. 4. Remove the tw o star wh ...
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Lexmark 4098-001 - page 41
Repair Inf or mation 4-7 4098-001 P aper Feed Motor Remov al 1. Remove all co vers. 2. Remove the sheet f eeder . 3. Disconnect (J12) the paper feed motor from the system board. 4. Remove the tw o screws mounting the paper f eed motor and remov e the motor . Note the routing of all cables. P ower / P arallel / USB Board Remo val 1. Remove all co ve ...
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Lexmark 4098-001 - page 42
4-8 Ser vice Man ual 4098-001 Printhead Cable and Cradle Remo val 1. Remove all co vers. 2. Remove the printhead carrier assembly . 3. Disconnect the pr inthead cab le from the encoder card. Note the routing of the cable under the retaining clip on the carrier . 4. Separate the cradle from the printhead carr ier assemb ly by pushing out the cradle ...
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Lexmark 4098-001 - page 43
Repair Inf or mation 4-9 4098-001 Sheet Feeder Remov al 1. Remove all co vers. 2. Remove the three mounting scre ws that hold the sheet feeder . 3. Remove the sheet f eeder . Note the routing of the cables. Small Feed Rollers 1. Remove all co vers. 2. Remove the sheet f eeder . 3. Disconnect spr ings from the small f eed roller . 4. Press down on t ...
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Lexmark 4098-001 - page 44
4-10 Ser vice Manual 4098-001 System Board Remo val 1. Remove all co vers. 2. Remove the sheet f eeder . 3. Disconnect all connectors from the system board. 4. Remove the tw o 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. ...
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Lexmark 4098-001 - page 45
Connector Locations 5-1 4098-001 5. Connector Locations J1 System Board J5 T ransport Motor J6 Printhead J10 Printhead J11 Printhead J12 P aper Feed Motor J13 T est Jumper J14 T est Jumper J16 Operator P anel ...
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Lexmark 4098-001 - page 46
5-2 Ser vice Man ual 4098-001 Connector Locations (cont.) *Under USB, the printer will be hot-plug-able into USB compliant versions of Windo ws 95 and NT operating systems. A nytime the printer is disconnected or reconnected, the change will be quickly detected and reflected in the operating system vie w of av ailable por ts . The printer firm w ar ...
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Lexmark 4098-001 - page 47
Pre ventiv e Maintenance 6-1 4098-001 6. Preventive Maintenance This chapter contains the lubrication specifications. F ollow these recommendations to pre vent problems and maintain optimum perf orm ance . Lubrication Specifications Lubricate only when par ts are replaced or as needed, not on a scheduled basis. Use g rease P/N 99A0394 to lubricate ...
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Lexmark 4098-001 - page 48
6-2 Ser vice Man ual 4098-001 ...
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Lexmark 4098-001 - page 49
P ar ts Catalog 7-1 4098-001 7. P ar ts Catalog How to Use This P arts Catalog • SIMILAR ASSEMBLIES: If two assemb lies contain a major ity of identical par ts, the y are shown on the same list. Common par ts are shown b y one index n umber . P ar ts peculiar to one or the other of the assemblies are listed separ ately and identified by descripti ...
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Lexmark 4098-001 - page 50
7-2 Ser vice Man ual 4098-001 Assembl y 1: Cover s ...
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Lexmark 4098-001 - page 51
P ar ts Catalog 7-3 4098-001 Assembl y 1: Co vers Asm- Index Par t Number Units Description 1-1 14R0187 1 Suppor t, P aper 2 14R0156 1 Buttons and Lens Asm 3 14R0171 1 Card, Operator Panel 4 14R0192 1 Screw , Operator P anel Card Mount (PP) 5 14R0157 1 T ray , Banner Paper 6 14R0192 2 Screws, Rear Co ver Mount (PP) 7 14R0151 1 Cover , Rear 8 14R014 ...
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Lexmark 4098-001 - page 52
7-4 Ser vice Man ual 4098-001 Assembl y 2: Frames ...
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Lexmark 4098-001 - page 53
P ar ts Catalog 7-5 4098-001 Assembl y 2: Frames Asm- Index Par t Number Units Description 2-1 14R0160 1 Fr ame, Main 2 14R0159 1 Fr ame, Mid ...
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Lexmark 4098-001 - page 54
7-6 Ser vice Man ual 4098-001 Assembl y 3: Paper Feed ...
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Lexmark 4098-001 - page 55
P ar ts Catalog 7-7 4098-001 Assembl y 3: P aper Feed Asm- Index Par t Number Units Description 3-1 14R0189 1 Auto Compensator Assemb ly 2 14R0161 1 Small Feed Roller Asm w/Holder & Flag 3 14R0192 1 Screws, Gear Plate Asm Mount (PP) 3 14R0192 1 Spr ing and C-Clip , Auto Compensator Shaft (PP) 4 14R0192 1 Screws, P aper Feed Motor Mount (PP) 5 1 ...
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Lexmark 4098-001 - page 56
7-8 Ser vice Man ual 4098-001 Assembl y 3 (cont.): Paper Feed ...
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Lexmark 4098-001 - page 57
P ar ts Catalog 7-9 4098-001 Assembl y 3 (cont.): P aper Feed Asm- Index Par t Number Units Description 3-8 14R0159 1 F rame, Mid 9 14R0192 2 Bushing, Large Feed Roll (PP) 10 14R0163 1 Large Feed Roller Asm w/Gear & Pulle y 11 14R0166 1 Exit Roller Asm 12 14R0192 2 Screws, Star Roller Mount (PP) 13 14R0162 1 Star Roller Crossbar Asm 14 14R0190 ...
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Lexmark 4098-001 - page 58
7-10 Ser vice Manual 4098-001 Assembl y 4: Electronics ...
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Lexmark 4098-001 - page 59
P ar ts Catalog 7-11 4098-001 Assembl y 4: Electronics Asm- Index Par t Number Units Description 4-1 14R0171 1 Card, Operator P anel 2 14R0170 1 Cab le, System Board 3 14R0169 1 Board, P ow er / Parallel / USB 4 12G1812 1 P ower Supply , Exter nal (L V) 100 V (Japan) 4 12G1813 1 P ower Supply , Exter nal (L V) 120 V (U.S .A.) 4 12G1814 1 P ower Sup ...
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Lexmark 4098-001 - page 60
7-12 Ser vice Manual 4098-001 Assembl y 5: Carrier ...
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Lexmark 4098-001 - page 61
P ar ts Catalog 7-13 4098-001 Assembl y 5: Carrier Asm- Index Par t Number Units Description 5-1 14R0175 1 Printhead Carr ier Asm (complete) 2 14R0192 1 Scre w , Encoder Card Mount (PP) 3 14R0179 1 Encoder Card Asm with T emperature Sensor 4 17A0124 2 Back e r , Printhead Rubber 5 14R0176 1 Cable , Printhead 6 14R0192 2 Bearing, Carrier (PP) 7 14R0 ...
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Lexmark 4098-001 - page 62
7-14 Ser vice Manual 4098-001 Assembl y 6: Carrier Transpor t ...
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Lexmark 4098-001 - page 63
P ar ts Catalog 7-15 4098-001 Assembl y 6: Carrier T ranspor t Asm- Index Par t Number Units Description 6-1 14R0181 1 Carr ier T ranspor t Motor Asm and Pulley 2 14R0182 1 Belt, Carrier 3 14R0183 1 Encoder Strip 4 14R0184 1 Pulle y , Idler T ension 5 14R0192 2 Scre ws, Carrier T ransport M otor (PP) 6 14R0192 1 Retainer , Encoder Strip (PP) ...
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Lexmark 4098-001 - page 64
7-16 Ser vice Manual 4098-001 Assembl y 7: Maintenance Station ...
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Lexmark 4098-001 - page 65
P ar ts Catalog 7-17 4098-001 Assembl y 7: Maintenance Station Asm- Index Par t Number Units Description 7-1 14R0190 1 Maintenance Station Asm 2 14R0191 1 Caps, Maintenance (PP) 3 14R0191 1 Wipers , Maintenance (PP) ...
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Lexmark 4098-001 - page 66
7-18 Ser vice Manual 4098-001 ...
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Lexmark 4098-001 - page 67
X-1 Inde x A Abbreviations 1-2 Adjustments 4-2 Assemblies 1 Covers 7-2 2F r a m e s 7-4 3 Paper Feed 7-6 3 Paper Feed (cont.) 7-8 4 Electronics 7-10 5 Carrier 7-12 6 Carrier Transport 7-14 7 Maintenance Station 7-16 C Connector Locations 5-1 D Diagnostic Aids Auto Compensator Operation 3-1 Encoder Test 3-4 End of Forms Test 3-3 NVRAM Dump 3-5 Test ...
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Lexmark 4098-001 - page 68
X-2 EOF 4-9 Exit Roller 4-6 Front Cover 4-5 Gear Plate 4-5 Gutter Pad 4-5 Large Feed Roller 4-6 Maintenance Station 4-5 Mid Frame 4-6 Operator Panel 4-6 Paper Feed Motor 4-7 Printhead Cable & Cradle 4-8 Rear Cover 4-8 Sheet Feeder 4-9 Small Feed Roller Holder 4-9 Small Feed Rollers 4-9 Star Wheel Roller Assembly 4-9 System Board 4-10 Temperatur ...
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Lexmark 4098-001 - page 69
Reader Comment Form Le xmar k Z51 Color Jetprinter (4098-00X) Ser vice Manual U .S. P/N 12G0147 - J apan P/N 12G0148 March 1999 Y ou may use this f or m to communicate your comments about this publication, with the understanding that Le xmark may use or distribute whate ver inf or mation you supply in any wa y it belie v es appropriate without incu ...
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Lexmark 4098-001 - page 70
NO POST A GE NECESSAR Y IF MAILED IN THE UNITED ST A TES ————————————————————————————————————————————————————— Cut Along Line POST AGE WILL BE P AID BY ADDRESSEE LEXMARK INTERNA TIONAL INC DEP ARTMENT D22A BUILDING 032-2 740 NEW CIRCLE RO AD NW ...
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