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Lexmark Z31 Color Jetprinter TM
4099
· 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.
4099
First Edition (August 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. 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 programs described may be made at any time. A form for reader's comments is provided at the back of this publication. If the form has been removed, comments may 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 purchase. Lexmark is a trademark of Lexmark International, Inc., registered in the United States and/or other countries. Color Jetprinter is a trademark of Lexmark International, Inc. Other trademarks are the property of their respective owners. © Copyright Lexmark International, Inc. 1999. All rights reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.
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Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2 1-3 1-3
Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-2 POST Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Carrier Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . . . . 2-7 Paper 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Base Cover Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . Ink Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buttons and Lenses Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Sheet Feeder Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . Printhead Carrier Assembly Removal . . . . . . . . . . . . . . . . . . . . . Maintenance Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . End-of-Forms Flag Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mid Frame / Star Roller Assembly Removal . . . . . . . . . . . . . . . . 4-1 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-3 4-4 4-5 4-5 4-6 4-6
iii
4099 Large Feed 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
iv Service Manual
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Preface
This manual describes the Lexmark Z31 Color JetprinterTM(4099) and 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
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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.
· ·
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Norme di sicurezza
· 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. 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
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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.
· ·
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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
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x Service Manual
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1. General Information
The Lexmark Z31 Color Jetprinter (4099) is a personal, near laserquality inkjet printer. The printer contains single-unit customer replaceable supply items. Dual printheads provide 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 (average) 25 Watts - Printing (peak)
General Information 1-1
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Operator Panel
Paper Feed button
Power button
Buttons
Application Turns the printer on or off.
Power button · 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.
Paper Feed button
1-2 Service Manual
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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 FRU HVPS LVPS OEM V ac V dc ZIF FPC Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Low Voltage Power Supply Original Equipment Manufacturer Volts alternating current Volts direct current Zero Insertion Force Flat Printhead Cable
General Information 1-3
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1-4 Service Manual
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2. Diagnostic Information
Start
Use the indicator light table, the symptom tables, service checks, and diagnostic aids in chapter 3, to determine the printer failure. Indicator Light Table
Indicator Light Power light is On Indicates Machine is on and ready to print.
Paper Feed light is Off Both lights are On Machine is printing.
Power light is On
May be out of paper or have a paper jam.
Paper Feed light is blinking 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 Check" on page 2-11.
Diagnostic Information 2-1
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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 comes on. 2. The carrier moves over the maintenance station three times and seals the printheads. 3. The paper feed gears turn. 4. All motors stop and the power light stays on. If your printer completes POST with no errors, go to the "Symptom Tables" on page 2-3, 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 No power light and no motors run Paper feed gears do not turn Carrier does not move Carrier slams side frame Action Go to the "Power Service Check" on page 2-11.
Go to the "Paper Feed Service Check" on page 2-8.
Go to the "Carrier Transport Service Check" on page 2-5. Go to the "Carrier Transport Service Check" on page 2-5.
2-2 Service Manual
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Symptom Tables
Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems
Symptom · · · · No carrier movement Slow carrier movement Carrier stops Carrier slams side frame Action Go to the "Carrier Transport Service Check" on page 2-5.
Maintenance Station Problems
Symptom Maintenance station: · Fails to cap the printheads · Fails to clean the printheads Action Go to the "Maintenance Station Service Check" on page 2-7.
Operator Panel Problems
Symptom · Paper feed or power buttons do not operate · Power or paper feed lights do not come on Action 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: J3-2 and Ground J3-3 and Ground J3-4 and Ground J3-6 and Ground If voltage is incorrect, replace the system board. If voltage is correct replace the operator panel.
Diagnostic Information 2-3
4099 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 Envelopes fail to feed Paper skews Action Go to the "Paper Feed Service Check" on page 2-8.
Go to the "Paper Feed Service Check" on page 2-8. Go to the "Paper Path Service Check" on page 2-10.
Power Problems
Symptom No power in machine, motors do not operate Action Go to the "Power Service Check" on page 2-11.
Print Quality Problems
Symptom · · · · · · · · 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 Action Go to the "Print Quality Service Check" on page 2-12.
· Ink smearing · Vertical streaks on paper · Print lines crowded
Go to the "Paper Feed Service Check" on page 2-8.
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Service Checks
Carrier Transport Service Check
FRU 1 System Board Action Unplug the printer and disconnect the carrier transport motor connector (J8) from the system board. Plug in the printer and check for approximately 12 V dc between (J8-1) and ground as the printer goes through POST. 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. 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:
2
Carrier Transport Motor
· 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 0 to 10 ohms between the following pins on the motor: J8-1 and J8-2 J8-3 and J8-4 If the readings are incorrect, replace the motor. 3 Carrier Guide Rod Clean the carrier rod. Note: Lubricate the rod and the carrier rod bearing surfaces with grease P/N 99A0394.
Diagnostic Information 2-5
4099
FRU 4 Carrier Transport Belt Idler Pulley Parts Carrier Frame Action Check for worn, loose or broken parts. Check for obstructions blocking carrier movement. Check the carrier belt idler pulley mounting screw. Loosen the screw and allow the tension spring to take up any slack in the belt. Tighten the screw. If the pulley mounting bracket has reached the stop, replace the belt. Carrier to carrier frame engagement should be lubricated with grease P/N 99A0394. 5 Printhead Carrier Assembly 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. A problem with the maintenance station can cause carrier movement problems at the right margin. Go to the "Maintenance Station Service Check" on page 2-7. If the carrier does not move toward the cartridge load position when the access cover is opened, verify that power is on. If the carrier still does not move, check the actuator arm for binds. If the sensor actuator is working correctly, replace the system board.
6
Maintenance Station
7
Access Cover Sensor
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Maintenance Station Service Check
The maintenance station has three functions: 1. Wipes the printhead nozzles to clean them of dirt. 2. Provides a place for printheads to fire all nozzles, keeping them clear prior to printing. 3. Seals the printhead when it is not being used to prevent the nozzles from drying
FRU 1 Maintenance Station Assembly
Action As the carrier moves to the right over the maintenance station, a slot on the bottom of the carrier engages a tab on the sled of the maintenance station 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 tab on the maintenance station engages a tab on the carrier, causing the wiper to lower. Check the maintenance station for worn or broken parts. Worn wipers cause degraded print quality just after a maintenance cleaning. Check for loose or worn wipers. Worn caps cause the printhead nozzles to dry and clog. Check for loose or worn caps.
Diagnostic Information 2-7
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Paper Feed Service Check
If your machine does not have paper jam problems, continue with the service check. If your machine does have a paper jam problem, examine it for the following before you begin the service check:
· · · ·
Check the entire 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 1 System Board
Action 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 to the motor housing. If you find a shorted pin, replace the motor. If you still have a failure after replacing the motor, replace the system board.
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FRU 2 Paper Feed Motor Action 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 paper feed mechanism With the paper feed motor cable disconnected from the system board, check for approximately 10 ohms between the following pins on the motor: Pin 1 to Pin 2 Pin 3 to Pin 4
If the readings are incorrect, replace the motor. Although the paper feeds in a forward direction only, the paper feed motor 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 feed motor and rotating the large gear by hand. If you notice a bind, replace the gear plate assembly. Check the pick roller for wear. Check the following for wear: · · · · 6 End-of-Forms Flag and Spring Small Feed rollers Large Feed roller Exit roller Star rollers
4 5
Auto Sheet Feeder Assembly Mid Frame Assembly
Check for binds or damage.
Diagnostic Information 2-9
4099
Paper Path Service Check
Examine the machine for the following before you begin this service check:
· Check the entire paper path for obstructions. · Be sure the correct type of paper is being used. · Be sure the printer is installed on a flat surface.
FRU 1 2 3 4 Large and Small Feed Rollers Small Feed Roller Springs Auto Sheet Feeder Assembly Mid Frame Asm Action Check for wear and binds. Check for damage. Check the pick roller for wear. Check the following for wear: · Exit roller · Star rollers 5 End-of-Forms Flag Check for binds or damage.
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Power Service Check
FRU 1 2 3 External Power Supply Power Connector Printhead Cable Carrier Home Sensor Parallel Cable Paper Feed Motor Carrier Transport Motor Operator Panel System Board Action Plug the external power supply into an outlet. Check for + 30 V dc. Check for continuity in the power connector cable. 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. If the symptom has not changed, replace the system board.
4
Diagnostic Information 2-11
4099
Print Quality Service Check
FRU / Function 1 2 Printhead Cartridge Color Printhead Cartridge Cross Contamination 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, (when yellow and blue are mixed in the printhead cartridge). This problem resolves quickly as the printhead cartridge is used. If cross contamination occurs, check the following: · The maintenance station wiper for damage. · The printhead nozzle plate was resealed with tape. 3 Printhead Carrier Assembly Reseat the printhead cables in the system board and check the following parts for wear or damage: · Printhead 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.
If there is a single break or random breaks in the diagonal line, remove the printhead cartridges and check the gold-plated contacts on the end of the printhead carrier cable for dirt, wear and damage. Use only a clean dry cloth to clean the contacts. If the symptom remains, replace the system board. 5 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station. Perform the "Maintenance Station Service Check" on page 2-7, and then return to this check.
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FRU / Function 6 Paper Feed Action 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. Also check the paper for curl or wrinkles. · Feed rollers for wear, dirt, or looseness. · Gears for wear or binds. · Paper path for obstructions. 7 Carrier Transport Blurred print and 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 adjustments. The user is directed, through the Printer Control program, to perform the printhead alignment adjustments, when replacing a printhead cartridge.
Diagnostic Information 2-13
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3. Diagnostic Aids
Test Page
This test prints the test page. To run a complete test page of black and color patterns, be sure the printhead cartridges are in good condition. To enter the test: 1. Turn the printer on. 2. Open the access cover. 3. Install a known good black printhead cartridge in the right side of the carrier and a good color printhead cartridge in the left side. 4. Close the access cover. 5. Install paper in the sheet feeder. 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 nozzle test pattern prints all nozzles on a diagonal line. There should be no breaks in the nozzle test pattern. A break in the pattern indicates one or more nozzles are not working. If a print quality problem exists, see "Print Quality Service Check" on page 2-12.
Diagnostic Aids 3-1
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3-2 Service Manual
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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). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards:
· · · · · ·
· · ·
Keep the ESD-sensitive part in its original shipping container (a special "ESD bag") until you are ready to install the part into the machine. Make the least-possible movements with your body to prevent an increase of static electricity from clothing fibers, carpets, and furniture. Put the ESD wrist strap on your wrist. Connect the wrist band to the system 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. Machine covers and metal tables are electrical grounds. They increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.) Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table. If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case). Be extra careful in working with ESD-sensitive parts when cold weather heating is used because low humidity increases static electricity.
Repair Information 4-1
4099
Adjustments
The user is directed, in the Printer Control program, to perform the printhead 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.
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.
4-2 Service Manual
4099
Access Cover Removal
1. Open the access cover. 2. Push the mounting tabs and remove the access cover.
Front Cover Removal
1. Remove the two cover mounting screws from the upper rear corners of the rear cover. Warning: When reassembling, do not overtighten these screws as they will damage the plastic threads. 2. Place the printer on its back. Lift up on the two cover latches located on each side of the base cover. 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 front cover. 2. Remove the base cover assembly. 3. Pry the ink pad off the base cover.
Buttons and Lenses Removal
1. Remove the front cover. 2. Pull up the button latches and slide the buttons off the front cover. 3. Lift and remove the lenses.
Repair Information 4-3
4099
Sheet Feeder Assembly Removal
1. Remove the front cover. 2. Remove the base cover assembly. Note the position of the access cover sensor actuator in the sheet feeder assembly. 3. Remove the two screws holding the sheet feeder to the carrier frame assembly. 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. 2. 3. 4. Remove the front cover. Remove the base cover assembly. Remove the sheet feeder assembly. Disconnect all connectors from the system board. Note the cable routings. 5. Remove the four mounting screws from the system board. Warning: When removing the system board, be careful not to damage the end-of-forms flag.
4-4 Service Manual
4099
Printhead Carrier Assembly Removal
1. 2. 3. 4. 5. 6. Remove the front cover. Remove the base cover assembly. Remove the sheet feeder assembly. Disconnect the printhead carrier cables from the system board. Remove the retainers from the ends of the carrier guide rod. 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.
7. Remove the carrier belt from the rear of the carrier. 8. Remove the printhead carrier assembly. 9. Depress and remove 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 installing the belt on the idler pulley.
Maintenance Station Removal
1. Remove the front cover. 2. Depress the two latches on the rear of the carrier frame and remove the maintenance station.
Small Feed Rollers Removal
1. 2. 3. 4. 5. Remove the front cover. Remove the base cover assembly. Remove the sheet feeder assembly. Unhook the four small feed roller springs from the carrier frame. Unlatch the small feed rollers from the carrier frame.
Repair Information 4-5
4099
End-of-Forms Flag Removal
1. 2. 3. 4. 5. Remove the front cover. Remove the base cover assembly. Remove the sheet feeder assembly. Remove the two center small feed rollers. Note the position of the end-of-forms flag spring. Unlatch the end-of-forms flag from the carrier frame and slide it to the right to remove.
Mid Frame / Star Roller Assembly Removal
1. 2. 3. 4. 5. Remove the front cover. Remove the base cover assembly. Remove the sheet feeder assembly. Remove the small feed roller assemblies. 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
Remove the front cover. Remove the base cover assembly. Remove the sheet feeder assembly. Remove the small feed roller assemblies. Remove the maintenance station assembly. Remove the bearing from the right end of the large feed roller. To remove the bearing, pull out the locking tab and rotate the bearing until the bearing fits through the slots in the carrier frame. 7. While lightly biasing the gear plate assembly to the left, push the large feed roller assembly to the far right and lift it out of the carrier frame. 1. 2. 3. 4. 5. 6.
4-6 Service Manual
4099
Gear Plate Assembly Removal
1. 2. 3. 4. 5. 6. 7. 8. Remove the front cover. Remove the base cover assembly. Remove the sheet feeder assembly. Remove the small feed roller assemblies. Remove the maintenance station assembly. Remove the large feed roller assembly. Disconnect the power connector from the system board. Remove the two gear plate assembly mounting screws and remove the gear plate assembly from the carrier frame.
Carrier Belt / Idler Pulley Removal
1. Remove the front cover. 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, loosen the carrier belt idler pulley mounting screw. Tighten the screw after installing the belt on the idler pulley.
Power Connector Removal
1. Remove the front cover. 2. Remove the base cover assembly. 3. It may be necessary to remove the gear plate assembly to access the power connector mounting screws.
Repair Information 4-7
4099
4-8 Service Manual
4099
5. Connector Locations
Units J3 J4 J5 J6 J7 J8 J9 J10 PS1 PS2
Description Operator Panel Parallel Port Printhead Cable 1 Printhead Cable 2 Printhead Cable 3 Carrier Transport Motor Paper Feed Motor Power Connector Access Door Sensor End-of-Forms Sensor
Connector Locations 5-1
4099
5-2 Service Manual
4099
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:
· · · ·
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.
Preventive Maintenance 6-1
4099
6-2 Service Manual
4099
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. 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.
· · ·
Parts Catalog 7-1
4099
Assembly 1: Covers
7-2 Service Manual
4099
AsmIndex 1 -1 2 3 4 5 NS Part Number 12G0190 12G0193 12G0192 12G0191 12G0195 7350512
Units 1 1 1 1 1 1
Description Base Cover with Feet, Exit Tray and Banner Support Felt Ink Pad Access Cover Front Cover Power Button and Lens Field Packaging B/M
Parts Catalog 7-3
4099
Assembly 2: Paper Feed
7-4 Service Manual
4099
AsmIndex 2 -1 2 3 4 5 6 7 8 Part Number 12G0209 12G0197 12G0209 12G0209 12G0206 12G0209 12G0196 12G0209
Units 7 1 2 1 1 2 1 1
Description Screws (PP) Carrier Transport Motor Retainer, Carrier Guide Rod (PP) Carrier Belt Tensioner (PP) Carrier Belt Bushing, Feed Roller (PP) Mid Frame with Star Rollers, Large and Small Feed Rollers End of Forms Flag & Spring (PP)
Parts Catalog 7-5
4099
Assembly 2: Paper Feed (Continued)
7-6 Service Manual
4099
AsmIndex 2 -1 6 9 10
Part Number 12G0209 12G0209 12G0199 12G0194
Units 2 2 1 1
Description Screws (PP) Bushing, Feed Roller (PP) Gear Plate Asm with Motor Power Connector with Cable (Note: Includes Op Panel Asm)
Parts Catalog 7-7
4099
Assembly 3: Electronics
7-8 Service Manual
4099
AsmIndex 3 -1 2 3 4 4 4 5 5 5 5 5 5 6 Part Number 12G1781 12G0209 12G0194 12G1826 12G1827 12G1825 11B6073 11B6074 11B6076 11B6077 11B6078 11B6138 42F1814
Units 1 5 1 1 1 1 1 1 1 1 1 1 2
Description System Board Screws (PP) Op Panel Asm with Cable (Note: Includes Power Connector) P/S External (LV) 120 V P/S External (HV) 220 V P/S External (LV) 100 V Japan Power Cord, United Kingdom, Hong Kong, Ireland Power Cord, Europe, Chile Power Cord, Australia/New Zealand, Brazil Power Cord, South Africa Power Cord, Peru Power Cord, China Parallel Port Cable Clip
Parts Catalog 7-9
4099
Assembly 4: Carrier
7-10 Service Manual
4099
AsmIndex 4 -1 2 3 Part Number 12G0204 12G0205 12g1868
Units 1 1 1
Description Printhead Carrier Asm with Cable and Sensor Carrier Guide Rod Holder, FPC (Flat Parallel Cable)
Parts Catalog 7-11
4099
Assembly 5: Automatic Sheet Feeder
7-12 Service Manual
4099
AsmIndex 5 -1 2 Part Number 12G0207 12G3619
Units 1 1
Description Automatic Sheet Feeder Asm Paper Support
Parts Catalog 7-13
4099
Assembly 6: Maintenance Station
7-14 Service Manual
4099
AsmIndex 6 -1 Part Number 12G0208
Units 1
Description Maintenance Station Assembly
Parts Catalog 7-15
4099
7-16 Service Manual
4099
Index
A
Abbreviations 1-3 Adjustments 4-2 Aids 3-1 Assembly 7-6 Assembly 1 Covers 7-2 Assembly 2 Paper Feed 7-4, 7-6 Assembly 3 Electronics 7-8 Assembly 4 Carrier 7-10 Assembly 5 Automatic Sheet Feeder 7-12 Assembly 6 Maintenance Station 7-14
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 Operator Panel 2-3 Paper Feed 2-4 Power 2-4 Print Quality 2-4
B
Buttons 1-2
C
Connector Locations 5-1
D
Diagnostic 2-1 Diagnostic Aids 3-1 Diagnostic Information Start 2-1
E
ESD-Sensitive Parts 4-1
R
Removals Access Cover 4-3 Base Cover 4-3 Buttons / Lenses 4-3 Carrier Belt 4-7 End-of-Forms Flag 4-6 Exit Roller 4-5 Front Cover 4-3, 4-5 Gear Plate Asm. 4-7 Idler Pulley 4-7 Ink Pad 4-3
G
General Information 1-1
I
Indicator Light Table 2-1
L
Lubrication Specifications 6-1
X-1
4099
Large Feed Roller 4-6 Maintenance Station 4-5 Mid Frame 4-6 Power Connector 4-7 Printhead Carrier Asm. 4-5 Sheet Feeder 4-4 Small Feed Rollers 4-5 Star Roller Asm. 4-6 System Board 4-4
S
Safety Information vi Service Checks Carrier Transport 2-5 Maintenance Station 2-7 Paper Feed 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
12G0206 12G0207 12G0208 12G0209 12G1812 12G1826 12G1827 12G3619 42F1814 7350512
7-5 7-13 7-15 7-5, 7-7, 7-9 7-9 7-9 7-9 7-13 7-9 7-3
T
Tests Test Page 3-1
Part Numbers
11B6073 11B6074 11B6076 11B6077 11B6078 11B6138 12G0190 12G0191 12G0192 12G0193 12G0194 12G0195 12G0196 12G0197 12G0199 12G0200 12G0204 12G0205
7-9 7-9 7-9 7-9 7-9 7-9 7-3 7-3 7-3 7-3 7-7, 7-9 7-3 7-5 7-5 7-7 7-9 7-11 7-11
X-2
Reader Comment Form
Lexmark Z31 Color Jetprinter (4099-001) Service Manual USA 12G1764 - Japan 12G178 August 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. 1. Did you find the book well organized? No Yes 2. Was the content of the book accurate and complete? No Yes 3. Was the book easy to use? No Yes 4. What can we do to improve the book?
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