Lexmark Optra Color 45 Service manual

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Lexmark Optra™ Color 45

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4080-001

• Index

Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

4080-001

Edition: March 24, 2006 The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXM ARK INTER N ATIONAL, 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 all o w di sc la im er o f e xp res s o r im plie d w ar r ant i es in ce rta in t r ansa ct io ns , t he refore, this statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are periodically ma de to the information herein; these changes will be incorporat ed in late r editions. Improvements or changes in the products or the programs described may be made at any time .

Comments may be addressed to Lexmark International, Inc., Department D22/035-3, 740 New Circle Road N.W., Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information yo u supply in any way it believes appropria te without incurring any obligation to you.

Lex mark an d O pt r a ar e t ra de marks of Lexmark Internatio na l, I nc ., r e gi ster e d in t he Uni t ed States and/or other count ries.

Other trademarks are the property of their respective owners.

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 th e Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

USA PN 11J0150 Japanese PN 11J0151

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Table of Contents

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operator Panel and Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Using the Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Printer Indicator Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Operator Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Printer Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Operator Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Printing the Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Disabling the Operator Panel Menus. . . . . . . . . . . . . . . . . . . . . . 1-9

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Error Indicator Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-4

Post Symptom Ta b le . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Symptom Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Controller Board Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Encoder Card / Strip Service Check . . . . . . . . . . . . . . . . . . . . . . 2-9

End of Forms (EOF) Service Check. . . . . . . . . . . . . . . . . . . . . . 2-10

Maintenance Station Service Check . . . . . . . . . . . . . . . . . . . . . 2-10

Noisy Paper Feed Motor Service Check . . . . . . . . . . . . . . . . . . 2-11

Operator Panel (Buttons) Service Check. . . . . . . . . . . . . . . . . . 2 -11

Operator Panel (LCD) Display Service Check. . . . . . . . . . . . . . 2-12

Options Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -13

Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Paper Path Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Power Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Print Quality Servi ce Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -21

Transport Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Transport Service Check II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -25

Tray 2 Service Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

User Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -27

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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Diagnostic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Aligning the Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Cleaning the Printheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Paper Lifters Operation Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Viewing the Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Clearing the Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Hardware Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

LCD Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

DRAM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

ROM Memory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Parallel Wrap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Serial Wrap Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Device Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Hex Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Quick Disk Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Disk Test/Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Flash Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Printer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Setting the Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Viewing the Permanent Page Count . . . . . . . . . . . . . . . . . . . . . .3-11

Restore Factory Defaults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Print Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Print Quality Test Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Printing Menu Settings Page. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Test Page (Quick Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Repa ir Informat ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Covers and Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Base Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Code SIMM Access Door Removal. . . . . . . . . . . . . . . . . . . . . . . .4-4

Controller Board Access Cover Removal . . . . . . . . . . . . . . . . . . .4-5

Controller Board Access Door Removal . . . . . . . . . . . . . . . . . . . .4-5

Envelope Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Front Access Door Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Front Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Gutter Pad Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Memory (SIMM) Card Cover Removal . . . . . . . . . . . . . . . . . . . . .4-7

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Metal / Plastic Controller Board Cover Removal . . . . . . . . . . . . . 4-7

Operator Panel Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Option Card(s) Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Rear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Rear Access Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Carrie r Frame Assembly Re moval. . . . . . . . . . . . . . . . . . . . . . . 4-11

Carrier Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Idler Pu lley Assemb ly Remov al . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Left Side F rame Assem bly Rem oval . . . . . . . . . . . . . . . . . . . . . 4-12

Mid Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -13

Right Side Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . 4 -13

Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Exit Ro ller As s embly Rem o v al. . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Gear Box Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -15

Large Feed Roller Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Manual Sheet Feeder Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -16

Paper Feed Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Paper Lifters Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -16

Paper Tray Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -17

Small Feed Roller Assembly Removal. . . . . . . . . . . . . . . . . . . . 4 -17

Small Feed Roller Holder Assembly Removal. . . . . . . . . . . . . . 4-17

Star Ro ller As s embly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -17

Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -18

Code or Flash SIMM Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Controller Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -20

Encoder / Thermistor Card Removal . . . . . . . . . . . . . . . . . . . . . 4-21

Engine Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Memory (S IMM) Card Re moval . . . . . . . . . . . . . . . . . . . . . . . . . 4 -22

Operator Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Operator Panel Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4 -25

Option Card(s) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -25

Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Tray 2 Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -27

Carrier Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Carrier Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Carr ier Trans p o r t Moto r Asse m b ly Remova l . . . . . . . . . . . . . . . 4-29

Encoder Strip / Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . 4-29

Printhead Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Maintenance Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -31

Maintenance Station Assembly Rem oval . . . . . . . . . . . . . . . . . . 4 -32

Wipers and Caps Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -32

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Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Engine Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Controller Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

How To Use The Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Assembly 2: Frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Assembly 3: Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

Assembly 4: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

Assembly 5: Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

Assembly 6: Carrier Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12

Assembly 7: Maintenance Station . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

Assembly 8: Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

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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 par ts.

• 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 precaut ions.

Consignes de Sécurité

• Ce produit a été conçu, testé et approuvé pour respecter les

normes strictes de sécur ité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certain s élémen ts ne sont pas toujours évidente s. 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 r isques électr iqu es, 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 approv ato in conf ormità 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 Ver antwortung oder Haftung für dieses Produkt übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinanderne hme ns und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

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Pautas de Seguridad

• Este producto se ha diseñado, verificado y aprobado para

cumplir los más estrictos estándares de seguridad globa l usando los componentes específicos de Lexmark. Pu ede 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.

4080-001

Inf ormació de Seguretat

• Aquest producte està dissenyat, comprovat i aprovat per tal

d'acomplir les estrictes nor me s de seguretat globals amb la utililització de co mp onent s específi cs 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.

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1. Gen e r a l In for matio n

The Lexmark OptraTM Color 45 printer is a network, near laser-

quality inkjet printer. The print cartridge 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 left. The color

cartridge has a total of 192 nozzles and installs on the right. The

printer is capable of printing in two directions from either cartridge.

Power Consumption

• 13 Watts - Idle Mode (power on - not printing)

• 21 Watts - Printing (average)

Maintenance Approach

The diagnostic information in this manual leads you to the correct

field replaceable unit (FRU) or part. Use the error indicator charts,

symptom index, service checks, and diagnostic aids to determine

the symptom and repair the failure.

This printer can be serviced without being connected to a host

computer. The user is directed, in the Printer Control program, to

perform the head to head and bidirectional alignment adjustments

after replacing a print cartridge.

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

repair.

Tools Required For Service

• Analog or digital multimeter

• Coax/serial debug cable P/N 1381964

• Paral l el wrap plug P/N 1319128

• Pliers: diagonal and needle-nose

• Screwdrivers: #1 an d # 2 Ph i llip s

• Twinax/serial debug cable P/N 1381963

General Information 1-1

4080-001

Abbreviations

EOF End of Forms ESD Electrostatic Discharge FRU Field Replaceable Unit LED Light-Emitting Diode POST Power-On Se lf Te st SIMM Single In-line Memo ry Module RAM Random Access Memory ROM Read Only Memory V ac Volts alternating current V dc Volts direct current

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4080-001

Operator Panel and Menus

Using the Operator Panel

The operator panel, on the front right side of your printer, has a

2-line by 16-character liquid crystal display (LCD), five buttons, and

one indicator light.

Operat or Panel Display

Printer Indica tor Light

Printer Indicator Light

The printer indicator light gives information about the status of your

printer.

Light Stat e Meaning

On solid Powered On and in the Ready state Flashing Powered On and Busy Off Unplugged from the power source

General Information 1-3

4080-001

Operator Panel Buttons

Use the five operator panel buttons to open a menu, scroll t hrough a list of values, change printer settings, and respond to printer messages. The following table describes the functions of each button.

Note: Buttons act upon the information that displays on the second line of the operator panel.

Button Function

Go Press t he Go button to :

• Return the printer to the Ready state if the printer is in an offline situat ion (Ready message does not appear on the display).

• Exit printer menus displa yed on the operator panel.

• Clear operator panel error messages.

If you have changed printer settings from the operator panel menus, pr ess Go before sending a job to print. The pri n ter mu st display Ready for jobs to print.

Menu>

and

<Menu

Each end of the butt on has a function. Press the Menu> or <Menu button:

• At the Ready message, to take the printer offline (out of the Ready state) and enter the menus .

• At the Busy message, to take the printer to the JOB MENU.

• When the printer is offline:

- Press Menu> to go to the next item in the menus, or

- Press <Menu to go to the previous item in the menus.

• For menu items that have numerical va lues, such as Copies, press and hold Menu> to scroll forward, or <Menu to scroll backward. Release the button when the number you want displays.

Select Pr ess the Select button to:

• Select the menu item shown on the second li ne of t he display. Depending on the type of men u, th is action:

- Opens the menu and displays the first item in the menu.

- Opens the menu item and displays the default setting.

• Save the displa yed menu item as the new default setting. The printer displays the Saved menu item.

1-4 Service Manual

message and then returns to the

4080-001

Button Function

Return Press the Return butto n to re tu r n to the p revi o us m e nu l evel. Stop Press the Stop button:

• At the Ready, Busy, or Waiting message to temporarily stop all activit y and take the printer offline. The printer operator panel status message changes to Not Ready.

Press Go to return the printer to the Ready state.

Printer Messages

The operator panel displays three types of messages:

• Status messages provide information about the current state of

the printer.

• Attendance messages indicate printer errors that you must

resolve.

• Service messages indicate printer failures that may require

servicing.

When the Ready status message displays, the printer is ready to receive a print job.

While a job is printing, the Busy status message appears on the first line of the operator panel display.

General Information 1-5

4080-001

Operator Panel Menus

Menus make it easy for y ou to change printer settings. Some menus appear only if a specific option is installed in the printer. Other menu items may only be effective for a particular printer language. Y ou can select these values at any time, but they only affect printer function when you use the specified printer language.

An asterisk (*) next to a value indicates the original factory default setting and may vary for different countries. When you select a new setting from the operator panel, the asterisk moves next to the selected setting to identify it as the current user default. These settings are active until new ones are stored or the factory defaults are restored. Changes made from a software application or driver override the user default settings made from the printer operator panel.

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Printing the Menu Settings Page

The menu settings page shows current settings for the menus and a list of installed options. You can use this page to verify that the printer options are properly installed and the printer settings are properly set.

Note: Before printing the menu settings page, make sure the Paper Type se tting for the source is Plain Paper.

To prin t a menu settings page:

1. Make sure the printer is plugged in and the message appears on the display.

2. Press Menu> or <Menu to enter the menus.

3. Continue to press and release Menu> until you see

Ready status

Tests Menu.

4. Press Sel ect .

Tes ts Menu appears on the first line and Print Menus is on

the second line.

5. Press Sel ect to select The message Printing Menu Settings appears and remains on the operator panel display until the page prints. The printer returns to the Ready state after the menu settings page prints.

6. If you installed options, verify that they are listed on the menu settings page under “Installed Features.” If an option you installed does not appear on the page, unplug the power cord and reinstall the option.

Print Menus.

General Information 1-7

4080-001

Changing Printer Settings

You can use the operator panel to change printer settings and customize your printer to meet your specific needs. To select a new value as the default setting:

1. From the menus.

2. Continue to press and release Menu> or <Menu until the menu you need appears on the second line of the display.

3. Press Select. The menu opens and the first menu item in the menu appears on the second line of the display.

4. Press Menu> or <Menu until the menu item you need appears on the display.

5. Press Select. An asterisk (*) appears beside the current user default setting for that menu item.

Note: Some menu items have sub-menus. You must select another menu (such as

6. Press Menu> or <Menu until the value you need appears on the second line of the display.

7. Press Select. An asterisk (*) appears beside the value to indicate that it is now the user default setting. The display shows the new setting for one second and then clears. The then the previous list of menu items appears on the operator panel display.

8. Press Return to go back to previous menus or menu items and set new default settings.

9. Press Go to return to want to change.

Note: User default settings remain in effect until you save new settings or restore the factory defaults. Changes made from a software application override the user default settings made from the printer operator panel.

Ready state, press Menu> or <Menu to enter the

Tray 1 Type) before the available values display.

Saved message displays,

Ready if this is the last printer setting you

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4080-001

Disabling the Operator Panel Menus

To disable the menus so that changes cannot be made to the printer default settings:

1. Unplug the printer.

2. While pressing Go and Stop, plug in the printer.

3. Release the buttons when When the printer self test completes, the message appears. If you press

Menus D i sabled

message displays.

Performing Self Test displays.

Ready status

Menu> or <Menu, the

General Information 1-9

4080-001

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2. Diagnostic Information

Use the error indicator table, symptom tables, service checks, and diagnostic aids to determine the printer failure.

Start

Service error indications are displayed on the operator panel. If your printer displays an error indication, locate the error number in the

“Error Indicator Table” on page 2-2 and take the indicated action.

Unplug the printer to clear the error indicator.

Diagnostic Information 2-1

4080-001

Error Indi cator Table

Error Symptom Action

900 RIP software Refer to the “Controller Board

Service Check” on page 2-9.

902 Engine error:

065 Address error 127 - 223 Software

detection error

910 930

931 939

941 RIP code - CRC Refer to the “Con troller Board

943 RIP font version Replace Font SIMM. 944

945 946

Carrier st al l Printhead error

Incomp le te p r in t RIP - engine

communication

Processor f ail ure ASIC failure SRAM failure

Replace the engi ne board, refer to the “Engine Board

Removal” on page 4-22.

Refer to the “Transport

Service Check” on page 2-24.

Check the c ontroll er board ca ble connections. If the connections are good, replace the controller board, refer to the “Controller

Board Service Check” on page 2-9.

If the problem remains, replace the engine board, refer to the

“Engine Board Removal” on page 4-22.

Note: The controller software

can cause a 939 error.

Service Check” on page 2-9.

Refer to the “Controller Board

Removal” on page 4-20.

947 Engine board Replace the engine board, refer

to the “Engine Board

Removal” on page 4-22.

953 954 960

NVRAM chip failure NVRAM CRC failure Controller Board DRAM

defective

Replace the controller board, refer to the “Controller Board

Removal” on page 4-20.

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Error Symptom Action

961 DRAM in (J6) is bad Repla ce the memory SIMM card

in (J6).

975 Unre cognized network card If the incorrect card is installed,

976

977

978

979

Unrecoverable software error in netw ork card

Communication error with network card

Network card checksum error

Flash/Network card error

replace the card. Go to the “Options Service

Check” on page 2-13.

If the prob lem remains, replace the control ler card.

Replace network card.

Diagnostic Information 2-3

4080-001

Power-On Self Test (POST) Sequence

Plug the printer in and check for a correct POST operation by observing the following:

1. The operator panel displays one row of rectangles followed by two rows of diamonds.

2. The printe r indicator (green light) comes on.

3. Performing Self Test is shown on the operator panel display and then turns off.

4. The carrie r moves to the center of the frame and returns to the maintenance station.

5. The paper feed motor turns.

6. The pri nter indicato r light turns off and then back on.

7. Ready is displayed indicating that POST is complete.

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

following table and take the indicated action.

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4080-001

Post Symptom Table

Symptom Action

Blank display, carrier moves, paperfeed motor turns

All diamonds on display Go to the “Operator Pane l (LC D)

Performing Self Test remains on displa y, no motors turn

Paper feed motor does not turn Go to the “Paper Feed Service

Transport motor does not turn Go to the “Transport Service

Carr ie r d r ives in to le ft si d e fram e Go to the “Transport Service

Printer indicator l ight do es not light , or remains on

POST incomplete, printer indicator light on, no motors turn and Performing Self Test is dis p layed

Printer inoperable Go to the “Power Service Check” on

Go to the “Operator P an el (LCD)

Display Service Chec k” on page 2-12.

Go to the “Po wer Se rvice Chec k” on

page 2-19.

Check” on page 2-15.

Check” on page 2-24.

Go to the “Operator P an el (LCD)

Display Service Chec k” on page 2-12.

Go to the “Po wer Se rvice Chec k” on

page 2-19.

Performing Self Test

remains on displa y, transport and paperfeed motors turn

Replace in the foll owing order:

• Code SIMM (if installed)

• Controller board

Diagnostic Information 2-5

4080-001

Symptom Tables

Locate the symptom in the following tables and take the appropriate action.

Carrier Transport Problems

Symptom Action

• No carrier movement

• Slow carrier movement

• Carrier stops

• Carrier strikes left side frame

Go to the “Transport Service

Check” on page 2-24.

Go to the “Transport Service Check

II” on page 2-25.

Communications Problems

Symptom Action

Printer not communicating with host computer

Go to the “Parallel Wrap Test” on

page 3-6.

Maintenance Station Problems

Symptom Action

• Fails to cap the printhead

• Fails to clean the printhead

Go to the “M aintenance Station

Service Check” on page 2-10.

2-6 S ervice Manual

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Operator Panel Problems

Symptom Action

Printer indicator light does not:

• Turn on

•Flash

• Turn off

• All diamonds One or two pels missing Replace the operator panel assembly. Only one button ino perative Replace the operat or panel assembly. More than one button i noperative Go to the “Operator Panel (Buttons)

All diamonds on display Go to the “Operator Pane l (LC D)

Go to the “Operator P an el (LCD)

Display Service Chec k” on page 2-12.

Service Check” on page 2-11.

Display Service Chec k” on page 2-12.

Paper Feed Problems

Symptom Action

Pap e r fails to stop at first prin t line

• Fa il s to pick paper

• Picks more than one sheet of

paper

• Picks paper but fails to feed

• Paper jams

• Paper fails to exit

• Noisy paper feed

• Paper skews

Go to the “Paper Feed Service

Check” on page 2-15.

Paper does not feed, motor does not turn

Paper does not feed motor attempts to turn

Go to the Paper Feed Service Check

“Pape r does not feed - paper feed motor does not turn” on page 2-16.

Go to the Paper Feed Service Check

“Pape r does not feed - paper feed moto r tu r n s in only on e di re c ti o n” on page 2-17.

Diagnostic Information 2-7

4080-001

Power Problems

Symptom Action

Printer inoperable Go to the “ P ower Servi ce Ch eck” o n

page 2-19.

Print Quality Problems

Symptom Action

• Voids in char acters

• Light print

• Prints off the page

• Fuzzy print

• Carrier moves but does not prin t

• Printhead drying prematurely

• Vertical alignment off

• Excessive ink flo w (Flooding)

• Horizontal banding

• Ink smearing

• Vertical streaks on paper

• Print lines crowded

Go to the “Print Quality Service

Check” on page 2-21.

Go to the “Paper Feed Service

Check” on page 2-15.

2-8 S ervice Manual

4080-001

Servi ce C he cks

Controller Board Service Check

FRU Action

1 Code SIMM Some printers may contain a code SIMM located

in the option card(s) (J6) on the cont ro ller board . If a SIMM is present, replace the code SIMM, go to the “Code or Flash SIMM Removal” on

page 4-19. If the problem remains, continue to

step 2.

2 Controller Board If the printer does not contain a code SIMM in the

option card(s) (J6), replace the controller board, go to the “Controller Board Removal” on

page 4-20.

Encoder Card / Strip Service Check

Note: Be sure the printer is unplugged from the AC outlet before

performing this service check. Disconnect the transport motor (CN5) from the engine board. Move

the carrier to where it is parked over the maintenance station, turn the printer on and after Performing Self Test appears on the display, wait approximately five seconds and move the carrier to the center of the printer and back to the maintenance station. Ready should appear on the display. If not, check the connection at the encoder card (CN1) and retest. If the problem remains, replace the encoder card, refer to the “En coder / Thermist or Card Remov al” on

page 4-21. You may have to perform this check several times.

Diagnostic Information 2-9

4080-001

End of Forms (EOF) Service Check

Before turning the printer on, remove any paper from the input tray and insert one sheet of paper into the manual paper tray slot. If paper feeds through the machine when the printer is turned on, the sensor is functioning properly . I f paper fails to feed, check the end of forms sensor flag for correct operation. If the operation is bad, replace the flag. If the operation is good, replace the engine board, refer to the “Engine Board Removal” on page 4-22.

Maintenance Station Service Check

The maintenance station has two functions:

1. Cleans the printhead noz zles during the print operation.

2. Sea ls the printhead when it is not being used to prevent the nozzles from drying.

FRU Action

1 Maintenance

Station Assembly

2 Wiper A worn wiper can cau se degr ad ed print quali ty j ust

3 Cap A worn cap can cause the printhead nozzles to

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 caps to rise and seal the printheads. Carrier movemen t to t he lef t will uncap the printheads. The wipers clean the printhead nozzl es 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 cleaning oper ati on is complete, a tab on the maintenance station engages a tab on the carrier, causing the wipers to lo wer.

Check the m aintenance stat ion for worn or broken parts.

after a maintenan ce cleaning. Check for loose or worn wiper.

dry and clog. Check for loose or worn cap.

2-10 Service Manual

4080-001

Noisy Paper Feed Motor Service Check

FRU Action

1 Paper F eed Motor Check the followi ng m otor pins for approximately

12.5 ohms:

(CN6-1) and (CN6-2) (CN6-3) and (CN6-4)

If incorrect, re place the paper feed moto r, refer to the “ P aper Feed M otor Remov al ” on page 4-16.

2 Gears Check the gears for proper alignment, chipped

teeth, loose motor, missing gear clip or worn gears.

Operator Panel (Buttons) Service Check

Note: Perform the “Butt on T est” on page 3-4, before continuing

this service check.

FRU Action

1 Operator Panel

Assembly

2 Controller Board

Operator Panel Assembly

If any button fails the button test, replace the operator panel ass em bly.

Be sure the voltage at (J T6-2) measures +5 V dc. If the voltage is incorrect, replac e the controller board. If the volt age is correct, check the continuity of t he o perat or panel cab le . Replac e the operator panel cab le if continuit y is incorrect. If correct, replace the operator panel assembly.

Diagnostic Information 2-11

4080-001

Operator Panel (LCD) Display Service Check

Note: Be sure the operator cable is properly installed at the

controller board (JT6) and at the operator panel. Check the continuity of the cable and replace if necessary.

Operator panel display blank - printer indicator light OFF, paperfeed motor turns, carrier moves.

FRU Action

1 Controlle r Board V eri fy the voltage at (JT6-2) on the controller

board is approximately +5 V dc. If incorre ct, replace the cont rol ler board. If correct , go to step

2 Operator Panel

Assembly

Verify that the resistance between (JT6-4) and ground on the contr oller board is approximately 0 ohms. If incor rect, replace the controller board. If correct, re place the operator panel assembly.

Operator panel display blank - printer indicator light ON.

FRU Action

1 Controller Board

Operator Panel Assembly

Verify that the resistance between (JT6-4) and ground on the contr oller board is approximately 0 ohms. If incor rect, replace the controller board. If correct, re place the operator panel assembly.

2-12 Service Manual

4080-001

Options Service Check

Flash Memory Opt i on(s)

Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Check to make sure that the Memory SIMM is installed correctly and is not broken or damaged. If the Memory SIMM is correctly installed, and not broken or damaged, then run the “Flash Test” on page 3-10. If the test fails, replace the flash SIMM. If the problem continues, replace the controller board, refer to the “Controller Boa rd Re m oval” on page 4-20.

DRAM Memor y O pt i on(s)

This service check is the same as the flash memor y option ser vice check with the following exception:

Run the “DRAM Memory Test” on page 3-5 from the menu if the DRAM Memory S IMM is correctly installed and not broken or damaged. If the test fails, replace the DRAM SIMM, refer to the

“Memory (SIMM) Card Cover Removal” on page 4-7. If the

problem continues, replace the controller board, refer to the

“Controller Board Removal” on page 4-20.

Hard Disk Option

Be sure the hard disk and the hard disk adapter board are correctly installed. Run the “Quick Disk Test” on page 3-8 from the Device Test on the Diagnost ic Menu when a problem is suspected either with the hard disk adapter board or with the hard disk.

Note: The Quick Disk Test is a non-destructive test and indicates Pass or Fail. If the test fails, replace the hard disk, refer to the

“Option Card(s) Removal” on page 4-25. If a probl em still exists,

replace the controller board, refer to the “Controller B oard

Removal” on page 4-20.

The “Disk Test/Clean” on page 3-9 is used to help restore the disk if the data is corrupted and unusable. This test is divided into a cleaning and a verifying section.

Note: The test can be very lengthy and leaves the hard disk unformatted. The servicer or user must reformat the disk using the

Diagnostic Information 2-13

4080-001

Format Disk Menu operation. This is a destructive test, as the data on the disk is destroyed and should not be performed on a known good disk.

Network Card Option Error Code 976 - Network Card

A 976 error code indicates an unrecoverab l e software error in network card. Verify that the network card is correctly installed in the controller board socket, and is properly grounded. If you find no problem, contact your next level of support before replacing the network card.

Error Code 977 - Network Card

A 977 error displays when the RIP software detects that a network card is installed, but cannot establish communications with the network card. Replace the network card, refer to “Option Card(s)

Removal” on page 4-25. If the problem remains, replace the

controller board, refer to “Contr oller B oard Remov al” on

page 4-20.

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4080-001

Paper Feed Service Check

Note: Be sure the printer is unplugged from the AC outlet before

performing this service check.

Perform the following, if you are experiencing a paper jam:

• Check the entire paper path for obstructions.

• Be sure the input tray contains not more than 150 sheets of

paper and the manual tray not more than 100.

• Be sure the correct type of paper is being used.

• Check for static in the paper.

• Ensure the correct position of the left paper adjuster guide lifter

assembly.

• Check for ske w by performing the “T est Page (Quick T est)” on

page 3-15.

FRU Action

1 Gears Check for binds in the gear train and paper feed

2 Paper Path Perform the “Paper Path Service Check” on

mechanism by rotating the lar ge feed roll by hand. Check all gear s f or correc t ins tall ation and s igns of

wear or damage. If there i s a bind, isolate it by removing one of the small i dler gears on the insid e of the left side f rame. Replace an y wo rn or bindi ng gears or rollers.

page 2-18.

Diagnostic Information 2-15

4080-001

Paper does not feed - paper feed motor does not turn

Note: A noisy or chattering motor or a motor that fails to turn can be

caused by:

• A defective motor

• A bind in the paper feed mechanism

• Defective gears

• Defective engine board

• Defective power supply (+30 V dc)

FRU Action

1 Engine Board With (CN6) connecte d and power on, check the

voltage bet ween Pins 1,2,3,4 and ground. The voltage should measure between +15 V dc and +32 V dc when paper is feed ing. If the voltage is correct, replace the engine board.

2 Paper Feed Motor Check the motor pins between (CN6-1) and

3 Power Supply Disconnect the AC line cord. Disc onnect (J2-6)

4 Engine Board Check continuity between (J2-6) on the controller

5 Controlle r Boar d

Cable

(CN6-2) for approximately 12.5 ohms. Also check (CN6-3) and (CN6-4) f or approximately 12. 5 ohms. If incorrect, replace the paper f eed motor assembly. If correct, check the continuity bet ween each motor pin on the motor connector and the motor case. If continuity exists, replace the paper feed moto r assembly. If the symptom remains, go to step 3.

Note: If a short exists in the paper feed motor, damage to the system board dri vers and power supply may occur.

from the contr oller board and v erify the voltage on the cable is app roximately +30 V dc. If incorrect, replace the power supply.

board and (C10-36) on th e system board. If correct, replace the engine board. If correct, go to step 5.

Check the conti nuity of the controller board cable. If incorrect, replace the cable. If correct, replace the controller board.

2-16 Service Manual

4080-001

Paper does not feed - paper feed motor turns

Note: A noisy or chattering motor or a motor that fails to turn can be

caused by:

• A def e ctive motor

• A bind in the paper feed mechanism

• Defective gears

• Defective engine board

FRU Action

1 Gear Box Check the clutch lever f or obstructions and the

2 Gears Check for binds in the gear train and paper feed

3 Large Feed Roller Be sure that the large feed roller is clean. 4 Paper Lift ers Check the paper lifters, pads and paper tray for

5 Paper Adjuster Check f or corr ect pos iti on o f the left pap er adj uster

gear box for binds and wear. Replace worn or binding gears.

mechanism by rotating the lar ge feed roll by hand. If you notice a bind, isolate it by removing one of the small idler gears on t he inside of the left side frame. Replace any worn or binding gears or rollers.

proper positioning.

guide lifter assembly.

Paper does not feed - paper feed motor turns in only one direction

• When paper is fed from the input tray, the paper feed motor

rotates counterclockwise actuating the paper lifters, followed by a clockwise rotation.

• When feeding from the manual tray, the paper feed motor

rotates in only one direction. If, when paper is fed from the input tray and the motor turns in one direction only , replace the engine board.

Diagnostic Information 2-17

4080-001

Paper Path Service Check

Examine the printer for the following before you begin this service check:

• Check the entire paper path for obstructions.

• Be sure the paper guides are not worn or broken, and the paper

is positioned properly.

• Be sure the correct type of paper is being used.

• Be sure the printer is installed on a flat surface.

FRU Action

1 Large and Small

Feed Roller s

2 Small Feed Rol ler

Springs

3Exit Roller

Star Rolle rs

4 Input / Output

Tray

5 End-of-Forms

Flag & Spring

Check for wear and binds.

Check for damage.

Check for wear and binds.

Check the following for wear or damage:

• Paper lifters assemblies

• All parts inside the left and righ t edge guides.

Check for binds or damage.

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4080-001

Po wer Service Chec k

Dead Machine

Note: Remove paper from printer prior to performing the dead

machine service check. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemblies.

FRU Action

1 AC Outlet Check the AC out let for correct line voltage. If

incorrect, inform the customer.

2 Power Line Cord Check the power line cord for damage. Check

the continuity of the line cord and replace if necessary.

3 Power Supply

Fuse (F1)

4 Power Supply If fuse (F1) continu es to fail, replace the fuse

V erify the v olta ge bet ween (J2- 1) on the po wer supply connector and ground is appro ximately +5 V dc. If incorrect, check fu se F1. If the fuse is defective, replace th e fuse and re-verify the voltage at (J2-1). If incor re c t, co n tin ue to st ep 4.

Note: Disconnect the line cord prior to checking fuse F1.

and disconnect the (J2) connector from the controller board before applying power.

Check for approximately +5 V dc between connector (J2-1) and ground. If incorrect replace the pow er supply. If correct, disco nnect all connectors to the controller board except (J2).

Check for approximately +5 V dc between connector (J2-1) and ground. If incorrect , replace the controller board.

Reconnect the (J1) engine board connector and disconnect all cables connected to the engine board. Che ck for approximately +5 V dc between connector (J2-1) and ground. If incorrect, repl ace the engine board. If correc t, reconnect one cable at a time checking the voltage at (J2) each time until the problem is found.

Diagnostic Information 2-19

4080-001

POST incomplete, printer indicator light on, Performing Self Test is displayed and no motors turn.

Note: Excessive ink may be present in the maintenance station

caps.

FRU Action

1 Power Supply Check for approximately +30 V dc at (J2- 6) on the

controlle r board.

2 Transport Motor

Engine Board

3 Controlle r Boar d

Cable

Check for approximately +30 V dc at ( CN5-1) on the engine board. If cor rect, disconnect the motor and check the resistance between (CN5-1) and (CN5-2), which should measure between 10.5 -

12.5 ohms. If the resistance is incorrect, replace the motor. If the resistance is correct, check for approximately +30 V dc on the transist or ta b Q17 on the engine board. If the voltage is incorrect, replace the engi ne board. If the voltage is correct, go to step 3.

Check the conti nuity of the controller board cable. If incorrect, replace the cable. If correct, replace the engine board. if the problem remains, replace the controller board.

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4080-001

Print Quality Service Check

Note: Before troubleshooting any print quality problem, be sure the

cartridge is in good condition. Set print quality to normal and be sure the correct paper type is selected in the paper menu. Set the color menu to Vivid and select black and white if checking B/W print quality.

FRU Action

1 Printhead Carrier

Assembly

Re-seat the printhead cables in the engine board and check the following parts for wear or damage:

• Print Cartridge Latch

• Latch Spring

•Carrier

Diagnostic Information 2-21

4080-001

FRU Action

2 Engine Board

Printhead Cable Rubber Backer

Per form the Clean Heads from the diagnost ic mode. Look for a break in the diagonal line of the test pattern. A broke n line indicates one or more print nozzles are not work ing. 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 engi ne board.

If there is a single break or random breaks in the diagonal line check the following:

• Check the gold-plated contact s, on the end of the cable that connect to the carrier , for dirt and wear. Use only a clean dry cloth to clean the contacts. Also check the cab le for damage. You may need to remove the cable f rom the carrier to inspect it.

• A worn rubber backer results in poor contact between the printhead cable and the print cartridge. Check the rubbe r backer for wear.

• Refer to the test page . Th e tempera ture v alue is Celsius.

Note: Printing slow s to pr event overheating and excess ive ink flow, when the temperature is a bove the normal operating range, or when printing complex graphics. The normal operating temperature range is 60 to 90° F (16 to 32° C). If the printer is operating in a warm environment , >104° F (40° C), excess ive ink may flow from the cartridge. The operating t emperat ure can be found by performing the “Cleaning the Printheads” on page 3-2.

3 Maintenance

Station

2-22 Service Manual

Intermittent nozz le f ail ures can b e caus ed b y wo rn parts in the maintenance stat ion. Perform the

“Maintenance Stati on Service Check” on page 2-10, then return to this ch e ck.

4080-001

FRU Action

4 Paper F eed Ink smudging and smearing can be caused by

paper problems or problems in the paper feed area.

Check the fol lowing:

• 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 obs truc ti ons.

5 Transport Blurred print and voids can be caused by

problems in the transport area. Check the following:

• T ranspo rt belt f or wear and fu ll eng agement i nto the carrier grip.

• Carrier guide rod for wear or dirt.

• Carrier to carrier frame engagement should be lubricated with grease P/N 99A0394. Lubricate the carrie r guide rod and carrier fr ame on both sides where the two surfaces ride on the frame.

• Idler pulley parts for wear, damage, or looseness.

• Encoder strip for wear or dirt.

6 Alignment Characters having uneven or jagged edges, or

uneven vertical, horizontal, bidirectional (black or color) alignment can be checked by en tering Diagnostics Mode and selecting Align Cartridges.

Diagnostic Information 2-23

4080-001

Transport Service Check

Note: If the carrier strikes the left side frame and continues to drive

into the frame, refer to the “Transp or t Ser vice Check II” on

page 2-25.

FRU Action

1 Transport Motor Check the motor for binds, or loose motor pulley.

Disconnect the t ransport motor (J5) from the engine board. Check for appro ximately 12 ohms between pins 1 and 2 on the motor cable. If the reading is incorrect, replace the motor.

Check for motor pins shorted to the motor housing. If you find a pin shorted to the housing, replace the motor. If the failure remains, replace the engine board.

2 Engine Board Disconnect (CN5) from the engine board and

3 Carrier Guide

Rod

4 Carri er Belt

Idler Pulley Parts Carrier Frame

5 Encoder Strip

Encoder Card

6 Printhead Cabl e Be sure all connectors ar e fully seated. Check the

7 Maintenance

Station

check for approximately +30 V dc between (CN5-1) and ground. If incorrect, replace the engine board.

Clean the carrier rod. Note: Lubricate the rod and the carri er rod bearing

surface. Check for worn, loose or broken parts. Check for

obstructions blocking carrier movement.

Check the encoder strip for wear, dirt and grease. Go to the “Encoder Card / Strip Service Check”

on page 2-9.

cables for damage. A problem with the maintena nce station can caus e

carrier mov ement probl ems at the right marg in. Go to the “Maintenance Station Service Chec k” on

page 2-10.

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Transport Service Check II

Carrier strikes left side frame and continues to drive into frame

Note: Be sure the printer is unplugged from the AC outlet before

performing this service check.

• Check the carrier cable connection at (CN2) and encoder

connection at (CN1) on the engine board.

• If the problem remains, disconnect the transport motor (CN5)

connection from the engine board, turn the printer on and wait until “Performing Self Test” appears on the display. Manually move the carrier to the c enter location and t hen back to where it is parked over the maintenance station. After several seconds, “Ready” should appear on the display. If not, check the connection at the encoder card (CN1) and retest. If the problem remains, replace the encoder card.

Tray 2 Service Check

Note: Be sure the tray 2 is properly installed and loaded.

Paper does not feed.

FRU Action

1 Drive Gear Check for bi nds and any obstructions in the paper

2 Tray 2 Drive Gear Be sure the drive gear clips are properly installed.

3 T r ay 2 Sensor Disconnect (CN11) and check the cont inui ty of t he

path.

Be sure the tray 2 driv e gear and left side frame drive gear are properly meshed together.

tray 2 sensor switch. If the switch is defective, replace the swi tch. If the switch is not defective, replace the system boar d.

Diagnostic Information 2-25

4080-001

Paper does not feed, but gears turn

FRU Action

1 Drive Belt Check for binds and any obstructions in the paper

path. Be sure the tray 2 and drive gear are properly installed. Be sure the drive belt is properly install ed.

2 Autocom pensato r Chec k the autocompe nsat or and clut ch spring. Be

sure the roller on th e autocompensato r turns when paper is fed. If the roller fails to turn, be sure the drive belt is in stalled properly. If the problem remains, replace the paper tray 2.

Paper Tray 2 is noisy when feeding paper.

FRU Action

1 Gears Be sure the tr ay 2, drive gear and cli p are inst alle d

2 Tray 2 Drive Gear Be sure the drive gear clips are properly installed.

properly.

Be sure the tra y 2 drive gear and left side frame drive gear are properl y m eshed together.

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User Error Messages

Message Explanation

30 Cartridges Missing:

• Color

•Black

•Photo

38 Memory Full Press Go to clear the message and continue

51 Defective Flash Press Go to clear the messa ge and continue

Press the Go but ton to clear the error. At this point the Supplies status appears on the display and the cartridge missing shows in the supplies menus. This remains until the user accesses the Tests Menu to instal l a cartridge and fill the empty slots. If a print job is sent while in this state, it may result in poor print quality sin ce the job most likely requi res the missing cartridge.

processing the job. Some data will be lost. You must allow addi tional me mory to complete your print job by:

• Deleting fonts, macros and other data in RAM.

• Simplifying your print job.

• Installing additional memory.

Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group.

Menu Lockout does not prevent access to the Busy/W aiting Menu group. The menu buttons are not active when Reset Control is Off.

processing the job. All downloaded fonts and macros not written to flash will be deleted.

Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group.

Menu Lockout does not prevent access to the Busy/W aiting Menu group. The menu buttons are not active when Reset Control is Off.

53 Unformatted Flash Press Go to clear the message. The flash will

be marked as bad and normal operation will continue. Flash operations wi ll not be al lowed until the flash is formatted.

54 Serial Option x Error This error indicates that the seri al port has

been improperly set.

Diagnostic Information 2-27

4080-001

Message Explanation

54 Parallel Error This error occurs when a IEEE 1284 protocol

error has been detected on the parallel host interf ace, or due to a faulty cable.

Once a host interface error has been displayed for the first ti m e, reporting of further host interf ace errors for the associated port is suppressed until the interface parameters are changed, or the printer is powered off.

Press Go to clear the message and continue processing the print job. The job may not print correctly. V erify that the correct cable is used. If a serial error has occurred, be sure the serial interf ace parameter s (protoco l, baud, parit y and data bits) are set correctly on the printer and the host computer. If a parallel error has occurred, check the cable connection between the host and printer.

Press Menu> or Menu< to access t he reset function in the Busy/Waiting Menu group.

Menu Lockout does not prev ent access to the Busy/Waiting Menu group. The menu buttons are not active when Reset Control is Off.

Press and hold Sel ect and the n press Re turn to determine the exact cause of host interface error.

If a serial error has occurred, a 16-bit error code displays in hexadecimal on the second line of the LCD. If bit 15 is on, a framing err or has occurred. If bit 14 is on, an overrun error has occurred. If bit 13 is on, a parity error has occurred.

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Message Explanation

56 Serial x Port Disabl ed This error occurs when data is sent to the

printer across the opt ional serial port x (where x=1, 2, or 3), but the port is disabled.

Once the error disp lays the first time, reporting of further errors is suppressed until the menus are entered, or the prin ter is reset.

Press Go to clear the message. The printer discards any data received on the seria l port. Enable the serial port.

Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group.

Note: The menu buttons are not active when Reset Control is Off .

Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group.

56 Parallel Port Disab led Once the error has been di splayed for the first

61 Defective Disk Press Go to clear the message . The d isk wil l be

time, reporting of further error is suppressed until the menus are entered, or the printer is reset.

Press Go to clear the message. The printer discards any data received on the seria l port. Enable the serial port.

Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group.

Note: The menu buttons are not active when Reset Control is Off .

Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group.

marked as defective and normal printer operation continues. Disk operations are not allowed with a defective disk, and the Format Disk menu item is not shown.

Diagnostic Information 2-29

4080-001

Message Explanation

62 Disk Full Press Go to clear the message and continue

processing the job. All downloaded fonts and macros not written to disk are del eted.

Press Menu> or Menu< to access t he reset function in the Busy/Waiting Menu group.

Note: The menu buttons are not active when Reset Control is Off.

Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group.

63 Unformatted Disk Press Go to cl ear t he message . The di sk wi ll be

marked as bad and normal operation continues. Disk operati ons are not allowed until the disk is formatted.

200 Paper Jam This message indi cates that a paper jam has

occurred. If the err o r does not clear after cleaning the paper jam, go to the “Paper Feed

Service Check” on page 2-15.

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3. Diagnostic Aids

Diagnostic Mode

To ente r the Diagnostic Mode:

1. Turn the printer off.

2. Press and hold the Go and Return buttons.

3. Turn the printer on.

4. Release the buttons when Performing Self Test displays on the operator panel.

Note: Select Exit Dia gnostics to return to normal mode. The tests display on the operator panel in the order shown:

• Print Tests

• Hardware Tests

• Printer Setup

• Error Log

• Align Cartridges

• Base Sensor Tests

• Exit Diagnostics

Diagnostic Aids 3-1

4080-001

Aligning the Cartridges

1. Enter Diagnostics Mode.

2. Select Align Cartridges.

3. Press <MENU> to select the test.

4. Press Select

• Horizontal Align

• Vertical Alig n

• Bi-di Black Align

• Bi-di Color Align

5. Test (A) Alignment = XX* - The alignment can be changed by pressing <MENU> to change the setting.

6. Press SELECT to save the settin g.

7. Once any changes have been made, a test page can be printed showing the changes by selecting Print Align Page.

8. Use the test page to check each alignment, A-D.

9. If changes are necessary repeat step 5.

Cleaning the Printheads

1. Enter Diagnostics Mode.

2. Select Hardware Test.

3. Press <MENU> to go to “Clean Heads”.

4. Press Select. The nozzle test pattern test page prints.

Paper Lifters Operation Theory

As the carrier applies pressure against the clutch lever, located in the gear box assembly, the left and right paper lifters engage, positioning the media into the printer. Media is then pulled through the printer by the combination of torque action between the paper feed motor and the large feed roller, and friction between the paper feed motor and the media.

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Error Lo g

Viewing the Error Log

The error log is helpful to the servicer by providing a history of printer errors. The error log contains the 12 most recent errors. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in consecutive positions in the log are entered. All 2xx and 9xx error messages are stored in the error log.

To view the Error Log:

1. Select Display Log from the Error Log menu. The Error log displays on 3 screens as only 4 entries display at a time.

2. To move to the next screen press Menu> to move forward or <Menu to move backward.

3. Press Return/Stop to exit the Error Log.

Clearing the Error Log

To clear the Error Log:

1. Select Clear Log from the Error Log menu.

2. Select YES to clear the Error Log or NO to exit the Clear Log menu. If YES is selected, the Empty Error Log displays on the screen.

3. Press Return/Stop to exit the Clear Log menu.

Diagnostic Aids 3-3

4080-001

Hardware Tests

The following Hardware Tests can be selected from this menu:

• Clean Heads

• LCD Test

• Button T est

• DRAM Memor y Test

• ROM Memory Test

• Parallel Wrap (if available)

• Serial Wrap (if available)

LCD Test

To run the LCD Test:

1. Select LCD Test from the Diagnostic menu. (The LCD test continually executes the LCD display test).

2. Press Return/Stop to cancel the test.

Button Test

To run the Button Test:

1. Select Button Test from the Diagnostic menu. With no buttons pressed several OP (Open) appear on the display.

2. Press eac h button one at a time and a CL (Closed) displays in place of an OP. The proper operation of each button can be checked.

3. Press Return/Stop to cancel the test.

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DRAM Memory Test

The purpose of this test is to check the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly.

To run the DR AM Memor y Test:

1. Select DRAM Memory Test from the menu. The power indicator blinks indicating the test is in progress.

2. Press Return/Stop to exit th e tes t.

P:###### represents the number of times the memory test has passed and finished successfully. Initially 000000 displays with the maximum pass count being 999,999.

F:##### represents the of time the memory test has failed and finished with errors. Initially 00000 displays with the maximum fail count being 99,999.

Once the maximum pass count or fail count is reached, the test is stopped, the power indicator is turned on solid, and the final results display. If the test fails, the message DRAM Error, displays for approximately 3 seconds and the failure count increases by 1.

Diagnostic Aids 3-5

4080-001

ROM Memory Test

The ROM Memory Test is used to check the validity of the RIP code and fonts.

To run the ROM Memory Test:

1. Select ROM Memory Test from the menu. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is in process. The test runs continuously.

2. Press Return/Stop to exit the test.

Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test f ai ls, one of the following messages displays f or approximately 3 seconds:

ROM Checksum Error, ROM Bur st Read Error

Once the maximum pass count or fail count is reached, the test stops with the power indicator on solid. The final results display on the screen.

Parallel Wrap Test

This test is used with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested.

To run the Parallel Wrap Test:

1. Disconnect the parallel interface cable and install the wrap plug (P/N 1319128).

2. Select the Parallel Wrap Test from the menu.The printer indicator light flashes indicating the test is in progress. The test runs continuously until canceled.

Each time the test finishes, the screen updates. If the test passes, the Pass Count increases by 1, however if the test fails, an error message displays for approximately 3 seconds. Once the maximum count is reached the test stops. The power indicator shows solid and the final results displ ay.

3. Press Return/Stop to exit the test.

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Serial Wrap Test

This test is used to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested.

To run t he Serial Wrap Test:

1. Disconnect the ser ial interface cable and install the wrap plug.

2. Select the Serial Wrap Test from the menu. The power indicator blinks indicating the test is running.

3. This test runs continuously unle ss canceled by pressing Return/Stop.

Each time the test finishes, the screen updates with the result. If the test passes, the Pass Count increases by 1, however if the test fails, a message displays for approximately 3 seconds and the Fail Count increases by 1. Once the maximum count is reached the test stops. The power indicator shows solid and the final results display.

4. Press Return/Stop to exit th e tes t.

Diagnostic Aids 3-7

4080-001

Device Tests

Hex Trace

Hex Trace can be used to help diagnose print job problems. To invoke the Hex Trace:

1. Select Hex Trace from the Tests Menu.

2. Sen d a print job to the printer. (The document should print in both hexadecimal and character formats.)

3. Select Reset Pri nter from the Tests Menu or unplug the printer, to exit Hex Trace.

Quick Disk Test

This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk.

To run the Quick Disk Test :

1. Select the Quick Disk Test from the Device Tests menu.

• The power indicator blinks while the test is in progress.

• Quick Disk Test/Test Passed message displays if the test

passes and the power indicator turns on solid.

• Quick Disk Test/Test Failed message displays if the test

failed and the power indicator turns on solid.

2. Press Go, Return, or Stop to return to the Device Te sts menu.

3-8 S ervice Manual

4080-001

Disk Test/Clean

WARNING: This test destroys all data on the disk and should not be

attempted on a good disk. Also note that this test may run approximately 1 1/2 hours depending on the disk size.

To run the Disk Test/Clean Test :

1. Select Di sk Test/Clean from the Device Tests menu. – Files will be lost/Go or S top? message displays to warn

the user that all contents on the disk will be lost.

2. T o exit the test immediately and return to the Device Tests

menu, press Return/Stop. To continue with th e test, press Go.

– If go is selected, Disk Test/Clean/BAD:000000 00%

message displays. The screen updates periodically indicating the percentage of test completed and the number of bad blocks found.

3. The power indicator blinks during the test. The test can be

canceled anytime during the test by pressing Return/Stop.

– Once the test is complete, the power indicator shows solid

and a message displays.

– XXXX Bad Blocks/YYYYYY Usable message displays if

fewer than 2000 bad blocks are detected. XXXX indicates the number of bad blocks and YYYYYY indicates the number of usable blocks.

– XXXX Bad Blocks/Replace Disk message displays if more

than 2000 bad blocks are detected. The disk cannot be recovered because too many bad blocks exist on the disk.

4. Press Go or Return/Stop to return to the Device Tests menu.

Diagnostic Aids 3-9

4080-001

Flash Test

This test causes th e fil e syst em to write and read d ata on th e f lash to test the flash.

WARNI NG: This test destroys all data on the flash because the flash is reformatted at the end of the test.

To run the Flash Test:

1. Select Flash Test from the Device Tests menu. – The power indicator blinks while the test is running. – Flash Test/T est Passed message displ ays i f the test passes

and the power indicator shows solid.

– Flash Test/T est Failed message displays if the test fails and

the power indicator shows solid.

2. Press Go or Return/Stop to return to the Device Tests menu.

3-10 Service Manual

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Printer Setup

Setting the Page Count

This lets the servicer change the page count from the diagnostic menu. This is used whenever the engine board is replaced because this board contains the printer's NVRAM Memor y where the page count is stored.

To set th e Page Count:

1. Select Printer Setup from the Diagnostic menu.

2. Select Page Count from the Diagnostic menu. a. The current page count displays. b. The leftmost digit blinks, indicating it is the first digit to be

changed.

3. Press either Menu> or <Menu until the value you want displays.

4. Press Sel ect to move to th e next digit, press Menu> or <Menu until the value you want displays. Continue with each digit until you set the page count. You can skip any digit by pressing Select.

5. Press Sel ect to save the new page count in NVRAM.

6. Press Return/Stop to exit.

Viewing the Permanent Page Count

The Permanent Page Count can only be viewed and cannot be changed.

To view the Permanent Page Count:

1. Select Perman ent Page Count from the menu.

2. Press Return/Stop to exit.

Diagnostic Aids 3-11

4080-001

Restore Factory Defaults

To restore each of the printer settings contained in the Setup menu to their factory default value select Restore from the menu. To exit the menu without restoring the settings to the factory default values, select Do Not Restore. Sometimes thi s is use d to help co r re ct p rin t quality problems.

Print Tests

The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. Each of the installed options is listed in the following order in the menu:

• Tray 1(input tray)

• Optional Paper Tray 2 (if installed)

• Manual T ray

For each input source selected you have the following choice:

• Single (prints the Quick Test Page once)

• Continuous (continue printing the Quick Tes t Page until Return

or Stop is pressed).

The contents of the Quick T est Page varies depending on the media installed in the selected input source.

To run the Prin t Test Page:

1. Select Print Tests from the Diagnostic menu.

2. Select Tray 1.

3. Select Single or Continuous.

• If single is selected no buttons are active during printing.

• If continuous is selected, Return or Stop can be selected to

cancel the test.

Check each Test Page from each source to assist in Print Quality and Paper Feed problems.

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Print Quality Test Page

The purpose of this diagnostic function is to allow printing of the print quality test page. This page must always be printed on letter, legal or A4 paper.

To run the Print Quality Test P age:

1. Turn the printer off.

2. Press and hold S elect and Return.

3. T urn on the printer.

4. Release the buttons once Performing the Self Test displays.

5. The printer performs its normal POR cycle then prints one copy of the Print Quality Test page. If you want more than one copy, perform these steps again.

The following is printed on page 1:

• Contents of the Diagnostic Error Log.

• Printer configuration information:

– printer serial number, controller code level, engine code

level, operator panel code level, installed memory, font versions, and so on.

• Values for the Quality Menu settings used to print the pages.

Diagnostic Aids 3-13

4080-001

Printing Menu Settings Page

This test page must be printed on letter, legal or A4 paper. To print the Menu Settings Page:

1. Select the TESTS MENU.

2. Select Print Me nus from the TESTS MENU.

The page contains the following information:

• A list of all the printer settings contained in the control panel

menus and their values.

• A list of the installed options and features such as RAM memory

SIMMs, optional input paper trays, flash or disk.

• Printer information such as serial number, page count, installed

RAM, engine code level, RIP code level, control panel code levels, font ROM version, SRAM availability, supplies status and color settings.

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Test Page (Quick Test)

Note: Paper can be fed from Tray 1 or the optional Tray 2.

To run a quick test page of black, be sure the print cartridges are in good condition. Install a black print cartridge in the left side of the printhead cradle and a color print cartridge in the right side. To check the color, run Hardware Tests, clean heads.

To run t he test:

1. Select Print Tests from the Diagnostic menu.

2. Select Tr ay 1 or optional Tray 2.

3. Select Single or Continuous.

• If single is selected, no buttons are active during printing.

• If continuous is selected, Return or Stop can be selected to

cancel the test

4. Check the test page from each source to assist in print quality and paper feed problems.

The test page contains the following:

• Page count

• Installed memory

• Serial nu mber

• Engine

• Base

• Panel

• Font

Diagnostic Aids 3-15

4080-001

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4. Repa ir Informa t i on

This chapter explains how to make adjustments to the printer and how to remove defective parts.

Note: Read the following before handling electronic part s. When working on the printer, always unplug the printer from the electrical outlet. High voltage is present in the power supply as long as it is plugged into the electrical outlet.

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 printer.

• 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 st r ap on you r w ris t. C on nect the wris t b and to the system

ground point. This discharges any static electricity in your body to the printer.

• Hold the ESD-sensitive part by its edge connector shroud (cover); do not

touch its pin s . If y ou are rem oving a pluggable module, use the correct too l .

• Do not place the ESD-sensitive part on the printer 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.

• Printer 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 printer covers when you are not working on the printer, 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 careful in working with ESD-sensitive parts when cold weather heating

is used because low humidity increases static electricity.

Repair Information 4-1

4080-001

Adjustments

The user is directed, in the Printer Control program, to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge.

Removal Procedures

The following procedures are arranged according to the name of the printer part discussed. 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.

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Covers and Doors

Repair Information 4-3

4080-001

Base Assembly Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to the “Covers and Doors” on

page 4-3.

3. Disco nnect the controller board cable from the engine board.

4. Remove the eight screws from the left and right side of the carrier frame assembly and remove the frame. Do not overtighten the screws, as this may strip the plastic.

5. Remove the controller board access cover, refer to “Controller

Board Access Cover Removal” on page 4-5.

6. Disco nnect the operator panel connector and the engine board connector from the contoller board.

7. Remove the four screws from the controller board and remove the board.

8. Remove the operator panel cable and the engine board cable. Note the routing of the cables.

9. Remove the power supply, refer to the “Power Supply

Removal” on page 4-26.

10. Remove the gutter pad.

Code SIMM Access Door Removal

1. Remove the rear access door, refer to “Rear Access Cover

Removal” on page 4-9.

2. Unsnap the hinge on either side of the Code SIMM access door, and remove the door.

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Controller Board Access Cover Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disconnect the operator panel cable and note the routing.

4. Remove the eight screws from the carrier frame assembly and note the ground strap cable.

5. Disengage the latches located on each side of the carrier frame assembly, refer to the “Covers and Doors” on page 4-3.

6. Slide the carrier frame assembly toward the rear, lift up and remove it from the base.

7. Remove the two screws from the controller board access cover and remove.

Controller Board Access Door Removal

1. Remove the input / output tray assembly .

2. Open the front access doo r, refer to “Covers and Doors” on

page 4-3.

3. Remove the paper tray, refer to the “Paper Tray Assembly

Removal” on page 4-17.

4. Depress the clip on the controller board access door, and remove.

Envelo pe Guide Remo v a l

1. Remove the input / output tray assembly .

2. Open the input / output tray and lift the envelope guide unclipping it from the lower input tray. Refer to “Covers and

Doors” on page 4-3.

Repair Information 4-5

4080-001

Front Access Door Removal

1. Remove the input / output tray assembly.

2. Open the front access door, refer to “Covers and Doors” on

page 4-3.

3. Depress the plastic hinges releasing the pressure and remove the front access door.

Front Cover Removal

1. Remove the input / output tray assembly.

2. Remove the two screws from the front cover, located on the bottom of the printer. Refer to “Covers and Doors” on

page 4-3.

3. Release th e latch beside each screw from the front cover and pull forward off the base.

4. Disco nnect the operator panel cable and note the routing.

Note: Do not turn the printer on its back, as this may cause the ink to spill.

Gutter Pad Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to the “Covers and Doors” on

page 4-3.

3. Remove the gutter pad.

4-6 S ervice Manual

4080-001

Memory (SIMM) Card Cover Removal

1. Remove the input / output tray assembly .

2. Open the front access doo r, by pulling up on the tab, as shown.

3. Remove the memory (SIMM) card cove r.

Tab

Metal / Plastic Controller Board Cover Removal

1. Remove the optional card(s) cover, refer to “Covers and

Doors” on page 4-3.

2. Facing the rear of the printer, remove the two screws securing the metal controller plate to the plastic controller board and remove the plate.

3. Remove the three screws holding the plastic controller board and remove the board.

Note: When reinstalling the metal plate, be sure the arrow points upward.

Repair Information 4-7

4080-001

Operator Panel Cover Removal

1. Remove the input / output tray assembly.

2. Remo ve t h e fr ont c over, re fe r t o th e “Front Cover Removal”

on page 4-6.

3. Disco nnect the operator panel cable and note the routing.

4. Remove the four screws securing the operator panel to the front cover, refer to “Covers and Doors” on page 4-3.

5. Be sure the front access door is open.

6. Unhook the two plastic guides and lift the operator panel up and out of the printer.

Option Card(s) Cover Removal

Depress the option card(s) cover and slide it to the rear of the printer to rem ove . R e fe r to the “C overs and Doors” on page 4-3.

Rear Cover Removal

1. Remove the input / output tray assembly.

2. Remo ve t h e fr ont c over, re fe r t o th e “Front Cover Removal”

on page 4-6.

3. Disco nnect the operator panel cable and note the routing.

4. Remove the metal and plastic controller board covers, refer to the “Metal / Plastic Controller Board Cover Removal” on

page 4-7.

5. Unlatch the three plastic rear cover latches located on the top edge of the carrier frame, refer to “Covers and Doors” on

page 4-3.

6. Unlatch the plastic latches from each side of the base assembly.

7. Lift and remove the rear cover.

4-8 S ervice Manual

4080-001

Rear Access Cover Removal

1. Turn the printer around so the back is facing you.

2. Depress the tabs located at the top of the rear access door cover and remove.

Repair Information 4-9

4080-001

Frames

4-10 Service Manual

4080-001

Carrier Frame Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disconnect the operator panel cable and note the routing.

4. Remove the four screws from the carrier frame assembly and note the ground strap cable.

5. Disconnect the controller board cable connector (CN10), the transport motor cable (CN5), and the paper feed motor cable (CN6), from the engine board.

6. Disengage the clips located on each side of the carrier frame assembly.

7. Slide the carrier frame assembly toward the rear, lift up and remove it from the base.

8. Remove the maintenance station, refer to the “Maintenance

Station Assembly Removal” on page 4-32.

9. Disconnect the five small feed roller springs from the small feed roller spring connector rail.

10. Remove the two screws securing the carrier frame to the left and right side frames.

11. Tilt the top of the carrier frame assembly toward the front of the machine and remove.

Carrier Rail Removal

1. Remove the input / output tray assembly .

2. Remove the front cover, refer to “Covers and Doors” on

page 4-3.

3. Disconnect the operator panel cable and note the routing.

4. Remove the three screws from the top of the carrier rail, refer to the “Frames” on page 4-10.

5. Slide the carrier rail to the left, lift and remove.

Repair Information 4-11

4080-001

Idler Pulley Assembly Removal

1. Remove the input / output tray assembly.

2. Remo ve the front c ove r, refe r to “Covers and Doors” on

page 4-3.

3. Move the printhead carrier assembly to the center of the printer.

4. Release th e tension on the idler pulley by pressing the idler pulley toward the transport carrier motor.

5. Remove the carrier belt from the carrier transport motor.

6. Remove the carrier belt from the idler pulley and slide the idler pulley out of the printer.

Left Side Frame Assembly Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the carrier frame assembly, refer to the “Carrier

Frame Assembly Removal” on page 4-11.

4. Remove the two screws securing the small feed roller spring connector rail and remove the rail, refer to “Frames” on

page 4-10.

5. Remove the two screws securing the star roller assembly and remove.

6. Remove the gear box assembly, refer to the “Gear Box

Assembly Removal” on page 4-15.

7. Remove the three screws from the left side frame.

8. Remove the spring from the large feed roll shaft and remove the left side frame.

Note: Notice the placement of the spring.

4-12 Service Manual

4080-001

Mid Frame Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the carrier frame assembly, refer to the “Carrier

Frame Assembly Removal” on page 4-11.

4. Remove the right side frame, refer to the “R ight Sid e Frame

Assembly Removal” on page 4-13.

Right Side Frame Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the carrier frame assembly, refer to the “Carrier

Frame Assembly Removal” on page 4-11.

4. Remove the two screws securing the small feed roller spring connector rail and remove the rail. Refer to “Fr am es” on

page 4-10.

5. Remove the two screws securing the star roller assembly, refer to the “Star Roller Assembly Removal” on page 4-17.

6. Remove the three screws from the right side frame and remove the frame.

Repair Information 4-13

4080-001

Paper Feed

4-14 Service Manual

4080-001

Exit Roller Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the carrier frame assembly, refer to the “Carrier

Frame Assembly Removal” on page 4-11.

4. Remove the three screws from the right side frame and remove the frame.

5. Remove the exit roller.

Gear Box Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the carrier frame, refer to the “Carrier Frame

Assembly Removal” on page 4-11.

4. Depress the plastic clip on the clutch lever at the end of the large feed roller shaft and remove the clutch lever. Be sure the grove on the clutch lever aligns with the clutch spring.

5. Remove the two screws securing the gear box assembly to the frame.

6. Depress the gear box clip on the bottom of the left side frame and remove the gear box assembly and shaft.

Large Feed Roller Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the exit roller assembly, refer to the “Exit Roller

Assembly Removal” on page 4-15.

4. Unlatch the spring at the left end of the large feed roller shaft, by lifting up on the latch release lever.

5. Remove the tension spring from the end of the large feed roller shaft and remove the large feed roller.

Repair Information 4-15

4080-001

Manual Sheet Feeder Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disco nnect the operator panel cable and note the routing.

4. Depress the manual guide clip on the right side frame and remove the guide from the rear of the printer.

Paper Feed Motor Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disconnect the paper feed motor cable from the controller board at (CN6).

4. Remove the two screws from the left frame and remove the paper feed motor, refer to “Frames” on page 4-10.

Paper Lifters Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disco nnect the operator panel cable and note the routing.

4. Remove the gear box assembly, refer to the “Gear Box

Assembly Removal” on page 4-15.

5. Remove the screw securing the paper tray to the paper lift assembly.

6. Remove the screws from each end of the hinge shaft.

7. Remove the screws from each end of the plastic side lifter rail.

8. Remove the hinge shaft and the left and right paper lifters.

4-16 Service Manual

4080-001

Paper Tray Assembly Removal

1. Open the front access door and remove. Refer to “Covers and

Doors” on page 4-3.

2. Move the manual paper guide to the left.

3. Remove the screw from the right side of the paper tray and remove the tray.

Small Feed Roller Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the carrier frame assembly, refer to the “Carrier

Frame Assembly Removal” on page 4-11.

4. Press down on the small feed rollers to remove, refer to the

“Paper Feed” on page 4-14.

Small Feed Roller Holder Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the carrier frame assembly, refer to the “Carrier

Frame Assembly Removal” on page 4-11.

4. Press down on the small feed rollers to remove, refer to the

“Paper Feed” on page 4-14.

5. Depress the three clips securing the small feed roller holder assembly and remove.

Star Roller Assembly Removal

1. Remove the input / output tray assembly .

2. Open the access door, refer to the “Covers and Doors” on

page 4-3.

3. Remove the two screws from the star roller assembly and remove.

Repair Information 4-17

4080-001

Electronics

4-18 Service Manual

4080-001

Code or Flash SIMM Removal

Note: The code SIMM is installed on some printers. The code

SIMM installs in the first option card slot (J6) only. Be sure to properly identify the code SIMM and the flash memor y card, if the printer contains both.

1. Remove the input / output tray assembly .

2. Turn the printer around so the back is facing you.

3. Disconnect the printer power cord and disconnect all cables from the back of the printer.

4. Press down on the two tabs located at the top of the rear access door and remove.

5. Pull the tab on the code SIMM access door until it rotates toward y ou.

6. Remove the Code SIMM, refer to the “Mem or y (SIMM) Card

Removal” on page 4-22.

Note: Reverse the removal to reinstall either the flash SIMM or the

code SIMM.

Repair Information 4-19

4080-001

Contr ol ler Board Removal

Note: V erify that your printer has a code SIMM in slot (J6).

1. Remove the input / output tray assembly.

2. Open the front access door, refer to “Covers and Doors” on

page 4-3.

3. Remove the paper tray, refer to the “Pap er Tray Assembly

Removal” on page 4-17.

4. Remove the controller board access door, refer to the

“Control ler Board Access Door Removal” on page 4-5.

5. Disconnect the engine board cable and the operator panel cable from the controller board.

6. Remove the memory (SIMM) card, refer to the “Memory

(SIMM) Card Removal” on page 4-22.

7. Remove the screw which secures the RIP bracket to the INA bracket located under the printer.

8. Remove the two screws securing the controller board access cover and remove the cover.

9. Remove the metal / plastic controller board covers, refer to the

“Metal / Plastic Controller Board Cover Removal” on page 4-7.

10. Remove the rear access door, refer to the “Co vers and Doors”

on page 4-3.

11. Open the code SIMM access door and remove the code SIMM, refer to the “Code or Flash SIMM Removal” on page 4-19.

12. Disconnect the power supply cable from the controller board.

13. Remove the two screws from the controller board.

14. Lift up on the front and rear of the controller board and remove.

Note: Be sure to unplug the option card from the right rear side of the printer, if one is present.

4-20 Service Manual

4080-001

Encoder / Thermistor Card Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Move the carrier assembly to the right side of the printer.

4. Disconnect the three printhea d cables from the engine board.

5. Remove the carrier shaft retainer clip from the right side of the carrier shaft.

6. Remove the screw from the left side of the carrier shaft.

7. Remove the carrier shaft by sliding it to the right.

8. Gently lift up on the carrier taking care not to damage the encoder strip and disconnect the carrier belt.

9. Disconnect the pr inthead cable from the encoder / thermistor card.

10. Remove the screw from the encoder / thermistor card and remove the card.

Repair Information 4-21

4080-001

Engine Board Removal

1. Remove the input / output tray assembly.

2. Remove all covers (except the base), refer to “Covers and

Doors” on page 4-3.

3. Disco nnect the three pr inthead cable connectors from the engine board.

4. Disco nnect the controller board cable from the engine card (CN10).

5. Disconnec t the transport carrier motor cable from the engine board at location (CN5) and the paper feed motor cable at location (CN6) and the tray 2 connector (CN11).

6. Remove the two screws from the engine board and remove the engine board.

Note: Take care with the routing of the paper feed motor cable. Pull the EOF flag out of the sensor while removing the engine board.

Memory (SIMM) Card Removal

1. Remove the input / output tray assembly.

2. Open the front access door, by pulling up on the tab, as shown.

4-22 Service Manual

4080-001

3. Remove the memory (SIMM) card cover, refer to “Memory

(SIMM) Card Cover Removal” on page 4-7.

4. Remove the memory (SIMM) card by pushing the metal clips at both ends of the connector outward and lifting the memory (SIMM) card up and out of the printer.

Repair Information 4-23

4080-001

To Reinstall:

1. Hold the memory (SIMM) card with the connection points toward the connector and position the notch as shown.

2. Insert the memory (SIMM) card all the way into the connector at a 45° angle, and rotate it down until it snaps into place.

3. Be sure both metal clips on the connector are fastened, and the two pins on each end are pushed through the holes on the memory (SIMM) card.

Operator Panel Removal

1. Remove the input / output tray assembly.

2. Remo ve the front c ove r, refe r to “Covers and Doors” on

page 4-3.

3. Disco nnect the operator panel cable and note the routing.

4. Remove the four screws securing the operator panel to the front cover and remove the operator panel.

4-24 Service Manual

4080-001

Operator Panel Cable Removal

1. Remove the input / output tray assembly .

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disconnect the operator panel cable from the operator panel and note the routing.

4. Remove the carrier frame, refer to the “Carrier Frame

Assembly Removal” on page 4-11.

5. Remove the controller board cover, refer to the “Controller

Board Removal” on page 4-20.

6. Disconnect the operator panel cable from the controller board.

Option Card(s) Removal

1. Remove the option card cover, ref er to “Covers and Doors” on

page 4-3.

2. Remove the two screws securing the optional card.

3. Gently pull the option card out of the connector and remove.

Option Card

Repair Information 4-25

4080-001

Power Supply Removal

Note: Always unplug the printer from the electrical outlet. High

voltage is present in the power supply as long as it is plugged into the electrical outlet.

1. Remove the input / output tray assembly.

2. Remove all covers (except the base), refer to “Covers and

Doors” on page 4-3.

3. Disconnec t the power supply cable from the controller board at (J2).

4. Disco nnect the ground strap from the right side of the power supply.

5. Remove the ground screw from behind the (J2) connector on the controller card.

6. Depress the clips on both sides of the power supply and slide the power supply out of the machine.

Note: When replacing the power supply, be sure the metal tab on the left side of the power supply is inserted under the controller board.

Tray 2 Sensor Rem oval

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disconnect the tray 2 sensor from the engine board (CN11) and note the routing of the cable.

4. Depres s the clips on the outside of the right side frame and remove the sensor.

4-26 Service Manual

4080-001

Carrier

Repair Information 4-27

4080-001

Carrier Belt Removal

1. Remove the input / output tray assembly.

2. Remo ve the front c ove r, refe r to “Covers and Doors” on

page 4-3.

3. Disco nnect the operator panel cable and note the routing.

4. Move the carrier assembly to the right side of the printer.

5. Remove the carrier shaft retainer clip from the right side of the carrier shaft.

6. Remove the screw from the left side of the carrier shaft.

7. Remove the carrier shaft by sliding it to the right.

8. Gently lift up on the carrier taking care not to damage the encoder strip and remove the carrier.

9. Push the idler pulley to the right to release the tension on the belt and remove the belt.

Note: When reinstallin g the carrie r belt, take care not to damage the encoder strip.

Carrier Rail Removal

Refer to the “Carrier Rail Removal” on page 4-11.

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4080-001

Carrier Transport Motor Assembly Removal

1. Remove the input / output tray assembly .

2. Remove all covers (except the left and base covers), refer to

“Covers and Doors” on pa ge 4-3.

3. Remove the carrier belt, refer to the “Carrier Belt Remo va l” on

page 4-28.

4. Disconnect the carrier transport motor connector (CN5) from the engine board.

5. Remove the belt from the carrier transport motor pulley.

6. Remove the two screws securing the carrier transport motor to the carrier frame and remove the motor. Note the routing of the motor cable.

Encoder Strip / Retainer Removal

1. Remove the input / output tray assembly .

2. Remove the front cover, refer to “Covers and Doors” on

page 4-3.

3. Gently release the tension on the encoder strip by flexing the encoder strip tensioner and remove the encoder strip.

4. Remove the encoder strip retainer if necessary.

Note: When reinstalling the encoder strip, be sure the ends of the strip are centered in their mounting notches and the strip does not bind in the encoder card on the carrier.

Repair Information 4-29

4080-001

Printhead Carrier Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Disco nnect the three pr inthead cables from the engine board.

4. Move the carrier assembly to the right side of the printer.

5. Remove the carrier shaft retainer clip from the right side of the carrier shaft.

6. Remove the screw from the left side of the carrier shaft.

7. Remove the carrier shaft by sliding it to the right.

8. Gently lift up on the printhead carrier, disconnect the carrier belt and remove the carrier.

Note: When reinstallin g the carrie r belt, take care not to damage the encoder strip.

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4080-001

Mainten an ce S tat ion

Repair Information 4-31

4080-001

Maintenance Station Assembly Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the two screws at the rear of the maintenance station and remove the maintenance station.

Wipers and Caps Removal

1. Remove the input / output tray assembly.

2. Remove all covers, refer to “Covers and Doors” on page 4-3.

3. Remove the maintenance station assembly, refer to the

“Maintenance Station Assembly Removal” on page 4-32.

4. Remove the wipers and caps.

Note: Be sure the wipers are completely seated.

4-32 Service Manual

Lexmark Optra Color 45 Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Information

1. Gen e r a l In for matio n

Power Consumption

Maintenance Approach

Tools Required For Service

Abbreviations

Operator Panel and Menus

Using the Operator Panel

Printer Indica tor Light

Operator Panel Buttons

Printer Messages

Operator Panel Menus

Printing the Menu Settings Page

Changing Printer Settings

Disabling the Operator Panel Menus

2. Diagnostic Information

Start

Error Indi cator Table

Power-On Self Test (POST) Sequence

Post Symptom Table

Symptom Tables

Servi ce C he cks

Controller Board Service Check

Encoder Card / Strip Service Check

End of Forms (EOF) Service Check

Maintenance Station Service Check

Noisy Paper Feed Motor Service Check

Operator Panel (Buttons) Service Check

Operator Panel (LCD) Display Service Check

Options Service Check

Paper Feed Service Check

Paper Path Service Check

Po wer Service Chec k

Print Quality Service Check

Transport Service Check

Transport Service Check II

Tray 2 Service Check

User Error Messages

3. Diagnostic Aids

Diagnostic Mode

Aligning the Cartridges

Cleaning the Printheads

Paper Lifters Operation Theory

Error Lo g

Viewing the Error Log

Clearing the Error Log

Hardware Tests

LCD Test

Button Test

DRAM Memory Test

ROM Memory Test

Parallel Wrap Test

Serial Wrap Test

Device Tests

Hex Trace

Quick Disk Test

Disk Test/Clean

Flash Test

Printer Setup

Setting the Page Count

Viewing the Permanent Page Count

Restore Factory Defaults

Print Tests

Print Quality Test Page

Printing Menu Settings Page

Test Page (Quick Test)

4. Repa ir Informa t i on

Handling ESD-Sensitive Parts

Adjustments

Removal Procedures

Releasing Plastic Latches

Covers and Doors

Base Assembly Removal

Code SIMM Access Door Removal

Controller Board Access Cover Removal

Controller Board Access Door Removal