Lexmark Optra Color 45 Service manual
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.
© Copyright Lexma rk Inte r na tion al, Inc. 19 98 .
All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of 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
4080-001
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.
vii
4080-001
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.
viii Service Manual
4080-001
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.
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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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4080-001
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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
1-2 Service Manual
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.
1-6 S ervice Manual
4080-001
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
1-8 S ervice Manual
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
1-10 Service Manual
4080-001
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.
2-2 S ervice Manual
4080-001
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.
2-4 S ervice Manual
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.
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.
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.
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
4080-001
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
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