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Lexmark OptraTM Color 45

4080-001

· Table of Contents · Start Diagnostics · Safety and Notices · Trademarks · Index · Manuals Menu

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

4080-001

Edition: October 2000 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION "AS IS" WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions, therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments may be addressed to Lexmark International, Inc., Department D22/035-2, 740 New Circle Road N.W., Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners. © Copyright Lexmark International, Inc. 1998, 2000. All rights reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

4080-001

Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tools Required For Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel and Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printing the Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . Changing Printer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disabling the Operator Panel Menus . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-3 1-3 1-3 1-4 1-5 1-6 1-7 1-8 1-9

Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Error Indicator Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Power-On Self Test (POST) Sequence . . . . . . . . . . . . . . . . . . . . 2-4 Post Symptom Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Service 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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4080-001 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 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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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4080-001 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 Carrier Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 4-11 Carrier Rail Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Idler Pulley Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Left Side Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . 4-12 Mid Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Right Side Frame Assembly Removal . . . . . . . . . . . . . . . . . . . . 4-13 Paper Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Exit Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Roller Assembly 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 (SIMM) Card Removal . . . . . . . . . . . . . . . . . . . . . . . . . 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 Carrier Transport Motor Assembly Removal . . . . . . . . . . . . . . . 4-29 Encoder Strip / Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . 4-29 Printhead Carrier Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Maintenance Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Maintenance Station Assembly Removal. . . . . . . . . . . . . . . . . . 4-32 Wipers and Caps Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

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4080-001 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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4080-001

Safety Information
· This product is designed, tested and approved to meet strict
global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions.

· ·

Consignes de Sécurité
· Ce produit a été conçu, testé et approuvé pour respecter les
normes strictes de sécurité globale lors de l'utilisation de composants Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires.

· ·

vii

4080-001

Norme di sicurezza
· Il prodotto è stato progettato, testato e approvato in conformità a
severi standard di sicurezza e per l'utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l'utilizzo di parti di ricambio di altri produttori. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie.

· ·

Sicherheitshinweise
· Dieses Produkt und die zugehörigen Komponenten wurden
entworfen und getestet, um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich. Sofern Teile eingesetzt werden, die nicht von Lexmark sind, wird von Lexmark keinerlei Verantwortung oder Haftung für dieses Produkt übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen.

· ·

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4080-001

Pautas de Seguridad
· Este producto se ha diseñado, verificado y aprobado para
cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias.

· ·

Informações de Segurança
· Este produto foi concebido, testado e aprovado para satisfazer
os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição. As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.

· ·

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4080-001

Informació de Seguretat
· Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi. La informació pel manteniment d'aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d'aquest producte. El personal professional ha d'estar-ne assabentat i prendre les mesures convenients.

· ·

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4080-001

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4080-001

xii Service Manual

4080-001

1. General Information
The Lexmark OptraTM Color 45 printer is a network, near laserquality 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 Parallel wrap plug P/N 1319128 Pliers: diagonal and needle-nose Screwdrivers: #1 and #2 Phillips Twinax/serial debug cable P/N 1381963 General Information 1-1

4080-001

Abbreviations
EOF ESD FRU LED POST SIMM RAM ROM V ac V dc End of Forms Electrostatic Discharge Field Replaceable Unit Light-Emitting Diode Power-On Self Test Single In-line Memory Module Random Access Memory Read Only Memory Volts alternating current 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.
Operator Panel Display

Printer Indicator Light

Printer Indicator Light
The printer indicator light gives information about the status of your printer.
Light State On solid Flashing Off Meaning Powered On and in the Ready state Powered On and Busy 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 through 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 Go Function Press the Go button to: · Return the printer to the Ready state if the printer is in an offline situation (Ready message does not appear on the display). · Exit printer menus displayed on the operator panel. · Clear operator panel error messages. If you have changed printer settings from the operator panel menus, press Go before sending a job to print. The printer must display Ready for jobs to print. Each end of the button has a function. Press the Menu> or to go to the next item in the menus, or - Press to scroll forward, or
Menu> and
Select

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Button Return Stop Function Press the Return button to return to the previous menu level. Press the Stop button: · At the Ready, Busy, or Waiting message to temporarily stop all activity 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.

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4080-001

Operator Panel Menus
Menus make it easy for you 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. You 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 setting for the source is Plain Paper. To print a menu settings page: 1. Make sure the printer is plugged in and the Ready status message appears on the display. 2. Press Menu> or until you see

Tests Menu.
4. Press Select.

Tests Menu appears on the first line and Print Menus is on the second line. 5. Press Select to select Print Menus. 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.

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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 Ready state, press Menu> or or or or
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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 Performing Self Test displays. When the printer self test completes, the Ready status message appears. If you press Menu> or
General Information 1-9

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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 Indicator Table
Error 900 902 Symptom RIP software Engine error: 065 Address error 127 - 223 Software detection error Carrier stall Printhead error Incomplete print RIP - engine communication Action Refer to the "Controller Board Service Check" on page 2-9. Replace the engine board, refer to the "Engine Board Removal" on page 4-22.

910 930 931 939

Refer to the "Transport Service Check" on page 2-24. Check the controller board cable 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.

941 943 944 945 946 947

RIP code - CRC RIP font version Processor failure ASIC failure SRAM failure Engine board

Refer to the "Controller Board Service Check" on page 2-9. Replace Font SIMM. Refer to the "Controller Board Removal" on page 4-20.

Replace the engine board, refer to the "Engine Board Removal" on page 4-22. Replace the controller board, refer to the "Controller Board Removal" on page 4-20.

953 954 960

NVRAM chip failure NVRAM CRC failure Controller Board DRAM defective

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Error 961 975 976 977 978 979 Symptom DRAM in (J6) is bad Unrecognized network card Unrecoverable software error in network card Communication error with network card Network card checksum error Flash/Network card error Action Replace the memory SIMM card in (J6). If the incorrect card is installed, replace the card. Go to the "Options Service Check" on page 2-13. If the problem remains, replace the controller card. Replace network card.

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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 printer indicator (green light) comes on. 3. Performing Self Test is shown on the operator panel display and then turns off. 4. The carrier moves to the center of the frame and returns to the maintenance station. 5. The paper feed motor turns. 6. The printer indicator 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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Post Symptom Table
Symptom Blank display, carrier moves, paperfeed motor turns All diamonds on display Action Go to the "Operator Panel (LCD) Display Service Check" on page 2-12. Go to the "Operator Panel (LCD) Display Service Check" on page 2-12. Go to the "Power Service Check" on page 2-19. Go to the "Paper Feed Service Check" on page 2-15. Go to the "Transport Service Check" on page 2-24. Go to the "Transport Service Check" on page 2-24. Go to the "Operator Panel (LCD) Display Service Check" on page 2-12. Go to the "Power Service Check" on page 2-19. Go to the "Power Service Check" on page 2-19. Replace in the following order: · Code SIMM (if installed) · Controller board

Performing Self Test remains on display, no motors turn Paper feed motor does not turn Transport motor does not turn Carrier drives into left side frame Printer indicator light does not light, or remains on POST incomplete, printer indicator light on, no motors turn and Performing Self Test is displayed Printer inoperable Performing Self Test remains on display, transport and paperfeed motors turn

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4080-001

Symptom Tables
Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems
Symptom · No carrier movement · Slow carrier movement · Carrier stops · Carrier strikes left side frame Action Go to the "Transport Service Check" on page 2-24. Go to the "Transport Service Check II" on page 2-25.

Communications Problems
Symptom Printer not communicating with host computer Action Go to the "Parallel Wrap Test" on page 3-6.

Maintenance Station Problems
Symptom · Fails to cap the printhead · Fails to clean the printhead Action Go to the "Maintenance Station Service Check" on page 2-10.

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4080-001 Operator Panel Problems
Symptom Printer indicator light does not: · · · · Turn on Flash Turn off All diamonds Action Go to the "Operator Panel (LCD) Display Service Check" on page 2-12.

One or two pels missing Only one button inoperative More than one button inoperative All diamonds on display

Replace the operator panel assembly. Replace the operator panel assembly. Go to the "Operator Panel (Buttons) Service Check" on page 2-11. Go to the "Operator Panel (LCD) Display Service Check" on page 2-12.

Paper Feed Problems
Symptom Paper fails to stop at first print line · Fails to pick paper · Picks more than one sheet of paper · Picks paper but fails to feed · Paper jams · Paper fails to exit · Noisy paper feed · Paper skews Paper does not feed, motor does not turn Paper does not feed motor attempts to turn Action Go to the "Paper Feed Service Check" on page 2-15.

Go to the Paper Feed Service Check "Paper does not feed - paper feed motor does not turn" on page 2-16. Go to the Paper Feed Service Check "Paper does not feed - paper feed motor turns in only one direction" on page 2-17.

Diagnostic Information 2-7

4080-001 Power Problems
Symptom Printer inoperable Action Go to the "Power Service Check" on page 2-19.

Print Quality Problems
Symptom · · · · · · · · · Voids in characters Light print Prints off the page Fuzzy print Carrier moves but does not print Printhead drying prematurely Vertical alignment off Excessive ink flow (Flooding) Horizontal banding Action Go to the "Print Quality Service Check" on page 2-21.

· Ink smearing · Vertical streaks on paper · Print lines crowded

Go to the "Paper Feed Service Check" on page 2-15.

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Service Checks
Controller Board Service Check
FRU 1 Code SIMM Action Some printers may contain a code SIMM located in the option card(s) (J6) on the controller 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. 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.

2

Controller Board

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 "Encoder / Thermistor Card Removal" 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. If 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 nozzles during the print operation. 2. Seals the printhead when it is not being used to prevent the nozzles from drying.
FRU 1 Maintenance Station Assembly Action As the carrier moves to the right over the maintenance station, a slot on the bottom of the carrier engages a tab on the sled of the maintenance station causing the caps to rise and seal the printheads. Carrier movement to the left will uncap the printheads. The wipers clean the printhead nozzles as the carrier leaves the maintenance station. The wipers clean the printheads only when the carrier is moving to the left. There should be no wiping action of the printhead nozzles when the carrier is moving to the right. After the cleaning operation is complete, a tab on the maintenance station engages a tab on the carrier, causing the wipers to lower. Check the maintenance station for worn or broken parts. 2 Wiper A worn wiper can cause degraded print quality just after a maintenance cleaning. Check for loose or worn wiper. A worn cap can cause the printhead nozzles to dry and clog. Check for loose or worn cap.

3

Cap

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Noisy Paper Feed Motor Service Check
FRU 1 Paper Feed Motor Action Check the following motor pins for approximately 12.5 ohms: (CN6-1) and (CN6-2) (CN6-3) and (CN6-4) If incorrect, replace the paper feed motor, refer to the "Paper Feed Motor Removal" 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 "Button Test" on page 3-4, before continuing this service check.
FRU 1 2 Operator Panel Assembly Controller Board Operator Panel Assembly Action If any button fails the button test, replace the operator panel assembly. Be sure the voltage at (JT6-2) measures +5 V dc. If the voltage is incorrect, replace the controller board. If the voltage is correct, check the continuity of the operator panel cable. Replace the operator panel cable if continuity 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 1 Controller Board Action Verify the voltage at (JT6-2) on the controller board is approximately +5 V dc. If incorrect, replace the controller board. If correct, go to step 2. Verify that the resistance between (JT6-4) and ground on the controller board is approximately 0 ohms. If incorrect, replace the controller board. If correct, replace the operator panel assembly.

2

Operator Panel Assembly

Operator panel display blank - printer indicator light ON.
FRU 1 Controller Board Operator Panel Assembly Action Verify that the resistance between (JT6-4) and ground on the controller board is approximately 0 ohms. If incorrect, replace the controller board. If correct, replace the operator panel assembly.

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Options Service Check
Flash Memory Option(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 Board Removal" on page 4-20. DRAM Memory Option(s) This service check is the same as the flash memory option service check with the following exception: Run the "DRAM Memory Test" on page 3-5 from the menu if the DRAM Memory SIMM 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 Diagnostic 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 problem still exists, replace the controller board, refer to the "Controller Board 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 unrecoverable 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 "Controller Board Removal" on page 4-20.

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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 skew by performing the "Test Page (Quick Test)" on page 3-15.
Action Check for binds in the gear train and paper feed mechanism by rotating the large feed roll by hand. Check all gears for correct installation and signs of wear or damage. If there is a bind, isolate it by removing one of the small idler gears on the inside of the left side frame. Replace any worn or binding gears or rollers. 2 Paper Path Perform the "Paper Path Service Check" on page 2-18.

FRU 1 Gears

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 1 Engine Board

Action With (CN6) connected and power on, check the voltage between Pins 1,2,3,4 and ground. The voltage should measure between +15 V dc and +32 V dc when paper is feeding. If the voltage is correct, replace the engine board. Check the motor pins between (CN6-1) and (CN6-2) for approximately 12.5 ohms. Also check (CN6-3) and (CN6-4) for approximately 12.5 ohms. If incorrect, replace the paper feed motor assembly. If correct, check the continuity between each motor pin on the motor connector and the motor case. If continuity exists, replace the paper feed motor assembly. If the symptom remains, go to step 3. Note: If a short exists in the paper feed motor, damage to the system board drivers and power supply may occur.

2

Paper Feed Motor

3

Power Supply

Disconnect the AC line cord. Disconnect (J2-6) from the controller board and verify the voltage on the cable is approximately +30 V dc. If incorrect, replace the power supply. Check continuity between (J2-6) on the controller board and (C10-36) on the system board. If correct, replace the engine board. If correct, go to step 5. Check the continuity of the controller board cable. If incorrect, replace the cable. If correct, replace the controller board.

4

Engine Board

5

Controller Board Cable

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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 defective motor A bind in the paper feed mechanism Defective gears Defective engine board

FRU 1 Gear Box

Action Check the clutch lever for obstructions and the gear box for binds and wear. Replace worn or binding gears. Check for binds in the gear train and paper feed mechanism by rotating the large feed roll by hand. If you notice a bind, isolate it by removing one of the small idler gears on the inside of the left side frame. Replace any worn or binding gears or rollers. Be sure that the large feed roller is clean. Check the paper lifters, pads and paper tray for proper positioning. Check for correct position of the left paper adjuster guide lifter assembly.

2

Gears

3 4 5

Large Feed Roller Paper Lifters Paper Adjuster

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.
Action 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 right edge guides. Check for binds or damage.

FRU 1 2 3 4 Large and Small Feed Rollers Small Feed Roller Springs Exit Roller Star Rollers Input / Output Tray

5

End-of-Forms Flag & Spring

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Power Service Check
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 1 2 AC Outlet Power Line Cord Action Check the AC outlet for correct line voltage. If incorrect, inform the customer. Check the power line cord for damage. Check the continuity of the line cord and replace if necessary. Verify the voltage between (J2-1) on the power supply connector and ground is approximately +5 V dc. If incorrect, check fuse F1. If the fuse is defective, replace the fuse and re-verify the voltage at (J2-1). If incorrect, continue to step 4. Note: Disconnect the line cord prior to checking fuse F1. 4 Power Supply If fuse (F1) continues to fail, replace the fuse 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 power supply. If correct, disconnect 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. Check for approximately +5 V dc between connector (J2-1) and ground. If incorrect, replace the engine board. If correct, reconnect one cable at a time checking the voltage at (J2) each time until the problem is found.

3

Power Supply Fuse (F1)

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 1 2 Power Supply Transport Motor Engine Board Action Check for approximately +30 V dc at (J2-6) on the controller board. Check for approximately +30 V dc at (CN5-1) on the engine board. If correct, 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 transistor tab Q17 on the engine board. If the voltage is incorrect, replace the engine board. If the voltage is correct, go to step 3. Check the continuity of the controller board cable. If incorrect, replace the cable. If correct, replace the engine board. if the problem remains, replace the controller board.

3

Controller Board Cable

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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 1 Printhead Carrier Assembly Action Re-seat the printhead cables in the engine board and check the following parts for wear or damage: · Print Cartridge Latch · Latch Spring · Carrier

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4080-001
FRU 2 Engine Board Printhead Cable Rubber Backer Action Perform the Clean Heads from the diagnostic mode. Look for a break in the diagonal line of the test pattern. A broken line indicates one or more print nozzles are not working. Run the test again to verify the failure. If there are even breaks in the diagonal line similar to the pattern shown below, replace the engine board.

If there is a single break or random breaks in the diagonal line check the following: · Check the gold-plated contacts, 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 cable for damage. You may need to remove the cable from the carrier to inspect it. · A worn rubber backer results in poor contact between the printhead cable and the print cartridge. Check the rubber backer for wear. · Refer to the test page. The temperature value is Celsius. Note: Printing slows to prevent overheating and excessive ink flow, when the temperature is above 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), excessive ink may flow from the cartridge. The operating temperature can be found by performing the "Cleaning the Printheads" on page 3-2. 3 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station. Perform the "Maintenance Station Service Check" on page 2-10, then return to this check.

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FRU 4 Paper Feed Action Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: · · · · · 5 Transport Correct type of paper is being used. Paper for curl or wrinkles. Feed rollers for wear, dirt, or looseness. Gears for wear or binds. Paper path for obstructions.

Blurred print and voids can be caused by problems in the transport area. Check the following: · Transport belt for wear and full engagement into 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 carrier guide rod and carrier frame 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 entering 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 "Transport Service Check II" on page 2-25.
FRU 1 Transport Motor Action Check the motor for binds, or loose motor pulley. Disconnect the transport motor (J5) from the engine board. Check for approximately 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 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 carrier rod bearing surface. Check for worn, loose or broken parts. Check for obstructions blocking carrier movement.

3

Carrier Guide Rod

4

Carrier Belt Idler Pulley Parts Carrier Frame

5

Encoder Strip Encoder Card

Check the encoder strip for wear, dirt and grease. Go to the "Encoder Card / Strip Service Check" on page 2-9. Be sure all connectors are fully seated. Check the cables for damage. A problem with the maintenance station can cause carrier movement problems at the right margin. Go to the "Maintenance Station Service Check" on page 2-10.

6 7

Printhead Cable Maintenance Station

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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 center location and then 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 1 2 Drive Gear Tray 2 Drive Gear Action Check for binds and any obstructions in the paper path. Be sure the drive gear clips are properly installed. Be sure the tray 2 drive gear and left side frame drive gear are properly meshed together. Disconnect (CN11) and check the continuity of the tray 2 sensor switch. If the switch is defective, replace the switch. If the switch is not defective, replace the system board.

3

Tray 2 Sensor

Diagnostic Information 2-25

4080-001 Paper does not feed, but gears turn.
FRU 1 Drive Belt Action 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 installed. Check the autocompensator and clutch spring. Be sure the roller on the autocompensator turns when paper is fed. If the roller fails to turn, be sure the drive belt is installed properly. If the problem remains, replace the paper tray 2.

2

Autocompensator

Paper Tray 2 is noisy when feeding paper.
FRU 1 2 Gears Tray 2 Drive Gear Action Be sure the tray 2, drive gear and clip are installed properly. Be sure the drive gear clips are properly installed. Be sure the tray 2 drive gear and left side frame drive gear are properly meshed together.

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User Error Messages

Message 30 Cartridges Missing: · Color · Black · Photo

Explanation Press the Go button 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 install a cartridge and fill the empty slots. If a print job is sent while in this state, it may result in poor print quality since the job most likely requires the missing cartridge. Press Go to clear the message and continue processing the job. Some data will be lost. You must allow additional memory 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/Waiting Menu group. The menu buttons are not active when Reset Control is Off.

38 Memory Full

51 Defective Flash

Press Go to clear the message and continue 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/Waiting 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 will not be allowed until the flash is formatted. This error indicates that the serial port has been improperly set.

54 Serial Option x Error

Diagnostic Information 2-27

4080-001
Message 54 Parallel Error Explanation This error occurs when a IEEE 1284 protocol error has been detected on the parallel host interface, or due to a faulty cable. Once a host interface error has been displayed for the first time, reporting of further host interface 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. Verify that the correct cable is used. If a serial error has occurred, be sure the serial interface parameters (protocol, baud, parity 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 the reset function in the Busy/Waiting Menu group. Menu Lockout does not prevent access to the Busy/Waiting Menu group. The menu buttons are not active when Reset Control is Off. Press and hold Select and then press Return 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 error 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 56 Serial x Port Disabled Explanation This error occurs when data is sent to the printer across the optional serial port x (where x=1, 2, or 3), but the port is disabled. Once the error displays the first time, reporting of further errors 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 serial 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 Disabled Once the error has been displayed for the first 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 serial 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. 61 Defective Disk Press Go to clear the message. The disk will be 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 62 Disk Full Explanation Press Go to clear the message and continue processing the job. All downloaded fonts and macros not written to disk are deleted. 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. 63 Unformatted Disk Press Go to clear the message. The disk will be marked as bad and normal operation continues. Disk operations are not allowed until the disk is formatted. This message indicates that a paper jam has occurred. If the error does not clear after cleaning the paper jam, go to the "Paper Feed Service Check" on page 2-15.

200 Paper Jam

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4080-001

3. Diagnostic Aids
Diagnostic Mode
To enter the Diagnostic Mode: Turn the printer off. Press and hold the Go and Return buttons. Turn the printer on. Release the buttons when Performing Self Test displays on the operator panel. Note: Select Exit Diagnostics to return to normal mode. The tests display on the operator panel in the order shown: 1. 2. 3. 4.

· · · · · · ·

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. 2. 3. 4. Enter Diagnostics Mode. Select Align Cartridges. Press to select the test. Press Select · Horizontal Align · Vertical Align · Bi-di Black Align · Bi-di Color Align Test (A) Alignment = XX* - The alignment can be changed by pressing to change the setting. Press SELECT to save the setting. Once any changes have been made, a test page can be printed showing the changes by selecting Print Align Page. Use the test page to check each alignment, A-D. If changes are necessary repeat step 5.

5. 6. 7. 8. 9.

Cleaning the Printheads
1. 2. 3. 4. Enter Diagnostics Mode. Select Hardware Test. Press to go to "Clean Heads". 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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4080-001

Error Log
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
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 Test DRAM Memory 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/Sto