Lexmark J110 4085-001 • 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.
4085-001 Edition: August 2001 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.
4085-001 Table of Contents Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Internal Power Supply Specifications . . . . . . . . . . . . . . . . . . . . . . . .
085-00X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26 Overriding Change Prompts . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28 Paper Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40 Power-On Self Test (POST) Sequence. . . . . . . . . . . . . . . . . . . .2-48 Post Symptom Table . . . . . . . .
4085-001 Diagnostics (Mode 2) - Input Tray Tests . . . . . . . . . . . . . . . . . . 3-27 Diagnostics (Mode 2) - Base Sensor Tests . . . . . . . . . . . . . . . . 3-29 Diagnostics (Mode 2) - Subsystem Tests . . . . . . . . . . . . . . . . . 3-31 Diagnostics (Mode 2) - Supplies Tests . . . . . . . . . . . . . . . . . . . 3-34 Diagnostics (Mode 2) - Printer Setup . . . . . . . . . . . . . . . . . . . . . 3-35 Diagnostics (Mode 2) - Error Log . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Menus . . . . .
4085-00X PerfectFinish Sensor Assembly/Rear Paper Path Sensor Removal . 4-26 Frame From Base Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Cam Engine Motor with Gear Removal . . . . . . . . . . . . . . . . . . . .4-29 Paper Feed Pick Arm Assembly with Motor and Paper Path Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31 PerfectFinish Gear Plate Removal . . . . . . . . . . . . . . . . . . . . . . .4-32 PerfectFinish Motor Removal .
4085-001 Preface This manual describes the Lexmark J110 printer (4085-001) and contains maintenance procedures for service personnel only. It is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions. 2.
4085-001 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.
4085-001 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.
4085-001 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.
4085-001 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.
4085-001 xii Service Manual
4085-001 1. General Information The Lexmark™ J110 printer is a high-performance, narrow-format, thermal inkjet printer designed to print high quality text, graphics, and images on a wide variety of media. It is intended for use by single users or by small workgroups shared using an external network solution or peer-to-peer networking. This printer features parallel and USB standard connectivity. The printheads provide color and true black printing.
4085-001 Internal Power Supply Specifications Built-in Universal Power Supply, 40 Watts Output (50 Watts input) Outputs: Output Name Nominal Voltage Minimum Voltage Maximum Voltage +5 V + 5.1 V +4.8 V +5.25 V 0.5 Amps Min. 1.6 Amps Max. 2.0 Amps Peak +36 V +36.0 V +32.4 V +39.6 V 0.1 Amps Min. 1.0 Amps Max. Avg. (1) 2.1 Amps Peak (1) 3.2 Amps Max. Peak (1) Load Range Note: Current of 1.0 A is long term average current. The +36 V output can supply peak currents of 2.
4085-001 Tools Required For Service • • • • • Analog or digital multimeter Parallel wrap plug P/N 1319128 Pliers: diagonal and needle-nose Screwdrivers: #1 and #2 Phillips Magnet Abbreviations EOF ESD FRU LED MPF NPA POR POST SIMM RAM ROM V ac V dc End of Forms Electrostatic Discharge Field Replaceable Unit Light-Emitting Diode Multi-Purpose Feeder Network Printer Alliance Power-On Reset Power-On Self Test Single In-line Memory Module Random Access Memory Read Only Memory Volts alternating current Volts
4085-001 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), six buttons (Menu is actually two buttons), and one power indicator light. The buttons have fixed functions, which are designated on the front cover. Operator Panel Display Power Indicator Light Menu Select Go Return Stop Power Indicator States The power indicator light gives information about the status of your printer.
4085-001 Operator Panel Button Functions Use the six 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 appears on the second line of the operator panel. Button Function Go Press the Go button. Menu> This button is used to place the printer in the Ready state after an off line situation.
4085-001 Button Function Return Press the Return button. Stop Returns to the previous menu level. If at the top level of the menus, then it functions like Go. Press the Stop button. Stop suspends job activity and displays the Not Ready message. Job activity resumes when Go is pressed. 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.
4085-001 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.
4085-001 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 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.
4085-001 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
4085-001 Disabling the Operator Panel Menus To disable the menus so that changes cannot be made to the printer default settings: 1. Turn off power. 2. While pressing Go and Stop, turn on the printer. 3. Release the buttons when Performing Self Test appears. When the printer self test completes, the Ready status message appears. If you press Menu> or
4085-001 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 2-3 . and take the indicated action. Turn the printer off and then back on to clear service errors.
4085-001 Service Messages These messages are displayed whenever the printer is in the Operator Intervention state, and the printer needs servicing. In general, service errors are non-recoverable. However, it may be possible to power the printer off and back on to temporarily recover from the error condition if it is intermittent in nature. When a Service Message occurs, the printer stops printing. The only recovery is to turn off the printer.
4085-001 Error Indicator Table Error Symptom Action 900 RIP Software Perform the “RIP Card Service Check” on page 2-64 . 902 Engine Software Replace the engine board. See the “Engine Board / Cover Removal” on page 4-14 . 903 RIP Software Check RIP/Engine cable. Replace the RIP card. See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . 904 Service Options Interface Check cables. Replace the board in the optional tray. 905 Engine Flash XX Replace the engine board.
4085-001 Error Symptom Action 907 Engine NVRAM Check cabling to index board. 10 Invalid data in flash memory 20 NVRAM checksum failure 30 Flash data programming failure 40 Engine NVRAM is not present or is not responding 50 Password rejected by engine NVRAM Note: When the index card and encoder dial FRU needs replacing, and a 907-10 error code is present, the engine board must be replaced.
4085-001 Error Symptom Action 915 Index System Perform the “Index System Test” on page 3-33 . 10 Index Motor Stall or loss of Encoder signals 20 Encoder Wheel “once-perrevolution” sensor failure 30 Unable to calibrate Analog Sensor See “Index Motor Service Check” on page 2-56 . If problem still exists, go to “Index System Test” on page 3-33 . 40 Index Motor wired backward 920 “Feed Motor” - Pick Motor stall or loss of Encoder signals See “Index Card/Sensor Service Check” on page 2-67 .
4085-001 Error Symptom Action 930 Black Printhead - P-lines shorted or Substrate Heater shorted Check all contacts and cables. If tests fail, replace the printheads. If failure still occurs, replace engine board.
4085-001 Error Symptom Action 934 Black Printhead Color Printheads Both Printheads TSR measurement indicates a cracked / open TSR or open connection. The debug data identifies the TSR that is open. Check the carrier/ printhead contacts. Try replacing both printheads before replacing carrier. Check the carrier cable. If cable is OK, replace carrier. See “Carrier/Cable Retainer Removal” on page 4-48 . If problem remains, replace engine board. See “Engine Board /Cover Removal” on page 4-14 .
4085-001 Error Symptom Action 939 RIP to Engine communications failure Unplug and replug the AC power cord to see if the problem goes away. Check the RIP card cable connections. If the connections are good, replace the engine board. See “Engine Board /Cover Removal” on page 4-14 . If the problem remains, replace the RIP card. See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . Note: The RIP software can cause a 939 error. 953 NVRAM Failure - NVRAM Chip failure Replace the RIP card.
4085-001 Error Symptom Action 960 RAM Memory Error - RAM soldered on the card is bad Replace the RIP card. See the “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 . 980 Tray 2 Communication Error Communication between Tray 2 and the Engine is unreliable. Check connection between engine board and optional card. 985 Tray 2 Error Check engine to tray 2 cable and contacts. Replace tray 2 card. Look for PerfectFinish leaks.
4085-001 User Status Messages User Status Message Status Action Ready The printer is ready to receive and process data from a host system. Press Menu> or Menu< to take the printer offline and access the Ready Menu group. The following function may be available via the Busy/ Waiting Menu group: -Reset Printer Note: The ready menu group is not accessible if Menu Lockout is turned on. Instead, access is automatically granted to the Busy/Waiting menu group. Press Stop to take the printer offline.
4085-001 User Status Message Status Action Busy The printer is processing data and/ or printing pages. The Power indicator blinks while the printer is processing data. Press Stop to take the printer offline. The Not Ready message appears. No more data is processed from the host computer; however, the printer processes all of the paper currently in motion in the printer’s paper path. Press Go to return the printer to the previous state. Note: Press Menu> or Menu< to access the Busy/Waiting Menu group.
4085-001 User Status Message Status Action Waiting The Waiting is displayed until the current job is terminated or until additional data is received on the active link. Press Go to print the contents of the printer’s buffer. Note: The Go press is ignored when Print Buffer Control is Off. Selection of Go does not terminate the current print job. Press Stop to take the printer offline. The Not Ready message appears.
4085-001 Warning Messages As shown in each of the Status Screens, only one warning message can be displayed at any one time. Once the current warning condition is cleared, the printer automatically shows the next highest priority warning message. If an event occurs which causes a higher priority warning, the higher priority warning message replaces the lower priority warning message.
4085-001 Status Messages These messages provide the operator with information on the current state of the printer. Status Message Status Action Activating Menu Changes The printer is being reset to activate a printer setting changed in the menus. No buttons are active while this message is displayed. Canceling Job Appears after the Cancel Job operation is selected. This message is displayed until the cancel operation is complete. Press Menu> or Menu< to access the Busy/ Waiting Menu group.
4085-001 Status Message Status Action Disabling/Enabling Menus A representation of the operator panel when the user has modified the Menu Lockout printer setting using the Configuration Menu Group. If the Menu Lockout value is changed to On (Panel Menus=Disable), then the Disabling message is displayed. If the Menu Lockout value is changed to Off (Panel Menus=Enable), then the Enabling message is displayed. No buttons are active while this message is displayed.
4085-001 Status Message Status Action Cancelling Job Appears after the Cancel Job operation is selected. This message is displayed until the cancel operation is complete. Press Menu> or Menu< to access the Busy/ Waiting Menu group. The printer is online while the Busy/Waiting Menu group is active. Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group.
4085-001 Status Message Status Action Invalid Engine Code A representation of the operator panel when either the engine code has not been programmed or has been programmed but is invalid. Once this condition occurs, the Ready and Busy messages will not be displayed until valid Engine code exits. Engine code can still be downloaded to the printer when this message is on the display. No buttons are active while this message is displayed.
85-001 Status Message Status Action Not Ready A representation of the operator panel when the printer is in the Not Ready state. All host links are marked as busy when the printer is Not Ready. In addition, all timeouts are stopped. Press Go to take the printer out of the Not Ready state. Press Menu> or Menu< to access the Busy/ Waiting Menu group. The printer is online while the Busy/Waiting Menu group is active.
4085-001 Status Message Status Action Performing Self Test A representation of the operator panel during Power-On Self Test (POST). When the test is complete, the printer enters the Ready state. No buttons are active while this message is displayed. Powering Down A representation of the operator panel during power-down cycle, after the user has turned the machine off. In the event that no errors are found, this is the last message shown before power is cut off to the RIP and engine.
4085-001 Status Message Status Action Printing Menu Settings A representation of the operator panel when Print Menu Settings is selected from the menu. This message appears until the Print Menus page or pages are formatted and submitted to the print engine and then Busy is shown. Press Stop to take the printer offline. The Not Ready message appears. No more data is processed from the host computer; however, the printer processes all of the paper in the printer’s paper path.
4085-001 Status Message Status Action Printing Alignment Page A representation of the operator panel when Align Printheads is selected from the menu. This message appears until the Alignment page is formatted and submitted to the print engine and then Busy is shown. Press Menu> or Menu< to access the Busy/ Waiting Menu group. The printer is online while the Busy/Waiting Menu group is active.
4085-001 Status Message Status Action Printing Test Page A representation of the operator panel when Clean Printheads is selected from the menu. This message appears until the Clean Printheads test page is formatted and submitted to the print engine and then Busy is shown. Press Menu> or Menu< to access the Busy/ Waiting Menu group. The printer is online while the Busy/Waiting Menu group is active.
4085-001 Status Message Status Action Programming System Code A representation of the operator panel when new code is programmed in the RIP code flash. This message is shown until the programming is complete. When the programming is complete, the printer performs a Power-On Reset. No buttons are active while this message is displayed. Resetting Printer A representation of the operator panel during a Printer Reset. The printer resets with the PowerOn Reset defaults.
4085-001 Attendance Messages These messages are displayed when the printer is in the Operator Intervention state. The operator is provided with a description of the operator intervention condition. When an operator intervention condition occurs, all host links are notified about the intervention required condition. All timeouts are stopped while the printer is in an operator intervention state. The only exception is the PostScript Feed timeout.
4085-001 Attendance Message Description Action 88 Cartridge Low XXXX A representation of the operator panel when cyan ink low occurs and the Ink Alarm is activated. A similar message appears when the black, magenta and yellow inks are low. The XXXX is a placeholder for some combination of C,M,Y, and K. Press Go to clear the message. Cartridge LIfe Expired XXXX A representation of the operator panel when an ink cartridge life expires.
4085-001 Attendance Message Description Action Change A representation of the operator panel when the printer is requesting the operator to change the media installed in one of the input sources. The input source is displayed on line 1 and could be one of the following: Sources equipped with both size-sensing and media-present hardware: Change Tray 1, Tray 2, MP Feeder.
4085-001 Attendance Message Description Action Change In all other cases, both the type and size are displayed on line 2.
4085-001 Overriding Change Prompts The size override function lets you override Change Prompts for any source for the remainder of a job. By overriding the prompt, the user is requesting the printer to do the following: • Print the page, as it is formatted, on the paper installed in the • tray. Therefore, some clipping may occur. In addition, the color tables used to create the bitmap are for the requested media, not necessarily the media in the tray.
4085-001 Attendance Message Description Action Check Tray x Connection A representation of the operator panel when the printer loses communications with one of the following devices: If the device was temporarily removed or not connected properly, reattach or reconnect it. When the device is recognized, the printer automatically clears the attendance condition and continues. Check MPF Connection -Tray 2 -Multi-Purpose Feeder This error could occur in two ways.
4085-001 Attendance Message Description Action Clean 1? =Go/Stop A representation of the operator panel when a Long Clean is requested and the printer is asking the user if the printhead that printed the bar label “1” needs to be cleaned. A similar message is shown if the printheads associated with bars 2, 3, and 4 need to be cleaned. Press Go if the long clean needs to be performed on the printhead represented by bar 1.
4085-001 Attendance Message Description Action 31 Defective Cartridge XXXX A representation of the operator panel when the printer detects a defective ink cartridge. In this representation, the XXX is a placeholder for some combination of C,M,Y, and K. The defective cartridge is identified in the XXXX string. Open the cover and replace the defective ink cartridge(s). The carrier appears at the ink cartridge change location.
4085-001 Attendance Message Description Action 54 Std Par ENA Connect Lost A representation of the operator panel when the printer detects during its power-on cycle that the connection to an External Network Adapter has been lost. Once a connection is initially established, a printer setting is modified to note a connection exists. Then, each time the power is cycled on, if the setting states a connection exists, the printer attempts to communicate with the adapter.
4085-001 Attendance Message Description Action 81 Engine Code CRC Failure A representation of the operator panel when microcode to be programmed in the engine flash code module has failed a CRC check. Press Go to clear the message. The microcode data is discarded and must be re-transmitted from the host computer. Flushing Buffer A representation of the operator panel when the printer is flushing a print job.
4085-001 Attendance Message Description Action 56 Std Parallel Port Disabled A representation of the operator panel when data is sent to the printer across a parallel port, but the parallel port is disabled. Press Go to clear the message. The printer discards any data received on the parallel port. Enable the parallel port. Once the error has been displayed for the first time, reporting of further errors is suppressed until the menus are entered, or the printer is reset.
4085-001 Attendance Message Description Action Load A representation of the operator panel when the indicated source is out of media. The input source is displayed on line 1 and could be one of the following: Sources equipped with both size-sensing and media-present hardware: Load Tray 1, Tray 2, MP Feeder. One of the following items is shown on line 2: In all cases, both the type and size are displayed on line 2.
4085-001 Attendance Message Description Action Load Manual A representation of the operator panel when the printer receives a request to manually feed paper or envelopes in the Manual Slot or MP Feeder. The request may have come through a print job or from the operator panel. If no media exists in the Manual Slot or MP Feeder, then manually feed a sheet. The printer automatically clears the message and continues the job. Load Manual One of the following items is shown on line 2.
4085-001 Attendance Message Load Manual Load Manual (CONTINUED) Description Action To request the printer to pick the sheet from an automatic source, press Select. Press Menu> or Menu> to access the Busy/ Waiting Menu group. The following functions may be available using the Busy/Waiting Menu group: -Cancel Job -Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting group.
4085-001 Attendance Message Description Action 31 Missing Cartridge XXXX A representation of the operator panel when the printer detects a missing ink cartridge. In this representation, XXXX is a placeholder for some combination of C,M,Y, and K. The missing ink cartridge(s) is identified in the XXXX string. Open the cover and insert an ink cartridge where an ink cartridge is missing.
4085-001 Attendance Message Description Action 31 Missing Printhead XXXX A representation of the operator panel when the printer detects a missing printhead. In this representation, XXXX is a placeholder for either: YMC,K or YMCK. The missing printhead(s) are identified in the XXXX string. Check printhead to carrier contacts. Open Cover 38 Memory Full Open the cover and replace the defective printhead.
4085-001 Paper Jams Multiple paper jam messages exist for this printer. Most paper jam messages have a unique error number. Each message also instructs the customer what action to take to resolve the jam or where in the printer to look to find the jammed paper. The following actions can be taken while this message is displayed: • Once all the jammed pages are cleared from the paper path, press Go to resume printing.
4085-001 204 Paper Jam (Printer Staging Sensor) Paper is jammed over the staging sensor. Open the cover and clear the jam. 205 Paper Jam (Printer Input Roller Sensor) Paper is jammed prior to the printer input roller sensor (PerfectFinish path). Open the cover and clear the jam. 206 Paper Jam (Fail to make Input Roller Sensor - Non PerfectFinish) Paper is jammed prior to the printer input roller sensor (non PerfectFinish path). Check Tray 2.
4085-001 250 Paper Jam (MPF) Paper was picked from the MPF but did not arrive at the input roller sensor. 251 Paper Jam (MPF) Paper was picked from the MPF but did not arrive at the input roller sensor.
4085-001 PerfectFinish Empty 87 PerfectFinish Empty The above is a representation of the operator panel when PerfectFinish empty occurs. This message indicates that the supply item must be replaced. The following actions can be taken while this message is displayed: • Press Go to clear the message and override the message. For • the rest of the current job, the printer prints without PerfectFinish. The message appears again at the beginning of every subsequent job until the empty condition is cleared.
4085-001 – Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. Note: If no function in the Busy/Waiting group is available, the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. Unsupported Ink Cartridge 32 Unsupported Cartridge XXXX The above is a representation of the operator panel when the top cover is closed and an unsupported ink cartridge is detected (for example, the software keys of the printer and ink cartridge do not match).
4085-001 Error Recovery from Attendance Conditions The following table indicates how the printer acts when each of the attendance/error conditions occurs. Attendance conditions can be categorized into these distinct groups: • Type 1 - When a Type 1 condition occurs during a job, the • • printer finishes printing all pages in the paper path. Furthermore, it may pick a few additional pages if they had already been committed to be printed.
4085-001 Error Recovery from Attendance Conditions Attendance Condition Error Type Auto Continue Available Sound Alarm (if Enabled) A Alignment Type 1 No No Cartridge Life Expired Type 1 No Yes Cartridge Life Warning Type 1 No Yes Change Type 1 No Yes Clean X? Go/Stop Type 1 No No Load Type 2 No Yes Type 2 No Yes Insert Duplex Pages & Press Go Type 1 No Yes Close Cover a N/A N/A N/A Open Cover Type 1 No No Check Tray x
4085-001 Attendance Condition Error Type Auto Continue Available Sound Alarm (if Enabled) 81 Engine Code CRC Failure Type 1 No Yes 87 PerfectFinish Empty Type 1 No Yes 88 Cartridge Low Type 1 Yes Yes (Ink Low Alarm) 89 Cartridge Empty Type 2 No Yes 200 Paper Jam Check Tray 1 Type 3 No Yes 201 Paper Jam Check Tray 1 203 Paper Jam Open Cover 204 Paper Jam Open Cover 205 Paper Jam Check Tray 1 206 Paper Jam Check Tray 2 207 Paper Jam Check Tray 2 208 Paper Jam Check
4085-001 Power-On Self Test (POST) Sequence 1. Turn on power switch. 2. The operator panel displays one row of rectangles followed by two rows of diamonds. 3. The printer indicator (green light) comes on. 4. “Performing Self Test” is displayed on the operator panel and then turns off. 5. The maintenance motor cycles and then stop. 6. The index motor cycles and then stops. 7. The printer indicator (green light) stays on. 8. Ready is displayed indicating that POST is complete.
4085-001 Post Symptom Table Symptom Action Blank display, carrier moves, paperfeed motor turns See the “Operator Panel (LCD) Display Service Check” on page 2-59 . All diamonds on display See the “Operator Panel (LCD) Display Service Check” on page 2-59 . Performing Self Test remains on display, no motors turn See the “Power Supply Service Check” on page 2-63 . Index motor does not turn See the “Index Motor Service Check” on page 2-56 .
4085-001 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 does not move to cartridge load position when opening access door • Carrier strikes left side frame. See page 2-48. Action See the “Transport Service Check” on page 2-67 . See the “Carrier System Test” on page 3-32 .
4085-001 Operator Panel Problems Symptom Action Printer indicator light does not: See the “Operator Panel (LCD) Display Service Check” on page 2-59 . • • • • Turn on Flash Turn off All diamonds One or two pels missing Replace the operator panel assembly. Only one button inoperative Replace the operator panel assembly. More than one button inoperative See the “Operator Panel (Buttons) Service Check” on page 2-58 .
4085-001 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 • Ink smearing • Vertical streaks on paper • Print lines crowded 2-52 Service Manual Action See the “Print Quality Service Check” on page 2-65 . See the “Paper Feed Service Check” on page 2-60 .
4085-001 Service Checks Maintenance Functions The maintenance station’s function is to maintain the printhead jetting over the life of the head. It also manages the waste ink used during the nozzle spitting maintenance routine. Most functional parts (except motor, pump and drivetrain) are mounted on a maintenance carrier that is driven front to back in the printer. This action is perpendicular to the printhead movement.
4085-001 Function Description Wet Wipe The maintenance station applies a cleaning solvent to the edge of the printhead that will be wiped across the entire bottom surface of the printhead. This will occur several time during the life of the printhead to facilitate the removal of ink debris. This solvent also serves to lubricate the wipers to reduce wear and prevent ink from drying on the wiper edge, which can reduce wiper efficiency.
4085-001 Maintenance Station Service Checks 1 FRU Action Maintenance Station Assembly The maintenance carrier is driven in a front to rear motion by the maintenance stepper motor. A homing sensor is provided at the rear of the maintenance station to home the maintenance carrier during power up. Engine code software controls the step count from the home position to the various positions the maintenance carrier must move to accomplish the various maintenance tasks on the printheads.
4085-001 Index Motor Service Check 1 FRU Action Index Motor Check the following motor pins for approximately 12.5 ohms: (J16-1) and (J16-2) If reading is incorrect, replace the index motor. See the “Index Motor Assembly Removal” on page 4-33 . 2 Gears Check the gears for proper alignment, chipped teeth, loose motor, missing gear clip or worn gears. 3 Sensor See “Index System Test” on page 3-33 .
4085-001 Multi-Purpose Feeder (MPF) Motor and Sensor Service Check 1. 2. 3. 4. Remove the rear cover from the printer. Remove the engine board cover. Install the multi-purpose feeder. Check for a voltage reading at connector (J10) pin 1 for approximately +36 V dc on the engine board. If the voltage is incorrect, replace the engine board. If the voltage is correct, go to step 5. 5. Remove the feeder from the printer. 6. Remove the left cover. 7.
4085-001 Operator Panel (Buttons) Service Check FRU Action 1 Operator Panel Assembly If any button fails the button test, replace the operator panel assembly. See “Button Test” on page 3-23 . 2 Engine Board With the operator panel connected to the engine board, be sure the voltage at (J4) pins 1, 2, 3 and 5 measures +5 V dc. If the voltage is incorrect, replace the engine board. If the voltage is correct, check the continuity of the operator panel cable.
4085-001 Operator Panel (LCD) Display Service Check Note: Be sure the operator cable is properly installed at the engine board (J4) and at the operator panel. Check the continuity of the cable and replace if necessary. • Operator panel display blank - printer indicator light Off, paper • feed motor turns, carrier moves. Operator panel display blank - printer indicator light On.
4085-001 Paper Feed Service Check Note: Be sure the printer is unplugged from the AC outlet before performing this service check. If you are experiencing a paper jam: 1. Check the 200 error code paper jams. See “Paper Jams” on page 2-40 . 2. Check the entire paper path for obstructions. 3. Be sure the input tray contains not more than 150 sheets of paper and the manual tray not more than 100. 4. Be sure the correct type of paper is being used. 5. Check for static in the paper. 6.
4085-001 Paper feed pick assembly does not feed, paper feed pick 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 FRU Action 1 Power Supply Check the power supply. See the “Power Supply Service Check” on page 2-63 . If the power supply voltage is incorrect, replace the power supply.
4085-001 5 FRU Action RIP Card Cable Check the continuity of the RIP card cable. If incorrect, replace the cable. If correct, replace the RIP card.
4085-001 3 FRU Action Paper Feed Pick Motor With the power on, check for the following readings: (J3) pin 3 to ground = 5 V dc (J3) pin 6 to ground = 35 V dc (J3) pin 7 to ground = 35 V dc (J3) pin 10 to ground = 5 V dc If voltage is incorrect, replace tray 2 card. If voltage is correct, disconnect (J3). Check between 6 and 7 on the connector for approximately 11.8 ohms. If reading is incorrect, replace the paper feed pick motor assembly.
4085-001 FRU Action 2 Power Line Cord Check the power line cord for damage. Check the continuity of the line cord and replace if necessary. 3 Power Switch Check the continuity on the power switch. If incorrect, replace the power switch. 4 Power Supply With the power switch turned on, verify the voltage readings at RIP card connector (J1) and engine board connector (J1). The RIP card voltage at J1-1 and J1-2 should be approximately +5 V dc at each pin.
4085-001 Print Quality Service Check Note: Before troubleshooting any print quality problem, be sure the cartridge is in good condition. Set print quality to normal and be sure the correct paper type is selected in the Paper Menu. FRU Action The machine print quality can look poor as a result of either faulty printheads or poor carrier to printhead electrical contact. Generally random missing nozzles indicate a printhead failure.
4085-001 4 FRU Action Engine Board If the missing nozzles are patterned, the problem could be the engine board or carrier card. First try replacing the engine board, then the carrier card. Carrier Card 5 Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: • • • • • • 6 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.
4085-001 Index Card/Sensor Service Check FRU Action 1 Index motor does not work. If the index motor does not work, see “Index Motor Service Check” on page 2-56 . If the index motor is working correctly see “Index System Test” on page 3-33 . If the test fails, replace the index/ encoder disk assembly. See “Encoder Disk Feed Roller Assembly Removal” on page 4-34 . 2 Index Sensor To check the sensor, see the “Index System Test” on page 3-33 .
4085-001 5 FRU Action Carrier Belt Check for worn, loose or broken parts. Check for obstructions blocking carrier movement. Idler Pulley Parts Carrier Frame 6 Encoder Strip Check the encoder strip for wear, dirt, and grease. See the “Carrier System Test” on page 3-32 . 7 Printhead Cable Be sure all connectors are fully seated. Check the cables for damage. 8 Maintenance Station A problem with the maintenance station can cause carrier movement problems at the right margin.
4085-001 Cam System Motor/Sensor Service Check 1 FRU Action Motor does not work. Bat Wings do not move. Check the voltage at connector (J8) on the engine board. At pins 1, 2, 3, and 4 with the power on. There should be approximately +34 V dc on each pin to ground. If the voltage is incorrect, replace the engine board. If the voltage is correct, disconnect (J8) and check between pins 2 and 4 on the connector for approximately 7.5 ohms.
4085-001 Message Explanation 38 Memory Full 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.
4085-001 Message Explanation 54 Parallel Error An IEEE 1284 protocol error is 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.
4085-001 Message Explanation 56 Parallel Port Disabled Once the error has been displayed for 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.
4085-001 3. Diagnostic Aids Printer Operations Operations Initiated by Pressing Buttons at Power-On Reset The table below contains a list of the printer operations that are activated by pressing a sequence of buttons while powering on the printer. Power-On Reset Button Functions Function POR Key Sequence Enter Configuration Menu Select and Return Disable/Enable Panel Menus Go and Stop Note: POR key sequence gains entry to Configuration Menu from which setting may be modified.
4085-001 Disable/Enable Operator Panel Menus To prevent users from accessing the Ready Menu group and modifying default printer settings, follow these steps: Note: These steps do not prevent access to the Busy Menu group and the Diagnostics Menu group. 1. Turn off the printer. 2. Press and hold the buttons identified in the “Power-On Reset Button Functions” on page 3-1 to gain access to the Configuration Menu Group. 3. Turn on the printer.
4085-001 Use the following steps to access the Diagnostics printer settings and operations. 1. Turn off the printer. 2. Press and hold the buttons identified in “Power-On Reset Button Functions” on page 3-1. 3. Turn on the printer. Release the buttons once the Performing Self Test message is displayed. Clear NVRAM (non-critical sections only) This operation restores factory default values for most printer settings. Warning: Extreme caution should be used when using this operation as it cannot be undone.
4085-001 Use the following steps to enter Flash Engine Code mode: 1. Turn off the printer. 2. Press and hold the buttons identified by the “Power-On Reset Button Functions” on page 3-1. 3. Turn on the printer. Release the buttons once the performing self Test message is displayed. 4. Begin programming the Engine code when the Invalid Engine Code message is displayed. Change Ink Cartridges When the cover is opened, the carrier moves to the far left.
4085-001 If an unsupported printhead is installed, an Attendance Message is shown. This can occur if the software keys in the printer and printhead are incompatible, as in the case of an OEM printer using Lexmark-branded printheads. Following a printhead replacement, the printer automatically initiates an alignment procedure. Aligning the Printheads User Alignment The printheads come from the factory pre-aligned and do not need to be aligned.
4085-001 Alignment Page Fixed Settings (User Alignment and Coarse Alignment) Printer Setting Value Used for Menus Page Separator Sheets None Orientation Portrait Paper Source If the User Default Paper Source contains letter, legal, or A4, the alignment page is printed from the User Default Paper Source. If not, another source is automatically chosen.
4085-001 Cleaning Printheads The Clean Printheads operation is used to clean and maintain the printheads. This mechanical operation performed by the print engine is recommended when print quality becomes degraded. There are two classes of cleaning that can be performed: • Short Clean is a “spit and wipe” cycle followed by a Print Quality test page. Short Clean should be used first.
4085-001 Print Quality Test Page Fixed Settings Printer Setting Value Used for Menus Page Separator Sheets None Orientation Portrait Paper Source If the User Default Paper Source contains letter, legal, or A4, the alignment page is printed from the User Default Paper Source. If not, another source is automatically chosen. Paper Size If the User Default Paper Source contains letter, legal or A4, the alignment page is printed on the User Default Paper Source’s installed size.
4085-001 Input tray linking description: • Input sources which contain the same paper size, custom • string, and paper type are linked automatically. Tray linking is always active. To prevent sources with the same media from being linked, the user must set the corresponding paper type settings to different values. PerfectFinish capability affects the ability of trays to link.
4085-001 Unsolicited Manual Feed When configured without a MP Feeder, a user may perform an unsolicited manual feed. Prior to sending a job (or before the first page of the job is picked), a user sticks a piece of paper in the manual slot. The engine “grabs” the paper and pulls it into the nip. The engine waits for the RIP to submit the print page. Regardless of which source the RIP requests for that page, it prints on the page that was inserted.
4085-001 Control Panel code level, Font ROM Version, and SRAM availability. • The RIP code level is appended with “:F” or “:R” to indicate whether the board is running code from flash (re programmable) or ROM (not re programmable). This may be useful for product engineers or Customer Support. • Miscellaneous supplies information that can be used by the Customer Support Center.
4085-001 TSC fields on the Print Menus Page The following fields are on the Print Menus page under the “Printer Information” heading. The fields are intended to aide the TSC or a CE in diagnosing problems. Field Definition TS1 Concatenation of C,M,Y, and K ink levels. TS2 Concatenation of C, M, Y, and K PH life remaining. E1 Concatenation of C, M, Y, and K expiration dates in mmyy format. R1 Concatenation of C, M, Y, and K tanks (0 indicates non-refilled, 1 indicates refilled.
4085-001 When each sheet is printed and the engine has placed the sheet in a printer bin, the print engine sends a “Print Complete” signal to the printer controller to indicate the associated sheet is complete. However, since most printer bins are not equipped with sensors to detect when a sheet has arrived in a bin, many printers use an existing sensor in the printer’s paper path located closest to the selected bin as a trigger for this signal.
4085-001 – If the host computer stops sending data without ending the canceled job, the printer initiates a timer which stops the canceled job. (For PCL emulation, the printer uses the Flushing timer value.) Note: If the host computer resumes sending data which belongs to a canceled job, then the timer value used to stop the job is reset and the printer resumes looking for a data stream command which indicates the job has ended.
4085-001 Warning: Use care when invoking this function. Other print jobs buffered in the printer may also be fully or partially lost! Note: Before performing a operator panel reset, instruct the host application to stop sending printer data. The reset printer function is in the operator panel JOB MENU. This menu is available in both the Ready Menu Group and the Busy/ Waiting Menu Group. Note: Some operations are restricted at certain times in the Busy/ Waiting Menu Group.
4085-001 Invoking Reset Printer (from the Ready message) 1. Press Menu> or Menu< to enter the menus. The following screen is displayed. SUPPLIES MENU 2. Press Menu> or Menu< until JOB MENU is displayed on the second line. Press Select. The following screen is displayed. JOB MENU Reset Printer 3. Press Select. The printer automatically exits the operator panel menus and performs the reset operation. As the operation is performed, the Resetting the Printer message appears.
4085-001 Other Resets Power On Reset -- and similar resets When the printer is turned on, the following events occur: • Fixed default settings are set to factory set values. • Portions of printer memory that store page, font, and macro information are cleared. Other resets which cause similar events: • NPA Cold Start (Front Panel, 01 or 03). • INA Hard Reset For these resets, currently active pages are discarded and emulators are reset.
4085-001 NPA Response Any reset conditions that cause the loss of resources or a change in emulation requires an NPA response to inform the host computer. See separate specifications on NPA implementation. NPA responses are only given if NPA bidirectional communication is active in the printer. Loss of Link Data and Link Response An operator panel reset is the only reset condition which causes the loss of link data.
4085-001 3. Press Select. The printer automatically exits the operator panel menus and prints the partial page. Note: If the Print Buffer operation is selected while the printer is not in the Waiting state, the printer automatically exits the operator panel menus, but no page is printed. Note: The system administrator can disable the Print Buffer function by turning the Print Buffer Control setting Off. Print Buffer is not displayed when Print Buffer Control is set to Off.
4085-001 The Registration menu is formatted so that all menu items fit on a single screen as shown. This allows manufacturing to quickly set and verify the registration setting. Tray 1 T= sxx* L= sxx* Terminology: • T represents Top Margin and L represents Left Margin. • s represents the sign for negative values. This space is blank for • • positive values. xx represents the margin value. An asterisk (*) is displayed next to the default value.
4085-001 The content of the Print Test page varies depending on the media installed in the selected input source. If a source is selected that contains paper (that is, letter, legal, and so on), then a page similar to the Quick Test page is printed. However, it does not contain the Print Registration diamonds. If a source is selected which contains envelopes, then an Envelope Print Test pattern is printed.
4085-001 Contacts Page Print Test This test prints the Contacts Page, which can be used by the Customer Support Center or CE to diagnose problems involving printheads, printhead cables, pogo pins, or electrical interfaces between the printheads and the carrier.
4085-001 Button Test The Button Test verifies the operation of each button on the operator panel. When Button Test is selected, the following screen is displayed. OP OP OP OP OP OP While a button is pressed, CL (Closed) is displayed. Likewise, while a button is not pressed, OP (Open) is displayed. If the wrong message is displayed, then the button is malfunctioning. To exit the button test, press Return or Stop. The previous menu screen will be displayed when the button is released.
4085-001 The power indicator blinks indicating the memory test is in process. The printer continually runs the same test until canceled from the operator panel (by pressing Return or Stop). Each time the test finishes, the screen is updated with the result. If the test passes, the Pass Count is incremented by 1. However, if the test fails, a failure message is displayed for approximately 3 seconds and the Fail Count is incremented by 1.
4085-001 Each time the test finishes, the screen is updated with the result. If the test passes, the Pass Count is incremented by 1. However, if the test fails, one of the following failure messages is displayed for approximately 3 seconds and the Fail Count is incremented by 1: • ROM Checksum Error • ROM Burst Read Error Once the maximum pass count or fail count is reached, the test is stopped and the final test results are displayed. Press Return or Stop to exit the test.
4085-001 The power indicator blinks indicating the test is in process. The printer continually runs the same test until canceled from the operator panel (by pressing Return or Stop). Each time the test finishes, the screen is updated with the result. If the test passes, the Pass Count is incremented by 1. However, if the test fails, one of the following failure messages is displayed for approximately 3 seconds and the Fail Count is incremented by 1.
4085-001 Diagnostics (Mode 2) - Input Tray Tests Tray 1 Sensor Test This test determines whether or not the Tray 1 input sensor is working correctly. To run the test, select Tray 1 from the INPUT TRAY TESTS menu. The following screen is displayed: Tray 1 PO=OP Terminology: • PO or Paper Out refers to the empty sensor. Once this screen is displayed, the sensor can be manually actuated. When the sensor is closed, CL is displayed. When the sensor is open, OP is displayed.
4085-001 sensor is open, OP is displayed. If the wrong message is displayed, the sensor is malfunctioning. PO=OP = Empty PO=CL = Not Empty PT=OP = Media Clear PT=CL = Media Present To exit the test, select Return or Stop. MP Feeder Sensor Test This test determines whether or not the MP Feeder input sensor is working correctly. To run the test, select MP Feeder from the INPUT TRAY TESTS menu. The following screen is displayed: MP Feeder PO=OP Terminology: • PO or Paper Out refers to the empty sensor.
4085-001 Diagnostics (Mode 2) - Base Sensor Tests Paper Path Sensors This test determines if a group of sensors related to the paper path are working correctly. To run the test, select Paper Path Sensors from the BASE SENSOR TESTS menu. The following screen is displayed: Paper Path TC=C IS=C CO=C Terminology: • TC refers to the PerfectFinish path pass-through sensor. • IS or Input Sensor refers to the input (grit roll) sensor. • CO or Cover Open refers to the cover open sensor.
4085-001 Terminology: • TP refers to the PerfectFinish tank presence sensor. • TF refers to the PerfectFinish fluid level sensor state. Once this screen is displayed, the sensor can be manually actuated. When the sensor is closed, C is displayed. When the sensor is open, O is displayed. If the wrong message is displayed, the sensor is malfunctioning. TP=O = Tank Missing TP=C = Tank Present TF=O = Cartridge Full TF=C = Not Full To exit the test, select Return or Stop.
4085-001 Ink Level Sensor Test This test determines if the ink level sensor is working correctly. To run the test, select Ink Level Sensor Test from the BASE SENSOR TESTS menu. The following screen is displayed: Ink Level Sensor Test Level = - 602 First the printheads are uncapped. The printheads move to the middle of the frame so that the servicer has unobstructed access to the ink-level sensor. Once the printheads have been presented, the analog ink-level sensor value begins updating in real time.
4085-001 After capping, this test automatically exits. Carrier System Test This test determines if the carrier system sensor is working correctly. To run the test, select Carrier System Test from the SUBSYSTEM TESTS menu. The following screen is displayed: Carrier System Test Position = 1050 Once the test is initiated, the printhheads are uncapped and the carrier attempts an “open-loop” safe move to the middle of the printer without use of any feedback signals from the encoder strip.
4085-001 Index System Test This test determines if the index system sensor is working correctly. To run the test, select Index System Test from the SUBSYSTEM TESTS menu. The following screen is displayed: Index System Test Position = 823 The index system is run open loop and the real time position count is displayed on the panel. To exit the test, select Return or Stop. Maintenance Sled Test This test determines if the maintenance sled sensor system is properly functioning.
4085-001 Diagnostics (Mode 2) - Supplies Tests For each of the following four tests, the sequence of events is the same: 1. The printheads are uncapped when the test is invoked. 2. The printheads moves to the middle of the frame to give the servicer access to the printheads and tanks under test. The data corresponding to the test being run begins updating real time on the panel as described. 3. When the test is ended by pressing Return or Stop, the carrier is homed and the printheads are capped.
4085-001 K&C TSR Test This test determines the status of the printhead TSR (thermal sense resistor). The resistance is displayed real time. The following screen is displayed: K & C TSR Test K=104B3 C=104A1 To exit the test, select Return or Stop. Note: If zero is displayed on “K”= or “C”=, replace the printhead. M&Y TSR Test This to determines the status of the printhead TSR (thermal sense resistor). The resistance is displayed real time.
4085-001 The left-most digit (‘1’ in this example) blinks, indicating it is the first digit to be changed. To change the value, press either Menu> or Menu< until the value you want is displayed. Press Select to move to the next digit. The next digit (‘2’ in this example) blinks. Continue modifying each digit using this method. To skip a digit (that is, and keep its current value), press Select. When Select is pressed after the final digit (‘7’ in this example), the new page count is stored in NVRAM.
4085-001 To reset the maintenance page counter, the user selects “Reset Maint Cnt.” Pressing Select causes the maintenance page counter to be reset back to zero. The following screen is displayed momentarily to indicate the counter is changing. Reset Maint Cnt SAVED When the reset operation is complete, the printer returns to the “PRINTER SETUP Reset Maint Cnt” screen. Diagnostics (Mode 2) - Error Log Viewing the Error Log The Error Log aids the Customer Engineer by providing a history of printer errors.
4085-001 forward in the log, press Menu>. To move backward in the log, press Menu<. Here is an example of the error log screens: 1-200 2-920 3-928 4-922 5-250 6-990 7-230 8-230 9-953 10-000 11-000 12-000 To exit the error log, press Return or Stop. Clearing the Error Log To clear the error log, select the Clear Log operation from the ERROR LOG menu. The following message is displayed. Clear Log =Yes Select Yes to confirm that you really want to clear the log.
4085-001 Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal user mode, press Exit Diagnostics. Menus This section describes the printer settings and operations that are accessible using the operator panel. In addition, it describes the format of the display and the operation of the buttons while the menus are active. See “Using the Operator Panel” on page 1-4 for an illustration of the operator panel and a description of the buttons and indicator lights.
4085-001 The buttons always act on the information displayed on the second line of the display. The buttons act as follows while the PAPER MENU screen is displayed: • Menu> displays the next menu in the list. • Menu< displays the previous menu in the list. • Return returns to the previous menu level displayed on line 1. • Since there is no previous level in this case (that is, line 1 is blank), pressing this button exits the menus and returns the printer to its previous state.
4085-001 Printer Setting Value List Display Paper Source =Tray 1* After a specific printer setting is selected (Paper Source in this example), the active printer setting is displayed on the first line and the default value (Tray 1) is displayed on the second line. An equal sign indicates it is assigned to the printer setting. An asterisk is displayed next to the currently selected or default value. The buttons always act on the information displayed on the second line of the display.
4085-001 Example of Modifying a Printer Setting Using the Operator Panel Use the following to modify any printer setting or initiate any operation in the Busy/Waiting Menu Group, Ready Menu Group, or Diagnostic Menu Group. The only variation is the action required to access the Diagnostics Menu Group (see “Entering CE Diagnostics Mode” on page 3-2 for details). To change the PCL Orientation setting in the Ready Menu Group: 1. Press Menu> when the Ready message is displayed to access the Ready Menu Group.
4085-001 sign precedes each value, indicating the entry on line 1 is a printer setting and it can be assigned to the value on line 2. Print Quality =Normal* 4. Press Menu> or Menu< repeatedly until the value that you want to select is displayed on the second line, then press Select. (Printer settings with a numeric value list let you scroll through the setting’s value list by pressing and holding Menu> or Menu<.
4085-001 Operator Panel Menu Definition The operator panel settings and operations are divided into 4 menus groups, which are described in the following table. Menu Groups Busy/Waiting Menu Group The Busy/Waiting menu group contains the operations that are accessible when the printer is receiving or processing data, waiting for additional data, or actually printing a job. One or more operations in this menu group may also be accessible with some error conditions or with certain status messages.
4085-001 Configuration Menu Group The Configuration menu group contains a set of menus, settings, and operations which are infrequently required by a user. Generally, the options made available in this menu group are used to configure a printer for operation. Use the Select and Return POR key sequence to access this menu. For additional information, see “Configuration Menu Group” on page 3-60. Diagnostic Menu Group Note: The Diagnostics Menu group should not be documented in any end-user documentation.
4085-001 Job Menu Job Menu Operations Operation Value or Description Cancel Job No selection exists for this operation. Press Select to initiate the cancel print job function. For additional information, see“Canceling a Print Job using the Operator Panel” on page 3-12. Note: This operation is only displayed in the JOB MENU when the menu is accessed through the Busy/Waiting Menu Group if Cancel Control is ON. (If a job is active, then the printer checks the value selected by the job.
4085-001 Job Menu Operations Operation Value or Description Reset Printer No selection exists for this operation. Press Select to initiate the reset function. For additional information, see “Resetting the Printer using the Operator Panel” on page 3-14. Note: This operation is only displayed in the JOB MENU when the menu is accessed through the Busy/Waiting Menu Group if Reset Control is On. (If a job is active, then the printer checks the value selected by the job.
4085-001 If no function is available in the JOB MENU at the time the JOB MENU is accessed, the printer prohibits entry into the JOB MENU, and the key press used to gain entry into the JOB MENU is ignored. To provide the user with some feedback, the Menus Disabled message is shown.
4085-001 Top-Level Menu Intermediate Menu, Setting, or Operation JOB MENU See “JOB MENU” on page 3-54 for a list of the operations. SETUP MENU See “SETUP MENU” on page 3-54 for a list of the menus or settings. PCL EMUL MENU See “PCL EMUL MENU” on page 3-56 for a list of the menus or settings. PARALLEL MENU See “PARALLEL MENU” on page 3-58 for a list of the menus or settings. USB MENU See “USB MENU” on page 3-59 for a list of the menus or settings.
4085-001 Intermediate Menu or Setting Value Yellow Cartridge =Low =Refilled =Life Warning Black Printhead =Life Warning Color Printhead =Life Warning PerfectFinish =Empty Tray 1 =Empty Tray 2 =Empty COLOR MENU The following table lists the settings in the COLOR MENU and their corresponding value choices. The factory default setting for each item is indicated with an asterisk.
4085-001 PAPER MENU The following table lists the menus and settings in the PAPER MENU, and their corresponding values. The factory default value for each setting is indicated with an asterisk. Intermediate Menu or Setting Value Paper Source =Tray 1* =Tray 2 =MP Feeder =Manual Paper =Manual Env If the Paper Source, Separator Source, or Staple Prime Source is set to MP Feeder when Configure MP is changed to Manual or First, then the setting is changed to Tray 1.
4085-001 Intermediate Menu or Setting Value Separator Sheets =None* =Between Jobs =Between Pages Separator Source Note: Only installed paper sources are displayed. MP Feeder is only displayed when Configure MP is set to Cassette. =Tray 1* =Tray 2 =MP Feeder UTILITIES MENU The following table lists the operations in the TESTS MENU. For a detailed description of each operation, see “Printer Operations” on page 3-1.
4085-001 Operation Value Print Menus No selections exist for this operation. Press Select to initiate this operation. See “Printing Menu Settings Page” on page 3-10. Align Printheads No selections exist for this operation. Press Select to initiate this operation. See “Aligning the Printheads” on page 3-5. After the alignment page is printed, the user enters alignment values for each of the sections of the alignment page. • A Alignment • B Alignment • C Alignment =1...
4085-001 Operation Value Factory Defaults See “Restoring Factory Defaults” on page 3-12. =Restore =Do Not Restore Hex Trace No selections exist for this operation. Press Select to initiate this operation. See “Activating Hex Trace Debug Mode” on page 3-19. JOB MENU The following table lists the operations in the JOB MENU. Operation Value Reset Printer Printer For information regarding this operation, see “Job Menu” on page 3-46.
4085-001 Setting or Operation Value Display Language Default set by country Note: Languages in this value list are only displayed if the printer’s operator panel ROM supports the required encoding for the specific language.
4085-001 Setting or Operation Value Ink Low Alarm =Off =Single* =Continuous Dry Time Delay =Disabled* =Auto =3...30 PCL EMUL MENU The following table lists the menus and settings in the PCL EMUL MENU, and their corresponding values. The factory default value for each setting is indicated by an asterisk. Note: Saving Font Source, Font Name, Point Size, Pitch, or Symbol Set has the affect of saving the selected font as the default.
4085-001 Intermediate Menu or Setting Value Orientation =Portrait* =Landscape Lines per Page =1... 255 (US=60* / NonUS=64*) Auto CR after LF =Off* =On Auto LF after CR =Off* =On Font Name Display Format The font names are shown on both lines of the operator panel using the following format. =S##### ThisIsTheFontName* An equal sign precedes the font name, signifying the value list level of the menus.
4085-001 Symbol Set Display Format The symbol sets are shown on both lines of the operator panel using the following format. =SSID ThisIsSymbolSetName An equal sign precedes the symbol set ID, signifying the value list level of the menus. SSID represents the symbol set ID (that is, 8U for Roman-8 symbol set). PARALLEL MENU The following table lists the menu and settings in the parallel port menus and their corresponding values. The factory default value for each setting is indicated by an asterisk.
4085-001 Setting Value Parallel Mode 1 =Off* Note: Only displayed when the associated Parallel Port supports this feature. =On Parallel Mode 2 =Off Note: Only displayed when the associated Parallel Port supports this feature. =On* a Whenever the value of NPA Mode, Parallel Buffer, or Job Buffering is changed from the operator panel, the printer automatically restarts upon exiting the menus to reconfigure memory.
4085-001 Configuration Menu Group The Configuration Menu group contains a set of menus, settings and operations which are infrequently required by a user. Generally, the options made available in this menu group are used to configure a printer for operation. Each option is displayed on the operator panel in the order shown. The names of the top-level menus are capitalized. For a detailed description of each operation, follow the reference contained in the following table.
4085-001 Intermediate Menu, Setting or Operation Coarse Alignment Value No selections exist for this operation. Press Select to initiate this operation. See “Aligning the Printheads” on page 3-5. After the alignment page is printed, the user enters alignment values for each of the sections of the alignment page. -D =1...15 (8*) -E =1...27 (13*) Enable PHCE Mode =Disable* =Enable Exit Config Menu No selections exist for this operation. Press Select to exit the CON-FIG MENU and restart the printer.
4085-001 Diagnostics Menu Group (Mode 1: Printing) The Diagnostics Menu group contains multiple menus. They are displayed on the operator panel in the order shown. The names of the top-level menus are capitalized. For a detailed description of each Diagnostic test, follow the reference contained in the following table. Note: Access is gained into the Diagnostics Menu Group (Mode 1) using the Go and Return POR key sequence. For additional information, see “Printer Operations” on page 3-1.
4085-001 Top-Level Menu Intermediate Menu, Setting, or Operation Value Tray 1 =Single PRINT TESTS =Continuous Tray 2 =Single Only displayed if Tray 2 is installed. =Continuous MP Feeder =Single Note: Only displayed if the printer is configured with a MultiPurpose Feeder =Continuous Prt Contacts Pg See “Contacts Page Print Test” on page 3-22. EXIT DIAGNOSTICS See “Exiting Diagnostics Mode” on page 3-39.
4085-001 Note: While the Diagnostic Menu Group is active, all host interfaces are offline. Top-Level Menu Intermediate Menu, Setting, or Operation Value INPUT TRAY TESTS Tray 1 See “Tray 1 Sensor Test” on page 3-27. Tray 2 See “Tray 2 Sensor Test” on page 3-27. MP Feeder See “MP Feeder Sensor Test” on page 3-28. LCD Test See “LCD Hardware Test” on page 3-22. Button Test See “Button Test” on page 3-23. DRAM Memory Test See “DRAM Memory Test” on page 3-23.
4085-001 Top-Level Menu Intermediate Menu, Setting, or Operation Value SUBSYSTEM TESTS Uncap Printheads See “Uncap Printheads” on page 3-31. Cap Printheads See “Cap Printheads” on page 3-31. Carrier System Test See “Carrier System Test” on page 3-32. Index System Test See “Index System Test” on page 3-33. Maintenance Sled Test See “Maintenance Sled Test” on page 3-33. Ink Tank Memories See “Ink Tank Memories” on page 3-34. Printhead Memories See “Printhead Memories” on page 3-34.
4085-001 Top-Level Menu Intermediate Menu, Setting, or Operation Value ERROR LOG Display Log See “Viewing the Error Log” on page 3-37. Clear Log See “Clearing the Error Log” on page 3-38. =Yes =No EXIT DIAGNOSTICS See “Exiting Diagnostics Mode” on page 3-39.
4085-001 4. Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. CAUTION: Read the following before handling electronic parts. When working on the printer, always unplug the printer from the electrical outlet. High voltage is present in the power supply as long as it is plugged into the electrical outlet. Handling ESD-Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).
4085-001 Adjustments The user is directed, in the Printer Control program, to perform the printhead to printhead and bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. CAUTION: Unplug the power cord before removing any parts. Releasing Plastic Latches Many of the parts are held in place with plastic latches. The latches break easily; release them carefully.
4085-001 Rear Cover Removal 1. 2. 3. 4. 5. 6. Open the rear door. Remove Multi-Purpose Feeder. Remove two clips and remove the top door. Remove the four screws {A}. Depress the four latches {B}. Remove the rear cover.
4085-001 4-4 Service Manual
4085-001 Operator Panel Cover/Operator Panel Removal 1. Remove the rear cover. 2. Remove the screw {A}. 3. Lift the cover and unplug the operator panel from the engine board. 4. Remove the four screws located on the rear operator panel housing. 5. Remove the operator panel. Exit Tray Removal 1. Remove the paper tray. 2. Depress the latch on the bottom of the tray. 3. Lift the front of the exit tray and pull forward to remove. Note: Use care not to damage the bat wings.
4085-001 Left Frame Cover Removal 1. Open the top door. 2. The restraint screw does not have to be removed. The restraint has a T-end which can be twisted and removed. Partially close the top cover, twist the end of the strap that is in the machine and remove. 3. Remove the two screw {A} from the left frame cover. 4. Remove the cover.
4085-001 Left Cover Removal 1. 2. 3. 4. 5. Remove the rear cover. Remove the exit tray cover. Move carrier to the right. Remove the screw {A} from the left side of the carrier frame. Remove the two screws {B} from the left front side of the paper tray frame. 6. Remove the cover. Note: When reinstalling, reinsert cover guides before installing the screws. Cover guides are located on the bottom edge of the cover.
4085-001 4-8 Service Manual
4085-001 Right Cover/Power Switch Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the exit tray. Refer to “Exit Tray Removal” on page 4-5. 3. Remove the operator panel cover. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5. 4. Move the carrier to the left. 5. Disconnect the power switch from the power supply. Note the wire routing. 6. Remove two screws {A} from the right carrier frame. 7.
4085-001 4-10 Service Manual
4085-001 Left Tray Cover Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5. 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7. 4. Remove the three screws {A} that secure the left tray cover. 5. Remove the left tray cover.
4085-001 Right Tray Cover Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5. 3. Remove the right cover. Refer to “Right Cover/Power Switch Removal” on page 4-9. 4. Remove the three screws {A} that secure the right tray cover. 5. Remove the right tray cover.
4085-001 Ink Levels and Temperature Sensor with Bracket Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the operator panel cover. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5. 3. Disconnect the ink level and temperature sensor connector (J12) on the engine board. Note the wire routing. 4. Remove the right cover. 5. Remove the screw {A} from the sensor bracket. 6. Remove the sensor and bracket {B}.
4085-001 Engine Board /Cover Removal 1. Remove the rear cover. 2. Remove left frame cover. Refer to “Left Frame Cover Removal” on page 4-6. 3. Remove the two screws {A} from the engine board cover and the cover. 4. Disconnect all connectors and cables from the engine board. 5. Remove the four screws and remove the engine board. Note the routing of the ground cable.
4085-001 Carrier with Card Removal 1. Remove all covers. 2. Remove all ink cartridges from carrier. 3. Remove engine board cover. Refer to “Tray 2 Covers Removal” on page 4-49. 4. Loosen the set screw {A} on the belt tensioner. 5. Remove the tension from the belt and retighten the set screw. 6. Remove the belt keepers from the ends of the belt {B}. The open end of the keepers should face the rear of the carrier. 7. Remove the belt. 8.
4085-001 4-16 Service Manual
4085-001 Carrier 1st Stage Drive Belt Removal 1. Remove the motor bracket from the printer frame. 2. Loosen the three screws securing the motor plate to the motor assembly. 3. Gently depress the motor so that the 1st stage drive belt is loosened. Retighten the three screws to fix this position. 4. Remove the original belt and install the new belt. 5. Loosen the three screws to allow the motor bracket to apply proper belt tension.
4085-001 4-18 Service Manual
4085-001 Power Supply Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Disconnect all power supply cables, and ground straps. Note routing of the cables and straps. 3. Remove the three mounting screws {A} that attach the power supply to the frame. 4. Remove the power supply.
4085-001 Pump Housing/Maintenance Station/Ink Waste Tank/ Transport Carrier Motor Removal 1. Remove all covers. 2. Remove the power supply. Refer to “Power Supply Removal” on page 4-19. 3. Slide the ink waste tank out the rear of the printer. Note the routing of the hose into tank. 4. Remove the carrier belt. Refer to “Engine Board /Cover Removal” on page 4-14. 5. Disconnect transport carrier motor cable from engine board. 6. Remove three screws {A} from the transport carrier motor bracket. 7.
4085-001 Repair Information 4-21
4085-001 Index Card Assembly Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5. 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7. 4. Unplug the index board connector. 5. Remove the three screws {A} from the index board. 6. Remove the index card. Note: The index card and the encoder disk feed roller must be replaced as a matching set.
4085-001 Cover-Open Sensor Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5. 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7. 4. Remove the engine card cover. 5. Unplug the cover-open sensor (J18) connector. 6. Depress two latches and remove the cover-open sensor.
4085-001 RIP-EMC Shield Assembly/RIP Card Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the power supply. Refer to “Power Supply Removal” on page 4-19. 3. Disconnect (J14) RIP cable from the engine board. 4. Remove the six screws {A} from the RIP card. 5. Remove the RIP card. Note routing of cable. 6. Remove the six screws {B} from the shield assembly. 7. Remove the shield assembly. Note: Anytime the RIP card is replaced, a course alignment has to be done.
4085-001 Repair Information 4-25
4085-001 PerfectFinish Sensor Assembly/Rear Paper Path Sensor Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the power supply. Refer to “Power Supply Removal” on page 4-19. 3. Remove the RIP-EMC shield assembly and RIP card. Refer to “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24. 4. Disconnect the wire from the PerfectFinish sensor. 5. Remove two screws from the PerfectFinish sensor. 6. Remove the PerfectFinish sensor. 7. Remove the PerfectFinish tank. 8.
4085-001 Frame From Base Removal 1. Remove all covers. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the power supply. Refer to “Power Supply Removal” on page 4-19. 3. Remove the maintenance tank through the rear of the printer. 4. Disconnect (J2) the transport carrier motor from the engine board. 5. Disconnect (J17) the paper port II from the engine board. 6. Disconnect the star wheel follower spring {A} from the base assembly. 7. Remove the four screws {B} from the left side frame plate. 8.
4085-001 4-28 Service Manual
4085-001 Cam Engine Motor with Gear Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5. 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7. 4. Disconnect the cam engine motor connector (J8) from the engine board. 5. Remove the two screws {A} from the motor. 6. Remove the motor through the front of the printer. Note the routing of the wires.
4085-001 4-30 Service Manual
4085-001 Paper Feed Pick Arm Assembly with Motor and Paper Path Sensor Removal 1. Remove all covers. 2. Remove power supply. Refer to “Power Supply Removal” on page 4-19. 3. Remove the frame from the base. Refer to “Frame From Base Removal” on page 4-27. 4. Remove the two lower screws on the base of the RIP shield. 5. Disconnect the integrated tray connector (J6) from the engine board and disconnect the paper path sensor. 6. Remove the E-clip {A} from the pick assembly shaft. 7.
4085-001 PerfectFinish Gear Plate Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove E-clips {A} from bellcrank diverter link and remove link. 3. Remove helical drive gear {B} and cartridge drive gear under it. Note the position of the cartridge drive gear under the helical drive gear. 4. Remove three screws and remove plate.
4085-001 PerfectFinish Motor Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Disconnect the PerfectFinish motor and encoder connector (J5) from the engine board. 3. Remove the two screws {A} from the motor. 4. Remove the motor. Note routing of wiring. Index Motor Assembly Removal 1. Remove rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove engine board cover. Refer to “Tray 2 Covers Removal” on page 4-49. 3. Disconnect (J16) from the engine board. 4.
4085-001 Encoder Disk Feed Roller Assembly Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the operator panel cover. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5. 3. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5. 4. Remove the left cover. Refer to “Left Cover Removal” on page 4-7. 5. Remove the thrust bracket CBM {A}. 6. Remove the index board assembly. 7. Remove the five backup roller springs {B}.
4085-001 Repair Information 4-35
4085-001 Star Wheel Shaft Assembly Removal 1. Remove all covers. 2. Remove the carrier and belt. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove pump housing maintenance station, tank, and transport carrier motor. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4. Disconnect the spring {A} connecting the base assembly to the star wheel cam follow assembly. 5. Remove the E-clip {B} from the right end of the star wheel shaft. 6.
4085-001 Repair Information 4-37
4085-001 Paper Feed Platen Assembly Removal 1. Remove all covers. 2. Remove the carrier and belt. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove the pump housing maintenance station, tank, and the transport carrier motor. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4. Remove the star wheel shaft. 5. Press down gently on both sides and remove the paper feed platen out through the front of the printer.
4085-001 Exit Shaft with Gear Removal 1. Remove all covers. 2. Remove carrier and belt. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove pump housing, maintenance station, tank, and transport carrier motor. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4. Remove star wheel shaft. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. 5. Remove paper feed platen. Refer to “Paper Feed Platen Assembly Removal” on page 4-38. 6.
4085-001 Paper Feed Frame and Motor/Cam Shaft Assembly Removal 1. Remove all covers. 2. Remove the carrier and belt. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove pump housing, maintenance station, tank and transport carrier motor. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4. Remove the star wheel shaft. See “Star Wheel Shaft Assembly Removal” on page 4-36. 5. Remove paper feed platen.
4085-001 Repair Information 4-41
4085-001 4-42 Service Manual
4085-001 Left Index Frame Pivot Assembly Removal 1. Remove all covers. 2. Remove the carrier and belt. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove the pump housing, maintenance station, tank, and transport carrier motor. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4. Remove the star wheel shaft. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. 5. Remove paper feed platen.
4085-001 4-44 Service Manual
4085-001 Right Index Frame Pivot Assembly Removal 1. Remove all covers. 2. Remove the carrier and belt. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove the pump housing, maintenance station, tank and the transport carrier motor. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4. Remove the star wheel shaft. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. 5. Remove the paper feed platen.
4085-001 Bat Wings and Bushings Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the spring between the cam followers. 3. Remove the two E-clips from the ends of the bat wing shaft. 4. Remove bushings. 5. Pull forward and remove.
4085-001 Backup Roller Assembly Removal 1. Remove all covers. 2. Remove carrier and belt. Refer to “Engine Board /Cover Removal” on page 4-14. 3. Remove pump housing, maintenance station, tank and transport carrier motor. Refer to “Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal” on page 4-20. 4. Remove star wheel shaft. Refer to “Star Wheel Shaft Assembly Removal” on page 4-36. 5. Remove the paper feed platen. Refer to “Paper Feed Platen Assembly Removal” on page 4-38. 6.
4085-001 Backup Roller Spring Removal 1. Lift the front door on the printer. 2. Press the coil on the backup roller spring to center and remove. Note the position of the spring before removing. Carrier/Cable Retainer Removal 1. 2. 3. 4. 5. Remove all covers. Remove the engine board cover. Disconnect carrier cables from the engine board. Remove the carrier guide shaft from the carrier. Unlatch the cable restraint, disconnect carrier cables from the rear of the carrier and remove. 6.
4085-001 Peristaltic Pump Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3. 2. Remove the exit tray. Refer to “Exit Tray Removal” on page 4-5. 3. Remove the operator panel cover. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5. 4. Remove right cover. Refer to “Right Cover/Power Switch Removal” on page 4-9. 5. Remove the power supply and tank. Note: When reinstalling the pump, be sure the gear alignment is correct. 6.
4085-001 Tray 2 Paper Pick Arm Assembly Removal 1. 2. 3. 4. 5. Remove all covers Remove eight screws {A} from Tray 2 base. Remove E-clip {B} from pick assembly shaft. Remove the screw {C} from the paper feed frame assembly. Slide the shaft to the left and remove the pick arm assembly.
4085-001 Repair Information 4-51
4085-001 Tray 2 Paper Feed Motor and Card Assembly Removal 1. 2. 3. 4. 5. 6. Remove the left cover from Tray 2. Remove the four screws from the paper port connector frame. Remove the paper port connector frame. Remove the two paper feed motor screws {A}. Disconnect the paper feed motor connector. Remove the motor.
4085-001 5.
4085-001 RIP Card 5-2 Service Manual
4085-001 RIP Card (cont.
4085-001 Optional Tray 2 J1 Paper Feed Motor J2 Passthru Sensor J3 Paper Feed Pic Motor J4 Paperport II and Power 5-4 Service Manual
4085-001 6. Preventive Maintenance This chapter contains lubrication specifications. Follow these recommendations to prevent problems and maintain optimum performance. Lubrication Specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than those specified can cause premature failure. Some unauthorized lubricants may chemically attack polycarbonate parts. Use IBM no.
4085-001 • Avoid oil contact with the outer pulley surface and flanges that contact the belt. Motor Pulley Studs • Apply Shell Tellus #100 oil to the idler stud and compound pulley stud {8}. The amount of Shell Tellus #100 to be used should be visible on the stud but not dripping or running onto the motor bracket, pulleys or frame. For reference, use approximately 0.005 grams on the compound pulley stud and approximately 0.003 grams on the idler pulley stud.
4085-001 7. Parts Catalog How To Use The Parts Catalog • NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not shown in the illustration. • PP: in the Description column indicates the part is available in the listed parts packet.
4085-001 Assembly 1: Covers 7-2 Service Manual
4085-001 Assembly 1: Covers AsmIndex Part Number Units Description 1-1 12G6073 1 Cover Assembly, Manual Feed 2 12G6070 1 Door, Rear 3 12G6069 1 Cover, Rear 4 12G6065 1 Cover, Operator Panel 5 12G6061 1 Cover, Right 6 12G6063 1 Cover, Right Tray 7 12G6072 1 Cover Assembly, Exit Tray 8 12G6075 1 Paper Tray Assembly 9 12G6062 1 Cover, Left Tray 10 12G6060 1 Cover, Left 11 12G6071 1 Top Door Assembly 12 12G6064 1 Cover, Left Frame NS 12G6076 Screws, (PP) P
4085-001 Assembly 2: Paper Feed 7-4 Service Manual
4085-001 Assembly 2: Paper Feed AsmIndex Part Number Units Description 2-1 12G6024 1 Paper Out Sensor 2 12G6000 1 Paper Feed Pick Assembly with Motor 3 12G6092 2 Pick Tires Parts Catalog 7-5
4085-001 Assembly 2 (cont.
4085-001 Assembly 2 (cont.
4085-001 Assembly 2 (cont.
4085-001 Assembly 2 (cont.
4085-001 Assembly 3: Electronics 7-10 Service Manual
4085-001 Assembly 3: Electronics AsmIndex Part Number Units Description 3-1 12G6059 1 RIP Card 2 12G6058 1 Shield, RIP Enclosure 3 12G6067 1 Cable, Operator Panel 4 12G6066 1 Operator Panel Assembly 5 12G6057 1 Power Supply 6 12G6048 1 Engine Board 7 12G6055 1 Sensor, Ink Level 8 12G6044 1 Index Card/Feedroll Encoder Disc Assembly 9 12G6018 1 Top Door Switch with Retainer 10 12G6053 1 Cable, Engine to RIP 11 12G6093 1 Bracket, Thrust 12 1339535 1 Power Cor
4085-001 Assembly 3 (cont.
4085-001 Assembly 3 (cont.
4085-001 Assembly 3 (cont.
4085-001 Assembly 3 (cont.
4085-001 Assembly 4: Carrier Transport 7-16 Service Manual
4085-001 Assembly 4: Carrier Transport AsmIndex Part Number Units Description 4-1 12G6033 1 Shaft, Upper Carrier with Brackets 2 12G6037 1 Belt, Carrier Drive with Keepers 3 12G6038 2 Pulley Assembly with Shaft-Top Idler 4 12G6040 1 Clip, Encoder Strip 5 12G6039 1 Encoder, Carrier Drive 6 12G6035 1 Carrier Cables with Retainer and Clamps 7 12G6016 1 Belt, Carrier Drive 8 12G6015 1 Motor, Carrier Drive Assembly with Belt 9 12G6034 1 Carrier Assembly with Cables and Cla
4085-001 Assembly 5: Maintenance Station 7-18 Service Manual
4085-001 Assembly 5: Maintenance Station AsmIndex Part Number Units Description 5-1 12G6056 1 Waste Ink Bottle with Belt Shield 2 12G6022 1 Maintenance Regulator Assembly 3 12G6019 1 Maintenance Motor Assembly with Gear 4 12G6021 1 Peristaltic Pump Assembly 5 12G6020 1 Maintenance Station Assembly 6 12G6091 2 Wipers, Maintenance 7 12G6024 1 Maintenance Homing Sensor 8 12G6099 1 Washer/Clip/Keeper/Tubing (PP) NS 12G6023 1 Maintenance Cable NS 12G6076 Screws, (PP) P
4085-001 Assembly 6: Optional Tray 2 7-20 Service Manual
4085-001 Assembly 6: Optional Tray 2 AsmIndex Part Number Units 6-1 12G6088 1 Cover, Rear (OP Tray 2) 2 12G6002 4 Wear Strips 3 12G6049 1 Paper Feed Pick Assembly with Motor - 250 Option Final Assembly 4 12G6046 1 Sensor, Tray 2 Passthru 5 12G6086 1 Cover, Right Side (OP Tray 2) 6 12G6085 1 Cover, Front (OP Tray 2) 7 12G6089 1 Card, Secondary Tray 8 12G6001 1 Detent - Paper Tray 2 with Spring Description 9 12G6083 1 Motor, Redrive with Gear Assembly 10 12G6087 1 C
4085-001 Assembly 7: Optional Multi-Purpose Feeder 7-22 Service Manual
4085-001 Assembly 7: Optional Multi-Purpose Feeder AsmIndex Part Number Units 7-1 12G6077 1 Guide, MPF Rear Paper 2 12G6011 1 Feeder, Auxillary Sheet 3 12G6084 1 MFP Motor with wire Description Parts Catalog 7-23
4085-001 Assembly 8: Optional MarkNet External Print Server 7-24 Service Manual
4085-001 Assembly 8: Optional MarkNet External Print Server AsmIndex Part Number Units 8-1 12G6090 1 MarkNet™ External Print Server NS 12G6251 1 MarkNet XP Cable Description Parts Catalog 7-25
4085-001 7-26 Service Manual
4085-001 Index A Abbreviations 1-3 Adjustments 4-2 Aids Diagnostic 3-1 Printer Operations 3-1 Aligning Printheads 3-5 Assemblies 1 Covers 7-2 2 Paper Feed 7-4, 7-6, 7-8 3 Electronics 7-10 4 Carrier Transport 7-16 5 Maintenance Station 7-18 6 Optional Tray 2 7-20 7 Optional Multi-Purpose Feeder 7-22 8 Optional MarkNet External Print Server 7-24 Attendance Messages 2-24 B Busy/Waiting Menu Group 3-45 Button Test 3-23 C Supplies Tests 3-34 Diagnostics Menu Group (Mode 1 Printing) 3-62 Diagnostics Menu Grou
4085-00X Power Consumption 1-1 Print Quality Test Page 3-8 Printer Indicator Light 1-4 Printer Messages 1-6 Printer Operations CE Diagnostics Mode 3-2 Clear NVRAM 3-3 Disable/Enable OP Menus 3-2 Flash Engine Code Mode 3-3 Power-On Reset Button Functions 3-1 Printer Settings 1-9 Printing Menu Settings Page 3-10 Problems Carrier Transport 2-50 Communications 2-50 Maintenance Station 2-50 Operator Panel 2-51 Paper Feed 2-51 Power 2-51 Print Quality 2-52 R Ready Menu Group 3-48 Removals Backup Roller Assembly
4085-001 Operator Panel (Buttons) 2-58 Operator Panel (LCD) Display 2-59 Options 2-59 Paper Feed 2-60 Power Supply 2-63 Print Quality 2-65 RIP Card 2-64 Transport 2-67 Service Messages 2-2 Start 2-1 Status Messages 2-14 Symptom Tables 2-50 T Tests Cap Printheads 3-31 Carrier System 3-32 DRAM Memory 3-23 Index System 3-33 Ink Level Sensor 3-31 Ink Tank Memories 3-34 K&C Thermal Sense Resistor 3-35 LCD Hardware 3-22 M&Y Thermal Sense Resistor 3-35 Maintenance Sled 3-33 Miscellaneous Sensors 3-30 MP Feeder Se
4085-00X 12G6044 12G6045 12G6046 12G6047 12G6048 12G6049 12G6051 12G6052 12G6053 12G6054 12G6055 12G6056 12G6057 12G6058 12G6059 12G6060 12G6061 12G6062 12G6063 12G6064 12G6065 12G6066 12G6067 12G6068 12G6069 12G6070 12G6071 12G6072 12G6073 12G6074 12G6075 12G6076 7-21 12G6077 12G6078 12G6080 12G6081 12G6083 12G6084 12G6085 12G6086 12G6087 12G6088 12G6089 12G6090 12G6091 12G6093 7-11 7-13 7-13 7-13 7-11 7-21 7-13 7-13 7-11 7-13 7-11 7-19 7-11 7-11 7-11 7-3 7-3 7-3 7-3 7-3 7-3 7-11 7-11 7-13 7-3 7-3 7-3 7-3
