Lexmark J110 Service Manual
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Lexmark J110 Service Manual

Lexmark J110 Service Manual

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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.

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Summary of Contents for Lexmark lexmark J110

  • Page 1 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.
  • Page 2 You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark, Lexmark with diamond design, MarkNet, and Optra are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    4085-001 Table of Contents Preface ..........vii Safety Information.
  • Page 4 4085-00X ..........2-25 .
  • Page 5 4085-001 Diagnostics (Mode 2) - Input Tray Tests ....3-27 Diagnostics (Mode 2) - Base Sensor Tests ....3-29 Diagnostics (Mode 2) - Subsystem Tests .
  • Page 6 4085-00X PerfectFinish Sensor Assembly/Rear Paper Path Sensor Removal . 4-26 Frame From Base Removal ......4-27 Cam Engine Motor with Gear Removal .

  • Page 7: Preface

    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.

  • Page 8: 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. •...
  • Page 9 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.
  • Page 10 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. •...
  • Page 11 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...
  • Page 12 4085-001 Service Manual...

  • Page 13: General Information

    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.

  • Page 14: Internal Power Supply Specifications

    4085-001 Internal Power Supply Specifications Built-in Universal Power Supply, 40 Watts Output (50 Watts input) Outputs: Output Nominal Minimum Maximum Load Range Name Voltage Voltage 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...

  • Page 15: Tools Required For Service

    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 End of Forms Electrostatic Discharge Field Replaceable Unit Light-Emitting Diode Multi-Purpose Feeder Network Printer Alliance Power-On Reset...

  • Page 16: Operator Panel And Menus

    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.

  • Page 17: Operator Panel Button Functions

    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.

  • Page 18: Printer Messages

    4085-001 Button Function Return Press the Return button. Returns to the previous menu level. If at the top level of the menus, then it functions like Go. Stop Press the Stop button. Stop suspends job activity and displays the Not Ready message. Job activity resumes when Go is pressed.

  • Page 19: Operator Panel Menus

    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.

  • Page 20: Printing The Menu Settings Page

    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.

  • Page 21: Changing Printer Settings

    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: Ready 1. From the state, press Menu> or <Menu to enter the menus.

  • Page 22: Disabling The Operator Panel Menus

    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.

  • Page 23: Diagnostic Information

    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”...

  • Page 24: Service Messages

    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.

  • Page 25: Error Indicator Table

    4085-001 Error Indicator Table Error Symptom Action RIP Software Perform the “RIP Card Service Check” on page 2-64 Engine Software Replace the engine board. See the “Engine Board / Cover Removal” on page 4-14 RIP Software Check RIP/Engine cable. Replace the RIP card. See “RIP-EMC Shield Assembly/RIP Card Removal”...
  • Page 26 4085-001 Error Symptom Action Engine NVRAM Check cabling to index board. 10 Invalid data in flash memory 10 - Replace engine 20 NVRAM checksum failure board. See “Engine Board 30 Flash data programming /Cover Removal” on failure page 4-14 40 Engine NVRAM is not present 20 - Replace index board.
  • Page 27 4085-001 Error Symptom Action Index System Perform the “Index System Test” on page 3-33 10 Index Motor Stall or loss of Encoder signals “Index Motor Service Check” on page 2-56 . If 20 Encoder Wheel “once-per- problem still exists, go to revolution”...
  • Page 28 4085-001 Error Symptom Action Black Printhead - P-lines shorted Check all contacts and or Substrate Heater shorted cables. If tests fail, replace the printheads. If failure Color Printheads - P-lines still occurs, replace engine shorted or Substrate Heater board. shorted Both Printheads - P-lines shorted or Substrate Heater shorted Black Printhead - Engine cannot...
  • Page 29 4085-001 Error Symptom Action Black Printhead - Check the carrier/ Color Printheads - printhead contacts. Try Both Printheads - replacing both printheads TSR measurement indicates a before replacing carrier. cracked / open TSR or open Check the carrier cable. If connection.
  • Page 30 4085-001 Error Symptom Action RIP to Engine communications Unplug and replug the AC failure power cord to see if the problem goes away. Check the RIP card cable connections. If the connections are good, replace the engine board. “Engine Board /Cover Removal”...
  • Page 31 4085-001 Error Symptom Action RAM Memory Error - RAM Replace the RIP card. See soldered on the card is bad “RIP-EMC Shield Assembly/RIP Card Removal” on page 4-24 Tray 2 Communication Error - Check connection Communication between Tray 2 between engine board and and the Engine is unreliable.

  • Page 32: User Status Messages

    4085-001 User Status Messages User Status Message Status Action Ready The printer is ready to Press Menu> or Menu< receive and process to take the printer offline data from a host and access the Ready system. Menu group. The following function may be available via the Busy/ Waiting Menu group: -Reset Printer...
  • Page 33 4085-001 User Status Message Status Action Busy The printer is Press Stop to take the processing data and/ printer offline. The Not or printing pages. The Ready message appears. Power indicator blinks No more data is while the printer is processed from the host processing data.
  • Page 34 4085-001 User Status Message Status Action Waiting The Waiting is Press Go to print the displayed until the contents of the printer’s current job is buffer. terminated or until Note: The Go press is additional data is ignored when Print Buffer received on the active Control is Off.

  • Page 35: Warning Messages

    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.

  • Page 36: Status Messages

    4085-001 Status Messages These messages provide the operator with information on the current state of the printer. Status Message Status Action Activating Menu The printer is being No buttons are active Changes reset to activate a while this message is printer setting displayed.
  • Page 37 4085-001 Status Message Status Action Disabling/Enabling A representation of No buttons are active Menus the operator panel while this message is when the user has displayed. modified the Menu Lockout printer setting using the Configuration Menu Group. If the Menu Lockout value is changed to On (Panel Menus=Disable), then...
  • Page 38 4085-001 Status Message Status Action Cancelling Job Appears after the Press Menu> or Menu< Cancel Job operation to access the Busy/ is selected. This Waiting Menu group. The message is displayed printer is online while the until the cancel Busy/Waiting Menu group operation is complete.
  • Page 39 4085-001 Status Message Status Action Invalid Engine Code A representation of No buttons are active the operator panel while this message is when either the displayed. 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...
  • Page 40 4085-001 Status Message Status Action Not Ready A representation of Press Go to take the the operator panel printer out of the Not when the printer is in Ready state. the Not Ready state. Press Menu> or Menu< All host links are to access the Busy/ marked as busy when Waiting Menu group.
  • Page 41 4085-001 Status Message Status Action Performing Self Test A representation of No buttons are active the operator panel while this message is during Power-On Self displayed. Test (POST). When the test is complete, the printer enters the Ready state. Powering Down A representation of No buttons are active the operator panel...
  • Page 42 4085-001 Status Message Status Action Printing Menu Settings A representation of Press Stop to take the the operator panel printer offline. The Not when Print Menu Ready message appears. Settings is selected No more data is from the menu. This processed from the host message appears computer;...
  • Page 43 4085-001 Status Message Status Action Printing Alignment A representation of Press Menu> or Menu< Page the operator panel to access the Busy/ when Align Printheads Waiting Menu group. The is selected from the printer is online while the menu. This message Busy/Waiting Menu group appears until the is active.
  • Page 44 4085-001 Status Message Status Action Printing Test Page A representation of Press Menu> or Menu< the operator panel to access the Busy/ when Clean Waiting Menu group. The Printheads is selected printer is online while the from the menu. This Busy/Waiting Menu group message appears is active.
  • Page 45 4085-001 Status Message Status Action Programming System A representation of No buttons are active Code the operator panel while this message is when new code is displayed. programmed in the RIP code flash. This message is shown until the programming is complete.

  • Page 46: Attendance Messages

    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.
  • Page 47 4085-001 Attendance Message Description Action 88 Cartridge Low A representation of Press Go to clear the XXXX the operator panel message. when cyan ink low occurs and the Ink Alarm is activated. A similar message appears when the black, magenta and yellow inks are low.
  • Page 48 4085-001 Attendance Message Description Action Change<input source> A representation of Sources equipped with <size> the operator panel both size-sensing and when the printer is media-present hardware: Change<input source> requesting the Load the requested size <type><size> operator to change and/or paper type in the the media installed in source indicated in the one of the input...
  • Page 49 4085-001 Attendance Message Description Action Change<input source> In all other cases, Sources equipped media- <size> both the type and size present hardware ONLY: are displayed on line Load the requested size Change<input source> 2. The requested type and/or type in the source <type><size>...

  • Page 50: Overriding Change Prompts

    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.
  • Page 51 4085-001 Attendance Message Description Action Check Tray x A representation of If the device was Connection the operator panel temporarily removed or when the printer loses not connected properly, Check MPF communications with reattach or reconnect it. Connection one of the following When the device is devices: recognized, the printer...
  • Page 52 4085-001 Attendance Message Description Action Clean 1? A representation of Press Go if the long clean =Go/Stop the operator panel needs to be performed on when a Long Clean is the printhead represented requested and the by bar 1. printer is asking the Press Stop if the long user if the printhead clean does not need to be...
  • Page 53 4085-001 Attendance Message Description Action 31 Defective A representation of Open the cover and Cartridge XXXX the operator panel replace the defective ink when the printer cartridge(s). The carrier detects a defective ink appears at the ink cartridge. In this cartridge change location.
  • Page 54 4085-001 Attendance Message Description Action 54 Std Par ENA A representation of Press Go to clear the Connect Lost the operator panel message. The printer when the printer clears the setting stating detects during its an external network power-on cycle that adapter connection exists the connection to an and restarts.
  • Page 55 4085-001 Attendance Message Description Action 81 Engine Code A representation of Press Go to clear the CRC Failure the operator panel message. The microcode when microcode to be data is discarded and programmed in the must be re-transmitted engine flash code from the host computer.
  • Page 56 4085-001 Attendance Message Description Action 56 Std Parallel A representation of Press Go to clear the Port Disabled the operator panel message. The printer when data is sent to discards any data the printer across a received on the parallel parallel port, but the port.
  • Page 57 4085-001 Attendance Message Description Action Load <input source> A representation of Sources equipped with <size> the operator panel both size-sensing and when the indicated media-present hardware: Load <input source> source is out of Load the requested size <type><size> media. The input and/or paper type in the source is displayed on source indicated in the...
  • Page 58 4085-001 Attendance Message Description Action Load Manual A representation of If no media exists in the <size> the operator panel Manual Slot or MP when the printer Feeder, then manually Load Manual receives a request to feed a sheet. The printer <type><size>...
  • Page 59 4085-001 Attendance Message Description Action Load Manual To request the printer to <size> pick the sheet from an automatic source, press Load Manual Select. <type><size> Press Menu> or Menu> to access the Busy/ (CONTINUED) Waiting Menu group. The following functions may be available using the Busy/Waiting Menu group:...
  • Page 60 4085-001 Attendance Message Description Action 31 Missing A representation of Open the cover and insert Cartridge XXXX the operator panel an ink cartridge where an when the printer ink cartridge is missing. detects a missing ink Press and hold Select cartridge.
  • Page 61 4085-001 Attendance Message Description Action 31 Missing A representation of Check printhead to carrier Printhead XXXX the operator panel contacts. when the printer Open the cover and detects a missing replace the defective printhead. In this printhead. representation, XXXX is a placeholder for Press and hold Select either: YMC,K or and then press Return to...

  • Page 62: Paper Jams

    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: •...
  • Page 63 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...
  • Page 64 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. 2-42 Service Manual...
  • Page 65 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: •...
  • Page 66 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 shown when Menu> or Menu< is Disabled message is temporarily pressed. Unsupported Ink Cartridge 32 Unsupported Cartridge XXXX The above is a representation of the operator panel when the top...
  • Page 67 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.
  • Page 68 4085-001 Error Recovery from Attendance Conditions Auto Sound Attendance Condition Error Type Continue Alarm Available (if Enabled) A Alignment Type 1 Cartridge Life Expired <cart(s)> Type 1 Cartridge Life Warning <cart(s)> Type 1 Change <src> <size> Type 1 Change <src> <type> <size> Clean X? Go/Stop Type 1 Load <src>...
  • Page 69 4085-001 Auto Sound Attendance Condition Error Type Continue Alarm Available (if Enabled) 81 Engine Code CRC Failure Type 1 87 PerfectFinish Empty Type 1 88 Cartridge Low <cart(s)> Type 1 Yes (Ink Low Alarm) 89 Cartridge Empty <cart(s)> Type 2 200 Paper Jam Check Tray 1 Type 3 201 Paper Jam Check Tray 1...

  • Page 70: Power-On Self Test (Post) Sequence

    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.

  • Page 71: Post Symptom Table

    4085-001 Post Symptom Table Symptom Action Blank display, carrier moves, See the “Operator Panel (LCD) paperfeed motor turns 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 See the “Power Supply Service remains on display, no motors turn...

  • Page 72: Symptom Tables

    4085-001 Symptom Tables Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems Symptom Action • No carrier movement See the “Transport Service Check” on • Slow carrier movement page 2-67 • Carrier stops • Carrier does not move to cartridge load position when See the “Carrier System Test”...
  • Page 73 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.
  • Page 74 4085-001 Print Quality Problems Symptom Action • Voids in characters See the “Print Quality Service Check” • Light print on page 2-65 • Prints off the page • Fuzzy print • Carrier moves but does not print • Printhead drying prematurely •...

  • Page 75: Service Checks

    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.
  • Page 76 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.

  • Page 77: Maintenance Station Service Checks

    4085-001 Maintenance Station Service Checks Action Maintenance The maintenance carrier is driven in a front to rear Station Assembly 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.

  • Page 78: Index Motor Service Check

    4085-001 Index Motor Service Check 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 Gears Check the gears for proper alignment, chipped teeth, loose motor, missing gear clip or worn gears.

  • Page 79: Multi-Purpose Feeder (Mpf) Motor And Sensor Service Check

    4085-001 Multi-Purpose Feeder (MPF) Motor and Sensor Service Check 1. Remove the rear cover from the printer. 2. Remove the engine board cover. 3. Install the multi-purpose feeder. 4. Check for a voltage reading at connector (J10) pin 1 for approximately +36 V dc on the engine board.

  • Page 80: Operator Panel (Buttons) Service Check

    4085-001 Operator Panel (Buttons) Service Check Action Operator Panel If any button fails the button test, replace the Assembly operator panel assembly. See “Button Test” on page 3-23 Engine Board With the operator panel connected to the engine board, be sure the voltage at (J4) pins 1, 2, 3 and Operator Panel 5 measures +5 V dc.

  • Page 81: Operator Panel (Lcd) Display Service Check

    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.

  • Page 82: Paper Feed Service Check

    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.
  • Page 83 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 • A defective motor • A bind in the paper feed mechanism •...
  • Page 84 4085-001 Action RIP Card Cable Check the continuity of the RIP card cable. If incorrect, replace the cable. If correct, replace the RIP card. Optional tray 2 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 •...

  • Page 85: Power Supply Service Check

    4085-001 Action Paper Feed Pick With the power on, check for the following Motor 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.

  • Page 86: Rip Card Service Check

    4085-001 Action Power Line Cord Check the power line cord for damage. Check the continuity of the line cord and replace if necessary. Power Switch Check the continuity on the power switch. If incorrect, replace the power switch. Power Supply With the power switch turned on, verify the voltage readings at RIP card connector (J1) and engine board connector (J1).

  • Page 87: Print Quality Service Check

    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. Action The machine print quality can look poor as a result of either faulty printheads or poor carrier to printhead electrical contact.
  • Page 88 4085-001 Action Engine Board If the missing nozzles are patterned, the problem could be the engine board or carrier card. First try Carrier Card replacing the engine board, then the carrier card. Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area.

  • Page 89: Index Card/Sensor Service Check

    4085-001 Index Card/Sensor Service Check Action Index motor does If the index motor does not work, see “Index Motor not work. Service Check” on page 2-56 . If the index motor is working correctly see “Index System Test” on page 3-33 .
  • Page 90 4085-001 Action Carrier Belt Check for worn, loose or broken parts. Check for obstructions blocking carrier movement. Idler Pulley Parts Carrier Frame Encoder Strip Check the encoder strip for wear, dirt, and grease. See the “Carrier System Test” on page 3-32 Printhead Cable Be sure all connectors are fully seated.

  • Page 91: Cam System Motor/Sensor Service Check

    4085-001 Cam System Motor/Sensor Service Check Action Motor does not Check the voltage at connector (J8) on the engine work. board. At pins 1, 2, 3, and 4 with the power on. Bat Wings do not There should be approximately +34 V dc on each move.
  • Page 92 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.
  • Page 93 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.
  • Page 94 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.

  • Page 95: Diagnostic Aids

    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 Reference Section...
  • Page 96 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.
  • Page 97 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.

  • Page 98: Change Ink Cartridges

    Message is shown. This can occur if the software keys in the printer and ink cartridge are incompatible, as in the case of an OEM printer using Lexmark-branded ink cartridges. Change Printheads Select Change Printhead from the Utilities Menu. Open the cover and the carrier moves to the middle and any combination of printheads can be replaced.

  • Page 99: Aligning The Printheads

    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.
  • Page 100 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.

  • Page 101: Cleaning Printheads

    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: •...

  • Page 102: Linking Input Trays

    Most network printers offered by Lexmark support an input tray linking feature. In all cases, the feature can be turned on and off by the user. For instance, some previous Lexmark laser printers let the user set tray linking to one of the following values: Off, Tray 1+2, Tray 1+3, Tray 1+2+3.
  • Page 103 PerfectFinish capability affects the ability of trays to link. For instance, in the following example, all the trays have the same size, type, and custom string, which for the traditional Lexmark network printer would mean the trays are all linked. However, the MP Feeder does not support PerfectFinish, so it would not automatically be linked with the other trays.

  • Page 104: Unsolicited Manual Feed

    Note: Unsolicited manual feed is not available when the MP Feeder is installed. The MP Feeder functions exactly like the Lexmark Optra™ T MP Feeder. Manual Duplex Through the driver, this printer supports manual duplex.
  • Page 105 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.

  • Page 106: Restoring Factory Defaults

    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 Concatenation of C,M,Y, and K ink levels.
  • Page 107 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.

  • Page 108: Resetting The Printer Using The Operator Panel

    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.
  • Page 109 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.
  • Page 110 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.

  • Page 111: Other Resets

    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.
  • Page 112 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.

  • Page 113: Activating Hex Trace Debug Mode

    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.
  • Page 114 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. •...
  • Page 115 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.

  • Page 116: Diagnostics (Mode 2) - Hardware Tests

    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. Prt Contacts Pg Printing Contacts Page Fixed Settings...
  • Page 117 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.
  • Page 118 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.
  • Page 119 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: •...
  • Page 120 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.

  • Page 121: Diagnostics (Mode 2) - Input Tray Tests

    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:...
  • Page 122 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.

  • Page 123: Diagnostics (Mode 2) - Base Sensor Tests

    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...
  • Page 124 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.

  • Page 125: Diagnostics (Mode 2) - Subsystem Tests

    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.
  • Page 126 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”...
  • Page 127 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.

  • Page 128: Diagnostics (Mode 2) - Supplies Tests

    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.

  • Page 129: Diagnostics (Mode 2) - Printer Setup

    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.
  • Page 130 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.

  • Page 131: Diagnostics (Mode 2) - Error Log

    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”...
  • Page 132 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.

  • Page 133: Menus

    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.
  • Page 134 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. •...
  • Page 135 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.

  • Page 136: Example Of Modifying A Printer Setting Using The Operator Panel

    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”...
  • Page 137 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.

  • Page 138: Operator Panel Menu Definition

    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 The Busy/Waiting menu group contains the operations that are accessible when the printer is receiving or Menu Group processing data, waiting for additional data, or actually printing a job.

  • Page 139: Busy/Waiting Menu Group

    4085-001 Configuration The Configuration menu group contains a set of menus, Menu Group 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.

  • Page 140: Job Menu

    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, Note: This operation is only see“Canceling a Print Job using the displayed in the JOB MENU Operator Panel”...
  • Page 141 4085-001 Job Menu Operations Operation Value or Description Reset Printer No selection exists for this operation. Press Select to initiate the reset function. Note: This operation is only For additional information, see “Resetting the Printer using the Operator Panel” on displayed in the JOB MENU page 3-14.

  • Page 142: Ready Menu Group

    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.
  • Page 143 4085-001 Top-Level Menu Intermediate Menu, Setting, or Operation JOB MENU “JOB MENU” on page 3-54 for a list of the operations. SETUP MENU “SETUP MENU” on page 3-54 for a list of the menus or settings. PCL EMUL MENU “PCL EMUL MENU” on page 3-56 for a list of the menus or settings.
  • Page 144 4085-001 Intermediate Menu Value or Setting 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.
  • Page 145 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 Value or Setting Paper Source =Tray 1* =Tray 2 =MP Feeder =Manual Paper...
  • Page 146 4085-001 Intermediate Menu Value or Setting 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.
  • Page 147 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”...
  • Page 148 4085-001 Operation Value Factory Defaults “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.
  • Page 149 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. =English =French =German =Italian =Spanish =Danish =Norwegian =Dutch =Swedish...
  • Page 150 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.
  • Page 151 4085-001 Intermediate Menu Value or Setting Orientation =Portrait* =Landscape Lines per Page =1... 255 (US=60* / NonUS=64*) Auto CR after LF =Off* Auto LF after CR =Off* Font Name Display Format The font names are shown on both lines of the operator panel using the following format.
  • Page 152 4085-001 Symbol Set Display Format The symbol sets are shown on both lines of the operator panel using the following format. =SSID ThisIsSym- bolSetName 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).
  • Page 153 4085-001 Setting Value Parallel Mode 1 =Off* Note: Only displayed when the associated Parallel Port supports this feature. Parallel Mode 2 =Off Note: Only =On* displayed when the associated Parallel Port supports this feature. 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.

  • Page 154: Configuration Menu Group

    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.
  • Page 155 4085-001 Intermediate Menu, Setting or Value Operation Coarse Alignment No selections exist for this operation. Press Select to initiate this operation. “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.

  • Page 156: Diagnostics Menu Group (Mode 1: Printing)

    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.

  • Page 157: Diagnostics Menu Group (Mode 2: Non-Printing)

    4085-001 Intermediate Menu, Top-Level Menu Value Setting, or Operation PRINT TESTS Tray 1 =Single =Continuous Tray 2 =Single Only displayed if Tray 2 =Continuous is installed. MP Feeder =Single Note: Only displayed =Continuous if the printer is configured with a Multi- Purpose Feeder Prt Contacts Pg “Contacts Page...
  • Page 158 4085-001 Note: While the Diagnostic Menu Group is active, all host interfaces are offline. Intermediate Menu, Top-Level Menu Value Setting, or Operation INPUT TRAY TESTS Tray 1 “Tray 1 Sensor Test” on page 3-27. Tray 2 “Tray 2 Sensor Test” on page 3-27.
  • Page 159 4085-001 Intermediate Menu, Top-Level Menu Value Setting, or Operation SUBSYSTEM TESTS Uncap Printheads “Uncap Printheads” on page 3-31. Cap Printheads “Cap Printheads” on page 3-31. Carrier System Test “Carrier System Test” on page 3-32. Index System Test “Index System Test” on page 3-33.
  • Page 160 4085-001 Intermediate Menu, Top-Level Menu Value Setting, or Operation ERROR LOG Display Log “Viewing the Error Log” on page 3-37. Clear Log “Clearing the Error Log” on page 3-38. =Yes EXIT DIAGNOSTICS “Exiting Diagnostics Mode” on page 3-39. 3-66 Service Manual...

  • Page 161: Repair Information

    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.

  • Page 162: Adjustments

    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.

  • Page 163: Rear Cover Removal

    4085-001 Rear Cover Removal 1. Open the rear door. 2. Remove Multi-Purpose Feeder. 3. Remove two clips and remove the top door. 4. Remove the four screws {A}. 5. Depress the four latches {B}. 6. Remove the rear cover. Repair Information...
  • Page 164 4085-001 Service Manual...

  • Page 165: Operator Panel Cover/Operator Panel Removal

    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.

  • Page 166: Left Frame Cover Removal

    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.

  • Page 167: Left Cover Removal

    4085-001 Left Cover Removal 1. Remove the rear cover. 2. Remove the exit tray cover. 3. Move carrier to the right. 4. Remove the screw {A} from the left side of the carrier frame. 5. Remove the two screws {B} from the left front side of the paper tray frame.
  • Page 168 4085-001 Service Manual...

  • Page 169: Right Cover/Power Switch Removal

    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”...
  • Page 170 4085-001 4-10 Service Manual...

  • Page 171: Left Tray Cover Removal

    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.

  • Page 172: Right Tray Cover Removal

    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”...

  • Page 173: Ink Levels And Temperature Sensor With Bracket Removal

    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.

  • Page 174: Engine Board /Cover Removal

    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.

  • Page 175: Carrier With Card Removal

    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.
  • Page 176 4085-001 4-16 Service Manual...

  • Page 177: Carrier 1St Stage Drive Belt Removal

    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.
  • Page 178 4085-001 4-18 Service Manual...

  • Page 179: Power Supply Removal

    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.

  • Page 180: Pump Housing/Maintenance Station/Ink Waste Tank/Transport Carrier Motor Removal

    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.
  • Page 181 4085-001 4-21 Repair Information...

  • Page 182: Index Card Assembly Removal

    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.

  • Page 183: Cover-Open Sensor Removal

    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.

  • Page 184: Rip-Emc Shield Assembly/Rip Card Removal

    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.
  • Page 185 4085-001 4-25 Repair Information...

  • Page 186: Perfectfinish Sensor Assembly/Rear Paper Path Sensor Removal

    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”...

  • Page 187: Frame From Base Removal

    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.
  • Page 188 4085-001 4-28 Service Manual...

  • Page 189: Cam Engine Motor With Gear Removal

    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”...
  • Page 190 4085-001 4-30 Service Manual...

  • Page 191: Paper Feed Pick Arm Assembly With Motor And Paper Path Sensor Removal

    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”...

  • Page 192: Perfectfinish Gear Plate Removal

    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.

  • Page 193: Perfectfinish Motor Removal

    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.

  • Page 194: Encoder Disk Feed Roller Assembly Removal

    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”...
  • Page 195 4085-001 4-35 Repair Information...

  • Page 196: Star Wheel Shaft Assembly Removal

    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”...
  • Page 197 4085-001 4-37 Repair Information...

  • Page 198: Paper Feed Platen Assembly Removal

    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”...

  • Page 199: Exit Shaft With Gear Removal

    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.

  • Page 200: Paper Feed Frame And Motor/Cam Shaft Assembly Removal

    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”...
  • Page 201 4085-001 4-41 Repair Information...
  • Page 202 4085-001 4-42 Service Manual...

  • Page 203: Left Index Frame Pivot Assembly Removal

    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”...
  • Page 204 4085-001 4-44 Service Manual...

  • Page 205: Right Index Frame Pivot Assembly Removal

    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”...

  • Page 206: Bat Wings And Bushings Removal

    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.

  • Page 207: Backup Roller Assembly Removal

    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.

  • Page 208: Backup Roller Spring Removal

    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. Remove all covers. 2.

  • Page 209: Peristaltic Pump Removal

    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”...

  • Page 210: Tray 2 Paper Pick Arm Assembly Removal

    4085-001 Tray 2 Paper Pick Arm Assembly Removal 1. Remove all covers 2. Remove eight screws {A} from Tray 2 base. 3. Remove E-clip {B} from pick assembly shaft. 4. Remove the screw {C} from the paper feed frame assembly. 5.
  • Page 211 4085-001 4-51 Repair Information...

  • Page 212: Tray 2 Paper Feed Motor And Card Assembly Removal

    4085-001 Tray 2 Paper Feed Motor and Card Assembly Removal 1. Remove the left cover from Tray 2. 2. Remove the four screws from the paper port connector frame. 3. Remove the paper port connector frame. 4. Remove the two paper feed motor screws {A}. 5.

  • Page 213: Connector Locations

    4085-001 5. Connector Locations Engine Board Power Supply Carrier Motor Maintenance Station Motor and Homing Operator Panel Thin-Coat Motor and Encoder Integrated Tray Cam System Thin-Coat Sensing MPF-Feeder Paper-Path Sensing Ink-Level and Temperature Sensing Index System Index Motor Paper Port II Tray2 Cover-Open Sensor Carrier Connector...

  • Page 214: Rip Card

    4085-001 RIP Card Service Manual...

  • Page 215: Rip Card (Cont.)

    4085-001 RIP Card (cont.) Power Supply Engine Parallel Connector Locations...

  • Page 216: Optional Tray 2

    4085-001 Optional Tray 2 Paper Feed Motor Passthru Sensor Paper Feed Pic Motor Paperport II and Power Service Manual...

  • Page 217: Preventive Maintenance

    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.
  • Page 218 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.

  • Page 219: Parts Catalog

    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.
  • Page 220 4085-001 Assembly 1: Covers Service Manual...
  • Page 221 4085-001 Assembly 1: Covers Asm- Part Units Description Index Number 12G6073 Cover Assembly, Manual Feed 12G6070 Door, Rear 12G6069 Cover, Rear 12G6065 Cover, Operator Panel 12G6061 Cover, Right 12G6063 Cover, Right Tray 12G6072 Cover Assembly, Exit Tray 12G6075 Paper Tray Assembly 12G6062 Cover, Left Tray 12G6060...
  • Page 222 4085-001 Assembly 2: Paper Feed Service Manual...
  • Page 223 4085-001 Assembly 2: Paper Feed Asm- Part Units Description Index Number 12G6024 Paper Out Sensor 12G6000 Paper Feed Pick Assembly with Motor 12G6092 Pick Tires Parts Catalog...
  • Page 224 4085-001 Assembly 2 (cont.): Paper Feed Service Manual...
  • Page 225 4085-001 Assembly 2 (cont.): Paper Feed Asm- Part Units Description Index Number 12G6003 Left Bat Wing with Bushings 12G6004 Right Bat Wing with Bushings 12G6005 Bat Wing Follower Assembly Parts Catalog...
  • Page 226 4085-001 Assembly 2 (cont.): Paper Feed Service Manual...
  • Page 227 4085-001 Assembly 2 (cont.): Paper Feed Asm- Part Units Description Index Number 12G6010 Deflector Assembly, Second Path 12G6031 Paper Exit Backup Roll Assembly 12G6008 Motor Assembly, PerfectFinish 12G6028 Platen with Spring and Levers Assembly 12G6027 Shaft, Exit Assembly with Gears 12G6029 Star Wheel Shaft Assembly 12G6006...
  • Page 228 4085-001 Assembly 3: Electronics 7-10 Service Manual...
  • Page 229 4085-001 Assembly 3: Electronics Asm- Part Units Description Index Number 12G6059 RIP Card 12G6058 Shield, RIP Enclosure 12G6067 Cable, Operator Panel 12G6066 Operator Panel Assembly 12G6057 Power Supply 12G6048 Engine Board 12G6055 Sensor, Ink Level 12G6044 Index Card/Feedroll Encoder Disc Assembly 12G6018 Top Door Switch with Retainer...
  • Page 230 4085-001 Assembly 3 (cont.): Electronics 7-12 Service Manual...
  • Page 231 4085-001 Assembly 3 (cont.): Electronics Asm- Part Units Description Index Number 1339545 Power Cord, Argentina 1339538 Power Cord, Albania, Algeria, Armenia, Austria, Azerbijan, Belarus, Belgium, Benin, Bosnia, Bulgaria, Burkina-Faso, Cameroon, Central African Republic, Chad, Chechenya, Comoros, Congo, Croatia, Czek Republic, Djbouti, Egypt, Equatorial Guinea, Estonia, Euro English, Finland, France, French Guyana, Gabon, Gambia, Georgia,...
  • Page 232 4085-001 Assembly 3 (cont.): Electronics 7-14 Service Manual...
  • Page 233 4085-001 Assembly 3 (cont.): Electronics Asm- Part Units Description Index Number 12G6097 Retainer/Bearing/Bushing (PP) 12G6098 Spring (PP) 12G6099 Washer/Clip/Keeper/Tubing (PP) 7-15 Parts Catalog...
  • Page 234 4085-001 Assembly 4: Carrier Transport 7-16 Service Manual...
  • Page 235 4085-001 Assembly 4: Carrier Transport Asm- Part Units Description Index Number 12G6033 Shaft, Upper Carrier with Brackets 12G6037 Belt, Carrier Drive with Keepers 12G6038 Pulley Assembly with Shaft-Top Idler 12G6040 Clip, Encoder Strip 12G6039 Encoder, Carrier Drive 12G6035 Carrier Cables with Retainer and Clamps 12G6016 Belt, Carrier Drive...
  • Page 236 4085-001 Assembly 5: Maintenance Station 7-18 Service Manual...
  • Page 237 4085-001 Assembly 5: Maintenance Station Asm- Part Units Description Index Number 12G6056 Waste Ink Bottle with Belt Shield 12G6022 Maintenance Regulator Assembly 12G6019 Maintenance Motor Assembly with Gear 12G6021 Peristaltic Pump Assembly 12G6020 Maintenance Station Assembly 12G6091 Wipers, Maintenance 12G6024 Maintenance Homing Sensor 12G6099 Washer/Clip/Keeper/Tubing (PP)
  • Page 238 4085-001 Assembly 6: Optional Tray 2 7-20 Service Manual...
  • Page 239 4085-001 Assembly 6: Optional Tray 2 Asm- Part Units Description Index Number 12G6088 Cover, Rear (OP Tray 2) 12G6002 Wear Strips 12G6049 Paper Feed Pick Assembly with Motor - 250 Option Final Assembly 12G6046 Sensor, Tray 2 Passthru 12G6086 Cover, Right Side (OP Tray 2) 12G6085 Cover, Front (OP Tray 2) 12G6089...
  • Page 240 4085-001 Assembly 7: Optional Multi-Purpose Feeder 7-22 Service Manual...
  • Page 241 4085-001 Assembly 7: Optional Multi-Purpose Feeder Asm- Part Units Description Index Number 12G6077 Guide, MPF Rear Paper 12G6011 Feeder, Auxillary Sheet 12G6084 MFP Motor with wire 7-23 Parts Catalog...
  • Page 242 4085-001 Assembly 8: Optional MarkNet External Print Server 7-24 Service Manual...
  • Page 243 4085-001 Assembly 8: Optional MarkNet External Print Server Asm- Part Units Description Index Number 12G6090 MarkNet™ External Print Server 12G6251 MarkNet XP Cable 7-25 Parts Catalog...
  • Page 244 4085-001 7-26 Service Manual...
  • Page 245 4085-001 Index Supplies Tests 3-34 Diagnostics Menu Group (Mode 1 Abbreviations Printing) 3-62 Adjustments Diagnostics Menu Group (Mode 2 Aids Non-printing) 3-63 Diagnostic Printer Operations Aligning Printheads Error Indicator Table Assemblies ESD-Sensitive Parts 1 Covers Exiting Diagnostics Mode 3-39 2 Paper Feed 3 Electronics 7-10 4 Carrier Transport...
  • Page 246 4085-00X Power Consumption Left Index Frame Pivot 4-43 Print Quality Test Page Left Tray Cover 4-11 Printer Indicator Light Maintenance Station 4-20 Printer Messages Multi-Purpose Feeder Motor 4-17 Printer Operations Multi-Purpose Feeder Sensor CE Diagnostics Mode 4-17 Clear NVRAM Operator Panel Disable/Enable OP Menus Paper Feed Frame 4-40...
  • Page 247 4085-001 Operator Panel (Buttons) 2-58 Operator Panel (LCD) Display Warning Messages 2-13 2-59 Options 2-59 Part Numbers Paper Feed 2-60 12G6000 Power Supply 2-63 12G6002 7-21 Print Quality 2-65 12G6003 RIP Card 2-64 12G6004 Transport 2-67 12G6005 Service Messages 12G6006 Start 12G6007 Status Messages...
  • Page 248 4085-00X 12G6044 7-11 12G6094 12G6045 7-13 12G6095 12G6046 7-13 12G6097 7-17 12G6047 7-13 12G6098 7-21 12G6048 7-11 12G6099 7-19 12G6049 7-21 12G6200 7-17 12G6051 7-13 12G6250 12G6052 7-13 12G6251 7-25 12G6053 7-11 1339535 7-11 12G6054 7-13 1339536 7-11 12G6055 7-11 1339537 7-11 12G6056...

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