Lexmark Optra Color 45 Service Manual
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Lexmark Optra Color 45 Service Manual

Lexmark Optra Color 45 Service Manual

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Lexmark Optra™ Color 45
4080-001
• Table of Contents
• Start Diagnostics
• Safety and Notices
• Trademarks
• Index
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 Optra Color 45

  • Page 1 Lexmark Optra™ Color 45 4080-001 • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Comments may be addressed to Lexmark International, Inc., Department D22/035-3, 740 New Circle Road N.W., Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.

  • Page 3: Table Of Contents

    4080-001 Table of Contents General Information ........1-1 Power Consumption .
  • Page 4 4080-001 Diagnostic Mode ........3-1 Aligning the Cartridges .
  • Page 5 4080-001 Metal / Plastic Controller Board Cover Removal ... . . 4-7 Operator Panel Cover Removal ......4-8 Option Card(s) Cover Removal .
  • Page 6 4080-001 Connector Locations ........5-1 Engine Board ......... . .5-1 Controller Board .

  • Page 7: 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 8 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 9 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 10 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 11 4080-001...
  • Page 12 4080-001 Service Manual...

  • Page 13: General Information

    4080-001 1. General Information The Lexmark Optra Color 45 printer is a network, near laser- quality inkjet printer. The print cartridge contains single-unit customer-replaceable supply items. Dual printheads provide color and true black printing without changing printheads. The black cartridge has a total of 208 nozzles and installs on the left. The color cartridge has a total of 192 nozzles and installs on the right.

  • Page 14: Abbreviations

    4080-001 Abbreviations End of Forms Electrostatic Discharge Field Replaceable Unit Light-Emitting Diode POST Power-On Self Test SIMM Single In-line Memory Module Random Access Memory Read Only Memory V ac Volts alternating current V dc Volts direct current Service Manual...

  • Page 15: Operator Panel And Menus

    4080-001 Operator Panel and Menus Using the Operator Panel The operator panel, on the front right side of your printer, has a 2-line by 16-character liquid crystal display (LCD), five buttons, and one indicator light. Operator Panel Display Printer Indicator Light Printer Indicator Light The printer indicator light gives information about the status of your printer.

  • Page 16: Operator Panel Buttons

    4080-001 Operator Panel Buttons Use the five operator panel buttons to open a menu, scroll through a list of values, change printer settings, and respond to printer messages. The following table describes the functions of each button. Note: Buttons act upon the information that displays on the second line of the operator panel.

  • Page 17: Printer Messages

    4080-001 Button Function Return Press the Return button to return to the previous menu level. Stop Press the Stop button: • At the Ready, Busy, or Waiting message to temporarily stop all activity and take the printer offline. The printer operator panel status message changes to Not Ready.

  • Page 18: Operator Panel Menus

    4080-001 Operator Panel Menus Menus make it easy for you to change printer settings. Some menus appear only if a specific option is installed in the printer. Other menu items may only be effective for a particular printer language. You can select these values at any time, but they only affect printer function when you use the specified printer language.

  • Page 19: Printing The Menu Settings Page

    4080-001 Printing the Menu Settings Page The menu settings page shows current settings for the menus and a list of installed options. You can use this page to verify that the printer options are properly installed and the printer settings are properly set.

  • Page 20: Changing Printer Settings

    4080-001 Changing Printer Settings You can use the operator panel to change printer settings and customize your printer to meet your specific needs. To select a new value as the default setting: Ready 1. From the state, press Menu> or <Menu to enter the menus.

  • Page 21: Disabling The Operator Panel Menus

    4080-001 Disabling the Operator Panel Menus To disable the menus so that changes cannot be made to the printer default settings: 1. Unplug the printer. 2. While pressing Go and Stop, plug in the printer. Performing Self Test 3. Release the buttons when displays.
  • Page 22 4080-001 1-10 Service Manual...

  • Page 23: Diagnostic Information

    4080-001 2. Diagnostic Information Use the error indicator table, symptom tables, service checks, and diagnostic aids to determine the printer failure. Start Service error indications are displayed on the operator panel. If your printer displays an error indication, locate the error number in the “Error Indicator Table”...

  • Page 24: Error Indicator Table

    4080-001 Error Indicator Table Error Symptom Action RIP software Refer to the “Controller Board Service Check” on page 2-9. Engine error: Replace the engine board, refer to the “Engine Board Address error Removal” on page 4-22. 127 - 223 Software detection error Carrier stall Refer to the...
  • Page 25 4080-001 Error Symptom Action DRAM in (J6) is bad Replace the memory SIMM card in (J6). Unrecognized network card If the incorrect card is installed, replace the card. Unrecoverable software Go to the “Options Service error in network card Check” on page 2-13.

  • Page 26: Power-On Self Test (Post) Sequence

    4080-001 Power-On Self Test (POST) Sequence Plug the printer in and check for a correct POST operation by observing the following: 1. The operator panel displays one row of rectangles followed by two rows of diamonds. 2. The printer indicator (green light) comes on. 3.

  • Page 27: Post Symptom Table

    4080-001 Post Symptom Table Symptom Action Blank display, carrier moves, Go to the “Operator Panel (LCD) paperfeed motor turns Display Service Check” on page 2-12. All diamonds on display Go to the “Operator Panel (LCD) Display Service Check” on page 2-12.

  • Page 28: Symptom Tables

    4080-001 Symptom Tables Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems Symptom Action • No carrier movement Go to the “Transport Service • Slow carrier movement Check” on page 2-24. • Carrier stops Go to the “Transport Service Check •...
  • Page 29 4080-001 Operator Panel Problems Symptom Action Go to the “Operator Panel (LCD) Printer indicator light does not: Display Service Check” on • Turn on page 2-12. • 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 30 4080-001 Power Problems Symptom Action Printer inoperable Go to the “Power Service Check” on page 2-19. Print Quality Problems Symptom Action • Voids in characters Go to the “Print Quality Service • Light print Check” on page 2-21. • Prints off the page •...

  • Page 31: Service Checks

    4080-001 Service Checks Controller Board Service Check Action Code SIMM Some printers may contain a code SIMM located in the option card(s) (J6) on the controller board. If a SIMM is present, replace the code SIMM, go to “Code or Flash SIMM Removal” on page 4-19.

  • Page 32: End Of Forms (Eof) Service Check

    4080-001 End of Forms (EOF) Service Check Before turning the printer on, remove any paper from the input tray and insert one sheet of paper into the manual paper tray slot. If paper feeds through the machine when the printer is turned on, the sensor is functioning properly.

  • Page 33: Noisy Paper Feed Motor Service Check

    4080-001 Noisy Paper Feed Motor Service Check Action Paper Feed Motor Check the following motor pins for approximately 12.5 ohms: (CN6-1) and (CN6-2) (CN6-3) and (CN6-4) If incorrect, replace the paper feed motor, refer to “Paper Feed Motor Removal” on page 4-16.

  • Page 34: Operator Panel (Lcd) Display Service Check

    4080-001 Operator Panel (LCD) Display Service Check Note: Be sure the operator cable is properly installed at the controller board (JT6) and at the operator panel. Check the continuity of the cable and replace if necessary. Operator panel display blank - printer indicator light OFF, paperfeed motor turns, carrier moves.

  • Page 35: Options Service Check

    4080-001 Options Service Check Flash Memory Option(s) Run a copy of the test page and check to see if the option you are checking is listed. The printer does not recognize the option being installed if the option is not listed. Check to make sure that the Memory SIMM is installed correctly and is not broken or damaged.
  • Page 36 4080-001 Format Disk Menu operation. This is a destructive test, as the data on the disk is destroyed and should not be performed on a known good disk. Network Card Option Error Code 976 - Network Card A 976 error code indicates an unrecoverable software error in network card.

  • Page 37: Paper Feed Service Check

    4080-001 Paper Feed Service Check Note: Be sure the printer is unplugged from the AC outlet before performing this service check. Perform the following, if you are experiencing a paper jam: • Check the entire paper path for obstructions. • Be sure the input tray contains not more than 150 sheets of paper and the manual tray not more than 100.
  • Page 38 4080-001 Paper does not feed - paper feed motor does not turn Note: A noisy or chattering motor or a motor that fails to turn can be caused by: • A defective motor • A bind in the paper feed mechanism •...
  • Page 39 4080-001 Paper does not feed - paper feed motor turns Note: A noisy or chattering motor or a motor that fails to turn can be caused by: • A defective motor • A bind in the paper feed mechanism • Defective gears •...

  • Page 40: Paper Path Service Check

    4080-001 Paper Path Service Check Examine the printer for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the paper guides are not worn or broken, and the paper is positioned properly. •...

  • Page 41: Power Service Check

    4080-001 Power Service Check Dead Machine Note: Remove paper from printer prior to performing the dead machine service check. Observe all necessary ESD precautions when removing and handling the controller board, engine board or any of the installed option cards or assemblies. Action AC Outlet Check the AC outlet for correct line voltage.
  • Page 42 4080-001 POST incomplete, printer indicator light on, Performing Self Test is displayed and no motors turn. Note: Excessive ink may be present in the maintenance station caps. Action Power Supply Check for approximately +30 V dc at (J2-6) on the controller board.

  • Page 43: Print Quality Service Check

    4080-001 Print Quality Service Check Note: Before troubleshooting any print quality problem, be sure the cartridge is in good condition. Set print quality to normal and be sure the correct paper type is selected in the paper menu. Set the color menu to Vivid and select black and white if checking B/W print quality.
  • Page 44 4080-001 Action Engine Board Perform the Clean Heads from the diagnostic mode. Look for a break in the diagonal line of the Printhead Cable test pattern. A broken line indicates one or more Rubber Backer print nozzles are not working. Run the test again to verify the failure.
  • Page 45 4080-001 Action Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: • Correct type of paper is being used. • Paper for curl or wrinkles. • Feed rollers for wear, dirt, or looseness. •...

  • Page 46: Transport Service Check

    4080-001 Transport Service Check Note: If the carrier strikes the left side frame and continues to drive into the frame, refer to the “Transport Service Check II” on page 2-25. Action Transport Motor Check the motor for binds, or loose motor pulley. Disconnect the transport motor (J5) from the engine board.

  • Page 47: Transport Service Check Ii

    4080-001 Transport Service Check II Carrier strikes left side frame and continues to drive into frame Note: Be sure the printer is unplugged from the AC outlet before performing this service check. • Check the carrier cable connection at (CN2) and encoder connection at (CN1) on the engine board.
  • Page 48 4080-001 Paper does not feed, but gears turn Action Drive Belt Check for binds and any obstructions in the paper path. Be sure the tray 2 and drive gear are properly installed. Be sure the drive belt is properly installed. Autocompensator Check the autocompensator and clutch spring.

  • Page 49: User Error Messages

    4080-001 User Error Messages Message Explanation 30 Cartridges Missing: Press the Go button to clear the error. At this point the Supplies status appears on the • Color display and the cartridge missing shows in the • Black supplies menus. This remains until the user •...
  • Page 50 4080-001 Message Explanation 54 Parallel Error This error occurs when a IEEE 1284 protocol error has been detected on the parallel host interface, or due to a faulty cable. Once a host interface error has been displayed for the first time, reporting of further host interface errors for the associated port is suppressed until the interface parameters are changed, or the printer is powered off.
  • Page 51 4080-001 Message Explanation 56 Serial x Port Disabled This error occurs when data is sent to the printer across the optional serial port x (where x=1, 2, or 3), but the port is disabled. Once the error displays the first time, reporting of further errors is suppressed until the menus are entered, or the printer is reset.
  • Page 52 4080-001 Message Explanation 62 Disk Full Press Go to clear the message and continue processing the job. All downloaded fonts and macros not written to disk are deleted. Press Menu> or Menu< to access the reset function in the Busy/Waiting Menu group. Note: The menu buttons are not active when Reset Control is Off.

  • Page 53: Diagnostic Aids

    4080-001 3. Diagnostic Aids Diagnostic Mode To enter the Diagnostic Mode: 1. Turn the printer off. 2. Press and hold the Go and Return buttons. 3. Turn the printer on. 4. Release the buttons when Performing Self Test displays on the operator panel.

  • Page 54: Aligning The Cartridges

    4080-001 Aligning the Cartridges 1. Enter Diagnostics Mode. 2. Select Align Cartridges. 3. Press <MENU> to select the test. 4. Press Select • Horizontal Align • Vertical Align • Bi-di Black Align • Bi-di Color Align 5. Test (A) Alignment = XX* - The alignment can be changed by pressing <MENU>...

  • Page 55: Error Log

    4080-001 Error Log Viewing the Error Log The error log is helpful to the servicer by providing a history of printer errors. The error log contains the 12 most recent errors. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred).

  • Page 56: Hardware Tests

    4080-001 Hardware Tests The following Hardware Tests can be selected from this menu: • Clean Heads • LCD Test • Button Test • DRAM Memory Test • ROM Memory Test • Parallel Wrap (if available) • Serial Wrap (if available) LCD Test To run the LCD Test: 1.

  • Page 57: Dram Memory Test

    4080-001 DRAM Memory Test The purpose of this test is to check the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Memory Test: 1.

  • Page 58: Rom Memory Test

    4080-001 ROM Memory Test The ROM Memory Test is used to check the validity of the RIP code and fonts. To run the ROM Memory Test: 1. Select ROM Memory Test from the menu. P and F represent the same numbers for DRAM. The power indicator blinks indicating the test is in process.

  • Page 59: Serial Wrap Test

    4080-001 Serial Wrap Test This test is used to check the operation of the Serial Port Hardware using a wrap plug. Each signal is tested. To run the Serial Wrap Test: 1. Disconnect the serial interface cable and install the wrap plug. 2.

  • Page 60: Device Tests

    4080-001 Device Tests Hex Trace Hex Trace can be used to help diagnose print job problems. To invoke the Hex Trace: 1. Select Hex Trace from the Tests Menu. 2. Send a print job to the printer. (The document should print in both hexadecimal and character formats.) 3.

  • Page 61: Disk Test/Clean

    4080-001 Disk Test/Clean WARNING: This test destroys all data on the disk and should not be attempted on a good disk. Also note that this test may run approximately 1 1/2 hours depending on the disk size. To run the Disk Test/Clean Test: 1.

  • Page 62: Flash Test

    4080-001 Flash Test This test causes the file system to write and read data on the flash to test the flash. WARNING: This test destroys all data on the flash because the flash is reformatted at the end of the test. To run the Flash Test: 1.

  • Page 63: Printer Setup

    4080-001 Printer Setup Setting the Page Count This lets the servicer change the page count from the diagnostic menu. This is used whenever the engine board is replaced because this board contains the printer's NVRAM Memory where the page count is stored. To set the Page Count: 1.

  • Page 64: Restore Factory Defaults

    4080-001 Restore Factory Defaults To restore each of the printer settings contained in the Setup menu to their factory default value select Restore from the menu. To exit the menu without restoring the settings to the factory default values, select Do Not Restore. Sometimes this is used to help correct print quality problems.

  • Page 65: Print Quality Test Page

    4080-001 Print Quality Test Page The purpose of this diagnostic function is to allow printing of the print quality test page. This page must always be printed on letter, legal or A4 paper. To run the Print Quality Test Page: 1.

  • Page 66: Printing Menu Settings Page

    4080-001 Printing Menu Settings Page This test page must be printed on letter, legal or A4 paper. To print the Menu Settings Page: 1. Select the TESTS MENU. 2. Select Print Menus from the TESTS MENU. The page contains the following information: •...

  • Page 67: Test Page (Quick Test)

    4080-001 Test Page (Quick Test) Note: Paper can be fed from Tray 1 or the optional Tray 2. To run a quick test page of black, be sure the print cartridges are in good condition. Install a black print cartridge in the left side of the printhead cradle and a color print cartridge in the right side.
  • Page 68 4080-001 3-16 Service Manual...

  • Page 69: Repair Information

    4080-001 4. Repair Information This chapter explains how to make adjustments to the printer and how to remove defective parts. Note: Read the following before handling electronic parts. When working on the printer, always unplug the printer from the electrical outlet.

  • Page 70: Adjustments

    4080-001 Adjustments The user is directed, in the Printer Control program, to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. Unplug the power cord before removing any parts.

  • Page 71: Covers And Doors

    4080-001 Covers and Doors Repair Information...

  • Page 72: Base Assembly Removal

    4080-001 Base Assembly Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to the “Covers and Doors” on page 4-3. 3. Disconnect the controller board cable from the engine board. 4. Remove the eight screws from the left and right side of the carrier frame assembly and remove the frame.

  • Page 73: Controller Board Access Cover Removal

    4080-001 Controller Board Access Cover Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Disconnect the operator panel cable and note the routing. 4. Remove the eight screws from the carrier frame assembly and note the ground strap cable.

  • Page 74: Front Access Door Removal

    4080-001 Front Access Door Removal 1. Remove the input / output tray assembly. 2. Open the front access door, refer to “Covers and Doors” on page 4-3. 3. Depress the plastic hinges releasing the pressure and remove the front access door. Front Cover Removal 1.

  • Page 75: Memory (Simm) Card Cover Removal

    4080-001 Memory (SIMM) Card Cover Removal 1. Remove the input / output tray assembly. 2. Open the front access door, by pulling up on the tab, as shown. 3. Remove the memory (SIMM) card cover. Metal / Plastic Controller Board Cover Removal 1.

  • Page 76: Operator Panel Cover Removal

    4080-001 Operator Panel Cover Removal 1. Remove the input / output tray assembly. 2. Remove the front cover, refer to the “Front Cover Removal” on page 4-6. 3. Disconnect the operator panel cable and note the routing. 4. Remove the four screws securing the operator panel to the front cover, refer to “Covers and Doors”...

  • Page 77: Rear Access Cover Removal

    4080-001 Rear Access Cover Removal 1. Turn the printer around so the back is facing you. 2. Depress the tabs located at the top of the rear access door cover and remove. Repair Information...

  • Page 78: Frames

    4080-001 Frames 4-10 Service Manual...

  • Page 79: Carrier Frame Assembly Removal

    4080-001 Carrier Frame Assembly Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Disconnect the operator panel cable and note the routing. 4. Remove the four screws from the carrier frame assembly and note the ground strap cable.

  • Page 80: Idler Pulley Assembly Removal

    4080-001 Idler Pulley Assembly Removal 1. Remove the input / output tray assembly. 2. Remove the front cover, refer to “Covers and Doors” on page 4-3. 3. Move the printhead carrier assembly to the center of the printer. 4. Release the tension on the idler pulley by pressing the idler pulley toward the transport carrier motor.

  • Page 81: Mid Frame Assembly Removal

    4080-001 Mid Frame Assembly Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Remove the carrier frame assembly, refer to the “Carrier Frame Assembly Removal” on page 4-11.

  • Page 82: Paper Feed

    4080-001 Paper Feed 4-14 Service Manual...

  • Page 83: Exit Roller Assembly Removal

    4080-001 Exit Roller Assembly Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Remove the carrier frame assembly, refer to the “Carrier Frame Assembly Removal” on page 4-11.

  • Page 84: Manual Sheet Feeder Removal

    4080-001 Manual Sheet Feeder Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Disconnect the operator panel cable and note the routing. 4. Depress the manual guide clip on the right side frame and remove the guide from the rear of the printer.

  • Page 85: Paper Tray Assembly Removal

    4080-001 Paper Tray Assembly Removal 1. Open the front access door and remove. Refer to “Covers and Doors” on page 4-3. 2. Move the manual paper guide to the left. 3. Remove the screw from the right side of the paper tray and remove the tray.

  • Page 86: Electronics

    4080-001 Electronics 4-18 Service Manual...

  • Page 87: Code Or Flash Simm Removal

    4080-001 Code or Flash SIMM Removal Note: The code SIMM is installed on some printers. The code SIMM installs in the first option card slot (J6) only. Be sure to properly identify the code SIMM and the flash memory card, if the printer contains both.

  • Page 88: Controller Board Removal

    4080-001 Controller Board Removal Note: Verify that your printer has a code SIMM in slot (J6). 1. Remove the input / output tray assembly. 2. Open the front access door, refer to “Covers and Doors” on page 4-3. 3. Remove the paper tray, refer to the “Paper Tray Assembly Removal”...

  • Page 89: Encoder / Thermistor Card Removal

    4080-001 Encoder / Thermistor Card Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Move the carrier assembly to the right side of the printer. 4. Disconnect the three printhead cables from the engine board. 5.

  • Page 90: Engine Board Removal

    4080-001 Engine Board Removal 1. Remove the input / output tray assembly. 2. Remove all covers (except the base), refer to “Covers and Doors” on page 4-3. 3. Disconnect the three printhead cable connectors from the engine board. 4. Disconnect the controller board cable from the engine card (CN10).
  • Page 91 4080-001 3. Remove the memory (SIMM) card cover, refer to “Memory (SIMM) Card Cover Removal” on page 4-7. 4. Remove the memory (SIMM) card by pushing the metal clips at both ends of the connector outward and lifting the memory (SIMM) card up and out of the printer.

  • Page 92: Operator Panel Removal

    4080-001 To Reinstall: 1. Hold the memory (SIMM) card with the connection points toward the connector and position the notch as shown. 2. Insert the memory (SIMM) card all the way into the connector at a 45° angle, and rotate it down until it snaps into place. 3.

  • Page 93: Operator Panel Cable Removal

    4080-001 Operator Panel Cable Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Disconnect the operator panel cable from the operator panel and note the routing. 4. Remove the carrier frame, refer to the “Carrier Frame Assembly Removal”...

  • Page 94: Power Supply Removal

    4080-001 Power Supply Removal Note: Always unplug the printer from the electrical outlet. High voltage is present in the power supply as long as it is plugged into the electrical outlet. 1. Remove the input / output tray assembly. 2. Remove all covers (except the base), refer to “Covers and Doors”...

  • Page 95: Carrier

    4080-001 Carrier 4-27 Repair Information...

  • Page 96: Carrier Belt Removal

    4080-001 Carrier Belt Removal 1. Remove the input / output tray assembly. 2. Remove the front cover, refer to “Covers and Doors” on page 4-3. 3. Disconnect the operator panel cable and note the routing. 4. Move the carrier assembly to the right side of the printer. 5.

  • Page 97: Carrier Transport Motor Assembly Removal

    4080-001 Carrier Transport Motor Assembly Removal 1. Remove the input / output tray assembly. 2. Remove all covers (except the left and base covers), refer to “Covers and Doors” on page 4-3. 3. Remove the carrier belt, refer to the “Carrier Belt Removal”...

  • Page 98: Printhead Carrier Removal

    4080-001 Printhead Carrier Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Disconnect the three printhead cables from the engine board. 4. Move the carrier assembly to the right side of the printer. 5.

  • Page 99: Maintenance Station

    4080-001 Maintenance Station 4-31 Repair Information...

  • Page 100: Maintenance Station Assembly Removal

    4080-001 Maintenance Station Assembly Removal 1. Remove the input / output tray assembly. 2. Remove all covers, refer to “Covers and Doors” on page 4-3. 3. Remove the two screws at the rear of the maintenance station and remove the maintenance station. Wipers and Caps Removal 1.

  • Page 101: Connector Locations

    4080-001 5. Connector Locations Engine Board Printhead Cable 1 Printhead Cable 2 Printhead Cable 3 Transport Motor Paper Feed Motor CN10 Controller Board Cable EOF Sensor CN11 Optional Tray 2 Sensor Transistor Tab Connector Locations...

  • Page 102: Controller Board

    4080-001 Controller Board Engine Board Power Supply Parallel Port Flash SIMM Code SIMM Memory SIMM INA Option Operator Panel Service Manual...

  • Page 103: Preventive Maintenance

    4080-001 6. Preventive Maintenance This chapter contains the 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 grease P/N 99A0394 to lubricate the following: •...
  • Page 104 4080-001 Service Manual...

  • Page 105: Parts Catalog

    4080-001 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 106: Assembly 1: Covers

    4080-001 Assembly 1: Covers Service Manual...
  • Page 107 4080-001 Assembly 1: Covers Asm- Part Units Description Index Number 1 - 1 99A0637 Cover, Rear Access 99A0636 Door, Code SIMM Access 99A0626 Cover, Metal Controller Board 99A0635 Cover, Plastic Controller Board 99A0623 Cover, Rear 99A0639 Operator Panel 99A0620 Cover, Front 99A0625 Cover, Controller Board Access 99A0763...

  • Page 108: Assembly 2: Frames

    4080-001 Assembly 2: Frames Service Manual...
  • Page 109 4080-001 Assembly 2: Frames Asm- Part Units Description Index Number 2 -1 99A0644 Rail, Carrier 99A0737 Rail, Small Feed Roller Spring Connector 99A0643 Frame, Carrier Asm 99A0732 Frame, Mid 99A0738 Roller, Star Asm 99A0761 Bearings, PP 99A0648 Frame, Right Side Asm 99A0694 Frame, Left Side Asm 99A0759...

  • Page 110: Assembly 3: Paper Feed

    4080-001 Assembly 3: Paper Feed Service Manual...
  • Page 111 4080-001 Assembly 3: Paper Feed Asm- Part Units Description Index Number 3 -1 99A0736 Roller, Small Feed Asm 99A0733 Holder, Small Feed Roller Asm 99A0735 Roller, Large Feed Asm with Gear 99A0738 Roller, Star Asm 99A0729 Sheet Feeder, Manual 99A0728 Roller, Exit Asm 99A0649 Paper Lifter, Right...

  • Page 112: Assembly 4: Electronics

    4080-001 Assembly 4: Electronics Service Manual...
  • Page 113 4080-001 Assembly 4: Electronics Asm- Part Units Description Index Number 99A0765 Board, Engine w/o EPROM 99A0748 Board, Engine 99A0751 Card, Encoder w/ Thermistor 99A0762 Sensor, Tray 2 99A0754 Power Supply, 100-240 V (Universal) 99A0749 Code SIMM 99A1114 Board, Controller 99A0753 Cable, Controller Board 99A0639 Panel, Operator...

  • Page 114: Assembly 5: Carrier

    4080-001 Assembly 5: Carrier 7-10 Service Manual...
  • Page 115 4080-001 Assembly 5: Carrier Asm- Part Units Description Index Number 5 -1 99A0740 Carrier, Printhead Asm 99A0757 Screws, (PP) 99A0751 Encoder Card w/ Thermistor 99A0734 Shaft, Carrier 99A0758 Spring, Carrier Shaft (PP) 99A0745 Printhead Interlock Key B/M 99A0761 Bearings (PP) 99A0761 Clamp, Bearings (PP) 13A3860...

  • Page 116: Assembly 6: Carrier Transport

    4080-001 Assembly 6: Carrier Transport 7-12 Service Manual...
  • Page 117 4080-001 Assembly 6: Carrier Transport Asm- Part Units Description Index Number 6 -1 99A0742 Motor, Carrier Transport 99A0744 Belt, Carrier 99A0646 Strip, Encoder 99A0757 Screw, Carrier Transport Motor (PP) 99A0645 Retainer, Encoder Strip 99A0743 Pulley, Idler Tension Asm 99A0644 Rail, Carrier 7-13 Parts Catalog...

  • Page 118: Assembly 7: Maintenance Station

    4080-001 Assembly 7: Maintenance Station 7-14 Service Manual...
  • Page 119 4080-001 Assembly 7: Maintenance Station Asm- Part Units Description Index number 7 -1 99A0755 Maintenance Station Asm 99A0756 Wiper and Cap B/M (PP) 7-15 Parts Catalog...

  • Page 120: Assembly 8: Options

    4080-001 Assembly 8: Options Asm- Part Units Description Index number 99A0517 Card, Memory SIMM 4MB 99A0518 Card, Memory SIMM 8MB 99A0519 Card, Memory SIMM 16MB 99A0520 Card, Memory SIMM 32MB 99A0724 Card, Memory SIMM 64MB 99A0726 Card, Memory SIMM - Japan DBCS Simm-1 99A0521 Card, Flash Memory 1MB 99A0522...

  • Page 121: Index

    4080-001 Index Abbreviations Maintenance Approach Adjustments Aids Aligning Cartridges Plastic Latches Clearing the Log POST Diagnostic Sequence Diagnostic Mode Power Consumption Error Log Printer Setup 3-11 Factory Defaults 3-12 Problems Paper Lifters Operation Carrier Transport Printing Menu Settings 3-14 Communications Setting Page Count 3-11 Dead Machine...
  • Page 122 4080-001 Print Quality 2-21 Logic Card Access Electronics Transport 2-24 2-25 An Illustration 4-18 Transport II 2-25 4-19 Code SIMM Start Controller Board 4-20 Symptom Tables 4-21 Encoder Card Engine Board 4-22 4-19 Flash SIMM Memory (SIMM) Card 4-22 Tests 4-24 Operator Panel Operator Panel Cable...

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