Lexmark J110 - Manuals

viii Service Manual 4085-001 Safety Information • This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement...

Safety Information ix 4085-001 Norme di sicurezza • Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark n...

x Service Manual 4085-001 Pautas de Seguridad • Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lex...

Safety Information xi 4085-001 Informació de Seguretat • Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre ...

General Information 1-1 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 us...

1-2 Service Manual 4085-001 Internal Power Supply Specifications Built-in Universal Power Supply, 40 Watts Output (50 Watts input)Outputs: Note: Current of 1.0 A is long term average current. The +36 V output can supply peak currents of 2.1 A for 100ms or less and 3.2 A for 30 ms or less. Maintenanc...

1-4 Service Manual 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 func...

General Information 1-5 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 inform...

1-6 Service Manual 4085-001 Printer Messages The operator panel displays three types of messages: • Status messages provide information about the current state of the printer. • Attendance messages indicate printer errors that you must resolve. • Service messages indicate printer failures that may r...

General Information 1-7 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...

1-8 Service Manual 4085-001 Printing the Menu Settings Page The menu settings page shows current settings for the menus and a list of installed options. You can use this page to verify that the printer options are properly installed and the printer settings are properly set. Note: Before printing th...

General Information 1-9 4085-001 Changing Printer Settings You can use the operator panel to change printer settings and customize your printer to meet your specific needs. To select a new value as the default setting: 1. From the Ready state, press Menu> or <Menu to enter the menus. 2. Contin...

1-10 Service Manual 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 ...

Diagnostic Information 2-1 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...

2-2 Service Manual 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 recov...

Diagnostic Information 2-3 4085-001 Error Indicator Table Error Symptom Action 900 RIP Software Perform the “RIP Card Service Check” on page 2-64 . 902 Engine Software Replace the engine board. See the “Engine Board / Cover Removal” on page 4-14 . 903 RIP Software Check RIP/Engine cable. Replace the...

2-10 Service Manual 4085-001 User Status Messages User Status Message Status Action Ready The printer is ready to receive and process data from a host system. Press Menu> or Menu< to take the printer offline and access the Ready Menu group. The following function may be available via the Busy/...

Diagnostic Information 2-13 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 ...

2-14 Service Manual 4085-001 Status Messages These messages provide the operator with information on the current state of the printer. Status Message Status Action Activating Menu Changes The printer is being reset to activate a printer setting changed in the menus. No buttons are active while this ...

2-24 Service Manual 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 ...

2-28 Service Manual 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...

2-40 Service Manual 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 acti...

Diagnostic Information 2-41 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 t...

2-44 Service Manual 4085-001 – Reset Printer Note: Menu Lockout does not prevent access to the Busy/Waiting Menu group. Note: If no function in the Busy/Waiting group is available, the Menus Disabled message is temporarily shown when Menu> or Menu< is pressed. Unsupported Ink Cartridge The abo...

Diagnostic Information 2-45 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...

2-46 Service Manual 4085-001 Error Recovery from Attendance Conditions Attendance Condition Error Type Auto ContinueAvailable Sound Alarm (if Enabled) A Alignment Type 1 No No Cartridge Life Expired <cart(s)> Type 1 No Yes Cartridge Life Warning <cart(s)> Type 1 No Yes Change <src>...

2-48 Service Manual 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...

Diagnostic Information 2-49 4085-001 Post Symptom Table Symptom Action Blank display, carrier moves, paperfeed motor turns See the “Operator Panel (LCD) Display Service Check” on page 2-59 . All diamonds on display See the “Operator Panel (LCD) Display Service Check” on page 2-59 . Performing Self T...

2-50 Service Manual 4085-001 Symptom Tables Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems Communications Problems Maintenance Station Problems Symptom Action • No carrier movement• Slow carrier movement• Carrier stops• Carrier does not move to...

Diagnostic Information 2-51 4085-001 Operator Panel Problems Paper Feed Problems Power Problems Symptom Action Printer indicator light does not: • Turn on• Flash• Turn off• All diamonds See the “Operator Panel (LCD) Display Service Check” on page 2-59 . One or two pels missing Replace the operator p...

2-52 Service Manual 4085-001 Print Quality Problems Symptom Action • Voids in characters• Light print• Prints off the page• Fuzzy print• Carrier moves but does not print• Printhead drying prematurely• Vertical alignment off• Excessive ink flow (flooding)• Horizontal banding See the “Print Quality Se...

Diagnostic Information 2-53 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 an...

Diagnostic Information 2-55 4085-001 Maintenance Station Service Checks FRU Action 1 Maintenance Station Assembly The maintenance carrier is driven in a front to rear motion by the maintenance stepper motor. A homing sensor is provided at the rear of the maintenance station to home the maintenance c...

2-56 Service Manual 4085-001 Index Motor Service Check Sensor Checks See “Diagnostics (Mode 2) - Input Tray Tests” on page 3-27 and “Diagnostics (Mode 2) - Base Sensor Tests” on page 3-29 . FRU Action 1 Index Motor Check the following motor pins for approximately 12.5 ohms: (J16-1) and (J16-2) If re...

Diagnostic Information 2-57 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 e...

Diagnostic Information 2-59 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 li...

2-60 Service Manual 4085-001 Paper Feed Service Check Note: Be sure the printer is unplugged from the AC outlet before performing this service check. If you are experiencing a paper jam: 1. Check the 200 error code paper jams. See “Paper Jams” on page 2-40 . 2. Check the entire paper path for obstru...

Diagnostic Information 2-63 4085-001 Power Supply 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 RIP card, engine board, or any of the installed option cards or assemb...

2-64 Service Manual 4085-001 RIP Card Service Check 2 Power Line Cord Check the power line cord for damage. Check the continuity of the line cord and replace if necessary. 3 Power Switch Check the continuity on the power switch. If incorrect, replace the power switch. 4 Power Supply With the power s...

Diagnostic Information 2-65 4085-001 Print Quality Service Check Note: Before troubleshooting any print quality problem, be sure the cartridge is in good condition. Set print quality to normal and be sure the correct paper type is selected in the Paper Menu. FRU Action The machine print quality can ...

Diagnostic Information 2-67 4085-001 Index Card/Sensor Service Check Transport Service Check Note: If the carrier strikes the left side frame and continues to drive into the frame, then see page 2-48. Go to the “Carrier System Test” on page 3-32 . FRU Action 1 Index motor does not work. If the index...

Diagnostic Information 2-69 4085-001 Cam System Motor/Sensor Service Check User Error Messages FRU Action 1 Motor does not work. Bat Wings do not move. Check the voltage at connector (J8) on the engine board. At pins 1, 2, 3, and 4 with the power on. There should be approximately +34 V dc on each pi...

2-70 Service Manual 4085-001 38 Memory Full Press Go to clear the message and continue processing the job. Some data will be lost. You must allow additional memory to complete your print job by: • Deleting fonts, macros, and other data in RAM. • Simplifying your print job.• Installing additional mem...

Diagnostic Aids 3-1 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 ...

3-2 Service Manual 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. ...

Diagnostic Aids 3-3 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 Te...

3-4 Service Manual 4085-001 Use the following steps to enter Flash Engine Code mode: 1. Turn off the printer. 2. Press and hold the buttons identified by the “Power-On Reset Button Functions” on page 3-1 . 3. Turn on the printer. Release the buttons once the performing self Test message is displayed...

Diagnostic Aids 3-5 4085-001 If an unsupported printhead is installed, an Attendance Message is shown. This can occur if the software keys in the printer and printhead are incompatible, as in the case of an OEM printer using Lexmark-branded printheads. Following a printhead replacement, the printer ...

Diagnostic Aids 3-7 4085-001 Cleaning Printheads The Clean Printheads operation is used to clean and maintain the printheads. This mechanical operation performed by the print engine is recommended when print quality becomes degraded. There are two classes of cleaning that can be performed: • Short C...

3-8 Service Manual 4085-001 Print Quality Test Page Fixed Settings As the operation is performed, Cleaning Printheads is displayed. 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 ...

3-10 Service Manual 4085-001 Unsolicited Manual Feed When configured without a MP Feeder, a user may perform an unsolicited manual feed. Prior to sending a job (or before the first page of the job is picked), a user sticks a piece of paper in the manual slot. The engine “grabs” the paper and pulls i...

Diagnostic Aids 3-11 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 Cus...

3-12 Service Manual 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. Restoring Factory Defaults The Factory Defaults operation returns most of ...

3-14 Service Manual 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 cance...

3-16 Service Manual 4085-001 Invoking Reset Printer (from the Ready message) 1. Press Menu> or Menu< to enter the menus. The following screen is displayed. 2. Press Menu> or Menu< until JOB MENU is displayed on the second line. Press Select. The following screen is displayed. 3. Press Se...

Diagnostic Aids 3-17 4085-001 Other Resets Power On Reset -- and similar resets When the printer is turned on, the following events occur: • Fixed default settings are set to factory set values. • Portions of printer memory that store page, font, and macro information are cleared. Other resets which...

3-18 Service Manual 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 ...

Diagnostic Aids 3-19 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...

3-20 Service Manual 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. Terminology: • T represents Top Margin and L represents Left Margin. • s represents the sign for negat...

3-22 Service Manual 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. Contacts Page Fixe...

Diagnostic Aids 3-23 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. While a button is pressed, CL (Closed) is displayed. Likewise, while a button is not pressed, OP (Open) is displayed...

3-24 Service Manual 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, th...

Diagnostic Aids 3-25 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:...

Diagnostic Aids 3-27 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: Terminology: • PO or Paper Out ...

3-28 Service Manual 4085-001 sensor is open, OP is displayed. If the wrong message is displayed, the sensor is malfunctioning. PO=OP = EmptyPO=CL = Not Empty PT=OP = Media ClearPT=CL = Media Present To exit the test, select Return or Stop. MP Feeder Sensor Test This test determines whether or not th...

Diagnostic Aids 3-29 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: Termino...

3-30 Service Manual 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 dis...

Diagnostic Aids 3-31 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: First the printheads are uncapped. The printheads move to the middl...

3-32 Service Manual 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: Once the test is initia...

Diagnostic Aids 3-33 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: The index system is run open loop and the real time position count is disp...

Diagnostic Aids 3-35 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: To exit the test, select Return or Stop.Note: If zero is displayed on “K”= or “C”=, replace the prin...

3-36 Service Manual 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) bl...

Diagnostic Aids 3-37 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. When the reset operation is comple...

3-38 Service Manual 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: 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 men...

Diagnostic Aids 3-39 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 th...

3-40 Service Manual 4085-001 The buttons always act on the information displayed on the second line of the display. The buttons act as follows while the PAPER MENU screen is displayed: • Menu> displays the next menu in the list. • Menu< displays the previous menu in the list. • Return returns ...

Diagnostic Aids 3-41 4085-001 Printer Setting Value List Display 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 assign...

3-42 Service Manual 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 D...

3-44 Service Manual 4085-001 Operator Panel Menu Definition The operator panel settings and operations are divided into 4 menus groups, which are described in the following table. Menu Groups Busy/Waiting Menu Group The Busy/Waiting menu group contains the operations that are accessible when the pri...

Diagnostic Aids 3-45 4085-001 Busy/Waiting Menu Group The Busy/Waiting Menu group contains two menus: JOB MENU and SUPPLIES MENU. Press Menu> from the BUSY screen and the following screen is displayed. The following table shows the menus in the Busy/Waiting Menu group. Configuration Menu Group Th...

3-46 Service Manual 4085-001 Job Menu Job Menu Operations Operation Value or Description Cancel Job Note: This operation is only displayed in the JOB MENU when the menu is accessed through the Busy/Waiting Menu Group if Cancel Control is ON. (If a job is active, then the printer checks the value sel...

3-48 Service Manual 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...

Diagnostic Aids 3-49 4085-001 SUPPLIES MENU The Supplies Menu updates as changes occur even if you are viewing it.The list is only status for the items which are near or past replacement. JOB MENU See “JOB MENU” on page 3-54 for a list of the operations. SETUP MENU See “SETUP MENU” on page 3-54 for ...

3-50 Service Manual 4085-001 COLOR MENU The following table lists the settings in the COLOR MENU and their corresponding value choices. The factory default setting for each item is indicated with an asterisk. Yellow Cartridge =Low =Refilled =Life Warning Black Printhead =Life Warning Color Printhead...

Diagnostic Aids 3-51 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. If the Paper Source, Separator Source, or Staple Prime Source is set to MP Feeder whe...

3-52 Service Manual 4085-001 UTILITIES MENU The following table lists the operations in the TESTS MENU. For a detailed description of each operation, see “Printer Operations” on page 3-1 . Separator Sheets =None* =Between Jobs =Between Pages Separator Source Note: Only installed paper sources are di...

3-54 Service Manual 4085-001 JOB MENU The following table lists the operations in the JOB MENU. SETUP MENU The following table lists the menus and printer settings in the SETUP MENU, and their corresponding values. The factory default value for each setting is indicated by an asterisk. Factory Defau...

Diagnostic Aids 3-55 4085-001 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 =Por...

3-56 Service Manual 4085-001 PCL EMUL MENU The following table lists the menus and settings in the PCL EMUL MENU, and their corresponding values. The factory default value for each setting is indicated by an asterisk. Note: Saving Font Source, Font Name, Point Size, Pitch, or Symbol Set has the affe...

Diagnostic Aids 3-57 4085-001 Font Name Display Format The font names are shown on both lines of the operator panel using the following format. An equal sign precedes the font name, signifying the value list level of the menus. S represents the font source abbreviation (R for resident, D for downloa...

3-58 Service Manual 4085-001 Symbol Set Display Format The symbol sets are shown on both lines of the operator panel using the following format. 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 s...

Diagnostic Aids 3-59 4085-001 a Whenever the value of NPA Mode, Parallel Buffer, or Job Buffering is changed from the operator panel, the printer automatically restarts upon exiting the menus to reconfigure memory. USB MENU The following table lists the menus and printer settings contained in the US...

3-60 Service Manual 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 displa...

Repair Information 4-1 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 ...

4-2 Service Manual 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...

Repair Information 4-3 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 4-5 4085-001 Operator Panel Cover/Operator Panel Removal 1. Remove the rear cover. 2. Remove the screw {A}. 3. Lift the cover and unplug the operator panel from the engine board. 4. Remove the four screws located on the rear operator panel housing. 5. Remove the operator panel. Ex...

4-6 Service Manual 4085-001 Left Frame Cover Removal 1. Open the top door. 2. The restraint screw does not have to be removed. The restraint has a T-end which can be twisted and removed. Partially close the top cover, twist the end of the strap that is in the machine and remove. 3. Remove the two sc...

Repair Information 4-7 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. 6. Remove the cove...

Repair Information 4-9 4085-001 Right Cover/Power Switch Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the exit tray. Refer to “Exit Tray Removal” on page 4-5 . 3. Remove the operator panel cover. Refer to “Operator Panel Cover/Operator Panel Removal” on pag...

Repair Information 4-11 4085-001 Left Tray Cover Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5 . 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7 . 4. Remove the three screws {A...

4-12 Service Manual 4085-001 Right Tray Cover Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5 . 3. Remove the right cover. Refer to “Right Cover/Power Switch Removal” on page 4-9 . 4. Remove the thr...

4-14 Service Manual 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. R...

Repair Information 4-15 4085-001 Carrier with Card Removal 1. Remove all covers. 2. Remove all ink cartridges from carrier. 3. Remove engine board cover. Refer to “Tray 2 Covers Removal” on page 4-49 . 4. Loosen the set screw {A} on the belt tensioner. 5. Remove the tension from the belt and retight...

Repair Information 4-19 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 fra...

4-22 Service Manual 4085-001 Index Card Assembly Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5 . 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7 . 4. Unplug the index board con...

Repair Information 4-23 4085-001 Cover-Open Sensor Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5 . 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7 . 4. Remove the engine card c...

Repair Information 4-27 4085-001 Frame From Base Removal 1. Remove all covers. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the power supply. Refer to “Power Supply Removal” on page 4-19 . 3. Remove the maintenance tank through the rear of the printer. 4. Disconnect (J2) the transport carri...

Repair Information 4-29 4085-001 Cam Engine Motor with Gear Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the exit tray cover. Refer to “Exit Tray Removal” on page 4-5 . 3. Remove the left cover. Refer to “Left Cover Removal” on page 4-7 . 4. Disconnect the ...

4-32 Service Manual 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 cartrid...

Repair Information 4-33 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...

4-34 Service Manual 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 Rem...

4-36 Service Manual 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 Was...

4-38 Service Manual 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 Statio...

Repair Information 4-39 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 T...

Repair Information 4-43 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 ...

Repair Information 4-45 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/Maintena...

4-46 Service Manual 4085-001 Bat Wings and Bushings Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the spring between the cam followers. 3. Remove the two E-clips from the ends of the bat wing shaft. 4. Remove bushings. 5. Pull forward and remove.

Repair Information 4-47 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 ...

Repair Information 4-49 4085-001 Peristaltic Pump Removal 1. Remove the rear cover. Refer to “Rear Cover Removal” on page 4-3 . 2. Remove the exit tray. Refer to “Exit Tray Removal” on page 4-5 . 3. Remove the operator panel cover. Refer to “Operator Panel Cover/Operator Panel Removal” on page 4-5 ....

4-50 Service Manual 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. Slide the shaft to the left and remove the pick arm asse...

4-52 Service Manual 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. Disconnect the paper feed mo...

Connector Locations 5-1 4085-001 5. Connector Locations Engine Board J1 Power Supply J2 Carrier Motor J3 Maintenance Station Motor and Homing J4 Operator Panel J5 Thin-Coat Motor and Encoder J6 Integrated Tray J8 Cam System J9 Thin-Coat Sensing J10 MPF-Feeder J11 Paper-Path Sensing J12 Ink-Level and...

5-4 Service Manual 4085-001 Optional Tray 2 J1 Paper Feed Motor J2 Passthru Sensor J3 Paper Feed Pic Motor J4 Paperport II and Power

Preventive Maintenance 6-1 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....

6-2 Service Manual 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 ...

Parts Catalog 7-1 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 par ts packet.

Parts Catalog 7-5 4085-001 Assembly 2: Paper Feed Asm-Index Part Number Units Description 2-1 12G6024 1 Paper Out Sensor 2 12G6000 1 Paper Feed Pick Assembly with Motor 3 12G6092 2 Pick Tires

7-10 Service Manual 4085-001 Assembly 3: Electronics

Parts Catalog 7-11 4085-001 Assembly 3: Electronics Asm-Index Part Number Units Description 3-1 12G6059 1 RIP Card 2 12G6058 1 Shield, RIP Enclosure 3 12G6067 1 Cable, Operator Panel 4 12G6066 1 Operator Panel Assembly 5 12G6057 1 Power Supply 6 12G6048 1 Engine Board 7 12G6055 1 Sensor, Ink Level 8...

7-16 Service Manual 4085-001 Assembly 4: Carrier Transport

Parts Catalog 7-17 4085-001 Assembly 4: Carrier Transport Asm-Index Part Number Units Description 4-1 12G6033 1 Shaft, Upper Carrier with Brackets 2 12G6037 1 Belt, Carrier Drive with Keepers 3 12G6038 2 Pulley Assembly with Shaft-Top Idler 4 12G6040 1 Clip, Encoder Strip 5 12G6039 1 Encoder, Carrie...

7-18 Service Manual 4085-001 Assembly 5: Maintenance Station

Parts Catalog 7-19 4085-001 Assembly 5: Maintenance Station Asm-Index Part Number Units Description 5-1 12G6056 1 Waste Ink Bottle with Belt Shield 2 12G6022 1 Maintenance Regulator Assembly 3 12G6019 1 Maintenance Motor Assembly with Gear 4 12G6021 1 Peristaltic Pump Assembly 5 12G6020 1 Maintenanc...

7-20 Service Manual 4085-001 Assembly 6: Optional Tray 2

Parts Catalog 7-21 4085-001 Assembly 6: Optional Tray 2 Asm- Index Part Number Units Description 6-1 12G6088 1 Cover, Rear (OP Tray 2) 2 12G6002 4 Wear Strips 3 12G6049 1 Paper Feed Pick Assembly with Motor - 250 Option Final Assembly 4 12G6046 1 Sensor, Tray 2 Passthru 5 12G6086 1 Cover, Right Side...

7-22 Service Manual 4085-001 Assembly 7: Optional Multi-Purpose Feeder

Parts Catalog 7-23 4085-001 Assembly 7: Optional Multi-Purpose Feeder Asm- Index Part Number Units Description 7-1 12G6077 1 Guide, MPF Rear Paper 2 12G6011 1 Feeder, Auxillary Sheet 3 12G6084 1 MFP Motor with wire

Parts Catalog 7-25 4085-001 Assembly 8: Optional MarkNet External Print Server Asm- Index Part Number Units Description 8-1 12G6090 1 MarkNet™ External Print Server NS 12G6251 1 MarkNet XP Cable

X-1 4085-001 A Abbreviations 1-3 Adjustments 4-2 Aids Diagnostic 3-1 Printer Operations 3-1 Aligning Printheads 3-5 Assemblies 1 Covers 7-2 2 Paper Feed 7-4 , 7-6 , 7-8 3 Electronics 7-10 4 Carrier Transport 7-16 5 Maintenance Station 7-18 6 Optional Tray 2 7-20 7 Optional Multi-Purpose Feeder 7-22 ...

X-3 4085-001 Operator Panel (Buttons) 2-58 Operator Panel (LCD) Display 2-59 Options 2-59 Paper Feed 2-60 Power Supply 2-63 Print Quality 2-65 RIP Card 2-64 Transport 2-67 Service Messages 2-2 Start 2-1 Status Messages 2-14 Symptom Tables 2-50 T Tests Cap Printheads 3-31 Carrier System 3-32 DRAM Mem...