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Diagnostic aids, Theory of operation, Power-On Self Test sequence - fuser unit

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5055-xxx Diagnostic aids 3-1 Power-On Self Test sequence 3-1 Using the operator panel 3-2 Operator panel buttons 3-3 Printing the menu settings 3-4 Operator menu disabled 3-4 Menu overview 3-4 Diagnostic Mode 3-6 Adjustment example 3-8 Print tests 3-10 Hardware tests 3-12 High-capacity feeder tests 3-18 Finisher tests 3-20 Device tests 3-23 Diagnostics - printer setup 3-26 Defaults 3-26 Viewing and resetting the drum counters 3-28 Diagnostics - error log 3-31 Theory of operation 3-33 Processes and configuration 3-33 Electrophotography process 3-33 Development unit 3-34 Transfer unit 3-34 Cleaning unit 3-35 Paper feeding / fusing 3-35 Drive system 3-36 Paper feeding 3-37 Cassette paper feeder 3-37 Multipurpose feeding 3-38 Registration unit 3-38 Separation unit 3-39 Fuser unit 3-40 Delivery 3-41 Belt unit 3-42 Belt up/down 3-43 Expansion paper feeder 3-43 Duplex unit 3-44 Paper weight 3-45 Clearing paper jams 3-46 High-capacity feeder (HCF 3-52 Maintenance Mode 3-60 Finisher 3-61 v

Section	Page
Contents	3
Safety information	11
Consignes de sécurité	11
Norme di sicurezza	12
Sicherheitshinweise	12
Pautas de Seguridad	13
Informações de Segurança	13
Informació de Seguretat	14
Preface	16
Definitions	16
1. General information	17
Overview	17
Resolution	17
Model differences	17
Technical specifications	18
Toner darkness	18
Color correction settings	18
Physical specifications and weight	19
Print speed and performance	20
Performance	21
Time to first print	21
Processor	21
Duty cycle	21
Printer memory	22
Memory configuration	22
Available memory options	22
Flash memory options	22
Memory and expansion slots	22
Resident fonts	23
Paper and media specifications	24
Input and output configurations	24
Media size supported	26
Input	26
Output	28
Input media types and weights	31
Output media types and weights	32
Input capacity by media and source	34
Output capacity by media and source	35
Media guidelines	36
Paper	36
Envelopes	36
Transparencies	37
Labels	37
Lexmark glossy paper	37
Print area	37
Options and features	38
Connectivity	39
Standard	39
Optional internal local connections	39
Network connections	40
Internal network connections	40
External network connections	40
Standard Ethernet and MarkNet compatibility	40
Data streams	41
Operating systems	41
Power and electrical specifications	42
Power requirements	42
Electrical specifications	42
Low voltage models	42
High voltage models	42
Operating clearances	43
Environment	43
Printer temperature and humidity	43
Operating	43
Power Off	43
Shipping printer without print cartridges	44
Storing printer without print cartridges	44
Shipping supply items	44
Storing supply items	44
Maintenance approach	45
Standard inspection and cleaning procedure	45
Return parts	46
Service recommendations	46
Tools	47
Serial number, configuration ID, and part number	48
Abbreviations	49
2. Diagnostic information	51
Adjustments and procedures following parts replacement	51
Start	53
Initial check	53
Printer messages	54
Service error message tables	54
900 - Unrecoverable Software Error	54
910 - Drive Motor Error	54
911 - Paper Exit Motor Error	55
912 - High-Capacity Feed Motor Error	55
917 - RIP Fan Error	55
918 - Main Unit Fan Error	56
919 - Power Supply Fan Error	56
920 - Fuser Error-Fuser Heater Trouble	56
923 - Upper Fuser Thermistor Open Error	57
924 - Lower Fuser Thermistor Open Error	57
925 - HVU Error	58
926(K), 927(C), 928(Y), 929(M) - Toner Sensor Error	59
930 - Yellow Printhead Error	60
931 - Magenta Printhead Error	61
932 - Cyan Printhead Error	62
933 - Black Printhead Error	63
934 - Color Drum Sensor Error	64
935 - Black Drum Sensor Error	64
936 - 939 Cassette Error	65
940 - High-Capacity Feed Sensor Error	65
941 - High-Capacity Feed Tray Error	65
942 - Duplex Error	66
945 - Engine Flash Error	66
946 - Printer/Printhead Controller Board Communication Error	66
947 - Finisher Communication Error	67
948 - Machine ID Error	67
949 - Tray (x) Comm	68
950 - Pr Control Board	68
952 - NVRAM Chip Failure	68
954 - NVRAM CRC Failure	68
955 - Code CRC	69
956 - Processor Failure	69
957 - ASIC Failure	69
958 - NAND Failure	69
960 - RAM Slot 1 Bad	69
961 - RAM Slot 2 Bad	69
962 - RAM Slot 3 Bad	69
964 - Emulation Error	69
970 - Standard Network Error	70
975 - Unrecognizable Network Port	70
976 - Unrecoverable Software Error in Network Port	70
978 - Bad Checksum While Programming Network Card	70
979 - Flash Parts Failed While Programming Network Port	70
980 - Face Up/Down Switching Error	71
981 - Belt Up/Down Sensor Error	72
982 - Sensor Controller Error	73
983 - Black Gear Sensor Error	74
984 - Yellow Gear Sensor Error	74
985 - Transfer Belt Thermistor Error	75
986 - Transparency (OHP) Sensor Error	75
992 - Temperature/Humidity Sensor Error	76
993 CPU Error	76
994 - Density Sensor Error	77
995 - Finisher Main Feed Motor abnormal	78
996 - Finisher Jogging Motor Error	80
997 - Finisher Tractor Motor Error	81
998 - Tray Elevator Motor Error	82
999 - Stapler Motor Error	83
Attendance messages	84
Clearing finisher messages	102
Maintenance analysis procedures (MAPS)	104
Map 1 - False Side Door Open message	104
Map 2 - False Close Front Door message	104
Map 3 - False Close Tray (x) Top Cover message	105
Map 4 - False Tray (x) Low/Empty message	106
Map 5 - False 30 Oil Coating Roll Missing message	107
Map 6 - False <color> Print Unit Missing message	107
Map 7 - False 88 <color> Toner Low/Toner Empty message	108
Map 8 - False 40 Tray (x) Size Sensor Error message	109
Map 9 - False 41 Open Bin 1 Exit Tray message	109
Map 10 - Unrecoverable Check Tray (x) or Duplex Connection message	110
Map 11 - Paper size map	112
Symptom table	113
Finisher	116
Service checks	118
Drive 1 DC motor service check	118
Drive 2 stepper motor service check	118
Duplex unit service check	119
Expansion paper feed service check	119
Face down stacker full service check	120
High-capacity feeder (HCF) service check	120
Finisher service check	121
Marks on paper service check	122
Operator panel service check	123
Paper carrying service check	124
Paper exit, face up service check	132
Paper skew service check	133
Paper tray missing service check	133
Photodeveloper missing service check	134
Power supply service check	135
210 Staple jam service check	136
Transfer belt up/down service check	137
Image quality troubleshooting	138
Print quality problems	138
No image	144
Black line	145
Black print	145
Missing colors	146
Uneven printing	147
Periodic dirt	147
White spots	147
Options service check	148
Serial port	148
Flash Memory Option(s)	148
DRAM Memory Option(s)	148
Hard Disk Option	149
Network Card Option	149
Error Code 976 - Network Card x (x=Network card 1, 2, or 3)	149
54 Network <x> Software Error	149
3. Diagnostic aids	151
Power-On Self Test sequence	151
Using the operator panel	152
Indicator light	152
Operator panel buttons	153
Printing the menu settings	154
Operator menu disabled	154
Menu overview	154
Diagnostic Mode	156
Setting Printer Alignment	157
Adjustment example	158
Summary Notes:	159
Print tests	160
Input Source Print Tests	160
Print Quality Pages	161
Hardware tests	162
LCD Hardware Test	162
Button Test	162
DRAM Memory Test	162
ROM Memory Test	163
Parallel Wrap Test	164
Serial Wrap Tests	166
High-capacity feeder tests	168
High-Capacity Paper Feed Test	168
High-Capacity Paper Feed Sensor / Switch Test	169
Finisher tests	170
Staple Test	170
Hole Punch Test	170
Finisher Sensor Test	170
Device tests	173
Quick Disk Test	173
Disk Test/Clean	174
Flash Test	175
Diagnostics - printer setup	176
Defaults	176
Light Quantity	176
Range = 0 to 45	176
Par S Strobe Adj	177
Par 1 Strobe Adj	177
Par 2 Strobe Adj	177
Par 3 Strobe Adj	177
Auto Color Adj	177
Reset Calibration	177
Viewing and resetting the drum counters	178
Setting the Page Count	179
Viewing the Permanent Page Count	179
Serial Number	179
Setting configuration ID	180
Diagnostics - error log	181
Viewing the error log	181
Clearing the error log	182
Maintenance Menu	182
Exiting Diagnostics Mode	182
Theory of operation	183
Processes and configuration	183
Electrophotography process	183
Development unit	184
Transfer unit	184
Cleaning unit	185
Paper feeding / fusing	185
Drive system	186
Paper feeding	187
Cassette paper feeder	187
Multipurpose feeding	188
Registration unit	188
Separation unit	189
Fuser unit	190
Delivery	191
Belt unit	192
Belt up/down	193
Expansion paper feeder	193
Duplex unit	194
Paper weight	195
Purpose:	195
Values:	195
Clearing paper jams	196
200 Paper Jam	196
240 Paper Jam	200
241-244 Paper Jam	201
249 Paper Jam	201
High-capacity feeder (HCF)	202
Paper feed and separation mechanism	202
Registration operation	203
Tray up/down mechanism	204
Tray up condition	206
Tray down condition	207
Size detection mechanism	207
Residual paper detection mechanism	208
Paper end detection	209
Maintenance Mode	210
DIP switch specifications	210
Finisher	211
Finisher cross section	213
Electrical parts function	214
Paper feed mechanism	215
Straight paper path (exit paper to upper tray)	215
Path select gate	216
Inverting paper path (exit paper to lower tray through accumulator)	217
Accumulator	218
Paper registration sequence	218
Punch unit driving sequence	219
Jogging / offset mechanism	220
Jogging sequence	220
Offsetting sequence	220
Detection of fixed position	221
Stapling mechanism	221
Elevator sequence	221
Finisher installation	223
Attaching the docking plate and guide rail	223
Combining the finisher and stand	225
Attaching the bins	229
Aligning the finisher and printer	230
Lowering or raising the finisher	232
Aligning the sides of the finisher	234
Aligning the top of the finisher	236
Adjusting the wheels	238
Attaching the cables	240
Interface cable	241
Power cable	242
Hole punch adjustment	244
4. Repair information	247
Service precautions	247
Handling printed circuit boards	247
Transportation/storage:	247
Replacement:	248
Inspection:	248
Adjustments	249
High-capacity paper feed timing belt adjustment	249
Removals	250
Cover, top removal	250
Cover, front removal	251
Cover, front left removal	251
Cover, rear removal	252
Cover, solenoid removal	252
Cover, left side removal	253
Cover, right side removal	254
Cover, RIP board removal	255
Tray, paper exit removal	256
Belt up/down clutch removal	256
Belt up/down detection sensor removal	257
Cassette guide removal	258
Connector, duplex unit removal	259
Separation fingers removal	260
Sensor cleaner removal	260
Drive gear unit sensor assembly removal	261
Drive motor assembly removal	262
Electronic box removal	263
Fanning pad removal	265
Front cover open switch actuator removal	266
Fuser removal	267
High voltage power supply board (HVU) removal	269
LED printhead removal	270
Eraser removal	273
Lock handle assembly removal	274
Main drive unit removal	275
Main unit fan removal	278
Motor drive board removal	279
Multipurpose feeder paper present sensor removal	279
Multipurpose feeder tray removal	280
Operator panel removal	280
Paper carrying frame removal	281
Paper carrying roller removal	282
Paper feed frame removal	283
Paper feed roller removal	284
Paper present sensor removal	284
Paper remaining sensor removal	285
Paper size sensor board assembly removal	285
Power supply 1 removal	286
Power supply 2 removal	287
Power switch removal	288
Printer controller removal	289
Printhead controller board removal	290
Registration sensor removal	294
Right slide rail removal	295
RIP box removal	295
Sensor board removal	296
Stay arm removal	297
Sub-frame removal	298
Sub frame F1, sub frame F2 removal	299
Top unit removal	301
Transfer belt removal	302
Alternate method: Operator panel is inoperable or unrecoverable error code	306
Alternate method: Transfer belt was partially removed	310
Turn guide cover sensor removal	311
Upper fan removal	312
Options removals	313
Expansion paper feeder removal	313
Duplex removals	321
Duplex unit separation removal	321
Duplex unit removal	322
Duplex timing belt removal	322
Duplex pressure roller and solenoid removal	323
Duplex feed roller and solenoid removal	324
Duplex side fence motor assembly/side fence removal	325
Duplex paper carrying motor removal	326
High-capacity feeder (HCF) removals	327
HCF covers removal	327
HCF call roller, paper feed roller, reverse roller removal	328
HCF pickup solenoid removal	329
HCF tray motor removal	332
HCF paper level sensor removal	333
HCF power supply removal	334
Finisher removals	335
External covers removals	335
Finisher control board removal	336
Elevator motor removal	337
Feed motor assembly removal	337
Hole punch removal	338
Inverter paper exit discharge brush removal	339
Inverter paper exit roller removal	339
Jogging unit removal	341
Path select gate removal	342
Patting roller removal	343
Power supply removal	345
Registration roller removal	346
Registration roller clutch removal	347
Stack area discharge brush removal	348
Staple unit removal	348
Straight paper exit discharge brush removal	349
Straight paper exit roller removal	349
Timing belts 1 and 2 removal	351
Tractor belt removal	352
Tractor drive motor assembly removal	354
5. Locations	355
Covers diagram	355
Major parts diagram	356
Sensor and switch locations	358
Component locations	360
Printer controller board	362
Printer controller board connectors	363
Printhead controller board	366
For printers with serial number XX-0XXXX:	366
For printers with serial number XX-1XXXX:	366
RIP board	367
Power source unit 1 board	368
Power source unit 2 board	368
High voltage power supply board	369
Sensor board	369
Expansion paper feeder controller board	370
Duplex unit controller board	370
Motor drive board	370
Size sensor board	371
High-capacity feeder (HCF)	372
High-capacity paper feed configuration	372
Electrical parts layout	373
Driving parts layout	374
Finisher locations	375
6. Preventive maintenance	383
Maintenance kit	383
Periodic maintenance	384
Lubricants and cleaners	384
7. Parts catalog	385
How to use this parts catalog	385
Assembly 1: Covers 1	386
Assembly 2: Covers 2	388
Assembly 3: Covers 3	390
Assembly 4: Covers 4	392
Assembly 5: Covers 5	394
Assembly 6: Upper unit	396
Assembly 7: Base 1	400
Assembly 8: Base 2	402
Assembly 9: Base 3	404
Assembly 10: Electrical	406
Assembly 11: Rip board	410
Assembly 12: Fuser unit	412
Assembly 13: Cassette	414
Assembly 14: Expansion feeder 1	416
Assembly 15: Expansion feeder 2	418
Assembly 16: Duplex unit 1	422
Assembly 17: Duplex unit 2	424
Assembly 18: High-capacity feeder 1	426
Assembly 19: High-capacity feeder 2	428
Assembly 20: High-capacity feeder 3	430
Assembly 21: High-capacity feeder 4	432
Assembly 22: High-capacity feeder 5	434
Assembly 23: High-capacity feeder 6	436
Assembly 24: Finisher covers	438
Assembly 25: Finisher frame	440
Assembly 26: Finisher feed 1	442
Assembly 27: Finisher feed 2	446
Assembly 28: Finisher elevator	448
Assembly 29: Finisher electronics	450
Assembly 30: Finisher docking 1	452
Assembly 31: Finisher docking 2	454
Assembly 32: Miscellaneous/options	456
Assembly 33: Finisher parts packet P/N 56P9480	465
Index	467
Part number index	475

Match case Limit results 1 per page

5055-

xxx

Diagnostic aids

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Power-On Self Test sequence

. . . . . . . . . . . . . . . . . . . . . . . . 3-1

Using the operator panel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Operator panel buttons

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Printing the menu settings

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Operator menu disabled

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Menu overview

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Diagnostic Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Adjustment example

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Print tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Hardware tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

High-capacity feeder tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Finisher tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Device tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Diagnostics - printer setup

. . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Defaults

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Viewing and resetting the drum counters

. . . . . . . . . . . . . . . 3-28

Diagnostics - error log

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Theory of operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Processes and configuration

. . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Electrophotography process

. . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Development unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Transfer unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Cleaning unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Paper feeding / fusing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Drive system

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Paper feeding

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Cassette paper feeder

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

Multipurpose feeding

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Registration unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Separation unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Fuser unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Delivery

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41

Belt unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Belt up/down

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Expansion paper feeder

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

Duplex unit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Paper weight

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Clearing paper jams

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

High-capacity feeder (HCF)

. . . . . . . . . . . . . . . . . . . . . . . . . 3-52

Maintenance Mode

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Finisher

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61