Service.bk Page i Thursday, October 4, 2001 12:20 PM C910 Color Printer 5055-01X • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Service.bk Page ii Thursday, October 4, 2001 12:20 PM 5055-01x Edition: November 2001 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Service.bk Page iii Thursday, October 4, 2001 12:20 PM 5055-01x Contents Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Standard Inspection and Cleaning Procedure . . . .
Service.bk Page iv Thursday, October 4, 2001 12:20 PM 5055-01x Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Adjustments and Procedures Following Parts Replacement . . . .2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Initial Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Printer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service.bk Page v Thursday, October 4, 2001 12:20 PM 5055-01x Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 High Capacity Paper Feed Timing Belt Adjustment . . . . . . . . . .
Service.bk Page vi Thursday, October 4, 2001 12:20 PM 5055-01x Registration Frame, Registration Clutch Removal . . . . . . . . . . .4-29 Transfer Belt Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30 Belt Up/Down Detection Sensor Removal. . . . . . . . . . . . . . . . . .4-34 Sensor Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Density Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36 Separation Fingers Removal .
Service.bk Page vii Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Pressure Roller and Solenoid Removal . . . . . . . . . . . . . Duplex Feed Roller And Solenoid Removal. . . . . . . . . . . . . . . . Duplex Side Fence Motor Assembly / Side Fence Removal . . . Duplex Paper Carrying Motor Removal . . . . . . . . . . . . . . . . . . . HCPF Covers Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HCPF Call Roller, Paper Feed Roller, Reverse Roller Removal HCPF Pickup Solenoid Removal .
Service.bk Page viii Thursday, October 4, 2001 12:20 PM 5055-01x Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 How to Use This Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Assembly 1: Covers 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Assembly 2: Covers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 Assembly 3: Covers 3 . . . . . . . . . . . . . . . . . . . . . . . . .
Service.bk Page ix Thursday, October 4, 2001 12:20 PM 5055-01x Safety Information Safety Notice • This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
Service.bk Page x Thursday, October 4, 2001 12:20 PM 5055-01x Norme di sicurezza • Il prodotto è stato progettato, testato e approvato in conformità a severi standard di sicurezza e per l’utilizzo con componenti Lexmark specifici. Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione. Lexmark non è responsabile per l’utilizzo di parti di ricambio di altri produttori.
Service.bk Page xi Thursday, October 4, 2001 12:20 PM 5055-01x Pautas de Seguridad • Este producto se ha diseñado, verificado y aprobado para cumplir los más estrictos estándares de seguridad global usando los componentes específicos de Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio.
Service.bk Page xii Thursday, October 4, 2001 12:20 PM 5055-01x Informació de Seguretat • Aquest producte està dissenyat, comprovat i aprovat per tal d'acomplir les estrictes normes de seguretat globals amb la utililització de components específics de Lexmark. Les característiques de seguretat d'algunes peces pot ser que no sempre siguin òbvies. Lexmark no es responsabilitza de l'us d'altres peces de recanvi.
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Service.bk Page 1 Thursday, October 4, 2001 12:20 PM 5055-01x 1. General Information Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure. The removals in the Repair Information chapter may help you identify parts. After you complete the repair, perform tests as needed to verify the repair.
Service.bk Page 2 Thursday, October 4, 2001 12:20 PM 5055-01x • Print a Demo page. • If additional paper sources are installed, print a Demo page from each of these, (if possible). Note: Failure to print from an additional tray or feeder may imply one or more pins are bent in the mating connector. Return Parts Engineering periodically analyzes returned parts for failure modes.
Service.bk Page 3 Thursday, October 4, 2001 12:20 PM 5055-01x Serial Number Open the front door, the serial number is located as shown. The serial number is also on the menu settings page you can print from the Tests Menu.
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Service.bk Page 5 Thursday, October 4, 2001 12:20 PM 5055-01x Processes and Configuration In this printer, the toner of four colors (magenta, cyan, yellow and black) melts and deposits on paper, dots which record color image information. This printing process is called the electrophotography process. Electrophotography Process In the electrophotography process, electrically charged toner, exposes, develops, transfers, and is cleaned with an aluminum photosensitive drum.
Service.bk Page 6 Thursday, October 4, 2001 12:20 PM 5055-01x Development Unit Toner forms the electrostatic image on the photosensitive drum during exposure. The single component, non-magnetic toner and the lusterless color toner are weather-resistant, and fade little under ultraviolet rays. This is helpful in saving documents. Toner in the hopper is agitated and supplied to the development roll by the supply roll. A (conductive rubber) doctor blade is fitted to the development roll.
Service.bk Page 7 Thursday, October 4, 2001 12:20 PM 5055-01x Cleaning Unit Toner remaining on the photosensitive drum following transfer, is scraped away with the cleaning blade, and collected in the recovery bag as waste toner. Residual toner on the photosensitive medium is removed by the eraser. Paper Feeding / Fusing The main unit drive is composed of drives 1 and 2.
Service.bk Page 8 Thursday, October 4, 2001 12:20 PM 5055-01x Drive System Drive 1, composed of a 100 dc motor and gear unit, feeds the registration paper from the paper feeder and drives the belt unit, photodeveloper / toner cartridge, fusing unit, and face-up delivery unit. The motor rotates by the ON signal from the printer controller/ motor drive unit and sends a rotation synchronization detection signal to the motor drive unit.
Service.bk Page 9 Thursday, October 4, 2001 12:20 PM 5055-01x Paper Feeding The paper feeder is a two-way system composed of the multi-paper feeder (100 sheets maximum) and an integrated 550 sheet tray). Optionally, the expansion paper feeders (550 sheets) can be increased to four layers. A high capacity paper feeding system (3,000 sheets) may be used.
Service.bk Page 10 Thursday, October 4, 2001 12:20 PM 5055-01x Multi-Purpose Feeding The multi-paper feed solenoid turns on by the signal from the printer controller. The multi-purpose feed roll interconnected with the drive 1 through the spring clutch, rotates and picks the paper in the multipurpose feeder.
Service.bk Page 11 Thursday, October 4, 2001 12:20 PM 5055-01x Registration Unit Media temporarily stops (registration) when adjusting the paper leading edge parallel with that of the image, or when adjusting the timing with the black image. The upper and lower registration rolls are arranged in parallel with the photosensitive drum for black imaging. The lower registration roll incorporates a registration clutch which feeds or stops the paper.
Service.bk Page 12 Thursday, October 4, 2001 12:20 PM 5055-01x Separation Unit The transfer belt and paper are separated with the belt drive roll by separation fingers.
Service.bk Page 13 Thursday, October 4, 2001 12:20 PM 5055-01x Fuser Unit By applying heat and pressure, the image is melted and fused to the paper. The upper and lower rollers are heated and pressure-fitted. A heater is positioned in the roller tube and a thermistor and thermostat remain in contact with the outside of the tube. Separation fingers are attached near the upper roller to separate the paper from the roller.
Service.bk Page 14 Thursday, October 4, 2001 12:20 PM 5055-01x Delivery After completing the fusing process, paper is discharged from the printer. The delivery sensor detects the paper condition and the FU/FD deflector switches between the face-up and face-down paper delivery. The paper from the fuser pulls down the sensing lever turning on the delivery sensor (photo interrupter).
Service.bk Page 15 Thursday, October 4, 2001 12:20 PM 5055-01x Belt Unit After passing through the registration unit, paper is electrostatically fed by the transfer belt through the positively charged feed roll at the inlet of the belt unit and fed by the running belt. The belt runs at the same speed as the photosensitive drum causing the image on the C, M, Y and K developer to transfer to paper.
Service.bk Page 16 Thursday, October 4, 2001 12:20 PM 5055-01x Belt Up/Down In monochrome printing, switching to color printing is not required. To avoid unnecessary wear of the photosensitive drum by the cleaning blade, this operation is stopped with the electromagnetic clutch in drive 1. The transfer belt is lowered so as not to touch the photosensitive drum during color printing. The transfer belt moves up and down with the switching shaft cam by the electromagnetic clutch in drive 1.
Service.bk Page 17 Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Unit A duplex unit can be optionally installed in the main unit, allowing two-sided printing. Selecting Paper feeding, Registration, Transfer, Separation, Fusing, or Face-Down paper discharging with the pulse motor in the duplex unit, feeding is stopped before the paper is delivered. Paper delivery is then reversed and fed to the duplex unit.
Service.bk Page 18 Thursday, October 4, 2001 12:20 PM 5055-01x Printing Mode Usually printing is performed in normal mode, OHP mode, thick paper mode, and envelope/postcard mode. The mode is switched by a command from the interface controller. Mode Paper/Media Weight PPM (Color) 16 - 29 lb 28 Thick paper 32 lb (glossy) 22 Envelope/postcard 90 lb or more 10 OHP Transparency 6 Normal OHP Mode OHP mode is used for improving color printing on transparencies.
Service.bk Page 19 Thursday, October 4, 2001 12:20 PM 5055-01x Envelope / Postcard Mode Envelope / postcard mode is used to improve printing quality on thick paper of small width. In this mode, the fusing temperature is set higher than usual and transfer voltage is switched according to the temperature. Operation Mode Operation modes such as sleep mode and registration mode are switched by command from the interface controller.
Service.bk Page 20 Thursday, October 4, 2001 12:20 PM 5055-01x Clearing Paper Jams 200 Paper Jam Pages Jammed (Check Areas A-F) A 200 Paper Jam message indicates that paper is jammed. The display alternates between 200 Paper Jam Pages Jammed and Check Areas A-F. If there is a paper jam when you turn the printer on, the second line of the 200 Paper Jam message will be blank. To resolve the message, you must clear all paper from the paper path. Check and clear areas A through F.
Service.bk Page 21 Thursday, October 4, 2001 12:20 PM 5055-01x Check Area C Jams that cause a Check Area C message require opening the duplex jam access door. If you are printing on small paper, the following steps may not clear the jam. See “Removing Small Size Paper From the Duplex Unit” on page 1-22. 1. Open the duplex jam access door on the right side of the printer. 2. Remove the jam. 3. Press Go. Note: If the paper jam message continues, check and clear all paper from the paper path.
Service.bk Page 22 Thursday, October 4, 2001 12:20 PM 5055-01x Removing Small Size Paper From the Duplex Unit When printing on both sides of A5 or other small size paper, you may need to partially remove the duplex unit to clear the jam. 1. 2. 3. 4. 5. 6. 7. Turn off the printer. Open the duplex unit door. Loosen the two screws. Pull out the duplex unit far enough to see the duplex unit inlet. Remove jam from the duplex unit inlet. Slide the duplex unit in.
Service.bk Page 23 Thursday, October 4, 2001 12:20 PM 5055-01x Check Area F 1. 2. 3. 4. 5. Pull the high capacity feeder away from the printer. Open the jam access door on the top optional drawer. Remove any jams. Close the jam access door. Slide the high capacity feeder until the feeder locks to the docking frame. When the feeder is in the correct position, you hear a click. 6. Press Go. Note: If the paper jam message continues, check and clear all paper from the paper path.
Service.bk Page 24 Thursday, October 4, 2001 12:20 PM 5055-01x 249 Paper Jam Check Tray A 249 Paper Jam Check Tray message indicates a jam has occurred in the high capacity feeder. 1. 2. 3. 4. Open the top cover. Remove the jam. Close the top cover. Press Go.
Service.bk Page 25 Thursday, October 4, 2001 12:20 PM 5055-01x High Capacity Paper Feeder (HCPF) Paper Feed and Separation Mechanism The high capacity paper feeder consists of a tray and paper transfer. The paper feed and separation mechanism uses a friction roller separation and paper feed system with a non-contact magnet type maintenance-free torque limiter. When the paper feed clutch turns on, the paper feed roller shaft rotates and the paper feed roller is driven with the one-way clutch.
Service.bk Page 26 Thursday, October 4, 2001 12:20 PM 5055-01x Registration Operation When the paper feed motor rotates, the transfer roller is driven with relay gears. The reverse roller shaft rotates the gears on the paper feed clutch in the direction of the arrow and stops by the friction force of the paper feed roller.
Service.bk Page 27 Thursday, October 4, 2001 12:20 PM 5055-01x Tray Up/Down Mechanism The driving force of the tray motor transmits to the tray driving pulley through the gears. Moving the tray moves up and down through the tray driving belt. After the paper loads, and the top cover is set, the pickup solenoid turns on to lower the call roller.
Service.bk Page 28 Thursday, October 4, 2001 12:20 PM 5055-01x When the down button is pressed, the tray motor reverses to move the tray down. During the down motion of the tray, as the top surface of paper passes the paper level sensor, the tray motor stops. The tray moves down by about 500 sheets. The down sensor detects the tray lower limit position.
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Service.bk Page 30 Thursday, October 4, 2001 12:20 PM 5055-01x Size Detection Mechanism The paper size can be switched between A4 and letter (11 inches) by changing the side fence position. The paper size sensor 2 detects the fixing screw 2 at the A4 position. The paper size sensor 1 detects the fixing screw 1 at the letter position. Tray up motion stops when the up sensor is OFF, not shielded.
Service.bk Page 31 Thursday, October 4, 2001 12:20 PM 5055-01x Residual Paper Detection Mechanism The residual paper quantity in the tray is detected with four photo interrupters.
Service.bk Page 32 Thursday, October 4, 2001 12:20 PM 5055-01x Paper End Detection A reflection type sensor is provided on the top stay to detect the paper top surface and the paper end.
Service.bk Page 33 Thursday, October 4, 2001 12:20 PM 5055-01x Maintenance Mode DIP Switch Specifications The DIP switches on the high capacity paper feed board have the following functions: • Function switching and initial setting of the standard machine or optional machine.
Service.bk Page 34 Thursday, October 4, 2001 12:20 PM 5055-01x • Test paper feed operation. 1. Turn on the docking safety switch with a non-metallic object. The interface cable with the printer controller board need not be connected. 2. Close the top cover or manually activate the cover switch. 3. Load paper. 4. Wait until the paper tray stops and the pickup solenoid turns off 5. With the cover closed or with the cover switch activated, press and hold the tray down button for more than 1/2 second.
Service.bk Page 35 Thursday, October 4, 2001 12:20 PM 5055-01x High Capacity Paper Feed Sensor / Switch Test The condition of each sensor can be checked from the lighting of LEDs on the high capacity paper feed board. When each sensor operates with the power supplied, the associated LED lights. To perform the test: Interrupt the photointerrupter sensor signal or actuate the microswitch being tested while observing the associated LED on the high capacity paper feed board.
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Service.bk Page 1 Thursday, October 4, 2001 12:20 PM 5055-01x 2. Diagnostic Information The diagnostic information in this chapter leads you to the failing part. Before you replace an entire assembly, determine if just the defective part is available in the parts catalog. Use the error code tables, symptom table, service checks and the diagnostic aids chapter to determine the symptom and repair the failure. The removal procedures in the Repair Information chapter may help you identify parts.
Service.bk Page 2 Thursday, October 4, 2001 12:20 PM 5055-01x Printer Controller Board/Printer Control EPROM (U5) If you replace the printer controller board, remove EPROM (U5) and install it on the new board. Also check the printhead alignment. If you change the EPROM, the following items must be checked and adjusted in the diagnostic mode.
Service.bk Page 3 Thursday, October 4, 2001 12:20 PM 5055-01x Start Initial Check Before you start troubleshooting, check the following: Installation Environment • The power supply line voltage is plus or minus 10% of the rated line voltage. • The machine is securely installed on a level surface in a well• • • ventilated place. The room temperature is between 10 and 32°C (50 and 90°F) and the relative humidity between 20 and 80%.
Service.bk Page 4 Thursday, October 4, 2001 12:20 PM 5055-01x Printer Messages The printer displays three types of messages: service messages, status messages, and attendance messages. Service messages indicate a problem that requires a service technician. Status messages provide information about the current state of the printer, requiring no action. Attendance messages alert the operator to printer problems that require operator intervention.
Service.bk Page 5 Thursday, October 4, 2001 12:20 PM 5055-01x 911 - Paper Exit Motor Error Step Questions / Actions Yes No 1 Is connector CN4 on the printer controller board securely connected? Replace the paper exit motor and go to step 2. Plug the connector in securely. 2 Did replacement of the paper exit motor solve the problem? Problem solved. Replace the printer controller board.
Service.bk Page 6 Thursday, October 4, 2001 12:20 PM 5055-01x 917 - RIP Fan Error 917 Service Fan Error Step Questions / Actions Yes No 1 Is connector J5 on the RIP board connected properly? Go to step 2. Properly connect J5. 2 Is 24 V dc present between pins 1 and 3 of connector J5 on the RIP board? Replace the RIP fan. Replace the RIP board.
Service.bk Page 7 Thursday, October 4, 2001 12:20 PM 5055-01x 920 - Fuser Error - Fuser Heater Trouble 92x Service Fuser Error Step Questions / Actions Yes No 1 Replace the fuser. Did this fix the problem? Problem solved. Return the fuser, replace the power supply 2 and go to step 2. 2 Did replacing power supply 2 fix the problem? Problem solved. Return power supply 2 and replace the printer controller board.
Service.bk Page 8 Thursday, October 4, 2001 12:20 PM 5055-01x 924 - Lower Fuser Thermistor Open Error Step Questions / Actions Yes No 1 Is connector CN44 on the printer controller board connected properly? Disconnect CN44 and turn the printer on. Go to step 2. Plug the connector in securely. 2 Is error 924 displayed? Turn the printer off and reconnect CN44. Go to step 3. Replace the printer controller board. 3 Power the printer off and short pins 8 and 11 of CN44 and turn the printer on.
Service.bk Page 9 Thursday, October 4, 2001 12:20 PM 5055-01x 926(K), 927(C), 928(Y), 929(M) - Toner Sensor Error 92x Service Toner Sensor Step Questions / Actions Yes No 1 Is the toner cartridge the correct type for the printer? Go to step 2. Recommend the customer replace the cartridge with the correct type. 2 Is the toner cartridge encoder wheel dirty? Clean the encoder wheel and toner sensor. Go to step 3. 3 Replace the toner cartridge for the color with the error.
Service.bk Page 10 Thursday, October 4, 2001 12:20 PM 5055-01x 930 - Yellow Printhead Error 930 Service Printhead Error Step 1 Questions / Actions Is fuse 5 on the printhead control board open? Yes Replace the printhead control board, cables, and LED printhead. No Replace the printhead controller board. 931 - Magenta Printhead Error Step 1 Questions / Actions Is fuse 6 on the printhead control board open? Yes Replace the printhead control board, cables, and LED printhead.
Service.bk Page 11 Thursday, October 4, 2001 12:20 PM 5055-01x 933 - Black Printhead Error Step 1 Questions / Actions Is fuse 4 on the printhead control board open? Yes Replace the printhead control board, cables, and LED printhead. No Replace the printhead controller board. 934 - Color Drum Sensor Error 934 Service Drum Sensor Step Questions / Actions Yes No 1 Is connector CN28 connected properly? Go to step 2. Plug the connector in securely. 2 Clean the color drum sensor LED.
Service.bk Page 12 Thursday, October 4, 2001 12:20 PM 5055-01x 935 - Black Drum Sensor Error Step Questions / Actions Yes No 1 Is connector CN27 connected properly? Go to step 2. Plug the connector in securely. 2 Clean the black drum sensor LED. Did this fix the problem? Problem solved. Replace the black drum sensor. Go to step 3. 3 Did replacing the black drum sensor fix the problem? Problem solved. Replace the printer controller board.
Service.bk Page 13 Thursday, October 4, 2001 12:20 PM 5055-01x 940 - High Capacity Paper Feed Sensor Error Step 1 Questions / Actions Is connector CN40 on the printer controller board connected properly? Yes No Go to “High Capacity Paper Feed (HCPF) Service Check” on page 2-57. Plug the connector in securely.
Service.bk Page 14 Thursday, October 4, 2001 12:20 PM 5055-01x 945 - Engine Flash Error 945 Service Engine Flash Reflash the engine code. 946 - Printer / Printhead Controller Board Communication Error 946 Service Communication Step 1 Questions / Actions Replace the printhead controller board. Did this fix the problem? 2-14 Service Manual Yes Problem solved. No Replace the printer controller board.
Service.bk Page 15 Thursday, October 4, 2001 12:20 PM 5055-01x 948 - Machine ID Error 948 Service Machine ID Step Questions / Actions Yes No 1 Turn the printer off and wait 30 seconds. Turn the printer on. Did this fix the problem? Problem solved. Verify proper installation of the EPROMs on both the printer controller board and the printhead controller board. Go to step 2. 2 Are the EPROMs installed correctly? Replace the printer controller board. Go to step 3. Install the EPROMs correctly.
Service.bk Page 16 Thursday, October 4, 2001 12:20 PM 5055-01x 956 - Processor Failure 956 Service System Board Replace the RIP board. 957 - ASIC Failure Replace the RIP board. 958 - NAND Failure 958 Service NAND Failure Replace the RIP board. 960 - RAM Slot 1 Bad 960 Service RAM Memory Error Replace RAM Card or the RIP board. 961 - RAM Slot 2 Bad Replace RAM Card or the RIP board. 962 - RAM Slot 3 Bad Replace RAM Card or the RIP board.
Service.bk Page 17 Thursday, October 4, 2001 12:20 PM 5055-01x 970 - Standard Network Error 970 Service Standard Network 970 Service Network Card X 975 - Unrecognizable Network Port Software error. 976 - Unrecoverable Software Error in Network Port Software error. To to the “Options Service Check” on page 2-77 and refer to the network card option section. 978 - Bad Checksum While Programming Network Card Software error. 979 - Flash Parts Failed While Programming Network Port Reflash network port.
Service.bk Page 18 Thursday, October 4, 2001 12:20 PM 5055-01x 980 - Face-Up/Down Switching Error 980 Service Switch Error Check Area B Step Questions / Actions Yes No 1 Is the linkage between the FU/FD deflector and the FU deflector solenoid operating properly? Go to step 2. Replace the face-up exit assembly. 2 Is there continuity on the FU deflector solenoid between pins 1 and 2 of CN14 on the printer controller board? Go to step 3. Replace the FU deflector solenoid. 3 Test the sensor.
Service.bk Page 19 Thursday, October 4, 2001 12:20 PM 5055-01x 981 - Belt Up/Down Sensor Error 981 Service Switch Error Step Questions / Actions Yes No 1 Are connectors CN409 and CN407 on the sensor board connected properly? Go to step 2. Plug the connectors in securely. 2 Are connectors CN26 and CN29 on the printer controller board connected properly? Go to step 3. Plug the connector in securely.
Service.bk Page 20 Thursday, October 4, 2001 12:20 PM 5055-01x Step Questions / Actions Yes No 5 Test the sensor. While actuating the sensor, does the voltage fluctuate between 0V and +5 V between pins 8 and 10 of connector CN29 on the printer controller board? Replace the belt up/ down clutch. Go to step 6. Replace the belt up/ down sensor. 6 Did replacing the belt up/down clutch fix the problem? Problem solved. Replace the printer controller board.
Service.bk Page 21 Thursday, October 4, 2001 12:20 PM 5055-01x 983 - Black Gear Sensor Error 983 Service Gear Sensor Step Questions / Actions Yes No 1 Is connector CN20 on the printer controller board connected properly? Go to step 2. Plug the connector in securely. 2 Clean the gear sensor. Does this fix the problem? Problem solved. Replace the K drive unit gear sensor. If the problem remains, replace the printer controller board.
Service.bk Page 22 Thursday, October 4, 2001 12:20 PM 5055-01x 985 - Transfer Belt Thermistor Error 985 Service Thermistor Error Step Questions / Actions Yes No 1 Are connectors CN407 and CN408 on the sensor board connected properly? Go to step 2. Plug the connector in securely. 2 Is connector CN29 on the printer controller board connected properly? Replace the transfer belt unit. If the problem remains, replace the printer controller board. Plug the connector in securely.
Service.bk Page 23 Thursday, October 4, 2001 12:20 PM 5055-01x Step 2 Questions / Actions Test the sensor. While actuating the sensor, does the voltage fluctuate between 0V and +5 between pins 2 and 3 of connector CN7 of the printer controller board? Yes No Replace the printer controller board. Replace the upper and lower transparency sensor.
Service.bk Page 24 Thursday, October 4, 2001 12:20 PM 5055-01x 994 - Density Sensor Error Step Questions / Actions Yes No 1 Are connectors CN406 and CN407 on the sensor board connected properly? Go to step 2. Plug the connector in securely. 2 Is connector CN29 on the printer controller board connected properly? Replace the density sensor. Go to step 3. Plug the connector in securely. 3 Did replacing the density sensor fix the problem? Problem solved. Replace the printer controller board.
Service.bk Page 25 Thursday, October 4, 2001 12:20 PM 5055-01x Attendance Messages g Message Meaning Action Activating Menu Changes The printer is activating changes made to the printer settings. Wait for the message to clear. Bin Full The specified bin is full. Remove the paper from the bin. Busy The printer is busy receiving, processing or printing data. Wait for the message to clear or press Menu to open the Job Menu and cancel the current job.
Service.bk Page 26 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action Close Side Door The printer side door is open. Close the printer side door. If the error cannot be reset, go to “Map 1 - False “Side Door Open” Message” on page 2-43. Close Top Door The printer top door is open. Close the printer top door and front door. If the error cannot be reset go to “Map 2 - False “Close Top Door” Message” on page 2-43. Close Tray Top Cover The high capacity feeder door is open.
Service.bk Page 27 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action Disk Corrupted Reformat? The printer has attempted a disk recovery process and cannot repair the disk. • Press Go to reformat the disk and delete all files currently stored on the disk. • Press Stop to clear the message without reformatting the disk. Disk Recovery x/5 yyy% The printer is attempting to recover the hard disk. Wait for the message to clear.
Service.bk Page 28 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action Held Jobs May be Lost The printer memory is too full. • Press Go to clear the message. The printer frees memory by deleting the oldest job and continues deleting jobs until there is enough memory. • Press Stop to clear the message without deleting jobs. • Press Menu to open the Job Menu and cancel the current job. Infrared An infrared interface is the active communication link. Wait for the message to clear.
Service.bk Page 29 Thursday, October 4, 2001 12:20 PM 5055-01x Message Load Meaning Action The printer is trying to feed paper from a source it detects is empty. Load paper of the size and type requested in the second line of the display in the specified tray. Press Menu to open the Job Menu and cancel the current job. • If Load (Tray) cannot be reset, go to “Map 4 False “Tray (X) Low/ Empty” Message” on page 2-45. • If Load (MPF), check the MPF paper present sensor.
Service.bk Page 30 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action Network , An network interface is the active communication link, where represents the active link and represents the channel. Wait for the message to clear. No Jobs Found, Retry? The PIN number entered is not associated with any confidential job. • Press Go to enter another PIN. • Press Stop to clear the PIN entry prompt. Not Ready The printer is not ready to receive or process data.
Service.bk Page 31 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action Printing Font List The printer is processing or printing a list of all available fonts for the specified printer language. Wait for the message to clear. Printing Job Accounting Stat The printer is processing or printing all job accounting statistics stored on the hard disk. Wait for the message to clear. Printing Menu Settings The printer is processing or printing the menu settings page.
Service.bk Page 32 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action Ready Hex The printer is in Hex Trace mode and is ready to receive and process print jobs • Send a job to print. All data is printed in hexadecimal. Control strings are printed, not executed. • Turn the printer off and then on to exit Hex Trace mode. Remove Paper The specified output bin is full. Remove the paper from the specified bin(s).
Service.bk Page 33 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action Tray Empty The specified tray is out of paper. Load paper in the tray and try to clear the message. If the message cannot be reset, go to “Map 4 - False “Tray (X) Low/Empty” Message” on page 2-45. Tray Low The specified tray is low of paper. Add paper in the tray and try to clear the message. If the message cannot be reset, go to “Map 4 - False “Tray (X) Low/Empty” Message” on page 2-45.
Service.bk Page 34 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action 30 Coating Roll Missing The oil coating roll is either missing or installed incorrectly. Correctly install the oil coating roll. If the message cannot be reset, go to “Map 5 - False “30 Oil Coating Roll Missing” Message” on page 2-46. 30 Print Unit Missing One or more of the color print units is either missing or incorrectly installed. Correctly install the color print unit(s).
Service.bk Page 35 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action 37 Insufficient Defrag Memory The printer cannot defragment flash memory. • Delete fonts, macros, and other data in printer memory. • Install additional printer memory. 37 Insufficient Memory The printer memory is full and cannot continue processing current jobs. • Press Go to clear the message and continue printing. • Press Stop to clear the message without deleting print jobs.
Service.bk Page 36 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action 40 Tray Size Sense Error The high capacity sheet feeder detects an error in the size sensing mechanism. • Turn off the printer and be sure that all the high capacity feeder connectors are installed properly. • Check the high capacity feeder size sensor and go to “Map 8 - False “40 Tray (X) Size Sensor Error” Message” on page 2-48.
Service.bk Page 37 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action 53 Unformatted Flash The printer detects unformatted flash memory. • Press Go to clear the message and continue printing. • Format the flash memory. If the error remains, the flash memory may be defective. 54 Serial Option Error The printer has detected a serial interface error on a serial port. • Make sure the serial link is set up correctly and you are using the appropriate cable.
Service.bk Page 38 Thursday, October 4, 2001 12:20 PM 5055-01x Message 56 Parallel Port Disabled Meaning Data has been sent to the printer through a disabled parallel port. • Press Go to clear the message. • Make sure the Parallel Buffer menu item in the Parallel Menu is set to Disabled. Data has been sent to the printer through a disabled USB port. • Press Go to clear the message. • Make sure the USB Buffer menu item in the USB Menu is set to Disabled. Too many output bins are installed.
Service.bk Page 39 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action 62 Disk Full Insufficient memory on the hard disk. • Press Go to clear the message and continue printing. • Delete fonts, macros, and other data stored on the hard disk. 63 Unformatted Disk The printer detects an unformatted hard disk. • Press Go to clear the message and continue printing. • Format the disk before performing disk operations. • Replace the hard disk.
Service.bk Page 40 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action 81 Engine Code CRC Failure Microcode in the engine flash code module has failed a system check. Press Go to clear the message and discard the code. Retransmit the microcode data from the host computer. 84 All Photo Devs Exhausted All of the photodevelopers have reached end of life. Replace all of the photodevelopers.
Service.bk Page 41 Thursday, October 4, 2001 12:20 PM 5055-01x Message 84 Color Photo Devs Exhausted Meaning The color photodevelopers have reached end of life. Action Replace the color photodevelopers (Cyan, Magenta and Yellow) at the same time. If print quality is still acceptable and you do not want to replace the photodevelopers, press Go to clear the message and continue printing. 84 Color Photo Dev Life Warning The color photodevelopers are nearing end of life.
Service.bk Page 42 Thursday, October 4, 2001 12:20 PM 5055-01x Message Meaning Action 88 Toner Empty The printer has ceased operating because the specified toner cartridge is empty. Install a new toner cartridge and go to “Map 7 - False “88 Toner Low/Toner Empty” Message” on page 2-47. 88 Toner Low The printer has detected that the specified toner cartridge is low. • Replace the specified toner cartridge. • Press Go to clear the message and continue printing.
Service.bk Page 43 Thursday, October 4, 2001 12:20 PM 5055-01x Maintenance Analysis Procedures (MAPS) Map 1 - False “Side Door Open” Message Step Questions / Actions Yes No 1 Close the side (turn guide) door. Does the message reset? Problem solved. Go to step 2. 2 Disconnect CN30 from the printer controller board. While activating the door switch, is there continuity at pins 1 and 2 of the connector? Replace the printer controller board. Replace the side door (turn guide) sensor assembly.
Service.bk Page 44 Thursday, October 4, 2001 12:20 PM 5055-01x Map 3 - False “Close Tray (X) Top Cover” Message Step 1 Questions / Actions Remove the rear cover on the high capacity paper feeder and observe LED 9 on the HCPF card while actuating the cover open micro-switch. Does the LED go on and off, while opening and closing the door? 2-44 Service Manual Yes Replace the HCPF card. No Replace the cover open micro-switch.
Service.bk Page 45 Thursday, October 4, 2001 12:20 PM 5055-01x Map 4 - False “Tray (X) Low/Empty” Message Step Questions / Actions Yes No 1 Is the “Tray X Low” message present? Go to step 2. Go to step 5. 2 Is the paper remaining actuator inside the cassette drawer binding, or operating incorrectly? Go to step 3. Repair or replace parts as necessary.
Service.bk Page 46 Thursday, October 4, 2001 12:20 PM 5055-01x Map 5 - False “30 Oil Coating Roll Missing” Message Step Questions / Actions Yes No 1 Is the OCR properly installed? Go to step 2. Properly install the OCR. 2 Is the OCR contact at the rear of the fuser damaged or broken? Replace the fuser. Go to step 3. 3 Is CN44 on the printer controller board properly connected? Replace the printer controller board. Properly connect CN44.
Service.bk Page 47 Thursday, October 4, 2001 12:20 PM 5055-01x Map 7 - False “88 Toner Low/Toner Empty” Message Step Questions / Actions Yes No 1 Ensure that the encoder located at the rear of the toner set is clean and free of dirt or paper dust. Is the encoder wheel clean and free of dirt or paper dust? Go to step 2. Clean the encoder wheel or replace the toner set. 2 Is the toner remaining photo interrupter sensor clean and free of obstructions? Go to step 3.
Service.bk Page 48 Thursday, October 4, 2001 12:20 PM 5055-01x Map 8 - False “40 Tray (X) Size Sensor Error” Message Step Questions / Actions Yes No 1 On the high capacity paper feeder, are the paper size adjusting screws present on the upper portion of the side fence and fully screwed into the adjusting bracket? Go to step 2. Replace the missing thumbscrew or screw them in all the way. 2 Observe the LEDs 1 and 2 on the HCPF control board while unscrewing the paper size adjusting thumbscrews.
Service.bk Page 49 Thursday, October 4, 2001 12:20 PM 5055-01x Map 10 - Unrecoverable “Check Tray (X) or Duplex Connection” Message Step Questions / Actions Yes No 1 Is the problem with a specific paper tray or the duplex unit? Go to step 2. Go to step 8. 2 Is the problem with tray 1? Go to step 3. Go to step 6. 3 Are connectors CN 35 and CN36 on the printer controller board properly connected? Go to step 4. Properly connect the connectors.
Service.bk Page 50 Thursday, October 4, 2001 12:20 PM 5055-01x Step Questions / Actions Yes 7 Exchange the expansion feeder control board for the problem tray with one above or below. Does the symptom follow the exchanged card? Replace the defective expansion feeder control card. Replace the upper and lower expansion paper feed drawer connecting cable assemblies. 8 Are any of the pins or contacts on the duplex drawer connectors bent or damaged? Go to step 9. Repair or replace the connector.
Service.bk Page 51 Thursday, October 4, 2001 12:20 PM 5055-01x Map 11 - Paper Size Map Step Questions / Actions Yes No 1 Do the paper size sensor actuators on the paper operation tray operate correctly, as you slide the paper location plate? Go to step 2. Replace parts as necessary. 2 Do the size sensor levers operate correctly? Go to step 3. Replace the size sensor levers. 3 Are the following connectors properly connected: Go to step 4. Properly connect the connectors. Problem solved.
Service.bk Page 52 Thursday, October 4, 2001 12:20 PM 5055-01x Symptom Table Symptom Action You cannot print color. Make sure the Color Correction menu item is not set to Black & White. Make sure the color print units are completely installed in the printer. Go to the “Transfer Belt Up/Down Service Check” on page 2-68. Transparencies curl excessively. Make sure you’re using the recommended Lexmark transparencies. Also be sure the paper delivery is set to the rear exit.
Service.bk Page 53 Thursday, October 4, 2001 12:20 PM 5055-01x Symptom Action Fuser failure. Go to the “920 - Fuser Error - Fuser Heater Trouble” on page 2-7. No paper pick-up from multipurpose tray. Go to the “Paper Carrying Service Check” on page 2-58. No paper pick-up from upper or lower cassettes. Go to the “Paper Carrying Service Check” on page 2-58. Registration roller does not rotate. Go to the “Paper Carrying Service Check” on page 2-58. Operator panel does not operate properly.
Service.bk Page 54 Thursday, October 4, 2001 12:20 PM 5055-01x Symptom Action Evenly spaced marks on the paper, or a single mark in the same place on every page. Go to the “Marks on Paper Service Check” on page 2-66. Poor fusing. Go to the “920 - Fuser Error - Fuser Heater Trouble” on page 2-7. Toner scatter on front or back of paper. Check the following: Paper will not feed from MPF. Be sure you have paper in the MPF. • Excessive toner buildup on the transfer belt.
Service.bk Page 55 Thursday, October 4, 2001 12:20 PM 5055-01x Service Checks Drive 1 DC Motor Service Check FRU 1 • DC Motor • Drive Unit 1 • Printer Controller Board Action If the motor does not attempt to turn and you receive a 910 error code, replace the driver 1 dc motor. Be sure the toner and photodeveloper units are not causing an overload on the dc motor. If the motor turns but the paper carrying section of the machine does not rotate, check the drive 1 unit gear train for damage.
Service.bk Page 56 Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Service Check FRU Action 1 Feed Roller Belts Check for wear or damage to the feed roller belts. Replace as necessary. 2 • Duplex Stepper Motor • Side Fence • Stepper Motor Gears Be sure the stepper motor turns freely with no binding. 3 • Feed Roller Solenoid Assembly • Paper Refeed Solenoid Assembly Check for proper operation of the solenoid and linkage. Replace as necessary.
Service.bk Page 57 Thursday, October 4, 2001 12:20 PM 5055-01x Face-Down Stacker Full Service Check FRU Action 1 Stacker Full Detection Lever Check the stacker full detection lever for damage. 2 • Stacker Full Detection Sensor • Printer Controller Board Check for a voltage fluctuation between 0 V and +5 V between pins 2 and 3 of connector CN9 on the printer controller board while actuating the sensor.
Service.bk Page 58 Thursday, October 4, 2001 12:20 PM 5055-01x Operator Panel Service Check When you replace the PC drum unit, all three color units must be replaced at the same time. FRU 1 • Operator Panel • Operator Panel Cable • RIP Board Action Run both the LCD Hardware Test and the Button Test in Diagnostic Mode. Be sure the operator panel cable connections are securely connected on the RIP board and operator panel.
Service.bk Page 59 Thursday, October 4, 2001 12:20 PM 5055-01x Paper is being picked up and carried to the registration roller (Areas C, E, 240, 24x). FRU Action • Paper Size Guide • Side Location Plates Be sure the paper cassette has the size guides and the side locator locks are working properly. • Paper Feed Roller (MPF) • Paper Feed Rolls MPF Tray 1, 2, 3, 4, 5 • Carrying Roller Tray 1, 2, 3, 4, 5 • Fanning Pad (MPF) Be sure the paper feed rollers are free of dirt and not damaged.
Service.bk Page 60 Thursday, October 4, 2001 12:20 PM 5055-01x Paper has stopped at the registration roller or has not reached the fuser (Areas C, E, 240, 24x). 1 2 FRU Action • Registration Roller Clutch • Registration Roller • Transfer Belt Unit • Rear Paper Feed Guide Check these parts for wear or damage. Replace as necessary. Be sure all guide surfaces in the paper path are free of dirt.
Service.bk Page 61 Thursday, October 4, 2001 12:20 PM 5055-01x Paper has entered the fuser and exited the printer (Area B). FRU Action 1 Fuser Remove any toner buildup and replace any worn or damaged parts. 2 • Fuser Exit Lower Roller • Exit Guide • FU/FD Flap Solenoid • Exit Flap Clutch Lever • Gears • Fuser Exit Upper Roller Be sure the exit FU/FD solenoid energizes in the correct position for either face-down or face-up delivery. Replace any damaged or worn parts.
Service.bk Page 62 Thursday, October 4, 2001 12:20 PM 5055-01x Paper has entered the duplex unit (Area D). FRU 1 Feed Rollers Action Check for wear or damage to feed rollers and belts. Belts 2 Duplex Unit Be sure the duplex unit is properly installed and that all connections are correct. 3 • Duplex Stopper Motor • Side Fence Stepper Motor Be sure the stepper motor turns freely with no binding.
Service.bk Page 63 Thursday, October 4, 2001 12:20 PM 5055-01x Paper Exit, FU/FD Service Check FRU Action 1 FU/FD Sensor Actuator If the paper is not exiting to the back paper face-up tray or the face-down tray, check the sensor for proper operation by checking for Check for a fluctuation of between 0V and +5 V between pins 1 and 2 of connector CN12, while actuating the sensor. 2 FU/FD Deflector Check the FU/FD deflector that directs the paper to the proper tray. Replace if necessary.
Service.bk Page 64 Thursday, October 4, 2001 12:20 PM 5055-01x Photodeveloper Missing Service Check When you replace the photodeveloper unit, all three color units must be replaced at the same time. FRU Action 1 Photodeveloper Check for dirt or damage to the sensing contacts on rear. Clean or replace the photodeveloper drum unit if necessary. 2 Sub-frame Unit Check the sensing contacts on the sub-frame assembly. Clean or replace the affected contacts or sub-frame.
Service.bk Page 65 Thursday, October 4, 2001 12:20 PM 5055-01x Power Supply Service Check FRU Action 1 Voltage Be sure the switch is on and the power cord is firmly plugged into the printer. Be sure the correct voltage is present at the outlet. 2 Power Cord Check the power cord for continuity. 3 • Fuse • Switch • Power Supply 1 The power supply fuses may be blown. Unplug the machine and check fuse F2 on the power supply 1 for continuity.
Service.bk Page 66 Thursday, October 4, 2001 12:20 PM 5055-01x Marks on Paper Service Check If you have evenly spaced marks on the paper, measure the distance between the marks and locate the symptom below. Check the assembly for dirt or damage and clean as necessary. Run a test print to verify the problem has been corrected. The indicated assemblies are replaced by the customer at prescribed intervals. If you remove the transfer belt, do not turn it upside down.
Service.bk Page 67 Thursday, October 4, 2001 12:20 PM 5055-01x Fuser Part Locations mm From Paper Center Thermistor Hot Roll -6 Thermistor BUR 0 TCO Hot Roll 66 TCO BUR 101 Detact Fingers Hot Roll Detact Fingers BUR 113.5/75/37.5/0/-37.5/-75/-113.5 134/90/45/0/-45/-90/-134 Exit Rollers 96/37.5/-37.
Service.bk Page 68 Thursday, October 4, 2001 12:20 PM 5055-01x Transfer Belt Up/Down Service Check FRU 1 Belt Up/Down Sensors Belt Up/Down Actuator Action Check the transfer belt up/down sensor. Be sure that connector CN29 is firmly connected to the printer controller board. Replace the sensor or the actuator if necessary. Check for a fluctuation between 0V and +5 V between pins 8 and 10, while actuating the sensor.
Service.bk Page 69 Thursday, October 4, 2001 12:20 PM 5055-01x Image Quality Troubleshooting Print Quality Problems Problem Print is too light, or printed images or characters have voids or dropouts. Action Be sure you’re using recommended paper or other media. Use media from a new package. Be sure you have selected the correct Paper Weight setting for the media you’re using. Be sure the affected print unit is completely installed in the printer. Set print darkness to 4 from the Color Menu.
Service.bk Page 70 Thursday, October 4, 2001 12:20 PM 5055-01x Problem Action Colored lines, streaks, or smudges appear on the printed page, or print appears blurred or unclear. Replace the photodevelopers. If the problem only occurs when printing black, you can replace just the black photoconductor and fuser coating roll. If the problem occurs when printing one of the colors, replace all three of the color photodevelopers. If the problem remains, go to “Black Line” on page 2-74.
Service.bk Page 71 Thursday, October 4, 2001 12:20 PM 5055-01x Problem Light lines or streaks appear on the printed page. Action Clean the LEDs. Make sure the affected photodeveloper is completely installed in the printer. Remove the affected photodeveloper and gently shake it back and forth to distribute the toner evenly. Reinsert the print unit and try printing the job again. Replace the affected toner cartridge. Replace the photodevelopers.
Service.bk Page 72 Thursday, October 4, 2001 12:20 PM 5055-01x Problem Action Toner adheres to the back of the page. Remove the fuser oil roll and wipe it with a dry, lint-free cloth, and clean the transfer belt. If there still is a problem, go to “Periodic Dirt” on page 2-76. Quality of printed transparencies is inadequate. Be sure you’re using the recommended Lexmark transparencies. Be sure you’re loading transparencies properly.
Service.bk Page 73 Thursday, October 4, 2001 12:20 PM 5055-01x No Image Possible Cause Action Moist Paper Be sure the printer is not in a damp environment and the paper is not curled or wavy due to moisture. If necessary inform the customer about correct storage. LED Printhead Be sure the LED printhead cable is securely connected to the printhead controller board and LED printhead assembly. If the problem remains, replace the LED printhead.
Service.bk Page 74 Thursday, October 4, 2001 12:20 PM 5055-01x Black Line Possible Cause Action Photodeveloper Drum Clean any dirt from the drum surface. Replace it if it is scratched. Fuser Detach Pawl Fuser Roller Surface Fuser Thermistor Surface Remove any toner buildup. Replace the fuser. LED Printhead Clean the LED printhead. Print a blank document. Replace the LED printhead if a black line appears on the paper.
Service.bk Page 75 Thursday, October 4, 2001 12:20 PM 5055-01x Missing Colors Possible Cause Toner Cartridge Unit Action Be sure the toner cartridge and the PC drum unit are properly seated. Be sure the contacts on the print unit are clean. Be sure the print unit is installed in the correct position. Run a print test. If the problem remains, switch the print unit with another color and run a test print. If the new color prints, replace the failing toner cartridge.
Service.bk Page 76 Thursday, October 4, 2001 12:20 PM 5055-01x Uneven Printing Possible Cause Action Photoconductor Drum Check for condensation or dirt on the photoconductor drum. LED Printhead Clean any dirt off the exposed surface of the LED printhead. Also check the locating pins of the printhead. Transfer Belt Unit Be sure the transfer belt is clean and not damaged. Replace parts as necessary. Top Cover Be sure the top cover is fully locked.
Service.bk Page 77 Thursday, October 4, 2001 12:20 PM 5055-01x Options Service Check Service Tip: When you have a problem with any of the options installed in the options slots on the interconnect board, switch the non operating option to one of the other option slots to isolate the failure. Serial Port Service Check Run the “Serial Wrap Tests” on page 3-15.
Service.bk Page 78 Thursday, October 4, 2001 12:20 PM 5055-01x Hard Disk Option Service Tip: The 5055-01x printers support one hard disk option. Be sure only one 3.2 GB or larger one hard disk option is installed. Be sure the fixed disk and the fixed disk board are correctly installed. Run the “Quick Disk Test” on page 3-17 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk.
Service.bk Page 1 Thursday, October 4, 2001 12:20 PM 5055-01x 3. Diagnostic Aids Note: When trouble shooting, or prior to making any adjustment to print quality, always be sure of the following: • The printer is installed on a level rigid surface. • The OPCs are never exchanged. Do not exchange a black OPC for a color OPC, as they have different surface phase counts. • Radar Page is always used when adjusting print registration. Power-On Self Test Sequence 1. Power on. 2.
Service.bk Page 2 Thursday, October 4, 2001 12:20 PM 5055-01x Using the Operator Panel The operator panel on your printer has a 2-line by 16-character liquid crystal display (LCD), five buttons, and one indicator light. The light indicates whether the printer power is on and whether the printer is idle or busy processing a job. Indicator Light State Indicates Off Printer power is off. On Printer is on, but idle. Flashing Printer is busy processing a job.
Service.bk Page 3 Thursday, October 4, 2001 12:20 PM 5055-01x Operator Panel Buttons Button Function Go Press Go to: • Exit printer menus and return the printer to the ready state. • Clear certain messages from the display. If you’ve changed printer settings from the operator panel menus, press Go before you send a job to print. Menu > and
Service.bk Page 4 Thursday, October 4, 2001 12:20 PM 5055-01x Printing the Menu Settings 1. From the printer operator panel, press Menu to enter the menus. 2. Continue to press and release Menu until you see TESTS MENU. 3. Press Select. TESTS MENU is displayed on the first line, and Print Menus is on the second line . 4. Press Select again to print the page. The message Printing Menu Settings is displayed. The printer returns to Ready status after the menu settings page prints.
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Service.bk Page 6 Thursday, October 4, 2001 12:20 PM 5055-01x Diagnostic Mode To access the diagnostics printer settings and operations: 1. Turn off the printer. 2. Press and hold Go and Return. 3. Turn on the printer. Release the buttons after the Performing Self Test message displays. Setting Printer Alignment X= sxxx* Y= sxxx* T= sxx* The Alignment menu is formatted so that all menu items fit on a single screen as shown below.
Service.bk Page 7 Thursday, October 4, 2001 12:20 PM 5055-01x must print the Alignment Test page. From the Alignment screen containing each of the alignment values, press Go. This button serves as a hot key to the alignment (X= sxxx* Y= sxxx* T= sxxx*) test page. While the page prints the Power indicator blinks and the following message displays: Alignment Test Printing... No buttons are active while the Alignment Test page is printing. Once it is complete, the Alignment screen will be displayed again.
Service.bk Page 8 Thursday, October 4, 2001 12:20 PM 5055-01x Print Tests Input Source Print Tests The Diagnostic Input Source Print Tests may be used to verify that the printer can print on media from the installed input sources, which are available within the Print Tests menu. Chose from following: • Single (prints the Print Test page once). • Continuous (prints the Print Test page until Return or Stop is pressed).
Service.bk Page 9 Thursday, October 4, 2001 12:20 PM 5055-01x Note: represents the input source selected for the Print Test. One of the following sources is displayed: Tray 1, MP Feeder, Standard Bin (Face-Down), or Output Bin 1. The value of the field is displayed when the narrow media sensor determines the media used for the Quick Test is narrow or wide, (N for narrow, W for wide).
Service.bk Page 10 Thursday, October 4, 2001 12:20 PM 5055-01x Hardware Tests LCD Hardware Test The LCD Hardware Test causes the printer to continually execute the LCD display test. To cancel the test, press Return or Stop. Button Test The Button Test is used to verify the operation of each button on the operator panel. When Button Test is selected, the following screen displays: OP OP OP OP OP OP When a button is depressed, CL (Closed) displays. When a button is not depressed, OP (Open) displays.
Service.bk Page 11 Thursday, October 4, 2001 12:20 PM 5055-01x DRAM Memory Test The DRAM Memory Test is used to check the validity of DRAM (both standard and optional). Patterns of data are written to DRAM verifying each bit in memory can be set and read correctly. When this test is selected from the operator panel, the printer begins testing DRAM memory and the following screen displays.
Service.bk Page 12 Thursday, October 4, 2001 12:20 PM 5055-01x ROM Memory Test The ROM Memory Test is used to check the validity of the RIP code and fonts. When this test is selected from the operator panel, the printer begins testing ROM memory and the following screen displays. ROM Memory Test P:##### F:##### Terminology: P:###### represents the number of times the memory test finishes successfully. Initially 000000 displays for ######. The maximum pass count is 999,999.
Service.bk Page 13 Thursday, October 4, 2001 12:20 PM 5055-01x Parallel Wrap Test The Parallel Wrap Test checks the operation of each parallel signal, using a wrap plug. To perform the wrap test, follow these steps: • Disconnect the parallel interface cable, and install the parallel wrap plug. • Select HARDWARE TESTS from the Diagnostics Menu. • Select Parallel Wrap to initiate the Parallel Wrap Test. • Select the appropriate Parallel Wrap Test (Parallel Wrap, Parallel 1 Wrap).
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Service.bk Page 15 Thursday, October 4, 2001 12:20 PM 5055-01x Serial Wrap Tests The Serial Wrap Test is used to check the each signal of the serial port hardware, using a wrap plug. To perform the wrap test, follow these steps: • Disconnect the serial interface cable, and install the serial wrap plug. • Select HARDWARE TESTS from the Diagnostics Menu. • Select the appropriate Serial Wrap Test (Serial Wrap, Serial 1 Wrap).
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Service.bk Page 17 Thursday, October 4, 2001 12:20 PM 5055-01x Device Tests Quick Disk Test The Quick Disk Test performs a non-destructive read/write on one block per track on the disk. The following message displays while the test is running: Quick Disk Test Testing... The Power indicator blinks while the test is in progress. If the test is successful, the following message displays. Quick Disk Test Test Passed... Press Go, Return, or Stop to return to the DEVICE TESTS screen.
Service.bk Page 18 Thursday, October 4, 2001 12:20 PM 5055-01x Disk Test/Clean The Disk Test/Clean Test causes the disk to be formatted, destroying all data on the disk and should not be attempted on a good disk. This test should only be used when the disk contains unusable data. Note: This can be an extremely lengthy test depending on the disk size, and leaves the disk unformatted. See Formatting the Hard Disk in the User’s Guide. To run this test, select Disk Test/Clean from the DEVICE TESTS menu.
Service.bk Page 19 Thursday, October 4, 2001 12:20 PM 5055-01x Flash Test The Flash Test writes and reads data to the flash device, destroying all data, leaving the flash unformatted. The servicer must reformat the flash using the Format Flash menu operation. To run this test, select Flash Test from the DEVICE TESTS menu. The following message displays warning the customer that all flash contents will be lost: Files Will be Lost Go/Stop? To continue the test, press Go.
Service.bk Page 20 Thursday, October 4, 2001 12:20 PM 5055-01x Diagnostics - Printer Setup Defaults The following printer settings are used to determine whether U.S or non-U.S. factory defaults should be used: • = U.S. * • = Non U.S. Light Quantity • • • • Cyan Magenta Yellow Black Range = 0 to 45 If you replace one or more of the printheads, or the EEPROM for the engine controller, the Light Quantity value must be set to the value that is marked on the printhead.
Service.bk Page 21 Thursday, October 4, 2001 12:20 PM 5055-01x Par S Strobe Adj Note: This message displays only if the printer is confused with the standard parallel port. Par 1 Strobe Adj Note: This message displays only if a parallel port is available through the PCL slot 1. Auto Color Adj • = On * • = OFF Reset Calibration Press Select to reset.
Service.bk Page 22 Thursday, October 4, 2001 12:20 PM 5055-01x Viewing and Resetting the Drum Counters The drum counters increment when a page is printed. The drum counter for a particular plane increments (if that color is printed), by 1 for Letter, A4, A5, B5 and envelopes, and by 1.2 for Legal and B4. It increments by 2 for 11 x 17 and A3. The counters are used to track printer usage.
Service.bk Page 23 Thursday, October 4, 2001 12:20 PM 5055-01x Setting the Page Count The page count can be changed through the Diagnostic menus. This menu is used by the servicer to reset the Page Count whenever the engine board, containing NVRAM memory, is replaced. When Page Count is selected from the PRINTER SETUP menu, the current page count displays as follows: Page Count =1234567* The left-most digit (‘1’ in this example) blinks, indicating it is the first digit to be changed.
Service.bk Page 24 Thursday, October 4, 2001 12:20 PM 5055-01x Setting Configuration ID The Configuration ID is used to communicate characteristics of the printer that cannot be determined by the hardware sensors. The Configuration ID is originally set when the printer is manufactured, but must be reset whenever the engine board, containing NVRAM memory, is replaced The Configuration ID can be set through the Diagnostic menus.
Service.bk Page 25 Thursday, October 4, 2001 12:20 PM 5055-01x Diagnostics - Error Log Viewing the Error Log The Error Log provides a history of printer errors, containing the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1, and the oldest error displays in position 12. If fewer than 12 errors have occurred, the oldest error displays in the position before the empty log entries begin. Empty log entries are identified with an error number of 000.
Service.bk Page 26 Thursday, October 4, 2001 12:20 PM 5055-01x Clearing the Error Log To clear the error log, select Clear Log from the ERROR LOG menu. The printer displays the following message: Clear Log = Yes Select Yes to clear the log, as the empty log message displays as follows: 1-000 3-000 2-000 4-000 Select No, Return or Stop to exit the Clear Log menu.
Service.bk Page 1 Thursday, October 4, 2001 12:20 PM 5055-01x 4. Repair Information Service Precautions Observe the following precautions whenever you service the printer: • Be sure to unplug the printer from the outlet before attempting • • • • • • to service the printer. To reassemble the printer, reverse the order of disassembly unless otherwise specified. Do not operate the printer anytime during disassembly.
Service.bk Page 2 Thursday, October 4, 2001 12:20 PM 5055-01x Handling Printed Circuit Boards The following precautions must be observed when handling circuit boards with metal oxide semiconductor integrated circuits. Transportation/Storage: • During transportation or when in storage, new circuit boards • • • must not be indiscriminately removed from their protective conductive bags. Do not store or place circuit boards in a location exposed to direct sunlight.
Service.bk Page 3 Thursday, October 4, 2001 12:20 PM 5055-01x Adjustments High Capacity Paper Feed Timing Belt Adjustment 1. 2. 3. 4. 5. Secure the bracket with the screw, as shown. Attach the spring and washer to the bracket with the screw. Adjust the screw to 6mm +/- 1mm. Tighten the screw completely. Adjust the timing belt on the rear in the same manner.
Service.bk Page 4 Thursday, October 4, 2001 12:20 PM 5055-01x Removals Cover, Top Removal 1. Remove the operator panel. 2. Remove five screws from the bottom, the four screws from the back side, and the screw from the left side. Operator Panel Removal 1. Open the top unit and remove the toner cartridges and photoconductor drum units. 2. Remove the operator panel. 3. Remove the two screws from the operator panel case, and remove the case. 4. Remove the cable from the operator panel.
Service.bk Page 5 Thursday, October 4, 2001 12:20 PM 5055-01x Cover, Front Removal 1. Remove the four hinge screws from the front cover. 2.
Service.bk Page 6 Thursday, October 4, 2001 12:20 PM 5055-01x Cover, Front Left 1. Open the front cover and remove the cassette. 2. Remove the left front cover by removing the three screws. Cover, Rear Removal 1. Open the top unit. 2. Remove the three screws from the rear cover, and remove the cover.
Service.bk Page 7 Thursday, October 4, 2001 12:20 PM 5055-01x Cover, Solenoid Removal 1. Remove the screw from the solenoid cover. 2. Remove the solenoid cover. Cover, Left Side Removal 1. Remove the upper cassette, front cover, paper exit tray, and duplex unit. 2. Remove the five screws from the left side cover, and remove the cover.
Service.bk Page 8 Thursday, October 4, 2001 12:20 PM 5055-01x Cover, Right Side Removal 1. Open the top unit and remove the front cover and upper cassette. 2. Remove the seven screws from the right side cover together with the turn guide, and remove the cover. 3. When installing the right side cover, insert the turn guide shaft into the bearing.
Service.bk Page 9 Thursday, October 4, 2001 12:20 PM 5055-01x Cover, RIP Board Removal 1. Loosen the eight screws and remove the RIP cover by sliding upward. 2. Remove the three harnesses and one flat cable of the RIP board connector. 3. Remove the two screws from the parallel port connector and the screw from the USB connector. 4. Remove the eight screws from the RIP board together with the parallel connector, and remove the RIP board.
Service.bk Page 10 Thursday, October 4, 2001 12:20 PM 5055-01x Tray, Paper Exit Removal 1. Unlatch the hinge at the back side, then unlatch the hinge on the front side. 2. Remove the paper exit tray.
Service.bk Page 11 Thursday, October 4, 2001 12:20 PM 5055-01x RIP Box Removal 1. Remove the five screws from the RIP box. 2. Slightly lift and remove the RIP box. Electronic Box Removal 1. Open the top unit and remove the back cover, front cover, cassette, turn guides and right side cover. 2. Remove the screws from the electronic box. 3. Disconnect the two cables from the rear of the electronic box and remove the box.
Service.bk Page 12 Thursday, October 4, 2001 12:20 PM 5055-01x LED Printhead Removal 1. Open the top unit, remove the top cover, toner cartridges and photoconductor drum units. Note: Remove the transfer belt, or spread a cloth or paper over the transfer belt to protect it from damage. 2. Remove the screw from the printhead holder, and remove the holder. 3. Remove the front and rear printhead springs. 4. Remove the two screws (front and rear) from the right slide rail, and remove the rail.
Service.bk Page 13 Thursday, October 4, 2001 12:20 PM 5055-01x 5. Remove the four connectors from LED printhead. 6. Remove the two screws from the ground wires. When replacing the LED printhead, replace the corresponding EEPROM shipped with the printhead, on the printhead controller board. Place the printer in Diagnostic Mode, input the printhead light quantity value plus eight (refer to note below) from the printhead label. Be sure to remove any fingerprints or stains from the printhead lens.
Service.bk Page 14 Thursday, October 4, 2001 12:20 PM 5055-01x Eraser Removal 1. Remove the appropriate printheads. Spread a cloth or paper over the transfer belt to protect it from damage. 2. Remove the two screws from HSP holder, and remove the holder. 3. Remove the top cover. 4. Disconnect the connector (see arrow). 5. Remove the eraser.
Service.bk Page 15 Thursday, October 4, 2001 12:20 PM 5055-01x Printhead Controller Board Removal 1. Remove the top cover. 2. Remove the 20 printhead controller board connectors. 3. Remove the 10 screws from the printhead controller board, and remove the board. Note: When replacing the board, be sure to return the four EEPROMs on the former board to the same positions on the new board.
Service.bk Page 16 Thursday, October 4, 2001 12:20 PM 5055-01x Upper Fan Removal 1. Open the top unit and remove the toner cartridges and photoconductor drum units, top cover, and face-down guide assembly. 2. Remove the four screws and the five screws from the upper bracket, and remove the bracket. 3. Remove the two screws from the left fan, and remove the fan. 4. Remove the two screws from the right fan, and remove the fan.
Service.bk Page 17 Thursday, October 4, 2001 12:20 PM 5055-01x Multi-Purpose Feeder Tray Removal 1. Open the top unit and remove the front cover, cassette feeder, turn guides and right side cover. 2. Open the multi-purpose feeder and slide it toward the magnet in the direction of the arrow, removing it from the printer.
Service.bk Page 18 Thursday, October 4, 2001 12:20 PM 5055-01x Paper Feed Roller Removal 1. 2. 3. 4. 5. Remove the front cover. Remove the manual paper feed tray. Remove the right side cover and turn guide. Remove the upper cassette. Release the clutch and until the paper feed roller screw is visible. Turn the paper feed roller, and remove the screw from the roller. 6. Remove the paper feed roller from the shaft.
Service.bk Page 19 Thursday, October 4, 2001 12:20 PM 5055-01x Paper Present Sensor Removal 1. Open the paper feed cover and pull out the duplex unit halfway. 2. Unclip the paper present sensor from the mounting. 3. Disconnect the connector and remove the sensor.
Service.bk Page 20 Thursday, October 4, 2001 12:20 PM 5055-01x Paper Feed Frame Removal 1. Open the top unit and remove the RIP board cover, RIP board, RIP box, and electronic box. Open the turn guide and paper feed cover and pull out the duplex unit halfway. 2. Remove the belt unit. 3. Disconnect the connector and remove the three screws, and the screw from the paper feed frame. 4. Remove the clip from the paper feed roller shaft and remove the gear. 5. Remove the paper feed frame. 6.
Service.bk Page 21 Thursday, October 4, 2001 12:20 PM 5055-01x Cassette Guide Removal 1. Remove the paper feed frame. 2. Remove the front cover, cassette, turn guide, right side cover and paper feed frame. 3. Remove the screws from the cassette guide, and remove the guide.
Service.bk Page 22 Thursday, October 4, 2001 12:20 PM 5055-01x Temperature/Humidity Sensor Removal Paper Feed Solenoid Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 2. Remove the screw from the temperature/humidity sensor, and remove the sensor. 3. Remove the two screws from the paper feed solenoid bracket and remove the solenoid. 4. Remove the spring from the solenoid plunger arm. Note: Be sure to use the specific screws during installation.
Service.bk Page 23 Thursday, October 4, 2001 12:20 PM 5055-01x Gear Cover Removal Multi-Purpose Feeder Roll Removal Multi-Purpose Feeder Clutch Removal OHP Detection Sensor (Upper) Removal 1. Open the top unit, and remove the upper cassette, front cover, multi-purpose feeder, right side cover, and turn guide. 2. Remove the two screws from the gear cover, and remove the cover. 3. Remove the four screws from the multi-purpose feeder frame and the ground board screw. 4.
Service.bk Page 24 Thursday, October 4, 2001 12:20 PM 5055-01x 6. Remove the screw from the OHP detection sensor (upper). 7. Turn the bearing stopper of the multi-purpose feeder roll forward 1/4 turn and remove upward. 8. Remove the C-clip and remove the multi-purpose feeder clutch. Note: After reassembling the components, coat the contact areas of the multi-purpose feeder roll shaft and multi-purpose feeder ground plate with conductive grease.
Service.bk Page 25 Thursday, October 4, 2001 12:20 PM 5055-01x Fanning Pad Removal 1. Open the top unit and remove the upper cassette, front cover, turn guide, multi-purpose feeder, right side cover, and multipurpose feeder roll. 2. Release clips at 4 positions and remove the fanning pad.
Service.bk Page 26 Thursday, October 4, 2001 12:20 PM 5055-01x Registration Sensor Removal 1. Open the top unit and remove the upper cassette, front cover, turn guide, multi-purpose feeder, right side cover, and multipurpose feeder frame. 2. Disconnect the connector of the registration sensor and remove the sensor.
Service.bk Page 27 Thursday, October 4, 2001 12:20 PM 5055-01x Multi-Purpose Feeder Paper Present Sensor Removal 1. Open the top unit and remove the upper cassette, front cover, turn guide, multi-purpose feeder, right side cover, turn guide, and multi-purpose feeder frame. 2. Disconnect the connector and remove the multi-purpose feeder paper present sensor.
Service.bk Page 28 Thursday, October 4, 2001 12:20 PM 5055-01x Paper Carrying Frame Removal Paper Carrying Roller (Upper) Removal Paper Carrying Clutch Removal OHP Detection Sensor (Lower) Removal 1. Open the top unit and remove the upper cassette, front cover, turn guide, multi-purpose feeder, right side cover, turn guide, OHP detection sensor (upper), multi-purpose feeder frame, back cover, RIP cover, RIP board, RIP box, and electronic box. 2. Remove the four screws from the paper carrying frame. 3.
Service.bk Page 29 Thursday, October 4, 2001 12:20 PM 5055-01x Registration Frame, Registration Clutch Removal 1. Open the top unit, open the turn guide, open the paper feed cover and pull out the duplex unit halfway. 2. Remove the two screws from the registration frame. 3. Remove the registration clutch. Note: When installing, set the clip of the registration clutch to the stopper.
Service.bk Page 30 Thursday, October 4, 2001 12:20 PM 5055-01x Transfer Belt Removal To replace the transfer belt before the Life Warning or Exhausted messages appear, open the supplies menu on the operator panel and select Replace Supplies, select Belt, and select Replace Now. If the 80 Transfer Belt Life Warning or Exhausted message appears on the display, press Select when the Select = Replace message appears.
Service.bk Page 31 Thursday, October 4, 2001 12:20 PM 5055-01x 3. Loosen the thumbscrews as shown.
Service.bk Page 32 Thursday, October 4, 2001 12:20 PM 5055-01x 4. Lift and remove the transfer belt cover. 5. Loosen the thumbscrews as shown.
Service.bk Page 33 Thursday, October 4, 2001 12:20 PM 5055-01x 6. Pull the transfer belt out. 7. After replacing the transfer belt and removing the four shipping spacers, tighten the transfer belt thumbscrews and reinstall the transfer belt cover. 8. Close the top unit and rotate the locking lever to the right, close the front cover. 9. Turn the printer on. Note: If the message Did you Replace Belt? appears, wait for the message Select = yes Stop = no and press Select.
Service.bk Page 34 Thursday, October 4, 2001 12:20 PM 5055-01x Belt Up/Down Detection Sensor Removal 1. Open the top unit and remove the waste toner bottle and belt unit. 2. Remove the belt up/down detection sensor from the mounting board. 3. Remove the connector from the belt up/down detection sensor.
Service.bk Page 35 Thursday, October 4, 2001 12:20 PM 5055-01x Sensor Board Removal 1. Remove the transfer belt unit. 2. Remove the four connectors. 3. Remove the three screws from the waste toner full sensor board.
Service.bk Page 36 Thursday, October 4, 2001 12:20 PM 5055-01x Density Sensor Removal Separation Fingers Removal Sensor Cleaner Removal 1. Open the top unit and remove the belt unit. 2. Remove the three screws from the sensor bracket. 3. Remove the harness band and remove the two screws from the density sensor from the sensor bracket. 4. Remove the three set screws from the sensor cleaner assembly from the sensor bracket. 5. Remove the four separating finger screws from the fuser entrance guide.
Service.bk Page 37 Thursday, October 4, 2001 12:20 PM 5055-01x Printer Controller Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 2. Remove the connectors and the eight screws from the printer controller. Note: When replacing the board, install the EPROM (U5) of the former board to the new board. Also, when replacing the EPROM, set the light intensity in the diagnostic mode and set the counter and printer alignment.
Service.bk Page 38 Thursday, October 4, 2001 12:20 PM 5055-01x High Voltage Power Supply Board (HVU) Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, electronic box, and printer controller board. 2. Remove the five screws from the printer controller board bracket. 3. Remove the connectors and remove the 12 screws. 4. Remove the high voltage power supply board.
Service.bk Page 39 Thursday, October 4, 2001 12:20 PM 5055-01x R Sub Frame Removal Toner Remaining Sensor Removal Drum Gear Sensor Removal 1. Open the top unit, and remove the RIP cover, RIP board, RIP box, electronic box, printer controller, printer controller bracket, and high voltage power supply board. 2. Remove the two screws from the sub frame R from inside of the main unit. 3. Remove the screw and C-clip from the sub frame cover. 4. Remove the screw from the toner remaining sensor.
Service.bk Page 40 Thursday, October 4, 2001 12:20 PM 5055-01x Sub Frame F1, Sub Frame F2 Removal 1. Open the top unit. 2. Remove the two screws from the sub frames F1 and F2. Note: Spread a paper or cloth over the belt to protect the belt. Set the sub frame F to the position of the following colors depending on presence of upper detection button.
Service.bk Page 41 Thursday, October 4, 2001 12:20 PM 5055-01x Drive Gear Unit Sensor Assembly Removal 1. Open the top unit and remove the gear cover, RIP cover, RIP board, RIP box, electronic box, printer controller, and high voltage power supply board. 2. Remove the screw from the drive gear unit sensor assembly. 3. Remove the two screws of the drive gear unit sensor from the drum drive gear sensor assembly.
Service.bk Page 42 Thursday, October 4, 2001 12:20 PM 5055-01x Belt Up/Down Clutch Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. Remove the printer controller. Remove the printer controller bracket and the high voltage power supply board. 2. Remove the C-clip from the belt up/down clutch, and remove the clutch.
Service.bk Page 43 Thursday, October 4, 2001 12:20 PM 5055-01x Power Supply 1 Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. Remove the cassette, left front cover, and back cover. Remove the left side cover. 2. Remove the insulation sheet connector, two ground wires, five screws, two screws with washers, two screws with spring washers and remove the power supply. (When installing, incline the ground wire by 45 degrees.
Service.bk Page 44 Thursday, October 4, 2001 12:20 PM 5055-01x Power Supply 2 Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 2. Disconnect the connector and remove the seven screws from Power Supply 2, and remove the power supply.
Service.bk Page 45 Thursday, October 4, 2001 12:20 PM 5055-01x Drive Motor Assembly Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 2. Remove the upper cassette, left front cover, and back cover. 3. Remove the turn guide. 4. Open the paper feed cover and remove the duplex unit. 5. Remove the side left cover. Remove the connector, two ground wires, and power supply 1. 6. Remove the connector (CN2, CN4 and CN5) from the motor drive board. 7.
Service.bk Page 46 Thursday, October 4, 2001 12:20 PM 5055-01x Power Switch Removal 1. Remove the upper cassette, left front cover, paper feed cover, and left side cover. 2. Unlock the power switch and pull out the power switch. 3. Remove each terminal connected to the power switch. Note: When connecting, be careful to connect the connectors correctly. Insert the insulator cover completely covering the terminal.
Service.bk Page 47 Thursday, October 4, 2001 12:20 PM 5055-01x Connector, Duplex Unit Removal 1. Open the top unit and remove the upper cassette, left front cover, paper feed cover, left side cover, RIP cover, RIP board, RIP box, and the electronic box. Remove the turn guide and open the paper feed cover and remove the duplex unit. Remove the left side cover and power supply A. 2. Disconnect the connector and remove the two screws from the mounting plate. 3.
Service.bk Page 48 Thursday, October 4, 2001 12:20 PM 5055-01x Paper Size Sensor Board Assembly Removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. Remove the upper cassette, front cover B, and back cover. Open the turn guide and paper feed cover and remove the duplex unit. Remove the left side cover and power supply A. 2. Disconnect the connector and remove the two screws from the paper size sensor board, removing the board. 3.
Service.bk Page 49 Thursday, October 4, 2001 12:20 PM 5055-01x Main Unit Fan Removal 1. Remove the left side cover, the solenoid cover, and the rear cover. 2. Remove the two screws from the main unit fan bracket. 3. Remove the fan.
Service.bk Page 50 Thursday, October 4, 2001 12:20 PM 5055-01x Main Drive Unit Removal 1. Open the top unit and remove the gear cover, upper cassette, left front cover, paper feed cover, RIP cover, RIP board, RIP box, electronic box, and rear cover. 2. Open the turn guide and paper feed cover and remove the duplex unit. 3. Remove the left side cover, power unit 1, and power unit 2. 4. Remove the printer controller board. 5. Remove the bracket, high voltage power supply board, and sub frame R. 6.
Service.bk Page 51 Thursday, October 4, 2001 12:20 PM 5055-01x 12. Remove the two screws of the fuser connector cable assembly from the fuser connector plate. Note: Note the direction, when installing. 13. After removing the two screws on the bracket that attaches the rear side and paper exit side of the machine, remove the five screws, and four screws from the bracket as shown.
Service.bk Page 52 Thursday, October 4, 2001 12:20 PM 5055-01x 14. Remove the bearing from the belt up/down switching shaft and remove the belt up/down switching shaft. 15. Remove the screw from the clutch stopper. The clutch stopper is attached to the ground plate with two screws.
Service.bk Page 53 Thursday, October 4, 2001 12:20 PM 5055-01x 16. Remove the five screws on the right side. 17. Remove the screw and the screw from the drive unit, and remove the unit. 18. Remove the two screws and the screw from the belt up/down clutch box and remove the belt up/down clutch. 19. Remove the screw from the drum gear sensor and remove the sensor.
Service.bk Page 54 Thursday, October 4, 2001 12:20 PM 5055-01x Face-Up Paper Exit Assembly Removal Face-Up/Down (Flapper Detection) Sensor Removal Face-Up/Down Solenoid Removal Paper Delivery Sensor Removal Paper Exit Tray Switch Removal 1. Open the top unit and remove the upper cassette. Open the duplex cover and remove the duplex unit. 2. Remove the left front cover, left side cover and rear cover. 3. Remove the three screws from the face-up delivery assembly and remove the assembly. 4.
Service.bk Page 55 Thursday, October 4, 2001 12:20 PM 5055-01x Face-Down Guide Assembly Removal Paper Exit Motor & Full Sensor Removal 1. Open the top unit and remove the toner cartridges, photoconductor drum units, and upper cover. 2. Remove the top cover. 3. Disconnect the connector and remove the five screws and two snap bands from the face-down guide assembly. Remove the assembly. 4. Remove the four screws from the face-down cover and the facedown guide assembly, and remove the assembly.
Service.bk Page 56 Thursday, October 4, 2001 12:20 PM 5055-01x 5. Remove the two screws of the motor from the face-down guide assembly. Remove the assembly. Note: When the motor is installed, press the motor 45 degrees in an upward direction when viewing from the rear. 6. Remove the face-down paper delivery full sensor from the facedown guide assembly.
Service.bk Page 57 Thursday, October 4, 2001 12:20 PM 5055-01x Turn Guide Cover Sensor Removal 1. Open the top unit and remove the upper cassette, front cover, multi-purpose feeder, right side cover, and turn guide. 2. Remove the two screws from turn guide sensor, and remove the sensor. 3. Remove the terminal.
Service.bk Page 58 Thursday, October 4, 2001 12:20 PM 5055-01x Right Slide Rail Removal 1. Remove the upper cassette. 2. Remove the screw from both left and right slide rails. Front Cover Open Switch Actuator Removal 1. Open the front cover. 2. Remove the two screws from the front cover open switch actuator.
Service.bk Page 59 Thursday, October 4, 2001 12:20 PM 5055-01x Lock Handle Assembly Removal 1. Open the top unit. 2. Turn the plastic latch on the front and rear sides by 90 degrees. 3. Remove the lock handle assembly.
Service.bk Page 60 Thursday, October 4, 2001 12:20 PM 5055-01x Top Unit Removal 1. Open the top unit and remove the top cover and face-down guide assembly. 2. Remove the screws and remove the top unit.
Service.bk Page 61 Thursday, October 4, 2001 12:20 PM 5055-01x Stay Arm Removal 1. Open the top unit and remove the face-down paper guide assembly. 2. Remove the yellow and black sub frame. 3. Remove the screw and the screw from the right stopper, and remove the stopper. 4. Remove the screw from the left stopper, and remove the stopper. 5. Remove the clip from the lock shaft. 6. Remove the 17 screws from the stay arm, and remove the arm.
Service.bk Page 62 Thursday, October 4, 2001 12:20 PM 5055-01x Fuser Removal 1. Open the top unit. 2. Pushing the front and back lock, hold the handle, raise and remove the fuser.
Service.bk Page 63 Thursday, October 4, 2001 12:20 PM 5055-01x Options Removals Expansion Paper Feeder Removal 1. Remove the cassette. 2. Remove the two screws from the front cover, removing the cover. 3. Remove the two screws from left side cover, and remove the cover. 4. Remove the two screws from right side cover A, and remove the cover. 5. Remove the two screws from right side cover B, and remove the cover. 6. Remove the screw from right side cover C, and remove the cover. 7.
Service.bk Page 64 Thursday, October 4, 2001 12:20 PM 5055-01x 9. Remove the screw from paper the detection cover, and remove the cover. 10. Remove the paper detection sensor. 11. Remove the high capacity feeder guide. The cover is hinged in place. 12. Remove the screw from the paper feed roller assembly N5 from 4 positions, and remove the roller.
Service.bk Page 65 Thursday, October 4, 2001 12:20 PM 5055-01x 13. Remove the screw from the gear cover, and remove the cover. 14. Remove the two screws from the paper carrying roller, and remove the roller. 15. Remove the connector and remove the two screws from the drive motor, and remove the motor.
Service.bk Page 66 Thursday, October 4, 2001 12:20 PM 5055-01x 16. Remove the six screws from the drive assembly, and remove the assembly. 17. Remove the two screws from the paper remaining detection board, and remove the board. 18. Remove the four screws from the solenoid assembly, and remove the assembly.
Service.bk Page 67 Thursday, October 4, 2001 12:20 PM 5055-01x 19. Remove the two bearings from the turn guide. The cover is hinged in place. 20. Remove the screw from the paper feed frame fuser plate, and remove the plate.
Service.bk Page 68 Thursday, October 4, 2001 12:20 PM 5055-01x 21. Remove the two screws from the fuser frame assembly, and remove the assembly. 22. Remove the three screws from the cassette guide assembly, and remove the assembly.
Service.bk Page 69 Thursday, October 4, 2001 12:20 PM 5055-01x 23. Remove the six screws from the second drive board assembly, and remove the assembly. 24. Remove the two screws from the paper size detection board, and remove the board. 25. Remove the screw from the size detection lever spring, and remove the spring. 26. Remove the two screws from the connector plate, and remove the plate. 27. Remove the two screws from the upper drawer connector (male), and remove the connector.
Service.bk Page 70 Thursday, October 4, 2001 12:20 PM 5055-01x 28. Remove the two screws from the lower drawer connector (female), and remove the connector.
Service.bk Page 71 Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Unit Separation Removal 1. Remove the thumbscrews, C-clips, and screws as shown from both sides. 2. Remove the connectors and separate the duplex frame from the duplex unit.
Service.bk Page 72 Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Unit Removal 1. Remove the four screws from the interface board, and remove the board. 2. Remove the two screws from the duplex connector, and remove the connector. Duplex Timing Belt Removal 1. Remove the three C-clips from the three timing gears and remove the timing belts. 2. Remove the knob screw and remove the timing belt.
Service.bk Page 73 Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Pressure Roller and Solenoid Removal 1. Remove the two screws securing the pressure roll solenoid assembly. Duplex Feed Roller And Solenoid Removal 1. Remove the two screws securing the feed roll solenoid assembly. 2. Remove the pressure roller and springs. 3. Remove the feed roller and springs.
Service.bk Page 74 Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Side Fence Motor Assembly / Side Fence Removal 1. Remove the three screws and remove the side fence motor assembly. 2. Remove the front and rear side fences. Note: When installing, spread the front and rear side fences to the sides and install.
Service.bk Page 75 Thursday, October 4, 2001 12:20 PM 5055-01x Duplex Paper Carrying Motor Removal 1. Remove the gear cover. 2. Remove the screws from the duplex paper carrying motor and remove the motor.
Service.bk Page 76 Thursday, October 4, 2001 12:20 PM 5055-01x HCPF Covers Removal 1. Remove the two screws from the drive cover, and remove the cover. 2. Remove the front cover. 3. Remove the two screws from the right cover, and remove the cover. 4. Remove the top cover. 5. Remove the rear cover. 6. Remove the four screws from the transfer cover, and remove the cover.
Service.bk Page 77 Thursday, October 4, 2001 12:20 PM 5055-01x HCPF Call Roller, Paper Feed Roller, Reverse Roller Removal 1. Open the top cover on the tray. 2. Remove the two screws from the transfer cover, and remove the cover. 3. Remove the retaining rings on the rollers, and remove the rollers.
Service.bk Page 78 Thursday, October 4, 2001 12:20 PM 5055-01x HCPF Pickup Solenoid Removal 1. Remove the four screws from the transfer cover, and remove the cover. 2. Remove the two screws from the drive cover, and remove the cover. 3. Remove the screw from the clamp plate, and remove the plate. 4. Remove the connector and the two screws from the pickup solenoid, and remove the solenoid.
Service.bk Page 79 Thursday, October 4, 2001 12:20 PM 5055-01x HCPF Paper End Sensor Removal HCPF Paper Size Sensors (1, 2) Removal 1. Cover the paper level sensor with your hand and press the down button. The tray moves down. Lower the tray until the down sensor turns on. 2. Remove the front cover and transfer cover. 3. Remove the two screws on the front and rear sides of the side fence. 4. Mark the locking position of the side fence locking stay. 5. Remove the two screws on the side fence locking stay.
Service.bk Page 80 Thursday, October 4, 2001 12:20 PM 5055-01x Notes: • To prevent damage to the stay, hold the stay when removing the • sensors. Be sure the side registration is not shifted, which may occur with the dismounting and mounting of the locking stay. If it is shifted, relocate the stay toward the front or rear to adjust. 8. Remove the top cover switches.
Service.bk Page 81 Thursday, October 4, 2001 12:20 PM 5055-01x HCPF Tray Motor Removal 1. Remove the rear cover and the drive cover. 2. Remove the two screws of the tray motor, and remove the motor.
Service.bk Page 82 Thursday, October 4, 2001 12:20 PM 5055-01x HCPF Paper Level Sensor Removal 1. Remove the four screws from the transfer cover, and remove the cover. 2. Remove the two screws from the sensor, and remove the cover. 3. Remove the connector and screw from paper level sensor, and remove the sensor.
Service.bk Page 83 Thursday, October 4, 2001 12:20 PM 5055-01x HCPF Power Supply Removal 1. 2. 3. 4. Move the paper tray upward. Disconnect the power cord. Remove the front cover. Remove the two screws from the power supply cover, and remove the cover. 5. Remove the four screws from the power supply unit and remove the unit. 6. Remove the two screws from the DC-DC converter, and remove the converter.
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Service.bk Page 1 Thursday, October 4, 2001 12:20 PM 5055-01x 6. Preventive Maintenance Maintenance Kit When nearing the end-of-life of the fuser or transfer belt, the following message appears on the printer display, indicating that it’s time to replace the fuser unit and/or transfer belt unit: 80 Belt Life Warning and/or 80 Fuser Life Warning Routine replacement of these parts ensures peak printer performance and helps prevent print quality problems and paper feed problems resulting from worn parts.
Service.bk Page 2 Thursday, October 4, 2001 12:20 PM 5055-01x Periodic Maintenance This table lists the parts to be periodically cleaned by the servicer. Part Name Method Paper Feed Unit: Remove any dust or dirt, and wipe the surface lightly with a dry cloth. If it is still dirty, clean with a soft cloth and alcohol.
Service.bk Page 1 Thursday, October 4, 2001 12:20 PM 5055-01x 7. Parts Catalog How to Use This Parts Catalog • • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration.
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5055-01x Assembly 9: Base 3 7-22 Service Manual
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