Lexmark 5056-000 Page 219 Service Manual Download | Manualshive

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Repair information

4-37

5056-

XXX

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.

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 screws from the printer controller. Pay attention to the location, or label
the two pin connectors when removing them from the board to avoid reconnection into the wrong location.

When replacing the board, install the EPROM (U7) 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.

Note:

After replacing any board on the printer, ensure all the connections are properly connected before closing

the covers.

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Summary of Contents for 5056-000

Page 1: ...XXX Table of contents Start diagnostics Safety and notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or o...

Page 2: ...t by calling 1 800 553 9727 In other countries contact your point of purchase References in this publication to products programs or services do not imply that the manufacturer intends to make these a...

Page 3: ...mory options 1 6 Memory and expansion slots 1 6 Resident fonts 1 6 Paper and media specifications 1 7 Media size supported 1 8 Input 1 8 Output 1 10 Input media types and weights 1 12 Input capacity b...

Page 4: ...3 932 Cyan Printhead Error 2 14 933 Black Printhead Error 2 14 934 Color Drum Sensor Error 2 15 935 Black Drum Sensor Error 2 15 936 939 Cassette Error 2 15 940 High Capacity Feed Sensor Error 2 16 94...

Page 5: ...Sensor Error message 2 46 Map 9 False 41 Open Bin 1 Exit Tray message 2 46 Map 10 Unrecoverable Check Tray x or Duplex Connection message 2 47 Map 11 Paper size map 2 48 Map 12 Unable to print from U...

Page 6: ...Cyan Yellow Magenta 3 7 Print Tests 3 8 Input Source Print Test 3 8 Output Bin 1 Print Tests 3 8 Print Quality Pages 3 8 Hardware Tests 3 8 Panel Test 3 8 Button Test 3 9 Cache Test 3 9 DRAM Test 3 1...

Page 7: ...and configuration 3 24 Electrophotography process 3 24 Development unit 3 24 Transfer unit 3 25 Cleaning unit 3 25 Fusing 3 26 Drive system 3 28 Paper feeding 3 29 Cassette paper feeder 3 29 Multipur...

Page 8: ...inisher 3 62 Aligning the top of the finisher 3 63 Adjusting the wheels 3 64 Attaching the cables 3 65 Interface cable 3 66 Power cable 3 67 Hole punch adjustment 3 69 Repair information 4 1 Handling...

Page 9: ...Relay roller removal 4 31 Face down guide assembly removal 4 32 Face down exit roll removal 4 32 Power supply 1 removal 4 35 Power supply 2 removal 4 36 Power switch removal 4 37 Printer controller re...

Page 10: ...k area discharge brush removal 4 74 Staple unit removal 4 74 Straight paper exit discharge brush removal 4 75 Straight paper exit roller removal 4 75 Timing belts 1 and 2 removal 4 77 Tractor belt rem...

Page 11: ...mbly 15 Expansion feeder 1 7 26 Assembly 16 Expansion feeder 2 7 28 Assembly 17 Duplex unit 1 7 30 Assembly 18 Duplex unit 2 7 32 Assembly 19 High capacity feeder 1 7 34 Assembly 20 High capacity feed...

Page 12: ...xii Service Manual 5056 XXX...

Page 13: ...urch den Kundendienst Laserbestrahlung die Klasse I bersteigen w rde Menschen keinesfalls erreicht Avis relatif l utilisation de laser Pour les Etats Unis cette imprimante est certifi e conforme aux p...

Page 14: ...pot ssio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nan metros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso...

Page 15: ...k f r att n gon person uts tts f r laserstr lning ver Klass I niv vid normal anv ndning underh ll som utf rs av anv ndaren eller annan f reskriven service tg rd Laser melding Skriveren er godkjent i U...

Page 16: ...xvi Service Manual 5056 XXX...

Page 17: ...nsignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le...

Page 18: ...n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y l...

Page 19: ...roducte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d a...

Page 20: ...vides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Prevent...

Page 21: ...Resolution 600 x 600 dpi 2400 image quality Model differences 1 All the options shown in the table are available for all C920 models 5056 000 C920 base 5056 010 C920n 5056 030 C920dn 5056 030 C920dtn...

Page 22: ...edia weights supported by the duplex unit see Media Support High capacity feeder provides an additional input tray tray 3 or 5 depending on the configuration with a total capacity of 3000 sheets 20 lb...

Page 23: ...s users to customize color correction output from the operator panel Setting selectable from the driver Off no color correction is implemented Physical specifications and weight Description Height Wid...

Page 24: ...27 Transparencies LEF 22 12 N S 22 12 Vinyl LEF N S N S 13 Card stock LEF N S N S 11 Envelopes LEF N S N S 11 Paper labels 22 N S 22 Duplex printing sides per minute Letter LEF 21 19 21 19 21 19 Lett...

Page 25: ...memory Media size and type Time to first print Simplex printing from any tray is rated at 9 5 seconds mono and 13 5 seconds color Processor 1 GHz Motorola MC7447A Duty cycle Maximum duty cycle 200 000...

Page 26: ...rk com There are 83 symbol sets in the PCL 6 emulation to support all the languages that use these characters Not all symbol sets are supported by all fonts Refer to the Technical Reference or use the...

Page 27: ...50 650 1 200 Optional 500 sheet drawer 550 550 550 550 High capacity feeder 3 000 3 000 3 000 3 000 Maximum additional drawers 3 3 3 2 Maximum input capacity without high capacity feeder 2 300 2 300 2...

Page 28: ...mm X X X 12 x 18 in 305 x 457 mm Lexmark C912 only X X A3 11 69 x 16 54 in 297 x 420 mm X X X Universal1 2 69 85 x 127mm to 229 x 355 6mm 2 75 x 5in to 9 01 x 14 in 148 x 182mm to 215 9 x 355 6mm 5 83...

Page 29: ...ed for 215 9 X 355 6mm 8 5 x 14 in 2 Narrow media should be loaded with the length in the feed direction portrait 3 A5 paper 148 x 210 mm 5 83 x 8 27 in is the smallest paper the C920 can duplex 4 Whe...

Page 30: ...in 305 x 457 mm Lexmark C912 only X X X A3 11 69 x 16 54 in 297 x 420 mm X X X Universal 69 85 x 127mm to 229 x 355 6mm 2 75 x 5in to 9 01 x 14 in 148 x 182mm to 215 9 x 355 6mm 5 83 x 7 17in to 8 5 x...

Page 31: ...information 1 11 5056 XXX Media type Paper X X X X Card stock X X X Transparencies X X X Envelopes X X Glossy paper X X X X Paper labels X X Vinyl labels X Standard output Bin 1 Finisher Bin 1 Finishe...

Page 32: ...Professional color laser 175 47 175 47 N S Labels Vinyl N S N S 300 N A N S Labels Paper 180 48 180 48 N S Envelopes Sulfite wood free Up to 100 cotton N S 10 10 N S N S not supported N A Not applicab...

Page 33: ...90 g m2 Plain paper letter A4 legal tabloid A3 100 sheets 24 28 lb 90 105 g m2 Transparencies 0 2 in 7 mm 50 sheets 47 lb 147 g m2 Card stock 0 4 in 11 mm 50 sheets 33 44 lb 121 165 g m2 Card stock 4...

Page 34: ...t bin Plain paper Varies 550 sheets Glossy paper Card stock 300 sheets Paper labels Bin 1 face up Plain paper Varies 100 sheets Glossy paper Transparencies 50 sheets Card stock 30 sheets Vinyl labels...

Page 35: ...elopes the finisher must be undocked during the job If envelope wrinkling occurs refer to the User s Guide for correct weight type loading and stacking of envelopes All envelopes should be new unused...

Page 36: ...gration Tool PDF Operating systems Windows 95 OSR2 Windows 98 Windows Me Windows NT SP6 Windows 2000 Professional and Server Windows XP Home and Professional Windows Server 2003 Novell NetWare 3 x 4 x...

Page 37: ...Electrical specifications Low voltage models 110 to 127 V at 50 to 60 hertz Hz nominal 99 to 135 V extreme High voltage models 220 to 240 V at 50 to 60 hertz Hz nominal 198 to 254 V extreme Note Using...

Page 38: ...nner Media tray 9 in 229 mm 13 in 330 mm 46 in 1168 mm 5 in 127 mm 27 in 686 mm Note Required clearance is 13 in 330 mm without HCF and 30 in 762 mm with HCF Environment Specifications Operating Air t...

Page 39: ...ust hair oil grease or toner Clean the printer interior using a lint free cloth Do not use solvents or chemical cleaners to clean the printer interior Use only the specified oil or lubricant on printe...

Page 40: ...over is open wipe any residual toner from the LEDs using a lint free cloth If you have serviced the finisher option and in the process pulled it away from the printer during repair ensure that it is p...

Page 41: ...upply HVU High voltage unit Hz Hertz LAN Local area network LASER Light amplification by stimulated emission of radiation LCD Liquid crystal display LED Light emitting diode LEF Long edge feed LVPS Lo...

Page 42: ...RH Relative humidity RIP Raster image processor ROM Read only memory ROS Read only storage SEF Short edge feed SOL Solenoid SRAM Static random access memory UPR Used parts replacement USB Universal se...

Page 43: ...requires at least two people to lift it safely Make sure your fingers are not under the printer when you lift or set the printer down CAUTION If the printer is kept on never touch the conductive parts...

Page 44: ...2 2 Service Manual 5056 XXX Print paper checks Use the recommended paper for this printer Paper dampness Make a trial print with paper from a newly opened package and check the result...

Page 45: ...lever If you cannot remove the jam replace the fuser The jam access panel can also be opened After letting the fuser cool unscrew the two thumbscrew and open the access panel You cannot clear the pap...

Page 46: ...owers the guide rail depending on which way the knobs are turned The edge of the guide rail should line up with the sticker where the white and gray portions divide Restrict use of the finisher to pla...

Page 47: ...e checked first Determine if the problem is constant or intermittent Constant 900 errors Step Action and questions Yes No 1 Disconnect the printer from any external connections Turn the power off and...

Page 48: ...tact your next level of support 900 Error Sub Codes 4 Restore factory defaults from the configuration menu WARNING When factory defaults are restored all menu items are returned to factory default val...

Page 49: ...process was running 12 12 sysdebug The 900 error occurred while the sysdebug process was running 13 13 insmod The 900 error occurred while the insmod process was running 20 20 Xprot The 900 error occu...

Page 50: ...ck The 900 error occurred while the P4TimerTick process was running 52 52 P4VidIrq The 900 error occurred while the P4VidIrq process was running 53 53 P4OSI_In The 900 error occurred while the P4OSI_I...

Page 51: ...ector CN9 on the CK2 daughter board connected properly Replace the motor drive board and go to step 4 Connect CN9 4 Did replacement of the motor drive board solve the problem Problem solved Replace th...

Page 52: ...lace the RIP board Replace the printer controller board Step Questions actions Yes No 1 Are CN14 on the printer controller board and CN03 on the printhead controller board properly connected Go to ste...

Page 53: ...ower off and reconnect CN19 Go to step 3 Replace the printer controller board 3 Power the printer off and short circuit pins 1 and 2 and 3 and 4 of CN19 and power on Is error 923 displayed Replace the...

Page 54: ...x the problem Problem solved Replace the high voltage power board HVU 92x Service Toner Sensor Step Questions actions Yes No 1 Is the toner cartridge the correct type for the printer Go to step 2 Reco...

Page 55: ...d controller board and go to step 3 3 Did replacement of the printhead controller board resolve the problem Problem solved Replace the printer controller board Step Questions actions Yes No 1 Check to...

Page 56: ...nd go to step 3 3 Did replacement of the printhead controller board resolve the problem Problem solved Replace the printer controller board Step Questions actions Yes No 1 Check to ensure that the cab...

Page 57: ...fix the problem Problem solved Replace the printer controller board Step Questions actions Yes No 1 Clean the black drum sensor LED Did this fix the problem Problem solved Go to step 2 2 Swap the bla...

Page 58: ...acity feeder HCF service check on page 2 53 Plug the connector in securely Step Questions actions Yes No 1 Is connector CN22 on the printer controller board connected properly Go to High capacity feed...

Page 59: ...oard Are all the EPROMS present Go to step 3 Install the EPROM s included with printhead FRU 3 Replace the printhead controller board Did this fix the problem Problem solved Replace the printer contro...

Page 60: ...nthead 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 3 Did replacing the printer controller board fi...

Page 61: ...r panel that generated the 950 error Contact your technical support center 3 Replace the RIP card that was just installed with the original RIP card Restart the printer Did this fix the problem Proble...

Page 62: ...4 Emulation Error Replace the DLE board If this does not fix the problem replace the RIP board 970 Standard Network Error Check the network card in slot x on the RIP card 975 Unrecognizable Network Po...

Page 63: ...t on output bin 1 Can you hear the FU FD solenoid move during the feed test Check to see if linkage from the FU FD solenoid to the FU FD deflector is broken Repair or replace the face up unit Go to st...

Page 64: ...ensor actuator flag Are there any binds other than when engaging the transfer belt Make sure the sensor is fully snapped in place and that the sensor connector is fully seated Are these items correct...

Page 65: ...Check the cable running to CN20 for damage Is the cable damaged Replace the cable Go to step 3 3 Clean the gear sensor Does this correct the problem Problem solved Go to step 4 4 Replace the sensor c...

Page 66: ...light receiving on the CK1 daughter board connected properly Go to step 2 Plug the connector in securely 2 Test the sensor While actuating the sensor does the voltage fluctuate between 0 V and 5 betw...

Page 67: ...the size sensing levers bent or damaged Replace the size sensing levers Go to step 4 4 Replace the CK 2 daughter board Did this solve the problem Problem solved Go to step 5 5 Are any actuators on th...

Page 68: ...se the density sensor actuator Go to step 3 3 Are connectors CN406 and CN407 on the sensor board connected properly Go to step 4 Plug the connector in securely 4 Is connector CN15 on the printer contr...

Page 69: ...olved Replace the finisher control board 6 Measure for 24 V dc between pins 1 and 2 on connector PJ3 on the finisher control board Measure for 5 V dc between pins 1 and 3 on PJ2 on the finisher contro...

Page 70: ...2 of PJ3 on the finisher control board Is 24 V dc present Replace the finisher control board Replace the power supply Step Questions actions Yes No 1 Are the connectors CN4 at the tray elevator motor...

Page 71: ...nisher control board securely connected Go to step 5 Securely connect the connectors 4 Did replacement of the stapler cartridge resolve the problem Problem resolved Replace the stapler 5 Make sure the...

Page 72: ...ear Change src Custom Type Name The printer is requesting a different type or size of paper Select Continue if you have changed the media Select Use current to print on media currently in the printer...

Page 73: ...essage to clear Note While the menus are disabled you cannot change the printer settings from the operator panel Disk corrupted The printer has attempted a disk recovery process and cannot repair the...

Page 74: ...to clear the message and print without installing a new fuser Install a new fuser Hex Trace The printer is in Hex Trace mode Hole Punch Box Full Self explanatory Empty the hole punch box Select Contin...

Page 75: ...eady installed in one of the input sources If the printer finds a tray that has paper of the correct type and size it feeds paper from that tray If the printer cannot find a tray with the correct pape...

Page 76: ...Saver The printer is in Power Saver Mode It is ready to receive a print job Send a job to print Press Select to warm the printer to normal operating temperature and display the Ready message Printer l...

Page 77: ...out replacing the photodevelopers Replace the cyan magenta yellow and black photodevelopers Replace Color Photo Dev The specified color photodeveloper is nearing the end of life and needs replacing Se...

Page 78: ...lf explanatory Wait for the message to clear Resetting the Printer Self explanatory Wait for the message to clear Restore Held Jobs Restore held jobs on the hard disk Select Continue to restore all Pr...

Page 79: ...The specified paper tray is low Add paper to the tray to clear the message Tray x Missing The specified paper tray is missing or improperly installed Insert the tray into the printer USB See action co...

Page 80: ...enable Resource Save Install additional memory 37 Insufficient memory to collate job The printer does not have enough memory to perform the specified task Select Continue to print the portion of the...

Page 81: ...flash memory Install a larger capacity flash memory card 53 Unformatted flash detected Self explanatory Select Continue to clear the message and continue printing You must format the flash memory befo...

Page 82: ...failed and the large capacity feeder is now configured incorrectly The large capacity feeder must be installed as Tray 3 or Tray 5 1 Turn off and unplug the printer 2 Replace or remove the failed inp...

Page 83: ...fer belt 80 Replace fuser The fuser needs replacing Select Continue to clear the message and continue printing Replace the fuser 81 Engine code CRC failure Microcode in the engine flash code has faile...

Page 84: ...clearing the paper path select Continue to resume printing Message Solution Bin x Full Remove the stack of paper from the bin to clear the message If you assigned the bin a name the bin name is displ...

Page 85: ...move the staple jam Go to 210 Staple jam service check on page 2 62 Step Questions actions Yes No 1 Close the side turn guide door Does the message reset Problem solved Go to step 2 2 Disconnect CN10...

Page 86: ...level sensor Replace the printer control board 4 Is the Tray x Empty Message present Go to step 5 Problem solved 5 Is the paper out sensor attached to its connector but not properly attached to the pa...

Page 87: ...Are they properly connected Replace the printer controller board Properly connect the cables Step Questions actions Yes No 1 Ensure the RIP board and the printer controller board are updated to the l...

Page 88: ...LEDs 1 and 2 on the HCF control board while unscrewing the paper size adjusting thumbscrews Do the LEDs light when the screws are loosened all the way Replace the HCF control board Replace the affecte...

Page 89: ...rays above and below properly connected Go to step 7 Properly connect the connectors 7 Exchange the expansion feeder control board for the problem tray with one above or below Does the symptom follow...

Page 90: ...o to step 3 Replace the size sensor levers 3 Are the following connectors properly connected CN4 on the expansion feeder control card trays 2 5 Go to step 4 Properly connect the connectors 4 If the pr...

Page 91: ...Go to step 7 7 Using a voltmeter check pin 6 for 3 3V and pin 2 for 5V on J26 on the RIP board Are the voltages correct Replace the USB cable Replace the RIP board Step Questions actions Yes No 1 Is t...

Page 92: ...FRU Action 1 Paper exit motor Check for frayed insulation on wires connecting the paper exit motor to the printhead controller board Check for severed wires connecting the paper exit motor to the prin...

Page 93: ...it Paper level sensor Turn the printer on and open the turn guide door Bypass the turn guide door open sensor With the paper tray empty and the paper out sensor blocked pull out and replace the casset...

Page 94: ...nificantly higher reading replace the clutch If you replace the clutch and the problem remains replace the printer controller board FRU Action 1 Feeder drive motor If the feeder drive motor works go t...

Page 95: ...perform the LED sensor test You can block each sensor to verify if it is working properly Replace the failing sensor 2 Tray motor Paper feed motor HCPF power supply Pickup solenoid Paper feed roller...

Page 96: ...or stapling problems first check the finisher to printer alignment Go to Aligning the finisher and printer on page 3 59 Run the finisher sensor test in diagnostic mode to test the sensors and switches...

Page 97: ...ion charge roller transfer roller 31 5 mm Photodeveloper charge roller 45 1 mm Supply roller toner cartridge 46 9 mm Upper registration roller 46 9 mm Lower registration roller 47 5 mm Developer rolle...

Page 98: ...to humidity conditions 2 Paper feed unit rollers Roller clutch Are the rollers dirty or worn Replace as needed If there is a failure to pick and the feed rollers are clean check the roller clutch on...

Page 99: ...ce the printer controller board If the voltage does not fluctuate replace the sensor FRU Action 1 Transfer belt unit Rear paper guide Discharge brush Fuser Remove any buildup of toner Replace any dama...

Page 100: ...oving the screw and gear from the bottom of the tray and pushing the paper edge guides up against the paper lift plate Reinstall the screw and gear FRU Action 1 Registration roller Paper exit rollers...

Page 101: ...at all sensors are operating properly by running the sensor test in diagnostic mode Replace sensors as necessary FRU Action 1 Timing belts Check finisher to printer alignment Go to Aligning the finish...

Page 102: ...down The tray guides are connected at the center of the tray by a toothed gear that ensures they move in unison If not remove the screw at the center of the gear and using a sheet of paper in the tray...

Page 103: ...ntroller board 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 cor...

Page 104: ...connector CN5 If 5 V dc is not present check for continuity on the stapler to finisher control board cable If there is no continuity on any pin position replace the cable If there is continuity replac...

Page 105: ...the job again Replace the affected toner cartridge Replace the photodevelopers If only black print appears light replace just the black photodeveloper If one of the colors prints too light replace all...

Page 106: ...tridge and try printing the job again Replace the affected toner cartridge Replace the photodevelopers If the problem only occurs when printing black replace just the black photodeveloper If the probl...

Page 107: ...when the top cover is closed Ensure the absorption roll charge roll on the belt is securely seated The black plastic T shaped bushings should both be below the flap on the right side of the belt A po...

Page 108: ...orage 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 High voltage uni...

Page 109: ...he toner cartridge with another color and run a test print If the new color prints replace the failing toner cartridge High voltage unit If the problem remains check the connector on the high voltage...

Page 110: ...tion is not listed Be sure the memory card assembly is installed correctly and is not broken or damaged If the Memory card assembly is correctly installed not broken or damaged then run the Flash Test...

Page 111: ...isk board Use the Disk Test Clean on page 3 16 to help restore the disk if it contains bad data and is unusable This test is divided into a cleaning and a verifying or testing section Warning This can...

Page 112: ...2 70 Service Manual 5056 XXX...

Page 113: ...ve different surface phase counts Radar Page is always used when adjusting print registration Power On Self Test sequence 1 Power on 2 Printer and RIP controller check ROM and RAM Fuser thermistor 3 P...

Page 114: ...opped the status line in the operator panel will show Stopped and a list of options will appear Navigation buttons The Up or Down buttons are used to move up and down lists When navigating through a l...

Page 115: ...rator print tests turn the machine off and then press Go and Stop as you turn the machine on Display panel The display panel shows messages and graphics describing the current state of the printer and...

Page 116: ...p Bin Setup REPORTS Menu Settings Printer Statistics Network Setup Page Profiles List Network Setup Page Print Fonts Print Directory SETTNGS Setup Menu Finishing Menu Quality Menu Utilities Menu PDF M...

Page 117: ...s Menu The diagnostics menu is navigated by using the and keys to scroll through the menus and the key to select the items in the menu Diagnostics Menu Overview Top Level Menus Intermediate Menu Items...

Page 118: ...Tests Quick Disk Test Disk Test Clean Flash Test Printer Setup Defaults Light Quantity Color Page Count Mono Page Count Perm Page Count Serial Number Model Name Configuration ID Reset Calibration Par...

Page 119: ...causes the entire image to compress or expand Theta Offset Cyan Yellow Magenta Modification of this setting allows users to shift right or left the position of the right margin on a per plane basis T...

Page 120: ...lected symbol set Note During a Continuous test involving an input source containing envelopes the device will generate the Envelope Print Test pattern on the first envelope and then leave each subseq...

Page 121: ...then posts Resetting the Printer and automatically performs a POR After the POR the panel displays the following P represents the number of times the Cache has passed the test and F represents the num...

Page 122: ...all of the printer s standard and optional DRAM has been tested Parallel Wrap Test This test verifies the proper functioning of the parallel port hardware using a wrap plug Each parallel signal is te...

Page 123: ...Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Ini...

Page 124: ...999 Initially only 4 digits appear for F a fifth and sixth digit will appear if required Each time the printer finishes a test it increments P or F by one according to the success or failure of the se...

Page 125: ...during this test After this test is selected the printer feeds media from the default source to each installed bin in the following order Standard Bin Bin 1 Bin 2 Bin 3 Bin 4 Bin 5 Bin 6 Bin 7 Bin 8 B...

Page 126: ...pages since the laser isn t engaged during this test Eight sheets of paper are fed and then the pages are hole punched with a 3 hole or a 4 hole pattern depending on the selected punch test Note The p...

Page 127: ...or to select the appropriate item then manually actuate the selected item When the item is closed the panel displays Closed When the sensor is open the panel displays Open To exit the sensor test pres...

Page 128: ...To exit this test and return to the DEVICE TESTS menu the user selects No This is the user s only chance to exit this test once the test has begun it cannot be stopped While this test runs the power i...

Page 129: ...total number of mono including blank and color pages generated by the printer The permanent page count can also be viewed in this sub menu After all manufacturing printing tests have been completed th...

Page 130: ...this will result in the new setting not being saved Model Name Selecting this menu item displays the printer s model name Configuration ID Use the configuration ID to communicate characteristics of th...

Page 131: ...ime this value is incremented by 1 the strobe is sampled 50 ns longer Each time this value is decreased by 1 the strobe is sampled 50 ns less When the value of this setting is 0 the factory default va...

Page 132: ...up and down using the and keys If there is more information than what can be displayed on a line you can access that information by using the and keys to scroll left and right Print Selecting this ite...

Page 133: ...er leaves the color around the edge of the text or line In this way the hole in the colored region is reduced in size which prevents the characteristic white gap that is caused by mis registration The...

Page 134: ...ting determines whether the printer performs an auto align adjust calibration after a certain initiating event such as a POR close door or new toner cartridge detection The settings are on and off Use...

Page 135: ...ged all information on the disk is destroyed A prompt is displayed asking for confirmation of the change before executing Font sharpening Font sharpening allows a user to set a text point size value b...

Page 136: ...e is recorded by irradiating light from the LED printhead This forms an electrostatic or latent image an invisible image on the surface of the light sensitive photodeveloper The area on the photodevel...

Page 137: ...elt by an electrostatic charge from a charge roller located inside the belt As the paper reaches each color position a transfer sheet located inside the belt underneath the paper will apply a charge t...

Page 138: ...A heater is positioned in the roller tube and a thermistor and thermostat remain in contact with the outside of the tube Fuser separation fingers are attached near the upper roller to separate the pa...

Page 139: ...or detects the paper and the FU FD deflector switches between the face up and face down paper delivery As the paper passes through the fuser it pulls down the sensing lever and turns on the delivery s...

Page 140: ...oner 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...

Page 141: ...actuator This will close the sensor and the paper tray lift motor will stop In this raised position the paper will be ready to feed to the engine Note To prevent a jam due to paper depletion there is...

Page 142: ...s at the registration rollers so the paper s leading edge can be adjusted so it will be parallel with the image to be printed The lower registration roll interfaces with the registration clutch and is...

Page 143: ...To keep this sensor clean a mechanism cleans the sensor surface when the front door is open and closed Note Adjust the printer alignment whenever the belt unit is replaced or removed Furthermore if th...

Page 144: ...down or face up Expansion paper feeder The optional expansion paper feeder can be installed at the lower part of the main unit Including the main unit up to five layers of cassettes can be used for c...

Page 145: ...s supported in a specific source Default value Menu Selection Purpose Values Plain Weight Transparency Weight Glossy Weight Labels Weight Vinyl Labels Bond Weight Envelope Weight Letterhead Weight Pre...

Page 146: ...points and squeeze the right top cover latch 4 Lift the cover Warning Do not use pointed objects to remove the paper They may damage the transfer belt Note The paper may be covered with unfused toner...

Page 147: ...event additional paper jams make sure both sides of the door are closed 18 Close the front door 19 Press Go If the paper jam message continues check and clear all paper from the paper path Check Area...

Page 148: ...feeder until it locks to the docking frame When the feeder is in the correct position you hear a click 6 Press Go If the paper jam message continues check and clear all paper from the paper path 250 P...

Page 149: ...3 Remove the jam 4 Close the jam access door 5 Pull out the paper tray indicated on the display 6 Remove any damaged paper 7 Push down on the remaining paper in the tray until the bottom plate clicks...

Page 150: ...roller rotates with the relay gears to feed the top paper The reverse roller rotates along with the paper feed roller During paper feed if two sheets feed the reverse roller rotates by the torque lim...

Page 151: ...aper loads and the top cover is set the pickup solenoid turns on to lower the call roller When the tray moves up the call roller is raised by the top surface of the paper and the shield plate on the u...

Page 152: ...ray moves down by about 500 sheets The down sensor detects the tray lower limit position Tray up condition Tray up motion stops when the Up sensor is OFF not shielded Power cord is connected and the j...

Page 153: ...itched 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 t...

Page 154: ...th four photo interrupters The quantity of pages remaining in the sheet feeder displays in the following increments Near end about 80 sheets About 300 sheets About 1 000 sheets About 2 000 sheets Pape...

Page 155: ...ion is valid without connecting to the printer controller board DIP switch Function switch Maintenance switch Description 4 3 2 1 OFF 1 Standard machine initial setting ON X X OFF X 2 Optional machine...

Page 156: ...accumulated number of sheets reaches a designated number it staples a batch of sheets and then exits the stapled set to the lower tray Punch invert and staple stops paper at the leading edge punches i...

Page 157: ...e Position Sensor locates home position for the drive belt Elevator Upper Limit Sensor detects when the lower tray is at the highest position Jogging Home Position Sensor locates home position for the...

Page 158: ...ute differs subject to the selected mode Straight paper path exit paper to upper tray The paper feed motor drives and rotates rollers The path select gate is changed by the path select solenoid and pa...

Page 159: ...path select gate and patting rollers Paper is detected by the invert path sensor Paper is then jogged by the jogging bar and driven by the belt drive motor before exiting to the lower tray accumulator...

Page 160: ...nges to close as the driving force transmits to register rollers and the paper transportation restarts Punch unit driving sequence When the paper feed motor drives the driving force is transmitted thr...

Page 161: ...the rack and pinion mechanism while the jogging motor rotates Each plate spring on the jogging bar pushes the rack in the direction of the pinion gear so that the rack and pinion gears meet securely...

Page 162: ...3 50 Service Manual 5056 XXX Stapling mechanism The stapler motor rotation drives a gear link and cam mechanism The cam movement allows the stapler mechanism to operate...

Page 163: ...aper feeds out to the lower tray and the paper full sensor A turns ON the lower tray moves down until the paper full sensor A turns OFF If paper feeds onto the lower tray when the elevator lower limit...

Page 164: ...ve You will need the tray when the finisher is attached 2 Insert the docking plate tabs into the printer 3 Align the thumbscrews on the docking plate with the holes in the side of the printer 4 Tighte...

Page 165: ...Diagnostic aids 3 53 5056 XXX 6 Tighten the guide rail plate thumbscrews 7 Align the thumbscrews on the guide rail with the holes in the guide rail plate 8 Tighten the guide rail thumbscrews...

Page 166: ...not push the stand all the way up against the printer 2 Remove and discard all shipping tape packing material and the metal shipping bracket CAUTION When assembled the finisher weighs 26 3 kg 56 9lb...

Page 167: ...iagnostic aids 3 55 5056 XXX 3 Open the stapler door 4 Remove all shipping tape and packing material 5 Lift the stapler locking lever 6 Raise the stapler 7 Remove all shipping tape and packing materia...

Page 168: ...3 56 Service Manual 5056 XXX 8 Close the stapler 9 Close the stapler door...

Page 169: ...the legs of the finisher stand 11 Lower the finisher onto the finisher stand CAUTION When assembled the finisher weighs 26 3 kg 56 9lb and requires at least two people to lift it safely 12 Remove both...

Page 170: ...ets on the rear of the finisher 2 Slide the bin down onto the metal brackets until it is fully seated Note When assembled the finisher and finisher stand are referred to as the finisher 3 Align the ta...

Page 171: ...ignment marks on top of the finisher must align with the edges of the cover on the side of the printer 4 Roll the finisher toward the printer until the finisher locks to the docking plate pins You hea...

Page 172: ...ins are above or below the holes in the finisher 2 Loosen the guide rail thumbscrews 3 Rotate the adjustment knobs as needed to align the holes in the finisher with the pins To raise the finisher rota...

Page 173: ...nisher locks to the docking plate pins You hear a click when the finisher locks into position If the pins go into the holes but the finisher did not lock to the pins go to Aligning the sides of the fi...

Page 174: ...he finisher Follow these instructions if the distance between the finisher and printer is not the same at the top and bottom 1 Loosen the guide rail thumbscrews If you previously lowered or raised the...

Page 175: ...isher locks into position Aligning the top of the finisher Note Anytime you move the printer or finisher recheck the printer and finisher top alignment Follow these instructions if the alignment marks...

Page 176: ...usting the wheels Adjust the wheels on the end of the finisher so the stand remains aligned when moved To adjust and lock the wheels 1 Rotate the left and right upper adjustment knobs on the rear whee...

Page 177: ...comes with an interface cable and Y power cord The interface cable connects the finisher to the printer and the Y power cord provides electrical power to the finisher and printer 1 Turn the printer o...

Page 178: ...ned off before continuing 1 Plug the interface cable into the bottom connector on the back of the printer 2 Tighten the thumbscrews 3 Plug the interface cable into the connector on the side of the fin...

Page 179: ...2 Plug the straight Y power cord connector into the socket on the side of the finisher 3 Plug the angled connector of the Y power cord into the socket on the side of the printer 4 Connect the previous...

Page 180: ...to the back of the top optional drawer 7 Place the finisher interface cable and power cord into the cable holder 8 Close the cable holder 9 Replug the power cord into the outlet and turn the printer o...

Page 181: ...fold the paper so the bottom punched hole is aligned with the top punched hole 3 Determine if the edge of the bottom of the page is below or above the top edge of the page 4 Loosen the guide rail thum...

Page 182: ...3 70 Service Manual 5056 XXX...

Page 183: ...part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on...

Page 184: ...ng printed circuit boards The following precautions must be observed when handling circuit boards with metal oxide semiconductor integrated circuits CAUTION If you are removing the motor driver board...

Page 185: ...cing the finisher After moving or servicing the finisher print some test pages to the finisher to ensure the vertical and horizontal alignment is correct If the finisher is not properly aligned refer...

Page 186: ...k photodeveloper for a color photodeveloper as they have different surface phase counts The Alignment Page is used when adjusting print registration Whenever you replace any of the following parts be...

Page 187: ...tic mode LED printhead controller board or LED printhead If you replace the LED printhead controller board or LED printhead check and adjust the following items in diagnostic mode Printer Alignment X...

Page 188: ...lopers to avoid damage from exposure to the light 2 Remove the two silver screws and remove the spacer 3 Remove five black screws from the bottom and the four silver screws from the back side 4 Remove...

Page 189: ...start the printer and let the startup cycle complete If the above procedure fails contact the technical support center for further instructions 1 Open the front door of the printer 2 Remove the screws...

Page 190: ...emove the operator panel from the door Note If the USB cable or the operator panel cable is being replaced use the toroids from the old cables with the new cables Cover front left removal 1 Open the f...

Page 191: ...rom the rear cover and then remove the cover 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 cov...

Page 192: ...cassette 2 Remove the operator panel cable and the USB cable from the operator panel See Front door operator panel removal 3 Remove the seven screws from the right side cover together with the turn g...

Page 193: ...4 Restart the printer and let the startup cycle complete If the above procedure fails you must contact the technical support center for further instructions 1 Loosen the eight screws and remove the RI...

Page 194: ...hinge on the front side 2 Remove the paper exit tray Belt up down clutch removal 1 Remove the RIP cover electronic box printer controller card and HVPS board 2 Unplug the belt up down clutch cable fro...

Page 195: ...board 4 While pinching the nylon standoffs that attach the card to the printer frame gently pull the CK1 daughter board away from the printer frame Note After replacing any board on the printer ensure...

Page 196: ...plex unit Remove the left side cover and power supply A 2 Disconnect the connector and remove the two screws from the mounting plate 3 Remove the two screws of the drawer connector from the mounting p...

Page 197: ...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 Drive gear unit sensor assembly removal...

Page 198: ...nic box removal 1 Open the top unit and remove the back cover 2 Remove the RIP board cover 3 Remove the RIP board 4 Remove the screws from the electronic box 5 Disconnect all cables from the rear of t...

Page 199: ...n 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 Front co...

Page 200: ...4 18 Service Manual 5056 XXX Fuser removal 1 Open the top unit 2 Pushing the front and back lock hold the handle and then raise and remove the fuser...

Page 201: ...gear cover and remove the cover 3 Remove the four screws from the multipurpose feeder frame and the ground screw 4 Disconnect the connector of the multipurpose feeder paper feed sensor 5 Pull out the...

Page 202: ...ny board on the printer ensure all the connections are properly connected before closing the covers See High voltage power supply board on page 5 14 LED printhead removal 1 Open the top unit remove th...

Page 203: ...d on the printhead controller board Note The LED printhead light intensity values do not have to be entered for the printer Eraser removal 1 Remove the appropriate printheads see LED printhead removal...

Page 204: ...4 22 Service Manual 5056 XXX Lock handle assembly removal 1 Open the top unit 2 Turn the plastic latch on the front and rear sides 90 3 Remove the spring 4 Remove the lock handle assembly...

Page 205: ...face up paper delivery unit belt up down clutch and DC drive motor 7 Remove the multipurpose feeder roll registration roll and paper carrying frame 8 Remove the eight screws from the power supply 2 b...

Page 206: ...six screws on the right side 16 Remove the two screws from the drive unit and remove the unit 17 Remove the E clip on the belt up down clutch and remove the changing shaft from the drive unit 18 Remov...

Page 207: ...the fan Motor drive board removal 1 Remove the upper cassette front cover B paper feed cover and the left side cover 2 Disconnect the five connectors remove five screws and remove two screws from the...

Page 208: ...ard the magnet in the direction of the arrow removing it from the printer Paper feed unit removal 1 Remove the front right left rear and rear covers 2 Remove the printer controller board and HVPS boar...

Page 209: ...ed clutch and two gears C not held in place with an E clip 7 Remove the 3 screws D and remove the cassette guide 8 Remove the brass screws E on the left side of the paper feed unit 9 Remove the paper...

Page 210: ...hite plastic retaining clips They will be needed to attach the new rollers 1 Turn off the printer and unplug the power source 2 Remove the paper cassette 3 Pull back on the tab and remove the pickup r...

Page 211: ...and electronic box 2 Remove the four screws from the paper carrying frame 3 Remove the paper carrying frame Note When installing the clip of the paper carrying clutch should be securely set to the sto...

Page 212: ...two screws from the registration frame 3 Remove the registration clutch Note When installing set the clip of the registration clutch to the stopper Registration sensor removal 1 Open the top unit and...

Page 213: ...the machine 2 Remove the e clips and bushings from each end of the relay roller shaft 3 Remove the five screws A that hold the top metal plate on the unit 4 Remove the top plate from the paper feed u...

Page 214: ...ck the wiring that connects the printer controller board to the face down unit Avoid pinching or cutting wiring that connects the face down unit to the printhead controller board Face down exit roll r...

Page 215: ...Repair information 4 33 5056 XXX 3 Remove the rear cover 4 Remove the motor and drive belt from the exit roller shaft 5 Remove the grounding strip A...

Page 216: ...4 34 Service Manual 5056 XXX 6 Remove the e clips and bushings A from both ends of the exit roller shaft 7 Pull the guide rib A to the left...

Page 217: ...front cover and back cover Remove the left side cover 3 Remove the insulation sheet connector yellow ground wire five screws two screws with washers and two screws with spring washers 4 Disconnect CN1...

Page 218: ...box 3 Disconnect the connector and remove the seven screws from power supply 2 and remove the power supply Note After replacing any board on the printer ensure all the connections are properly connect...

Page 219: ...the top unit and remove the RIP cover RIP board RIP box and electronic box 2 Remove the connectors and the screws from the printer controller Pay attention to the location or label the two pin connect...

Page 220: ...top cover and then remove the 20 printhead controller board connectors 2 Remove the six screws from the printhead controller board and remove the board Note When replacing the board be sure to return...

Page 221: ...4 39 5056 XXX Left slide rail removal 1 Remove the upper cassette 2 Remove the screw from both left and right slide rails RIP box removal 1 Remove the six screws from the RIP box 2 Slightly lift and...

Page 222: ...sensor board 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 from the right stopper and remove the stopper...

Page 223: ...ad the entire procedure before removal 1 Open the top unit and remove the RIP cover RIP board RIP box electronic box printer controller printer controller bracket and HVPS board 2 Remove the cable tie...

Page 224: ...per detection buttons Temperature humidity sensor removal 1 Remove the rear cover printer controller board and HVU board 2 Disconnect the cable from connector on the temperature humidity sensor 3 Remo...

Page 225: ...belt up down clutch The supplies menu no longer needs to accessed to remove the transfer belt unit Note If the operator panel is inoperable or if you have an unrecoverable error code this procedure ca...

Page 226: ...4 44 Service Manual 5056 XXX 3 Loosen the thumbscrews as shown 4 Lift and remove the transfer belt cover...

Page 227: ...Repair information 4 45 5056 XXX 5 Loosen the thumbscrews as shown 6 Press down on the transfer belt release lever as shown...

Page 228: ...king lever to the right and close the front cover 10 Turn the printer on 11 Adjust the registration if needed by pressing the Menu key scrolling to Settings scrolling to Utilities and selecting Alignm...

Page 229: ...ct the sensor cable from CN10 on the CK1 daughter card board 4 Remove two screws from the turn guide sensor assembly and remove the sensor Upper fan removal 1 Open the top unit and remove the toner ca...

Page 230: ...4 48 Service Manual 5056 XXX 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...

Page 231: ...1 Remove six screws from the expansion feeder rear cover 2 Unplug all cables from the expansion feeder controller board 3 Remove six screws from the controller card 4 Remove the controller board Note...

Page 232: ...l 1 Remove the expansion feeder rear cover 2 Disconnect the stepper motor power cable from the expansion feeder controller board 3 Remove three screws from the stepper motor assembly A 4 Remove the st...

Page 233: ...move the screws A holding the paper feed gear assembly 6 Remove the gear assembly B and the paper feed clutch C 7 Remove three gears from the paper feed unit 8 Remove the three cassette guide screws D...

Page 234: ...lack screws from the paper tray lift motor A 5 Remove the paper tray lift motor Expansion feeder turn guide door sensor assembly removal 1 Remove the rear cover 2 Disconnect the cable from CN15 on the...

Page 235: ...mation 4 53 5056 XXX Duplex removals 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...

Page 236: ...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 a...

Page 237: ...noid removal Remove the two screws securing the pressure roller solenoid assembly Duplex feed roller and solenoid removal 1 Remove the two screws securing the feed roll solenoid assembly 2 Remove the...

Page 238: ...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 s...

Page 239: ...Repair information 4 57 5056 XXX Duplex paper carrying motor removal 1 Remove the gear cover 2 Remove the screws from the duplex paper carrying motor and remove the motor...

Page 240: ...val 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 rea...

Page 241: ...over 3 Remove the retaining rings on the rollers and remove the rollers HCF pickup solenoid removal 1 Remove the four screws from the transfer cover and remove the cover 2 Remove the two screws from t...

Page 242: ...Mark the locking position of the side fence locking stay 5 Remove the two screws on the side fence locking stay 6 Remove the screw and connector from paper end sensor and remove the sensor 7 Remove t...

Page 243: ...Remove the top cover switches HCF 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 Top Cover Switch 1 Blue White Green Yel...

Page 244: ...e the connector and screw from paper level sensor and remove the sensor HCF power supply removal 1 Move the paper tray upward 2 Disconnect the power cord 3 Remove the front cover 4 Remove the two scre...

Page 245: ...o the finisher to ensure the vertical and horizontal alignment is correct If the finisher is not properly aligned refer to Aligning the finisher and printer on page 3 59 for alignment instructions Ext...

Page 246: ...the two screws from the top cover and remove the cover Finisher control board removal 1 Remove the external covers 2 Disconnect all of the associated connectors 3 Remove the four finisher control boar...

Page 247: ...e bracket 3 Remove the elevator motor assembly Feed motor assembly removal 1 Remove the finisher control board mounting bracket 2 Loosen the tension bracket mounting screw 3 Disconnect the feed motor...

Page 248: ...ve the tension spring 4 Remove the screw and E ring from the tension bracket and remove the bracket Note When installing the tension bracket use the left side screw hole for the three hole punch unit...

Page 249: ...3 Remove the upper left panel 4 Remove the two discharge brush screws and remove the brush Inverter paper exit roller removal 1 Remove the front and rear external covers 2 Remove the four lower left...

Page 250: ...rter drive gear and bushing 7 Remove the inverter paper exit roller Jogging unit removal 1 Remove the dust box 2 Remove the two screws and remove the cover 3 Disconnect the jogging motor connector 4 D...

Page 251: ...Remove the gate solenoid with mounting bracket 4 Remove the straight paper exit sensor connector 5 Remove the upper guide plate for the straight paper exit 6 Remove the two screws and two springs for...

Page 252: ...racket 3 Remove the two screws from the upper left panel and remove the panel 4 Disconnect the sensor connector 5 Remove the sensor harness from the harness clamp 6 Remove the four upper guide plate s...

Page 253: ...Repair information 4 71 5056 XXX 8 Remove the tension springs Use the upper hole when installing the spring 9 Remove the gear and bushing 10 Remove the patting roller Patting Roller...

Page 254: ...ernal covers 3 Remove the lower left panel 4 Remove the cable connector for the left panel 5 Remove the four lower guide support plate screws and remove the plate 6 Remove the two power supply screws...

Page 255: ...stration roller bushing 4 Remove the registration roller Registration roller clutch removal 1 Remove the harness from the clamp 2 Remove the three control board mounting bracket screws and remove the...

Page 256: ...56 XXX Stack area discharge brush removal 1 Remove the dust box 2 Remove the stack area discharge brushes Staple unit removal 1 Remove the staple unit connector 2 Pull outward on the staple cover and...

Page 257: ...r and remove the cover 3 Remove the two lever screws and remove the lever 4 Remove the two discharge brush screws and remove the brush Straight paper exit roller removal 1 Remove the external covers 2...

Page 258: ...4 76 Service Manual 5056 XXX 6 Remove the rear straight paper exit roller E ring and bushing 7 Remove the straight paper exit roller...

Page 259: ...he finisher control board mounting bracket 2 Remove the feed motor mounting bracket 3 Remove the tension bracket mounting screw 4 Remove the tension spring 5 Remove the timing belt 1 6 Loosen the tens...

Page 260: ...overs 2 Remove the lower left panel 3 Remove the cable connector of the left panel 4 Remove the belt motor unit 5 Remove the four lower guide support plate screws for the invert paper exit 6 Remove th...

Page 261: ...t tooth just under the plastic hook aligns with the hook on the other belt Tractor drive motor assembly removal 1 Remove the outer covers 2 Remove the drive belt 3 Remove the three screws and disconne...

Page 262: ...4 80 Service Manual 5056 XXX...

Page 263: ...Locations 5 1 5056 XXX 5 Locations Covers diagram...

Page 264: ...rption roll 20 Belt drive roller 6 Registration roll upper 21 Paper delivery detection lever 7 Registration roll lower 22 Press roller 8 Registration sensor 23 Heater 9 Registration detector lever 24...

Page 265: ...Locations 5 3 5056 XXX Sensor and switch locations...

Page 266: ...size detector board expansion paper feed option 6 MPF clutch 20 Power supply 1 7 Registration clutch 21 Drive motor extended paper feeder option 8 CK1 daughter board 22 Paper lift motor expansion pape...

Page 267: ...Locations 5 5 5056 XXX Printer controller board...

Page 268: ...ner sensor assembly CN2 Vertical Tan White 8 4 black 4 yellow Toner drum sensor assembly CN3 Vertical Tan Tan 15 15 green CK1 connector 1 CN4 Vertical Tan Tan 14 14 green CK1 connector 2 CN5 Vertical...

Page 269: ...White 15 4 gray 1 black 1 white 1 red 2 gray 6 white Fuser CN20 Vertical White White 6 6 black Gear phase sensor CN21 Horizontal White White 2 White Black RFID antenna CN22 Vertical White White 12 1 y...

Page 270: ...n 2 2 blue C LED eraser CN07 Yellow Green 2 2 black Y LED eraser CN08 Black Green 2 2 black K LED eraser CN09 White White 4 Yellow Orange Brown Black PEX motor CN10 White White 3 3 brown Face down CN1...

Page 271: ...ical Blue Blue 2 2 blue Relay clutch CN10 Vertical Brown Brown 2 2 brown Turn guide door closed sensor CN11 Vertical Orange Orange 2 2 white Belt up down clutch CN12 Vertical White 2 2 black Carrying...

Page 272: ...Tan Tan 12 12 green Controller board CN3 Horizontal Magenta Red 2 2 red Duplex CN4 Horizontal Green Green 2 2 green Face up CN5 Horizontal White White 3 3 gray Paper exit CN6 Horizontal White White 3...

Page 273: ...y J7 Memory J9 7 USB port J14 14 3 yellow 1 brown 3 purple 7 black LVPS 2 J15 8 Green 2 blue 2 red 2 yellow Printhead controller J16 36 35 blue 1 white Printhead controller J17 26 25 green 1 white Pri...

Page 274: ...d connectors Conn Orientation Board connector color Cable connector color Wires Wire color Connector CN01 White White 4 Red White Blue Black Main switch CN04A White White 2 Black White LVPS 2 CN106 A...

Page 275: ...e Motor drive board CN104 Horizontal White White 8 2 yellow 4 black 2 red Printer controller CN105 Horizontal White White 6 Gray White Red Purple Orange Black Printer controller CN102 Horizontal White...

Page 276: ...on Board connector color Cable connector color Wires Wire color Connector CN406 White White 5 Brown Blue Black Density sensor CN407 White White 14 1 white 13 blue Printer controller CN409 White White...

Page 277: ...Locations 5 15 5056 XXX Expansion paper feeder controller board...

Page 278: ...nnector color Wires Wire color Connector CN2 Horizontal White White 3 White Black Red Motor CN4 Horizontal White White 5 White Yellow Blue Black Red Motor CN5 Horizontal White White 3 White Black Red...

Page 279: ...Locations 5 17 5056 XXX Size sensor board...

Page 280: ...5 18 Service Manual 5056 XXX Paper feed actuators Paper feed roller clutch A Paper tray present actuator B Paper out actuator...

Page 281: ...End Sensor Paper Size Sensor 1 2 Paper Feed Motor H C F Paper feed and separation mechanism Tray up down mechanism Size detection mechanism Residual paper detection mechanism Paper end detection mech...

Page 282: ...5 20 Service Manual 5056 XXX Electrical parts layout Driving parts layout...

Page 283: ...Locations 5 21 5056 XXX Finisher locations...

Page 284: ...switch Detects connection with printer Staple cartridge set switch Detects staple cartridge open Punch box detect sensor Detects punch box Invert path sensor Detects invert paper jam Paper exit sensor...

Page 285: ...for paper feeding Staple motor Stapling Path select solenoid Path changing Paper jogging motor Jogging of paper Punch clutch Punching Registration clutch Paper registration feeding Elevator motor Fac...

Page 286: ...home position sensor 5 Tractor drive motor 18 Staple cartridge set switch 6 Elevator motor 19 Paper upper level sensor B 7 Elevator lower limit sensor 20 Paper exit sensor lower tray 8 Invert path sen...

Page 287: ...t s is replaced Paper path maintenance A paper path maintenance kit can be used when a machine is experiencing misfeeds and jams after 200 000 pages The order number for this kit is 40X1109 The kit is...

Page 288: ...ghtly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Charge exposure unit LED head Remove any dust or dirt and wipe the surface lightly with a dry cloth If it is still dirty...

Page 289: ...he item number 1 Part number identifies the unique number that identifies this FRU Units mach refers to the number of units actually used in the machine or product NS Not shown in the Asm Index column...

Page 290: ...7 2 Service Manual 5056 XXX Assembly 1 Covers 1 3 11 7 13 5 9 15 2 10 6 4 12 8 14 1...

Page 291: ...5 40X1123 1 Cover assembly front 1 6 56P9545 1 Label operator panel 1 7 40X1132 1 Cover waste toner bottle 1 8 40X1140 1 Magnet front cover latch 1 9 40X1129 1 Cover left front 1 10 40X1126 1 Cover l...

Page 292: ...7 4 Service Manual 5056 XXX Assembly 2 Covers 2 Index P N Units Description 2 1 40X1026 1 Exit assembly face up 1...

Page 293: ...Parts catalog 7 5 5056 XXX Assembly 3 Covers 3 Index P N Units Description 3 1 40X1027 1 Guide assembly face down 3 2 40X1064 1 Exit roller face down 2 1...

Page 294: ...7 6 Service Manual 5056 XXX Assembly 4 Covers 4 Index P N Units Description 4 1 40X1242 1 Guide assembly turn...

Page 295: ...Parts catalog 7 7 5056 XXX Assembly 5 Covers 5 Index P N Units Description 5 1 40X1135 1 Feeder assembly multipurpose...

Page 296: ...7 8 Service Manual 5056 XXX Assembly 6 Upper unit 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 33 28 21 31 26 24 29 22 32 27 25 30 3 3 10 5 6 5...

Page 297: ...nt upper 6 17 40X1146 1 Hook left 6 18 40X1144 1 Rod interlocking 6 19 56P9630 1 Hook left link 6 20 40X1142 4 Holder front hsp 6 21A 40X1133 1 Assembly LED printhead K 6 21B 40X1134 3 Assembly LED pr...

Page 298: ...7 10 Service Manual 5056 XXX Assembly 7 Paper feed 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 28 21 26 24 29 22 27 25 11 18...

Page 299: ...imiter 7 13 40X1078 1 Roller paper feed 7 14 40X1077 1 Roller pickup 7 15 40X1173 2 Interrupt photo 7 16 40X1098 1 Cable asm paper feed type 1 7 17 40X1076 1 Plate guide rocking 7 18 56P9503 4 Foot ru...

Page 300: ...7 12 Service Manual 5056 XXX Assembly 8 Base 2...

Page 301: ...67 4 Pin upper unit support 3 40X2776 1 Stop right 4 40X2779 1 Cover black photodeveloper 5 40X1208 1 Handle assembly lock 6 56P9669 1 Handle lock 7 40X2778 1 Stop left 8 40X1151 1 Cover electronic 9...

Page 302: ...7 14 Service Manual 5056 XXX Assembly 9 Base 3 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 21 24 22...

Page 303: ...40X1211 1 Sensor upper OHP 9 11 40X1039 1 Frame assembly MPF 9 12 40X1154 1 Frame assembly registration 9 13 40X1114 1 Cable carrying clutch 9 14 40X1040 1 Clutch registration used on carrying frame...

Page 304: ...7 16 Service Manual 5056 XXX Assembly 10 Electrical A 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 28 21 31 26 24 29 22 32 27 25 30 33...

Page 305: ...ble asm conditioning printer controller 10 20 40X1164 1 Card conditioning 230V only 10 21 56P9747 1 Cable motor driver power 10 22 40X1048 1 Cable asm duplex connector 10 23 40X1160 1 Supply 120V powe...

Page 306: ...7 18 Service Manual 5056 XXX Assembly 10 continued Electrical A 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 28 21 31 26 24 29 22 32 27 25 30 33...

Page 307: ...azil HV LV NS 40X0278 Cord HV 6ft straight Austria Russia NS 40X0279 Cord 6ft straight Denmark Finland Norway Sweden NS 40X0280 Cord 10A 3 cond 6ft straight Korea NS 40X0281 Cord 13A 3 cond 6ft straig...

Page 308: ...7 20 Service Manual 5056 XXX Assembly 11 Electrical B...

Page 309: ...IP harness 4 56P9720 1 Cable assembly printhead controller power 5 40X1099 1 Cable assembly paper tray lift motor 6 40X1100 1 Cable assembly cassette bottom sensor 7 40X1098 1 Cable assembly paper fee...

Page 310: ...P9749 1 Cable assembly power RIP 2 40X2644 1 Card assembly RIP 3 40X1520 1 Fan RIP box 4 40X1165 1 Box RIP 5 40X1054 1 Cable assembly 26 pin RIP printer controller 6 40X1255 1 Cable USB 7 40X1256 1 Ca...

Page 311: ...Parts catalog 7 23 5056 XXX Assembly 13 Fuser unit Index P N Units Description 13 1 40X1056 1 Fuser 120V 1 40X1057 1 Fuser 230V 1...

Page 312: ...7 24 Service Manual 5056 XXX Assembly 14 Cassette 3 2 1...

Page 313: ...Parts catalog 7 25 5056 XXX Assembly 14 Cassette Index P N Units Description 14 1 40X1058 1 Cassette paper feed 2 40X1501 1 Kit rack guard holder 3 40X1105 1 Flag bottom sense...

Page 314: ...7 26 Service Manual 5056 XXX Assembly 15 Expansion feeder 1 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 23 21 24 22 25 9...

Page 315: ...to 9 56P9503 4 Foot rubber 10 40X1200 1 Cover front feed 11 56P9524 1 Screw slide rail 12 40X1034 1 Rail base left side 13 40X1201 1 Cover left side 14 11G0199 2 Guide wire 15 56P9521 1 Lever size sen...

Page 316: ...7 28 Service Manual 5056 XXX Assembly 16 Expansion feeder 2 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 21 1 2 3...

Page 317: ...X1076 1 Plate guide rocking 8 40X1111 1 Roller relay expansion feed 9 40X3484 1 Guide HCPF 10 40X1103 1 Bushing turn guide 11 40X1106 2 Clip paper feed shaft 12 40X1079 2 Roller separator 13 40X1080 1...

Page 318: ...7 30 Service Manual 5056 XXX Assembly 17 Duplex unit 1 3 7 5 9 2 6 4 8 1 5...

Page 319: ...d duplex interface 3 40X1168 1 Frame duplex 4 40X1172 1 Cable assembly duplex connection 5 40X1169 2 Screw duplex mounting 6 40X1170 1 Motor duplex stepping 7 40X1171 1 Interrupter photo 8 56P9806 1 C...

Page 320: ...7 32 Service Manual 5056 XXX Assembly 18 Duplex unit 2...

Page 321: ...ter photo 11 56P9526 2 Spring feed roller 12 56P9815 6 Spring reed roller 13 40X1178 3 Solenoid assembly feed roller 14 40X1180 1 Cable assembly duplex drawer 15 40X1175 1 Roller follow up feed 16 56P...

Page 322: ...7 34 Service Manual 5056 XXX Assembly 19 High capacity feeder 1 3 11 7 5 9 2 10 6 4 12 8 1...

Page 323: ...X1181 1 Magnet latch 3 40X1215 1 Cover upper 4 40X1214 1 Cover upper rear 5 40X1218 1 Cover lower rear 6 40X1245 1 Cover right 7 40X1213 1 Cover front 8 56P9836 1 Fence end 9 56P9940 1 Ring snap 10 40...

Page 324: ...7 36 Service Manual 5056 XXX Assembly 20 High capacity feeder 2 11 3 11 7 5 9 2 10 6 4 12 8 1...

Page 325: ...r feed 3 40X1183 1 Motor assembly transport 4 56P9941 1 Arm pick up 5 56P9501 1 Spring pressure 6 40X1184 1 Interrupter photo 7 56P9849 1 Roller manual feed pickup 8 56P9850 1 Roller manual feed 9 56P...

Page 326: ...7 38 Service Manual 5056 XXX Assembly 21 High capacity feeder 3 3 7 5 9 2 6 4 8 1 3...

Page 327: ...cription 21 1 40X1244 1 Sensor assembly photo 2 40X1186 1 Interrupter photo 3 56P9529 4 Caster HCF 4 56P9856 1 Spring tension 5 40X1188 1 Switch micro 6 40X1187 1 Switch push 7 40X1190 1 Connector inl...

Page 328: ...7 40 Service Manual 5056 XXX Assembly 22 High capacity feeder 4 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 19 1 20 21 22 12 18 10 10 10 6...

Page 329: ...93 1 Cable assembly sensor 9 40X3492 1 Cable assembly paper size sensor 10 40X3491 1 Cable assembly lift motor 11 40X1219 1 Board high capacity feed 12 40X1061 1 Cable assembly power supply out 13 40X...

Page 330: ...7 42 Service Manual 5056 XXX Assembly 23 High capacity feeder 5 3 7 5 2 6 4 8 1 2 2 2 1 4 6...

Page 331: ...P N Units Description 23 1 56P9883 2 Spring pressure 2 40X1184 4 Interrupter photo 3 40X1198 1 Bracket rear idler 4 56P9884 2 Belt timing 5 56P9886 1 Gear drive 6 56P9885 2 Pulley timing 7 40X1196 1 M...

Page 332: ...7 44 Service Manual 5056 XXX Assembly 24 High capacity feeder 6 3 7 5 2 6 4 8 1 7 3 2...

Page 333: ...cription 24 1 40X1199 1 Plate upper side fence 2 56P9893 2 Knob stopper 3 56P9891 2 Knob tray 4 56P9890 2 Plate paper adhesion 5 56P9915 1 Fence assembly front side 6 56P9894 1 Fence assembly rear sid...

Page 334: ...7 46 Service Manual 5056 XXX Assembly 25 Finisher covers...

Page 335: ...top 2 56P4065 1 Cover front 3 56P4067 1 Tray upper 4 56P4068 1 Tray lower 5 56P4062 1 Panel left upper 6 40X1227 1 Assembly lower left panel 7 56P4066 1 Cover rear 8 56P4063 1 Assembly staple cover 9...

Page 336: ...7 48 Service Manual 5056 XXX Assembly 26 Finisher frame 3 7 2 4 1 4 6 8 3 5 2...

Page 337: ...69 1 Handle 2 40X2628 2 Sensor photo 3 56P9386 2 Spring 4 40X2626 2 Screw M4 5 40X2607 1 Assembly exit guide inverter 6 56P9399 2 Sensor photo 7 40X1223 1 Assembly exit guide straight 8 40X2608 1 Unit...

Page 338: ...7 50 Service Manual 5056 XXX Assembly 27 Finisher feed 1...

Page 339: ...1 Gear Z19 5 56P9310 1 Gate 6 56P9400 1 Roller 7 56P9361 1 Roller patting 8 56P9401 2 Roller I 9 56P9312 1 Roller F 10 56P9405 1 Roller G 11 40X2616 1 Clutch registration 12 56P9407 1 Belt timing 60S...

Page 340: ...e Manual 5056 XXX Assembly 28 Finisher feed 2 Index P N Units Description 28 1 40X2600 1 Assembly jogging unit 2 56P9333 1 Belt timing 60S3M408 3 40X2612 1 Assembly tractor motor 4 40X2601 1 Assembly...

Page 341: ...Index P N Units Description 29 1 40X2606 1 Assembly elevator motor 2 56P9451 1 Shutter 3 56P9332 2 Spring C 4 40X2614 2 Wire 5 56P9459 2 Drum wire 6 56P9460 1 Gear Z30 7 56P4073 1 Panel lower left 8...

Page 342: ...Units Description 30 1 40X2604 1 Assembly upper limit sensor 2 40X2603 1 Supply power 3 56P9358 1 Cord Y power 3 56P9368 1 Cord Y power 230 V only 4 40X1225 1 Board finisher control 5 56P9410 1 Cable...

Page 343: ...Parts catalog 7 55 5056 XXX Assembly 31 Finisher docking 1 Index P N Units Description 31 1 56P9467 2 Screw thumb...

Page 344: ...docking 2 Index P N Units Description 32 1 40X1237 1 Bracket rail 2 56P9472 2 Screw lock 3 40X1238 1 Screw rail 4 40X1239 1 Chassis rail 5 56P9474 4 Roller 6 40X1241 1 Stud lock f 7 56P9473 1 Stud loc...

Page 345: ...C920 dtn printer relocation NS 40X1511 1 Kit C920 net printer relocation NS 40X1502 1 Card IPDS NS 40X1504 1 Card Prescribe NS 40X1505 1 Card PrintCryptionTM NS 40X1507 1 Card forms Double byte NS 40X...

Page 346: ...Zn 3K 5 Bind P tight screws 3x10 Zn 3K 5 Bind screws M3x4 Zn 3K 5 Bind screws M3x8 Zn 3K 5 Bind screws M3x6 Ni 3 5 Screws with washers M3x30 Zn 3K 5 E rings ES 6 ACP NS 40X1264 1 Parts packet includi...

Page 347: ...3K 5 Pans with flange P tight screws 3x10 Zn 3K 5 Screws with washers M3x30 Zn 3K 5 Screws with washers M4x8 Zn 3K 5 Screws with washers M4x12 Zn 3K 5 Screws with washers M3x6 Ni 3 BS 5 Screws with wa...

Page 348: ...ings ES 6 ACP 5 R screws M3x6 5 R screws M3x8 5 R screws M4x6 5 Pans S tight screws M3x6 5 RP tight screws M3x8 NS 40X1272 1 Parts packet including 5 Bind S tight screws 3x6 Zn 3R 5 Bind P tight screw...

Page 349: ...5 E rings ES 4 ACP 5 RS tight screws M3x8 5 RS tight screws M3x14 5 RS tight screws M4x6 5 RS tight screws M4x8 NS 40X1521 1 Parts packet including 5 ZM 3R screws 4x30 5 E rings ES 5 ACP 5 ZN 3R wash...

Page 350: ...r parts packet P N 402623 Pin Retaining Ring E Type Screw Spring Pin Screw Screw Tapping Screw Spring Lock Washer Tapping Screw Toothed Lock Washer Tapping Screw Resin Ring Tapping Screw Nut Set Screw...

Page 351: ...2 41 80 Replace fuser 2 41 80 Scheduled maintenance 2 41 81 Engine code CRC failure 2 41 84 photo developer abnormal 2 41 84 Black photo developer life warning 2 41 84 Color photo developer life warn...

Page 352: ...pansion feeder parts catalog 7 26 7 28 theory of operation 3 32 F fans main unit fan removal 4 25 upper fan removal 4 47 finisher adjusting wheels 3 64 aligning finisher and printer 3 59 aligning side...

Page 353: ...Manual 2 33 Load Staples 2 33 Load with 2 33 locations 5 1 components 5 4 covers 5 1 high capacity feeder 5 19 major parts 5 2 sensor and switches 5 3 lubricants 6 2 M Magenta Low 2 30 Maintenance 2...

Page 354: ...ing from USB drive 2 34 printing menu settings 3 3 Programming Disk 2 34 Programming Flash 2 34 Programming System Code 2 34 R Reading USB drive 2 34 Ready 2 35 Remote Management Active 2 35 removals...

Page 355: ...eplace Photo Dev 2 35 Replace Transfer Belt 2 36 Replace Yellow 2 36 Resetting Active Bin 2 36 Resetting Fuser Count 2 36 Resetting the Printer 2 36 Restore Held Jobs 2 36 Restoring Factory Defaults 2...

Page 356: ...2 27 996 finisher jogging motor 2 27 997 finisher tractor motor 2 28 999 stapler motor 2 29 tray elevator motor 2 28 service errors 2 5 service precautions 4 1 size detection 3 41 Some held jobs were...

Page 357: ...40X1029 Lamp C erase 7 9 40X1030 Lamp Y erase 7 9 40X1031 Lamp K erase 7 9 40X1032 Fan upper right 7 9 40X1033 Fan upper left 7 9 40X1034 Rail base left side 7 11 7 27 40X1035 Unit drive 120V 7 11 40X...

Page 358: ...guide switch option 7 29 40X1089 Cable asm paper feed type 2 7 29 40X1090 Motor asm stepping 7 27 40X1091 Cable asm expansion paper level 7 27 40X1092 Cable asm exp lift motor 7 27 40X1093 Gear IDS 3...

Page 359: ...40X1145 Hook middle 7 9 40X1146 Hook left 7 9 40X1147 Hook right 7 9 40X1148 Bracket rear upper 7 9 40X1149 Frame printhead controller 7 9 40X1150 Clutch drive unit 7 11 40X1151 Cover electronic 7 13...

Page 360: ...A 7 27 40X1203 Cover right side B 7 27 40X1204 Cover right side C 7 27 40X1205 Cable asm conditioning printer controller 7 17 40X1207 Support assembly upper unit 7 13 40X1208 Handle assembly lock 7 13...

Page 361: ...RAM memory 7 57 40X1509 Card assembly 256MB SDRAM memory 7 57 40X1510 Card assembly 512MB SDRAM memory 7 57 40X1511 Kit C920 net printer relocation 7 57 40X1512 Kit Japanese font 7 57 40X1513 Kit Simp...

Page 362: ...ensor 7 41 40X3494 Cable paper volume 7 41 40X3495 Cable up down switch 7 41 40X9432 Cable assembly paper size sensor 7 41 56P4060 Assembly punch drive 7 51 56P4061 Belt 7 51 56P4062 Panel left upper...

Page 363: ...9 56P9626 Cover hook 7 9 56P9627 Bearing roller 7 9 56P9628 Pivot color link 7 9 56P9629 Link frame 7 9 56P9630 Hook left link 7 9 56P9632 Shroud cable 7 9 56P9638 Holder cable 7 9 56P9641 Actuator fr...

Page 364: ...e 7 33 56P9828 Motor assembly paper guide 7 33 56P9836 Fence end 7 35 56P9842 Spring tension 7 35 56P9845 Sensor assembly paper feed 7 37 56P9847 Spring compression 7 37 56P9849 Roller manual feed pic...

Page 365: ...16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 VDD1M VDD1M G...

Page 366: ...Staple Motor GR YL BL BL R DC5V GND NC Staple Home Position Sensor Low Staple Switch Staple Cartridge Switch Staple Motor Staple Motor Staple Motor NC NC Staple Motor Staple Home Position Sensor Stapl...

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