Lexmark C91 Series Service Manual Download Page 235

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Diagnostic aids

3-85

5055-xxx

2. Rotate the rear adjustment knobs to equally align the top and

bottom of the finisher with the printer.

•

To move the top of the finisher closer to the printer, rotate the
adjustment knobs clockwise.

•

To move the top of the finisher away from the printer, rotate
the adjustment knobs counterclockwise.

3. Roll the finisher toward the printer until the finisher locks to the

docking plate pins. You hear a click when the finisher locks into
position.

Summary of Contents for C91 Series

Page 1: ...C91x Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks S...

Page 2: ...Kentucky 40550 U S A or electronically mailed e mail to ServiceInfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without in...

Page 3: ...rint 1 5 Processor 1 5 Duty cycle 1 5 Printer memory 1 6 Resident fonts 1 7 Paper and media specifications 1 8 Input and output configurations 1 8 Media size supported 1 10 Input media types and weigh...

Page 4: ...error message tables 2 4 Attendance messages 2 34 Maintenance analysis procedures MAPS 2 54 Symptom table 2 63 Service checks 2 68 Drive 1 DC motor service check 2 68 Drive 2 stepper motor service che...

Page 5: ...ty feeder tests 3 18 Finisher tests 3 20 Device tests 3 23 Diagnostics printer setup 3 26 Defaults 3 26 Viewing and resetting the drum counters 3 28 Diagnostics error log 3 31 Theory of operation 3 33...

Page 6: ...circuit boards 4 1 Adjustments 4 3 High capacity paper feed timing belt adjustment 4 3 Removals 4 4 Cover top removal 4 4 Cover front removal 4 5 Cover front left removal 4 5 Cover rear removal 4 6 C...

Page 7: ...r feed frame removal 4 37 Paper feed roller removal 4 38 Paper present sensor removal 4 38 Paper remaining sensor removal 4 39 Paper size sensor board assembly removal 4 39 Power supply 1 removal 4 40...

Page 8: ...al 4 87 HCF power supply removal 4 88 Finisher removals 4 89 External covers removals 4 89 Finisher control board removal 4 90 Elevator motor removal 4 91 Feed motor assembly removal 4 91 Hole punch r...

Page 9: ...Duplex unit controller board 5 16 Motor drive board 5 16 Size sensor board 5 17 High capacity feeder HCF 5 18 High capacity paper feed configuration 5 18 Electrical parts layout 5 19 Driving parts la...

Page 10: ...mbly 20 High capacity feeder 3 7 46 Assembly 21 High capacity feeder 4 7 48 Assembly 22 High capacity feeder 5 7 50 Assembly 23 High capacity feeder 6 7 52 Assembly 24 Finisher covers 7 54 Assembly 25...

Page 11: ...plug the product before you begin or use caution if the product must receive power in order to perform the task Consignes de s curit La s curit de ce produit repose sur des tests et des agr ations por...

Page 12: ...o deve essere alimentato per eseguire l intervento Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendun...

Page 13: ...fe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a A seguran a deste produto baseia se em testes e aprova es do modelo original e de componentes espec ficos O...

Page 14: ...ducte 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 aqu...

Page 15: ...Safety information xv 5055 xxx...

Page 16: ...ovides 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 Preven...

Page 17: ...quality for high volume printing Resolution 600 x 600 dpi 2400 image quality Model differences 5055 230 C912 5055 210 C912 5055 200 C912 5055 01N C910 5055 010 C910 28 29 ppm engine X X X X X USB par...

Page 18: ...rovide flexibility in choosing the type of color correction to be applied when printing a file Auto default provides ease of use with no color science knowledge required Vivid adjusts CMYK components...

Page 19: ...4 in 695 mm 25 8 in 655 mm 40 8 lb 18 5 kg High capacity feeder 3000 sheet 25 0 in 635 mm 14 2 in 360 mm 20 7 in 525 mm 50 0 lb 22 6 kg Staple Punch finisher 1100 sheet with stand 41 7 in 1060 mm 19 5...

Page 20: ...A 16 Legal 8 5 in x 14 in 19 N A 19 A3 16 N A 16 A4 3 4 in x 11 7 in 29 29 29 A5 Executive N A N A 38 B4 18 N A 18 B5 N A N A 32 Transparencies 22 N A 22 Card stock N A N A 11 Envelopes N A N A 11 Pap...

Page 21: ...1 Folio and statement paper support from multipurpose feeder only 2 Speeds 3 When printing from the multipurpose feeder Simplex the first three pages print a legal speed with the balance printing at t...

Page 22: ...e expansion slot for optional interface cards One optional firmware expansion slots application solution firmware card One on board hard disk interface for optional hard disk SDRAM and flash memory op...

Page 23: ...by each font Support for the euro currency character is included in all applicable fonts for both PostScript and PCL emulations Twelve PCL symbol sets support the euro character including all seven W...

Page 24: ...C91x Lexmark C91xn Lexmark C91xdn Input sources Number of standard sources 2 3 3 Optional input drawers 3 2 2 High capacity feeder 1 1 1 Maximum number of input sources 6 6 6 Input capacities sheets S...

Page 25: ...bin 100 100 100 Optional Finisher3 4 1 000 1 000 1 000 Maximum output capacity 1 650 1 650 1 650 Other Duplex unit Yes Yes Standard 1 The heavy media tray is supported only as Tray 1 top 2 A maximum o...

Page 26: ...m x 210 mm X X X JIS B5 7 17 in x 10 23 in 182 mm x 257mm X X JIS B4 4 34 in x 10 1 in 364 mm x 252 mm X X X X Letter 8 5 in x 11 in 216 mm x 279 mm X X X X X Legal 8 5 in x 14 in 216 mm x 256 mm X X...

Page 27: ...5 in x 7 5 in 98 mm x 191 mm X 9 Envelope 3 875 in x 8 9 in 98 mm x 225 4 mm X 10 Envelope 4 125 in x 9 5 in 105 mm x 241 mm X DL Envelope 4 33 in x 8 66 in 110 mm x 220 mm X C4 Envelope 9 in x 12 75...

Page 28: ...ard output Bin 1 Finisher Bin 1 Finisher Bin 2 A4 8 27 in x 11 7 in 210 mm x 297 mm X X X X A5 5 83 in x 8 27 in 148 mm x 210 mm X X X JIS B5 7 17 in x 10 23 in 182 mm x 257mm X X JIS B4 14 34 in x 10...

Page 29: ...1 2 Banner 11 69 x 36 in 297 2 x 914 4 mm Lexmark C912 only 2 75 x 5 in to 8 5 x 14 in 69 85 x 127 mm to 229 x 355 6 mm 5 83 x 7 17 in to 8 5 x 14 in 148 x 182 mm to 215 9 x 355 6 mm X X X X X 7 Envel...

Page 30: ...ow media should be loaded with the length in the feed direction portrait 3 A5 paper 5 83 x 8 27 in 148 x 210 mm is the smallest size the printer can duplex 4 When Other Envelope is selected the page i...

Page 31: ...120 g m2 Card stock upper limit Index Bristol 90 lb index 44 lb bond 165 g m2 Transparencies laser printer type 47 lb bond 175 g m2 Labels upper limit paper 48 lb bond 180 g m2 Envelopes sulfite wood...

Page 32: ...0 to 105 g m2 Specialty papers glossy laser1 80 lb book 32 lb bond 120 g m2 Card stock upper limit Index Bristol 90 lb index 44 lb bond 165 g m2 Transparencies laser printer type2 47 lb bond 175 g m2...

Page 33: ...except for transparencies envelopes labels and paper less than 80 g m2 21 3 lb bond or greater than 105 g m2 28 lb bond 4 Bin 1 represents engine side output and Finisher Bin 1 face up 5 Finisher sup...

Page 34: ...er 0 4 in 11 mm 100 sheets 20 lb 75 g m2 Transparencies 50 transparencies Envelopes 10 envelopes Card stock 55 sheets 90 lb index 163 g m2 Paper labels 55 sheets up to 48 lb 180 g m2 Glossy paper Manu...

Page 35: ...unch Finisher Bin 1 Plain paper Varies 100 sheets 20 lb 75 g m2 Transparencies Varies 50 transparencies 47 lb 175 g m2 Bin 2 Staple Punch Finisher Plain paper 6 0 in 152 mm 1 000 sheets 20 lb 75 g m2...

Page 36: ...chemically treated papers coated synthetic and thermal papers and preprinted papers requiring a high degree of registration Recycled paper less than 21 lb 80 g m2 may cause unacceptable results Envelo...

Page 37: ...25 cotton bond envelopes is recommended Note Under high humidity conditions over 60 the envelopes may seal during printing Transparencies Use letter p n 12A5940 or A4 p n 12A5941 only Labels Labels sh...

Page 38: ...er This is supported only as Tray 1 top drawer location Duplex unit offers two side printing and is designed to complement the Lexmark C91x printers Finisher offers stapling hole punching offset stack...

Page 39: ...d C91xdn 2 optional drawers Connectivity Standard Lexmark C91x Bidirectional parallel and USB Lexmark C91xn and Lexmark C91xdn 10 100BaseTX Ethernet and USB Note USB is supported only under Windows 98...

Page 40: ...rt for Ethernet 10BaseT 100BaseTX MarkNet X2012e 1 port for Ethernet 10BaseT 100BaseTX 10BaseT 10Base2 MarkNet X2031e 3 port for Ethernet 10BaseT 100BaseTX MarkNet X2030t 3 port for Token Ring attachm...

Page 41: ...series external print servers support a resident Web page with Microsoft Internet Explorer 4 0 or later and Netscape Navigator 4 5 or later for Windows 95 Windows 98 Windows Me Windows 2000 Windows X...

Page 42: ...40 V at 50 to 60 hertz Hz nominal 198 to 254 V extreme Note Using a 220 to 110 power converter with the 110 V printer is not recommended Printing states average power Non network Network Duplex networ...

Page 43: ...ature 80 1 F 26 7 C Altitude 10 000 ft 0 to 3 048 meters Dimension Measurement Notes Left side 13 in 330 mm Clearance on the left side should be 9 in 228 6 with the finisher attached Right side C91x n...

Page 44: ...C Relative humidity 5 to 80 Maximum wet bulb temperature 85 F 30 C Altitude 34 000 ft 10 300 meters Shipping supply items Temperature 40 to 104 F 40 to 40 C Relative humidity 5 to 100 Maximum wet bul...

Page 45: ...outlet Remove and inspect the photodevelopers and toner cartridges shielding them from strong light Inspect the interior of the printer removing foreign matter such as paper clips staples pieces of pa...

Page 46: ...onnector Return parts Engineering periodically analyzes returned parts for failure modes Include a printed test DEMO page before and after the repair and tag any returnable parts with a description of...

Page 47: ...Magnetic tip Phillips screwdrivers large and small Flat blade screwdrivers Analog volt ohmmeter a digital volt ohmmeter may also be used Needle nose pliers Tweezers C ring pliers Magnifier 20 times or...

Page 48: ...r configuration ID and part number Open the front door The serial number configuration ID and part number are located as shown The serial number is also on the menu settings page you can print from th...

Page 49: ...work LASER Light amplification by stimulated emission of radiation LCD Liquid crystal display LED Light emitting diode LVPS Low voltage power supply NVRAM Nonvolatile random access memory OEM Original...

Page 50: ...1 34 Service Manual 5055 xxx...

Page 51: ...2 4 the Attendance messages on page 2 34 or the Symptom table on page 2 63 and take the appropriate action If an error message appears while you are working on the printer go to the error message tab...

Page 52: ...If you replace the RIP controller board move the solid state drive memory and option cards from the old card to the new one After replacing the RIP controller board it is necessary to type in the foll...

Page 53: ...well ventilated place The room temperature is between 10 and 32 C 50 and 90 F and the relative humidity between 20 and 80 Avoid sites generating ammonia gas high temperature high humidity near water...

Page 54: ...rror 910 Drive Motor Error 910 Service Motor Error Step Questions actions Yes No 1 Are connectors CN1 and CN5 on the motor drive board connected properly Go to step 2 Connect CN1 and CN5 2 Is connecto...

Page 55: ...ontroller board Step Questions actions Yes No 1 Is connector CN40 on the printer controller board securely connected Go to High capacity feeder HCF service check on page 2 70 Plug the connector in sec...

Page 56: ...printer controller board Step Questions actions Yes No 1 Is 24 V present between pins 1 and 3 of connector CN6 on the printer controller board Replace the power supply fan Replace the printer control...

Page 57: ...923 displayed Replace the fuser Replace the printer controller board Step Questions actions Yes No 1 Turn off the printer and reinstall the fuser making sure it clicks into place Turn on the printer D...

Page 58: ...ltage board HVU for a broken component Q906 Replace the high voltage board HVU if necessary Go to step 2 2 Is connector CN42 on the printer controller board connected properly Replace the printer cont...

Page 59: ...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 Did this fix the problem Problem solved Go...

Page 60: ...o to step 4 Properly connect the cables 2 For serial number XX 0XXXX Is fuse 5 on the printhead control board open Replace the printhead control board cables CL13 CL24 and LED printhead Replace the pr...

Page 61: ...4 Properly connect the cables 2 For serial number XX 0XXXX Is fuse 6 on the printhead control board open Replace the printhead control board cables CL13 CL24 and LED printhead Replace the printhead c...

Page 62: ...perly connect the cables 2 For serial number XX 0XXXX Is fuse 3 on the printhead control board open Replace the printhead control board cables CL13 CL24 and LED printhead Replace the printhead control...

Page 63: ...to step 4 Properly connect the cables 2 For serial number XX 0XXXX Is fuse 4 on the printhead control board open Replace the printhead control board cables K13 K24 and LED printhead Replace the print...

Page 64: ...olved Replace the color drum sensor Go to step 3 3 Did replacing the color drum sensor fix the problem Problem solved Replace the printer controller board Step Questions actions Yes No 1 Is connector...

Page 65: ...properly Replace the printer controller board Plug the connector in securely Step Questions actions Yes No 1 Is connector CN40 on the printer controller board connected properly Go to High capacity f...

Page 66: ...nnected properly Replace the printer controller board Plug the connector in securely 945 Service Engine Flash 946 Service Communication Step Questions actions Yes No 1 Make sure all printhead LED EPRO...

Page 67: ...replacement resolve the problem Problem solved Replace the printer control board 948 Service Machine ID Step Questions actions Yes No 1 Turn the printer off and wait 30 seconds Turn the printer on Did...

Page 68: ...roblem Problem solved Replace the expansion feeder control board for trays 2 5 If the problem is with the high capacity paper feeder replace the HCPF board 952 Service NVRAM Failure Step Questions act...

Page 69: ...RAM Slot 1 Bad Replace the RAM card or the RIP board 961 RAM Slot 2 Bad Replace the RAM card or the RIP board 962 RAM Slot 3 Bad Replace the RAM card or the RIP board 964 Emulation Error Replace the...

Page 70: ...r 976 Unrecoverable Software Error in Network Port Software error Go to the Options service check on page 2 98 and refer to the network card option section 978 Bad Checksum While Programming Network C...

Page 71: ...tep 3 Go to step 4 3 Is there continuity on the FU FD deflector solenoid between pins 1 and 2 of CN14 on the printer controller board Go to step 5 Replace the FU exit assembly 4 Make sure that the FU...

Page 72: ...ter controller board connected properly Go to step 4 Plug the connector in securely 4 Remove the transfer belt Verify the belt up down sensor actuator flag is properly installed not broken and in the...

Page 73: ...er board Replace the belt up down clutch Go to step 7 Replace the belt up down sensor 7 Did replacing the belt up down clutch fix the problem Problem solved Replace the printer controller board 982 Se...

Page 74: ...sor Does this correct the problem Problem solved Go to step 4 4 Replace the sensor card Did this resolve the problem Problem solved Replace the drive unit Step Questions actions Yes No 1 Is connector...

Page 75: ...transfer belt unit If the problem remains replace the printer controller board Plug the connector in securely 986 Service OHP Sensor Step Questions actions Yes No 1 Are connectors CN15 light emitting...

Page 76: ...d Step Questions actions Yes No 1 Is connector CN3 on the printer controller board connected properly Go to step 2 Plug the connector in securely 2 Replace the temperature and humidity sensor a compon...

Page 77: ...elease 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 CN29 on the printer c...

Page 78: ...cted Go to step 3 Properly connect the cables 3 Make sure the finisher set switch is activated Measure for 24 V dc 10 between pins 7 and 8 and 5 V dc 10 between pins 7 and 6 on the feed motor assembly...

Page 79: ...etween 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 control board Is either voltage missing Replace the power supply Repla...

Page 80: ...he finisher set switch is activated Measure for 24 V dc 10 between pin 1 on CN2 and frame ground Is 24 V dc present Go to step 4 Go to step 5 4 Replace the jogging motor assembly Did this resolve the...

Page 81: ...e finisher set switch is activated Measure 24 V dc between pin 1 of tractor motor connector CN3 and frame ground Is 24 V dc 10 Go to step 4 Go to step 5 4 Replace the tractor motor assembly Did this r...

Page 82: ...vator motor Power the printer on and observe the voltage meter during the first 12 seconds of power up Is 24 V dc present while the printer is powering up Replace the tray elevator motor Go to step 3...

Page 83: ...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 84: ...b The printer is processing a request to cancel the current print job Wait for the message to clear Change x The printer is requesting a different type of paper Change paper Check device connection Th...

Page 85: ...processing a copy job originating from the scanner Wait for the message to clear Defragmenting The printer is defragmenting the flash memory to reclaim storage space occupied by deleted resources Wai...

Page 86: ...rming The printer is warming the fuser assembly Wait for the message to clear Enter PIN ______ The printer is waiting for you to enter your four digit PIN number Use the operator panel buttons to ente...

Page 87: ...ted Insert the specified tray If the error cannot be reset go to Paper tray missing service check on page 2 83 Install device or Cancel Job The printer is requesting a specified device be installed so...

Page 88: ...Load a sheet of paper specified in the second line of the display in the manual feed tray or multipurpose feeder Press Select or Go to ignore the manual feed request and print on paper already in the...

Page 89: ...e to clear Power Saver The printer is ready to receive data It is reducing electricity consumption while idle Send a job to the printer Press Go to quickly warm the printer to normal operating tempera...

Page 90: ...gramming new system code Wait for the message to clear Program Flash The printer is storing resources such as fonts or macros in flash memory Wait for the message to clear Programming Disk The printer...

Page 91: ...message to clear Restore Held Jobs Go Stop The printer has been reset or has been turned on and the printer detects print and hold jobs stored on the hard disk Press Go All jobs on hard disk are resto...

Page 92: ...n page 2 83 Unsupported Disk The printer detects an unsupported disk Press Go to clear the message Format the disk USB x The printer is processing data through the specified USB port Wait for the mess...

Page 93: ...x Config Error The optional heavy media tray is inserted into any tray location except tray 1 Remove the heavy media tray from the invalid location 34 Short Paper The paper is too short Press Go to cl...

Page 94: ...current job 38 Memory Full The printer is processing data but the memory is full Press Go to clear the message and continue printing Press Menu to open the Job Menu and cancel the current job 39 Comp...

Page 95: ...age and continue If the message cannot be reset go to Map 9 False 41 Open Bin 1 Exit Tray message on page 2 59 51 Defective Flash The printer detects defective flash memory Press Go to clear the messa...

Page 96: ...en the Job Menu and reset the printer 54 Std Par ENA Connection Lost 54 Par x ENA Connection Lost The printer has lost the connection to an external print server Make sure the cable connecting the ENA...

Page 97: ...e the excess hard disks Plug the printer in and turn it on 58 Too Many Flash Options Too many flash options are installed Turn off and unplug the printer Remove the excess flash options Plug the print...

Page 98: ...life Press Go to clear the message and continue printing The supplies message is displayed until you replace the transfer belt and fuser 80 Belt Life Warning The transfer belt is nearing end of life P...

Page 99: ...has reached end of life Replace the black photodeveloper Make sure you also install the new oil coating roll that is included in the kit If print quality is still acceptable and you do not want to re...

Page 100: ...oll Exhausted 88 Black Toner Empty The oil coating roll has reached end of life The black toner cartridge is empty See note below Replace the oil coating roll and black toner cartridge Note If the cus...

Page 101: ...e specified toner cartridge is empty Install a new toner cartridge and go to Map 7 False 88 color Toner Low Toner Empty message on page 2 58 88 color Toner Low The printer has detected that the specif...

Page 102: ...Leave Staple Job in Finisher The printer has detected a paper jam while printing a job that must be stapled The message Leave Staple Job in Finisher alternates with the Paper Jam message Leave the pr...

Page 103: ...d incorrectly Correctly install the staple cartridge Go to Finisher service check on page 2 71 to check the staple cartridge set sensor 210 Staple Jam Open the finisher stapler door remove the paper f...

Page 104: ...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 Step Questions actions Yes No 1 C...

Page 105: ...Step Questions actions Yes No 1 Remove the rear cover on the high capacity feeder and observe LED 9 on the HCF card while actuating the cover open micro switch Does the LED go on and off while openin...

Page 106: ...operly connected Go to step 4 Properly connect the connectors 4 Replace the paper remaining sensor board for the problem tray Does this fix the problem Problem solved Replace the expansion feeder cont...

Page 107: ...ar of the fuser damaged or broken Replace the fuser Go to step 4 4 Is CN44 on the printer controller board properly connected Replace the printer controller board Properly connect CN44 Step Questions...

Page 108: ...r 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 3 Clean the encoder wheel or replace the toner set 3...

Page 109: ...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 affect...

Page 110: ...the connectors 5 Replace the tray 1 expansion feeder control card Does this fix the problem Problem solved Return the tray 1 expansion feeder control card and replace the printer controller board If...

Page 111: ...nect the connectors 10 Replace the duplex interface card Does this fix the problem Problem solved Return the duplex interface card and go to step 11 11 Replace the duplex interface cable Does this fix...

Page 112: ...the size sensor levers operate correctly Go to step 3 Replace the size sensor levers 3 Are the following connectors properly connected CN2 tray 1 on the printer controller board CN4 on the expansion f...

Page 113: ...ther Paper Type setting such as Plain Paper or Letterhead If Printer Usage is set to Maximum Yield the printer calibrates the print head timing The printer performs this same calibration each time you...

Page 114: ...check on page 2 74 Operator panel does not operate properly Go to the Diagnostic aids chapter and run the LCD and Button tests If the tests fail replace the operator panel If you still have a problem...

Page 115: ...paper Check the following Excessive toner buildup on the transfer belt Clean off the toner and run a test print Transfer belt assembly Transfer belt toner waste bottle Transfer belt separation fingers...

Page 116: ...nment knobs closest to the holding plate This action raises or lowers 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 wh...

Page 117: ...nt pins Recheck the finisher and printer for additional jams Pages are not stapled Attempting to staple too many sheets The staple cartridge is empty The stapler is jammed Reduce the number of pages i...

Page 118: ...re 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 Be sure the clutch on the gear...

Page 119: ...d roller solenoid assembly Paper re feed solenoid assembly Check for proper operation of the solenoid and linkage Replace as necessary 4 Photo interrupter assembly Ensure that the photo interrupter ac...

Page 120: ...1 4 Paper level sensor Lower limit switch Docking switch Upper limit Paper sensor switch Paper feed sensor Go to the High Capacity Paper Feed Sensor Switch Test on page 3 19 and perform the LED senso...

Page 121: ...lower limit sensor Jogging assembly Pap upper level sensor Fin set switch sensor Staple cart set sensor Note For frequent jams hole punch problems or stapling problems First check the finisher to prin...

Page 122: ...elt This causes lower transfer efficiency and washed out colors 3 Registration roller Paper exit rollers Registration sensor Registration clutch Punch clutch punch unit Timing belt Run the hole punch...

Page 123: ...l 113 5 75 37 5 0 37 5 75 113 5 Detact fingers BUR 134 90 45 0 45 90 134 Exit rollers 96 37 5 37 5 96 Star rollers 127 60 15 15 60 127 FRU Action 1 Operator panel Operator panel cable RIP board Make s...

Page 124: ...d Clean or replace parts as necessary 2 Paper feed clutch Paper feed motor Sensors Set up and run a test in Maintenance Mode and go to the High capacity feeder HCF service check on page 2 70 Ensure al...

Page 125: ...feed gears are not damaged 4 Paper feed solenoid Paper feed clutch MPF clutch MPF frame assembly Be sure the paper feed solenoid activates the paper feed clutch and the clutch engages properly Check...

Page 126: ...onnector CN13 on the printer controller board is connected properly 2 Registration sensor Printer controller board Check for a fluctuation of between 0 V and 5 V between pins 1 and 2 of connector CN11...

Page 127: ...her face down or face up delivery Do a continuity check of the solenoid Be sure connector CN122 is properly connected to the printer controller board 3 Face down exit assembly Face down feed roller be...

Page 128: ...Be sure the stepper motor turns freely with no binding Check for wear or damage to the associated gears Replace as necessary 4 Feed roller solenoid assembly Paper re feed solenoid assembly Check for...

Page 129: ...r damage Check the registration roller for wear or damage Check for obstructions Check the registration sensor by running the finisher sensor tests in diagnostic mode Check the registration clutch by...

Page 130: ...ng roller 2 Path select solenoid Path select gate Guide stack assembly Jogging assembly Stapler Check for proper operation of the guide stack assembly and jogging assembly by running the staple test i...

Page 131: ...assembly Check to ensure that all rollers are operating correctly by running the hole punch and staple tests in diagnostic mode 3 Paper exit sensor tray1 Paper exit sensor tray 2 Paper full sensor A t...

Page 132: ...between 0 V and 5 V between pins 1 and 2 of connector CN12 while actuating the sensor Check the FU FD deflector that directs the paper to the proper tray Check the FU FD solenoid for continuity Also b...

Page 133: ...s under the corner bucklers The paper lift tray must be pushed down to the lock position every time the drawer is closed FRU Action 1 Size sensor actuators Cassette Check to ensure that the paper size...

Page 134: ...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 th...

Page 135: ...plug the machine and check fuse F2 on the power supply 1 for continuity If the fuse is good check the power switch connector for continuity 4 Power supply 2 The power supply 2 may be defective Check t...

Page 136: ...board Stapler cable If the error occurs and there is no staple jam check to ensure that connectors CN5 on the stapler and PJ1 on the finisher control board are properly connected Make sure that the fi...

Page 137: ...e the sensor or the actuator if necessary Check for a fluctuation between 0 V and 5 V between pins 8 and 10 while actuating the sensor 2 Belt up down clutch Be sure connector CN26 is firmly connected...

Page 138: ...nstalled in the printer Set print darkness to 4 from the Color Menu Clean the printhead LEDs If you suspect a toner cartridge is low on toner remove the appropriate toner cartridge and gently shake it...

Page 139: ...ns go to Black line on page 2 95 Toner specks appear on the page Replace the oil coating roll Toner colors the background of the page Be sure the affected photodevelopers and toner cartridges are comp...

Page 140: ...he photodevelopers If the problem only occurs when printing black replace just the black photodeveloper If the problem occurs when printing one of the colors replace all three of the color photodevelo...

Page 141: ...ner Wipe one at a time and proceed from the front of the printer to the back in one gentle swipe It may take more than one pass Use a different spot on the cloth or a new cloth for each LED Reinstall...

Page 142: ...cs Mode under Print Test Print Quality Pages This often identifies the color that has a problem If you switch the toner cartridges and the problem also changes color on the test pages the problem is i...

Page 143: ...o corner tabs at the front of the tray Be sure charge roll or belt is seated properly A white gap is noticeable between color fills due to poor color registration Be sure all four corners of the print...

Page 144: ...rinthead controller board and LED printhead assembly If the problem remains replace the LED printhead High voltage unit HVU Be sure all the connectors to the high voltage unit are securely connected I...

Page 145: ...thead Print a blank document Replace the LED printhead if a black line appears on the paper Possible cause Action High voltage unit HVU The printed paper has black print Be sure the high voltage unit...

Page 146: ...h 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 unit Replace the high...

Page 147: ...cover is fully locked Possible cause Action Oil coating fuser roller OCR Check for dirt or damage to the fuser rolls or the oil coating roller OCR Photoconductor drum Check for scratches on the surfac...

Page 148: ...ce the RIP board Flash Memory Option s Run a copy of the test page and check to see if the option you are checking is listed The printer does not recognize the option being installed if the option is...

Page 149: ...g section Warning This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk Menu operation...

Page 150: ...2 100 Service Manual 5055 xxx...

Page 151: ...face 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 Printer hardware...

Page 152: ...r light The light indicates whether the printer power is on and whether the printer is idle or busy processing a job Indicator light Use the five operator panel buttons to open a menu scroll through a...

Page 153: ...view the available menu items Select the menu item shown on the second line of the display and view the available values and the current user default setting for that menu item Save the value displaye...

Page 154: ...machine on Menu overview SUPPLIES MENU Belt Block Photo Dev Coating Roll Color Photo Dev color Toner Fuser Replace Supplies Supplies Life UTILITIES MENU Color Samples Print Alignment Print Menus Print...

Page 155: ...Switch PS SmartSwitch MAC Binary PS NPA Mode Parallel Buffer Job Buffering Advanced Status Protocol Honor Init Parallel Mode 1 Parallel Mode 2 SERIAL MENU PCL SmartSwitch PS SmartSwitch NPA Mode Seria...

Page 156: ...registration X Y and Theta Adjust X and Y first and then adjust Theta X controls the horizontal plane By adjusting X you move the radar image left negative and right positive Y controls the vertical...

Page 157: ...t adjustment If it is not acceptable go back to the color and adjust it again 5 When all the values are acceptable for all colors exit diagnostics Note If Return is pressed to exit the Alignment menu...

Page 158: ...ht The Y value for magenta is incorrect The magenta radar image is too far above the black In the case of Y increase the value for Y to move the magenta image down the page This may not seem intuitive...

Page 159: ...lues are taken from the left side Theta is taken from the right Increasing values for X drives the color radar right Increasing values for Y and Theta drive the color radar image down the page Do both...

Page 160: ...pe Print Test pattern prints This pattern contains text of each character in the selected symbol set If Continuous is selected all sources printing with paper sizes print the same page continuously un...

Page 161: ...nted from the Configuration Menu Group When printing using this method the toner cartridge lockout functionality is enabled These pages cannot print unless a cartridge with a Machine Class ID matching...

Page 162: ...oning To exit the button test press Return or Stop DRAM Memory Test The DRAM Memory Test checks the validity of DRAM both standard and optional Patterns of data are written to DRAM verifying each bit...

Page 163: ...following message is displayed Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 F represents the numb...

Page 164: ...rallel hardware and the following message is displayed Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 99...

Page 165: ...ta 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 Init Rise Error False Init Rise Erro...

Page 166: ...ial 1 optional serial port 1 P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 F represents the number of times the...

Page 167: ...Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error...

Page 168: ...r closed or with the cover switch activated press and hold the tray down button for more than 1 2 second In steps 1 and 2 paper feeding starts and is continuously fed until the cover is opened The tes...

Page 169: ...tuate the micro switch being tested while observing the associated LED on the high capacity paper feed board LED Sensor Name 1 Paper size sensor 1 switch letter size 11 inches 2 Paper size sensor 1 sw...

Page 170: ...Test The media is fed from the default paper source After selecting a destination bin the printer feeds eight pieces of media hole punches them and feeds them to bin 1 The printer prints an alignment...

Page 171: ...ssage is displayed then the sensor is malfunctioning To exit the senor test press Return or Stop Go into diagnostic mode Finisher tests Sensor sw tests Input Path This is the paper exit sensor in the...

Page 172: ...ay 2 Exit Remove tray 2 and activate the tray 2 exit sensor Elev Upper Limit Activate by pressing the paper full A and the paper upper level together This causes the elevator motor to operate allowing...

Page 173: ...The Power indicator blinks while the test is in progress If the test is successful the following message is displayed Press Go Return or Stop to return to the DEVICE TESTS screen If the test fails th...

Page 174: ...all disk contents will be lost To continue with the test press Go To exit the test immediately and return to the DEVICE TESTS screen press Return or Stop The Power indicator blinks while the test is...

Page 175: ...e the test press Go To exit the test immediately and return to the DEVICE TESTS screen press Return or Stop The following message is displayed while the test is running The Power indicator blinks whil...

Page 176: ...ange 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 plus 8 To set this v...

Page 177: ...be Adj This message displays only if a parallel port is available through the PCI slot 1 Par 2 Strobe Adj This message displays only if a parallel port is available through the PCI slot 2 Par 3 Strobe...

Page 178: ...is value is not viewable from the Ready menu The following screen illustrates the operator panel when the cyan drum counter displays The leftmost digit 1 in this example blinks indicating it is the fi...

Page 179: ...desired value displays Press Select to move to the next digit The next digit 2 in this example blinks Continue modifying each digit using this method To skip a digit and keep its current value press S...

Page 180: ...igit to be changed To change the value press Menu until the desired value displays Press Select to move to the next digit The next digit 2 in this example blinks Continue modifying each digit using th...

Page 181: ...log when a 925 service error occurs If an error occurs after the log is full the oldest error in the log is discarded to make room for the new error The printer stores identical errors in consecutive...

Page 182: ...clear the log as the empty log message appears Select No Return or Stop to exit the Clear Log menu Maintenance Menu Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal u...

Page 183: ...is recorded by irradiating light from the LED printhead forming the electrostatic image The LED printhead array along with the Selfoc lens array provide a single dot line of the image in a one to one...

Page 184: ...velopment roll and doctor blade by the rotating development roll and is negatively charged forming the electrostatic image on the photosensitive drum Toner attaches to the bright portion of the photos...

Page 185: ...ed by the eraser Paper feeding fusing The main unit drive is composed of drives 1 and 2 Drive 1 feeds paper stands by drives the belt unit separates fuses feeds the face up delivery unit and drives th...

Page 186: ...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 187: ...s A high capacity paper feeding system 3 000 sheets may be used Combining the multi paper feeder expansion paper feeders and high capacity paper feeding system gives the printer a maximum paper supply...

Page 188: ...ng 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...

Page 189: ...Diagnostic aids 3 39 5055 xxx Separation unit The transfer belt and paper are separated with the belt drive roll by separation fingers Drive Roll Paper Separation Fingers...

Page 190: ...t with the outside of the tube Separation fingers are attached near the upper roller to separate the paper from the roller Each thermistor sends the surface temperature of the roller to the printer co...

Page 191: ...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 If the delivery unit r...

Page 192: ...he drum with a cleaning blade and recovered into the waste toner bottle Adjust the registration when the belt unit is replaced The registration is adjusted at the leading edge of the image or by adjus...

Page 193: ...fer belt moves up and down with the switching shaft cam by the electromagnetic clutch in drive 1 The belt position is used to detect the cam position with the photo sensor using the fan shaped light b...

Page 194: ...duplex unit stops once and the center position is corrected by the operation of the side guide plate Paper is then re fed by the printer controller signal to the main unit and following printing on t...

Page 195: ...in a specific source and ensure that the toner adheres properly to the printed page Values Light 16 20 lb Normal 20 24 lb Heavy 24 28 lb Plain weight Preprint weight Bond weight Labels weight Card st...

Page 196: ...to clear the message Check Areas A B This message indicates a paper jam in the transfer belt fuser or output roller area To clear areas A B 1 Open the front door 2 Rotate the top cover locking lever...

Page 197: ...pull the paper out toward the inside of the printer 9 Rotate the fuser pressure release lever down Note The top cover will not close until the lever is in the down position 10 Check the top cover for...

Page 198: ...e indicates a paper jam in the duplex unit area To clear area D 1 Open the duplex jam access door on the right side of the printer 2 Gently pull out the duplex unit 3 Turn the paper forwarding dial co...

Page 199: ...e the jam 6 Close the door 7 Open the jam access door on the bottom drawer 8 Remove the jam 9 Close the door 10 Press Go If the paper jam message continues clear any paper from the paper path Check Ar...

Page 200: ...op cover locking lever to the left 4 Place both hands on the lifting points and squeeze the right top cover latch 5 Lift the cover Warning Do not use pointed objects to remove the paper They may damag...

Page 201: ...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 202: ...aper feed clutch turns on the paper feed roller shaft rotates and the paper feed roller is driven with the one way clutch The call roller rotates with the relay gears to feed the top paper The reverse...

Page 203: ...peration 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...

Page 204: ...oving 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 When the tray moves up the call roll...

Page 205: ...ting and the up sensor is shielded the tray motor again rotates forward to raise the paper When the down button is pressed the tray motor reverses to move the tray down During the down motion of the t...

Page 206: ...he 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 joint switch is ON Up sensor is ON sh...

Page 207: ...is detected 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 po...

Page 208: ...hanism The residual paper quantity in the tray is detected with four photo interrupters The quantity of pages remaining in the sheet feeder displays in the following increments Near end about 80 sheet...

Page 209: ...Diagnostic aids 3 59 5055 xxx Paper end detection A reflection type sensor is provided on the top stay to detect the paper top surface and the paper end...

Page 210: ...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 211: ...he 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 punche...

Page 212: ...3 62 Service Manual 5055 xxx...

Page 213: ...cross section Input Paper Guide Register Roller Accumulator Stapler Unit Register Idle Roller Straight Exit Idle Roller Invert Exit Idle Roller Invert Exit Roller Upper Tray Lower Tray Straight Exit...

Page 214: ...jogged paper and paper jams Paper Exit Sensor detects that paper has exited the printer Tractor Home Position Sensor locates home position for the drive belt Elevator Upper Limit Sensor detects when t...

Page 215: ...ers subject to the selected mode Straight paper path exit paper to upper tray Paper feed motor drives and rotates rollers The path select gate is changed by the path select solenoid and paper goes out...

Page 216: ...3 66 Service Manual 5055 xxx Path select gate...

Page 217: ...rollers path select gate and patting rollers Paper is detected by the invert path sensor Paper is then jogged by jogging bar and driven by the belt drive motor before exiting to the lower tray accumul...

Page 218: ...ers The paper then stops at register rollers and since the finisher keeps feeding the paper from the host printer the leading edge of the paper stops at the register rollers The paper buckles at the e...

Page 219: ...mitted to the driving shaft When the punch clutch turns ON it is closed and unlocked The driving force is then transmitted from the clutch gears to the driving shaft As the shaft turns the rotation of...

Page 220: ...nsor detects the paper position for stapling Offsetting sequence Sheets of jogged paper are offset by the horizontal movement of the jogging bar The jogging bar is moved horizontally by the rack and p...

Page 221: ...echanism The stapler motor rotation drives a gear link and cam mechanism The cam movement allows the stapler mechanism to operate Elevator sequence The wire drum rotates by the elevator motor as the w...

Page 222: ...l sensor B turns ON paper feeding from host printer is prohibited When paper is removed from the lower tray and the paper upper level sensor B turns OFF the lower tray moves up Belt Paper Full Sensor...

Page 223: ...ove 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 Tight...

Page 224: ...3 74 Service Manual 5055 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 225: ...sher and stand 1 Roll the finisher stand onto the guide rail Do not push the stand all the way up against the printer 2 Remove and discard all shipping tape packing material and the metal shipping bra...

Page 226: ...76 Service Manual 5055 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 material...

Page 227: ...Diagnostic aids 3 77 5055 xxx 8 Close the stapler 9 Close the stapler door 10 Align the two sockets on the bottom of the finisher with the legs of the finisher stand...

Page 228: ...xxx 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 thumbscrew spacers 13 Tig...

Page 229: ...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 230: ...operly to prevent paper jams 1 The docking plate pins must enter the holes in the finisher 2 The space between the printer and finisher must be the same at the top and bottom of the finisher 3 The ali...

Page 231: ...il the finisher locks to the docking plate pins You hear a click when the finisher locks into position If the pins did not go into the holes in the finisher go to Lowering or raising the finisher on p...

Page 232: ...ng or raising the finisher Follow these instructions if the holes on the finisher are above or below the pins on the docking plate 1 Determine if the pins are above or below the holes in the finisher...

Page 233: ...he finisher rotate the adjustment knobs counterclockwise 4 Roll the finisher toward the printer until the finisher locks to the docking plate pins You hear a click when the finisher locks into positio...

Page 234: ...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 235: ...o move the top of the finisher closer to the printer rotate the adjustment knobs clockwise To move the top of the finisher away from the printer rotate the adjustment knobs counterclockwise 3 Roll the...

Page 236: ...er are not aligned with the edges of the cover on the side of the printer 1 Loosen the guide rail thumbscrews If you made previous adjustments the thumbscrews are already loose 2 Rotate the adjustment...

Page 237: ...Diagnostic aids 3 87 5055 xxx 4 Roll the finisher toward the printer until the finisher locks to the docking pins You hear a click when the finisher locks into position...

Page 238: ...stand remains aligned when moved To adjust and lock the wheels 1 Rotate the left and right upper adjustment knobs on the rear wheels until the wheels touch the floor To lower the wheels rotate the ad...

Page 239: ...Diagnostic aids 3 89 5055 xxx 3 Rotate the locking knobs counterclockwise until they contact the finisher base...

Page 240: ...r 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 off and unplug the power cord from the pow...

Page 241: ...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 242: ...plug the power cord from the side of the printer Set the cord aside 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 co...

Page 243: ...xx 4 Connect the previously removed printer power cord to the Y power cord 5 Remove the protective paper from the back of the cable holder 6 Firmly press the adhesive backed cable holder onto the back...

Page 244: ...enter the punched holes onto the paper or if you hole punch a printed job on different finishers Note The following procedures are used for both three and four hole punch finishers 1 Verify the alignm...

Page 245: ...Rotate both adjustment knobs the same amount to raise or lower the side of the finisher A half turn of the knob moves the position of the hole approximately one third to one half the distance of the p...

Page 246: ...3 96 Service Manual 5055 xxx...

Page 247: ...e printer stops running Always unplug connectors by holding the connector housing Be sure to use the fuse listed in the parts catalog Do not forget to install the ground wire or ground plate to ensure...

Page 248: ...ace it in position by holding only the edges of the board Before you plug connectors into the board be sure the power cord has been unplugged from the power outlet Inspection Avoid checking the integr...

Page 249: ...paper feed timing belt adjustment 1 Secure the bracket with the screw as shown 2 Attach the spring and washer to the bracket with the screw 3 Adjust the screw to 6mm 1mm 4 Tighten the screw completel...

Page 250: ...oval 1 Open the top unit and remove the photodevelopers and toner cartridges 2 Remove the two silver screws and remove the operator panel 3 Remove five black screws from the bottom and the four silver...

Page 251: ...r front removal 1 Remove the four brass hinge screws from the front cover 2 Remove the front cover Cover front left removal 1 Open the front cover and remove the cassette 2 Remove the left front cover...

Page 252: ...l 5055 xxx Cover rear removal 1 Open the top unit 2 Remove the three silver screws from the rear cover and remove the cover Cover solenoid removal 1 Remove the screw from the solenoid cover 2 Remove t...

Page 253: ...Repair information 4 7 5055 xxx 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...

Page 254: ...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 sid...

Page 255: ...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 Remo...

Page 256: ...then unlatch the hinge on the front side 2 Remove the paper exit tray 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...

Page 257: ...down clutch and remove the clutch 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 mountin...

Page 258: ...nual 5055 xxx 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 re...

Page 259: ...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...

Page 260: ...move 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 f...

Page 261: ...p 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...

Page 262: ...ver 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 con...

Page 263: ...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 the two cables from the rear...

Page 264: ...unit and remove the toner cartridges photodeveloper 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...

Page 265: ...it 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 Fanning pad removal 1 Open the top unit and remove...

Page 266: ...4 20 Service Manual 5055 xxx Front cover open switch actuator removal 1 Open the front cover 2 Remove the two screws from the front cover open switch actuator...

Page 267: ...Repair information 4 21 5055 xxx Fuser removal 1 Open the top unit 2 Pushing the front and back lock hold the handle raise and remove the fuser...

Page 268: ...front cover multipurpose 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 multipurpose feeder frame and the gr...

Page 269: ...ove upward 8 Remove the multipurpose feeder frame assembly 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 control...

Page 270: ...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 short black screw from the printhead holder and remove the holder 3 R...

Page 271: ...l numbers XX 1XXXX and above go to step 7 For serial numbers XX 0XXXX continue with step 5 5 For printers with serial numbers XX 0XXXX and above Remove the four connectors from LED printhead 6 Remove...

Page 272: ...at the both ends of the printhead are fixed with hexagon nuts Do not loosen or remove either nut as the image will unfocus Note Light intensity value printhead label value plus eight 7 For serial numb...

Page 273: ...XX 1XXXX and above Eraser removal 1 Remove the appropriate printheads see LED printhead removal on page 4 24 Spread a cloth or paper over the transfer belt to protect it from damage 2 Remove the two...

Page 274: ...4 28 Service Manual 5055 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 275: ...nit 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 Remove the fuser unit face up paper delivery unit belt up down clutc...

Page 276: ...nnector 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 nine screws from the bra...

Page 277: ...55 xxx 15 Remove the screw from the clutch stopper The clutch stopper is attached to the ground plate with two screws 16 Remove the six screws on the right side 17 Remove the two screws from the drive...

Page 278: ...n clutch box and remove the belt up down clutch 19 Remove the screw from the drum gear sensor and remove the sensor Main unit fan removal 1 Remove the left side cover the solenoid cover and the rear c...

Page 279: ...ve connectors and remove five screws and two screws from the motor drive board Multipurpose feeder paper present sensor removal 1 Open the top unit and remove the upper cassette front cover turn guide...

Page 280: ...the multipurpose feeder and slide it toward the magnet in the direction of the arrow removing it from the printer Operator panel removal 1 Open the top unit and remove the toner cartridges and photod...

Page 281: ...etection sensor upper multipurpose feeder frame back cover RIP cover RIP board RIP box and electronic box 2 Remove the four screws from the paper carrying frame 3 Remove the paper carrying frame Note...

Page 282: ...4 36 Service Manual 5055 xxx Paper carrying roller removal 1 Open the turn guide 2 Remove the two screws from the paper carrying roller and slide the bearing forward...

Page 283: ...ronic 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...

Page 284: ...s are visible Turn the paper feed roller and remove the screws from the roller 6 Remove the paper feed roller from the shaft Note If the paper feed roller surface is stained with oil or other contamin...

Page 285: ...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 un...

Page 286: ...c box Remove the cassette left 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...

Page 287: ...pply 2 removal 1 Unplug the power cord from the printer 2 Open the top unit and remove the RIP cover RIP board RIP box and electronic box 3 Disconnect the connector and remove the seven screws from po...

Page 288: ...ront 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...

Page 289: ...screws from the printer controller Pay attention to the location or label the two pin connectors when removing them from the board to avoid re connection into the wrong location When replacing the boa...

Page 290: ...XX 1 Remove the top cover 2 Remove the 20 printhead controller board connectors 3 Remove the screws from the printhead controller board and remove the board Note When replacing the board be sure to re...

Page 291: ...r information 4 45 5055 xxx For S N s XX 1XXXX 1 Remove the top cover 2 Remove the 12 printhead controller board connectors 3 Remove the six screws from the printhead controller board and remove the b...

Page 292: ...4 46 Service Manual 5055 xxx Note When replacing the board be sure to return the four EEPROMs on the former board to the same positions on the new board...

Page 293: ...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...

Page 294: ...ation sensor removal 1 Open the top unit and remove the upper cassette front cover turn guide multipurpose feeder right side cover and multipurpose feeder frame 2 Disconnect the connector of the regis...

Page 295: ...4 49 5055 xxx Right 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 296: ...4 50 Service Manual 5055 xxx 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...

Page 297: ...own paper guide assembly 2 Remove the yellow and black sub frame 3 Remove the screw from the right stopper and remove the stopper 4 Remove the screw from the left stopper and remove the stopper 5 Remo...

Page 298: ...ire 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 high voltage power supply board 2 Remove ca...

Page 299: ...paper or cloth over the belt to protect the belt Set the sub frame F to the position of the following colors depending on the presence of the upper detection buttons Magenta Sub frame F1 Detection but...

Page 300: ...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 Re...

Page 301: ...Repair information 4 55 5055 xxx 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...

Page 302: ...er Belt Life Warning or Exhausted message appears press Select when the Select Replace message appears The message Preparing for Maintenance appears followed by Printer Ready for Maintenance then Powe...

Page 303: ...Repair information 4 57 5055 xxx 3 Loosen the thumbscrews as shown 4 Lift and remove the transfer belt cover...

Page 304: ...4 58 Service Manual 5055 xxx 5 Loosen the thumbscrews as shown...

Page 305: ...er 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 If you replaced the belt before the Life Warning or Exhausted message...

Page 306: ...ave an unrecoverable error code use this method 1 Turn the printer off along with any optional devices connected to the printer 2 Open the front cover and top unit Warning Do not touch drop or place a...

Page 307: ...ion 4 61 5055 xxx 4 Remove the transfer belt cover 5 Override the front cover interlock switch 6 Turn the printer on 7 Look for the belt to lower during power on sequence 8 Turn the printer off when t...

Page 308: ...4 62 Service Manual 5055 xxx 9 Loosen the thumbscrews as shown...

Page 309: ...r 13 Turn the printer on Note If the message Did you Replace Belt appears wait for the message Select yes Stop no and press Select If you replaced the belt before the Life Warning or Exhausted message...

Page 310: ...oner bottle Note Be careful not to spill the toner 4 Look behind the white handle do not turn the handle for one of the cams that raises the belt A metal follower has fallen off the cam 5 With a screw...

Page 311: ...55 xxx Turn guide cover sensor removal 1 Open the top unit and remove the upper cassette front cover multipurpose feeder right side cover and turn guide 2 Remove the two screws from the turn guide sen...

Page 312: ...tridges and photodeveloper 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...

Page 313: ...ve 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...

Page 314: ...from the paper 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 four screws from the paper...

Page 315: ...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 d...

Page 316: ...emove 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...

Page 317: ...Repair information 4 71 5055 xxx 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...

Page 318: ...4 72 Service Manual 5055 xxx 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...

Page 319: ...ve 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 detec...

Page 320: ...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 28 Remove the two screws from the lower drawer conn...

Page 321: ...mation 4 75 5055 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 322: ...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 323: ...Repair information 4 77 5055 xxx Duplex pressure roller and solenoid removal 1 Remove the two screws securing the pressure roller solenoid assembly...

Page 324: ...ervice Manual 5055 xxx 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 sp...

Page 325: ...x 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...

Page 326: ...4 80 Service Manual 5055 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 327: ...moval 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 r...

Page 328: ...x HCF 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 rol...

Page 329: ...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 con...

Page 330: ...ensor 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...

Page 331: ...e 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 Rem...

Page 332: ...4 86 Service Manual 5055 xxx 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...

Page 333: ...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 pape...

Page 334: ...pward 2 Disconnect the power cord 3 Remove the front cover 4 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 u...

Page 335: ...on 4 89 5055 xxx Finisher removals External covers removals 1 Remove the finisher trays 2 Remove the two screws from the front cover and remove the cover 3 Remove the two screws of the rear cover and...

Page 336: ...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 337: ...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 338: ...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 339: ...e finisher control board 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 Rem...

Page 340: ...4 94 Service Manual 5055 xxx 4 Remove the inverter paper exit roller bushing 5 Remove the inverter idle gear 6 Remove the inverter drive gear and bushing 7 Remove the inverter paper exit roller...

Page 341: ...5 5055 xxx Jogging unit removal 1 Remove the dust box 2 Remove the two screws and remove the cover 3 Disconnect the jogging motor connector 4 Disconnect the jogging home position sensor connector 5 Re...

Page 342: ...emove 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 t...

Page 343: ...oval 1 Remove the front and rear covers 2 Remove the finisher control board mounting bracket 3 Remove the two screws from the upper left panel and remove the panel 4 Disconnect the sensor connector 5...

Page 344: ...r guide plate screws from the inverter paper exit and remove the plate 7 Remove the four screws from the inverter guide plate and remove the plate 8 Remove the tension springs Use the upper hole when...

Page 345: ...er Power supply removal 1 Unplug the power cord from the printer 2 Remove the external covers 3 Remove the lower left panel 4 Remove the cable connector for the left panel 5 Remove the four lower guid...

Page 346: ...ve the screw from the ground wire 8 Disconnect the power supply connector and remove the power supply Registration roller removal 1 Remove the hole punch unit 2 Remove the registration roller clutch 3...

Page 347: ...emoval 1 Remove the harness from the clamp 2 Remove the three control board mounting bracket screws and remove the bracket 3 Remove the registration roller clutch set screw 4 Remove the registration r...

Page 348: ...55 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 349: ...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 350: ...4 104 Service Manual 5055 xxx 6 Remove the rear straight paper exit roller E ring and bushing 7 Remove the straight paper exit roller...

Page 351: ...the 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 ten...

Page 352: ...Remove the external covers 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 p...

Page 353: ...information 4 107 5055 xxx 7 Remove the paper jam removal knob 8 Remove the tractor belts Note Install the belt so that the belt tooth just under the plastic hook aligns with the hook on the other bel...

Page 354: ...xxx Tractor drive motor assembly removal 1 Remove the outer covers 2 Remove the drive belt 3 Remove the three screws and disconnect the connector from the tractor drive motor assembly 4 Remove the tra...

Page 355: ...1 5055 xxx 5 Locations Covers diagram Rear Cover Top Cover Operator Panel Right Side Cover MPF Turn Guide Inner Cover Front Cover Left Front Cover Left Side Cover Cover PF SOL Cover Face Down Cover F...

Page 356: ...5 2 Service Manual 5055 xxx Major parts diagram...

Page 357: ...orption roll 20 Transfer belt 6 Registration upper roll 21 Belt dive roller 7 Registration lower roll 22 Paper delivery detection lever 8 Registration sensor 23 Press roll 9 Registration detection lev...

Page 358: ...5 4 Service Manual 5055 xxx Sensor and switch locations...

Page 359: ...Locations 5 5 5055 xxx...

Page 360: ...5 6 Service Manual 5055 xxx Component locations...

Page 361: ...rd 7 High voltage unit HVU 8 Upper left fan 9 Main drive motor 10 Upper right fan 11 Power supply fan 12 Temperature humidity sensor 13 Paper remaining detection sensor main unit 14 Paper remaining de...

Page 362: ...20 CN44 CN12 CN33 CN6 CN14 CN43 CN31 CN38 CN37 CN1 CN47 CN45 CN48 CN46 CN10 CN3 CN42 CN41 CN29 CN36 CN39 CN35 CN2 CN8 CN25 CN24 CN16 CN23 CN13 CN26 CN30 CN22 CN34 CN40 CN11 CN19 CN21 CN27 CN18 CN28 CN...

Page 363: ...Printer controller board connectors CN Board connector orientation Board conn color Cable conn color wires in cable Wire colors 20 Vertical White White 6 Black 12 Vertical White White 6 3 Blue 3 gray...

Page 364: ...blue gray white brown blue 2 red black yellow 36 Horizontal White White 7 White gray blue 3 yellow brown 35 Horizontal White White 5 Yellow 2 black red black 41 Horizontal White White 6 Black purple o...

Page 365: ...hite 4 Yellow 7 Vertical White White 3 White 28 Vertical Yellow White 4 Yellow 18 Vertical Red White 4 Red 15 Vertical Black Black 2 Black 9 Horizontal White White 3 Brown 4 Horizontal White White 4 B...

Page 366: ...5055 xxx Printhead controller board For printers with serial number XX 0XXXX For printers with serial number XX 1XXXX CN03 CN02 CN01 CN14 CN04 CN13 CN17 CN19 CN20 CN18 CN16 CN11 CN06 CN07 CN08 CN05 C...

Page 367: ...ns 5 13 5055 xxx RIP board J6 J7 J8 J10 J13 J12 J11 JT14 J5 J4 J2 J3 J1 1 1 1 1 1 2 83 84 85 86 167 168 A1 A2 A61 A61 A62 A62 B61 B61 B62 B62 B1 B2 1 2 85 86 1 2 85 86 83 84 167 168 83 84 167 168 1 1...

Page 368: ...5 14 Service Manual 5055 xxx Power source unit 1 board Power source unit 2 board CN106A CN01...

Page 369: ...Locations 5 15 5055 xxx High voltage power supply board Sensor board CN102 CN101 3 1 2 4 5 5 3 1 2 4...

Page 370: ...5 16 Service Manual 5055 xxx Expansion paper feeder controller board Duplex unit controller board Motor drive board...

Page 371: ...Locations 5 17 5055 xxx Size sensor board...

Page 372: ...er 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 me...

Page 373: ...Locations 5 19 5055 xxx Electrical parts layout...

Page 374: ...5 20 Service Manual 5055 xxx Driving parts layout...

Page 375: ...Locations 5 21 5055 xxx Finisher locations...

Page 376: ...xx Input Paper Guide Register Roller Accumulator Stapler Unit Register Idle Roller Straight Exit Idle Roller Invert Exit Idle Roller Invert Exit Roller Upper Tray Lower Tray Straight Exit Roller Paddl...

Page 377: ...home position sensor Finds home position for stapling H No staple sensor Detects staple empty I Finisher set switch Detects connection with printer J Staple cartridge set switch Detects staple cartri...

Page 378: ...5 24 Service Manual 5055 xxx C B A M Q E R N P F H J D G I K Punch c f d g a e b h Finisher Face Up Bin Tray1 Finisher Face Down Bin Tray2 L...

Page 379: ...ng and inverting b Tractor drive motor Tractor drive for paper feeding c Staple motor Stapling d Path select solenoid Path changing e Paper jogging motor Jogging of paper f Punch clutch Punching g Reg...

Page 380: ...5 26 Service Manual 5055 xxx Finisher electrical parts...

Page 381: ...ensor 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 sensor 21 Paper fu...

Page 382: ...5 28 Service Manual 5055 xxx...

Page 383: ...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 w...

Page 384: ...y 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 clean with a s...

Page 385: ...ajority 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 descr...

Page 386: ...7 2 Service Manual 5055 xxx Assembly 1 Covers 1 1 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 1...

Page 387: ...4 1 Magnet right side latch 8 56P9540 1 Cover waste toner bottle 9 56P9545 1 Label operator guide 10 56P9532 1 Cover assembly front C910 10 56P9970 1 Cover assembly front C912 11 56P9543 1 Magnet fron...

Page 388: ...7 4 Service Manual 5055 xxx Assembly 2 Covers 2 1...

Page 389: ...Parts catalog 7 5 5055 xxx Assembly 2 Covers 2 Index P N Units Description 2 1 56P9557 1 Exit assembly face up...

Page 390: ...7 6 Service Manual 5055 xxx Assembly 3 Covers 3 2 4 3 1 2 3...

Page 391: ...7 5055 xxx Assembly 3 Covers 3 Index P N Units Description 3 1 56P9566 1 Guide assembly face down 2 56P9575 4 Bushing face down pinch roller 3 56P9576 2 Pulley face down feed roller 4 56P9578 1 Belt f...

Page 392: ...7 8 Service Manual 5055 xxx Assembly 4 Covers 4 1...

Page 393: ...Parts catalog 7 9 5055 xxx Assembly 4 Covers 4 Index P N Units Description 4 1 56P9584 1 Guide assembly turn...

Page 394: ...7 10 Service Manual 5055 xxx Assembly 5 Covers 5 1...

Page 395: ...Parts catalog 7 11 5055 xxx Assembly 5 Covers 5 Index P N Units Description 5 1 56P9972 1 Feeder assembly multipurpose...

Page 396: ...7 12 Service Manual 5055 xxx Assembly 6 Upper unit...

Page 397: ...Cable assembly 30 pin PH controller S N XX 0XXXX 10 56P9717 1 Cable assembly 18 pin PH controller S N XX 0XXXX 11 56P9720 1 Cable assembly PH controller power 12 56P9637 1 Frame printhead controller...

Page 398: ...7 14 Service Manual 5055 xxx Assembly 6 continued Upper unit...

Page 399: ...6 56P9610 4 Rail right side 37 56P9593 4 Holder rear printhead 38 56P9619 1 Bracket rear upper 39 56P9622 1 Fan upper right 40 56P9623 1 Fan upper left 41 56P9621 1 Bracket fan holder NS 56P9629 1 Fra...

Page 400: ...7 16 Service Manual 5055 xxx Assembly 7 Base 1 3 11 7 13 18 5 16 9 2 10 6 17 4 12 8 14 19 20 23 26 24 22 25 1 14 4 15 21 28 27...

Page 401: ...11 56P9516 1 Spring left cassette guide 12 56P9518 1 Guide lower left cassette 13 56P9515 1 Guide upper cassette 14 56P9503 4 Foot rubber 15 56P9641 1 Actuator front cover open switch 16 56P9505 1 Rai...

Page 402: ...7 18 Service Manual 5055 xxx Assembly 8 Base 2 3 7 5 2 6 4 8 1 2 2 2...

Page 403: ...ption 8 1 56P9666 1 Support assembly upper unit 2 56P9667 4 Pin upper unit support 3 56P9668 1 Handle assembly lock 4 56P9669 1 Handle lock 5 56P9673 1 Cover electronic 6 56P9670 1 Shroud cable 7 56P9...

Page 404: ...7 20 Service Manual 5055 xxx Assembly 9 Base 3 1 3 11 7 14 5 15 2 10 6 4 13 8 16 9 10 12 11...

Page 405: ...6 1 Cable assembly belt thermistor 7 56P9694 1 Unit transfer belt 8 56P9674 1 Guide assembly fuser entrance 9 56P9676 1 Sensor density 10 56P9684 2 Frame assembly F1 sub 11 56P9685 2 Frame assembly F2...

Page 406: ...7 22 Service Manual 5055 xxx Assembly 10 Electrical...

Page 407: ...Cable asm conditioning printer controller 12 56P9742 1 Board heater drive 13 56P9741 4 Resistor conditioning 230 V only 14 56P9738 3 Cable assembly conditioning joint 230 V only 15 56P9943 1 Fuse the...

Page 408: ...7 24 Service Manual 5055 xxx Assembly 10 continued Electrical...

Page 409: ...upply 230 V 2 33 56P9715 1 Cable high voltage power supply board NS 11D0328 1 Power cord USA Canada APG LAD NS 11D0329 1 Power cord Peru NS 11D0330 1 Power cord Argentina NS 11D0331 1 Power cord Brazi...

Page 410: ...7 26 Service Manual 5055 xxx Assembly 11 Rip board 3 7 5 2 6 4 8 1...

Page 411: ...56P9977 1 Board RIP controller network C910 3 56P9973 1 Board RIP controller C912 3 56P9974 1 Board RIP controller network C912 4 56P9750 1 Fan RIP 5 56P9745 1 Box RIP 6 56P9719 1 Cable assembly 80 p...

Page 412: ...7 28 Service Manual 5055 xxx Assembly 12 Fuser unit 1...

Page 413: ...Parts catalog 7 29 5055 xxx Assembly 12 Fuser unit Index P N Units Description 12 1 56P9751 1 Fuser 120 V 1 56P9752 1 Fuser 230 V NS 56P9953 1 Parts packet...

Page 414: ...7 30 Service Manual 5055 xxx Assembly 13 Cassette 1 2 3...

Page 415: ...Parts catalog 7 31 5055 xxx Assembly 13 Cassette Index P N Units Description 13 1 56P9500 1 Cassette paper feed NS 56P9902 1 Cassette heavy media 2 56P9979 1 Guide stop 3 56P9980 1 Guard rack...

Page 416: ...7 32 Service Manual 5055 xxx Assembly 14 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 4 15 13 15 15 15...

Page 417: ...er front feeder 11 56P9504 1 Rail left side 12 56P9524 2 Screw slide rail 13 56P9503 6 Foot rubber 14 56P9505 1 Rail right side 15 11G0399 5 Plate ground 16 56P9766 1 Cover left side 17 56P9522 1 Boar...

Page 418: ...7 34 Service Manual 5055 xxx Assembly 15 Expansion feeder 2 3 11 7 13 18 5 16 9 15 2 6 17 4 12 8 14 19 1 20 23 21 31 24 29 22 34 25 33 2 3 4 5 5 5 6 6 6 7 7 7 10 27 26 28 29 29 30 29 32...

Page 419: ...assette guide 14 56P9518 1 Guide lower left cassette 15 56P9515 1 Guide upper cassette 16 11G0563 1 Interrupter photo 17 56P9786 1 Spring paper detection sensor 18 56P9784 1 Actuator paper detection 1...

Page 420: ...7 36 Service Manual 5055 xxx Assembly 15 continued Expansion feeder 2 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 2 3 4 5 5 5 6 6 6 7 7 7 8 27 27 27...

Page 421: ...Parts catalog 7 37 5055 xxx Assembly 15 continued Expansion feeder 2 Index P N Units Description NS 56P9956 1 Parts packet...

Page 422: ...7 38 Service Manual 5055 xxx Assembly 16 Duplex unit 1...

Page 423: ...9804 1 Board duplex interface 3 56P9799 1 Frame duplex 4 56P9800 2 Screw duplex mounting 5 56P9803 1 Motor duplex stepping 6 56P9525 1 Interrupter photo 7 56P9806 1 Cable assembly paper detection 8 56...

Page 424: ...7 40 Service Manual 5055 xxx Assembly 17 Duplex unit 2 3 5 2 4 1 5 11 7 13 18 16 9 15 10 6 17 12 8 14 19 20 23 21 26 24 22 27 25 6 16 18 20 20 25 25 26 26 5 5 12 7 11...

Page 425: ...errupter photo 11 56P9526 2 Spring feed roller 12 56P9815 6 Spring reed roller 13 56P9829 3 Solenoid assembly feed roller 14 56P9831 1 Cable assembly duplex drawer 15 56P9810 1 Roller follow up feed 1...

Page 426: ...7 42 Service Manual 5055 xxx Assembly 18 High capacity feeder 1 3 11 7 5 9 2 10 6 4 12 8 1...

Page 427: ...P9835 1 Magnet latch 3 56P9837 1 Cover upper 4 56P9834 1 Cover upper rear 5 56P9843 1 Cover lower rear 6 56P9839 1 Cover right 7 56P9833 1 Cover front 8 56P9836 1 Fence end 9 56P9940 1 Ring snap 10 56...

Page 428: ...7 44 Service Manual 5055 xxx Assembly 19 High capacity feeder 2 11 3 11 7 5 9 2 10 6 4 12 8 1...

Page 429: ...r feed 3 56P9844 1 Motor assembly transport 4 56P9941 1 Arm pick up 5 56P9501 1 Spring pressure 6 56P9528 1 Interrupter photo 7 56P9849 1 Roller manual feed pickup 8 56P9850 1 Roller manual feed 9 56P...

Page 430: ...7 46 Service Manual 5055 xxx Assembly 20 High capacity feeder 3 3 7 5 9 2 6 4 8 1 3...

Page 431: ...cription 20 1 56P9854 1 Sensor assembly photo 2 56P9855 1 Interrupter photo 3 56P9529 4 Caster HCF 4 56P9856 1 Spring tension 5 56P9857 1 Switch micro 6 56P9530 1 Switch push 7 56P9859 1 Connector inl...

Page 432: ...7 48 Service Manual 5055 xxx Assembly 21 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 433: ...78 1 Cable assembly sensor 9 56P9877 1 Cable assembly paper size sensor 10 56P9876 1 Cable assembly lift motor 11 56P9868 1 Board high capacity feed 12 56P9873 1 Cable assembly power supply out 13 56P...

Page 434: ...7 50 Service Manual 5055 xxx Assembly 22 High capacity feeder 5 3 7 5 2 6 4 8 1 2 2 2 1 4 6...

Page 435: ...P N Units Description 22 1 56P9883 2 Spring pressure 2 56P9528 4 Interrupter photo 3 56P9888 1 Bracket rear idler 4 56P9884 2 Belt timing 5 56P9886 1 Gear drive 6 56P9885 2 Pulley timing 7 56P9882 1 M...

Page 436: ...7 52 Service Manual 5055 xxx Assembly 23 High capacity feeder 6 3 7 5 2 6 4 8 1 7 3 2...

Page 437: ...cription 23 1 56P9892 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 438: ...7 54 Service Manual 5055 xxx Assembly 24 Finisher covers 3 11 7 13 5 9 15 2 10 6 4 12 8 14 1 2...

Page 439: ...Cover front 4 56P9359 1 Tray upper 5 56P9360 1 Tray lower 6 56P9347 1 Panel left upper 7 56P9352 1 Assembly lower left panel 8 56P9356 1 Cover rear 9 56P9350 1 Assembly staple cover 10 56P9366 1 Lever...

Page 440: ...7 56 Service Manual 5055 xxx Assembly 25 Finisher frame 3 11 7 13 18 5 16 9 15 2 10 6 17 4 12 8 14 1 20 23 24 29 1 31 32 25 27 26 30 19 21 28 13 21 22 33...

Page 441: ...to 14 56P9381 1 Frame B guide 15 56P9418 1 Guide stack 16 56P9399 2 Sensor photo 17 56P9382 1 Sensor photo 18 56P9383 1 Cushion 19 56P9309 1 Assembly exit guide inverter 20 56P9302 1 Assembly center g...

Page 442: ...7 58 Service Manual 5055 xxx Assembly 26 Finisher feed 1 3 11 7 5 10 6 4 1 5 7 7 7 7 7 7 18 16 9 15 2 17 13 8 14 19 20 23 33 28 21 31 26 24 34 29 22 32 27 25 30 12 12 2...

Page 443: ...g 11 56P9401 1 Roller I 12 56P9402 2 Bushing 13 56P9403 1 Spring A 14 56P9404 1 Spring F 15 56P9312 1 Roller F 16 56P9405 1 Roller G 17 56P9335 1 Clutch registration 18 56P9338 1 Pulley T56 19 56P9406...

Page 444: ...7 60 Service Manual 5055 xxx Assembly 26 continued Finisher feed 1 3 11 7 5 10 6 4 1 5 7 7 7 7 7 7 18 16 9 15 2 17 13 8 14 19 20 23 33 28 21 31 26 24 34 29 22 32 27 25 30 12 12 2...

Page 445: ...Parts catalog 7 61 5055 xxx Assembly 26 continued Finisher feed 1 Index P N Units Description 26 31 56P9316 1 Bushing 32 56P9415 1 Pulley gear Z36 T24 33 56P9317 1 Belt 34 56P9417 1 Flange...

Page 446: ...7 62 Service Manual 5055 xxx Assembly 27 Finisher feed 2 2 3 7 5 6 4 8 1 7...

Page 447: ...Index P N Units Description 27 1 56P9300 1 Assembly jogging unit 2 56P9422 1 Pin N 3 56P9423 1 Pulley Z19 Z20 4 56P9417 1 Flange 5 56P9333 1 Belt timing 60S3M408 6 56P9329 1 Assembly tractor motor 7...

Page 448: ...7 64 Service Manual 5055 xxx Assembly 28 Finisher elevator 11 13 18 5 16 9 15 2 10 17 4 12 8 14 19 1 20 23 21 22 17 15 11 9 10 7 6 4 7 6 7 3...

Page 449: ...n O 7 56P9453 4 Roller C 8 56P9304 1 Assembly hook front 9 56P9332 2 Spring C 10 56P9331 2 Wire 11 56P9455 2 Bracket 12 56P9456 1 Gear Z46 Z33 13 56P9457 1 Gear Z90 Z14 14 56P9458 1 Gear Z25 Z20 15 56...

Page 450: ...7 66 Service Manual 5055 xxx Assembly 29 Finisher electronics 3 5 2 4 1 11 7 13 9 15 10 6 12 8 14 16...

Page 451: ...itch 5 56P9358 1 Cord Y power 5 56P9368 1 Cord Y power 230 V only 6 56P9342 1 Assembly bridge 7 56P9326 1 Cable DC power supply 8 56P9349 1 Board finisher control 9 56P9428 1 Cable 10 56P9410 1 Cable...

Page 452: ...7 68 Service Manual 5055 xxx Assembly 30 Finisher docking 1 3 2 4 1 1...

Page 453: ...Parts catalog 7 69 5055 xxx Assembly 30 Finisher docking 1 Index P N Units Description 30 1 56P9467 2 Screw thumb 2 56P9468 1 Spring 3 56P9469 1 Bracket 4 56P9470 1 Switch set...

Page 454: ...7 70 Service Manual 5055 xxx Assembly 31 Finisher docking 2 3 7 5 2 6 4 1 1 1 1 3 3 3 8 8...

Page 455: ...mbly 31 Finisher docking 2 Index P N Units Description 31 1 56P9472 2 Screw lock 2 56P9473 1 Stud lock 3 56P9474 4 Roller 4 56P9475 2 Knob caster 5 56P9476 2 Stop caster 6 56P9477 2 Housing caster 7 5...

Page 456: ...allel 1284 A C interface NS 99A0560 1 Card Tri Port adapter NS 99A0424 1 Card infrared adapter NS 99A0545 1 Card external serial adapter NS 56P0159 1 Card Coax Twinax adapter for SCS NS 56P0162 1 Adap...

Page 457: ...drive NS 56P9936 1 Simplified Chinese font kit NS 56P9935 1 Traditional Chinese font kit NS 56P9975 1 Japanese font kit NS 7370516 1 Kit printer relocation NS 7370567 1 Kit duplex relocation NS 737056...

Page 458: ...containing 50 Bind S tight screws 3x6 Zn 3R 50 Bind P tight screws 2x10 Zn 3K 50 Bind P tight screws 3x4 Zn 3K 50 Bind P tight screws 3x6 Zn 3K 50 Bind P tight screws 3x8 Zn 3K 50 Bind P tight screws...

Page 459: ...s packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind P tight screws 3x6 Zn 3K 50 Bind P tight screws 3x8 Zn 3K 50 Bind screws M3x4 Zn 3K 50 Bind screws M3x6 Zn 3K 50 Bind screws M3x8 Zn 3K 50 P...

Page 460: ...washers M3x30 Zn 3K 50 Screws with washers M4x8 Zn 3K 50 Screws with washers M4x12 Zn 3K 50 Screws with washers M3x6 Ni 3 BS 50 Screws with washers M4x8 Ni 3 BS 50 Screws with spring washers M3x8 Ni 3...

Page 461: ...with washers M3x6 Ni 3 BS 50 E rings ES 4 ACP 50 E rings ES 5 ACP 50 C rings C 21 ACP NS 56P9954 1 Parts packet including 50 Bind P tight screws 3x6 Zn 3K 50 Bind P tight screws 3x8 Zn 3K 50 Bind scr...

Page 462: ...CP NS 56P9957 Parts packet including 50 E rings ES 3 ACP 50 E rings ES 4 ACP 50 E rings ES 6 ACP 50 R screws M3x6 50 R screws M3x8 50 R screws M4x6 50 Pans S tight screws M3x6 50 RP tight screws M3x8...

Page 463: ...CP 50 RS set screw cp M3x3 Zn 3K 50 RS tight screws M4x6 50 RS tight screws M4x8 NS 56P9960 1 Parts packet including 50 Bind S tight screws 3x10 Zn 3R 50 E rings ES 4 ACP 50 RS tight screws M3x24 50 R...

Page 464: ...ACP 50 Plain washers M4 Zn 3R 50 RS tight screws M4x6 NS 56P9963 1 Parts packet including 50 Bind S tight screws 3x8 Zn 3R 50 Bind S tight screws 4x6 Zn 3R 50 Pan screws M4x20 Zn 3R 50 E rings ES 6 AC...

Page 465: ...embly 33 Finisher parts packet P N 56P9480 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 Sc...

Page 466: ...7 82 Service Manual 5055 xxx Plain Washer Tapping Screw Screw...

Page 467: ...unter 3 29 setting page count 3 29 covers front left removal 4 5 front removal 4 5 left side removal 4 7 locations 5 1 operator panel removal 4 34 parts catalog 7 2 7 4 7 6 7 8 7 10 rear removal 4 6 r...

Page 468: ...installation 3 73 inverted paper path 3 67 jogging 3 70 lowering and raising 3 82 offsetting 3 70 parts catalog covers 7 54 docking 7 68 7 70 electronics 7 66 elevator 7 64 feed 1 7 58 feed 2 7 62 fr...

Page 469: ...6 covers 5 1 high capacity feeder 5 18 major parts 5 2 sensor and switches 5 4 lubricants 6 2 M maintenance approach 1 29 cleaning 1 29 6 2 dip switch specifications 3 60 inspection 1 29 lubricants 6...

Page 470: ...unit 7 12 parts packets 7 74 7 81 parts return 1 30 periodic maintenance 6 2 permanent page count 3 29 POST 3 1 power and electrical specifications 1 26 power on self test sequence 3 1 preventive main...

Page 471: ...4 106 tractor drive motor assembly 4 108 front cover open switch actuator 4 20 full sensor 4 18 fuser 4 21 gear cover 4 22 high voltage power supply board 4 23 high capacity feeder call roller 4 82 co...

Page 472: ...checks 2 68 drive 1 DC motor 2 68 drive 2 stepper motor 2 68 duplex 2 69 expansion paper feed 2 69 face down stacker full 2 70 face up exit assembly 2 82 high capacity feeder HCF 2 70 marks on paper 2...

Page 473: ...troller 2 23 983 black gear sensor 2 24 984 yellow gear sensor 2 24 985 transfer belt thermistor 2 25 986 transparency OHP sensor 2 25 993 CPU 2 26 994 density sensor 2 27 995 finisher main feed motor...

Page 474: ...eder 3 43 fuser unit 3 40 high capacity feeder HCF 3 52 maintenance mode 3 60 multipurpose feeding 3 38 paper feeding 3 37 paper feeding fusing 3 35 processes 3 33 processes and configuration 3 33 reg...

Page 475: ...ica 7 25 11G0199 Guide wire 7 33 11G0219 Interrupter photo 7 35 11G0243 Interrupter photo 7 17 7 23 11G0283 Pad fanning 7 21 11G0291 Clutch paper feed 7 35 11G0297 Gear paper carrying 7 35 11G0399 Pla...

Page 476: ...7 57 56P9314 Unit 4 hole punch non U S 7 57 56P9315 Assembly punch drive 7 59 56P9316 Bushing 7 61 56P9317 Belt 7 61 56P9318 Spring B 7 59 56P9319 Assembly exit guide straight 7 57 56P9321 Spring I 7...

Page 477: ...ler patting 7 59 56P9363 Stapler 7 55 56P9364 Cover staple B 7 55 56P9365 Cover staple A 7 55 56P9366 Lever B 7 55 56P9367 Cartridge staple 7 55 56P9368 Cord Y power 230 V only 7 67 56P9369 Assembly s...

Page 478: ...56P9408 Knob 7 59 56P9409 Cable 7 67 56P9410 Cable 7 67 56P9411 Pulley 7 59 56P9412 Spacer 7 59 56P9413 Assembly motor bracket 7 59 56P9414 Pulley 7 59 56P9415 Pulley gear Z36 T24 7 61 56P9417 Flange...

Page 479: ...79 Cap 7 71 56P9480 Parts packet finisher 7 81 56P9482 Shaft A 7 65 56P9500 Cassette paper feed 7 31 56P9501 Spring pressure 7 45 56P9501 Spring pressure pickup 7 49 56P9502 Sensor turn guide door 7 2...

Page 480: ...push 7 47 7 49 56P9531 Tray assembly exit 7 3 56P9532 Cover assembly front C910 7 3 56P9533 Cover assembly right side 7 3 56P9534 Magnet right side latch 7 3 56P9535 Cover solenoid 7 3 56P9536 Cover...

Page 481: ...607 Cable assembly LFG 7 15 56P9608 Holder front HSP 7 13 56P9609 Spring printhead 7 13 56P9610 Rail right side 7 15 56P9611 Holder front printhead 7 13 56P9612 Bracket front upper 7 13 56P9613 Rod in...

Page 482: ...able 7 19 56P9672 Guide cable 7 19 56P9673 Cover electronic 7 19 56P9674 Guide assembly fuser entrance 7 21 56P9676 Sensor density 7 21 56P9680 Frame assembly registration 7 21 56P9681 Clutch registra...

Page 483: ...3 56P9721 Cable assembly drum eraser 7 25 56P9722 Power supply 120 V 1 7 23 56P9723 Power supply 230 V 1 7 23 56P9724 Power supply 120 V 2 7 25 56P9725 Power supply 230 V 2 7 25 56P9726 Cable assembly...

Page 484: ...7 35 56P9782 Spring solenoid 7 35 56P9783 Solenoid feeder 7 35 56P9784 Actuator paper detection 7 35 56P9785 Cover paper present sensor 7 35 56P9786 Spring paper detection sensor 7 35 56P9787 Cable p...

Page 485: ...drawer 7 41 56P9826 Guide front side 7 41 56P9827 Guide rear side 7 41 56P9828 Motor assembly paper guide 7 41 56P9829 Solenoid assembly feed roller 7 41 56P9830 Solenoid assembly paper re feed 7 41...

Page 486: ...9 56P9871 Cable assembly I F 7 49 56P9872 Cable assembly power supply in 7 49 56P9873 Cable assembly power supply out 7 49 56P9874 Cable assembly power supply 7 49 56P9875 Cable assembly safety switch...

Page 487: ...ash 7 72 56P9932 Hard Disk Lexmark Forms 7 73 56P9934 Card Token Ring 7 72 56P9935 Traditional Chinese font kit 7 73 56P9936 Simplified Chinese font kit 7 73 56P9940 Ring snap 7 43 56P9941 Arm pick up...

Page 488: ...formatted 7 72 56P9985 Printhead LED K black S N XX 1XXXX 7 15 56P9986 Printhead LED Y M C color S N XX 1XXXX 7 15 56P9987 Board printhead controller S N XX 1XXXX 7 13 56P9988 Post mini S N XX 1XXXX...

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Page 490: ......

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Page 492: ...4 24 CN15 24 CN13 24 Y head CN20 24 CN18 CN19 24 CN17 24 K head CN CN CN CN Print head controller DC Motor Motor driver asm Fuser Sub frame Residual toner kit presencedetection Transparency sensor Tra...

Page 493: ......

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Lexmark C91 Series, Service Manual

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Summary of Contents for C91 Series

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