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Lexmark C910, C912 5055-XXX Service Manual

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4. rp er ox E ris mm CNO6 5 CN20 CN07 CN11 CN16 9 ENOS 4 CNO me E CN c 2 2222 E ECNIO mn SS CN04 0 o LJ CN19 CN15 gt CN13 5 12 Service Manual 5055 xxx RIP board Locations 5 13 5055 xxx Power source unit 1 board mA CN106A Power source unit 2 board CN04 CN106 CN02 co o CN103 CN105 CN102 CN104 5 14 Service Manual 5055 xxx High voltage power supply board CN101 CN102 TII Sensor board CN406 1 CN409 CN408 CN407 Locations 5 15 5055 xxx Expansion paper feeder controller boa
5. FENCES ES BL PJ10 3 PJ8 3 GND 1 2 Signal 1 DC5V Paper Upper Level Sensor 1 ap 10 Signal DC5V Tractor Motor 7 M4 5 lt gt Invert Path Sensor eje Nia em I a N G ON oo PC4 PC6 3 END END 2 Signal igna SL1 1 peasy DC5V DC24V med MER Belt Home Positio Jogging Home Position Sensor Jogging Motor B Jogging Motor A_ Gate Solenoid Jogging PJ7 PC7 PJ 5 3 GND 2 Signal 2 Signal 1 DC5V 1 DC5V Paper Detecting Sensor Tray Upper Limit Sensor M2 PC5 o 23 CN11P OCN11 CN13P CN13 PJ11 PC11 3 GND 2 Signal 1
6. x Temperature 3 42 Service Manual 5055 xxx Belt up down In monochrome printing switching to color printing is not required To avoid unnecessary wear of the photosensitive drum by the cleaning blade this operation is stopped with the electromagnetic clutch in drive 1 The transfer belt is lowered so as not to touch the photosensitive drum during color printing The transfer belt moves up and down with the switching shaft cam by the electromagnetic clutch in drive 1 The belt position is used to detect the cam position with the photo sensor using the fan shaped light blocking plate attached to the switching shaft Printing with the transfer belt lowered is called monochrome mode and color printing is called color mode N Electromagnetic Clutch BUD Expansion paper feeder The optional expansion paper feeder can be installed at the lower part of the main unit Including the main unit up to five layers of cassettes can be used for cassette paper feeding Diagnostic aids 3 43 5055 xxx Duplex unit A duplex unit can be optionally installed in the main unit allowing two sided printing Selecting Paper feeding Registration Transfer Separation Fusing or Face Down paper discharging with the pulse motor in the duplex unit feeding is stopped before the paper is delivered Paper delivery
7. 7 25 1100331 Power Brazil 7 25 1100332 Power cord Chile 7 25 1100333 Power Denmark 7 25 11D0334 Power cord Belgium Europe England France Germany so der se ae ed ee 7 25 1100335 Power cord Italy 7 25 11D0336 Power cord Swiss French German Italian 7 25 1100337 Power cord UK Israel South Africa 7 25 11G0199 Guide wire L u eee 7 33 1160219 Interrupter photo 7 35 1160243 Interrupter photo 7 17 7 23 1160283 Pad fanning 7 21 1160291 Clutch paper feed 7 35 11000297 Gear paper carrying 7 35 11G0399 Plate ground 7 33 11G0422 Gear feeder B 7 33 11G0423 Gear feeder 7 33 11G0563 Interrupter photo 7 35 12G1695 Card Ethernet 10 100 7 72 1261696 Card Ethernet 10BaseT 2 7 72 12G6509 Card SDRAM DIMM 7 72 1267360 Board operator 7 3 13A0296 Cable Twinax 7 72 13A0297 Cable Coax
8. 7 43 56P9834 Cover upper rear 7 43 56P9835 Magnet latch 7 43 56P9836 Fence end 7 43 56P9837 Cover upper 7 43 56P9838 Catch door 7 43 56P9839 Cover right 7 43 56P9840 Lever vertical transport 7 43 56P9841 Cover assembly upper 7 43 56P9842 Spring tension 7 43 56P9843 Cover lower rear 7 43 56P9844 Motor assembly transport 7 45 56P9845 Sensor assembly paper feed 7 45 56P9846 Solenoid assembly paper pickup 7 45 56P9847 Spring compression 7 45 56P9848 Clutch paper feed 7 45 56P9849 Roller manual feed pickup 7 45 56P9850 Roller manual feed 7 45 56P9851 Roller manual feed separate 7 45 56P9852 Limiter torque 7 45 56P9853 Screw shoulder 7 47 56P9854 Sensor assembly photo 7 47 56P9855 Interrupter photo 7 47 56P9856 Spring tension 7 47 56P9857 Switch micro
9. 7 51 56P9885 Pulley timing 7 51 56P9886 Gear drive 7 51 56P9887 Bracket front idler 7 51 56P9888 Bracket rear idler 7 51 56P9889 Pad friction 7 53 56P9890 Plate paper adhesion 7 53 56P9891 Knob 7 53 56P9892 Plate upper side fence 7 53 56P9893 Knob stopper 7 53 56P9894 Fence assembly rear side 7 53 56P9902 Cassette heavy media 7 31 56P9905 Kit operator panel overlay 7 3 56P9910 Card assembly 128MB SDRAM memory 7 72 56P9911 Card assembly 256MB SDRAM memory 7 72 56P9912 Card assembly 4MB Flash DIMM memory 7 72 56P9913 Card assembly 8MB Flash DIMM memory 7 72 56P9914 Card assembly 16MB Flash DIMM memory 7 72 56P9915 Fence assembly front side 7 53 56P9916 Gard riser cuisse ee 7 27 56P9923 Card ImageQuick C910 7 72 56P9925 Card PRESCRIBE 7 72 56P9926 Software Optra Forms 7 72 56P9927 Software Optra Forms Director 7 72 56P9928 DIMM Lexmark Forms 4MB Flash
10. 7 72 40X2776 Stop Right ees 7 19 40X2777 Guide lock 7 19 40X2778 Stop left 7 19 56P0159 Card Coax Twinax adapter for SCS 7 72 56P0161 Card RS 232C serial parallel 1284 A C interface 7 72 56P0162 Adapter parallel 1284 C B 7 72 56P0598 Card CGM 7 72 56P1121 Card bar code C910 7 72 56P1204 IPDS SCS TNe C910 7 72 56P1762 IPDS SCS TNe 912 7 72 Part number index 1 9 5055 xxx 56P4557 Cover black photo developer 7 19 56P9300 Assembly jogging unit 7 63 56P9301 Assembly guide stack 7 63 56P9302 Assembly center guide 7 57 56P9303 Supply power 7 67 56P9304 Assembly hook front 7 65 56P9305 Assembly tension D 7 59 56P9306 Assembly upper limit sensor 7 67 56P9307 Assembly hook rear 7 65 56P9308 Assembly elevator motor 7 65 56P9309 Assembly exit guide 7 57 56P9310 Gale zi tregerni s ue aar 7 59 56P9311 Bushing 7 59 7 65 56P93
11. 2 74 Paper exit face up service check 2 82 Paper skew service check 2 83 Paper tray missing service 2 83 Photodeveloper missing service check 2 84 Power supply service check 2 85 210 Staple jam service 2 86 Transfer belt up down service check 2 87 Image quality troubleshooting 2 88 Print quality problems rtm 2 88 Options service checK 2 98 iV Service Manual 5055 xxx Diagnostic aids 3 1 Power On Self Test sequence 3 1 Using the operator 3 2 Operator panel uU nx Q o EE DNE EE ITE ES ED 3 3 Printing the menu settings sire RR 9 ru 3 4 perator menu disabled csse bu eo E EROUDEEE ERE 3 4 Menu OVGIVIOW siccum 3 rur CES TIE Rest 3 4 Beene Quee da xg 3 6 Adjustment example 52233 3 8 Fi StS 3 10 Hardware 651 e wa ex RR 3 12 High capacity feeder 3 18 Se EE 24 3 20 6918 musa demi 3 23
12. 7 67 56P9369 Assembly spring plate C 7 57 56P9370 Frame guide 7 57 56P9374 Sptlng diese REED aer 7 57 56P9372 Brush static discharge 7 57 56P9373 Screw MA papas eens 7 57 56P9374 Frame C guide 7 57 56P9375 Shaft ioci au hin hA DIS LE San 7 57 56P9376 Bushing 7 57 56P9377 Roller D Z liap ke e ERE TR a 7 57 56P9378 Plate E spring 7 57 56P9380 Sensor photo 7 57 56P9381 Frame B guide 7 57 56P9382 Sensor esee 7 65 56P9382 Sensor photo 7 57 56P9383 Cushion llle 7 57 56P9384 Plate B spring 7 57 B6P9386 Spring 44552425 mibi Eus same safe 7 57 56P9387 Handle jam 7 57 56P9388 Sensor 1 photo 7 57 56P9389 Bracket 7 57 56P9390 Plate 7 57 56P9393 Plate guide holder 7 59 56P9394 Handle uuu sss ubah eee 7 57 56P9395 Assembly guide plate 7 59 Part number index I 11 5055 xxx 56P9396 Springs Hi l sys bat b e Nam ei
13. oaa 7 47 56P9858 Connector 7 47 56P9859 Connector 7 47 56P9861 Roller eee 7 49 56P9863 Switch HCF push 7 49 56P9864 Switch Micro u ee ee 7 49 56P9865 Cable assembly HCF motor 7 49 56P9866 Cable assembly paper feed sensor 7 49 56P9867 Cable assembly drawer ground 7 49 Part number index I 19 5055 xxx 56P9868 Board high capacity feed 7 49 56P9869 Power supply HCF 7 49 56P9870 Converter DC DC 7 49 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 7 49 56P9876 Cable assembly lift motor 7 49 56P9877 Cable assembly paper size sensor 7 49 56P9878 Cable assembly sensor 7 49 56P9879 Cable paper volume 7 49 56P9880 Cable up down switch 7 49 56P9882 Motor HCF DC 7 51 56P9883 Spring pressure 7 51 56P9884 Belt timing
14. 7 17 56P9513 Bushing carrying 7 35 56P9514 Roller noise reduction 7 35 56P9515 Guide upper cassette 7 17 7 35 56P9516 Spring left cassette guide 7 17 7 35 56P9517 Spring right cassette guide 7 17 7 35 56P9518 Guide lower left cassette 7 17 7 35 56P9519 Guide lower right cassette 7 17 7 35 56P9520 Handle waste bottle cam 7 17 56P9521 Lever size Sensor 7 17 7 33 56P9522 Board size sensor 7 17 7 33 Part number index I 13 5055 xxx 56P9523 Cable assembly size sensor 7 17 56P9524 Screw slide rail 7 17 7 33 56P9525 Interrupter assembly photo 7 41 56P9525 Interrupter photo 7 39 56P9526 Spring feed 7 41 56P9527 Gear idler 7 41 56P9528 Interrupter photo 7 45 7 51 7 53 56P9529 Caster HOF 7 47 56P9530 Switch 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 latc
15. 3 46 High capacity feeder HGF 3 52 Maintenance Mod 6 hh hn 3 60 sees 3 61 5055 xxx Finisher installation 3 73 Attaching the docking plate and guide rail 3 73 Combining the finisher and stand 3 75 Altachigi the DIAS sw esed kg ug 3 79 Aligning the finisher and printer 3 80 Adj suno ie Wheels ERE Endo eria 3 88 Altachirig the Cable8 s 3 90 Hols punen adjustMonth 3 94 Repair information s men 4 1 Service precautions a s a 4 1 Handling printed circuit 4 1 Adjusimenis 22 224 9 9 x99 m x REY CER TRE EE 4 3 High capacity paper feed timing belt adjustment 4 3 GEER PEPE EP ad edge e RP E 4 4 COVED top lemovali uy 4 4 Cover frontiremoval io sies rhe max rr er ER RE RR 4 5 Cover ontleent removal i4 ia xw dei se Sus UE eoe cx RR OR 4 5 Covor roar e usss 4 6 Cover solenoid remoVal a ssa xxr m E E RERO OR m 4 6 Cover left side removal 4 7 Cover right side rtm mmn 4 8 Cover RIP Board removal siisi 4 n
16. Parts packet Parts catalog 7 19 5055 xxx Assembly 9 Base 3 7 20 Service Manual 5055 xxx Assembly 9 Base 3 Index P N Units Description 9 56P9971 1 Frame assembly MPF 2 11G0283 1 Pad fanning 3 56P9681 1 Clutch registration 4 56P9680 1 Frame assembly registration 5 56P9682 1 Frame assembly carrying 6 56P9696 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 sub 12 56P9686 1 Rod lock 13 56P9687 1 Cover gear 14 56P9693 1 Stopper clutch 15 56P9502 1 Sensor turn guide door 16 56P9695 1 Cable turn guide door sensor NS 56P9697 1 Bushing NS 56P9692 1 Cable assembly reg MPF sensor NS 56P9950 1 Parts packet Parts catalog 7 21 5055 xxx Assembly 10 Electrical 7 22 Service Manual 5055 xxx Assembly 10 Electrical Index P N Units Description 10 4 56P9705 1 Cable assembly feeder 2 56P9704 1 Cable assembly paper remaining sensor 3 56P9700 1 Solenoid assembly paper feed temperature humidity sensor and paper remaining sensor included 4 11G0243 Interrupter photo 5 56P9702 Cable belt up down sensor 6 56P9701 Board sensor 7 56P9703 Cable assembly sensor board 8 56P9707 Switch power 9 56P9706 10 56P9709 10 56P9710 11 56P9739 12 56P9742 1
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18. 7 72 56P9929 DIMM Lexmark Forms 8MB Flash 7 72 56P9930 DIMM Lexmark Forms 16MB Flash 7 72 56P9932 Hard Disk Lexmark Forms 7 73 l 20 Service Manual 5055 xxx 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 7 45 56P9942 Mounting Kit hard drive 7 73 56P9943 Fuse thermal 230 V only 7 23 56P9945 Parts packet 7 3 7 74 56P9946 Parts packet 7 74 56P9947 Parts packet 7 15 7 74 56P9948 Parts packet 7 17 7 75 56P9949 Parts packet 7 19 7 75 56P9950 Parts packet 7 21 7 75 56P9951 Parts packet 7 25 7 76 56P9952 Parts packet 7 27 7 76 56P9953 Parts packet 7 29 7 77 56P9954 Parts packet 7 77 56P9955 Parts packet 7 33 7 77 56P9956 Parts packet 7 37 7 78 56P9957 Parts packet 7 41 7 78 56P9958 Parts pac
19. 0 W Always active and drawing voltage Electrical specifications Low voltage models e 110 to 127 V at 50 to 60 hertz Hz nominal 99 to 135 V extreme High voltage models e 220 to 240 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 1 26 Service Manual Operating clearances 5055 xxx 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 C91 x n 6 in 152 mm Clearance on right side should side be 30 in 762 mm with the C91xdn 131 330 mm high capacity feeder attached Clearance on the right side should be 13 in 330 mm with the duplex attached but not the high capacity feeder Front 26 in 660 mm Rear 5 in 127 mm Top 9 in 229 mm With the high capacity feeder or finisher attached the top clearance needs to be 43 8 in 1 113 mm Environment Printer temperature and humidity Operating Temperature 60 to 90 F 15 6 to 32 3 C Relative humidity 8 to 8096 Maximum wet bulb temperature 73 F 22 8 C Altitude 10 000 ft 0 to 3 048 meters Atmospheric pressure 74 6 kPa Power Off Temperature 50 to 110 F 10 to 43 3 C Relative humidity 8 to 8096 e Maximum wet bulb temperature 80 1 F 26 7 C Altitude 10 000 ft 0 to 3 048 meters
20. 56P9972 1 Feeder assembly multipurpose Parts catalog 7 11 5055 xxx Assembly 6 Upper unit OTER 8 AG 7 12 Service Manual 5055 xxx Assembly 6 Upper unit Index P N Units Description 6A 56P9591 1 Frame upper 2A 56P9987 1 Board printhead controller S N XX 1XXXX 2B 56P9620 1 Board printhead controller S N XX OXXXX 3 56P9638 6 Holder cable 4 56P9600 2 Cable assembly K13 5 56P9601 2 Cable assembly K24 6 56P9602 6 Cable assembly CL13 7 56P9603 6 Cable assembly CL24 8 56P9716 1 Cable assembly 8 pin PH controller 1 9A 56P9991 Cable assembly 48 pin PH controller S N XX 1XXXX 9B 56P9718 1 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 Cable assembly PH controller power 12 56P9637 Frame printhead controller 13 56P9625 Hook right link 14 56P9626 Cover hook 15 56P9628 Pivot color link 16 56P9614 Spring return 17 56P9618 Hook right 18 56P9615 Hook middle 19 56P9612 Bracket front upper 20 56P9617 Hook left 21 56P9613 22 56P9624 23 56P9627 24 56P9616 25 56P9630 26 56P9611 27 56P9608 28 56P9609 29 56P9592 Rod interlocking Link frame Bearing roller Handle upper opening Hook left link Holder front printhead Holder front HSP Spring printhead Rail left side BR 0 amp BR oA po wp s Ba ae oa Ap a
21. Discharge Brush Straight paper exit roller removal 1 Remove the external covers 2 Remove the finisher control board 3 Remove the upper left panel 4 Remove the front straight paper exit roller bushing Bushing 5 Remove the belt and pulley Repair information 4 103 5055 xxx 6 Remove the rear straight paper exit roller E ring and bushing Pulley E Ring 7 Remove the straight paper exit roller Exit Roller 4 104 Service Manual 5055 xxx Timing belts 1 and 2 removal Remove the finisher control board mounting bracket Remove the feed motor mounting bracket Remove the tension bracket mounting screw Remove the tension spring Remove the timing belt 1 P Screw Tension Bracket Tension Spring Timing Belt 1 6 Loosen the tension bracket mounting screw for timing belt 2 7 Remove the timing belt 2 Mounting Screw Timing Belt 2 Repair information 4 105 5055 xxx Tractor belt removal Remove the external covers Remove the lower left panel Remove the cable connector of the left panel Remove the belt motor unit Remove the four lower guide support plate screws for the invert paper exit O Spring 4 106 Service Manual 5055 xxx
22. 58 Too Many Trays Attached Too many trays are installed Turn off and unplug the printer Remove the excess trays Plug the printer in and turn it on 61 Defective Disk The printer detects defective hard disk Press Go to clear the message and continue printing Install a different hard disk before you perform any operations that require one 62 Disk Full Insufficient memory on the hard disk Press Go to clear the message and continue printing Delete fonts macros and other data stored on the hard disk Diagnostic information 2 47 5055 xxx Message Meaning Action 63 The printer detects an Press Go to clear the Unformatted unformatted hard disk message and continue Disk printing Format the disk before performing disk operations Replace the hard disk 64 The printer detects an Press Go to clear the Unsupported unsupported disk format message Disk Format Format the disk 80 Belt The transfer belt has Replace the transfer belt Exhausted reached end of life 80 Belt Fuser The transfer belt and fuser Replace the transfer belt and Exhausted have reached end of life fuser 80 Belt Fuser The transfer belt and fuser Press Go to clear the Life Warning are nearing end of life message and continue printing The supplies message is displayed until you replace the transfer belt and fuser 80 Belt Life The tra
23. AUR AC d dame 1 5 Duty c ae 1 5 Printer memofy cue sme asas RE 1 6 Resident fonts lisa neret RR hmm vas asa sas 1 7 Paper and media specifications 1 8 Input and output configurations 1 8 Media size supported xx RR mame oe 1 10 Input media types and weights 1 15 Output media types and weights 1 16 Input capacity by media and source 1 18 Output capacity by media and source 1 19 Media guideliniaS 52 2 2 cei erras 1 20 Print alea sess usa M E RR AUN 1 21 Options and features 1 22 ee GN iio ioa caer 1 23 Standa seas C PE SERE 1 23 Optional internal local connections 1 23 Network BolnectiBS aaen E cadens 1 24 PE re Ge RER EE EE 1 25 ERE WEG annum ewes 1 25 Power and electrical specifications 1 26 Powel TeSllreitislllS occa epu iir xcu riy x md or wd y wd 1 26 Electrical 44448644 441435 643484848814 1 26 5055 xxx Operating Clearances 2 52 54 844 44454448414444448848 1 27 Environment 1 27 Printer temperature and humidity
24. Diagnostic aids 3 63 5055 xxx Electrical parts function Finisher Set Switch detects the connection with the printer Staple Cartridge Set Switch detects when the staple cartridge is open Staple Existence Sensor detects when the stapler is empty Staple Home Position Sensor locates home position for stapling Paper Register Sensor detects when paper enters into the finisher detects paper jams and triggers the punch Paper Exit Sensor Upper Tray Letter Invert Path Sensor A4 detects when paper feeds into the lower tray the end of 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 the lower tray is at the highest position Jogging Home Position Sensor locates home position for the jogging bar Paper Detecting Sensor detects when the paper is at the correct position for stapling Paper Full Sensor A detects when there is a full stack of paper on the lower tray Paper Upper Level Sensor B Locates the top of the stacked paper on lower tray Also detects when paper is removed from stacked papers on the lower tray while stacking Elevator Lower Limit Sensor detects when the lower tray is at the lowest position 3 64 Service Manual 5055 xxx Paper feed mechanism Paper is transported after it is detected at paper register sensor by drive gears and dr
25. at the tractor motor and PJ4 on the finisher control board securely connected Go to step 3 Securely connect the connectors Make sure the 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 Replace the tractor motor assembly Did this resolve the problem Problem solved Replace the finisher control board Disconnect CN3 and PJ4 on the finisher control board and perform a continuity check on all positions Is there continuity on all positions Go to step 6 Replace the cable Check for 24 V dc between pins 1 and 2 of PJ3 on the finisher control board Is 24 V dc present Replace the finisher control board Replace the power supply Diagnostic information 2 31 5055 xxx 998 Tray Elevator Motor Error Step Questions actions Yes No Are the connectors CN4 at the tray elevator motor and connector PJ4 on the finisher control board properly connected Go to step 2 Properly connect the connectors Make sure that the finisher Set switch is activated Power the printer off Measure for approximately 24 V dc 10 between pins 1 and 2 of connector CN4 at the tray elevator 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
26. 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 paper present sensor 7 35 56P9788 Guide HCF 7 35 56P9789 Guide turn unusual ees 7 35 56P9790 Roller paper carrying 7 35 56P9791 Spring paper carrying 7 35 56P9792 Holder roller 7 35 56P9793 Spring left turn guide 7 35 56P9794 Spring right turn guide 7 35 56P9795 Cable paper present sensor 7 35 56P9796 Roller assembly carrying 7 35 56P9797 Cover gear 7 35 56P9798 Duplex assembly 7 39 56P9799 Frame duplex 7 39 56P9800 Screw duplex mounting 7 39 56P9803 Motor duplex stepping 7 39 56P9804 Board duplex interface 7 39 56P9805 Cable assembly duplex connection 7 39 56P9806 Cable assembly paper detection 7 39 56P9807 Cable assembly duplex interface 7 39 56P9808 Interrupter photo 7
27. 933 Black Printhead Error 5055 xxx Step Questions actions Yes No 1 Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables printhead and the printhead number controller board as well as go the cables between the to step 2 printhead controller board and the printer controller If you have a board are properly printer with serial connected number XX AXXXX and Are they properly above go to connected step 4 2 For serial number Replace the Replace the Is fuse 4 on printhead control printhead the printhead control board board cables controller board open K13 K24 and LED printhead 3 Did replacement of the Problem solved Replace the printhead controller board printer controller correct the problem board 4 For serial number Problem solved Replace the XX AXXXX and above printhead Replace the LED printhead controller board for the affected color and go to step 5 Did this resolve the problem 5 Did replacement of the Problem solved Replace the printhead controller board printer controller resolve the problem board Diagnostic information 2 13 5055 xxx 934 Color Drum Sensor Error 934 Service Drum Sensor Step Questions actions Yes No 1 Is connector CN28 Go to step 2 Plug the connected properly connector in sec
28. Step Questions actions Yes No 1 Is 24 V present between Replace the Replace the pins 1 and 3 on connectors failing fan printer controller CN17 upper left fan and board CN5 upper right fan on the printer controller board 919 Power Supply Fan Error Step Questions actions Yes No 1 Is 24 V present between Replace the Replace the printer controller board 92x Service Fuser Error 920 Fuser Error Fuser Heater Trouble 2 fix the problem Step Questions actions Yes No 1 Replace the fuser Did this Problem solved Return the fuser fix the problem replace the power supply 2 and go to step 2 2 Did replacing power supply Problem solved Return power supply 2 and replace the printer controller board 2 6 Service Manual 923 Upper Fuser Thermistor Open Error 5055 xxx and power on Is error 923 displayed Step Questions actions Yes No 1 Is connector CN44 on the Disconnect Plug the printer controller board CN44 and turn connector in connected properly the printer on securely Go to step 2 2 Is error 923 displayed Power off and Replace the reconnect CN44 printer controller Go to step 3 board 3 Power the printer off and Replace the Replace the short pins 1 and 4 of CN44 fuser printer controller board 924 Lower Fuser Thermistor Open Error CN44 Turn on the printer Is error 924 displayed
29. 1 8 Noz so CN18 24 No6 24 CN12 CN10 24 16 24 CN14 24 CN20 24 ENos 24 ON 14 24 CNOS 19 24 0 17 24 10 6 PLEV PJ Paper size sensor Pulse motor PM type Extension paper feeder controll Cassette paper feeding OOPWR OOSGN OIPWR OISGN CN9 5 8 7 CN7 6 CN3 8 Option second paper feeding Lower tier drawer connector 12
30. Source Printing Power indicator also blinks while the page prints If Single is selected no buttons are active while the Print Test page prints If Continuous is selected Return or Stop can be pressed to cancel the test producing the following message Canceling 3 10 Service Manual 5055 xxx Note input source represents the input source selected for the Print Test One of the following sources is displayed Tray 1 MP feeder standard bin face down or Output Bin 1 The value of the media width field is displayed when the narrow media sensor determines the media used for the Quick Test is narrow or wide N for narrow W for wide Print Quality Pages Execution of this diagnostic function causes the printer to print the Print Quality Test Pages Since the printer is in diagnostics mode the toner cartridge lockout functionality is disabled Print Quality Pages can be printed 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 the Machine Class ID stored in NVRAM is installed Note Additional diagnostic information relating to print quality may be printed on the Print Quality Pages when executing this diagnostic function This additional information is not printed when the Configuration Menu Group method is used As the pages are printed
31. 1 27 Maintenance approach 1 29 Standard inspection and cleaning procedure 1 29 KENO P ETT 1 30 Service recommendations 1 30 108 1 31 Serial number configuration ID and part number 1 32 1 33 Diagnostic information 2 1 Adjustments and procedures following parts replacement 2 1 au is 2 3 Geo EE PE ET EE 2 3 Printer messages 2 4 Service error message tables 2 4 Attendance messages 7 s s 5445424 2 34 Maintenance analysis procedures MAPS 2 54 Symptom table 2 pex 44488488 44888448 2 63 Service checks 2 68 Drive 1 DC motor service check secu rx o RR Rn 2 68 Drive 2 stepper motor service check 2 68 Duplex unit service Check enun 2 69 Expansion paper feed service 2 69 Face down stacker full service check 2 70 High capacity feeder HCF service check 2 70 Finisher service check sees e e Rn RR Rx m 2 71 Marks on paper service 2 72 Operator panel service check 2 73 Paper carrying service
32. 1 Open the top unit and remove the RIP cover RIP board RIP box and electronic box 2 Remove the screw from the temperature humidity sensor and remove the sensor 3 Remove the two screws from the paper feed solenoid bracket and remove the solenoid 4 Remove the spring from the solenoid plunger arm Note Be sure to use the specific screws during installation Long screws will damage the solenoid Paper Feed Solenoid Paper Remaining Sensor Temperature Humidity Sensor 4 54 Service Manual 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 Repair information 4 55 5055 xxx Transfer belt removal Note If the transfer belt removal was attempted without using the Supplies Menu to lower the belt and the transfer belt is jammed or stuck go to Alternate method Transfer belt was partially removed on page 4 64 To replace the transfer belt before the Life Warning or Exhausted messages appear open the Supplies Menu on the operator panel and select Replace Supplies select Belt and select Replace Now If the 80 Transfer Belt Life Warning or Exhausted message appears press Select when the Select Replace message appears The message Preparing for Maintenance appears followed by Printer Ready for Maintenance then Power Off to Replace Items Note If the operator panel is inoperable or if y
33. 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 Complex Page The print information on the page is too complex Press Go to clear the message and continue printing Press Menu to open the Job Menu and cancel the current job 4 x Unsupported Firmware Card The printer detects an unsupported version of firmware on the installed firmware card Turn the printer off and then press and hold Go while turning it on bypassing the code on the firmware card Remove the firmware card 2 44 Service Manual 5055 xxx Message Meaning Action 40 Tray x The high capacity feeder Turn off the printer and be Size Sense detects an error in the size sure that all the high Error sensing mechanism capacity feeder connectors are installed properly Check the high capacity feeder size sensor and go to Map 8 False 40 Tray x Size Sensor Error message on page 2 59 41 Open Bin 1 The printer wants to send Open bin 1 to clear the Exit Tray paper to the bin 1 output tray message but the tray is closed Press Go to clear the message 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 t
34. P i NY 7 9 7 DEG en 5055 xxx 6 Remove the two power supply screws Remove the screw from the ground wire 8 Disconnect the power supply connector and remove the power supply SJM ANM N Registration roller removal 1 Remove the hole punch unit 2 Remove the registration roller clutch 3 Remove the registration roller bushing 4 Remove the registration roller 4 100 Service Manual 5055 xxx Registration roller clutch removal 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 roller clutch connector 5 Remove the registration roller clutch Set Screw Registration Clutch Repair information 4 101 5055 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 Connector 2 Pull outward on the staple cover and remove the staple unit 4 102 Service Manual 5055 xxx Straight paper exit discharge brush removal 1 Remove the external covers 2 Remove the two screws from the top cover 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 Lever
35. Punch Clutch Staple Home Position Sensor 4 Staple Home Position Sensor GND Term 4 LB 4 Registration Clutch Stal Loy Staple Switch 5 Low Staple Switch GND 6 Punch Clutch Switch ile GND RMT RET 7 CL 1 CN6 Staple Motor 8 Staple Motor AMT 8 PG eee oe ye um Staple Motor 11 Staple Motor RMT Ret 1 NC Staple Motor Staple Motor RMT SD Registration Clutch PJ8 RD PJ3 PC3 GND 3 B 1 GND Signal 2 BL 2 Paper Exit Sensor Face Down Bin DC5V 1 3 DESV 4 Paper Exit Sensor BL 5 Paper Exit Sensor Face Up Bin Face Down Bin Ed BL 6 DD 8 Paper Registration Sensor Signal 2 9 DC5V DC5V 1 Paper Exit Sensor NO Finisher Control Board Finisher Set Switch DC24V In GND In PC1 GND 3 BL 1 Finisher Set Switch COM lie 2 BL 2 Finisher Set Switch NO CN2 Power Supply DC5V Out GND Out Power Supply GND Out AC In GND Out NC DC24V Out AC In DC24V Out RMT In Paper Registration
36. Transparencies Jaser printer type 47 Ib bond 175 g m Labels upper limit paper 48 Ib bond 180 g m Envelopes sulfite wood free up to 10096 cotton 20 to 28 Ib bond 75 to 105 g m High capacity feeder Paper xerographic or business 16 to 28 bond 60 to 105 g m The duplex option supports the same weights and types as the printer except for transparencies envelopes labels and paper less than 80 g m 21 3 Ib bond or greater than 105 g m 28 Ib bond 100 cotton content maximum weight is 90 g m 24 Ib bond 105 g m 28 Ib bond envelopes are limited to 25 cotton content Part numbers 12A5950 letter and 12A5951 A4 Part numbers 12A5940 letter and 12A5941 A4 Refer to Cardstock amp Label Guide for media guidelines General information 1 15 5055 xxx Output media types and weights Media Weight Standard output Paper xerographic or business 16 to 28 bond 60 to 105 g m Specialty papers glossy laser 80 Ib book 32 Ib bond 120 g m Card stock upper limit Index Bristol 90 Ib index 44 Ib bond 165 g m Transparencies Jaser printer type 47 bond 175 g m Labels upper limit paper 48 Ib bond 180 g m Bin 134 Paper xerographic or business 16 to 28 Ib bond 60 to 105 g m Specialty papers glossy laser 80 Ib book 32 Ib bond 120 g m Ca
37. gt Replace the RIP board 956 Processor Failure 956 Service System Board Replace the RIP board 957 ASIC Failure Replace the RIP board 958 NAND Failure 958 Service NAND Failure Replace the RIP board 960 RAM Slot 1 Bad 960 Service RAM Memory Error Replace 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 964 Service Emulation Error Replace the DLE board If this does not fix the problem replace the RIP board Diagnostic information 2 19 5055 xxx 970 Standard Network Error 970 Service Standard Network 970 Service Network Card x Check the network card in slot x on the RIP card 975 Unrecognizable Network Port Software error 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 Card Software error 979 Flash Parts Failed While Programming Network Port Reflash network port 2 20 Service Manual 980 Face Up Down Switching Error 5055 xxx 980 Service Switch Error Check Area B Step Questions actions Yes No 1 Does the Face Up Down Go to step 2 Go to step 3 FU FD de
38. 3 84 Service Manual 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 P ao Z 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 Diagnostic aids 3 85 5055 xxx Aligning the top of the finisher Note Anytime you move the printer or finisher recheck the printer and finisher top alignment Follow these instructions if the alignment marks on top of the finisher 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 knobs as needed to raise or lower the side of the finisher To raise the finisher rotate the adjustment knobs clockwise To lower the finisher rotate the adjustment knobs counterclockwise 3 Tighten the guide rail thumbscrews 3 86 Service Manual 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 Diagnostic aids 3 87 5055 xxx Adjusting the wheels Adjust the wheel
39. 5055 xxx Assembly 12 Fuser unit 7 28 Service Manual Assembly 12 Fuser unit 5055 xxx Index P N Units Description 124 56P9751 1 Fuser 120 V 1 56P9752 1 Fuser 230 V NS 56P9953 1 Parts packet Parts catalog 7 29 5055 xxx Assembly 13 Cassette 7 30 Service Manual Assembly 13 Cassette 5055 xxx Index P N Units Description 19 56P9500 1 Cassette paper feed NS 56P9902 1 Cassette heavy media 2 56P9979 1 Guide stop 3 56P9980 1 Guard rack Parts catalog 7 31 5055 xxx Assembly 14 Expansion feeder 1 7 32 Service Manual Assembly 14 Expansion feeder 1 5055 xxx Index P N Units Description 144 11G0199 4 Guide wire 2 56P9773 1 Gear feeder E 3 56P9771 1 Gear feeder C 4 11G0422 2 Gear feeder B 5 56P9772 1 Gear feeder D 6 11G0423 1 Gear feeder A 7 56P9770 1 Cover right side C 8 56P9769 1 Cover right side B 9 56P9767 1 Cover right side A 10 56P9765 1 Cover 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 Board size sensor 18 56P9521 1 Lever size sensor 19 56P9779 1 Board expansion feeder control 20 56P9768 1 Cover rear 21 56P9776 1 Board paper remaining sensor 22 56P9778 1 Cable assembly lower optional drawer 23 56P9777 1 Cable assembly upper optional drawer
40. 7 Remove the paper jam removal knob 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 belt Repair information 4 107 5055 xxx Tractor drive motor assembly removal 1 Remove the outer covers 2 Remove the drive belt Drive Belt 3 Remove the three screws and disconnect the connector from the tractor drive motor assembly 4 Remove the tractor drive motor assembly 4 108 Service Manual 5055 xxx 5 Locations Covers diagram Turn Guide Front Cover Inner Cover Left Front Cover o S Sg oc Ag On 2 o s o gt 5 83 3 EO Locations 5 1 5055 xxx Major parts diagram 5 2 Service Manual 5055 xxx Major parts diagram legend Part Part 1 Development roll 16 Paper out detect
41. If additional paper sources are installed print a Demo page from each of these if possible Note Failure to print from an additional tray or feeder may imply one or more pins are bent in the mating connector Return parts Engineering periodically analyzes returned parts for failure modes Include a printed test DEMO page before and after the repair and tag any returnable parts with a description of the failure Service recommendations Before leaving the printer check the following Be sure printer is on a flat level strong tabletop or level floor This is very important for color printers that use belts Check and set registration as necessary Shake all cartridges and be sure they are correctly installed and fully seated While the cover is open wipe any residual toner from the LEDs using a lint free cloth If you have serviced the finisher option and in the process pulled it away from the printer during repair ensure that it is properly aligned with the printer 1 30 Service Manual Tools 5055 xxx The removal and adjustment procedures require the following tools and equipment Magnetic tip Phillips screwdrivers large and small Flat blade screwdrivers Analog volt ohmmeter a digital volt onmmeter may also be used Needle nose pliers Tweezers C ring pliers Magnifier 20 times or higher 6 angle wrench 1 5 mm When you make voltage readings always use frame ground unless another ground is spec
42. Serial X Wrap Terminology x indicates which serial port is being tested blank standard serial 1 optional serial port 1 P3HHHHHE represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail count is 99 999 The power indicator blinks indicating the memory test is in process The printer runs this test continually The test can be terminated by powering off the printer Each time the test finishes the screen is updated with the result If the test is successful the Pass Count increments by 1 If the test fails a failure message displays for approximately three seconds and the Fail Count increments by 1 3 16 Service Manual 5055 xxx Once the maximum pass count or fail count is reached the test stops and final test results display Receive Status Interrupt Error Status 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 Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Press Return or Stop to exit the test Diagnostic aids 3
43. Spread a cloth or paper over the transfer belt to protect it from damage 2 Remove the two screws from HSP holder and remove the holder 3 Remove the top cover 4 Disconnect the connector see arrow 5 Remove the eraser Repair information 4 27 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 4 28 Service Manual 5055 xxx Main drive unit removal 1 Open the top unit and remove the gear cover upper cassette left front cover paper feed cover RIP cover RIP board RIP box electronic box and rear cover Open the turn guide and paper feed cover and remove the duplex unit Remove the left side cover power unit 1 and power unit 2 Remove the printer controller board Remove the bracket high voltage power supply board and sub frame R Remove the fuser unit face up paper delivery unit belt up down clutch and DC drive motor Remove the multipurpose feeder roll registration roll and paper carrying frame Remove the eight screws from the power supply 2 bracket Remove the two screws from the belt power supply 2 10 11 Remove the two screws from the fan bracket Remove the three screws from the fuser connector plate Repair information 4 29 5055 xxx 12 Remove the two screws of the fuser connector cable assembly
44. 14 5055 xxx Component locations legend Number Component 1 Printhead controller board 2 Operator panel 3 RIP box 4 Motor driver board 5 Power switch 6 Printer controller board 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 detection sensor expansion feeder 15 Power supply 2 16 Power supply 1 17 Expansion feeder control board 18 Paper size sensor board expansion feeder 19 Paper size sensor board main unit Locations 5 7 Printer controller board 5055 xxx Jejuud JO WOI A IA ND 9ENO SENO CN43 CN14 ENO NO CN12 CN19 CN22 ZNO SINO CN28 CN27 CN11 CN30 CN18 CN21 SNO ZENO 6NO 5 8 Service Manual 5055 xxx Printer controller board connectors The connectors are listed in the order they appear on the e
45. 24 56P9774 1 Motor feeder drive NS 56P9775 1 Cable assembly size sensor NS 56P9955 1 Parts packet Parts catalog 7 33 5055 xxx Assembly 15 Expansion feeder 2 7 34 Service Manual Assembly 15 Expansion feeder 2 5055 xxx Index P N Units Description 154 56P9796 1 Roller assembly carrying 2 56P9514 2 Roller noise reduction 3 56P9513 2 Bushing carrying 4 56P9509 2 Bushing metal 5 56P9790 4 Roller paper carrying 6 56P9792 4 Holder roller 7 56P9791 4 Spring paper carrying 8 56P9794 1 Spring right turn guide 9 56P9789 1 Guide turn 10 56P9793 1 Spring left turn guide 11 56P9517 1 Spring right cassette guide 12 56P9519 1 Guide lower right cassette 13 56P9516 1 Spring left cassette 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 19 56P9787 1 Cable paper present sensor 20 56P9785 1 Cover paper present sensor 21 56P9788 1 Guide HCF 22 56P9507 1 Actuator paper feed sensor 23 56P9795 1 Cable paper present sensor 24 11G0219 1 Interrupter photo 25 56P9510 1 Shaft paper feed 26 56P9782 1 Spring solenoid 27 56P9783 1 Solenoid feeder 28 56P9781 1 Lever clutch 29 56P9511 4 Roller assembly paper feed 30 56P9506 1 Frame paper feed 31 56P9508 1 Bracket ground 32 11G0291 1 Clutch paper feed 33 56P9797 1 Cover gear 34 11G0297
46. 5 4 75 Duplex unit separation 4 75 Duplex unit removal 4 76 Duplex timing belt 4 76 Duplex pressure roller and solenoid removal 4 77 Duplex feed roller and solenoid removal 4 78 Duplex side fence motor assembly side fence removal 4 79 Duplex paper carrying motor removal 4 80 High capacity feeder HCF removals 4 81 HGF covers removal bere RR CERES 4 81 HCF call roller paper feed roller reverse roller removal 4 82 HCF pickup solenoid 4 83 HGF tray motor removal 2222 22 22 hn 4 86 HCF paper level sensor removal 4 87 vii 5055 xxx power supply removal occ se 22 m RR RI 4 88 Finisher 8 4 89 External covers 4 89 Finisher control board 4 90 Elevator motortermoval 245323 33 yy ec re ag 4 91 Feed motor assembly 4 91 Hole punch removal RR ES 4 92 Inverter paper exit discharge brush removal 4 93 Inverter paper exit roller removal 4 93 UN Gad oe ER 4 95 Path select gate removal 4 96 Pating Teller rem
47. ES 4 ACP 50 E rings ES 5 ACP 50 C rings C 21 ACP Parts packet including 50 Bind P tight screws 3x6 Zn 3K 50 Bind P tight screws 3x8 Zn 3K 50 Bind screws M4x8 Zn 3K 50 Pans with flange P tight screws 3x10 Zn 3K 50 E rings ES 5 ACP Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind screws M3x6 Zn 3K 50 Bind screws M3x8 Ni 3 50 E rings ES 5 ACP Parts catalog 7 77 5055 xxx Assembly 32 Parts packets continued Index P N Units Description NS 56P9956 1 Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind S tight screws 3x8 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 E rings ES 5 ACP 50 E rings ES 6 ACP 50 Spring pins 2x10 ACP 50 Spring pins 3x10 ACP NS 56P9957 Parts packet including 50 E rings ES 8 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 NS 56P9958 1 Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind P tight screws 4x8 Zn 3R 50 Pan screws M4x6 Zn 3R 50 Pan screws M4x12 Zn 3R 50 E rings ES 6 ACP 50 RP tight screws M4x12 50 RS tight screws M4x6 50 RS tight screws M4x8 50 RS tight screws M4x12 NS
48. 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 4 BR GN 4 86 Service Manual p d Tray Motor 5055 xxx HCF paper level sensor removal 1 Remove the four screws from the transfer cover and remove the cover 2 Remove the two screws from the sensor and remove the cover 3 Remove the connector and screw from paper level sensor and remove the sensor Paper Lever Sensor Sensor Cover Repair information 4 87 5055 xxx HCF power supply removal Move the paper tray upward Disconnect the power cord Remove the front cover Remove the two screws from the power supply cover and remove the cover 5 Remove the four screws from the power supply unit and remove the unit 6 Remove the two screws from the DC DC converter and remove the converter Ce S lt Power Supply Cover DC DC Converter Power Supply 4 88 Service Manual 5055 xxx Finisher removals External covers removals 1 Remove the finisher trays Upper Tray Lower Tray 2 Remove the two screws from the front cover and remove the cover 3 Remove the two screws of the rear cover and remove the cover Repair information 4 89 5055 xxx 4 Remove the two screws f
49. IE NODAL r z zu eu uorauoAo41d gt 5 x afora 5 z cipue ERE EE e vest NS H aT cp tps 3 TT ac pepnHqee speeesee 1 T t seme z 1 T 1 p 5 See eee ee aes onse somnos 5 al i i 7 7 z 1 I se 22 xosueg zosu s XXXXI XX soN S Buu AA 2160 C91X General Circuit Diagram
50. Lift the printer exit tray halfway and remove 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 Tighten the docking plate thumbscrews 5 Align the thumbscrews on the guide rail plate with the holes in the side of the printer cabinet or stand Diagnostic aids 3 73 5055 xxx 6 Tighten the guide rail plate thumbscrews Docking Plate Tab Guide Rail Plate Tab 7 Align the thumbscrews on the guide rail with the holes in the guide rail plate 8 Tighten the guide rail thumbscrews 3 74 Service Manual 5055 xxx Combining the finisher and stand 1 Roll the finisher stand onto the guide rail Do not push the stand all the way up against the printer Docking Plate Pins 2 Remove and discard all shipping tape packing material and the metal shipping bracket CAUTION The finisher weighs 19 7 kg 42 2 Ib Metal Shipping Bracket Fra Diagnostic aids 3 75 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 Stapler Stapler Locking Lever 3 76 Service Manual 5055 xxx 8 Close the stapler CEST 10 Align the two sockets on the
51. Maintenance Mode DIP switch specifications The DIP switches on the high capacity paper feed board have the following functions Function switching and initial setting of the standard machine or optional machine Function switch Maintenance switch DIP ME switch Description 4 3 2 1 OFF 1 Standard machine initial setting ON X X OFF X 2 Optional machine initial setting ON X Maintenance switch test mode selection is valid without connecting to the printer controller board Function switch Maintenance switch DIP Test paper feed gt mode standalone 4 3 2 1 OFF Test OFF mode ON X X OFF X Linear velocity 101 mm s ON X Thick paper mode OFF X X Linear velocity 129 mm s ON Plain paper mode OFF X Linear velocity 180 mm s ON X 3 60 Service Manual 5055 xxx Finisher The finisher communicates with the host engine through serial interface signals and performs the following operating modes Straight exits paper to the upper tray Punch and straight stops paper at the leading edge punches it and exits it to the upper tray Invert sends paper to the accumulator and exits it to the lower tray Punch and invert stops paper at the leading edge punches it and sends it to the accumulator where it exits to the lower tray Invert and staple jogs each sheet of paper in the accumulator When the accumulat
52. S N XX 0XXXX 7 13 56P9719 Cable assembly 80 pin RIP printer controller 7 27 56P9720 Cable assembly PH controller power 7 13 56P9721 Cable assembly drum eraser 7 25 56P9722 Power supply 120 V 1 7 23 56P9723 Power supply 230 1 7 23 56P9724 Power supply 120 2 7 25 56P9725 Power supply 230 V 2 7 25 56P9726 Cable assembly printer controller power 1 7 25 56P9727 Cable assembly printer controller power 2 7 25 56P9729 EPROM printer controller 7 23 56P9730 Cable assembly 7 25 56P9731 Cable assembly finisher 7 25 56P9732 Belt power supply 7 23 56P9733 Cable assembly HCPF interface 7 25 56P9734 HCF finisher D sub assembly 7 25 56P9736 Cable operator panel 7 3 7 27 56P9737 Insulator sheet 7 23 56P9738 Cable assembly conditioning joint 230 V only 7 23 56P9739 Cable asm conditioning printer controller 7 23 56P9740 Cable conditioning resistor 7 23 56P9741 Resistor conditioning 230 V only 7 23 56P9742 Board heater drive 7 23 56P9745 BOX RIP 2 u eere do de desee xt 7 27 5
53. allows printer and network administrators to lock the printer in a mode that will only print black This feature cannot be overridden with any other menu or driver selection 1 2 Service Manual 5055 xxx Physical specifications and weight Description Height Width Depth Weight Printers Lexmark C91 x 20 2 in 27 4 in 25 8 in 177 Ib 512 mm 695 mm 655 mm 80 5 kg Lexmark C91xn 25 2 in 27 4 in 25 8 in 217 8 Ib 641 mm 695 mm 655 mm 99 0 kg Lexmark C91 xdn 25 2 in 27 4 in 25 8 in 230 8 Ib 641 mm 695 mm 655 mm 104 9 kg Lexmark C91 xfn 40 5 in 46 9 in 25 8 in 336 4 Ib 1028 mm 1191 mm 655 mm 152 9 kg Fully configured 40 5 in 60 0 in 25 8 in 443 3 Ib 1028 mm 1520 mm 655 mm 201 5 kg Options Duplex unit 4 7 in 27 4 in 13 8 in 13 0 Ib 120mm 695mm 850mm 5 9 kg 550 Sheet drawer 5 1 in 27 4 in 25 8 in 40 8 Ib 129 mm 695 mm 655 mm 18 5 kg High capacity feeder 25 0 in 14 2 in 20 7 in 50 0 Ib 3000 sheet 635 mm 360 mm 525 mm 22 6 kg Staple Punch finisher 41 7 in 19 5 in 20 5 in 56 9 Ib 1100 sheet 1060 mm 495 mm 520 mm 25 9 kg with stand Furniture Printer cabinet 20 4 in 26 6 in 23 6 in 57 5 Ib b17 mm 675 mm 598 mm 26 0 kg Printer base 10 2 in 26 6 in 23 6 in 33 0 Ib 260 mm 675 mm 547 mm 15 0 kg Base model with standard 550 sheet input tra
54. invert assembly Exit guide tray 1 straight 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 tray 2 Paper upper level sensor B tray 2 Ensure that the sensors are working properly by running the sensor test in diagnostic mode 4 Elevator upper limit sensor Elevator lower limit sensor Elevator motor Ensure that the elevator upper limit sensor elevator lower limit sensor and the elevator motor are operating correctly at power up Diagnostic information 2 81 5055 xxx Paper exit face up service check FRU Action 1 Face up exit assembly If the paper is not exiting to the back paper face up tray or the face down tray check the sensor for proper operation by checking for a fluctuation of 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 be sure the connector is properly connected to the printer controller board Check the gears and the actuating mechanism for wear or damage 2 Printer controller board Check connectors CN2 and CN14 for proper connection on the printer controller board 2 82 Service Manual 5055 xx
55. is then reversed and fed to the duplex unit Paper fed with the 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 the back side is delivered to the normal feeding path m N VG gt 1 When non offset type color toner is used the process speed in the OHP mode is decreased causing toner to melt sufficiently with the fusing unit while the fusing temperature is set higher than usual to increase the smoothness on the surface of the toner image This mode restricts paper feeding to multipaper feeding not cassette feeding 3 44 Service Manual Paper weight Purpose 5055 xxx To identify the relative weight of the paper loaded in a specific source and ensure that the toner adheres properly to the printed page Values Plain weight Preprint weight Bond weight Labels weight Card stock weight Colored weight Envelope weight Letterhead weight Transparency Custom x Glossy weight weight Light 16 20 Ib Normal 20 24 Ib Heavy 24 28 Ib Diagnostic aids 3 45 5055 xxx Clearing paper jams 250 MMH WN SS D F 249 200 This message identifies the a
56. open the turn guide open the paper feed cover and pull out the duplex unit halfway 2 Remove the two screws from the registration frame 3 Remove the registration clutch Note When installing set the clip of the registration clutch to the stopper Repair information 4 47 5055 xxx Registration 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 registration sensor and remove the sensor Registration Sensor 4 48 Service Manual 5055 xxx Right slide rail removal 1 Remove the upper cassette 2 Remove the screw from both left and right slide rails _ _ ge gt Remove the six screws from the RIP box RIP box removal 1 Gy M D 0 2 Slightly lift and remove the RIP box Repair information 4 49 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 AA oM Doo J 9 4 50 Service Manual 5055 xxx Stay arm removal 1 Open the top unit and remove the face down paper guide assembly 2 Remove the yellow and black sub frame 3 Remove the screw from the right stopper and remove t
57. optional drawer paper path area To clear area E Note If you have a high capacity feeder pull it away from the printer ON ON Open the jam access door on the top optional drawer Remove the jam Close the jam access door Open the jam access door on the middle drawer Remove the jam Close the door Open the jam access door on the bottom drawer Remove the jam Close the door Press Go If the paper jam message continues clear any paper from the paper path Check Area F Pull the high capacity feeder away from the printer Open the jam access door on the top optional drawer Remove any jam Close the jam access door Slide the high capacity feeder until it locks to the docking frame When the feeder is in the correct position you hear a click Press Go If the paper jam message continues check and clear all paper from the paper path Diagnostic aids 3 49 5055 xxx 240 Paper Jam 1 ON 0 10 11 Slowly pull the jam out of the multipurpose feeder Note If you are feeding banner paper do not pull the paper out instead begin with step 2 If the paper will not come out proceed with step 2 If it does go to step 10 Open the front door Rotate the top cover locking lever to the left Place both hands on the lifting points and squeeze the right top cover latch Lift the cover Wa
58. printer detects print and hold jobs stored on the hard disk Press Return or Stop No jobs are restored and the printer returns to Ready Restoring The printer is restoring Wait for the message to Factory factory default settings clear Defaults Restoring Held Jobs The printer is restoring held jobs from the hard disk Wait for the message to clear Serial x A serial interface is the Wait for the message to active communication link clear Std Bin Full The standard bin is full Remove the paper in the bin to clear the message Supplies One of the printer supplies Press Menu to open the requires attention Supplies Menu and identify which supply item needs replacing Diagnostic information 2 41 5055 xxx Message Tray x Empty Meaning The specified tray is out of paper Action Load paper in the tray and try to clear the message If the message cannot be reset go to Map 4 False Tray x Low Empty message on page 2 56 Tray x Low The specified tray is low of paper Add paper in the tray and try to clear the message If the message cannot be reset go to Map 4 False Tray x Low Empty message on page 2 56 code version Tray x The specified tray is either Insert the tray completely If Missing missing or not fully inserted the message cannot be reset go to Paper tray missing service check on page 2 83
59. rear 4 6 right side 4 8 RIP board 4 9 solenoid 4 6 top 4 4 density sensor 4 14 drive gear unit sensor assembly 4 15 drive motor assembly 4 16 duplex unit 4 76 connector 4 75 feed roller and solenoid 4 78 paper carrying motor 4 80 pressure roller and solenoid 4 77 side fence motor assembly 4 79 side fence removal 4 79 timing belt 4 76 duplex unit connector 4 13 electronic box 4 17 eraser 4 27 expansion paper feeder 4 67 face down guide assembly 4 18 face up paper exit assembly 4 19 fanning pad 4 19 finisher control board 4 90 elevator motor 4 91 external covers 4 89 feed motor assembly 4 91 hole punch 4 92 inverter paper exit discharge brush 4 93 inverter paper exit roller 4 93 jogging unit 4 95 path select gate removal 4 96 power supply 4 99 registration roller 4 100 registration roller clutch 4 101 stack area discharge brush 4 102 staple unit 4 102 straight paper exit discharge brush 4 103 straight paper exit roller 4 103 timing belts 1 and 2 4 105 tractor belt removal 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 covers 4 81 paper end sensor 4 84 paper feed roller 4 82 paper level sensor 4 87 paper size sensors 1 2 4 84 pickup solenoid 4 83 power supply 4 88 reverse roller 4 82 5055 xxx tray motor 4 86 LED printhead 4 24 lock handle assembly
60. 1 8 SAFETY oo SWITCH2 T8 T9 1 PAPER FEED ROLL CN7 24V 1 1 CL PAPER CN3 PAPERFEED 2 2 2 et CLUTCH CLUTCH 3 i i SDA 24V PICKUP SCL PICKUP 4 2 2 soL SOLENOID SOLENOID GND CN10 RED 45V seNp H 1 PAPER FEED Reset PAPER FEED 5 2 SENSOR SENSOR 3 3 45V 4 5 5 6 6 SENSOR 45V HCFP CONTROL 7 ME 8 8 UPPER LIMIT UPPER LIMIT SENSOR 9 9 SENSOR 5V CN2 5V IN PTr 5V OUT LED 24 PGND one 45V SGND SGND up switcH 1 2 2 SGND 3 3 oto CN12 DOWN SWITCH 4 4 27 24V SW 45V 5 5 7 PGND LED 6 6 CN11 DOWN SWITCH _ _ J TRG H 1 i RESIDUAL PAPER 2 2 RESIDUAL PAPER p SENSOR 1 SENSOR 1 sv 3 3 CN5 24V SGND 1 RESIDUAL 5 2 RESIDUAL PAPER 24v sw SENSOR 2 6 3 SENSOR 2 5V TRACKING SGND 17 1 SENSOR RESIDUAL PAPER 8 2 RESIDUAL PAPER SGND SENSOR 3 2 45V CN3 SEND 110 1 DOWN RESIDUAL PAPER 11 2 RESIDUAL PAPER COM UP SENSOR 4 45V dm PAPER LEVEL PAPER LEVEL 14 2 SENSOR COM UP SENSOR SGND 15 3 HIGH WITH LIGHT CN6 N O UP WM 45V 1 LOWER LIMIT N C PGND LOWE
61. 1 Gear paper carrying Parts catalog 7 35 5055 xxx Assembly 15 continued Expansion feeder 2 7 36 Service Manual 5055 xxx Assembly 15 continued Expansion feeder 2 Index P N Units Description NS 56P9956 1 Parts packet Parts catalog 7 37 5055 xxx Assembly 16 Duplex unit 1 7 38 Service Manual Assembly 16 Duplex unit 1 5055 xxx Index P N Units Description 16 56P9798 1 Duplex assembly 2 56P9804 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 56P9994 1 Plate duplex guide NS 56P9807 1 Cable assembly duplex interface NS 56P9805 1 Cable assembly duplex connection Parts catalog 7 39 5055 xxx Assembly 17 Duplex unit 2 7 40 Service Manual 5055 xxx Assembly 17 Duplex unit 2 Index P N Units Description 17 56 9825 1 Plate paper re feed drawer 2 56P9827 1 Guide rear side 3 56P9826 1 Guide front side 4 56P9830 1 Solenoid assembly paper re feed 5 56P9814 8 Bearing release 6 56P9816 2 Spring re feed roller 7 56P9813 4 Roll release 8 56P9525 1 Interrupter assembly photo 9 56P9828 1 Motor assembly paper guide 10 56P9808 1 Interrupter photo 11 56P9526 2 Spring feed roller 12 56P9815 6 Spring reed roller 13 56P9829 3 Solenoid assembly fee
62. 16 Motor drive BOSld s RP T ESerP RUPES 5 16 SPE SENSO DOA 5 17 High capacity feeder 5 18 High capacity paper feed configuration 5 18 Electrical parts iaa ne err RI Rer rex 5 19 viii Service Manual 5055 xxx Assembly 33 Driving parts 2 216 3 er RS 5 20 sulcis MD DP 5 21 Preventive maintenance 6 1 Maintenance snakke 6 1 Periodic 6 2 Lubricants and cleaners 2 2 22 cerne 6 2 Parts vcd okie s sede aat Sa ES DES 7 1 How to use this parts catalog 7 1 Assembly 1 Covers 1 2 2 na anna 7 2 Assembly 2 22 2 cccacecesseencaceaseasadan 7 4 Assembly 3 Covers 3 7 6 Assembly 4 Covers 4 7 8 Assembly 5 Covers 5 heu xxu 7 10 Assembly 6 Upper unit 2 2222 7 12 Assembly 7 Base 1 22 2422 cue iua hun 7 16 Assembly 8 Base 2 7 18 Assembly 9 Base 3 7 20 Assembly 10 Electrical 2 222 acus 7 22 Assembly 11 Rip board s sss sasawa 7 26 Assembly 12 F ser nit i 22 2 urhe 7 2
63. 17 56P9663 Clutch belt up down 7 17 56P9664 Frame paper feed 7 17 Part number index I 15 5055 xxx 56P9665 Sensor paper feed 7 17 56P9666 Support assembly upper unit 7 19 56P9667 Pin upper unit support 7 19 56P9668 Handle assembly lock 7 19 56P9669 Handle lock 7 19 56P9670 Shroud cable 7 19 56P9671 Guide cable 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 registration 7 21 56P9682 Frame assembly carrying 7 21 56P9684 Frame assembly F1 sub 7 21 56P9685 Frame assembly F2 sub 7 21 56P9686 Rod lock 7 21 56P9687 Cover gear 7 21 56P9692 Cable assembly reg MPF sensor 7 21 56P9693 Stopper clutch 7 21 56P9694 Unit transfer belt 7 21 56P9695 Cable turn guide door
64. 4 28 main drive unit 4 29 main unit fan 4 32 motor drive board 4 33 multipurpose feeder frame assembly 4 22 multipurpose feeder paper present sensor 4 33 multipurpose feeder tray 4 34 paper carrying frame 4 35 paper carrying roller 4 36 paper exit motor 4 18 paper exittray 4 10 paper feed frame 4 37 paper feed roller 4 38 paper feed solenoid 4 54 paper present sensor 4 38 paper remaining sensor 4 39 paper size sensor board assembly 4 39 power supply 1 4 40 power supply 2 4 41 power switch 4 42 printer controller 4 43 printhead controller board 4 44 registration clutch 4 47 registration frame 4 47 registration sensor 4 48 right slide rail 4 49 RIP box 4 49 sensor board 4 50 sensorcleaner 4 14 separation fingers 4 14 stay arm 4 51 sub frame 4 52 temperature humidity sensor 4 54 top unit 4 55 transfer belt inoperable operator panel 4 60 normal removal 4 56 partially removed 4 64 unrecoverable error code 4 60 turn guide cover sensor 4 65 upper fan 4 66 repair information Index 1 5 5055 xxx handling printed circuit boards 4 1 Service precautions 4 1 S safety information 1 sensors belt up down detection 4 11 density 4 14 drive gear unit 4 15 finisher functions 3 64 high capacity feeder paper end sensor removal 4 84 high capacity feeder paper level 4 87 high capacity feeder paper size sensors 1 2 removal 4 84 humidity 4 54 locations 5 4 multipurpose feeder paper present 4 33 paper full 4 18 paper
65. 5 For printers with serial numbers and above Remove the four connectors from LED printhead 6 Remove the two screws from the ground wires C910 C912 S N s Repair information 4 25 5055 xxx When replacing the LED printhead replace the corresponding EEPROM shipped with the printhead on the printhead controller board Place the printer in Diagnostic Mode input the printhead light quantity value plus eight refer to note below from the printhead label Be sure to remove any fingerprints or stains from the printhead lens The positioning pins 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 numbers 4 and above Disconnect the affected LED printhead connectors from the printhead controller board Remove the screw from the ground wire located on the LED printhead C912 S N s XXAXXXX 8 Remove the LED printhead and the cables from the printer When replacing the LED printhead replace the corresponding EEPROM shipped with the printhead on the printhead controller board 4 26 Service Manual 5055 xxx Note The LED printhead light intensity values do not have to be entered for the printer S N 4 and above Eraser removal 1 Remove the appropriate printheads see LED printhead removal on page 4 24
66. 5055 xxx Options and features Lexmark C91 x printers support only Lexmark C91 x paper handling options These options are not compatible with any other Lexmark printer 550 Sheet drawer includes 550 sheet tray and support unit installs beneath the printer and holds approximately 550 sheets of 20 Ib paper Multiple optional drawers up to 3 are supported simultaneously High capacity feeder is designed to provide an additional input tray Tray 3 or Tray 5 depending on the configuration with a total capacity of 3 000 sheets plain paper letter or A4 20 Ib 75 g m The high capacity feeder is customer installable and attaches to the right side of the printer Heavy media tray is intended for special media such as transparencies labels and glossy paper This is supported only as Tray 1 top drawer location Duplex unit offers two side printing and is designed to complement the Lexmark C91 x printers Finisher offers stapling hole punching offset stacking and an additional output bin Two models are available 3 or 4 hole left edge hole punching is available The single staple position is the upper left corner The finisher can support up to 1 100 sheets of unstapled unpunched media For stapled media the output bin supports up to 30 stapled sets or 1 000 sheets The stapler can staple a maximum of 30 sheets per set Each printer can support a single finisher Printer cabinet is customer installable and attaches so
67. 70 parts catalog covers 7 54 docking 7 68 7 70 electronics 7 66 elevator 7 64 feed 1 7 58 feed2 7 62 frame 7 56 removals control board 4 90 elevator motor 4 91 external covers 4 89 1 2 Service Manual feed motor assembly 4 91 hole punch 4 92 inverter paper exit discharge brush 4 93 inverter paper exit roller jogging unit 4 95 path select gate 4 96 power supply 4 99 registration roller 4 100 registration roller clutch 4 101 stack area discharge brush 4 102 staple unit 4 102 straight paper exit discharge brush 4 103 straight paper exit roller 4 103 timing belts 1 and 2 4 105 tractor belt 4 106 tractor drive motor assembly 4 108 stand 3 75 stapling mechanism 3 71 straight paper path 3 65 tests 3 20 theory of operation 3 61 fuser unit parts catalog 7 28 removal 4 21 theory of operation 3 40 G general information 1 1 H hardware tests 3 12 high capacity feeder call roller removal 4 82 covers removal 4 81 diagram 5 18 high capacity paper feed timing belt adjustment 4 3 paper end sensor removal 4 84 paper feed configuration 5 18 paper feed roller removal 4 82 paper level sensor removal 4 87 paper size sensors 1 2 removal 4 93 4 84 parts catalog 7 42 7 44 7 46 7 48 7 50 7 52 pickup solenoid removal power supply removal reverse roller removal tests 3 18 sensor switch test 3 19 theory 3 52 tray motor removal hole punch adjustment 3 94 removal 4 92 test 3 20 theory of
68. Core Ferrite S N XX 1XXXX 7 15 56P9990 Tape Core S N XX 1XXXX 7 15 56P9991 Cable assembly 48 pin PH controller S N XX 1XXXX 7 13 56P9992 Board printer controller 912 S N XX 1XXXX 7 23 56P9993 Shield light used on P N 56P9594 for S N XX 1XXXX 7 15 56P9994 Plate duplex guide 7 39 7370516 Kit printer relocation 7 73 7370567 Kit duplex relocation 7 73 7370569 Kit 500 sheet tray relocation 7 73 99A0424 Card infrared adapter 7 72 99A0545 Card external serial adapter 7 72 99A0560 Card Tri Port adapter 7 72 99A1501 Board operator panel Japan 7 3 1 22 Service Manual C91x Finisher Wiring Diagram CN12 12 P GND z 3 Finisher 12 Control Board CN10P CN10 DC5V 7 M3 Finisher BL Paper Full Sensor GND Control Board Paper Full Sensor DC5V DC24V GND DC24V Paper Upper Level Sensor Tractor Motor A DC5V Tractor Motor B GND Tractor Motor A_ Invert Path Sensor Tractor Motor B_ DC5V Tray Motor GND Tray Motor Tractor Home Position Sensor DC24V Gate Solenoid 1 G Tray Motor Paper Detecting Sensor DC5V
69. DC5V GND Jogging Home Position Sensor DC5V GND Tray Upper Limit Sensor DC24V DC5V GND GND DC5V Tray Lower Limit Sensor GND DC5V Feed Motor H L GND Feed Motor On Off Punch Dust Box Sensor Feed Motor Clock DC5V Feed Motor LD GND Option Sensor Punch Dust Box Sensor DC5V Jogging Motor 12 11 HO 9 Tray Lower Limit Sensor Ko oo 4 O 0748 KO O9 M 14 CO PO PJ12 M1 ilo IN blod Ins 2T er eor wiale 3 2 1 eoo 01 14 0 014 50 1 4 Feed Motor Finisher Control Board Finisher Control STAPLER 2 CL2 8 PJ7 Control Board oar Desv h Desy 1f E 1 DC24V GND 2 GND GND 2 22 R
70. Diagnostics printer setup 3 26 Bee ERE RE 3 26 Viewing and resetting the drum counters 3 28 Diagnostics 3 31 Theory of operation 3 33 Processes and configuration 3 33 Electrophotography 3 33 Development unit 3 34 Transfer Unit haa 3 34 Cleaning eiu mem komm waren mas 3 35 Paper feeding f sing ohh hun 3 35 Drive 5 uns 3 36 Paper feeding 3 37 Cassette paper feeder scire aee m xm xn 3 37 Multipurpose feeding hh 3 38 Registration unit 3 38 Separation Unll 8 3 39 ERAT 3 40 ac DT 3 41 Bell unit PPP ITTITT 3 42 Belt UP dOWN cee hr haa mamma 3 43 Expansion paper feeder 3 43 Duplex cece cece hr ham kun 3 44 Paper arcu uus 3 45 Clearing paperjams 2222225 cece eee
71. EAS S GAGE 7 59 56P9397 Gear Z20 7 59 56P9398 Gear 219 7 59 56P9399 Sensor photo 7 57 56P9400 ROEN z c l ae 7 59 56P9401 Roller Lau u ss 7 59 56P9402 Bushing ere SEG 7 59 56P9408 Spring A m ERU bales 7 59 56P9404 Springs 7 59 56P9405 Roller ees 7 59 56P9406 Pulley 224 742 gear 7 59 56P9407 Belt timing 6082M184 7 59 56P9408 Khob uox meo baade Kveld idae 7 59 56 9409 rule eR vag iet 7 67 56P9410 Gable sca cee keke t rke Ee ea qe 7 67 56P9411 Pulley 7 59 56P9412 Spacer 7 59 56P9413 Assembly motor bracket 7 59 56P9414 Pulley 7 59 56P9415 Pulley gear 236 24 7 61 56P9417 Flange 7 61 7 63 56P9418 Guide stack 7 57 56P9420 Bracket finisher control board 7 67 5629422 PIM N revet aes Gi NR Saa a wee 7 63 56P9423 Pulley Z19 Z20 7 63 DEP 9428 G ble e deeds acer s REOR 7 67 56P9435 Cable set switch 7 67 56P
72. For example if you need to load paper in a tray while a job is printing press Stop and wait for the printer motors to idle before removing the tray from the printer Reinsert the loaded tray and then press Go Diagnostic aids 3 3 5055 xxx Printing the menu settings 1 From the printer operator panel press Menu to enter the menus 2 Continue to press and release Menu until you see TESTS MENU 3 Press Select TESTS MENU is displayed on the first line and Print Menus is on the second line 4 Press Select again to print the page The message Printing Menu Settings is displayed The printer returns to Ready status after the menu settings page prints Operator menu disabled If the operator has disabled the menu and you want to run operator print tests turn the machine off and then press Go and Stop as you turn the machine on Menu overview SUPPLIES MENU Belt Block Photo Dev Coating Roll Color Photo Dev color Toner UTILITIES MENU Color Samples Print Alignment Print Menus Print Net Setup Print Fonts COLOR MENU Color Correction Manual Color Print Mode Toner Darkness Fuser Print Directory Replace Supplies Factory Defaults Supplies Life Format Flash Defragment Flash Format Disk Job Acct Stat Hex Trace PAPER MENU FINISHING MENU USB MENU Paper Source Duplex PCL SmartSwitch PAPER SIZE Duplex Bind PS SmartSwitch PAPER TYPE Copies MAC Binary PS CUSTOM TYPES Blank Pages
73. General information 1 27 5055 xxx Shipping printer without print cartridges Temperature 0 to 140 F 0 6 to 60 C Relative humidity 5 to 10096 Maximum wet bulb temperature 85 F 30 C Altitude 34 000 ft 10 300 meters Storing printer without print cartridges Temperature 0 to 140 F 0 6 to 60 C Relative humidity 5 to 8096 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 10096 Maximum wet bulb temperature 80 F 27 C Storing supply items Temperature 0 to 104 F 0 6 to 40 C Relative humidity 5 to 8096 Maximum wet bulb temperature 80 F 27 C In some cases performance specifications such as paper OCF or EP cartridge usage are specified to be measured at an ambient condition 1 28 Service Manual 5055 xxx Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the error code charts symptom index and service checks to determine the symptom and repair the failure The removals in the repair information chapter may help you identify parts Printer messages on page 2 4 Symptom table on page 2 63 Service checks on page 2 68 Repair information on page 4 1 After you complete the repair perform tests as needed to verify the repair See Diagnostic aid
74. Interrupter photo 7 56P9849 Roller manual feed pickup 8 56P9850 Roller manual feed 9 56P9852 10 56P9851 11 56P9847 12 56P9845 NS 56P9959 Limiter torque Roller manual feed separate Spring compression Sensor assembly paper feed po oa oa oa mo om Parts packet Parts catalog 7 45 5055 xxx Assembly 20 High capacity feeder 3 gt 7 46 Service Manual 5055 xxx Assembly 20 High capacity feeder 3 Index P N Units Description 20 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 inlet 8 56P9858 1 Connector I F 9 56P9853 3 Screw shoulder NS 56P9960 1 Parts packet Parts catalog 7 47 5055 xxx Assembly 21 High capacity feeder 4 7 48 Service Manual Assembly 21 High capacity feeder 4 5055 xxx Index P N Units Description 21 56P9541 1 Sensor resistor 2 56P9875 1 Cable assembly safety switch 3 56P9865 1 Cable assembly HCF motor 4 56P9871 1 Cable assembly 5 56P9866 1 Cable assembly paper feed sensor 6 56P9880 1 Cable up down switch 7 56P9879 1 Cable paper volume 8 56P9878 1 Cable assembly sensor 9 56P9877 1 Cable assembly paper size sensor 10 56P9876 1 Cable assembly lift
75. Manual 5055 xxx Message Solution Insert Staple Cartridge The staple cartridge is either missing or installed 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 from the accumulator and remove the staple jam Go to 210 Staple jam service check on page 2 86 Diagnostic information 2 53 5055 xxx Maintenance analysis procedures MAPS Map 1 False Side Door Open message Step Questions actions Yes No 1 Close the side turn guide Problem solved Go to step 2 door Does the message reset 2 Disconnect CN30 from the Replace the Replace the side printer controller board printer controller door turn guide While activating the door board sensor Switch is there continuity at assembly pins 1 and 2 of the connector Map 2 False Close Front Door message Step Questions actions Yes No 1 Close the top unit and front Problem solved Go to step 2 cover Does the message reset 2 Is the interlock switch Replace the Go to step 3 actuator broken front door 3 Is the actuator rod that Replace the Replace the activates the interlock actuator rod power supply 2 switch on power supply 2 damaged or broken 2 54 Service Manual Map 3 False Close Tray x Top Cover message 5055
76. NPA Mode Configure Bins Collation USB Buffer Assign Type Bin Substitute Size Configure MP Paper Weight Paper Loading Universal Setup Separator Sheets Separator Source Multipage Print Multipage Order Multipage View Multipage Border Job Buffering 3 4 Service Manual 5055 xxx JOB MENU Reset Printer Cancel Fax Confidential Job Held Job SETUP MENU Printer Language Printer Usage Power Saver Resource Save Download Target Print Timeout Auto Continue Wait Timeout Jam Recovery Page Protect Display Language Alarm Control Job Accounting Job Acct Limit PCL EMUL MENU Font Source Font Name Point Size Pitch Symbol Set Orientation Lines per Page A4 Width Auto CR after LF Auto LF after CR Tray Renumber POSTSCRIPT MENU Print PS Error Font Priority Image Smoothing PARALLEL MENU PCL SmartSwitch 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 Serial Buffer Job Buffering RS 232 RS 422 RS 422 Polarity Serial Protocol Robust XON Baud Data Bits Parity Honor DSR NETWORK MENU PCL SmartSwitch PS SmartSwitch MAC Binary PS NPA Mode Network Buffer Job Buffering Network x setup Std Net Setup INFRARED MENU Infrared Port PCL SmartSwitch PS SmartSwitch NPA Mode Infrared Buffer Job Buffering Window S
77. Network Card An internal print server is Wait for the message to Busy being reset clear Network x A network interface is the active communication link Wait for the message to clear 2 38 Service Manual 5055 xxx Message Meaning Action Network Network interface is the Wait for the message to X y active communication link clear where x represents the active link and y represents the channel No Jobs The PIN number entered is Press Go to enter another Found Retry not associated with any confidential job PIN Press Stop to clear the PIN entry prompt Not Ready The printer is not ready to Press Go to make the printer receive or process data ready Parallel lt x gt A parallel interface is the Wait for the message to active communication link Clear Performing Self Test The printer is running the series of start up tests it performs after it is turned on Wait for the message 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 temperature and display the Ready message Print Jobs on Disk Jobs spooled to the hard disk before the printer was last turned off have not yet printed Press Go to print the jobs Press Return or Stop to delete jobs Print
78. Parts catalog 7 13 5055 xxx Assembly 6 continued Upper unit PY AQ 29 TX V 7 14 Service Manual 5055 xxx Assembly 6 continued Upper unit Index P N Units Description 30 56P9594 4 Cover eraser 31 56P9595 1 Lamp M erase 32 56P9596 1 Lamp C erase 33 56P9597 1 Lamp Y erase 34 56P9598 1 Lamp K erase 35A 56P9985 1 Printhead LED K black S N XX 1XXXX 35B 56P9986 3 Printhead LED Y M C color S N XX 1XXXX 35C 56P9599 4 Printhead LED S NXX 0XXXX 36 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 Frame link NS 56P9639 4 Connector upper NS 56P9604 8 Core ferrite NS 56P9605 8 Cable assembly HDFG NS 56P9606 4 Cable assembly RSPFG NS 56P9607 2 Cable assembly LFG NS 56P9993 4 Shield light used on P N 56P9594 for S N XX AXXXX NS 56P9947 1 Parts packet NS 56P9988 1 Post mini S N XX 1XXXX NS 56P9989 1 Core Ferrite S N XX 1XXXX NS 56P9990 1 Tape Core S N XX 1XXXX Parts catalog 7 15 5055 xxx Assembly 7 Base 1 7 16 Service Manual 5055 xxx Assembly 7 Base 1 Index P N Units Description 7 4 56P9664 Frame paper feed 2 56P9508 Bracket ground 3 56P9512 Roller assembly paper carrying 4 56P9511 Roller assembly paper feed 5 11G0243 Interrupter photo 6 56P9665 Sens
79. Service Manual 5055 xxx Cover RIP board removal 1 Loosen the eight screws and remove the RIP cover by sliding upward 2 Remove the three harnesses and one flat cable of the RIP board connector 3 Remove the two screws from the parallel port connector and the screw from the USB connector 4 Remove the eight screws from the RIP board together with the parallel connector and remove the RIP board Repair information 4 9 5055 xxx Tray paper exit removal 1 Unlatch the hinge at the back side then unlatch the hinge on the front side 2 Remove the paper exit tray Belt up down clutch removal 1 Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the printer controller Remove the printer controller bracket and the high voltage power supply board 4 10 Service Manual 5055 xxx 2 Remove the C clip from the belt up 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 mounting board 3 Remove the connector from the belt up down detection sensor Repair information 4 11 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 remove
80. Straight Exit Straight Exit Idle Roller Path Select Gate i Register Idle Roller Input Paper Guide Register Roller i Accumulator j Stapler Unit 5055 xxx Sensor Switch Purpose A Paper input path sensor Detects paper input from printer Paper registration sensor Trigger for punching C Paper exit sensor face up Confirming paper path bin D Tractor home position Finds home position for driving belt sensor E Paper full sensor A Detecting paper full on tray 2 Paper detecting sensor Detects paper for stapling G Staple home position Finds home position for stapling sensor H No staple sensor Detects staple empty Finisher set switch Detects connection with printer J Staple cartridge set switch Detects staple cartridge open K Punch box detect sensor Detects punch box L Invert path sensor Detects invert paper jam M Paper exit sensor face Confirming paper path down bin N Elevator upper limit sensor Detecting face down bin P Elevator lower limit sensor Detecting face down bin Q Jogging home position Jogging home position for driving sensor bar R Paper upper level sensor B Detecting paper upper level Locations 5 23 5055 xxx Finisher Face Up Bin Tray1 Finisher Face Down Bin Tr
81. Type g 22 ge Screw Spring Pin L Screw Screw CD Dy S3 Tapping Screw Spring Lock Washer Tapping Screw Toothed Lock Washer Tapping Screw Resin Ring AQ 0 Tapping Screw Nut Set Screw Tapping Screw Parts catalog 7 81 5055 xxx Plain Washer Tapping Screw Screw 7 82 Service Manual Index A abbreviations adjustments finisher hole punch alignment 3 94 high capacity paper feed timing belt 4 3 procedures after replacement 2 1 attendance messages 2 34 C clearing the error log 3 32 communication error finisher 2 17 printer printhead controller board 2 16 1 33 configuration ID 1 32 3 30 connectivity 1 23 connectors duplex unit controller board 5 16 extension paper feeder controller board 5 16 high voltage power supply board 5 15 motor drive board 5 16 power source unit 1 board 5 14 power source unit 2 board 5 14 printer controller board 5 8 printhead controller board 5 12 RIP board 5 13 sensor board 5 15 size sensor board 5 17 counters permanent page counter setting page count 3 29 covers front left removal front removal 4 5 left side removal locations 5 1 operator panel removal 4 34 parts catalog 7 2 7 4 7 6 7 8 7 10 3 29 4 5 4 7 5055 xxx rear removal 4 6 right side removal RIP board removal solenoid removal top cover removal D defaults 3 26 dev
82. and printer on page 3 80 The staple test cannot be canceled or terminated once the test has begun As a result no buttons are active during the execution of this test Finisher Sensor Test This test determines whether or not the finisher sensors and switches are working correctly To run the test select the Sensor Sw Test operation from the Finisher Tests top level menu The following sensors and switches are listed in the bottom level menu Input Path Paper Register Tray 1 Exit Tractor Home Pos Paper Full A Paper Detect Staple Home Pos 3 20 Service Manual 5055 xxx No Staple Punch Box Detect Invert Path Tray 2 Exit Elev Upper Limit Tray Near Full Elev Lower Limit Jogging Home Pos Pap Upper Level Fin Set Switch Staple Cart Set To select one of the sensors switches above press Menu until the sensor switch is displayed Press Select The following is a sample screen that may be displayed Input Path CL Once the screen is displayed you can manually actuate each of the sensors or switches When the sensor is closed CL is displayed Likewise when the sensor is open OP is displayed If the wrong message 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 fuser activated by moving the sensor actuator Paper Register Activate the
83. assembly front C910 10 56P9970 1 Cover assembly front C912 11 56P9543 1 Magnet front cover latch 12 56P9542 1 Cover left front 13 56P9536 1 Cover left side 14 56P9537 1 Cover paper feed 15 56P9535 1 Cover solenoid 16 56P9531 1 Tray assembly exit 17 56P9538 1 Cover rear 18 56P9551 1 Cover adjustment NS 56P9544 1 Label MPT NS 56P9554 3 Core ferrite NS 56P9905 1 Kit operator panel overlay NS 56P9945 1 Parts packet Parts catalog 7 3 5055 xxx Assembly 2 Covers 2 S 7 4 Service Manual Assembly 2 Covers 2 5055 xxx Index P N Units Description 2 3 56P9557 1 Exit assembly face up Parts catalog 7 5 5055 xxx Assembly 3 Covers 3 7 6 Service Manual 5055 xxx Assembly 3 Covers 3 Index P N Units Description 3 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 face down roller Parts catalog 7 7 5055 xxx Assembly 4 Covers 4 7 8 Service Manual Assembly 4 Covers 4 5055 xxx Index P N Units Description 44 56P9584 1 Guide assembly turn Parts catalog 7 9 5055 xxx Covers 5 Assembly 5 7 10 Service Manual 5055 xxx Assembly 5 Covers 5 Index P N Units Description 5 1
84. condition Tray down motion stops when the Paper level sensor is OFF Down button is pressed Paper end 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 position The paper size sensor 1 detects the fixing screw 1 at the letter position Tray up motion stops when the up sensor is OFF not shielded Fixing Screw 1 Paper Size Sensor 1 gt 0 ae E 2 227 2 Eu T Fixing Screw 2 A Paper Size Sensor 2 N Side Fence e S lt 7 4 SS Positioning li EM Bracket Diagnostic aids 3 57 5055 xxx Residual paper detection mechanism 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 sheets About 300 sheets About 1 000 sheets About 2 000 sheets Near End Sensor 3 58 Service Manual 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 Paper End Sensor OT Paper Tray Edge Diagnostic aids 3 59 5055 xxx
85. control EPROM U5 If you replace the printer controller board remove EPROM U5 and install it on the new board Also check the printhead alignment If you change the EPROM record and input the following items using the diagnostic mode following EPROM replacement LED Printhead Light Quantity Printer Alignment X Y and Theta All Counters RIP controller board 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 following items in Diagnostic Mode Set Serial Number Configuration ID Transfer belt If you replace the transfer belt check the printer alignment X Y and Theta adjusted in diagnostic mode LED printhead controller board or LED printhead If you replace the LED printhead controller board or LED printhead check and adjust the following items in diagnostic mode LED Printhead Light Quantity Printer Alignment X Y and Theta 2 2 Service Manual 5055 xxx Start Initial check Before you start troubleshooting check the following Installation environment The power supply line voltage is plus or minus 1096 of the rated line voltage The machine is securely installed on a level surface in a well ventilated place The room temperature is between 10 and 32 50 and 90 F and the relative humidity between 20 and 80 Avo
86. der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen ACHTUNG Dieses Symbol weist auf eine AN gef hrliche elektrische Spannung hin die in diesem Bereich des Produkts auftreten kann Ziehen Sie vor den Arbeiten am Ger t den Netzstecker des Ger ts bzw arbeiten Sie mit gro er Vorsicht wenn das Produkt f r die Ausf hrung der Arbeiten an den Strom angeschlossen sein mu xii Service Manual 5055 xxx Pautas de Seguridad La seguridad de este producto se basa en pruebas y aprobaciones del disefio original y componentes espec ficos El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas La informaci n sobre el mantenimiento de este producto esta dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCI N este s mbolo indica que el voltaje A N de la parte del equipo con la que est trabajando es peligroso Antes de empezar desenchufe el equipo o tenga cuidado si para trabajar con l debe conectarlo Informa es de Seguran a e A seguran a deste produto baseia se em testes e apro
87. detection CN39 8 ON45 80 Cassette paper 2 2 3 6 CN37 3 CN38 4 L feeding solenoid sensor Color MCY ON OFF Closed turn guide detected Color MCY CNRCL PE DUPSG DUPPW ON OFF D GE Paper presence Cassette paper presence detection rawer connector 12 detection Photo interrupter Paper size 3 sensor Heater ON OFF Temperature pl CN406 BUS vi RIP Card v v v z CN407 CN409 sensor TNF CN102 13 101 4 CN104 3 CN106 9 Photo interrupter Photo interrupter Belt thermister p CN40822 Sensor cord CN14 103 7 CN105 22 3 3 zm 107 2 Charging bias transfer charged belt Y PE y A lt Sub frame R Operation CN Y 22 Panel U GNA 8108 iem Y Safety SW Power Supply 2 M contact point CN DC5V 3 3V Drum new sensor C contact point v ICN106 04 CNO3 102 Option Duplex unit SV 24 Solenoid Solenoid Bolenoid Solenoid contact point Drum new sensor CN106 HUAN contact point DS v Power supply 1 AC100V Eod 2 DC24V ncoder gt CNS Tija oNN CN01 4 1 9 main switch J CM AC100V inlet otor MOTOR 4 2 Motor driver asm Power cord J AC100V 50 60Hz v ov Y pper tier drawer connector 12 Encoder Paper presence Residual paper Paper detection sensor photo sensor Print head controll interruptor photo interruptor rint head controller CN04 14
88. gear unit sensor assembly 3 Remove the two screws of the drive gear unit sensor from the drum drive gear sensor assembly Repair information 4 15 5055 xxx Drive motor assembly removal 1 of Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the upper cassette left front cover and back cover Remove the turn guide Open the paper feed cover and remove the duplex unit Remove the side left cover Remove the connector two ground wires and power supply 1 Remove the connector CN2 CN4 and CN5 from the motor drive board Remove the four screws with spring washers from the drive motor Note When installing hold the motor securely and mount the Screws 4 16 Service Manual 5055 xxx Electronic box removal OQ Open the top unit and remove the back cover Remove the RIP board cover Remove the RIP board Remove the screws from the electronic box Disconnect the two cables from the rear of the electronic box and remove the box Repair information 4 17 5055 xxx Face down guide assembly removal Paper exit motor and full sensor removal 1 Open the top 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 t
89. hae ae 7 71 56P9474 Roller 7 71 56P9475 Knob caster 7 71 56P9476 Stop caster 7 71 56P9477 Housing caster 7 71 56P9478 Caster e aa 7 71 56P9479 au saos s delta we ede ac e CE 7 71 56P9480 Parts packet finisher 7 81 56P9482 Shaft A oov Rx demere fe 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 21 56P9503 Foot rubber 7 17 7 33 56P9504 Rail base right side 7 17 56P9504 Rail left side 7 33 56P9505 Rail base left side 7 17 56P9505 Rail right side 7 33 56P9506 Frame paper feed 7 35 56P9507 Actuator paper feed sensor 7 17 7 35 56P9508 Bracket ground 7 17 7 35 56P9509 Bushing metal 7 35 56P9510 Shaft paper feed 7 35 56P9511 Roller assembly paper feed 7 17 7 35 56P9512 Roller assembly paper carrying
90. light in black dots These black dots form an image of dots on the photosensitive drum The LED printhead minimizes the displacement of images during the color print process when images of multiple printheads overlap causing dot position accuracy to be much higher Since light from the volume of the LED array varies depending on the LED printheads the light emitting value is recorded in the EPROM of the printer controller When the LED printhead is replaced the light emitting value should be entered for each printhead while the printer is in maintenance mode Since the LED printhead and EPROM on the printhead controller board of this printer are paired the EPROM on the printhead controller board should also be replaced whenever the printhead is replaced Diagnostic aids 3 33 5055 xxx Development unit Toner forms the electrostatic image on the photosensitive drum during exposure The single component non magnetic toner and the lusterless color toner are weather resistant and fade little under ultraviolet rays This is helpful in saving documents Toner in the hopper is agitated and supplied to the development roll by the supply roll A conductive rubber doctor blade is fitted to the development roll Toner enters between the development 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 photosen
91. motor 11 56P9868 1 Board high capacity feed 12 56P9873 1 Cable assembly power supply out 13 56P9872 1 Cable assembly power supply in 14 56P9874 1 Cable assembly power supply 15 56P9870 1 Converter DC DC 16 56P9869 1 Power supply HCF 17 56P9867 1 Cable assembly drawer ground 18 56P9861 4 Roller track 19 56P9864 1 Switch micro 20 56P9530 1 Switch push 21 56P9501 1 Spring pressure pickup 22 56P9863 1 Switch HCF push NS 56P9961 1 Parts packet Parts catalog 7 49 5055 xxx Assembly 22 High capacity feeder 5 BY ri 9 5 N 3 3 gt x i gt 4 7 50 Service Manual 5055 xxx Assembly 22 High capacity feeder 5 Index P N Units Description 22 4 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 Motor HCF DC 8 56P9887 1 Bracket front idler NS 56P9962 1 Parts packet Parts catalog 7 51 5055 xxx Assembly 23 High capacity feeder 6 7 52 Service Manual 5055 xxx Assembly 23 High capacity feeder 6 Index P N Units Description 23 1 56P9892 1 Plate upper side fence 2 56P9893 2 Knob stopper 3 56P98
92. paper registration sensor and observe the display OP CL Tray 1 Exit Activate the tray 1 exit sensor OP CL Tractor Home Pos Activate the tractor home sensor by rotating the green paper clearing knob so that the tractor belt flag actuates the sensor Paper Full Activate the paper full A sensor by operating the sensor flag while observing the display Paper Detect Activate the paper detect sensor by placing a piece of paper into the sensor photo interrupter Diagnostic aids 3 21 5055 xxx Staple Home Position Activate the staple home position sensor by rotating the geared wheel inside the stapler clockwise If the sensor is working properly the display should change from CL to OP at approximately 180 of rotation of the wheel No Staple Remove the staple cartridge to activate the no staple sensor Punch Box Detect Remove the punch box and activate the punch box detector sensor level Invert Path Activate by placing a piece of paper into the sensor photo interrupter Tray 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 the sensor flag to clear the elevator upper limit sensor thereby activating the sensor Elevator Lower Limit Activate by inserting a piece of paper into the elevator lower limit sensor photo interrupter Jogging Home
93. 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 photodevelopers and the transfer belt If the problem remains go to Uneven printing on page 2 97 Cyan dots or streaks in area of like cyan coverage L Make sure the printer code is at EC2 level or later The page is blank Be sure the affected print unit is completely installed in the printer Replace the affected toner cartridge If the problem remains go to image on page 2 94 2 90 Service Manual 5055 xxx Problem Action Toner smears or rubs off the Be sure you re using recommended page paper or media Be sure you have selected the correct Paper Weight setting for the media you re using Be sure the top cover is completely closed and both sides are snapped shut You may need to replace the fuser Color fades with fuzzy poorly Print out a Menu Setting page and check defined edges the level of supplies If a toner cartridge shows 10 or less shaking the cartridge may improve the printout Remove the cartridges and photodevelopers from the printer Use a lint free dry cloth to clean the LED s of any stray toner 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
94. pins 3x12 ACP 50 Parallel pins 2 5x18 NS 56P9947 1 Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind P tight screws 3x8 Zn 3K 50 Bind P tight screws 3x10 Zn 3K 50 Bind screws M3x4 Zn 3K 50 Bind screws M3x8 Zn 3K 50 Bind screws M3x6 Ni 3 50 Screws with washers M3x30 Zn 3K 50 E rings ES 6 ACP 7 74 Service Manual 5055 xxx Assembly 32 Parts packets continued Index P N Units Description NS NS NS 56P9948 56P9949 56P9950 1 Parts 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 Pans with flange P tight screws 3x8 Zn 3K 50 E rings ES 5 ACP 50 E rings ES 6 ACP 50 Spring pins 2x10 ACP Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind S tight screws 3x8 Zn 3R 50 E rings ES 4 ACP Parts 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 E rings ES 3 50 E rings ES 5 ACP 50 E rings ES 6 ACP 50 Spring pins 2x10 ACP 50 Bind screws M3x8 Zn 3K 50 Bind screws M2x8 Ni 3 Parts catalog 7 75 5055 xxx Assembly 32 Parts packets continued Index P N Units D
95. powering up Replace the tray elevator motor Go to step 3 Disconnect CN4 at the tray elevator motor Disconnect PJ4 on the finisher control board Measure for continuity between CN4 pin 1 and PJ4 pin 7 Measure for continuity between CN4 pin 2 and PJ4 pin 8 Is there continuity in both locations Go to step 4 Replace the cable Measure for 24 V dc 10 between pins 1 and 2 on connector Is 24 V dc present Replace the finisher control board Replace the finisher power supply 2 32 Service Manual 999 Stapler Motor Error 5055 xxx board cable Step Questions actions Yes No 1 Are staples jammed in the Go to step 2 Go to step 3 stapler 2 Clear the staple jam and Replace the Problem solved run the staple test in staple cartridge diagnostic mode or run a and to go step 4 staple job Does the problem reoccur 3 Are the connectors CN5 Go to step 5 Securely the stapler and PJ1 on the connect the finisher control board connectors securely connected 4 Did replacement of the Problem Replace the stapler cartridge resolvethe resolved stapler problem 5 Make sure the finisher set Replace the Replace the Switch is activated stapler finisher control Measure for 5 V dc board between pins 11 and 12 on stapler connector CN5 Is 5 V dc present 6 Did replacement of the Problem solved Go to step 7 finisher control b
96. remaining 4 39 paper size sensor board assembly 4 39 sensor board 4 50 temperature 4 54 turn guide cover 4 65 serial number 1 32 3 29 service 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 72 operator panel 2 73 options 2 98 paper carrying 2 74 paper exit face up exit assembly 2 82 paper tray missing 2 83 photodeveloper missing 2 84 power supply 2 85 serial port 2 98 1 6 Service Manual transfer belt up down 2 87 service communication 2 16 service error tray elevator motor 2 32 900 unrecoverable software error 2 4 910 drive motor error 2 4 911 paper exit motor error 2 5 912 high capacity feed motor error 2 5 917 RIP fan error 2 5 918 main unit fan error 2 6 919 power supply fan error 2 6 92x toner sensor error 2 9 920 fuser error fuser heater trouble 2 6 923 upper fuser thermistor open error 2 7 924 lower fuser thermistor open error 2 7 925 HVU error 2 8 930 printhead error yellow 2 10 931 printhead error magenta 2 11 932 printhead error yellow 2 12 933 printhead error black 2 13 934 drum sensor color 2 14 935 drum sensor black 2 14 936 9 cassette error 2 15 940 high capacity feed sensor error 2 15 941 high capacity feed tray error 2 15 942 duplex error 2 16 945 engine flash error 2 1
97. sassa a 4 9 Tray paper sos wr ERE ERG Ee wd 4 10 Belt up down clutch removal 4 10 Belt up down detection sensor removal 4 11 Cassette quide removal 5235 21 33 3 9 Red 4 12 Connector duplex unitremoval 4 13 Separation fingers removal 4 14 Sensor cleaner removal u e se 4 14 Drive gear unit sensor assembly removal 4 15 Drive motor assembly 4 16 Electronic box 4 17 Fanning 4 19 Front cover open switch actuator removal 4 20 Fuser removal eX 4 21 High voltage power supply board HVU removal 4 23 LED piinttiead removal ue ee e 4 24 Eraser enda sue as d odd eoe d 4 27 Lock handle assembly removal 4 28 Main drive unit removal 4 29 Main unit fam rempVal 4 32 Motor drive board see does Rm 4 33 vi Service Manual 5055 xxx Multipurpose feeder paper present sensor removal 4 33 Multipurpose feeder tray removal 4 34 Operator panel removal 4 34 Paper carrying fram
98. symptom table 2 63 disk test clean 3 24 DRAM memory 3 12 finisher hole punch 3 20 finisher sensor test 3 20 finisher staple 3 20 flash 3 25 hardware 3 12 high capacity paper feed 3 18 high capacity paper feed sensor switch 3 19 input source print 3 10 LCD hardware 3 12 parallel wap 3 14 print 3 10 print quality pages 3 11 quick disk 3 23 ROM memory 3 13 serial wrap 3 16 theory belt unit 3 42 belt up down 3 43 cassette paper feeder 3 37 cleaning unit 3 35 clearing paper jams 3 46 configuration 3 33 delivery 3 41 development unit 3 34 drive system 3 36 duplex unit 3 44 electrophotography 3 33 electrophotography process 3 33 expansion paper feeder 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 registration unit 3 38 Index 1 7 5055 xxx separation unit 3 39 transfer unit 3 34 tools 1 31 transfer belt removal 4 56 removal inoperable operator panel 4 60 removal partial removed 4 64 tray up down mechanism 3 54 troubleshooting 2 88 V viewing the error Log 3 31 viewing the permanent page count 3 29 weight printer 1 3 1 8 Service Manual 5055 xxx Part number index P N Description Page 1100328 Power cord USA Canada APG LAD 7 25 1100329 Power cord 7 25 1100330 Power cord
99. the cover Remove the two screws from the drive cover and remove the Cover Remove the screw from the clamp plate and remove the plate Remove the connector and the two screws from the pickup solenoid and remove the solenoid Clamp Plate Clamp Paper Feed Front and Rear Repair information 4 83 5055 xxx HCF paper end sensor removal HCF paper size sensors 1 2 removal 1 Cover the paper level sensor with your hand and press the down button The tray moves down Lower the tray until the down sensor turns on Remove the front cover and transfer cover Remove the two screws on the front and rear sides of the side fence Mark the locking position of the side fence locking stay Remove the two screws on the side fence locking stay Remove the screw and connector from paper end sensor and remove the sensor Remove the screw and connector from the clamp plane and remove the paper size sensors 1 and 2 Side Fence Locking Stay Paper Size Sensors 1 2 Marking Side Fence Front 4 84 Service Manual 5055 xxx Notes To prevent damage to the stay hold the stay when removing the sensors Besure 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 Black Yellow Top Cover Switch 2 Repair information 4 85 5055 xxx
100. the printer sits on top of the printer stand The printer cabinet raises the printer to the correct height for use with the optional finisher and high capacity feeder The printer cabinet and high capacity feeder can be installed at the same time C91x 1 optional drawer C91xn or dn no optional drawers 1 22 Service Manual 5055 xxx Printer base is customer installable and attaches so the printer sits on top of the printer base If used with two optional 550 sheet drawers the printer base raises the printer to the correct height for use with the optional finisher and high capacity feeder The printer base and high capacity feeder can be installed at the same time C91 x 8 optional drawers C91 and C91 2 optional drawers Connectivity Standard Lexmark C91x Bidirectional parallel and USB Lexmark C91xn and Lexmark C91 xdn 10 100BaseTX Ethernet and USB Note USB is supported only under Windows 98 SE Windows Me Windows XP Windows 2000 operating systems Sun s Sun Ray appliances running Sun Ray Server code version 1 2 or later Sun Blade workstations and Apple Macintosh iMac computer with Operating System 8 6 or higher A USB cable is included with this card Optional internal local connections Tri Port Adapter RS 232 RS 422 Serial LocalTalk and Infrared e RS 232C Serial Parallel C Interface Card General information 1 23 5055 xxx Network connections Internal netwo
101. the clip of the paper carrying clutch should be securely set to the stop and the shaft of the paper carrying clutch and spring should be securely in contact with each other Repair information 4 35 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 4 36 Service Manual 5055 xxx Paper feed frame removal 1 Open the top unit and remove the RIP board cover RIP board RIP box and electronic box Open the turn guide and paper feed cover and pull out the duplex unit halfway 2 Remove the belt unit 3 Disconnect the connector and remove the three screws and the screw from the paper feed frame 4 Remove the clip from the paper feed roller shaft and remove the gear 5 Remove the paper feed frame 6 Disconnect the sensor cable Repair information 4 37 5055 xxx Paper feed roller removal oR Remove the front cover Remove the manual paper feed tray Remove the right side cover and turn guide Remove the upper cassette Release the clutch until the paper feed roller screws are visible Turn the paper feed roller and remove the screws from the roller Sets T Seu T DR 6 Remove the paper feed roller from the shaft Note If the paper feed roller surface is stained with oil or other contaminants clean it with cloth moistened with alcohol Paper present senso
102. the jam Close the cover Press Go Diagnostic aids 3 51 5055 xxx High capacity feeder HCF Paper feed and separation mechanism The high capacity feeder consists of a tray and paper transfer mechanisms The paper feed and separation mechanism uses a friction roller separation and paper feed system with a non contact magnet type maintenance free torque limiter When the paper feed clutch turns on the paper feed roller shaft rotates and the paper feed roller is driven with the one way clutch The call roller rotates with the relay gears to feed the top paper The reverse roller rotates along with the paper feed roller During paper feed if two sheets feed the reverse roller rotates by the torque limiter returning the lower sheet When the paper feed sensor reflection type sensor detects the paper the pickup solenoid turns off to raise the call roller transferring the paper to the registration roller Paper Feed Clutch Paper Feed Motor Pickup Solenoid 3 52 Service Manual 5055 xxx Registration operation When the paper feed motor rotates the transfer roller is driven with relay gears The reverse roller shaft rotates the gears on the paper feed clutch in the direction of the arrow and stops by the friction force of the paper feed roller Paper Feed Clutch Paper Feed Motor Transfer Roller Call Roller Paper Feed Roller Reverse Roller torque limiter built in Diagnostic aids 3 53 50
103. the screen is updated with the result If the test is successful the Pass Count increments by 1 If the test fails a failure message displays for approximately three seconds and the Fail Count increments by 1 Once the maximum pass count or fail count is reached the test stops and final test results appear e ROM Checksum Error ROM Burst Read Error Press Return or Stop to exit the test Diagnostic aids 3 13 5055 xxx Parallel Wrap Test The Parallel Wrap Test checks the operation of each parallel signal using a wrap plug To perform the wrap test 1 Disconnect the parallel interface cable and install the parallel wrap plug 2 Select HARDWARE TESTS from the Diagnostics Menu 3 Select Parallel Wrap to initiate the Parallel Wrap Test 4 Select the appropriate Parallel Wrap Test Parallel Wrap Parallel 1 Wrap The printer begins testing the parallel hardware and the following message is displayed Parallel Wrap PAHHHHE Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail count is 99 999 The power indicator blinks indicating the memory test is in process The printer continually runs the same test until canceled from the operator panel by pressing Re
104. wheel toner set is clean and free or replace the of dirt or paper dust toner set Is the encoder wheel clean and free of dirt or paper dust 3 Is the toner remaining Go to step 4 Clean or replace photo interrupter sensor the toner clean and free of remaining photo obstructions interrupter 4 Is the connector of the Replace the Properly connect problem color properly printer controller the connector connected on the printer board controller board Magenta CN18 Yellow CN21 Cyan CN19 Black CN22 2 58 Service Manual 5055 xxx Map 8 False 40 Tray x Size Sensor Error message Step Questions actions Yes No 1 On the high capacity Go to step 2 Replace the feeder are the paper size missing adjusting screws present on thumbscrew or the upper portion of the screw them in all side fence and fully the way screwed into the adjusting bracket 2 Observe the LEDs 1 and 2 Replace the Replace the on the HCF control board HCF control affected sensor while unscrewing the paper board Paper size size adjusting sensor 1 for thumbscrews Do the LEDs 11 inch or paper light when the screws are size sensor 2 for loosened all the way A4 Map 9 False 41 Open Bin 1 Exit Tray message Step Questions actions Yes No 1 Is the exit tray switch Replace the Go to step 2 actuator broken or paper exit tray damaged 2 Disconnect CN31 from the Replace the Replace the printer controller board When activa
105. xxx Step Questions actions Yes No 1 Remove the rear cover on Replace the Replace the the high capacity feeder HCF card cover open and observe LED 9 on the micro switch HCF card while actuating the cover open micro Switch Does the LED go on and off while opening and closing the door Diagnostic information 2 55 5055 xxx Map 4 False Tray x Low Empty message Step Questions actions Yes No 1 Is the Tray xLow message Go to step 2 Go to step 5 present 2 Is the paper remaining Go to step 3 Repair or actuator inside the cassette replace the drawer binding or operating cassette incorrectly 3 Are connectors CN35 and Go to step 4 Properly connect CN36 on the printer the connectors controller board and CN10 on the expansion feeder control card associated with the failing tray properly connected 4 Replace the paper Problem solved Replace the remaining sensor board for expansion the problem tray Does this feeder control fix the problem card 5 Is the paper present flag Go to step 6 Repair or operating correctly replace the failing parts 6 Are connectors CN35 and Go to step 7 Properly connect CN36 on the printer the connectors controller board and CN6 on the expansion feeder control card associated with the failing tray properly connected 7 Replace the paper present Problem solved Replace the sensor Does this fix the associated pr
106. xxx Assembly 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 56P9478 4 Caster 8 56P9479 2 Cap Parts catalog 7 71 5055 xxx Assembly 32 Miscellaneous options Index P N Units Description NS 12G6509 Card SDRAM DIMM NS 56P9910 Card assembly 128MB SDRAM memory NS 56P9911 Card assembly 256MB SDRAM memory NS 56P9912 Card assembly 4MB Flash DIMM memory NS 56P9913 Card assembly 8MB Flash DIMM memory NS 56P9914 Card assembly 16MB Flash DIMM memory a ln ln nol on NS 56P9982 Hard Disk 5 GB w Mounting Kit formatted Card Token Ring Card Ethernet 10 100Base TX Card Ethernet 10BaseT 2 Card RS 232C serial parallel 1284 A C interface NS 56P9934 NS 1261695 NS 1261696 NS 56P0161 m ln n NS 99A0560 NS 99A0424 NS 99A0545 NS 56P0159 Card Tri Port adapter Card infrared adapter Card external serial adapter Card Coax Twinax adapter for SCS NS 56P0162 Adapter parallel 1284 C B NS 13A0296 Cable Twinax NS 13A0297 Cable Coax NS 56P0598 Card CGM NS 56P1204 IPDS SCS TNe C910 NS 56P1762 IPDS SCS TNe C912 NS 56P9923 Card ImageQuick C910 NS 56P9442 Card ImageQuick C912 NS 56P1121 Card bar code C910 NS 56P9440 Card bar code C912 NS 56P9441 Card PrintCryption C912 NS 56P9925 N
107. 055 xxx Upper fan removal 1 Open the top unit and remove the toner cartridges 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 4 Remove the two screws from the right fan and remove the fan 4 66 Service Manual 5055 xxx Options removals Expansion paper feeder removal 1 2 Remove the cassette Remove the two screws from the front cover and remove the cover Remove the two screws from left side cover and remove the cover Remove the two screws from right side cover A and remove the cover Remove the two screws from right side cover B and remove the cover Remove the screw from right side cover C and remove the cover Remove the six screws from rear cover and remove the cover Remove the turn guide The cover is hinged in place Repair information 4 67 5055 xxx 9 Remove the screw from the paper detection cover and remove the cover 11 Remove the high capacity feeder guide The cover is hinged in place 12 Remove the four screws from the paper feed roller assembly N5 and remove the roller S lt SA OP E SN 4 68 Service Manual 5055 xxx 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 conn
108. 12 RollerF Lu indie e e ag rs duos 7 59 56P9313 Unit hole punch U S only 7 57 56P9314 Unit 4 hole punch non U S 7 57 56P9315 Assembly punch drive 7 59 56P9316 Bushing 7 61 9 17 tas alin pee psu 7 61 S6P9318 Sprifigy Br seanse mace spasere 7 59 56P9319 Assembly exit guide straight 7 57 56P9321 Springs eR 7 57 56P9324 Cable sensor relay 7 57 7 67 56P9325 Cable front side panel 7 67 56P9326 Cable DC power supply 7 67 56P9327 Cable upper side panel 7 57 56P9329 Assembly tractor motor 7 63 56P9331 Wile gre Ren a Ri ta SW uy ae 7 65 56P9332 Spring G 2 eS A ELS 7 65 56P9333 Belt timing 60S3M408 7 63 56P9334 Assembly solenoid 7 59 56P9335 Clutch registration 7 59 56P9338 Pulley T56 7 59 56P9339 Belt timing 6082M334 7 59 56P9340 Packet parts 7 67 56P9341 Assembly feed motor 7 59 56P9342 Assembly bridge 7 67 56P9343 Assembly sensor cable 7 67 56P9344 Cover s
109. 17 5055 xxx High capacity feeder tests High Capacity Paper Feed Test Test paper feed operation 1 Turn on the docking safety switch with a non metallic object The interface cable with the printer controller board need not be connected Close the top cover or manually activate the cover switch Load paper Wait until the paper tray stops and the pickup solenoid turns off With the cover closed or with the cover switch activated press and hold the tray down button for more than 1 2 second OQ GC In steps 1 and 2 paper feeding starts and is continuously fed until the cover is opened The test ends when the tray motor stops and the paper ejects or the tray down button is released Test sequence 1 The tray motor moves the tray to the upper limit 2 The pickup solenoid activates then de activates 3 When the tray down switch is pressed for longer than 1 2 second the paper feed motor starts the paper feed clutch operates and feeding begins 4 Feeding can be stopped by releasing the tray down button 3 18 Service Manual 5055 xxx High Capacity Paper Feed Sensor Switch Test Check the condition of each sensor from the lighting of LEDs on the high capacity paper feed board When each sensor operates with the power supplied the associated LED lights To perform the test Interrupt the photointerrupter sensor signal or actuate the micro Switch being tested while observing the associated LED on
110. 3 56P9741 14 56P9738 Cable power switch Board 120 V motor driver Board 230 V motor driver Cable asm conditioning printer controller Board heater drive Resistor conditioning 230 V only U A nono Cable assembly conditioning joint 230 V only Fuse thermal 230 V only Motor assembly 120 V Motor assembly 230 V Cable conditioning resistor 15 56P9943 16 56P9698 16 56P9699 17 56P9740 18 56P9713 19 56P9708 20 56P9722 20 56P9723 21 56P9737 22 56P9711 22 56P9712 23 56P9981 Fan power supply Cable assembly duplex connector Power supply 120 V 1 Power supply 230 V 1 Insulator sheet Cable THB drawer Cable THB drawer EMEA Board printer controller C910 C912 S N XX 0XXXX 23 56P9992 1 Board printer controller C912 S N XX 1XXXX 24 56P9729 1 EPROM printer controller 25 56P9732 1 Belt power supply ln ol 0 4 0 4 0 4 0 4 0 4 Parts catalog 7 23 5055 xxx Assembly 10 continued Electrical 7 24 Service Manual 5055 xxx Assembly 10 continued Electrical Index P N Units Description 10 26 56P9734 27 56P9731 28 56P9730 29 56P9714 30 56P9727 31 56P9726 32 56P9724 32 56P9725 33 56P9715 NS 11D0328 NS 11D0329 NS 11D0330 NS 11D0331 NS 11D0332 NS 11D0333 NS 11D0334 HCF finisher D sub assembly Cable assembly finisher Cable assembly HCF Board high voltage power supply Cable assembly print
111. 41 56P9809 Roller drive feed 7 41 56P9810 Roller follow up feed 7 41 56P9811 Roller middle feed 7 41 56P9812 Roller re feed 7 41 56P9813 Roll release 7 41 56P9814 Bearing release 7 41 56P9815 Spring reed roller 7 41 56P9816 Spring re feed roller 7 41 56P9817 Gear carrying roller 7 41 56P9818 Pulley carrying roller timing 7 41 56P9819 Pulley feed roller 7 41 56P9820 Pulley re feed roller 7 41 56P9821 Knob paper re feed 7 41 l 18 Service Manual 5055 xxx 56P9822 Belt timing 7 41 56P9823 Belt timing llis 7 41 56P9824 Plate paper carrying drawer 7 41 56P9825 Plate paper re feed 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 56P9831 Cable assembly duplex drawer 7 41 56P9833 Cover front
112. 412 1 Spacer 26 56P9413 1 Assembly motor bracket 27 56P9341 1 Assembly feed motor 28 56P9414 1 Pulley 29 56P9315 1 Assembly punch drive 30 56P9318 1 Spring B Parts catalog 7 59 5055 xxx Assembly 26 continued Finisher feed 1 7 60 Service Manual Assembly 26 continued Finisher feed 1 5055 xxx 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 Parts catalog 7 61 5055 xxx Assembly 27 Finisher feed 2 7 62 Service Manual Assembly 27 Finisher feed 2 5055 xxx Index P N Units Description 27 1 56P9300 1 Assembly jogging unit 2 56P9422 1 Pin N 3 56P9423 1 Pulley 219 220 4 56P9417 1 Flange 5 56P9333 1 Belt timing 60S3M408 6 56P9329 1 Assembly tractor motor 7 56P9437 2 Belt timing 8 56P9301 1 Assembly guide stack Parts catalog 7 63 5055 xxx Assembly 28 Finisher elevator HMM 3 9 7 64 Service Manual 5055 xxx Assembly 28 Finisher elevator Index P N Units Description 28 1 56P9308 1 Assembly elevator motor 2 56P9448 1 Washer 3 56P9449 1 Pin 4 56P9450 2 Pulley wire A 5 56P9451 1 Shutter 6 56P9452 1 Pin 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 246 733 13 56P9457 1 Gear 790 714 14 56P9458 1 G
113. 5 Remove the two hole punch unit screws and remove the unit 4 92 Service Manual 5055 xxx Inverter paper exit discharge brush removal Remove the external covers Remove the finisher control board Remove the upper left panel Remove the two discharge brush screws and remove the brush Bog m Inverter paper exit roller removal 1 Remove the front and rear external covers 2 Remove the four lower left panel screws and remove the panel 3 Disconnect the harness connect from the lower left panel Repair information 4 93 5055 xxx 4 Remove the inverter paper exit roller bushing Inverter Paper Exit Roller 5 Remove the inverter idle gear 6 Remove the inverter drive gear and bushing Drive Gear and Bushing Idler Gear 7 Remove the inverter paper exit roller 4 94 Service Manual 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 Sensor Connector Motor Connector 5 Remove the jogging unit Repair information 4 95 5055 xxx Path select gate removal Remove the external covers Remove the two screws from the top cover and remove the cover Remove the gate solenoid with mounting bracket Remove the straight paper e
114. 55 xxx Tray up down mechanism The driving force of the tray motor transmits to the tray driving pulley through the gears Moving the tray moves up and down through the tray driving belt After the paper loads and the top cover is set the pickup solenoid turns on to lower the call roller When the tray moves up the call roller is raised by the top surface of the paper and the shield plate on the up sensor is released from the up sensor which turns off the tray motor Tray Driving Pulley 3 54 Service Manual 5055 xxx Also when the top surface of the paper lowers during printing and the up sensor is shielded the tray motor again rotates forward to raise the paper Pickup Up Sensor mS 27 A lt 4 Call Roller When the down button is pressed the tray motor reverses to move the tray down During the down motion of the tray as the top surface of paper passes the paper level sensor the tray motor stops The Diagnostic aids 3 55 5055 xxx tray moves down by about 500 sheets The down sensor detects the tray lower limit position Down Button Paper Level Sensor Motor 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 Upsensor is ON shielded during printing Top cover is closed or when up sensor is ON 3 56 Service Manual 5055 xxx Tray down
115. 56P9959 1 Parts packet including 50 E rings ES 3 7 78 Service Manual 5055 xxx Assembly 32 Parts packets continued Index P N Units Description NS NS 56P9960 56P9961 50 E rings ES 4 ACP 50 E rings ES 6 ACP 50 RS set screw cp M3x3 Zn 3K 50 RS tight screws M4x6 50 RS tight screws M4x8 Parts packet including 50 Bind S tight screws 3x10 Zn 3R 50 E rings ES 4 ACP 50 RS tight screws M3x14 50 RS tight screws M4x6 50 RS tight screws M4x8 50 RS tight round top screws M3x6 Parts packet including 50 E rings ES 4 ACP 50 RS tight screws M3x8 50 RS tight screws M3x14 50 RS tight screws M4x6 50 RS tight screws M4x8 Parts catalog 7 79 5055 xxx Assembly 32 Parts packets continued Index P N Units Description NS NS 56P9962 56P9963 1 Parts packet including 50 Screws with spring washers M4x30 Zm 3R 50 E rings ES 5 ACP 50 Plain washers M4 Zn 3R 50 RS tight screws M4x6 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 ACP 50 RS tight screws M4x6 50 RS tight round top screws M4x6 7 80 Service Manual 5055 xxx Assembly 33 Finisher parts packet P N 56P9480 Pin Retaining Ring E
116. 6 946 printer printhead controller board communication 2 16 947 finisher communication error 2 17 948 machine ID error 2 17 949 tray x communication error 2 18 950 printer control board 2 18 952 NVRAM chip failure 2 18 954 NVRAM CRC failure 2 18 955 code CRC 2 19 956 processor failure 2 19 5055 xxx 957 ASIC failure 2 19 T 958 NAND failure 2 19 960 RAM slot 1 bad 2 19 technical specifications 1 2 961 slot 2 bad 2 19 onm 3 12 962 RAM slot bad 2 19 device 3 23 964 emulation error 2 19 970 standard network error 2 20 975 unrecognizable network port 2 20 976 unrecoverable software error in network port 2 20 978 bad checksum 2 20 979 Flash parts failed 2 20 980 face up down switching error 2 21 981 belt up down sensor 2 22 982 sensor controller 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 2 28 996 finisher jogging motor 2 30 997 finisher tractor motor 2 31 999 stapler motor 2 33 Service errors 2 4 service precautions 4 1 setting configuration ID 3 30 setting the page count 3 29 size detection 3 57 specifications connectivity 1 23 environment 1 27 paper and media 1 8 power and electrical 1 26 technical 1 2 start 2 3 sub frame parts catalog 7 17 removal 4 52 Switches locations 5 4
117. 6P9746 Cover RIP box 7 27 56P9747 Cable assembly power MAC 7 27 56P9748 Cable assembly MIF 7 27 56P9749 Cable assembly power RIP 7 27 56P9750 Fan RIP 7 27 56P9751 Fuser 120 V eee eens 7 29 56P9752 Fuser 230 7 29 56P9765 Cover front feeder 7 33 56P9766 Cover left side 7 33 56P9767 Cover right side A 7 33 56P9768 Cover rear 7 33 56P9769 Cover right side B 7 33 56P9770 Cover right side C 7 33 56P9771 Gear feeder 7 33 56P9772 Gear feeder D 7 33 56P9773 Gear feeder E 7 33 56P9774 Motor feeder drive 7 33 56P9775 Cable assembly size Sensor 7 33 Part number index 1 17 5055 xxx 56P9776 Board paper remaining sensor 7 33 56P9777 Cable assembly upper optional drawer 7 33 56P9778 Cable assembly lower optional drawer 7 33 56P9779 Board expansion feeder control 7 33 56P9781 Lever clut hk ads near t epe ULLA sad 7 35 56P9782 Spring solenoid
118. 8 Assembly 13 CGassetle s s 7 30 Assembly 14 Expansion feeder 1 7 32 Assembly 15 Expansion feeder 2 7 34 Assembly 16 Duplex unit 1 22r 7 38 Assembly 17 Duplex unit 2 22 seen 7 40 Assembly 18 High capacity feeder 1 7 42 Assembly 19 High capacity feeder 2 7 44 Assembly 20 High capacity feeder 3 7 46 Assembly 21 High capacity 4 7 48 Assembly 22 High capacity feeder 5 7 50 Assembly 23 High capacity feeder6 7 52 Assembly 24 Finisher 7 54 Assembly 25 Finisher 7 56 Assembly 26 Finisher feed 1 7 58 Assembly 27 Finisher feed 2 7 62 Assembly 28 Finisher 7 64 Assembly 29 Finisher 7 66 Assembly 30 Finisher docking 1 7 68 Assembly 31 Finisher docking 2 1 222 ern 7 70 Assembly 32 Miscellaneous options 7 72 Finisher parts packet 5055 xxx P SEP O onia E E 7 81 EE E ER NU e e dE l 1 Part number MOX cedes mud x ace Een 1 9 X Service Manual 5055 xxx Safety information The safety of this product is based on testing and approvals of the origina
119. 91 2 Knob tray 4 56P9890 2 Plate paper adhesion 5 56P9915 1 Fence assembly front side 6 56P9894 1 Fence assembly rear side 7 56P9528 2 Interrupter photo 8 56P9889 1 Pad friction NS 56P9963 1 Parts packet Parts catalog 7 53 5055 xxx Assembly 24 Finisher covers 13 EPI TM z 2 7 54 Service Manual 5055 xxx Assembly 24 Finisher covers Index P N Units Description 24 1 56P9353 1 Cover top 2 56P9348 5 Screw A 3 56P9355 1 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 B 11 56P9365 1 Cover staple A 12 56P9367 1 Cartridge staple 13 56P9363 1 Stapler 14 56P9364 1 Cover staple B 15 56P9354 1 Assembly dust box Parts catalog 7 55 5055 xxx Assembly 25 Finisher frame 7 56 Service Manual 5055 xxx Assembly 25 Finisher frame Index P N Units Description 25 1 56P9321 2 Spring 2 56P9324 1 Cable sensor relay 3 56P9369 12 Assembly spring plate C 4 56P9370 1 Frame guide 5 56P9371 1 Spring 6 56P9372 1 Brush static discharge 7 56P9373 2 Screw M4 8 56P9374 2 Frame C guide 9 56P9375 1 Shaft D 10 56P9376 1 Bushing 11 56P9377 1 Roller D 12 56P9378 1 Plate E spring 13 56P9380 2 Sensor photo 14 56P9381 1 Fra
120. 9436 Cable ans earl tatg 7 57 56P9437 Belt timing 7 63 56P9440 Card bar code C912 7 72 56P9441 Card PrintCryption C912 7 72 56P9442 ImageQuick C912 7 72 56P9448 Washer 7 65 6 9449 Smedt baken dO NUR RR AUR tere 7 65 56P9450 Pulley wire 7 65 56P9451 Shutter reset sonar getan 7 65 56P9452 redde Pere 7 65 56P9453 Roler dd keel Ad dar 7 65 56P9455 Bracket EEN ee 7 65 56P9456 Gear 246 233 7 65 56P9457 Gear Z90 Z14 7 65 56P9458 Gear Z25 Z20 7 65 56P9459 Drum wire ce e 7 65 1 12 Service Manual 5055 xxx 56P9460 Gear 230 b aqu a dci 7 65 56P9463 Pulley wire B 7 65 56P9465 Assembly Sensor 7 65 56P9467 Screw thumb 7 69 56 468 5 10 45888 ex hd 7 69 56P9469 Bracket 7 69 56P9470 Switch 66 7 69 56P9472 Screw lock 7 71 56P9473 Stud lo k Maeda
121. 99 represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail count is 99 999 3 12 Service Manual 5055 xxx The power indicator blinks indicating the memory test is in process The printer runs this test continually The test can be terminated by powering off the printer Each time the test finishes the screen is updated with the result If the test is successful the Pass Count increments by 1 If the test fails a failure message displays for approximately three seconds and the Fail Count increments by 1 Once the maximum pass count or fail count is reached the test stops and final test results display ROM Memory Test The ROM Memory Test checks the validity of the RIP code and fonts When this test is selected from the operator panel the printer begins testing ROM memory and the following message is displayed ROM Memory Test Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail count is 99 999 The power indicator blinks indicating the memory test is in process The printer runs this test continually The test can be terminated by powering off the printer Each time the test finishes
122. Diagnostic aids 3 67 5055 xxx Accumulator Tractor Drive Motor Invert Path Sensor Paper Detection Sensor Belt Home Position Sensor Paper registration sequence Paper is stopped at the hole punching position momentarily before the paper standstill clutch turns ON and changes to open At this point the driving force cannot be transmitted to the register rollers 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 entrance The paper buckle feeds downward to the lower entrance paper guide where it is hole punched at the leading edge The paper standstill clutch turns OFF and changes to close as the driving force transmits to register rollers and the paper transportation restarts 3 68 Service Manual 5055 xxx Punch unit driving sequence When the paper feed motor drives the driving force is transmitted through the punch unit drive gear to the clutch gears of the punch unit Since the punch clutch is normally opened OFF the driving force is not transmitted 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 the cam causes the paper to be hole punched Immediately after one turn of the shaft the punch clutch turns OFF and the driv
123. E 8 3 B E i Universal Banner 11 69 x 36 in 297 2 x 914 4 mm Lexmark C912 only 2 75 5 to 8 5 x 14 in X XP 69 85 x 127 mm to 229 x 355 6 mm 5 83 x 7 17 in to 8 5 x 14 in X 148 x 182 mm to 215 9 355 6 mm 7 34 Envelope 3 875 in x X 7 5 in 98 mm x 191 mm 9 Envelope 3 875 in x 8 9 in X 98 mm x 225 4 mm 10 Envelope 4 125 in x X 9 5 in 105 mm x 241 mm DL Envelope 4 33 in x X 8 66 in 110 mm x 220 mm C4 Envelope 9 in x 12 75 in X 229 mm x 324 mm C5 Envelope 6 38 in x X 9 01 in 162 mm x 229 mm B5 Envelope 6 93 in x X 9 84 in 176 mm x 250 mm Other Envelope X 11 69 in x 11 69 in 297 mm to 297 mm General information 1 11 5055 xxx 5 5 v 2 g 2 S z 9 3 Q 5 x D hi 9 2 8 315138 8 E r a r Media type Paper X X X X Card stock X Transparencies Envelopes X Glossy paper X x8 X X Paper labels x x8 Output 5 a r N 5 9 m m 5 G E a 5 8 m iL iL A4 8 27 in x 11 7 in X X X X 210 mm x 297 mm A5 5 83 in x 8 27 in X X X 148 mm x 210 mm JIS B5 7 17 in x 10 23 in X X 182 mm x 257mm JIS B4 14 34 in x 10 1 in X X X 864 mm x 252 mm Letter 8 5 in x 11 in X X X X 216 mm x 279 mm 1 12 Service Manual 5055 xxx Finisher Bin 1 F
124. FRU Action 1 Feed rollers Belts Check for wear or damage to feed rollers and belts 2 Duplex unit Be sure the duplex unit is properly installed and that all connections are correct 3 Duplex stopper motor Side fence stepper motor Be sure the stepper motor turns freely with no binding Check for wear or damage to the associated gears Replace as necessary 4 Feed roller solenoid assembly Paper re feed solenoid assembly Check for proper operation of the solenoid and linkage Replace as necessary 5 Paper tray Check to see if the paper edge guides have shifted If so re time by removing the screw and gear from the bottom of the tray and pushing the paper edge guides up against the paper lift plate Reinstall the screw and gear 2 78 Service Manual 5055 xxx Paper jammed in finisher area G FRU Action 1 Registration roller Check finisher to printer alignment Go to Paper exit rollers Aligning the finisher and printer on Registration sensor page 3 80 Registration clutch Punch clutch punch Check all belts for wear or damage Check unit 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 running the staple test or hole punch test in diagnostic mode Replace parts as necessary 2 Pap
125. I Eu I YU ayn ates santa wea E 00 I sant zem me L 4dOH Tod ao H z i ag a ek 1 Du i ENE po 9758 L L m E rosea IE MU cer 3 1 3 T zosu s pamogasauaaoen Q2222222222 z xeded ienpisew 1 rp SE Tv iosues 31XH T vs T ZW TJ we z prn5 uana 203 e te iosuos memed warana HIT pusse T TE 4 pose eee eee z fete T s z EE 1 sseud i zb T lt LE TE sp eh sosues asega seem z a uot esa TIS 23 z E LEA ES fl 5 2 4 z Jedd DAH a T T dor L 1 umm do ____ R Qi 1 T dHO tayan savne 1 HETE eueij ans 1 ERIS I dea qa 1 22 T Het teuna soiedo s ssepe I zeded qa amas 1 E T or for l epe s E Fed z 1 5 __ e t x i 5 z sour wnaq IE EE es ES UE A ATWO nosz
126. Location Protocol NTP Network Timing Protocol Printers with standard Ethernet MarkNet N2000 series and MarkNet N2003 series internal print servers and MarkNet X2000 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 XP or Windows NT The remote operator panel is available using the standard Ethernet connection MarkNet N2000 MarkNet N2003 or MarkNet X2000 Series external print servers installed in or used with a Lexmark C91 x printer Data streams PostScript 3 Emulation Hewlett Packard Company PCL 6 Emulation Operating systems These printers are compatible with applications running under the previously mentioned operating systems for either local or network connections General information 1 25 5055 xxx Power and electrical specifications Power requirements Average nominal power requirements for the base printer configuration 110 volt Power level are shown in watts Printing states average Non Network Duplex power network network Off OW Average power while printing Continuous mono Continuous color 400 W 400 W 410W 290 W 290 W 300W Average power while printing Continuous mono Continuous color 13 W 14 W 15 W 125 W 125 W 125 W Average power while printing Continuous mono Continuous color 11A 11A 11A 6A 6A 6A
127. Ms are available from Lexmark Flash memory options Optional 4MB 8MM and 16MB DIMMs are available from Lexmark Memory and expansion slots Memory slots for extra flash or DRAM Two for Lexmark C910 n and Lexmark 912 for Lexmark C910 dn and Lexmark C912 dn One 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 options are interchangeable within any of the memory slots available on the system board However only one flash memory Maintenance Approach option will be recognized If multiple flash memory options are installed the system will recognize the largest one 1 6 Service Manual 5055 xxx Resident fonts Emulation Scalable Fonts Bitmapped fonts PCL 6 84 2 PostScript 3 156 0 For a listing of specific fonts visit www lexmark com There are 83 symbol sets in the PCL 6 emulation to support all the languages that use these characters Not all symbol sets are supported by all fonts Refer to the Technical Reference or use the printer operator panel to find which symbol sets are supported 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 Windows symbol Sets A
128. Position Activate by rotating the jogging motor wheel Pap Upper Level Activate by operating the paper upper level sensor flag Fin Set Switch Activate by inserting a non conductive tool into the opening below the staple door e Staple Cart Set Activate by removing then inserting the staple cartridge 3 22 Service Manual 5055 xxx Device tests Quick Disk Test The Quick Disk Test performs a non destructive read write on one block per track on the disk The following message appears while the test is running Quick Disk Test Testing The Power indicator blinks while the test is in progress If the test is successful the following message is displayed Quick Disk Test Test Passed Press Go Return or Stop to return to the DEVICE TESTS screen If the test fails then the following message is displayed Quick Disk Test Test Failed Press Go Return or Stop to return to the DEVICE TESTS screen You cannot cancel this test Diagnostic aids 3 23 5055 xxx Disk Test Clean The Disk Test Clean Test causes the disk to be formatted destroying all data on the disk and should not be attempted on a good disk This test should only be used when the disk contains unusable data Note This can be an extremely lengthy test depending on the disk size and leaves the disk unformatted To run this test select Disk Test Clean from the DEVICE TESTS menu The following messa
129. RLIMIT 2 2 O SENSOR SWITCH sawp 3 1 T4 UP n 1 1 SGND 5 UP PAPER SIZE 2 2 PAPER SIZE SENSOR 2 SENSOR 2 COVER SENSOR 45V 3 3 sano 4 SGND PAPER S 5 5 PAPER SIZE SENSOR 1 6 SENSOR 1 T8 UP 45V UP
130. RU Action Paper size sensors 1 and 2 Residual paper sensors 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 sensor test You can block each sensor to verify if itis working properly Replace the failing sensor Tray motor Paper feed motor HCPF power supply Pickup solenoid Paper feed roller Transfer roller Paper feed clutch Tray drive belt Be sure that all rollers gears and belts are in good working order Replace as necessary Paper feed clutch Pickup solenoid HCF power supply Paper feed motor Tray motor HCPF board Go to the Maintenance Mode on page 3 60 and run the tests 2 70 Service Manual 5055 xxx Finisher service check FRU Action 1 Input path sensor Note For frequent jams hole punch Paper register sensor problems or stapling problems First check Upper tray exit sensor the finisher to printer alignment Go to Guide stack assembly Aligning the finisher and printer on Paper full A sensor page 3 80 Paper detect sensor Staple home position Run the finisher sensor test in diagnostic sensor mode to test the sensors and switches No staple sensor Punch box detect sensor Invert path sensor Lower tray exit sensor Elevator upper limit sensor Tray near full
131. Revised July 11 2006 e Service Manual LDexmarkC9ix 5055 xxx e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks Index LEXMARK 5055 xxx Edition July 11 2006 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or electronically mailed e mail to ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countrie
132. S 56P9926 NS 56P9927 NS 56P9928 NS 56P9929 NS 56P9930 Card PRESCRIBE Software Optra Forms Software Optra Forms Director DIMM Lexmark Forms 4MB Flash DIMM Lexmark Forms 8MB Flash DIMM Lexmark Forms 16MB Flash 4 A o 0o Xo oO Ao Wak EO 26 A 87 b 24 X 024 26 4 7 72 Service Manual 5055 xxx Assembly 32 Miscellaneous options Index P N Units Description NS 56P9932 1 Hard Disk Lexmark Forms NS 56P9942 1 Mounting Kit hard 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 7370569 1 Kit 500 sheet tray relocation Parts catalog 7 73 5055 xxx Assembly 32 Parts packets Index P N Units Description NS 56P9945 1 Parts packet containing 50 Bind S tight screws 3x6 Zn 3R 50 Bind S tight screws 3x15 Zn 3K 50 Bind P tight screws 3x8 Zn 3K 50 Bind P tight screws 3x10 Zn 3K 50 Bind P tight screws 3x6 Zn 3K 50 Bind P tight screws 3x8 Ni 3 50 Bind screws M3x6 Ni 3 NS 56P9946 1 Parts packet 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 3x8 Ni 3 50 Bind screws M3x4 Zn 3K 50 E rings ES 5 ACP 50 Spring
133. Sensor In RMT Out GND In oo co no 1 co No gt coro C91 x High Capacity Paper Feeder Wiring Diagram Printer Side SHIELD 12222222 1 SDA 9 ft SCL s 2 5 3 3 GND E al 4 4 5V P 5 5 Reset L m Ore 1 P P PSU 9 Tu R R S w INLET AC100V 120V 230V ew PGND S R Q P 1 1 CN1 DC DC 2 2 CONVERTER 5 Tu 3 CN2 4 4 1 1 ae 2 PAPER 3 FEED MOTOR 4 4 5 5 1 INTERLOCK Er BLUE SWITCH Ho og 2 T 1 T TRACKING T12 713 3 SENSOR FO OF r PRERE 4 j TRAY I MOTOR RED 2 COM BLACK 1 _ Ti UP DOWN SWITCH N O 75 YELLOW 2 N C T3 GREEN 3 4 SAFETY 7777777777777 BLUE SWITCH T4 O T5 5 7o op 6 COVER i L SENSOR IPM BEER
134. Step Questions actions Yes No 1 Turn off the printer and Problem solved Go to step 2 reinstall the fuser making sure it clicks into place Turn on the printer Did this resolve the problem 2 Is connector CN44 on the Disconnect Plug the printer controller board CN44 and turn connector in connected properly the printer on securely Go to step 3 3 Is error 924 displayed Turn the printer Replace the off and printer controller reconnect CN44 board Go to step 4 4 Turn off the printer and Replace the Replace the short pins 8 and 11 of fuser printer controller board Diagnostic information 2 7 5055 xxx 925 HVU Error Step Questions actions Yes No 1 Has the high voltage power Inspect the Go to step 2 board HVU been secondary card removed replaced on the high voltage board HVU for a broken component Q906 Replace the high voltage board HVU if necessary 2 Is connector CN42 on the Replace the Plug the printer controller board printer controller connector in connected properly board securely Go to step 3 3 Did replacing the printer Problem solved Replace the high controller board fix the voltage power problem board HVU 2 8 Service Manual 926 K 927 C 928 Y 929 M Toner Sensor Error 92x Service Toner Sensor 5055 xxx Step Questions actions Yes No 1 Is the toner cartridge the Go to step 2 Recommend the c
135. Unsupported The printer detects an Press Go to clear the Disk unsupported disk message Format the disk USB x The printer is processing Wait for the message to data through the specified clear USB port Waiting The printer is waiting for an Press Go to print the End of Job command a contents of the buffer Form Feed Command or Press Menu to open the additional data Job Menu and cancel the current job 1565 Emul The download emulator Download the correct Error Load version on the firmware card emulator version from Emul Option does not match the printer Lexmark s Web site 2 xx Paper Jam The printer detects a paper jam Clear the paper path If the message cannot be reset go to the Paper carrying service check on page 2 74 2 42 Service Manual 5055 xxx Message Meaning Action 30 Coating Roll The oil coating roll is either Correctly install the oil Missing missing or installed coating roll If the message incorrectly cannot be reset go to Map 5 False 30 Oil Coating Roll Missing message on page 2 57 30 color One or more of the color Correctly install the color Print Unit print units is either missing print unit s If the message Missing or incorrectly installed cannot be reset go to Map 6 False lt color gt Print Unit Missing message on page 2 57 32 The printer detects an Replace the cartridge Unsupported unsupported toner cartridge c
136. ad 7 15 56P9594 Cover eraser 7 15 56P9595 Lamp M erase 7 15 56P9596 Lamp C erase 7 15 56P9597 Lamp Y erase 7 15 56P9598 Lamp erase 7 15 56P9599 Printhead S N XX 0XXXX 7 15 l 14 Service Manual 5055 xxx 56P9600 Cable assembly K13 7 13 56P9601 Cable assembly K24 7 13 56P9602 Cable assembly CL13 7 13 56P9603 Cable assembly 124 7 13 56P9604 Core ferrite 7 15 56P9605 Cable assembly HDFG 7 15 56P9606 Cable assembly RSPFG 7 15 56P9607 Cable assembly LFG 7 15 56P9608 Holder front 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 interlocking 7 13 56P9614 Spring return 7 13 56P9615 Hook middle 7 13 56P9616 Handle upper opening 7 13 56P9617 Ho
137. affected color and go to step 5 Did this resolve the problem 5 Did replacement of the Problem solved Replace the printhead controller board printer controller resolve the problem board Diagnostic information 2 11 5055 xxx 932 Cyan Printhead Error Step Questions actions Yes No 1 Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables printhead and the printhead number controller board as well as go the cables between the to step 2 printhead controller board and the printer controller If you have a board are properly printer with serial connected number XX AXXXX and Are they properly above go to connected step 4 2 For serial number Replace the Replace the Is fuse 3 on printhead control printhead the printhead control board board cables controller board open CL13 CL24 and go to step 3 and LED printhead 3 Did replacement of the Problem solved Replace the printhead controller board printer controller correct the problem board 4 For serial number Problem solved Replace the XX AXXXX and above printhead Replace the LED printhead controller board for the affected color and go to step 5 Did this resolve the problem 5 Did replacement of the Problem solved Replace the printhead controller board printer controller resolve the problem board 2 12 Service Manual
138. ait for the message to Disk yyy hard disk The second line clear shows percentage complete Formatting The printer is formatting Wait for the message to Flash flash memory clear Fuser The counter that tracks wear Press Go to continue printing If print quality is unacceptable replace the fuser 2 36 Service Manual 5055 xxx Message Held Jobs May be Lost Meaning The printer memory is too full Action Press Go to clear the message The printer frees memory by deleting the oldest job and continues deleting jobs until there is enough memory Press Stop to clear the message without deleting jobs Press Menu to open the Job Menu and cancel the current job Infrared x An infrared interface is the active communication link Wait for the message to clear Insert Tray x The specified tray is either missing or not fully inserted 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 it can print Turn the printer off install the specified device and restart the printer Press Menu to open the Job Menu and cancel the current job Invalid Engine Code The printer engine code has not been programmed or is not valid Call for service Invalid Network x Code The code
139. al 5055 xxx Duplex side fence motor assembly side fence removal 1 Remove the three screws and remove the side fence motor assembly 2 Remove the front and rear side fences Note When installing spread the front and rear side fences to the sides and install Repair information 4 79 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 4 80 Service Manual 5055 xxx High capacity feeder HCF removals HCF covers removal 1 Remove the two screws from the drive cover and remove the cover 2 Remove the front cover 3 Remove the two screws from the right cover and remove the cover 4 Remove the top cover 5 Remove the rear cover 6 Remove the four screws from the transfer cover and remove the cover Drive Cover Rear Cover Transfer Cover Ju 9 Top Cover e Front Cover Right Cover Repair information 4 81 5055 xxx 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 rollers and remove the rollers Paper Feed Roller Torque Limiter 4 82 Service Manual 5055 xxx HCF pickup solenoid removal 1 Remove the four screws from the transfer cover and remove
140. and pressing Select 3 28 Service Manual 5055 xxx Setting the Page Count The page count can be changed through the Diagnostic menus The Servicer uses this menu to reset the page count whenever the engine board containing NVRAM memory is replaced When Page Count is selected from the PRINTER SETUP menu the current page count is displayed as follows Page Count 1234567 The left most digit 1 in this example blinks indicating it is the first digit 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 this method To skip a digit and keep its current value press Select When Select is pressed after the final digit 7 in this example the new page count is stored in NVRAM Viewing the Permanent Page Count The permanent page count setting cannot be modified through the operator panel It can only be viewed using the Diagnostics menus When Permanent Page Count is selected the following appears Perm Page Count 1234567 Serial Number XXXXXXX Printer Serial Number This function shows the printer serial number Diagnostic aids 3 29 5055 xxx Setting configuration ID Use the configuration ID to communicate characteristics of the printer that cannot be determined by the hardware sensors The configuration ID is originally set w
141. aper Delivery Sensing Sensor Lever Diagnostic aids 3 41 5055 xxx Belt unit After passing through the registration unit paper is electrostatically fed by the transfer belt through the positively charged feed roll at the inlet of the belt unit and fed by the running belt The belt runs at the same speed as the photosensitive drum causing the image on the C M Y and K developer to transfer to paper Since the photosensitive drum has a small diameter and the paper is electrostatically fed by the transfer belt the paper is easily separated after toner image transfer and fed to the next developer Excess toner is scraped from the 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 adjusting the color image This should be adjusted in maintenance mode when the belt unit is replaced The transfer belt is conductive and seamless If the transfer belt is damaged toner can cling to the belt and contaminate the paper When fingerprints or other stains appear on the belt wipe them away with a dry cloth or cloth moistened with alcohol A density sensor is positioned facing the belt drive roller for automatic density adjustment and registration adjustment A mechanism is provided to clean the sensor surface which is interconnected with the opening and closing of the front cover 29
142. appeared open the Supplies Menu on the operator panel and select Replace Supplies then select Belt and select Replaced The message Printing Alignment Page appears and the printer prints the alignment page Follow the instructions on the display to set the alignment values for the new transfer belt Repair information 4 63 5055 xxx Alternate method Transfer belt was partially removed Use this method when the transfer belt removal was attempted without using the Supplies Menu to lower the belt 1 2 3 N Turn the printer off Remove the two thumbscrews on the transfer belt cover Remove the waste toner bottle Note Be careful not to spill the toner 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 With a screwdriver push up on the follower and gently push it back on the transfer belt frame Seat the transfer belt back into the printer Reinstall the waste toner bottle Use the proper removal of the belt by lowering the transfer belt in the Supplies Menu Go to Transfer belt removal on page 4 56 4 64 Service Manual 5055 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 sensor and remove Ny 7 g p Repair information 4 65 5
143. ard density sensor connector in connected properly Go to step 5 securely 5 Did replacing the density Problem solved Replace the printer controller board Diagnostic information 2 27 5055 xxx 995 Finisher Main Feed Motor abnormal 995 Service Finisher Step Questions actions Yes No Is there jammed paper or other obstructions in the paper path Clear the paper path Go to step 2 Check to ensure the connector PJ6 on the finisher control board and the feed motor assembly cable are properly connected Are the cables properly connected Go to step 3 Properly connect the cables Make sure the finisher set Switch is activated Measure for 24 V dc 410 between pins 7 and 8 and 5 V 410965 between pins 7 and 6 on the feed motor assembly cable connector CN1 Is either voltage missing Go to step 4 Go to step 5 Disconnect the feed motor assembly cable and PJ6 on the finisher control board Measure continuity on the cable for all positions Is there continuity Go to step 6 Replace the cable Replace the feed motor assembly Did this resolve the problem Problem solved Replace the finisher control board 2 28 Service Manual 5055 xxx Step Questions actions Yes No 6 Measure for 24 V dc Replace the Replace the between pins 1 and 2 on power supply finisher control connector PJ3 on the
144. attached Turn the printer off and then on to reset 54 Par x Press Go to clear the ENA message and continue Connection printing Lost 56 Serial Port Data has been sent to the Press Go to clear the x Disabled printer through a disabled message Make sure the Serial Buffer menu item in the Serial Menu is set to Disabled 56 Parallel Port x Disabled 56 Std Parallel Port Disabled Data has been sent to the printer through a disabled parallel port Press Go to clear the message Make sure the Parallel Buffer menu item in the Parallel Menu is set to Disabled 2 46 Service Manual 5055 xxx Message Meaning Action 56 USB Port Data has been sent to the Press Go to clear the x Disabled printer through a disabled message USB port Make sure the USB Buffer 56 Std USB menu item in the USB Port Disabled Menu is set to Disabled 58 Too Many Too many output bins are Turn off and unplug the Bins Attached installed Unsupported output bins are installed printer Remove or reconfigure the output bins Plug the printer in and turn it on 58 Too Many Disks Installed Too many disks are installed Turn off and unplug the printer Remove 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 printer in and turn it on
145. ay2 5 24 Service Manual 5055 xxx Motor Solenoid Clutch Purpose Paper feed motor Paper feeding and inverting Tractor drive motor Tractor drive for paper feeding Staple motor Stapling Path select solenoid Path changing Paper jogging motor Jogging of paper Punch clutch Punching Registration clutch Paper registration feeding Elevator motor Face down bin movement Locations 5 25 5055 xxx Finisher electrical parts 5 26 Service Manual 5055 xxx Number Part name Number Part name 1 Paper exit sensor 14 Power supply PWBA upper tray 2 Paper register sensor 15 Staple motor 3 Path select solenoid 16 Staple existence sensor 4 Elevator upper limit 17 Staple home position sensor Sensor 5 Tractor drive motor 18 Staple cartridge set switch 6 Elevator motor 19 Paper upper level sensor B 7 Elevator lower limit 20 Paper exit sensor sensor lower tray 8 Invert path sensor 21 Paper full sensor A 9 Punch box detect 22 Paper feed motor sensor 10 Belt home position 23 Paper detecting sensor sensor 11 Finisher set switch 24 Finisher control board 12 Paper jogging motor 25 Registration clutch 13 Jogging home 26 Punch clutch position sensor Locations 5 27 5055 xxx 5 28 Service Manual 5055 xxx 6 Preventive maintenance Maintenance kit When nea
146. b paper If you attempt to staple a larger stack of paper the finisher ejects the stack without stapling it Install a new staple cartridge Check the stapler for a staple jam Diagnostic information 2 67 5055 xxx Service checks Drive 1 DC motor service check FRU Action 1 DC motor If the motor does not attempt to turn and Drive unit 1 you receive a 910 error code replace the Printer controller driver 1 dc motor board Be sure the toner and photodeveloper units are not causing an overload on the dc motor If the motor turns but the paper carrying section of the machine does not rotate check the drive 1 unit gear train for damage Be sure the clutch on the gear train engages for color printing Replace the drive 1 unit if necessary If this does not correct the problem replace the printer controller board Drive 2 stepper motor service check FRU Action 1 Drive 2 stepper motor Be sure connector CN4 on the printer controller board is firmly connected If there still is a problem replace the drive 2 stepper motor 2 68 Service Manual 5055 xxx Duplex unit service check FRU Action 1 Feed roller belts Check for wear or damage to the feed roller belts Replace as necessary 2 Duplex stepper motor Be sure the stepper motor turns freely with Side fence no binding Stepper motor gears Check for wear or damage to the as
147. ber standard 1 1 1 Output capacities sheets Standard output bin 550 550 550 Face up bin 100 100 100 Optional Finisher 1 000 1 000 1 000 Maximum output 1 650 1 650 1 650 capacity Other Duplex unit Yes Yes Standard The heavy media tray is supported only as Tray 1 top A maximum of one high capacity input drawer is supported on any model 3 A maximum of one finisher is supported on any model The finisher requires installation of the 2 x 550 sheet drawer with the base or printer cabinet General information 1 9 5055 xxx Media size supported 297 mm x 420 mm Input 5 o 541313 9 5 e S S D 2 Q 2 23 o gt 2 5 S 3 2 8 i A4 8 27 x 11 7 in X X X X X 210 mm x 297 mm A5 5 83 x 8 27 in X X X 148 mm x 210 mm JIS B5 7 17 in x 10 23 in X X 182 mm x 257mm JIS B4 4 34 in x 10 1 in X X X X 864 mm x 252 mm Letter 8 5 in x 11 in X X X X X 216 mm x 279 mm Legal 8 5 in x 14 in X X X X 216 mm x 256 mm Executive 7 25 in x 10 5 in X X 184 mm x 267 mm Tabloid 11 in x 17 in X X X X 279 4 mm x 431 8 mm 12 in x 18 in X X X X 805 mm x 457 mm Lexmark C912 only 11 69 in x 16 54 in X X X X 1 10 Service Manual 5055 xxx 5 ko 514314 2 e S o o e 2 5 2 2 gt H E amp
148. bottom of the finisher with the legs of the finisher stand Diagnostic aids 3 77 5055 xxx 11 Lower the finisher onto the finisher stand CAUTION When assembled the finisher weighs 26 3 kg 56 910 and requires at least two people to lift it safely 12 Remove both thumbscrew spacers 13 Tighten the two thumbscrews Thumbscrew Spacers 3 78 Service Manual 5055 xxx Attaching the bins 1 Align the slots on bin 2 with the metal brackets 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 Metal Brackets 3 Align the tabs on bin 1 with the slots on the rear of the finisher 4 Lower the bin until it is fully seated Slots Diagnostic aids 3 79 5055 xxx Aligning the finisher and printer The following three areas must align properly 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 alignment marks on top of the finisher must align with the edges of the cover on the side of the printer Alignment Marks Pp Spacing 3 80 Service Manual 5055 xxx 4 Rollthe finisher toward the printer until the finisher locks to the docking plate pins You hear a click when the finisher locks int
149. ce the paper size Problem solved Replace the sensor card Does this fix printer controller the problem board tray 1 Replace the expansion feeder control card trays 2 5 2 62 Service Manual Symptom table 5055 xxx Symptom Action You cannot print color Make sure the Color Correction menu item is not set to Black amp White Make sure the color print units are completely installed in the printer Go to the Transfer belt up down service check on page 2 87 Transparencies curl excessively Make sure you re using the recommended Lexmark transparencies Also be sure the paper delivery is set to the rear exit The printer seems slow to print If you set the Paper Type to Transparency or Card Stock the printer increases the fuser temperature and slows printing to improve the print quality After printing on these media the printer requires additional time to cool the fuser after you select another 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 turn the printer on and each time you open and close the top cover Depending on the types of jobs you print these adjustments may significantly slow print time You cannot remove paper jammed in the fuser Open the fuser rollers by operating the fuser pressure relief lever If
150. d call roller are free of dirt and are not damaged 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 all motors clutches and sensors operate correctly 3 HCPF control card HCPF power supply Set up and run a test in Maintenance Mode and go to the High capacity feeder HCF service check on page 2 70 If no LEDs light check the power source Replace the HCF control card Replace the HCF power supply 2 74 Service Manual 5055 xxx Paper is being picked up and carried to the registration roller areas C E 240 24x FRU Action 1 Paper feed cassette Be sure the paper cassette has the size guides and the side locator locks are working properly Replace parts as necessary Paper feed roller MPF Paper feed rolls MPF tray 1 2 3 4 5 Carrying roller tray 1 2 3 4 5 Fanning pad MPF Be sure the paper feed rollers are free of dirt and not damaged Be sure the fanning pad is free of dirt and not damaged Replace parts as necessary Paper feed clutch MPF clutch MPF frame assembly 3 Gears Be sure the paper feed gears are not damaged 4 Paper feed solenoid Be sure the paper feed solenoid activates the paper feed clutch and the clutch engages properly Check the failing paper f
151. d roller 14 56P9831 1 Cable assembly duplex drawer 15 56P9810 1 Roller follow up feed 16 56P9527 2 Gear idler 17 56 9817 1 Gear carrying roller 18 56P9818 2 Pulley carrying roller timing 19 56P9819 1 Pulley feed roller 20 56P9822 3 Belt timing 21 56P9823 1 Belt timing 22 56P9821 1 Knob paper re feed 23 56P9820 1 Pulley re feed roller 24 56P9809 1 Roller drive feed 25 56P9824 3 Plate paper carrying drawer 26 56P9811 3 Roller middle feed 27 56P9812 1 Roller re feed NS 56P9957 1 Parts packet Parts catalog 7 41 5055 xxx Assembly 18 High capacity feeder 1 7 42 Service Manual 5055 xxx Assembly 18 High capacity feeder 1 Index P N Units Description 18 56P9838 1 Catch door 2 56P9835 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 56P9841 1 Cover assembly upper 11 56P9840 1 Lever vertical transport 12 56P9842 1 Spring tension NS 56P9958 1 Parts packet Parts catalog 7 43 5055 xxx Assembly 19 High capacity feeder 2 7 44 Service Manual 5055 xxx Assembly 19 High capacity feeder 2 Index P N Units Description 19 56P9846 Solenoid assembly paper pickup 2 56P9848 Clutch paper feed 3 56P9844 Motor assembly transport 4 56P9941 Arm pick up 5 56P9501 Spring pressure 6 56P9528
152. d supplies and go solve the problem to step 5 5 Did replacement of the Problem solved Replace the supplies solve the problem drive motor 2 4 Service Manual 911 Paper Exit Motor Error 5055 xxx Step Questions actions Yes No 1 Is connector CN4 on the Replace the Plug the printer controller board paper exit motor connector in securely connected and go to step 2 securely 2 Did replacement of the Problem solved Replace the paper exit motor solve the printer controller problem board 912 High Capacity Feed Motor Error Step Questions actions Yes No 1 Is connector CN40 on the Go to High Plug the printer controller board capacity feeder connector in securely connected HCF service securely check on page 2 70 917 RIP Fan Error 917 Service Fan Error Step Questions actions Yes No 1 Is connector J5 on the RIP Go to step 2 Properly connect board connected properly J5 2 Is 24 V dc present between Replace the RIP Goto step 3 pins 1 and 3 of connector fan J5 on the RIP board 3 Is 24 V dc present between Replace the RIP Replace the pin 80 of the RIP printer board printer controller controller and ground board Diagnostic information 2 5 5055 xxx 918 Main Unit Fan Error pins 1 and 3 of connector CN6 on the printer controller board power supply fan
153. dditional fonts can be downloaded to the printer RAM optional Flash DIMM or hard disk PCL emulation supports both scalable and bitmapped downloadable fonts PostScript emulation supports only downloadable scalable fonts Font cards and font cartridges are not supported General information 1 7 5055 xxx Paper and media specifications Capacity may vary and is subject to media specifications and printer operating environment Capacities listed are based on plain paper at 75 g m Input and output configurations Sources and Lexmark Lexmark Lexmark capacities C91x C91xn C91 xdn Input sources Number of standard 2 3 3 sources Optional input drawers 3 2 2 High capacity feeder 1 1 1 Maximum number of 6 6 6 input sources Input capacities sheets Standard Primary tray 550 550 550 Second tray N A 550 550 Multipurpose tray 100 100 100 Total standard 650 1 200 1 200 capacity Optional 500 sheet drawer 550 550 550 Heavy media tray Yes Yes Yes High capacity feeder 3 000 3 000 3 000 Maximum additional 3 2 2 drawers 1 8 Service Manual 5055 xxx Sources and Lexmark Lexmark Lexmark capacities C91x C91xn 91 2 300 2 300 2 300 capacity without high capacity feeder Maximum input 5 300 5 300 5 300 capacity and high capacity feeder Output destination Num
154. der paper present sensor removal 1 Open the top unit and remove the upper cassette front cover turn guide multipurpose feeder right side cover turn guide and multipurpose feeder frame 2 Disconnect the connector and remove the multipurpose feeder paper present sensor MPF Paper Present Sensor Repair information 4 33 5055 xxx Multipurpose feeder tray removal 1 Open the top unit and remove the front cover cassette feeder turn guides and right side cover ER QOOOQOQ t O 2000 N 20 2 Open the multipurpose feeder and slide it toward the magnet in the direction of the arrow removing it from the printer Operator panel removal Open the top unit and remove the toner cartridges and photodeveloper drum units 2 Remove the operator panel Remove the two screws from the operator panel case and remove the case Remove the cable from the operator panel 1 4 34 Service Manual 5055 xxx Paper carrying frame removal 1 Open the top unit and remove the upper cassette front cover turn guide multipurpose feeder right side cover turn guide OHP detection 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 00000 022 3 Remove the paper carrying frame Note When installing
155. e 4 35 Paper carrying roller 4 36 Paper feed frame 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 4 40 Power supply 2 removal ius xe sesame eae EE 4 41 Power switoh removal uus oa aer RR ER ec Y RS 4 42 Printer controller removal 4 43 Printhead controller board removal 4 44 Registration sensor 4 48 Right slide rail removal 4 49 RIP be Te 4 49 Sensor board removal 2 222 o ERR 4 50 4 51 BUBATAMETEMOVAl 4 52 Sub frame F1 sub frame F2 removal 4 53 Top unit rembvala 2i a ea Rem cR tees dagen cd 4 55 Transiter Belt rermoyal 4 56 Turn guide cover sensor removal 4 65 Unser Tat EBITIBVAL s soon neg RE eg 4 66 Options removals 4 67 Expansion paper feeder removal 4 67 Duplex removals
156. e density White and black lines and bands Go to Print quality problems on page 2 88 2 64 Service Manual 5055 xxx Symptom Action Evenly spaced marks on the paper or a single mark in the same place on every page Go to the Transfer belt up down service check on page 2 87 Poor fusing Go to the 920 Fuser Error Fuser Heater Trouble on page 2 6 Toner scatter on front or back of 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 Fuser separation pawl Paper will not feed from MPF Be sure you have paper in the MPF Be sure the MPF paper present sensor connector CN11 is connected to the printer controller board If the paper still does not feed go to the Paper carrying service check on page 2 74 Diagnostic information 2 65 5055 xxx Finisher Use the following table to find solutions to problems with the optional finisher Symptom Cause Solution Paper The finisher and Paper frequently jams in the frequently jams in the finisher printer are misaligned The printer and finisher have been moved Attempting to staple hole punch or offset print jobs on print media other than paper finisher Properly align the finisher with the printer Align the top o
157. e printer is deleting all job statistics stored on the hard disk Wait for the message to clear 2 34 Service Manual 5055 xxx Message Meaning Action Close Side The printer side door is Close the printer side door If Door open the error cannot be reset go to Map 1 False Side Door Open message on page 2 54 Close Front The printer front door is Close the printer top door Door open and front door If the error cannot be reset go to Map 2 False Close Front Door message on page 2 54 Close Tray x Top Cover The high capacity feeder door is open Close the HCF door and the top cover If the error cannot be reset go to Map 3 False Close Tray x Top Cover message on page 2 55 Copying The printer is 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 Wait for the message to clear Warning Do not turn the printer off while this message is displayed Delete All Jobs The printer is requesting confirmation to delete all held jobs Press Go to continue The printer deletes all held jobs Press Stop to cancel the operation Deleting Jobs The printer is deleting one or more held jobs Wait for the message to clear Disabling Menus The printer is responding to a reque
158. e shaft stops Cover Paper Entrance Sensor Clutch Registration EN Idler Roller Registration Registration Clutch Roller Diagnostic aids 3 69 5055 xxx Jogging offset mechanism Plate Spring Jogging Bar Rack B Jogging Home Position Sensor Registration Plate Paper Detect Sensor Offset Bar Rack A Jogging sequence Each sheet upon entering the accumulator is aligned by the jogging bar which moves the sheet horizontally until the edge of the sheet contacts the registration plate The paper detecting sensor 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 pinion mechanism while the jogging motor rotates Each plate spring on the jogging bar pushes the rack in the direction of the pinion gear so that the rack and pinion gears meet securely The distance of the offset bar movement depends on paper size A4 or letter 3 70 Service Manual 5055 xxx Detection of fixed position The fixed position of the jogging bar is detected by the jogging home position sensor and a sensor flag united with the pinion The fixed position is set when the sensor detects the sensor flag This fixed position is used as a reference point to calculate the distance of the movement of the jogging bar and offset bar dependin
159. ear 225 720 15 56P9459 2 Drum wire 16 56P9460 1 Gear Z30 17 56P9311 2 Bushing 18 56P9482 1 Shaft A 19 56P9352 1 Panel lower left 20 56P9382 1 Sensor 21 56P9307 1 Assembly hook rear 22 56P9463 2 Pulley wire B 23 56P9465 1 Assembly sensor Parts catalog 7 65 5055 xxx Assembly 29 Finisher electronics 7 66 Service Manual 5055 xxx Assembly 29 Finisher electronics Index P N Units Description 29 1 56P9306 1 Assembly upper limit sensor 2 56P9303 1 Supply power 3 56P9351 1 Assembly power supply plate 4 56P9435 1 Cable set switch 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 11 56P9325 1 Cable front side panel 12 56P9343 1 Assembly sensor cable 13 56P9340 1 Packet parts 14 56P9420 1 Bracket finisher control board 15 56P9409 1 Cable 16 56P9324 1 Cable sensor relay NS 56P9357 1 Cable interface Parts catalog 7 67 5055 xxx Assembly 30 Finisher docking 1 7 68 Service Manual Assembly 30 Finisher docking 1 5055 xxx Index P N Units Description 30 1 56P9467 2 Screw thumb 2 56P9468 1 Spring 3 56P9469 1 Bracket 4 56P9470 1 Switch set Parts catalog 7 69 5055 xxx Assembly 31 Finisher docking 2 7 70 Service Manual 5055
160. eck the serial port hardware by using a wrap plug P N 1329048 and invoking the Serial Post Diagnostic Test The test helps isolate the printer from the serial cable and host computer The test provides failure information on the display for approximately three seconds If the test indicates a problem replace 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 not listed Be sure the memory card assembly is installed correctly and is not broken or damaged If the Memory card assembly is correctly installed not broken or damaged then run the Flash Test on page 3 25 If the test fails replace the Flash card assembly If the problem continues replace the RIP board DRAM Memory Option s This service check is the same as the flash memory option service check with the following exception Run the DRAM Memory Test on page 3 12 from the menu if the DRAM Memory card assembly is correctly installed and not broken or damaged If the test fails replace the DRAM card assembly If the problem continues replace the RIP board 2 98 Service Manual 5055 xxx Hard Disk Option Service Tip The 5055 01 x printers support one hard disk option Be sure only one 3 2 GB or larger hard disk option is installed Be sure the hard disk and the hard disk board are correctly installed Run the Quick D
161. ector and remove the two screws from the drive motor and remove the motor Repair information 4 69 5055 xxx 16 Remove the six screws from the drive assembly and remove the assembly 17 Remove the two screws from the paper remaining detection board and remove the board 18 Remove the four screws from the solenoid assembly and remove the assembly 4 70 Service Manual 5055 xxx 19 Remove the two bearings from the turn guide The cover is hinged in place M III Antin 20 Remove the screw from the paper feed frame fuser plate and remove the plate Repair information 4 71 5055 xxx 21 Remove the two screws from the fuser frame assembly and remove the assembly UT U ammen TI Ao 22 Remove the three screws from the cassette guide assembly and remove the assembly S e 11 41 11 BERN Tora mili rut SENE 4 72 Service Manual 5055 xxx 23 Remove the six screws from the second drive board assembly and remove the assembly eS cs gt 24 Remove the two screws from the paper size detection board and remove the board 25 Remove the screw from the size detection le
162. ed card assemblies 2 60 Service Manual 5055 xxx Step Questions actions Yes No 8 Are any of the pins or Go to step 9 Repair or contacts on the duplex replace the drawer connectors bent or connector damaged 9 Are connectors CN101 and Goto step 10 Properly connect CN102 on the duplex the connectors interface card properly connected 10 Replace the duplex Problem solved Return the interface card Does this fix duplex interface the problem card and go to step 11 11 Replace the duplex Problem solved Go to step 12 interface cable Does this fix the problem 12 CN37 CN38 on the Replace the Properly connect printer controller board printer controller the connectors properly connected board If the problem remains replace the duplex connector cable Diagnostic information 2 61 5055 xxx Map 11 Paper size map Step Questions actions Yes No 1 Do the paper size sensor Go to step 2 Replace parts as actuators on the paper necessary operation tray operate correctly as you slide the paper location plate 2 Do the size sensor levers Go to step 3 Replace the size operate correctly sensor levers 3 Are the following Go to step 4 Properly connect connectors properly the connectors connected CN2 tray 1 on the printer controller board CN4 on the expansion feeder control card trays 2 5 4 Repla
163. ed number of sheets reaches a designated number it staples a batch of sheets and then exits the stapled set to the lower tray Punch invert and staple stops paper at the leading edge punches it sends it to the accumulator and jogs each sheet When the accumulated number of sheets reaches a designated number the batch is stapled and exited to the lower tray Invert and offset jogs each paper in the accumulator shifts it by the offset then exits it to the lower tray Punch invert and offset stops paper at the leading edge punches it sends it to accumulator and jogs each page offsets it and then exits it to the lower tray Note Capacity is up to 100 sheets of 20 Ib paper in tray 1 top tray up to 1000 sheets of 20 Ib paper in tray 2 lower tray Diagnostic aids 3 61 5055 xxx Bin 1 Hole Punch Box Stapler Bin 2 Entry Guide Latch Stapler Door Finisher Stand Guide Rail Top Cover Bin 1 Bin 2 Latch Finisher Stand 3 62 Service Manual 5055 xxx Finisher cross section Paddle Roller Straight Exit Idle Roller Path Select Gate Upper Tray Straight Exit Register Inver Exit Idle Idle Roller Roller Input Paper Guide Lower Tray Invert Exit Roller Register Roller _ Accumulator Xeon Stapler Unit
164. eed solenoid for continuity Also check connector CN24 tray1 and CN16 MPF on the printer controller board and CN5 on the expansion feeder control card Registration sensor MPF sensor Printer controller board Check for a fluctuation between 0 and 5 V on the printer controller board between the following pins when actuating the sensor Registration sensor CN11 pins 1 and 2 MPF sensor CN11 pins 4 and 5 If the voltage fluctuates as stated above replace the printer controller board If the voltage does not fluctuate replace the sensor Diagnostic information 2 75 5055 xxx Paper has stopped at the registration roller or has not reached the fuser areas C E 240 24x FRU Action 1 Registration roller clutch Registration roller Transfer belt unit Rear paper feed Check these parts for wear or damage Replace as necessary Be sure all guide surfaces in the paper path are free of dirt Check the registration roller clutch for Printer controller board guide continuity Be sure connector CN13 on the printer controller board is connected properly 2 Registration sensor Check for a fluctuation of between 0 V and 5 V between pins 1 and 2 of connector CN11 on the printer controller board while actuating the sensor If the voltage fluctuates as stated above replace the printer controller board If the voltage does not fluctuate replace the sens
165. elopment unit 3 34 device tests 3 23 diagnostic aids 3 1 diagnostic information 2 1 diagnostic mode accessing the menu 3 6 exiting 3 32 diagnostics image quality troubleshooting 2 88 maintenance analysis procedures MAPS 2 54 printer setup 3 26 service checks 2 68 Service error messages 2 4 symptom tables 2 63 DIP switch settings 3 60 driving parts layout 5 20 drum counters 3 28 duplex unit parts catalog 7 38 7 40 removals 4 76 connector 4 75 feed roller and solenoid 4 78 paper carrying motor 4 80 side fence 4 79 side fence motor assembly 4 79 timing belt 4 76 theory of operation 3 44 E electrical diagram 5 19 finisher diagram 5 26 finisher parts catalog 7 66 high capacity feeder diagram 5 19 4 8 4 9 4 6 4 4 Index 1 1 5055 xxx parts catalog 7 22 eraser removal 4 27 error log clearing 3 32 viewing 3 31 error messages 2 4 exiting diagnostics mode 3 32 expansion feeder parts catalog 7 32 7 34 removal 4 67 theory of operation 3 43 F fans main unit fan removal 4 32 upper fan removal 4 66 finisher adjusting wheels 3 88 aligning finisher and printer 3 80 aligning sides of finisher 3 84 aligning top of finisher 3 86 attaching cables 3 90 bins attaching 3 79 docking plate and guide rail attaching 3 73 electrical 5 26 electrical parts functions 3 64 elevator sequence 3 71 hole punch theory 3 69 installation 3 73 inverted paper path 3 67 jogging 3 70 lowering and raising 3 82 offsetting 3
166. ely 2 Check the cable running to Replace the Go to step 3 CN20 for damage cable Is the cable damaged 3 Clean the gear sensor Problem solved Go to step 4 Does this correct the problem 4 Replace the sensor card Problem solved Replace the Did this resolve the drive unit problem 984 Yellow Gear Sensor Error Step Questions actions Yes No 1 Is connector CN20 on the Go to step 2 Plug the printer controller board connector in connected properly securely 2 Check the cable running to Replace the Go to step 3 CN20 for damage cable Is the cable damaged 3 Clean the gear sensor Problem solved Go to step 4 Does this correct the problem 4 Replace the sensor card Problem solved Replace the Did this resolve the drive unit problem 2 24 Service Manual 985 Transfer Belt Thermistor Error 985 Service Thermistor Error 5055 xxx Step Questions actions Yes No 1 Are connectors CN407 and Go to step 2 Plug the CN408 on the sensor board connector in connected properly securely 2 Is connector CN29 on the Replace the Plug the printer controller board transfer belt unit connector in connected properly If the problem securely remains replace the printer controller board 986 Transparency OHP Sensor Error 986 Service OHP Sensor Step Questions actions Yes No 1 Are connectors CN15 light Go to step 2 Plug the emi
167. eplace the printhead controller board printer controller correct the problem board 4 For serial number Problem solved Replace the XX AXXXX and above printhead Replace the LED printhead controller board for the affected color and go to step 5 Did this resolve the problem 5 Did replacement of the Problem solved Replace the printhead controller board printer controller resolve the problem board 2 10 Service Manual 931 Magenta Printhead Error 5055 xxx Step Questions actions Yes No 1 Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables printhead and the printhead number controller board as well as go the cables between the to step 2 printhead controller board and the printer controller If you have a board are properly printer with serial connected Are they number properly connected 4 and above go to step 4 2 For serial number Replace the Replace the Is fuse 6 on printhead control printhead the printhead control board board cables controller board open CL13 CL24 and go to step 3 and LED printhead 3 Did replacement of the Problem solved Replace the printhead controller board printer controller correct the problem board 4 For serial number Problem solved Replace the XX AXXXX and above printhead Replace the LED printhead controller board for the
168. er Check for condensation or dirt on the photodeveloper LED printhead Clean any dirt off the exposed surface of the LED printhead Also check the locating pins of the printhead Transfer belt unit Be sure the transfer belt is clean and not damaged Replace parts as necessary Top cover Be sure the top cover is fully locked Periodic dirt 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 surface and replace if necessary Transfer belt unit Be sure the transfer belt is clean and not damaged Replace parts as necessary White spots Possible cause Action LED printhead Photodeveloper Toner cartridge Firmly install the photodeveloper and the toner cartridge into the printer Belt unit Check the transfer belt unit for scratches or nicks Be sure there is no toner buildup on the belt Replace the belt unit if it is damaged Diagnostic information 2 97 5055 xxx Options service check Service Tip When you have a problem with any of the options installed in the options slots on the interconnect board switch the non operating option to one of the other option slots to isolate the failure Serial port Run the Serial Wrap Tests on page 3 16 Note The Serial Wrap Test is designed to ch
169. er 3 37 paper jams 3 46 theory 3 37 weight of paper 3 45 paper jams 3 46 part number 1 32 parts catalog base 7 16 7 18 7 20 cassette 7 30 covers 7 2 7 4 7 6 7 8 7 10 duplex unit 7 38 7 40 electrical 7 22 expansion feeder finisher covers 7 54 docking 7 68 7 70 electronics 7 66 elevator 7 64 feed 7 58 7 62 frame 7 56 finisher parts packet 7 81 fuser unit 7 28 high capacity feeder 7 46 7 48 7 50 7 52 miscellaneous 7 72 options 7 72 parts packets 7 74 RIP board 7 26 upper 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 maintenance 6 1 print quality pages 3 11 print quality problems 2 88 printed circuit boards inspection 4 2 precautions 4 1 replacement 4 2 transportation and storage 4 1 7 32 7 34 7 42 7 44 1 4 Service Manual printer controller board communication error 2 16 printer environment 1 27 printer messages 2 4 printer setup 3 26 configuration ID 3 30 drum counters 3 28 printhead LED printhead removal 4 24 parts catalog 7 15 printhead controller board 7 13 printhead controller board removal 4 44 printing menu settings 3 4 R relocation 7 73 removals belt up down clutch 4 10 belt up down detection sensor 4 11 cassette guide 4 12 connector duplex unit 4 13 covers front 4 5 front left 4 5 left side 4 7 operator panel 4 34
170. er The printer is adjusting the Wait for the message to Calibrating color tables to correct clear variations caused by environmental conditions Printing The printer is processing or Wait for the message to Alignment printing a test page that clear Page shows alignment values Printing The printer is processing or Wait for the message to Directory List printing a directory of all files stored in flash memory or on a hard disk Clear Diagnostic information 2 39 5055 xxx Message Printing Font List Meaning The printer is processing or printing a list of all available fonts for the specified printer language Action Wait for the message to clear Printing Job Accounting Stat The printer is processing or printing all job accounting statistics stored on the hard disk Wait for the message to clear Printing Menu The printer is processing or Wait for the message to Settings printing the menu settings clear page Prog Engine The printer is programming Wait for the message to Code new code into flash memory clear Prog System Code The printer is programming 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 is storing resources such as fonts or macros on hard disk Wait for
171. er controller power 2 Cable assembly printer controller power 1 Power supply 120 V 2 Power supply 230 V 2 Cable high voltage power supply board Power cord USA Canada APG LAD Power cord Peru Power cord Argentina Power cord Brazil Power cord Chile Power cord Denmark eo c2 lc ol 0 4 ol 0 4 0 4 lll Power cord Belgium Europe England France Germany Spain NS 11D0335 NS 11D0336 NS 11D0337 NS 56P9951 NS 56P9733 NS 56P9721 NS 56P9964 Power cord Italy Power cord Swiss French German Italian Power cord UK Israel South Africa Parts packet Cable assembly HCPF interface Cable assembly drum eraser ln a k Transformer power Japan only Parts catalog 7 25 5055 xxx Assembly 11 Rip board 7 26 Service Manual 5055 xxx Assembly 11 RIP board Index P N Units Description 11 4 56P9749 1 Cable assembly power RIP 2 56P9916 1 Card riser 3 56P9976 1 Board RIP controller C910 3 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 pin RIP printer controller 7 56P9736 1 Cable operator panel 8 56P9746 1 Cover RIP box NS 56P9747 1 Cable assembly power MAC NS 56P9748 1 Cable assembly MIF NS 56P9952 1 Parts packet Parts catalog 7 27
172. er feed motor Check the paper feed motors by running the Finisher control board staple test or hole punch test in diagnostic mode If the paper feed motor has been replaced replace the finisher control board Diagnostic information 2 79 5055 xxx Paper jammed in finisher area H FRU Action Timing belts Patting roller Check finisher to printer alignment Go to Aligning the finisher and printer on page 3 80 Check for obstructions in the paper path Check all belts for wear or damage Check for wear or damage on the patting roller 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 in diagnostic mode Check the tractor belts for proper alignment Replace parts as necessary Belt home position sensor Paper detecting sensor Invert path sensor Finisher control board Ensure that all sensors are operating properly by running the sensor test in diagnostic mode Replace sensors as necessary 2 80 Service Manual Paper jammed area I 5055 xxx FRU Action 1 Timing belts Check finisher to printer alignment Go to Aligning the finisher and printer on page 3 80 Check the paper path for obstructions Check all belts for wear or damage 2 Invert tray 2 exit roller Exit guide tray 2
173. escription NS NS 56P9951 56P9952 1 Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind S tight screws 3x8 Zn 3R 50 Bind S tight screws 3x12 Zn 3R 50 Bind P tight screws 3x8 Zn 3K 50 Bind screws M3x4 Zn 3K 50 Bind screws M3x6 Zn 3K 50 Bind screws M3x12 Zn 3K 50 Pans with flange P tight screws 3x10 Zn 3K 50 Screws with 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 BS 50 Screws with spring washers M4x8 Ni 3 BS 50 Natt with flange sereit M3 Ni 3 50 E rings ES 2 5 ACP 50 Spring pins 3x10 ACP Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind screws M3x6 Zn 3K 50 Bind screws M3x10 Zn 3K 50 Bind screws M3x6 Ni 3 7 76 Service Manual 5055 xxx Assembly 32 Parts packets continued Index P N Units Description NS NS NS 56P9953 56P9954 56P9955 1 Parts packet including 50 Bind S tight screws 3x6 Zn 3R 50 Bind P tight screws 3x6 Ni 3 50 Bind screws M3x4 Zn 3K 50 Bind screws M3x4 Zn 3K 50 Bind screws M3x5 Zn 3K 50 Screws with washers M3x10 Zn 3R 50 Screws with washers M3x8 Zn 3K 50 Screws with washers M3x6 Ni 3 BS 50 E rings
174. exit the Clear Log menu Maintenance Menu 80 Fuser Maint 0 to XXXXXXX Reset 80 Fuser Yes 80 Belt Maint 0 tO XXXXXXX Reset Belt Maint Yes Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal user mode press EXIT DIAGNOSTICS 3 32 Service Manual 5055 xxx Theory of operation Processes and configuration In this printer the toner of four colors magenta cyan yellow and black melts and deposits dots on paper which record color image information This printing process is called the electrophotography process Electrophotography process In the electrophotography process electrically charged toner exposes develops transfers and is cleaned with an aluminum photosensitive drum A photoconductive layer forms on the surface of the drum when the drum is exposed to light The surface of the photosensitive drum is negatively charged forming the electrostatic image on the surface of the photosensitive drum This charge is directed to the photosensitive medium at a low voltage reducing the generation of ozone to a very low level When the drum surface is charged the image 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 arrangement The image data from the printhead controller causes the LED to emit
175. f the guide rail with the line on the holding plate by rotating the two alignment 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 white and gray portions divide Restrict use of the finisher to plain paper You cannot hole punch transparencies card stock labels or envelopes Printer only prints to bin 1 or bin 2 The finisher cables are not connected properly The printer driver and the operator panel settings are different Check the cable connections Make sure your printer driver is set to direct the output to the bin you want Printer settings selected from a software application or driver override default settings selected from the operator panel 2 66 Service Manual 5055 xxx Symptom Cause Solution You cannot clear the paper jam message The cover is not closed finisher is against the printer or there is paper somewhere in the paper path Open and close the top cover and make sure the finisher is locked onto the alignment 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 in the staple job The finisher can staple up to 30 sheets of 20 I
176. finisher control board Measure for 5 V dc between pins 1 and 3 on PJ2 on the finisher control board Is either voltage missing board Diagnostic information 2 29 5055 xxx 996 Finisher Jogging Motor Error between pins 1 and 2 of PJ3 on the finisher control board Is 24 V dc present finisher control board Step Questions actions Yes No 1 Are there foreign objects or Cleartheobjects Go to step 2 obstructions in the jogging or obstruction assembly 2 Are the jogging motor Go to step 3 Securely connectors CN2 on the connect the finisher control board connectors securely connected 3 Make sure the finisher set Go to step 4 Go to step 5 Switch is activated Measure for 24 V dc 10 between pin 1 on CN2 and frame ground Is 24 V dc present 4 Replace the jogging motor Problem solved Replace the assembly Did this resolve finisher control the problem board 5 Disconnect CN2 and PJ5 Go to step 6 Replace the Perform a continuity check cable on the cable for all positions Is there continuity 6 Check for 24 V dc 51095 Replace the Replace the power supply 2 30 Service Manual 997 Finisher Tractor Motor Error 5055 xxx Step Questions actions Yes No Are there obstructions or foreign objects in the accumulator or face down paper path Remove the objects or obstructions Go to step 2 Are the connectors
177. flector move at all during power up 2 Manually operate the FU Go to step 3 Go to step 4 FD deflector Does it properly lock into position when manually operated 3 Is there continuity on the Go to step 5 Replace the FU FU FD deflector solenoid exit assembly between pins 1 and 2 of CN14 on the printer controller board 4 Make sure that the FU FD Replace the FU Place the FU FD deflector pivot arm is in the exit assembly pivot arm in the proper position proper position Is it in the proper position with its operating linkage 5 Is fuse 1 on the printer Replace the Replace the controller board open printer controller printer controller board and drum board eraser cable assembly Diagnostic information 2 21 5055 xxx 981 Belt Up Down Sensor Error 981 Service Switch Error Step Questions actions Yes No 1 Is engine code level 41D or Go to step 2 Update the above printer with code level 41D or above If this dies not resolve the problem continue with step 2 2 Are connectors CN409 and Go to step Plug the CN407 on the sensor board connectors in connected properly securely 3 Are connectors CN26 and Go to step 4 Plug the CN29 on the printer connector in controller board connected securely properly 4 Remove the transfer belt Go to step 5 If the sensor is Verify the belt up down out of position or sensor actuator flag is disconnected properl
178. from the fuser connector plate Note Note the direction when installing 13 After removing the two screws on the bracket that attaches the rear side and paper exit side of the machine remove the nine screws from the bracket 14 Remove the bearing from the belt up down switching shaft and remove the belt up down switching shaft C Xi CU 2 O O UO O O O O O 4 30 Service Manual 5055 xxx 15 Remove the screw from the clutch stopper The clutch stopper is attached to the ground plate with two screws 17 Remove the two screws from the drive unit and remove the unit Repair information 4 31 5055 xxx 18 Remove the three screws from the belt up down clutch box and remove the belt up down clutch 19 Remove the screw from the drum gear sensor and remove the sensor Main unit fan removal 1 Remove the left side cover the solenoid cover and the rear cover 2 Remove the two screws from the main unit fan bracket 3 Remove the fan 4 32 Service Manual 5055 xxx Motor drive board removal 1 Remove the upper cassette front cover B paper feed cover and the left side cover 2 Disconnect the five connectors and remove five screws and two screws from the motor drive board Multipurpose fee
179. g at the speed consistent with the actual media size Duplex all pages print at legal speed Average duplex print performance measured under the following conditions Simplex text document from the printer s integrated tray to the printer s standard output bin with a job stream sufficiently long for the printer system to enter the maximum duplex print performance page sequence 2 4 6 1 3 5 The first two sides 2 and 4 are not included in the performance computation since they seed the printer System s paper path to achieve the maximum duplex print performance Performance The Lexmark C91 x printers support the speeds listed above Performance depends on Interface to the host USB serial parallel network Host system and application Page complexity and content Certain printer options installed or selected Printer memory Media size and type Time to first print Time to first print is 15 seconds Processor 400 MHz C910 600 MHz C912 Duty cycle e Maximum duty cycle 00 000 pages True continuous duty cycle 0 000 pages Lifetime maximum duty cycle 600 000 pages General information 1 5 5055 xxx Printer memory Memory configuration DRAM memory Standard Maximum Lexmark C910 n 64MB 512MB Lexmark C910dn 128MB 512MB Lexmark C912 n 128MB 512MB Lexmark C912 dn 256MB 512MB Available memory options Optional 64MB 128MB and 256MB SDRAM DIM
180. g on paper size Stapling mechanism The stapler motor rotation drives a gear link and cam mechanism The cam movement allows the stapler mechanism to operate Staple Existence Sensor Staple Cartridge Staple Cartridge Z Set Switch Staple Home Staple Table Elevator sequence The wire drum rotates by the elevator motor as the wire drum rolls the wire pulling the hook plate up and down The lower tray moves up by the driving force of the elevator motor until the elevator upper limit sensor is ON the paper feeds onto the tray or until the paper upper level sensor B is ON if no paper feeds onto the tray When paper feeds out to the lower tray and the paper full sensor A turns ON the lower tray moves down until the paper full sensor A Diagnostic aids 3 71 5055 xxx turns OFF If paper feeds onto the lower tray when the elevator lower limit sensor turns ON and the paper upper level 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 Paper Full Sensor A Paper Upper Level Sensor B Wire Elevator Upper Hook Limit Sensor Plate Belt Drive Motor Elevator Lower Limit Sensor Wire Drum Elevating Motor 3 72 Service Manual 5055 xxx Finisher installation Attaching the docking plate and guide rail 1
181. ge appears to warn the customer that all disk contents will be lost Files will be lost Go Stop 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 in progress Once Go is selected the following screen is displayed to indicate the operation has begun Disk Test Clean Testing If the test is successful the following message is displayed Disk Test Clean Test Passed Press Go Return or Stop to return to the DEVICE TESTS screen If the test fails the following message appears Disk Test Clean Test Failed Press Go Return or Stop to return to the DEVICE TESTS screen You cannot cancel this test 3 24 Service Manual 5055 xxx Flash Test The Flash Test writes and reads data to the flash device destroying all data leaving the flash unformatted The servicer must reformat the flash using the Format Flash menu operation To run this test select Flash Test from the DEVICE TESTS menu The following message appears warning the customer that all flash contents will be lost Files Will be Lost Go Stop To continue 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 Flash Test Testing The Power indicator blink
182. gh voltage unit is properly connected If the problem remains replace the high voltage unit Sub frame If the problem remains replace the right sub frame contacts Photodeveloper drum set If the problem remains after replacing the sub frame be sure the photodeveloper has clean contacts If necessary replace the photodeveloper Diagnostic information 2 95 5055 xxx Missing colors Possible cause Action Toner cartridge unit Photodeveloper Be sure the toner cartridge and the PC drum unit are properly seated Be sure the contacts on the print unit are clean Be sure the print unit is installed in the correct position Run a print test If the problem remains switch the toner cartridge with another color and run a test print If the new color prints replace the failing toner cartridge High voltage unit If the problem remains check the connector on the high voltage unit Replace the high voltage unit If the problem remains LED printhead unit If the problem remains replace the printhead and EPROM LED printhead controller board If the problem remains replace the printhead controller board High voltage unit HVU If the problem remains replace the high voltage unit Transfer belt unit If the problem remains replace the transfer belt unit 2 96 Service Manual Uneven printing 5055 xxx Possible cause Action Photodevelop
183. h 7 3 56P9535 Cover solenoid 7 3 56P9536 Cover left side 7 3 56P9537 Cover paper feed 7 3 56P9538 Cover rear 7 3 56P9539 Cover top 7 3 56P9540 Cover waste toner bottle 7 3 56P9541 Sensor resistor 7 49 56P9542 Cover left front 7 3 56P9543 Magnet front cover latch 7 3 56P9544 Label 7 3 56P9545 Label operator guide 7 3 56P9551 Cover adjustment 7 3 56P9554 Core ferrite 7 3 56P9555 Housing upper operator panel 7 3 56P9556 Housing lower operator panel 7 3 56P9557 Exit assembly face up 7 5 56P9566 Guide assembly face down 7 7 56P9575 Bushing face down pinch roller 7 7 56P9576 Pulley face down feed roller 7 7 56P9578 Belt face down roller 7 7 56P9584 Guide assembly turn 7 9 56P9591 Frame upper 7 13 56P9592 Rail left side 7 13 56P9593 Holder rear printhe
184. he message and continue printing Install different flash memory before downloading 52 Flash Full There is not enough free space in flash memory Press Go to clear the message and continue printing Delete fonts macros and other data stored on flash memory Install flash memory with more storage capacity 53 Unformatted Flash The printer detects unformatted flash memory Press Go to clear the message and continue printing Format the flash memory If the error remains the flash memory may be defective Diagnostic information 2 45 5055 xxx x Software Error 54 Standard or Std Software Error communications with an installed network port Message Meaning Action 54 Serial The printer has detected a Make sure the serial link is Option x serial interface error on a set up correctly and you Error serial port are using the appropriate cable Press Go to clear the message and continue Press Menu to open the Job Menu and reset the printer 54 Network The printer cannot establish Press Go to clear the message and continue printing Program new firmware for the network interface by way of the parallel port Press Menu to open the Job Menu and reset the printer serial port 54 Std Par The printer has lost the Make sure the cable ENA connection to an external connecting the ENA and Connection print server the printer is securely Lost
185. he stopper 4 Remove the screw from the left stopper and remove the stopper 5 Remove the clip from the lock shaft 6 Remove the 17 screws from the stay arm and remove the arm Repair information 4 51 5055 xxx Sub frame removal Important Read the entire procedure before removal 3 UT EE De oe aM 8 Ls a 2 10 JTD 810 19 CD 10 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 cable ties Remove the 12 screws from the sub frame 4 Remove sub frame 4 52 Service Manual 5055 xxx Sub frame F1 sub frame F2 removal 1 Open the top unit 2 Remove the two screws from the sub frames F1 and F2 Note Spread a paper or cloth over the belt to protect the belt Set the sub frame F to the position of the following colors depending on the presence of the upper detection buttons Magenta Sub frame F1 Detection button available Cyan Sub frame F2 Detection button unavailable Yellow Sub frame F1 Detection button unavailable Black Sub frame F2 Detection button available Repair information 4 53 5055 xxx Temperature humidity sensor removal Paper feed solenoid removal
186. he face down guide assembly 4 Remove the four screws from the face down cover and the face down guide assembly and remove the assembly 4 18 Service Manual 5055 xxx Face up paper exit assembly removal 1 Open the top unit and remove the upper cassette Open the duplex cover and remove the duplex unit 2 Remove the left front cover left side cover and rear cover 3 Remove the three screws from the face up delivery assembly and remove the assembly Fanning pad removal 1 Open the top unit and remove the upper cassette front cover turn guide multipurpose feeder right side cover and multipurpose feeder roll 2 Release clips at 4 positions and remove the fanning pad Fanning Pad Repair information 4 19 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 4 20 Service Manual 5055 xxx Fuser removal 1 Open the top unit 2 Pushing the front and back lock hold the handle raise and remove the fuser Repair information 4 21 5055 xxx Gear cover removal Multipurpose feeder frame assembly 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 gear cover and remove the cover Wc E A Ib 3 Remove the fo
187. he new transfer belt Repair information 4 59 5055 xxx Alternate method Operator panel is inoperable or unrecoverable error code If the operator panel is inoperable or if you have 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 anything on the transfer belt Touching the surface of the transfer belt or placing items on the belt may cause damage 3 Loosen the thumbscrews as shown 4 60 Service Manual 5055 xxx Remove the transfer belt cover Override the front cover interlock switch Turn the printer on Look for the belt to lower during power on sequence Turn the printer off when the belt lowers Repair information 4 61 5055 xxx 9 Loosen the thumbscrews as shown 4 62 Service Manual 5055 xxx 10 Pull the transfer belt out 11 After replacing the transfer belt and removing the four shipping spacers tighten the transfer belt thumbscrews and reinstall the transfer belt cover 12 Close the top unit and rotate the locking lever to the right close the front cover 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
188. he power supply Note When installing incline the ground wire by 45 4 40 Service Manual 5055 xxx Power supply 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 power supply 2 and remove the power supply 5 c P I med I Note Remove the black actuator from the old power supply and install it on the new power supply before installing the new power supply Repair information 4 41 5055 xxx Power switch removal 1 Remove the upper cassette left front cover paper feed cover and left side cover 2 Unlock the power switch and pull out the power switch ZF eg 3 Remove each terminal connected to the power switch Note When connecting be careful to connect the connectors correctly Insert the insulator cover completely covering the terminal 4 42 Service Manual 5055 xxx Printer controller removal 1 2 Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the connectors and the eight 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 board install the EPROM U5 of the fo
189. he 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 cord into the socket on the side of the printer 3 92 Service Manual 5055 xxx 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 of the top optional drawer Diagnostic aids 3 93 5055 xxx 7 Place the finisher interface cable and power cord into the cable holder 8 Close the cable holder 9 Replug the power cord into the outlet and turn the printer on The finisher does not have a power switch Power is controlled by the printer Hole punch adjustment You can adjust the hole punch alignment by approximately 4 mm 8 16 in This adjustment is useful when you want to center 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 alignment of the printer and finisher is correct e f the alignment is not correct go to Aligning the finisher and printer on page 3 80 and then print and hole punch another sheet of paper and see if an adjustment is needed f an adjustment is needed continue with step 2 2 Using a sheet of pape
190. hen the printer is manufactured but must be reset whenever the engine board containing NVRAM memory is replaced The configuration ID can be set through the Diagnostic menus When Configuration ID is selected from the PRINTER SETUP menu the current ID is displayed Configuration ID 2123456 The left most digit 1 in this example blinks indicating it is the first digit 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 this method To skip a digit and keep its current value press Select When Select is pressed after the final digit 6 in this example the configuration ID is validated If the ID is invalid then the Invalid ID displays momentarily on Line 2 before the ID re displays If the ID is valid it is stored in NVRAM and the printer automatically activates the new setting If a configuration ID has not been set then upon entry into diagnostics the configuration ID setup is the only Diagnostic function displayed until a valid ID is entered 3 30 Service Manual 5055 xxx Diagnostics error log Viewing the error log The Error Log provides a history of printer errors containing the 12 most recent errors that have occurred The most recent error displays in position 1 and the oldest error displays in position 12 If fewer than 12 errors have occu
191. her must be undocked during the job If envelope wrinkling occurs refer to the User s Guide for correct weight type loading and stacking of envelopes All envelopes should be new unused and without package damage Envelopes with excessive curl or twist exceeding 0 12 in 6 mm stuck together with bent corners or nicked edges or those that interlock should not be used 1 20 Service Manual 5055 xxx Minimum weight 20 Ib 75 g m The following envelopes should not be used Envelopes with windows holes perforations cutouts deep embossing or package damage Envelopes with metal clasps string ties or metal folding bars Envelopes with exposed flap adhesive when the flap is in the closed position For best results printing on new 24 Ib 90 g m sulfite or 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 should be selected using guidelines found in the User s Guide or the Cardstock and Label Guide and tested for acceptability Lexmark glossy paper Use letter p n 1245950 or A4 p n 1245951 only Glossy paper is only supported from Tray 1 Multipurpose Feeder and Heavy Media Tray Print area Printable area for the printer is to within 0 16 in 4 2 mm of all edges of the media except envelopes General information 1 21
192. ical White White 6 Yellow 3 white black white 27 Vertical Black White 4 Black 21 Vertical Yellow White 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 Black brown orange yellow 17 Horizontal White White 3 Black yellow red 5 Horizontal White White 3 Red yellow black 32 Horizontal White Gray 8 2 Black 2 yellow 2 blue 2 red 1 Vertical White N A Empty N A Locations 5 11 5055 xxx Printhead controller board For printers with serial number OD 1 y O fommll CN16 CN15 CN12 11 CNo8 07 o o D 2 12 ut4 C uiz Jute o _ 5 E j e U11 U13 U16 U18 2 z LI LJ uo U21 015 03 2 rcd Fuse 3 Fuse 6 O Fuse 5 CN14 CN13 CN10 CN09 06 5 o rpm Dm D For printers with serial number XX 4
193. id sites generating ammonia gas high temperature high humidity near water faucets kettles humidifiers cold spaces near open flames and dusty areas Avoid sites exposed to direct sunlight Print paper checks Use the recommended paper for this printer Paper dampness Make a trial print with paper from a newly opened package and check the result Diagnostic information 2 3 5055 xxx Printer messages The printer displays three types of messages service messages status messages and attendance messages Service messages indicate a problem that requires a service technician Status messages provide information about the current state of the printer requiring no action Attendance messages alert the operator to printer problems that require operator intervention Service error message tables 900 Unrecoverable Software Error 910 Service Motor Error 910 Drive Motor Error Step Questions actions Yes No 1 Are connectors CN1 and Go to step 2 Connect CN1 CN5 on the motor drive and CN5 board connected properly 2 Is connector CN33 on the Replace the Connect CN33 printer controller board motor drive connected properly board and go to step 3 3 Did replacement of the Problem solved Replace the motor drive board solve the printer controller problem board and go to step 4 4 Did replacement of the Problem solved Replace all the printer controller boar
194. ified General information 1 31 5055 xxx Serial number 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 the Tests Menu Config ID P N Serial Number EE 4 1 32 Service Manual 5055 xxx Abbreviations ASIC CSU DRAM EP EPROM ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR V ac V dc Application specific integrated circuit Customer setup Dynamic random access memory Electrophotographic process Erasable programmable read only memory Electrostatic discharge Field replaceable unit High voltage power supply Local area network Light amplification by stimulated emission of radiation Liquid crystal display Light emitting diode Low voltage power supply Nonvolatile random access memory Original equipment manufacturer Problem isolation charts Picture element Power on reset Power on self test Print quality enhancement technology Raster image processor Read only storage Static random access memory Used parts replacement Volts alternating current Volts direct current General information 1 33 5055 xxx 1 34 Service Manual 5055 xxx 2 Diagnostic information The diagnostic information in this chap
195. ight If you cannot rotate the locking lever the cover is not fully closed Open the jam access door on the left side of the printer Remove any paper inside the printer Close the jam access door To prevent additional paper jams make sure both sides of the door are closed 18 Close the front door 19 Press Go If the paper jam message continues check and clear all paper from the paper path Diagnostic aids 3 47 5055 xxx Check Area C This message indicates a paper jam in the duplex unit area by the access door To clear area C 1 2 3 Open the duplex jam access door on the right side of the printer Remove the jam Press Go If the paper jam message continues clear any paper from the paper path Check Area D This message indicates a paper jam in the duplex unit area To clear area D 1 2 Open the duplex jam access door on the right side of the printer Gently pull out the duplex unit 3 Turn the paper forwarding dial counterclockwise OAN O QO If the paper advances remove the jam and go to step 7 If it does not advance go to step 4 Open the duplex unit covers Remove the jam Close the duplex unit covers Push in the duplex unit Close the duplex jam access door Press Go If the paper jam message continues clear any paper from the paper path 3 48 Service Manual 5055 xxx Check Area E This message indicates a paper jam in the top middle or bottom
196. ignal from the printer controller The paper feeding roller interconnected with drive 1 rotates with the spring clutch and picks the paper in the paper cassette Diagnostic aids 3 37 5055 xxx Multipurpose feeding The multipaper feed solenoid turns on by the signal from the printer controller The multipurpose feed roll interconnected with the drive 1 through the spring clutch rotates and picks the paper in the multipurpose feeder Registration unit Media temporarily stops registration when adjusting the paper leading edge parallel with that of the image or when adjusting the timing with the black image The upper and lower registration rolls are arranged in parallel with the photosensitive drum for black imaging The lower registration roll incorporates a registration clutch which feeds or stops the paper In the forward direction of the registration roll a registration sensor photo interrupter is provided to detect paper fed from the paper feeder and to stop paper jam feeding Registration Sensor Q Registration Roller QD 3 1 3 38 Service Manual 5055 xxx Separation unit The transfer belt and paper are separated with the belt drive roll by separation fingers y og sC TO Separation Fingers E lt V Diagnostic aids 3 39 5055 xxx Fuser unit By applying heat and pressure the image is melted and fused t
197. in an internal print server is not valid The printer cannot receive and process jobs until valid code is programmed into the internal print server Download valid code to the printer internal print server Diagnostic information 2 37 5055 xxx Message Load x Meaning The printer is trying to feed paper from a source it detects is empty Action Load paper of the size and type requested in the second line of the display in the specified tray Press Menu to open the Job Menu and cancel the current job If Load Tray cannot be reset go to Map 4 False Tray x Low Empty message on page 2 56 If Load MPF check the MPF paper present sensor Load Manual A request for a manual feed job has been sent to the printer The printer is ready for insertion of a single sheet into the manual feed slot 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 printer Press Menu to open the Job Menu and cancel the current job LocalTalk lt x gt A LocalTalk interface is the active communication link Wait for the message to clear Menus The printer menus are You can still open the Job Disabled disabled Menu to cancel a job that is printing or to select a confidential job or a held job that you want to print
198. inisher Bin 2 Legal 8 5 in x 14 in 216 mm x 256 mm gt Standard output gt Bin1 gt Executive 7 25 in x 10 5 in 184 mm x 267 mm gt gt gt Tabloid 11 in x 17 in 279 4 mm x 431 8 mm 12 in x 18 in 805 mm x 457 mm Lexmark C912 only 11 69 in x 16 54 in 297 mm x 420 mm Universal Banner 11 69 x 36 in 297 2 x 914 4 mm Lexmark C912 only 2 75 x 5 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 7 34 Envelope 3 875 in x 7 5 in 98 mm x 191 mm 9 Envelope 3 875 in x 8 9 in 98 mm x 225 4 mm 10 Envelope 4 125 in x 9 5 in 105 mm x 241 mm DL Envelope 4 33 in x 8 66 in 110 mm x 220 mm C4 Envelope 9 in x 12 75 in 229 mm x 324 mm General information 1 13 5055 xxx 5 g T N 5 S s r 8 3 5 E 7 m ir iL C5 Envelope 6 38 in x 9 01 in X X 162 mm x 229 mm B5 Envelope 6 93 in x 9 84 in X X 176 mm x 250 mm Other Envelope 11 69 in x 11 69 in p X 297 mm to 297 mm Media type Paper X X X X Card stock X X X Transparencies X X Envelopes X X Glossy paper X X X X Paper labels X X mm unless the size is specified in the software application 355 6 mm unless the size is specified in the software applica
199. ion lever 2 Supply roll 17 Paper out detection sensor 3 Doctor blade 18 Duplex unit 4 Agitator 19 Transfer sheet 5 Absorption 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 lever 24 Heater 10 MPF roll 25 Fuser roller 11 MPF unit 26 Oil coating roller 12 Fanning pad 27 Cleaning blade 13 Upper feed roll 28 Photosensitive drum 14 Lower feed roll 29 Charged roll 15 Paper feed roll 30 LED head Locations 5 3 Sensor and switch locations 5055 xxx Josuas umoq dn Josueg JOSUAS Ausuaq jaded p 1901 10 9 Aouasedsue D JOSU 1ueseJg JR JOSUAS Joded uonoejeq qana u ddn 10sues YDNMS 4x3 1edeg preog Josues 9715 4 Aouesedsues 1 JOSUSS JOSUSS JOSUSS JOSUSS d xa YMS losu s mo Aypiwiny uni 5 4 Service Manual 5055 xxx 10109 JOSUaS 1299 eAuq Josuas SJOSUSS JOUO Mg Josuas 1299 uniq 10109 JOSUAS Jean unuq Locations 5 5 5055 xxx Component locations 10 Rear 9 Left Side Top 5 6 Service Manual 15
200. is On Diagnostic information 2 93 5055 xxx No image Possible cause Action Moist paper Be sure the printer is not in a damp environment and the paper is not curled or wavy due to moisture If necessary inform the customer about correct storage LED printhead Be sure the LED printhead cable is securely connected to the printhead controller board and LED printhead assembly If the problem remains replace the LED printhead High voltage unit HVU Be sure all the connectors to the high voltage unit are securely connected If the problem remains replace the high voltage unit Printer controller board Be sure all connectors are securely connected to the printer controller board If the problem remains replace the printer controller board Printhead controller board If the problem remains replace the printhead controller board 2 94 Service Manual 5055 xxx Black line Possible cause Action Photodeveloper drum Clean any dirt from the drum surface Replace it if it is scratched Fuser detach pawl Remove any toner buildup Replace Fuser roller surface the fuser Fuser thermistor surface LED printhead Clean the LED printhead Print a blank document Replace the LED printhead if a black line appears on the paper Black print Possible cause Action High voltage unit HVU The printed paper has black print Be sure the hi
201. isk Test on page 3 23 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk Note The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If a problem still exists replace the hard disk board Use the Disk Test Clean on page 3 24 to help restore the disk if it contains bad data and is unusable This test is divided into a cleaning and a verifying or testing section Warning This can 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 This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network Card Option The network is installed on the system board on network model printers Error Code 976 Network Card x x Network card 1 2 or 3 A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly installed in the Socket on the interconnect board and is properly grounded If you find no problem contact your next level of support before replacing the network card 54 Network x Software Error This error displays when the RIP software detects that a network card is installed in slot x on the interconnect board but cannot establish communicatio
202. ive belts driven by the paper feed motor or tractor drive motor and other rollers Paper path route differs 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 to the upper tray by the exit rollers 1 Path select gate solenoid 2 Solenoid Paper Exit Paper Exit Sensor Upper Tray Upper Tray Idle Roller Registration 4 Idle 7 Roller Paper Exit Roller Paper Register Sensor Registration Roller Path Select Gate Diagnostic aids 3 65 5055 xxx Path select gate Path Select Gate Us Solenoid 3 66 Service Manual 5055 xxx Inverting paper path exit paper to lower tray through accumulator The paper feed motor drives and rotates the rollers as paper feeds through the registration 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 accumulator Patting Roller Path Select Gate Invert Exit Paper Idle Roller Registration Sensor Roller Registration Roller it Accumulator N Invert Path Sensor Tractor gt
203. ize Transmit Delay Max Baud Rate LOCALTALK MENU LocalTalk Port PCL SmartSwitch PS SmartSwitch NPA Mode LocalTalk Buffer Job Buffering NPA Hosts LocalTalk Name LocalTalk Addr LocalTalk Zone Diagnostic aids 3 5 5055 xxx Diagnostic Mode To access the diagnostics printer settings and operations 1 2 3 Turn off the printer Press and hold Go and Return Turn on the printer Release the buttons after the Performing Self Test message is displayed The alignment menu displays first Press Select and using the menu key scroll to Alignment Test Press Select to print the test This prints the three color registration pages These pages are the same for X Y Theta and for the three colors and are available under the X Adjustment Y Adjustment and the Theta Adjustment There are three adjustments for each color 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 plane and by adjusting the value for Y you move the color radar image up negative and down positive These values are determined by examining the left side of the radar page Values for X are 1 600th of an inch and Y values are 1 2400th of an inch Theta controls the skew or angle of rotation To get the correct reading adjust X and Y before Theta Examine the left side
204. ket 7 43 7 78 56P9959 Parts packet 7 45 7 78 56P9960 Parts packet 7 47 7 79 56P9961 Parts packet 7 49 7 79 56P9962 Parts packet 7 51 7 80 56P9963 Parts packet 7 53 7 80 56P9964 Transformer power Japan only 7 25 56P9970 Cover assembly front C912 7 3 56P9971 Frame assembly MPF 7 21 56P9972 Feeder assembly multipurpose 7 11 56P9973 Board RIP controller C912 7 27 56P9974 Board RIP controller network C912 7 27 56P9975 Japanese fontkit 7 73 56P9976 Board RIP controller 0910 7 27 56P9977 Board RIP controller network C910 7 27 56P9979 Guide stop 7 31 56P9980 Guard rack 7 31 56P9981 Board printer controller 912 S N XX 0XXXX 7 23 56P9982 Hard Disk 5 GB w Mounting Kit formatted 7 72 56P9985 Printhead LED 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 1 7 13 56P9988 Post mini S N 1 7 15 Part number index 1 21 5055 xxx 56P9989
205. l design and specific components The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug 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 portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilit concernant la s curit en cas d utilisation de pi ces de rechange non agr es Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires ATTENTION Ce symbole indique la pr sence AN d une tension dangereuse dans la partie du produit sur laquelle vo
206. me FRU Action 1 Photodeveloper Check for dirt or damage to the sensing contacts on rear Clean or replace the photodeveloper drum unit if necessary 2 Sub frame unit Check the sensing contacts on the sub frame assembly Clean or replace the affected contacts or sub frame 3 High voltage unit If the problem remains replace the high voltage unit HVU 4 Printer controller board If the problem remains replace the printer controller board 2 84 Service Manual 5055 xxx Power supply service check FRU Action 1 Voltage Be sure the switch is on and the power cord is firmly plugged into the printer Be sure the correct voltage is present at the outlet 2 Power cord Check the power cord for continuity 3 Fuse The power supply fuses may be blown Switch Unplug the machine and check fuse F2 on Power supply 1 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 the dc power of the power supply for the following pins CN102 pins 8 and 11 for 3 3 V CN103 pins 7 and 14 for 3 3 V CN105 pin 5 for 3 3 V CN102 pins 12 and 14 for 5 V CN103 pins 1 3 8 9 for 5 V CN104 pins 1 and 2 for 5 V CN104 pins 7 and 8 for 24 V CN105 pin 4 for 24 V CN106 pins 5 and 6 for 24 V Replace power supply 2 if necessary Diagnostic info
207. me 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 guide 21 56P9384 2 Plate B spring 22 56P9386 1 Spring 23 56P9387 1 Handle jam 24 56P9389 1 Bracket 25 56P9345 1 Cover staple inner B 26 56P9344 1 Cover staple inner A 27 56P9327 1 Cable upper side panel 28 56P9390 1 Plate cover 29 56P9436 1 Cable 30 56P9313 1 Unit 3 hole punch U S only 30 56P9314 1 Unit 4 hole punch non U S 31 56P9388 1 Sensor 1 photo 32 56P9319 1 Assembly exit guide straight 33 56P9394 1 Handle Parts catalog 7 57 5055 xxx Assembly 26 Finisher feed 1 7 58 Service Manual 5055 xxx Assembly 26 Finisher feed 1 Index P N Units Description 26 1 56P9395 1 Assembly guide plate 2 56P9393 2 Plate guide holder 3 56P9334 1 Assembly solenoid 4 56P9396 1 Spring H 5 56P9397 2 Gear Z20 6 56P9398 1 Gear Z19 7 56P9311 9 Bushing 8 56P9310 1 Gate 9 56P9400 1 Roller 10 56P9361 1 Roller patting 11 56P9401 1 Roller 1 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 1 Pulley Z24 T42 gear 20 56P9407 1 Belt timing 60S2M184 21 56P9408 1 Knob 22 56P9339 1 Belt timing 60S2M334 23 56P9305 1 Assembly tension D 24 56P9411 1 Pulley 25 56P9
208. mited to 25 cotton content General information 1 17 5055 xxx Input capacity by media and source Media Stack height Capacity 500 Sheet trays Plain paper letter A4 2 2 in 56 mm 550 sheets legal tabloid A3 20 Ib 75 g m Plain paper letter A4 1 in 25 mm 240 sheets legal tabloid A3 24 Ib 90 g m Glossy paper 0 6 in 15 mm 130 sheets 32 Ib 120 g m Multipurpose feeder Plain paper 100 sheets 20 Ib 75 g m Transparencies 50 transparencies 0 4 in 11 mm Envelopes 10 envelopes Card stock 55 sheets 90 Ib index 163 g m Paper labels 55 sheets up to 48 Ib 180 g m Glossy paper Manual 1 sheet 32 Ib 120 g m High capacity feeder Plain paper 12 5 in 317 mm 3 000 sheets 20 Ib 75 g m Heavy media tray Plain paper 1 6 in 40 mm 300 sheets 32 Ib 120 g m Transparencies 0 8 in 20 mm 150 transparencies 47 Ib 175 g m Paper labels 1 6 in 40 mm 200 sheets up to 48 Ib 180 g m Glossy paper 1 6 in 40 mm 360 sheets 32 Ib 120 g m 1 18 Service Manual 5055 xxx Output capacity by media and source Media Stack heights Capacity Standard output bin Plain paper Varies 550 sheets 20 Ib 75 g m Glossy paper Varies 130 sheets 32 Ib 120 g m Bin 1 and Staple Punch Finisher Bin 1 Plain paper Varies 100 sheets 20 Ib 75 g m Transparencie
209. nd detection mechanism 5 18 Service Manual Friction roller separation system with a non contact magnet type maintenance free torque limiter Tray elevating system consisting of a tray motor and a timing belt Fixed to the side fence and size is entered from the printer Tray level is detected with the fillers and photo interrupters 4 pieces A reflection type sensor on the upper stay detects the paper 5055 xxx Electrical parts layout Paper Feed Clutch Paper Feed Motor Pickup SOL oo Residual Paper Paper Size Sensor 2 Sensori Residual Paper Sensor 2 Paper End Sensor s lt Residual Paper Paper Level Sensor Sensor 3 Down Button 798 Control lt 1 Cover SW 1 2 Tray Motor a Supply PCB Joint SW 1 2 DC DC Converter Locations 5 19 5055 xxx Driving parts layout Paper Feed Clutch Paper Feed Roller Paper Feed Motor Sy s Reverse Roller Call Roller Tray Driving Belt Tray Motor Tray Elevating Shaft 5 20 Service Manual 5055 xxx Finisher locations Bin 1 Hole Punch Box Stapler Bin 2 Entry Guide Latch Stapler Door Guide Rail Top Cover Bin 2 Finisher Stand Locations 5 21 5055 xxx Upper Tray Invert Exit Idle Roller Lower Tray Invert Exit Roller 5 22 Service Manual Paddle Roller
210. ne assabentat i prendre les mesures convenients PRECAUCI aquest s mbol indica que el voltatge de la part de l equip amb la qual esteu treballant s perill s Abans de comen ar desendolleu l equip o extremeu les precaucions si per treballar amb l equip l heu de connectar OF At St LL EWES wela 9 Sa T EI el 39 9 s porte cepa ja q o FAA orat g AA EI 1 H AT 8 81 A Ol T O L ERE L T H WITT Se m AO 12424 0 utrq T g MYSA 18 epus wap gA SS HA L Ef 0 Er 3 Tl H TF B 189 FAY Xiv Service Manual 5055 xxx Z SB ih E A IR BEDT A KORI fli J 2 il SPEDE ASP tin SED fr ES MIRA EH HAT FE ib ME H YET TESS RIXA SEDI f MESTE e NER AE A ROS UMA Br T f HARDEE PDT f Wie BABI SIT Vi TESTER m CE tf eru EET BEP ft aga RER DEN rk Se 21 ND A Safety information Xv 5055 xxx Preface This manual contains maintenance procedures for service personnel It is divided into the following chapters 1 General information contains a general description of the printe
211. ngine board beginning at CN20 in the top right and continuing clockwise around the edge of the board Note the orientation of the printer controller board diagram Board connectors in this table are attached to the board and cable connectors are made up of various number of wires of various colors Vertical connectors list wire colors top to bottom Horizontal connectors list wire colors left to right Printer controller board connectors Board Board Cable wires CN connector conn conn in Wire colors orientation color color cable 20 Vertical White White 6 Black 12 Vertical White White 6 3 Blue 3 gray 44 Vertical White White 11 1 Red 1 black 4 gray 5 white 33 Vertical White White 6 Brown blue gray white black yellow 6 Vertical White White 3 Black yellow red 14 Vertical White White 2 Blue 43 Vertical White White 4 3 Gray 1 red HV only 31 Horizontal White White 2 Black red 38 Horizontal White White 4 Yellow red 2 black 37 Horizontal White White 13 Brown red orange yellow blue purple gray white brown red orange yellow blue 47 Horizontal White White 30 29 White 1 blue 48 Horizontal White White 18 17 White 1 blue Locations 5 9 5055 xxx Printer controller board connectors continued Board Board Cable wires CN connector conn co
212. nn in Wire colors orientation color color cable 46 Vertical White White 8 2 Green 2 blue 2 red 2 yellow 45 Horizontal Brown Brown 80 1 Red 79 brown ribbon 10 Horizontal White Green 6 Brown 3 Horizontal White White 4 Yellow brown black blue 29 Horizontal White White 10 Brown blue gray white brown yellow blue black gray white 2 Horizontal White White 4 Brown 42 Horizontal White White 15 Brown blue gray white yellow brown 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 orange red gray white 39 Horizontal White White 8 2 red 4 black 2 yellow 8 Horizontal White White 3 Blue 25 Horizontal Black White 2 Black 24 Vertical White White 2 White 16 Vertical Yellow Yellow 2 Yellow 23 Vertical Blue Blue 2 Blue 13 Vertical White White 2 White 5 10 Service Manual 5055 xxx Printer controller board connectors continued Board Board Cable wires CN connector conn conn in Wire colors orientation color color cable 26 Vertical White Gray 2 White 30 Vertical White White 2 Red black 22 Vertical Black White 4 Black 34 Vertical White White 8 7 Black white 11 Vertical White White 6 3 Black 3 white 19 Vertical Blue White 4 Blue 40 Vert
213. ns with the network card Diagnostic information 2 99 5055 xxx 2 100 Service Manual 5055 xxx 3 Diagnostic aids Note When troubleshooting or prior to making any adjustment to print quality always be sure The printer is installed on a level rigid surface The OPCs are never exchanged Do not exchange a black OPC for a color OPC as they have different surface phase counts e Radar Page is always used when adjusting print registration Power On Self Test sequence 1 2 k O MAND Power on Printer and RIP controller check ROM and RAM Fuser thermistor Printer hardware check Paper jam Printer cartridge unit Toner supply Paper cassette present Fuser temperature check Temperature regulated Ready Printer controller RIP controller Printer condition Motor Fan Heater DC motor drive 1 Feeding paper Print Stepper motor drive 2 Paper exit Stop Diagnostic aids 3 1 5055 xxx Using the operator panel The operator panel on your printer has a 2 line by 16 character liquid crystal display LCD five buttons and one indicator light The light indicates whether the printer power is on and whether the printer is idle or busy processing a job Indicator light State Indicates Off Printer power is off On Printer is on but idle Flashing Printer is busy processing a job Use the five operator panel bu
214. nsfer belt is nearing Press Go to clear the Warning end of life message and continue printing The supplies message is displayed until you replace the transfer belt and fuser 80 Fuser The fuser has reached end Replace the fuser Exhausted of life 80 Fuser Life The fuser is nearing end of Press Go to clear the Warning life message and continue printing The supplies message is displayed until you replace the transfer belt and fuser 81 Engine Microcode in the engine Press Go to clear the Code CRC flash code module has failed message and discard the Failure a system check code Retransmit the microcode data from the host computer 2 48 Service Manual 5055 xxx Message Meaning Action 84 All Photo All of the photodevelopers Replace all of the Devs have reached end of life photodevelopers Make sure Exhausted you also install the new fuser coating roll that is included in each photodeveloper kit 84 Black Photo The printer has detected Install a new black Dev Abnormal abnormal black photodeveloper photodeveloper to clear the message and continue printing 84 Black Photo Dev Exhausted The black photodeveloper 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 replace the photodeveloper press Go to clear the message and contin
215. nter controller board Replace the belt up down unit if necessary 3 Belt up down lift cams Check and replace the belt up down lift cam shaft if necessary 4 Printer controller board If there still is a problem replace the printer controller board Diagnostic information 2 87 5055 xxx Image quality troubleshooting Print quality problems Problem images or characters or dropouts Print is too light or printed have voids IN L Action Be sure you re using recommended paper or other media Use media from a new package Be sure you have selected the correct Paper Weight setting for the media you re using Be sure the affected print unit is completely installed in the printer Set print darkness to 4 from the Color Menu Clean the printhead LEDs If you suspect a toner cartridge is low on toner remove the appropriate toner cartridge and gently shake it back and forth to distribute the toner evenly Reinsert the print unit and try printing the job again Replace the affected toner cartridge Replace the photodevelopers If only black print appears light replace just the black photodeveloper If one of the colors prints too light replace all three of the color photodevelopers If there is still a problem go to Uneven printing on page 2 97 2 88 Service Manu al 5055 xxx Problem Colored lines streaks or smudges a
216. o position If the pins did not go into the holes in the finisher go to Lowering or raising the finisher on page 3 82 Otherwise go to Aligning the sides of the finisher on page 3 84 Diagnostic aids 3 81 5055 xxx Lowering 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 Hole in Finisher 3 82 Service Manual 5055 xxx 3 Rotate the adjustment knobs as needed to align the holes in the finisher with the pins To raise the finisher rotate the adjustment knobs clockwise To lower the 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 position If the pins go into the holes but the finisher did not lock to the pins go to Aligning the sides of the finisher on page 3 84 Otherwise go to Aligning the top of the finisher on page 3 86 Diagnostic aids 3 83 5055 xxx Aligning the sides of the 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 thumbscrews If you previously lowered or raised the guide rail plate the thumbscrews are already loose
217. o the paper fe 277 Temperature Fuser uuo d Fuse S 00 ENG Heater Temperature Backup Roller thermistor Fuse The upper and lower rollers are heated and pressure fitted A heater is positioned in the roller tube and a thermistor and thermostat remain in contact with the outside of the tube Separation fingers are attached near the upper roller to separate the paper from the roller Each thermistor sends the surface temperature of the roller to the printer controller The printer controller turns the heater on or off according to the voltage of each thermistor If the controller fails and the temperature of the roller exceeds specifications the temperature fuse TCO connected to each heater opens preventing overheating 3 40 Service Manual 5055 xxx Delivery After completing the fusing process paper is discharged from the printer The delivery sensor detects the paper condition and the FU FD deflector switches between the face up and face down paper delivery The paper from the fuser pulls down the sensing lever turning on the delivery sensor photo interrupter If the delivery unit remains on longer than specified the printer controller determines that the printer is jammed and the paper delivery flap lever switches to either face down or face up P
218. oard correct the problem 7 Is there continuity on the Replace the Replace the stapler to finisher control power supply cable Diagnostic information 2 33 5055 xxx Attendance messages Message Activating Menu Changes Meaning The printer is activating changes made to the printer settings Action Wait for the message to clear Bin Full The specified bin is full Remove the paper from the bin Busy The printer is busy receiving Waitforthe message to clear processing or printing data or press Menu to open the Job Menu and cancel the current job Canceling Fax The printer is processing a request to cancel a fax job Wait for the message to clear Canceling Job 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 The specified device is not fully connected Hardware failure Reestablish communication by reattaching the device Press Go to clear the message If a hardware failure turn the printer off and back on If the error recurs turn the printer off remove the specified device and call for service If the error cannot be reset go to Map 10 Unrecoverable Check Tray x or Duplex Connection message on page 2 60 Clearing Job Accounting Stat Th
219. oblem expansion feeder control card 2 56 Service Manual Map 5 False 30 Oil Coating Roll Missing message 5055 xxx connected Step Questions actions Yes No 1 Is the OCR properly Go to step 2 Properly install installed the OCR 2 Is the OCR fuse missing Replace the Go to step 3 OCR 3 Is the OCR contact at the Replace the Go to step 4 rear of the fuser damaged fuser or broken 4 Is CN44 on the printer Replace the Properly connect controller board properly printer controller CN44 connected board Map 6 False color Print Unit Missing message Step Questions actions Yes No 1 Are all connectors that the Go to step 2 Replace the sub print unit photodeveloper frame contacts when the top cover is closed operating correctly and not damaged worn or missing 2 Is CN42 on the printer Replace the Properly connect controller board properly printer controller CN42 board Diagnostic information 2 57 5055 xxx Map 7 False 88 color Toner Low Toner Empty message Step Questions actions Yes No 1 Ensure the RIP board and Go to step 2 Upgrade the RIP the printer controller board and controller are updated to the latest board codes to code Microcode EC2 or the latest level higher Are the boards at EC2 or higher 2 Ensure that the encoder Go to step 3 Clean the located at the rear of the encoder
220. ok left 7 13 56P9618 Hook right 7 13 56P9619 Bracket rear upper 7 15 56P9620 Board printhead controller S N 7 13 56P9621 Bracket fan holder 7 15 56P9622 Fan upper right 7 15 56P9623 Fan upperleft 7 15 56P9624 Link frame 7 13 56P9625 Hook right link 7 13 56P9626 Cover hook 7 13 56P9627 Bearing roller 7 13 56P9628 Pivot color link 7 13 56P9629 Frame link 7 15 56P9630 Hook left link 7 13 56P9637 Frame printhead 7 13 56P9638 Holder cable 7 13 56P9639 Connector upper 7 15 56P9641 Actuator front cover open switch 7 17 56P9642 Unit drive 7 17 56P9643 Clutch drive unit 7 17 56P9644 Cable assembly drive unit sensor 7 17 56P9645 Sensor drive unit gear 7 17 56P9646 Frame sub 7 17 56P9662 Shaft changing 7
221. olor Cartridge 33 Tray x The optional heavy media Remove the heavy media Config Error tray is inserted into any tray location except tray 1 tray from the invalid location 34 Short Paper The paper is too short Press Go to clear the message Make sure the paper size setting in the Paper Menu is correct for the size you are using Press Menu to open the Job Menu and cancel the current job 35 Res Save Off Deficient Memory The printer lacks the memory to enable Resource Save Press Go to disable Resource Save and continue printing Install additional memory 37 Insufficient Collation Area The printer memory does not have the free space necessary to collate the job Press Go to print the portion of the job already stored and begin collating the rest of the job Press Menu to open the Job Menu and cancel the current job Diagnostic information 2 43 5055 xxx Message 37 Insufficient Defrag Memory Meaning The printer cannot defragment flash memory Action Delete fonts macros and other data in printer memory Install additional printer memory 37 Insufficient Memory The printer memory is full and cannot continue processing current jobs Press Go to clear the message and continue printing Press Stop to clear the message without deleting print jobs Press Menu to open the Job Menu and cancel the current job
222. on the cloth or a new cloth for each LED Reinstall supplies and test Remove the supplies from the printer Check the LEDs are free to move upward With the supplies out the metal post is visible on the LED Push up on the post and make sure it returns to its previous position If the LED is binding it is possible there is an incorrect screw holding the cover in place If too long a screw is installed in the cover it will bind against the LED The correct screw length is 3 5 mm Install the screws and test Debris in the contact blocks may cause fading Make sure there is nothing in the contact block to keep it from seating securely when the top cover is closed Diagnostic information 2 91 5055 xxx Problem continued Color fades with fuzzy poorly defined edges IN Action Ensure the absorption roll charge roll on the belt is securely seated The black plastic T shaped bushing should both be below the flap on the right side of the belt A poorly seated roll can cause both skewing of the paper and problems with the magenta print Check that the top cover is firmly closed on the printer If the cover is not closed completely the LED may be out of focus and allow light print on the bottom of a letter size page Close the cover firmly and test Print the quality pages in the Diagnostics Mode under Print Test Print Quality Pages This often identifies the color that has a problem If
223. operation 3 69 4 83 4 88 4 82 4 86 image quality troubleshooting 2 88 initial check 2 3 installation environment 2 3 L LEDs cleaning 2 90 locations 5 1 components 5 6 covers 5 1 high capacity feeder 5 18 major parts 5 2 sensor and switches 5 4 lubricants 6 2 maintenance approach 1 29 cleaning 1 29 6 2 dip switch specifications 3 60 inspection 1 29 lubricants 6 2 periodic 6 2 recommendations 1 30 maintenance analysis procedures MAPS false close top door 2 54 false close tray x top cover 2 55 5055 xxx false print unit missing 2 57 false side door open 2 54 false tray x low empty 2 56 false 30 oil coating roll missing 2 57 false 40 tray x size sensor error 2 59 false 41 open bin 1 exit tray 2 59 false 88 toner low toner empty 2 58 paper size 2 62 unrecoverable check tray x or duplex connection 2 60 maintenance kit 6 1 maintenance menu 3 32 menu overview 3 4 menu settings 3 4 messages printer messages 2 4 Service errors 2 4 models 1 1 multipurpose feeder theory of operation 3 38 tray removal 4 34 O operator menu disabled 3 4 operator panel buttons 3 3 using 3 2 options 1 22 parts catalog 7 72 P page count 3 29 paper and media guidelines 1 20 paper checks 2 3 print area 1 21 printer capacity sizes 1 10 specifications 1 8 types 1 15 weights 1 15 paper exit tray removal 1 18 4 10 Index 1 3 5055 xxx paper feeding casette feeder 3 37 multipurpose feed
224. or Paper has exited the registration roller and entered the fuser areas A and B FRU Action Transfer belt unit Rear paper guide Discharge brush Fuser Remove any buildup of toner Replace any damaged or worn parts Check the paper exit flag on the fuser for damage Replace the fuser if necessary 2 Fuser separation pawl Replace the fuser if paper jams cannot be removed 2 76 Service Manual 5055 xxx Paper has entered the fuser and exited the printer area B FRU Action 1 Fuser Remove any toner buildup and replace any worn or damaged parts 2 Fuser exit lower roller Fuser exit upper roller Face up exit assembly Be sure the exit FU FD solenoid energizes in the correct position for either 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 belt Be sure that connector CN4 is properly connected to the controller board Check the face down feed roller belt Check for a fluctuation of between 0 V and 5 V on the printer controller board between the following pins when actuating the sensor Paper exit switch CN12 pins 4 and 5 Face up face down sensor CN12 pins 1and 2 Diagnostic information 2 77 5055 xxx Paper has entered the duplex unit area D
225. or paper feed 7 56P9507 Actuator paper feed sensor 8 56P9520 Handle waste bottle cam 9 56P9517 10 56P9519 11 56P9516 12 56P9518 13 56 9515 14 56 9503 15 56 9641 16 56 9505 17 56 9524 18 56 9504 19 56 9521 20 56 9522 21 56P9523 22 56P9642 23 56P9643 24 56P9644 25 56P9645 26 56P9663 27 56P9646 28 56P9662 NS 56P9948 Spring right cassette guide Guide lower right cassette Spring left cassette guide Guide lower left cassette Guide upper cassette Foot rubber Actuator front cover open switch Rail base left side Screw slide rail Rail base right side Lever size sensor Board size sensor Cable assembly size sensor Unit drive Clutch drive unit Cable assembly drive unit sensor Sensor drive unit gear Clutch belt up down Frame sub Shaft changing L oL oL o R A RPF LLL M Parts packet Parts catalog 7 17 5055 xxx Assembly 8 Base 2 7 18 Service Manual 5055 xxx Assembly 8 Base 2 Index P N Units Description 8 56P9666 1 Support assembly upper unit 2 56P9667 4 Pin upper unit support 3 40X2776 1 Stop Right 4 56P4557 1 Cover Black photo developer 5 56P9668 1 Handle assembly lock 6 56P9669 1 Handle lock 7 40X2778 Stop left 8 56P9673 Cover electronic 9 40X2777 10 56P9670 11 56P9672 12 56P9671 NS 56P9949 Guide lock Shroud cable Guide cable Guide cable n ln ol on
226. orrect type for the printer customer replace the cartridge with the correct type 2 Is the toner cartridge Clean the Go to step 3 encoder wheel dirty encoder wheel and toner sensor 3 Replace the toner cartridge Problem solved Goto step 4 for the color with the error Did this fix the problem 4 Test the sensors Replace the Replace the printer controller affected toner While actuating the sensor board sensor does the voltage fluctuate between 0 V and 5 V between pins 1 and 2 on connectors CN22 K CN21 Y CN18 M CN19 C on the printer controller board Diagnostic information 2 9 5055 xxx 930 Yellow Printhead Error 930 Service Printhead Error Step Questions actions Yes No 1 Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables printhead and the printhead number controller board as well as XX 0XXXX go the cables between the to step 2 printhead controller board and the printer controller If you have a board are properly printer with serial connected number XX AXXXX and Are they properly above go to connected step 4 2 For serial number Replace the Replace the Is fuse 5 on printhead control printhead the printhead control board board cables controller board open CL13 CL24 and go to step 3 and LED printhead 3 Did replacement of the Problem solved R
227. ou have an unrecoverable error code go to Alternate method Operator panel is inoperable or unrecoverable error code on page 4 60 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 anything on the transfer belt Touching the surface of the transfer belt or placing items on the belt may cause damage 4 56 Service Manual 5055 xxx 3 Loosen the thumbscrews as shown 4 Lift and remove the transfer belt cover Repair information 4 57 5055 xxx 5 Loosen the thumbscrews as shown 4 58 Service Manual 5055 xxx 6 Pull the transfer belt out 7 After replacing the transfer belt and removing the four shipping spacers tighten the transfer belt thumbscrews and reinstall the transfer belt cover 8 Close the top unit and rotate the locking lever to the right and close the front cover 9 Turn the printer on Note If the message Did you Replace Belt appears wait for the message Select yes Stop no and press Select If you replaced the belt before the Life Warning or Exhausted message appeared open the Supplies Menu on the operator panel and select Replace Supplies then select Belt and select Replaced The message Printing Alignment Page appears and the printer prints the alignment page Follow the instructions on the display to set the alignment values for t
228. oval s agisce werd erar e ward queda ae 4 97 Power supply removal Re Eye sd 4 99 Registration roller 4 100 Registration roller clutch removal 4 101 Stack area discharge brush removal 4 102 otapls UNL reroVal 4 102 Straight paper exit discharge brush removal 4 103 Straight paper exit roller removal 4 103 Timing belts 1 and 2 4 105 Aractorbeltfemoval 4 4 106 Tractor drive motor assembly removal 4 108 Locations 2 R 5 1 COVES asi ei TS sees Pare ie 5 1 Mao uua ugue wed Nuus e ad 5 2 Sensor amd switch locallons 25 2222 5 4 Component DSO ere ed 5 6 Printer controller board select e hr 5 8 Printer controller board connectors 5 9 Printhead controller board erre IIIA 5 12 RIP Dodd DTE EE PE 5 13 Power source unit 1 board ieu RR RR AR 5 14 Power souwe UNICZIDOSIU 4 erar Ee ward Guru dde ws 5 14 High voltage power supply 5 15 Delon DOA 5 15 Expansion paper feeder controller board 5 16 Duplex unit controller board sisse RR 5
229. ppear on the printed page or print appears blurred or unclear N N L I Action Replace the photodevelopers If the problem only occurs when printing black replace just the black photodeveloper and fuser coating roll If the problem occurs when printing one of the colors replace all three of the color photodevelopers If the problem remains go to Black line on page 2 95 Toner specks appear on the page E Replace the oil coating roll Toner colors the background of the page T Be sure the affected photodevelopers and toner cartridges are completely installed in the printer The page has 100 coverage of one color Be sure the affected photodevelopers are completely installed in the printer Replace the photodevelopers If the page is black replace just the black photodeveloper If the page is another color replace all three of the color photodevelopers If this does not fix the problem go to Black print on page 2 95 Diagnostic information 2 89 5055 xxx Problem Light lines or streaks appear on the printed page L Action Clean the LEDs Make sure the affected photodeveloper is completely installed in the printer Remove the affected toner cartridge and gently shake it back and forth to distribute the toner evenly Reinsert the toner cartridge and try printing the job again Replace the affected toner cartridge Replace the
230. printer with its covers removed use care not to allow your clothing to be caught in revolving parts such as the gears rollers and fan motor Never touch the terminals of electrical parts or high voltage parts such as the high voltage power supply board Be sure to handle the fuser carefully as it remains hot for a while after the 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 positive conduction Install the screw with a toothed washer in the correct position at reassembly Handling printed circuit boards The following precautions must be observed when handling circuit boards with metal oxide semiconductor integrated circuits Transportation storage During transportation or when in storage new circuit boards must not be indiscriminately removed from their protective conductive bags Do not store or place circuit boards in a location exposed to direct sunlight When it becomes absolutely necessary to remove a board from its conductive bag or case always place it on its conductive mat in an area as free as possible from static electricity Do not touch pins of the integrated circuits with your bare hands Repair information 4 1 5055 xxx Replacement Before you unplug connectors from the circuit boards be sure the power cord has been unplugged from the power outle
231. problem 948 Service Machine ID Step Questions actions Yes No 1 Turn the printer off and wait Problem solved Verify proper installation of the EPROMs on both the printer controller board and the problem printhead controller board Go to step 2 2 Are the EPROMs installed Replace the Install the correctly printer controller EPROMs board correctly Go to step 3 3 Did replacing the printer Problem solved Replace the controller board fix the printhead controller board Diagnostic information 2 17 5055 xxx 949 Tray x Comm Does this fix the problem Step Questions actions Yes No 1 Replace the printer Problem solved Replace the controller board expansion feeder control board for trays 2 5 If the problem is with the high capacity paper feeder replace the HCPF board 950 Pr Control Board Replace the printer controller board 952 NVRAM Chip Failure 952 Service NVRAM Failure Step Questions actions Yes No 1 Make sure the 80 pin RIP Replace the Go to step 2 printer controller cable is cable not broken or damaged Is the cable broken or damaged 2 Is EPROM U5 present on Replace the Install EPROM the printer controller board printer controller U5 board 954 NVRAM CRC Failure Replace the RIP board 2 18 Service Manual 5055 xxx 955 Code CRC 955 Service Code CRC lt
232. r and the maintenance approach used to repair it Special tools and test equipment are listed as well as general environmental and safety instructions 2 Diagnostic information contains an error indicator table symptom tables and service checks used to isolate failing field replaceable units FRUs 3 Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems 4 Repair information provides 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 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Definitions Note A note provides additional information Warning A warning identifies something that might damage the product hardware or software CAUTION A caution identifies something that might cause a servicer harm CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task Xvi Service Manual 5055 xxx 1 General information Overview The Lexmark C91 x printers are high speed wide format color LED Electrophotographic color p
233. r cartridge with the yellow cartridge Run through the procedure making the correct adjustments to the yellow X Y and Theta adjustment Remember to swap the supplies position back to the correct position when you finish Diagnostic aids 3 9 5055 xxx Print tests Input Source Print Tests The Diagnostic Input Source Print Tests may be used to verify that the printer can print on media from the installed input sources which are available within the Print Tests menu Chose from following Single prints the Print Test page once Continuous prints the Print Test page until Return or Stop is pressed The content of the Print Test page varies depending on the media installed in the selected input source If a source is selected that contains paper then a page similar to the Quick Test page prints If a source is selected containing envelopes the Envelope 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 until the test is stopped If the source contains envelopes then the envelope print test pattern prints on the first envelope and subsequent envelopes are blank Note The Print Test page can be printed on any paper or envelope Size More than one sheet may be required The Print Test page always print in simplex While the page prints the following message is displayed The
234. r previously punched from the finisher fold the paper so the bottom punched hole is aligned with the top punched hole 3 94 Service Manual N 5055 xxx Determine if the edge of the bottom of the page is below or above the top edge of the page Loosen the guide rail thumbscrews Note Do not move the adjustment knobs more than three complete turns from their starting position Adjustments greater than three turns may cause paper jams 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 punched hole To move the bottom of the paper down rotate the knobs clockwise To move the bottom of the paper up rotate the knobs counterclockwise one quarter turn Tighten the guide rail thumbscrews Print and punch another piece of paper Repeat steps 2 and 3 If the holes are not aligned repeat steps 3 through 8 Diagnostic aids 3 95 5055 xxx 3 96 Service Manual 5055 xxx 4 Repair information Service precautions Observe the following precautions whenever you service the printer Be sure to unplug the printer from the outlet before attempting to service the printer To reassemble the printer reverse the order of disassembly unless otherwise specified Do not operate the printer anytime during disassembly If it is absolutely necessary to run the
235. r removal 1 Open the paper feed cover and pull out the duplex unit halfway 2 Unclip the paper present sensor from the mounting 2000 SECRET 0000000 LO 3 Disconnect the connector and remove the sensor 4 38 Service Manual 5055 xxx Paper remaining sensor removal 1 Remove the paper feed frame 2 Remove the two screws from the paper remaining detection sensor and remove the sensor Paper size sensor board assembly removal 1 Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the upper cassette front cover B and back cover Open the turn guide and paper feed cover and remove the duplex unit Remove the left side cover and power supply A OG I 2 Disconnect the connector and remove the two screws from the paper size sensor board and remove the board 3 Remove the screw from the size detection lever and remove the lever Repair information 4 39 5055 xxx Power supply 1 removal 1 2 Unplug the power cord from the printer Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the cassette left front cover and back cover Remove the left side cover Remove the insulation sheet connector yellow ground wire five Screws two screws with washers and two screws with spring washers Disconnect CN01 at the motor driver board CN106 and CN04 at power supply 2 Remove t
236. radar images for their deviation from black Look at all the radar images along the left and make a judgment on the value of the adjustment When the color is correctly adjusted the color radar image should lay directly on the black radar image 3 6 Service Manual 5055 xxx Setting Printer Alignment 1 2 Press Menu until the color you want to adjust displays and then press Select Change the displayed value and press Select You see a message displayed that the value is Saved If you want to skip a selection press Select X sxxx Y sxxx T sxx Press Menu until Alignment Test Printing is displayed and press Select Alignment Test Printing Look at the color and the value you have changed and see if this is acceptable If so go to the next adjustment If it is not acceptable go back to the color and adjust it again When all the values are acceptable for all colors exit diagnostics Note If Return is pressed to exit the Alignment menu after a margin value has been incremented or decremented then the default value is not changed However if the Alignment Test page is requested after a margin value has been incremented or decremented then the default value is changed and then the Alignment Test page is printed using the new value The alignment test page should be printed on letter of A4 paper only To exit the alignment menu press Return Diagnostic aids 3 7 5055
237. rd Duplex unit controller board CN105 B11 Motor drive board CN4 CN5 5 16 Service Manual 5055 xxx Size sensor board SW403 SW402 SW401 Locations 5 17 5055 xxx High capacity feeder HCF Paper End Sensor Up Sensor Pickup Solenoid Paper Feed Roller Paper Feed Sensor 229 0 Transfer TE o Reverse Roller Paper Size Sensor 1 2 Paper Feed Motor Call Roller Near End Sensor Residual Paper Sensor 1 Residual Paper Sensor 2 Paper Level Sensor Tray Driving Belt Down Sensor 24 n Residual Paper Sensor 3 Tray Motor Call Roller r High capacity paper feed configuration 1 Paper feed and separation H mechanism F _ Tray up amp down mechanism Size detection mechanism Residual paper detection mechanism Paper e
238. rd stock upper limit Index Bristol 90 Ib index 44 Ib bond 165 g m Transparencies Jaser printer type 47 bond 175 g m Labels upper limit paper 48 Ib bond 180 g m Envelopes sulfite wood free up to 10096 cotton 20 to 28 Ib bond 673 75 to 105 g m Finisher bin 13 4 Paper xerographic or business 16 to 28 bond 60 to 105 g m Specialty papers glossy laser 80 Ib book 32 Ib bond 120 g m Card stock upper limit Index Bristol 90 Ib index 44 Ib bond 165 g m Transparencies Jaser printer type 47 bond 175 g m Labels upper limit paper 48 Ib bond 180 g m 1 16 Service Manual 5055 xxx Media Weight Finisher bin 2 5 Paper xerographic or business 16 to 28 Ib bond 60 to 105 g m 1 Part numbers 1245950 letter and 1245951 A4 2 Part numbers 1245940 letter and 12 5941 A4 The duplex option supports the same weights and types as the printer except for transparencies envelopes labels and paper less than 80 g m 21 3 lb bond or greater than 105 g m 28 Ib Bin 1 represents engine side output and Finisher Bin 1 face up Finisher supports hole punch job offset and stapling Finisher only supports long edge fed envelopes wider than 5 8 in 148 mm feed direction dimension 100 cotton content maximum weight is 90 g m 24 Ib bond 105 g m 28 Ib bond envelopes are li
239. reas A F MPF or T1 T5 you need to check to remove the paper or 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 1 Open the front door 2 Rotate the top cover locking lever to the left 3 Place both hands on the lifting points and squeeze the right top cover latch 3 46 Service Manual 10 11 12 13 14 15 16 17 5055 Lift the cover Warning Do not use pointed objects to remove the paper They may damage the transfer belt Note The paper may be covered with unfused toner which can stain garments Remove any paper on the transfer belt If the paper source was the multipurpose feeder check the area between the multipurpose feeder and the transfer belt Check the fuser area and top cover for additional jams If there is no jammed paper in the fuser area or top cover go to step 12 If jammed paper is present continue with step 7 Lift the fuser pressure release lever Slowly pull the paper out toward the inside of the printer Rotate the fuser pressure release lever down Note The top cover will not close until the lever is in the down position Check the top cover for additional jams If none go to step 12 Remove the jam Place both hands on the top cover Press down firmly until the top cover clicks into place Rotate the top cover locking lever to the r
240. rge roller transfer roller 31 5 mm Photodeveloper charge roller 45 1 mm Supply roller toner cartridge 46 9 mm Upper registration roller 46 9 mm Lower registration roller 47 5 mm Developer roller toner cartridge 64 5 mm OCR oil coating roller 94 2 mm Photodeveloper drum 139 2 mm Fuser upper roller 2 72 Service Manual 5055 xxx Distance between marks FRU supply item 140 mm Fuser lower roller 824 5 mm Transfer belt Fuser part locations From paper center mm Thermistor hot roll 6 Thermistor BUR 0 TCO hot roll 66 TCO BUR 101 Detact fingers hot roll 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 Operator panel service check FRU Action 1 Operator panel Operator panel cable RIP board Make sure code is at least EC2 or later Run both the LCD Hardware Test and the Button Test in Diagnostic Mode Be sure the operator panel cable connections are securely connected on the RIP board and operator panel Diagnostic information 2 73 5055 xxx Paper carrying service check Paper has not exited or is stopped in the high capacity feeder area F 249 FRU Action 1 Paper feed roller Transfer roller Be sure the paper feed roller transfer roller reverse roller an
241. ring the end of life of the fuser or transfer belt the following message appears indicating that it s time to replace the fuser unit and or transfer belt unit 80 Belt Life Warning and or 80 Fuser Life Warning Routine replacement of these parts ensures peak printer performance and helps prevent print quality problems and paper feed problems resulting from worn parts The parts are in the maintenance kits listed Maintenance kit P N Unit Printer power supply 56P9903 Transfer Belt 115 V 230 V 56P9900 Fuser 115 V 56P9901 Fuser 230 V The status message appears until the appropriate part s is replaced Preventive maintenance 6 1 5055 xxx Periodic maintenance This table lists the parts to be periodically cleaned by the servicer Part name Method Paper feed unit Paper feed roller MPF roll Remove any dust or dirt and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Registration unit Registration roller upper and lower Remove any dust or dirt and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol 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 soft cloth and alcohol Transfer unit Transfer belt Remove any dust or dirt and wipe the surface lightly with a d
242. rinters with superior print quality for high volume printing Resolution 600 x 600 dpi 2400 image quality Model differences e e e e aa NN 8 5 o 5 WA 5 20 20 Te 28 29 USB parallel X X USB Ethernet X X X Memory MB 256 256 128 64 64 Options available 550 sheet drawer X X X Duplex X X Hard disk X X Staple and punch X X finisher w stand Printer cabinet X X General information 1 1 5055 xxx Technical specifications Toner darkness Toner darkness settings offer four user selectable settings to balance print darkness and toner savings The higher the setting the darker the print The toner darkness default setting is 4 The toner darkness setting is available through the operator panel under the Print Quality menu Color correction settings There are four color correction settings to provide 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 e Vivid adjusts CMYK components with the result being colors that are more saturated Off no color correction is implemented from RGB or CMYK applications CMYK provides the application s color correction instead of the printer s algorithms Black and White Lock in configuration menu
243. rk connections Lexmark MarkNet N2000 Series Internal Print Servers MarkNet 20001 Token Ring attachment MarkNet N2001e for Ethernet 10BaseT 100BaseTX MarkNet N2002e for Ethernet 10BaseT 10Base2 Lexmark MarkNet N2003 Series Internal Fiber Print Servers including MarkNet N2003fx SC MarkNet N2003fx MTRJ External network connections MarkNet X2000 Series External Print Servers MarkNet 2011 1 port for Ethernet 10BaseT 100BaseTX MarkNet X2012e 1 port for Ethernet 10BaseT 100BaseTX 10BaseT 10Base2 MarkNet X2031e 3 port for Ethernet 10BaseT 100BaseTX MarkNet X20301 3 port for Token Ring attachment Standard Ethernet and MarkNet compatibility The standard Ethernet connection MarkNet N2000 series and MarkNet N2003 series internal and MarkNet X2000 series external print servers support NetPnP 7 0 or later on Windows NT 4 0 Windows 2000 and Windows XP systems The Ethernet and Token Ring print servers and the standard Ethernet connection support the following protocols TCP IP Novell IPX SPX including NetWare Directory Services AppleTalk LexLink DLC LLC 1 24 Service Manual 5055 xxx The TCP IP standard set of application services is supported including DHCP WINS SNMP industry standard printer MIB http Ipr Ipd ftp tftp ping finger telnet bootp and rarp The following protocols are also supported PP Internet Printing Protocol SLP Service
244. rmal Abnormal coating roll Replace the coating roll with Coating Roll Installed a valid one to clear this message 85 Coating Roll Coating roll is nearing it s If the print quality is still Life Warning expected lift good press Go to continue Otherwise replace the oil coating roll 84 color Abnormal photodeveloper Install correct Photo Dev installed photodeveloper Abnormal 2 50 Service Manual 5055 xxx Message Meaning Action Replace Oil A new black toner cartridge Press Go to clear or replace Coating Roll has been installed This isa the oil coating roll with a new reminder to install a new oil one coating roll 88 color The printer has ceased Install a new toner cartridge Toner Empty operating because the specified toner cartridge is empty 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 specified toner cartridge is low Replace the specified toner cartridge Press Go to clear the message and continue printing The supplies message is displayed until you replace the specified toner cartridge Go to Map 7 False 88 color Toner Low Toner Empty message on page 2 58 Diagnostic information 2 51 5055 xxx Clearing finisher messages Message Solution Bin x Full Remove the stack of paper from the bin to clear the message If yo
245. rmation 2 85 5055 xxx 210 Staple jam service check FRU Action 1 Stapler Staple cartridge holder Check for jammed staples in the stapler Clear the staple jam go into diagnostic mode and run a staple test If the problem reoccurs replace the staple cartridge holder If this does not resolve the problem replace the stapler 2 Stapler Finisher control 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 finisher set switch is activated Measure for 5 V dc between pins 11 and 12 on stapler connector CN5 If 5 V dc is not present check for continuity on the stapler to finisher control board cable If there is no continuity on any pin position replace the cable If there is continuity replace the finisher control board If 5 V dc is present replace the stapler 2 86 Service Manual 5055 xxx Transfer belt up down service check FRU Action 1 Belt up down sensors Check the transfer belt up down sensor Be sure that connector CN29 is firmly Belt up down actuator connected to the printer controller board Replace 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 to the pri
246. rmer board to the new board Also when replacing the EPROM set the light intensity in the diagnostic mode and set the counter and printer alignment Repair information 4 43 5055 xxx Printhead controller board removal For S N s 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 e ma 6 mm asm IT Ny Satyra Note When replacing the board be sure to return the four EEPROMSs on the former board to the same positions on the new board 4 44 Service Manual 5055 xxx For S N s 4 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 board kn M UE e _ 22 HEG E 95 r eO 2 0 4 Repair information 4 45 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 Orientation Mark EEPROM Label 4 46 Service Manual 5055 xxx Registration frame Registration clutch removal 1 Open the top unit
247. rning Do not use pointed objects to remove the paper They may damage the transfer belt Remove the paper on the transfer belt Place both hands on the top cover Press down firmly until the top cover clicks Rotate the top cover locking lever to the right If you cannot rotate the locking lever the cover is not fully closed Close the front door Press Go 3 50 Service Manual 5055 xxx 241 244 Paper Jam Note Although tray 1 is shown you can use the same procedure to clear any of the 241 244 or Check Tray 1 4 messages Paper jam messages 241 244 and Check Tray 1 4 indicate a jam in one of the paper trays To remove the jam 1 2 O O W If you have a high capacity feeder pull it away from the printer Open the jam access door for the paper tray indicated on the display Remove the jam Close the jam access door Pull out the paper tray indicated on the display Remove any damaged paper Push down on the remaining paper in the tray until the bottom plate clicks Close the paper tray Press Go If the paper jam message continues clear any paper from the paper path 249 Paper Jam Note If you have an optional printer cabinet the high capacity feeder will be identified as tray 3 A 249 Paper Jam Check Tray 5 message indicates a jam in the high capacity feeder To remove the jam Open the high capacity feeder top cover Remove
248. rom 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 board mounting screws and remove the board 22 CS o uL nm SU 9 lt lt i o 2 46 4 90 Service Manual 5055 xxx Elevator motor removal 1 Disconnect the elevator motor connector 2 Remove the two elevator motor bracket screws from the bracket 3 Remove the elevator motor assembly Elevator Motor Feed motor assembly removal 1 Remove the finisher control board mounting bracket 2 Loosen the tension bracket mounting screw Mounting Screw 3 Disconnect the feed motor connector 4 Remove the three screws and connector from the feed motor mounting bracket and remove the feed motor assembly 5 Remove the feed motor pulley Repair information 4 91 5055 xxx Hole punch removal Remove the external covers Remove the hole punch unit cables Remove the tension spring Remove the screw and E ring from the tension bracket and remove the bracket GQ Hole Punch Assembly Tension Spring lt 2428 Tension Bracket Note When installing the tension bracket use the left side screw hole for the three hole punch unit and the right side screw hole for the four hole punch unit
249. ront 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 by removing the three silver screws 227 7 27 E 77 TV Repair information 4 5 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 the solenoid cover 4 6 Service Manual 5055 xxx Cover left side removal 65067 SEL 2700 S 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 Repair information 4 7 5055 xxx Cover right side removal TIT NY m In LIN gt gt 1 Open the top unit and remove the front cover and upper cassette 2 Remove the seven screws from the right side cover together with the turn guide and remove the cover 3 When installing the right side cover insert the turn guide shaft into the bearing 4 8
250. rred the oldest error displays in the position before the empty log entries begin Empty log entries are identified with an error number of 000 Occupied log entries contain the error number for the message displayed on the operator panel For example 925 is contained in the 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 positions in the log The following error messages are stored in the error log All 2xx paper jam messages All 9xx service messages To view the error log select the Display Log operation from the Diagnostics ERROR LOG menu The entire error log cannot display on a single screen Four error log entries appear per screen requiring three screens To move forward in the log press Menu to move backward press lt The following are examples of the error log screens 1 200 2 290 3 928 4 922 5 250 6 990 7 230 8 230 9 953 10 000 11 000 12 000 To exit the error log press Return or Stop Diagnostic aids 3 31 5055 xxx Clearing the error log To clear the error log select Clear Log from the ERROR LOG menu The following message is displayed Clear Log Yes Select Yes to clear the log as the empty log message appears 1 000 2 000 3 000 4 000 Select No Return or Stop to
251. ry cloth If it is still dirty clean with a soft cloth and alcohol Fuser unit Heat rollers Clean with a soft cloth silicon oil or alcohol Outer covers Use a synthetic detergent and a damp cloth Lubricants and cleaners Lubricating Cleaning Oil 10 Apply between gears and shafts Grease 23 Apply to gears Alcohol or isopropyl on plastic rubber and external parts 6 2 Service Manual 5055 xxx T Parts catalog How to use this parts catalog SIMILAR ASSEMBLIES If two assemblies contain a majority of identical parts they are shown on the same list Common parts are shown by one index number Parts peculiar to one or the other of the assemblies are listed separately and identified by description NS Not Shown in the Asm ndex column indicates that the part is procurable but is not pictured in the illustration Parts catalog 7 1 5055 xxx Assembly 1 Covers 1 7 2 Service Manual Assembly 1 Covers 1 5055 xxx Index P N Units Description 1 4 1207360 1 Board operator panel 1 99A1501 1 Board operator panel Japan 2 56P9736 1 Cable operator panel 3 56P9555 1 Housing upper operator panel 4 56P9556 1 Housing lower operator panel 5 56P9539 1 Cover top 6 56P9533 1 Cover assembly right side 7 56P9534 1 Magnet right side latch 8 56P9540 1 Cover waste toner bottle 9 56P9545 1 Label operator guide 10 56P9532 1 Cover
252. s ImageQuick Optra Forms and PrintCryption are trademarks of Lexmark International Inc is a registered trademark of the Hewlett Packard Company PostScript is a registered trademark of Adobe Systems Incorporated Other trademarks are the property of their respective owners 2003 2004 Lexmark International Inc All rights reserved UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense P N 12G9292 5055 xxx Contents Safety rasa dad xi Prelate cosas cu EE xvi Definitions 2 2 25 Rh ERRARE 1 xvi General information 1 1 Q Yep SW QE Pg 1 1 KEEP EE ges Gad REIP EEE 1 1 Modsldifferenees osca p ssssvssutasssyvakapasqssuqaka 1 1 Technical specifications 1 2 TonerdarknesSS sss esu Rx ewe ems RR 1 2 Color correction settings 2 222222 eee hne 1 2 Physical specifications and weight 1 3 Print speed and performance 1 4 Performante usu ua s EROR RR ORG RR dekar eed asia swe 1 5 Time to first nhu 1 5 PIOGBSSOL nec op SOC
253. s 5 toner kit presencedetection FD paper delivery Top Upper heater Upper heater 100V ikw ES oner PEX motor 621 Fuser heater UA Temperature sensor M asm Upper len fan pet Thermoeialluppor fuselupper Fan lock detection i prev Lower heater 100V 1kw Toner paper delivery Upper right Eraser Y Lower Heater sensor C fen Eraser K Temperature Frsmostnower fuse lower Toner gt Drum static eliminator Thermister lower Drive sensor Y Thermister upper Gear phase Toner sensor OCR presence detection spring sensor K Color monochrome gear phase adjustment detection Drum phase Color monochrome drum phase adjustment sensor Y Drum phase sensor K FUSER Transparency Printer Controller U3 FINISHER Option finisher Transparency gt Registration CN19 U1 Bi sensor sensor Y 4 4 Large capacity paper feeding CN1 CN1 MPF Y LCF HVU control FU D sensor FU paper delivery U sensor CN40 MAIN Evang corral 6 FU licker control aper delivel Residual paper CN31 CN22 Video TRM F DBG sensor ESSO angor motor control FU tray detection PFU Solenet MOTOR F UD flap switching Temperature humidity sensor FLICKER nd ane bak fer BUD clutch p Flicker prevention Standby clutch CN48 18 CN47 30 FUDSOL CN46 Feeding clutch 2 CN35 HD YK HD MC CN16 5 CN51 RF RIP fan CN30 Manual feeding 2 v gt 3 Power supply fan clutch Y gt CN24 CN25 CN8 ONA HDVCLK Fan lock
254. s on page 3 1 Standard inspection and cleaning procedure Switch off printer power and disconnect the AC power cord from the electrical 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 paper or transparencies paper dust hair oil grease or toner Clean the printer interior using a lint free cloth dampened slightly with cold water Do not use solvents or chemical cleaners to clean the printer interior Use only the specified oil or lubricant on printer parts some service parts are lubricated at the factory Inspect and if necessary clean all rubber plastic and D rolls with a lint free cloth dampened slightly with cold water Dry the rolls with a lint free cloth While cleaning inspect the interior of the printer for damaged wires loose connections toner leakage loose springs and damaged or worn parts Be sure the printer is on a single flat strong table or desk top General information 1 29 5055 xxx Inspect all supplies OCR cartridges photodevelopers toner cartridges belts fuser CRUs and paper sources cassettes trays feeders duplex drawers finishers mailbox trays for obvious damage and proper installation paper under corner bucklers paper guides not too tight Inspect for correct media usage paper transparencies labels Print a Demo page
255. s Varies 50 transparencies 47 Ib 175 g m Bin 2 Staple Punch Finisher Plain paper 6 0 in 1 000 sheets 152 mm 20 Ib 75 g m Notes Performance may vary subject to media specifications and printer operating environment Media at ambient environment All media is letter A4 unless otherwise noted All paper weights are stated in bond unless otherwise noted General information 1 19 5055 xxx Media guidelines Paper Following are media guidelines for successful printing Rough highly textured limp or pre curled papers will result in lower print quality and more frequent paper feed failures Colored papers treated and preprinted papers letterhead and labels must be able to withstand 338 F 170 C fusing temperature Preprinted forms and letterhead should be selected using guidelines found in the printer User s Guide The chemical process used in preprinting may render some papers unsuitable Unsuitable papers include multipart forms and documents chemically treated papers coated synthetic and thermal papers and preprinted papers requiring a high degree of registration Recycled paper less than 21 Ib 80 g m may cause unacceptable results Envelopes Envelopes should be fed long edge first with flap trailing When the finisher is attached only long edge fed envelopes wider than 5 8 in 148 mm feed direction dimension may be used To print smaller envelopes the finis
256. s on the end of the finisher so the stand remains aligned when moved To adjust and lock the wheels 1 Rotate the left and right upper adjustment knobs on the rear wheels until the wheels touch the floor To lower the wheels rotate the adjustment knobs clockwise N DQ Vs gt 2 Turn the wheels until the locking knobs are aligned with the finisher base 3 88 Service Manual 5055 xxx 3 Rotate the locking knobs counterclockwise until they contact the finisher base Diagnostic aids 3 89 5055 xxx Attaching the cables The finisher comes with an interface cable and Y power cord The interface cable connects the finisher to the printer and the Y power cord provides electrical power to the finisher and printer 1 Turn the printer off and unplug the power cord from the power outlet 2 Push the latch in and hold it 3 Roll the finisher away from the printer 4 Release the latch 3 90 Service Manual 5055 xxx Interface cable CAUTION Make sure the printer is turned 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 finisher The plug will be on a slight angle when connected 4 Tighten the thumbscrews Diagnostic aids 3 91 5055 xxx Power cable 1 Unplug the power cord from t
257. s while the test is in progress If the test is successful the following message appears Flash Test Test Passed Press Go Return or Stop to return to the DEVICE TESTS screen The Power indicator turns on solid If the test fails the following message is displayed Flash Test Test Failed Press Go Return or Stop to return to the DEVICE TESTS screen Diagnostic aids 3 25 5055 xxx Diagnostics printer setup Defaults The following printer settings are used to determine whether U S or non U S factory defaults should be used U S Non U S Light Quantity Cyan Magenta Yellow Black Range 0 to 45 If you replace one or more of the printheads or the EEPROM for the engine controller the Light Quantity value must be set to the value that is marked on the printhead plus 8 To set this value 1 Select Diagnostic Mode 2 Select Printer Setup 3 Select Light Quantity and enter the value from the label on the printhead plus 8 Note If the printer has S N XX XXXX or above the procedure above does not have to be done LED Printhead e Label 3 26 Service Manual 5055 xxx Par S Strobe Adj This message displays only if the printer is configured with the standard parallel port Par 1 Strobe Adj This message displays only if a parallel port is available through the PCI slot 1 Par 2 Strobe Adj This message di
258. sensor 7 21 56P9696 Cable assembly belt thermistor 7 21 56P9697 Bushing 7 21 56P9698 Motor assembly 120 V 7 23 56P9699 Motor assembly 230 V 7 23 56P9700 Solenoid assembly paper feed 7 23 56P9701 Board 7 23 56P9702 Cable belt up down sensor 7 23 56P9703 Cable assembly sensor board 7 23 56P9704 Cable assembly paper remaining sensor 7 23 56P9705 Cable assembly feeder 7 23 56P9706 Cable power switch 7 23 56P9707 Switch 7 23 56P9708 Cable assembly duplex connector 7 23 56P9709 Board 120 V motor driver 7 23 56P9710 Board 230 V motor driver 7 23 56P9711 Cable THB drawer 7 23 56P9712 Cable THB drawer EMEA 7 23 56P9713 Fan power supply 7 23 56P9714 Board high voltage power supply 7 25 56P9715 Cable high voltage power supply board 7 25 56P9716 Cable assembly 8 Pin PH controller 7 13 1 16 Service Manual 5055 xxx 56P9717 Cable assembly 18 Pin PH controller S N XX 0XXXX 7 13 56P9718 Cable assembly 30 Pin PH controller
259. sensor Elevator lower limit sensor Jogging assembly Pap upper level sensor Fin set switch sensor Staple cart set sensor 2 Timing belts Run the staple test in diagnostic mode to Patting roller test feeding and stapling function Path select solenoid Path select gate Guide stack assembly Jogging unit assembly Tractor drive assembly Stapler Diagnostic information 2 71 5055 xxx FRU Action 3 Registration roller Paper exit rollers Registration sensor Registration clutch Punch clutch punch unit Timing belt Run the hole punch test in diagnostic mode to test the hole punch function 4 Elevator motor Tray wires Observe the elevator motor operation while powering the printer up Marks on paper service check If you have evenly spaced marks on the paper measure the distance between the marks and locate the symptom below Check the assembly for dirt or damage and clean as necessary Run a test print to verify the problem has been corrected The indicated assemblies are replaced by the customer at prescribed intervals If you remove the transfer belt do not turn it upside down Toner will fall from the waste toner box onto the transfer sheets and roller s inside the belt This causes lower transfer efficiency and washed out colors Distance between marks FRU supply item 27 mm Absorption cha
260. sitive drum per the voltage of the development roll Z 8 S S Toner Doctor Blade 1 gt LED Printhead Supply Roll 9 Photosensitive Drum Development Roll Transfer unit Paper feeds electrostatically by the transfer belt and is carried to the transfer unit which turn at the speed of the photodeveloper drum A charge roller applies a positive charge to the paper The toner image formed on the photoconductor drum is transferred to the paper from the back side by the positive dc voltage applied to the transfer sheet which is in contact with the paper through the transfer belt 3 34 Service Manual 5055 xxx Cleaning unit Toner remaining on the photosensitive drum following transfer is scraped away with the cleaning blade and collected in the recovery bag as waste toner Residual toner on the photosensitive medium is removed by the eraser Eraser Cleaning Blade X NN N LZ Transfer Coil 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 the photodevelopers and toner cartridge by rotations of the dc motor Drive 2 drives the face down delivery unit by rotations of the stepper motor The expansion paper feeder and the duplex unit use independent mo
261. sociated gears 3 Feed roller solenoid Check for proper operation of the solenoid assembly and linkage Replace as necessary Paper re feed solenoid assembly 4 Photo interrupter Ensure that the photo interrupter actuators assembly are operating correctly and are in the proper position Expansion paper feed service check If you have a 200 Paper Jam Tray x error code check the option connection cable for proper connection to the printer or other paper feeder FRU Action 1 Feeder drive motor If the feeder drive motor works go to the Paper carrying service check on page 2 74 2 Gears If the motor turns but the drive gears do not Feeder solenoid replace the gears as necessary Check the Paper feed clutch feeder solenoid and paper feed clutch for Expansion feeder proper operation and replace as necessary control board If this does not correct the problem replace the expansion feeder control board Diagnostic information 2 69 5055 xxx Face down stacker full service check FRU Action 1 Stacker full detection lever Check the stacker full detection lever for damage 2 Stacker full detection sensor Printer controller board Check for a voltage fluctuation between 0 V and 5 V between pins 2 and 3 of connector CN9 on the printer controller board while actuating the sensor High capacity feeder HCF service check F
262. splays only if a parallel port is available through the PCI slot 2 Par 3 Strobe Adj This message displays only if a parallel port is available through PCI Slot 3 Auto Color Adj On e OFF Reset Calibration Press Select to reset Diagnostic aids 3 27 5055 xxx Viewing and resetting the drum counters The drum counters increment when a page is printed The drum counter for a particular plane increments if that color is printed by 1 for Letter A4 A5 B5 and envelopes and by 1 2 for Legal and B4 It increments by 2 for 11 x 17 12 x 18 C912 only and A3 The counters are used to track printer usage The current value of the drum counter may be viewed in the Diagnostic menus by selecting the Drum Count menu but this 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 first digit to be changed To change the value press Menu until the desired value display 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 Select After the final digit 5 in this example press Select and the new page count is stored in NVRAM Cyan Drum Count 12345 The drum counts can be reset by scrolling to the appropriate drum color
263. st to disable the menus Wait for the message to clear Note While the menus are disabled you cannot change the printer settings from the operator panel Diagnostic information 2 35 5055 xxx Message Disk Corrupted Reformat Meaning The printer has attempted a disk recovery process and cannot repair the disk Action Press Go to reformat the disk and delete all files currently stored on the disk Press Stop to clear the message without reformatting the disk Disk Recovery The printer is attempting to Wait for the message to incoming fax 5 recover the hard disk clear Warning Do not turn the printer off while this message is displayed Enabling The printer is responding to Wait for the message to clear Menus arequest to make the menus and press Menu to view the available to all users menus available Engine The printer is warming the Wait for the message to Warming fuser assembly clear Enter PIN The printer is waiting for you Use the operator panel to enter your four digit PIN buttons to enter the PIN number Fax x The printer is processing Wait for the message to Clear Flushing Buffer The printer is flushing corrupted print data and discarding the current print job Wait for the message to clear Maintenance on the fuser has reached its limit Formatting The printer is formatting the W
264. t When you remove a board from its conductive bag or case do not touch the pins of the integrated circuits or the printed pattern Place 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 integrated circuits directly with a multimeter use connectors on the board e Never create a closed circuit across integrated circuits pins with a metal tool When it is absolutely necessary to touch the integrated circuits and other electrical components on the board be sure to ground your body 4 2 Service Manual 5055 xxx Adjustments High capacity paper feed timing belt adjustment Secure the bracket with the screw as shown Attach the spring and washer to the bracket with the screw Adjust the screw to 6mm 1mm Tighten the screw completely Adjust the timing belt on the rear in the same manner Screw Spring Screw Washer Front Idler Bracket Repair information 4 3 5055 xxx Removals Cover top removal 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 screws from the back side 4 Remove the top cover 4 4 Service Manual 5055 xxx Cover f
265. taple inner A _ 7 57 56P9345 Cover staple inner B 7 57 56P9347 Panel left 7 55 56P9348 Screw Acc Lis Ade Sabha ik e 7 55 56P9349 Board finisher control 7 67 l 10 Service Manual 5055 xxx 56P9350 Assembly staple 7 55 56P9351 Assembly power supply plate 7 67 56P9352 Assembly lower left panel 7 55 56P9352 Panel lower left 7 65 56P9353 Cover OD satt sacha Shane GiGi da 7 55 56P9354 Assembly dust 7 55 56P9355 Cover 7 55 56P9356 Cover rear 7 55 56P9357 Cable 7 67 56P9358 Cord Y 7 67 56P9359 Tray upper 7 55 56P9360 Tray lower 7 55 56P9361 Roller patting 7 59 56P9363 Stapler 7 55 56P9364 Cover staple B 7 55 56P9365 Cover staple A 7 55 56P9366 Lever 7 55 56P9367 Cartridge staple 7 55 56P9368 Cord Y power 230 V only
266. ter leads you to the failing part Before you replace an entire assembly determine if just the defective part is available in the parts catalog Use the error code tables symptom table service checks and the diagnostic aids chapter to determine the symptom and repair the failure The removal procedures in the Repair information chapter may help you identify parts After you complete the repair perform the appropriate tests to verify the repair If an error is displayed locate it in the Service error message tables on page 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 table and take the indicated action Adjustments and procedures following parts replacement Note When troubleshooting or prior to making any adjustment to print quality always be sure The printer is installed on a level rigid surface The photodevelopers are never exchanged Do not exchange a black photodeveloper for a color photodeveloper as they have different surface phase counts The Alignment Page is used when adjusting print registration Whenever you replace any of the following parts be sure to perform the required adjustments or procedures The adjustments are in the Repair information and Diagnostic aids chapters Diagnostic information 2 1 5055 xxx Printer controller board printer
267. the guide 4 12 Service Manual 5055 xxx Connector duplex unit removal 1 Open the top unit and remove the upper cassette left front cover paper feed cover left side cover RIP cover RIP board RIP box and the electronic box Remove the turn guide and open the paper feed cover and remove the duplex unit Remove the left side cover and power supply A 2 Disconnect the connector and remove the two screws from the mounting plate 3 Remove the two screws of the drawer connector from the mounting plate drawer bracket Repair information 4 13 5055 xxx Density sensor removal Separation fingers removal Sensor cleaner removal 1 Open the top unit and remove the belt unit 2 Remove the three screws from the sensor bracket Separation Finger Screws NC Cannon 5 Density Sensor Sensor Cleaner 3 Remove the harness band and remove the two screws from the density sensor from the sensor bracket 4 Remove the three set screws from the sensor cleaner assembly from the sensor bracket 5 Remove the four separating finger screws from the fuser entrance guide 4 14 Service Manual 5055 xxx Drive gear unit sensor assembly removal 1 Open the top unit and remove the gear cover RIP cover RIP board RIP box electronic box printer controller and high voltage power supply board 2 Remove the screw from the drive
268. the high capacity paper feed board LED Sensor Name Paper size sensor 1 switch letter size 11 inches Paper size sensor 1 switch A4 size Residual paper sensor 1 switch Residual paper sensor 2 switch Residual paper sensor 3 switch Residual paper sensor 4 switch Paper level sensor switch Lower limit switch RAI OJN Cover open sensor switch Docking sensor switch Upper limit switch r Paper sensor switch Co Paper feed sensor switch Diagnostic aids 3 19 5055 xxx Finisher tests Staple Test This test verifies the operation of the staple mechanism in the finisher The media is fed from the default paper source After selecting a destination bin the printer feeds eight pieces of media and accumulates them in the finisher accumulator The printer prints an alignment pattern during this test After the last sheet is accumulated the eight sheets are stapled and fed to bin 2 The staple test cannot be canceled or terminated once the test has begun As a result no buttons are active during the execution of this test Hole Punch 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 pattern during this test Go to Aligning the finisher
269. the message to clear Programming An error occurred while the Correct the problem Deleting Jobs Error x printer was programming specified on the second line code into memory of the display Queuing and The printer is deleting one or Wait for the message to more held jobs and sending one or more jobs to print Clear Queuing Jobs The printer is sending one or more held jobs to print Wait for the message to clear Ready The printer is ready to receive and process print jobs Send job to print 2 40 Service Manual 5055 xxx Message Ready Hex Meaning The printer is in Hex Trace mode and is ready to receive and process print jobs Action Send a job to print All data is printed in hexadecimal Control strings are printed not executed Turn the printer off and then on to exit Hex Trace mode Remove Paper The specified output bin is Remove the paper from the specified bin full specified bin s Resetting The printer is resetting the Wait for the message to Maint Cnt counter that tracks wearon clear Value the fuser Resetting the Printer The printer is resetting to the current default settings Any active print jobs are canceled Wait for the message to clear Restore Held The printer has been reset or Press Go All jobs on hard Jobs Go has been turned on and the disk are restored Stop
270. the printer posts Prt Quality Pgs Printing Once started this operation cannot be canceled All keys are ignored while this message is posted Note The media width field displays once the narrow media sensor determines the media used for the Quick Test is narrow or wide N for narrow W for wide Diagnostic aids 3 11 5055 xxx Hardware tests LCD Hardware Test The LCD Hardware Test causes the printer to continually execute the LCD display test To cancel the test press Return or Stop Button Test The Button Test verifies the operation of each button on the operator panel When Button Test is selected the following appears on the display OP OP OP OP OP OP When a button is pressed CL Closed displays When a button is not pressed OP Open displays If the wrong message displays the button is malfunctioning 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 in memory can be set and read correctly When selecting this test from the operator panel the printer begins testing DRAM memory and the following message is displayed DRAM Memory Test PAHHHHE F AHHHBE Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 9
271. tic information 2 15 5055 xxx 942 Duplex Error 942 Service Duplex Step Questions actions Yes No 1 Is connector CN37 on the Replace the Plug the printer controller board printer controller connector in connected properly board securely 945 Engine Flash Error 945 Service Engine Flash Reflash the engine code 946 Printer Printhead Controller Board Communication Error 946 Service Communication board Are all the EPROMS present Step Questions actions Yes No 1 Make sure all printhead Go to step 2 Install the LED EPROMS are present EPROM s on the printhead controller included with printhead FRU 2 Replace the printhead controller board Did this fix the problem Problem solved Replace the printer controller board 2 16 Service Manual 947 Finisher Communication Error 5055 xxx replacement resolve the problem Step Questions actions Yes No 1 Are the finisher to printer Go to step 2 Properly connect interface cable and power the cable cable properly connected 2 Replace the interface cable Problem solved Replace the Did this resolve the control finisher problem board Go to step 3 3 Did finisher control board Problem solved Replace the printer control board 948 Machine ID Error 30 seconds Turn the printer on Did this fix the
272. ting the paper exit tray switch is there continuity between pins 1 and 2 printer controller board paper exit tray Switch Diagnostic information 2 59 5055 xxx Map 10 Unrecoverable Check Tray x or Duplex Connection message Step Questions actions Yes No 1 Is the problem with a Go to step 2 Go to step 8 specific paper tray or the duplex unit 2 Is the problem with tray 1 Go to step 3 Go to step 6 3 Are connectors CN 35 and Go to step 4 Properly connect CN36 on the printer the connectors controller board properly connected 4 Are connectors CN3 and Go to step 5 Properly connect CN1 on the expansion the connectors paper feed control card for tray 1 properly connected 5 Replace the tray 1 Problem solved Return the tray 1 expansion feeder control expansion card Does this fix the feeder control problem card and replace the printer controller board If the problem remains replace the expansion feeder cable assembly 6 Are connectors CN9 CN8 Go to step 7 Properly connect CN7 and CNG on the the connectors expansion feeder control card for the problem tray and the trays above and below properly connected 7 Exchange the expansion Replace the Replace the feeder control board for the defective upper and lower problem tray with one expansion expansion paper above or below Does the feeder control feed drawer symptom follow the card connecting cable exchang
273. tion Tray Referto Cardstock amp Label Guide for media guidelines Narrow media should be loaded with the length in the feed direction portrait A5 paper 5 83 x 8 27 in 148 x 210 mm is the smallest size the printer can duplex When Other Envelope is selected the page is formatted for 8 5 x 14 in 215 9 x Maximum stack of 50 sheets if more input is required use Heavy Media Tray Manual feed one sheet at a time only if more input is required use Heavy Media Maximum stack of 30 sheets if more input is required use Heavy Media Tray When Universal is selected the page is formatted for 8 5 x 14 in 215 9 x 355 6 1 14 Service Manual 5055 xxx Input media types and weights Media Weight Standard trays gt 3 Paper xerographic or business 16 to 28 bond 60 to 105 g m Specialty papers glossy laser 80 book 32 Ib bond 120 g m Heavy media tray Paper xerographic or business 28 to 47 Ib bond 105 to 176 g m Specialty papers glossy laser4 80 book 32 Ib bond 120 g m Transparencies Jaser printer type5 47 bond 175 g m Labels upper limit paper 48 Ib bond 180 g m Multipurpose feeder Paper xerographic or business 16 to 28 Ib bond 60 to 105 g m Specialty papers glossy laser 80 Ib book 32 Ib bond 120 g m Card stock upper limit Index Bristol 90 Ib index 44 Ib bond 165 g m
274. tors to drive the paper delivery unit Diagnostic aids 3 35 5055 xxx Drive system Drive 1 composed of a 100 V dc motor and gear unit feeds the registration paper from the paper feeder and drives the belt unit photodevelopers toner cartridge fusing unit and face up delivery unit The motor rotates by the ON signal from the printer controller motor drive unit and sends a rotation synchronization detection signal to the motor drive unit Note The gear unit of drive 1 is adjusted in phase and should not be disassembled Drive 2 composed of a hybrid stepping motor and gear unit drives the face down delivery unit Stepping Motor Drive 2 152 94 L _ DC Motor Drive 1 Electromagnetic Clutch 3 36 Service Manual 5055 xxx Paper feeding The paper feeder is a two way system composed of the multi paper feeder 100 sheets maximum and an integrated 550 sheet tray Optionally the expansion paper feeders 550 sheets can be increased to four layers A high capacity paper feeding system 3 000 sheets may be used Combining the multi paper feeder expansion paper feeders and high capacity paper feeding system gives the printer a maximum paper supply of up to 5 850 sheets pem Paper Feeding Spring Cassette paper feeder The paper feeding solenoid turns on by the s
275. tting and CN7 light connector in receiving on the printer securely controller board connected properly 2 Test the sensor While Replace the Replace the actuating the sensor does printer controller upper and lower the voltage fluctuate board transparency between 0 V and 5 sensor between pins 2 and 3 of connector CN7 of the printer controller board Diagnostic information 2 25 5055 xxx 992 Temperature Humidity Sensor Error and humidity sensor a component of the paper feed solenoid assembly Did this fix the problem Step Questions actions Yes No 1 Is connector CN3 on the Go to step 2 Plug the printer controller board connector in connected properly securely 2 Replace the temperature Problem solved Replace the printer controller board 993 CPU Error Replace the printer controller board 2 26 Service Manual 994 Density Sensor Error 5055 xxx sensor fix the problem Step Questions actions Yes No 1 Is the front door fully Go to step 2 Close the front closed door 2 Is the density sensor Release the Go to step 3 actuator stuck in place density sensor actuator S bul fT oriel 3 Are connectors CN406 and Go to step 4 Plug the CN407 on the sensor board connector in connected properly securely 4 Is connector CN29 on the Replace the Plug the printer controller bo
276. ttons to open a menu scroll through a list of values select printer settings and clear error messages Select Return 3 2 Service Manual 5055 xxx Operator panel buttons Button Function Go Press Go to Exit printer menus and return the printer to the ready state Clear certain messages from the display If you ve changed printer settings from the operator panel menus press Go before you send a job to print Menu Press Menu Enter the menus from the ready state Scroll to the next Menu gt or the previous Menu menu menu item or value Increase or decrease a numerical value for a menu item setting Display the Job Menu or the Supplies Menu while the printer is busy Select Press Select to Select the menu shown on the second line of the display and 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 displayed on the second line of the display as the new user default setting Clear certain messages from the display Return Press Return to back up to the previous level of the menu structure without selecting a new menu item or value Stop Press Stop when the printer displays the Busy or Waiting message to temporarily stop all activity The message Not Ready is then displayed until you press Go to continue printer activity
277. turn or Stop Each time the test finishes the screen is updated with the result If the test is successful the Pass Count increments by 1 3 14 Service Manual 5055 xxx If the test fails the Fail Count increments by 1 and one of the following failure messages displays for approximately three seconds Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fall Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error False Init Fall Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum pass count or fail count is reached the test stops and the final test results display Press Return or Stop to exit the test Diagnostic aids 3 15 5055 xxx Serial Wrap Tests The Serial Wrap Test checks each signal of the serial port hardware using a wrap plug To perform the wrap test 1 Disconnect the serial interface cable and install the serial wrap plug 2 Select HARDWARE TESTS from the Diagnostics Menu 3 Select the appropriate Serial Wrap Test Serial Wrap Serial 1 Wrap The printer begins testing the serial hardware and the following message is displayed
278. u assigned the bin a name the bin name is displayed instead of the bin number Press Go to clear the message and continue printing Check Finisher Installation Make sure the finisher is flush against the printer If this does not resolve the problem go to Finisher service check on page 2 71 to check the finisher set switch Close Finisher Top Cover Close the finisher top cover and align the finisher flush against the printer to clear the message Empty Box Empty the hole punch box to continue printing 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 printed pages on the stacking tray inside the finisher and clear the paper jam in the printer Press Go to clear the message and continue printing Staples Empty Replace the staple cartridge if you want to continue stapling You can press Go to clear the message and continue printing without stapling Stapler Missing The staple holder is missing Place the staple holder in the stapler to clear the message Go to Finisher service check on page 2 71 to check the no staple sensor Insert Hole Punch Box Install the hole punch box The printer will automatically clear the message Go to Finisher service check on page 2 71 to check the punch box detect sensor 2 52 Service
279. ue printing 84 Black Photo The black photodeveloper is Press Go to clear the Dev Life nearing end of life message and continue Warning printing The supplies message is displayed until you replace the photodeveloper 84 Color Photo The printer has detected an Install a new color Dev Abnormal abnormal color photodeveloper photodeveloper to clear the message and continue printing Diagnostic information 2 49 5055 xxx 88 Black Toner Empty empty See note below Message Meaning Action 84 Color Photo The color photodevelopers Replace the color Devs have reached end of life photodevelopers Cyan Exhausted Magenta and Yellow at the same time If print quality is still acceptable and you do not want to replace the photodevelopers press Go to clear the message and continue printing 84 Color The color photodevelopers Press Go to clear the Photo Dev Life are nearing end of life message and continue Warning printing The supplies message is displayed until you replace the photodevelopers 85 Toner The oil coating roll has Replace the oil coating roll Empty reached end of life and black toner cartridge Coating Roll Exhausted The black toner cartridge is Note If the customer has replaced the black toner cartridge before this message displays the oil coating roller message will not display until the cartridge is empty 86 Abno
280. ur screws from the multipurpose feeder frame and the ground screw 4 Disconnect the connector of the multipurpose feeder paper feed sensor 5 Pull out the multipurpose feeder frame slightly 4 22 Service Manual 5055 xxx 6 Remove the screw from the OHP detection sensor upper 7 Turn the bearing stopper of the multipurpose feeder roll forward 1 4 turn and remove 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 controller board 2 Remove the five screws from the printer controller board bracket 3 Remove the connectors and remove the 12 screws 4 Remove the high voltage power supply board Repair information 4 23 5055 xxx LED printhead removal 1 Open the top unit remove the top cover toner cartridges and photodeveloper 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 Remove the front and rear printhead springs 4 Remove the two screws front and rear from the right slide rail and remove the rail 4 24 Service Manual 5055 xxx Note For printers with serial numbers XX XXXX and above go to step 7 For serial numbers XX 0XXXX continue with step 5
281. urely 2 Clean the color drum Problem solved Replace the sensor LED color drum sensor Did this fix the problem Go to step 3 3 Did replacing the color Problem solved Replace the drum sensor fix the printer controller problem board 935 Black Drum Sensor Error Step Questions actions Yes No 1 Is connector CN27 Go to step 2 Plug the connected properly connector in securely 2 Clean the black drum Problem solved Replace the sensor LED Did this fix the black drum problem sensor Go to step 3 3 Did replacing the black Problem solved Replace the drum sensor fix the printer controller problem board 2 14 Service Manual 936 939 Cassette Error 5055 xxx 936 Service Paper Option Step Questions actions Yes No 1 Are connectors CN35 and Replace the Plug the CN36 on the printer printer controller connector in controller board connected board securely properly 940 High Capacity Feed Sensor Error Step Questions actions Yes No 1 Is connector CN40 on the Go to High Plug the printer controller board capacity feeder connector in connected properly HCF service securely check on page 2 70 941 High Capacity Feed Tray Error Step Questions actions Yes No 1 Is connector CN40 on the Go to High Plug the printer controller board capacity feeder connector in connected properly HCF service securely check on page 2 70 Diagnos
282. us travaillez D branchez le produit avant de commencer ou faites preuve de vigilance si l ex cution de la t che exige que le produit reste sous tension Safety information xi 5055 xxx Norme di sicurezza La sicurezza del prodotto si basa sui test e sull approvazione del progetto originale e dei componenti specifici II produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona pi elevato ll personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie ATTENZIONE Questo simbolo indica la presenza AN di tensione pericolosa nell area del prodotto Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l intervento Sicherheitshinweise e Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des urspr nglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung f r die Sicherheit bernommen e Die Wartungsinformationen f r dieses Produkt sind ausschlie lich f r die Verwendung durch einen Wartungsfachmann bestimmt e W hrend des Auseinandernehmens und
283. va es do modelo original e de componentes espec ficos O fabricante n o respons vel pela segunran a no caso de uso de pe as de substitui o n o autorizadas e As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas e Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios CUIDADO Quando vir este s mbolo existe a A N poss vel presen a de uma potencial tens o perigosa na zona do produto em que est a trabalhar Antes de come ar desligue o produto da tomada el ctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente el ctrica para realizar a tarefa necess ria Safety information xiii 5055 xxx Informaci de Seguretat e La seguretat d aquest producte es basa en l avaluaci i aprovaci del disseny original i els components espec fics El fabricant no es fa responsable de les q estions de seguretat si s utilitzen peces de recanvi no autoritzades Lainformaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui Elrisc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar
284. ver spring and remove the spring Repair information 4 73 5055 xxx 26 Remove the two screws from the connector plate and remove the plate 27 Remove the two screws from the upper drawer connector male and remove the connector 28 Remove the two screws from the lower drawer connector female and remove the connector 4 74 Service Manual 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 duplex unit Repair information 4 75 5055 xxx Duplex unit removal 1 Remove the four screws from the interface board and remove the board 2 Remove the two screws from the duplex connector and remove the connector Duplex timing belt removal 1 Remove the three C clips from the three timing gears and remove the timing belts 2 Remove the knob screw and remove the timing belt 4 76 Service Manual 5055 xxx Duplex pressure roller and solenoid removal 1 Remove the two screws securing the pressure roller solenoid assembly Repair information 4 77 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 springs 4 78 Service Manu
285. x Paper skew service check FRU Action 1 Cassette Remove the tray and turn it upside down The tray guides are connected at the center of the tray by a toothed gear that ensures they move in unison If not remove the screw at the center of the gear and using a sheet of paper in the tray as a template realign the guides Reseat the roller at the leading edge of the transfer belt Make sure the correct amount of paper is in the tray and that it is under the corner bucklers The paper lift tray must be pushed down to the lock position every time the drawer is closed Paper tray missing service check FRU Action 1 Size sensor actuators Check to ensure that the paper size Cassette adjustment is correct for the paper being used Ensure that the paper size sensor actuators are not bent or broken Make sure that there are no broken parts on the cassette that would allow the cassette to move or shift from it s intended position inside the printer 2 Size sensor board Be sure that connector CN2 on the printer Expansion paper controller board is connected properly Also feeder control board check CN4 on the expansion paper feeder Printer controller control board for the associated tray board Diagnostic information 2 83 5055 xxx Photodeveloper missing service check When you replace the photodeveloper unit all three color units must be replaced at the same ti
286. xit sensor connector Remove the upper guide plate for the straight paper exit Remove the two screws and two springs for the upper guide plate Ww Spring 7 Remove the path select gate Exit Sensor Connector Note Adjust the solenoid bracket mounting position so that the gate arm is contacting the solenoid 4 96 Service Manual 5055 xxx Patting roller removal 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 Remove the sensor harness from the harness clamp Repair information 4 97 5055 xxx 6 Remove the four upper 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 installing the spring Tension Spring 9 Remove the gear and bushing I 4 98 Service Manual 5055 xxx 10 Remove the patting roller Patting Roller Power supply removal Unplug the power cord from the printer Remove the external covers Remove the lower left panel Remove the cable connector for the left panel Remove the four lower guide support plate screws and remove the plate ENN FE L RS Repair information 4 99 OQ GQ
287. xxx Adjustment example Here is a sample of the magenta radar image Looking down the left side for both X and Y you can see the X value is close to correct It may be a little to the right 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 but increasing the value increases the timing delay thus moving the image down the page The images may be off by different amounts Make the best overall judgement using all the radar images on the left side 3 8 Service Manual 5055 xxx When the Y value is correctly adjusted the magenta radar image should look like the following example The Theta adjustment is done in the same manner as the Y except Theta values are taken from the right side of the test pages Summary Notes Objective Using the X Y and T adjustment procedure adjust the color to overlay the radar image as precisely as possible X and Y values 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 the X and Y before attempting Theta Use a loop or magnifying glass 4x or higher to make the job easier Yellow is very difficult When you make the yellow adjustment swap the cyan tone
288. y Network model is network ready printer with standard 550 sheet input tray plus one optional 550 sheet drawer Finisher model is a duplex model printer with 1100 sheet punch finisher and printer cabinet Fully configured models include base printer with four standard 550 sheet input trays 3000 sheet feeder 1100 sheet staple punch finisher duplex unit and printer base General information 1 3 5055 xxx Print speed and performance Standard and heavy media tray High capacity feeder Multipurpose feeder Simplex printing on letter size media pages per minute Letter 8 5 in x 11 in 28 28 28 Ledger 16 N 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 Paper labels 22 N A 22 Duplex printing on letter size media sides per minute 2 3 4 Letter 8 5 in x 11 in 19 19 19 Ledger 11 N A 11 Legal 8 5 in x 14 in 12 N A 12 A3 11 N A 11 A4 3 4 in x 11 7 in 19 19 19 A5 Executive N A N A 20 1 4 Service Manual 5055 xxx B4 12 N A 12 B5 N A N A 19 ang statement paper support from multipurpose feeder only peeds When printing from the multipurpose feeder Simplex the first three pages print a legal speed with the balance printin
289. y installed not properly install broken and in the proper the sensor and position Make sure the securely connect sensor is fully snapped in the sensor place and that the sensor connector connector is fully seated Are these items correct If the sensor actuator flag is broken replace the belt up down changing shaft 5 Clean the belt up down Problem solved Go to step 5 sensor Does this fix the problem 2 22 Service Manual 5055 xxx Step Questions actions Yes No 6 Test the sensor While Replace the belt Replace the belt actuating the sensor does up down clutch up down sensor the voltage fluctuate Go to step 7 between 0 V and 5 V between pins 7 and 8 of connector CN29 on the printer controller board 7 Did replacing the belt up Problem solved Replace the down clutch fix the printer controller problem board 982 Sensor Controller Error 982 Service Sensor Control Is error 982 displayed Step Questions actions Yes No 1 Turn the printer off and wait Replace the Problem 30 seconds Turn the printer printer solved on controller board Diagnostic information 2 23 5055 xxx 983 Black Gear Sensor Error 983 Service Gear Sensor Step Questions actions Yes No 1 Is connector CN20 on the Go to step 2 Plug the printer controller board connector in connected properly secur
290. you cannot remove the jam replace the fuser You cannot clear the paper jam To clear the paper jam messages you must remove all paper from the printer paper path Check both inside the message printer as well as the paper source you were using Open and close the front cover and press Go If the message does not clear go to Paper carrying service check on page 2 74 Paper jam in Go to the Paper carrying service check on pick up page 2 74 assembly Diagnostic information 2 63 5055 xxx Symptom Action Fuser failure Go to the 920 Fuser Error Fuser Heater Trouble on page 2 6 No paper pick up from multipurpose tray Go to the Paper carrying service check on page 2 74 No paper pick up from upper or lower cassettes Go to the Paper carrying service check on page 2 74 Registration roller does not rotate Go to the Paper carrying service 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 replace the RIP controller board If your machine beeps 5 times and the screen is blank or all diamonds replace the operator panel Foggy print Black pages Blank print White spots Poor reproduction Incorrect color image registration Dirt on back of paper Low imag
291. you switch the toner cartridges and the problem also changes color on the test pages the problem is in one of the cartridges Replace the proper color cartridge Toner adheres to the back of the page Remove the fuser oil roll and wipe it with a dry lint free cloth and clean the transfer belt If there still is a problem go to Periodic dirt on page 2 97 Quality of printed transparencies is inadequate Be sure you re using the recommended Lexmark transparencies Be sure you have selected the correct paper weight setting for the media you are using When printing transparencies always set the Paper Type to Transparency Avoid getting fingerprints on transparencies before printing 2 92 Service Manual 5055 xxx Problem Print on the page is skewed N L Action Be sure the width guides in the paper tray or the multipurpose feeder fit snugly against the media you loaded Be sure the paper you load fits under the two 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 printer are resting on a steady flat surface Turn the printer off and back on The printer calibrates the print head timing which may improve registration Be sure that Auto Registration in diagnostic mode

Lexmark C910, C912 5055-XXX Service Manual

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