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Lexmark 5056 Printer User Manual

1. Staple unit removal 1 Remove the staple unit connector Staple Assembly gt x lt Connector 2 Pull outward on the staple cover and remove the staple unit 4 74 Service Manual 5056 XXX Straight paper exit discharge brush removal Remove the external covers Remove the two screws from the top cover and remove the cover Remove the two lever screws and remove the lever Remove the two discharge brush screws and remove the brush Soh Lever Discharge Brush Straight paper exit roller removal Remove the external covers Remove the finisher control board Remove the upper left panel Remove the front straight paper exit roller bushing Pons Bushing 5 Remove the belt and pulley Repair information 4 75 5056 XXX 6 Remove the rear straight paper exit roller E ring and bushing Pulley 7 Remove the straight paper exit roller Exit Roller 4 76 Service Manual Timing belts 1 and 2 removal 1 Remove the finisher control board mounting bracket 2 Remove the feed motor mounting bracket 3 Remove the tension bracket mounting screw Screw Tension Bracket Tension Spring Timing Belt 1 4 Remove the tension spring 5 Remove the timing belt 1 6 Loosen the tension bracket mounting screw for timing belt 2
2. 4 Disconnect the connector of the multipurpose feeder paper feed sensor 5 Pull out the multipurpose feeder frame slightly 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 Repair information 4 19 5056 XXX High voltage power supply board HVPS removal Note When removing the high voltage power supply be careful to avoid damaging the secondary daughter card Q906 If the daughter card gets damaged a 925 service error will result 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 then remove the 12 screws 4 Remove the HVPS board Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers 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
3. Mounting Screw Timing Belt 2 7 Remove the timing belt 2 5056 XXX Repair information 4 77 5056 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 ORONT 7 Remove the paper jam removal knob Knob 4 78 Service Manual 5056 XXX 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 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 Repair information 4 79
4. Repair information 4 53 5056 XXX Duplex unit removal 1 Remove the four screws from the interface board and remove the board 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 54 Service Manual 5056 XXX Duplex pressure roller and solenoid removal Remove the two screws securing the pressure roller solenoid assembly Duplex feed roller and solenoid removal 1 Remove the two screws securing the feed roll solenoid assembly 2 Remove the pressure roller and springs 3 Remove the feed roller and springs Repair information 4 55 5056 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 4 56 Service Manual 5056 XXX Duplex paper carrying motor removal 1 Remove the gear cover 2 Remove the screws from the duplex paper carrying motor and remove the motor Repair information 4 57 5056 XXX High capacity feeder HCF removals HCF covers removal Remove the two screws from the drive cover and remove the cover Remove the front cover Remove the two screws from the right cover and remove the cover Remove the top cover Remove
5. 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 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 Paper tray lift motor removal Remove the front right left rear and rear covers Remove the cassette Disconnect the cable from the paper tray lift motor Remove the three black screws from the paper tray lift motor Remove the paper tray lift motor ROND 4 14 Service Manual 5056 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 D 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 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 b
6. and remove the rail Note When replacing the rail be sure to use the short black screw A longer screw can interfere with the LED head causing the image to be out of focus 4 20 Service Manual 5056 XXX 5 Disconnect the affected LED printhead connectors from the printhead controller board Remove the screw from the ground wire located on the LED printhead 6 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 Note The LED printhead light intensity values do not have to be entered for the printer Eraser removal 1 Remove the appropriate printheads see LED printhead removal on page 4 20 Spread a cloth 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 eraser cable from the printhead controller board C CNO6 M CNO5 Y CNO7 K CNO8 5 Carefully thread the eraser cable through the upper unit and remove the eraser Repair information 4 21 5056 XXX Lock handle assembly removal Open the top unit Turn the plastic latch on the front and rear sides 90 Remove the spring Remove the lock handle assembly AONT 4 22 Service Manual 5056 XXX Main drive unit removal Open the top unit and remove the gear cover
7. 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 HVPS 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 Remove the two screws from the fan bracket Remove the three screws from the fuser connector plate eS PoOnouSoh oh l 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 Repair information 4 23 5056 XXX 14 Remove the screw from the clutch stopper The clutch stopper is attached to the ground plate with two screws 16 Remove the two screws from the drive unit and remove the unit 17 Remove the E clip on the belt up down clutch and remove the changing shaft from the drive unit 18 Remove the three screws from the belt up
8. Remove the RIP cover electronic box printer controller card and HVPS board 2 Unplug the belt up down clutch cable from CN1 in the CK1 daughter card board 3 Remove the C clip from the belt up down clutch and remove the clutch 4 12 Service Manual 5056 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 the guide ooo na i oes cr ooo 7 WOOO OOO CK1 daughter board removal Remove the front right left rear and rear covers Remove printer controller board and HVPS board Disconnect all cables from the daughter board While pinching the nylon standoffs that attach the card to the printer frame gently pull the CK1 daughter board away from the printer frame Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers RODT CK2 daughter board removal Remove the front right left rear and rear covers Remove power supply 1 Unplug all cables from the daughter board Remove four screws from the daughter board and remove the board Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers ARONS Repair information 4 13 5056 XXX Connector duplex unit removal
9. back the wiring that connects the printer controller board to the face down unit Avoid pinching or cutting wiring that connects the face down unit to the printhead controller board Face down exit roll removal Note When replacing the face down exit roller lubricate the ends of the roller shaft with a small amount of Nyogel 744 part number 40X0179 Open the top unit and remove the toner cartridges photodeveloper drum units and upper cover 1 Remove the face down unit from the printer 2 Remove the three screws A that hold the rear cover to the face down unit 4 32 Service Manual 5056 XXX 3 Remove the rear cover 4 Remove the motor and drive belt from the exit roller shaft 5 Remove the grounding strip A Repair information 4 33 5056 XXX 6 Remove the e clips and bushings A from both ends of the exit roller shaft amp gt 7 Pull the guide rib A to the left 4 34 Service Manual 5056 XXX 8 Remove the exit roller Power supply 1 removal 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 CN106 and CN04 at power supply 2 Remove the power supply Note When installi
10. is a small blue tab on the pickup roller 4 Remove the white plastic retaining clip from the shaft and slide the paperfeed roller B off the shaft 5 Remove the white plastic retaining clip and slide the separator roller C off the shaft The torque limiter D can be removed by sliding off the shaft if it needs replacement 4 28 Service Manual 5056 XXX Paper carrying frame removal roll 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 VOGO O O 3 Remove the paper carrying frame Note When installing 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 one another 4 Remove the carry clutch and plastic bushing on the left side of the carrying frame 5 Remove the E clip and bushing on the right side of the carrying frame 6 Remove the carrying roller Repair information 4 29 5056 XXX Registration frame Registration clutch removal 1 Open the top unit open the turn guide open the paper feed cover and pull out the duplex unit halfway 2 Remove the two screws from the registratio
11. 056 XXX 7 Pull the transfer belt out 8 After replacing the transfer belt and removing the four shipping spacers tighten the transfer belt thumbscrews and reinstall the transfer belt cover 9 Close the top unit rotate the locking lever to the right and close the front cover 10 Turn the printer on 11 Adjust the registration if needed by pressing the Menu key scrolling to Settings scrolling to Utilities and selecting Alignment Info From here you can adjust the settings for the belt Print an alignment page to confirm that the belt is properly adjusted Perform further adjustments if needed Note The belt adjustment can be adversely affected by a toner low condition 4 46 Service Manual 5056 XXX Turn guide cover sensor removal Remove the left rear rear and right covers Remove the print controller card and the HVPS Disconnect the sensor cable from CN10 on the CK1 daughter card board Remove two screws from the turn guide sensor assembly and remove the sensor Son 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 Repair information 4 47 5056 XXX 3 Remove the two screws from the left fan and remove the fan 4 Remove the two screws from the right fan and remove the fan 4 48 Service Manual
12. 5056 XXX Expansion feeder removals Turn guide door removal 1 Open the turn guide door 2 Pull the door hinge from the right turn guide bushing 3 Pull the turn guide door clear of the expansion feeder Expansion feeder controller board removal 1 Remove six screws from the expansion feeder rear cover 2 Unplug all cables from the expansion feeder controller board 3 Remove six screws from the controller card 4 Remove the controller board Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers Size sensor board removal 1 Remove the expansion feeder controller board 2 Remove two screws on the size sensor board 3 Remove the size sensor board Repair information 4 49 5056 XXX Stepper motor removal 1 Remove the expansion feeder rear cover 2 Disconnect the stepper motor power cable from the expansion feeder controller board 3 Remove three screws from the stepper motor assembly A 8 gt Oy s ae x N gt 4 Remove the stepper motor assembly from the expansion feeder 4 50 Service Manual 5056 XXX Paper feed assembly removal Remove the rear cover Remove the cassette Remove the stepper motor assembly Disconnect the cables from connectors CN11 CN13 CN18 on the expansion feeder c
13. LEXMARK Lexmark C920 5056 XXX Lexmark Repair Catalog The following information is from Lexmark s Service Mnaual 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 e mail at 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 Lexmark with diamond design and MarkNet are trademarks of Lexmark International Inc registered in the United States and or other countries ImageQuick Optra Forms and PrintCryption are trademarks of Lexmark International Inc LEXFAX is a
14. SD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity 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 printer with its covers removed do not 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 HVPS high voltage power supply board Be sure to handle the fuser careful
15. achine and let it go through the startup cycle After this procedure is completed successfully there is no need to adjust any settings If the above procedure fails you must contact the technical support center for further instructions Handling printed circuit boards The following precautions must be observed when handling circuit boards with metal oxide semiconductor integrated circuits CAUTION If you are removing the motor driver board or the low voltage power supply boards ensure they are properly discharged before handling Transportation storage e During transportation or when in storage new circuit boards must not be indiscriminately removed from their protective conductive bags e Do not store or place circuit boards in a location exposed to direct sunlight e 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 e Do not touch pins of the integrated circuits with your bare hands Replacement e Before you unplug connectors from the circuit boards be sure the power cord has been unplugged from the power outlet e 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 e Before you plug connectors into the board be sure the power cord has been unplugged from t
16. ble Temperature humidity sensor removal 1 Remove the rear cover printer controller board and HVU board 2 Disconnect the cable from connector on the temperature humidity sensor ni je 3 Remove the screw A holding the sensor to the paperfeed gear linkage 4 Remove the temperature humidity sensor 4 42 Service Manual 5056 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 Transfer belt removal Transfer belt removal has been simplified with a redesign of the changing shaft linkage to the belt up down clutch The supplies menu no longer needs to accessed to remove the transfer belt unit Note If the operator panel is inoperable or if you have an unrecoverable error code this procedure can still be used 1 Turn the printer off along with any optional devices connected to the printer 2 Open the front cover and top unit Warning Donottouch drop or place anything on the transfer belt Touching the surface of the transfer belt or placing items on the belt may cause damage Repair information 4 43 5056 XXX 3 Loosen the thumbscrews as shown 4 Lift and remove the transfer belt cover 4 44 Service Manual 5056 XXX 5 Loosen the thumbscrews as shown If Nm AG AG CA SF 6 Press down on the transfer belt release lever as shown Repair information 4 45 5
17. d HVPS board Unplug connectors CN23 CN16 CN10 CN20 CN12 CN15 and CN7 on the CK1 daughter card board Remove the e clip and bushing A from the paper feed clutch Remove four screws B from the paper feed gear unit ROND 4 26 Service Manual 5056 XXX 6 Remove the paper feed gear unit paper feed clutch and two gears C not held in place with an E clip 8 Remove the brass screws E on the left side of the paper feed unit 9 Remove the paper feed unit being careful to route the sensor cabling through the wire guides Repair information 4 27 5056 XXX Paper feed rollers removal Paperpath maintenance A paper path maintenance kit can be used when a machine is experiencing misfeeds and jams after 200 000 pages The order number for this kit is 40X1109 The kit is composed of the following parts 56P9683 Carrying roller 40X1154 Registration frame 40X1077 Pickup roll 40X1078 Paper feed roll 40X1079 Separator roll 40X1064 FD paper exit roller In addition to the paper path maintenance kit the relay roller 40X1108 and turn guide rollers 40X1072 can be ordered Note This removal can be used for the expansion paper feed roller removal Do not discard the white plastic retaining clips They will be needed to attach the new rollers 1 Turn off the printer and unplug the power source 2 Remove the paper cassette 3 Pull back on the tab and remove the pickup roller Note There
18. down clutch box and remove the belt up down clutch 19 Remove the screw from the drum gear sensor and remove the sensor 4 24 Service Manual 5056 XXX Main unit fan removal 1 Remove the left side cover the solenoid cover and the rear cover 2 Remove the LVPS low voltage power supply 1 3 Remove two screws from the main unit fan bracket 4 Disconnect the fan power cable from CN6 on the CK2 daughter card board 5 Remove the fan Motor drive board removal 1 Remove the upper cassette front cover B paper feed cover and the left side cover 2 Disconnect the five connectors remove five screws and remove two screws from the motor drive board Multipurpose feeder 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 25 5056 XXX Multipurpose feeder tray removal 1 Open the top unit and remove the front cover cassette feeder turn guides and right side cover 2 Open the multipurpose feeder and slide it toward the magnet in the direction of the arrow removing it from the printer Paper feed unit removal Remove the front right left rear and rear covers Remove the printer controller board an
19. e the plate 4 70 Service Manual 5056 XXX 8 Remove the tension springs Use the upper hole when installing the spring Tension Spring 9 Remove the gear and bushing Gear and Bushing Patting Roller Repair information 4 71 5056 XXX 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 ORONT 6 Remove the two power supply screws A i Dh 7 Remove the screw from the ground wire 8 Disconnect the power supply connector and remove the power supply 4 72 Service Manual 5056 XXX Registration roller removal Remove the hole punch unit Remove the registration roller clutch Remove the registration roller bushing Remove the registration roller Son 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 Set Screw Registration Clutch 4 Remove the registration roller clutch connector 5 Remove the registration roller clutch Repair information 4 73 5056 XXX Stack area discharge brush removal 1 Remove the dust box 2 Remove the stack area discharge brushes
20. erent surface phase counts e 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 Printer controller board printer control EPROM U7 If you replace the printer controller board remove EPROM U7 and install it on the new board Also check the printhead alignment Printhead controller board If you replace the printhead controller board replace all the eeproms from the old printhead controller board RIP controller board If you replace the RIP controller board move the memory and option cards from the old card to the new one 4 4 Service Manual 5056 XXX 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 Printer Alignment X Y and Theta Print the alignment pages Make sure that you installed the EEPROMS supplied with the printhead on the printhead controller board Repair information 4 5 5056 XXX Removals Cover top removal 1 Open the top unit and remove the photodevelopers and toner cartridges Cover the photodevelopers to avoid damage from exposure to the light Re
21. g brackets to the printer 7 Remove the front door from the printer Repair information 4 7 5056 XXX 8 Remove six screws C that hold the operator panel to the front door 9 Remove the operator panel from the door Note If the USB cable or the operator panel cable is being replaced use the toroids from the old cables with the new cables Cover front left removal 1 Open the front cover and remove the cassette 2 Remove the left front cover by removing the three silver screws al eens SS Ae Wim 4 8 Service Manual 5056 XXX Cover rear removal 1 Open the top unit 2 Remove the three silver screws from the rear cover and then remove the cover Cover solenoid removal 1 Remove the screw from the solenoid cover 2 Remove the solenoid cover Cover left side removal 1 Remove the upper cassette front cover paper exit tray and duplex unit 2 Remove the five screws from the left side cover and remove the cover Repair information 4 9 5056 XXX Cover right side removal 1 Open the top unit and remove the front cover and upper cassette 2 Remove the operator panel cable and the USB cable from the operator panel See Front door operator panel removal 3 Remove the seven screws from the right side cover together with the turn guide and remo
22. he power outlet Inspection e Avoid checking the integrated circuits directly with a multimeter use connectors on the board e Never create a closed circuit across integrated circuit pins with a metal tool e When itis absolutely necessary to touch the integrated circuits and other electrical components on the board be sure to ground your body 4 2 Service Manual 5056 XXX Check finisher alignment when moving or servicing the finisher After moving or servicing the finisher print some test pages to the finisher to ensure the vertical and horizontal alignment is correct If the finisher is not properly aligned refer to Aligning the finisher and printer on page 3 59 for alignment instructions Repair information 4 3 5056 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 ROND Screw Spring Screw Washer Front Idler Bracket Adjustments and procedures following parts replacement Note When troubleshooting or prior to making any adjustment to print quality always be sure e The printer is installed on a level rigid surface e The photodevelopers are never exchanged Do not exchange a black photodeveloper for a color photodeveloper as they have diff
23. ing them from the board to avoid reconnection into the wrong location When replacing the board install the EPROM U7 of the former board to the new board Also when replacing the EPROM set the light intensity in the diagnostic mode and set the counter and printer alignment Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers Repair information 4 37 5056 XXX Printhead controller board removal 1 Remove the top cover and then remove the 20 printhead controller board connectors 2 Remove the six screws from the printhead controller board and remove the board sini mk rth 00 00 FW egge Bet en Mie tf i 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 38 Service Manual 5056 XXX Left slide rail removal 1 Remove the upper cassette 2 Remove the screw from both left and right slide rails RIP box removal 1 Remove the six screws from the RIP box 2 Slightly lift and remove the RIP box Repair information 4 39 5056 XXX Sensor board removal 1 Remove the transfer belt unit 2 Remove the four connectors 3 Re
24. ly 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 Repair information 4 1 5056 XXX RIP board operator panel replacement Warning If the operator panel and the RIP board are being replaced at the same time replace the parts in this order to avoid damage to the machine 1 Replace the RIP card first Note Do not replace the new operator panel and RIP card in the machine at the same time 2 After installing the new RIP card and before installing the new operator panel start the printer 3 After the printer has completed startup turn off the printer and replace the operator panel Note If the operator panel display has failed the printers startup cycle is complete when the driver motor and fans shut down and the machine is quiet 4 After installing the new operator panel start the printer and allow the printer to go through a complete startup cycle and the display to go to Ready 5 If the problems persist leave the new operator panel in the machine place the old RIP card back in the machine and start it up After the machine startup shut down the machine and install the new RIP card After installing the new RIP card restart the m
25. move the three screws from the waste toner full sensor board Stay arm removal 1 Open the top unit and remove the face down paper guide assembly 2 Remove the yellow and black sub frame 3 Remove the screw from the right stopper and remove the stopper 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 4 40 Service Manual 5056 XXX Sub frame removal Important Read the entire procedure before removal a Open the top unit and remove the RIP cover RIP board RIP box electronic box printer controller printer controller bracket and HVPS board Remove the cable ties Remove the 12 screws from the sub frame Remove sub frame PON Repair information 4 41 5056 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 availa
26. move the two screws from the DC DC converter and remove the converter Se ae ea Power Supply Cover DC DC Converter Power Supply 4 62 Service Manual 5056 XXX Finisher removals Note Check finisher alignment when moving or servicing the finisher After moving or servicing the finisher print some test pages to the finisher to ensure the vertical and horizontal alignment is correct If the finisher is not properly aligned refer to Aligning the finisher and printer on page 3 59 for alignment instructions 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 from the rear cover and remove the cover Repair information 4 63 5056 XXX 4 Remove the two screws from the top cover and remove the cover Finisher control board removal 1 Remove the external covers 2 Disconnect all of the associated connectors 3 Remove the four finisher control board mounting screws and remove the board 4 64 Service Manual 5056 XXX Elevator motor removal 1 Disconnect the elevator motor connector 2 Remove the two elevator motor bracket screws from the bracket Elevator Motor 3 Remove the elevator motor assembly Feed motor assembly removal 1 Remove the finisher control board mounting bracket 2 Loosen the tension bracket moun
27. move the two silver screws and remove the spacer Remove five black screws from the bottom and the four silver screws from the back side Remove the top cover Note When replacing the top cover avoid pinching or cutting wires that connect the printhead controller board to the face down unit PON 4 6 Service Manual 5056 XXX Front door operator panel removal Warning If the operator panel and the RIP board are being replaced at the same time replace the parts in the order described in steps a through d below to avoid damage to the machine a b c d Replace the RIP card this must be the first part replaced Restart the printer Let the machine finish the startup cycle which takes several minutes The machine is silent when startup is complete Install the new operator panel Restart the printer and let the startup cycle complete If the above procedure fails contact the technical support center for further instructions 1 Open the front door of the printer 2 Remove the screws A from the stiffener bracket 3 Remove the stiffener bracket 4 Clip the wire tie that holds the USB and operator panel cables to the door Note Refasten and properly route the cables using a wire tie to avoid pinching them with the stiffener 5 Unplug the two cables from the operator panel Note To continue removing only the operator panel skip steps 6 and 7 6 Unscrew the four screws B that hold the front door mountin
28. n frame 3 Remove the registration clutch Note When installing set the clip of the registration clutch to the stopper Registration sensor removal 1 Open the top unit and 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 30 Service Manual 5056 XXX Relay roller removal Note This removal can be used for the expansion paper feed unit relay roller removal as well 1 Remove the paper feed unit from the machine 2 Remove the e clips and bushings from each end of the relay roller shaft 3 Remove the five screws A that hold the top metal plate on the unit 4 Remove the top plate from the paper feed unit 5 Slide the relay roller to the right B and tilt the roller up and out of the unit 6 Pull the relay roller to the left C and remove the roller from the paper feed unit Repair information 4 31 5056 XXX Face down guide assembly removal 1 Remove the top cover 2 Disconnect the connector and remove the five screws and two snap bands from the face down guide assembly 3 Remove the four screws from the face down cover and the face down guide assembly and remove the assembly Note When replacing the face down unit use a tie to hold
29. ng incline the ground wire by 45 ae 2 YS Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers Repair information 4 35 5056 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 Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers Note Before installing the new power supply remove the black actuator guide A from the old power supply and install it on the new power supply 4 36 Service Manual 5056 XXX Power switch removal 1 Remove the upper cassette left front cover paper feed cover and left side cover 2 Unlock the power switch and pull out the power switch A UP 3 Remove each terminal connected to the power switch Note When connecting be careful to connect the connectors correctly Insert the insulator cover completely covering the terminal Printer controller removal 1 Open the top unit and remove the RIP cover RIP board RIP box and electronic box 2 Remove the connectors and the screws from the printer controller Pay attention to the location or label the two pin connectors when remov
30. oard 2 Remove the screw from the drive gear unit sensor assembly 3 Remove the two screws of the drive gear unit sensor from the drum drive gear sensor assembly Repair information 4 15 5056 XXX Electronic box removal 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 ROND Y l mi Wy W dO 5 Disconnect all cables from the rear of the electronic box and remove the box 4 16 Service Manual 5056 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 Front cover open switch actuator removal 1 Open the front cover 2 Remove the two screws from the front cover open switch actuator Repair information 4 17 5056 XXX Fuser removal 1 Open the top unit 2 Pushing the front and back lock hold the handle and then raise and remove the fuser 4 18 Service Manual 5056 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
31. ontroller board Remove the screws A holding the paper feed gear assembly Remove the gear assembly B and the paper feed clutch C Remove three gears from the paper feed unit oooh 8 Remove the three cassette guide screws D 9 Remove three screws E 10 Remove three screws from the left side of the paper feed unit F 11 Feed the sensor cables through the side Use care to avoid damaging the insulation 12 Gently lift the paper feed unit out of the expansion feeder Repair information 4 51 5056 XXX Paper tray lift motor removal Remove the rear cover Remove the cassette Disconnect the cable from the paper tray lift motor Remove three black screws from the paper tray lift motor A Sah 5 Remove the paper tray lift motor Expansion feeder turn guide door sensor assembly removal Remove the rear cover Disconnect the cable from CN15 on the controller board Open the turn guide door Remove two black screws from the door sensor Thread cable avoid fraying insulation through side frame and remove the sensor ROND 4 52 Service Manual 5056 XXX Duplex removals Duplex unit separation removal 1 Remove the thumbscrews C clips and screws as shown from both sides en A
32. service mark of Lexmark International Inc PostScript is a registered trademark of Adobe Systems Incorporated PCL is a registered trademark of the Hewlett Packard Company Other trademarks are the property of their respective owners 2006 Copyright 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 5056 XXX Repair information Handling ESD sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive parts use the following instructions in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the E
33. sor 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 Notes e To prevent damage to the stay hold the stay when removing the sensors e Be sure the side registration is not shifted which may occur with the dismounting and mounting of the locking stay If it is shifted relocate the stay toward the front or rear to adjust 4 60 Service Manual 5056 XXX 8 Remove the top cover switches 1 A eS Black Yellow Top Cover Switch 2 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 Tray Motor Repair information 4 61 5056 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 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 Remove the four screws from the power supply unit and remove the unit Re
34. the rear cover Remove the four screws from the transfer cover and remove the cover DARON Drive Cover Rear Cover Transfer Cover Top Cover Front Cover Right Cover 4 58 Service Manual 5056 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 HCF pickup solenoid removal Remove the four screws from the transfer cover and remove 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 al alk Clamp Plate Clamp Paper Feed Front and Rear Drive Cover Repair information 4 59 5056 XXX HCF paper end sensor removal HCF paper size sensors 1 2 removal 1 NOURYON 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 sen
35. ting 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 65 5056 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 REN o Hole Punch Assembly Tension Spring 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 5 Remove the two hole punch unit screws and remove the unit 4 66 Service Manual 5056 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 Soh 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 4 Remove the inverter paper exit roller bushing Inverter Paper Exit Roller Repair information 4 67 5056 XXX 5 Remove the inverter idle gear 6 Remove the in
36. ve the cover 4 te ee slieseelecteuclsstccidsed NT m imm Door ii 10111111111117 4 10 Service Manual 5056 XXX Cover RIP board removal Warning If the operator panel and the RIP board are being replaced at the same time replace the parts in this order to avoid damage to the machine Replace the RIP card first this must be the first part replaced Restart the printer Let the machine finish the startup cycle This takes a few minutes The machine is silent when startup is complete Install the new operator panel Restart the printer and let the startup cycle complete fo NS If the above procedure fails you must contact the technical support center for further instructions 1 Loosen the eight screws and remove the RIP cover by sliding upward 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 Note After replacing any board on the printer ensure all the connections are properly connected before closing the covers Repair information 4 11 5056 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
37. verter drive gear and bushing Drive Gear and Bushing Idler Gear 7 Remove the inverter paper exit roller Jogging unit removal 1 Remove the dust box 2 Remove the two screws and remove the cover 3 Disconnect the jogging motor connector 4 Disconnect the jogging home position sensor connector Sensor Connector Motor Connector 5 Remove the jogging unit 4 68 Service Manual 5056 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 exit sensor connector Remove the upper guide plate for the straight paper exit Remove the two screws and two springs for the upper guide plate DARON Spring Gate Solenoid Mounting Bracket 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 Repair information 4 69 5056 XXX Patting roller removal 1 Remove the front and rear covers 2 Remove the finisher control board mounting bracket 4 Disconnect the sensor connector 5 Remove the sensor harness from the harness clamp 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 remov

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