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Lexmark C920 Service Manual

Color laser printer
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Download this manual See also: Service Manual, Reference Manual
Edition: October 17, 2006
™
Lexmark
C920
Color Laser Printer
5056-XXX
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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Summary of Contents for Lexmark C920

  • Page 1 C920 Color Laser Printer 5056-XXX • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PrintCryption is a trademark of Lexmark International, Inc.

  • Page 3: Table Of Contents

    Lexmark glossy paper ........
  • Page 4 5056-XXX Maintenance approach ............. . . 1-19 Standard inspection and cleaning procedure .
  • Page 5 5056-XXX 983 - Black Gear Sensor Error ..........2-23 984 - Yellow Gear Sensor Error .
  • Page 6 5056-XXX Vertical white banding ............2-68 .
  • Page 7 5056-XXX Par 3 Strobe Adj ............3-19 Event Log .
  • Page 8 5056-XXX Maintenance Mode ............. . 3-43 DIP switch specifications .
  • Page 9 5056-XXX Paper tray lift motor removal ........... . . 4-14 Density sensor removal/Separation fingers removal/Sensor cleaner removal .
  • Page 10 5056-XXX Duplex paper carrying motor removal ..........4-57 High-capacity feeder (HCF) removals .
  • Page 11 5056-XXX Finisher locations ............. . 5-21 Preventive maintenance .
  • Page 12 5056-XXX Service Manual...

  • Page 13: Notices And Safety Information

    5056-XXX Notices and safety information Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 14 5056-XXX Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 15 5056-XXX Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
  • Page 16 5056-XXX Service Manual...

  • Page 17: Safety Information

    5056-XXX Safety information • The safety of this product is based on testing and approvals of the original 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.
  • Page 18 5056-XXX Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 19 5056-XXX Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...

  • Page 20: Preface

    5056-XXX Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed, as well as general environmental and safety instructions.

  • Page 21: General Information

    5056-XXX 1. General information Overview The Lexmark C920 is a high-speed, wide-format color LED electrophotographic printer with superior print quality for high-volume printing. Resolution • 600 x 600 dpi • 2400 image quality Model differences 5056-000 5056-010 5056-030 5056-030 C920 (base)

  • Page 22: Options And Features

    5056-XXX Options and features Compatibility The Lexmark C920 color printer supports only Lexmark C920 paper-handling options. The Lexmark C920 media options include: • 550-sheet optional drawer–can be installed beneath the printer to offer an added input source which holds approximately 550 sheets of 20 lb paper. Multiple optional drawers are supported simultaneously (up to four drawers).

  • Page 23: Technical Specifications

    • Off – no color correction is implemented. Physical specifications and weight Description Height Width Depth Weight Printer dimensions Lexmark C920 20.2 in. 27.4 in. 28 in. (705 mm) 177.1 lb (512 mm) (695 mm) (80.5 kg) Lexmark C920n 20.2 in.

  • Page 24: Print Speed And Performance

    5056-XXX Print speed and performance Standard tray (ppm) High-capacity feeder Multipurpose feeder Media size (mono /color) (ppm) (mono /color) (ppm) (mono /color) Simplex printing (pages per minute) Letter - LEF 36/32 36/32 36/32 Letter - SEF 28/25 Ledger - SEF 20/17 20/17 Legal - SEF...

  • Page 25: Performance

    5056-XXX Performance The Lexmark C920 printer supports the speeds previously listed. 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 •...

  • Page 26: Printer Memory

    DDR-DRAM and Flash memory options are interchangeable within any of the memory slots available on the Lexmark C920 system board. However, only one Flash memory option is recognized at a time. If multiple Flash memory options are installed, the system recognizes the largest one.

  • Page 27: Paper And Media Specifications

    5056-XXX Paper and media specifications Lexmark Lexmark Lexmark Lexmark Sources and capacities C920 C920n C920dn C920dtn Input sources Number of standard sources Optional input drawers High-capacity feeder Maximum number of input sources Input capacities (sheets) Standard Primary tray Second tray...

  • Page 28: Media Size Supported

    (184 x 267 mm) Tabloid–11 x 17 in. (279.4 x 431.8 mm) 12 x 18 in. (305 x 457 mm) Lexmark C912 only A3–11.69 x 16.54 in. (297 x 420 mm) Universal 69.85 x 127mm to 229 x 355.6mm (2.75 x 5in to 9.01 x 14 in) 148 x 182mm to 215.9 x 355.6mm...
  • Page 29 2 Narrow media should be loaded with the length in the feed direction (portrait). 3 A5 paper(148 x 210 mm / 5.83 x 8.27 in) is the smallest paper the C920 can duplex. 4 When other envelope is selected, the page is formatted for 215.9 x 355.6 (8.5 x 14 in) unless a size is specified by the soft- ware application.

  • Page 30: Output

    (184 x 267 mm) Tabloid–11 x 17 in. (279.4 x 431.8 mm) 12 x 18 in. (305 x 457 mm) Lexmark C912 only A3–11.69 x 16.54 in. (297 x 420 mm) Universal 69.85 x 127mm to 229 x 355.6mm (2.75 x 5in to 9.01 x 14 in) 148 x 182mm to 215.9 x 355.6mm...
  • Page 31 5056-XXX Standard Bin 1 Finisher Bin 1 Finisher Bin 2 output Media type Paper Card stock Transparencies Envelopes Glossy paper Paper labels Vinyl labels 1-11 General information...

  • Page 32: Input Media Types And Weights

    5056-XXX Input media types and weights Multipurpose High capacity Standard tray feeder feeder Media Type bond bond bond Paper Xerographic or business 60—105 16—28 60—105 16—28 60—105 16—28 Specialty paper Glossy laser 106— 29—32 Card stock Index bristol 121— 33—102 121—...

  • Page 33: Input Capacity By Media And Source

    5056-XXX Input capacity by media and source Media Stack height Capacity 500-Sheet trays Plain paper (letter, A4, legal, 2.2 in. (56 mm) 550 sheets 16—20 lb (60—75 g/m tabloid, A3) Plain paper (letter, A4, legal, 550 sheets 20—24 lb (75—90 g/m tabloid, A3) Plain paper (letter, A4, legal, 550 sheets 24—28 lb (90—105 g/m...

  • Page 34: Output Capacity By Media And Source

    5056-XXX Output capacity by media and source Media Stack heights Capacity Standard output bin Plain paper Varies 550 sheets Glossy paper Card stock 300 sheets Paper labels Bin 1 (face-up) Plain paper Varies 100 sheets Glossy paper Transparencies 50 sheets Card stock 30 sheets Vinyl labels...

  • Page 35: Media Guidelines

    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 Card Stock + Label Guide, and tested for acceptability. Lexmark glossy paper • Use letter (p/n 12A5950) or A4 (p/n 12A5951) only. •...

  • Page 36: Connectivity

    5056-XXX Connectivity Standard Optional internal local connection. Network connections Internal network connections Standard ethernet and MarkNet compatibility Data streams • PCL 6 Emulation • PostScript 3 Emulation • PPDS Migration Tool • Operating systems Windows 95 (OSR2), Windows 98, Windows Me, Windows NT (SP6), Windows 2000 (Professional and Server), Windows XP (Home and Professional), Windows Server 2003, Novell NetWare 3.x, 4.x, 5.x, 6x (including NDS and NPDS support), HP-UX (11.00, 11.11), Sun Solaris(7, 8, 9, 10), IBM AIX (5.1, 5.2, 5.3), SuSE Linux (8.0 and later), Red Hat Enterprise 3.0, Debian 3.0 rev 2, Linspire 4.5, Red Flag 4.0 (Simplified Chinese), Limpus 9.2...

  • Page 37: Power And Electrical Specifications

    5056-XXX Power and electrical specifications The following table specifies the nominal average power requirements for the standard printer configuration (no options installed). All power levels are shown in watts (W). Maximum current is given in amperes (A). Power requirements Average nominal power requirements for the base printer configuration (110 volt). Power levels are shown in watts.

  • Page 38: Operating Clearances

    5056-XXX Operating clearances The following clearances are recommended to ensure proper operation. Minimum clearance requirements Left side Right side Rear Front Printer 9 in. 13 in. 6 in. 5 in. 27 in. 229 mm 330 mm 153 mm 127 mm 686 mm Duplex 9 in.

  • Page 39: Maintenance Approach

    5056-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. •...

  • Page 40: Return Parts

    5056-XXX Return parts Engineering periodically analyzes returned parts for failure modes. Include a printed quality page and a menu 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: •...

  • Page 41: Acronyms

    5056-XXX Acronyms ASIC Application-specific integrated circuit Belt up down CMYK Cyan yellow magenta black Central processing unit Cyclic redundancy check Customer replaceable unit Customer setup DIMM Dual inline memory module Downloadable emulator DRAM Dynamic random access memory Electrophotographic process EPROM Erasable programmable read-only memory Electrostatic discharge Face down...
  • Page 42 5056-XXX RFID Radio frequency identification Relative humidity Raster image processor Read only memory Read-only storage Short edge feed Solenoid SRAM Static random access memory Used parts replacement Universal serial bus V ac Volts alternating current V dc Volts direct current 1-22 Service Manual...

  • Page 43: Diagnostic Information

    Warning: Do not use a RIP board or operator panel from another C920 for diagnosing problems or errors on the printer being serviced. This can damage the machine. CAUTION: Unplug power cord from the printer or electrical outlet before you connect or disconnect any cable or electronic board or assembly for personal safety and to prevent damage to the printer.
  • Page 44 5056-XXX Print paper checks • Use the recommended paper for this printer. • Paper dampness. Make a trial print with paper from a newly opened package, and check the result. Service Manual...

  • Page 45: Symptom Table

    “Transfer belt up/down service check” on page 2-62. 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.
  • Page 46 5056-XXX Symptom Action Poor fusing. Go to “920 - Fuser Error–Fuser Heater Trouble” on page 2-11. Toner scatter on front or back of Check the following: paper. • Excessive toner buildup on the transfer belt. Clean off the toner, and run a test print.

  • Page 47: Printer Messages

    5056-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.
  • Page 48 5056-XXX Restore factory defaults from the configuration menu. Record the Problem solved secondary error WARNING: When factory defaults are restored, all codes. With the menu items are returned to factory default values 900 Service RIP except: Error displayed, press Menu then •...
  • Page 49 5056-XXX 04 Objstore The 900 error occurred while the Objstore process was running. 05 Nv2 The 900 error occurred while the Nv2 process was running. 06 ErrorExit The 900 error occurred while the ErrorExit process was running. 07 Sysmgr The 900 error occurred while the Sysmgr process was running. 08 VacuumServer The 900 error occurred while the Vacuum-Server process was running.
  • Page 50 5056-XXX 43 P4.PS The 900 error occurred while the P4.PS process was running. 44 P4.Pcl The 900 error occurred while the P4.Pcl process was running. 45 P4.Pjl The 900 error occurred while the P4.Pjl process was running. 46 P4PageTask The 900 error occurred while the P4PageTask process was running. 47 P4RenderC The 900 error occurred while the P4RenderC process was running.

  • Page 51: Drive Motor Error

    5056-XXX 90 Lxkfax The 900 error occurred while the Lxkfax process was running. 91 Faxcntl The 900 error occurred while the Faxcntl process was running. 92 Fax_Print The 900 error occurred while the Fax_Print process was running. 99 900 The 900 error occurred outside of a process context (for example, during kernel boot or other kernel operation).

  • Page 52: High-Capacity Feed Motor Error

    5056-XXX 912 - High-Capacity Feed Motor Error Step Questions/actions Is connector CN22 on the printer controller board Go to “High- Plug the securely connected? capacity feeder connector in (HCF) service securely. check” on page 2-53. 917 - RIP Fan Error 917 Service Fan Error Step...

  • Page 53: Fuser Error-Fuser Heater Trouble

    5056-XXX 920 - Fuser Error–Fuser Heater Trouble 92x Service Fuser Error Step Questions/actions Replace the fuser. Did this fix the problem? Problem solved. Return the fuser, replace the power supply 2, and go to step 2. Did replacing power supply 2 fix the problem? Problem solved.

  • Page 54: Hvu Error

    5056-XXX 925 - HVU Error Step Questions/actions Has the high voltage power board (HVU) been Inspect the Go to step 2. removed/replaced? secondary card on the high voltage board (HVU) for a broken component (Q906). Replace the high voltage board (HVU) if necessary.

  • Page 55: Yellow Printhead Error

    5056-XXX 930 - Yellow Printhead Error 930 Service Printhead Error Step Questions/actions Check to ensure that the cables between the LED Go to step 2. Properly connect printhead and the printhead controller board as well as the cables. the cables between the printhead controller board and the printer controller board are properly connected.

  • Page 56: Cyan Printhead Error

    5056-XXX 932 - Cyan Printhead Error Step Questions/actions Check to ensure that the cables between the LED Go to step 2. Properly connect printhead and the printhead controller board as well as the cables. the cables between the printhead controller board and the printer controller board are properly connected.

  • Page 57: Color Drum Sensor Error

    5056-XXX 934 - Color Drum Sensor Error 934 Service Drum Sensor Step Questions/actions Clean the color drum sensor LED. Problem solved. Go to step 2 Did this fix the problem? Swap the yellow photo developer with a different color Replace the Go to step 3.

  • Page 58: High-Capacity Feed Sensor Error

    5056-XXX 940 - High-Capacity Feed Sensor Error Step Questions/actions Is connector CN22 on the printer controller board Go to “High- Plug the connected properly? capacity feeder connector in (HCF) service securely. check” on page 2-53. 941 - High-Capacity Feed Tray Error Step Questions/actions Is connector CN22 on the printer controller board...

  • Page 59: Printer/Printhead Controller Board Communication Error

    5056-XXX 946 - Printer/Printhead Controller Board Communication Error 946 Service Communication Step Questions/actions Is CN03 on the printhead controller board or CN14 on Go to step 2. Connect cables. the printer controller board connected properly? Make sure all printhead LED EPROMS are present on Go to step 3.

  • Page 60: Machine Id Error

    5056-XXX 948 - Machine ID Error 948 Service Machine ID Step Questions/actions Turn the printer off, and wait 30 seconds. Turn the Problem solved. Verify proper printer on. Did this fix the problem? installation of the EPROMs on both the printer controller board and the printhead controller board.

  • Page 61: Mirror Mismatch

    5056-XXX 950 - Mirror Mismatch Step Questions/actions Is 950.xx(xx= 30 or greater) displayed? Go to step 2. Go to step 3 Replace the operator panel that was just installed with Problem solved. Contact your the original operator panel. Restart the printer. Did this Install a new technical support fix the problem?

  • Page 62: Processor Failure

    5056-XXX 956 - Processor Failure 956.00 Service System Board - RIP card failure: proces- sor failure 956.01 Service System Board - Pro- cessor overtemp Replace the RIP board. 957 - ASIC Failure Replace the RIP board. 958 - NAND Failure 958 Service NAND Failure Replace the RIP board.

  • Page 63: Unrecoverable Software Error In Network Port

    5056-XXX 976 - Unrecoverable Software Error in Network Port Software error. Go to the “Options service check” on page 2-68, 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.

  • Page 64: Belt Up/Down Sensor Error

    5056-XXX 981 - Belt Up/Down Sensor Error 981 Service Switch Error Step Questions/actions Is the engine code the latest level? Go to step 2. Update the printer with latest code level. If this does not resolve the problem, continue with step 2.

  • Page 65: Sensor Controller Error

    5056-XXX 982 - Sensor Controller Error 982 Service Sensor Control Step Questions/actions Turn the printer off, and wait 30 seconds. Turn the Replace the Problem solved. printer on. printer controller board. Is error 982 displayed? 983 - Black Gear Sensor Error 983 Service Gear Sensor Step...

  • Page 66: Transfer Belt Thermistor Error

    5056-XXX 985 - Transfer Belt Thermistor Error 985 Service Thermistor Error Step Questions/actions Are connectors CN407 and CN411 on the sensor Go to step 2. Plug the board connected properly? connector in securely. Is connector CN15 on the printer controller board Replace the Plug the connected properly?

  • Page 67: Service Paper Option

    5056-XXX 991 - Service Paper Option Step Questions/actions POR the printer. Does the error return? Go to step 2. Problem solved. Check connections CN3,4,5,17,18 on the printer Go to step 3. Properly connect controller board. Are they properly connected? the connectors. Are the size sensing levers bent or damaged? Replace the size Go to step 4.

  • Page 68: Density Sensor Error

    5056-XXX 994 - Density Sensor Error Step Questions/actions Is the front door fully closed? Go to step 2. Close the front door. Is the density sensor actuator stuck in place? Release the Go to step 3. density sensor actuator. Are connectors CN406 and CN407 on the sensor Go to step 4.

  • Page 69: Finisher Main Feed Motor Abnormal

    5056-XXX 995 - Finisher Main Feed Motor abnormal 995 Service Finisher Step Questions/actions Is there jammed paper or other obstructions in the Clear the paper Go to step 2. paper path? path. Check to ensure the connector PJ6 on the finisher Go to step 3.

  • Page 70: Finisher Tractor Motor Error

    5056-XXX 997 - Finisher Tractor Motor Error Step Questions/actions Are there obstructions or foreign objects in the Remove the Go to step 2. accumulator or face down paper path? objects or obstructions. Are the connectors CN3 at the tractor motor and PJ4 Go to step 3.

  • Page 71: Stapler Motor Error

    5056-XXX 999 - Stapler Motor Error Step Questions/actions Are staples jammed in the stapler? Go to step 2. Go to step 3. Clear the staple jam and run the staple test in Replace the Problem solved. diagnostic mode or run a staple job. Does the problem staple cartridge reoccur? and to go step 4.

  • Page 72: Attendance Messages

    5056-XXX Attendance messages Note: For more information on clearing paper jams, refer to “Clearing paper jams” on page 3-34. Message Meaning Action Activating Menu Changes The printer is activating changes Wait for the message to clear. made to the printer settings. All Photo Dev Life Warning All photodevelopers are nearing -Select Continue to clear the...
  • Page 73 5056-XXX Message Meaning Action Color Photo Dev Life Warning The color photodevelopers are -Select Continue to continue nearing the end of life. printing without replacing the color photodevelopers. -Replace the color photodevelopers. Copies Enter the desired number of copies. Defragmenting Flash The printer is defragmenting its Warning: Do not turn the printer off DO NOT POWER OFF...
  • Page 74 5056-XXX Message Meaning Action Enter PIN Enter the PIN you identified in the driver when you sent the confidential job to the printer. Enter PIN to lock Enter the correct pin number to lock the operator panel and prevent menu changes.
  • Page 75 5056-XXX Message Meaning Action Invalid Network <x> Code Download valid code to the printer internal print server. Note: You can download network code while this message is displayed. Invalid Engine Code The printer engine code has not Download valid engine code to the been programmed or is invalid.
  • Page 76 5056-XXX Message Meaning Action Menus are Disabled The printer menus are disabled. Note: You can still cancel a job, print You cannot change the printer a confidential job, or print a held job. settings from the operator panel. Network See action column. A network interface is the active communication link.
  • Page 77 5056-XXX Message Meaning Action Ready The printer is ready to receive and Send a job to print. process print jobs. Remote Management Active The printer settings are being DO NOT POWER OFF configured, and the printer was taken offline to ensure it is not currently printing and processing jobs.
  • Page 78 5056-XXX Message Meaning Action Replace Black Photo Dev The black photodeveloper is -Select Continue to clear the nearing the end of life and needs message and print without replacing replacing. the black photodeveloper. -Replace the black photodeveloper. Replace Fuser The fuser is nearing the end of life -Select Continue to clear the and needs replacing.
  • Page 79 1565 Emul Error The printer automatically clears Download the correct download Load Emul Option the message in 30 seconds, and emulator version from the Lexmark then disables the download Web site. emulator on the firmware card. 30 Coating roll missing...
  • Page 80 5056-XXX Message Meaning Action 34 Short Paper The paper used in a print job is -Select Continue to clear the too short in length for the current message and continue printing. print job. The printer does not automatically reprint the page that prompted the message.
  • Page 81 5056-XXX Message Meaning Action 40 Tray <x> size sense error The hi-cap feeder detects an error -Select Continue to clear the in the size sensing mechanism. message and continue printing. The job may not print correctly. -Cancel the current job. -Turn the printer off, check high capacity feeder connectors, then turn the printer on.
  • Page 82 5056-XXX Message Meaning Action 56 Parallel port <x> disabled Data has been sent to the printer -Select Continue to clear the through a disabled parallel port. message. 56 Std parallel port disabled The printer discards any data received through the parallel port. -Make sure the Parallel Buffer menu item is not set to Disabled.
  • Page 83 5056-XXX Message Meaning Action 63 Unformatted disk Self explanatory. -Select Continue to clear the message and continue printing. -Format the disk. If the error message remains, the hard disk may be defective and require replacing. 64 Unsupported disk format Self explanatory. -Select Continue to clear the message and continue printing.

  • Page 84: Clearing Finisher Messages

    5056-XXX Message Meaning Action 86 Abnormal coating roll The coating roller is damaged, or Replace the coating roll. performing abnormally. 88 <color> Toner is low Self explanatory. Replace the specified toner cartridge. Select Continue to clear the message and continue printing. 88 Replace <color>...

  • Page 85: Maintenance Analysis Procedures (Maps)

    5056-XXX Message Solution 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 2-54 check the no staple sensor. Insert Hole Punch Box Install the hole punch box. The printer will automatically clear the message.

  • Page 86: Map 4 - False Tray (X) Low/Empty Message

    5056-XXX Map 4 - False Tray (x) Low/Empty message Step Questions/actions Is the “Tray (x) Low” message present? Go to step 2. Go to step 4. Is the paper level flag on the rear of the cassette Repair or replace Go to step 3.

  • Page 87: Map 6 - False Print Unit Missing Message

    5056-XXX Map 6 - False <color> Print Unit Missing message Step Questions/actions Are all the toner cartridges and photodevelopers Go to step 3. Install the installed? missing cartridge photodeveloper. Did this fix the problem? Problem solved. Go to step 3. Are all connectors that the print unit photodeveloper Go to step 4.

  • Page 88: Map 8 - False 40 Tray (X) Size Sensor Error Message

    5056-XXX Map 8 - False 40 Tray (x) Size Sensor Error message Step Questions/actions On the high-capacity feeder, are the paper size Go to step 2. Replace the adjusting screws present on the upper portion of the missing side fence and fully screwed into the adjusting thumbscrew or bracket? screw them in all...

  • Page 89: Map 10 - Unrecoverable Check Tray (X) Or Duplex Connection Message

    5056-XXX Map 10 - Unrecoverable Check Tray (x) or Duplex Connection message Step Questions/actions Is the problem with a specific paper tray or the duplex Go to step 2. Go to step 8. unit? Is the problem with tray 1? Go to step 3.

  • Page 90: Map 11 - Paper Size Map

    5056-XXX Map 11 - Paper size map Step Questions/actions Do the paper size sensor actuators on the paper Go to step 2. Replace parts as operation tray operate correctly as you slide the paper necessary. location plate? Do the size sensor levers operate correctly? Go to step 3.

  • Page 91: Map 12 - Unable To Print From Usb Drive Service Check

    5056-XXX Map 12 - Unable to print from USB drive service check Step Questions / actions Is the file being printed, a supported format? Go to step 2. Try a supported file format. Is the USB drive properly inserted? Go to step 3. Properly insert the USB drive.

  • Page 92: Service Checks

    5056-XXX Service checks Drive 1 DC motor service check Action • DC motor If the motor does not attempt to turn, and you receive a 910 error code, replace the driver 1 dc motor. • Drive unit 1 • Printer controller board Be sure the toner and photodeveloper units are not causing an overload on the dc motor.

  • Page 93: Paper Feed Unit Service Check

    5056-XXX Paper feed unit service check Note: These tests can also be performed on the expansion paper-feed units. Action Turn guide door sensor • Turn the printer on. • Open the door. • Check the operator panel for “Close Door” message. Paper tray level motor •...

  • Page 94: Expansion Paper Feed Service Check

    5056-XXX Action Relay sensor • Bypass the turn guide door open sensor*. • Turn the printer on while holding down the paper relay sensor. - If the operator panel does not display “Paper Jam”, check for a dirty paper relay sensor. - If the paper relay sensor is clean, or the actuator for the paper relay sensor is broken, replace the sensor.

  • Page 95: High-Capacity Feeder (Hcf) Service Check

    5056-XXX High-capacity feeder (HCF) service check Action • Paper size sensors Go to “Sensor/Sw Test” on page 3-14, and perform the LED 1 and 2 sensor test. You can block each sensor to verify if it is working properly. Replace the failing sensor. •...

  • Page 96: Finisher Service Check

    5056-XXX Finisher service check Action • Input path sensor Note: For frequent jams, hole punch problems, or stapling problems, first check the finisher to printer alignment. Go to • Paper register sensor “Aligning the finisher and printer” on page 3-59. •...

  • Page 97: Marks On Paper Service Check

    5056-XXX Marks on paper service check If you have evenly spaced marks on the paper, measure the distance between the marks, and locate the symptom in the following table. Check the assembly for dirt or damage and clean as necessary. Run a test print to verify the problem has been corrected.

  • Page 98: Paper Carrying Service Check

    5056-XXX Paper carrying service check Paper has not exited or is stopped in the high-capacity feeder (area F, 249). Action • Paper feed roller Be sure the paper feed roller transfer roller, reverse roller, and call roller are free of dirt and are not damaged. Clean or replace parts •...
  • Page 99 5056-XXX Paper has stopped at the registration roller or has not reached the fuser (areas C, E, 250, 24x). Action • Registration roller Check these parts for wear or damage. Replace as necessary. Be clutch sure all guide surfaces in the paper path are free of dirt. •...
  • Page 100 5056-XXX Paper has entered the duplex unit (area D). Action Feed rollers Check for wear or damage to feed rollers and belts. Belts Duplex unit Be sure the duplex unit is properly installed and that all connections are correct. • Duplex stopper motor Be sure the stepper motor turns freely with no binding.
  • Page 101 5056-XXX Paper jammed in finisher (area H). Action “Aligning the finisher • Timing belts Check finisher to printer alignment. Go to and printer” on page 3-59. • Patting roller Check for obstructions in the paper path. Check all belts for wear or damage.

  • Page 102: Paper Exit, Face Up Service Check

    5056-XXX Paper exit, face up service check Action 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. Look for a fluctuation of between 0 V and +5 V between pins 1 and 2 of connector CN5 of the CK2 daughter board while actuating the sensor.

  • Page 103: Photodeveloper Missing Service Check

    5056-XXX Photodeveloper missing service check When you replace the photodeveloper unit, all three color units must be replaced at the same time. Action Photodeveloper Check for dirt or damage to the sensing contacts on the rear. Clean or replace the photodeveloper drum unit if necessary. Sub-frame unit Check the sensing contacts on the sub-frame assembly.

  • Page 104: Staple Jam Service Check

    5056-XXX 210 Staple jam service check Action Stapler Check for jammed staples in the stapler. Clear the staple jam, go into diagnostic mode, and run a staple test. If the problem recurs, Staple cartridge holder replace the staple cartridge holder. If this does not resolve the problem, replace the stapler.

  • Page 105: Image Quality Troubleshooting

    5056-XXX Image quality troubleshooting Print quality problems Problem Action Print is too light, or printed Be sure you’re using recommended paper or other media. Use media images or characters have from a new package. voids or dropouts. Be sure you have selected the correct Paper Weight setting for the media you’re using.
  • Page 106 5056-XXX Problem Action The page has 100% coverage Be sure the affected photodevelopers are completely installed in the of one color. 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.
  • Page 107 “Periodic dirt” on page 2-68. Quality of printed Be sure you’re using the recommended Lexmark transparencies. transparencies is inadequate. 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.

  • Page 108: No Image

    5056-XXX Problem Action Print on the page is skewed. Be sure the width guides in the paper tray or the multipurpose feeder fit snugly against the media you loaded. Be sure the charge roll or belt is seated properly. A white gap is noticeable Be sure all four corners of the printer are resting on a steady flat between color fills, due to poor surface.

  • Page 109: Black Print

    5056-XXX Black print Possible cause Action High voltage unit (HVU) The printed paper has black print. Be sure the high 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.

  • Page 110: Periodic Dirt

    5056-XXX 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.

  • Page 111: Hard Disk Option

    5056-XXX This service check is the same as the flash memory option service check with the following exception: Run the “DRAM Test” on page 3-10 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.
  • Page 112 5056-XXX 2-70 Service Manual...

  • Page 113: Diagnostic Aids

    5056-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 photodevelopers are never exchanged. Do not exchange a black photodeveloper for a color photodeveloper, as they have different surface phase counts.

  • Page 114: Understanding The Printer Operator Panel

    5056-XXX Understanding the printer operator panel The operator panel on your printer is a 4-line, back-lit, gray scale display that can show both graphics and text. The Back, Menus, and Stop buttons are located to the left of the display, the navigation buttons are located below the display, and the numeric pad is located to the right of the display.

  • Page 115: Printing The Menu Settings

    5056-XXX Button Function The display panel shows messages and graphics describing Display panel the current state of the printer and indicating possible printer problems you must resolve. The top line of the display is the header line. If applicable, it will contain the graphic indicating the Back button can be used.

  • Page 116: Menu Overview

    5056-XXX Menu overview SUPPLIES MENU PAPER MENU REPORTS Cyan Toner Default Source Menu Settings Magenta Toner Paper Size / Type Printer Statistics Yellow Toner Configure MP Network Setup Page Black Toner Profiles List Substitute Size Cyan PC Drum Paper Weight Network Setup Page Magenta PC Drum Paper Loading...

  • Page 117: Diagnostics

    5056-XXX Diagnostics Enter diagnostics mode by holding down the key and the key while PORing the printer. Release the keys when Performing Self Test displays on the screen. When the printer completes its startup, the following screen displays. Navigating the Diagnostics Menu The diagnostics menu is navigated by using the keys to scroll through the menus, and the key to select the items in the menu.
  • Page 118 5056-XXX Top Level Menus Intermediate Menu Items Output Bin Tests Feed Tests Feed To All Bins Sensor Tests Finisher Tests Staple Test Hole Punch Test Sensor/Sw Test Feed Tests Device Tests Quick Disk Test Disk Test/Clean Flash Test Printer Setup Defaults Light Quantity Color Page Count...

  • Page 119: Alignment

    5056-XXX Alignment Auto Alignment Use the key to navigate to the alignment menu item. Press to select alignment. Press to select the Auto Align test. Note: The printer will display Printer Calibrating while this test is running. Three alignment pages will print (Cyan, Magenta, Yellow).

  • Page 120: Print Tests

    5056-XXX Print Tests When “PRINT TESTS” is selected from the main Diagnostics menu, the printer’s panel displays “PRINT TESTS” in the header row. Below the header row in vertical order from top to bottom, the panel displays each installed input source on its own line. “Prt Quality Pages” appears as the very last option in the list. “[Input Source]”...

  • Page 121: Button Test

    5056-XXX Button Test The Button Test is used to verify the operation of each button on the operator panel. When this option is selected, the following is displayed: When a user presses a physical button on the panel, an “X” appears over that button’s graphic on the operator panel.

  • Page 122: Dram Test

    5056-XXX DRAM Test The DRAM Test is used to check the validity of both the printer’s standard and optional DRAM. The test involves writing patterns of data to DRAM to verify that each bit in memory can be set and read correctly. When a user selects this test, the panel displays “DRAM Test Testing...”, then posts “Resetting the Printer”...
  • Page 123 5056-XXX If a test fails, one of the following errors will display: • Sync Busy Error • Byte Interrupt Request Error • Strobe Interrupt Request Error • Init Fall Error • Init Busy Error • Init Rise Error • Host Busy Error •...

  • Page 124: Serial Wrap Test

    5056-XXX Serial Wrap Test The Serial Wrap Test is used to check the operation of the serial port hardware using a wrap plug. Each serial signal is tested. To perform the wrap test, follow these steps: Disconnect the serial interface cable, and install the serial wrap plug. Select “HARDWARE TESTS”...

  • Page 125: Output Bin Tests

    5056-XXX Output Bin Tests Feed Tests (Output Bin) This test is used to verify that media from the device’s default input source can be fed to a specific output bin. No information is printed on the feed test pages. Note: The feed test can be run using any of the supported paper and envelope sizes. Each of the printer’s installed bins appears as an option within this menu.

  • Page 126: Finisher Tests

    5056-XXX Finisher Tests Feed Test This test feeds one sheet of media from the device’s default input source to a finisher output bin. The device can perform this test using any paper size that is supported by the finisher. No information is printed on the test page.

  • Page 127: Staple Test

    5056-XXX The sensor tests are divided into these three groups: • Finisher device sensors: — Elev Lower Limit — Elev Upper Limit — Fin Set Switch — No Staple — Punch Box Detect — Staple Home Pos — Staple Cart Set •...

  • Page 128: Device Tests

    5056-XXX Device Tests Quick Disk Test This test will perform a non-destructive read/write on one block per track on the disk. While this test runs, the power indicator light blinks green, and the panel displays “Quick Disk Test Testing...”. This test cannot be canceled. When the test finishes, the panel posts either “Quick Disk Test Test Passed”...

  • Page 129: Printer Setup

    5056-XXX Printer Setup Defaults The value of this setting determines whether the printer uses the US or Non-US factory default value for the following printer settings: Printer Setting US value Non-US value Paper Sizes Letter (Paper feeding sources which do not have hardware size sensing capability) Envelope Size 10 Envelope...

  • Page 130: Serial Number

    Use the configuration ID to communicate characteristics of the printer that cannot be determined by the hardware sensors. The configuration ID is originally set when the printer is manufactured, The C920 uses 2 Configuration IDs, each of which consists of 8 digits. When Configuration ID is selected from the PRINTER SETUP menu, the current ID is displayed: The Configuration ID menu item allows you to set both Configuration ID settings for the printer.

  • Page 131: Reset Color Calibration

    5056-XXX When you are finished setting the configuration ID, press the key. This will save the setting. Note: Do not press the Back key before pressing the key. Doing this will result in the new setting not being saved. After one or both configuration ID settings are saved, the printer will not POR. After saving the new configuration ID, press the Back key to return to the Printer Setup menu.

  • Page 132: Event Log

    5056-XXX Event Log Display When “Display Log” is selected, the panel posts, “Display Log” in the header row and up to the first three log entries in the area below the header row. Each logged event is identified by the panel text that appeared when the event occurred.

  • Page 133: Configuration Menu

    5056-XXX Configuration menu To enter the configuration menu, POR the printer holding down the key and the key until the operator panel displays “Performing Self Test”. The configuration menu can be navigated by pressing the keys, and then pressing the key to select the item.

  • Page 134: Factory Defaults

    5056-XXX Factory defaults Enables a user to restore all the printer’s settings to either network or base printer settings. When “Restore Base” is selected, all non-critical base printer NVRAM settings are restored. When “Restore Network” is selected, all network NVRAM settings are restored to their factory default values. To restore default settings, use the key or to scroll to the base or network defaults and press the...

  • Page 135: Jobs On Disk

    5056-XXX Jobs on disk This setting only appears if there is a disk installed on the machine. Jobs on disk is used to delete buffered jobs that are on the hard disk. This option appears even if there are no buffered jobs on the disk. The values for this setting are delete and do not delete (default).

  • Page 136: Theory Of Operation

    5056-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 (EP) process, 6 steps take place to image toner on the page: Charge Expose...

  • Page 137: Transfer Unit

    5056-XXX As the photodeveloper rotates, it comes into contact with toner on the development roll of the cartridge. Due to the charge differences between the electrostatic image and the rest of the surface of the photodeveloper, toner will only cling to the electrostatic image created by the light from the LED printhead. Transfer unit Paper is fed onto the transfer belt by the registration rollers while the belt rotates at the same speed as the photodevelopers.

  • Page 138: Fusing

    5056-XXX Fusing Once the paper has been imaged, the paper is detached from the transfer belt by the separation fingers. After separation, it enters the fuser where heat and pressure are applied to the paper. The toner is melted and bonded to the fibers of the paper.
  • Page 139 5056-XXX After completing the fusing process, paper is discharged from the printer. The delivery sensor detects the paper, and the FU/FD deflector switches between the face-up and face-down paper delivery. As the paper passes through the fuser, it pulls down the sensing lever and turns on the delivery sensor. If the delivery unit remains on longer than specified, the printer controller determines that the printer is jammed.

  • Page 140: Drive System

    5056-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.

  • Page 141: Paper Feeding

    5056-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.

  • Page 142: Multipurpose Feeding

    5056-XXX Multipurpose feeding The multipurpose feed clutch turns on when a signal is received by the printer controller board. The multipurpose feed roll is interconnected with drive unit 1 by a spring clutch. When the signal is received to print, the clutch engages and rotates the pick roller to feed paper.

  • Page 143: Belt Unit

    5056-XXX Belt unit The transfer belt acts as a transport for the paper as it is carried from the registration rollers, underneath the photoconductor drums, and finally to the fuser. The paper is held to the belt by an electrostatic charge that is applied by a charge roller located inside the transfer belt.

  • Page 144: Delivery

    5056-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.

  • Page 145: Paper Weight

    5056-XXX Paper weight Purpose: This menu selection is used to set the paper weight for each of the defined media types. This allows the printer to optimize the print quality for the media weight. This menu can be accessed in the Paper Menu in normal mode.

  • Page 146: Clearing Paper Jams

    5056-XXX Clearing paper jams 200 Paper Jam This message identifies the areas (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 A—B: Open the front door.
  • Page 147 5056-XXX Slowly pull the paper out toward the inside of the printer. If the paper jam is difficult to remove, let the fuser cool down, and remove the fuser. Unscrew the two thumbscrews and open the jam access door on the fuser to remove the jam Rotate the fuser pressure release lever down.

  • Page 148: Paper Jam

    5056-XXX Check Area E This message indicates a paper jam in the top, middle, or bottom optional drawer paper path area. To clear area E: Note: If you have a high-capacity feeder, pull it away from the printer. Open the jam access door on the top optional drawer. Remove the jam.

  • Page 149: Paper Jam

    5056-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: If you have a high-capacity feeder, pull it away from the printer.

  • Page 150: High-Capacity Feeder (Hcf)

    5056-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.

  • Page 151: Tray Up/Down Mechanism

    5056-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.

  • Page 152: Tray Up Condition

    5056-XXX When the down button is pressed, the tray motor reverses to move the tray down. During the down motion of the tray, as the top surface of paper passes the paper level sensor, the tray motor stops. The tray moves down by about 500 sheets.

  • Page 153: Size Detection Mechanism

    5056-XXX 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.

  • Page 154: Residual Paper Detection Mechanism

    5056-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 •...

  • Page 155: Maintenance Mode

    5056-XXX 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 Description switch 1 Standard machine initial setting 2 Optional machine initial setting...

  • Page 156: Finisher

    5056-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. •...

  • Page 157: Finisher Cross Section

    5056-XXX Finisher cross section Straight Exit Idle Roller Paddle Roller Upper Tray Path Select Gate Straight Exit Roller Register Idle Invert Exit Roller Idle Roller Input Paper Guide Lower Tray Invert Exit Roller Register Roller Accumulator Stapler Unit Electrical parts function •...

  • Page 158: Paper Feed Mechanism

    5056-XXX Paper feed mechanism Paper is transported, after it is detected at paper register sensor by drive gears and drive 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) The paper feed motor drives and rotates rollers.

  • Page 159: Inverting Paper Path (Exit Paper To Lower Tray Through Accumulator)

    5056-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 the jogging bar and driven by the belt drive motor before exiting to the lower tray (accumulator).

  • Page 160: Paper Registration Sequence

    5056-XXX 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.

  • Page 161: Jogging / Offset Mechanism

    5056-XXX Jogging / offset mechanism 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.

  • Page 162: Stapling Mechanism

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

  • Page 163: Elevator Sequence

    5056-XXX 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.

  • Page 164: Finisher Installation

    5056-XXX Finisher installation Attaching the docking plate and guide rail Lift the printer exit tray halfway and remove. You will need the tray when the finisher is attached. Insert the docking plate tabs into the printer. Align the thumbscrews on the docking plate with the holes in the side of the printer. Tighten the docking plate thumbscrews.
  • Page 165 5056-XXX Tighten the guide rail plate thumbscrews. Align the thumbscrews on the guide rail with the holes in the guide rail plate. Tighten the guide rail thumbscrews. 3-53 Diagnostic aids...

  • Page 166: Combining The Finisher And Stand

    5056-XXX Combining the finisher and stand Roll the finisher stand onto the guide rail. Do not push the stand all the way up against the printer. Docking Plate Pins Remove and discard all shipping tape, packing material, and the metal shipping bracket. CAUTION: When assembled, the finisher weighs 26.3 kg (56.9lb) and requires at least two people to lift it safely.).
  • Page 167 5056-XXX Open the stapler door. Remove all shipping tape and packing material. Lift the stapler locking lever. Raise the stapler. Remove all shipping tape and packing material. 3-55 Diagnostic aids...
  • Page 168 5056-XXX Close the stapler. Close the stapler door. 3-56 Service Manual...
  • Page 169 5056-XXX Align the two sockets on the bottom of the finisher with the legs of the finisher stand. Lower the finisher onto the finisher stand. CAUTION: When assembled, the finisher weighs 26.3 kg (56.9lb) and requires at least two people to lift it safely.

  • Page 170: Attaching The Bins

    5056-XXX Attaching the bins Align the slots on bin 2 with the metal brackets on the rear of the finisher. 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. Align the tabs on bin 1 with the slots on the rear of the finisher.

  • Page 171: Aligning The Finisher And Printer

    5056-XXX Aligning the finisher and printer The following three areas must align properly to prevent paper jams. The docking plate pins must enter the holes in the finisher. The space between the printer and finisher must be the same at the top and bottom of the finisher. The alignment marks on top of the finisher must align with the edges of the cover on the side of the printer.

  • Page 172: Lowering Or Raising The Finisher

    5056-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. Determine if the pins are above or below the holes in the finisher. Alignment Marks Spacing Hole in Finisher Loosen the guide rail thumbscrews.
  • Page 173 5056-XXX 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”...

  • Page 174: Aligning The Sides Of The Finisher

    5056-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. Loosen the guide rail thumbscrews. If you previously lowered or raised the guide rail plate, the thumbscrews are already loose. 3-62 Service Manual...

  • Page 175: Aligning The Top Of The Finisher

    5056-XXX 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. Roll the finisher toward the printer until the finisher locks to the docking plate pins.

  • Page 176: Adjusting The Wheels

    5056-XXX Roll the finisher toward the printer until the finisher locks to the docking pins. You hear a click when the finisher locks into position. Adjusting the wheels Adjust the wheels on the end of the finisher so the stand remains aligned when moved. To adjust and lock the wheels: Rotate the left and right upper adjustment knobs on the rear wheels until the wheels touch the floor.

  • Page 177: Attaching The Cables

    5056-XXX Rotate the locking knobs counterclockwise until they contact the finisher base. 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. Turn the printer off, and unplug the power cord from the power outlet.

  • Page 178: Interface Cable

    5056-XXX Interface cable CAUTION: Make sure the printer is turned off before continuing. Plug the interface cable into the bottom connector on the back of the printer. Tighten the thumbscrews. Plug the interface cable into the connector on the side of the finisher. The plug will be on a slight angle when connected.

  • Page 179: Power Cable

    5056-XXX Power cable Unplug the power cord from the side of the printer. Set the cord aside. Plug the straight Y-power cord connector into the socket on the side of the finisher. Plug the angled connector of the Y-power cord into the socket on the side of the printer. Connect the previously removed printer power cord to the Y-power cord.
  • Page 180 5056-XXX Firmly press the adhesive-backed cable holder onto the back of the top optional drawer. Place the finisher interface cable and power cord into the cable holder. Close the cable holder. Replug the power cord into the outlet, and turn the printer on. The finisher does not have a power switch.

  • Page 181: Hole Punch Adjustment

    5056-XXX Hole punch adjustment You can adjust the hole punch alignment by approximately 4 mm (3/16 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.
  • Page 182 5056-XXX 3-70 Service Manual...

  • Page 183: Repair Information

    5056-XXX 4. 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: •...

  • Page 184: Rip Board/Operator Panel Replacement

    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. Replace the RIP card first. Note: Do not replace the new operator panel and RIP card in the machine at the same time. After installing the new RIP card, and before installing the new operator panel, start the printer.

  • Page 185: Check Finisher Alignment When Moving Or Servicing The Finisher

    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”...

  • Page 186: Adjustments

    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. Adjustments and procedures following parts replacement Note: When troubleshooting, or prior to making any adjustment to print quality, always be sure: •...

  • Page 187: Transfer Belt

    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.

  • Page 188: Removals

    5056-XXX Removals Cover, top removal Open the top unit, and remove the photodevelopers and toner cartridges. Cover the photodevelopers to avoid damage from exposure to the light. Remove 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.

  • Page 189: Front Door / Operator Panel Removal

    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. Replace the RIP card (this must be the first part replaced).

  • Page 190: Cover, Front Left Removal

    5056-XXX Remove six screws (C) that hold the operator panel to the front door. 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.

  • Page 191: Cover, Rear Removal

    5056-XXX Cover, rear removal Open the top unit. Remove the three silver screws from the rear cover, and then remove the cover. Cover, solenoid removal Remove the screw from the solenoid cover. Remove the solenoid cover. Cover, left side removal Remove the upper cassette, front cover, paper exit tray, and duplex unit.

  • Page 192: Cover, Right Side Removal

    5056-XXX Cover, right side removal Open the top unit, and remove the front cover and upper cassette. Remove the operator panel cable and the USB cable from the operator panel. (See “Front door / operator panel removal”.) Remove the seven screws from the right side cover together with the turn guide, and remove the cover. When installing the right side cover, insert the turn guide shaft into the bearing.

  • Page 193: Cover, Rip Board Removal

    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.

  • Page 194: Tray, Paper Exit Removal

    5056-XXX Tray, paper exit removal Unlatch the hinge at the back side, then unlatch the hinge on the front side. Remove the paper exit tray. Belt up/down clutch removal Remove the RIP cover, electronic box, printer controller card, and HVPS board. Unplug the belt up/down clutch cable from CN1 in the CK1 daughter card board.

  • Page 195: Cassette Guide Removal

    5056-XXX Cassette guide removal Remove the paper feed frame. Remove the front cover, cassette, turn guide, right side cover, and paper feed frame. Remove the screws from the cassette guide, and remove the guide. CK1 daughter board removal Remove the front, right, left rear, and rear covers. Remove printer controller board and HVPS board.

  • Page 196: Connector, Duplex Unit Removal

    5056-XXX Connector, duplex unit removal 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.

  • Page 197: Drive Gear Unit Sensor Assembly Removal

    5056-XXX Density sensor removal/Separation fingers removal/Sensor cleaner removal Open the top unit and remove the belt unit. Remove the three screws from the sensor bracket. Remove the harness band and remove the two screws from the density sensor from the sensor bracket. Remove the three set screws from the sensor cleaner assembly from the sensor bracket.

  • Page 198: Electronic Box Removal

    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. Disconnect all cables from the rear of the electronic box, and remove the box. 4-16 Service Manual...

  • Page 199: Face Up Paper Exit Assembly Removal

    5056-XXX Face up paper exit assembly removal Open the top unit, and remove the upper cassette. Open the duplex cover, and remove the duplex unit. Remove the left front cover, left side cover, and rear cover. Remove the three screws from the face up delivery assembly, and remove the assembly. Front cover open switch actuator removal Open the front cover.

  • Page 200: Fuser Removal

    5056-XXX Fuser removal Open the top unit. Pushing the front and back lock, hold the handle, and then raise and remove the fuser. 4-18 Service Manual...

  • Page 201: Gear Cover Removal/Multipurpose Feeder Frame Assembly

    5056-XXX Gear cover removal/Multipurpose feeder frame assembly Open the top unit, and remove the upper cassette, front cover, multipurpose feeder, right side cover, and turn guide. Remove the two screws from the gear cover, and remove the cover. Remove the four screws from the multipurpose feeder frame and the ground screw. Disconnect the connector of the multipurpose feeder paper feed sensor.

  • Page 202: High Voltage Power Supply Board (Hvps) Removal

    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. Open the top unit, and remove the RIP cover, RIP board, RIP box, electronic box, and printer controller board.

  • Page 203: Eraser Removal

    5056-XXX Disconnect the affected LED printhead connectors from the printhead controller board. Remove the screw from the ground wire located on the LED printhead. 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.

  • Page 204: Lock Handle Assembly Removal

    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. 4-22 Service Manual...

  • Page 205: Main Drive Unit Removal

    5056-XXX Main drive unit removal 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.
  • Page 206 5056-XXX Remove the screw from the clutch stopper. The clutch stopper is attached to the ground plate with two screws. Remove the six screws on the right side. Remove the two screws from the drive unit, and remove the unit. Remove the E-clip on the belt up/down clutch, and remove the changing shaft from the drive unit.

  • Page 207: Main Unit Fan Removal

    5056-XXX Main unit fan removal Remove the left side cover, the solenoid cover, and the rear cover. Remove the LVPS (low voltage power supply) 1. Remove two screws from the main unit fan bracket. Disconnect the fan power cable from CN6 on the CK2 daughter card board. Remove the fan.

  • Page 208: Multipurpose Feeder Tray Removal

    5056-XXX Multipurpose feeder tray removal Open the top unit, and remove the front cover, cassette feeder, turn guides and right side cover. Open the multipurpose feeder and slide it toward the magnet in the direction of the arrow, removing it from the printer.
  • Page 209 5056-XXX Remove the paper feed gear unit, paper feed clutch, and two gears (C) not held in place with an E-clip. Remove the 3 screws (D), and remove the cassette guide. Remove the brass screws (E) on the left side of the paper feed unit. Remove the paper feed unit, being careful to route the sensor cabling through the wire guides.

  • Page 210: Paper-Feed Rollers Removal

    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 40X1...

  • Page 211: Paper Carrying Frame Removal / Roll Removal

    5056-XXX Paper carrying frame removal / roll removal 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.

  • Page 212: Registration Frame

    5056-XXX Registration frame Registration clutch removal Open the top unit, open the turn guide, open the paper feed cover, and pull out the duplex unit halfway. Remove the two screws from the registration frame. Remove the registration clutch. Note: When installing, set the clip of the registration clutch to the stopper. Registration sensor removal Open the top unit, and remove the upper cassette, front cover, turn guide, multipurpose feeder, right side cover, and multipurpose feeder frame.

  • Page 213: Relay Roller Removal

    5056-XXX Relay roller removal Note: This removal can be used for the expansion paper-feed unit relay roller removal as well. Remove the paper feed unit from the machine. Remove the e-clips and bushings from each end of the relay roller shaft. Remove the five screws (A) that hold the top metal plate on the unit.

  • Page 214: Face Down Guide Assembly Removal

    5056-XXX Face down guide assembly removal Remove the top cover. Disconnect the connector, and remove the five screws and two snap bands from the face down guide assembly. Remove the four screws from the face down cover and the face down guide assembly, and remove the assembly.
  • Page 215 5056-XXX Remove the rear cover. Remove the motor and drive belt from the exit roller shaft. Remove the grounding strip (A). 4-33 Repair information...
  • Page 216 5056-XXX Remove the e-clips and bushings (A) from both ends of the exit roller shaft. Pull the guide rib (A) to the left. 4-34 Service Manual...

  • Page 217: Power Supply 1 Removal

    5056-XXX 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.

  • Page 218: Power Supply 2 Removal

    5056-XXX Power supply 2 removal Unplug the power cord from the printer. Open the top unit, and remove the RIP cover, RIP board, RIP box, and electronic box. Disconnect the connector, and remove the seven screws from power supply 2, and remove the power supply.

  • Page 219: Power Switch Removal

    5056-XXX Power switch removal Remove the upper cassette, left front cover, paper feed cover, and left side cover. Unlock the power switch, and pull out the power switch. 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.

  • Page 220: Printhead Controller Board Removal

    5056-XXX Printhead controller board removal Remove the top cover, and then remove the 20 printhead controller board connectors. Remove the six screws from the printhead controller board and remove the board. Note: When replacing the board, be sure to return the four EEPROMs on the former board to the same positions on the new board.

  • Page 221: Left Slide Rail Removal

    5056-XXX Left slide rail removal Remove the upper cassette. Remove the screw from both left and right slide rails. RIP box removal Remove the six screws from the RIP box. Slightly lift and remove the RIP box. 4-39 Repair information...

  • Page 222: Sensor Board Removal

    5056-XXX Sensor board removal Remove the transfer belt unit. Remove the four connectors. Remove the three screws from the waste toner full sensor board. Stay arm removal Open the top unit, and remove the face down paper guide assembly. Remove the yellow and black sub frame. Remove the screw from the right stopper, and remove the stopper.

  • Page 223: Sub-Frame Removal

    5056-XXX Sub-frame removal Important: Read the entire procedure before removal. 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.

  • Page 224: Sub Frame F1, Sub Frame F2 Removal

    5056-XXX Sub frame F1, sub frame F2 removal Open the top unit. 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.

  • Page 225: Top Unit Removal

    5056-XXX Top unit removal Open the top unit, and remove the top cover and face-down guide assembly. 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.
  • Page 226 5056-XXX Loosen the thumbscrews as shown. Lift and remove the transfer belt cover. 4-44 Service Manual...
  • Page 227 5056-XXX Loosen the thumbscrews as shown. Press down on the transfer belt release lever as shown. 4-45 Repair information...
  • Page 228 5056-XXX Pull the transfer belt out. After replacing the transfer belt and removing the four shipping spacers, tighten the transfer belt thumbscrews, and reinstall the transfer belt cover. Close the top unit, rotate the locking lever to the right, and close the front cover. Turn the printer on.

  • Page 229: Turn Guide Cover Sensor Removal

    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. Upper fan removal Open the top unit, and remove the toner cartridges and photodeveloper drum units, top cover, and face- down guide assembly.
  • Page 230 5056-XXX Remove the two screws from the left fan, and remove the fan. Remove the two screws from the right fan, and remove the fan. 4-48 Service Manual...

  • Page 231: Expansion Feeder Removals

    5056-XXX Expansion feeder removals Turn guide door removal Open the turn guide door. Pull the door hinge from the right turn guide bushing. Pull the turn guide door clear of the expansion feeder. Expansion feeder controller board removal Remove six screws from the expansion feeder rear cover. Unplug all cables from the expansion feeder controller board.

  • Page 232: Stepper Motor Removal

    5056-XXX Stepper motor removal Remove the expansion feeder rear cover. Disconnect the stepper motor power cable from the expansion feeder controller board. Remove three screws from the stepper motor assembly (A). Remove the stepper motor assembly from the expansion feeder. 4-50 Service Manual...

  • Page 233: Paper Feed Assembly Removal

    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 controller board. Remove the screws (A) holding the paper feed gear assembly. Remove the gear assembly (B) and the paper feed clutch (C).

  • Page 234: Paper Tray Lift Motor Removal

    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). Remove the paper tray lift motor. Expansion feeder turn guide door sensor assembly removal Remove the rear cover.

  • Page 235: Duplex Removals

    5056-XXX Duplex removals Duplex unit separation removal Remove the thumbscrews, C-clips, and screws as shown from both sides. Remove the connectors, and separate the duplex frame from the duplex unit. 4-53 Repair information...

  • Page 236: Duplex Unit Removal

    5056-XXX Duplex unit removal Remove the four screws from the interface board, and remove the board. Remove the two screws from the duplex connector, and remove the connector. Duplex timing belt removal Remove the three C-clips from the three timing gears, and remove the timing belts. Remove the knob screw, and remove the timing belt.

  • Page 237: Duplex Pressure Roller And Solenoid Removal

    5056-XXX Duplex pressure roller and solenoid removal Remove the two screws securing the pressure roller solenoid assembly. Duplex feed roller and solenoid removal Remove the two screws securing the feed roll solenoid assembly. Remove the pressure roller and springs. Remove the feed roller and springs. 4-55 Repair information...

  • Page 238: Duplex Side Fence Motor Assembly/Side Fence Removal

    5056-XXX Duplex side fence motor assembly/side fence removal Remove the three screws, and remove the side fence motor assembly. 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...

  • Page 239: Duplex Paper Carrying Motor Removal

    5056-XXX Duplex paper carrying motor removal Remove the gear cover. Remove the screws from the duplex paper carrying motor, and remove the motor. 4-57 Repair information...

  • Page 240: High-Capacity Feeder (Hcf) Removals

    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 the rear cover.

  • Page 241: Hcf Call Roller, Paper Feed Roller, Reverse Roller Removal

    5056-XXX HCF call roller, paper feed roller, reverse roller removal Open the top cover on the tray. Remove the two screws from the transfer cover, and remove the cover. Remove the retaining rings on the rollers, and remove the rollers. HCF pickup solenoid removal Remove the four screws from the transfer cover, and remove the cover.

  • Page 242: Hcf Paper End Sensor Removal

    5056-XXX HCF paper end sensor removal HCF paper size sensors (1, 2) removal 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.

  • Page 243: Hcf Tray Motor Removal

    5056-XXX Remove the top cover switches. White Blue Top Cover Switch 1 Blue Green Yellow Black Top Cover Switch 2 HCF tray motor removal Remove the rear cover and the drive cover. Remove the two screws of the tray motor, and remove the motor. 4-61 Repair information...

  • Page 244: Hcf Paper Level Sensor Removal

    5056-XXX HCF paper level sensor removal Remove the four screws from the transfer cover, and remove the cover. Remove the two screws from the sensor, and remove the cover. Remove the connector and screw from paper level sensor, and remove the sensor. HCF power supply removal Move the paper tray upward.

  • Page 245: Finisher Removals

    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”...

  • Page 246: Finisher Control Board Removal

    5056-XXX Remove the two screws from the top cover, and remove the cover. Finisher control board removal Remove the external covers. Disconnect all of the associated connectors. Remove the four finisher control board mounting screws, and remove the board. 4-64 Service Manual...

  • Page 247: Elevator Motor Removal

    5056-XXX Elevator motor removal Disconnect the elevator motor connector. Remove the two elevator motor bracket screws from the bracket. Remove the elevator motor assembly. Feed motor assembly removal Remove the finisher control board mounting bracket. Loosen the tension bracket mounting screw. Disconnect the feed motor connector.

  • Page 248: Hole Punch Removal

    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. 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.

  • Page 249: Inverter Paper Exit Discharge Brush Removal

    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. Inverter paper exit roller removal Remove the front and rear external covers. Remove the four lower left panel screws, and remove the panel.

  • Page 250: Jogging Unit Removal

    5056-XXX Remove the inverter idle gear. Remove the inverter drive gear and bushing. Remove the inverter paper exit roller. Jogging unit removal Remove the dust box. Remove the two screws, and remove the cover. Disconnect the jogging motor connector. Disconnect the jogging home position sensor connector. Remove the jogging unit.

  • Page 251: Path Select Gate Removal

    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.

  • Page 252: Patting Roller Removal

    5056-XXX Patting roller removal Remove the front and rear covers. Remove the finisher control board mounting bracket. Remove the two screws from the upper left panel, and remove the panel. Disconnect the sensor connector. Remove the sensor harness from the harness clamp. Remove the four upper guide plate screws from the inverter paper exit, and remove the plate.
  • Page 253 5056-XXX Remove the tension springs. Use the upper hole when installing the spring. Remove the gear and bushing. Remove the patting roller. Patting Roller 4-71 Repair information...

  • Page 254: Power Supply Removal

    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. Remove the two power supply screws.

  • Page 255: Registration Roller Removal

    5056-XXX Registration roller removal Remove the hole punch unit. Remove the registration roller clutch. Remove the registration roller bushing. Remove the registration roller. Registration roller clutch removal Remove the harness from the clamp. Remove the three control board mounting bracket screws, and remove the bracket. Remove the registration roller clutch set screw.

  • Page 256: Stack Area Discharge Brush Removal

    5056-XXX Stack area discharge brush removal Remove the dust box. Remove the stack area discharge brushes. Staple unit removal Remove the staple unit connector. Pull outward on the staple cover, and remove the staple unit. 4-74 Service Manual...

  • Page 257: Straight Paper Exit Discharge Brush Removal

    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. Straight paper exit roller removal Remove the external covers.
  • Page 258 5056-XXX Remove the rear straight paper exit roller E-ring and bushing. Remove the straight paper exit roller. 4-76 Service Manual...

  • Page 259: Timing Belts 1 And 2 Removal

    5056-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. Loosen the tension bracket mounting screw for timing belt 2. Remove the timing belt 2.

  • Page 260: Tractor Belt Removal

    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. Remove the tension spring from the shaft. Remove the paper jam removal knob.

  • Page 261: Tractor Drive Motor Assembly Removal

    5056-XXX 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 Remove the outer covers. Remove the drive belt. Remove the three screws, and disconnect the connector from the tractor drive motor assembly.
  • Page 262 5056-XXX 4-80 Service Manual...

  • Page 263: Locations

    5056-XXX 5. Locations Covers diagram Locations...

  • Page 264: Major Parts Diagram

    5056-XXX Major parts diagram Number Part Number Part Development roll Paper feed roll separator Supply roll Duplex unit Doctor blade Transfer sheet Agitator Transfer belt Absorption roll Belt drive roller Registration roll upper Paper delivery detection lever Registration roll lower Press roller Registration sensor Heater...

  • Page 265: Sensor And Switch Locations

    5056-XXX Sensor and switch locations Locations...

  • Page 266: Component Locations

    5056-XXX Component locations Number Component Number Component Printhead controller board Main unit fan Operator panel Power supply 2 Motor driver board CK2 daughter board Power switch Expansion paper feed controller Sensor board Paper size detector board (expansion paper feed option) MPF clutch Power supply 1 Registration clutch...

  • Page 267: Printer Controller Board

    5056-XXX Printer controller board Locations...

  • Page 268: Printer Controller Board Connectors

    5056-XXX Printer controller board connectors The connectors are listed in numerical order. 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 wires of various numbers and colors.

  • Page 269: Printhead Controller Board

    5056-XXX Print controller board connectors (continued) Board Cable Conn # Orientation connector connector # Wires Wire color Connector color color CN16 Horizontal White White • Brown Duplex unit • Red • Orange • Yellow • Blue • Purple • Gray •...

  • Page 270: Printhead Controller Board Connectors

    5056-XXX Printhead controller board connectors Board Cable Conn # Orientation connector connector # Wires Wire color Connector color color CN01 White • 2 green RIP board • 2 blue • 2 red • 2 yellow CN02 White • 35 blue RIP board •...

  • Page 271: Ck1 Board Connectors

    5056-XXX CK1 board connectors Board Cable Conn # Orientation connector connector # Wires Wire color Connector color color Vertical Magenta • 2 red Lower OHP Vertical Green Green • 3 green Upper OHP Vertical White White • 3 white Registration sensor •...

  • Page 272: Ck2 Board Connectors

    5056-XXX CK2 board connectors Board Cable Conn # Orientation connector connector # Wires Wire color Connector color color Horizontal • 8 green Controller board Horizontal • 12 green Controller board Horizontal Magenta • 2 red Duplex Horizontal Green Green • 2 green Face up Horizontal White...

  • Page 273: Rip Board

    5056-XXX RIP board RIP board connectors Connection # Wires Wire colors Connects to Black, red, yellow Rip box fan Parallel port Ethernet port Memory Memory USB port 3 yellow, 1 brown, 3 LVPS 2 purple, 7 black Green, 2 blue, 2 red, 2 Printhead controller yellow 35 blue, 1 white...

  • Page 274: Lvps 1 Board Connectors

    5056-XXX LVPS 1 board connectors CN106A CN01 Cable Board Conn # Orientation connector connector # Wires Wire color Connector color color CN01 White White • Red Main switch • White • Blue • Black CN04A White White • Black LVPS 2 •...

  • Page 275: Lvps 2 Board Connectors

    5056-XXX LVPS 2 board connectors Board Cable Conn # Orientation connector connector # Wires Wire color Connector color color CN02 Horizontal White White • Red Fuser • White • Black CN03 Horizontal White White • Black Motor drive board • White CN104 Horizontal White...

  • Page 276: High Voltage Power Supply Board

    5056-XXX High voltage power supply board Sensor board connectors Board Cable Conn # Orientation connector connector # Wires Wire color Connector color color CN406 White White • Brown Density sensor • Blue • Black CN407 White White • 1 white Printer controller •...

  • Page 277: Expansion Paper Feeder Controller Board

    5056-XXX Expansion paper feeder controller board 5-15 Locations...

  • Page 278: Duplex Unit Controller Board

    5056-XXX Duplex unit controller board Motor drive board connectors Board Cable Conn # Orientation connector connector # Wires Wire color Connector color color Horizontal White White • White Motor • Black • Red Horizontal White White • White Motor • Yellow •...

  • Page 279: Size Sensor Board

    5056-XXX Size sensor board 5-17 Locations...

  • Page 280: Paper Feed Actuators

    5056-XXX Paper feed actuators Paper tray present actuator Paper out actuator Paper feed roller clutch 5-18 Service Manual...

  • Page 281: High-Capacity Feeder (Hcf)

    5056-XXX High-capacity feeder (HCF) Paper End Sensor Up Sensor Paper Size Sensor 1,2 Paper Feed Motor Pickup Solenoid Paper Feed Roller Call Roller Paper Feed Sensor Near End Sensor Residual Paper Sensor 1 Transfer Roller Residual Paper Sensor 2 Reverse Roller Tray Paper Level Sensor Tray Driving Belt...

  • Page 282: Electrical Parts Layout

    5056-XXX Electrical parts layout Driving parts layout 5-20 Service Manual...

  • Page 283: Finisher Locations

    5056-XXX Finisher locations 5-21 Locations...
  • Page 284 5056-XXX Straight Exit Idle Roller Paddle Roller Upper Tray Path Select Gate Straight Exit Roller Register Idle Invert Exit Roller Idle Roller Input Paper Guide Lower Tray Invert Exit Roller Register Roller Accumulator Stapler Unit Sensor, Switch Purpose Paper input path sensor Detects paper input from printer Paper registration sensor Trigger for punching...
  • Page 285 5056-XXX Finisher Face Up Bin (Tray1) Punch Finisher Face Down Bin (Tray2) 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...
  • Page 286 5056-XXX Finisher electrical parts Number Part name Number Part name Paper exit sensor Power supply PWBA (upper tray) Paper register sensor Staple motor Path select solenoid Staple existence sensor Elevator upper limit Staple home position sensor Sensor Tractor drive motor Staple cartridge set switch Elevator motor Paper upper level sensor B...

  • Page 287: Preventive Maintenance

    5056-XXX 6. Preventive maintenance Maintenance kit When nearing 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.

  • Page 288: Periodic Maintenance

    5056-XXX Periodic maintenance This table lists the parts to be periodically cleaned by the servicer. Part name Method Paper feed unit • Pick roller 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. •...

  • Page 289: Parts Catalog

    5056-XXX 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: Asm- Part Units/ Description Index number mach • Asm-index: identifies the assembly and the item in the diagram. For example, 3-1 indicates assembly 3 and the item number 1.

  • Page 290: Assembly 1: Covers 1

    5056-XXX Assembly 1: Covers 1 Service Manual...
  • Page 291 5056-XXX Assembly 1: Covers 1 Index Units Description 1—1 40X1131 Cover, top 1—2 40X1124 Cover assembly, right side 1—3 40X1139 Magnet, right side latch 1—4 40X1259 Operator panel 1—5 40X1123 Cover assembly, front 1—6 56P9545 Label, operator panel 1—7 40X1132 Cover, waste toner bottle 1—8 40X1140...

  • Page 292: Assembly 2: Covers 2

    5056-XXX Assembly 2: Covers 2 Index Units Description 2 — 1 40X1026 Exit assembly, face up Service Manual...

  • Page 293: Assembly 3: Covers 3

    5056-XXX Assembly 3: Covers 3 Index Units Description 3 — 1 40X1027 Guide assembly, face-down 3 — 2 40X1064 Exit roller, face-down Parts catalog...

  • Page 294: Assembly 4: Covers 4

    5056-XXX Assembly 4: Covers 4 Index Units Description 4 — 1 40X1242 Guide assembly, turn Service Manual...

  • Page 295: Assembly 5: Covers 5

    5056-XXX Assembly 5: Covers 5 Index Units Description 5 — 1 40X1135 Feeder assembly, multipurpose Parts catalog...

  • Page 296: Assembly 6: Upper Unit

    5056-XXX Assembly 6: Upper unit Service Manual...
  • Page 297 5056-XXX Assembly 6: Upper unit Index Units Description 6—1 56P9632 Shroud, cable 6—2 56P9591 Frame, upper 6—3 56P9638 Holder, cable 6—4 40X1220 Board, printhead controller 6—5 56P9628 Pivot, color link 6—6 56P9627 Bearing, roller 6—7 56P9624 Link, frame 6—8 40X1149 Frame, printhead controller 6—9 56P9625...

  • Page 298: Assembly 7: Paper Feed

    5056-XXX Assembly 7: Paper feed 7-10 Service Manual...
  • Page 299 5056-XXX Assembly 7: Paper feed Index Units Description 7 — 1 40X1119 Shaft, changing 7 — 2 40X1103 Bushing, turn guide 7 — 3 40X1112 Assembly, drive link 7 — 4 40X1247 Sensor, humidity (not included in 7-3) 7 — 5 40X1082 Clutch, paper feed 7 —...

  • Page 300: Assembly 8: Base 2

    5056-XXX Assembly 8: Base 2 7-12 Service Manual...
  • Page 301 5056-XXX Assembly 8: Base 2 Index Units Description 8 — 1 40X1207 Support assembly, upper unit 56P9667 Pin, upper unit support 40X2776 Stop, right 40X2779 Cover, black photodeveloper 40X1208 Handle assembly, lock 56P9669 Handle, lock 40X2778 Stop, left 40X1151 Cover, electronic 40X2777 Guide, lock 56P9670...
  • Page 302 5056-XXX Assembly 9: Base 3 7-14 Service Manual...
  • Page 303 5056-XXX Assembly 9: Base 3 Index Units Description 9 — 1 40X1067 Clutch, MPF 9 — 2 40X1085 Switch, turn guide 9 — 3 40X1040 Clutch, registration 9 — 4 40X1113 Cable, registration clutch 9 — 5 40X1116 Cable, MPF clutch 9 —...

  • Page 304: Assembly 10: Electrical A

    5056-XXX Assembly 10: Electrical A 7-16 Service Manual...
  • Page 305 5056-XXX Assembly 10: Electrical A Index Units Description 10 — 1 40X1101 Asm, HCF/FIN D-Sub 10 — 2 40X1102 Cable asm, finisher 10 — 3 56P9715 Cable asm, HVU 10 — 4 56P9727 Cable asm, printer controller power 2 10 — 5 40X1053 Cable asm, printer controller power 1 10 —...
  • Page 306 5056-XXX Assembly 10 (continued): Electrical A 7-18 Service Manual...
  • Page 307 5056-XXX Assembly 10 (continued): Electrical A Index Units Description 40X0275 Cord (6ft straight), Israel 40X0276 Cord (6ft straight), South Africa 40X0277 Cord (6ft high amp straight), Brazil (HV, LV) 40X0278 Cord (HV 6ft straight), Austria, Russia 40X0279 Cord (6ft straight), Denmark, Finland, Norway, Sweden 40X0280 Cord (10A 3 cond.

  • Page 308: Assembly 11: Electrical B

    5056-XXX Assembly 11: Electrical B 7-20 Service Manual...
  • Page 309 5056-XXX Assembly 11: Electrical B Index Units Description 11—1 40X1068 Cable assembly, 8 pin PH controller 40X1074 Cable assembly, 30 pin RIP harness 40X1073 Cable assembly, 36 pin RIP harness 56P9720 Cable assembly, printhead controller power 40X1099 Cable assembly, paper tray lift motor 40X1100 Cable assembly, cassette bottom sensor 40X1098...

  • Page 310: Assembly 12: Rip Board

    5056-XXX Assembly 12: RIP board Index Units Description 12—1 56P9749 Cable assembly, power RIP 40X2644 Card assembly, RIP 40X1520 Fan, RIP box 40X1165 Box, RIP 40X1054 Cable assembly, 26 pin RIP printer controller 40X1255 Cable, USB 40X1256 Cable, operator panel 40X1166 Cover, RIP box 40X1268...

  • Page 311: Assembly 13: Fuser Unit

    5056-XXX Assembly 13: Fuser unit Index Units Description 13—1 40X1056 Fuser, 120V 40X1057 Fuser, 230V 7-23 Parts catalog...

  • Page 312: Assembly 14: Cassette

    5056-XXX Assembly 14: Cassette 7-24 Service Manual...
  • Page 313 5056-XXX Assembly 14: Cassette Index Units Description 14—1 40X1058 Cassette, paper feed 40X1501 Kit, rack guard holder 40X1105 Flag, bottom sense 7-25 Parts catalog...

  • Page 314: Assembly 15: Expansion Feeder 1

    5056-XXX Assembly 15: Expansion feeder 1 7-26 Service Manual...
  • Page 315 5056-XXX Assembly 15: Expansion feeder 1 Index Units Description 40X2634 — Assembly, expansion feeder 15—1 40X1090 Motor asm, stepping 56P9777 Cable asm, upper optional drawer 56P9778 Cable asm, lower optional drawer 40X1204 Cover, right side C 40X1203 Cover, right side B 40X1202 Cover, right side A 40X1091...

  • Page 316: Assembly 16: Expansion Feeder 2

    5056-XXX Assembly 16: Expansion feeder 2 7-28 Service Manual...
  • Page 317 5056-XXX Assembly 16: Expansion feeder 2 Index Units Description 16—1 40X1140 Magnet, front cover latch 40X1071 Spring, paper carry 2 40X1070 Bushing, pressure 40X1072 Roller, follow up 40X1069 Guide assembly, expansion turn guide 40X1086 Assembly, paper feed expansion 40X1076 Plate, guide rocking 40X1111 Roller, relay expansion feed 40X3484...

  • Page 318: Assembly 17: Duplex Unit 1

    5056-XXX Assembly 17: Duplex unit 1 7-30 Service Manual...
  • Page 319 5056-XXX Assembly 17: Duplex Unit 1 Index Units Description 17—1 40X1252 Duplex assembly 40X1060 Board, duplex interface 40X1168 Frame, duplex 40X1172 Cable assembly, duplex connection 40X1169 Screw, duplex mounting 40X1170 Motor, duplex stepping 40X1171 Interrupter, photo 56P9806 Cable assembly, paper detection 56P9994 Plate, duplex guide 56P9807...

  • Page 320: Assembly 18: Duplex Unit 2

    5056-XXX Assembly 18: Duplex unit 2 7-32 Service Manual...
  • Page 321 5056-XXX Assembly 18: Duplex unit 2 Index Units Description 18—1 56P9825 Plate, paper re-feed drawer 56P9827 Guide, rear side 56P9826 Guide, front side 40X1179 Solenoid assembly, paper re-feed 56P9814 Bearing, release 56P9816 Spring, re-feed roller 56P9813 Roll, release 40X1171 Interrupter, photo 56P9828 Motor assembly, paper guide 40X1173...

  • Page 322: Assembly 19: High-Capacity Feeder 1

    5056-XXX Assembly 19: High-capacity feeder 1 7-34 Service Manual...
  • Page 323 5056-XXX Assembly 19: High-capacity feeder 1 Index Units Description 19—1 40X1182 Catch, door 40X1181 Magnet, latch 40X1215 Cover, upper 40X1214 Cover, upper rear 40X1218 Cover, lower rear 40X1245 Cover, right 40X1213 Cover, front 56P9836 Fence, end 56P9940 Ring, snap 40X1217 Cover assembly, upper 40X1216 Lever, vertical transport...

  • Page 324: Assembly 20: High-Capacity Feeder 2

    5056-XXX Assembly 20: High-capacity feeder 2 7-36 Service Manual...
  • Page 325 5056-XXX Assembly 20: High-capacity feeder 3 Index Units Description 20—1 40X1185 Solenoid assembly, paper pickup 40X1153 Clutch, paper feed 40X1183 Motor assembly, transport 56P9941 Arm, pick-up 56P9501 Spring, pressure 40X1184 Interrupter, photo 56P9849 Roller, manual feed pickup 56P9850 Roller, manual feed 56P9852 Limiter, torque 56P9851...

  • Page 326: Assembly 21: High-Capacity Feeder 3

    5056-XXX Assembly 21: High-capacity feeder 3 7-38 Service Manual...
  • Page 327 5056-XXX Assembly 21: High-capacity feeder 3 Index Units Description 21—1 40X1244 Sensor assembly, photo 40X1186 Interrupter, photo 56P9529 Caster, HCF 56P9856 Spring, tension 40X1188 Switch, micro 40X1187 Switch, push 40X1190 Connector, inlet 40X1189 Connector, I/F 56P9853 Screw, shoulder 40X1274 Parts packet 7-39 Parts catalog...

  • Page 328: Assembly 22: High-Capacity Feeder 4

    5056-XXX Assembly 22: High-capacity feeder 4 7-40 Service Manual...
  • Page 329 5056-XXX Assembly 22: High-capacity feeder 4 Index Units Description 22—1 40X1192 Sensor, resistor 40X3490 Cable assembly, safety switch 40X3486 Cable assembly, HCF motor 40X3489 Cable assembly, I/F 40X3487 Cable assembly, paper feed sensor 40X3495 Cable, up/down switch 40X3494 Cable, paper volume 40X3493 Cable assembly, sensor 40X3492...

  • Page 330: Assembly 23: High-Capacity Feeder 5

    5056-XXX Assembly 23: High-capacity feeder 5 7-42 Service Manual...
  • Page 331 5056-XXX Assembly 23: High-capacity feeder 5 Index Units Description 23—1 56P9883 Spring, pressure 40X1184 Interrupter, photo 40X1198 Bracket, rear idler 56P9884 Belt, timing 56P9886 Gear, drive 56P9885 Pulley, timing 40X1196 Motor, HCF DC 40X1197 Bracket, front idler 40X1521 Parts packet 7-43 Parts catalog...

  • Page 332: Assembly 24: High-Capacity Feeder 6

    5056-XXX Assembly 24: High-capacity feeder 6 7-44 Service Manual...
  • Page 333 5056-XXX Assembly 24: High-capacity feeder 6 Index Units Description 24-1 40X1199 Plate, upper side fence 56P9893 Knob, stopper 56P9891 Knob, tray 56P9890 Plate, paper adhesion 56P9915 Fence assembly, front side 56P9894 Fence assembly, rear side 40X1184 Interrupter, photo 56P9889 Pad, friction 40X1522 Parts packet 7-45...

  • Page 334: Assembly 25: Finisher Covers

    5056-XXX Assembly 25: Finisher covers 7-46 Service Manual...
  • Page 335 5056-XXX Assembly 25: Finisher covers Index Units Description 25-1 56P4064 Cover, top 56P4065 Cover, front 56P4067 Tray, upper 56P4068 Tray, lower 56P4062 Panel, left upper 40X1227 Assembly, lower left panel 56P4066 Cover, rear 56P4063 Assembly, staple cover 56P9365 Cover, staple A 56P9367 Cartridge, staple 40X2622...

  • Page 336: Assembly 26: Finisher Frame

    5056-XXX Assembly 26: Finisher frame 7-48 Service Manual...
  • Page 337 5056-XXX Assembly 26: Finisher frame Index Units Description 26-1 56P4069 Handle 40X2628 Sensor, photo 56P9386 Spring 40X2626 Screw, M4 40X2607 Assembly, exit guide inverter 56P9399 Sensor, photo 40X1223 Assembly, exit guide straight 40X2608 Unit, 3 hole punch (U.S. only) 40X2609 Unit, 4 hole punch (non U.S.) 56P4072 Kit, punch speed up...

  • Page 338: Assembly 27: Finisher Feed 1

    5056-XXX Assembly 27: Finisher feed 1 7-50 Service Manual...
  • Page 339 5056-XXX Assembly 27: Finisher feed 1 Index Units Description 27-1 40X2640 Assembly, guide plate 40X2615 Assembly, solenoid 56P9396 Spring, H 56P9398 Gear, Z19 56P9310 Gate 56P9400 Roller 56P9361 Roller, patting 56P9401 Roller, I 56P9312 Roller, F 56P9405 Roller, G 40X2616 Clutch, registration 56P9407 Belt, timing 60S2M184...

  • Page 340: Assembly 28: Finisher Feed 2

    5056-XXX Assembly 28: Finisher feed 2 Index Units Description 28-1 40X2600 Assembly, jogging unit 56P9333 Belt, timing 60S3M408 40X2612 Assembly, tractor motor 40X2601 Assembly, guide stack 7-52 Service Manual...

  • Page 341: Assembly 29: Finisher Elevator

    5056-XXX Assembly 29: Finisher elevator Index Units Description 29-1 40X2606 Assembly, elevator motor 56P9451 Shutter 56P9332 Spring, C 40X2614 Wire 56P9459 Drum, wire 56P9460 Gear, Z30 56P4073 Panel, lower left 40X2639 Assembly, sensor 40X2605 Assembly, hook rear 7-53 Parts catalog...

  • Page 342: Assembly 30: Finisher Electronics

    5056-XXX Assembly 30: Finisher electronics Index Units Description 30-1 40X2604 Assembly, upper limit sensor 40X2603 Supply, power 56P9358 Cord, Y power 56P9368 Cord, Y power (230 V only) 40X1225 Board, finisher control 56P9410 Cable 40X2618 Bracket, finisher control board 56P9357 Cable, interface 7-54 Service Manual...

  • Page 343: Assembly 31: Finisher Docking 1

    5056-XXX Assembly 31: Finisher docking 1 Index Units Description 31-1 56P9467 Screw, thumb 7-55 Parts catalog...

  • Page 344: Assembly 32: Finisher Docking 2

    5056-XXX Assembly 32: Finisher docking 2 Index Units Description 32-1 40X1237 Bracket, rail 56P9472 Screw, lock 40X1238 Screw, rail 40X1239 Chassis, rail 56P9474 Roller 40X1241 Stud, lock-f 56P9473 Stud, lock 40X1240 Screw, lock 40X1254 Bracket, lock 7-56 Service Manual...

  • Page 345: Assembly 33: Miscellaneous/Options

    40X1513 Kit, Simplified Chinese font 40X1514 Kit, Traditional Chinese font 40X1515 Kit, Korean font 40X1503 Card, bar code 7374460 Kit, C920 dtn printer relocation 40X1511 Kit, C920 net printer relocation 40X1502 Card, IPDS 40X1504 Card, Prescribe 40X1505 Card, PrintCryption 40X1507...

  • Page 346: Assembly 34: Parts Packets

    5056-XXX Assembly 34: Parts packets Index Units Description 40X1262 Parts packet, containing: • 5 Bind S-tight screws, 3x6, Zn-3R • 5 Bind S-tight screws, 3x15, Zn-3K • 5 Bind P-tight screws, 3x8, Zn-3K • 5 Bind P-tight screws, 3x10, Zn-3K •...
  • Page 347 5056-XXX Assembly 34: Parts packets (continued) Index Units Description 40X1266 Parts packet, including: • 5 Bind S-tight screws, 3x6, Zn-3R • 5 Bind P-tight screws, 3x6, Zn-3K • 5 Bind P-tight screws, 3x8, Zn-3K • 5 E-rings, ES-3, ACP • 5 E-rings, ES-5, ACP •...
  • Page 348 5056-XXX Assembly 34: Parts packets (continued) Index Units Description 40X1270 Parts packet, including: • 5 Bind S-tight screws, 3x6, Zn-3R • 5 Bind S-tight screws, 3x8, Zn-3R • 5 Bind P-tight screws, 3x6, Zn-3K • 5 Bind P-tight screws, 3x8, Zn-3K •...
  • Page 349 5056-XXX Assembly 34: Parts packets (continued) Index Units Description 40X1274 Parts packet, including: • 5 Bind S-tight screws, 3x10, Zn-3R • 5 E-rings, ES-4, ACP • 5 RS-tight screws, M3x14 • 5 RS-tight screws, M4x6 • 5 RS-tight screws, M4x8 •...

  • Page 350: Assembly 35: Finisher Parts Packet P/N 402623

    5056-XXX Assembly 35: Finisher parts packet P/N 402623 Retaining Ring -E Type Screw Spring Pin Screw Screw Tapping Screw Spring Lock Washer Tapping Screw Toothed Lock Washer Tapping Screw Resin Ring Tapping Screw Set Screw Tapping Screw Plain Washer Tapping Screw Screw 7-62 Service Manual...

  • Page 351: Index

    5056-XXX Index Numerics 2-42 88 OCR exhausted 2-42 88 Replace \> toner 2-37 1565 Emul Error Load Emul Option 2-42 200.yy Paper jam 2-42 249.yy Paper jam 2-30 Activating Menu Changes 2-42 24x.yy Paper jam adjustments 2-42 250.yy Paper jam 3-69 finisher hole punch alignment 2-37...
  • Page 352 5056-XXX solenoid removal top cover removal fans 2-30 Cyan Low 4-25 main unit fan removal 4-47 upper fan removal finisher 2-31 Defragmenting Flash 3-64 adjusting wheels 2-31 Delete 3-59 aligning finisher and printer 2-31 Delete all 3-62 aligning sides of finisher 2-31 Delete all confidential jobs 3-63...
  • Page 353 5056-XXX 7-23 parts catalog 4-18 removal 2-30 Magenta Low 2-33 Maintenance maintenance Handling ESD-sensitive parts 1-19 approach 2-32 Hex Trace 1-19 cleaning high-capacity feeder 3-43 dip switch specifications 4-59 call roller removal 1-19 inspection 4-58 covers removal lubricants 5-19 diagram periodic high-capacity paper feed timing belt adjustment 1-20...
  • Page 354 5056-XXX 2-34 paper feeding Programming System Code 3-29 multipurpose feeder 3-34 paper jams 2-34 Reading USB drive 3-29 theory 2-35 Ready 3-33 weight of paper 2-35 Remote Management Active 3-34 paper jams removals 2-34 Parallel 4-12 belt up/down clutch 1-20 part number 4-13 cassette guide...
  • Page 355 5056-XXX 4-60 2-36 paper end sensor Resetting Active Bin 4-59 2-36 paper feed roller Resetting Fuser Count 4-62 2-36 paper level sensor Resetting the Printer 4-60 2-36 paper size sensors (1, 2) Restore Held Jobs 4-59 2-36 pickup solenoid Restoring Factory Defaults 4-62 2-36 power supply...
  • Page 356 5056-XXX 2-15 934 - drum sensor, color 2-15 935 - drum sensor, black technical specifications 2-15 936-9 - cassette error theory 2-16 940 - high-capacity feed sensor error 3-31 belt unit 2-16 941 - high-capacity feed tray error 3-31 belt up/down 2-16 942 - duplex error 3-28...

  • Page 357: Part Number Index

    5056-XXX Part number index Description Page 11G0199 Guide, wire - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27 11G0399 Plate, ground - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 358 5056-XXX 40X1059 Board, expansion feeder controller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27 40X1060 Board, duplex interface - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 359 5056-XXX 40X1116 Cable, MPF clutch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15 40X1117 Assembly, RFID - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 360 5056-XXX 40X1177 Roller, re-feed - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33 40X1178 Solenoid assembly, feed roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 361 Kit, C920 net printer relocation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 362 5056-XXX 40X2623 Parts packet, finisher - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62 40X2626 Screw, M4 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 363 5056-XXX 56P9407 Belt, timing 60S2M184 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-51 56P9410 Cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 364 Kit, C920 dtn printer relocation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 365 LED Fan Fuser Fan Eraser M Eraser C LVPS-2 Eraser Y Eraser K power supply for 120V only Toner Sensor Assembly P622-RFID(B)ASSY (Antenna) ç ç ç Operation panel (U) Toner Drum Sensor Assembly ç for 230V only VCC5 CK-OHPL Lower OHP Sensor /CK-OHPDET ç...
  • Page 366 C920 Finisher Wiring Diagram CN12 CN12P CN12 Signal Finisher DC5V Control Board CN10P CN10 PJ10 CN10 Paper Full Sensor Finisher Control Board Paper Full Sensor DC5V PJ10 DC24V Tractor Motor PC10 Paper Upper Level Sensor DC24V Tractor Motor A DC5V...

This manual is also suitable for:

C920nC920dn5056-030C920dtn5056-0005056-010

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