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Lexmark C91x Service Manual

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Lexmark C91x

5055-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 C91x

Page 1 Lexmark C91x 5055-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 You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
Page 3: Table Of Contents
5055-xxx Contents Safety information........xi Preface .
Page 4 5055-xxx Power and electrical specifications ....1-26 Power requirements ....... .1-26 Electrical specifications .
Page 5 5055-xxx Image quality troubleshooting ......2-88 Print quality problems ......2-88 Options service check .
Page 6 5055-xxx Duplex unit ........3-44 Paper weight .
Page 7 5055-xxx Front cover open switch actuator removal ....4-20 Fuser removal ........4-21 High voltage power supply board (HVU) removal .
Page 8 5055-xxx Duplex removals ........4-75 Duplex unit separation removal ..... . .4-75 Duplex unit removal .
Page 9 5055-xxx Locations ..........5-1 Covers diagram.
Page 10 5055-xxx Assembly 10: Electrical ......7-22 Assembly 11: Rip board ......7-26 Assembly 12: Fuser unit.
Page 11: Safety Information
5055-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 12 5055-xxx Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
Page 13 5055-xxx Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
Page 14 5055-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 15 5055-xxx Safety information...
Page 16: Preface
5055-xxx Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the 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 17: General Information
5055-xxx 1. General information Overview The Lexmark™ C91x printers are high-speed, wide-format color LED Electrophotographic color printers with superior print quality for high-volume printing. Resolution • 600 x 600 dpi • 2400 image quality Model differences 28/29 ppm engine USB/parallel...
Page 18: Technical Specifications
5055-xxx Technical specifications Toner darkness Toner darkness settings offer four user-selectable settings to balance print darkness and toner savings. The higher the setting, the darker the print. The toner darkness default setting is 4. The toner darkness setting is available through the operator panel under the Print Quality menu.
Page 19: Physical Specifications And Weight
5055-xxx Physical specifications and weight Description Height Width Depth Weight Printers Lexmark C91x 20.2 in. 27.4 in. 25.8 in. 177 lb (512 mm) (695 mm) (655 mm) (80.5 kg) Lexmark C91xn 25.2 in. 27.4 in. 25.8 in. 217.8 lb (641 mm)
Page 20: Print Speed And Performance
5055-xxx Print speed and performance Standard and High-capacity Multipurpose heavy media feeder feeder tray Simplex printing on letter-size media (pages per minute) Letter—8.5 in. x 11 in. Ledger Legal—8.5 in. x 14 in. A4—3.4 in. x 11.7 in. A5/Executive Transparencies Card stock Envelopes Paper labels...
Page 21: Performance
“seed” the printer system’s paper path to achieve the maximum duplex print performance. Performance The Lexmark C91x printers support the speeds listed above. Performance depends on: • Interface to the host (USB, serial, parallel, network) •...
Page 22: Printer Memory
Available memory options Optional 64MB, 128MB and 256MB SDRAM DIMMs are available from Lexmark. Flash memory options Optional 4MB, 8MM and 16MB DIMMs are available from Lexmark. Memory and expansion slots • Memory slots for extra flash or DRAM – Two for Lexmark C910(n) and Lexmark C912(n) –...
Page 23: Resident Fonts
Bitmapped fonts PCL 6 PostScript 3 For a listing of specific fonts, visit www.lexmark.com. There are 83 symbol sets in the PCL 6 emulation to support all the languages that use these characters. Not all symbol sets are supported by all fonts. Refer to the Technical Reference or use the printer operator panel to find which symbol sets are supported by each font.
Page 24: Paper And Media Specifications
Capacity may vary and is subject to media specifications and printer operating environment. Capacities listed are based on plain paper at 75 g/m Input and output configurations Sources and Lexmark Lexmark Lexmark capacities C91x C91xn C91xdn Input sources Number of standard sources Optional input drawers High-capacity feeder Maximum number of...
Page 25 5055-xxx Sources and Lexmark Lexmark Lexmark capacities C91x C91xn C91xdn Maximum input 2,300 2,300 2,300 capacity (without high-capacity feeder) Maximum input 5,300 5,300 5,300 capacity and high-capacity feeder Output destination Number (standard) Output capacities sheets Standard output bin Face-up bin...
Page 26: Media Size Supported
(184 mm x 267 mm) Tabloid—11 in. x 17 in. (279.4 mm x 431.8 mm) 12 in. x 18 in. (305 mm x 457 mm) Lexmark C912 only A3—11.69 in. x 16.54” in. (297 mm x 420 mm) 1-10 Service Manual...
Page 27 5055-xxx Universal Banner 11.69 x 36 in. (297.2 x 914.4 mm) Lexmark C912 only 2.75 x 5 in. to 8.5 x 14 in. (69.85 x 127 mm to 229 x 355.6 mm) 5.83 x 7.17 in. to 8.5 x 14 in.
Page 28 5055-xxx Media type Paper Card stock Transparencies Envelopes Glossy paper Paper labels Output A4—8.27 in. x 11.7 in. (210 mm x 297 mm) A5—5.83 in. x 8.27 in. (148 mm x 210 mm JIS-B5—7.17 in. x 10.23 in. (182 mm x 257mm) JIS-B4—14.34 in.
Page 29 (184 mm x 267 mm) Tabloid—11 in. x 17 in. (279.4 mm x 431.8 mm) 12 in. x 18 in. (305 mm x 457 mm) Lexmark C912 only A3—11.69 in. x 16.54 in. (297 mm x 420 mm) Universal Banner 11.69 x 36 in.
Page 30 5055-xxx C5 Envelope—6.38 in. x 9.01 in. (162 mm x 229 mm) B5 Envelope—6.93 in. x 9.84 in. (176 mm x 250 mm) Other Envelope —11.69 in. x 11.69 in. (297 mm to 297 mm) Media type Paper Card stock Transparencies Envelopes Glossy paper...
Page 31: Input Media Types And Weights
5055-xxx Input media types and weights Media Weight 1, 2, 3 Standard trays Paper–xerographic or business 16 to 28 lb bond (60 to 105 g/m Specialty papers–glossy laser 80 lb book (32 lb bond) (120 g/m Heavy media tray Paper–xerographic or business 28 to 47 lb bond (105 to 176 g/m Specialty papers–glossy laser4 80 lb book (32 lb bond) (120 g/m...
Page 32: Output Media Types And Weights
5055-xxx Output media types and weights Media Weight Standard output Paper–xerographic or business 16 to 28 lb bond (60 to 105 g/m Specialty papers–glossy laser 80 lb book (32 lb bond) (120 g/m Card stock–upper limit Index 90 lb index (44 lb bond) (165 g/m Bristol Transparencies–laser printer type 47 lb bond (175 g/m...
Page 33 5055-xxx Media Weight 3, 4, 5 Finisher bin 2 Paper–xerographic or business 16 to 28 lb bond (60 to 105 g/m Part numbers 12A5950 (letter) and 12A5951 (A4). Part numbers 12A5940 (letter) and 12A5941 (A4). The duplex option supports the same weights and types as the printer, except for transparencies, envelopes, labels and paper less than 80 g/m (21.3 lb bond) or greater than 105 g/m...
Page 34: Input Capacity By Media And Source
5055-xxx Input capacity by media and source Media Stack height Capacity 500-Sheet trays Plain paper (letter, A4, 2.2 in. (56 mm) 550 sheets legal, tabloid, A3) 20 lb (75 g/m Plain paper (letter, A4, 1 in. (25 mm) 240 sheets legal, tabloid, A3) 24 lb (90 g/m Glossy paper...
Page 35: Output Capacity By Media And Source
5055-xxx Output capacity by media and source Media Stack heights Capacity Standard output bin Plain paper Varies 550 sheets 20 lb (75 g/m Glossy paper Varies 130 sheets 32 lb (120 g/m Bin 1 and Staple Punch Finisher Bin 1 Plain paper Varies 100 sheets...
Page 36: Media Guidelines
5055-xxx Media guidelines Paper Following are media guidelines for successful printing: • Rough, highly textured, limp or pre-curled papers will result in lower print quality and more frequent paper feed failures. • Colored papers, treated and preprinted papers, letterhead and labels must be able to withstand 338°...
Page 37: Print Area
Labels Labels should be selected using guidelines found in the User's Guide or the Cardstock and Label Guide, and tested for acceptability. Lexmark glossy paper • Use letter (p/n 12A5950) or A4 (p/n 12A5951) only • Glossy paper is only supported from Tray 1, Multipurpose Feeder, and Heavy Media Tray.
Page 38: Options And Features
5055-xxx Options and features Lexmark C91x printers support only Lexmark C91x paper-handling options. These options are not compatible with any other Lexmark printer. • 550-Sheet drawer—(includes 550-sheet tray and support unit) installs beneath the printer and holds approximately 550 sheets of 20 lb paper.
Page 39: Connectivity
• Lexmark C91x – Bidirectional parallel and USB • Lexmark C91xn and Lexmark C91xdn – 10/100BaseTX Ethernet and USB Note: USB is supported only under Windows 98 SE, Windows Me, Windows XP, Windows 2000 operating systems, Sun's Sun Ray appliances running Sun Ray Server code version 1.2 or later, Sun Blade workstations and Apple Macintosh iMac computer with Operating System 8.6 or higher.
Page 40: Network Connections
Lexmark MarkNet N2000 Series Internal Print Servers – MarkNet N2000t for Token-Ring attachment – MarkNet N2001e for Ethernet 10BaseT/100BaseTX – MarkNet N2002e for Ethernet 10BaseT/10Base2 • Lexmark MarkNet N2003 Series Internal Fiber Print Servers, including: – MarkNet N2003fx SC – MarkNet N2003fx MTRJ External network connections •...
Page 41: Data Streams
XP or Windows NT. The remote operator panel is available using the standard Ethernet connection, MarkNet N2000, MarkNet N2003 or MarkNet X2000 Series external print servers installed in or used with a Lexmark C91x printer. Data streams • PostScript 3 Emulation •...
Page 42: Power And Electrical Specifications
5055-xxx Power and electrical specifications Power requirements Average nominal power requirements for the base printer configuration (110 volt). Power level are shown in watts. Printing states (average Non- Duplex/ Network power) network network Average power while printing Continuous mono 400 W 400 W 410 W Continuous color...
Page 43: Operating Clearances
Left side 13 in. (330 mm) Clearance on the left side should be 9 in. (228.6) with the finisher attached. Right C91x(n) 6 in. (152 mm) Clearance on right side should side be 30 in. (762 mm) with the C91xdn 13 in.
Page 44 5055-xxx Shipping printer without print cartridges • Temperature: 0 to 140° F (0.6 to 60° C) • Relative humidity: 5 to 100% • Maximum wet bulb temperature: 85° F (30° C) • Altitude: 34,000 ft. (10,300 meters) Storing printer without print cartridges •...
Page 45: Maintenance Approach
5055-xxx Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the error code charts, symptom index, and service checks to determine the symptom and repair the failure. The removals in the repair information chapter may help you identify parts.
Page 46: Return Parts
5055-xxx • Inspect all supplies (OCR, cartridges, photodevelopers/toner cartridges, belts, fuser CRUs) and paper sources (cassettes, trays, feeders, duplex drawers, finishers, mailbox trays) for obvious damage and proper installation (paper under corner bucklers, paper guides not too tight). Inspect for correct media usage (paper, transparencies, labels).
Page 47: Tools
5055-xxx Tools The removal and adjustment procedures require the following tools and equipment: • Magnetic tip Phillips screwdrivers, large and small • Flat-blade screwdrivers • Analog volt ohmmeter (a digital volt ohmmeter may also be used) • Needle nose pliers •...
Page 48: Serial Number, Configuration Id, And Part Number
5055-xxx Serial number, configuration ID, and part number Open the front door. The serial number, configuration ID, and part number are located as shown. The serial number is also on the menu settings page you can print from the Tests Menu. Serial Number Config ID 1-32 Service Manual...
Page 49: Abbreviations
5055-xxx Abbreviations ASIC Application-specific integrated circuit Customer setup DRAM Dynamic random access memory Electrophotographic process EPROM Erasable programmable read-only memory Electrostatic discharge Field replaceable unit HVPS High voltage power supply Local area network LASER Light amplification by stimulated emission of radiation Liquid crystal display Light-emitting diode...
Page 50 5055-xxx 1-34 Service Manual...
Page 51: Diagnostic Information
5055-xxx 2. Diagnostic information The diagnostic information in this chapter leads you to the failing part. Before you replace an entire assembly, determine if just the defective part is available in the parts catalog. Use the error code tables, symptom table, service checks and the diagnostic aids chapter to determine the symptom and repair the failure.
Page 52 5055-xxx Printer controller board/printer control EPROM (U5) If you replace the printer controller board, remove EPROM (U5) and install it on the new board. Also check the printhead alignment. If you change the EPROM, record and input the following items using the diagnostic mode following EPROM replacement: •...
Page 53: Start
5055-xxx Start Initial check Before you start troubleshooting, check the following: Installation environment • The power supply line voltage is plus or minus 10% of the rated line voltage. • The machine is securely installed on a level surface in a well- ventilated place.
Page 54: Printer Messages
5055-xxx Printer messages The printer displays three types of messages: service messages, status messages, and attendance messages. Service messages indicate a problem that requires a service technician. Status messages provide information about the current state of the printer, requiring no action. Attendance messages alert the operator to printer problems that require operator intervention.
Page 55 5055-xxx 911 - Paper Exit Motor Error Step Questions/actions Is connector CN4 on the Replace the Plug the printer controller board paper exit motor connector in securely connected? and go to step 2. securely. Did replacement of the Problem solved. Replace the paper exit motor solve the printer controller...
Page 56 5055-xxx 918 - Main Unit Fan Error Step Questions/actions Is +24 V present between Replace the Replace the pins 1 and 3 on connectors failing fan. printer controller CN17 (upper left fan) and board. CN5 (upper right fan) on the printer controller board? 919 - Power Supply Fan Error Step...
Page 57 5055-xxx 923 - Upper Fuser Thermistor Open Error Step Questions/actions Is connector CN44 on the Disconnect Plug the printer controller board CN44 and turn connector in connected properly? the printer on. securely. Go to step 2. Is error 923 displayed? Power off and Replace the reconnect CN44.
Page 58 5055-xxx 925 - HVU Error Step Questions/actions Has the high voltage power Inspect the Go to step 2 board (HVU) been secondary card removed/replaced? on the high voltage board (HVU) for a broken component (Q906). Replace the high voltage board (HVU) if necessary.
Page 59 5055-xxx 926(K), 927(C), 928(Y), 929(M) - Toner Sensor Error 92x Service Toner Sensor Step Questions/actions Is the toner cartridge the Go to step 2. Recommend the correct type for the printer? customer replace the cartridge with the correct type. Is the toner cartridge Clean the Go to step 3.
Page 60 5055-xxx 930 - Yellow Printhead Error 930 Service Printhead Error Step Questions/actions Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables. printhead and the printhead number controller board as well as XX–0XXXX, go the cables between the to step 2.
Page 61 5055-xxx 931 - Magenta Printhead Error Step Questions/actions Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables. printhead and the printhead number controller board as well as XX–0XXXX, go the cables between the to step 2.
Page 62 5055-xxx 932 - Cyan Printhead Error Step Questions/actions Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables. printhead and the printhead number controller board as well as XX–0XXXX, go the cables between the to step 2.
Page 63 5055-xxx 933 - Black Printhead Error Step Questions/actions Check to ensure that the If you have a Properly connect cables between the LED printer with serial the cables. printhead and the printhead number controller board as well as XX–0XXXX, go the cables between the to step 2.
Page 64 5055-xxx 934 - Color Drum Sensor Error 934 Service Drum Sensor Step Questions/actions Is connector CN28 Go to step 2. Plug the connected properly? connector in securely. Clean the color drum Problem solved. Replace the sensor LED. color drum sensor. Did this fix the problem? Go to step 3.
Page 65 5055-xxx 936 - 939 Cassette Error 936 Service Paper Option Step Questions/actions Are connectors CN35 and Replace the Plug the CN36 on the printer printer controller connector in controller board connected board. securely. properly? 940 - High-Capacity Feed Sensor Error Step Questions/actions Is connector CN40 on the...
Page 66 5055-xxx 942 - Duplex Error 942 Service Duplex Step Questions/actions Is connector CN37 on the Replace the Plug the printer controller board printer controller connector in connected properly? board. securely. 945 - Engine Flash Error 945 Service Engine Flash Reflash the engine code. 946 - Printer/Printhead Controller Board Communication Error 946 Service Communication...
Page 67 5055-xxx 947 - Finisher Communication Error Step Questions/actions Are the finisher to printer Go to step 2. Properly connect interface cable and power the cable. cable properly connected? Replace the interface cable. Problem solved. Replace the Did this resolve the control finisher problem? board.
Page 68 5055-xxx 949 - Tray (x) Comm Step Questions/actions Replace the printer Problem solved. Replace the controller board. expansion feeder control Does this fix the problem? board for trays 2-5. If the problem is with the high- capacity paper feeder, replace the HCPF board.
Page 69 5055-xxx 955 - Code CRC 955 Service Code CRC <loc> Replace the RIP board. 956 - Processor Failure 956 Service System Board Replace the RIP board. 957 - ASIC Failure Replace the RIP board. 958 - NAND Failure 958 Service NAND Failure Replace the RIP board.
Page 70 5055-xxx 970 - Standard Network Error 970 Service Standard Network 970 Service Network Card x Check the network card in slot x on the RIP card. 975 - Unrecognizable Network Port Software error. 976 - Unrecoverable Software Error in Network Port Software error.
Page 71 5055-xxx 980 - Face Up/Down Switching Error 980 Service Switch Error Check Area Step Questions/actions Does the Face Up/Down Go to step 2. Go to step 3. (FU/FD) deflector move at all during power up? Manually operate the FU/ Go to step 3. Go to step 4.
Page 72 5055-xxx 981 - Belt Up/Down Sensor Error 981 Service Switch Error Step Questions/actions Is engine code level 41D or Go to step 2. Update the above. printer with code level 41D or above. If this dies not resolve the problem, continue with step 2.
Page 73 5055-xxx Step Questions/actions Test the sensor. While Replace the belt Replace the belt actuating the sensor, does up/down clutch. up/down sensor. the voltage fluctuate Go to step 7. between 0 V and +5 V between pins 7 and 8 of connector CN29 on the printer controller board? Did replacing the belt up/...
Page 74 5055-xxx 983 - Black Gear Sensor Error 983 Service Gear Sensor Step Questions/actions Is connector CN20 on the Go to step 2. Plug the printer controller board connector in connected properly? securely. Check the cable running to Replace the Go to step 3. CN20 for damage.
Page 75 5055-xxx 985 - Transfer Belt Thermistor Error 985 Service Thermistor Error Step Questions/actions Are connectors CN407 and Go to step 2. Plug the CN408 on the sensor board connector in connected properly? securely. Is connector CN29 on the Replace the Plug the printer controller board transfer belt unit.
Page 76 5055-xxx 992 - Temperature/Humidity Sensor Error Step Questions/actions Is connector CN3 on the Go to step 2. Plug the printer controller board connector in connected properly? securely. Replace the temperature Problem solved. Replace the and humidity sensor (a printer controller component of the paper board.
Page 77 5055-xxx 994 - Density Sensor Error Step Questions/actions Is the front door fully Go to step 2. Close the front closed? door. Is the density sensor Release the Go to step 3. actuator stuck in place? density sensor actuator. Are connectors CN406 and Go to step 4 Plug the CN407 on the sensor board...
Page 78 5055-xxx 995 - Finisher Main Feed Motor abnormal 995 Service Finisher Step Questions/actions Is there jammed paper or Clear the paper Go to step 2. other obstructions in the path. paper path? Check to ensure the Go to step 3. Properly connect connector PJ6 on the the cables.
Page 79 5055-xxx Step Questions/actions Measure for +24 V dc Replace the Replace the between pins 1 and 2 on power supply. finisher control connector PJ3 on the board. finisher control board. Measure for +5 V dc between pins 1 and 3 on PJ2 on the finisher control board.
Page 80 5055-xxx 996 - Finisher Jogging Motor Error Step Questions/actions Are there foreign objects or Clear the objects Go to step 2. obstructions in the jogging or obstruction. assembly? Are the jogging motor Go to step 3. Securely connectors CN2 on the connect the finisher control board connectors.
Page 81 5055-xxx 997 - Finisher Tractor Motor Error Step Questions/actions Are there obstructions or Remove the Go to step 2. foreign objects in the objects or accumulator or face down obstructions. paper path? Are the connectors CN3 at Go to step 3. Securely the tractor motor and PJ4 connect the...
Page 82 5055-xxx 998 - Tray Elevator Motor Error Step Questions/actions Are the connectors CN4 at Go to step 2. Properly connect the tray elevator motor and the connectors. connector PJ4 on the finisher control board properly connected? Make sure that the finisher Replace the tray Go to step 3.
Page 83 5055-xxx 999 - Stapler Motor Error Step Questions/actions Are staples jammed in the Go to step 2. Go to step 3. stapler? Clear the staple jam and Replace the Problem solved. run the staple test in staple cartridge diagnostic mode or run a and to go step 4.
Page 84: Attendance Messages
5055-xxx Attendance messages Message Meaning Action Activating The printer is activating Wait for the message to Menu Changes changes made to the printer clear. settings. Bin <x> Full The specified bin is full. Remove the paper from the bin. Busy The printer is busy receiving, Wait for the message to clear processing, or printing data.
Page 85 5055-xxx Message Meaning Action Close Side The printer side door is Close the printer side door. If Door open. the error cannot be reset, go “Map 1 - False Side Door Open message” on page 2-54. Close Front The printer front door is Close the printer top door Door open.
Page 86 5055-xxx Message Meaning Action Disk Corrupted The printer has attempted a • Press Go to reformat the Reformat? disk recovery process and disk and delete all files cannot repair the disk. currently stored on the disk. • Press Stop to clear the message without reformatting the disk.
Page 87 5055-xxx Message Meaning Action Held Jobs May The printer memory is too • Press Go to clear the be Lost full. message. The printer frees memory by deleting the oldest job and continues deleting jobs until there is enough memory. •...
Page 88 5055-xxx Message Meaning Action Load <x> The printer is trying to feed Load paper of the size and paper from a source it type requested in the second detects is empty. line of the display in the specified tray. Press Menu to open the Job Menu and cancel the current job.
Page 89 5055-xxx Message Meaning Action Network Network interface is the Wait for the message to <x>, <y> active communication link, clear. where <x> represents the active link and <y> represents the channel. No Jobs The PIN number entered is • Press Go to enter another Found, Retry? not associated with any PIN.
Page 90 5055-xxx Message Meaning Action Printing Font The printer is processing or Wait for the message to List printing a list of all available clear. fonts for the specified printer language. Printing Job The printer is processing or Wait for the message to Accounting printing all job accounting clear.
Page 91 5055-xxx Message Meaning Action Ready Hex The printer is in Hex Trace • Send a job to print. All mode and is ready to receive data is printed in and process print jobs. hexadecimal. Control strings are printed, not executed. •...
Page 92 Download the correct Error Load version on the firmware card emulator version from Emul Option does not match the printer Lexmark’s Web site. code version. 2 <xx> Paper The printer detects a paper Clear the paper path. If the jam.
Page 93 5055-xxx Message Meaning Action 30 Coating Roll The oil coating roll is either Correctly install the oil Missing missing or installed coating roll. If the message incorrectly. cannot be reset, go to “Map 5 - False 30 Oil Coating Roll Missing message”...
Page 94 5055-xxx Message Meaning Action 37 Insufficient The printer cannot • Delete fonts, macros, and Defrag defragment flash memory. other data in printer Memory memory. • Install additional printer memory. 37 Insufficient The printer memory is full • Press Go to clear the Memory and cannot continue message and continue...
Page 95 5055-xxx Message Meaning Action 40 Tray <x> The high-capacity feeder • Turn off the printer and be Size Sense detects an error in the size sure that all the high- Error sensing mechanism. capacity feeder connectors are installed properly. • Check the high-capacity feeder size sensor and go “Map 8 - False 40 Tray (x) Size Sensor Error...
Page 96 5055-xxx Message Meaning Action 54 Serial The printer has detected a • Make sure the serial link is Option <x> serial interface error on a set up correctly and you Error serial port. are using the appropriate cable. • Press Go to clear the message and continue.
Page 97 5055-xxx Message Meaning Action 56 USB Port Data has been sent to the • Press Go to clear the <x> Disabled printer through a disabled message. USB port. • Make sure the USB Buffer 56 Std USB menu item in the USB Port Disabled Menu is set to Disabled.
Page 98 5055-xxx Message Meaning Action The printer detects an • Press Go to clear the Unformatted unformatted hard disk. message and continue Disk printing. • Format the disk before performing disk operations. • Replace the hard disk. The printer detects an •...
Page 99 5055-xxx Message Meaning Action 84 All Photo All of the photodevelopers Replace all of the Devs have reached end of life. photodevelopers. Make sure Exhausted you also install the new fuser coating roll that is included in each photodeveloper kit. 84 Black Photo The printer has detected an Install a new black...
Page 100 5055-xxx Message Meaning Action 84 Color Photo The color photodevelopers Replace the color Devs have reached end of life. photodevelopers (Cyan, Exhausted Magenta and Yellow) at the same time. If print quality is still acceptable and you do not want to replace the photodevelopers, press Go to clear the message and continue printing.
Page 101 5055-xxx Message Meaning Action Replace Oil A new black toner cartridge Press Go to clear or replace Coating Roll has been installed. This is a the oil coating roll with a new reminder to install a new oil one. coating roll. 88 <color>...
Page 102 5055-xxx Clearing finisher messages Message Solution Bin <x> Full Remove the stack of paper from the bin to clear the message. If you assigned the bin a name, the bin name is displayed instead of the bin number. Press Go to clear the message and continue printing. Check Finisher Make sure the finisher is flush against the printer.
Page 103 5055-xxx Message Solution Insert Staple The staple cartridge is either missing or installed Cartridge incorrectly. Correctly install the staple cartridge. Go to “Finisher service check” on page 2-71 to check the staple cartridge set sensor. 210 Staple Jam Open the finisher stapler door, remove the paper from the accumulator, and remove the staple jam.
Page 104: Maintenance Analysis Procedures (Maps)
5055-xxx Maintenance analysis procedures (MAPS) Map 1 - False Side Door Open message Step Questions/actions Close the side (turn guide) Problem solved. Go to step 2. door. Does the message reset? Disconnect CN30 from the Replace the Replace the side printer controller board.
Page 105 5055-xxx Map 3 - False Close Tray (x) Top Cover message Step Questions/actions Remove the rear cover on Replace the Replace the the high-capacity feeder HCF card. cover open and observe LED 9 on the micro-switch. HCF card while actuating the cover open micro- switch.
Page 106 5055-xxx Map 4 - False Tray (x) Low/Empty message Step Questions/actions Is the “Tray x Low” message Go to step 2. Go to step 5. present? Is the paper remaining Go to step 3. Repair or actuator inside the cassette replace the drawer binding, or operating cassette.
Page 107 5055-xxx Map 5 - False 30 Oil Coating Roll Missing message Step Questions/actions Is the OCR properly Go to step 2. Properly install installed? the OCR. Is the OCR fuse missing? Replace the Go to step 3. Is the OCR contact at the Replace the Go to step 4.
Page 108 5055-xxx Map 7 - False 88 <color> Toner Low/Toner Empty message Step Questions/actions Ensure the RIP board and Go to step 2. Upgrade the RIP the printer controller board and controller are updated to the latest board codes to code (Microcode EC2 or the latest level.
Page 109 5055-xxx Map 8 - False 40 Tray (x) Size Sensor Error message Step Questions/actions On the high-capacity Go to step 2. Replace the feeder, are the paper size missing adjusting screws present on thumbscrew or the upper portion of the screw them in all side fence and fully the way.
Page 110 5055-xxx Map 10 - Unrecoverable Check Tray (x) or Duplex Connection message Step Questions/actions Is the problem with a Go to step 2. Go to step 8. specific paper tray or the duplex unit? Is the problem with tray 1? Go to step 3.
Page 111 5055-xxx Step Questions/actions Are any of the pins or Go to step 9. Repair or contacts on the duplex replace the drawer connectors bent or connector. damaged? Are connectors CN101 and Go to step 10. Properly connect CN102 on the duplex the connectors.
Page 112 5055-xxx Map 11 - Paper size map Step Questions/actions Do the paper size sensor Go to step 2. Replace parts as actuators on the paper necessary. operation tray operate correctly, as you slide the paper location plate? Do the size sensor levers Go to step 3.
Page 113: Symptom Table
Go to the “Transfer belt up/down service check” on page 2-87. Transparencies Make sure you’re using the recommended Lexmark curl excessively. transparencies. Also be sure the paper delivery is set to the rear exit. The printer If you set the Paper Type to Transparency or Card Stock,...
Page 114 5055-xxx Symptom Action Fuser failure. Go to the “920 - Fuser Error—Fuser Heater Trouble” on page 2-6. No paper pick-up Go to the “Paper carrying service check” on from page 2-74. multipurpose tray. No paper pick-up Go to the “Paper carrying service check” on from upper or page 2-74.
Page 115 5055-xxx Symptom Action Evenly spaced Go to the “Transfer belt up/down service check” on marks on the page 2-87. paper, or a single mark in the same place on every page. Poor fusing. Go to the “920 - Fuser Error—Fuser Heater Trouble” on page 2-6.
Page 116 5055-xxx Finisher Use the following table to find solutions to problems with the optional finisher. Symptom Cause Solution Paper The finisher and Paper frequently jams in the frequently jams printer are finisher. Properly align the finisher in the finisher. misaligned. with the printer.
Page 117 5055-xxx Symptom Cause Solution You cannot The cover is not Open and close the top cover and clear the paper closed, finisher is make sure the finisher is locked jam message. against the printer, onto the alignment pins. Recheck or there is paper the finisher and printer for somewhere in the additional jams.
Page 118: Service Checks
5055-xxx Service checks Drive 1 DC motor service check Action • DC motor If the motor does not attempt to turn and • Drive unit 1 you receive a 910 error code, replace the • Printer controller driver 1 dc motor. board Be sure the toner and photodeveloper units are not causing an overload on the dc...
Page 119: Duplex Unit Service Check
5055-xxx Duplex unit service check Action Feed roller belts Check for wear or damage to the feed roller belts. Replace as necessary. • Duplex stepper motor Be sure the stepper motor turns freely with • Side fence no binding. • Stepper motor gears Check for wear or damage to the associated gears.
Page 120: Face Down Stacker Full Service Check
5055-xxx Face down stacker full service check Action Stacker full detection Check the stacker full detection lever for lever damage. • Stacker full detection Check for a voltage fluctuation between 0 V sensor and +5 V between pins 2 and 3 of connector •...
Page 121: Finisher Service Check
5055-xxx Finisher service check Action • Input path sensor Note: For frequent jams, hole punch • Paper register sensor problems or stapling problems. First check • Upper tray exit sensor the finisher to printer alignment. Go to • Guide stack assembly “Aligning the finisher and printer”...
Page 122: Marks On Paper Service Check
5055-xxx Action • Registration roller Run the hole punch test in diagnostic mode • Paper exit rollers to test the hole punch function. • Registration sensor • Registration clutch • Punch clutch punch unit • Timing belt • Elevator motor Observe the elevator motor operation while •...
Page 123: Operator Panel Service Check
5055-xxx Distance between marks FRU / supply item 140 mm Fuser lower roller 824.5 mm Transfer belt Fuser part locations From paper center (mm) Thermistor hot roll Thermistor BUR TCO hot roll TCO BUR Detact fingers hot roll 113.5/75/37.5/0/-37.5/-75/-113.5 Detact fingers BUR 134/90/45/0/-45/-90/-134 Exit rollers 96/37.5/-37.5/-96...
Page 124: Paper Carrying Service Check
5055-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, • Transfer roller reverse roller, and call roller are free of dirt and are not damaged.
Page 125 5055-xxx Paper is being picked up and carried to the registration roller (areas C, E, 240, 24x). Action Paper feed cassette Be sure the paper cassette has the size guides and the side locator locks are working properly. Replace parts as necessary. •...
Page 126 5055-xxx Paper has stopped at the registration roller or has not reached the fuser (areas C, E, 240, 24x). Action • Registration roller Check these parts for wear or damage. clutch Replace as necessary. Be sure all guide • Registration roller surfaces in the paper path are free of dirt.
Page 127 5055-xxx Paper has entered the fuser and exited the printer (area B). Action Fuser Remove any toner buildup and replace any worn or damaged parts. • Fuser exit lower roller Be sure the exit FU/FD solenoid energizes • Fuser exit upper roller in the correct position for either face down or •...
Page 128 5055-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 •...
Page 129 5055-xxx Paper jammed in finisher (area G). Action • Registration roller Check finisher to printer alignment. Go to • Paper exit rollers “Aligning the finisher and printer” on • Registration sensor page 3-80. • Registration clutch Check all belts for wear or damage. Check •...
Page 130 5055-xxx Paper jammed in finisher (area H). Action • Timing belts Check finisher to printer alignment. Go to • Patting roller “Aligning the finisher and printer” on page 3-80. Check for obstructions in the paper path. Check all belts for wear or damage. Check for wear or damage on the patting roller.
Page 131 5055-xxx Paper jammed (area I). Action Timing belts Check finisher to printer alignment. Go to “Aligning the finisher and printer” on page 3-80. Check the paper path for obstructions. Check all belts for wear or damage. • Invert (tray 2) exit Check to ensure that all rollers are operating roller correctly by running the hole punch and...
Page 132: Paper Exit, Face Up Service Check
5055-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 by checking for a fluctuation of between 0 V and +5 V between pins 1 and 2 of connector CN12, while actuating the sensor.
Page 133: Paper Skew Service Check
5055-xxx Paper skew service check Action Cassette Remove the tray and turn it upside down. The tray guides are connected at the center of the tray by a toothed gear that ensures they move in unison. If not, remove the screw at the center of the gear and, using a sheet of paper in the tray as a template, realign the guides.
Page 134: Photodeveloper Missing Service Check
5055-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 rear. Clean or replace the photodeveloper drum unit if necessary. Sub-frame unit Check the sensing contacts on the sub- frame assembly.
Page 135: Power Supply Service Check
5055-xxx Power supply service check Action Voltage Be sure the switch is on and the power cord is firmly plugged into the printer. Be sure the correct voltage is present at the outlet. Power cord Check the power cord for continuity. •...
Page 136: 210 Staple Jam Service Check
5055-xxx 210 Staple jam service check Action Stapler Check for jammed staples in the stapler. Clear the staple jam, go into diagnostic Staple cartridge holder mode, and run a staple test. If the problem reoccurs, replace the staple cartridge holder. If this does not resolve the problem, replace the stapler.
Page 137: Transfer Belt Up/Down Service Check
5055-xxx Transfer belt up/down service check Action Belt up/down sensors Check the transfer belt up/down sensor. Be sure that connector CN29 is firmly Belt up/down actuator connected to the printer controller board. Replace the sensor or the actuator if necessary. Check for a fluctuation between 0 V and +5 V between pins 8 and 10, while actuating the sensor.
Page 138: Image Quality Troubleshooting
5055-xxx Image quality troubleshooting Print quality problems Problem Action Print is too light, or printed Be sure you’re using recommended images or characters have voids paper or other media. Use media from a or dropouts. new package. Be sure you have selected the correct Paper Weight setting for the media you’re using.
Page 139 5055-xxx Problem Action Colored lines, streaks, or Replace the photodevelopers. If the smudges appear on the printed problem only occurs when printing black, page, or print appears blurred or replace just the black photodeveloper and unclear. fuser coating roll. If the problem occurs when printing one of the colors, replace all three of the color photodevelopers.
Page 140 5055-xxx Problem Action Light lines or streaks appear on Clean the LEDs. the printed page. Make sure the affected photodeveloper is completely installed in the printer. Remove the affected toner cartridge and gently shake it back and forth to distribute the toner evenly.
Page 141 5055-xxx Problem Action Toner smears or rubs off the Be sure you’re using recommended page. paper or media. Be sure you have selected the correct Paper Weight setting for the media you’re using. Be sure the top cover is completely closed and both sides are snapped shut.
Page 142 “Periodic dirt” on page 2-97. Quality of printed transparencies Be sure you’re using the recommended is inadequate. Lexmark transparencies. Be sure you have selected the correct paper weight setting for the media you are using. When printing transparencies, always set the Paper Type to Transparency.
Page 143 5055-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 paper you load fits under the two corner tabs at the front of the tray. Be sure charge roll or belt is seated properly.
Page 144 5055-xxx No image Possible cause Action Moist paper Be sure the printer is not in a damp environment and the paper is not curled or wavy due to moisture. If necessary inform the customer about correct storage. LED printhead Be sure the LED printhead cable is securely connected to the printhead controller board and LED printhead assembly.
Page 145 5055-xxx Black line Possible cause Action Photodeveloper drum Clean any dirt from the drum surface. Replace it if it is scratched. • Fuser detach pawl Remove any toner buildup. Replace • Fuser roller surface the fuser. • Fuser thermistor surface LED printhead Clean the LED printhead.
Page 146 5055-xxx Missing colors Possible cause Action Toner cartridge unit Be sure the toner cartridge and the PC drum unit are properly seated. Photodeveloper Be sure the contacts on the print unit are clean. Be sure the print unit is installed in the correct position. Run a print test.
Page 147 5055-xxx Uneven printing Possible cause Action Photodeveloper Check for condensation or dirt on the photodeveloper. LED printhead Clean any dirt off the exposed surface of the LED printhead. Also check the locating pins of the printhead. Transfer belt unit Be sure the transfer belt is clean and not damaged.
Page 148: Options Service Check
5055-xxx Options service check Service Tip: When you have a problem with any of the options installed in the options slots on the interconnect board, switch the non operating option to one of the other option slots to isolate the failure.
Page 149 5055-xxx Hard Disk Option Service Tip: The 5055-01x printers support one hard disk option. Be sure only one 3.2 GB or larger hard disk option is installed. Be sure the hard disk and the hard disk board are correctly installed. Run the “Quick Disk Test”...
Page 150 5055-xxx 2-100 Service Manual...
Page 151: Diagnostic Aids
5055-xxx 3. Diagnostic aids Note: When troubleshooting, or prior to making any adjustment to print quality, always be sure: • The printer is installed on a level rigid surface. • The OPCs are never exchanged. Do not exchange a black OPC for a color OPC, as they have different surface phase counts.
Page 152: Using The Operator Panel
5055-xxx Using the operator panel The operator panel on your printer has a 2-line by 16-character liquid crystal display (LCD), five buttons, and one indicator light. The light indicates whether the printer power is on and whether the printer is idle or busy processing a job. Indicator light State Indicates...
Page 153: Operator Panel Buttons
5055-xxx Operator panel buttons Button Function Press • Exit printer menus and return the printer to the ready state. • Clear certain messages from the display. If you’ve changed printer settings from the operator panel menus, press Go before you send a job to print. Menu Press Menu...
Page 154: Printing The Menu Settings
5055-xxx Printing the menu settings 1. From the printer operator panel, press to enter the menus. Menu 2. Continue to press and release until you see Menu TESTS MENU 3. Press is displayed on the first line, and Select TESTS MENU is on the second line Print Menus 4.
Page 155 5055-xxx JOB MENU SETUP MENU PCL EMUL MENU Reset Printer Printer Language Font Source Cancel Fax Printer Usage Font Name Confidential Job Power Saver Point Size Held Job Resource Save Pitch Download Target Symbol Set Print Timeout Orientation Auto Continue Lines per Page Wait Timeout A4 Width...
Page 156: Diagnostic Mode
5055-xxx Diagnostic Mode To access the diagnostics printer settings and operations: 1. Turn off the printer. 2. Press and hold Go and Return. 3. Turn on the printer. Release the buttons after the Performing Self Test message is displayed.The alignment menu displays first.
Page 157 5055-xxx Setting Printer Alignment 1. Press Menu until the color you want to adjust displays and then press Select. 2. Change the displayed value and press Select. You see a message displayed that the value is Saved. If you want to skip a selection press Select.
Page 158: Adjustment Example
5055-xxx Adjustment example Here is a sample of the magenta radar image. Looking down the left side for both X and Y, you can see the X value is close to correct. It may be a little to the right. The Y value for magenta is incorrect. The magenta radar image is too far above the black.
Page 159 5055-xxx When the Y value is correctly adjusted, the magenta radar image should look like the following example. The Theta adjustment is done in the same manner as the Y except Theta values are taken from the right side of the test pages. Summary Notes: Objective: Using the X, Y, and T adjustment procedure, adjust the color to overlay the radar image as precisely as possible.
Page 160: Print Tests
5055-xxx Print tests Input Source Print Tests The Diagnostic Input Source Print Tests may be used to verify that the printer can print on media from the installed input sources, which are available within the Print Tests menu. Chose from following: •...
Page 161 5055-xxx Note: <input source> represents the input source selected for the Print Test. One of the following sources is displayed: Tray 1, MP feeder, standard bin (face-down), or Output Bin 1. The value of the <media width> field is displayed when the narrow media sensor determines the media used for the Quick Test is narrow or wide, (N for narrow, W for wide).
Page 162: Hardware Tests
5055-xxx Hardware tests LCD Hardware Test The LCD Hardware Test causes the printer to continually execute the LCD display test. To cancel the test, press Return or Stop. Button Test The Button Test verifies the operation of each button on the operator panel.
Page 163 5055-xxx The power indicator blinks indicating the memory test is in process. The printer runs this test continually. The test can be terminated by powering off the printer. Each time the test finishes, the screen is updated with the result. If the test is successful, the Pass Count increments by 1.
Page 164 5055-xxx Parallel Wrap Test The Parallel Wrap Test checks the operation of each parallel signal, using a wrap plug. To perform the wrap test: 1. Disconnect the parallel interface cable, and install the parallel wrap plug. 2. Select HARDWARE TESTS from the Diagnostics Menu. 3.
Page 165 5055-xxx If the test fails, the Fail Count increments by 1 and one of the following failure messages displays for approximately three seconds: Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fall Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error...
Page 166 5055-xxx Serial Wrap Tests The Serial Wrap Test checks each signal of the serial port hardware using a wrap plug. To perform the wrap test: 1. Disconnect the serial interface cable, and install the serial wrap plug. 2. Select HARDWARE TESTS from the Diagnostics Menu. 3.
Page 167 5055-xxx Once the maximum pass count or fail count is reached, the test stops and final test results display: Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error...
Page 168: High-Capacity Feeder Tests
5055-xxx High-capacity feeder tests High-Capacity Paper Feed Test Test paper feed operation. 1. Turn on the docking safety switch with a non-metallic object. The interface cable with the printer controller board need not be connected. 2. Close the top cover or manually activate the cover switch. 3.
Page 169 5055-xxx High-Capacity Paper Feed Sensor / Switch Test Check the condition of each sensor from the lighting of LEDs on the high-capacity paper feed board. When each sensor operates with the power supplied, the associated LED lights. To perform the test: Interrupt the photointerrupter sensor signal or actuate the micro- switch being tested while observing the associated LED on the high- capacity paper feed board.
Page 170: Finisher Tests
5055-xxx Finisher tests Staple Test This test verifies the operation of the staple mechanism in the finisher. The media is fed from the default paper source. After selecting a destination bin, the printer feeds eight pieces of media and accumulates them in the finisher accumulator. The printer prints an alignment pattern during this test.
Page 171 5055-xxx No Staple Punch Box Detect Invert Path Tray 2 Exit Elev. Upper Limit Tray Near Full Elev. Lower Limit Jogging Home Pos. Pap. Upper Level Fin. Set Switch Staple Cart. Set To select one of the sensors/switches above, press Menu until the sensor/switch is displayed.
Page 172 5055-xxx • Staple Home Position—Activate the staple home position sensor by rotating the geared wheel inside the stapler clockwise. If the sensor is working properly, the display should change from CL to OP at approximately 180° of rotation of the wheel.
Page 173: Device Tests
5055-xxx Device tests Quick Disk Test The Quick Disk Test performs a non-destructive read/write on one block per track on the disk. The following message appears while the test is running: Quick Disk Test Testing... The Power indicator blinks while the test is in progress. If the test is successful, the following message is displayed: Quick Disk Test Test Passed...
Page 174 5055-xxx Disk Test/Clean The Disk Test/Clean Test causes the disk to be formatted, destroying all data on the disk and should not be attempted on a good disk. This test should only be used when the disk contains unusable data. Note: This can be an extremely lengthy test depending on the disk size, and leaves the disk unformatted.
Page 175 5055-xxx Flash Test The Flash Test writes and reads data to the flash device, destroying all data, leaving the flash unformatted. The servicer must reformat the flash using the Format Flash menu operation. To run this test, select Flash Test from the DEVICE TESTS menu. The following message appears warning the customer that all flash contents will be lost: Files Will be...
Page 176: Diagnostics - Printer Setup
5055-xxx Diagnostics - printer setup Defaults The following printer settings are used to determine whether U.S. or non-U.S. factory defaults should be used: • = U.S. * • = Non U.S. Light Quantity • Cyan • Magenta • Yellow • Black Range = 0 to 45 If you replace one or more of the printheads, or the EEPROM for the...
Page 177 5055-xxx Par S Strobe Adj This message displays only if the printer is configured with the standard parallel port. Par 1 Strobe Adj This message displays only if a parallel port is available through the PCI slot 1. Par 2 Strobe Adj This message displays only if a parallel port is available through the PCI slot 2.
Page 178: Viewing And Resetting The Drum Counters
5055-xxx Viewing and resetting the drum counters The drum counters increment when a page is printed. The drum counter for a particular plane increments (if that color is printed), by 1 for Letter, A4, A5, B5 and envelopes, and by 1.2 for Legal and B4. It increments by 2 for 11 x 17, 12 x 18 (C912 only), and A3.
Page 179 5055-xxx Setting the Page Count The page count can be changed through the Diagnostic menus. The servicer uses this menu to reset the page count whenever the engine board, containing NVRAM memory, is replaced. When Page Count is selected from the PRINTER SETUP menu, the current page count is displayed as follows: Page Count =1234567*...
Page 180 5055-xxx Setting configuration ID Use the configuration ID to communicate characteristics of the printer that cannot be determined by the hardware sensors. The configuration ID is originally set when the printer is manufactured, but must be reset whenever the engine board, containing NVRAM memory, is replaced The configuration ID can be set through the Diagnostic menus.
Page 181: Diagnostics - Error Log
5055-xxx Diagnostics - error log Viewing the error log The Error Log provides a history of printer errors, containing the 12 most recent errors that have occurred. The most recent error displays in position 1, and the oldest error displays in position 12. If fewer than 12 errors have occurred, the oldest error displays in the position before the empty log entries begin.
Page 182 5055-xxx Clearing the error log To clear the error log, select Clear Log from the ERROR LOG menu. The following message is displayed: Clear Log = Yes Select Yes to clear the log, as the empty log message appears: 1-000 2-000 3-000 4-000...
Page 183: Theory Of Operation
5055-xxx Theory of operation Processes and configuration In this printer, the toner of four colors (magenta, cyan, yellow and black) melts and deposits dots on paper, which record color image information. This printing process is called the electrophotography process. Electrophotography process In the electrophotography process, electrically charged toner exposes, develops, transfers, and is cleaned with an aluminum photosensitive drum.
Page 184: Development Unit
5055-xxx Development unit Toner forms the electrostatic image on the photosensitive drum during exposure. The single component, non-magnetic toner and the lusterless color toner are weather-resistant, and fade little under ultraviolet rays. This is helpful in saving documents. Toner in the hopper is agitated and supplied to the development roll by the supply roll.
Page 185: Cleaning Unit
5055-xxx Cleaning unit Toner remaining on the photosensitive drum following transfer, is scraped away with the cleaning blade, and collected in the recovery bag as waste toner. Residual toner on the photosensitive medium is removed by the eraser. Paper feeding / fusing The main unit drive is composed of drives 1 and 2.
Page 186: Drive System
5055-xxx Drive system Drive 1, composed of a 100 V dc motor and gear unit, feeds the registration paper from the paper feeder and drives the belt unit, photodevelopers / toner cartridge, fusing unit, and face-up delivery unit. The motor rotates by the ON signal from the printer controller/motor drive unit and sends a rotation synchronization detection signal to the motor drive unit.
Page 187: Paper Feeding
5055-xxx Paper feeding The paper feeder is a two-way system composed of the multi-paper feeder (100 sheets maximum) and an integrated 550-sheet tray. Optionally, the expansion paper feeders (550 sheets) can be increased to four layers. A high-capacity paper feeding system (3,000 sheets) may be used.
Page 188: Multipurpose Feeding
5055-xxx Multipurpose feeding The multipaper feed solenoid turns on by the signal from the printer controller. The multipurpose feed roll interconnected with the drive 1 through the spring clutch, rotates and picks the paper in the multipurpose feeder. MPF Clutch Registration unit Media temporarily stops (registration) when adjusting the paper leading edge parallel with that of the image, or when adjusting the...
Page 189: Separation Unit
5055-xxx Separation unit The transfer belt and paper are separated with the belt drive roll by separation fingers. Drive Roll Paper Separation Fingers 3-39 Diagnostic aids...
Page 190: Fuser Unit
5055-xxx Fuser unit By applying heat and pressure, the image is melted and fused to the paper. The upper and lower rollers are heated and pressure-fitted. A heater is positioned in the roller tube and a thermistor and thermostat remain in contact with the outside of the tube. Separation fingers are attached near the upper roller to separate the paper from the roller.
Page 191: Delivery
5055-xxx Delivery After completing the fusing process, paper is discharged from the printer. The delivery sensor detects the paper condition and the FU/FD deflector switches between the face-up and face-down paper delivery. The paper from the fuser pulls down the sensing lever turning on the delivery sensor (photo interrupter).
Page 192: Belt Unit
5055-xxx Belt unit After passing through the registration unit, paper is electrostatically fed by the transfer belt through the positively charged feed roll at the inlet of the belt unit and fed by the running belt. The belt runs at the same speed as the photosensitive drum causing the image on the C, M, Y and K developer to transfer to paper.
Page 193: Belt Up/Down
5055-xxx Belt up/down In monochrome printing, switching to color printing is not required. To avoid unnecessary wear of the photosensitive drum by the cleaning blade, this operation is stopped with the electromagnetic clutch in drive 1. The transfer belt is lowered so as not to touch the photosensitive drum during color printing.
Page 194: Duplex Unit
5055-xxx Duplex unit A duplex unit can be optionally installed in the main unit, allowing two-sided printing. Selecting Paper feeding, Registration, Transfer, Separation, Fusing, or Face-Down paper discharging with the pulse motor in the duplex unit, feeding is stopped before the paper is delivered. Paper delivery is then reversed and fed to the duplex unit.
Page 195: Paper Weight
5055-xxx Paper weight Purpose: To identify the relative weight of the paper loaded in a specific source and ensure that the toner adheres properly to the printed page. Values: Plain weight Preprint weight Bond weight Labels weight Card stock weight Colored weight Envelope weight Letterhead...
Page 196: Clearing Paper Jams
5055-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.
Page 197 5055-xxx 4. Lift the cover. Warning: Do not use pointed objects to remove the paper. They may damage the transfer belt. Note: The paper may be covered with unfused toner, which can stain garments. 5. Remove any paper on the transfer belt. If the paper source was the multipurpose feeder, check the area between the multipurpose feeder and the transfer belt.
Page 198 5055-xxx Check Area C This message indicates a paper jam in the duplex unit area by the access door. To clear area C: 1. Open the duplex jam access door on the right side of the printer. 2. Remove the jam. 3.
Page 199 5055-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. 1. Open the jam access door on the top optional drawer. 2.
Page 200 5055-xxx 240 Paper Jam 1. Slowly pull the jam out of the multipurpose feeder. Note: If you are feeding banner paper, do not pull the paper out; instead, begin with step 2. If the paper will not come out, proceed with step 2. If it does, go to step 10.
Page 201 5055-xxx 241–244 Paper Jam Note: Although tray 1 is shown, you can use the same procedure to clear any of the 241–244 or Check Tray 1–4 messages. Paper jam messages 241–244 and Check Tray 1–4 indicate a jam in one of the paper trays. To remove the jam: 1.
Page 202: High-Capacity Feeder (Hcf)
5055-xxx High-capacity feeder (HCF) Paper feed and separation mechanism The high-capacity feeder consists of a tray and paper transfer mechanisms. The paper feed and separation mechanism uses a friction roller separation and paper feed system with a non-contact magnet type maintenance-free torque limiter. When the paper feed clutch turns on, the paper feed roller shaft rotates and the paper feed roller is driven with the one-way clutch.
Page 203 5055-xxx Registration operation When the paper feed motor rotates, the transfer roller is driven with relay gears. The reverse roller shaft rotates the gears on the paper feed clutch in the direction of the arrow and stops by the friction force of the paper feed roller.
Page 204 5055-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 205 5055-xxx Also, when the top surface of the paper lowers during printing and the up sensor is shielded, the tray motor again rotates forward to raise the paper. When the down button is pressed, the tray motor reverses to move the tray down.
Page 206 5055-xxx tray moves down by about 500 sheets. The down sensor detects the tray lower limit position. Tray up condition Tray up motion stops when the: • Up sensor is OFF (not shielded) • Power cord is connected and the joint switch is ON •...
Page 207 5055-xxx Tray down condition Tray down motion stops when the: • Paper level sensor is OFF • Down button is pressed • Paper end is detected Size detection mechanism The paper size can be switched between A4 and letter (11 inches) by changing the side fence position.
Page 208 5055-xxx Residual paper detection mechanism The residual paper quantity in the tray is detected with four photo interrupters. The quantity of pages remaining in the sheet feeder displays in the following increments: • Near end, about 80 sheets • About 300 sheets •...
Page 209 5055-xxx Paper end detection A reflection type sensor is provided on the top stay to detect the paper top surface and the paper end. 3-59 Diagnostic aids...
Page 210: Maintenance Mode
5055-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 211: Finisher
5055-xxx Finisher The finisher communicates with the host engine through serial interface signals and performs the following operating modes: • Straight—exits paper to the upper tray. • Punch and straight—stops paper at the leading edge, punches it, and exits it to the upper tray. •...
Page 212 5055-xxx 3-62 Service Manual...
Page 213 5055-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 3-63 Diagnostic aids...
Page 214 5055-xxx Electrical parts function • Finisher Set Switch—detects the connection with the printer. • Staple Cartridge Set Switch—detects when the staple cartridge is open. • Staple Existence Sensor—detects when the stapler is empty. • Staple Home Position Sensor—locates home position for stapling.
Page 215 5055-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.
Page 216 5055-xxx Path select gate 3-66 Service Manual...
Page 217 5055-xxx Inverting paper path (exit paper to lower tray through accumulator) The paper feed motor drives and rotates the rollers as paper feeds through the registration rollers, path select gate, and patting rollers. Paper is detected by the invert path sensor. Paper is then jogged by jogging bar and driven by the belt drive motor before exiting to the lower tray (accumulator).
Page 218 5055-xxx Accumulator 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 219 5055-xxx Punch unit driving sequence When the paper feed motor drives, the driving force is transmitted through the punch unit drive gear to the clutch gears of the punch unit. Since the punch clutch is normally opened OFF, the driving force is not transmitted to the driving shaft.
Page 220 5055-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. Offsetting sequence Sheets of jogged paper are offset by the horizontal movement of the jogging bar.
Page 221 5055-xxx Detection of fixed position The fixed position of the jogging bar is detected by the jogging home position sensor and a sensor flag united with the pinion. The fixed position is set when the sensor detects the sensor flag. This fixed position is used as a reference point to calculate the distance of the movement of the jogging bar and offset bar depending on paper size.
Page 222 5055-xxx turns OFF. If paper feeds onto the lower tray when the elevator lower limit sensor turns ON, and the paper upper level sensor B turns ON, paper feeding from host printer is prohibited. When paper is removed from the lower tray and the paper upper level sensor B turns OFF, the lower tray moves up.
Page 223: Finisher Installation
5055-xxx Finisher installation Attaching the docking plate and guide rail 1. Lift the printer exit tray halfway and remove. You will need the tray when the finisher is attached. 2. Insert the docking plate tabs into the printer. 3. Align the thumbscrews on the docking plate with the holes in the side of the printer.
Page 224 5055-xxx 6. Tighten the guide rail plate thumbscrews. 7. Align the thumbscrews on the guide rail with the holes in the guide rail plate. 8. Tighten the guide rail thumbscrews. 3-74 Service Manual...
Page 225: Combining The Finisher And Stand
5055-xxx Combining the finisher and stand 1. Roll the finisher stand onto the guide rail. Do not push the stand all the way up against the printer. 2. Remove and discard all shipping tape, packing material, and the metal shipping bracket. CAUTION: The finisher weighs 19.7 kg (42.2 lb).
Page 226 5055-xxx 3. Open the stapler door. 4. Remove all shipping tape and packing material. 5. Lift the stapler locking lever. 6. Raise the stapler. 7. Remove all shipping tape and packing material. 3-76 Service Manual...
Page 227 5055-xxx 8. Close the stapler. 9. Close the stapler door. 10. Align the two sockets on the bottom of the finisher with the legs of the finisher stand. 3-77 Diagnostic aids...
Page 228 5055-xxx 11. Lower the finisher onto the finisher stand. CAUTION: When assembled, the finisher weighs 26.3 kg (56.9lb) and requires at least two people to lift it safely. 12. Remove both thumbscrew spacers. 13. Tighten the two thumbscrews. 3-78 Service Manual...
Page 229: Attaching The Bins
5055-xxx Attaching the bins 1. Align the slots on bin 2 with the metal brackets on the rear of the finisher. 2. Slide the bin down onto the metal brackets until it is fully seated. Note: When assembled, the finisher and finisher stand are referred to as the finisher.
Page 230: Aligning The Finisher And Printer
5055-xxx Aligning the finisher and printer The following three areas must align properly to prevent paper jams. 1. The docking plate pins must enter the holes in the finisher. 2. The space between the printer and finisher must be the same at the top and bottom of the finisher.
Page 231 5055-xxx 4. Roll the finisher toward the printer until the finisher locks to the docking plate pins. You hear a click when the finisher locks into position. If the pins did not go into the holes in the finisher, go to “Lowering or raising the finisher”...
Page 232 5055-xxx Lowering or raising the finisher Follow these instructions if the holes on the finisher are above or below the pins on the docking plate. 1. Determine if the pins are above or below the holes in the finisher. 2. Loosen the guide rail thumbscrews. 3-82 Service Manual...
Page 233 5055-xxx 3. Rotate the adjustment knobs as needed to align the holes in the finisher with the pins. • To raise the finisher, rotate the adjustment knobs clockwise. • To lower the finisher, rotate the adjustment knobs counterclockwise. 4. Roll the finisher toward the printer until the finisher locks to the docking plate pins.
Page 234 5055-xxx Aligning the sides of the finisher Follow these instructions if the distance between the finisher and printer is not the same at the top and bottom. 1. Loosen the guide rail thumbscrews. If you previously lowered or raised the guide rail plate, the thumbscrews are already loose.
Page 235 5055-xxx 2. Rotate the rear adjustment knobs to equally align the top and bottom of the finisher with the printer. • To move the top of the finisher closer to the printer, rotate the adjustment knobs clockwise. • To move the top of the finisher away from the printer, rotate the adjustment knobs counterclockwise.
Page 236 5055-xxx Aligning the top of the finisher Note: Anytime you move the printer or finisher, recheck the printer and finisher top alignment. Follow these instructions if the alignment marks on top of the finisher are not aligned with the edges of the cover on the side of the printer. 1.
Page 237 5055-xxx 4. Roll the finisher toward the printer until the finisher locks to the docking pins. You hear a click when the finisher locks into position. 3-87 Diagnostic aids...
Page 238: Adjusting The Wheels
5055-xxx 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: 1. Rotate the left and right upper adjustment knobs on the rear wheels until the wheels touch the floor. To lower the wheels, rotate the adjustment knobs clockwise.
Page 239 5055-xxx 3. Rotate the locking knobs counterclockwise until they contact the finisher base. 3-89 Diagnostic aids...
Page 240: Attaching The Cables
5055-xxx Attaching the cables The finisher comes with an interface cable and Y-power cord. The interface cable connects the finisher to the printer, and the Y-power cord provides electrical power to the finisher and printer. 1. Turn the printer off and unplug the power cord from the power outlet.
Page 241 5055-xxx Interface cable CAUTION: Make sure the printer is turned off before continuing. 1. Plug the interface cable into the bottom connector on the back of the printer. 2. Tighten the thumbscrews. 3. Plug the interface cable into the connector on the side of the finisher.
Page 242 5055-xxx Power cable 1. Unplug the power cord from the side of the printer. Set the cord aside. 2. Plug the straight Y-power cord connector into the socket on the side of the finisher. 3. Plug the angled connector of the Y-power cord into the socket on the side of the printer.
Page 243 5055-xxx 4. Connect the previously removed printer power cord to the Y-power cord. 5. Remove the protective paper from the back of the cable holder. 6. Firmly press the adhesive-backed cable holder onto the back of the top optional drawer. 3-93 Diagnostic aids...
Page 244: Hole Punch Adjustment
5055-xxx 7. Place the finisher interface cable and power cord into the cable holder. 8. Close the cable holder. 9. Replug the power cord into the outlet and turn the printer on. The finisher does not have a power switch. Power is controlled by the printer.
Page 245 5055-xxx 3. Determine if the edge of the bottom of the page is below or above the top edge of the page. 4. Loosen the guide rail thumbscrews. Note: Do not move the adjustment knobs more than three complete turns from their starting position. Adjustments greater than three turns may cause paper jams.
Page 246 5055-xxx 3-96 Service Manual...
Page 247: Repair Information
5055-xxx 4. Repair information Service precautions Observe the following precautions whenever you service the printer: • Be sure to unplug the printer from the outlet before attempting to service the printer. • To reassemble the printer, reverse the order of disassembly unless otherwise specified.
Page 248 5055-xxx Replacement: • Before you unplug connectors from the circuit boards, be sure the power cord has been unplugged from the power outlet. • When you remove a board from its conductive bag or case, do not touch the pins of the integrated circuits or the printed pattern.
Page 249: Adjustments
5055-xxx Adjustments High-capacity paper feed timing belt adjustment 1. Secure the bracket with the screw, as shown. 2. Attach the spring and washer to the bracket with the screw. 3. Adjust the screw to 6mm ±1mm. 4. Tighten the screw completely. 5.
Page 250: Removals
5055-xxx Removals Cover, top removal 1. Open the top unit and remove the photodevelopers and toner cartridges. 2. Remove the two silver screws and remove the operator panel. 3. Remove five black screws from the bottom and the four silver screws from the back side.
Page 251: Cover, Front Removal
5055-xxx Cover, front removal 1. Remove the four brass hinge screws from the front cover. 2. Remove the front cover Cover, front left removal 1. Open the front cover and remove the cassette. 2. Remove the left front cover by removing the three silver screws. Repair information...
Page 252: Cover, Rear Removal
5055-xxx Cover, rear removal 1. Open the top unit. 2. Remove the three silver screws from the rear cover, and remove the cover. Cover, solenoid removal 1. Remove the screw from the solenoid cover. 2. Remove the solenoid cover. Service Manual...
Page 253: Cover, Left Side Removal
5055-xxx Cover, left side removal 1. Remove the upper cassette, front cover, paper exit tray, and duplex unit. 2. Remove the five screws from the left side cover, and remove the cover. Repair information...
Page 254: Cover, Right Side Removal
5055-xxx Cover, right side removal 1. Open the top unit and remove the front cover and upper cassette. 2. Remove the seven screws from the right side cover together with the turn guide, and remove the cover. 3. When installing the right side cover, insert the turn guide shaft into the bearing.
Page 255: Cover, Rip Board Removal
5055-xxx Cover, RIP board removal 1. Loosen the eight screws and remove the RIP cover by sliding upward. 2. Remove the three harnesses and one flat cable of the RIP board connector. 3. Remove the two screws from the parallel port connector and the screw from the USB connector.
Page 256: Tray, Paper Exit Removal
5055-xxx Tray, paper exit removal 1. Unlatch the hinge at the back side, then unlatch the hinge on the front side. 2. Remove the paper exit tray. Belt up/down clutch removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box.
Page 257: Belt Up/Down Detection Sensor Removal
5055-xxx 2. Remove the C-clip from the belt up/down clutch, and remove the clutch. Belt up/down detection sensor removal 1. Open the top unit and remove the waste toner bottle and belt unit. 2. Remove the belt up/down detection sensor from the mounting board.
Page 258: Cassette Guide Removal
5055-xxx Cassette guide removal 1. Remove the paper feed frame. 2. Remove the front cover, cassette, turn guide, right side cover, and paper feed frame. 3. Remove the screws from the cassette guide, and remove the guide. 4-12 Service Manual...
Page 259: Connector, Duplex Unit Removal
5055-xxx Connector, duplex unit removal 1. Open the top unit and remove the upper cassette, left front cover, paper feed cover, left side cover, RIP cover, RIP board, RIP box, and the electronic box. Remove the turn guide and open the paper feed cover and remove the duplex unit. Remove the left side cover and power supply A.
Page 260: Separation Fingers Removal
5055-xxx Density sensor removal Separation fingers removal Sensor cleaner removal 1. Open the top unit and remove the belt unit. 2. Remove the three screws from the sensor bracket. 3. Remove the harness band and remove the two screws from the density sensor from the sensor bracket.
Page 261: Drive Gear Unit Sensor Assembly Removal
5055-xxx Drive gear unit sensor assembly removal 1. Open the top unit and remove the gear cover, RIP cover, RIP board, RIP box, electronic box, printer controller, and high voltage power supply board. 2. Remove the screw from the drive gear unit sensor assembly. 3.
Page 262: Drive Motor Assembly Removal
5055-xxx Drive motor assembly removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 2. Remove the upper cassette, left front cover, and back cover. 3. Remove the turn guide. 4. Open the paper feed cover and remove the duplex unit. 5.
Page 263: Electronic Box Removal
5055-xxx Electronic box removal 1. Open the top unit and remove the back cover. 2. Remove the RIP board cover. 3. Remove the RIP board. 4. Remove the screws from the electronic box. 5. Disconnect the two cables from the rear of the electronic box and remove the box.
Page 264 5055-xxx Face down guide assembly removal Paper exit motor and full sensor removal 1. Open the top unit and remove the toner cartridges, photodeveloper drum units, and upper cover. 2. Remove the top cover. 3. Disconnect the connector and remove the five screws and two snap bands from the face down guide assembly.
Page 265: Fanning Pad Removal
5055-xxx Face up paper exit assembly removal 1. Open the top unit and remove the upper cassette. Open the duplex cover and remove the duplex unit. 2. Remove the left front cover, left side cover, and rear cover. 3. Remove the three screws from the face up delivery assembly and remove the assembly.
Page 266: Front Cover Open Switch Actuator Removal
5055-xxx Front cover open switch actuator removal 1. Open the front cover. 2. Remove the two screws from the front cover open switch actuator. 4-20 Service Manual...
Page 267: Fuser Removal
5055-xxx Fuser removal 1. Open the top unit. 2. Pushing the front and back lock, hold the handle, raise and remove the fuser. 4-21 Repair information...
Page 268 5055-xxx Gear cover removal Multipurpose feeder frame assembly 1. Open the top unit, and remove the upper cassette, front cover, multipurpose feeder, right side cover, and turn guide. 2. Remove the two screws from the gear cover, and remove the cover.
Page 269: High Voltage Power Supply Board (Hvu) Removal
5055-xxx 6. Remove the screw from the OHP detection sensor (upper). 7. Turn the bearing stopper of the multipurpose feeder roll forward 1/4 turn and remove upward. 8. Remove the multipurpose feeder frame assembly. High voltage power supply board (HVU) removal 1.
Page 270: Led Printhead Removal
5055-xxx LED printhead removal 1. Open the top unit, remove the top cover, toner cartridges, and photodeveloper drum units. Note: Remove the transfer belt, or spread a cloth or paper over the transfer belt to protect it from damage. 2. Remove the short black screw from the printhead holder, and remove the holder.
Page 271 5055-xxx Note: For printers with serial numbers XX–1XXXX and above, go to step 7. For serial numbers XX–0XXXX, continue with step 5. 5. For printers with serial numbers XX–0XXXX and above: Remove the four connectors from LED printhead. 6. Remove the two screws from the ground wires. C910, C912 S/N’s XX–0XXXX 4-25 Repair information...
Page 272 5055-xxx When replacing the LED printhead, replace the corresponding EEPROM shipped with the printhead, on the printhead controller board. Place the printer in Diagnostic Mode, input the printhead light quantity value plus eight (refer to note below) from the printhead label. Be sure to remove any fingerprints or stains from the printhead lens.
Page 273: Eraser Removal
5055-xxx Note: The LED printhead light intensity values do not have to be entered for the printer S/N XX–1XXXX and above. Eraser removal 1. Remove the appropriate printheads (see “LED printhead removal” on page 4-24). Spread a cloth or paper over the transfer belt to protect it from damage.
Page 274: Lock Handle Assembly Removal
5055-xxx Lock handle assembly removal 1. Open the top unit. 2. Turn the plastic latch on the front and rear sides 90°. 3. Remove the spring. 4. Remove the lock handle assembly. 4-28 Service Manual...
Page 275: Main Drive Unit Removal
5055-xxx Main drive unit removal 1. Open the top unit and remove the gear cover, upper cassette, left front cover, paper feed cover, RIP cover, RIP board, RIP box, electronic box, and rear cover. 2. Open the turn guide and paper feed cover and remove the duplex unit.
Page 276 5055-xxx 12. Remove the two screws of the fuser connector cable assembly from the fuser connector plate. Note: Note the direction, when installing. 13. After removing the two screws on the bracket that attaches the rear side and paper exit side of the machine, remove the nine screws from the bracket.
Page 277 5055-xxx 15. Remove the screw from the clutch stopper. The clutch stopper is attached to the ground plate with two screws. 16. Remove the six screws on the right side. 17. Remove the two screws from the drive unit, and remove the unit.
Page 278: Main Unit Fan Removal
5055-xxx 18. Remove the three screws from the belt up/down clutch box and remove the belt up/down clutch. 19. Remove the screw from the drum gear sensor and remove the sensor. Main unit fan removal 1. Remove the left side cover, the solenoid cover, and the rear cover.
Page 279: Motor Drive Board Removal
5055-xxx Motor drive board removal 1. Remove the upper cassette, front cover B, paper feed cover, and the left side cover. 2. Disconnect the five connectors and remove five screws, and two screws from the motor drive board. Multipurpose feeder paper present sensor removal 1.
Page 280: Multipurpose Feeder Tray Removal
5055-xxx Multipurpose feeder tray removal 1. Open the top unit and remove the front cover, cassette feeder, turn guides and right side cover. 2. Open the multipurpose feeder and slide it toward the magnet in the direction of the arrow, removing it from the printer. Operator panel removal 1.
Page 281: Paper Carrying Frame Removal
5055-xxx Paper carrying frame removal 1. Open the top unit and remove the upper cassette, front cover, turn guide, multipurpose feeder, right side cover, turn guide, OHP detection sensor (upper), multipurpose feeder frame, back cover, RIP cover, RIP board, RIP box, and electronic box. 2.
Page 282: Paper Carrying Roller Removal
5055-xxx Paper carrying roller removal 1. Open the turn guide. 2. Remove the two screws from the paper carrying roller, and slide the bearing forward. 4-36 Service Manual...
Page 283: Paper Feed Frame Removal
5055-xxx Paper feed frame removal 1. Open the top unit and remove the RIP board cover, RIP board, RIP box, and electronic box. Open the turn guide and paper feed cover and pull out the duplex unit halfway. 2. Remove the belt unit. 3.
Page 284: Paper Feed Roller Removal
5055-xxx Paper feed roller removal 1. Remove the front cover. 2. Remove the manual paper feed tray. 3. Remove the right side cover and turn guide. 4. Remove the upper cassette. 5. Release the clutch until the paper feed roller screws are visible. Turn the paper feed roller, and remove the screws from the roller.
Page 285: Paper Remaining Sensor Removal
5055-xxx Paper remaining sensor removal 1. Remove the paper feed frame. 2. Remove the two screws from the paper remaining detection sensor and remove the sensor. Paper size sensor board assembly removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box.
Page 286: Power Supply 1 Removal
5055-xxx Power supply 1 removal 1. Unplug the power cord from the printer. 2. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. Remove the cassette, left front cover, and back cover. Remove the left side cover. 3.
Page 287: Power Supply 2 Removal
5055-xxx Power supply 2 removal 1. Unplug the power cord from the printer. 2. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 3. Disconnect the connector and remove the seven screws from power supply 2, and remove the power supply.
Page 288: Power Switch Removal
5055-xxx Power switch removal 1. Remove the upper cassette, left front cover, paper feed cover, and left side cover. 2. Unlock the power switch and pull out the power switch. 3. Remove each terminal connected to the power switch. Note: When connecting, be careful to connect the connectors correctly.
Page 289: Printer Controller Removal
5055-xxx Printer controller removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 2. Remove the connectors and the eight screws from the printer controller. Pay attention to the location or label the two pin connectors when removing them from the board to avoid re-connection into the wrong location.
Page 290: Printhead Controller Board Removal
5055-xxx Printhead controller board removal For S/N’s XX–0XXXX: 1. Remove the top cover. 2. Remove the 20 printhead controller board connectors. 3. Remove the screws from the printhead controller board, and remove the board. Note: When replacing the board, be sure to return the four EEPROMs on the former board to the same positions on the new board.
Page 291 5055-xxx For S/N’s XX–1XXXX: 1. Remove the top cover. 2. Remove the 12 printhead controller board connectors. 3. Remove the six screws from the printhead controller board and remove the board. 4-45 Repair information...
Page 292 5055-xxx Note: When replacing the board, be sure to return the four EEPROMs on the former board to the same positions on the new board. 4-46 Service Manual...
Page 293: Registration Clutch Removal
5055-xxx Registration frame Registration clutch removal 1. Open the top unit, open the turn guide, open the paper feed cover and pull out the duplex unit halfway. 2. Remove the two screws from the registration frame. 3. Remove the registration clutch. Note: When installing, set the clip of the registration clutch to the stopper.
Page 294: Registration Sensor Removal
5055-xxx Registration sensor removal 1. Open the top unit and remove the upper cassette, front cover, turn guide, multipurpose feeder, right side cover, and multipurpose feeder frame. 2. Disconnect the connector of the registration sensor and remove the sensor. 4-48 Service Manual...
Page 295: Right Slide Rail Removal
5055-xxx Right slide rail removal 1. Remove the upper cassette. 2. Remove the screw from both left and right slide rails. RIP box removal 1. Remove the six screws from the RIP box. 2. Slightly lift and remove the RIP box. 4-49 Repair information...
Page 296: Sensor Board Removal
5055-xxx Sensor board removal 1. Remove the transfer belt unit. 2. Remove the four connectors. 3. Remove the three screws from the waste toner full sensor board. 4-50 Service Manual...
Page 297: Stay Arm Removal
5055-xxx Stay arm removal 1. Open the top unit and remove the face down paper guide assembly. 2. Remove the yellow and black sub frame. 3. Remove the screw from the right stopper, and remove the stopper. 4. Remove the screw from the left stopper, and remove the stopper.
Page 298: Sub-Frame Removal
5055-xxx Sub-frame removal Important: Read the entire procedure before removal. 1. Open the top unit, and remove the RIP cover, RIP board, RIP box, electronic box, printer controller, printer controller bracket, and high voltage power supply board. 2. Remove cable ties. 3.
Page 299: Sub Frame F1, Sub Frame F2 Removal
5055-xxx Sub frame F1, sub frame F2 removal 1. Open the top unit 2. Remove the two screws from the sub frames F1 and F2. Note: Spread a paper or cloth over the belt to protect the belt. Set the sub frame F to the position of the following colors, depending on the presence of the upper detection buttons.
Page 300 5055-xxx Temperature/humidity sensor removal Paper feed solenoid removal 1. Open the top unit and remove the RIP cover, RIP board, RIP box, and electronic box. 2. Remove the screw from the temperature/humidity sensor, and remove the sensor. 3. Remove the two screws from the paper feed solenoid bracket and remove the solenoid.
Page 301: Top Unit Removal
5055-xxx Top unit removal 1. Open the top unit and remove the top cover and face-down guide assembly. 2. Remove the screws and remove the top unit. 4-55 Repair information...
Page 302: Transfer Belt Removal
5055-xxx Transfer belt removal Note: If the transfer belt removal was attempted without using the Supplies Menu to lower the belt and the transfer belt is jammed or stuck, go to “Alternate method: Transfer belt was partially removed” on page 4-64.
Page 303 5055-xxx 3. Loosen the thumbscrews as shown. 4. Lift and remove the transfer belt cover. 4-57 Repair information...
Page 304 5055-xxx 5. Loosen the thumbscrews as shown. 4-58 Service Manual...
Page 305 5055-xxx 6. Pull the transfer belt out. 7. After replacing the transfer belt and removing the four shipping spacers, tighten the transfer belt thumbscrews and reinstall the transfer belt cover. 8. Close the top unit and rotate the locking lever to the right, and close the front cover.
Page 306 5055-xxx Alternate method: Operator panel is inoperable or unrecoverable error code If the operator panel is inoperable or if you have an unrecoverable error code, use this method. 1. Turn the printer off along with any optional devices connected to the printer.
Page 307 5055-xxx 4. Remove the transfer belt cover. 5. Override the front cover interlock switch. 6. Turn the printer on. 7. Look for the belt to lower during power on sequence. 8. Turn the printer off when the belt lowers. 4-61 Repair information...
Page 308 5055-xxx 9. Loosen the thumbscrews as shown. 4-62 Service Manual...
Page 309 5055-xxx 10. Pull the transfer belt out. 11. After replacing the transfer belt and removing the four shipping spacers, tighten the transfer belt thumbscrews and reinstall the transfer belt cover. 12. Close the top unit and rotate the locking lever to the right, close the front cover.
Page 310 5055-xxx Alternate method: Transfer belt was partially removed Use this method when the transfer belt removal was attempted without using the Supplies Menu to lower the belt. 1. Turn the printer off. 2. Remove the two thumbscrews on the transfer belt cover. 3.
Page 311: Turn Guide Cover Sensor Removal
5055-xxx Turn guide cover sensor removal 1. Open the top unit and remove the upper cassette, front cover, multipurpose feeder, right side cover, and turn guide. 2. Remove the two screws from the turn guide sensor, and remove the sensor. 4-65 Repair information...
Page 312: Upper Fan Removal
5055-xxx Upper fan removal 1. Open the top unit and remove the toner cartridges and photodeveloper drum units, top cover, and face-down guide assembly. 2. Remove the four screws and the five screws from the upper bracket, and remove the bracket. 3.
Page 313: Options Removals
5055-xxx Options removals Expansion paper feeder removal 1. Remove the cassette. 2. Remove the two screws from the front cover, and remove the cover. 3. Remove the two screws from left side cover, and remove the cover. 4. Remove the two screws from right side cover A, and remove the cover.
Page 314 5055-xxx 9. Remove the screw from the paper detection cover, and remove the cover. 10. Remove the paper detection sensor. 11. Remove the high-capacity feeder guide. The cover is hinged in place. 12. Remove the four screws from the paper feed roller assembly N5 and remove the roller.
Page 315 5055-xxx 13. Remove the screw from the gear cover, and remove the cover. 14. Remove the two screws from the paper carrying roller, and remove the roller. 15. Remove the connector and remove the two screws from the drive motor, and remove the motor. 4-69 Repair information...
Page 316 5055-xxx 16. Remove the six screws from the drive assembly, and remove the assembly. 17. Remove the two screws from the paper remaining detection board, and remove the board. 18. Remove the four screws from the solenoid assembly, and remove the assembly. 4-70 Service Manual...
Page 317 5055-xxx 19. Remove the two bearings from the turn guide. The cover is hinged in place. 20. Remove the screw from the paper feed frame fuser plate, and remove the plate. 4-71 Repair information...
Page 318 5055-xxx 21. Remove the two screws from the fuser frame assembly, and remove the assembly. 22. Remove the three screws from the cassette guide assembly, and remove the assembly. 4-72 Service Manual...
Page 319 5055-xxx 23. Remove the six screws from the second drive board assembly, and remove the assembly. 24. Remove the two screws from the paper size detection board, and remove the board. 25. Remove the screw from the size detection lever spring, and remove the spring.
Page 320 5055-xxx 26. Remove the two screws from the connector plate, and remove the plate. 27. Remove the two screws from the upper drawer connector (male), and remove the connector. 28. Remove the two screws from the lower drawer connector (female), and remove the connector. 4-74 Service Manual...
Page 321: Duplex Removals
5055-xxx Duplex removals Duplex unit separation removal 1. Remove the thumbscrews, C-clips, and screws as shown from both sides. 2. Remove the connectors and separate the duplex frame from the duplex unit. 4-75 Repair information...
Page 322: Duplex Unit Removal
5055-xxx Duplex unit removal 1. Remove the four screws from the interface board, and remove the board. 2. Remove the two screws from the duplex connector, and remove the connector. Duplex timing belt removal 1. Remove the three C-clips from the three timing gears and remove the timing belts.
Page 323: Duplex Pressure Roller And Solenoid Removal
5055-xxx Duplex pressure roller and solenoid removal 1. Remove the two screws securing the pressure roller solenoid assembly. 4-77 Repair information...
Page 324: Duplex Feed Roller And Solenoid Removal
5055-xxx Duplex feed roller and solenoid removal 1. Remove the two screws securing the feed roll solenoid assembly. 2. Remove the pressure roller and springs. 3. Remove the feed roller and springs. 4-78 Service Manual...
Page 325: Duplex Side Fence Motor Assembly/Side Fence Removal
5055-xxx Duplex side fence motor assembly/side fence removal 1. Remove the three screws and remove the side fence motor assembly. 2. Remove the front and rear side fences. Note: When installing, spread the front and rear side fences to the sides and install.
Page 326: Duplex Paper Carrying Motor Removal
5055-xxx Duplex paper carrying motor removal 1. Remove the gear cover. 2. Remove the screws from the duplex paper carrying motor and remove the motor. 4-80 Service Manual...
Page 327: High-Capacity Feeder (Hcf) Removals
5055-xxx High-capacity feeder (HCF) removals HCF covers removal 1. Remove the two screws from the drive cover, and remove the cover. 2. Remove the front cover. 3. Remove the two screws from the right cover, and remove the cover. 4. Remove the top cover. 5.
Page 328: Hcf Call Roller, Paper Feed Roller, Reverse Roller Removal
5055-xxx HCF call roller, paper feed roller, reverse roller removal 1. Open the top cover on the tray. 2. Remove the two screws from the transfer cover, and remove the cover. 3. Remove the retaining rings on the rollers, and remove the rollers.
Page 329: Hcf Pickup Solenoid Removal
5055-xxx HCF pickup solenoid removal 1. Remove the four screws from the transfer cover, and remove the cover. 2. Remove the two screws from the drive cover, and remove the cover. 3. Remove the screw from the clamp plate, and remove the plate. 4.
Page 330 5055-xxx HCF paper end sensor removal HCF paper size sensors (1, 2) removal 1. Cover the paper level sensor with your hand and press the down button. The tray moves down. Lower the tray until the down sensor turns on. 2.
Page 331 5055-xxx Notes: • To prevent damage to the stay, hold the stay when removing the sensors. • Be sure the side registration is not shifted, which may occur with the dismounting and mounting of the locking stay. If it is shifted, relocate the stay toward the front or rear to adjust.
Page 332: Hcf Tray Motor Removal
5055-xxx HCF tray motor removal 1. Remove the rear cover and the drive cover. 2. Remove the two screws of the tray motor, and remove the motor. 4-86 Service Manual...
Page 333: Hcf Paper Level Sensor Removal
5055-xxx HCF paper level sensor removal 1. Remove the four screws from the transfer cover, and remove the cover. 2. Remove the two screws from the sensor, and remove the cover. 3. Remove the connector and screw from paper level sensor, and remove the sensor.
Page 334: Hcf Power Supply Removal
5055-xxx HCF power supply removal 1. Move the paper tray upward. 2. Disconnect the power cord. 3. Remove the front cover. 4. Remove the two screws from the power supply cover, and remove the cover. 5. Remove the four screws from the power supply unit and remove the unit.
Page 335: Finisher Removals
5055-xxx Finisher removals External covers removals 1. Remove the finisher trays. 2. Remove the two screws from the front cover and remove the cover. 3. Remove the two screws of the rear cover and remove the cover. 4-89 Repair information...
Page 336: Finisher Control Board Removal
5055-xxx 4. Remove the two screws from the top cover and remove the cover. Finisher control board removal 1. Remove the external covers. 2. Disconnect all of the associated connectors. 3. Remove the four finisher control board mounting screws and remove the board.
Page 337: Elevator Motor Removal
5055-xxx Elevator motor removal 1. Disconnect the elevator motor connector. 2. Remove the two elevator motor bracket screws from the bracket. 3. Remove the elevator motor assembly. Feed motor assembly removal 1. Remove the finisher control board mounting bracket. 2. Loosen the tension bracket mounting screw. 3.
Page 338: Hole Punch Removal
5055-xxx Hole punch removal 1. Remove the external covers. 2. Remove the hole punch unit cables. 3. Remove the tension spring. 4. Remove the screw and E-ring from the tension bracket and remove the bracket. Note: When installing the tension bracket, use the left side screw hole for the three hole punch unit and the right side screw hole for the four hole punch unit.
Page 339: Inverter Paper Exit Discharge Brush Removal
5055-xxx Inverter paper exit discharge brush removal 1. Remove the external covers. 2. Remove the finisher control board. 3. Remove the upper left panel. 4. Remove the two discharge brush screws and remove the brush. Inverter paper exit roller removal 1.
Page 340 5055-xxx 4. Remove the inverter paper exit roller bushing. 5. Remove the inverter idle gear. 6. Remove the inverter drive gear and bushing. 7. Remove the inverter paper exit roller. 4-94 Service Manual...
Page 341: Jogging Unit Removal
5055-xxx Jogging unit removal 1. Remove the dust box. 2. Remove the two screws and remove the cover. 3. Disconnect the jogging motor connector. 4. Disconnect the jogging home position sensor connector. 5. Remove the jogging unit. 4-95 Repair information...
Page 342: Path Select Gate Removal
5055-xxx Path select gate removal 1. Remove the external covers. 2. Remove the two screws from the top cover and remove the cover. 3. Remove the gate solenoid with mounting bracket. 4. Remove the straight paper exit sensor connector. 5. Remove the upper guide plate for the straight paper exit. 6.
Page 343: Patting Roller Removal
5055-xxx Patting roller removal 1. Remove the front and rear covers. 2. Remove the finisher control board mounting bracket. 3. Remove the two screws from the upper left panel and remove the panel. 4. Disconnect the sensor connector. 5. Remove the sensor harness from the harness clamp. 4-97 Repair information...
Page 344 5055-xxx 6. Remove the four upper guide plate screws from the inverter paper exit and remove the plate. 7. Remove the four screws from the inverter guide plate and remove the plate. 8. Remove the tension springs. Use the upper hole when installing the spring.
Page 345: Power Supply Removal
5055-xxx 10. Remove the patting roller. Patting Roller Power supply removal 1. Unplug the power cord from the printer. 2. Remove the external covers. 3. Remove the lower left panel. 4. Remove the cable connector for the left panel. 5. Remove the four lower guide support plate screws and remove the plate.
Page 346: Registration Roller Removal
5055-xxx 6. Remove the two power supply screws. 7. Remove the screw from the ground wire. 8. Disconnect the power supply connector and remove the power supply. Registration roller removal 1. Remove the hole punch unit. 2. Remove the registration roller clutch. 3.
Page 347: Registration Roller Clutch Removal
5055-xxx Registration roller clutch removal 1. Remove the harness from the clamp. 2. Remove the three control board mounting bracket screws and remove the bracket. 3. Remove the registration roller clutch set screw. 4. Remove the registration roller clutch connector. 5.
Page 348: Stack Area Discharge Brush Removal
5055-xxx Stack area discharge brush removal 1. Remove the dust box. 2. Remove the stack area discharge brushes. Staple unit removal 1. Remove the staple unit connector. 2. Pull outward on the staple cover and remove the staple unit. 4-102 Service Manual...
Page 349: Straight Paper Exit Discharge Brush Removal
5055-xxx Straight paper exit discharge brush removal 1. Remove the external covers. 2. Remove the two screws from the top cover and remove the cover. 3. Remove the two lever screws and remove the lever. 4. Remove the two discharge brush screws and remove the brush. Straight paper exit roller removal 1.
Page 350 5055-xxx 6. Remove the rear straight paper exit roller E-ring and bushing. 7. Remove the straight paper exit roller. 4-104 Service Manual...
Page 351: Timing Belts 1 And 2 Removal
5055-xxx Timing belts 1 and 2 removal 1. Remove the finisher control board mounting bracket. 2. Remove the feed motor mounting bracket. 3. Remove the tension bracket mounting screw. 4. Remove the tension spring. 5. Remove the timing belt 1. 6.
Page 352: Tractor Belt Removal
5055-xxx Tractor belt removal 1. Remove the external covers. 2. Remove the lower left panel. 3. Remove the cable connector of the left panel. 4. Remove the belt motor unit. 5. Remove the four lower guide support plate screws for the invert paper exit.
Page 353 5055-xxx 7. Remove the paper jam removal knob. Knob 8. Remove the tractor belts. Note: Install the belt so that the belt tooth just under the plastic hook aligns with the hook on the other belt. 4-107 Repair information...
Page 354: Tractor Drive Motor Assembly Removal
5055-xxx Tractor drive motor assembly removal 1. Remove the outer covers. 2. Remove the drive belt. 3. Remove the three screws and disconnect the connector from the tractor drive motor assembly. 4. Remove the tractor drive motor assembly. 4-108 Service Manual...
Page 355: Locations
5055-xxx 5. Locations Covers diagram Locations...
Page 356: Major Parts Diagram
5055-xxx Major parts diagram Service Manual...
Page 357 5055-xxx Major parts diagram, legend Part Part Development roll Paper out detection lever Supply roll Paper out detection sensor Doctor blade Duplex unit Agitator Transfer sheet Absorption roll Transfer belt Registration upper roll Belt dive roller Registration lower roll Paper delivery detection lever Registration sensor Press roll...
Page 358: Sensor And Switch Locations
5055-xxx Sensor and switch locations Service Manual...
Page 359 5055-xxx Locations...
Page 360: Component Locations
5055-xxx Component locations Service Manual...
Page 361 5055-xxx Component locations, legend Number Component Printhead controller board Operator panel RIP box Motor driver board Power switch Printer controller board High voltage unit (HVU) Upper left fan Main drive motor Upper right fan Power supply fan Temperature/humidity sensor Paper remaining detection sensor (main unit) Paper remaining detection sensor (expansion feeder) Power supply 2 Power supply 1...
Page 362: Printer Controller Board
5055-xxx Printer controller board CN33 CN44 CN20 CN14 CN43 CN12 CN40 CN34 CN25 CN22 CN19 CN21 CN18 CN30 CN28 CN27 CN11 Service Manual...
Page 363: Printer Controller Board Connectors
5055-xxx Printer controller board connectors The connectors are listed in the order they appear on the engine board, beginning at CN20 in the top right and continuing clockwise around the edge of the board. Note the orientation of the printer controller board diagram.
Page 364 5055-xxx Printer controller board connectors (continued) Board Board Cable # wires connector conn. conn. Wire colors orientation color color cable Vertical White White 2 Green, 2 blue, 2 red, 2 yellow Horizontal Brown Brown 1 Red, 79 brown (ribbon) Horizontal White Green Brown...
Page 365 5055-xxx Printer controller board connectors (continued) Board Board Cable # wires connector conn. conn. Wire colors orientation color color cable Vertical White Gray White Vertical White White Red, black Vertical Black White Black Vertical White White 7 Black, white Vertical White White 3 Black, 3 white...
Page 366: Printhead Controller Board
5055-xxx Printhead controller board For printers with serial number XX–0XXXX: For printers with serial number XX–1XXXX: CN06 CN05 CN11 CN07 CN01 CN20 CN18 CN16 CN14 CN03 CN08 CN12 CN02 CN09 CN10 CN04 CN19 CN17 CN15 CN13 5-12 Service Manual...
Page 367: Rip Board
5055-xxx RIP board JT14 JT13 5-13 Locations...
Page 368: Power Source Unit 1 Board
5055-xxx Power source unit 1 board CN106A CN01 Power source unit 2 board 5-14 Service Manual...
Page 369: High Voltage Power Supply Board
5055-xxx High voltage power supply board CN102 CN101 Sensor board 5-15 Locations...
Page 370: Expansion Paper Feeder Controller Board
5055-xxx Expansion paper feeder controller board Duplex unit controller board Motor drive board 5-16 Service Manual...
Page 371: Size Sensor Board
5055-xxx Size sensor board 5-17 Locations...
Page 372: High-Capacity Feeder (Hcf)
5055-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 373: Electrical Parts Layout
5055-xxx Electrical parts layout 5-19 Locations...
Page 374: Driving Parts Layout
5055-xxx Driving parts layout 5-20 Service Manual...
Page 375: Finisher Locations
5055-xxx Finisher locations 5-21 Locations...
Page 376 5055-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 5-22 Service Manual...
Page 377 5055-xxx Sensor, Switch Purpose Paper input path sensor Detects paper input from printer Paper registration sensor Trigger for punching Paper exit sensor (face up Confirming paper path bin) Tractor home position Finds home position for driving belt sensor Paper full sensor A Detecting paper full on tray 2 Paper detecting sensor Detects paper for stapling...
Page 378 5055-xxx Finisher Face Up Bin (Tray1) Punch Finisher Face Down Bin (Tray2) 5-24 Service Manual...
Page 379 5055-xxx Motor, Solenoid, Clutch Purpose Paper feed motor Paper feeding and inverting Tractor drive motor Tractor drive for paper feeding Staple motor Stapling Path select solenoid Path changing Paper jogging motor Jogging of paper Punch clutch Punching Registration clutch Paper registration/feeding Elevator motor Face down bin movement 5-25...
Page 380 5055-xxx Finisher electrical part 5-26 Service Manual...
Page 381 5055-xxx 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 Elevator lower limit...
Page 382 5055-xxx 5-28 Service Manual...
Page 383: Preventive Maintenance
5055-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 384: Periodic Maintenance
5055-xxx Periodic maintenance This table lists the parts to be periodically cleaned by the servicer. Part name Method Paper feed unit: Remove any dust or dirt, and wipe the surface lightly with a dry cloth. If • Paper feed roller it is still dirty, clean with a soft cloth •...
Page 385: Parts Catalog
5055-xxx 7. Parts catalog How to use this parts catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.
Page 386: Assembly 1: Covers 1
5055-xxx Assembly 1: Covers 1 Service Manual...
Page 387 5055-xxx Assembly 1: Covers 1 Index Units Description 1 – 1 12G7360 Board, operator panel 99A1501 Board operator panel (Japan) 56P9736 Cable, operator panel 56P9555 Housing, upper operator panel 56P9556 Housing, lower operator panel 56P9539 Cover, top 56P9533 Cover assembly, right side 56P9534 Magnet, right side latch 56P9540...
Page 388: Assembly 2: Covers 2
5055-xxx Assembly 2: Covers 2 Service Manual...
Page 389 5055-xxx Assembly 2: Covers 2 Index Units Description 2–1 56P9557 Exit assembly, face up Parts catalog...
Page 390 5055-xxx Assembly 3: Covers 3 Service Manual...
Page 391: Assembly 3: Covers 3
5055-xxx Assembly 3: Covers 3 Index Units Description 3–1 56P9566 Guide assembly, face-down 56P9575 Bushing, face down pinch roller 56P9576 Pulley, face down feed roller 56P9578 Belt, face down roller Parts catalog...
Page 392: Assembly 4: Covers 4
5055-xxx Assembly 4: Covers 4 Service Manual...
Page 393 5055-xxx Assembly 4: Covers 4 Index Units Description 4–1 56P9584 Guide assembly, turn Parts catalog...
Page 394: Assembly 5: Covers 5
5055-xxx Assembly 5: Covers 5 7-10 Service Manual...
Page 395 5055-xxx Assembly 5: Covers 5 Index Units Description 5–1 56P9972 Feeder assembly, multipurpose 7-11 Parts catalog...
Page 396: Assembly 6: Upper Unit
5055-xxx Assembly 6: Upper unit 7-12 Service Manual...
Page 397 5055-xxx Assembly 6: Upper unit Index Units Description 6–1 56P9591 Frame, upper 56P9987 Board, printhead controller–S/N XX-1XXXX 56P9620 Board, printhead controller–S/N XX-0XXXX 56P9638 Holder, cable 56P9600 Cable assembly, K13 56P9601 Cable assembly, K24 56P9602 Cable assembly, CL13 56P9603 Cable assembly, CL24 56P9716 Cable assembly, 8-pin PH controller 56P9991...
Page 398 5055-xxx Assembly 6 (continued): Upper unit 7-14 Service Manual...
Page 399 5055-xxx Assembly 6 (continued): Upper unit Index Units Description 56P9594 Cover, eraser 56P9595 Lamp, M erase 56P9596 Lamp, C erase 56P9597 Lamp, Y erase 56P9598 Lamp, K erase 56P9985 Printhead, LED K (black)–S/N XX-1XXXX 56P9986 Printhead, LED Y/M/C (color)–S/N XX-1XXXX 56P9599 Printhead, LED–S/NXX-0XXXX 56P9610...
Page 400: Assembly 7: Base 1
5055-xxx Assembly 7: Base 1 7-16 Service Manual...
Page 401 5055-xxx Assembly 7: Base 1 Index Units Description 7–1 56P9664 Frame, paper feed 56P9508 Bracket, ground 56P9512 Roller assembly, paper carrying 56P9511 Roller assembly, paper feed 11G0243 Interrupter, photo 56P9665 Sensor, paper feed 56P9507 Actuator, paper feed sensor 56P9520 Handle, waste bottle cam 56P9517 Spring, right cassette guide 56P9519...
Page 402: Assembly 8: Base 2
5055-xxx Assembly 8: Base 2 7-18 Service Manual...
Page 403 5055-xxx Assembly 8: Base 2 Index Units Description 8–1 56P9666 Support assembly, upper unit 56P9667 Pin, upper unit support 56P9668 Handle assembly, lock 56P9669 Handle, lock 56P9673 Cover, electronic 56P9670 Shroud, cable 56P9672 Guide, cable 56P9671 Guide, cable 56P9949 Parts packet 7-19 Parts catalog...
Page 404: Assembly 9: Base 3
5055-xxx Assembly 9: Base 3 7-20 Service Manual...
Page 405 5055-xxx Assembly 9: Base 3 Index Units Description 9–1 56P9971 Frame assembly, MPF 11G0283 Pad, fanning 56P9681 Clutch, registration 56P9680 Frame assembly, registration 56P9682 Frame assembly, carrying 56P9696 Cable assembly, belt thermistor 56P9694 Unit, transfer belt 56P9674 Guide assembly, fuser entrance 56P9676 Sensor, density 56P9684...
Page 406: Assembly 10: Electrical
5055-xxx Assembly 10: Electrical 7-22 Service Manual...
Page 407 5055-xxx Assembly 10: Electrical Index Units Description 10–1 56P9705 Cable assembly, feeder 56P9704 Cable assembly, paper remaining sensor 56P9700 Solenoid assembly, paper feed (temperature/humidity sensor and paper remaining sensor included) 11G0243 Interrupter, photo 56P9702 Cable, belt up/down sensor 56P9701 Board, sensor 56P9703 Cable assembly, sensor board 56P9707...
Page 408 5055-xxx Assembly 10 (continued): Electrical 7-24 Service Manual...
Page 409 5055-xxx Assembly 10 (continued): Electrical Index Units Description 10–26 56P9734 HCF/finisher D-sub assembly 56P9731 Cable assembly, finisher 56P9730 Cable assembly, HCF 56P9714 Board, high voltage power supply 56P9727 Cable assembly, printer controller power 2 56P9726 Cable assembly, printer controller power 1 56P9724 Power supply, 120 V (2) 56P9725...
Page 410: Assembly 11: Rip Board
5055-xxx Assembly 11: Rip board 7-26 Service Manual...
Page 411 5055-xxx Assembly 11: RIP board Index Units Description 11–1 56P9749 Cable assembly, power RIP 56P9916 Card, riser 56P9976 Board, RIP controller (C910) 56P9977 Board, RIP controller, network (C910) 56P9973 Board, RIP controller (C912) 56P9974 Board, RIP controller, network (C912) 56P9750 Fan, RIP 56P9745 Box, RIP...
Page 412: Assembly 12: Fuser Unit
5055-xxx Assembly 12: Fuser unit 7-28 Service Manual...
Page 413 5055-xxx Assembly 12: Fuser unit Index Units Description 12–1 56P9751 Fuser, 120 V 56P9752 Fuser, 230 V 56P9953 Parts packet 7-29 Parts catalog...
Page 414: Assembly 13: Cassette
5055-xxx Assembly 13: Cassette 7-30 Service Manual...
Page 415 5055-xxx Assembly 13: Cassette Index Units Description 13–1 56P9500 Cassette, paper feed 56P9902 Cassette, heavy media 56P9979 Guide, stop 56P9980 Guard, rack 7-31 Parts catalog...
Page 416: Assembly 14: Expansion Feeder 1
5055-xxx Assembly 14: Expansion feeder 1 7-32 Service Manual...
Page 417 5055-xxx Assembly 14: Expansion feeder 1 Index Units Description 14–1 11G0199 Guide, wire 56P9773 Gear, feeder E 56P9771 Gear, feeder C 11G0422 Gear, feeder B 56P9772 Gear, feeder D 11G0423 Gear, feeder A 56P9770 Cover, right side C 56P9769 Cover, right side B 56P9767 Cover, right side A 56P9765...
Page 418: Assembly 15: Expansion Feeder 2
5055-xxx Assembly 15: Expansion feeder 2 7-34 Service Manual...
Page 419 5055-xxx Assembly 15: Expansion feeder 2 Index Units Description 15–1 56P9796 Roller assembly, carrying 56P9514 Roller, noise reduction 56P9513 Bushing, carrying 56P9509 Bushing, metal 56P9790 Roller, paper carrying 56P9792 Holder, roller 56P9791 Spring, paper carrying 56P9794 Spring, right turn guide 56P9789 Guide, turn 56P9793...
Page 420 5055-xxx Assembly 15 (continued): Expansion feeder 2 7-36 Service Manual...
Page 421 5055-xxx Assembly 15 (continued): Expansion feeder 2 Index Units Description 56P9956 Parts packet 7-37 Parts catalog...
Page 422: Assembly 16: Duplex Unit 1
5055-xxx Assembly 16: Duplex unit 1 7-38 Service Manual...
Page 423 5055-xxx Assembly 16: Duplex unit 1 Index Units Description 16–1 56P9798 Duplex assembly 56P9804 Board, duplex interface 56P9799 Frame, duplex 56P9800 Screw, duplex mounting 56P9803 Motor, duplex stepping 56P9525 Interrupter, photo 56P9806 Cable assembly, paper detection 56P9994 Plate, duplex guide 56P9807 Cable assembly, duplex interface 56P9805...
Page 424: Assembly 17: Duplex Unit 2
5055-xxx Assembly 17: Duplex unit 2 7-40 Service Manual...
Page 425 5055-xxx Assembly 17: Duplex unit 2 Index Units Description 17–1 56P9825 Plate, paper re-feed drawer 56P9827 Guide, rear side 56P9826 Guide, front side 56P9830 Solenoid assembly, paper re-feed 56P9814 Bearing, release 56P9816 Spring, re-feed roller 56P9813 Roll, release 56P9525 Interrupter assembly, photo 56P9828 Motor assembly, paper guide 56P9808...
Page 426: Assembly 18: High-Capacity Feeder 1
5055-xxx Assembly 18: High-capacity feeder 1 7-42 Service Manual...
Page 427 5055-xxx Assembly 18: High-capacity feeder 1 Index Units Description 18–1 56P9838 Catch, door 56P9835 Magnet, latch 56P9837 Cover, upper 56P9834 Cover, upper rear 56P9843 Cover, lower rear 56P9839 Cover, right 56P9833 Cover, front 56P9836 Fence, end 56P9940 Ring, snap 56P9841 Cover assembly, upper 56P9840 Lever, vertical transport...
Page 428: Assembly 19: High-Capacity Feeder 2
5055-xxx Assembly 19: High-capacity feeder 2 7-44 Service Manual...
Page 429 5055-xxx Assembly 19: High-capacity feeder 2 Index Units Description 19–1 56P9846 Solenoid assembly, paper pickup 56P9848 Clutch, paper feed 56P9844 Motor assembly, transport 56P9941 Arm, pick-up 56P9501 Spring, pressure 56P9528 Interrupter, photo 56P9849 Roller, manual feed pickup 56P9850 Roller, manual feed 56P9852 Limiter, torque 56P9851...
Page 430: Assembly 20: High-Capacity Feeder 3
5055-xxx Assembly 20: High-capacity feeder 3 7-46 Service Manual...
Page 431 5055-xxx Assembly 20: High-capacity feeder 3 Index Units Description 20–1 56P9854 Sensor assembly, photo 56P9855 Interrupter, photo 56P9529 Caster, HCF 56P9856 Spring, tension 56P9857 Switch, micro 56P9530 Switch, push 56P9859 Connector, inlet 56P9858 Connector, I/F 56P9853 Screw, shoulder 56P9960 Parts packet 7-47 Parts catalog...
Page 432: Assembly 21: High-Capacity Feeder 4
5055-xxx Assembly 21: High-capacity feeder 4 7-48 Service Manual...
Page 433 5055-xxx Assembly 21: High-capacity feeder 4 Index Units Description 21–1 56P9541 Sensor, resistor 56P9875 Cable assembly, safety switch 56P9865 Cable assembly, HCF motor 56P9871 Cable assembly, I/F 56P9866 Cable assembly, paper feed sensor 56P9880 Cable, up/down switch 56P9879 Cable, paper volume 56P9878 Cable assembly, sensor 56P9877...
Page 434: Assembly 22: High-Capacity Feeder 5
5055-xxx Assembly 22: High-capacity feeder 5 7-50 Service Manual...
Page 435 5055-xxx Assembly 22: High-capacity feeder 5 Index Units Description 22–1 56P9883 Spring, pressure 56P9528 Interrupter, photo 56P9888 Bracket, rear idler 56P9884 Belt, timing 56P9886 Gear, drive 56P9885 Pulley, timing 56P9882 Motor, HCF DC 56P9887 Bracket, front idler 56P9962 Parts packet 7-51 Parts catalog...
Page 436: Assembly 23: High-Capacity Feeder 6
5055-xxx Assembly 23: High-capacity feeder 6 7-52 Service Manual...
Page 437 5055-xxx Assembly 23: High-capacity feeder 6 Index Units Description 23-1 56P9892 Plate, upper side fence 56P9893 Knob, stopper 56P9891 Knob, tray 56P9890 Plate, paper adhesion 56P9915 Fence assembly, front side 56P9894 Fence assembly, rear side 56P9528 Interrupter, photo 56P9889 Pad, friction 56P9963 Parts packet 7-53...
Page 438: Assembly 24: Finisher Covers
5055-xxx Assembly 24: Finisher covers 7-54 Service Manual...
Page 439 5055-xxx Assembly 24: Finisher covers Index Units Description 24-1 56P9353 Cover, top 56P9348 Screw, A 56P9355 Cover, front 56P9359 Tray, upper 56P9360 Tray, lower 56P9347 Panel, left upper 56P9352 Assembly, lower left panel 56P9356 Cover, rear 56P9350 Assembly, staple cover 56P9366 Lever, B 56P9365...
Page 440 5055-xxx Assembly 25: Finisher frame 7-56 Service Manual...
Page 441: Assembly 25: Finisher Frame
5055-xxx Assembly 25: Finisher frame Index Units Description 25-1 56P9321 Spring, I 56P9324 Cable, sensor relay 56P9369 Assembly, spring plate C 56P9370 Frame, guide 56P9371 Spring 56P9372 Brush, static discharge 56P9373 Screw, M4 56P9374 Frame, C guide 56P9375 Shaft, D 56P9376 Bushing 56P9377...
Page 442: Assembly 26: Finisher Feed 1
5055-xxx Assembly 26: Finisher feed 1 7-58 Service Manual...
Page 443 5055-xxx Assembly 26: Finisher feed 1 Index Units Description 26-1 56P9395 Assembly, guide plate 56P9393 Plate, guide holder 56P9334 Assembly, solenoid 56P9396 Spring, H 56P9397 Gear, Z20 56P9398 Gear, Z19 56P9311 Bushing 56P9310 Gate 56P9400 Roller 56P9361 Roller, patting 56P9401 Roller, I 56P9402 Bushing...
Page 444 5055-xxx Assembly 26 (continued): Finisher feed 1 7-60 Service Manual...
Page 445 5055-xxx Assembly 26 (continued): Finisher feed 1 Index Units Description 26-31 56P9316 Bushing 56P9415 Pulley, gear Z36/T24 56P9317 Belt 56P9417 Flange 7-61 Parts catalog...
Page 446: Assembly 27: Finisher Feed 2
5055-xxx Assembly 27: Finisher feed 2 7-62 Service Manual...
Page 447 5055-xxx Assembly 27: Finisher feed 2 Index Units Description 27-1 56P9300 Assembly, jogging unit 56P9422 Pin, N 56P9423 Pulley, Z19/Z20 56P9417 Flange 56P9333 Belt, timing (60S3M408) 56P9329 Assembly, tractor motor 56P9437 Belt, timing 56P9301 Assembly, guide stack 7-63 Parts catalog...
Page 448: Assembly 28: Finisher Elevator
5055-xxx Assembly 28: Finisher elevator 7-64 Service Manual...
Page 449 5055-xxx Assembly 28: Finisher elevator Index Units Description 28-1 56P9308 Assembly, elevator motor 56P9448 Washer 56P9449 56P9450 Pulley, wire A 56P9451 Shutter 56P9452 Pin, O 56P9453 Roller, C 56P9304 Assembly, hook front 56P9332 Spring, C 56P9331 Wire 56P9455 Bracket 56P9456 Gear, Z46/Z33 56P9457 Gear, Z90/Z14...
Page 450: Assembly 29: Finisher Electronics
5055-xxx Assembly 29: Finisher electronics 7-66 Service Manual...
Page 451 5055-xxx Assembly 29: Finisher electronics Index Units Description 29-1 56P9306 Assembly, upper limit sensor 56P9303 Supply, power 56P9351 Assembly, power supply plate 56P9435 Cable, set switch 56P9358 Cord, Y power 56P9368 Cord, Y power (230 V only) 56P9342 Assembly, bridge 56P9326 Cable, DC power supply 56P9349...
Page 452: Assembly 30: Finisher Docking 1
5055-xxx Assembly 30: Finisher docking 1 7-68 Service Manual...
Page 453 5055-xxx Assembly 30: Finisher docking 1 Index Units Description 30-1 56P9467 Screw, thumb 56P9468 Spring 56P9469 Bracket 56P9470 Switch, set 7-69 Parts catalog...
Page 454: Assembly 31: Finisher Docking 2
5055-xxx Assembly 31: Finisher docking 2 7-70 Service Manual...
Page 455 5055-xxx Assembly 31: Finisher docking 2 Index Units Description 31-1 56P9472 Screw, lock 56P9473 Stud, lock 56P9474 Roller 56P9475 Knob, caster 56P9476 Stop, caster 56P9477 Housing, caster 56P9478 Caster 56P9479 7-71 Parts catalog...
Page 456: Assembly 32: Miscellaneous/Options
Card, bar code (C912) 56P9441 Card, PrintCryption™ (C912) 56P9925 Card, PRESCRIBE 56P9926 Software, Optra Forms™ 56P9927 Software, Optra Forms Director 56P9928 DIMM, Lexmark Forms 4MB Flash 56P9929 DIMM, Lexmark Forms 8MB Flash 56P9930 DIMM, Lexmark Forms 16MB Flash 7-72 Service Manual...
Page 457 5055-xxx Assembly 32: Miscellaneous/options Index Units Description 56P9932 Hard Disk, Lexmark Forms 56P9942 Mounting Kit, hard drive 56P9936 Simplified Chinese font kit 56P9935 Traditional Chinese font kit 56P9975 Japanese font kit 7370516 Kit, printer relocation 7370567 Kit, duplex relocation 7370569...
Page 458 5055-xxx Assembly 32: Parts packets Index Units Description 56P9945 Parts packet, containing: • 50 Bind S-tight screws, 3x6, Zn-3R • 50 Bind S-tight screws, 3x15, Zn-3K • 50 Bind P-tight screws, 3x8, Zn-3K • 50 Bind P-tight screws, 3x10, Zn-3K •...
Page 459 5055-xxx Assembly 32: Parts packets (continued) Index Units Description 56P9948 Parts packet, including: • 50 Bind S-tight screws, 3x6, Zn-3R • 50 Bind P-tight screws, 3x6, Zn-3K • 50 Bind screws, M3x4, Zn-3K • 50 Bind screws, M3x6, Zn-3K • 50 Bind screws, M3x8, Zn-3K •...
Page 460 5055-xxx Assembly 32: Parts packets (continued) Index Units Description 56P9951 Parts packet, including: • 50 Bind S-tight screws, 3x6, Zn-3R • 50 Bind S-tight screws, 3x8, Zn-3R • 50 Bind S-tight screws, 3x12, Zn-3R • 50 Bind P-tight screws, 3x8, Zn-3K •...
Page 461 5055-xxx Assembly 32: Parts packets (continued) Index Units Description 56P9953 Parts packet, including: • 50 Bind S-tight screws, 3x6, Zn-3R • 50 Bind P-tight screws, 3x6, Ni-3 • 50 Bind screws, M3x4, Zn-3K • 50 Bind screws, M3x4, Zn-3K • 50 Bind screws, M3x5, Zn-3K •...
Page 462 5055-xxx Assembly 32: Parts packets (continued) Index Units Description 56P9956 Parts packet, including: • 50 Bind S-tight screws, 3x6, Zn-3R • 50 Bind S-tight screws, 3x8, Zn-3R • 50 Bind P-tight screws, 3x6, Zn-3K • 50 Bind P-tight screws, 3x8, Zn-3K •...
Page 463 5055-xxx Assembly 32: Parts packets (continued) Index Units Description 56P9958 Parts packet, including: • 50 E-rings, ES-3, ACP • 50 E-rings, ES-4, ACP • 50 E-rings, ES-6, ACP • 50 RS-set screw cp, M3x3, Zn-3K • 50 RS-tight screws, M4x6, •...
Page 464 5055-xxx Assembly 32: Parts packets (continued) Index Units Description 56P9962 Parts packet, including: • 50 Screws with spring-washers, M4x30, Zm-3R • 50 E-rings, ES-5, ACP • 50 Plain washers, M4, Zn-3R • 50 RS-tight screws, M4x6 56P9963 Parts packet, including: •...
Page 465: Assembly 33: Finisher Parts Packet P/N 56P9480
5055-xxx Assembly 33: Finisher parts packet P/N 56P9480 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 7-81 Parts catalog...
Page 466 5055-xxx Plain Washer Tapping Screw Screw 7-82 Service Manual...
Page 467: Index
5055-xxx Index parts catalog 7-10 abbreviations 1-33 rear removal adjustments right side removal finisher hole punch alignment 3-94 RIP board removal high-capacity paper feed timing belt solenoid removal top cover removal procedures after replacement attendance messages 2-34 defaults 3-26 development unit 3-34 clearing the error log 3-32...
Page 468 5055-xxx parts catalog covers 7-54 electrical docking 7-68 7-70 diagram 5-19 electronics 7-66 finisher diagram 5-26 elevator 7-64 finisher, parts catalog 7-66 feed 1 7-58 high-capacity feeder diagram 5-19 feed 2 7-62 parts catalog 7-22 frame 7-56 eraser removal 4-27 removals error log control board...
Page 469 5055-xxx hardware tests 3-12 maintenance high-capacity feeder approach 1-29 call roller removal 4-82 cleaning 1-29 covers removal 4-81 dip switch specifications 3-60 diagram 5-18 inspection 1-29 high-capacity paper feed timing belt lubricants adjustment periodic paper end sensor removal 4-84 recommendations 1-30 paper feed configuration 5-18...
Page 470 5055-xxx permanent page count 3-29 POST page count 3-29 power and electrical specifications paper and media 1-26 guidelines 1-20 power-on self-test sequence paper checks preventive maintenance print area 1-21 print quality pages 3-11 printer capacity 1-18 print quality problems 2-88 sizes 1-10 printed circuit boards...
Page 471 5055-xxx drive gear unit sensor assembly gear cover 4-22 4-15 high voltage power supply board drive motor assembly 4-16 4-23 duplex unit 4-76 high-capacity feeder connector 4-75 call roller 4-82 feed roller and solenoid 4-78 covers 4-81 paper carrying motor 4-80 paper end sensor 4-84...
Page 472 5055-xxx separation fingers 4-14 service checks 2-68 stay arm 4-51 drive 1 DC motor 2-68 sub-frame 4-52 drive 2 stepper motor 2-68 temperature/humidity sensor 4-54 duplex 2-69 top unit 4-55 expansion paper feed 2-69 transfer belt face down stacker full 2-70 inoperable operator panel 4-60...
Page 473 5055-xxx 940 - high-capacity feed sensor service errors error 2-15 service precautions 941 - high-capacity feed tray error setting configuration ID 3-30 2-15 setting the page count 3-29 942 - duplex error 2-16 size detection 3-57 945 - engine flash error 2-16 specifications 946 - printer/printhead controller...
Page 474 5055-xxx theory belt unit 3-42 belt up/down 3-43 cassette paper feeder 3-37 cleaning unit 3-35 clearing paper jams 3-46 configuration 3-33 delivery 3-41 development unit 3-34 drive system 3-36 duplex unit 3-44 electrophotography 3-33 electrophotography process 3-33 expansion paper feeder 3-43 fuser unit 3-40...
Page 475: Part Number Index
5055-xxx Part number index Description Page 11D0328 Power cord - USA, Canada, APG, LAD ....7-25 11D0329 Power cord - Peru ........7-25 11D0330 Power cord - Argentina .
Page 476 5055-xxx 56P1121 Card, bar code (C910) ....... 7-72 56P1204 IPDS/SCS/TNe (C910) ....... 7-72 56P1762 IPDS/SCS/TNe (C912) .
Page 477 5055-xxx 56P9347 Panel, left upper ........7-55 56P9348 Screw, A .
Page 478 5055-xxx 56P9390 Plate, cover ........7-57 56P9393 Plate, guide holder .
Page 479 5055-xxx 56P9453 Roller, C ......... .7-65 56P9455 Bracket .
Page 480 5055-xxx 56P9516 Spring, left cassette guide ..... . . 7-17 7-35 56P9517 Spring, right cassette guide ..... . 7-17 7-35 56P9518 Guide, lower left cassette .
Page 481 5055-xxx 56P9584 Guide assembly, turn ....... . .7-9 56P9591 Frame, upper ........7-13 56P9592 Rail, left side .
Page 482 5055-xxx 56P9638 Holder, cable ........7-13 56P9639 Connector, upper .
Page 483 5055-xxx 56P9704 Cable assembly, paper remaining sensor ....7-23 56P9705 Cable assembly, feeder ......7-23 56P9706 Cable, power switch .
Page 484 5055-xxx 56P9750 Fan, RIP ......... . 7-27 56P9751 Fuser, 120 V .
Page 485 5055-xxx 56P9808 Interrupter, photo ........7-41 56P9809 Roller, drive feed ........7-41 56P9810 Roller, follow-up feed .
Page 486 5055-xxx 56P9851 Roller, manual feed separate ......7-45 56P9852 Limiter, torque ........7-45 56P9853 Screw, shoulder .
Page 487 56P9930 DIMM, Lexmark Forms 16MB Flash .....7-72 56P9932 Hard Disk, Lexmark Forms ......7-73 56P9934 Card, Token-Ring .
Page 488 5055-xxx 56P9963 Parts packet ........7-53 7-80 56P9964 Transformer, power (Japan only) .
Page 492 C91X General Circuit Diagram Fuser Sub-frame 24 Drawer connector FD paper delivery Upper heater/100V 1kw Residual toner/kit presencedetection Upper heater Toner Eraser M PEX motor 621 Fuser heater UA Temperature Upper left fan Thermostat/upper sensor M fuse/upper Eraser C Fan lock detection...

This manual is also suitable for:

C91 series