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Lexmark C910 5055-01x Printer User Manual

1. Size Sensor Board C SW403 SW402 5 10 Service Manual 5055 01x High Capacity Paper Feed HCPF Paper End Sensor Up Sensor Paper Size Sensor 1 2 Pickup Solenoid Paper Feed Motor Paper Feed Roller Call Roller Near End Sensor Paper Feed Sensor Residual Paper Sensor 1 Transfer Roller Residual Paper Sensor 2 Reverse Roller Tray Paper Level Senso Tray Driving Belt Residual Paper Sensor 3 Down Sensor Tray Motor Call Roller Colo 1 l Locations 5 11 5055 01x High Capacity Paper Feed Configuration Paper feed and separation mechanism TUOT _ Tray up amp down mechanism Size detection mechanism Residual paper detection mechanism Paper end detection mechanism 5 12 Service Manual Friction roller separation system with a non contact magnet type maintenance free torque limiter Tray elevating system consisting of a tray motor and a timing belt Fixed to the side fence and size is entered from the printer Tray level is detected with the fillers and photo interrupters 4 pieces A reflection type sensor on the upper stay detects the paper 5055 01x Electrical Parts Layout Paper Feed Clutch
2. 7 50 Service Manual 5055 01x Asm Part index Number Units Description 21 1 56P9541 1 Sensor Resistor 2 56P9875 1 Cable Assembly Safety Switch 3 56P9865 1 Cable Assembly HCPF Motor 4 56P9871 1 Cable Assembly I F 5 56P9866 1 Cable Assembly Paper Feed Sensor 6 56P9880 1 Cable Up Down Switch 7 56P9879 1 Cable Paper Volume 8 56P9878 1 Cable Assembly Sensor 9 56P9877 1 Cable Assembly Paper Size Sensor 10 56P9876 1 Cable Assembly Lift Motor 11 56P9868 1 Board High Capacity Paper Feed 12 56P9873 1 Cable Assembly Power Supply Out 13 56P9872 1 Cable Assembly Power Supply In 14 56P9874 1 Cable Assembly Power Supply 15 56P9870 1 Converter DC DC 16 56P9869 1 Power Supply HCPF 17 56P9867 1 Cable Assembly Drawer Ground 18 56P9861 4 Roller Track 19 56P9864 1 Switch Micro 20 56P9530 1 Switch Push 21 56P9862 1 Spring Pressure Pickup 22 56P9863 1 Switch HCPF Push Parts Catalog 7 51 5055 01x Assembly 22 High Capacity Paper Feed 5 5 A NN f MANN LR M o sedimo A L 4 7 52 Service Manual 5055 01x Asm Part index Number Units Description 22 1 56P9883 2 Spring Pressure 2 56P9528 4 Interrupter Photo 3 56P9888 1 Bracket Rear Idler 4 56P9884 2 Belt Timing 5 56P9886 1 G
3. Tray Driving Pulley __ 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 General Information 1 27 5055 01x Pickup coer p Sensor pH e Zee 4 Call Roller When the down button is pressed the tray motor reverses to move the tray down During the down motion of the tray as the top surface of paper passes the paper level sensor the tray motor stops The tray moves down by about 500 sheets The down sensor detects the tray lower limit position Down Button Paper Level Sensor Motor Down Sensor 1 28 Service Manual 5055 01x Tray Up Condition Tray up motion stops when the Up sensor is OFF not shielded Power cord is connected and the joint SW is ON Up sensor is ON shielded during printing Top cover is closed or when up sensor is ON Tray Down Condition Tray down motion stops when the Paper level sensor is OFF Down button is pressed Paper end is detected General Information 1 29 5055 01x Size Detection Mechanism The paper size can be switched between A4 and letter 11 inches by changing the side fence position The paper size sensor 2 detects the fixing screw 2 at the A4 position The paper size sensor 1 detects the fixing screw 1 at the letter position Tray up motion stops when the up sensor is OFF
4. 4 68 Service Manual 5055 01x 23 Remove the six screws from the second drive board assembly and remove the assembly La 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 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 Repair Information 4 69 5055 01x 28 Remove the two screws from the lower drawer connector female and remove the connector 4 70 Service Manual 5055 01x Duplex Unit Separation Removal 1 Remove the thumbscrews C clips and screws as shown from both sides E sni 4 2 Remove the connectors and separate the duplex frame from the duplex unit Repair Information 4 71 5055 01x Duplex Unit Removal 1 Remove the four screws from the interface board and remove the board 2 Remove the two screws from the duplex connector and remove the connector Duplex Timing Belt Removal 1 Remove the three C clips from the three timing gears and remove the timing belts 2 Remove the knob screw and remove the timing belt 4 72 Service Manual 5055 01x Duplex Pressure Roller and Solenoid Removal 1 Rem
5. Right Side Cover yy he p A DIA LLL is p N o RN 2 SON o i o 5 5 i xt og m ag 9 On is o gt o o o S i D uz a gt o oo FO s c tr Locations 5 1 5055 01x Major Parts Diagram a 4B Hj 5 2 Service Manual 5055 01x Part Part 1 Development Roll 16 Paper Out Detection Lever 2 Supply Roll 17 Paper Out Detection Sensor 3 Doctor Blade 18 Duplex Unit 4 Agitator 19 Transfer Sheet 5 Absorption Roll 20 Transfer Belt 6 Registration Upper Roll 21 Belt Drive Roller 7 Registration Lower Roll 22 Paper Delivery Detection Lever 8 Registration Sensor 23 Press Roll 9 Registration Detection Lever 24 Heater 10 MPF Roll 25 Fuser Roller 11 MPF Unit 26 Oil Coating Roller 12 Fanning Pad 27 Cleaning Blade 13 Upper Feed Roll 28 Photosensitive Drum 14 Lower Feed Roll 29
6. 0 000 cece eee e eens 2 4 Attendance Messages Q eee eee cece eee e eens 2 25 Maintenance Analysis Procedures MAPS 2 43 Symptom Tabie sz cda suec ixcgese eere eer me ed 2 52 SONKO CHECKS isosta ee pet diues aub ers tae add e e md amp 2 55 Drive 1 DC Motor Service Check eeeseeess 2 55 Drive 2 Stepper Motor Service Check elss 2 55 Duplex Servite GHecK assacicceiR o e rec rsatadi 2 56 Expansion Paper Feed Service Check e 2 56 Face Down Stacker Full Service Check 2 57 High Capacity Paper Feed HCPF Service Check 2 57 Operator Panel Service Check 20200 s cence eee eee 2 58 Paper Carrying Service Check x sic nic dona denies dmed Ems 2 58 Paper Exit FU FD Service Check 20000eeeeeeeee 2 63 Paper Tray Missing Service Check llesleesss 2 63 Photodeveloper Missing Service Check se 2 64 Power Supply Service Check 0000e eee e ee eee eee 2 65 Marks on Paper Service Check 220eee eee e eee eeeeee 2 66 Transfer Belt Up Down Service Check 2 68 Image Quality Troubleshooting sees 2 69 Print Quality Prabletmiss set iram ome nateedegeads 2 69 Options Service Check 20e cece eee ences 2 77 Diagnostic Aids 2022060008600 c0e0c cease eee cee hmm 3 1 Power On Self Test Sequence 0 0es cece eee eee 3 1 Using the Operator Panel 2 2 near ee e
7. INFRARED MENU Infrared Port PCL SmartSwitch PS SmartSwitch NPA Mode Infrared Buffer Job Buffering Window Size Transmit Delay Max Baud Rate LOCALTALK MENU LocalTalk Port PCL SmartSwitch PS SmartSwitch NPA Mode LocalTalk Buffer Job Buffering NPA Hosts LocalTalk Name LocalTalk Addr LocalTalk Zone Diagnostic Aids 3 5 5055 01x 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 displays Setting Printer Alignment X sxxx Y sxxx T sxx The Alignment menu is formatted so that all menu items fit on a single screen as shown below This allows manufacturing to quickly set and verify the registration setting Terminology X represents the X alignment horizontal Y represents Y alignment vertical and T represents Theta alignment The alignment of a curve of the horizontal position over the length of the line e s represents the sign for negative values This space is blank for positive values xx represents the margin value e An asterisk is displayed next to the default value Upon first entering the Alignment menu the X alignment sign value pair will flash This indicates it is the alignment value being changed To change the value press Menu Once the desired value is displayed press Select to save the va
8. 88 Black Toner Empty 85 Toner Empty Coating Roll Exhausted The black toner cartridge is empty See note below The oil coating roll has reached end of life Replace the oil coating roll and black toner cartridge Note If the customer has replaced the black toner cartridge before this message displays the oil coating roller message will not display until the cartridge is empty Diagnostic Information 2 41 5055 01x Message 88 lt color gt Toner Empty Meaning The printer has ceased operating because the specified toner cartridge is empty Action Install a new toner cartridge and go to Map 7 False 88 lt Color gt Toner Low Toner Empty Message on page 2 47 88 color Toner Low The printer has detected that the specified toner cartridge is low Replace the specified toner cartridge Press Go to clear the message and continue printing The supplies message is displayed until you replace the specified toner cartridge Go to Map 7 False 88 Color Toner Low Toner Empty Message on page 2 47 2 42 Service Manual 5055 01x Maintenance Analysis Procedures MAPS Map 1 False Side Door Open Message Step Questions Actions Yes No 1 Close the side turn guide Problem Go to step 2 door Does the message reset solved 2 Disconnect CN30 from the Replace the Replace t
9. Soot JOO e 17 Remove the screw and the screw from the drive unit and remove the unit 18 Remove the two screws and the screw from the belt up down clutch box and remove the belt up down clutch Q me 6 2 4 By ji l Eyi NM Te Y z i 19 Remove the screw from the drum gear sensor and remove the sensor Repair Information 4 53 5055 01x Face Up Paper Exit Assembly Removal Face Up Down Flapper Detection Sensor Removal Face Up Down Solenoid Removal Paper Delivery Sensor Removal Paper Exit Tray Switch 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 4 Remove the paper delivery sensor from the face up paper delivery assembly 5 Remove the face up down sensor from the face up paper delivery 6 Remove the two screws from the face up down solenoid and the face up paper delivery assembly Remove the assembly 7 Remove the screw from the paper exit tray switch and the face up paper delivery assembly Remove the assembly 4 54 Service Manual 5055 01x Face Down Guide Assembly Removal Paper Exit Motor amp Full Sensor Removal 1 Open the top unit and remove the toner cartridges photoconductor drum units and upper cover 2 Remove the t
10. 7 8 Service Manual 5055 01x Asm Index Part Number Units Description 4 1 56P9584 Guide Assembly Turn Parts Catalog 7 9 5055 01x Assembly 5 Covers 5 7 10 Service Manual 5055 01x Asm Part index Number Units Description 5 1 56P9587 1 Feeder Assembly Multi Purpose 2 56P9589 1 Extender MPF 3 56P9588 1 Cover MPF 4 56P9590 1 Spring MPF 5 11G0118 1 Pinion MPF 6 11G0117 1 Rack MPF 7 11G0120 1 Spring Feeder Lock Parts Catalog 7 11 5055 01x Assembly 6 Upper Unit 31 32 33 34 lt 7 12 Service Manual 5055 01x Asm Part Index Number 6 1 56P9591 2 56P9620 Units Description Frame Upper Board Printhead Controller 3 56P9638 Holder Cable 4 56P9600 Cable Assembly K13 5 56P9601 Cable Assembly K24 6 56P9602 Cable Assembly CL13 7 56P9603 Cable Assembly CL24 8 56P9716 Cable Assembly 8 Pin PH Controller 9 56P9718 10 56P9717 11 56P9720 12 56P9637 13 56P9625 14 56P9626 15 56P9628 16 56P9614 Cable Assembly 30 Pin PH Controller Cable Assembly 18 Pin PH Controller Cable Assembly PH Controller Power Frame Printhead Controller Hook Right Link Cover Hook Pivot Color Link Spring Return 17 56P9618 Hook Right 18 56P9615 Hook Middle 19 56P9612 Bracket Front Upper 20 56P9617 Hook Left 21 56P9613 22 56P9624 23
11. code version Tray x The specified tray is either Insert the tray completely Missing missing or not fully inserted If the message cannot be reset go to Paper Tray Missing Service Check on page 2 63 Unsupported The printer detects an Press Go to clear the Disk unsupported disk message Format the disk USB x The printer is processing data Wait for the message to through the specified USB clear port Waiting The printer is waiting for an Press Go to print the End of Job command a Form contents of the buffer Feed Command or additional Press Menu to open the data Job Menu and cancel the current job 1565 Emul The download emulator Download the correct Error Load version on the firmware card emulator version from Emul Option does not match the printer Lexmark s Web site 2 xx Paper Jam The printer detects a paper jam Clear the paper path If the message cannot be reset go to the Paper Carrying Service Check on page 2 58 Diagnostic Information 2 33 5055 01x Message 30 Coating Roll Missing Meaning The oil coating roll is either missing or installed incorrectly Action Correctly install the oil coating roll If the message cannot be reset go to Map 5 False 30 Oil Coating Roll Missing Message on page 2 46 30 lt color gt Print One or more of the color print Correctly install the color Config Error is inser
12. 1 47 7 53 7 55 7 49 7 49 7 51 INN NN NNN NN NNN NN NN WW C0 Q0 C2 C0 C0 O1 C0 Q2 C2 WWW WWW CO Index l 5 5055 01x 56P9549 56P9550 56P9551 56P9554 56P9555 56P9556 56P9557 56P9558 56P9559 56P9560 56P9561 56P9562 56P9563 56P9564 56P9565 56P9566 56P9567 56P9568 56P9569 56P9570 56P9571 56P9572 56P9573 56P9574 56P9575 56P9576 56P9577 56P9578 56P9579 56P9580 56P9581 56P9582 56P9583 56P9584 56P9587 56P9588 56P9589 56P9590 56P9591 56P9592 56P9593 56P9594 56P9595 56P9596 56P9597 56P9598 56P9599 NNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNNYNNY di a a dae a AAA AA k d O ENN SN IN SNI SSI NNA N AI A A LOT OT O 01 O1 O1 Or O1 Oi O0 0 00 O0 OO AWWWwWwWOwWwWAA A l 6 Service Manual 56P9600 56P9601 56P9602 56P9603 56P9604 56P9605 56P9606 56P9607 56P9608 56P9609 56P9610 56P9611 56P9612 56P9613 56P9614 56P9615 56P9616 56P9617 56P9618 56P9619 56P9620 56P9621 56P9622 56P9623 56P9624 56P9625 56P9626 56P9627 56P9628 56P9629 56P9630 56P9637 56P9638 56P9639 56P9641 56P9642 56P9643 56P9644 56P9645 56P9646 56P9648 56P9649 56P9650 56P9651 56P9652 56P9653 56P9654 NNN NN NNN TEMERE a RE MEME MEME MEME MEAE MEME TAE ME MEME MEME MEME ME META MEME TAE MEM o lI I ll lA Il lA Il ll ll lI ll ll lA ll l lA l Il lI Il lA Il lI l l Il Il l Il l l l l cl AS RA A A eu uuuumeooouoo0o0doU000 O0 QOO OCOCOOO QOO OO O O O w O 5055 01x 56P9655 56P9656
13. 2 Did replacing the Problem solved Replace the high printer controller voltage power board board fix the HVU problem 2 8 Service Manual 5055 01x 926 K 927 C 928 Y 929 M Toner Sensor Error 92x Service Toner Sensor Questions Ste Yes No p Actions 1 Is the toner cartridge Go to step 2 Recommend the the correct type for customer replace the printer the cartridge with the correct type 2 Is the toner cartridge Clean the encoder Go to step 3 encoder wheel dirty wheel and toner sensor 3 Replace the toner Problem solved Go to step 4 cartridge for the color with the error Did this fix the problem 4 Test the sensors Replace the printer Replace the While actuating the sensor does the voltage fluctuate between 0 Vand 5 V between pins 1 and 2 on connectors CN22 K CN21 Y CN18 M and CN19 C on the printer controller board controller board affected toner sensor Diagnostic Information 2 9 5055 01x 930 Yellow Printhead Error board open board cables and LED printhead 930 Service Printhead Error Questions Ste Yes No p Actions 1 Is fuse 5 on the Replace the Replace the printhead control printhead control printhead controller board 931 Magenta Printhead Error printhead control board open printhead control board cables and LED prin
14. Press Go to continue The printer deletes all held jobs Press Stop to cancel the operation Deleting Jobs The printer is deleting one or more held jobs Wait for the message to clear Disabling Menus The printer is responding to a request to disable the menus Wait for the message to clear Note While the menus are disabled you cannot change the printer settings from the operator panel 2 26 Service Manual 5055 01x 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 Disk Recovery The printer is attempting to Wait for the message to x 5 yyy recover the hard disk clear Warning Do not turn the printer off while this message is displayed Enabling Menus The printer is responding to a Wait for the message to request to make the menus clear and press Menu to available to all users view the menus available Engine The printer is warming the Wait for the message to Warming fuser assembly clear Enter PIN The printer is waiting for you Use the operator panel to enter your four digit PIN buttons to enter the PIN number Fax lt x gt The printer is processing an Wait for the message to incoming fax clear Flushing B
15. Install a new black photodeveloper to clear the message and continue printing 84 Black Photo Dev Exhausted The black photodeveloper has reached end of life Replace the black photodeveloper Make sure you also install the new fuser coating roll that is included in the kit If print quality is still acceptable and you do not want to replace the photodeveloper press Go to clear the message and continue printing 84 Black Photo Dev Life Warning The black photodeveloper is nearing end of life Press Go to clear the message and continue printing The supplies message is displayed until you replace the photodeveloper 84 Color Photo Dev Abnormal The printer has detected an abnormal color photodeveloper Install a new color photodeveloper to clear the message and continue printing 2 40 Service Manual 5055 01x Message 84 Color Photo Devs Exhausted Meaning The color photodevelopers have reached end of life Action Replace the color photodevelopers Cyan Magenta and Yellow at the same time If print quality is still acceptable and you do not want to replace the photodevelopers press Go to clear the message and continue printing 84 Color Photo Dev Life Warning The color photodevelopers are nearing end of life Press Go to clear the message and continue printing The supplies message is displayed until you replace the photodevelopers
16. Parts Catalog 7 41 5055 01x Assembly 17 Duplex Unit 2 7 42 Service Manual 5055 01x Asm Part Index Number 17 1 56P9825 Units Description Plate Paper Re Feed Drawer 2 56P9827 Guide Rear Side 3 56P9826 Guide Front Side 4 56P9830 Solenoid Assembly Paper Re feed 5 56P9814 Bearing Release 6 56P9816 Spring Re feed Roller 7 56P9813 Roll Release 8 56P9525 Interrupter Assembly Photo 9 56P9828 10 56P9808 11 56P9526 12 56P9815 13 56P9829 14 56P9831 15 56P9810 16 56P9527 17 56P9817 18 56P9818 19 56P9819 20 56P9822 21 56P9823 22 56P9821 23 56P9820 24 56P9809 25 56P9824 26 56P9811 27 56P9812 NS 56P9832 Motor Assembly Paper Guide Interrupter Photo Spring Feed Roller Spring Feed Roller Solenoid Assembly Feed Roller Cable Assembly Duplex Drawer Roller Follow up Feed Gear Idler Gear Carrying Roller Pulley Carrying Roller Timing Pulley Feed Roller Belt Timing Belt Timing Knob Paper Re feed Pulley Re feed Roller Roller Drive Feed Plate Paper Carrying Drawer Roller Middle Feed Roller Re feed Parts Packet Screw HCPF a 00 438 4 WOaArnaArtinNaB BH WwooonAtaart RDN WA a Parts Catalog 7 43 5055 01x Assembly 18 High Capacity Paper Feed 1 7 44 Service Manual 5055 01x Asm Part index Number Units Description 18 1 56P9838 1 Catch Door 2 56P9835 1 Magnet Latch 3 56P983
17. The call roller rotates with the relay gears to feed the top paper The reverse roller rotates along with the paper feed roller During paper feed if two sheets feed the reverse roller rotates by the torque limiter returning the lower sheet When the paper feed sensor reflection type sensor detects the paper the pickup solenoid turns off to raise the call roller transferring the paper to the registration roller Paper Feed Clutch Paper Feed Motor Pickup Solenoid General Information 1 25 5055 01x Registration Operation When the paper feed motor rotates the transfer roller is driven with relay gears The reverse roller shaft rotates the gears on the paper feed clutch in the direction of the arrow and stops by the friction force of the paper feed roller Paper Feed Clutch Paper Feed Motor RS OP A A vss RA Transfer Roller Call Roller Paper Feed Roller Reverse Roller torque limiter built in 1 26 Service Manual 5055 01x Tray Up Down Mechanism The driving force of the tray motor transmits to the tray driving pulley through the gears Moving the tray moves up and down through the tray driving belt After the paper loads and the top cover is set the pickup solenoid turns on to lower the call roller When the tray moves up the call roller is raised by the top surface of the paper and the shield plate on the up sensor is released from the up sensor which turns off the tray motor
18. This table lists the parts to be periodically cleaned by the servicer Part Name Method Paper Feed Unit Paper Feed Roller MPF Roll Remove any dust or dirt and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Registration Unit Registration Roller Upper and Lower Remove any dust or dirt and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Charge Exposure Unit LED Head Remove any dust or dirt and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Transfer Unit Transfer Belt Remove any dust or dirt and wipe the surface lightly with a dry cloth If it is still dirty clean with a soft cloth and alcohol Fuser Unit Heat Rollers Clean with a soft cloth silicon oil or alcohol Outer Covers Use a synthetic detergent and a damp cloth Lubricants and Cleaners Lubricating Cleaning Oil 10 Apply between gears and shafts Grease 23 Apply to gears Alcohol or Isopropyl on plastic rubber and external parts 6 2 Service Manual 5055 01x 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
19. Turn the printer off and back on The printer calibrates the photodevelopers and drive gears which may improve registration Be sure that Auto Registration in the Service Menu is On 2 72 Service Manual 5055 01x No Image Possible Cause Action Moist Paper Be sure the printer is not in a damp environment and the paper is not curled or wavy due to moisture If necessary inform the customer about correct storage LED Printhead Be sure the LED printhead cable is securely connected to the printhead controller board and LED printhead assembly If the problem remains replace the LED printhead High Voltage Unit HVU Be sure all the connectors to the high voltage unit are securely connected If the problem remains replace the high voltage unit Printer Controller Board Be sure all connectors are securely connected to the printer controller board If the problem remains replace the printer controller board Printhead Controller Board If the problem remains replace the printhead controller board Diagnostic Information 2 73 5055 01x Black Line Possible Cause Action Photodeveloper Drum Clean any dirt from the drum surface Replace it if it is scratched Fuser Detach Pawl Fuser Roller Surface Fuser Thermistor Surface Remove any toner buildup Replace the fuser LED Printhead Clean the LED printhead Print a blank document Replace the LED
20. 56P9657 56P9658 56P9659 56P9660 56P9661 56P9662 56P9663 56P9664 56P9665 56P9666 56P9667 56P9668 56P9669 56P9670 56P9671 56P9672 56P9673 56P9674 56P9675 56P9676 56P9677 56P9678 56P9679 56P9680 56P9681 56P9682 56P9683 56P9684 56P9685 56P9686 56P9687 56P9688 56P9689 56P9690 56P9691 56P9692 56P9693 56P9694 56P9695 56P9696 56P9697 56P9698 56P9699 56P9700 56P9701 ee mh ue mmi mhi 7M 7M CO CO CO CO CO cO 1 L Li M SI NNNN NNN REEL SE SM mo m 56P9702 56P9703 56P9704 56P9705 56P9706 56P9707 56P9708 56P9709 56P9710 56P9711 56P9712 56P9713 56P9714 56P9715 56P9716 56P9717 56P9718 56P9719 56P9720 56P9722 56P9723 56P9724 56P9725 56P9726 56P9727 56P9728 56P9729 56P9730 56P9731 56P9732 56P9734 56P9736 56P9737 56P9738 56P9739 56P9740 56P9741 56P9742 56P9745 56P9746 56P9747 56P9748 56P9749 56P9750 56P9751 56P9752 56P9753 Index l 7 5055 01x 56P9754 7 35 56P9755 7 35 56P9756 7 35 56P9757 7 35 56P9758 7 35 56P9759 7 35 56P9760 7 35 56P9761 7 35 56P9762 7 35 56P9763 7 35 56P9764 7 35 56P9765 7 37 56P9766 7 37 56P9767 7 37 56P9768 7 37 56P9769 7 37 56P9770 7 37 56P9771 7 37 56P9772 7 37 56P9773 7 37 56P9774 7 37 56P9775 7 37 56P9776 7 37 56P9777 7 37 56P9778 7 37 56P9779 7 37 56P9780 7 37 56P9781 7 39 56P9782 7 39 56P9783 7 39 56P9784 7 39 56P9785 7 39 56P9786 7 39 56P9787 7 39 56P9788 7 39 56P9789 7 39 56P9790 7 39 56P9791
21. Lower Transparency Roller Assembly Upper Carrying Frame Assembly Carrying Unit Transfer Belt Cable Assembly Belt Thermistor Sensor Turn Guide Door Cable Turn Guide Door Sensor Rod Cleaner Guide Assembly Fuser Entrance Sensor Cleaner Sensor Density Cable Density Sensor Pawl Separation Frame Assembly F1 Sub Frame Assembly F2 Sub 26 56P9686 Rod Lock 27 56P9687 Cover Gear 28 56P9693 Stopper Clutch NS 56P9697 Bushing a 32 48 4 4a pop Ba a ae oa so oe oe eo on on on on on 4 on on on on on 14 1 i NS 56P9692 Cable Assembly Reg MPF Sensor Parts Catalog 7 23 5055 01x Assembly 10 Electrical 7 24 Service Manual 5055 01x Asm Part Index Number 10 1 56P9705 Units Description Cable Assembly Feeder 2 56P9704 Cable Assembly Paper Remaining Sensor 3 56P9700 Solenoid Assembly Paper Feed 4 11G0243 Interrupter Photo 5 56P9702 Cable Belt Up Down Sensor 6 56P9701 Board Sensor 7 56P9703 Cable Assembly Sensor Board 8 56P9707 Switch Power 9 56P9706 10 56P9709 10 56P9710 11 56P9739 12 56P9742 13 56P9741 14 56P9738 15 56P9698 15 56P9699 16 56P9740 17 56P9713 18 56P9708 19 56P9722 19 56P9723 20 56P9737 21 56P9711 21 56P9712 22 56P9728 23 56P9729 24 56P9732 25 56P9734 26 56P9731 27 56P9730 Cable Power Switch Board 120 V Motor Driver Board 230 V Motor Driver Cable Asm Conditioning Printer Controller Board Heater Drive Resistor
22. Program new firmware for the network interface by way of the parallel port Press Menu to open the Job Menu and reset the printer 54 Std Par ENA Connection Lost 54 Par lt x gt ENA Connection Lost The printer has lost the connection to an external print server Make sure the cable connecting the ENA and the printer is securely attached Turn the printer off and then on to reset Press Go to clear the message and continue printing 56 Serial Port lt x gt Disabled Data has been sent to the printer through a disabled serial port Press Go to clear the message Make sure the Serial Buffer menu item in the Serial Menu is set to Disabled Diagnostic Information 2 37 5055 01x Message 56 Parallel Port lt x gt Disabled 56 Std Parallel Port Disabled Meaning Data has been sent to the printer through a disabled parallel port Action Press Go to clear the message Make sure the Parallel Buffer menu item in the Parallel Menu is set to Disabled 56 USB Port x Disabled 56 Std USB Port Disabled Data has been sent to the printer through a disabled USB port Press Go to clear the message Make sure the USB Buffer menu item in the USB Menu is set to Disabled 58 Too Many Bins Attached Too many output bins are installed Unsupported output bins are installed Turn off and unplug the printer Remove or reconfigure the out
23. Remove the high capacity feeder guide The cover is hinged in place 12 Remove the screw from the paper feed roller assembly N5 from 4 positions and remove the roller 4 64 Service Manual 5055 01x 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 Repair Information 4 65 5055 01x 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 66 Service Manual 5055 01x 19 Remove the two bearings from the turn guide The cover is hinged in place Ji dild dI CA ttt ti MEME MINIME 20 Remove the screw from the paper feed frame fuser plate and remove the plate Repair Information 4 67 5055 01x 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 See ot a a L1 WILL TD II Ho uv 1 1 1 1
24. 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 LED Sensor Name 1 Paper size sensor 1 switch letter size 11 inches 2 Paper size sensor 1 switch A4 size 3 Residual paper sensor 1 switch 4 Residual paper sensor 2 switch 5 Residual paper sensor 3 switch 6 Residual paper sensor 4 switch 7 Paper level sensor switch 8 Lower limit switch 9 Cover open sensor switch 10 Docking sensor switch 11 Upper limit switch 12 Paper sensor switch 13 Paper feed sensor switch General Information 1 35 5055 01x 1 36 Service Manual 5055 01x 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 The removal procedures in the Repair Information chapter may help you identify parts After you complete the repair perform the appropriate tests to verify the repair If an error is displayed locate it in the Service Error Message Table on page 2 4 the Attendance Messages g on p
25. but the tray is closed Open bin 1 to clear the message Press Go to clear the message and continue If the message cannot be reset go to Map 9 False 41 Open Bin 1 Exit Tray Message on page 2 48 51 Defective The printer detects defective Flash flash memory Press Go to clear the message and continue printing Install different flash memory before downloading 52 Flash Full There is not enough free space in flash memory Press Go to clear the message and continue printing Delete fonts macros and other data stored on flash memory Install flash memory with more storage capacity 2 36 Service Manual 5055 01x Message 53 Unformatted Flash Meaning The printer detects unformatted flash memory Action Press Go to clear the message and continue printing Format the flash memory If the error remains the flash memory may be defective 54 Serial Option lt x gt Error The printer has detected a serial interface error ona serial port Make sure the serial link is set up correctly and you are using the appropriate cable Press Go to clear the message and continue Press Menu to open the Job Menu and reset the printer 54 Network lt x gt Software Error 54 Standard or Std lt x gt Software Error The printer cannot establish communications with an installed network port Press Go to clear the message and continue printing
26. 4 27 Paper Carrying Frame Removal 2 eee cece ees 4 28 Paper Carrying Roller Upper Removal 4 28 Paper Carrying Clutch Removal lllee s 4 28 OHP Detection Sensor Lower Removal 4 28 5055 01x Registration Frame Registration Clutch Removal 4 29 Transfer Belt HBImOVdlas ss sms tepud rm e tamsemaadasdasd 4 30 Belt Up Down Detection Sensor Removal 4 34 Sensor Board Hemoval asiesmecueteR n nm RM ei ina 4 35 Density Sensor Removal a2 eeigeerticegeseesenreg d 4 36 Separation Fingers Hemoval eus mmm opus eed Rumes 4 36 Sensor Cleaner Removal leeeeeeeeeeeee 4 36 Printer Controller Removal 222 2592238 Pre rm RESTE Se 4 37 High Voltage Power Supply Board HVU Removal 4 38 ASU Frame Removal x5 2s d dns etti mA e DEAE 4 39 Toner Remaining Sensor Removal lle 4 39 Drum Gear Sensor Removal eese 4 39 Sub Frame F1 Sub Frame F2 Removal 4 40 Drive Gear Unit Sensor Assembly Removal 4 41 Belt Up Down Clutch Removal eesseseeee 4 42 Powersupply 1 Removal sas cher Rd TREE mes 4 43 Power Supply 2 Removal xx2 22 x rne REESE 4 44 Drive Motor Assembly Removal eee 4 45 Motor Drive Board Removal 220eee cece eee eeeeee 4 45 Power Switch Removal aesecuccteum t e mE ANE oe eee 4 46 Connector Duplex Unit Removal s
27. 4 81 high capacity paper feeder HCPF 4 76 high voltage power supply board 4 38 LED printhead 4 12 lock handle assembly 4 59 main drive unit 4 50 main unit fan 4 49 multi purpose feeder clutch 4 23 multi purpose feeder paper present sensor 4 27 multi purpose feeder roll 4 23 multi purpose feeder tray 4 17 OHP detection sensor lower 4 28 OHP detection sensor upper 4 23 paper carrying clutch 4 28 paper carrying frame 4 28 paper carrying roller 4 18 paper carrying roller upper paper delivery sensor 4 54 paper exit motor 4 55 paper exit tray 4 10 paper exit tray switch 4 54 paper feed frame 4 20 paper feed roller 4 18 paper feed solenoid 4 22 paper present sensor 4 19 paper remaining sensor 4 22 paper size sensor board assembly 4 48 power supply 1 4 43 power supply 2 4 44 power switch 4 46 printer controller 4 37 printhead controller board 4 15 R sub frame 4 39 4 28 registration clutch 4 29 registration frame 4 29 registration sensor 4 26 right slide rail 4 58 RIP box 4 11 sensor board 4 35 sensor cleaner 4 36 separation fingers 4 36 stay arm 4 61 sub frame F1 sub frame F2 4 40 temperature humidity sensor 4 22 toner remaining sensor 4 39 top unit 4 60 transfer belt 4 30 turn guide cover sensor upper fan 4 16 Repair Information 4 1 S Safety Information ix Sensor and Switch Locations 5 15 Serial Number 1 3 3 23 Service Checks 2 55 drive 1 DC motor 2 55 drive
28. 5 Remove the paper feed frame 6 Disconnect the sensor cable 4 20 Service Manual 5055 01x Cassette Guide Removal 1 Remove the paper feed frame 2 Remove the front cover cassette turn guide right side cover and paper feed frame 3 Remove the screws from the cassette guide and remove the guide ooo ooo Repair Information 4 21 5055 01x 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 4 Remove the spring from the solenoid plunger arm Note Be sure to use the specific screws during installation Long screws will damage the solenoid Paper Feed Solenoid Paper Remaining Sensor Temperature Humidity Sensor 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 4 22 Service Manual 5055 01x Gear Cover Removal Multi Purpose Feeder Roll Removal Multi Purpose Feeder Clutch Removal OHP Detection Sensor Upper Removal 1 Open the top unit and remove the upper cassette front cover multi purpose feeder right side cover and turn guide 2 Remove the two scr
29. 910 AA St NHA CS FEO YE AA BA ESSI en SoelsteHAeLjcp Qt Ho ANA stAt t ARIA Z ch Lexmark ChE ala 9 ASA chest AAS xx SBC Al Sol H FA Ba AAS AB AB 784823 AME AolSe ul ABE ABS g amp tct ASS spuerpje HH gl AS 7 49 24S WAL AAS elg oslo ATHACH A 7 amp Ak Ol MAS SISH Best of AES SAS Ho zm I gt og Pl fil Safety Information xiii 5055 01x xiv Service Manual 5055 01x 1 General Information 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 After you complete the repair perform tests as needed to verify the repair Standard Inspection and Cleaning Procedure Switch off Printer power and disconnect the AC power cord from the wall outlet Remove and inspect the photodevelopers and toner cartridges shielding them from strong light Inspect the interior of the printer removing foreign matter such as paper clips staples pieces of paper transparencies paper dust hair oil grease or toner Clean the printer interior using a lint free cloth dampened slightly with cold water Do not use solvents or chemical cleaners to clean the printer interior Use only the specified oil or lubricant on printer parts some service parts ar
30. C Jams that cause a Check Area C message require opening the duplex jam access door If you are printing on small paper the following steps may not clear the jam See Removing Small Size Paper From the Duplex Unit on page 1 22 1 2 3 Open the duplex jam access door on the right side of the printer Remove the jam Press Go Note If the paper jam message continues check and clear all paper from the paper path Check Area D This message indicates a paper jam in the duplex unit area To clear area D 1 2 3 OAN DOO A Open the duplex jam access door on the right side of the printer Gently pull out the duplex unit Turn the paper forwarding dial counterclockwise If the paper advances out of the duplex unit remove the jam and go to step 7 If the paper does not advance go to step 4 Open the duplex unit covers Remove the jam Close the duplex unit covers Push the duplex unit back into the printer Close the access door Press Go If the paper jam message continues check and clear all paper from the paper path General Information 1 21 5055 01x Removing Small Size Paper From the Duplex Unit When printing on both sides of A5 or other small size paper you may need to partially remove the duplex unit to clear the jam NOOR WD 8 9 Turn off the printer Open the duplex unit door Loosen the two screws Pull out the duplex unit far enough to see the duplex
31. Duplex UNI 2 uius ptr EFC ae antec 7 42 Assembly 18 High Capacity Paper Feed 1 7 44 Assembly 19 High Capacity Paper Feed 2 7 46 Assembly 20 High Capacity Paper Feed 3 7 48 Assembly 21 High Capacity Paper Feed 4 7 50 Assembly 22 High Capacity Paper Feed 5 7 52 Assembly 23 High Capacity Paper Feed 6 7 54 i4 Mm x 1 viii Service Manual 5055 01x Safety Information Safety Notice This product is designed tested and approved to meet strict global safety standards with the use of specific Lexmark components The safety features of some parts may not always be obvious Lexmark is not responsible for the use of other replacement parts The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t concu test et approuv pour respecter les normes strictes de s curit globale lors de l utilisation de composants Lexmark sp cifiques Les caract ristiques de s curit de certains l ments ne sont pas toujours videntes Lexmark ne peut tre tenu responsable de l utili
32. Lett Side Removal c c ccs 65005000660 RSLURRRE EA RES 4 7 Cover Fight Side Removal un eines mtm mers 4 8 Cover RIP Board Removal e rm Rh RII Rm RS 4 9 Tray Paper Exit Removal vecteur oh 4 10 AIP Box Removal assa e son an RO REA URN ARP Eo dE 4 11 Electronic Box Removal 2 mmm RP ewes awe 3E YS 4 11 LED Printhead Removal ipt Rb ERR ios 4 12 Eraser Removals sse ksmetescuhtrkerremteet M TA EE 4 14 Printhead Controller Board Removal 4 15 Upper Fan BemoVval xs sete mm Rhe RR RR supra ae gum 4 16 Multi Purpose Feeder Tray Removal Lese 4 17 Paper Feed Roller Removal lllleleeses 4 18 Paper Carrying Roller Removal 22 rrr RR RR Ra 4 18 Paper Present Sensor Removal leere 4 19 Paper Feed Frame Removal 222000ee eee eeeeeee 4 20 Cassette Guide Hemoval 24 kn hm mh Re hin 4 21 Temperature Humidity Sensor Removal 4 22 Paper Feed Solenoid Removal llsuls 4 22 Paper Remaining Sensor Removal L u 4 22 Gear Gover Removal sauce sese saws saiya Cea IC E GR 4 23 Multi Purpose Feeder Roll Removal 4 23 Multi Purpose Feeder Clutch Removal 4 23 OHP Detection Sensor Upper Removal 4 23 Fanning Pad Removal si xxn km sated hmm xen 4 25 Registration Sensor Removal 200e cece cere eee 4 26 Multi Purpose Feeder Paper Present Sensor Removal
33. Remove the printer controller board Remove the bracket high voltage power supply board and sub frame R Remove the fuser unit face up paper delivery unit belt up down clutch and DC drive motor Remove the multi purpose feeder roll registration roll and paper carrying frame Remove the eight screws from the power supply 2 bracket Remove the two screws from the belt power supply 2 10 11 Remove the two screws from the fan bracket Remove the three screws from the fuser connector plate 4 50 Service Manual 5055 01x 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 five screws and four screws from the bracket as shown Repair Information 4 51 5055 01x 14 Remove the bearing from the belt up down switching shaft and remove the belt up down switching shaft VIV 15 Remove the screw from the clutch stopper The clutch stopper is attached to the ground plate with two screws 4 52 Service Manual 5055 01x 16 Remove the five screws on the right side TO F C E o imn 29 CN ik
34. Ruhr RE 1 7 Paper Feeding FUSIN serus rein ERR RR 1 7 Drive System i l il luuuu m mnia irai acne an hun 1 8 Paper Feedingasisicncsicrcicesez kk e e Re xx rex oR den 1 9 Cassette Paper Feeder icerum RR 1 9 Multi Purpose Feeding 2 22 0000ee0ee sees nnn 1 10 Registration Unit 2 2 l2ulu RR nee 1 11 Separation Unit ccerirecrscrrisd inss them mmm mas 1 12 FuserUnil ii2iixce kk t mre xr mene es RIA 1 13 DeliVOty amp aiimuccickeeikmsmex ecexc med wem x XO xOA E x Rn n Rx 1 14 Belt Unit sec eicc cee lur RR RR rh m RRRRRR E EIER 1 15 Belt Up DOWflssss suse suec imu RR RE rmx x REX EE ERE EE 1 16 Expansion Paper Feeder lllzi liar 1 16 Duplex Unit i2as iuuc irum hte xx Ix xS RE 1 17 Printing Mode ual rnm hne 1 18 el C da mare cepa sonas eae a gaara ani dann 1 18 Thick Paper MOde 2ccccecccccecereceteeeaeeeeeee ana 1 18 Envelope Postcard Mode eslleessleees 1 19 Operation Mode 2 cillee il mirari 1 19 Clearing Paper Jams 2222 22 iorum 1 20 High Capacity Paper Feeder HCPF sees 1 25 Maintenance Mode luucl uuu hh Rx eR ae 1 33 High Capacity Paper Feed Sensor Switch Test 1 35 5055 01x Diagnostic Information 000e eee eee eee eee 2 1 Adjustments and Procedures Following Parts Replacement 2 1 SOU s s iic rE aud ee ard tended ud ene EE QE RUE RENE eed EE ene 2 3 MU Chek er PECTUS 2 3 Printer Massages eco pe RIA 9r c gae Es eR RRd EE 2 4 Service Error Message Table
35. printhead if a black line appears on the paper Black Print Possible Cause Action High Voltage Unit HVU The printed paper has black print Be sure the high voltage unit is properly connected If the problem remains replace the high voltage unit Sub frame If the problem remains replace the right sub frame contacts Photodeveloper Drum Set If the problem remains after replacing the sub frame be sure the drum has clean contacts If necessary replace the drum set 2 74 Service Manual 5055 01x Missing Colors Possible Cause Action Toner Cartridge Unit Be sure the toner cartridge and the PC drum unit are properly seated Be sure the contacts on the print unit are clean Be sure the print unit is installed in the correct position Run a print test If the problem remains switch the print unit with another color and run a test print If the new color prints replace the failing toner cartridge High Voltage Unit If the problem remains check the connector on the high voltage unit Replace the high voltage unit If the problem remains LED Printhead Unit Replace the printhead and EPROM If the problem remains LED Printhead Controller Board If the problem remains replace the printhead controller board High Voltage Unit HVU If the problem remains replace the high voltage unit Transfer Belt Unit If the problem remains replace the transfer belt u
36. replace the the problem printer controller board 923 Upper Fuser Thermistor Open Error Step Questions i Yes No Actions 1 Is connector CN44 Disconnect CN44 Plug the connector in on the printer and turn the printer securely controller board on connected Go to step 2 properly 2 Is error 923 Power off and Replace the printer displayed reconnect CNA4 controller board Go to step 3 3 Power the printer Replace the fuser Replace the printer off and short pins controller board 1 and 4 of CN44 and power on Is error 923 displayed Diagnostic Information 2 7 5055 01x 924 Lower Fuser Thermistor Open Error off and short pins 8 and 11 of CN44 and turn the printer on Is error 924 displayed Questions Ste Yes No p Actions 1 Is connector CN44 Disconnect CN44 Plug the connector in on the printer and turn the printer securely controller board on connected Go to step 2 properly 2 Is error 924 Turn the printer off Replace the printer displayed and reconnect controller board CN44 Go to step 3 3 Power the printer Replace the fuser Replace the printer controller board 925 High Pressure Controller Error Step Questions Yes No Actions 1 Is connector CN42 Replace the printer Plug the connector in on the printer controller board securely controller board Go to step 2 connected properly
37. replace the sensor Paper has exited the registration roller and entered the fuser Areas A and B FRU Action 1 Transfer Belt Remove any buildup of toner Replace any damaged Unit or worn parts Rear Paper Guide Check the paper exit flag on the fuser for damage Discharge Replace the fuser if necessary Brush Fuser 2 Fuser Replace the fuser if paper jams cannot be removed Separation Pawl 2 60 Service Manual 5055 01x Paper has entered the fuser and exited the printer Area B FRU Action 1 Fuser Remove any toner buildup and replace any worn or damaged parts 2 Fuser Exit Lower Roller Exit Guide FU FD Flap Solenoid Exit Flap Clutch Lever Gears Fuser Exit Upper Roller Be sure the exit FU FD solenoid energizes in the correct position for either face down or face up delivery Replace any damaged or worn parts Do a continuity check of the solenoid Be sure connector CN122 is properly connected to the printer controller board 3 Paper Exit Motor Drive 2 Stepper Motor Face Down Feed Roller Belt Be sure that connector CN4 is properly connected to the controller board 4 Paper Exit Switch face up face down Sensor Check for a fluctuation of between OV and 5 V on the printer controller board between the following pins when actuating the sensor Paper exit switch CN12 pins 4 and 5 fac
38. temperature and display the Ready message Print Jobs on Jobs spooled to the hard disk Press Go to print the jobs Disk before the printer was last turned off have not yet Press Return or Stop to printed delete jobs Printer The printer is adjusting the Wait for the message to Calibrating color tables to correct clear variations caused by environmental conditions Printing The printer is processing or Wait for the message to Alignment Page printing a test page that clear shows alignment values Printing The printer is processing or Wait for the message to Directory List printing a directory of all files clear stored in flash memory or on a hard disk 2 30 Service Manual 5055 01x Message Meaning Action Printing Font List The printer is processing or printing a list of all available fonts for the specified printer language Wait for the message to clear Printing Job Accounting Stat The printer is processing or printing all job accounting statistics stored on the hard disk Wait for the message to clear Printing Menu The printer is processing or Wait for the message to Settings printing the menu settings clear page Prog Engine The printer is programming Wait for the message to Code new code into flash memory clear Prog System Code The printer is programming new system code Wait for the message to clear Program F
39. the duplex unit use independent motors to drive the paper delivery unit General Information 1 7 5055 01x Drive System Drive 1 composed of a 100 dc motor and gear unit feeds the registration paper from the paper feeder and drives the belt unit photodeveloper toner cartridge fusing unit and face up delivery unit The motor rotates by the ON signal from the printer controller motor drive unit and sends a rotation synchronization detection signal to the motor drive unit Note The gear unit of drive 1 is adjusted in phase and should not be disassembled Drive 2 composed of a hybrid stepping motor and gear unit drives the face down delivery unit Stepping Motor Drive 2 p o wai ns DC Motor Drive 1 Electromagnetic Clutch SS he z Mae a Y 1 8 Service Manual 5055 01x Paper Feeding The paper feeder is a two way system composed of the multi paper feeder 100 sheets maximum and an integrated 550 sheet tray Optionally the expansion paper feeders 550 sheets can be increased to four layers A high capacity paper feeding system 3 000 sheets may be used Combining the multi paper feeder expansion paper feeders and high capacity paper feeding system the printer has a maximum paper supply of up to 5 850 sheets NUS C iE wig QO Paper Feeding Spring o Cassette Paper Fee
40. to one or the other of the assemblies are listed separately and identified by description NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Parts Catalog 7 1 5055 01x Assembly 1 Covers 1 7 2 Service Manual 5055 01x Asm Part Index Number 1 1 12G7360 Units Description Board Operator Panel 2 56P9736 Cable Operator Panel 3 56P9555 Housing Upper Operator Panel 4 56P9556 Housing Lower Operator Panel 5 56P9539 Cover Top 6 56P9533 Cover Assembly Right Side 7 56P9534 Magnet Right Side Latch 8 56P9540 Cover Waste Toner Bottle 9 56P9545 Label Operator Guide 10 56P9549 11 56P9532 12 56P9548 13 56P9543 14 56P9542 15 56P9550 16 56P9536 17 56P9537 18 56P9535 19 56P9531 20 56P9546 20 56P9547 Label Model Name Cover Assembly Front Label Jam Removal Magnet Front Cover Latch Cover Left Front Label Consumable Cover Left Side Cover Paper Feed Cover Solenoid Tray Assembly Exit Label Voltage 120 Label Voltage 230 21 56P9538 Cover Rear 22 56P9551 Cover Adjustment NS 56P9544 Label MPT NS 56P9554 NS 56P9905 Core Ferrite Kit Operator Panel Overlay 2 2 c L cl LL L we cl cl cl cl c LL oL oL oL oL oll Parts Catalog 7 3 5055 01x Assembly 2 Covers 2 7 4 Service Manual 5055 01x dol ecd Units Descript
41. unit inlet Remove jam from the duplex unit inlet Slide the duplex unit in Align the thumbscrews on the duplex unit with the holes in the printer Tighten the thumbscrews to secure the duplex unit Close the duplex unit door Check Area E This message indicates a jam in the top middle or bottom optional drawer paper path area If you have a high capacity feeder pull the feeder away from the printer o 100 20 nmn c Open the jam access door on the top optional drawer Remove the jam Close the jam access door Open the jam access door on the middle optional drawer Remove the jam Close the jam access door Open the jam access door on the bottom optional drawer Remove the jam Close the jam access door 10 Press Go Note If the paper jam message continues check and clear all paper from the paper path 1 22 Service Manual 5055 01x Check Area F ok wWNDM 6 Pull the high capacity feeder away from the printer Open the jam access door on the top optional drawer Remove any jams Close the jam access door Slide the high capacity feeder until the feeder locks to the docking frame When the feeder is in the correct position you hear a click Press Go Note If the paper jam message continues check and clear all paper from the paper path 240 Paper Jam Check MP Feeder 1 of W P Slowly pull the jam straight out of the multipurpose feeder I
42. which is interconnected with the opening and closing of the front cover yo WA Temperature General Information 1 15 5055 01x Belt Up Down In monochrome printing switching to color printing is not required To avoid unnecessary wear of the photosensitive drum by the cleaning blade this operation is stopped with the electromagnetic clutch in drive 1 The transfer belt is lowered so as not to touch the photosensitive drum during color printing The transfer belt moves up and down with the switching shaft cam by the electromagnetic clutch in drive 1 The belt position is used to detect the cam position with the photo sensor using the fan shaped light blocking plate attached to the switching shaft Printing with the transfer belt lowered is called monochrome mode and color printing is called color mode Electromagnetic Clutch BUD Expansion Paper Feeder The optional expansion paper feeder can be installed at the lower part of the main unit Including the main unit up to five layers of cassettes can be used for cassette paper feeding 1 16 Service Manual 5055 01x 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 du
43. 0 on Go to High Plug the the printer controller Capacity Paper connector in board securely Feed HCPF securely connected Service Check on page 2 57 Diagnostic Information 2 5 5055 01x 917 RIP Fan Error 917 Service Fan Error Step Questions Actions Yes No 1 Is connector J5 on the Go to step 2 Properly RIP board connected connect J5 properly 2 Is 24 V dc present Replace the RIP Replace the between pins 1 and 3 of fan RIP board connector J5 on the RIP board 918 Main Unit Fan Error Step Questions Actions Yes No 1 Is 24 V present between Replace the failing Replace the pins 1 and 3 on fan printer connectors CN17 upper controller left fan and CN5 upper board right fan on the printer controller board 919 Power Supply Fan Error Step Questions Actions Yes No 1 Is 24 V present between Replace the power Replace the pins 1 and 3 of connector supply fan printer CN6 on the printer controller controller board board 2 6 Service Manual 5055 01x 920 Fuser Error Fuser Heater Trouble 92x Service Fuser Error Questions Step Yes No Actions 1 Replace the fuser Problem solved Return the fuser Did this fix the replace the power problem supply 2 and go to step 2 2 Did replacing Problem solved Return power supply power supply 2 fix 2 and
44. 2 stepper motor 2 55 duplex 2 56 expansion paper feed 2 56 face down stacker full 2 57 high capacity paper feed HCPF 2 57 4 57 2 66 2 58 marks on paper operator panel options 2 77 paper carrying 2 58 paper exit FU FD 2 63 paper tray missing 2 63 photodeveloper missing 2 64 power supply 2 65 serial port 2 77 Transfer Belt Up Down 2 68 Service Error Message Table 2 4 Service Precautions 4 1 Setting Configuration ID 3 24 Setting the Page Count 3 23 Start 2 3 Symptom Table 2 52 Index l 3 5055 01x T Test 3 10 Tests button 3 10 device 3 17 disk test clean 3 18 DRAM memory 3 11 flash 3 19 hardware 3 10 input source print 3 8 LCD hardware 3 10 parallel wrap 3 13 print 3 8 print quality pages 3 9 quick disk 3 17 ROM memory 3 12 serial wrap 3 15 Theory belt unit 1 15 belt up down 1 16 cassette paper feeder cleaning unit 1 7 clearing paper jams 1 20 delivery 1 14 development unit 1 6 drive system 1 8 duplex unit 1 17 Troubleshooting 2 69 U Using the Operator Panel 3 2 V Viewing And Resetting The Drum Counters 3 22 Viewing and Resetting the Drum Counters 3 22 Viewing the Error Log 3 25 Viewing the Permanent Page Count 3 23 electrophotography process 1 5 envelope postcard mode 1 19 expansion paper feeder 1 16 fuser unit 1 13 high capacity paper feeder HCPF 1 25 maintenance mode 1 33 multi purpose feeding 1 10 OHP mode 1 18 operation mode 1 19 paper feeding 1 9
45. 516 13 56P9518 14 56P9515 15 11G0563 16 56P9786 17 56P9784 18 56P9787 19 56P9785 20 56P9788 21 56P9795 22 11G0219 23 56P9510 24 56P9782 25 56P9783 26 56P9781 27 56P9511 28 56P9506 29 56P9508 30 11G0291 31 56P9797 32 11G0297 NS 56P9793 NS 56P9507 Guide Turn Spring Right Cassette Guide Guide Lower Right Cassette Spring Left Cassette Guide Guide Lower Left Cassette Guide Upper Cassette Interrupter Photo Spring Paper Detection Sensor Actuator Paper Detection Cable Paper Present Sensor Cover Paper Present Sensor Guide HCPF Cable Paper Present Sensor Interrupter Photo Shaft Paper Feed Spring Solenoid Solenoid Feeder Lever Clutch Roller Assembly Paper Feed Frame Paper Feed Bracket Ground Clutch Paper Feed Cover Gear Gear Paper Carrying Spring Left Turn Guide a ee oa a oa on Pan on ln 2n on 2 2 2l 2 2n 2 2n in 2n in an un nin Pp BPR PO HPD Actuator Paper Feed Sensor Parts Catalog 7 39 5055 01x Assembly 16 Duplex Unit 1 7 40 Service Manual 5055 01x Asm Part index Number Units Description 16 1 56P9798 1 Duplex Assembly 2 56P9804 1 Board Duplex Interface 3 56P9799 1 Frame Duplex 4 56P9800 2 Screw Duplex Mounting 5 56P9803 1 Motor Duplex Stepping 6 56P9525 1 Interrupter Photo 7 56P9806 1 Cable Assembly Paper Detection NS 56P9807 1 Cable Assembly Duplex Interface NS 56P9805 1 Cable Assembly Duplex Connection
46. 55 01x Number Component 1 Printhead Controller Board 2 Operator Panel 3 RIP Box 4 Motor Driver Board 5 Power Switch 6 Printer Controller Board 7 High Voltage Unit HVU 8 Upper Left Fan 9 Main Drive Motor 10 Upper Right Fan 11 Power Supply Fan 12 Temperature Humidity Sensor 13 Paper Remaining Detection Sensor Main Unit 14 Paper Remaining Detection Sensor Expansion Feeder 15 Power Supply 2 16 Power Supply 1 17 Expansion Feeder Control Board 18 Paper Size Sensor Board Expansion Feeder 19 Paper Size Sensor Board Main Unit 5 18 Service Manual 5055 01x 6 Preventive Maintenance Maintenance Kit When nearing the end of life of the fuser or transfer belt the following message appears on the printer display indicating that it s time to replace the fuser unit and or transfer belt unit 80 Belt Life Warning and or 80 Fuser Life Warning Routine replacement of these parts ensures peak printer performance and helps prevent print quality problems and paper feed problems resulting from worn parts The parts are contained in the maintenance kits listed below Maintenance Kit P N Unit Printer Power Supply 56P9903 Transfer Belt 115 V 230 V 56P9900 Fuser 115 V 56P9901 Fuser 230 V The status message appears on the display until the appropriate part s is replaced Preventive Maintenance 6 1 5055 01x Periodic Maintenance
47. 56P9627 24 56P9616 25 56P9630 26 56P9611 27 56P9608 28 56P9609 29 56P9592 30 56P9594 31 56P9595 32 56P9596 33 56P9597 34 56P9598 Rod Interlocking Link Frame Bearing Roller Handle Upper Opening Hook Left Link Holder Front Printhead Holder Front HSP Spring Printhead Rail Left Side Cover Eraser Lamp M Erase Lamp C Erase Lamp Y Erase a amp RO BR RA PO YM H BB ase aan DAP Ba Be oa An An OD DO PWN OO A Lamp K Erase Parts Catalog 7 13 5055 01x Assembly 6 Upper Unit Continued 7 14 Service Manual 5055 01x Asm Part index Number Units Description 6 35 56P9599 4 Printhead LED 36 56P9610 4 Rail Right Side 37 56P9593 4 Holder Rear Printhead 38 56P9619 1 Bracket Rear Upper 39 56P9622 1 Fan Upper Right 40 56P9623 1 Fan Upper Left 41 56P9621 1 Bracket Fan Holder NS 56P9629 1 Frame Link NS 56P9639 4 Connector Upper NS 56P9604 8 Core Ferrite NS 56P9605 8 Cable Assembly HDFG NS 56P9606 4 Cable Assembly RSPFG NS 56P9607 2 Cable Assembly LFG Parts Catalog 7 15 5055 01x Assembly 7 Base 1 7 16 Service Manual 5055 01x Asm Part Index Number 7 1 56P9664 2 56P9503 Units Description Frame Paper Feed Foot Rubber 3 56P9512 Roller Assembly Paper Carrying 4 56P951 1 Roller Assembly Paper Feed 5 11G0243 Interrupter Photo 6 56P9665 Sensor Paper Feed 7 56P9507 Actuator Paper
48. 7 1 Cover Upper 4 56P9834 1 Cover Upper Rear 5 56P9843 1 Cover Lower Rear 6 56P9839 1 Cover Right 7 56P9833 1 Cover Front 8 56P9836 1 Fence End 9 56P9940 1 Ring Snap 10 56P9841 1 Cover Assembly Upper 11 56P9840 1 Lever Vertical Transport 12 56P9842 1 Spring Tension Parts Catalog 7 45 5055 01x Assembly 19 High Capacity Paper Feed 2 7 46 Service Manual 5055 01x ae caries Units Description 19 1 56P9846 1 Solenoid Assembly Paper Pickup 2 56P9848 1 Clutch Paper Feed 3 56P9844 1 Motor Assembly Transport 4 56P9941 1 Arm Pick up 5 56P9501 1 Spring Pressure 6 56P9528 1 Interrupter Photo 7 56P9849 1 Roller Manual Feed Pickup 8 56P9850 1 Roller Manual Feed 9 56P9852 1 Limiter Torque 10 56P9851 1 Roller Manual Feed Separate 11 56P9847 2 Spring Compression 12 56P9845 1 Sensor Assembly Paper Feed Parts Catalog 7 47 5055 01x Assembly 20 High Capacity Paper Feed 3 v A ZEN cap 7 48 Service Manual 5055 01x Asm Part index Number Units Description 20 1 56P9854 1 Sensor Assembly Photo 2 56P9855 1 Interrupter Photo 3 56P9529 1 Caster HCPF 4 56P9856 1 Spring Tension 5 56P9857 1 Switch Micro 6 56P9530 1 Switch Push 7 56P9859 1 Connector Inlet 8 56P9858 1 Connector I F 9 56P9853 3 Screw Shoulder Parts Catalog 7 49 5055 01x Assembly 21 High Capacity Paper Feed 4
49. 7 39 56P9792 7 39 56P9793 7 39 56P9794 7 39 56P9795 7 39 56P9796 7 39 56P9797 7 39 56P9798 7 41 56P9799 7 41 56P9800 7 41 l 8 Service Manual 56P9803 56P9804 56P9805 56P9806 56P9807 56P9808 56P9809 56P9810 56P9811 56P9812 56P9813 56P9814 56P9815 56P9816 56P9817 56P9818 56P9819 56P9820 56P9821 56P9822 56P9823 56P9824 56P9825 56P9826 56P9827 56P9828 56P9829 56P9830 56P9831 56P9832 56P9833 56P9834 56P9835 56P9836 56P9837 56P9838 56P9839 56P9840 56P9841 56P9842 56P9843 56P9844 56P9845 56P9846 56P9847 56P9848 56P9849 5055 01x 56P9850 56P9851 56P9852 56P9853 56P9854 56P9855 56P9856 56P9857 56P9858 56P9859 56P9861 56P9862 56P9863 56P9864 56P9865 56P9866 56P9867 56P9868 56P9869 56P9870 56P9871 56P9872 56P9873 56P9874 56P9875 56P9876 56P9877 56P9878 56P9879 56P9880 56P9882 56P9883 56P9884 56P9885 56P9886 56P9887 56P9888 56P9889 56P9890 56P9891 56P9892 56P9893 56P9894 56P9897 56P9898 56P9899 56P9904 7 47 7 47 7 47 7 49 7 49 7 49 7 49 7 49 7 49 7 49 7 51 7 51 551 7 51 1 91 Fol 7 51 FED 7 51 sb1 fol 7 51 51 7 51 7 51 1 91 7 51 1 51 7 51 fol 7 53 7 53 4 53 7 53 7 53 7 53 4 53 55 290 IT 59 7 55 7 59 7 55 7 29 7 23 1 23 7 29 56P9905 56P9910 56P9911 56P9912 56P9913 56P9914 56P9915 56P9916 56P9926 56P9927 56P9928 56P9929 56P9930 56P9932 56P9933 56P9934 56P9940 56P9941 99A0424 99A0545 99A0560 99A0629
50. 99A2489 7 3 7 29 7 29 7 29 7 29 7 29 7 55 7 29 7 31 7 31 7 31 7 31 7 31 7 31 7 29 7 29 7 45 7 47 7 29 7 29 1 29 7 29 1 29 Index l 9 5055 01x l 10 Service Manual
51. Catalog 7 27 5055 01x Assembly 11 I F Controller 7 28 Service Manual 5055 01x Asm Part Index Number 11 1 56P9749 Units Description Cable Assembly Power RIP 2 56P9916 Card Riser 3 56P9897 Board RIP Controller 4 56P9750 Fan RIP 5 56P9745 Box RIP 6 56P9719 Cable Assembly 80 Pin RIP Printer Controller 7 56P9736 Cable Operator Panel 8 56P9746 Cover RIP Box NS 56P9747 NS 56P9748 NS 56P9904 NS 12G6509 NS 56P9910 NS 56P991 1 NS 56P9912 NS 56P9913 NS 56P9914 NS 99A2489 NS 56P9933 NS 56P9934 NS 12G1695 NS 12G1696 NS 56P0161 Cable Assembly Power MAC Cable Assembly MIF Board RIP Controller Network Card SDRAM DIMM Card Assembly 128MB SDRAM memory Card Assembly 256MB SDRAM memory Card Assembly 4MB Flash DIMM memory Card Assembly 8MB Flash DIMM memory Card Assembly 16MB Flash DIMM memory Hard Disk 5 GB w Mounting Kit formatted Mounting Kit Hard Drive Card Token Ring Card Ethernet 10 100Base TX Card Ethernet 10BaseT 2 Card RS 232C Serial Parallel 1284 A C Interface Card Tri Port Adapter Card Infrared Adapter a 2 c c c cl c clc cl cl cl ol oc c COs Cron Cos COs Cres Cs Ce NS 99A0560 NS 99A0424 NS 99A0545 NS 99A0629 NS 56P0162 NS 13A0296 NS 13A0297 Card External Serial Adapter Card Coax Twinax Adapter for SCS Adapter Parallel 1284 C B Cable Twinax Cable Coax ae ln ln o2 l2 n Parts Ca
52. Charged Roll 15 Paper Feed Roll 30 LED Head Locations 5 3 5055 01x Printer Controller Board TE 2 a CN15CN7 CN40 CN3 CN19 CN22 CN18 CN21 CN13 CN16 CN28 CN27 CN11 CN30CN26 CN23 CN24 CN9 CN4 CN17 CN5 CN25 CN8 5 4 Service Manual 5055 01x Printhead Controller Board Ooo lo oxo fol CN16 CN15 CN12 CNI1 d 2 CNO8 CNO7 5 1 8 Llu ut ut7 jute o 28 2 GO v M e e Zz zZz 6 6 ee j UT U13 U16 U18 O 8 z I oo Zz oC 1 LJ LJ LJ F U20 U21 U15 U3 38 Z rcg Fuse 3 Fuse6 O amp j Fuse 5 A CN14 CN13 CN10 CNO9 CNO6 CNO5 zs O a pa Q Locations 5 5 5055 01x R
53. Check the failing paper feed solenoid for continuity MPF Clutch Also check connector CN24 tray1 and CN16 MPF on the printer controller board and CN5 on the expansion feeder control card 5 Registration Check for a fluctuation between 0 and 5 V on the Sensor printer controller board between the following pins e MPF Sensor when actuating the sensor Pi Registration sensor CN11 pins 1 and 2 Board MPF sensor CN11 pins 4 and 5 If the voltage fluctuates as stated above replace the printer controller board If the voltage does not fluctuate replace the sensor Diagnostic Information 2 59 5055 01x Paper has stopped at the registration roller or has not reached the fuser Areas C E 240 24x FRU Action 1 Registration Roller Clutch Registration Roller Transfer Belt Unit Rear Paper Feed Guide Check these parts for wear or damage Replace as necessary Be sure all guide surfaces in the paper path are free of dirt Check the registration roller clutch for continuity Be sure connector CN13 on the printer controller board is connected properly 2 Registration Sensor Printer Controller Board Check for a fluctuation of between OV and 5 V between pins 1 and 2 of connector CN11 on the printer controller board while actuating the sensor If the voltage fluctuates as stated above replace the printer controller board If the voltage does not fluctuate
54. Conditioning Cable Assembly Conditioning Joint Motor Assembly 120 V Motor Assembly 230 V Cable Conditioning Resistor Fan Power Supply Cable Assembly Duplex Connector Power Supply 120 V 1 Power Supply 230 V 1 Insulator Sheet Cable THB Drawer Cable THB Drawer EMEA Board Printer Controller EPROM Printer Controller Belt Power Supply HCPF Finisher D sub Assembly Cable Assembly Finisher Cable Assembly HCPF c 2 c c c2 c cl clc c clc cl c c c c c c o Parts Catalog 7 25 5055 01x Assembly 10 Electrical Continued 7 26 Service Manual 5055 01x Asm Part Index Number 10 28 56P9714 29 56P9727 30 56P9726 31 56P9724 31 56P9725 32 56P9715 NS 11D0328 NS 11D0329 NS 11D0330 NS 11D0331 NS 11D0332 NS 11D0333 NS 11D0334 Units Description Board High Voltage Power Supply Cable Assembly Printer Controller Power 2 Cable Assembly Printer Controller Power 1 Power Supply 120 V 2 Power Supply 230 V 2 Cable High Voltage Power Supply Board Power Cord USA Canada APG LAD Power Cord Peru Power Cord Argentina Power Cord Brazil Power Cord Chile Power Cord Denmark 2 2 c2 l2 ol cl lll Power Cord Belgium Europe England France Germany Spain NS 11D0335 1 Power Cord Italy NS 11D0336 1 Power Cord Swiss French German Italian NS 11D0337 1 Power Cord UK Israel South Africa Parts
55. Each time the test finishes the screen is updated with the result If the test is successful the Pass Count increments by 1 Diagnostic Aids 3 13 5055 01x If the test fails the Fail Count increments by one and one of the following failure messages displays for approximately three seconds Sync Busy Error Byte Interrupt Request Error Strobe Interrupt Request Error Init Fall Error Init Busy Error Init Rise Error Host Busy Error RAM Data FF Error RAM Data AA Error RAM Data 00 Error RAM Data 55 Error DMA Count Error DMA Address Error DMA Interrupt Error DMA Memory Error DMA Background Error Clear Init Rise Error False Init Rise Error False Init Fall Error Autofeed Rising Interrupt Error Clear Autofeed Rise Error False Autofeed Rise Error Autofeed Falling Interrupt Error Clear Autofeed Fall Error Once the maximum pass count or fail count is reached the test stops and the final test results display Press Return or Stop to exit the test 3 14 Service Manual 5055 01x Serial Wrap Tests The Serial Wrap Test is used to check the each signal of the serial port hardware using a wrap plug To perform the wrap test follow these steps e Disconnect the serial interface cable and install the serial wrap plug e Select HARDWARE TESTS from the Diagnostics Menu Select the appropriate Serial Wrap Test Serial Wrap Serial 1 Wrap the printer begins testing the serial hardware and the following screen displa
56. Feed Sensor 8 56P9520 Handle Waste Bottle Cam 9 56P9517 10 56P9519 11 56P9516 12 56P9518 13 56P9515 14 56P9503 15 56P9641 16 56P9505 17 56P9504 18 56P9521 19 56P9522 20 56P9523 21 56P9642 22 56P9643 23 56P9644 24 56P9645 25 56P9663 26 56P9659 27 56P9660 28 56P9654 29 56P9653 30 56P9652 31 56P9649 32 56P9648 33 56P9651 34 56P9650 Spring Right Cassette Guide Guide Lower Right Cassette Spring Left Cassette Guide Guide Lower Left Cassette Guide Upper Cassette Foot Rubber Actuator Front Cover Open Switch Rail Base Left Side Rail Base Right Side Lever Size Sensor Board Size Sensor Cable Assembly Size Sensor Unit Drive Clutch Drive Unit Cable Assembly Drive Unit Sensor Sensor Drive Unit Gear Clutch Belt Up Down Sensor Assembly Y Drum Gear Sensor Assembly K Drum Gear Sensor Right Drum Sensor Left Drum Power Supply T Power Supply G Power Supply D Power Supply S Power Supply K BR BR BR BR BR BP BP oe oa oe oe eo eo oe oa oe eo eo on a Pe on on on on on on on on in 4 QR S Parts Catalog 7 17 5055 01x Assembly 7 Base 1 Continued 7 18 Service Manual 5055 01x Asm Part index Number Units Description 35 56P9658 1 Sensor Assembly K Toner Remaining 36 56P9646 1 Frame Sub 37 56P9657 1 Sensor Assembly Y Toner Remaining 38 56P9656 1 Sensor Assembly C Toner Remaining 39 56P9655 1 Sensor Assembly M Toner Rema
57. IP Board 5 6 Service Manual 5055 01x Power Source Unit 1 Board Power Source Unit 2 Board CNO02 CN04 CN105A CNO6 CNO3 CN105 CN104 CN103 OO CN104 Locations 5 7 5055 01x High Voltage Power Supply Board aA CN101 5 8 Service Manual 5055 01x Sensor Board Expansion Paper Feeder Controller Board Locations 5 9 5055 01x Duplex Unit Controller Board CN105 B11 Motor Drive Board CN4 CN5
58. Paper Feed Motor Pickup SOL SS oo Residual Paper Paper Size Sensor 2 amp 2 Sensori M Residual Paper M S 2 Paper End Sensor S ensor Residual Paper Paper Level Sensor Q Sensor 3 Down Button Np 2 Control PCB Em Cover SW 1 2 Tray Motor d Supply PCB Joint SW 1 2 DC DC Converter Locations 5 13 5055 01x Driving Parts Layout Paper Feed Clutch Paper Feed Roller Paper Feed Motor Reverse Roller Call Roller Tray Motor Tray Driving Belt Tray Elevating Shaft 5 14 Service Manual Sensor and Switch Locations 5055 01x Josues umoa dn Josues Josues 9d Ausueq youms Aes pee 4x4 Jedeg Jedeg E S P 1901 10sues mi Fi Aouesedsue i CN D epee MR det Josue jdedddW 1 uonoeieq A LEESN Wwe ered 4addn 10sues peog 10sueg azis Jaded Aoueigedsuei dHO j suge Josuas eed Josuas BuiureueH Josueg Jedeg Jedeg ux uonensi H uus Josueg dd epint Aypiung un J eijejedue Locations 5 15 5055 01x 10102 10sueg 1eoo saud dd Mg 10sues 1299 eAuq WMG Josues Ayisueq SJOSUGS JOUO yg 10sueg 1299 wnq 1002 10suegs 1899 WMG 5 16 Service Manual 5055 01x Component Locations o T co co G 2 7 e o Lo rT Ke y e x N T Left Side 4 5 Top Locations 5 17 50
59. Press Go Return or Stop to return to the DEVICE TESTS screen The Power indicator turns on solid If the test fails the following message displays Flash Test Test Failed Press Go Return or Stop to return to the DEVICE TESTS screen Diagnostic Aids 3 19 5055 01x Diagnostics Printer Setup Defaults The following printer settings are used to determine whether U S or non U S factory defaults should be used e U S e Non U S Light Quantity e Cyan e Magenta Yellow e Black Range 0 to 45 If you replace one or more of the printheads or the EEPROM for the engine controller the Light Quantity value must be set to the value that is marked on the printhead To set this value Select Diagnostic Mode e Select Printer Setup Select Light Quantity and enter the value from the label on the printhead LED Printhead A N See ok Label 3 20 Service Manual 5055 01x Par S Strobe Adj Note This message displays only if the printer is confused with the standard parallel port Par 1 Strobe Adj Note This message displays only if a parallel port is available through the PCL slot 1 Auto Color Adj e On e OFF Reset Calibration Press Select to reset Diagnostic Aids 3 21 5055 01x 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 col
60. 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 60 Service Manual 5055 01x 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 and the screw from the right stopper and remove the stopper 4 Remove the screw from the left stopper and remove the stopper 5 Remove the clip from the lock shaft 6 Remove the 17 screws from the stay arm and remove the arm Repair Information 4 61 5055 01x Fuser Removal 1 Open the top unit 2 Pushing the front and back lock hold the handle raise and remove the fuser 4 62 Service Manual 5055 01x Options Removals Expansion Paper Feeder Removal 1 2 Remove the cassette Remove the two screws from the front cover removing the cover Remove the two screws from left side cover and remove the cover Remove the two screws from right side cover A and remove the cover Remove the two screws from right side cover B and remove the cover Remove the screw from right side cover C and remove the cover Remove the six screws from rear cover and remove the cover Remove the turn guide The cover is hinged in place Repair Information 4 63 5055 01x 9 Remove the screw from paper the detection cover and remove the cover 11
61. a Re doe bidid t ii 5 13 Driving Parts LaybUtassa og ues ma anus kn nena xa a Ra eon 5 14 Sensor and Switch Locations 2 21oilla icu rau 5 15 Gomponent LOCANONS 4a a ace enema x RR RR a REY n 5 16 Preventive Maintenance leelees 6 1 Maintenance Kit uues iuue eme Ruhr mr nh rr ec 6 1 Periodic Mallitenar ee ssssecsacse xe m x xx EORR swe 6 2 Lubricants and OleallelS oss soeur dre r Ide ue ume c erac 6 2 vii 5055 01x Parts Catalog 22 2 lcm cce pr ena 7 1 How to Use This Parts Catalog 2 2 2 e erm 7 1 Assembly 1 Covers lel Re RR LR RE 7 2 ASSeITIDIy 2 COVES 2 ea sen xcu Rex e E RETE EUR TEE ER 7 4 Assembly 9 COVEIS Deesreopeesccii9eree ee Rr ee decks 7 6 Assembly 4 COVEIS 4 usa xp gib ep Epis e URS eR ae aie 7 8 Assembly D COVENS B cl scel eme eremi metre RES 7 10 Assembly 6 Upper Unib s sei m mper mem mecs es 7 12 Assembly T Base 1 21 b eR aides 7 16 Assemb 8 Base 2 usus ipricssesiepxe ew ecc ES IEEE 7 20 Assembly 9 Base d wc icc e e Rire eee m RmE RR S 7 22 Assembly T0 Electa ssec m rte E Ex Reale 7 24 Assembly T1 VF Controllers iie 7 28 Assembly 11 I F Controller Continued lesse 7 30 Assembly 12 Fuser Uni 2 2 ec RR Rm 7 32 Asseinbly 13 Cassellges ssa reg rr eC Qe c Ex E qM S 7 34 Assembly 14 Expansion Feeder 1 Lese 7 36 Assembly 15 Expansion Feeder 2 Lees 7 38 Assembly 16 Duplex Unit1 eee ee eee eee 7 40 Assembly 17
62. additional time to cool the fuser after you select another Paper Type setting such as Plain Paper or Letterhead If Printer Usage is set to Maximum Yield the printer must adjust the photodevelopers as it prepares to print a color page after printing a mono page The printer performs this same calibration each time you turn the printer on and each time you open and close the top cover Depending on the types of jobs you print these adjustments may significantly slow print time You cannot remove paper jammed in the fuser Open the fuser rollers by operating the fuser pressure relief lever If you cannot remove the jam replace the fuser You cannot clear the paper jam To clear the paper jam messages you must remove all paper from the printer s paper path Check both inside message the printer as well as the paper source you were using Open and close the front cover and press Go If the message does not clear go to Paper Carrying Service Check on page 2 58 Paper jam in Go to the Paper Carrying Service Check on pick up page 2 58 assembly 2 52 Service Manual 5055 01x Symptom Action Fuser failure Go to the 920 Fuser Error Fuser Heater Trouble on page 2 7 No paper pick up from multipurpose tray Go to the Paper Carrying Service Check on page 2 58 No paper pick up from upper or lower cassettes Go to the Paper Carrying Service Check
63. age 2 25 or the Symptom Table on page 2 52 and take the appropriate action If an error message appears while you are working on the printer go to the error message table and take the indicated action Adjustments and Procedures Following Parts Replacement Note When trouble shooting or prior to making any adjustment to print quality always be sure The printer is installed on a level rigid surface The photodevelopers are never exchanged Do not exchange a black photodeveloper for a color photodeveloper as they have different surface phase counts The Alignment Page is used when adjusting print registration Whenever you replace any of the following parts be sure to perform the required adjustments or procedures The adjustments are in the Repair Information and Diagnostic Aids chapters Diagnostic Information 2 1 5055 01x 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 the following items must be checked and adjusted in the diagnostic mode LED Printhead Light Quantity Printer Alignment X Y and Theta Counters Configuration ID RIP Controller Board If you replace the RIP controller board be sure to move the solid state drive memory and option cards from the old card to the new one Transfer Belt If you replace the trans
64. age power supply board 4 38 Service Manual 5055 01x R Sub Frame Removal Toner Remaining Sensor Removal Drum Gear Sensor 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 the two screws from the sub frame R from inside of the main unit 3 Remove the screw and C clip from the sub frame cover 4 Remove the screw from the toner remaining sensor A different toner remaining sensor is used for each color 5 Remove the screw from the drum gear sensor Note Install the drum gear sensor to the colors specified Yellow Y drum sensor assembly Black K drum sensor assembly Repair Information 4 39 5055 01x 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 presence of upper detection button Magenta Sub frame F1 Detection button available e Cyan Sub frame F2 Detection button unavailable Yellow Sub frame F2 Detection button unavailable e Black Sub frame F1 Detection button available 4 40 Service Manual 5055 01x Drive Gear Unit Sensor Assembly Remov
65. al 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 Remove the two screws of the drive gear unit sensor from the drum drive gear sensor assembly Repair Information 4 41 5055 01x Belt Up Down Clutch Removal 1 Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the printer controller Remove the printer controller bracket and the high voltage power supply board 2 Remove the C clip from the belt up down clutch and remove the clutch 4 42 Service Manual 5055 01x Power Supply 1 Removal 1 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 2 Remove the insulation sheet connector two ground wires five screws two screws with washers two screws with spring washers and remove the power supply When installing incline the ground wire by 45 degrees Repair Information 4 43 5055 01x Power Supply 2 Removal 1 Open the top unit and remove the RIP cover RIP board RIP box and electronic box 2 Disconnect the connector and remove the seven screws from Power Supply 2 and remove the power supply 4 44 Service M
66. alled in the printer Replace the affected toner cartridge If there still is a go to No Image on page 2 73 Toner smears or rubs off the Be sure you re using recommended page paper or media Be sure you have selected the correct Paper Weight setting for the media you re using Be sure the top cover is completely closed and both sides are snapped shut You may need to replace the fuser Diagnostic Information 2 71 5055 01x Problem Toner adheres to the back of the page Action Remove the fuser oil roll and wipe it with a dry lint free cloth and clean the transfer belt If there still is a problem go to Periodic Dirt on page 2 76 Quality of printed transparencies is inadequate Be sure you re using the recommended Lexmark transparencies Be sure you re loading transparencies properly When printing transparencies always set the Paper Type to Transparency Avoid getting fingerprints on transparencies before printing Print on the page is skewed N L 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 A white gap is noticeable between color fills due to poor color registration Be sure all four corners of the printer are resting on a level surface
67. and fully screwed into in all the way the adjusting bracket 2 Observe the LEDs 1 and 20n Replace the Replace the the HCPF control board while HCPF control affected unscrewing the paper size board sensor Paper size sensor 1 for 11 or paper size 2 for A4 Map 9 False 41 Open Bin 1 Exit Tray Message between pins 1 and 2 Step Questions Actions Yes No 1 Is the exit tray switch actuator Replace the Go to step 2 broken or damaged paper exit tray 2 Disconnect CN31 from the Replace the Replace the printer controller board When printer paper exit tray activating the paper exit tray controller switch switch is there continuity board 2 48 Service Manual 5055 01x Map 10 Unrecoverable Check Tray X or Duplex Connection Message Step Questions Actions Yes No 1 Is the problem with a specific Go to step 2 Go to step 8 paper tray or the duplex unit 2 Is the problem with tray 1 Go to step 3 Go to step 6 3 Are connectors CN 35 and Go to step 4 Properly CN36 on the printer controller connect the board properly connected connectors 4 Are connectors CN3 and CN1 Go to step 5 Properly on the expansion paper feed connect the control card for tray 1 connectors properly connected 5 Replace the tray 1 expansion Problem Return the feeder control card Does this solved tray 1 fix the problem expansion feeder control card and replace the printer cont
68. anual 5055 01x Drive Motor Assembly Removal L or WwW Iv o Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the upper cassette left front cover and back cover Remove the turn guide Open the paper feed cover and remove the duplex unit Remove the side left cover Remove the connector two ground wires and power supply 1 Remove the connector CN2 CN4 and CN5 from the motor drive board Remove the four screws with spring washers from the drive motor Note When installing hold the motor securely and mount the Screws Motor Drive Board Removal T 2 Remove the upper cassette front cover B paper feed cover and the left side cover Disconnect the five connectors and remove five screws and two screws from the motor drive board Repair Information 4 45 5055 01x 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 g LPs i 3 Remove each terminal connected to the power switch Note When connecting be careful to connect the connectors correctly Insert the insulator cover completely covering the terminal 4 46 Service Manual 5055 01x 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 an
69. apacity Residual Paper Sensors 1 4 Paper Feed Sensor Switch Paper Level Sensor Test on page 1 35 and Lower Limit Switch perform the LED sensor test Docking Switch You can block each sensor to Upper Limit verify if it is working properly Paper Sensor Switch Replace the failing sensor Paper Sensor Switch Paper Feed Sensor 2 Tray Motor Be sure that all rollers gears Paper Feed Motor and belts are in good working HCPF Power Supply order Replace as necessary Pickup Solenoid Paperfeed Roller Transfer Roller Paper Feed Clutch Tray Drive Belt 3 Paper Feed Clutch Go to the Maintenance Pickup Solenoid Mode on page 1 33 and run HCPF Power Supply the tests Paper Feed Motor Tray Motor HCPF Board Diagnostic Information 2 57 5055 01x Operator Panel Service Check When you replace the PC drum unit all three color units must be replaced at the same time FRU Action 1 Operator Run both the LCD Hardware Test and the Button Panel Test in Diagnostic Mode Operator Panel Cable Be sure the operator panel cable connections are RIP Board securely connected on the RIP board and operator panel Paper Carrying Service Check Paper has not exited or is stopped in the high capacity paper feeder Area F 249 FRU Action Paper Feed Roller Transfer Roller Be sure the paper feed roller and transfer rolle
70. be pressed to cancel the test producing the following message Cancelling 3 8 Service Manual 5055 01x Note lt input source gt 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 lt media width gt field is displayed when the narrow media sensor determines the media used for the Quick Test is narrow or wide N for narrow W for wide Print Quality Pages Execution of this diagnostic function causes the printer to print the Print Quality Test Pages Since the printer is in diagnostics mode the toner cartridge lockout functionality is disabled Print Quality Pages can be printed from the Configuration Menu Group When printing using this method the toner cartridge lockout functionality is enabled These pages cannot print unless a cartridge with a Machine Class ID matching the Machine Class ID stored in NVRAM is installed Note Additional diagnostic information relating to print quality may be printed on the Print Quality Pages when executing this diagnostic function This additional information is not printed when the Configuration Menu Group method is used As the pages are printed the printer posts Prt Quality Pgs Printing Once started this operation cannot be cancelled All keys are ignored while this message is posted Note The lt media width gt field is
71. busy processing a job Use the five operator panel buttons to open a menu scroll through a list of values select printer settings and clear error messages Select Return 3 2 Service Manual 5055 01x Operator Panel Buttons Button Go Function Press Go to Exit printer menus and return the printer to the ready state Clear certain messages from the display If you ve changed printer settings from the operator panel menus press Go before you send a job to print Menu and Menu Press Menu or Menu to Enter the menus from the ready state Scroll to the next Menu or the previous Menu menu menu item or value Increase or decrease a numerical value for a menu item setting Display the Job Menu or the Supplies Menu while the printer is busy Select Press Select to Select the menu shown on the second line of the display and view the available menu items Select the menu item shown on the second line of the display and view the available values and the current user default setting for that menu item Save the value displayed on the second line of the display as the new user default setting Clear certain messages from the display Return Press Return to back up to the previous level of the menu structure without selecting a new menu item or value Stop Press Stop when the printer displays the Busy or Waiting message to temporarily s
72. cause damage 4 30 Service Manual 5055 01x 3 Loosen the thumbscrews as shown Repair Information 4 31 5055 01x 4 Lift and remove the transfer belt cover 5 Loosen the thumbscrews as shown 4 32 Service Manual 5055 01x 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 close the front cover 9 Turn the printer on Note If the message Did you Replace Belt appears wait for the message Select yes Stop no and press Select If you replaced the belt before the Life Warning or Exhausted message appeared open the supplies menu on the operator panel and select Replace Supplies then select Belt and select Replaced The message Printing Alignment Page appears and the printer prints the alignment page Follow the instructions on the display to set the alignment values for the new transfer belt Repair Information 4 33 5055 01x Belt Up Down Detection Sensor Removal 1 Open the top unit and remove the waste toner bottle and belt unit 2 Remove the belt up down detection sensor from the mounting board 3 Remove the connector from the belt up down detection sensor 4 34 Service Manual 5055 01x Sensor Board Removal 1 Remove the transfer bel
73. ctive communication link Wait for the message to clear Menus Disabled The printer menus are disabled You can still open the Job Menu to cancel a job that is printing or to select a confidential job or a held job that you want to print Network Card Busy An internal print server is being reset Wait for the message to clear Network x A network interface is the active communication link Wait for the message to clear Diagnostic Information 2 29 5055 01x Message Meaning Action Network An 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 Found The PIN number entered is Press Go to enter Retry not associated with any another PIN confidential job Press Stop to clear the PIN entry prompt Not Ready The printer is not ready to Press Go to make the receive or process data printer ready Parallel x A parallel interface is the Wait for the message to active communication link clear Performing Self The printer is running the Wait for the message to Test series of start up tests it clear performs after it is turned on Power Saver The printer is ready to receive Send a job to the printer data It is reducing electricity Press Go to quickly consumption while idle warm the printer to normal operating
74. d return to the DEVICE TESTS screen press Return or Stop The Power indicator blinks while the test is in progress Once Go is selected the following screen displays to indicate the operation has begun Disk Test Clean Testing If the test is successful the following message is displays Disk Test Clean Test Passed Press Go Return or Stop to return to the DEVICE TESTS screen If the test fails the following message displays Disk Test Clean Test Failed Press Go Return or Stop to return to the DEVICE TESTS screen Because of the nature of this operation canceling of this test is not permitted 3 18 Service Manual 5055 01x 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 displays warning the customer that all flash contents will be lost Files Will be Lost Go Stop To continue the test press Go To exit the test immediately and return to the DEVICE TESTS screen press Return or Stop The following message displays while the test is running Flash Test Testing The Power indicator blinks while the test is in progress If the test is successful the following message displays Flash Test Test Passed
75. d the electronic box Remove the turn guide and open the paper feed cover and remove the duplex unit Remove the left side cover and power supply A 2 Disconnect the connector and remove the two screws from the mounting plate 3 Remove the two screws of the drawer connector from the mounting plate drawer bracket Repair Information 4 47 5055 01x Paper Size Sensor Board Assembly Removal 1 Open the top unit and remove the RIP cover RIP board RIP box and electronic box Remove the upper cassette front cover B and back cover Open the turn guide and paper feed cover and remove the duplex unit Remove the left side cover and power supply A 2 Disconnect the connector and remove the two screws from the paper size sensor board removing the board 3 Remove the screw from the size detection lever and remove the lever 4 48 Service Manual 5055 01x Main Unit Fan Removal 1 Remove the left side cover the solenoid cover and the rear cover 2 Remove the two screws from the main unit fan bracket EN 3 Remove the fan Repair Information 4 49 5055 01x Main Drive Unit Removal 1 Open the top unit and remove the gear cover upper cassette left front cover paper feed cover RIP cover RIP board RIP box electronic box and rear cover Open the turn guide and paper feed cover and remove the duplex unit Remove the left side cover power unit 1 and power unit 2
76. der The paper feeding solenoid turns on by the signal from the printer controller The paper feeding roller interconnected with drive 1 rotates with the spring clutch and picks the paper in the paper cassette General Information 1 9 5055 01x Multi Purpose Feeding The multi paper feed solenoid turns on by the signal from the printer controller The multi purpose feed roll interconnected with the drive 1 through the spring clutch rotates and picks the paper in the multi purpose feeder 8 BEES tch me GO F i 4 1 10 Service Manual 5055 01x Registration Unit Media temporarily stops registration when adjusting the paper leading edge parallel with that of the image or when adjusting the timing with the black image The upper and lower registration rolls are arranged in parallel with the photosensitive drum for black imaging The lower registration roll incorporates a registration clutch which feeds or stops the paper In the forward direction of the registration roll a registration sensor photo interrupter is provided to detect paper fed from the paper feeder and to stop paper jam feeding Registration Sensor Registration Roller OL General Information 1 11 5055 01x Separation Unit The transfer belt and paper are separated with the belt drive roll by separation fingers iL Ve e o separauon Fingers 1 12 Se
77. displays once the printer s narrow media sensor determines the media used for the Quick Test is narrow or wide N for narrow W for wide Diagnostic Aids 3 9 5055 01x 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 is used to verify the operation of each button on the operator panel When Button Test is selected the following screen displays OP OP OP OP OP OP When a button is depressed CL Closed displays When a button is not depressed OP Open displays If the wrong message displays the button is malfunctioning To exit the button test press Return or Stop 3 10 Service Manual 5055 01x DRAM Memory Test The DRAM Memory Test is used to check the validity of DRAM both standard and optional Patterns of data are written to DRAM verifying each bit in memory can be set and read correctly When this test is selected from the operator panel the printer begins testing DRAM memory and the following screen displays DRAM Memory Test P HH F AHHHHE Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 F represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail coun
78. ds 3 7 5055 01x Print Tests Input Source Print Tests The Diagnostic Input Source Print Tests may be used to verify that the printer can print on media from the installed input sources which are available within the Print Tests menu Chose from following Single prints the Print Test page once Continuous prints the Print Test page until Return or Stop is pressed The content of the Print Test page varies depending on the media installed in the selected input source If a source is selected that contains paper then a page similar to the Quick Test page prints If a Source is selected containing envelopes the Envelope Print Test pattern prints This pattern contains text of each character in the selected symbol set If Continuous is selected all sources printing with paper sizes will print the same page continuously until the test is stopped If the Source contains envelopes then the envelope print test pattern prints on the first envelope and subsequent envelopes are blank Note The Print Test page can be printed on any paper or envelope size More than one sheet of some media sizes may be required The Print Test page will always print in simplex While the page prints the following message displays Source Printing The Power indicator also blinks while the page prints If Single is selected no buttons are active while the Print Test page prints If Continuous is selected Return or Stop can
79. e Switch DIP Test paper feed mode Switch stand alone 4 3 2 1 OFF Test OFF mode ON X X OFF X Linear velocity 101 mm s ON X Thick paper mode OFF X X Linear velocity 129 mm s ON Plain paper mode OFF X Linear velocity 180 mm s ON X General Information 1 33 5055 01x O10 In Test paper feed operation Turn on the docking safety switch with a non metallic object The interface cable with the printer controller board need not be connected Close the top cover or manually activate the cover switch Load paper Wait until the paper tray stops and the pickup solenoid turns off With the cover closed or with the cover switch activated press and hold the tray down button for more than 1 2 second In steps 1 and 2 paper feeding starts and is continuously fed until the cover is opened The test ends when the tray motor stops and the paper ejects or the tray down button is released Test Sequence The tray motor moves the tray to the upper limit The pickup solenoid activates then de activates When the tray down switch is pressed for longer than 1 2 second the paper feed motor starts the paper feed clutch operates and feeding begins Feeding can be stopped by releasing the tray down button 1 34 Service Manual 5055 01x High Capacity Paper Feed Sensor Switch Test The condition of each sensor can be checked from the lighting of LEDs on the high capacity paper feed board
80. e displays for approximately three seconds and the Fail Count increments by 1 Once the maximum pass count or fail count is reached the test stops and final test results display e ROM Checksum Error e ROM Burst Read Error Once the maximum pass count or fail count is reached the test stops and the final test results display Press Return or Stop to exit the test 3 12 Service Manual 5055 01x Parallel Wrap Test The Parallel Wrap Test checks the operation of each parallel signal using a wrap plug To perform the wrap test follow these steps e Disconnect the parallel interface cable and install the parallel wrap plug e Select HARDWARE TESTS from the Diagnostics Menu Select Parallel Wrap to initiate the Parallel Wrap Test Select the appropriate Parallel Wrap Test Parallel Wrap Parallel 1 Wrap The printer begins testing the parallel hardware and the following screen displays Parallel Wrap PUHHHHE FHHHHHE Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 F represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail count is 99 999 The power indicator blinks indicating the memory test is in process The printer continually runs the same test until cancelled from the operator panel by pressing Return or Stop
81. e pre lubed from the factory Inspect and if necessary clean all rubber plastic and D rollers with A lint free cloth dampened slightly with cold water Dry the rollers with a lint free cloth While cleaning inspect the interior of the printer for damaged wires loose connections toner leakage loose springs and damaged or worn parts Be sure the printer is on a single flat strong table or desk top Inspect all supplies OCR Cartridges photodeveloper 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 General Information 1 1 5055 01x e Print a Demo page e f additional paper sources are installed print a Demo page from each of these if possible Note Failure to print from an additional tray or feeder may imply one or more pins are bent in the mating connector Return Parts Engineering periodically analyzes returned parts for failure modes Please Include a printed test DEMO page before and after the repair and tag any returnable parts with a description of the failure Recommendations For Service Before leaving the printer check the following Be sure printer is on a single flat strong tabletop This is very important for color printers that use belts Check and set
82. e printer Repair Information 4 17 5055 01x Paper Feed Roller Removal Remove the front cover Remove the manual paper feed tray Remove the right side cover and turn guide Remove the upper cassette Release the clutch and until the paper feed roller screw is visible Turn the paper feed roller and remove the screw from the roller aor 0n ES 2p 1p i NEN NEU 6 Remove the paper feed roller from the shaft Note If the paper feed roller surface is stained with oil or other contaminants clean it with cloth moistened with alcohol Paper Carrying Roller Removal 1 Open the turn guide 2 Remove the two screws from the paper carrying roller and slide the bearing forward 4 18 Service Manual 5055 01x Paper Present Sensor Removal 1 Open the paper feed cover and pull out the duplex unit halfway 2 Unclip the paper present sensor from the mounting 2000 WO CUTE 3920OOO OO dO 3 Disconnect the connector and remove the sensor Repair Information 4 19 5055 01x Paper Feed Frame Removal 1 Open the top unit and remove the RIP board cover RIP board RIP box and electronic box Open the turn guide and paper feed cover and pull out the duplex unit halfway 2 Remove the belt unit 3 Disconnect the connector and remove the three screws and the screw from the paper feed frame 4 Remove the clip from the paper feed roller shaft and remove the gear
83. e the cover 3 Remove the retaining rings on the rollers and remove the rollers Paper Feed Roller Repair Information 4 77 5055 01x HCPF 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 Remove the connector and the two screws from the pickup solenoid and remove the solenoid Clamp Plate Clamp Paper Feed Front and Rear 4 78 Service Manual 5055 01x HCPF Paper End Sensor Removal HCPF Paper Size Sensors 1 2 Removal ils Cover the paper level sensor with your hand and press the down button The tray moves down Lower the tray until the down sensor turns on Remove the front cover and transfer cover Remove the two screws on the front and rear sides of the side fence Mark the locking position of the side fence locking stay Remove the two screws on the side fence locking stay Remove the screw and connector from paper end sensor and remove the sensor Remove the screw and connector from the clamp plane and remove the paper size sensors 1 and 2 Side Fence Locking Stay Paper Size Sensors 1 2 Marking Side Fence Front Repair Information 4 79 5055 01x Notes To prevent damage to the stay hold the stay when removing the sensors e Be sure the side registration i
84. e two screws from the registration frame 3 Remove the registration clutch Note When installing set the clip of the registration clutch to the stopper Repair Information 4 29 5055 01x Transfer Belt Removal To replace the transfer belt before the Life Warning or Exhausted messages appear open the supplies menu on the operator panel and select Replace Supplies select Belt and select Replace Now If the 80 Transfer Belt Life Warning or Exhausted message appears on the display press Select when the Select Replace message appears The message Preparing for Maintenance appears on the display followed by Printer Ready for Maintenance then Power Off to Replace Items If the operator panel is inoperable or if you have an unrecoverable error code perform steps 1 through 4 and then e Remove the transfer belt cover e Override the front cover interlock switch Turn the printer on Look for the belt to lower during power on sequence Turn the printer off when the belt lowers Turn the printer off and proceed with step 5 WARNING Do not turn the printer off until the Power Off to Replace Items message appears 1 Turn the printer off along with any optional devices connected to the printer 2 Open the front cover and top unit WARNING Do not touch drop or place anything on the transfer belt Touching the surface of the transfer belt or placing items on the belt may
85. e up face down sensor CN12 pins 1and 2 If the voltage does not fluctuate replace the sensor Diagnostic Information 2 61 5055 01x Paper has entered the duplex unit Area D FRU Action 1 Feed Rollers Check for wear or damage to feed rollers and belts Belts 2 Duplex Unit Be sure the duplex unit is properly installed and that all connections are correct 3 Duplex Be sure the stepper motor turns freely with no Stopper binding Motor Side Fence Check for wear or damage to the associated gears Stepper Replace as necessary Motor 4 Feed Roller Check for proper operation of the solenoid and Solenoid linkage Replace as necessary Assembly Paper Re feed Solenoid Assembly 2 62 Service Manual 5055 01x Paper Exit FU FD Service Check FRU Action FU FD Sensor Actuator 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 Check for a fluctuation of between OV and 5 V between pins 1 and 2 of connector CN12 while actuating the sensor FU FD Deflector Check the FU FD deflector that directs the paper to the proper tray Replace if necessary FU FD Solenoid Check the FU FD solenoid for continuity Also be sure the connector is properly connected to the printer controller board Face Up Exit Check the gears and the actuating mechanism for Assembly wear o
86. ear Drive 6 56P9885 2 Pulley Timing 7 56P9882 1 Motor HCPF DC 8 56P9887 1 Bracket Front Idler Parts Catalog 7 53 5055 01x Assembly 23 High Capacity Paper Feed 6 7 54 Service Manual 5055 01x Asm Part index Number Units Description 23 1 56P9892 1 Plate Upper Side Fence 2 56P9893 2 Knob 3 56P9891 2 Knob Tray 4 56P9890 2 Plate Paper Adhesion 5 56P9915 1 Fence Assembly Front Side 6 56P9894 1 Fence Assembly Rear Side 7 56P9528 2 Interrupter Photo 8 56P9889 1 Pad Friction Parts Catalog 7 55 5055 01x 7 56 Service Manual 5055 01x Index A Abbreviations 1 4 Adjustments 2 1 Attendance Messages 2 25 C Clearing the Error Log 3 26 Component Locations 5 16 Connectors covers diagram 5 1 duplex unit controller board 5 10 extension paper feeder controller board 5 9 high voltage power supply board major parts diagram 5 2 motor drive board 5 10 power source unit 1 board 5 7 power source unit 2 board 5 7 printer controller board 5 4 printhead controller board 5 5 RIP board 5 6 sensor board 5 9 size sensor board 5 10 D Defaults 3 20 Device Tests 3 17 Diagnostic Aids 3 1 Diagnostic Information 2 1 Diagnostic Mode 3 6 Diagnostics Printer Setup 3 20 Driving Parts Layout 5 14 E Electrical Parts Layout 5 13 ErrorLog 3 25 Exiting Diagnostics Mode 3 26 G General Info
87. eder 1 7 36 Service Manual 5055 01x Asm Part Index Number 14 1 56P9780 Units Description Guide Wire 2 56P9773 Gear Feeder E 3 56P9771 Gear Feeder C 4 11G0422 Gear Feeder B 5 56P9772 Gear Feeder D 6 11G0423 Gear Feeder A 7 56P9770 Cover Right Side C 8 56P9769 Cover Right Side B 9 56P9767 10 56P9765 11 56P9504 12 56P9524 13 56P9503 14 56P9505 15 11G0399 16 56P9766 17 56P9522 18 56P9521 19 56P9779 20 56P9768 21 56P9776 22 56P9778 23 56P9777 24 56P9774 NS 56P9775 Cover Right Side A Cover Front Feeder Rail Left Side Screw Slide Rail Foot Rubber Rail Right Side Plate Ground Cover Left Side Board Size Sensor Lever Size Sensor Board Expansion Feeder Control Cover Rear Board Paper Remaining Sensor Cable Assembly Lower Optional Drawer Cable Assembly Upper Optional Drawer Motor Feeder Drive 2 2 2 2 2 2 on 2 2a Oa on a a sa a pa a sx Cable Assembly Size Sensor Parts Catalog 7 37 5055 01x Assembly 15 Expansion Feeder 2 7 38 Service Manual 5055 01x Asm Part Index Number 15 1 56P9796 Units Description Roller Assembly Carrying 2 56P9514 Roller Noise Reduction 3 56P9513 Bushing Carrying 4 56P9509 Bushing Metal 5 56P9790 Roller Paper Carrying 6 56P9792 Holder Roller 7 56P9791 Spring Paper Carrying 8 56P9794 Spring Right Turn Guide 9 56P9789 10 56P9517 11 56P9519 12 56P9
88. emove the two screws from HSP holder and remove the holder 3 Remove the top cover 4 Disconnect the connector see arrow 5 Remove the eraser 4 14 Service Manual 5055 01x Printhead Controller Board Removal 1 Remove the top cover 2 Remove the 20 printhead controller board connectors sett rcs alo uie Vs tes 3 Remove the 10 screws from the printhead controller board and remove the board Note When replacing the board be sure to return the four EEPROMSs on the former board to the same positions on the new board Orientation Mark EEPROM Label Repair Information 4 15 5055 01x Upper Fan Removal 1 Open the top unit and remove the toner cartridges and photoconductor drum units top cover and face down guide assembly 2 Remove the four screws and the five screws from the upper bracket and remove the bracket 4 Remove the two screws from the right fan and remove the fan 4 16 Service Manual 5055 01x Multi Purpose Feeder Tray Removal 1 Open the top unit and remove the front cover cassette feeder turn guides and right side cover lol RSP gilo J o 2 Ol JO O19 OLIO OO OLIO ENT DCN 2 Open the multi purpose feeder and slide it toward the magnet in the direction of the arrow removing it from th
89. er operation of the solenoid and Solenoid linkage Replace as necessary Assembly Paper Re feed Solenoid Assembly 4 Photo Ensure that the photo interrupter actuators are interrupter operating correctly and are in the proper position Assembly Expansion Paper Feed Service Check If you have a 200 Paper Jam Tray X error code check the option connection cable for proper connection to the printer or other paper feeder FRU Action 1 Feeder Drive If the feeder drive motor works go to the Paper Motor Carrying Service Check on page 2 58 2 Gears If the motor turns but the drive gears do not replace Feeder the gears as necessary Check the feeder solenoid Solenoid and paper feed clutch for proper operation and Paper Feed replace as necessary If this does not correct the Clutch problem replace the expansion feeder control Expansion board Feeder Control Board 2 56 Service Manual 5055 01x Face Down Stacker Full Service Check FRU Action 1 Stacker Full Check the stacker full detection lever for damage Detection Lever 2 Stacker Full Check for a voltage fluctuation between 0 V and 5 Detection V between pins 2 and 3 of connector CN9 on the Sensor printer controller board while actuating the sensor Printer Controller Board High Capacity Paper Feed HCPF Service Check FRU Action 1 Paper Size Sensors 1 amp 2 Go to the High C
90. etwork card is installed in slot x on the interconnect board but cannot establish communications with the network card 2 78 Service Manual 5055 01x 3 Diagnostic Aids Note When trouble shooting or prior to making any adjustment to print quality always be sure of the following The printer is installed on a level rigid surface The OPCs are never exchanged Do not exchange a black OPC for a color OPC as they have different surface phase counts e Radar Page is always used when adjusting print registration Power On Self Test Sequence 1 2 a ot 00 WON Power on Printer and RIP controller check e ROM and RAM Fuser thermistor Printer hardware check Paper jam Printer cartridge unit Toner supply Paper cassette present Fuser temperature check Temperature regulated Ready Printer controller RIP controller Printer condition Motor Fan Heater DC motor drive 1 Feeding paper Print Stepper motor drive 2 Paper exit Stop Diagnostic Aids 3 1 5055 01x Using the Operator Panel The operator panel on your printer has a 2 line by 16 character liquid crystal display LCD five buttons and one indicator light The light indicates whether the printer power is on and whether the printer is idle or busy processing a job Indicator Light State Indicates Off Printer power is off On Printer is on but idle Flashing Printer is
91. ews from the gear cover and remove the cover 3 Remove the four screws from the multi purpose feeder frame and the ground board screw 4 Disconnect the connector of the multi purpose feeder paper feed sensor 5 Pull out the multi purpose feeder frame slightly Repair Information 4 23 5055 01x 6 Remove the screw from the OHP detection sensor upper 7 Turn the bearing stopper of the multi purpose feeder roll forward 1 4 turn and remove upward 8 Remove the C clip and remove the multi purpose feeder clutch e Note After reassembling the components coat the contact areas of the multi purpose feeder roll shaft and multi purpose feeder ground plate with conductive grease If the paper feed roller surface is stained by oil or other contaminant clean with cloth moistened with alcohol 4 24 Service Manual 5055 01x Fanning Pad Removal 1 Open the top unit and remove the upper cassette front cover turn guide multi purpose feeder right side cover and multi purpose feeder roll 2 Release clips at 4 positions and remove the fanning pad S Fanning Pad Repair Information 4 25 5055 01x Registration Sensor Removal 1 Open the top unit and remove the upper cassette front cover turn guide multi purpose feeder right side cover and multi purpose feeder frame 2 Disconnect the connector of the registration sensor and remove the sensor Registration Sens
92. f the paper will not come out continue Open the top cover Remove the paper on the transfer belt Close the top cover Press Go 24 lt x gt Paper Jam Check Tray lt x gt Jams in five areas result in a 24 lt x gt Paper Jam message where x represents the tray number where the jam has occurred Paper jam messages 241 244 indicate a jam has occurred in one of the trays 241 244 Paper Jam 1 2 3 4 5 Pull out the tray indicated on the display Remove any wrinkled or creased paper Push down on the remaining paper in the tray until the bottom plate clicks into place Close the tray Press Go Note If the paper jam message continues check and clear all paper from the paper path General Information 1 23 5055 01x 249 Paper Jam Check Tray lt x gt A 249 Paper Jam Check Tray lt x gt message indicates a jam has occurred in the high capacity feeder Open the top cover Remove the jam Close the top cover Press Go hon 1 24 Service Manual 5055 01x High Capacity Paper Feeder HCPF Paper Feed and Separation Mechanism The high capacity paper feeder consists of a tray and paper transfer 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
93. fer belt check the printer alignment X Y and Theta adjusted in diagnostic mode LED Printhead Controller Board or LED Printhead If you replace the LED printhead controller board or LED printhead the following items must be checked and adjusted in diagnostic mode LED printhead light quantity Printer alignment X Y and Theta 2 2 Service Manual 5055 01x 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 The room temperature is between 10 and 32 C 50 and 90 F and the relative humidity between 20 and 80 Avoid sites generating ammonia gas high temperature high humidity near water faucets kettles humidifiers cold spaces near open flames and dusty areas Avoid sites exposed to direct sunlight Print Paper Checks e Be sure to use the recommended paper for this printer Check the paper for dampness Make a trial print with paper from a newly opened package and check the result Diagnostic Information 2 3 5055 01x 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
94. fficient Memory The printer memory is full and cannot continue processing current jobs Press Go to clear the message and continue printing Press Stop to clear the message without deleting print jobs Press Menu to open the Job Menu and cancel the current job 38 Memory Full The printer is processing data but the memory is full Press Go to clear the message and continue printing Press Menu to open the Job Menu and cancel the current job 39 Complex The print information on the Press Go to clear the Page page is too complex message and continue printing Press Menu to open the Job Menu and Cancel the current job 4 x The printer detects an Turn the printer off and Unsupported unsupported version of then press and hold Go Firmware Card firmware on the installed firmware card while turning it on bypassing the code on the firmware card Remove the firmware card Diagnostic Information 2 35 5055 01x Message Meaning Action 40 Tray lt x gt The high capacity sheet Turn off the printer and Size Sense feeder detects an error in the be sure that all the high Error size sensing mechanism capacity feeder connectors are installed properly Check the high capacity feeder size sensor and go to Map 8 False 40 Tray X Size Sensor Error Message on page 2 48 41 Open Bin 1 The printer wants to send Exit Tray paper to the in 1 output tray
95. ge 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 N Paper Weight setting for the media you re using i Be sure the affected print unit is completely installed in the printer Set print darkness to 4 from the Color Menu Clean the printhead LEDs If you suspect a toner cartridge is low on toner remove the appropriate toner cartridge and gently shake it back and forth to distribute the toner evenly Reinsert the print unit and try printing the job again Replace the affected toner cartridge Replace the photodevelopers If only black print appears light replace just the black photoconductor If one of the colors prints too light replace all three of the color photodevelopers If there is still a problem go to Uneven Printing on page 2 76 Diagnostic Information 2 69 5055 01x Problem Colored lines streaks or smudges appear on the printed page or print appears blurred or unclear IN IN L Action Replace the photodevelopers If the problem only occurs when printing black you can replace just the black photoconductor and fuser coating roll If the problem occurs when printing one of the colors replace all three of the color photodevelopers If
96. he printer Press Menu to open the Job Menu and cancel the current job Invalid Engine Code The printer engine code has not been programmed or is not valid Call for service Invalid Network x Code The code in an internal print server is not valid The printer cannot receive and process jobs until valid code is programmed into the internal print server Download valid code to the printer internal print server 2 28 Service Manual 5055 01x Message Load lt x gt Meaning The printer is trying to feed paper from a source it detects is empty Action Load paper of the size and type requested in the second line of the display in the specified tray Press Menu to open the Job Menu and cancel the current job If Load Tray cannot be reset go to Map 4 False Tray X Low Empty Message on page 2 45 If Load MPF check the MPF paper present sensor Load Manual A request for a manual feed job has been sent to the printer The printer is ready for insertion of a single sheet into the manual feed slot Load a sheet of paper specified in the second line of the display in the manual feed tray or multipurpose feeder Press Select or Go to ignore the manual feed request and print on paper already in the printer Press Menu to open the Job Menu and cancel the current job LocalTalk lt X gt A LocalTalk interface is the a
97. he printer controller board printer side door turn While activating the door controller guide sensor switch is there continuity at board assembly pins 1 and 2 of the connector Map 2 False Close Top Door Message Step Questions Actions Yes No 1 Close the top unit and front Problem Go to step 2 cover Does the message solved reset 2 Is the interlock switch actuator Replace the Go to step 3 broken front door 3 Is the actuator rod that Replace the Replace the activates the interlock switch actuator rod power supply on power supply 2 damaged or 2 broken Diagnostic Information 2 43 5055 01x Map 3 False Close Tray X Top Cover Message Step Questions Actions Yes No 1 Remove the rear cover on the Replace the Replace the high capacity paper feeder and HCPF card cover open observe LED 9 on the HCPF micro switch card while actuating the cover open micro switch Does the LED go on and off while opening and closing the door 2 44 Service Manual 5055 01x Map 4 False Tray X Low Empty Message Step Questions Actions Yes No 1 Is the Tray X Low message Goto step 2 Goto step 5 present 2 Is the paper remaining Go to step 3 Repair or actuator inside the cassette replace parts drawer binding or operating as necessary incorrectly 3 Are connectors CN35 and Go to step 4 Properly CN36 on the printe
98. he image in a one to one arrangement The image data from the printhead controller causes the LED to emit light in black dots These black dots form an image of dots on the photosensitive drum The LED printhead minimizes the displacement of images during the color print process when images of multiple printheads overlap causing dot position accuracy to be much higher Since light from the volume of the LED array varies depending on the LED printheads the light emitting value is recorded in the EPROM of the printer controller When the LED printhead is replaced the light emitting value should be entered for each printhead while the printer is in maintenance mode Since the LED printhead and EPROM on the printhead controller board of this printer are paired the EPROM on the printhead controller board should also be replaced whenever the printhead is replaced General Information 1 5 5055 01x Development Unit Toner forms the electrostatic image on the photosensitive drum during exposure The single component non magnetic toner and the lusterless color toner are weather resistant and fade little under ultraviolet rays This is helpful in saving documents Toner in the hopper is agitated and supplied to the development roll by the supply roll A conductive rubber doctor blade is fitted to the development roll Toner enters between the development roll and doctor blade by the rotating development roll and is negatively charged fo
99. he second line of the 200 Paper Jam message will be blank To resolve the message you must clear all paper from the paper path Check and clear areas A through F Check Areas A B This message indicates a paper jam in the transfer belt fuser or output roller area To clear areas A B 1 10 11 Open the top cover Never touch the photodeveloper drum on the underside of the toner cartridge The paper may be covered with un fused toner which can stain clothing 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 Do not use any pointed objects to remove the paper This could cause permanent damage to the transfer belt Check the fuser area and top cover for additional jams If there is no jam in the fuser area or top cover close the top cover and front door and then press Go If a jam is present continue with step 4 Lift the fuser pressure release lever and slowly pull the paper out of the fuser toward the inside of the printer Rotate the fuser pressure release lever down The top cover will not close until the lever is in the down position Check the top cover for additional jams If there is no jam in the top cover close the top cover and front door and then press Go Remove the jam from the top cover Close the top cover and the front door 1 20 Service Manual 5055 01x Check Area
100. he transfer belt Exhausted end of life 80 Belt Fuser The transfer belt and fuser Replace the transfer belt Exhausted have reached end of life and fuser 80 Belt Fuser The transfer belt and fuser are Press Go to clear the Life Warning nearing end of life message and continue printing The supplies message is displayed until you replace the transfer belt and fuser 80 Belt Life The transfer belt is nearing Press Go to clear the Warning end of life message and continue printing The supplies message is displayed until you replace the transfer belt and fuser 80 Fuser The fuser has reached end of Replace the fuser Exhausted life 80 Fuser Life The fuser is nearing end of Press Go to clear the Warning life message and continue printing The supplies message is displayed until you replace the transfer belt and fuser Diagnostic Information 2 39 5055 01x Message 81 Engine Code Meaning Microcode in the engine flash Action Press Go to clear the CRC Failure code module has failed a message and discard the system check code Retransmit the microcode data from the host computer 84 All Photo All of the photodevelopers Replace all of the Devs have reached end of life photodevelopers Make Exhausted sure you also install the new fuser coating roll that is included in each photodeveloper kit 84 Black Photo Dev Abnormal The printer has detected an abnormal black photodeveloper
101. ice RAM Memory Error Replace RAM Card or the RIP board 961 RAM Slot 2 Bad Replace RAM Card or the RIP board 962 RAM Slot 3 Bad Replace RAM Card or the RIP board 964 Emulation Error 964 Service Emulation Error Replace the DLE board If this does not fix the problem replace the RIP board 2 16 Service Manual 5055 01x 970 Standard Network Error 970 Service Standard Network 970 Service Network Card X 975 Unrecognizable Network Port Software error 976 Unrecoverable Software Error in Network Port Software error To to the Options Service Check on page 2 77 and refer to the network card option section 978 Bad Checksum While Programming Network Card Software error 979 Flash Parts Failed While Programming Network Port Reflash network port Diagnostic Information 2 17 5055 01x 980 Face Up Down Switching Error 980 Service Switch Error B Check Area Step Questions Actions Yes No Is the linkage between the FU FD deflector and the FU deflector solenoid operating properly Go to step 2 Replace the face up exit assembly Is there continuity on the FU deflector solenoid between pins 1 and 2 of CN14 on the printer controller board Go to step 3 Replace the FU deflector solenoid Test the sensor While actuating the sensor does the voltage fluctuate betwee
102. igh capacity paper feed 5 7 52 high capacity paper feed 6 7 54 I F controller 7 28 upper unit 7 12 Periodic Maintenance 6 2 POST 3 1 Power On Self Test Sequence 3 1 Preventive Maintenance 6 1 Print Quality Pages 3 9 Print Quality Problems 2 69 Printer Messages 2 4 Printing Menu Settings 3 4 l 2 Service Manual R Removals belt up down clutch 4 42 belt up down detection sensor 4 34 cassette guide 4 21 connector duplex unit 4 47 covers front 4 5 front left 4 6 IF controller 4 9 left side 4 7 operator panel 4 4 rear 4 6 right side 4 8 RIP board 4 9 solenoid 4 7 top 4 4 density sensor 4 36 drive gear unit sensor assembly 4 41 drive motor assembly 4 45 drum gear sensor 4 39 duplex feed roller and solenoid duplex paper carrying motor 4 75 duplex pressure roller and solenoid 4 73 duplex side fence motor side fence 4 74 duplex timing belt 4 72 duplex unit 4 72 duplex unit separation 4 71 electronic box 4 11 eraser 4 14 expansion paper feeder 4 63 face down guide assembly 4 55 face up paper exitassembly 4 54 face up down flapper detection sensor 4 54 face up down solenoid 4 54 fanning pad 4 25 front cover open switch actuator 4 58 fullsensor 4 55 fuser 4 62 gearcover 4 23 5055 01x HCPF call roller paper feed roller reverse roller 4 77 covers 4 76 paperendsensor 4 79 paper level sensor 4 82 paper size sensors 1 2 4 79 pickup solenoid 4 78 power supply 4 83 tray motor
103. ining 40 56P9661 1 Rod Lock 41 56P9662 1 Shaft Changing NS 56P9524 2 Screw Slide Rail NS 11G0569 1 Parts Packet NS 11G0579 1 Parts Packet NS 11G0616 1 Parts Packet NS 11G0572 1 Parts Packet NS 11G0562 1 Parts Packet NS 11G0577 1 Parts Packet NS 11G0540 1 Parts Packet NS 11G0617 1 Parts Packet NS 11G0565 1 Parts Packet NS 11G0566 1 Parts Packet Parts Catalog 7 19 5055 01x Assembly 8 Base 2 7 20 Service Manual 5055 01x Asm Part index Number Units Description 8 1 56P9666 1 Support Assembly Upper Unit 2 56P9667 4 Pin Upper Unit Support 3 56P9668 1 Handle Assembly Lock 4 56P9669 1 Handle Lock 5 56P9673 1 Cover Electronic 6 56P9670 1 Shroud Cable 7 56P9672 1 Guide Cable 8 56P9671 1 Guide Cable Parts Catalog 7 21 5055 01x Assembly 9 Base 3 7 22 Service Manual 5055 01x Asm Part Index Number 9 1 56P9688 2 56P9689 Units Description Frame Assembly MPF Clutch MPF 3 56P9690 Actuator MPF 4 11G0243 Interrupter Photo 5 56P9691 Actuator Resist 6 11G0219 Interrupter Photo 7 56P9899 Sensor Upper Transparency 8 11G0283 Pad Framing 9 56P9681 Clutch Registration 10 56P9680 11 56P9898 12 56P9683 13 56P9682 14 56P9694 15 56P9696 16 56P9502 17 56P9695 18 56P9679 19 56P9674 20 56P9678 21 56P9676 22 56P9677 23 56P9675 24 56P9684 25 56P9685 Frame Assembly Registration Sensor
104. ion 2 1 56P9557 1 Exit Assembly Face Up 2 56P9558 2 Screw Stopper 3 11G0243 2 Interrupter Photo 4 56P9564 1 Cable Face Up Sensor 5 56P9559 1 Roller Paper Exit 6 56P9561 1 Deflector Face Up 7 56P9502 1 Switch Paper Exit Tray 8 56P9565 1 Cable Paper Exit Switch 9 56P9560 1 Brush Face Up Static Discharge 10 56P9563 1 Solenoid Assembly Face Up Deflector 11 56P9562 1 Spring Face Up Deflector Parts Catalog 7 5 5055 01x Assembly 3 Covers 3 7 6 Service Manual 5055 01x Asm Part Index Number Units Description 3 1 56P9566 Guide Assembly Face Down 2 56P9572 Spring Face Down Paper Full 3 56P9573 Lever Face Down Paper Full 4 56P9574 Roller Face Down Upper Feed 5 11G0135 Roller Face Down Pinch 6 56P9568 Spring Face Down Pinch Roller 7 56P9569 Arm Face Down Pinch Roller 8 56P9577 Roller Face Down Lower Feed 9 56P9571 Arm Face Down Lower Pinch Roller 10 56P9570 11 56P9583 12 56P9567 13 56P9575 14 56P9576 15 56P9582 16 56P9578 17 56P9579 18 56P9580 19 11G0219 20 56P9581 Spring Face Down Lower Pinch Roller Cover Face Down Door Face Down Jam Access Bushing Face Down Pinch Roller Pulley Face Down Feed Roller Brush Face Down Static Discharge Belt Face Down Roller Gear Face Down Roller Drive Motor Paper Exit Interrupter Photo a l 44 4 au po Ra sa RRs WW A a 4 Cable Assembly Exit Sensor Parts Catalog 7 7 5055 01x Assembly 4 Covers 4
105. is fix the Go to step 3 problem 3 Did replacing the Problem solved Replace the printer black drum sensor controller board fix the problem 936 939 Cassette Error 936 Service Paper Option Questions Ste Yes No p Actions 1 Are connectors Replace the printer Plugthe connector in CN35 and CN36 controller board on the printer controller board connected properly securely 2 12 Service Manual 5055 01x 940 High Capacity Paper Feed Sensor Error on the printer controller board connected properly Capacity Paper Feed HCPF Service Check on page 2 57 Questions Ste Yes N p Actions x 1 Is connector CN40 Go to High Plug the connector in securely 941 High Capacity Paper Feed Tray Error Questions Ste Y N p Actions 2 1 Is connector CN40 Go to High Plug the connector on the printer Capacity Paper in securely controller board Feed HCPF connected properly Service Check on page 2 57 942 Duplex Error 942 Service Duplex Questions Ste Y N p Actions et ii Is connector CN37 on the printer controller board connected properly Replace the printer controller board Plug the connector in securely Diagnostic Information 2 13 5055 01x 945 Engine Flash Error 945 Service Engine Flash Reflash the engine code 946 Printer Printhead Co
106. ither face down or face up Paper Delivery Sensing Sensor Lever 1 14 Service Manual 5055 01x Belt Unit After passing through the registration unit paper is electrostatically fed by the transfer belt through the positively charged feed roll at the inlet of the belt unit and fed by the running belt The belt runs at the same speed as the photosensitive drum causing the image on the C M Y and K developer to transfer to paper Since the photosensitive drum has a small diameter and the paper is electrostatically fed by the transfer belt the paper is easily separated after toner image transfer and fed to the next developer Excess toner is scraped from the drum with a cleaning blade and recovered into the waste toner bottle Adjust the registration when the belt unit is replaced The registration is adjusted at the leading edge of the image or by adjusting the color image This should be adjusted in maintenance mode when the belt unit is replaced The transfer belt is conductive and seamless If the transfer belt is damaged toner can cling to the belt and contaminate the paper When fingerprints or other stains appear on the belt wipe them away with a dry cloth or cloth moistened with alcohol A density sensor is positioned facing the belt drive roller for automatic density adjustment and registration adjustment A mechanism is provided to clean the sensor surface
107. lash The printer is storing resources such as fonts or macros in flash memory Wait for the message to clear Programming Disk The printer is storing resources such as fonts or macros on hard disk Wait for the message to clear Programming An error occurred while the Correct the problem Error lt x gt printer was programming specified on the second code into memory line of the display Queuing and The printer is deleting one or Wait for the message to Deleting Jobs more held jobs and sending one or more jobs to print clear Queuing Jobs The printer is sending one or more held jobs to print Wait for the message to clear Ready The printer is ready to receive and process print jobs Send a job to print Diagnostic Information 2 31 5055 01x 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 Turn the printer off and then on to exit Hex Trace mode Remove Paper The specified output bin is Remove the paper from lt specified bin gt full the specified bin s Resetting Maint The printer is resetting the Wait for the message to Cnt Value counter that tracks wear on clear the fuser Resetting the The printer is resetting to the Wait for the message to Printe
108. lex PCL SmartSwitch PAPER SIZE Duplex Bind PS SmartSwitch PAPER TYPE Copies MAC Binary PS CUSTOM TYPES Blank Pages NPA Mode Configure Bins Collation USB Buffer Assign Type Bin Substitute Size Configure MP Paper Weight Paper Loading Universal Setup Separator Sheets Separator Source Multipage Print Multipage Order Multipage View Multipage Border Job Buffering 3 4 Service Manual 5055 01x JOB MENU Reset Printer Cancel Fax Confidential Job Held Job SETUP MENU Printer Language Printer Usage Power Saver Resource Save Download Target Print Timeout Auto Continue Wait Timeout Jam Recovery Page Protect Display Language Alarm Control Job Accounting Job Acct Limit PCL EMUL MENU Font Source Font Name Point Size Pitch Symbol Set Orientation Lines per Page A4 Width Auto CR after LF Auto LF after CR Tray Renumber POSTSCRIPT MENU Print PS Error Font Priority Image Smoothing PARALLEL MENU PCL SmartSwitch PS SmartSwitch MAC Binary PS NPA Mode Parallel Buffer Job Buffering Advanced Status Protocol Honor Init Parallel Mode 1 Parallel Mode 2 SERIAL MENU PCL SmartSwitch PS SmartSwitch NPA Mode Serial Buffer Job Buffering RS 232 RS 422 RS 422 Polarity Serial Protocol Robust XON Baud Data Bits Parity Honor DSR NETWORK MENU PCL SmartSwitch PS SmartSwitch MAC Binary PS NPA Mode Network Buffer Job Buffering network lt x gt setup Std Net Setup
109. llee e 4 47 Paper Size Sensor Board Assembly Removal 4 48 Main Unit Far nemoyval z xax eee hr RS PUITS E 4 49 Main Drive Unit Removal assecuti tr me RETE ER 4 50 Face Up Paper Exit Assembly Removal 4 54 Face Up Down Flapper Detection Sensor Removal 4 54 Face Up Down Solenoid Removal Lees 4 54 Paper Delivery Sensor Removal leere 4 54 Paper Exit Tray Switch Removal else 4 54 Face Down Guide Assembly Removal lee 4 55 Paper Exit Motor amp Full Sensor Removal 4 55 Turn Guide Cover Sensor Removal esee 4 57 Right Slide Rall Removal 9 RR RR RRRES 4 58 Front Cover Open Switch Actuator Removal 4 58 Lock Handle Assembly Removal eee 4 59 Top Uni nemoVval sssescsamicsseseumertedae p mx memes 4 60 Stay Aum Removal zisisascck 1i ss Rex eorbpe sme soe 4 61 Fuser Removal assa nation eee T CHEER ET ESSE 4 62 Options REMOVES ix ecLIkacziseeride mmm rh m ers 4 63 Expansion Paper Feeder Removal sees 4 63 Duplex Unit Separation Removal lssu 4 71 Duplex Unit ReMOVGlianccsmntvaccaamad aun en t rero os 4 72 Duplex Timing Belt Removal sees 4 72 vi Service Manual 5055 01x Duplex Pressure Roller and Solenoid Removal 4 73 Duplex Feed Roller And Solenoid Removal 4 73 Duplex Side Fence Motor Assemb
110. lue and move to the next margin value The margin values are traversed in this order X alignment Y alignment Theta alignment If you need to skip an alignment value then just press Select The default value will remain the same If Return is pressed to exit the Alignment menu after a margin value has been incremented or decremented then the default value is not changed However if the Alignment Test page is requested after a margin value has been incremented or decremented then the default value is changed and then the Alignment Test page is printed using the new value To verify the margin values are correct you 3 6 Service Manual 5055 01x must print the Alignment Test page From the Alignment screen containing each of the alignment values press Go This button serves as a hot key to the alignment X sxxx Y sxxx T sxxx test page While the page prints the Power indicator blinks and the following message displays Alignment Test Printing No buttons are active while the Alignment Test page is printing Once it is complete the Alignment screen will be displayed again The previously active margin value flashes The printer attempts to print the Alignment Test page from the default paper source If the default source only supports envelopes then the page prints from Tray 1 Note The Alignment Test page should be printed on Letter or A4 paper only To exit the Alignment menu press Return Diagnostic Ai
111. ly Side Fence Removal 4 74 Duplex Paper Carrying Motor Removal e 4 75 HOPF Covers Removal i eezipereRedesPIeRebex e xg 4 76 HCPF Call Roller Paper Feed Roller Reverse Roller Removal 4 77 HCPF Pickup Solenoid Removal L lsss 4 78 HCPF Paper End Sensor Removal Less 4 79 HCPF Paper Size Sensors 1 2 Removal 4 79 HOPF Tray Motor DetmoVal summum tior RR et amare en 4 81 HCPF Paper Level Sensor Removal 4 82 HCPF Power Supply Removal sees 4 83 BosntubIcaeR tee 5 1 Covers DIagralm usus iim mime Rn ee mme cn 5 1 Major Parts DIAA 3 4 2 372 Se aed wed dos KR Reed doen 5 2 Printer Controller BOBIO i53 rb Ex mx oy ra ee NUR Ray cs 5 4 Printhead Controller Board 45 5 2n rrr rr Rmus 5 5 RIP Boastd ssosdacesernspiessrasssideegssesqi dee ebd 5 6 Power Source Unit 1 Boaldiuackeicue mace er eek 5 7 Power Source Unit 2 Board xus sess sc pepe ri DERE tien 5 7 High Voltage Power Supply Board sesleesee 5 8 Sensor Boats si inse suspe E E RIEN RE Eam eR 5 9 Expansion Paper Feeder Controller Board 5 9 Duplex Unit Controller Board 2 xu oh rmx 5 10 Motor Drive Boal isiaeuc ee RR rre er Rr rs nore 5 10 Size SensorBoald soiiissbeseaeiesirenausesdremxd e 5 10 High Capacity Paper Feed HCPF Llseeesee 5 11 High Capacity Paper Feed Configuration 5 12 EleciricallParts Layouts zu uidere n
112. ly necessary to remove a board from its conductive bag or case always place it on its conductive mat in an area as free as possible from static electricity Do not touch pins of the integrated circuits with your bare hands 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 Place it in position by holding only the edges of the board Before you plug connectors into the board be sure the power cord has been unplugged from the power outlet Inspection Avoid checking the IC directly with a multimeter use connectors on the board Never create a closed circuit across IC pins with a metal tool When it is absolutely necessary to touch the integrated circuits and other electrical components on the board be sure to ground your body 4 2 Service Manual 5055 01x Adjustments High Capacity Paper Feed Timing Belt Adjustment Secure the bracket with the screw as shown Attach the spring and washer to the bracket with the screw Adjust the screw to 6mm 1mm Tighten the screw completely Adjust the timing belt on the rear in the same manner ark woONM Screw Spring Screw Washer Front Idler Bracket Repair Information 4 3 5055 01x Removals Cove
113. mperature is set higher than usual to increase the smoothness on the surface of the toner image This mode restricts paper feeding to multi paper feeding not cassette feeding Thick Paper Mode Thick paper mode is used to improve print quality on thick paper More than 105 g m 90kg 1 18 Service Manual 5055 01x Envelope Postcard Mode Envelope postcard mode is used to improve printing quality on thick paper of small width In this mode the fusing temperature is set higher than usual and transfer voltage is switched according to the temperature Operation Mode Operation modes such as sleep mode and registration mode are switched by command from the interface controller By carefully selecting print media and loading them properly you can avoid most paper jams If jams do occur follow the steps outlined in this section To resolve the paper jam messages you must clear the jammed area and then press Go to clear the message and resume printing The printer prints a new copy of the page that jammed if Jam Recovery is set to On or Auto however the Auto setting does not guarantee the page will print General Information 1 19 5055 01x Clearing Paper Jams 200 Paper Jam lt x gt Pages Jammed Check Areas A F A 200 Paper Jam message indicates that paper is jammed The display alternates between 200 Paper Jam lt x gt Pages Jammed and Check Areas A F If there is a paper jam when you turn the printer on t
114. n OV and 5 V between pins 1 and 2 on connector CN12 on the printer controller board Replace the printer controller board Replace the FU FD deflector sensor 2 18 Service Manual 5055 01x 981 Belt Up Down Sensor Error 981 Service Switch Error Questions Step Yes No Actions 1 Are connectors Go to step 2 Plug the connectors CN409 and in securely CN407 on the sensor board connected properly 2 Are connectors Go to step 3 Plug the connector in CN26 and CN29 securely on the printer controller board connected properly 3 Verify the belt up Go to step 4 Replace the sensor down sensor or actuator as actuator is necessary properly blocking the sensor by manually operating the belt up down shaft Is it properly blocking the sensor 4 Clean the belt up Problem solved Go to step 5 down sensor Does this fix the problem Diagnostic Information 2 19 5055 01x Step Questions Actions Yes No Test the sensor While actuating the sensor does the voltage fluctuate between OV and 5 V between pins 8 and 10 of connector CN29 on the printer controller board Replace the belt up down clutch Go to step 6 Replace the belt up down sensor Did replacing the belt up down clutch fix the problem Problem solved Replace the printer controller board 982 Sensor Controlle
115. nit Diagnostic Information 2 75 5055 01x Uneven Printing Possible Cause Action Photoconductor Drum Check for condensation or dirt on the photoconductor drum LED Printhead Clean any dirt off the exposed surface of the LED printhead Also check the locating pins of the printhead Transfer Belt Unit Be sure the transfer belt is clean and not damaged Replace parts as necessary Top Cover Be sure the top cover is fully locked Periodic Dirt Possible Cause Action Fuser Heat Roll Fuser Press Roll Fuser Oil Roll Check for dirt or damage to the fuser heat the fuser press roll or the fuser oil roll Photoconductor Drum Check for scratches on the surface and replace if necessary White Spots Possible Cause Action LED Printhead Photodeveloper Toner Cartridge Firmly install the PC drum unit into the toner cartridge and the print unit into the printer Belt Unit Check the belt unit for scratches or nicks Be sure there is no toner buildup on the belt Replace the belt unit if it is damaged 2 76 Service Manual 5055 01x Options Service Check Service Tip When you have a problem with any of the options installed in the options slots on the interconnect board switch the non operating option to one of the other option slots to isolate the failure Serial Port Service Check Run the Serial W
116. nnect the two cables from the rear of the electronic box and remove the box Repair Information 4 11 5055 01x LED Printhead Removal 1 Open the top unit remove the top cover toner cartridges and photoconductor 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 screw from the printhead holder and remove the holder 3 Remove the front and rear printhead springs 4 Remove the two screws front and rear from the right slide rail and remove the rail 4 12 Service Manual 5055 01x 5 Remove the four connectors from LED printhead 6 Remove the two screws from the ground wires When replacing the LED printhead replace the corresponding EEPROM shipped with the printhead on the printhead controller board Place the printer in Diagnostic Mode input the printhead light quantity value plus eight refer to note below from the printhead label Be sure to remove any fingerprints or stains from the printhead lens The positioning pins at the both ends of the printhead are fixed with hexagon nuts Do not loosen or remove either nut as the image will un focus Note Light intensity value printhead label value plus eight Repair Information 4 13 5055 01x Eraser Removal 1 Remove the appropriate printheads Spread a cloth or paper over the transfer belt to protect it from damage 2 R
117. not shielded Fixing Screw 1 Paper Size Sensor 1 A 2 A M v at ff Side Fence Ss iN ui Fence S gt Positioning l Bracket SE 1 30 Service Manual 5055 01x Residual Paper Detection Mechanism The residual paper quantity in the tray is detected with four photo interrupters The quantity of pages remaining in the sheet feeder displays in the following increments Near end about 80 sheets About 300 sheets About 1 000 sheets About 2 000 sheets Near End Sensor General Information 1 31 5055 01x Paper End Detection A reflection type sensor is provided on the top stay to detect the paper top surface and the paper end Paper End Sensor Tray Edge 1 32 Service Manual 5055 01x 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 DIE Description Switch 4 3 2 1 OFF 1 Standard machine initial setting ON X X OFF X 2 Optional machine initial setting ON X Maintenance switch test mode selection is valid without connecting to the printer controller board Function Switch Maintenanc
118. ntroller Board Communication Error 946 Service Communication Questions Actions Yes No Step 1 Replace the Problem solved Replace the printhead controller printer controller board Did this fix the board problem 2 14 Service Manual 5055 01x 948 Machine ID Error board fix the problem 948 Service Machine ID Questions Ste Yes No p Actions 1 Turn the printer off Problem solved Verify proper and wait 30 seconds installation of the Turn the printer on EPROMs on both Did this fix the the printer problem controller board and the printhead controller board Go to step 2 2 Are the EPROMs Replace the printer Install the installed correctly controller board EPROMs Go to step 3 correctly 3 Did replacing the Problem solved Replace the printer controller printhead controller board 952 NVRAM Chip Failure 952 Service NVRAM Failure Replace the printer controller board 954 NVRAM CRC Failure Replace the RIP board 955 Code CRC 955 Service Code CRC lt loc gt Replace the RIP board Diagnostic Information 2 15 5055 01x 956 Processor Failure 956 Service System Board Replace the RIP board 957 ASIC Failure Replace the RIP board 958 NAND Failure 958 Service NAND Failure Replace the RIP board 960 RAM Slot 1 Bad 960 Serv
119. oe C910 Color Printer 5055 01X Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK 5055 01x Edition November 2001 The following paragraph does not apply to any country where such provisions are inconsistent with local law LEXMARK INTERNATIONAL INC PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND EITHER EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Some states do not allow disclaimer of express or implied warranties in certain transactions therefore this statement may not apply to you This publication could include technical inaccuracies or typographical errors Changes are periodically made to the information herein these changes will be incorporated in later editions Improvements or changes in the products or the programs described may be made at any time Comments may be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or electronically mailed e mail to ServicelnfoAndTraining Lexmark com Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you You can purchase additional copies of publications related to this product by calling 1 800 553 9727 In other countries contact your point of pu
120. of the printer requiring no action Attendance messages alert the operator to printer problems that require operator intervention Service Error Message Table 900 Unrecoverable Software Error Operator Manual 910 Service Motor Error 910 Drive Motor Error Questions Ste Yes No p Actions 1 Are connectors CN1 Go to step 2 Connect CN1 and CN5 on the motor and CN5 drive board connected properly 2 Is connector CN330on Go to step 3 Connect CN33 the printer controller board connected properly 3 Is there an abnormal Replace the Replace the load on the toner or toner or drum printer controller drum unit unit board and go to step 4 4 Did replacement ofthe Problem Replace the printer controller board solved motor drive solve the problem board and go to step 5 5 Did replacement of the Problem Replace the motor drive board solved drive motor solve the problem 2 4 Service Manual 5055 01x 911 Paper Exit Motor Error Questions Step Yes No Actions 1 Is connector CN4 on Replace the Plug the the printer controller paper exit connector in board securely motor and go to securely connected step 2 2 Did replacement of the Problem solved Replace the paper exit motor solve printer controller the problem board 912 High Capacity Paper Feed Motor Error Questions Step Actions o Po 1 Is connector CN4
121. on page 2 58 Registration roller does not rotate Go to the Paper Carrying Service Check on page 2 58 Operator panel does not operate properly Go to the Diagnostic Aids chapter and run the LCD and Button tests If the tests fail replace the operator panel If you still have a problem replace the RIP controller board If your machine beeps 5 times and the screen is blank or all diamonds replace the operator panel Foggy print Black pages Blank print White spots Poor reproduction Incorrect color image registration Dirt on back of paper Low image density White and black lines and bands Go to Print Quality Problems on page 2 69 Diagnostic Information 2 53 5055 01x Symptom Action Evenly spaced marks on the paper or a single mark in the same place on every page Go to the Marks on Paper Service Check on page 2 66 Poor fusing Go to the 920 Fuser Error Fuser Heater Trouble on page 2 7 Toner scatter on front or back of paper Check the following Excessive toner buildup on the transfer belt Clean off the toner and run a test print Transfer belt assembly Transfer belt toner waste bottle Transfer belt separation fingers Fuser separation pawl Paper will not feed from MPF Be sure you have paper in the MPF Be sure the MPF paper present sensor connector CN11 is connected
122. on Charge Roller 139 2 mm Fuser Upper Roller 140 mm Fuser Lower Roller 824 5 mm Transfer Belt 46 9 mm Upper Registration Roller 46 9 mm Lower Registration Roller 45 1 mm Supply Roller cartridge 58 8 mm Developer Roller cartridge 94 2 mm Photodeveloper Drum 2 66 Service Manual 5055 01x Fuser Part Locations mm From Paper Center Thermistor Hot Roll 6 Thermistor BUR 0 TCO Hot Roll 66 TCO BUR 101 Detact Fingers Hot Roll 113 5 75 37 5 0 37 5 75 113 5 Detact Fingers BUR 134 90 45 0 45 90 134 Exit Rollers 96 37 5 37 5 96 Star Rollers 127 60 15 15 60 127 Diagnostic Information 2 67 5055 01x Transfer Belt Up Down Service Check FRU Action 1 Belt Up Down Sensors Belt Up Down Actuator Check the transfer belt up down sensor Be sure that connector CN29 is firmly connected to the printer controller board Replace the sensor or the actuator if necessary Check for a fluctuation between OV and 5 V between pins 8 and 10 while actuating the sensor 2 Belt Up Down Clutch Be sure connector CN26 is firmly connected to the printer controller board Replace the belt up down unit if necessary 3 Belt Up Down Check and replace the belt up down lift cam shaft if Lift Cams necessary 4 Printer If there still is a problem replace the printer Controller controller board Board 2 68 Service Manual 5055 01x Ima
123. op cover 3 Disconnect the connector and remove the five screws and two snap bands from the face down guide assembly Remove the assembly 4 Remove the four screws from the face down cover and the face down guide assembly and remove the assembly Repair Information 4 55 5055 01x 5 Remove the two screws of the motor from the face down guide assembly Remove the assembly Note When the motor is installed press the motor 45 degrees in an upward direction when viewing from the rear 6 Remove the face down paper delivery full sensor from the face down guide assembly 4 56 Service Manual 5055 01x Turn Guide Cover Sensor Removal 1 Open the top unit and remove the upper cassette front cover multi purpose feeder right side cover and turn guide 2 Remove the two screws from turn guide sensor and remove the sensor 3 Remove the terminal Repair Information 4 57 5055 01x Right Slide Rail Removal 1 Remove the upper cassette 2 Remove the screw from both left and right slide rails Z o NR Front Cover Open Switch Actuator Removal 1 Open the front cover 2 Remove the two screws from the front cover open switch actuator 4 58 Service Manual 5055 01x Lock Handle Assembly Removal 1 Open the top unit 2 Turn the plastic latch on the front and rear sides by 90 degrees 3 Remove the lock handle assembly Repair Information 4 59 5055 01x Top
124. or 4 26 Service Manual 5055 01x Multi Purpose Feeder Paper Present Sensor Removal 1 Open the top unit and remove the upper cassette front cover turn guide multi purpose feeder right side cover turn guide and multi purpose feeder frame 2 Disconnect the connector and remove the multi purpose feeder paper present sensor MPF Paper Present Sensor Repair Information 4 27 5055 01x Paper Carrying Frame Removal Paper Carrying Roller Upper Removal Paper Carrying Clutch Removal OHP Detection Sensor Lower Removal 1 Open the top unit and remove the upper cassette front cover turn guide multi purpose feeder right side cover turn guide OHP detection sensor upper multi purpose feeder frame back cover RIP cover RIP board RIP box and electronic box 2 Remove the four screws from the paper carrying frame CQODOOOQO Ao 3 Remove the screw from the OHP sensor lower 4 Remove the paper carrying roller upper 5 Remove the paper carrying clutch Note When installing the clip of the paper carrying clutch should be securely set to the stop and the shaft of the paper carrying clutch and spring should be securely in contact with each other 4 28 Service Manual 5055 01x 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 th
125. or 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 and A3 The counters are used to track printer usage The current value of the drum counter may be viewed in the Diagnostic menus by selecting the Drum Count menu but this value is not viewable from the Ready menu The following screen illustrates the operator panel when the cyan drum counter displays The leftmost digit 1 in this example blinks indicating it is the first digit to be changed To change the value press Menu until the desired value display Press Select to move to the next digit The next digit 2 in this example blinks Continue modifying each digit using this method To skip a digit and keep its current value press Select When Select is pressed after the final digit 5 in this example the new page count is stored in NVRAM Cyan Drum Count 12345 The drum counts can be reset by scrolling to the appropriate drum color and pressing Select 3 22 Service Manual 5055 01x Setting the Page Count The page count can be changed through the Diagnostic menus This menu is used by the servicer 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 displays as follows Page Count 1234567 The left most digit 1 in this example blinks indica
126. ove the two screws securing the pressure roll solenoid assembly Duplex Feed Roller And Solenoid Removal 1 Remove the two screws securing the feed roll solenoid assembly 2 Remove the pressure roller and springs 3 Remove the feed roller and springs Repair Information 4 73 5055 01x Duplex Side Fence Motor Assembly Side Fence Removal 1 Remove the three screws and remove the side fence motor assembly 2 Remove the front and rear side fences Note When installing spread the front and rear side fences to the sides and install 4 74 Service Manual 5055 01x Duplex Paper Carrying Motor Removal 1 Remove the gear cover 2 Remove the screws from the duplex paper carrying motor and remove the motor Repair Information 4 75 5055 01x HCPF Covers Removal 1 OOA Transfer Cover Front Cover Remove the two screws from the drive cover and remove the cover Remove the front cover Remove the two screws from the right cover and remove the cover Remove the top cover Remove the rear cover Remove the four screws from the transfer cover and remove the cover Drive Cover Rear Cover Top Cover Right Cover 4 76 Service Manual 5055 01x HCPF 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 remov
127. over Repair Information 4 7 5055 01x Cover Right Side Removal NT 1 Open the top unit and remove the front cover and upper cassette 2 Remove the seven screws from the right side cover together with the turn guide and remove the cover 3 When installing the right side cover insert the turn guide shaft into the bearing 4 8 Service Manual 5055 01x Cover RIP Board Removal 1 Loosen the eight screws and remove the RIP cover by sliding upward 2 Remove the three harnesses and one flat cable of the RIP board connector 3 Remove the two screws from the parallel port connector and the screw from the USB connector 4 Remove the eight screws from the RIP board together with the parallel connector and remove the RIP board Repair Information 4 9 5055 01x 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 4 10 Service Manual 5055 01x RIP Box Removal 1 Remove the five screws from the RIP box 2 Slightly lift and remove the RIP box Electronic Box Removal 1 Open the top unit and remove the back cover front cover cassette turn guides and right side cover 2 Remove the screws from the electronic box 3 Disco
128. p 11 Paper Size Map Step Questions Actions Yes No 1 Do the paper size sensor Go to step 2 Replace parts actuators on the paper as necessary operation tray operate correctly as you slide the paper location plate 2 Do the size sensor levers Go to step 3 Replace the operate correctly size sensor levers 3 Are the following connectors Go to step 4 Properly properly connected connect the connectors CN2 tray 1 on the printer controller board CN4 on the expansion feeder control card trays 2 5 4 Replace the paper size sensor Problem Replace the card Does this fix the solved printer problem controller board tray 1 Replace the expansion feeder control card trays 2 5 Diagnostic Information 2 51 5055 01x Symptom Table Symptom Action You cannot print color Make sure the Color Correction menu item is not set to Black amp White Make sure the color print units are completely installed in the printer Go to the Transfer Belt Up Down Service Check on page 2 68 Transparencies curl excessively Make sure you re using the recommended Lexmark transparencies Also be sure the paper delivery is set to the rear exit The printer seems slow to print If you set the Paper Type to Transparency or Card Stock the printer increases the fuser temperature and slows printing to improve the print quality After printing on these media the printer requires
129. paper feeding fusing 1 7 printing mode 1 18 processes and configuration 1 5 registration unit 1 11 separation unit 1 12 thick paper mode 1 18 transfer unit 1 6 Tools 1 2 l 4 Service Manual 5055 01x Part Numbers 11D0328 11D0329 11D0330 11D0331 11D0332 11D0333 11D0334 11D0335 11D0336 11D0337 11G0117 11G0118 11G0120 11G0135 11G0219 11G0243 11G0283 11G0284 11G0291 11G0297 11G0385 11G0399 11G0422 11G0423 11G0540 11G0562 11G0563 11G0565 11G0566 11G0569 11G0572 11G0577 11G0579 11G0616 11G0617 1281695 1281696 12G6509 12G7360 13A0296 13A0297 56P0161 56P0162 56P9500 56P9501 7 27 1 27 7 27 f 27 fear f 27 Y 27 27 7 27 T 27 7 11 7 11 7 35 7 11 7 35 fof l f 28 39 TB 7 17 7 23 7 25 7 23 7 35 7 39 7 39 7 35 7 37 7 37 7 37 7 19 7 19 7 39 7 19 7 19 7 19 7 19 7 19 7 19 7 19 7 19 1 29 7 29 7 29 T 3 7 29 29 7 29 7 29 7 35 7 47 56P9502 56P9503 56P9504 56P9505 56P9506 56P9507 56P9508 56P9509 56P9510 56P9511 56P9512 56P9513 56P9514 56P9515 56P9516 56P9517 56P9518 56P9519 56P9520 56P9521 56P9522 56P9523 56P9524 56P9525 56P9526 56P9527 56P9528 56P9529 56P9530 56P9531 56P9532 56P9533 56P9534 56P9535 56P9536 56P9537 56P9538 56P9539 56P9540 56P9541 56P9542 56P9543 56P9544 56P9545 56P9546 56P9547 56P9548 7 5 7 23 7 17 7 37 T7 7 37 FAL 7 37 7 39 T 17 7 39 7 39 7 39 n Q2 C0 Go OO O CO cO co o d Wo NN
130. plex unit feeding is stopped before the paper is delivered Paper delivery is then reversed and fed to the duplex unit Paper fed with the duplex unit stops once and the center position is corrected by the operation of the side guide plate Paper is then re fed by the printer controller signal to the main unit and following printing on the back side is delivered to the normal feeding path General Information 1 17 5055 01x Printing Mode Usually printing is performed in normal mode OHP mode thick paper mode and envelope postcard mode The mode is switched by a command from the interface controller Mode Paper Media Weight PPM Color Normal 16 29 lb 28 Thick paper 32 Ib glossy 22 Envelope postcard 90 Ib or more 10 OHP Transparency 6 OHP Mode OHP mode is used for improving color printing on transparencies With an overhead projector OHP light transmitted through OHP paper original document projects an image on the lens If the smoothness of the surface of the toner image on the OHP paper is too low transmission is prevented due to the diffused reflection Images projected in color printing appear in monochrome When non offset type color toner is used the process speed in the OHP mode is decreased causing toner to melt sufficiently with the fusing unit while the fusing te
131. ps and the final test results display Press Return or Stop to exit the test 3 16 Service Manual 5055 01x 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 displays 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 displays Quick Disk Test Test Passed Press Go Return or Stop to return to the DEVICE TESTS screen If the test fails then the following message is displayed Quick Disk Test Test Failed Press Go Return or Stop to return to the DEVICE TESTS screen Canceling this test is not allowed Diagnostic Aids 3 17 5055 01x 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 See Formatting the Hard Disk in the User s Guide To run this test select Disk Test Clean from the DEVICE TESTS menu The following message displays to warn the customer that all disk contents will be lost Files will be lost Go Stop To continue on with the test press Go To exit the test immediately an
132. put bins Plug the printer in and turn it on 58 Too Many Disks Installed Too many disks are installed Turn off and unplug the printer Remove the excess hard disks Plug the printer in and turn it on 58 Too Many Flash Options Too many flash options are installed Turn off and unplug the printer Remove the excess flash options Plug the printer in and turn it on 58 Too Many Trays Attached Too many trays are installed Turn off and unplug the printer Remove the excess trays Plug the printer in and turn it on 61 Defective Disk The printer detects a defective hard disk Press Go to clear the message and continue printing Install a different hard disk before you perform any operations that require one 2 38 Service Manual 5055 01x Message 62 Disk Full Meaning Insufficient memory on the hard disk Action Press Go to clear the message and continue printing Delete fonts macros and other data stored on the hard disk 63 Unformatted Disk The printer detects an unformatted hard disk Press Go to clear the message and continue printing Format the disk before performing disk operations Replace the hard disk 64 Unsupported Disk Format The printer detects an unsupported disk format Press Go to clear the message Format the disk 80 Belt The transfer belt has reached Replace t
133. r reverse roller and call roller are free of dirt and are not damaged Clean or replace parts as necessary Paper Feed Clutch Paper Feed Motor Set up and run a test in Maintenance Mode and go to the High Capacity Paper Feed HCPF Service Check on page 2 57 Sensors Ensure all motors clutches and sensors operate correctly HCPF Set up and run a test in Maintenance Mode and go Control Card HCPF Power Supply to the High Capacity Paper Feed HCPF Service Check on page 2 57 If no LEDs light check the power source Replace the HCPF control card Replace the HCPF power supply 2 58 Service Manual 5055 01x Paper is being picked up and carried to the registration roller Areas C E 240 24x Side Location Plates FRU Action 1 Paper Size Be sure the paper cassette has the size guides and Guide the side locator locks are working properly Replace parts as necessary 2 Paper Feed Be sure the paper feed rollers are free of dirt and not Roller MPF damaged Paper Feed Rolls MPF Be sure the fanning pad is free of dirt and not Tray 1 2 3 damaged 4 5 e Carrying Replace parts as necessary Roller Tray 1 2 3 4 5 Fanning Pad MPF 3 Gears Be sure the paper feed gears are not damaged 4 Paper Feed Be sure the paper feed solenoid activates the paper Solenoid feed clutch and the clutch engages properly Paper Feed Clutch
134. r Top Removal 1 Remove the operator panel 2 Remove five screws from the bottom the four screws from the back side and the screw from the left side Operator Panel Removal 1 Open the top unit and remove the toner cartridges and photoconductor drum units 2 Remove the operator panel 3 Remove the two screws from the operator panel case and remove the case 4 Remove the cable from the operator panel 4 4 Service Manual 5055 01x Cover Front Removal 1 Remove the four hinge screws from the front cover 2 Remove the front cover Repair Information 4 5 5055 01x Cover Front Left 1 Open the front cover and remove the cassette 2 Remove the left front cover by removing the three screws BS e BZ S e fi SS S Ll Cover Rear Removal 1 Open the top unit 2 Remove the three screws from the rear cover and remove the cover 4 6 Service Manual 5055 01x Cover Solenoid Removal 1 Remove the screw from the solenoid cover 2 Remove the solenoid cover Cover Left Side Removal ASY E P opt ee 2 d o o to d 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 c
135. r Error 982 Service Sensor Control Step Questions Actions Yes No Turn the printer off and wait 30 seconds Turn the printer on Is error 982 displayed Replace the board printer controller Problem solved 2 20 Service Manual 5055 01x 983 Black Gear Sensor Error 983 Service Gear Sensor Step Questions Actions Yes No Is connector CN20 on the printer controller board connected properly Go to step 2 Plug the connector in securely Clean the gear sensor Does this fix the problem Problem solved Replace the K drive unit gear sensor If the problem remains replace the printer controller board 984 Yellow Gear Sensor Error sensor Does this fix the problem Questions Ste Yes p Actions No 1 Is connector CN20 Go to step 2 Plug the connector on the printer in securely controller board connected properly 2 Clean the gear Problem solved Replace the Y drive unit gear sensor If the problem remains replace the printer controller board Diagnostic Information 2 21 5055 01x 985 Transfer Belt Thermistor Error 985 Service Thermistor Error Questions Ste Yes No p Actions 1 Are connectors Go to step 2 Plug the connector CN407 and CN408 in securely on the sensor board connected p
136. r controller connect the board and CN10 on the connectors expansion feeder control card associated with the failing tray properly connected 4 Replace the paper remaining Problem Replace the sensor board for the problem solved expansion tray Does this fix the feeder control problem card 5 Is the paper present flag Go to step 6 Repair or operating correctly replace the failing parts 6 Are connectors CN35 and Go to step 7 Properly CN36 on the printer controller connect the board and CN6 on the connectors expansion feeder control card associated with the failing tray properly connected 7 Replace the paper present Problem Replace the sensor Does this fix the solved associated problem expansion feeder control card Diagnostic Information 2 45 5055 01x Map 5 False 30 Oil Coating Roll Missing Message Step Questions Actions Yes No 1 Is the OCR properly installed Go to step 2 Properly install the OCR 2 Is the OCR contact at the rear Replace the Go to step 3 of the fuser damaged or fuser broken 3 Is CN44 on the printer Replace the Properly controller board properly printer connect connected controller CN44 board Map 6 False lt Color gt Print Unit Missing Message Step Questions Actions Yes No 1 Insure that all connectors that Go to step 2 Replace the the print unit photodeveloper sub frame contacts when the top cove
137. r current default settings Any clear active print jobs are canceled Restore Held The printer has been reset or Press Go All jobs on hard Jobs Go Stop has been turned on and the disk are restored printer detects print and hold jobs stored on the hard disk Press Return or Stop No jobs are restored and the printer returns to Ready Restoring The printer is restoring factory Wait for the message to Factory default settings clear Defaults Restoring Held The printer is restoring held Wait for the message to Jobs jobs from the hard disk clear Serial lt x gt A serial interface is the active Wait for the message to communication link clear Std Bin Full The standard bin is full Remove the paper in the bin to clear the message Supplies One of the printer supplies Press Menu to open the requires attention Supplies Menu and identify which supply item needs replacing 2 32 Service Manual 5055 01x Message Tray lt x gt Empty Meaning The specified tray is out of paper Action Load paper in the tray and try to clear the message If the message cannot be reset go to Map 4 False Tray X Low Empty Message on page 2 45 Tray lt x gt Low The specified tray is low of paper Add paper in the tray and try to clear the message If the message cannot be reset go to Map 4 False Tray X Low Empty Message on page 2 45
138. r damage Replace as necessary Printer Check connectors CN2 and CN14 for proper Controller connection on the printer controller board Board Paper Tray Missing Service Check FRU Action Actuator Check the paper remaining sensor actuator for damage Check the paper remaining sensor for dust Sensor dirt or damage Repair or replace as necessary Printer Be sure CN35 and CN36 on the printer controller Controller board are connected properly or CN10 on the Board expansion paper feeder control board for the associated tray Expansion Paper Feeder Control Board Diagnostic Information 2 63 5055 01x Photodeveloper Missing Service Check When you replace the photodeveloper unit all three color units must be replaced at the same time FRU Action 1 Photodeveloper Check for dirt or damage to the sensing contacts on rear Clean or replace the photodeveloper drum unit if necessary 2 Sub frame Unit Check the sensing contacts on the sub frame assembly Clean or replace the affected contacts or sub frame 3 High Voltage If the problem remains replace the high voltage unit Unit HVU 4 Printer If the problem remains replace the printer controller Controller board Board 2 64 Service Manual 5055 01x Power Supply Service Check FRU Action 1 Voltage Be sure the switch is on and the power cord is firmly plugged into the printer Be
139. r is closed are operating correctly and are not damaged worn or missing Are the connectors operating properly with no damage or wear 2 Is CN42 on the printer Replace the Properly controller board properly printhead connect connected controller CN42 2 46 Service Manual 5055 01x Map 7 False 88 lt Color gt Toner Low Toner Empty Message Step Questions Actions Yes No 1 Ensure that the encoder Go to step 2 Clean the located at the rear of the toner encoder set is clean and free of dirt or wheel or paper dust Is the encoder replace the wheel clean and free of dirt or toner set paper dust 2 Is the toner remaining photo Go to step 3 Clean or interrupter sensor clean and replace the free of obstructions toner remaining photo interrupter 3 Is the connector of the problem Replace the Properly color properly connected on printer connect the the printer controller board controller connector board Magenta CN18 Yellow CN21 Cyan CN19 Black CN22 Diagnostic Information 2 47 5055 01x Map 8 False 40 Tray X Size Sensor Error Message adjusting thumbscrews Do the LEDs light when the screws are loosened all the way Step Questions Actions Yes No 1 On the high capacity paper Go to step 2 Replace the feeder are the paper size missing adjusting screws present on thumbscrew the upper portion of the side or screw them fence
140. rap Tests on page 3 15 Note The Serial Wrap Test is designed to check the serial port hardware by using a wrap plug P N 1329048 and invoking the Serial Post Diagnostic Test The test helps isolate the printer from the serial cable and host The test provides failure information on the display for approximately three seconds If the test indicates a problem replace the RIP board Flash Memory Option s Run a copy of the test page and check to see if the option you are checking is listed The printer does not recognize the option being installed if the option is not listed Be sure the memory card assembly is installed correctly and is not broken or damaged If the Memory card assembly is correctly installed not broken or damaged then run the Flash Test on page 3 19 If the test fails replace the Flash card assembly If the problem continues replace the RIP board DRAM Memory Option s This service check is the same as the flash memory option service check with the following exception Run the DRAM Memory Test on page 3 11 from the menu if the DRAM Memory card assembly is correctly installed and not broken or damaged If the test fails replace the DRAM card assembly If the problem continues replace the RIP board Diagnostic Information 2 77 5055 01x Hard Disk Option Service Tip The 5055 01x printers support one hard disk option Be sure only one 3 2 GB or larger one hard disk option is installed Be sure
141. rchase Lexmark and Lexmark with diamond design and Optralmage are trademarks of Lexmark International Inc registered in the United States and or other countries Other trademarks are the property of their respective owners Copyright Lexmark International Inc 2001 All rights reserved UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS Use duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph c 1 ii of the Rights in Technical Data and Computer Software clause at DFARS 252 227 7013 and in applicable FAR provisions Lexmark International Inc Lexington KY 40550 U S A P N 12G9081 5055 01x Contents Safety Information 22 22 c200c0sencseee eee ees eee Rn ix salely NOIE iisscites essei Xe dinen enban ai ix General Information llle eee 1 1 Maintenance Approach 2 ccl uii rx 1 1 Standard Inspection and Cleaning Procedure 1 1 Het rn Parls sssscenciimescehestwu9erkebeze we ikn er ce 1 2 Recommendations For Service llelsllees 1 2 Hi EUIS 1 2 Serial Number 22 2x1x4x kk tr mm RR ee ee 1 3 Abbreviations 2 2m22 3 lh intr n mE ee eee cus 1 4 Processes and Configuration ssucc rra RR rRrRrh Ex 1 5 Electrophotography Process i e mr mr mr ee ee 1 5 Development Unit 2 2 22 2222l nh 1 6 Transter Unit 22 2222 mr Rr mmi Rr Res 1 6 Cleaning Unit RR
142. rded to make room for the new error The printer stores identical errors in consecutive positions in the log The following error messages are stored in the error log All 2xx paper jam messages All 9xx service messages To view the error log select the Display Log operation from the Diagnostics ERROR LOG menu The entire error log cannot display on a single screen four error log entries display per screen requiring three screens To move forward in the log press Menu to move backward press Menu The following are examples of the error log screens 1 200 2 290 3 928 4 922 5 250 6 990 7 230 8 230 9 953 10 000 11 000 12 000 To exit the error log press Return or Stop Diagnostic Aids 3 25 5055 01x Clearing the Error Log To clear the error log select Clear Log from the ERROR LOG menu The printer displays the following message Clear Log Yes Select Yes to clear the log as the empty log message displays as follows 1 000 2 000 3 000 4 000 Select No Return or Stop to exit the Clear Log menu Maintenance Menu 80 Fuser Maint 0 to XXXXXXX Reset 80 Fuser Yes 80 Belt Maint 0 to XXxxxxx Reset Belt Maint Yes Exiting Diagnostics Mode To exit diagnostics mode and POR the printer into normal user mode press EXIT DIAGNOSTICS 3 26 Service Manual 5055 01x 4 Repair Information Service P
143. recautions Observe the following precautions whenever you service the printer Be sure to unplug the printer from the outlet before attempting to service the printer To reassemble the printer reverse the order of disassembly unless otherwise specified Do not operate the printer anytime during disassembly If it is absolutely necessary to run the printer with its covers removed use care not to allow your clothing to be caught in revolving parts such as the gears rollers and fan motor Never touch the terminals of electrical parts or high voltage parts such as the high voltage power supply board Be sure to handle the fuser carefully as it remains hot for a while after the printer stops running Always unplug connectors by holding the connector housing Be sure to use the fuse listed in the parts catalog Do not forget to install the ground wire or ground plate to ensure positive conduction Install the screw with a toothed washer in the right position at reassembly Repair Information 4 1 5055 01x Handling Printed Circuit Boards The following precautions must be observed when handling circuit boards with metal oxide semiconductor integrated circuits Transportation Storage During transportation or when in storage new circuit boards must not be indiscriminately removed from their protective conductive bags Do not store or place circuit boards in a location exposed to direct sunlight When it becomes absolute
144. registration as necessary e Shake all cartridges and be sure they are correctly installed and fully seated While the cover is open wipe any residual toner from the LEDs using a lint free cloth 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 Tweezers C ring pliers Magnifier 10 times or equivalent 6 angle wrench 1 5 mm When you make voltage readings always use frame ground unless another ground is specified 1 2 Service Manual 5055 01x Serial Number Open the front door the serial number is located as shown The serial number is also on the menu settings page you can print from the Tests Menu Serial Number Cy ar X f ii IT e LL oN la MIS o General Information 1 3 5055 01x Abbreviations ASIC CSU DRAM EPROM EP ESD FRU HVPS LAN LASER LCD LED LVPS NVRAM OEM PICS PIXEL POR POST PQET RIP ROS SRAM UPR Vac Vdc Application Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Erasable Programmable Read Only Memory Electrophotographic Process Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Local Area Network Light Amplification b
145. rly Go to step 2 Plug the connector in securely Is connector CN29 on the printer controller board connected properly Replace the density sensor Go to step 3 Plug the connector in securely Did replacing the density sensor fix the problem Problem solved Replace the printer controller board 2 24 Service Manual 5055 01x Attendance Messages g Message Activating Menu Meaning The printer is activating Action Wait for the message to 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 processing or printing data clear or press Menu to open the Job Menu and cancel the current job Canceling Fax The printer is processing a request to cancel a fax job Wait for the message to clear Canceling Job The printer is processing a request to cancel the current print job Wait for the message to clear Change x The printer is requesting a different type of paper Change paper Check device connection The specified device is not fully connected Hardware failure Reestablish communication by reattaching the device Press Go to clear the message If a hardware failure turn the printer off and back on If the error recurs turn the printer off remove the
146. rmation 1 1 H Handling Printed Circuit Boards 4 2 Hardware Tests 3 10 HCPF Sensor Switch Test 1 35 High Capacity Paper Feed Configuration 5 12 High Capacity Paper Feed Diagram 5 11 Image Quality Troubleshooting 2 69 Index 1 Initial Check 2 3 L LEDs cleaning 2 71 Locations 5 1 Lubricants And Cleaners 6 2 Maintenance Analysis Procedures 2 43 Maintenance Approach 1 1 Maintenance Kit 6 1 Maps 1 False Side Door Open Message 2 43 10 Unrecoverable Check Tray X or Duplex Connection Message 2 49 11 Papersize 2 51 2 False Close Top Door Message 2 43 3 False Close Tray X Top Cover Message 2 44 4 False Tray X Low empty Message 2 45 5 False 30 Oil Coating Roll Missing Message 2 46 6 False Print Unit Missing Message 2 46 Index l 1 5055 01x 7 False 88 Toner Low toner Empty Message 2 47 8 False 40 Tray X Size Sensor Error Message 2 48 9 False 41 Open Bin 1 Exit Tray Message 2 48 Menu Overview 3 4 Menu Settings 3 4 O Operator Menu Disabled 3 4 Operator Panel Buttons 3 3 P Parts Catalog 7 1 base 1 7 16 base 2 7 20 base3 7 22 cassette 7 34 covers 7 2 covers2 7 4 covers 3 7 6 covers 4 7 8 covers5 7 10 duplex unit 1 7 40 duplex unit2 7 42 electrical 7 24 expansion feeder 1 7 36 expansion feeder 2 7 38 fuser unit 7 32 high capacity paper feed 1 7 44 high capacity paper feed 2 7 46 high capacity paper feed 3 7 48 high capacity paper feed 4 7 50 h
147. rming the electrostatic image on the photosensitive drum Toner attaches to the bright portion of the photosensitive drum per the voltage of the development roll Doctor Blade Li c CE VOD D NESE j n Development Roll Photosensitive Drum 1 Ld LED Printhead MN Transfer Unit Paper feeds electrostatically by the transfer belt and is carried to the transfer unit which turn at the speed of the photoconductor drum A charge roller applies a positive charge to the paper The toner image formed on the photoconductor drum is transferred to the paper from the back side by the positive dc voltage applied to the transfer sheet which is in contact with the paper through the transfer belt 1 6 Service Manual 5055 01x Cleaning Unit Toner remaining on the photosensitive drum following transfer is scraped away with the cleaning blade and collected in the recovery bag as waste toner Residual toner on the photosensitive medium is removed by the eraser Eraser B XG Cleaning E EXT Transfer Coil Paper Feeding Fusing The main unit drive is composed of drives 1 and 2 Drive 1 feeds paper stands by drives the belt unit separates fuses feeds the face up delivery unit and drives the photodeveloper and toner cartridge by rotations of the dc motor Drive 2 drives the face down delivery unit by rotations of the stepper motor The expansion paper feeder and
148. roller board If the problem remains replace the expansion feeder cable assembly 6 Are connectors CN9 CN8 Go to step 7 Properly CN7 and CN3 on the connect the expansion feeder control card connectors for the problem tray and the trays above and below properly connected Diagnostic Information 2 49 5055 01x Step Questions Actions Yes No 7 Exchange the expansion Replace the Replace the feeder control board for the defective upper and problem tray with one above or expansion lower below Does the symptom feeder control expansion follow the exchanged card card paper feed drawer connecting cable assemblies 8 Are any of the pins or contacts Go to step 9 Repair or on the duplex drawer replace the connectors bent or damaged connector 9 Are connectors CN101 and Go to step 10 Properly CN102 on the duplex interface connect the card properly connected connectors 10 Replace the duplex interface Problem Return the card Does this fix the solved duplex problem interface card and go to step 11 11 Replace the duplex interface Problem Go to step 12 cable Does this fix the solved problem 12 Are CN37 and CN38 on the Replace the Properly printer controller board printer connect the properly connected controller connectors board If the problem remains replace the duplex connector cable 2 50 Service Manual 5055 01x Ma
149. roperly 2 Is connector CN29 Replace the transfer Plug the connector on the printer belt unit If the in securely controller board problem remains connected properly replace the printer controller board 986 Transparency OHP Sensor Error 986 Service OHP Sensor Questions Ste Yes No p Actions 1 Are connectors Go to step 2 Plug the connector CN15 light emitting and CN7 light receiving on the printer controller board connected properly in securely 2 22 Service Manual 5055 01x While actuating the sensor does the voltage fluctuate between OV and 5 between pins 2 and 3 of connector CN7 of the printer controller board controller board uestions Step Q Yes No Actions 2 Test the sensor Replace the printer Replace the upper and lower transparency sensor 992 Temperature Humidity Sensor Error Step Questions i Yes No Actions 1 Is connector CN3 on Go to step 2 Plug the connector the printer controller in securely board connected properly 2 Replace the Problem solved Replace the temperature and printer controller humidity sensor Did board this fix the problem 993 CPU Error Replace the printer controller board Diagnostic Information 2 23 5055 01x 994 Density Sensor Error Step Questions Actions Yes No Are connectors CN406 and CN407 on the sensor board connected prope
150. ros componentes de substitui o As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante a desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Safety Information xi 5055 01x Informacio de Seguretat Aquest producte esta dissenyat comprovat i aprovat per tal d acomplir les estrictes normes de seguretat globals amb la utililitzaci de components espec fics de Lexmark Les caracter stiques de seguretat d algunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui El risc de xoc el ctric i de danys personals pot augmentar durant el proc s de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients xii Service Manual 5055 01x SER AR AE ARPA Lexmark 7 ffr FFARR MAREE WER WARE ALE EY LET BE A BEA GE ATT At SERS EA Lexmark MEA iz ARP d BY HEP BE EE RS A REH SEED RE FAA o ARP mm EDR ERR TERS ta AAS ERE ABE BMLIRS ARIS BDA BT TR FREE TU Ta TE re eal AFE ASS SA Lexmark TH 259 ASA
151. rvice Manual 5055 01x Fuser Unit By applying heat and pressure the image is melted and fused to the paper EN Thermistor 777 Temperature Fuser p ca Fuse 1 Re DEn vA Heater Temperature Backup Roller thermistor Fuse The upper and lower rollers are heated and pressure fitted A heater is positioned in the roller tube and a thermistor and thermostat remain in contact with the outside of the tube Separation fingers are attached near the upper roller to separate the paper from the roller Each thermistor sends the surface temperature of the roller to the printer controller The printer controller turns the heater on or off according to the voltage of each thermistor If the controller fails and the temperature of the roller exceeds specifications the temperature fuse TCO connected to each heater opens preventing overheating General Information 1 13 5055 01x Delivery After completing the fusing process paper is discharged from the printer The delivery sensor detects the paper condition and the FU FD deflector switches between the face up and face down paper delivery The paper from the fuser pulls down the sensing lever turning on the delivery sensor photo interrupter If the delivery unit remains on longer than specified the printer controller determines that the printer is jammed and the paper delivery flap lever switches to e
152. s neem ane dee we 3 2 Operator Panel BONGNS sc cade iu ua mi Rr Rx Ree ae 3 3 Printing the Menu Settings s ssiecime Rh eR RR deine 3 4 Operator Menu Disabled 2mm text mmm tnmen ene 3 4 Menu DOVerviOW uhcssemcicecscee rie oe done ces sus 3 4 piBgnosuc Mode cadis cas eme BE tuse sm ninku kiasia 3 6 Punt T85l8 ziczccezchReccc ee bec e RsGd operire de Re 3 8 Hardware T6SlS do nodcccwaceasiag spat ennmes samt asper ats 3 10 Device TVesis cdi allum E Se m mec Re bd meade eats 3 17 Diagnostics Printer Setup aeised me ERE Er De uL EET 3 20 D taulls a csse ni ede bok arcs ined UPC bs anand edis 3 20 Viewing and Resetting the Drum Counters 3 22 Diagnostics Error Log 22e se eR RSERRE x 3 25 iV Service Manual 5055 01x Repair Information cl cem orc ee erre RES 4 1 Service PrecaultiOrgz us sce cux mecum soe srren meee sme 4 1 Handling Printed Circuit Boards eee rans 4 2 Adjustients icsnseresdeccen essere Ete bee cee 4 3 High Capacity Paper Feed Timing Belt Adjustment 4 3 Removal ansam ees um Cade aa d fui SUL are ae ai 4 4 Cover Top Removal 25 x2 pecs een Ss Sere ee ey Rae bees 4 4 Operator Panel REMOVAl ssi cima sm t RR REESE ETE 4 4 Cover Froni Removal s bse ds epis ie Rag Ep dfe aod oad Gas 4 5 COVER Front LEM 1s rm reb E Roux N E pan 4 6 Cover Hear Hembval i quie ur i IR Xr eee ee eo SS 4 6 Cover Solenoid Removal nn ke cccccee reek decals eae E NES 4 7 Cover
153. s 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 Yellow Black Top Cover Switch 2 4 80 Service Manual 5055 01x HCPF 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 li m S N a SR A aes Tray Motor Repair Information 4 81 5055 01x HCPF Paper Level Sensor Removal 1 Remove the four screws from the transfer cover and remove the cover 2 Remove the two screws from the sensor and remove the cover 3 Remove the connector and screw from paper level sensor and remove the sensor Paper Lever Sensor Sensor Cover 4 82 Service Manual 5055 01x HCPF Power Supply Removal 1 2 3 4 Move the paper tray upward Disconnect the power cord Remove the front cover Remove the two screws from the power supply cover and remove the cover Remove the four screws from the power supply unit and remove the unit S DC DC Converter CR Remove the two screws from the DC DC converter and remove the converter Power Supply Cover Repair Information 4 83 5055 01x 4 84 Service Manual 5055 01x 5 Locations Covers Diagram Turn Guide Front Cover nner Cover
154. sation d autres pi ces de rechange Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Safety Information ix 5055 01x Norme di sicurezza Il prodotto stato progettato testato e approvato in conformit a severi standard di sicurezza e per l utilizzo con componenti Lexmark specifici Le caratteristiche di sicurezza di alcune parti non sempre sono di immediata comprensione Lexmark non responsabile per l utilizzo di parti di ricambio di altri produttori Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato Durante lo smontaggio e la manutenzione di questo prodotto il rischio di subire scosse elettriche e danni alla persona piu elevato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit g ltigen Sicherheitsanforderungen zu erf llen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht von Lexmark sind wird von Lexmark keinerlei Verantwor
155. specified device and call for service If the error cannot be reset go to Map 10 Unrecoverable Check Tray X or Duplex Connection Message on page 2 49 Clearing Job Accounting Stat The printer is deleting all job statistics stored on the hard disk Wait for the message to clear Diagnostic Information 2 25 5055 01x Message Close Side Door Meaning The printer side door is open Action Close the printer side door If the error cannot be reset go to Map 1 False Side Door Open Message on page 2 43 Close Top Door The printer top door is open Close the printer top door and front door If the error cannot be reset go to Map 2 False Close Top Door Message on page 2 43 Close Tray lt x gt Top Cover The high capacity feeder door is open Close the HCPF door and the top cover If the error cannot be reset go to Map 3 False Close Tray X Top Cover Message on page 2 44 Copying The printer is processing a copy job originating from the Optralmage scanner Wait for the message to clear Defragmenting The printer is defragmenting the flash memory to reclaim storage space occupied by deleted resources Wait for the message to clear Warning Do not turn the printer off while this message is displayed Delete All Jobs The printer is requesting confirmation to delete all held jobs
156. sure the correct voltage is present at the outlet 2 Power Cord Check the power cord for continuity 3 Fuse The power supply fuses may be blown Unplug the Switch machine and check fuse F2 on the power supply 1 Power Supply 1 for continuity If the fuse is good check the power switch connector for continuity 4 Power Supply 2 The power supply 2 may be defective Check the dc power of the power supply for the following pins CN102 pins 8 and 11 for 3 3 V CN103 pins 7 and 14 for 3 3 V CN105 pin 5 3 3 V CN102 pins 12 and 14 for 5 V CN103 pins 1 3 8 9 for 5 V CN104 pins 1 and 2 for 5 V CN104 pins 7 and 8 for 24 V CN105 pin 4 for 24 V CN106 pins 5 and 6 for 24 V Replace power supply 2 if necessary Diagnostic Information 2 65 5055 01x Marks on Paper Service Check If you have evenly spaced marks on the paper measure the distance between the marks and locate the symptom below Check the assembly for dirt or damage and clean as necessary Run a test print to verify the problem has been corrected The indicated assemblies are replaced by the customer at prescribed intervals If you remove the transfer belt do not turn it upside down Toner will fall from the waste toner box onto the transfer sheets and roller s inside the belt This causes lower transfer efficiency and washed out colors Distance between marks FRU SUPPLY ITEM 27 mm Absorpti
157. t is 99 999 The power indicator blinks indicating the memory test is in process The printer runs this test continually The test can be terminated by powering off the printer Each time the test finishes the screen is updated with the result If the test is successful the Pass Count increments by 1 If the test fails a failure message displays for approximately three seconds and the Fail Count increments by 1 Once the maximum pass count or fail count is reached the test stops and final test results display Diagnostic Aids 3 11 5055 01x ROM Memory Test The ROM Memory Test is used to check the validity of the RIP code and fonts When this test is selected from the operator panel the printer begins testing ROM memory and the following screen displays ROM Memory Test PAHHHHE F HHHHH Terminology P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 F represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail count is 99 999 The power indicator blinks indicating the memory test is in process The printer runs this test continually The test can be terminated by powering off the printer Each time the test finishes the screen is updated with the result If the test is successful the Pass Count increments by 1 If the test fails a failure messag
158. t unit 2 Remove the four connectors 3 Remove the three screws from the waste toner full sensor board Repair Information 4 35 5055 01x Density Sensor Removal Separation Fingers Removal Sensor Cleaner Removal 1 Open the top unit and remove the belt unit 2 Remove the three screws from the sensor bracket Separation Finger Screws b Density Sensor Sensor Cleaner 3 Remove the harness band and remove the two screws from the density sensor from the sensor bracket 4 Remove the three set screws from the sensor cleaner assembly from the sensor bracket 5 Remove the four separating finger screws from the fuser entrance guide 4 36 Service Manual 5055 01x 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 Note When replacing the board install the EPROM U5 of the former board to the new board Also when replacing the EPROM set the light intensity in the diagnostic mode and set the counter and printer alignment Repair Information 4 37 5055 01x High Voltage Power Supply Board HVU Removal 1 Open the top unit and remove the RIP cover RIP board RIP box electronic box and printer controller board 2 Remove the five screws from the printer controller board bracket 3 Remove the connectors and remove the 12 screws 4 Remove the high volt
159. talog 7 29 5055 01x Assembly 11 I F Controller Continued Sos S 7 30 Service Manual 5055 01x Asm Part index Number Units Description NS 56P9926 1 Software Optra Forms NS 56P9927 1 Software Optra Forms Director NS 56P9928 1 DIMM Lexmark Forms 4MB Flash NS 56P9929 1 DIMM Lexmark Forms 8MB Flash NS 56P9930 1 DIMM Lexmark Forms 16MB Flash NS 56P9932 1 Hard Disk Lexmark Forms 5 GB Parts Catalog 7 31 5055 01x Assembly 12 Fuser Unit 7 32 Service Manual 5055 01x Asm Part Index Number Units Description 12 1 56P9751 1 Fuser 120 V 1 56P9752 1 Fuser 230 V Parts Catalog 7 33 5055 01x Assembly 13 Cassette 7 34 Service Manual 5055 01x Asm Part Index Number 18 1 56P9500 Units Description Cassette Paper Feed 13 56P9756 14 11G0118 15 56P9762 16 11G0385 17 11G0120 Rack PF Cassette Pinion PF Cassette Plate Lower Sensor Actuator 1 2 56P9761 1 Pawl Rear 3 56P9754 1 Plate Right Rear Location 4 56P9755 1 Spring Location Plate 5 56P9753 1 Plate Left Rear Location 6 56P9763 2 Spring A Push Up 7 56P9764 2 Spring B Push Up 8 56P9757 1 Locator Front Side 9 56P9758 1 Pawl Front 10 56P9759 1 Lock A Side 11 11G0284 1 Spring Lock 12 56P9760 1 Lock B Side 2 1 1 3 1 Spring Tray Lock Parts Catalog 7 35 5055 01x Assembly 14 Expansion Fe
160. ted into any tray location except tray 1 Unit Missing units is either missing or print unit s If the incorrectly installed message cannot be reset go to Map 6 False lt Color gt Print Unit Missing Message on page 2 46 32 Unsupported The printer detects an Replace the cartridge lt color gt unsupported toner cartridge Cartridge 33 Tray lt x gt The optional heavy media tray Remove the heavy media tray from the invalid location 34 Short Paper The paper is too short Press Go to clear the message Make sure the paper size setting in the Paper Menu is correct for the size you are using Press Menu to open the Job Menu and cancel the current job 35 Res Save Off Deficient Memory The printer lacks the memory to enable Resource Save Press Go to disable Resource Save and continue printing Install additional memory 37 Insufficient Collation Area The printer memory does not have the free space necessary to collate the job Press Go to print the portion of the job already stored and begin collating the rest of the job Press Menu to open the Job Menu and cancel the current job 2 34 Service Manual 5055 01x Message 37 Insufficient Defrag Memory Meaning The printer cannot defragment flash memory Action Delete fonts macros and other data in printer memory Install additional printer memory 37 Insu
161. the fixed disk and the fixed disk board are correctly installed Run the Quick Disk Test on page 3 17 from the Device Test on the Diagnostic Menu when a problem is suspected either with the hard disk system board or with the hard disk Note The Quick Disk Test is a non destructive test and indicates Pass or Fail If the test fails replace the hard disk If a problem still exists replace the hard disk board Use the Disk Test Clean on page 3 18 to help restore the disk if it contains bad data and is unusable This test is divided into a cleaning and a verifying or testing section WARNING This can be a very lengthy test depending on the disk size This test leaves the hard disk unformatted The servicer or user must reformat the disk using the Format Disk Menu operation This is a destructive type of test All the data on the disk is destroyed and should not be performed on a known good disk Network Card Option Note The network is installed on the system board on network model printers Error Code 976 Network Card X X Network card 1 2 or 3 A 976 error code indicates an unrecoverable software error in network card x Verify that network card x is correctly installed in the socket on the interconnect board and is properly grounded If you find no problem contact your next level of support before replacing the network card 54 Network X Software Error This error displays when the RIP software detects that a n
162. the problem remains go to Black Line on page 2 74 Toner specks appear on the page E Y Replace the oil coating roll Toner colors the background of the page Ls Be sure the affected photodevelopers are completely installed in the printer The page has 100 coverage of one color Be sure the affected photodevelopers are completely installed in the printer Replace the photodevelopers If the page is black replace just the black photoconductor If the page is another color replace all three of the color photodevelopers If this does not fix the problem go to Black Print on page 2 74 2 70 Service Manual 5055 01x 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 N N L Remove the affected photodeveloper and gently shake it back and forth to distribute the toner evenly Reinsert the print unit and try printing the job again Replace the affected toner cartridge Replace the photodevelopers If the problem only occurs when printing black replace just the black photoconductor If the problem occurs when printing one of the colors replace all three of the color photodevelopers and the transfer belt If there still is a go to Uneven Printing on page 2 76 The page is blank Be sure the affected print unit is completely inst
163. thead uestions Step 2 Yes No Actions 1 Is fuse 6 on the Replace the Replace the printhead controller board 932 Cyan Printhead Error printhead control board open printhead control board cables and LED printhead Questions Ste Yes No p Actions 1 Is fuse 3 on the Replace the Replace the printhead controller board 2 10 Service Manual 5055 01x 933 Black Printhead Error board open board cables and LED printhead Questions Step Yes No Actions 1 Is fuse 4 on the Replace the Replace the printhead control printhead control printhead controller board 934 Color Drum Sensor Error 934 Service Drum Sensor Questions Step Yes No Actions 1 Is connector CN28 Go to step 2 Plug the connector connected properly in securely 2 Clean the color drum Problem solved Replace the color sensor LED Did this drum sensor fix the problem Go to step 3 3 Did replacing the Problem solved Replace the color drum sensor fix printer controller the problem board Diagnostic Information 2 11 5055 01x 935 Black Drum Sensor Error Questions Ste Yes No p Actions 1 Is connector CN27 Go to step 2 Plug the connector connected properly in securely 2 Clean the black Problem solved Replace the black drum sensor LED drum sensor Did th
164. ting it is the first digit to be changed To change the value press Menu until the desired value displays Press Select to move to the next digit The next digit 2 in this example blinks Continue modifying each digit using this method To skip a digit i e and keep it s current value press Select When Select is pressed after the final digit 7 in this example the new page count is stored in NVRAM Viewing the Permanent Page Count The permanent page count setting cannot be modified through the operator panel It can only be viewed using the Diagnostics menus When Permanent Page Count is selected the following screen displays Perm Page Count 1234567 Serial Number XXXXXXX Printer Serial Number This function displays the printer serial number Diagnostic Aids 3 23 5055 01x Setting Configuration ID The Configuration ID is used 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 When Configuration ID is selected from the PRINTER SETUP menu the current ID displays as follows Configuration ID 123456 The left most digit 1 in this example blinks indicating it is the first digit to be changed To change the val
165. to the printer controller board If the paper still does not feed go to the Paper Carrying Service Check on page 2 58 2 54 Service Manual 5055 01x Service Checks Drive 1 DC Motor Service Check FRU Action 1 DC Motor Drive Unit 1 Printer Controller Board If the motor does not attempt to turn and you receive a 910 error code replace the driver 1 dc motor Be sure the toner and photodeveloper units are not causing an overload on the dc motor If the motor turns but the paper carrying section of the machine does not rotate check the drive 1 unit gear train for damage Be sure the clutch on the gear train engages for color printing Replace the drive 1 unit if necessary If this does not correct the problem replace the printer controller board Drive 2 Stepper Motor Service Check FRU Action 1 Drive 2 Stepper Motor Be sure connector CN4 on the printer controller board is firmly connected If there still is a problem replace the drive 2 stepper motor Diagnostic Information 2 55 5055 01x Duplex Service Check FRU Action 1 Feed Roller Check for wear or damage to the feed roller belts Belts Replace as necessary 2 Duplex Be sure the stepper motor turns freely with no Stepper binding Motor Side Fence Check for wear or damage to the associated gears Stepper Motor Gears 3 Feed Roller Check for prop
166. top all activity The message Not Ready is then displayed until you press Go to continue printer activity For example if you need to load paper in a tray while a job is printing press Stop and wait for the printer motors to idle before removing the tray from the printer Reinsert the loaded tray and then press Go Diagnostic Aids 3 3 5055 01x Printing the Menu Settings 1 2 3 4 From the printer operator panel press Menu to enter the menus Continue to press and release Menu until you see TESTS MENU Press Select TESTS MENU is displayed on the first line and Print Menus is on the second line Press Select again to print the page The message Printing Menu Settings is displayed The printer returns to Ready status after the menu settings page prints Operator Menu Disabled If the operator has disabled the menu and you want to run operator print tests turn the machine off and then press Go and Stop as you turn the machine on Menu Overview SUPPLIES MENU Belt Block Photo Dev Coating Roll Color Photo Dev color Toner Fuser Replace Supplies UTILITIES MENU Color Samples Print Alignment Print Menus Print Net x Setup Print Fonts Print Directory Factory Defaults COLOR MENU Color Correction Manual Color Print Mode Toner Darkness Supplies Life Format Flash Defragment Flash Format Disk Job Acct Stat Hex Trace PAPER MENU FINISHING MENU USB MENU Paper Source Dup
167. tung oder Haftung f r dieses Produkt bernommen Die Wartungsinformationen f r dieses Produkt sind ausschlieBlich f r die Verwendung durch einen Wartungsfachmann bestimmt W hrend des Auseinandernehmens und der Wartung des Ger ts besteht ein zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung Das zust ndige Fachpersonal sollte entsprechende VorsichtsmaBnahmen treffen X Service Manual 5055 01x Pautas de Seguridad e Este producto se ha dise ado verificado y aprobado para cumplir los m s estrictos est ndares de seguridad global usando los componentes espec ficos de Lexmark Puede que las caracter sticas de seguridad de algunas piezas no sean siempre evidentes Lexmark no se hace responsable del uso de otras piezas de recambio La informaci n sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga el ctrica y de da os personales durante el desmontaje y la reparaci n de la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a e Este produto foi concebido testado e aprovado para satisfazer os padr es globais de seguran a na utiliza o de componentes espec ficos da Lexmark As fun es de seguran a de alguns dos componentes podem n o ser sempre bvias A Lexmark n o respons vel pela utiliza o de out
168. ue press Menu until the desired value displays Press Select to move to the next digit The next digit 2 in this example blinks Continue modifying each digit using this method To skip a digit i e and keep it s current value press Select When Select is pressed after the final digit 6 in this example the Configuration ID is validated If the ID is invalid then the Invalid ID displays momentarily on Line 2 before the ID re displays If the ID is valid it is stored in NVRAM and the printer automatically activates the new setting in normal mode If a Configuration ID has not been set then upon entry into diagnostics the Configuration ID setup is the only Diagnostic function displayed until a valid ID is entered 3 24 Service Manual 5055 01x 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 on the printer 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 Empty log entries are identified with an error number of 000 Occupied log entries contain the error number for the message displayed on the operator panel For example 925 is contained in the log when a 925 service error occurs If an error occurs after the log is full the oldest error in the log is disca
169. uffer The printer is flushing Wait for the message to corrupted print data and clear discarding the current print job Formatting Disk The printer is formatting the Wait for the message to yyy hard disk The second line clear shows percentage complete Formatting The printer is formatting flash Wait for the message to Flash memory clear Fuser The counter that tracks wear Press Go to continue Maintenance on the fuser has reached its printing limit f print quality is unacceptable replace the fuser Diagnostic Information 2 27 5055 01x Message Held Jobs May be Lost Meaning The printer memory is too full Action Press Go to clear the message The printer frees memory by deleting the oldest job and continues deleting jobs until there is enough memory Press Stop to clear the message without deleting jobs Press Menu to open the Job Menu and cancel the current job Infrared x An infrared interface is the active communication link Wait for the message to clear Insert Tray x The specified tray is either missing or not fully inserted Insert the specified tray If the error cannot be reset go to Paper Tray Missing Service Check on page 2 63 Install device or Cancel Job The printer is requesting a specified device be installed so it can print Turn the printer off install the specified device and restart t
170. y Stimulated Emission of Radiation Liquid Crystal Display Light Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Problem Isolation Charts Picture Element Power On Reset Power On Self Test Print Quality Enhancement Technology Raster Image Processor Read Only Storage Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current 1 4 Service Manual 5055 01x Processes and Configuration In this printer the toner of four colors magenta cyan yellow and black melts and deposits on paper dots which record color image information This printing process is called the electrophotography process Electrophotography Process In the electrophotography process electrically charged toner exposes develops transfers and is cleaned with an aluminum photosensitive drum A photoconductive layer forms on the surface of the drum when the drum is exposed to light The surface of the photosensitive drum is negatively charged forming the electrostatic image on the surface of the photosensitive drum This charge is directed to the photosensitive medium at a low voltage reducing the generation of ozone to a very low level When the drum surface is charged the image is recorded by irradiating light from the LED printhead forming the electrostatic image The LED printhead array along with the Selfoc lens array provide a single dot line of t
171. ys Serial X Wrap PHHHHHE FAH Terminology x indicates which serial port is being tested blank standard serial 1 optional serial port 1 P represents the number of times the memory test finishes successfully Initially 000000 displays for The maximum pass count is 999 999 F represents the number of times the memory test finishes with errors Initially 00000 displays for The maximum fail count is 99 999 The power indicator blinks indicating the memory test is in process The printer runs this test continually The test can be terminated by powering off the printer Each time the test finishes the screen is updated with the result If the test is successful the Pass Count increments by 1 If the test fails a failure message displays for approximately three seconds and the Fail Count increments by 1 Diagnostic Aids 3 15 5055 01x Once the maximum pass count or fail count is reached the test stops and final test results display Receive Status Interrupt Error Status Error Receive Data Interrupt Error Transmit Data Interrupt Error Transmit Empty Error Threshold Error Receive Data Ready Error Break Interrupt Error Framing Error Parity Error Overrun Error Data Error Data 232 Error Data 422 Error FIFO Error DSR Error DSR PIO Error DSR Interrupt Error CTS Error CTS PIO Error CTS Interrupt Error Once the maximum pass count or fail count is reached the test sto

Lexmark C910 5055-01x Printer User Manual

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