Lexmark 5056 - Manual

4-4 Service Manual 5056- XXX Adjustments High-capacity paper feed timing belt adjustment 1. Secure the bracket with the screw, as shown. 2. Attach the spring and washer to the bracket with the screw. 3. Adjust the screw to 6mm ±1mm. 4. Tighten the screw completely. 5. Adjust the timing belt on the r...

Repair information 4-5 5056- XXX Transfer belt If you replace the transfer belt, check the printer alignment ( X , Y , and Theta ), adjusted in diagnostic mode. LED printhead controller board or LED printhead If you replace the LED printhead controller board or LED printhead, check and adjust the fo...

4-6 Service Manual 5056- XXX Removals Cover, top removal 1. Open the top unit, and remove the photodevelopers and toner cartridges. Cover the photodevelopers to avoid damage from exposure to the light. 2. Remove the two silver screws, and remove the spacer. 3. Remove five black screws from the botto...

Repair information 4-7 5056- XXX Front door / operator panel removal Warning: If the operator panel and the RIP board are being replaced at the same time, replace the parts in the order described in steps a through d below to avoid damage to the machine. a. Replace the RIP card (this must be the fir...

4-8 Service Manual 5056- XXX 8. Remove six screws (C) that hold the operator panel to the front door. 9. Remove the operator panel from the door. Note: If the USB cable or the operator panel cable is being replaced, use the toroids from the old cables with the new cables. Cover, front left removal 1...

Repair information 4-9 5056- XXX Cover, rear removal 1. Open the top unit. 2. Remove the three silver screws from the rear cover, and then remove the cover. Cover, solenoid removal 1. Remove the screw from the solenoid cover. 2. Remove the solenoid cover. Cover, left side removal 1. Remove the upper...

4-10 Service Manual 5056- XXX Cover, right side removal 1. Open the top unit, and remove the front cover and upper cassette. 2. Remove the operator panel cable and the USB cable from the operator panel.(See “Front door / operator panel removal” .) 3. Remove the seven screws from the right side cover...

Repair information 4-11 5056- XXX Cover, RIP board removal Warning: If the operator panel and the RIP board are being replaced at the same time, replace the parts in this order to avoid damage to the machine. 1. Replace the RIP card first (this must be the first part replaced). 2. Restart the printe...

4-12 Service Manual 5056- XXX Tray, paper exit removal 1. Unlatch the hinge at the back side, then unlatch the hinge on the front side. 2. Remove the paper exit tray. Belt up/down clutch removal 1. Remove the RIP cover, electronic box, printer controller card, and HVPS board. 2. Unplug the belt up/d...

Repair information 4-13 5056- XXX Cassette guide removal 1. Remove the paper feed frame. 2. Remove the front cover, cassette, turn guide, right side cover, and paper feed frame. 3. Remove the screws from the cassette guide, and remove the guide. CK1 daughter board removal 1. Remove the front, right,...

4-14 Service Manual 5056- XXX Connector, duplex unit removal 1. Open the top unit and remove the upper cassette, left front cover, paper feed cover, left side cover, RIP cover, RIP board, RIP box, and the electronic box. Remove the turn guide, open the paper feed cover, and remove the duplex unit. R...

Repair information 4-15 5056- XXX Density sensor removal/Separation fingers removal/Sensor cleaner removal 1. Open the top unit and remove the belt unit. 2. Remove the three screws from the sensor bracket. 3. Remove the harness band and remove the two screws from the density sensor from the sensor b...

4-16 Service Manual 5056- XXX Electronic box removal 1. Open the top unit, and remove the back cover. 2. Remove the RIP board cover. 3. Remove the RIP board. 4. Remove the screws from the electronic box. 5. Disconnect all cables from the rear of the electronic box, and remove the box.

Repair information 4-17 5056- XXX Face up paper exit assembly removal 1. Open the top unit, and remove the upper cassette. Open the duplex cover, and remove the duplex unit. 2. Remove the left front cover, left side cover, and rear cover. 3. Remove the three screws from the face up delivery assembly...

4-18 Service Manual 5056- XXX Fuser removal 1. Open the top unit. 2. Pushing the front and back lock, hold the handle, and then raise and remove the fuser.

Repair information 4-19 5056- XXX Gear cover removal/Multipurpose feeder frame assembly 1. Open the top unit, and remove the upper cassette, front cover, multipurpose feeder, right side cover, and turn guide. 2. Remove the two screws from the gear cover, and remove the cover. 3. Remove the four scre...

4-20 Service Manual 5056- XXX High voltage power supply board (HVPS) removal Note: When removing the high voltage power supply, be careful to avoid damaging the secondary daughter card (Q906). If the daughter card gets damaged, a 925 service error will result. 1. Open the top unit, and remove the RI...

Repair information 4-21 5056- XXX 5. Disconnect the affected LED printhead connectors from the printhead controller board. Remove the screw from the ground wire located on the LED printhead. 6. Remove the LED printhead and the cables from the printer.When replacing the LED printhead, replace the cor...

4-22 Service Manual 5056- XXX Lock handle assembly removal 1. Open the top unit. 2. Turn the plastic latch on the front and rear sides 90°. 3. Remove the spring. 4. Remove the lock handle assembly.

Repair information 4-23 5056- XXX Main drive unit removal 1. Open the top unit, and remove the gear cover, upper cassette, left front cover, paper feed cover, RIP cover, RIP board, RIP box, electronic box, and rear cover. 2. Open the turn guide and paper feed cover, and remove the duplex unit. 3. Re...

Repair information 4-25 5056- XXX Main unit fan removal 1. Remove the left side cover, the solenoid cover, and the rear cover. 2. Remove the LVPS (low voltage power supply) 1. 3. Remove two screws from the main unit fan bracket. 4. Disconnect the fan power cable from CN6 on the CK2 daughter card boa...

4-26 Service Manual 5056- XXX Multipurpose feeder tray removal 1. Open the top unit, and remove the front cover, cassette feeder, turn guides and right side cover. 2. Open the multipurpose feeder and slide it toward the magnet in the direction of the arrow, removing it from the printer. Paper feed u...

4-28 Service Manual 5056- XXX Paper-feed rollers removal Paperpath maintenance A paper path maintenance kit can be used when a machine is experiencing misfeeds and jams after 200,000 pages. The order number for this kit is 40X1109. The kit is composed of the following parts: In addition to the paper...

Repair information 4-29 5056- XXX Paper carrying frame removal / roll removal 1. Open the top unit, and remove the upper cassette, front cover, turn guide, multipurpose feeder, right side cover, turn guide, OHP detection sensor (upper), multipurpose feeder frame, back cover, RIP cover, RIP board, RI...

4-30 Service Manual 5056- XXX Registration frame Registration clutch removal 1. Open the top unit, open the turn guide, open the paper feed cover, and pull out the duplex unit halfway. 2. Remove the two screws from the registration frame. 3. Remove the registration clutch. Note: When installing, set...

Repair information 4-31 5056- XXX Relay roller removal Note: This removal can be used for the expansion paper-feed unit relay roller removal as well. 1. Remove the paper feed unit from the machine. 2. Remove the e-clips and bushings from each end of the relay roller shaft. 3. Remove the five screws ...

4-32 Service Manual 5056- XXX Face down guide assembly removal 1. Remove the top cover. 2. Disconnect the connector, and remove the five screws and two snap bands from the face down guide assembly. 3. Remove the four screws from the face down cover and the face down guide assembly, and remove the as...

Repair information 4-35 5056- XXX 8. Remove the exit roller. Power supply 1 removal 1. Unplug the power cord from the printer. 2. Open the top unit, and remove the RIP cover, RIP board, RIP box, and electronic box. Remove the cassette, left front cover, and back cover. Remove the left side cover. 3....

4-36 Service Manual 5056- XXX Power supply 2 removal 1. Unplug the power cord from the printer. 2. Open the top unit, and remove the RIP cover, RIP board, RIP box, and electronic box. 3. Disconnect the connector, and remove the seven screws from power supply 2, and remove the power supply. Note: Aft...

Repair information 4-37 5056- XXX Power switch removal 1. Remove the upper cassette, left front cover, paper feed cover, and left side cover. 2. Unlock the power switch, and pull out the power switch. 3. Remove each terminal connected to the power switch. Note: When connecting, be careful to connect...

4-38 Service Manual 5056- XXX Printhead controller board removal 1. Remove the top cover, and then remove the 20 printhead controller board connectors. 2. Remove the six screws from the printhead controller board and remove the board. Note: When replacing the board, be sure to return the four EEPROM...

Repair information 4-39 5056- XXX Left slide rail removal 1. Remove the upper cassette. 2. Remove the screw from both left and right slide rails. RIP box removal 1. Remove the six screws from the RIP box. 2. Slightly lift and remove the RIP box.

4-40 Service Manual 5056- XXX Sensor board removal 1. Remove the transfer belt unit. 2. Remove the four connectors. 3. Remove the three screws from the waste toner full sensor board. Stay arm removal 1. Open the top unit, and remove the face down paper guide assembly. 2. Remove the yellow and black ...

4-42 Service Manual 5056- XXX Sub frame F1, sub frame F2 removal 1. Open the top unit. 2. Remove the two screws from the sub frames F1 and F2. Note: Spread a paper or cloth over the belt to protect the belt. Set the sub frame F to the position of the following colors, depending on the presence of th...

Repair information 4-43 5056- XXX Top unit removal 1. Open the top unit, and remove the top cover and face-down guide assembly. 2. Remove the screws, and remove the top unit. Transfer belt removal Transfer belt removal has been simplified with a redesign of the changing shaft linkage to the belt up ...

Repair information 4-47 5056- XXX Turn guide cover sensor removal 1. Remove the left rear, rear, and right covers. 2. Remove the print controller card and the HVPS. 3. Disconnect the sensor cable from CN10 on the CK1 daughter card board. 4. Remove two screws from the turn guide sensor assembly, and ...

Repair information 4-49 5056- XXX Expansion feeder removals Turn guide door removal 1. Open the turn guide door. 2. Pull the door hinge from the right turn guide bushing. 3. Pull the turn guide door clear of the expansion feeder. Expansion feeder controller board removal 1. Remove six screws from th...

4-50 Service Manual 5056- XXX Stepper motor removal 1. Remove the expansion feeder rear cover. 2. Disconnect the stepper motor power cable from the expansion feeder controller board. 3. Remove three screws from the stepper motor assembly (A). 4. Remove the stepper motor assembly from the expansion f...

Repair information 4-51 5056- XXX Paper feed assembly removal 1. Remove the rear cover. 2. Remove the cassette. 3. Remove the stepper motor assembly. 4. Disconnect the cables from connectors CN11, CN13, CN18 on the expansion feeder controller board. 5. Remove the screws (A) holding the paper feed ge...

4-52 Service Manual 5056- XXX Paper tray lift motor removal 1. Remove the rear cover. 2. Remove the cassette. 3. Disconnect the cable from the paper tray lift motor. 4. Remove three black screws from the paper tray lift motor (A). 5. Remove the paper tray lift motor. Expansion feeder turn guide door...

Repair information 4-53 5056- XXX Duplex removals Duplex unit separation removal 1. Remove the thumbscrews, C-clips, and screws as shown from both sides. 2. Remove the connectors, and separate the duplex frame from the duplex unit.

4-54 Service Manual 5056- XXX Duplex unit removal 1. Remove the four screws from the interface board, and remove the board. 2. Remove the two screws from the duplex connector, and remove the connector. Duplex timing belt removal 1. Remove the three C-clips from the three timing gears, and remove the...

Repair information 4-55 5056- XXX Duplex pressure roller and solenoid removal Remove the two screws securing the pressure roller solenoid assembly. Duplex feed roller and solenoid removal 1. Remove the two screws securing the feed roll solenoid assembly. 2. Remove the pressure roller and springs. 3....

4-56 Service Manual 5056- XXX Duplex side fence motor assembly/side fence removal 1. Remove the three screws, and remove the side fence motor assembly. 2. Remove the front and rear side fences. Note: When installing, spread the front and rear side fences to the sides, and install.

Repair information 4-57 5056- XXX Duplex paper carrying motor removal 1. Remove the gear cover. 2. Remove the screws from the duplex paper carrying motor, and remove the motor.

4-58 Service Manual 5056- XXX High-capacity feeder (HCF) removals HCF covers removal 1. Remove the two screws from the drive cover, and remove the cover. 2. Remove the front cover. 3. Remove the two screws from the right cover, and remove the cover. 4. Remove the top cover. 5. Remove the rear cover....

Repair information 4-59 5056- XXX HCF call roller, paper feed roller, reverse roller removal 1. Open the top cover on the tray. 2. Remove the two screws from the transfer cover, and remove the cover. 3. Remove the retaining rings on the rollers, and remove the rollers. HCF pickup solenoid removal 1....

4-60 Service Manual 5056- XXX HCF paper end sensor removal HCF paper size sensors (1, 2) removal 1. Cover the paper level sensor with your hand, and press the down button. The tray moves down. Lower the tray until the down sensor turns on. 2. Remove the front cover and transfer cover. 3. Remove the ...

Repair information 4-61 5056- XXX 8. Remove the top cover switches. HCF tray motor removal 1. Remove the rear cover and the drive cover. 2. Remove the two screws of the tray motor, and remove the motor. Top Cover Switch 1 Blue White Green Yellow Black Blue Top Cover Switch 2

4-62 Service Manual 5056- XXX HCF paper level sensor removal 1. Remove the four screws from the transfer cover, and remove the cover. 2. Remove the two screws from the sensor, and remove the cover. 3. Remove the connector and screw from paper level sensor, and remove the sensor. HCF power supply rem...

Repair information 4-63 5056- XXX Finisher removals Note: Check finisher alignment when moving or servicing the finisher. After moving or servicing the finisher, print some test pages to the finisher to ensure the vertical and horizontal alignment is correct. If the finisher is not properly aligned,...

4-64 Service Manual 5056- XXX 4. Remove the two screws from the top cover, and remove the cover. Finisher control board removal 1. Remove the external covers. 2. Disconnect all of the associated connectors. 3. Remove the four finisher control board mounting screws, and remove the board.

Repair information 4-65 5056- XXX Elevator motor removal 1. Disconnect the elevator motor connector. 2. Remove the two elevator motor bracket screws from the bracket. 3. Remove the elevator motor assembly. Feed motor assembly removal 1. Remove the finisher control board mounting bracket. 2. Loosen t...

4-66 Service Manual 5056- XXX Hole punch removal 1. Remove the external covers. 2. Remove the hole punch unit cables. 3. Remove the tension spring. 4. Remove the screw and E-ring from the tension bracket, and remove the bracket. Note: When installing the tension bracket, use the left side screw hole...

Repair information 4-67 5056- XXX Inverter paper exit discharge brush removal 1. Remove the external covers. 2. Remove the finisher control board. 3. Remove the upper left panel. 4. Remove the two discharge brush screws, and remove the brush. Inverter paper exit roller removal 1. Remove the front an...

4-68 Service Manual 5056- XXX 5. Remove the inverter idle gear. 6. Remove the inverter drive gear and bushing. 7. Remove the inverter paper exit roller. Jogging unit removal 1. Remove the dust box. 2. Remove the two screws, and remove the cover. 3. Disconnect the jogging motor connector. 4. Disconne...

Repair information 4-69 5056- XXX Path select gate removal 1. Remove the external covers. 2. Remove the two screws from the top cover, and remove the cover. 3. Remove the gate solenoid with mounting bracket. 4. Remove the straight paper exit sensor connector. 5. Remove the upper guide plate for the ...

4-70 Service Manual 5056- XXX Patting roller removal 1. Remove the front and rear covers. 2. Remove the finisher control board mounting bracket. 3. Remove the two screws from the upper left panel, and remove the panel. 4. Disconnect the sensor connector. 5. Remove the sensor harness from the harness...

4-72 Service Manual 5056- XXX Power supply removal 1. Unplug the power cord from the printer. 2. Remove the external covers. 3. Remove the lower left panel. 4. Remove the cable connector for the left panel. 5. Remove the four lower guide support plate screws, and remove the plate. 6. Remove the two ...

Repair information 4-73 5056- XXX Registration roller removal 1. Remove the hole punch unit. 2. Remove the registration roller clutch. 3. Remove the registration roller bushing. 4. Remove the registration roller. Registration roller clutch removal 1. Remove the harness from the clamp. 2. Remove the ...

4-74 Service Manual 5056- XXX Stack area discharge brush removal 1. Remove the dust box. 2. Remove the stack area discharge brushes. Staple unit removal 1. Remove the staple unit connector. 2. Pull outward on the staple cover, and remove the staple unit.

Repair information 4-75 5056- XXX Straight paper exit discharge brush removal 1. Remove the external covers. 2. Remove the two screws from the top cover, and remove the cover. 3. Remove the two lever screws, and remove the lever. 4. Remove the two discharge brush screws, and remove the brush. Straig...

Repair information 4-77 5056- XXX Timing belts 1 and 2 removal 1. Remove the finisher control board mounting bracket. 2. Remove the feed motor mounting bracket. 3. Remove the tension bracket mounting screw. 4. Remove the tension spring. 5. Remove the timing belt 1. 6. Loosen the tension bracket moun...

4-78 Service Manual 5056- XXX Tractor belt removal 1. Remove the external covers. 2. Remove the lower left panel. 3. Remove the cable connector of the left panel. 4. Remove the belt motor unit. 5. Remove the four lower guide support plate screws for the invert paper exit. 6. Remove the tension sprin...

Repair information 4-79 5056- XXX 8. Remove the tractor belts. Note: Install the belt so that the belt tooth just under the plastic hook aligns with the hook on the other belt. Tractor drive motor assembly removal 1. Remove the outer covers. 2. Remove the drive belt. 3. Remove the three screws, and ...