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Lexmark C792 Family, Service Manual

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Lexmark C792 Family Service Manual Download Page 613

Preventive maintenance 

6-1

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6.  Preventive maintenance

This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help 
prevent problems and maintain optimum performance.

Safety inspection guide

The purpose of this inspection guide is to aid you in identifying unsafe conditions.

If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you 
correct the hazard.

Check the following items:

•

Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply 

•

Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover 

•

Possible safety exposure from any non-Lexmark attachments

Individual maintenance part expected life

Lubrication specifications

Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than 
those specified can cause premature failure. Some unauthorized lubricants may chemically attack 
polycarbonate parts. 

The motor drive FRUs contain the proper lubricant in the FRU. Use only the lubricant included.

Lubrication for replacement motors

When you install a motor drive assembly, you must grease the posts and gears to ensure proper performance 
from the printer.

Description

Part number

Expected part life

CRU/FRU

2000-sheet high-capacity feeder pick

roll assembly

40X6275

250K

CRU

Fuser assembly, 115V

40X7100

150K

CRU

Fuser assembly, 220V

40X7101

150K

CRU

Fuser assembly, 100V

40X7102

150K

CRU

ITU assembly

40X7103

200K

CRU

MPF pick tires and wear parts

 40X7178

15K

FRU

Pick roll assembly

40X6104

250K

FRU

Summary of Contents for C792 Family

Page 1: ...2 2xx Table of Contents Start Diagnostics Safety and Notices Trademarks Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Revision May 14 2012 ...

Page 2: ...ication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe any existing intellectual property right m...

Page 3: ...ristics 1 10 Unacceptable paper 1 10 Selecting paper 1 11 Tools required for service 1 12 Acronyms 1 13 Diagnostic information 2 1 Troubleshooting map 2 1 Error code divisions 2 2 Power on Self Test POST sequence 2 2 Paper jams 2 3 Understanding jam numbers and locations 2 3 200 paper jam 2 4 201 paper jam 2 7 202 203 paper jams 2 9 230 239 paper jams 2 12 24x paper jam 2 14 250 paper jam 2 20 Out...

Page 4: ... 68 121 xx Fuser error service check 2 70 125 xx 145 xx ITU error service check 2 72 126 xx LVPS error service check 2 73 133 xx Cartridge sensor error service check 2 74 141 xx Black cartridge motor error service check 2 80 142 xx Cyan cartridge motor error service check 2 81 143 xx Magenta cartridge motor error service check 2 83 144 xx Yellow cartridge motor error service check 2 84 146 xx Auto...

Page 5: ...8 16 MPF paper out sensor error service check 2 135 938 18 Waste toner sensor error service check 2 136 938 19 Waste toner full sensor error service check 2 137 938 27 938 29 938 30 Weather station error service check 2 138 938 28 Remote weather station error service check 2 139 950 00 950 29 EPROM mismatch failure 2 140 956 02 Processor fan failure service check 2 141 990 xx POST error service ch...

Page 6: ... TESTS 3 14 Panel Test 3 14 Button Test 3 14 DRAM Test 3 14 Serial Wrap Test 3 15 USB HS Test Mode 3 16 Beacons Test 3 16 DUPLEX TESTS 3 16 Duplex Quick Test 3 16 Duplex Top Margin Offset 3 16 INPUT TRAY TESTS 3 17 Feed Test 3 17 Sensor Test 3 17 OUTPUT BIN TESTS 3 18 Feed Test 3 18 Feed to All Bins 3 18 Sensor Test 3 18 Diverter Test 3 19 Mechanical Test 3 19 FINISHER TESTS 3 19 Staple Test 3 19 ...

Page 7: ...8 Factory Defaults 3 28 Energy Conserve 3 28 Color Adjustment 3 28 Auto Align Adj 3 29 Color Alignment 3 29 Motor Calibration 3 29 Paper Prompts 3 29 Envelope Prompts 3 29 Action for Prompts 3 29 Jobs On Disk 3 29 Disk Encryption 3 29 Wipe Disk 3 30 Font Sharpening 3 30 Require Standby 3 30 UI Automation 3 30 Key Repeat Initial Delay 3 30 Key Repeat Rate 3 30 Clear Custom Status 3 30 USB Speed 3 3...

Page 8: ...m board shield removal 4 27 Top cap cover removal 4 29 Top cover removal 4 30 Waste toner left cover removal 4 34 Waste toner sensor cover removal 4 35 Base printer removals 4 36 ACM bias spring removal 4 36 Bin full flag removal 4 37 Bin full sensor removal 4 38 Cartridge blower assembly removal 4 39 Cartridge contact block assembly removal 4 42 Cartridge memory block removal 4 44 Cartridge meter...

Page 9: ...ligning the printhead 4 125 Aligning the printhead 4 129 Dual diode alignment 4 129 Registration black 4 130 Color alignment cyan yellow and magenta 4 131 Redrive gears removal 4 134 Redrive motor removal 4 135 Sensor D1 D2 and fuser bubble removal 4 137 Sensor input S1 narrow media near narrow media removal 4 138 Speaker removal 4 139 Staging deflector assembly removal 4 140 Staging paper path re...

Page 10: ...city feeder pick roll assembly removal 4 224 2000 sheet high capacity feeder rear cover removal 4 228 2000 sheet high capacity feeder right anti tip latch assembly removal 4 230 2000 sheet high capacity feeder right side cover removal 4 231 Output option removals 4 234 5 bin mailbox 4 234 5 bin mailbox access door removal 4 234 5 bin mailbox backup roll plate assembly removal 4 235 5 bin mailbox b...

Page 11: ... stacker tamper drive motor assembly removal 4 278 Finisher or stacker tamper recoil spring removal 4 279 Finisher or stacker top cover removal 4 280 Finisher stapler unit assembly removal 4 281 Horizontal transport unit HTU and Holepunch unit 4 282 HTU access door removal 4 282 HTU access door paper jam beacon with cover and cable removal 4 283 HTU access door rollers removal 4 284 HTU bin divert...

Page 12: ... 5 2 System board 5 2 550 sheet tray option system card 5 11 2000 sheet high capacity feeder option system card 5 14 UICC card 5 17 5 bin mailbox system card 5 18 Finisher Stacker system card 5 20 HTU system card 5 20 Preventive maintenance 6 1 Safety inspection guide 6 1 Individual maintenance part expected life 6 1 Lubrication specifications 6 1 Lubrication for replacement motors 6 1 Redrive par...

Page 13: ...th hole punch left interior 7 50 Assembly 23 Miscellaneous 7 52 Assembly 24 Internal options 7 54 Cable and thermistor location table 7 55 Screw and retainer identification table 7 59 Appendix A Print samples A 1 Print tests A 1 Print Quality Pages Title page total of five 1 Print Quality Pages Page 1 total of five 2 Print Quality Pages Page 2 total of five 3 Print Quality Pages Page 3 total of fi...

Page 14: ...xiv Service Manual 5062 Go Back Previous Next ...

Page 15: ...ahlt Das Lasersystem und der Drucker sind so konzipiert daß im Normalbetrieb bei der Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung die Klasse I übersteigen würde Menschen keinesfalls erreicht Avis relatif à l utilisation de laser Pour les Etats Unis cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produ...

Page 16: ...mente a impressora contém um produto laser da Classe IIIb 3b designado laser de arseneto de potássio de 5 milliwatts operando numa faixa de comprimento de onda entre 770 e 795 nanómetros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal a manutenção feita pelo ut...

Page 17: ...kitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle Älä katso säteeseen VARNING Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad Betrakta ej strålen Laser notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J för laserprodukter av Klass I 1 I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven ...

Page 18: ...its d IEC 60825 1 Els productes làser de classe I no es consideren perillosos Aquesta impressora conté un làser de classe IIIb 3b d arseniür de gal li nominalment de 5 mil liwats i funciona a la regió de longitud d ona de 770 795 nanòmetres El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d un nivell de classe I durant una opera...

Page 19: ...Notices and safety information xix 5062 Go Back Previous Next ...

Page 20: ...xx Service Manual 5062 Go Back Previous Next ...

Page 21: ... Les consignes d entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vou...

Page 22: ...ación sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo con...

Page 23: ...d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu t...

Page 24: ... user and service menus and the basic theory of printer operation 4 Repair information provides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and pa...

Page 25: ...ge 7 45 2011 10 11 Updated the action for the 938 15 Electronics Hardware Error on page 2 62 Updated step 4 of Bin full sensor service check on page 2 144 Changed the expected part life for the MPF pick tires and wear parts under Individual maintenance part expected life on page 6 1 2011 9 20 Updated the margin descriptions for step 2 in setting the REGISTRATION on page 3 10 Added the Change histo...

Page 26: ...atements CAUTION A caution identifies something that might cause a servicer harm CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface CAUTION This type of ca...

Page 27: ...s a wide variety of paper sizes and has a standard multipurpose feeder that makes it easy to print on envelopes transparencies labels card stock and non standard size paper You can add optional inputs to the base printer which can increase the printer paper capacity to 3750 sheets Models The Lexmark C792 5062 2xx laser printer is available in the following models Maintenance approach The diagnosti...

Page 28: ... four 550 sheet trays or one 2000 sheet tray with up to two 550 sheet trays CAUTION TIPPING HAZARD Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a high capacity input tray a duplex unit and an input option or more than one input option If you purchased a multifunction printer MFP that scans copies and fa...

Page 29: ...ly Lexmark C792 paper handling options These options are not compatible with any other Lexmark printer Some of the following options are not available in every country or region Available internal options Memory cards Printer memory Flash memory Fonts 1 Horizontal transport unit HTU redrive 2 StapleSmart finisher or 5 bin mailbox mailbox pictured 2 1 ...

Page 30: ...ations Power specifications Average nominal power requirements for the base printer configuration Power levels are shown in watts Maximum current shown in amp ergs Notes Using a power converter or inverter is not recommended The C792de C792dte and C792dhe are ENERGY STAR Qualified All models ship with Sleep Mode set to On Electrical specifications Low voltage models 100 to 127 V ac at 50 to 60 her...

Page 31: ... 8 mm 12 in Allow additional clearance around the printer for adding options such as additional input drawers high capacity output stacker banner tray StapleSmart finisher or 5 bin mailbox Status 1 meter average sound pressure dBA Declared sound power level Bels Idle Standby 29 dBA 4 3 Bels Simplex printing Mono 52 dBA 6 6 Bels Simplex printing Color 53 dBA 6 7 Bels Duplex printing Mono 52 dBA 6 7...

Page 32: ...the host USB serial parallel network Host system and application Page complexity and content Printer options installed or selected Available printer memory Media size and type Resolution Processor 1 2 GHZ Power PC processor Time to first print All first copy times are measured for 600 image quality simplex printing on letter size paper The test job consists of the character A followed by a form fe...

Page 33: ...0 1 in Letter 216 x 279 mm 8 5 x 11 in Legal 216 x 356 mm 8 5 x14 in Executive1 184 x 267 mm 7 3 x 10 5 in Oficio 216 x340 mm 8 5 x 13 4 in Folio 216 x 330 mm 8 5 x 13 in Statement1 140 x 216 mm 5 5 x8 5 in Universal1 Note Turn size sensing off to support universal paper sizes that are close to standard sizes Note When the Horizontal Transport Unit HTU is installed the maximum supported length is ...

Page 34: ... mm 8 5 x 14 in unless the size is specified by the software application Paper type 550 sheet trays standard or optional Optional 2000 sheet feeder Multipurpose feeder Duplex unit Paper Plain Bond Colored Custom Letterhead Light Heavy Preprinted Rough Cotton Recycled Card stock x Transparencies1 Labels2 Paper Vinyl x Envelopes3 1 Do not use inkjet or 3M CG3710 transparencies 2 Paper labels are sup...

Page 35: ...ble print quality We recommend Lexmark part number 12A5950 letter size glossy paper and Lexmark part number 12A5951 A4 size glossy paper Always print several samples before buying large quantities of any type of media When choosing any media consider the weight fiber content and color The Laser printing process heats paper to high temperatures of 180 C 356 F for non MICR applications Use only pape...

Page 36: ...e paper affects both print quality and the ability of the printer to feed the paper properly Leave the paper in its original wrapper until it is time to use it This limits the exposure of the paper to moisture changes that can degrade its performance Condition paper while it is still in the original wrapper To condition it store it in the same environment as the printer for 24 to 48 hours before p...

Page 37: ...rs Recycled papers that fail EN12281 2002 European Paper having a weight less than 60 g m2 16 lb Multiple part forms or documents Selecting paper Proper paper loading helps prevent jams and ensures trouble free printing To help avoid jams or poor print quality Always use new undamaged paper Before loading paper know the recommended print side of the paper This information is usually indicated on t...

Page 38: ...r 1 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic 2 Phillips screwdriver magnetic short blade Needlenose pliers Diagonal side cutters Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Twinax serial debug cable 1381963 Coax serial debug cable 1381964 ...

Page 39: ...sfer Unit K Black LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply M Magenta MROM Masked Read Only Memory MS Microswitch NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer OPT Optical Sensor PC Photoconductor pel pixel Picture element POR Power On Reset POST Power On Self Test PSD...

Page 40: ...1 14 Service Manual 5062 Go Back Previous Next ...

Page 41: ... 200 299 400 499 Paper jams on page 2 3 User messages text 0 99 User messages on page 2 51 Error codes 100 199 900 999 Service errors on page 2 60 Other symptoms Symptoms on page 2 66 Service checks Service checks on page 2 67 CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic card or assembly for personal safety and to prevent damage ...

Page 42: ...ay if the front access door is open or the print cartridge is missing Any cartridge errors such as Defective Cartridge or Missing Cartridge 7 Ready appears on the display 8 The main drive motor turns on 9 The EP drive assembly drives the developer shaft located in the print cartridge 10 The exit rollers turn 11 The printer may begin calibration Range Description Go to page Text prompts User prompt...

Page 43: ...per jam message you must clear all jammed paper from the paper path Area Jam number What to do See 1 200 203 230 239 Open the side door and then remove the jammed paper 200 paper jam on page 2 4 201 paper jam on page 2 7 202 203 paper jams on page 2 9 230 239 paper jams on page 2 12 2 24x Open the side door of the specified tray and then remove the jammed paper 24x paper jam on page 2 14 6 5 4 1 2...

Page 44: ...er path that might cause the paper to jam 2 If clearing a paper jam does not fix the problem go to Input S1 narrow media and near narrow media sensor service check on page 2 153 200 02 Paper hit the input sensor too soon Possible causes Damaged input sensor flag or input sensor Loose input sensor 1 Clear away anything in the paper path that might cause the paper to jam 2 The input sensor may not b...

Page 45: ... 3 If clearing a paper jam does not fix the problem go to 147 xx Staging motor error service check on page 2 87 200 31 Near narrow media sensor is made when the printer tries to print from an idle state Possible causes Paper jam leaving paper over the sensor Defective near narrow media sensor Faulty system board 1 Clear away anything in the paper path that might cause the paper to jam 2 If clearin...

Page 46: ...vice check on page 2 153 200 42 Narrow media sensor is made early Possible causes Incorrect paper settings Defective narrow media sensor 1 Clear away anything in the paper path that might cause the paper to jam 2 Be sure the paper settings match the media 3 If clearing a paper jam does not fix the problem go to 200 42 Paper Jam error service check on page 2 102 200 43 Narrow media sensor is never ...

Page 47: ...ring a paper jam does not fix the problem go to Input S1 narrow media and near narrow media sensor service check on page 2 153 Error code Description Action 201 01 Bubble sensor active when printer powers up or a cover is closed Possible causes Paper jam leaving paper over the sensor Damaged bubble sensor Damaged fuser autoconnect Faulty fuser DC cable connection Faulty fuser Faulty system board 1...

Page 48: ... on page 2 70 201 05 201 07 201 08 Bubble sensor is never made or is made late See 201 03 on page 2 8 201 42 A narrow banner media error has occurred 1 Clear away anything in the paper path that might cause the paper to jam 2 If clearing a paper jam does not fix the problem go to Input S1 narrow media and near narrow media sensor service check on page 2 153 201 51 Bubble sensor active when printer...

Page 49: ...e fuser access door 3 Firmly grasp the jammed paper on each side and then gently pull it out Note Make sure all paper fragments are removed 4 Close the door 5 From the operator panel touch Continue jam cleared Paper jam under the fuser 1 Open the left access door 2 If the paper is not visible then remove the fuser unit 3 Firmly grasp the jammed paper on each side and then gently pull it out Note M...

Page 50: ... 04 Exit sensor broke early Possible causes Damaged paper exit sensor or paper exit sensor flag Faulty fuser Faulty system board The fuser exit sensor may not be functioning properly Go to 121 xx Fuser error service check on page 2 70 202 05 202 07 Exit sensor never broke Possible causes Damaged paper exit sensor or paper exit sensor flag Faulty fuser Faulty system board Faulty output bin flag 1 C...

Page 51: ...ssible causes Faulty cable connector Faulty fuser motor Faulty system board 1 Clear away anything in the paper path that might cause the paper to jam 2 If clearing a paper jam does not fix the problem go to 120 xx Motor fuser error service check on page 2 68 202 51 Exit sensor is made when the printer tries to print from an idle state Fuser past life See 202 01 on page 2 10 202 52 Exit sensor is m...

Page 52: ... to jam 2 Be sure the paper settings match the media used 3 Go to Redrive bubble sensor service check on page 2 165 203 05 203 07 Redrive bubble sensor does not break or breaks late Possible causes Incorrect paper settings Redrive bubble sensor failure 1 Clear away anything in the paper path that might cause the paper to jam 2 Be sure the paper settings match the media used 3 Go to Redrive bubble ...

Page 53: ...sensor may not be functioning properly Go to D1 and D2 sensor service check on page 2 147 231 05 231 07 D1 sensor never broke Possible causes Damaged D1 sensor Faulty fuser Faulty system board 1 Check for anything in the paper path that might cause the paper to jam 2 If clearing the jam does not solve the problem go to D1 and D2 sensor service check on page 2 147 231 08 D1 sensor is never made See...

Page 54: ... door 4 From the operator panel touch Continue jam cleared 232 04 D2 sensor broke early Possible causes Damaged D2 sensor Faulty fuser Faulty system board The D2 sensor may not be functioning properly Go to D1 and D2 sensor service check on page 2 147 232 05 232 07 D2 sensor never broke Possible causes Damaged D2 sensor Faulty fuser Faulty system board 1 Check for anything in the paper path that m...

Page 55: ...3 05 244 05 245 05 Paper jam 550 sheet 2000 sheet input option service check on page 2 110 241 04 S1sensor flag broke early Possible cause Incorrect paper settings Defective S1 sensor Faulty system board 1 Clear away anything in the paper path that might cause the paper to jam 2 Be sure the paper settings match the media 3 Go to Input S1 narrow media and near narrow media sensor service check on p...

Page 56: ...lly open Drive assembly failure 1 Remove anything in the paper path 2 Flex the media and stack it flat in the tray 3 Check if the jam clearance cover can close properly 4 If problem persists go to 241 03 242 03 243 03 244 03 242 05 243 05 244 05 245 05 Paper jam 550 sheet 2000 sheet input option service check on page 2 110 242 05 While feeding from tray 2 the paper took a long time to clear the pa...

Page 57: ...241 03 242 03 243 03 244 03 242 05 243 05 244 05 245 05 Paper jam 550 sheet 2000 sheet input option service check on page 2 110 243 05 While feeding from tray 3 the paper took a long time to clear the pass thru sensor Possible causes Incorrect paper size Incorrect paper guide setting Obstruction on the paper path Drive assembly failure Paper pick mechanism failure System board failure Obstructed p...

Page 58: ...03 242 03 243 03 244 03 242 05 243 05 244 05 245 05 Paper jam 550 sheet 2000 sheet input option service check on page 2 110 244 05 While feeding from tray 4 the paper took a long time to clear the pass thru sensor Possible causes Incorrect paper size Incorrect paper guide setting Obstruction on the paper path Drive assembly failure Paper pick mechanism failure System board failure Obstructed pass ...

Page 59: ...e setting Obstruction on the paper path Drive assembly failure Paper pick mechanism failure System board failure Obstructed pass thru sensor Pick rolls failure 1 Clear the paper path 2 Make sure the paper setting match the media 3 Check if the pick roll are worn out 4 If problem persists go to 241 03 242 03 243 03 244 03 242 05 243 05 244 05 245 05 Paper jam 550 sheet 2000 sheet input option servi...

Page 60: ...e MPF Possible causes Improper paper loading Damaged paper S1sensor Faulty system board 1 Clear away anything in the paper path that might cause the paper to jam 2 The S1 sensor may not be functioning properly Go to Input S1 narrow media and near narrow media sensor service check on page 2 153 250 05 S1 sensor never broke Possible causes Damaged S1sensor Faulty system board 1 Check for anything in...

Page 61: ...ght cause the paper to jam 2 Be sure the paper settings match the media 3 Go to 401 xx HTU input sensor error service check on page 2 117 401 05 401 07 HTU input sensor breaks late or never breaks paper jam Possible cause Incorrect paper settings Defective HTU input sensor 1 Clear away anything in the paper path that might cause the paper to jam 2 Be sure the paper settings match the media 3 Go to...

Page 62: ...r second removal on page 4 324 to access the sensor 403 03 403 08 HTU second sensor is never made or is made late Possible cause Faulty HTU second sensor 1 Clear away anything in the paper path that might cause the paper to jam 2 If clearing a paper jam does not fix the problem go to 403 xx HTU second sensor error service check on page 2 119 403 04 HTU second sensor early leaving paper jam Possibl...

Page 63: ... sensor early leaving paper jam Possible cause Incorrect paper settings Defective 5 bin mailbox input sensor 1 Clear away anything in the paper path that might cause the paper to jam 2 Be sure the paper settings match the media 3 Go to 431 xx 5 bin mailbox input sensor error service check on page 2 121 431 05 431 07 5 bin mailbox input sensor breaks late or never breaks paper jam Possible cause In...

Page 64: ...r Stacker transport motor encoder not detected The transport motor encoder detection is lost during normal operation 1 Turn the machine off on 2 If the problem persists go to 450 20 450 21 450 22 450 23 450 32 Finisher Stacker main motor error service check on page 2 125 450 21 Finisher Stacker main motor stalled 1 Turn the machine off on 2 If the problem persists go to 450 20 450 21 450 22 450 23...

Page 65: ...rror service check on page 2 126 451 02 Finisher Stacker sensor pass thru early arrival paper jam Possible cause Loose Finisher Stacker sensor pass thru 1 POR the machine 2 Check if the Finisher Stacker sensor pass thru is damage or loose See Finisher or stacker sensor pass thru removal on page 4 275 451 03 451 08 Finisher Stacker sensor pass thru never made or made late jam Go to 451 xx Finisher ...

Page 66: ... output option controller card 2 Check the tamper drive belt for damage and replace if needed 3 Replace the right tamper motor assembly See Finisher or stacker tamper drive motor assembly removal on page 4 278 4 Replace the sensor tamper HP See Finisher or stacker sensor tamper HP left and right removal on page 4 276 5 Replace the output option if problem remains 454 31 Finisher Stacker right tamp...

Page 67: ...sembly removal on page 4 281 456 01 Finisher stapler home sensor is made when the printer powers up 1 Clear away anything in the paper path that might cause the paper to jam 2 If clearing a paper jam does not fix the problem go to 456 01 456 08 Finisher stapler home sensor error service check on page 2 127 456 02 Finisher stapler home sensor early arrival paper jam Possible cause Loose Finisher st...

Page 68: ...tapler motor is not defined A software failure has occurred with the output option 1 Turn the machine off on 2 If the problem persists replace the stapler unit See Finisher stapler unit assembly removal on page 4 281 458 03 458 08 Finisher Stacker paddle home position jam The sensor paddle HP does not detect that the paddle is operating 1 Check all the connections on the output option controller c...

Page 69: ...he paper path that might cause the paper to jam 2 If clearing a paper jam does not fix the problem go to 461 01 461 08 Hole punch sensor error service check on page 2 130 461 04 Hole punch sensor early leaving paper jam Possible cause Incorrect paper settings Defective hole punch sensor 1 Clear away anything in the paper path that might cause the paper to jam 2 Be sure the paper settings match the...

Page 70: ...ge Replace if damaged 5 If paper other than 20 lb plain letter A4 paper is being used load 20 lb plain letter A4 and print the Print Quality pages to see if the problem remains Use Tray 1 to test print quality problems 6 Print the Print Quality Pages and then look for variations in the print from what is expected An incorrect printer driver for the installed software can cause problems Incorrect c...

Page 71: ...e paper path RECALIBRATE THE PRINTER Perform color adjust from the operator panel Quality menu CHECK THE SOFTWARE PROGRAM OR APPLICATION The software program or application may have specified an off white background Print is too light Go to Print is too light on page 2 41 Random marks Go to Random marks on page 2 42 Repeating defects Go to Repeating defects on page 2 43 Shadow images Go to Shadow ...

Page 72: ...embly removal on page 4 80 Is the problem found Replace the ITU block assembly Go to step 3 3 Reseat the JHVPS1 connector on the system board Does this fix the problem Problem solved Go to step 4 4 Replace the HVPS See High voltage power supply HVPS board removal on page 4 71 Does this fix the problem Problem solved Go to step 5 5 Clean the printhead Does this fix the problem Problem solved Replac...

Page 73: ... the print cartridge of the color that is not printing Additional checks blank page Step Questions actions Yes No 1 Are all the packing material for the cartridge in question removed Go to step 2 Remove the packing material 2 Replace the cartridge for the color in question Does this fix the problem Problem solved Go to step 3 3 Check the high voltage contact from the HVPS to the photoconductor cha...

Page 74: ... print can be caused by incorrect feeding from one of the input paper sources paper trays or duplex paper path CHECK THE HIGH VOLTAGE CONTACTS Check the high voltage spring contacts to ensure they are not bent corroded or damaged Replace as necessary Characters have jagged or uneven edges If you are using downloaded fonts verify that the fonts are supported by the printer the host computer and the...

Page 75: ...E PRINTER QUALITY MENU REMOVE AND REINSTALL THE PRINT CARTRIDGE ADJUST THE COLOR ALIGNMENT FROM THE CONFIGURATION MENU 1 Enter the Configuration menu Turn the printer off hold down 2 and 6 while turning the printer back on and release the buttons when the splash screen appears 2 Touch Color Alignment Print Alignment Page The color alignment pages print 3 Touch Color Alignment 4 On the printed alig...

Page 76: ...ective transfer belt For more information see the instruction sheet that came with the replacement part Horizontal lines Try one or more of the following SELECT ANOTHER TRAY OR FEEDER From the operator panel Paper Menu select Default Source For Windows users select the paper source from Print Properties For Macintosh users select the paper source from the Print dialog and pop up menus MAKE SURE TH...

Page 77: ...oute for contamination or obstacles Are there obstacles in the route Go to step 3 Remove obstacles or contamination 3 Check the print cartridge for proper installation Is the above component properly installed Go to step 4 Inspect clean and reinstall or replace the print cartridge 4 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and contamina...

Page 78: ...r 5 Re print the defective image Does the error continue Go to step 3 Problem solved 3 1 Check the media condition 2 Load new dry recommended media 3 Re print the defective image Does the error continue Go to step 4 Problem solved 4 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and contamination Go to step 5 Replace the ITU assembly Go to IT...

Page 79: ...GS Make sure the paper type and weight settings match the paper loaded in the tray 1 From the printer Paper menu check the Paper Type and Paper Weight settings 2 Before sending the job to print specify the correct type settings from the computer For Windows users specify the setting from Print Properties For Macintosh users specify the setting from the Print dialog LOAD PAPER FROM A FRESH PACKAGE ...

Page 80: ...o print specify the correct type settings from the computer For Windows users specify the setting from Print Properties For Macintosh users specify the setting from the Print dialog LOAD STANDARD PAPER WITHOUT TEXTURED OR ROUGH FINISHES MAKE SURE THERE IS NO DEFECTIVE PRINT CARTRIDGE Replace the worn or defective print cartridge MAKE SURE THE TRANSFER BELT IS NOT DEFECTIVE Replace the defective tr...

Page 81: ... the paper type setting matches the paper loaded in the tray 1 From the operator panel Paper menu check the Paper Type setting 2 Before sending the job to print specify the correct type setting from the computer For Windows users specify the type from Print Properties For Macintosh users specify the type from the Print dialog MAKE SURE THERE IS NO DEFECTIVE PRINT CARTRIDGE Replace the defective pr...

Page 82: ... photoconductor drum Doing so may affect the print quality of future print jobs 2 Firmly shake the cartridge side to side and front to back several times to redistribute the toner 3 Reinsert the print cartridge Note If print quality does not improve replace the print cartridge of the color that is not printing MAKE SURE THERE IS NO DEFECTIVE PRINT CARTRIDGE Replace the defective print cartridge Ra...

Page 83: ...o the corresponding measurement in the chart Using the charts Measure repeating horizontal lines from the reference lines at the top to determine what may have caused the lines to form in that pattern Be sure to use portrait orientation for the test file Distance between defects Part to replace 37 7 mm 3 71 in 41 6 mm 1 64 in 42 7 mm 1 68 in 94 2 mm 3 71 in Print cartridge 95 mm 3 74 in 146 7 mm 5...

Page 84: ...rtridges or whichever color has the shadow images 1 Remove the print cartridge Warning Be careful not to touch the photoconductor drum Doing so may affect the print quality of future print jobs 2 Firmly shake the cartridge side to side and front to back several times to redistribute the toner 3 Reinsert the print cartridge Note If print quality does not improve replace the print cartridge of the c...

Page 85: ...the black line to find L1 L2 T1 T2 R1 R2 B1 and B2 as shown below 2 Determine if the printer meets the skew specifications based on the values listed on the table Skew Specification L2 L1 R2 R1 T2 T1 B2 B1 Letter 1 4 mm 1 4 mm 1 mm 1 mm A4 1 5 mm 1 5 mm Legal 1 8 mm 1 8 mm Leading edge Trailing edge T1 L1 T2 R1 B2 R2 B1 L2 ...

Page 86: ... Re print the defective image Does the error continue Go to step 3 Problem solved 3 Check for obstructions in the area of the media feed units Are the media feed unit assemblies free from any obstructions Go to step 4 Remove obstructions 4 Check the ITU assembly for contamination and wear Is the above component free of excess wear and contamination Go to step 5 Replace ITU assembly Go to ITU assem...

Page 87: ... No 1 Replace the print cartridge for the color in question Does this fix the problem Problem solved Go to step 2 2 Check the high voltage contact from the HVPS to the cartridge See Cartridge contact block assembly removal on page 4 42 Are the spring s defective Replace the cartridge contact block assembly Go to step 3 3 Turn the printer off and then check the continuity of the HVPS cable See High...

Page 88: ...fy the paper type from Print Properties For Macintosh users specify the paper type from the Print dialog CHECK THE PAPER TEXTURE SETTING From the operator panel Paper menu make sure the Paper Texture setting matches the paper loaded in the tray or feeder If necessary change the Paper Texture setting from Normal to Rough Additional checks toner rubs off Step Questions actions Yes No 1 Is the fuser ...

Page 89: ...r loaded in the tray or feeder 1 From the operator panel Paper menu check the Paper Type setting 2 Before sending the print job specify the correct paper type setting For Windows users specify the paper type from Print Properties For Macintosh users specify the paper type from the Print dialog Uneven print density MAKE SURE THERE IS NO DEFECTIVE OR WORN PRINT CARTRIDGE Replace the print cartridge ...

Page 90: ... and wear Is the above component free of excess wear and contamination Go to step 4 Replace the print cartridge 4 Check the ITU assembly for contamination and wear Is the above component free of excess wear and contamination Go to step 5 Replace the ITU assembly Go to ITU assembly removal on page 4 77 5 Check the print cartridge for proper installation Is the above component properly installed Go ...

Page 91: ...ustom String Load paper in the indicated source and select Continue Additional messages may include Show Me The printer will present instructions Cancel Job The printer job can be canceled Wait for supplies If job parking is enabled and the job meets all the requirements for allowing the job to be parted the printer adds this message Load source size Load paper in the indicated source and of the i...

Page 92: ...ove the media to continue Remove Packaging Material If packaging material is detected by the printer Check all areas Check area name or Check number of areas may appear Press Select to continue Restore Held Jobs Go Stop If the printer detects Print and Hold or parked jobs stored on the hard disk during Power On Self Test POST Choices are Restore Print jobs are restored and Restoring Held Jobs x y ...

Page 93: ...age Check the tray length and width guides to ensure the media is properly fitted Make sure the print job is requesting the correct size of media Adjust the Paper Size setting for the media size being used If the MP Feeder Size is set to Universal make sure the media is large enough for the formatted data Cancel the current job Replace the paper pick mechanism See Paper pick mechanism assembly rem...

Page 94: ...stem board removal on page 4 151 39 Complex Page The page is too complex to print Options are Select Continue to continue The job may not print correctly Cancel the job 50 PPDS Font Error Select Continue to clear the message and continue printing The job may not print correctly Cancel the current job If this does not fix the problem replace the system board See System board removal on page 4 151 5...

Page 95: ...set to Disabled If this does not fix the problem replace the PCI card 56 Parallel Port x Disabled Select Continue to clear the message The printer discards any data received through the parallel port Make sure the Parallel Buffer menu item is not set to Disabled If this does not fix the problem replace the PCI card 56 Serial Port x Disabled Select Continue to clear the message The printer discards...

Page 96: ...s does not fix the problem replace the system board See System board removal on page 4 151 63 Unformatted disk Select Continue to clear the message and continue printing Format the disk If the error message remains replace the hard disk If this does not fix the problem replace the system board See System board removal on page 4 151 64 Unsupported disk format Select Continue to clear the message an...

Page 97: ...ge If the connector is damaged on system board replace the system board See System board removal on page 4 151 If the fuser cable is damaged replace the cable Check for continuity in the fuser cable If continuity is not present replace the fuser cable If the problem persists after replacing cable replace the system board See System board removal on page 4 151 82 Waste Toner Nearly Full Select Cont...

Page 98: ...a replacement transfer module When print quality is reduced install the new transfer module using the instruction sheet that comes with the replacement transfer module If the problem persists replace the system board See System board removal on page 4 151 83 xx Replace Transfer Module Replace the transfer module using the instruction sheet that comes with the replacement transfer module See ITU as...

Page 99: ...conductor unit using the instruction sheet that comes with the replacement specified photoconductor unit If the problem persists replace the system board See System board removal on page 4 151 88 xx color Cartridge Low Show Me View Supplies and Tell Me More displays additional information Replace the specified print cartridge Select Continue to clear the message and continue printing If the proble...

Page 100: ...cartridge sensor 133 01 black 133 02 cyan 133 03 magenta and 133 04 yellow 133 05 A timeout error has occurred while waiting for the indicated cartridge POR the printer If the error message persists go to 133 xx Cartridge sensor error service check on page 2 74 141 01 141 09 Black cartridge motor error An error has occurred in the black cartridge motor POR the printer If the error message persists...

Page 101: ... motor has failed POR the printer If the error message persists go to 150 xx Duplex motor error service check on page 2 89 151 01 151 09 ITU Motor Error An error has occurred in the ITU motor POR the printer If the error message persists go to 151 xx ITU motor error service check on page 2 90 171 01 171 03 Main Fan Error An error has occurred in the main fan POR the printer If the error message pe...

Page 102: ...ror The printhead PLL failed to achieve lock POR the printer If the error message persists go to 110 xx Printhead error service check on page 2 67 938 10 Electronics Hardware Error The humidity sensor failed POR the printer If the error message persists go to System board removal on page 4 151 938 11 938 14 Electronics Hardware Error A cartridge sensor failed POR the printer If the error message p...

Page 103: ...te weather station failure occurred POR the printer If the error message persists go to 938 28 Remote weather station error service check on page 2 139 938 29 938 30 Electronics Hardware Error A weather station failure occurred POR the printer If the error message persists go to 938 27 938 29 938 30 Weather station error service check on page 2 138 938 31 Electronics Hardware Error A printhead fai...

Page 104: ...System Failure A system board failure has occurred POR the printer If the error message persists replace the system board See System board removal on page 4 151 960 00 960 99 Memory Error A memory failure has occurred POR the printer If the error message persists RAM soldered on board is bad Replace the system board See System board removal on page 4 151 961 00 961 99 Memory Failure A memory failu...

Page 105: ...option error has occurred Go to 990 xx POST error service check on page 2 142 991 00 991 99 device Error The specified device has detected an error POR the printer If the error message persists replace the system board See System board removal on page 4 151 Error code Description Action ...

Page 106: ... sheet input option service check on page 2 150 Printout is skewed Go to Skew 550 sheet input option service check on page 2 166 Tray LED won t light up during paper jam or tray empty Go to Tray jam indicator 550 sheet 2000 sheet input option service check on page 2 171 Symptom Action Printer fails to recognize the option is installed Go to Input option not detected 550 sheet 2000 sheet input opti...

Page 107: ...ce the printhead See Printhead removal installation and alignment on page 4 123 Go to step 2 2 Turn the printer off and open the system board shield Check the printhead cables A in connectors JMM1 JPH1 and JPH2 for proper connection to the system board Are the cables properly connected Go to step 3 Reseat the cables 3 Check the printhead cables in connectors JMM1 JPH1 and JPH2 for damage Are the c...

Page 108: ...pass the test Replace the printhead See Printhead removal installation and alignment on page 4 123 Replace the system board See System board removal on page 4 151 Step Questions actions Yes No 1 Turn the printer off open the system board shield and remove the connector shield Check the cable in connector JYF1 BLDE Y Fuser cable for proper connection to the system board Is the cable properly connec...

Page 109: ... the cable properly connected Go to step 4 Reseat the cable 4 Is the BLDE Y Fuser cable damaged Replace the BLDE Y Fuser cable See EP drive assembly removal on page 4 56 Go to step 5 5 Replace the fuser motor See Fuser drive assembly removal on page 4 65 Does the problem reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No B ...

Page 110: ...board shield Check the cable in connector JFSR1 D for proper connection to the system board Is the cable properly connected Go to step 3 Reseat the cable 3 Check the cable for damage Is the cable damaged Replace the Fuser and system card LVPS cable See Fuser system card and LVPS cable removal on page 4 67 Go to step 4 4 Check the cable E on the LVPS for proper connection Is the cable properly conn...

Page 111: ... 4 67 Go to step 6 6 Open the left access door remove the two screws A and pull out the fuser autoconnect enough to check the cable for proper connection Is the cable properly connected Go to step 7 Reseat the cable 7 Check the cable for damage Is the cable damaged Replace the Fuser and system card LVPS cable See Fuser system card and LVPS cable removal on page 4 67 Reseat the cable Step Questions...

Page 112: ...Check the ITU autoconnect cable in connector JITM1 B for proper connection to the system board Is the cable properly connected Go to step 3 Reseat the cable 3 Check the cable for damage Is the cable damaged Replace the ITU autoconnect cable See ITU autoconnect removal on page 4 78 Go to step 4 4 Measure the resistance across fuse F15 on the system board Is the fuse blown Replace the system board S...

Page 113: ...problems Do nothing Go to step 2 2 Turn the printer off open the system board shield and remove the connector shield Check the cables in connector JLVPS1 and J9 E for proper connection to the system board Are the cables properly connected Go to step 2 Reseat the cables 3 Check the cables for damage Are the cables damaged Replace the LVPS See Low voltage power supply LVPS removal on page 4 86 Repla...

Page 114: ...ress and hold 3 and 6 while turning on the printer c Select Base Sensor Test d Select the failing sensor e Remove all the cartridges f Defeat the front access door switch with a screwdriver as shown g Depress the arm of the failing sensor Replace the cartridge Go to step 2 Error code Sensor 133 01 K TMC sensor 133 02 C TMC sensor 133 03 M TMC sensor 133 04 Y TMC sensor A B C D ...

Page 115: ...shield Check the cables in the indicated connectors for proper connection to the system board The cables are interchangeable on the terminals so check all four cables for any 133 xx error Are the cables properly connected Go to step 3 Reseat the cable Step Questions actions Yes No Error code Sensor 133 01 D 133 02 B 133 03 C 133 04 A A B C D ...

Page 116: ...bles in the indicated connectors for proper connection to the system board 133 01 Black D JCMKM1 133 02 Cyan C JCMCY1 133 03 Magenta D JCMKM1 133 04 Yellow C JCMCY1 Are the cables properly connected Go to step 4 Reseat the cable Step Questions actions Yes No D C ...

Page 117: ...or damage and then remove all four cartridges and check the other ends of the cables connected to the sensors on the memory blocks 133 01 Black B JCMKM1 133 02 Cyan A JCMCY1 133 03 Magenta B JCMKM1 133 04 Yellow A JCMCY1 Is either cable damaged Replace the cable Go to step 3 Step Questions actions Yes No A B ...

Page 118: ...ated by the error code and rotate the developer input gear E clockwise to locate the tab as indicated 2 Rotate the toner metering paddle cam G up to force the tab F until it sticks out Problem solved Replace the system board See System board removal on page 4 151 Step Questions actions Yes No Error code Memory block Cable 133 01 Black JCMKM1 133 02 Cyan JCMCY1 133 03 Magenta JCMKM1 133 04 Yellow J...

Page 119: ... clockwise until the tab H is up against the tab on the larger gear J Print two demo pages 1 Replace all cartridges 2 Turn on the machine 3 Select Menu Reports Print Demo Demo Page 4 Do step three again to get the second demo page Does this fix the problem Step Questions actions Yes No H J ...

Page 120: ...DC K ITU cable for proper connection to the system board Is the cable properly connected Go to step 2 Reseat the cable 2 Check the cable in the connector JKI1 BLDC K ITU cable for damage Is the cable damaged Replace the BLDC K ITU cable See EP drive assembly removal on page 4 56 Go to step 3 3 Measure the resistance across the fuse F10 on the system board Is the fuse blown Replace the system board...

Page 121: ...seat the cable 5 Replace the EP drive assembly See EP drive assembly removal on page 4 56 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Turn the printer off open the system board shield and remove the connector shield Check the cable in the connector JCM1 BLDC C M cable for proper connection to the system board...

Page 122: ... system board See System board removal on page 4 151 Go to step 4 4 Remove the system board cage See System board cage with board removal on page 4 155 Check the cable connected to the cyan cartridge motor Is the cable connected properly Go to step 5 Reseat the cable 5 Replace the EP drive assembly See EP drive assembly removal on page 4 56 Does the error reoccur Replace the system board See Syste...

Page 123: ...le in the connector JCM1 BLDC C M cable for proper connection to the system board Is the cable properly connected Go to step 2 Reseat the cable 2 Check the cable for damage Is the cable damaged Replace the BLDC C M cable See EP drive assembly removal on page 4 56 Go to step 3 3 Measure the resistance across the fuse F7 on the system board Is the fuse blown Replace the system board See System board...

Page 124: ... the cable 5 Replace the EP drive assembly See EP drive assembly removal on page 4 56 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Turn the printer off open the system board shield and remove the connector shield Check the cable in the connector JYF1 BLDC Y Fuser cable for proper connection to the system board...

Page 125: ...e the system board See System board removal on page 4 151 Go to step 4 4 Remove the system board cage See System board cage with board removal on page 4 155 Check the cable connected to the yellow cartridge motor Is the cable connected properly Go to step 5 Reseat the cable 5 Replace the EP drive assembly See EP drive assembly removal on page 4 56 Does the error reoccur Replace the system board Se...

Page 126: ...the cable 2 Check the cable for damage Is the cable damaged Replace the Tray 1 machine side cable See Autocomp W2W cable on page 7 56 Go to step 3 3 Remove the standard media tray Check the cable A from the paper pick mechanism assembly to the printer Is the cable properly connected Go to step 4 Reseat the cable 4 Remove the paper pick mechanism assembly See Paper pick mechanism assembly removal o...

Page 127: ...to the system board Is the cable properly connected Go to step 2 Reseat the cable 2 Check the cable for damage Is the cable damaged Replace the staging motor cable See Staging paper path reference edge assembly removal on page 4 142 to access the cable Go to step 3 3 Remove the LVPS See Low voltage power supply LVPS removal on page 4 86 Check the cable connection to the motor Is the cable connecte...

Page 128: ...e System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Turn the printer off and open the system board shield Check the cable in connector JRDR1 for proper connection to the system board Is the cable properly connected Go to step 2 Reseat the cable 2 Replace the redrive motor See Redrive motor removal on page 4 135 Does the error reoccur Replace the system board See Sys...

Page 129: ...assembly See Duplex assembly removal on page 4 53 Go to step 2 2 Turn the printer off and open the system board shield Check the cable in connector JDUPL1 Duplex motor cable for proper connection to the system board Is the cable properly connected Go to step 3 Reseat the cable 3 Check the cable for damage Is the cable damaged Replace the duplex motor cable See Staging paper path reference edge ass...

Page 130: ...seat the cable 5 Replace the housing interlock assembly See Housing interlock assembly removal on page 4 75 Dose the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Turn the printer off open the system board shield and remove the connector shield Check the cable in connector JKI1 BLDC K ITU cable for proper connection to ...

Page 131: ...k the cable connection to the ITU motor Is the cable properly connected Go to step 4 Reseat the cable 4 Replace the EP drive assembly See EP drive assembly removal on page 4 56 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Turn the printer off and open the system board shield Check the cable in connector JM1 fo...

Page 132: ... Problem solved Step Questions actions Yes No 1 Turn the printer off and open the system board shield Check the cable in connector JL1 for proper connection to the system board Is the cable properly connected Go to step 2 Reseat the cable 2 Replace the LVPS fan See LVPS fan removal on page 4 90 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved St...

Page 133: ...right side waste cable for damage Is the cable damaged Replace the blower right side waste cable See Printhead access cover removal on page 4 19 to access the cable on top of the frame Go to step 3 3 Remove the cartridge blower assembly See Cartridge blower assembly removal on page 4 39 Check the cable B connected to the assembly Is the cable connected to the blower fan Go to step 4 Reseat the cab...

Page 134: ... the input sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 2 2 Remove the staging deflector assembly See Staging deflector assembly removal on page 4 140 Is the input sensor A in the staging deflector assembly loose Reseat the sensor and add a sensor retainer See Sensor input S1 narrow media near narrow media removal on page 4 138 Contact your next level ...

Page 135: ...lag A for damage Is the input sensor flag damaged Replace the input sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 3 3 Is the staging deflector assembly damaged Replace the staging deflector assembly See Staging deflector assembly removal on page 4 140 Go to step 4 4 Turn the printer off and open the system board shield Check the cable in connector JPP2 ...

Page 136: ...ia removal on page 4 138 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Reseat the ITU Did the error clear Problem solved Go to step 2 2 Open the left access door Check the input sensor flag A for damage Is the input sensor flag damaged Replace the input sensor See Sensor input S1 narrow media near narrow media ...

Page 137: ...embly removal on page 4 140 Is the cable connected correctly Go to step 6 Reseat the cable 6 Replace the input sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No ...

Page 138: ...lace the near narrow media sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 2 2 Remove the staging deflector assembly See Staging deflector assembly removal on page 4 140 Is the near narrow media sensor D in the staging deflector assembly loose Reseat the sensor and add a sensor retainer See Sensor input S1 narrow media near narrow media removal on page 4 ...

Page 139: ...for damage Is the near narrow media sensor flag damaged Replace the near narrow media sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 3 3 Is the staging deflector assembly damaged Replace the staging deflector assembly See Staging deflector assembly removal on page 4 140 Go to step 4 4 Turn the printer off and open the system board shield Check the cable ...

Page 140: ... 6 6 Remove the staging deflector assembly See Staging deflector assembly removal on page 4 140 Is the cable connected correctly Go to step 7 Reseat the cable 7 Replace the near narrow media sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes ...

Page 141: ...val on page 4 138 Go to step 3 3 Is the staging deflector assembly damaged Replace the staging deflector assembly See Staging deflector assembly removal on page 4 140 Go to step 4 4 Replace the ITU Does the error clear Problem solved Go to step 5 5 Remove the staging deflector assembly See Staging deflector assembly removal on page 4 140 Is the cable connected correctly Go to step 6 Reseat the cab...

Page 142: ...e the narrow media sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 2 2 Remove the staging deflector assembly See Staging deflector assembly removal on page 4 140 Is the narrow media sensor C in the staging deflector assembly loose Reseat the sensor and add a sensor retainer See Sensor input S1 narrow media near narrow media removal on page 4 138 Contact y...

Page 143: ... for damage Is the narrow media sensor flag damaged Replace the narrow media sensor flag See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 3 3 Is the staging deflector assembly damaged Replace the staging deflector assembly See Staging deflector assembly removal on page 4 140 Go to step 4 4 Turn the printer off and open the system board shield Check the cable in c...

Page 144: ...age 4 138 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Reseat the ITU Does the error clear Problem solved Go to step 2 2 Open the left access door Check the near narrow media sensor flag D for damage Is the near narrow media sensor flag damaged Replace the near narrow media sensor See Sensor input S1 narrow me...

Page 145: ...e 4 138 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Replace the fuser Does the problem clear Problem solved Go to step 2 2 Open the system board shield Check the cable in connector JFSR1 for proper connection to the system card Is the cable connected correctly Go to step 3 Reseat the cable 3 Check the cable f...

Page 146: ... autoconnect enough to check the cable for proper connection Is the cable connected correctly Go to step 5 Reseat the cable 5 Check the cable for damage Is the cable damaged Replace the fuser system card and LVPS cable See Fuser system card and LVPS cable removal on page 4 67 Reseat the cable Step Questions actions Yes No ...

Page 147: ...ervice check Step Questions actions Yes No 1 Is the bin full flag damaged Replace the bin full flag See Bin full flag removal on page 4 37 Go to step 2 2 Remove the top cover assembly Is the sensor in the top cover assembly loose Reseat the sensor Contact your next level of support ...

Page 148: ...lace the S1 sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 2 2 Remove the staging deflector assembly See Staging deflector assembly removal on page 4 140 Is the S1 sensor B in the staging deflector assembly loose Reseat the sensor and add a sensor retainer See Sensor input S1 narrow media near narrow media removal on page 4 138 Contact your next level of...

Page 149: ...awer assembly 3 Check if the pass thru sensor is seated correctly and the sensor flag can move back to its original position when it is triggered Is the pass thru sensor free of obstruction Go to step 4 Install the pass thru sensor correctly 4 1 Bring the printer up in Diagnostics mode turn off the printer press and hold 3 and 6 turn on the printer and hold the buttons until the splash screen appe...

Page 150: ...rawer assembly removal on page 4 166 For 2000 sheet input option Replace the 2000 sheet drawer assembly Problem solved Step Questions actions Yes No 1 Check for any obstruction on the paper path Is the paper path free of obstruction Go to step 2 Clear paper path for obstructions 2 1 Check if the jam clearance cover can close properly 2 Check if jam clearance cover friction lock is not retracted Do...

Page 151: ...eet tray pick roll assembly removal on page 4 180 For 2000 sheet input option Replace the pick roll assembly See 2000 sheet high capacity feeder pick roll assembly removal on page 4 224 5 Check the drive assembly for wear or damage Make sure the rollers are touching each other when the jam clearance cover is closed Is the drive assembly not damaged Go to step 6 For 550 sheet input option Replace t...

Page 152: ...n page 4 215 Does the problem persists For 550 sheet input option Replace the 550 sheet drawer assembly See 550 sheet drawer assembly removal on page 4 166 For 2000 sheet input option Replace the 2000 sheet high capacity feeder input option Problem solved Step Questions actions Yes No 1 Check for any obstruction on the paper path Is the paper path free of obstruction Go to step 2 Clear paper path ...

Page 153: ... turn on the printer and hold the buttons until the splash screen appears 2 Navigate to INPUT TRAY TESTS FEED TEST 3 Select the input source 4 Select Single Does the error persists Go to step 5 Problem solved 5 Check the pick roll assembly Is the pick roll assembly not damaged Go to step 6 For 550 sheet input option Replace the pick roll assembly See 550 sheet tray pick roll assembly removal on pa...

Page 154: ...h capacity feeder pick assembly removal on page 4 218 7 For 550 sheet input option Replace the media tray assembly See 550 sheet media tray assembly removal on page 4 166 For 2000 sheet input option Replace the media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 Does the problem persists For 550 sheet input option Replace the 550 sheet drawer assembly ...

Page 155: ...ee MPF pick parts packet including on page 7 5 Replace the MPF paper pick assembly See MPF paper pick assembly removal including the MPF ratchet collar and MPF drive pulley on page 4 101 3 Turn the printer off and open the system board shield Check the cable in connector JTRAY1 for proper connection to the system card Is the cable connected correctly Go to step 4 Reseat the cable 4 Check the cable...

Page 156: ...4 86 Is the MPF drive belt B broken Replace the MPF drive belt See MPF drive assembly removal on page 4 106 Go to step 7 7 Is the MPF drive assembly damaged Replace the MPF drive assembly See MPF drive assembly removal on page 4 106 Go to step 8 8 Replace the Input tray feed assembly Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Question...

Page 157: ...3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Open the HTU access door 3 Check the HTU input sensor for damage Is the sensor damaged Replace the HTU input sensor See HTU sensor input removal on page 4 322 Go to step 3 3 Remove the HTU rear standard bin cover See HTU rear standard bin ...

Page 158: ...le Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Check the HTU output sensor for damage See HTU output sensor removal on page 4 309 Is the sensor damaged Replace the HTU output sensor See HTU output sensor removal on page 4 309 Go to step 3 3 Remove the HTU rear standard bin cover See HTU rear standard bin cover rem...

Page 159: ...inter and hold the buttons until the splash screen appears 2 Navigate to INPUT TRAY TESTS Feed Test 3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Open the HTU access door 3 Check the HTU second sensor for damage Is the sensor damaged Replace the HTU second sensor See HTU sensor second...

Page 160: ...e 4 312 Check the cable in the indicated connector Is the cable proper connected Go to step 4 Reseat the connector 4 Replace the HTU second sensor See HTU sensor second removal on page 4 324 Does the error reoccur Replace the HTU controller card See HTU controller card removal on page 4 289 Problem solved Step Questions actions Yes No ...

Page 161: ... buttons until the splash screen appears 2 Navigate to INPUT TRAY TESTS Feed Test 3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Open the 5 bin mailbox access door 5 Check the 5 bin mailbox input sensor for damage Is the sensor damaged Replace the 5 bin mailbox input sensor See 5 bin m...

Page 162: ... the indicated connector Is the cable proper connected Go to step 4 Reseat the connector 4 Replace the 5 bin mailbox input sensor See 5 bin mailbox sensor input assembly removal on page 4 252 Does the error reoccur Replace the 5 bin mailbox controller card See 5 bin mailbox controller card removal on page 4 238 Problem solved Step Questions actions Yes No ...

Page 163: ...tons until the splash screen appears 2 Navigate to INPUT TRAY TESTS Feed Test 3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Open the 5 bin mailbox access door 3 Check the 5 bin mailbox pass thru sensor for damage Is the sensor damaged Replace the 5 bin mailbox pass thru sensor See 5 b...

Page 164: ... indicated connector Is the cable proper connected Go to step 4 Reseat the connector 4 Replace the 5 bin mailbox pass thru sensor See 5 bin mailbox sensor pass thru assembly removal on page 4 252 Does the error reoccur Replace the 5 bin mailbox controller card See 5 bin mailbox controller card removal on page 4 238 Problem solved Step Questions actions Yes No ...

Page 165: ...ed Test 3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Remove the Finisher Stacker front cover See Finisher or stacker front cover removal on page 4 260 3 Check the cable in the indicated connector Is the cable properly connected Go to step 3 Reseat the cable 3 Replace the Finisher Sta...

Page 166: ...ntil the splash screen appears 2 Navigate to INPUT TRAY TESTS Feed Test 3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Open the Finisher Stacker access door 3 Check the Finisher Stacker sensor pass thru for damage Is the sensor damaged Replace the Finisher Stacker sensor pass thru See ...

Page 167: ...ller card See Finisher or stacker controller card assembly removal on page 4 258 Problem solved Step Questions actions Yes No 1 1 Bring the printer up in Diagnostics menu turn off the printer press and hold 3 and 6 turn on the printer and hold the buttons until the splash screen appears 2 Navigate to INPUT TRAY TESTS Feed Test 3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Pro...

Page 168: ...or reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Remove the Finisher Stacker front cover See Finisher or stacker front cover removal on page 4 260 3 Check the cable in the indicated connector Is the cable properly connected Go to step 3 Reseat the cable 3 Replace the Finisher stapler unit assembly See Finisher stapler unit assembl...

Page 169: ... the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Remove the Finisher Stacker front cover See Finisher or stacker front cover removal on page 4 260 3 Check the cable in the indicated connector Is the cable properly connected Go to step 3 Reseat the cable 3 Replace the paddle motor See Finisher or stacker paddle drive motor ...

Page 170: ...te to INPUT TRAY TESTS Feed Test 3 Select Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Remove the HTU rear standard bin cover See HTU rear standard bin cover removal on page 4 312 2 Check the cable in the indicated connector Is the cable properly connected Go to step 3 Reseat the cable 3 Replace the punch unit See HTU punch unit removal on page 4 336 Does the error...

Page 171: ...Tray 1 4 Select Single Does the error reoccur Go to step 2 Problem solved 2 1 Clear away anything in the paper path that might cause the paper to jam 2 Remove the HTU front standard bin cover See HTU front standard bin cover removal on page 4 294 3 Check the cable in the indicated connector Is the cable properly connected Go to step 3 Reseat the cable 3 Replace the hole punch motor assembly See HT...

Page 172: ...device off Clear the print queues Disconnect all communication cables and remove all memory options Remove all ISP and modem cards Restart the device into diagnostic mode Does the 900 xx error reoccur during startup Go to step 3 Go to step 6 3 Check all the cables connected to the RIP board for proper connectivity Are the cables properly connected Go to step 5 Go to step 4 4 Properly connect the c...

Page 173: ...cur Go to step 31 Problem resolved 16 Is there a modem installed on the device Go to step 17 Go to step 21 17 Reinstall the modem Restart the device Does the 900 xx error reoccur Go to step 18 Go to step 20 18 Upgrade the firmware Contact your next level of support for the correct firmware level to use Restart the printer to operating mode Send the printer a print job Does the 900 xx error reoccur...

Page 174: ...correct firmware level to use Restart the printer to operating mode Does the 900 xx error reoccur Go to step 30 Go to step 26 30 Replace the faulty ISP option Restart the device Does the 900 xx error reoccur Go to step 31 Go to step 26 31 Contact your next level of support You will need the following information for them Exact 900 xx error digits and complete error message Printed menu settings pa...

Page 175: ...heck the cable in the JMPF1 MPF sensor cable connector for damage Is the cable damaged Replace the MPF sensor cable See MPF sensor cable on page 7 56 Go to step 3 3 Remove the MPF sensor plate assembly See MPF sensor plate assembly removal on page 4 108 Check the cable connected to the sensor Is the cable properly connected Go to step 4 Reseat the cable 4 Replace the MPF sensor plate assembly See ...

Page 176: ...at the cable 2 Check the cable for damage Is the cable damaged Replace the waste toner cable See Waste toner cable removal on page 4 160 Go to step 3 3 Remove the waste toner sensor See Waste toner sensor removal on page 4 159 Check the cable connected to the sensor Is the cable properly connected Go to step 4 Reseat the cable 4 Replace the waste toner sensor See Waste toner sensor removal on page...

Page 177: ... cable 2 Check the cable for damage Is the cable damaged Replace the waste toner cable See Waste toner full cable removal on page 4 161 Go to step 3 3 Remove the waste toner full sensor See Waste toner full sensor removal on page 4 162 Check the cable connected to the sensor Is the cable properly connected Go to step 4 Reseat the cable 4 Replace the waste toner full sensor See Waste toner full sen...

Page 178: ... cable 2 Check the cable for damage Is the cable damaged Replace the thermistor and redrive cable See Fuser thermistor removal on page 4 70 Go to step 3 3 Remove the fuser and check the connection of the thermistor and redrive cable A See Fuser assembly removal on page 4 63 Is the cable properly connected Go to step 4 Reseat the cable 4 Replace the fuser thermal guide assembly See Fuser thermistor...

Page 179: ...n thermistor for proper connection to the system board Is the cable properly connected Go to step 2 Reseat the cable 2 Check the cable for damage Is the cable damaged Replace the weather station compensation thermistor See step 3 Go to step 3 3 Replace the weather station compensation thermistor Clip the cable tie to remove the thermistor from the LVPS Does the error reoccur Replace the system boa...

Page 180: ...cently Replace the system board with a new and not previously installed system board See System board removal on page 4 151 Go to step 3 3 Turn the printer power off for ten or more seconds Then turn the printer back on POR the printer Is the error gone and can the printer print Problem solved Go to step 4 4 Clear the NVRAM of the printer 1 Turn the printer power off 2 With the printer off press a...

Page 181: ...ystem board shield Check the cable in connector J3 system board fan connector for proper connection to the system board Is the cable properly connected Go to step 2 Reseat the cable 2 Replace the processor fan See CPU cooling fan removal on page 4 49 POR the printer Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved ...

Page 182: ...nector Pick motor connector Feed motor connector Elevator motor connector Are all connectors properly connected Go to step 4 Properly connect all connectors 4 Replace the 2000 sheet high capacity feeder elevator home sensor See 2000 sheet high capacity feeder elevator home sensor removal on page 4 190 Does the problem persist Go to step 5 Problem solved 5 Replace the 2000 sheet high capacity feede...

Page 183: ... 2000 sheet high capacity feeder drive assembly See 2000 sheet high capacity feeder drive assembly removal on page 4 186 Does the problem persist Go to step 10 Problem solved 10 Replace the 2000 sheet high capacity feeder controller card assembly See 2000 sheet high capacity feeder controller card assembly removal on page 4 185 Does the problem persist Replace the 2000 sheet high capacity feeder i...

Page 184: ...e cable properly connected Go to step 3 Reseat the cable 3 Check the cable in connector JTCVR1 for damage Is the cable damaged Replace the bin full and output beacon cable To access the cable see Top cover removal on page 4 30 Go to step 4 4 Remove the printhead access cover See Printhead access cover removal on page 4 19 Is the cable properly connected Go to step 5 Reseat the cable 5 Replace the ...

Page 185: ...amaged sensor See Sensor D1 D2 and fuser bubble removal on page 4 137 Go to step 2 2 Open the system board shield Check the cable in connector JDP1 for proper connection to the system card Is the cable properly connected Go step 3 Reseat the cable 3 Check the cable for damage Is the cable damaged Replace the duplexer cable To access the cable see LVPS exit duct removal on page 4 89 and Left cover ...

Page 186: ...ble for damage Is the cable connected correctly Replace the duplexer cable To access the cable see LVPS exit duct removal on page 4 89 and Left cover removal on page 4 11 Go to step 6 6 Replace the duplex assembly See Duplex assembly removal on page 4 53 Is the problem fixed Problem solved Replace the system board See System board removal on page 4 151 Step Questions actions Yes No A 88A0323 B ...

Page 187: ...ccess door and open the duplex assembly Is the D1 or D2 flag damaged Replace the damaged sensor See Sensor D1 D2 and fuser bubble removal on page 4 137 Go to step 2 2 Open the system board shield Check the cable in connector JDP1 for proper connection to the system card Is the cable properly connected Go step 3 Reseat the cable D2 D1 ...

Page 188: ...ace the duplexer cable To access the cable see LVPS exit duct removal on page 4 89 and Left cover removal on page 4 11 Go step 4 4 Remove the duplex cable cover Check the cable for proper connection Is the cable connected correctly Go to step 5 Reseat the cable Step Questions actions Yes No A 88A0323 B ...

Page 189: ...age 4 53 Does the problem persists Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No 1 Is the AC line cord damaged Replace the line cord Go to step 2 2 Turn the printer off open the system board shield and remove the connector shield Check the system board for 5 V dc between JLVPS1 pin 6 and ground Is the voltage correct Replace the system...

Page 190: ... actions Yes No 1 Check if the media supported and environmental specification are supported by this machine See Environment on page 1 5 and Supported paper sizes types and weights on page 1 7 to check the printer specifications Are the media and environment supported Go to step 3 Replace the media 2 Check the pick rolls for contamination and wear Are the pick rolls free of contamination and wear ...

Page 191: ...pacity feeder pick assembly removal on page 4 218 Go to step 4 4 1 Check the media trays for mechanical damage 2 Check the media restrains 3 Check for wears on the dams for 2000 sheet input option only Is there damage or wear on the media tray Replace the whole input option For 550 sheet input option Replace the media tray assembly See 550 sheet media tray assembly removal on page 4 166 For 2000 s...

Page 192: ...page 4 212 2 Be sure that Power In PWR IN PPORT engine and PPORT Next option connectors are connected properly on the controller card Are the connectors connected properly Go to step 4 Properly connect the connectors 3 For 550 sheet input option Replace the controller card assembly See 550 sheet tray controller card assembly removal on page 4 167 For 2000 sheet input option Replace the controller ...

Page 193: ...sensor Is the sensor flag damaged Replace the input sensor See Sensor input S1 narrow media near narrow media removal on page 4 138 Go to step 2 2 Turn the printer off and open the system board shield Check the cable in connector JPP2 for proper connection to the system board Is the cable properly connected Go to step 3 Reseat the cable 3 Check the cable in connector JPP2 for damage Is the cable d...

Page 194: ...page 4 140 A Input sensor B S1 sensor C Narrow media sensor D Near narrow media sensor Is the cable properly connected Go to step 5 Reseat the cable 5 Replace the sensor Sensor input S1 narrow media near narrow media removal on page 4 138 Does the error reoccur Replace the system board See System board removal on page 4 151 Problem solved Step Questions actions Yes No ...

Page 195: ...Replace the printhead See Printhead removal installation and alignment on page 4 123 Reseat the cable 3 Turn the printer off and open the system board shield Check the cable in connectors JCRV1 for proper connection to the system board Is the cable connected correctly Replace the interlock housing See Housing interlock assembly removal on page 4 75 Reseat the cable 4 Replace the interlock housing ...

Page 196: ...50 sheet input option Replace the drawer assembly See 550 sheet drawer assembly removal on page 4 166 For 2000 sheet input option Replace the jam clearance cover See 2000 sheet high capacity feeder jam clearance cover removal on page 4 194 2 Check if the jam clearance cover flag is broken Is the jam clearance cover flag not damaged Go to step 2 For 550 sheet input option Replace the drawer assembl...

Page 197: ...0 sheet input option Replace the jam door clearance sensor See 2000 sheet high capacity feeder jam door clearance sensor removal on page 4 199 4 For 550 sheet input option Replace the controller card assembly See 550 sheet tray controller card assembly removal on page 4 167 For 2000 sheet input option Replace the controller card assembly See 2000 sheet high capacity feeder controller card assembly...

Page 198: ...eck the rear restrain on the media tray for any damage Is the rear restrain not damaged Go to step 5 For 550 sheet input option Replace the media tray assembly See 550 sheet media tray assembly removal on page 4 166 For 2000 sheet input option Replace the media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 5 For 550 sheet input option Replace the contr...

Page 199: ...mbly is inserted to the correct hole and slot during installation Is the tray pick assembly inserted on the correct hole and slot Go to step 2 Properly install the 550 sheet tray pick assembly 2 Check the 550 sheet tray pick assembly for damage Is the tray pick assembly damaged Replace the 550 sheet tray pick assembly See 550 sheet tray pick assembly removal on page 4 176 Go to step 3 ...

Page 200: ... 1 Does the 2000 sheet high capacity feeder media tray assembly close properly Go to step 2 Go to step 4 2 Check the media size actuator Is the media actuator not deformed or not damaged Go to step 3 Replace the 2000 sheet high capacity feeder drawer assembly 3 Check each of the tact switch at the back of the controller card if it ticks when pressed Is the tact switch not damaged Go to step 4 Repl...

Page 201: ...heck the 2000 sheet high capacity feeder bellcrank assembly if the recoil spring is loose Is the recoil spring fastened on the bellcrank Go to step 7 Reinstall the recoil spring 7 Check the tray slide assembly for damage Does the tray slide assembly retracts Replace the 2000 sheet high capacity feeder media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215...

Page 202: ...ne status under Printers and Faxes on the host computer Delete all print jobs in the print queue Is the printer online and in a Ready state Go to step 5 Go to step 4 4 Change the printer status to online Is the problem solved Problem solved Go to step 5 5 Does the IP address displayed on the network settings page match the IP address in the port of the drivers using the printer Go to step 10 Go to...

Page 203: ...he correct wireless network to the printer Is the problem solved Problem solved Go to step 17 17 Are the other devices on the wireless network communicating properly Go to step 18 Contact the network administrator 18 Verify that the ISP wireless card cable is properly seated in their connectors Is the wireless card seated correctly Go to step 20 Go to step 19 19 Properly reseat the ISP cables Is t...

Page 204: ... 1 With the assembly still in the printer push up on the bar on the bottom of the pick arm to raise the arm and then pull the larger latch in the back forward to lock it in place Is the problem solved Problem solved Replace the paper pick mechanism assembly See Paper pick mechanism assembly removal on page 4 120 ...

Page 205: ...assembly See Paper path redrive assembly with sensors removal on page 4 117 Go to step 2 2 Turn the printer off and open the system board shield Check the cable in connector JRDR1 for proper connection to the system card Is the cable properly connected Go to step 3 Reseat the cable 3 Replace the paper path redrive assembly See Paper path redrive assembly with sensors removal on page 4 117 Does the...

Page 206: ...orm a print test on each of the 550 sheet input option Is one of the 550 sheet input options causing the skew Go to step 4 Go to step 1 4 1 Check the paper restrains for damage and if it s set correctly 2 Check for mechanical damage on the tray Is the media tray damaged Replace the 550 sheet media tray assembly See 550 sheet media tray assembly removal on page 4 166 Go to step 5 5 Check the pick r...

Page 207: ...buttons until the splash screen appears 2 Select PRINT TESTS 3 Select Tray 1 for the paper source 4 Select Single Is the printout skewed Go to Skew on page 2 45 Go to step 2 2 Are there any 550 sheet input options between the base printer and the 2000 sheet high capacity feeder input option Go to step 3 Go to step 4 3 Perform a print test on each of the 550 sheet input option Is one of the 550 she...

Page 208: ...age 4 186 6 1 Remove the 2000 sheet high capacity feeder media tray assembly from the drawer 2 Check the media tray for damage 3 Check if the elevator plate is level 4 Check the lift drive gears for damage Is the media tray assembly damaged Replace the 2000 sheet high capacity feeder media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 Go to step 7 7 Ch...

Page 209: ...et high capacity feeder pick assembly removal on page 4 218 2 Check if the elevator plate moves up when you close the 2000 sheet high capacity feeder media tray 1 Open the jam clearance cover 2 Close the 2000 sheet high capacity feeder media tray 3 Check if the elevator plate moves up Does the elevator tray moves up Go to step 5 Go to step 3 3 Check the tray elevator coupling gear for damage Is th...

Page 210: ...n page 4 212 Go to step 5 5 Check if the 2000 sheet high capacity feeder elevator home sensor is seated properly Is the elevator home sensor seated properly Go to step 6 Reseat the elevator home sensor 6 Replace the 2000 sheet high capacity feeder controller card assembly See 2000 sheet high capacity feeder controller card assembly removal on page 4 185 Does the problem persist Replace the 2000 sh...

Page 211: ...rs 3 For 550 sheet input option Replace the controller card assembly See 550 sheet tray controller card assembly removal on page 4 167 For 2000 sheet input option Replace the controller card assembly See 2000 sheet high capacity feeder controller card assembly removal on page 4 185 Does the problem persist For 550 sheet input option Replace the drawer assembly See 550 sheet drawer assembly removal...

Page 212: ...2 172 Service Manual 5062 Go Back Previous Next ...

Page 213: ...te Mode The following actions wake the printer from Sleep Mode Touching the screen or any hard buttons Opening an input tray cover or door Sending a print job from a computer Performing a Power on Reset POR 5 Indicator light Off The printer is off Blinking green The printer is warming up processing data or printing Solid green The printer is on but idle Solid red Operator intervention is required ...

Page 214: ...iles on a flash drive 5 Menus Opens the administrative menus 6 Status message bar Shows the current printer status such as Ready or Busy Note Make sure Ready appears before performing any printer task Shows printer conditions such as Toner Low or Cartridge Low Shows intervention messages and gives instructions for the printer to continue processing 7 Status Supplies Displays a warning or error mes...

Page 215: ...bs to the folder to delete them 3 Left arrow Scrolls left 4 Right arrow Scrolls right 5 Right scroll increase Increases a value 6 Left scroll decrease Decreases a value 7 Down arrow Scrolls down 8 Accept Submit Saves a setting 9 Cancel Cancels an action or selection Cancels out of a screen and return the previous screen 10 Back Navigates back to the previous screen ...

Page 216: ... the home screen Unselected radio button Indicates that an item is not selected Selected radio button Indicates a selection Index Displays information about the key functions of the printer including instructions on how to operate it Search Lets you search for files and menus Warning Indicates a warning or error condition ...

Page 217: ...rint Fonts Quality Menu Transfer Module Paper Loading Print Directory Job Accounting Menu Staples Custom Types Print Demo Utilities Menu Hole Punch Box Custom Names Asset Report XPS Menu Custom Bin Names PDF Menu Universal Setup PostScript Menu Bin Setup PCL Emul Menu PPDS Menu HTML Menu Image Menu PictBridge Menu Security Network Ports Help Miscellaneous Security Settings Active NIC Print All Gui...

Page 218: ...or more information see Diagnostics menu on page 3 7 Configuration menu 1 Turn off the printer 2 Press and hold 2 and 6 3 Turn on the printer 4 Release the buttons when the splash screen appears The Configuration menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this menu group are used to configure a printe...

Page 219: ...ow Diode Alignment Page REGISTRATION See REGISTRATION on page 3 10 Top Margin Bottom Margin Left Margin Right Margin Quick Test See Quick Test on page 3 10 Alignment Menu See Alignment Menu on page 3 11 Cyan Yellow Magenta Factory Scanner Factory Manual Drift Sensors See Drift Sensors on page 3 12 MISC TESTS Toggle ITU See Toggle ITU on page 3 13 Printhead Inst See Printhead Inst on page 3 13 Auto...

Page 220: ... 18 Diverter Test See Diverter Test on page 3 19 Mechanical Test See Mechanical Test on page 3 19 BASE SENSOR TEST See BASE SENSOR TEST on page 3 21 FINISHER TESTS Staple Test See Staple Test on page 3 19 Hole Punch Test See Hole Punch Test on page 3 19 Feed Test See Finisher Feed Test on page 3 20 Sensor Test See Finisher Sensor Test on page 3 20 Mechanical Test See Mechanical Test on page 3 19 D...

Page 221: ...n to adjust the dual diode alignment for Black Cyan Magenta and Yellow 3 Reprint the alignment page and adjust the settings as needed Par 1 Strobe Adj if installed See Par 1 Strobe Adj on page 3 24 EP SETUP EP Defaults See EP Defaults on page 3 24 Fuser Temp See Fuser Temp on page 3 24 DC Charge Adjust See DC Charge Adjustment on page 3 24 Dev Bias Adj See Dev Bias Adj on page 3 24 Transfer Adjust...

Page 222: ... See REGISTRATION on page 3 10 for information on using the Quick Test page to set registration See Quick Test Page on appendix page A 6 for a sample printout Current margin settings are listed on the printout The page includes Arrow points diamonds are shown in the margins to determine page registration General printer information including current page count installed memory Specific information...

Page 223: ...t 7 Repeat steps 4 through 6 if required 8 Continue until all three colors are aligned A separate Quick Test prints for each color Touch Back to exit the Alignment Menu Adjusting Linearity Adjusting Linearity physically adjusts the placement of the laser beam as it scans across the PC drum Each color plane has three correction settings to compensate for any linearity errors relative to the black p...

Page 224: ...esults If Error appears replace the system board See System board removal on page 4 151 If a number Open or Short appears check the following a Check the cable of the appropriate thermistor cyan magenta yellow or black to make sure it is installed correctly to the system board and to the thermistor board If correct go to step b b Check the continuity of the appropriate cable Replace the cable if t...

Page 225: ...of the paper input sources Each of the installed sources is available within the Print Tests menu The content of the 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 is printed and does not contain the Print Registration diamonds If a source is selected which contains envelopes then...

Page 226: ...st This test verifies the operator panel button function To run the Button Test 1 From the Diagnostics menu navigate to HARDWARE TESTS Button Test 2 With no buttons pressed a pattern matching the operator panel buttons is displayed Press each operator panel button one at a time and an X displays in the box that represents the button 3 Press Stop X or touch Back to exit the test DRAM Test This test...

Page 227: ...al 1 Wrap Serial 2 Wrap or Serial 3 Wrap Each time the test finishes the screen updates with the result P and F represent the same numbers for DRAM If the test passes the Pass Count increases by 1 However if the test fails one of the following failure messages appears for approximately three seconds and the Fail Count increases by 1 Receive Status Interrupt Error Status Error Receive Data Interrup...

Page 228: ...nt the Quick Test Page from the default paper source If the default paper source supports only envelopes then the page is printed from Tray 1 Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet If adjustment is necessary the Top Margin in the Registration menu must be adjusted first The Duplex Top Margin Offse...

Page 229: ... this test to determine if the input tray sensors are working correctly To run the Sensor Test 1 From the Diagnostics menu navigate to INPUT TRAY TESTS Sensor Test 2 Select the input source All installed sources appear Not all sensors appear for all trays The following table indicates which tray sensors are available for each input source 3 Manually actuate each sensor The tray empty sensor can be...

Page 230: ...the selected output bin or Continuous media continues feeding to the selected output bin until Stop X is pressed 4 Press Stop X to exit the test Feed to All Bins One page is fed to every bin including the finisher if available The test runs continuously until Stop X is pressed Sensor Test This test verifies that the output bin sensors are working correctly To run the Output Bin Sensor Test 1 From ...

Page 231: ...inisher The printer feeds eight pieces of media to the finisher and accumulates all eight pieces in the finisher After the last sheets are accumulated the pack is stapled To exit the test press Stop X Hole Punch Test This test verifies that media can be fed to the finisher output bin and then hole punched The printer feeds eight pieces of blank media to the finisher and then hole punches them This...

Page 232: ...creen Finisher Sensor Test This test determines if the finisher sensors are working correctly The sensors that are tested are Bin Level Bin Empty Bin Full Bin Near Full Cover and Door Top Cover Side Door Pass and Media Passthru Media Staple Sensors Cartridge Presence Staple Low Self priming Home Signal To run the Finisher Sensor Test select Finisher Sensor Test from FINISHER TESTS in the Diagnosti...

Page 233: ...he sensors to verify that each sensor switches from open to closed DEVICE TESTS Quick Disk Test This test performs a non destructive read write on one block per track on the disk The test reads one block on each track saves the data and proceeds to write and read four test patterns to the bytes in the block If the block is good the saved data is written back to the disk 1 From the Diagnostics menu...

Page 234: ...Flash Test A Contents will be lost warning appears 2 To exit the test immediately and return to DEVICE TESTS select No and touch To continue with the test select Yes and touch When the test starts a progress bar appears The test cannot be stopped or canceled once it has begun 3 Once the test is complete the power indicator turns on solid and a message appears indicating whether the test passed or ...

Page 235: ...rd The IDs consist of eight hexadecimal characters including 0 through 9 and A through F Note When the printer detects a Configuration ID that is not defined or invalid the following occurs The default standard model Configuration ID is used instead Configuration ID is the only function available in DIAGNOSTICS Unless the menu is in DIAGNOSTICS Check Config ID appears To set the configuration ID 1...

Page 236: ...he menu without restoring the settings to the factory defaults touch Back Fuser Temp Warning This setting should not be changed without specific instructions from the next level of support DC Charge Adjustment Warning This setting should not be changed without specific instructions from the next level of support Dev Bias Adj Warning This setting should not be changed without specific instructions ...

Page 237: ... all packages when error occurred Panel message when error occurred except for 900 service RIP software errors Debug information and secondary error codes depending on the error The Clear Log operation clears out the errors that print in this report The errors listed in the Display Log operation do not necessarily match in number nor in order with the errors from the printer log Note This log can ...

Page 238: ...n page 3 27 Tray Insert Msg See Tray Insert Msg on page 3 27 SIZE SENSING See SIZE SENSING on page 3 28 Panel Menus See Panel Menus on page 3 28 PPDS Emulation See PPDS Emulation on page 3 28 Download Emuls See Download Emuls on page 3 28 Factory Defaults See Factory Defaults on page 3 28 Energy Conserve See Energy Conserve on page 3 28 Color Adjustment See Color Adjustment on page 3 28 Auto Align...

Page 239: ...Log Color Trapping Color trapping is an aid to graphics and text When text or graphics appear over other colors a misalignment may allow white paper to show through at the borders of the colors Color trapping increases the amount of color under the upper image so a slight misalignment does not show This affects PCL 5e PCL XL PDF and PostScript printing Increasing the value increases the amount of ...

Page 240: ... the network settings or the base printer settings to their factory default values When Restore Base is selected non critical base printer NVRAM settings are restored When Restore STD Net is selected all network NVRAM settings are restored to their factory default settings This option is available only on models with an integrated network adapter When Restore LES is selected all non standard appli...

Page 241: ...tray a change prompt is directed to when the envelopes are sensed to be the wrong size Action for Prompts This setting enables users to have the printer resolve media change prompt situations automatically Such prompts occur when the selected media for the job is not available when the job prints This setting applies only to jobs that cannot be parked Prompt user default setting The user must resp...

Page 242: ... Require Standby If set to Off this setting disables Standby Mode in the General Settings menu UI Automation Once enabled this setting creates an ENABLE_UI_AUTOMATION file in the shared directory As long as this file exists the printer permits external developers to test the stability of their applications against the printer to ensure that their applications have an appropriate level of stability...

Page 243: ...e if the paper being used matches the user s settings It is not uncommon to find a user printing on cardstock with the printer programmed to print on a plain paper setting The printer s feed and transport components can fail and cause paper jams or other feed and transport problems These components should be examined for damage or wear and replaced if necessary Paper path Information The printer h...

Page 244: ...age The redrive bubble sensor located after the fuser exit rollers in the paper path senses the bubble in the paper as it exits the fuser It then adjusts the fuser motor speed as necessary to avoid jams and smearing on the trailing edge of the paper Duplexing models with duplex support only Printers with duplex support use a secondary paper path to print on the second side of a sheet of paper The ...

Page 245: ...econd transfer to the paper 5 Fuse the toner to the paper 6 Clean erase the photoconductor and the ITU In summary the printer s controller board receives print data and the command to print The controller board then initiates the print process The controller board is the command center for the EP process and coordinates the various motors and signals The high voltage power supply HVPS sends charge...

Page 246: ... it for the laser beam Service tips If the surface of the charge roller is damaged such as a nick or pit it will cause the charge on the photoconductor to be uneven This will cause a repeating mark on the printed page Check the service manual for the repeating marks table If the charge roller is severely damaged the surface of the photoconductor will not be not be properly charged and heavy amount...

Page 247: ... gets contaminated with toner or other debris it will cause vertical streaking of white lightness on the page Cleaning the lens will solve the problem Never touch the surface of the photoconductor with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not properly stick The result would be repeating blotches of voids light print on a page Then the ...

Page 248: ...sing glue to write on a can and then rolling it over glitter The glitter sticks to the glue but won t stick to the rest of the can Service tips Never touch the surface of the developer roller with your bare hand The oil from your skin may cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the affec...

Page 249: ...ce contact between the Photoconductors and the ITU transfer belt Service tips Never touch the surface of the ITU belt with your bare hand The oil from your skin will cause a charge differential on the surface and toner will not stick properly The result would be repeating blotches of voids light print on a page Then the ITU belt will have to be replaced Do not use solvents or other cleaners to cle...

Page 250: ...e a positive charge Once the image on the transfer belt reaches the transfer roll the negatively charged toner clings to the paper and the entire image is transferred from the transfer belt to the paper Service tips If the transfer roller has nicks pits or flat spots on it the surface doesn t come into contact with the paper and transfer unit This will cause voids or light spots on the page or rep...

Page 251: ...aged they can cause toner to be pulled off the page or cause paper jams Toner that rubs off a printed page can be a sign of a malfunctioning fuser or an improper paper setting Always check the paper type setting before replacing the fuser A common mistake is to print on heavier media such as cardstock with the paper type set to plain paper When removing paper jams from the fuser be sure to use the...

Page 252: ...G This occurs for every page that is printed After the toner is moved to the cleaning blade the toner is moved to the waste toner area using an auger system Photoconductor Clean Erase After each plane of color has been transferred to the transfer belt from the photoconductors a cleaning blade H scrapes the remaining toner from the surface of each photoconductor This is the clean erase process Now ...

Page 253: ...ve all cords and cables from the printer before beginning 2 Place the printer on a corner of a work area so the front and back can be accessed 3 Remove the system board shield a Open the system board shield door and remove the two screws A from the system board shield CAUTION POTENTIAL INJURY The printer weight is greater than 32 kg 70 lb and requires three or more trained personnel to lift it saf...

Page 254: ...nd motor cables from the new printhead to the system board Note Use the packaging that came with the printhead FRU to prop up the printhead 5 Connect the power cord to the outlet and to the printer Reconnect any cords 6 Turn on the printer and check for the error message If the error still appears replace the system board See System board removal on page 4 151 If the error no longer appears replac...

Page 255: ...are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a tab...

Page 256: ...iner identification table on page 7 59 for descriptions and actual size illustrations of the screws Arrangement of removals in this chapter The removals in this chapter are arranged by area of the printer Base printer cover removals on page 4 3 Base printer removals on page 4 36 Input option removals on page 4 165 Output option removals on page 4 234 ...

Page 257: ...r removals Front access door assembly removal See Top right and front covers on page 7 3 for the part number 1 Remove the operator panel assembly See Operator panel OP assembly removal on page 4 110 2 Remove the three screws A from the front access door pivot A 88A0323 ...

Page 258: ...4 4 Service Manual 5062 Go Back Previous Next 3 Use a flat blade screwdriver to carefully pry up the front access door pivot and lift the pivot enough to remove the door ...

Page 259: ...Back Previous Next Left access door assembly removal See Left and rear covers on page 7 5 for the part number 1 Open the left access door assembly 2 Remove the three screws A from the cable cover and remove the cable cover A 88A0323 ...

Page 260: ...4 6 Service Manual 5062 Go Back Previous Next 3 Lift the locking tabs B on the connectors to disconnect the two cables 4 Remove the cables from the cable retainers C 5 Close the left access door B C ...

Page 261: ...the paper guide all the way to the left Carefully use a flat blade screwdriver to lift the multipurpose feeder inner cover and remove Note Be careful not to scratch or mar the cover Note Using a flat blade screwdriver pry out the back pin D far enough to be able to grasp the ends D 10J2832 ...

Page 262: ... the left access cover slightly grasp one of the pins and move the left access door back and forth gently while pulling the pin out This aligns the holes so the pins come out easily 9 Remove the other pin E in the same manner See steps 7 and 8 E 10J2831 ...

Page 263: ...ormation 4 9 5062 Go Back Previous Next 10 Open the left access door all the way and disconnect the rear piston by pulling apart the clamps F from the tabs 11 Remove the E clip G from the front piston F G 1126829 ...

Page 264: ...llation 1 Place the MPF cover on the bottom of the left cover and hold it in place while you put the assembly into place 2 Replace the pins making sure the flat side of each pin faces away from the printer 3 Reconnect the rear piston and then reconnect the front piston 4 Close the left access door open the MPF and replace the inner cover of the MFP 5 Close the MPF open the left access door and rec...

Page 265: ...oval See Left and rear covers on page 7 5 for the part numbers 1 Remove the rear cover See Rear cover removal on page 4 20 2 Use a flat blade screwdriver to disconnect the cable from the low voltage power supply 3 Open the MPF door enough to remove the screw A from the lower left cover under it ...

Page 266: ...062 Go Back Previous Next 4 Open the left access door and remove two screws B from the top and middle of the left cover 5 Open the standard media tray and remove the screw C from the front of the printer B 88A0323 C 88A0323 ...

Page 267: ...formation 4 13 5062 Go Back Previous Next 6 Lift the top cover enough to free the top of the left cover 7 Close the left access door and use a flat blade screwdriver to pop out the front of the lower left cover ...

Page 268: ...by pulling apart the clamps F from the tabs 10 Slide the left cover over the piston arm to remove the left cover and lower left cover together Note If you are removing the left cover to access another part then leave the left cover attached to the lower left cover If you need to replace the left cover FRU or the lower left cover FRU then continue with the next step to separate them F ...

Page 269: ...Repair information 4 15 5062 Go Back Previous Next 11 Slide the lower left cover down to remove it from the left cover ...

Page 270: ...Next Lower frame cable cover removal See Front on page 7 7 for the part number 1 Remove the ITU assembly See ITU assembly removal on page 4 77 2 Remove the screw A 3 Slide the cover toward the rear of the printer and lift to remove it A 88A0323 ...

Page 271: ...us Next Multipurpose feeder MPF cover removal See Left and rear covers on page 7 5 for the part number 1 Remove the left access door assembly See Left access door assembly removal on page 4 5 2 Separate the MPF from the left access door assembly ...

Page 272: ...A and then remove the bezel Note Three bezels are in the FRU Be sure the bezel you install matches the one you remove OP panel cover removal See Top right and front covers on page 7 3 for the part number 1 Remove the OP panel display See OP panel display removal on page 4 113 2 Remove any other cables or cards from the operator panel cover Note Your operator panel assembly may have more or fewer c...

Page 273: ...moval on page 4 22 2 Remove the top cap cover See Top cap cover removal on page 4 29 Note If you have any output options installed then the top cap cover is already removed Remove the output options and HTU redrive unit instead 3 Remove the two screws A on the right side 4 Lift and slide the cover toward the right of the printer to unlatch the tabs on the right edge and remove the cover A 88A0323 ...

Page 274: ...and rear covers on page 7 5 for the part number 1 Remove the rear upper cover See Rear upper cover removal on page 4 22 2 Remove the system board shield See System board shield removal on page 4 27 3 Remove the three screws A and the two screws B A 88A0323 B 88A0212 A 88A0323 ...

Page 275: ...revious Next 4 Push in the indicated areas of the right side and left side covers and pull out the rear cover tabs Note On the right cover side start with the top tab On the left cover side start with the bottom tab 5 Remove the rear cover ...

Page 276: ...upper cover removal See Left and rear covers on page 7 5 for the part number 1 Open the system board shield door and remove the two screws A and the one screw B 2 Pull toward the rear and lift the corner off the rear upper cover post A 88A0323 B 88A0212 ...

Page 277: ...Repair information 4 23 5062 Go Back Previous Next 3 Separate the system board shield door from the rear upper cover ...

Page 278: ...oval on page 4 150 2 Remove the rear cover See Rear cover removal on page 4 20 3 Remove the top cap cover See Top cap cover removal on page 4 29 Note If you have any output options installed then the top cap cover is already removed Remove the output options and HTU redrive unit instead 4 Open the front access door and remove the black and magenta cartridges 5 Remove the screw A A 88A0323 ...

Page 279: ...Repair information 4 25 5062 Go Back Previous Next 6 Remove the screw B 7 Remove the four screws C B 88A0212 C 88A0323 ...

Page 280: ...4 26 Service Manual 5062 Go Back Previous Next 8 Pull the tabs D away from the pins and then pull out and down on the rear of the right cover to remove it D ...

Page 281: ...emove the system board shield door remove the rear upper cover See Rear upper cover removal on page 4 22 System board shield removal See Left and rear covers on page 7 5 for the part number 1 Open the system board shield door and remove the two screws A on the system board shield A 27S2839 ...

Page 282: ...4 28 Service Manual 5062 Go Back Previous Next 2 Swing the shield open about an inch and slide the shield to the left to remove the shield ...

Page 283: ...062 Go Back Previous Next Top cap cover removal See Top right and front covers on page 7 3 for the part number 1 Squeeze the cover and rock it back to disengage the latches 2 With the cover tilted back and pull up to remove it ...

Page 284: ...emove the printhead access cover See Printhead access cover removal on page 4 19 2 Remove the rear cover See Rear cover removal on page 4 20 3 Remove the screw A to disconnect the ground cable 4 Remove the front access door See Front access door assembly removal on page 4 3 5 Remove three screws on the front B A 880A0212 B 88A0323 ...

Page 285: ...Repair information 4 31 5062 Go Back Previous Next 6 Open the left access door and remove the screw C 7 On the top remove two metal screws D C 88A0323 D 88A0212 ...

Page 286: ...4 32 Service Manual 5062 Go Back Previous Next 8 On the right side remove two screws E and one screw F 9 Pull the tabs away from the pins and lift the top cover E 88A0323 F 88A0212 ...

Page 287: ...in full sensor 11 Remove the top cover Note If you are removing the top cover to replace the cover or the cables tied to it then clip the four cable ties and remove the operator panel and sensor cables If you are replacing the cover then also disconnect the output option cable from JOOPT1 on the system board H G ...

Page 288: ...ront covers on page 7 3 for the part number 1 Remove the standard media tray See Standard media tray removal on page 4 150 2 Remove the logo panel See Logo panel removal on page 4 85 3 Remove the yellow print cartridge 4 Remove the eight screws A from the waste toner left cover A 88A0323 88A0323 A ...

Page 289: ...revious Next 5 Pinch the release tab D and disconnect the beacon cable Waste toner sensor cover removal 1 Remove the waste toner container See Waste toner container removal on page 4 158 2 Remove the screw A to remove the cover D A 88A0323 ...

Page 290: ...Next Base printer removals ACM bias spring removal See Left on page 7 11 for the part number 1 Remove the paper pick mechanism assembly See Paper pick mechanism assembly removal on page 4 120 2 Remove the screw A to remove the spring A 88A0323 ...

Page 291: ...information 4 37 5062 Go Back Previous Next Bin full flag removal See Top right and front covers on page 7 3 for the part number 1 Pull the flag forward out of the clips 2 Rotate the flag and pull to remove it ...

Page 292: ...ck Previous Next Bin full sensor removal See Sensors parts packet including on page 7 7 for the part number 1 Remove the top cover See Top cover removal on page 4 30 2 Press in the tabs to remove the sensor from under the top cover ...

Page 293: ...ge blower assembly removal See Front on page 7 7 for the part number 1 Remove the right cover See Right cover removal on page 4 24 2 Remove the front access door See Front access door assembly removal on page 4 3 3 Remove the screw A in the top cover A 88A0323 ...

Page 294: ...rvice Manual 5062 Go Back Previous Next 4 Lift the blower assembly slightly up and to the left to free the bottom 5 Flex the top cover up and rotate the blower assembly to the right to free the hook at the top ...

Page 295: ...Repair information 4 41 5062 Go Back Previous Next 6 Press the release tab B to disconnect the cable from the assembly B ...

Page 296: ...bly removal See Front continued on page 7 9 for the part number 1 Remove the waste toner container See Waste toner container removal on page 4 158 2 Remove the print cartridges 3 Remove the three screws A from the cartridge contact block assembly 4 Remove the assembly A 88A0212 ...

Page 297: ...Repair information 4 43 5062 Go Back Previous Next Installation note Be sure to line up the notches in the HVPS board with the ridges on the cartridge contact block assembly ...

Page 298: ...cable A B C or D for the memory block you want to remove The terminals are interchangeable so trace the cable back from the memory block to locate the correct connector Note To easily route the new cable to the system board tie a string at least twelve inches long to the end of the cable you disconnect from the system board When you pull the cable through the printer be careful to leave the other ...

Page 299: ...le through be sure to leave the string in the path from the memory block to the system board Installation notes 1 Attach the memory block and tie the string to its cable 2 Connect the sensor cable to the sensor and then attach the sensor to the memory block 3 From the rear of the printer pull the string to feed the memory block cable through the frame to the system board Warning Be sure to pull th...

Page 300: ...n page 4 77 3 Disconnect the cyan yellow cables A or the black magenta cables B from the sensors Note To easily route the new cable to the system board tie a string at least twelve inches long to the end of each sensor cable you disconnect When you pull the cables through the printer be careful to leave one end of each string inside the printer and the other end on the system board 4 Disconnect th...

Page 301: ...ble 3 From the inside of the printer pull the strings to feed the sensor cables through to the memory blocks 4 Connect the sensor cables to the sensors Cartridge rail removal See Front on page 7 7 for the part number 1 Remove the print cartridges 2 Remove the screw A from the rail you want to remove 3 Slide the rail forward and drop it down to remove it A 88A0212 ...

Page 302: ...ual 5062 Go Back Previous Next Installation notes 1 Insert the tab on the rail into the slot B in the back and then lift and slide the rail into the notches C on the top 2 Apply the correct color label to new rail C B ...

Page 303: ...nformation 4 49 5062 Go Back Previous Next CPU cooling fan removal See Rear on page 7 15 for the part number 1 Open the system board shield door and remove the two screws A on the system board shield A 27S2839 ...

Page 304: ...4 50 Service Manual 5062 Go Back Previous Next 2 Open the shielddoor 3 Disconnect the cable A from the system board and remove the four screws B 4 Remove the fan from the heatsink B A ...

Page 305: ...umber 1 Remove the ITU assembly See ITU assembly removal on page 4 77 2 Remove the fuser See Fuser assembly removal on page 4 63 Front crank a Remove the waste toner left cover See Waste toner left cover removal on page 4 34 b Remove the E clip A c Unhook the spring B and pull to remove the bell crank B A 1126830 ...

Page 306: ...r crank a Remove the left cover See Left cover removal on page 4 11 b Remove two screws B and the four screws C to remove the rear fuser guide c Remove the E clip D d Unhook the spring E and pull to remove the bell crank C 88A0212 B 10J1046 D 1126830 E ...

Page 307: ...See Left and rear covers on page 7 5 for the part number 1 Remove the left access door assembly See Left access door assembly removal on page 4 5 2 Remove the screw A that secures the duplex assembly to the left access cover 3 Lift the duplex assembly from the left access door ...

Page 308: ...Previous Next Installation notes 1 If you are replacing the duplex drive belt then carefully check the routing as you install the new belt 2 Align the edge A of the duplex assembly under the back edge of the left access door assembly A ...

Page 309: ...Repair information 4 55 5062 Go Back Previous Next 3 Align the top edge of the duplex assembly with the post and then replace the screw ...

Page 310: ...1 Remove the system board cage with board See System board cage with board removal on page 4 155 2 Disconnect the cable A from the fuser motor Note If you are replacing the cables remove the toroids from the old cables and use cable ties to attach the toroids to the new cables 3 Remove the eight screws B A B 88A0212 ...

Page 311: ...Repair information 4 57 5062 Go Back Previous Next 4 Push the assembly up and pull to remove it ...

Page 312: ...t ESD bracket removal See Top right and front covers on page 7 3 for the part number 1 Remove the operator panel assembly See Operator panel OP assembly removal on page 4 110 2 Remove the screw A securing the ESD bracket to the top cover A 88A0232 ...

Page 313: ...Repair information 4 59 5062 Go Back Previous Next 3 Push on the wall of the top cover and rotate the front of the ESD bracket upward 4 Slide the ESD bracket off the bin full bracket 2 1 ...

Page 314: ...e part number 1 Remove the system board cage with board See System board cage with board removal on page 4 155 2 Remove the main fan See Main fan removal on page 4 92 3 Remove one screw A and three screws B 4 Clip two cable ties and pull enough slack in the cables to remove the duct B 88A0323 A 88A0212 ...

Page 315: ... toner left cover See Waste toner left cover removal on page 4 34 2 Remove the two screws A from the beacon cover and then lift off the cover 3 Carefully pull the cable through the holes B to remove it Installation notes Feed the cable through the holes with the beacon LED end first Place the beacon LED into the beacon cover so that the LED extends from the end A 88A0323 B ...

Page 316: ...4 62 Service Manual 5062 Go Back Previous Next Be sure the beacon LED extends through the opening in the waste toner left cover before attaching the beacon cover screws ...

Page 317: ... Go Back Previous Next Fuser assembly removal See Left on page 7 11 for the part numbers 1 Open the left access door assembly 2 Pull down the two fuser latches A CAUTION Be sure the fuser assembly has cooled before you remove it A ...

Page 318: ... Service Manual 5062 Go Back Previous Next 3 Pull to remove the fuser assembly Installation note After inserting the fuser assembly push up the handles and then push up the tab under the right handle 2 1 1 ...

Page 319: ...ee Rear on page 7 15 for the part number 1 Remove the rear cover See Rear cover removal on page 4 20 2 Remove the fuser assembly See Fuser assembly removal on page 4 63 3 Remove the E clip A and the washer under it from the fuser gears and then slide the gears off the post A 1126829 ...

Page 320: ...the cable B from the fuser motor 5 Remove the three screws C 6 Remove the fuser drive assembly Installation note Be sure to apply grease to the gear and post using the instruction sheet and two kinds of grease that came with the fuser drive assembly B C 88A0212 ...

Page 321: ...tinued on page 7 13 for the part number 1 Remove the ITU See ITU assembly removal on page 4 77 2 Remove the fuser See Fuser assembly removal on page 4 63 3 Remove the waste toner left cover See Waste toner left cover removal on page 4 34 4 Remove three screws A 5 Remove three screws B A 88A0323 B 10J1046 ...

Page 322: ...support guide from the frame Note If you are just testing the cable as part of a service check then stop here 7 Remove the OP panel See Operator panel OP assembly removal on page 4 110 8 Clip all cable ties securing the cable 9 Remove the system board shield See System board shield removal on page 4 27 C ...

Page 323: ...Repair information 4 69 5062 Go Back Previous Next 10 Disconnect the fuser system card cable D from the system board 11 Push in the tab E to disconnect the cable from the LVPS and remove the cable D E ...

Page 324: ...s Next Fuser thermistor removal See Fuser thermal guide assembly on page 7 58 for the part number 1 Remove the fuser See Fuser assembly removal on page 4 63 2 Disconnect the cable A 3 Remove four screws B to remove the thermistor A B 88A0212 ...

Page 325: ...n page 7 7 for the part number 1 Remove the ITU block assembly See ITU block assembly removal on page 4 80 2 Remove the rear cover See Rear cover removal on page 4 20 3 Remove the two screws A to remove the connector shield from the system board 4 Disconnect the HVPS cable B from the system board A 88A0232 B ...

Page 326: ... 5062 Go Back Previous Next 5 Remove three screws C and then pull out the cartridge contact block assembly 6 Remove the screw D from the center of the plate over the HVPS 7 Pull the HVPS board forward C 88A0212 D 88A0121 ...

Page 327: ... the HVPS board 9 Pull the board all the way out of the printer Note If you are replacing only the HVPS cable then stop here 10 Remove the screw E and three screws F from the bottom of the board to remove the metal post G and the plastic contact bracket H F 88A0323 E 88A0121 H G ...

Page 328: ...ice Manual 5062 Go Back Previous Next Installation notes Be sure the HVPS cable sits in the groove under the HVPS board Be sure the ITU block assembly sits flat before attaching the three screws to reinstall it ...

Page 329: ...USB cable 3 Disconnect the cable from the UICC card to remove it Housing interlock assembly removal See Front on page 7 7 for the part number 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 86 2 Remove the lower frame cable cover See Lower frame cable cover removal on page 4 16 3 Remove the waste toner left cover See Waste toner left cover removal on page 4 34 4 Remove one sc...

Page 330: ...ble B from the sensor and remove three screws C 6 Disconnect the cable from the system board JCVR1 7 Route the cable through the printer to remove the assembly Clip and remove cable ties as needed Note Observe the cable routing for reinstallation C 88A0323 B A 88A0323 ...

Page 331: ...aste toner container See Waste toner container removal on page 4 158 2 Remove the print cartridges 3 Open the left access door assembly all the way 4 Grasp the ITU handle A and carefully slide the ITU assembly from the printer Warning Be careful to support the ITU as you remove it to avoid damaging the components on the left access door A ...

Page 332: ...Remove the rear cover See Rear cover removal on page 4 20 2 Remove the right cover See Right cover removal on page 4 24 3 Remove the ITU assembly See ITU assembly removal on page 4 77 4 Remove two screws A to remove the connector shield from the system board 5 Disconnect the cable B from connector JITM1 A 88A0232 B ...

Page 333: ...nformation 4 79 5062 Go Back Previous Next 6 Clip the cable tie and remove the toroid Note Be sure to replace the toroid during reinstallation 7 From the right side and back of the printer remove four screws C ...

Page 334: ...ous Next 8 Pull to remove the autoconnect ITU block assembly removal See Front on page 7 7 for the part number 1 Remove the ITU assembly See ITU assembly removal on page 4 77 2 Remove the three screws A from the ITU block assembly A 88A0323 ...

Page 335: ...Repair information 4 81 5062 Go Back Previous Next 3 Pull up to remove the assembly Installation note Be sure the ITU block assembly sits flat before attaching the three screws to reinstall it ...

Page 336: ...ual 5062 Go Back Previous Next Left access door piston removal See Left continued on page 7 13 for the part number 1 Open the left access door assembly Front piston a Remove the E clip G from the front piston G 1126829 ...

Page 337: ... b Remove the post H from the piston where it attaches to the printer Note The piston is under pressure from the spring Hold the piston firmly as you remove the post c Remove the E clip I and post J from the other end to remove the piston H I 1126830 J ...

Page 338: ...ce Manual 5062 Go Back Previous Next Rear piston a Disconnect the piston by pulling apart the clamps F from the tabs b Remove the E clip G and post H from the piston where it attaches to the printer F H G 1126830 ...

Page 339: ...ious Next c Remove the E clip I and post J from the other end to remove the piston Logo panel removal See Top right and front covers on page 7 3 for the part number 1 Open the front access door 2 Remove the three screws A C I 1126827 A 88A0323 ...

Page 340: ...the panel up and pull to remove it Low voltage power supply LVPS removal See Rear on page 7 15 for the part number 1 Remove the rear cover See Rear cover removal on page 4 20 2 Push the release A to disconnect the power cable B and the fuser cable C C B A A ...

Page 341: ...Repair information 4 87 5062 Go Back Previous Next 3 Remove two screws D to remove the connector shield from the system board 4 Disconnect the LVPS cables E from the system board D 88A0232 E ...

Page 342: ...4 88 Service Manual 5062 Go Back Previous Next 5 Disconnect the thermistor cable from the system board 6 Remove the three screws F and the two screws G 7 Remove the LVPS F 88A0212 G G 88A0323 ...

Page 343: ...the old LVPS and then attach the thermistor to the replacement LVPS with a new cable tie 10B1648 LVPS exit duct removal See Rear on page 7 15 for the part number 1 Remove the LVPS See Low voltage power supply LVPS removal on page 4 86 2 Remove the LVPS fan See LVPS fan removal on page 4 90 3 Disconnect the MPF sensor cable A from JMFP1 on the system board A ...

Page 344: ... Go Back Previous Next 4 Remove two screws B LVPS fan removal See Rear on page 7 15 for the part number 1 Remove the rear cover See Rear cover removal on page 4 20 2 Disconnect the fan cable A from the system board B 88A0323 A ...

Page 345: ...mation 4 91 5062 Go Back Previous Next 3 Push in to open the cable clip B behind the system board shield 4 Feed the cable through the slot in the system board cage and the clip 5 Remove the two screws C B C 10B1580 ...

Page 346: ... Feed the cable through the slot in the fan housing D as you remove the fan Main fan removal See Rear on page 7 15 for the part number 1 Remove the rear cover See Rear cover removal on page 4 20 2 Disconnect the fan cable A from the system board D A ...

Page 347: ...Repair information 4 93 5062 Go Back Previous Next 3 Remove the screws B 4 Feed the cable through the slot in the system board cage and remove the fan B 10B1580 ...

Page 348: ...ay See Standard media tray removal on page 4 150 2 Remove the waste toner container See Waste toner container removal on page 4 158 3 Remove the print cartridges 4 Remove the rail Left rail a Shut the front access door b Gently lay the printer on its back c Remove the screw A on the bottom of the printer and the screw B on the front A 10J1046 B 88A0323 ...

Page 349: ...Repair information 4 95 5062 Go Back Previous Next d Lift the rail out of the printer Right rail a Remove the screw C to release the tension on the right side cover C 88A0323 ...

Page 350: ...2 Go Back Previous Next b Shut the front access door c Gently lay the printer on its back d Remove the screw D on the bottom of the printer and the screw E and screw F on the front of the printer D 10J1046 E 88A0323 F 88A0212 ...

Page 351: ...Repair information 4 97 5062 Go Back Previous Next e Pull aside the right side cover f Pull up and to the left to remove the rail from the printer ...

Page 352: ...ace and then fit them over the pins on the front of the printer MPF breakaway assemblies removal See Left on page 7 11 for the part numbers 1 Remove the rear cover See Rear cover removal on page 4 20 2 Remove the standard media tray See Standard media tray removal on page 4 150 3 Gently lay the printer on its back 4 Remove the screw 88A0212 from the LVPS ...

Page 353: ...ws B and remove the bottom plate Note If you are replacing the input option cable then push it up through the frame and then stand the printer back up to remove the cable Rear breakaway assembly a Remove three screws D b Pull to remove the assembly A 88A0323 B 10J1046 B 10J1046 D 88A0323 ...

Page 354: ...4 100 Service Manual 5062 Go Back Previous Next Front breakaway assembly a Remove two screws E b Using a flat blade screwdriver pry out the top and then pull to remove the assembly E 88A0323 ...

Page 355: ...drive pulley See Left and rear covers on page 7 5 for the part numbers 1 Remove the left cover See Left cover removal on page 4 11 2 Remove the waste toner left cover See Waste toner left cover removal on page 4 34 3 Carefully pull the MPF drive belt from the MPF drive pulley 4 Remove the E clip A and then remove the pulley B ...

Page 356: ...ervice Manual 5062 Go Back Previous Next 5 Remove the ratchet collar C and remove the bushing under it 6 From the front of the printer rotate the front bushing so the tabs line up with the slots in the frame C ...

Page 357: ... 4 103 5062 Go Back Previous Next 7 Slide the rod toward the front of the printer to free the rear side Installation note Be sure to replace the thrust washer in the ratchet collar before installing the MPF drive pulley ...

Page 358: ...number Always replace both pick rolls and the special wear strip at the same time 1 Open the left access door 2 Remove the screw A in the top cover Remove the rubber rolls A from the hubs The hubs stay on the printer 3 Insert a flat blade screwdriver behind the top of the special wear strip and then twist the screwdriver to pop out the strip A ...

Page 359: ...k Previous Next Installation notes Slide the edge of a pick tire between the rear hub extension and the printer frame and then slide the roll down to the hub Be sure the flaps on the pick rolls slant away from the direction the rolls turn ...

Page 360: ... Back Previous Next Verify the rolls turn freely MPF drive assembly removal See Rear on page 7 15 for the part number 1 Remove the LVPS exit duct See LVPS exit duct removal on page 4 89 2 Slide the belt off the MPF redrive pulley ...

Page 361: ...Repair information 4 107 5062 Go Back Previous Next 3 Remove four screws A and remove the assembly 4 Remove the E clip B and the gear C to remove the belt from the assembly ...

Page 362: ...g the belt be sure the belt sits on the teeth at the base of the gear MPF sensor plate assembly removal See Left and rear covers on page 7 5 for the part number 1 Open the left access door assembly 2 Use a flat blade screwdriver to push in the tab and lift to remove the assembly 1 2 ...

Page 363: ...ensor cable A and remove the assembly MPF wear strips removal See Left and rear covers on page 7 5 for the part numbers 1 Open the left access door assembly 2 Insert a flat blade screwdriver behind the top of the strip and then twist the screwdriver to pop out the strip A ...

Page 364: ...Top cap cover removal on page 4 29 Note If you have any output options installed then the top cap cover is already removed Remove the output options and HTU redrive unit instead 2 Remove the OP panel bezel See OP panel bezel removal on page 4 18 3 Remove four screws A 4 Rotate the panel up and pull it out A 88A0323 ...

Page 365: ...Repair information 4 111 5062 Go Back Previous Next 5 Disconnect the cables B going from the UICC card to the printer 6 Remove the operator panel assembly B ...

Page 366: ...oval See Top right and front covers on page 7 3 for the part number 1 Remove the OP panel UICC card See OP panel UICC card removal on page 4 114 2 Remove the button you want by squeezing in the latches A and pushing the button through the front of the operator panel A ...

Page 367: ...Previous Next OP panel display removal See Top right and front covers on page 7 3 for the part number 1 Remove the OP panel UICC card See OP panel UICC card removal on page 4 114 2 Remove the four screws A and lift off the holder A 88A0323 ...

Page 368: ...ed component and then perform a POR before replacing a second component listed above If this procedure is not followed the printer will be rendered inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components On...

Page 369: ...e card Note Be sure to secure the ESD ground under the screw next to the bracket 3 Enter the Diagnostics menu hold 3 and 6 turn the printer on and release the buttons when the splash screen appears 4 Determine if the problem is resolved Do not perform a normal POR until you are sure you have resolved the problem If the problem is not resolved then turn the printer off and reinstall the old part If...

Page 370: ... Remove the standard media tray See Standard media tray removal on page 4 150 2 Remove the waste toner container See Waste toner container removal on page 4 158 3 Remove the print cartridges 4 Shut the front access door 5 Gently lay the printer on its back 6 Remove the screw A from the pad you want to remove A 10J1046 ...

Page 371: ...page 4 150 2 Push down on the sensor to remove it from the rear frame and then disconnect the cable A Paper path redrive assembly with sensors removal See Left continued on page 7 13 for the part number 1 Remove the OP panel See Operator panel OP assembly removal on page 4 110 2 Remove the main fan See Main fan removal on page 4 92 3 Remove the fuser See Fuser assembly removal on page 4 63 A ...

Page 372: ...4 118 Service Manual 5062 Go Back Previous Next 4 Disconnect the sensor cables A 5 Clip the cable tie and route the cables through the frame A ...

Page 373: ...rom the rear and three from the front 7 Insert a flat blade screwdriver angled toward the top of the front side of the assembly and deflect the front plate enough to drop down the front end of the assembly 8 Pull the sensor cables through the frame to remove the assembly B B 88A0323 ...

Page 374: ...ensor cables are routed as shown before you reinstall the assembly Paper pick mechanism assembly removal See Front continued on page 7 9 for the part number 1 Remove the standard media tray See Standard media tray removal on page 4 150 2 Disconnect the cable A from the connector A ...

Page 375: ...ower the pick arm all the way 4 Rotate the release lever B pull it toward you and then lower the assembly to remove it from the printer Installation note See Pick arm stuck down service check on page 2 164 to out the pick arm back to its original position B ...

Page 376: ...the part number Note Replace both rolls at the same time 1 Remove the paper pick mechanism assembly See Paper pick mechanism assembly removal on page 4 120 2 Remove the screws A from both sides to release the pick roll hubs 3 Remove the pick rolls Installation notes Verify the rolls turn freely A 88A0412 ...

Page 377: ...rs on page 7 3 for the part number 1 Remove the printhead access cover See Printhead access cover removal on page 4 19 2 Remove the system board shield See System board shield removal on page 4 27 3 Disconnect the three printhead cables A from the system board and feed the cables through the slot in the system board shield A ...

Page 378: ...4 124 Service Manual 5062 Go Back Previous Next 4 Remove the six screws B from the brackets and remove the brackets 5 Tilt the printhead forward and lift to remove it B 10J3568 ...

Page 379: ...d coarse aligning the printhead 1 Place the printhead into the printer angled forward sliding the adjustment screws into the slots in the printer frame 2 Lower the back of the printhead until the post on the back right corner drops into the hole in the printer frame ...

Page 380: ...to the system board Warning Be careful reconnecting the printhead ribbon cables Flat ribbon cables can easily be damaged and should be connected gently by hand 4 Slide the left side of the printhead toward the back of the printer until the bottom of the coarse alignment screw B stops against the ridge in the printer frame A B ...

Page 381: ...e the triangles on the top of the test page go to Top Margin on page 4 130 and adjust the top margin until the triangles are visible 9 Use a flat blade screwdriver to adjust the coarse alignment screw C until the triangles on the sheet are parallel to the edges of the paper Turning the screw clockwise moves the left triangles lower and the right triangles higher tilts the printed image to the left...

Page 382: ...4 128 Service Manual 5062 Go Back Previous Next 12 Attach the front bracket and tighten the screws E 13 Reprint the alignment page and adjust the screw if necessary ...

Page 383: ...ve 2 From the Diagnostic menu select Diode Alignment Page An alignment test page prints If the alignment is correct the color bars on the page should look solid in the middle between 1 and 1 with white lines starting to form near the top and bottom of each bar 3 If the solid color area of a bar is above 1 or below 1 then adjust the Dual Diode value for that color Enter the number nearest the cente...

Page 384: ...creasing the value moves the alignment marks up the page 3 Reprint the test page and make adjustments as needed until you are satisfied with the alignment Left Margin 1 Select Left Margin 2 Adjust the left margin until the points of the left alignment marks touch the edge of the page Increasing the value moves the alignment marks to the left Decreasing the value moves the alignment marks to the ri...

Page 385: ...To use the skew tool punch a screwdriver through the center of the wheel Using a mark on the screwdriver handle as a point of reference turn the paper until 0 lines up with your mark 3 From the Diagnostic menu navigate to ALIGNMENT MENU Yellow Quick Test Two alignment pages print The first page is for adjusting the Skew and Top Margin and the second page is for the Left Margin and Right Margin For...

Page 386: ...enta selecting Cyan and Magenta from the Alignment menu Note Do not move on to the Top Margin settings until the Skew A and B values are within 1 of 0 7 From the Diagnostic menu navigate to ALIGNMENT MENU Yellow Top Margin 8 Set Top Margin to 0 and save the value 9 Do the same for Linearity It is important to set the values to 0 before continuing 10 From the Yellow menu select Quick Test to reprin...

Page 387: ...ray stripe extends above 12 or below 12 where it crosses the Left Center or Right line then adjust the Left Adjustment Center Adjustment or Right Adjustment for that color Enter the number closest to where the gray stripe crosses the line Example The gray stripe on the following test page extends up to around 16 near the Center line From the Yellow Linearity menu enter 16 for the Center Adjustment...

Page 388: ...al See Left on page 7 11 for the part number 1 Remove the top cover See Top cover removal on page 4 30 2 Remove the E clip A and the washer behind it and then remove the gears Note You might need to use a flat blade screwdriver to carefully pry the gears from the posts ...

Page 389: ...Repair information 4 135 5062 Go Back Previous Next Redrive motor removal See Left on page 7 11 for the part number 1 Remove the top cover See Top cover removal on page 4 30 2 Slide off the cap A A ...

Page 390: ...4 136 Service Manual 5062 Go Back Previous Next 3 Disconnect the cable B from the motor 4 Remove the two screws C to remove the motor B C 88A0212 ...

Page 391: ...ensor D1 D2 and fuser bubble removal 1 Open the left access door 2 Remove two screws A from the duplex unit and remove the rail cover 3 Pull out the sensor assembly and rotate it up 4 Slide out the sensor you are replacing fuser bubble A D1 B D2 C A A B C ...

Page 392: ...e notch in the duplex unit before you reattach the rail cover Sensor input S1 narrow media near narrow media removal See Left on page 7 10 for the part number 1 Remove the staging deflector assembly See Staging deflector assembly removal on page 4 140 2 Locate the sensor you need to replace input A S1 B narrow media C near narrow media D ...

Page 393: ... sensor cable to remove the sensor Installation note Reinstall a sensor retainer after you attach the new sensor Speaker removal See Top right and front covers on page 7 3 for the part number 1 Remove the operator panel assembly See Operator panel OP assembly removal on page 4 110 2 Remove the screw A and the pull to remove the speaker A 88A0323 ...

Page 394: ...or assembly removal See Left on page 7 11 for the part number 1 Remove the ITU assembly See ITU assembly removal on page 4 77 2 Push the top of the deflector down and rotate it back to release the upper hooks 3 Disconnect the cables A from the four sensors 1 1 2 A ...

Page 395: ...n notes Be sure the cables are routed through the cable hooks B before you snap the assembly into place Use the cable lengths as a guide to make sure you connect the correct cable to each sensor Be sure the hooks engage both the bottom and top posts on each side B ...

Page 396: ...4 20 2 Remove the left cover See Left cover removal on page 4 11 3 Remove the fuser See Fuser assembly removal on page 4 63 4 Remove the ITU assembly See ITU assembly removal on page 4 77 5 Remove the standard media tray See Standard media tray removal on page 4 150 6 Lower the pick arm all the way 7 Push the top of the deflector assembly down and rotate it back to release the upper hooks 1 1 2 ...

Page 397: ...Repair information 4 143 5062 Go Back Previous Next 8 Set the deflector assembly out of the way as far as the sensor cables will allow 9 Remove the screw A to remove the ground cable ...

Page 398: ...4 144 Service Manual 5062 Go Back Previous Next 10 Remove two screws C from the ITU DS roller plate and then remove the plate 11 Remove two screws D ...

Page 399: ... the bottom of the staging assembly and then rock it back to free it from the frame 13 Disconnect the two cables from the motors to remove the assembly Installation notes Be sure the duplex motor cable is not pinched or bound by the reference edge assembly 1 2 ...

Page 400: ... alignment of the reference edge See Aligning the staging paper path reference edge on page 4 147 Notes When installing the staging paper path reference edge do not turn the adjustment screw during installation Do not replace or adjust the printhead and the staging paper path reference at the same time See Pick arm stuck down service check on page 2 164 to put the pick arm back to position ...

Page 401: ...embly use the following instructions to make sure it is properly aligned Aligning the staging paper path reference edge 1 Verify that the media is square Do the following steps a Remove two consecutive pieces of paper from the ream b Flip one of the pages over in the direction shown below c This shows the final position of the two pages 1 2 Long Edge 1 2 1 ...

Page 402: ... the tray guides in Tray 1 for the media being used and place at least 100 sheets in the tray 3 Power on the printer and make Tray 1 as the defualt tray Do any of the following From the control panel select the Default Source from the Paper Menu For Windows users select the paper source from Print Properties Square Media Top and sides are perfectly aligned The two pages do not align perfectly at t...

Page 403: ...p margin until the marks are visible 6 If the left and right top alignment marks are not parallel with the top edge of the page then adjust the screw A accordingly Turn the screw clockwise to move the left marks up the page or turn it counterclockwise to move the right marks up 7 Reprint the Quick Test page to check the changes and then continue adjusting the screw as needed Aligning the top margi...

Page 404: ...5062 Go Back Previous Next Standard media tray removal See Top right and front covers on page 7 3 for the part number Pull the tray out and lift slightly The tray will lift out of the slides A and the slides will retract A ...

Page 405: ...ed inoperable Never replace two or more of the components listed above without a POR after installing each one or the printer will be rendered inoperable Warning Never install and remove components listed above as a method of troubleshooting components Once you install one of these components in a printer and perform a POR the component cannot be used in another printer It must be returned to the ...

Page 406: ...ote Some cables have special connectors that require you to press in tabs to disconnect the cables Note The cables may or may not include a pigtail connector B 5 Remove any options from the system board Be sure to replace them during reinstallation 6 Remove the screws C from the ports B C 88A0232 ...

Page 407: ...Repair information 4 153 5062 Go Back Previous Next 7 Remove the nine screws D and then remove the system board by sliding it to the left so the Ethernet port E clears the shield D 88A0232 E ...

Page 408: ...et caught in the EP drive motors 2 Enter the Diagnostics menu hold 3 and 6 turn the printer on and release the buttons when the splash screen appears 3 Determine if the problem is resolved Do not perform a normal POR until you are sure you have resolved the problem If the problem is not resolved then turn the printer off and reinstall the old part If the problem is resolved then turn the printer o...

Page 409: ...e 4 86 2 Remove two screws A to remove the connector shield from the system board 3 Disconnect all cables from the system board and feed them through the slots in the system board cage Note Some cables have special connectors that require you to press in tabs to disconnect the cables Note The cables may or may not include a pigtail connector B A 88A0232 B ...

Page 410: ...4 156 Service Manual 5062 Go Back Previous Next 4 Remove the screw C 5 Tilt the cage forward and slide it up to remove it C 88A0212 ...

Page 411: ...ure each cable is connected to the correct connector For diagrams and tables showing where each cable connects see Locations on page 5 1 Note The four cables can be plugged into any of the four connectors JPK1 JPM1 JPY1 and JPC1 on the board Note Pull the four cables into the system board cage area as far as possible so that they would not get caught in the EP drive motors ...

Page 412: ... Flip the green handles forward and pull out the waste toner container Waste toner gears removal See Rear on page 7 15 for the part number 1 Remove the EP drive See EP drive assembly removal on page 4 56 2 Remove the E clip A from the larger gear and remove the gear 3 Remove the E clip A from the smaller gear and remove the gear A 1126830 ...

Page 413: ...e part number 1 Remove the waste toner container See Waste toner container removal on page 4 158 2 Remove the screw A and remove the waste toner sensor cover 3 From the left side of the printer push in the clips and then pull the sensor out from the front 4 Disconnect the cable to remove the sensor A 88A0323 ...

Page 414: ...r frame cable cover See Lower frame cable cover removal on page 4 16 4 Remove the LVPS See Low voltage power supply LVPS removal on page 4 86 5 Disconnect the cable connector from the system board at JWTB1 Note The waste toner cable splits to connect to three beacons and two sensors on the front of the printer You disconnected the cable from one beacon when you removed the waste toner left cover 6...

Page 415: ...holding the cable and then pull the cable through the frame to remove it Waste toner full cable removal See Waste toner full cable on page 7 57 for the part number 1 Remove the ITU block assembly See ITU block assembly removal on page 4 80 2 Remove the HVPS See High voltage power supply HVPS board removal on page 4 71 3 Disconnect the cable from the system board at JWTBF1 A A 88A0313 B A ...

Page 416: ...sensor and pull the cable through the frame Waste toner full sensor removal See Front on page 7 7 for the part number 1 Remove the waste toner container See Waste toner container removal on page 4 158 2 Pry out the sensor from the front and disconnect the cable to remove the sensor ...

Page 417: ...bracket removal See Front on page 7 7 for the part number 1 Remove the lower frame cable cover See Lower frame cable cover removal on page 4 16 2 Disconnect the cable 3 Using a short screwdriver remove five screws D four from the bottom of the tray and one from the front ...

Page 418: ...4 164 Service Manual 5062 Go Back Previous Next 4 Pull the right frame back to free the side of the tray and then pull the tray forward to remove it ...

Page 419: ...Repair information 4 165 5062 Go Back Previous Next Input option removals 550 sheet tray Note Carefully remove the 550 sheet tray option from the base printer before proceeding ...

Page 420: ...7 17 for the part number 1 Remove the 550 sheet media tray assembly from the 550 sheet drawer assembly The 550 sheet drawer assembly remains 550 sheet media tray assembly removal See Optional 550 sheet tray on page 7 17 for the part number 1 Open the media tray assembly until it stops 2 Slightly lift up the media tray ...

Page 421: ...oval on page 4 166 2 Remove the top metal cover See 550 sheet tray top metal cover removal on page 4 183 3 Remove the deflector See 550 sheet tray deflector removal on page 4 169 4 Remove the pick assembly See 550 sheet tray pick assembly removal on page 4 176 5 Remove the drive assembly See 550 sheet tray drive assembly removal on page 4 170 6 Disconnect all connectors from the controller card as...

Page 422: ...4 168 Service Manual 5062 Go Back Previous Next 8 Remove the 550 sheet tray controller card assembly from the shield ...

Page 423: ...emove the top metal cover See 550 sheet tray top metal cover removal on page 4 183 2 Disconnect the pass thru sensor connector A from the pass thru sensor 3 Remove the pass thru sensor cable 4 Remove the screw B securing the deflector to the drawer 5 Remove the 550 sheet tray deflector A B ...

Page 424: ...e assembly removal 1 Remove the media tray assembly See 550 sheet media tray assembly removal on page 4 166 2 Remove the top metal cover See 550 sheet tray top metal cover removal on page 4 183 3 Remove the deflector See 550 sheet tray deflector removal on page 4 169 4 Remove the pick assembly See 550 sheet tray pick assembly removal on page 4 176 ...

Page 425: ...5 Release the cord with a prying tool 6 Remove the six screws A and one screw B securing the drive assembly to the drawer 7 Open the jam clearance cover 8 Lift the left side of the drive assembly to access the controller card assembly B 88A0001 A 88A0323 ...

Page 426: ...Service Manual 5062 Go Back Previous Next 9 Disconnect the three drive connectors C from the controller card assembly 10 Pull up the left side of the drive assembly until the left tip D clears the drawer C D ...

Page 427: ...l 550 sheet drawer assembly on page 7 19 for the part number 1 Remove the media tray assembly See 550 sheet media tray assembly removal on page 4 166 2 Place the drawer on a vertical position to have access to the bottom cover screws 3 Remove the nine screws A and the two screws B securing the bottom cover to the drawer A 88A0323 B 88A0233 B 88A0233 ...

Page 428: ... Go Back Previous Next Warning Do not forcefully separate the bottom cover from the drawer the ground cable C is still attached to it 4 Remove the two screws D securing the left anti tip latch assembly to the drawer C D 88A0232 ...

Page 429: ...hru sensor removal See Optional 550 sheet drawer assembly on page 7 19 for the part number 1 Remove the top metal cover See 550 sheet tray top metal cover removal on page 4 183 2 Remove the deflector See 550 sheet tray deflector removal on page 4 169 3 Release the latch securing the pass thru sensor to the deflector ...

Page 430: ...sensor 550 sheet tray pick assembly removal See Optional 550 sheet drawer assembly on page 7 19 for the part number 1 Remove the media tray assembly See 550 sheet media tray assembly removal on page 4 166 2 Disconnect the pick assembly connector A from the drive assembly A ...

Page 431: ...Repair information 4 177 5062 Go Back Previous Next 3 Turn the shaft clockwise until the tab B aligns with the opening 4 Pull down the pick arm to release the pick assembly B ...

Page 432: ...4 178 Service Manual 5062 Go Back Previous Next 5 Pull out the pick assembly 6 Remove the 550 sheet tray pick assembly Warning Do not change the location of the spring ...

Page 433: ...Repair information 4 179 5062 Go Back Previous Next Installation notes 1 Align the shaft to the left hole of the drive assembly 2 Insert the shaft into the hole ...

Page 434: ...ee Optional 550 sheet drawer assembly on page 7 19 for the part number 1 Remove the media tray assembly See 550 sheet media tray assembly removal on page 4 166 2 Remove the pick assembly See 550 sheet tray pick assembly removal on page 4 176 3 Remove the screw A securing the pick tire to the pick arm 4 Remove the pick tire 5 Repeat steps 3 4 to remove the other pick tire A 88A0412 ...

Page 435: ...information 4 181 5062 Go Back Previous Next This is the photo of the pick roll assembly Installation note Before installing the pick tire be sure that the pick tire is fully aligned against one end of the hub ...

Page 436: ... tray assembly See 550 sheet media tray assembly removal on page 4 166 2 Remove the top metal cover See 550 sheet tray top metal cover removal on page 4 183 3 Remove the two screws A securing the right anti tip latch assembly to the drawer Note Hold the right anti tip latch assembly to prevent it from falling off after removing the screws 4 Remove the right anti tip latch assembly A 88A0232 ...

Page 437: ...ray top metal cover removal 1 Remove the media tray assembly See 550 sheet media tray assembly removal on page 4 166 2 Remove the 10 screws A and one screw B securing the top metal cover to the drawer 3 Remove the 550 sheet tray top metal cover A 88A0323 B 88A0001 ...

Page 438: ...feeder bellcrank assembly removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 2 Remove the recoil spring from the bellcrank 3 Remove the E clip A securing the bellcrank to the frame 4 Remove the bellcrank 5 Repeat steps 2 4 to remove the bellcrank on the ...

Page 439: ...ity feeder controller card assembly removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 2 Disconnect all connectors from the controller card assembly 3 Remove the four screws A securing the controller card assembly A 88A0313 ...

Page 440: ...et high capacity feeder media tray assembly removal on page 4 215 2 Remove the jam clearance top cover See 2000 sheet high capacity feeder jam clearance top cover removal on page 4 198 3 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 4 Remove the right side cover See 2000 sheet high capacity feeder right side cover removal on page 4 231 5 Remove the pick...

Page 441: ...ir information 4 187 5062 Go Back Previous Next 6 Remove the screw A to disconnect the ground cable from the rear 7 Remove the three drive assembly connectors B from the controller card assembly A 88A0231 B ...

Page 442: ...4 188 Service Manual 5062 Go Back Previous Next 8 Release the three drive assembly cables from the cable guides C C ...

Page 443: ...Repair information 4 189 5062 Go Back Previous Next 9 Remove the three screws D securing the drive assembly to the drawer 10 Remove the drive assembly D 88A0442 ...

Page 444: ...gh capacity feeder elevator home sensor removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 2 Open the media tray assembly 3 Disconnect the elevator home sensor connector A from the controller card assembly A ...

Page 445: ...Repair information 4 191 5062 Go Back Previous Next 4 Remove the three screws B securing the controller card housing B 88A0231 ...

Page 446: ...vious Next 5 Detach the controller card housing Note The controller card housing does not need to be completely removed from the machine It may be allowed to hang on the side 6 Remove the screw C securing the elevator home sensor C 88A0312 ...

Page 447: ...Repair information 4 193 5062 Go Back Previous Next 7 Press the latch D to remove the elevator home sensor 8 Remove the elevator home sensor cable D ...

Page 448: ...0 sheet high capacity feeder rear cover removal on page 4 228 4 Remove the left side cover See 2000 sheet high capacity feeder left side cover removal on page 4 204 5 Remove the right side cover See 2000 sheet high capacity feeder right side cover removal on page 4 231 6 Remove the pick assembly See 2000 sheet high capacity feeder pick assembly removal on page 4 218 7 Remove the drive assembly See...

Page 449: ... Back Previous Next 10 Release the jam clearance cover cable from the cable guides B 11 Open the jam clearance cover 12 Remove the 4 screws C securing the jam clearance cover to the drawer 13 Close the jam clearance cover B C 88A0231 ...

Page 450: ...ice Manual 5062 Go Back Previous Next 14 Pull out the jam clearance cover to clear the slots from the frame 15 Press the metal tab to release the jam clearance cover and pull up to remove the jam clearance cover ...

Page 451: ...Repair information 4 197 5062 Go Back Previous Next Warning Be careful not to damage the jam clearance cover sensor This is the photo of the 2000 sheet high capacity feeder jam clearance cover ...

Page 452: ...ty feeder jam clearance top cover removal 1 Open the jam clearance cover 2 Remove the two screws A and one screw B securing the jam clearance top cover to the drawer 3 Lift the right side of the jam clearance top cover to clear it from the LED bracket A 88A0414 B 88A0231 ...

Page 453: ...op cover See 2000 sheet high capacity feeder jam clearance top cover removal on page 4 198 3 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 4 Remove the right side cover See 2000 sheet high capacity feeder right side cover removal on page 4 231 5 Remove the pick assembly See 2000 sheet high capacity feeder pick assembly removal on page 4 218 6 Remove the...

Page 454: ...0 Service Manual 5062 Go Back Previous Next 8 Release the jam clearance cover cable from the cable guides B 9 Remove the screw C and press the latch D to release the jam clearance cover sensor B D C 88A0312 ...

Page 455: ...e 2000 sheet high capacity feeder rear cover removal on page 4 228 2 Remove the left side cover See 2000 sheet high capacity feeder left side cover removal on page 4 204 3 Remove the right side cover See 2000 sheet high capacity feeder right side cover removal on page 4 231 4 Remove the pick assembly See 2000 sheet high capacity feeder pick assembly removal on page 4 218 ...

Page 456: ...et high capacity feeder left anti tip latch assembly removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the jam clearance top cover See 2000 sheet high capacity feeder jam clearance top cover removal on page 4 198 2 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 3 Remove the left side cover See 2000 sheet high ...

Page 457: ...ext 4 Remove the two screws A securing the left anti tip latch assembly to the drawer Note Hold the left anti tip latch assembly to prevent it from falling off after removing the screws This is the photo of the left anti tip latch assembly A 88A0231 ...

Page 458: ...heet high capacity feeder left side cover removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 2 Open the media tray assembly 3 Remove the seven screws A securing the left side cover to the drawer 4 Open the jam clearance cover B A A 88A0442 ...

Page 459: ...Repair information 4 205 5062 Go Back Previous Next 5 Remove the left side cover by slightly lifting it This is the photo of the 2000 sheet high capacity feeder left side cover ...

Page 460: ...pacity feeder lift drive gear assembly removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 2 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 ...

Page 461: ... 207 5062 Go Back Previous Next 3 Disconnect the lift drive motor connector from the controller card assembly 4 Release the lift drive motor cable from the cable guide A 5 Remove the four screws B to remove the bracket B A ...

Page 462: ... Remove the E clip securing the elevator gear C to the frame Note The spring from gear C will pop out when removing the E clip 7 Remove the elevator gear C 8 Remove the E clip securing the elevator gear D to the frame 9 Remove the elevator gear D C D ...

Page 463: ...209 5062 Go Back Previous Next 10 Remove the E clip securing the elevator gear E to the frame 11 Remove the elevator gear E 12 Remove the E clip securing the elevator gear F to the bracket 13 Remove the elevator gear F E F ...

Page 464: ...4 210 Service Manual 5062 Go Back Previous Next 14 Remove the bearing G This is the photo of the 2000 sheet high capacity feeder lift motor drive assembly G ...

Page 465: ...Repair information 4 211 5062 Go Back Previous Next Installation notes Make sure that the bearing is reinstalled as shown in the picture Make sure that the gear is reassembled as shown in the picture ...

Page 466: ...t high capacity feeder on page 7 23 for the part number 1 Remove the media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 2 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 3 Disconnect the lift drive motor connector from the controller card assembly ...

Page 467: ...on 4 213 5062 Go Back Previous Next 4 Release the lift drive motor cable from the cable guide A 5 Remove the four screws B to remove the bracket 6 Remove the two screws C securing the motor to the bracket B A C 18B1199 ...

Page 468: ...4 214 Service Manual 5062 Go Back Previous Next 7 Remove the motor from the bracket ...

Page 469: ...mbly removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Open the media tray assembly until it stops 2 Slightly pull the media tray to the right push the latch on the media tray slide and push the slide until it clears the tray 3 Do the same on the other side 1 2 3 ...

Page 470: ...4 216 Service Manual 5062 Go Back Previous Next 4 Slightly lift the tray to clear it from the stopper and pull to remove the media tray assembly out of the drawer ...

Page 471: ...s thru sensor removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Open the media tray assembly 2 Open the jam clearance cover 3 Disconnect the pass thru sensor connector A from the pass thru sensor 4 Release the latch B securing the pass thru sensor B A ...

Page 472: ... the media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 2 Remove the jam clearance top cover See 2000 sheet high capacity feeder jam clearance top cover removal on page 4 198 3 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 4 Remove the right side cover See 2000 sheet high capacity feeder right side cover re...

Page 473: ...4 219 5062 Go Back Previous Next 5 Remove the five screws A and one screw B securing the pick assembly to the drawer 6 Disconnect the four pick assembly connectors C from the controller card assembly A 88A0442 B 88A0414 C ...

Page 474: ...4 220 Service Manual 5062 Go Back Previous Next 7 Release the pick assembly cables from the cable guide D 8 Remove the two screws E securing the cave light to the drawer D E 88A0231 ...

Page 475: ...Repair information 4 221 5062 Go Back Previous Next 9 Lift the lower right side of the pick assembly and pull to remove it This is the photo of the 2000 sheet high capacity feeder pick assembly ...

Page 476: ...4 222 Service Manual 5062 Go Back Previous Next Installation note 1 Align the upper left part of the pick assembly 2 Align the frame tabs to their corresponding pick arm slots ...

Page 477: ...ious Next Installation note Make sure that the pick arm lever A is on top of the actuator lever B If the pick arm is hanging press the actuator lever as shown in the picture Make sure that the pick arm is positioned as shown in the picture A B ...

Page 478: ...k roll assembly removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the media tray assembly See 2000 sheet high capacity feeder media tray assembly removal on page 4 215 2 Open the jam clearance cover 3 Push down the pick arm until it clicks ...

Page 479: ...Repair information 4 225 5062 Go Back Previous Next 4 Press down the black latch A to release the pick tire 5 Remove the pick roll tire 6 Repeat steps 4 5 to remove the pick tire on the other side A ...

Page 480: ...ext This is the photo of the 2000 sheet high capacity feeder pick roll assembly Installation note Be sure that the pick arm lever A is on top of the actuator lever B If the pick arm is hanging press the actuator lever as shown in the picture A B ...

Page 481: ...Repair information 4 227 5062 Go Back Previous Next Be sure that the pick arm is positioned as shown in the picture ...

Page 482: ...h capacity feeder rear cover removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the two screws A securing the rear cover to the drawer 2 Position the printer so that the rear cover is over the edge of the table A 88A0442 ...

Page 483: ...Repair information 4 229 5062 Go Back Previous Next 3 Release the two latches and remove the rear cover This is the photo of the 2000 sheet high capacity feeder rear cover ...

Page 484: ...See 2000 sheet high capacity feeder rear cover removal on page 4 228 2 Remove the right side cover See 2000 sheet high capacity feeder right side cover removal on page 4 231 3 Remove the two screws A securing the right anti tip latch assembly to the drawer Note Hold the right anti tip latch assembly to prevent it from falling off after removing the screws This is the photo of the right anti tip la...

Page 485: ...assembly B 2000 sheet high capacity feeder right side cover removal See Optional 2000 sheet high capacity feeder on page 7 23 for the part number 1 Remove the rear cover See 2000 sheet high capacity feeder rear cover removal on page 4 228 2 Open the media tray assembly 3 Remove the seven screws A securing the right side cover to the drawer B A A 88A0442 ...

Page 486: ...4 232 Service Manual 5062 Go Back Previous Next 4 Pull the upper back portion of the right side cover 5 Lift the right side cover to remove it ...

Page 487: ...Repair information 4 233 5062 Go Back Previous Next This is the photo of the 2000 sheet high capacity feeder right side cover ...

Page 488: ...sembly covers on page 7 35 for the part number 1 Remove the mailbox from the printer 2 Remove the front cover See Finisher or stacker front cover removal on page 4 260 3 Open the access door and press in to release the support pins from each side of the door 4 Flex a side plate enough to free one hinge of the door and then remove the door ...

Page 489: ...ox backup roll plate assembly removal See 5 bin mailbox assembly interior on page 7 37 for the part number 1 Remove the mailbox from the printer 2 Remove the mailbox rear cover See 5 bin mailbox rear cover removal on page 4 249 3 Open the left access door and press in to release the support pins from each side of the door ...

Page 490: ...4 236 Service Manual 5062 Go Back Previous Next 4 Flex the sides to remove the roller frame ...

Page 491: ... mailbox from the printer 2 Remove the mailbox front cover See 5 bin mailbox front cover removal on page 4 242 3 Remove the five screws A and then remove the beacon card and covers 5 bin mailbox cave beacon removal See 5 bin mailbox assembly interior on page 7 37 for the part number 1 Remove the mailbox from the printer 2 Remove the three screws A from the bottom to remove the cable cover ...

Page 492: ...ear cover and disconnect the cable from the printer circuit board See 5 bin mailbox rear cover removal on page 4 249 5 bin mailbox controller card removal See 5 bin mailbox assembly interior on page 7 37 for the part number 1 Remove the mailbox from the printer 2 Remove the rear cover See 5 bin mailbox rear cover removal on page 4 249 3 Disconnect all cables from the board 4 Remove the two screws ...

Page 493: ... with plate See 5 bin mailbox feed motor with plate removal on page 4 241 3 Remove the four screws A securing the diverter plate 4 Remove the screw B of the deflector gate solenoid you need to remove 5 Carefully unroute the deflector gate solenoid cables from the cable clips under the top cover 6 Disconnect the appropriate deflector gate solenoid cable from the controller card 7 Route the cable th...

Page 494: ...bin mailbox diverter spring removal See 5 bin mailbox assembly interior on page 7 37 for the part number 1 Remove the mailbox option from the printer 2 Open the left access door 3 Using a spring hook or needlenose pliers remove the spring off the hooks ...

Page 495: ...e mailbox from the printer 2 Remove the mailbox front cover See 5 bin mailbox front cover removal on page 4 242 3 Remove the printer circuit board See 5 bin mailbox controller card removal on page 4 238 4 Remove four screws A and remove the feed motor side plate 5 Squeeze the tabs and push up to release the option connector and then slide the plate over the cable to remove it ...

Page 496: ... mailbox front cover removal See 5 bin mailbox assembly covers on page 7 35 for the part number 1 Remove the mailbox from the printer 2 Remove two screws A from the bottom 3 From the left side use a flat blade screwdriver to pry up and disengage the tabs ...

Page 497: ... on the right side to disengage the tabs and then remove the cover 5 Disconnect the cable from the beacon card Note If you are replacing the cover FRU then remove the bin full beacon card See 5 bin mailbox bin full beacon card and light pipe removal on page 4 237 ...

Page 498: ...interior on page 7 37 for the part number 1 Remove the front cover See 5 bin mailbox front cover removal on page 4 242 2 Pry the front hinge of the media bin full actuator towards the rear until the front boss is released from its socket 3 Pull the media bin full actuator toward the front and out of 5 bin mailbox assembly ...

Page 499: ... the mailbox from the printer 2 Remove the rear cover See 5 bin mailbox rear cover removal on page 4 249 3 Press the tabs to release the cable and push the cable through the frame 4 Disconnect the cable A from the controller card and press the latch to disconnect cable B from the controller card ...

Page 500: ...he printer 2 Remove the mailbox access door roller assembly 3 Remove the rear cover See 5 bin mailbox rear cover removal on page 4 249 4 Remove the mailbox feed motor with plate assembly See 5 bin mailbox feed motor with plate removal on page 4 241 5 If you are removing deflectors 1 through 4 then remove the deflector spring 6 Rotate the right side of the deflector out 7 Pull the left side out ...

Page 501: ...r Top bail 1 Remove the mailbox from the printer 2 Remove the top cover See 5 bin mailbox top cover removal on page 4 253 3 From the top cover lift the bail to line up the bail arm with the slot A and squeeze the bail to release the rear side 4 Remove the bail Lower four bails 1 Squeeze both sides of the bail to release the arms from the slots 2 Remove the bail ...

Page 502: ...the roller out of the mailbox 5 bin mailbox output bin sensors removal See 5 bin mailbox assembly interior on page 7 37 for the part number 1 Remove the mailbox from the printer 2 Remove the rear cover See 5 bin mailbox rear cover removal on page 4 249 3 Press in the tabs to pop out the sensor you need to replace 4 Disconnect the cable to remove the sensor Installation note When you put the sensor...

Page 503: ...2 Remove the mailbox front cover See 5 bin mailbox front cover removal on page 4 242 3 Remove the mailbox access door See 5 bin mailbox access door removal on page 4 234 4 Remove one screw A and remove the beacon LED card 5 bin mailbox rear cover removal See 5 bin mailbox assembly covers on page 7 35 for the part number 1 Remove the mailbox from the printer 2 Remove two screws A from the bottom ...

Page 504: ...ce Manual 5062 Go Back Previous Next 3 Use a flat blade screwdriver to pry out the right side to disengage the latches 4 Use the screwdriver to disengage the two latches on the left side and then remove the cover ...

Page 505: ...rior on page 7 37 for the part number 1 Remove the 5 bin mailbox option from the printer 2 Remove the output bin deflector that covers the roller to be removed See 5 bin mailbox tray extension removal on page 4 254 3 Rotate the clips forward that are holding the roller in place 4 Lift the roller out of the option ...

Page 506: ...utput bin roller removal on page 4 248 3 Release the tabs holding the sensor and then remove the sensor with its cable 5 bin mailbox sensor pass thru assembly removal See 5 bin mailbox assembly interior on page 7 37 for the part number 1 Remove the 5 bin mailbox option from the printer 2 Remove the 4th mailbox output bin roller 3 Release the tabs holding the sensor and then remove the sensor with ...

Page 507: ...e 7 35 for the part number 1 Remove the mailbox from the printer 2 Remove the front cover See 5 bin mailbox front cover removal on page 4 242 3 Remove the two screws A and remove the top cover 4 Remove the rear cover See 5 bin mailbox rear cover removal on page 4 249 5 Remove the two screws B and then lift off the top cover ...

Page 508: ... bin mailbox tray extension removal See 5 bin mailbox assembly covers on page 7 35 for the part number 1 Pull out the extension until it stops 2 Push to release the two tabs A on the bottom of the extension and then pull the extension out to remove it ...

Page 509: ...ccess door beacon LED and beacon housing removal See Finisher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove the left access door assembly See Finisher or stacker left access door assembly removal on page 4 262 3 Remove the screw A and remove the beacon card ...

Page 510: ... on page 7 25 for the part number 1 Remove the option from the printer 2 To remove the front spring remove the front cover See Finisher or stacker front cover removal on page 4 260 To remove the rear spring remove the controller card See Finisher or stacker controller card assembly removal on page 4 258 3 Using a spring hook remove the spring ...

Page 511: ...r assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove the standard output bin LED and LED lens See Finisher or stacker standard output bin LED and LED lens removal on page A 277 3 Press the tabs on the bin media present to remove the sensor from the cover 4 Disconnect the cable from the beacon card ...

Page 512: ...tion from the printer 2 Remove the front cover See Finisher or stacker front cover removal on page 4 260 3 Disconnect all cables from the controller card 4 Remove the three screws A securing the stapler stacker controller card assembly 5 Remove the stapler stacker controller card assembly Installation note Be sure to place the black plastic under the controller card before you put the card in plac...

Page 513: ...sher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Open the option left access door 3 Using a screwdriver force the rear hinge A out of the slot by pushing the door to the front 4 Remove the screw B to remove the roller you are replacing ...

Page 514: ...vious Next Finisher or stacker front cover removal See Finisher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove the two screws A on the inside of the exit bin compartment ...

Page 515: ...Repair information 4 261 5062 Go Back Previous Next 3 Using a flat blade screwdriver pry up to disengage the tabs on the right left and top sides of the cover 4 Remove the left cover ...

Page 516: ...inisher bin media present removal on page 4 273 Finisher or stacker left access door assembly removal See Finisher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Open the left access door 3 Using a screwdriver force the rear hinge A out of the slot to lower the door all the way and then pry the rear hinge out by pushing the door to the...

Page 517: ...Repair information 4 263 5062 Go Back Previous Next 6 Disconnect the cable D from the beacon card 7 Remove the beacon lens E and remove the door assembly ...

Page 518: ... 7 27 for the part number 1 Remove the option from the printer 2 Remove the top cover See Finisher or stacker top cover removal on page 4 280 3 Use plyers to straighten the locking tab A of the actuator you are replacing and then slide the actuator to the right to remove it Installation note Use a flat blade screwdriver to bend the locking tab back into place after you position the actuator ...

Page 519: ...Finisher or stacker rear cover removal on page 4 269 3 Remove the front cover See Finisher or stacker front cover removal on page 4 260 4 Disconnect the cable A and press the latch to disconnect the cable B from the controller card 5 Route the cables through option 6 Press the tabs to disconnect the option connector and route the cables through to remove it ...

Page 520: ... the left and right tabs and pry up the center tab Finisher or stacker output bin LED and LED lens removal See Finisher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove the top cover See Finisher or stacker top cover removal on page 4 280 3 Remove the screw A and then disconnect the cable to remove the beacon LED 4 Remove the scre...

Page 521: ...oval on page 4 267 3 Remove the E clip A and remove the gear Finisher or stacker paddle drive motor assembly removal See Finisher High capacity output stacker assembly continued on page 7 27 for the part number 1 Remove the option from the printer 2 Remove the front cover See Finisher or stacker front cover removal on page 4 260 3 Disconnect the paddle motor cable from the controller card 4 Remove...

Page 522: ... 5062 Go Back Previous Next 5 Remove the three screws A securing the two paddle drive motor assemblies 6 Remove the paddle drive motor assembly Installation note Be sure to line up the locator B when you install the motor ...

Page 523: ...rear cover removal See Finisher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove the four screws A from the bottom of the option 3 Using a flat blade screwdriver pry out the bottom plate and then remove it ...

Page 524: ...4 270 Service Manual 5062 Go Back Previous Next 4 Remove the two screws B on the inside of the exit bin compartment 5 Pull out on the right side of the cover to disengage the tabs and remove the cover ...

Page 525: ...al See Finisher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove the option rear cover See Finisher or stacker rear cover removal on page 4 269 3 Remove the two screws A securing the sensor 4 Disconnect the cable and remove the sensor ...

Page 526: ...acity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove the finisher or stacker controller card assembly See Finisher or stacker controller card assembly removal on page 4 258 3 Remove the two screws A securing the sensor 4 Disconnect the cable and remove the sensor ...

Page 527: ...resent removal See Finisher High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove two screws A and pull out the sensor cover 3 Press the tabs to remove the sensor from the cover 4 Disconnect the cable from the sensor to remove the sensor ...

Page 528: ...ve the paddle drive motor See Finisher or stacker paddle drive motor assembly removal on page 4 267 3 Disconnect the cable from the sensor 4 Press the tabs to remove the sensor Finisher sensor stapler access door interlock removal 1 Remove the finisher from the printer 2 Remove the finisher rear cover See Finisher or stacker rear cover removal on page 4 269 3 Disconnect the cable from the sensor 4...

Page 529: ...Finisher or stacker rear cover removal on page 4 269 3 Remove the finisher front cover See Finisher or stacker front cover removal on page 4 260 4 Open the left access door and pry out the left hinge A to lower the door 5 Push the door to the right to release the left hinge and then release the right hinge 6 Remove the four screws B and pull out the deflector plate 7 Disconnect the cable C from th...

Page 530: ...e the sensor Finisher or stacker sensor tamper HP left and right removal 1 Remove the option from the printer 2 Remove the option top cover See Finisher or stacker top cover removal on page 4 280 3 Disconnect the cable from the sensor 4 Pinch the tabs A to remove the sensors ...

Page 531: ...r High capacity output stacker assembly on page 7 25 for the part number 1 Remove the option from the printer 2 Remove two screws A and pull out the sensor cover 3 To remove the LED remove the screw B and then disconnect the cable from the LED card 4 To remove the lens remove the screw B and the screw C and then remove the lens ...

Page 532: ... holder and remove the belt from the pulley Finisher or stacker tamper drive motor assembly removal See Finisher High capacity output stacker assembly continued on page 7 27 for the part number Note The left tamper motor controls the front tamper and the right tamper motor controls the rear tamper 1 Remove the option from the printer 2 Remove the top cover See Finisher or stacker top cover removal...

Page 533: ...s F from the motor you are removing and remove the motor assembly Finisher or stacker tamper recoil spring removal See Finisher High capacity output stacker assembly continued on page 7 27 for the part number 1 Remove the option from the printer 2 Remove the top cover See Finisher or stacker top cover removal on page 4 280 3 Using a spring hook remove the spring A you need to replace ...

Page 534: ...Remove the option from the printer 2 Remove the front cover See Finisher or stacker front cover removal on page 4 260 3 Remove the rear cover See Finisher or stacker rear cover removal on page 4 269 4 Remove the screw A on each side of the top cover 5 Open the left access door and use a screwdriver to force the rear hinge B out of the slot by pushing the door to the front ...

Page 535: ...er 1 Remove the finisher from the printer 2 Remove the finisher rear cover See Finisher or stacker rear cover removal on page 4 269 3 Remove two screws A to remove rear cable from the stapler unit assembly and then remove the other three cables B attached to the assembly 4 Remove the three screws C 5 Remove the stapler unit assembly Installation note Be sure to secure the ground cable with the fro...

Page 536: ...it HTU and Holepunch unit HTU access door removal 1 Remove all output options from the printer 2 Open the access door and disconnect the beacon cable 3 Insert a flat blade screwdriver below the bottom hinge and flex the door enough to pull out the hinge 4 Remove the door A ...

Page 537: ...val 1 Remove all output options from the printer 2 Remove the HTU access door See HTU access door removal on page 4 282 3 Remove six screws A and turn over the beacon cover 4 Remove the screw B to remove the beacon card and disconnect the cable Note Observe the cable routing for installation A 3015189 B 3014513 ...

Page 538: ...us Next HTU access door rollers removal 1 Remove all output options from the printer 2 Remove the HTU access door See HTU access door removal on page 4 282 3 Remove the screw A from the roller you are replacing and remove the roller A 3015189 ...

Page 539: ...formation 4 285 5062 Go Back Previous Next Installation note Rollers B are different from rollers C Make sure that the color of the roller you will reinstall matches the color of the roller you have removed B C ...

Page 540: ...the front standard bin cover See HTU front standard bin cover removal on page 4 294 3 Use a spring hook to remove the spring A HTU bin media exit spring removal 1 Remove all output options from the printer 2 Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 3 Use a spring hook to remove the spring A ...

Page 541: ...move all output options from the printer 2 Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 3 Remove the two screws A and then remove the sensor card 4 Disconnect the cable to remove the sensor 5 If you are replacing the lens then remove two screws B to remove it ...

Page 542: ... all output options from the printer 2 Remove the HTU controller card See HTU controller card removal on page 4 289 3 Remove the two screws A and then remove the sensor card 4 Disconnect the cable from the sensor to remove the sensor 5 If you are replacing the lens then remove two screws B to remove it ...

Page 543: ...standard bin cover See HTU rear standard bin cover removal on page 4 312 3 Disconnect all cables connected to the controller card 4 Remove the four screws A Installation note Be sure to connect the solenoid cables into the correct connector There are black lines A on the cable connector that goes into the black connector on the system board A ...

Page 544: ...revious Next HTU drive belt removal 1 Remove all output options from the printer 2 Remove the HTU controller card See HTU controller card removal on page 4 289 3 Remove three screws A and one screw B 4 Slide the belt off the lowest gear ...

Page 545: ... 291 5062 Go Back Previous Next HTU drive gear spring removal 1 Remove all output options from the printer 2 Remove the controller card See HTU controller card removal on page 4 289 3 Use a spring hook to remove the spring ...

Page 546: ...92 Service Manual 5062 Go Back Previous Next HTU engagement roller removal 1 Remove all output options from the printer 2 Lay the HTU on its back 3 Remove the screw A to remove the roller you are replacing ...

Page 547: ...t shaft See HTU upper exit shaft removal on page 4 331 2 Unsnap the left side of the roller from the cover and remove the roller HTU front redrive cover removal 1 Remove all output options from the printer 2 Lay the HTU on its back and open the access door 3 Remove four screws A and remove the cover ...

Page 548: ...4 294 Service Manual 5062 Go Back Previous Next HTU front standard bin cover removal 1 Remove all output options from the printer 2 Remove two screws A from the bottom 3 Remove the screw B from the top ...

Page 549: ... Remove the screw C inside the output bin and remove the cover HTU locking lever removal 1 Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 2 Remove the two E Clips A and the one E clip B holding the locking lever ...

Page 550: ...4 296 Service Manual 5062 Go Back Previous Next 3 Use a flat blade screwdriver to slide the lever out 4 Remove the screw C ...

Page 551: ...n page 4 295 2 Disconnect the cable to remove the locking level card HTU lower redrive guide removal 1 Remove all output options from the printer 2 Remove the upper guide See HTU upper guide removal on page 4 332 3 Remove 13 screws A from the bottom of the transport unit 4 Remove the two screws B from the edge of the transport unit B 3015189 ...

Page 552: ...4 298 Service Manual 5062 Go Back Previous Next 5 Remove the three screws C from the front of the transport unit 6 Press the tabs to remove the connector from the rear frame C 3015189 ...

Page 553: ...Go Back Previous Next 7 Lift the back edge of the plate and then slide the plate to the rear to remove it Installation note When installing the guide be sure to use a screwdriver to clear the post A from the belt B as shown 1 2 A B ...

Page 554: ...he printer Front hook a Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 b Remove one screw A and then remove the hook Installation note From the back of the hook turn the spring arm 1 2 turn counterclockwise and then hold the arm in place while you install the hook ...

Page 555: ...he rear standard bin cover See HTU rear standard bin cover removal on page 4 312 b Remove the screw A and then remove the hook Installation note From the back of the hook turn the spring arm 1 2 turn counterclockwise and then hold the arm in place while you install the hook ...

Page 556: ...m the printer Front roller a Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 b Remove the screw A to remove the roller Rear roller a Remove the rear standard bin cover See HTU rear standard bin cover removal on page 4 312 b Remove the screw A to remove the roller ...

Page 557: ...e bin up and then pull back to remove it Installation note If you are replacing the output bin FRU then remove the wire stop See HTU output bin wire stop removal on page 4 305 HTU output bin extension removal 1 Remove the output bin wire stop HTU output bin wire stop removal on page 4 305 2 Extend the extension until it stops ...

Page 558: ...utput bin solenoid removal 1 Remove the rear standard bin cover See HTU rear standard bin cover removal on page 4 312 2 Disconnect the output bin solenoid cable A Note Tie a string onto the cable so you can route the new cable through the HTU 3 Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 ...

Page 559: ... plunger B from stopper diverter and the spring C from the solenoid 5 Remove the two screws D and remove the solenoid HTU output bin wire stop removal 1 Remove the output option from the HTU 2 Rotate the extension cover down 3 Pull out the sides of the stop to remove it ...

Page 560: ...4 306 Service Manual 5062 Go Back Previous Next HTU output option removal 1 Press the release lever slide the top option to the right and lift the top option off 1 2 3 ...

Page 561: ...Repair information 4 307 5062 Go Back Previous Next 2 Open the top access door press the lever and slide the HTU to the right to remove 1 2 3 ...

Page 562: ...rd bin cover removal on page 4 312 2 Slide the cables through the rear standard bin cover HTU output option solenoid removal 1 Remove the rear standard bin cover See HTU rear standard bin cover removal on page 4 312 2 Disconnect the output bin solenoid cable A Note Tie a string to the cable so you can route the new cable through the HTU ...

Page 563: ...age 4 294 4 Disconnect the plunger B from the stopper diverter and the spring C from the solenoid 5 Remove the two screws D and then remove the solenoid HTU output sensor removal 1 Remove the right inner cover See HTU right inner cover removal on page 4 316 2 Release the tabs that hold the sensor in place and then disconnect the cable ...

Page 564: ...tput options from the printer 2 Push up the tabs to release the latches and rotate the cover up to remove it HTU rear redrive cover removal 1 Remove all output options from the printer 2 Remove the access door See HTU access door removal on page 4 282 3 Remove the two screws A from the inside A 3015189 ...

Page 565: ...Repair information 4 311 5062 Go Back Previous Next 4 Remove the screw B from the rear 5 Use a screwdriver to release the two tabs and remove the cover B 3014523 ...

Page 566: ...2 Service Manual 5062 Go Back Previous Next HTU rear standard bin cover removal 1 Remove all output options from the printer 2 Remove two screws A from the bottom 3 Remove the screw B inside the output bin ...

Page 567: ... 4 313 5062 Go Back Previous Next 4 Remove the screw C from the left side 5 Remove two screws D and one screw E from the top 6 LIft off the output option connector bracket F and then lift off the rear standard bin cover ...

Page 568: ...2 Go Back Previous Next 7 Disconnect the cable F and press the tab to disconnect the cable G from the controller card Note If you are replacing the rear standard bin cover FRU then feed the cables through the slot in the cover ...

Page 569: ...mation 4 315 5062 Go Back Previous Next HTU right bottom cover removal 1 Remove all output options from the printer 2 Remove three screws A from the inside 3 Remove two screws B from the bottom and remove the cover ...

Page 570: ...put bin See HTU output bin removal on page 4 303 3 Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 4 Remove the two screws A one screw B and disconnect the cable C 5 Remove the HTU drive belt See HTU drive belt removal on page 4 290 6 Remove the two screws D one screw E and disconnect the cable F ...

Page 571: ...Repair information 4 317 5062 Go Back Previous Next 7 Remove the right lower cover Note Observe the routing of cable G through the side frame ...

Page 572: ...4 318 Service Manual 5062 Go Back Previous Next 8 Remove the two screws H 9 Remove the two screws I and two screws J ...

Page 573: ...Repair information 4 319 5062 Go Back Previous Next 10 Lift up the frame and slide the right inner cover out ...

Page 574: ...removal 1 Remove all output options from the printer 2 Remove the front redrive cover See HTU front redrive cover removal on page 4 293 3 Press the outer tabs A to remove the sensor cover 4 Press the inner tabs B to pull out the sensor 5 Disconnect the cable to remove the sensor A B ...

Page 575: ...the printer 2 Remove the rear standard bin cover See HTU rear standard bin cover removal on page 4 312 3 Disconnect the sensor cable A from the controller card 4 Remove the output bin See HTU output bin removal on page 4 303 5 Press tabs to pull out the sensor 6 Pull the cable through the frame to remove the sensor ...

Page 576: ...t HTU sensor input removal 1 Remove all output options from the printer 2 Remove the HTU lower redrive guide See HTU lower redrive guide removal on page 4 297 3 Press the tabs to release the sensor and then disconnect the cable to remove the sensor ...

Page 577: ...U sensor output option position removal 1 Remove all output options from the printer 2 Remove the rear standard bin cover See HTU rear standard bin cover removal on page 4 312 3 Press the tabs to pull out the sensor 4 Disconnect the cable to remove sensor ...

Page 578: ...n page 4 297 3 Press the tabs to release the sensor and then disconnect the cable to remove the sensor HTU sensor cable bin full send and receive removal 1 Remove all output options from the printer 2 Remove both bin full sensors See HTU card bin full send card and lens removal on page 4 288 and HTU card bin full receive card and lens removal on page 4 287 3 Route the cable through the frame ...

Page 579: ...s Next HTU stopper diverter removal 1 Remove the front standard bin cover See HTU front standard bin cover removal on page 4 294 2 Remove the solenoid plunger and spring from the stopper diverter and then slide the stopper diverter off the option ...

Page 580: ...ts rear removal 1 Remove all output options from the printer 2 Remove the rear redrive cover See HTU rear redrive cover removal on page 4 310 3 Remove one of the gears A to remove the belt you are replacing Note Remove the center belt to access the other two belts ...

Page 581: ...62 Go Back Previous Next HTU to printer cable removal 1 Remove the right inner cover See HTU right inner cover removal on page 4 316 2 Remove the screw A to disconnect the ground cable 3 Press on the tabs to release the connector ...

Page 582: ... 1 Remove all output options from the printer 2 Remove the front redrive cover See HTU front redrive cover removal on page 4 293 3 Remove two screws A 4 Remove the rear redrive cover See HTU rear redrive cover removal on page 4 310 5 Remove two screws B and then remove the cover ...

Page 583: ...op right cover removal 1 Remove all output options from the printer 2 Remove the rear standard bin cover See HTU rear standard bin cover removal on page 4 312 3 Remove two screws A from the top 4 Remove two screws B from the rear and then remove the top cover ...

Page 584: ...k Previous Next HTU transport gear removal 1 Remove the HTU drive belt See HTU drive belt removal on page 4 290 2 Use a flat screwdriver to remove the gear A 3 Remove the E clip B and E clip C and then slide the gears off their posts ...

Page 585: ...l 1 Remove the right inner cover See HTU right inner cover removal on page 4 316 2 Remove the two screws A and then remove the transport motor HTU upper exit shaft removal 1 Remove the right inner cover See HTU right inner cover removal on page 4 316 2 Remove the metal beam slide ...

Page 586: ...t 3 Unsnap the upper exit shaft out of the cover HTU upper guide removal 1 Remove all output options from the printer 2 Remove the top redrive cover See HTU top redrive cover removal on page 4 328 3 Remove the two screws A from the front A 3015189 ...

Page 587: ...Repair information 4 333 5062 Go Back Previous Next 4 Slide the guide to the left and remove 1 2 ...

Page 588: ...nch motor removal 1 Remove the HTU rear standard bin cover See HTU rear standard bin cover removal on page 4 312 2 Disconnect the punch motor cable A from the HTU controller card 3 Remove the three screws B and remove the motor with the bracket A B 3014523 ...

Page 589: ...Repair information 4 335 5062 Go Back Previous Next 4 Remove the two screws C and then remove the bracket C 3014523 ...

Page 590: ...ove the HTU rear standard bin cover See HTU rear standard bin cover removal on page 4 312 2 Remove the HTU top right cover See HTU top right cover removal on page 4 329 3 Remove the E clip A and then remove the gear and gear cap 4 Disconnect the cable B from the punch unit A B ...

Page 591: ...o the left and right while you pull it out of the frame HTU punch gear removal 1 Remove the HTU rear standard bin cover See HTU rear standard bin cover removal on page 4 312 2 Remove the HTU top right cover See HTU top right cover removal on page 4 329 3 Remove the E clip A and then remove the gear and gear cap C D A ...

Page 592: ...4 338 Service Manual 5062 Go Back Previous Next ...

Page 593: ...Connector locations 5 1 5062 Go Back Previous Next 5 Connector locations Locations System board cabling reference For more information see the connector diagram for the System board on page 5 2 ...

Page 594: ...5 2 Service Manual 5062 Go Back Previous Next Connectors System board ...

Page 595: ...e System board on page 5 2 Connector Pin Signal Pin Signal J1 OP panel UICC card Cable 10J0972 User Interface Card 1 UI REset NR 2 GND 3 TX1 4 TX1 5 TX2 6 TX2 7 CLKTX 8 CLKTX 9 GND 10 V15_UI w RES 11 I2C_CLK_LL 12 I2C_DATA_LL 13 TXO 14 TXO 15 GND 16 V15_UI 17 V15_UI 18 V15_UI 19 WAKE_L 20 GND 21 PWR_LED2_L 22 PWR_LED1_L 23 B10_ 5V_CTNL 24 PWR_BUTTON_L J3 Processor Fan Cable In FRU 1 5V _DC 2 5V_DC...

Page 596: ...ther Station 1 REMOTE_WS 2 GND JCM1 C M Block Cable 10J0932 BLDC C M 1 C_BLDC_HOME 2 GND 3 C_BLDC_HALL_U 4 V45_M_WIND_W 5 C_BLDC_HALL_V 6 V45_M_WIND_V 7 C_BLDC_HALL_W 8 V45_M_WIND_U 9 C_BLDC_FG 10 5V_SW 11 GND 12 GND 13 RV_SW 14 M_BLDC_FG 15 V45_C_WIND_U 16 M_BLDC_HALL_W 17 V45_C_WIND_V 18 M_BLDC_HALL_V 19 V45_C_WIND_W 20 M_BLDC_HALL_U 21 GND 22 M_BLDC_HOME JCMCY1 C Y Metering Cable 10J0955 C Y Ca...

Page 597: ...ED Cable 10J0948 Duplex Door 1 SDLED1 2 5V or GND 3 SDLED3 4 5V or GND 5 SDLED5 6 5V or GND 7 SDLED7 8 5V or GND JDIMM1 Card Opt NA NA JDP1 Duplex Paperpath Sensor Cable 10J0957 Duplexer 1 GND 2 GND 3 VS10_S2_DUP 4 VS10_DUP_PARK 5 S_S2_DUP_SNS 6 S_DUP_PARK_SNS 7 NO NAME 8 S_DUP_DOOR_LED 9 S_FSR_BUBBL_SNS 10 VS10_FSR_BUBBL 11 GND 12 GND JDUPL1 Duplex Mtr Cable 10J0935 Duplex Motor 1 VS10_DUPLEX_LED...

Page 598: ...UT 6 K_DEV_PWM_OUT 7 C_DEV_PWM_OUT 8 K_AC_PWM_OUT 9 C_CHG_PWM_OUT 10 M_CHG_PWM_OUT 11 Y_CHG_PWM_OUT 12 K_CHG_PWM_OUT 13 Y_AC_PWM_OUT 14 GND 15 Y_DEV_PWM_OUT 16 GND 17 GND 18 GND 19 ITM_TX_PWM_CUR_O 20 KCMY_TX_ENA_OUT 21 ITM_TX_ENA_OUT 22 K_TX_PWM_OUT 23 ITM_TX_PWM_OUT 24 K_SERVO_INTO 25 CHG_AC_FREQ 26 M_SERVO_INTO 27 ITM_SERVO_INTO 28 3 3v_ENG 29 Y_SERVO_INTO 30 M_TX_PWM_OUT 31 Y_TX_PWM_OUT 32 PNR...

Page 599: ...2 I2C_CLK_F 13 V10_FRU_3 3V 14 GND 15 GND 16 I_BLDC_FG 17 5V_SW 18 I_BLDC_HALL_W 19 V45_K_WIND_U 20 I_BLDC_HALL_V 21 V45_K_WIND_V 22 I_BLDC_HALL_U 23 V45_K_WIND_W 24 I_BLDC_HOME JL1 LVPS fan Cable Part of fan 1 S_LFAN_STALL 2 GND 3 LFAN_OUT 4 V20_LFAN JLVPS1 LVPS Cable Part of LVPS 1 LVPS1_TEMP 2 GND 3 24V_LOW_PWR_OUT 4 LVPS2_TEMP 5 AC_CURRENT 6 5V_RIP_PWR_OUT 7 GND 8 GND 9 5V_ENG_PWR_OUT 10 BR_HE...

Page 600: ...F_PIO_ENC JOOPT1 Output Option Cable 10J0941 Output Options 1 TXD1_OPT_OUT 2 GND 3 GND 4 RXD1_OPT_IN 5 24V_TOPT 6 GND 7 5V_OPTS 8 GND 9 F_BLDC_FG_OUT 10 V10_LVPS_FSR_RLY JPC1 Cyan Memory Cable Part of unit 1 V_CART_3V 2 XP_DAT_C 3 XP_CLK_C 4 GND JPH1 Printhead Cable Part of printhead Flat NA JPH2 Printhead Cable Part of printhead Flat NA JPK1 Black Memory Cable Part of unit 1 V_CART_3V 2 XP_DAT_C ...

Page 601: ...G1 Staging Motor Cable 10J0936 Staging Motor 1 VS10_STAGING_LED 2 S_STAGING_ENC 3 GND 4 V20_STAGING_MTR 5 V20_STAGING_MTR JTCVR1 Bin Full Sensor Cable 10J0950 Bin Full 1 S_LED5 2 NO NAME 3 GND 4 GND 5 GND 6 GND 7 VS10_BIN_FULL 8 S_BF_IN 9 GND 10 GND 11 S_RD2_SNS 12 VS10_RD2_LED JTRAY1 Autocomp Cable 10J0933 Tray 1 Machine Side 1 VS10_ATO_CMP_LED 2 VS10_TRAY1_HALF 3 S_AUTOCOMP_ENC 4 S_PAPER_HALF_IN...

Page 602: ...S_FD_OPEN_SNS 18 VS10_FD_OPEN JWTBF1 Waste Toner Full Sensor Cable 10J0967 Waste Toner Full 1 VS_WST_FUL 2 S_WST_FUL 3 GND JYF1 Yellow Fuser BLDC Cable 10J0931 BLDC Fuser 1 Y_BLDC_HOME 2 V45_F_WIND_W 3 Y_BLDC_HALL_U 4 V45_F_WIND_V 5 Y_BLDC_HALL_V 6 V45_F_WIND_U 7 Y_BLDC_HALL_W 8 5V_SW 9 Y_BLDC_FG 10 GND 11 GND 12 F_BLDC_FG 13 5V_SW 14 F_BLDC_HALL_W 15 V45_Y_WIND_U 16 17 V45_Y_WIND_V 18 19 V45_Y_WI...

Page 603: ...Connector locations 5 11 5062 Go Back Previous Next 550 sheet tray option system card J35 J34 J32 J30 J10 J3 JPTS1 J4 J17 J2 ...

Page 604: ... 2 Input 3 5V_Switch J3 Pick motor 1 5V_Switch 2 ENCODER 3 GND 4 Motor 5 Motor J4 Paper level sensor 1 5V_Switch 2 P_LEV_SENSOR_1 3 GND 4 5 5V_Switch 6 P_LEV_SENSOR_2 7 GND J10 Feed motor 1 5V_Switch 2 ENCODER 3 GND 4 Motor 5 Motor 6 J17 Jam Led 1 JAM_LIGHTPIPE 2 Ground 3 JAM_DOOR_LED 4 Ground J30 Paper port to next option 1 GND 2 PP_RXD 3 GND 4 PP_TXD 5 MTR2 ENCODER 6 S2 J32 Paper port to printer...

Page 605: ... Next J34 LED tray 1 TRAY_LIGHTPIPE 2 GND J35 Power IN 1 24V 2 5V 3 Ground JPTS1 Pass thru sensor 1 24V 2 5V 3 5V_Switch 550 sheet tray option system card connectors See 550 sheet tray option system card on page 5 11 Connector Pin Signal Pin Signal ...

Page 606: ...5 14 Service Manual 5062 Go Back Previous Next 2000 sheet high capacity feeder option system card J35 J34 J32 J10 J3 JPTS1 J4 J17 J11 J2 J16 ...

Page 607: ... Pin Signal J2 Jam door sensor 1 GND 2 Input 3 5V_Switch J3 Pick motor 1 5V_Switch 2 ENCODER 3 GND 4 Motor 5 Motor J4 Paper level sensor 1 5V_Switch 2 P_LEV_SENSOR_1 3 GND 4 5 5V_Switch 6 P_LEV_SENSOR_2 7 GND J10 Feed motor 1 5V_Switch 2 ENCODER 3 GND 4 Motor 5 Motor 6 J11 Elevator sensor 1 5V_Switch 2 Input 3 Ground 4 Ground J16 Elevator motor 1 5V_Switch 2 ENCODER 3 Ground 4 Motor 5 Motor J17 Ja...

Page 608: ...ND 4 PP_TXD 5 S2 J34 LED tray 1 TRAY_LIGHTPIPE 2 GND J35 Power IN 1 24V 2 5V 3 Ground JPTS1 Pass thru sensor 1 24V 2 5V 3 5V_Switch 2000 sheet high capacity feeder option system card connectors See 2000 sheet high capacity feeder option system card on page 5 14 Connector Pin Signal Pin Signal ...

Page 609: ...Previous Next UICC card UICC card UICC card connectors with no cables attached Connector J1 J8 UICC card connectors Connector Connects to J2 Speaker J3 Display J4 System board J5 USB to USB port J6 USB to card reader J7 USB to system board ...

Page 610: ...5 18 Service Manual 5062 Go Back Previous Next 5 bin mailbox system card ...

Page 611: ...e 5 18 Connector Connects to J1A HTU connector J1B HTU connector J2 Motor J3 Bin1 Output bin 1 sensor J4 Bin4 Solenoid 4 J5 Bottom Input sensor J6 Bin2 Output bin 2 sensor J7 Bin3 Solenoid 3 J8 Bin3 Output bin 3 sensor J9 Bin2 Solenoid 2 J10 Bin4 Output bin 4 sensor J11 Top Pass thru sensor J12 Bin1 Solenoid 1 J13 Bin5 Output bin 5 sensor J17 LED Output bin LEDs J18 Program HTU connector J21 Beaco...

Page 612: ...5 20 Service Manual 5062 Go Back Previous Next Finisher Stacker system card HTU system card ...

Page 613: ...re from any non Lexmark attachments Individual maintenance part expected life Lubrication specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can cause premature failure Some unauthorized lubricants may chemically attack polycarbonate parts The motor drive FRUs contain the proper lubricant in the FRU Use only the ...

Page 614: ...5062 Go Back Previous Next Redrive parts packet 1 Using the 739A grease that came with the redrive assembly lubricate the four posts A 2 Install the gears 3 Using the 744 grease lubricate the teeth B of the gears as shown ...

Page 615: ...e 6 3 5062 Go Back Previous Next Fuser drive assembly 1 Using the 739A grease that came with the fuser drive assembly lubricate the post A 2 Install the gear 3 Using the 744 grease lubricate the teeth B of the gear as shown ...

Page 616: ...6 4 Service Manual 5062 Go Back Previous Next ...

Page 617: ...nclude the rest of the base machine Units FRU Refers to the number of units packaged together and identified by the part number Description Provides more descriptive information to help identify the part Removal procedure Links directly to the instructions for removing the part NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Model ...

Page 618: ...7 2 Service Manual 5062 Go Back Previous Next Assembly 1 Top right and front covers 1 2 3 4 5 6 7 9 10 11A 15 13 16 8 11B 14 12 ...

Page 619: ... door and pivot Front access door assembly removal on page 4 3 9 40X7125 1 1 Waste toner left cover with beacon Waste toner left cover removal on page 4 34 10 40X7113 1 1 Logo panel Logo panel removal on page 4 85 11A 40X7118 1 1 OP panel bezel 210 3 bezels Bezel Bezel with USB Bezel with USB and card reader OP panel bezel removal on page 4 18 40X7119 1 1 OP panel bezel 230 3 bezels Bezel Bezel wi...

Page 620: ...7 4 Service Manual 5062 Go Back Previous Next Assembly 2 Left and rear covers 1 2 4 5 6 7 8 9 10 11 12 13 14 3 ...

Page 621: ...ess door assembly removal on page 4 5 7 40X7147 1 1 MPF door assembly including MPF door cover MPF outer plate MPF side restraint Paper guide slide Multipurpose feeder MPF cover removal on page 4 17 8 40X7121 Lower left cover Lower left cover removal on page 4 11 9 40X7157 1 1 Belts parts packet including MPF drive belt Duplex drive belt MPF drive assembly removal on page 4 106 Duplex assembly rem...

Page 622: ...7 6 Service Manual 5062 Go Back Previous Next Assembly 3 Front 1 2 4 5 6 7 8 3 3 3 3 ...

Page 623: ...uding Waste toner sensors 2 Paper auto size sensor Paper path sensors not shown Bin full sensor not shown Waste toner sensor removal on page 4 159 Waste toner full sensor removal on page 4 162 Paper auto size sensor removal on page 4 117 Bin full sensor removal on page 4 38 5 40X7161 1 1 Waste toner tray bracket Waste toner tray bracket removal on page 4 163 6 40X7139 1 1 HVPS assembly with cable ...

Page 624: ...7 8 Service Manual 5062 Go Back Previous Next Assembly 3 1 Front continued 1 2 4 5 1 1 1 3 ...

Page 625: ...rtridge memory block removal on page 4 44 2 40X7160 1 1 Paper pick mechanism assembly Paper pick mechanism assembly removal on page 4 120 3 40X6104 2 2 Pick tire roll assembly Pick rolls removal on page 4 122 4 40X7143 4 1 Cartridge contact block assembly Cartridge contact block assembly removal on page 4 42 5 40X7126 1 1 Media tray rails 1 right 1 left Media tray rail removal on page 4 94 ...

Page 626: ...7 10 Service Manual 5062 Go Back Previous Next Assembly 4 Left 1 2 4 5 6 8 7 3 ...

Page 627: ...taging deflector assembly removal on page 4 140 4 40X7146 1 1 Staging deflector assembly with sensors Staging deflector assembly removal on page 4 140 5 40X7172 1 1 Fuser MPF autocomp parts packet including Fuser datum rear bellcrank Fuser datum front bellcrank Fuser datum bellcrank spring 2 Autocomp ACM bias spring MPF rear breakaway support MPF front breakaway support Datum bell crank removal on...

Page 628: ...7 12 Service Manual 5062 Go Back Previous Next Assembly 4 1 Left continued 1 2 3 4 ...

Page 629: ...assembly 220 V 40X7102 Fuser assembly 100 V 2 40X7153 1 1 Left access door pistons parts packet including Piston clip pin Left door spring support Piston housing assembly Door support anchor pin 3 Left access door piston removal on page 4 82 3 40X7165 1 1 Fuser system card and LVPS cable with cable ties Fuser system card and LVPS cable removal on page 4 67 4 40X7103 1 1 ITU module assembly ITU ass...

Page 630: ...7 14 Service Manual 5062 Go Back Previous Next Assembly 5 Rear 1 2 3 6 11 8 9 12 4 7 5 13 10 ...

Page 631: ...ssembly removal on page 4 106 6 40X7135 1 1 Fuser drive assembly including Gear thrust washer Gear Fuser Dr Compound Fuser drive assembly removal on page 4 65 7 40X7162 1 1 Waste toner gears parts packet including Gear 30T Helical Gear 46T Spur 17T Helical Waste toner gears removal on page 4 158 8 40X7137 1 1 Low voltage power supply LVPS with thermistor retainer Low voltage power supply LVPS remo...

Page 632: ...7 16 Service Manual 5062 Go Back Previous Next Assembly 6 Optional 550 sheet tray 2 3 1 ...

Page 633: ...ndex P N Units opt Units FRU Description Removal procedure 6 1 40X6967 1 1 550 sheet tray option N A 2 40X6102 1 1 550 sheet drawer assembly 550 sheet drawer assembly removal on page 4 166 3 40X6099 1 1 550 sheet media tray assembly 550 sheet media tray assembly removal on page 4 166 ...

Page 634: ...7 18 Service Manual 5062 Go Back Previous Next Assembly 7 Optional 550 sheet drawer assembly 4 5 3 2 2 1 ...

Page 635: ... 167 2 40X6101 2 2 Anti tip latch assembly 550 sheet tray right anti tip latch assembly removal on page 4 182 and 550 sheet tray left anti tip latch removal on page 4 173 3 40X6274 1 3 550 sheet 2000 sheet input option sensor pack 550 sheet tray pass thru sensor removal on page 4 175 4 40X6103 1 1 550 sheet tray pick assembly 550 sheet tray pick assembly removal on page 4 176 5 40X6104 2 2 Pick ro...

Page 636: ...7 20 Service Manual 5062 Go Back Previous Next Assembly 8 Optional 2000 sheet high capacity feeder complete 1 ...

Page 637: ...1 5062 Go Back Previous Next Assembly 8 Optional 2000 sheet high capacity feeder complete Index P N Units opt Units FRU Description Removal procedure 8 1 40X6968 1 1 2000 sheet high capacity feeder media tray option N A ...

Page 638: ...7 22 Service Manual 5062 Go Back Previous Next Assembly 9 Optional 2000 sheet high capacity feeder 2 4 5 6 8 1 9 13 6 14 11 3 7 10 12 ...

Page 639: ...ty feeder controller card assembly removal on page 4 185 7 40X6101 2 2 Anti tip latch assembly 2000 sheet high capacity feeder right anti tip latch assembly removal on page 4 230 and 2000 sheet high capacity feeder left anti tip latch assembly removal on page 4 202 8 40X6971 1 1 2000 sheet high capacity feeder right cover 2000 sheet high capacity feeder right side cover removal on page 4 231 9 40X...

Page 640: ...7 24 Service Manual 5062 Go Back Previous Next Assembly 10 Finisher High capacity ouput stacker assembly ...

Page 641: ...sher or stacker bottom cover removal on page 4 257 9 40X4618 1 1 Sensor bin media present Finisher or stacker sensor finisher bin media present removal on page 4 273 10 40X4619 1 1 Output bin extension Finisher or stacker output bin extension removal on page 4 266 11 40X7241 1 1 Finisher controller card assembly Finisher or stacker controller card assembly removal on page 4 258 11 40X7253 1 1 Stac...

Page 642: ...7 26 Service Manual 5062 Go Back Previous Next Assembly 10 1 Finisher High capacity output stacker assembly continued ...

Page 643: ...ge 4 266 4 40X4622 1 1 Rear tamper motor assembly Finisher or stacker tamper drive motor assembly removal on page 4 278 5 40X4624 1 1 Tamper recoil spring Finisher or stacker tamper recoil spring removal on page 4 279 6 40X5909 1 1 Sensor tamper front and rear paddle Finisher or stacker sensor paddle HP removal on page 4 274 7 40X4623 1 1 Tamper drive belt Finisher or stacker tamper drive belt rem...

Page 644: ...7 28 Service Manual 5062 Go Back Previous Next Assembly 11 Finisher stapler assembly 1 2 ...

Page 645: ...apler assembly Asm Index Part number Units mach Units FRU Description Removal procedure 11 1 40X7246 1 1 Stapler assembly Finisher stapler unit assembly removal on page 4 281 2 40X5909 1 1 Sensor media in stapler Finisher or stacker sensor pass thru removal on page 4 275 ...

Page 646: ...7 30 Service Manual 5062 Go Back Previous Next Assembly 12 Finisher Stacker assembly complete 1 ...

Page 647: ...5062 Go Back Previous Next Assembly 12 Finisher Stacker assembly complete Asm Index Part number Units mach Units FRU Description Removal procedure 13 1 40X7230 1 1 Finisher assembly N A 1 40X7251 1 1 Stacker assembly N A ...

Page 648: ...7 32 Service Manual 5062 Go Back Previous Next Assembly 13 5 bin mailbox assembly complete 1 ...

Page 649: ...Parts catalog 7 33 5062 Go Back Previous Next Assembly 13 5 bin mailbox assembly complete Index P N Units mach Units FRU Description Removal procedure 14 1 40X7254 5 bin mailbox total option N A ...

Page 650: ...7 34 Service Manual 5062 Go Back Previous Next Assembly 14 5 bin mailbox assembly covers 1 5 6 10 11 3 4 2 7 9 8 ...

Page 651: ...in full beacon card and light pipe removal on page 4 237 5 40X7256 1 1 LED card assembly 5 bin mailbox bin full beacon card and light pipe removal on page 4 237 6 40X7255 1 1 Front cover 5 bin mailbox front cover removal on page 4 242 7 40X7261 1 1 LED jam cover 5 bin mailbox access door removal on page 4 234 8 40X4528 1 1 Scanner reference LED cable assembly 5 bin mailbox paper jam beacon removal...

Page 652: ...7 36 Service Manual 5062 Go Back Previous Next Assembly 15 5 bin mailbox assembly interior 1 2 11 7 8 8 8 8 9 12 13 3 4 5 2 2 2 14 11 10 10 10 6 ...

Page 653: ...nsor 5 bin mailbox sensor pass thru assembly removal on page 4 252 7 40X4633 1 1 Bin full sensor 5 bin mailbox output bin sensors removal on page 4 248 8 40X7268 1 1 Bin full flag 5 bin mailbox media bin full actuator removal on page 4 244 9 40X4635 4 1 Deflector gate solenoid 5 bin mailbox diverter solenoid removal on page 4 239 10 40X5750 4 1 Diverter spring 5 bin mailbox diverter spring removal...

Page 654: ...7 38 Service Manual 5062 Go Back Previous Next Assembly 16 HTU complete 1 ...

Page 655: ...Parts catalog 7 39 5062 Go Back Previous Next Assembly 16 HTU complete Index P N Units mach Units FRU Description Removal procedure 16 1 40X7275 1 1 Redrive unit total asm N A ...

Page 656: ...7 40 Service Manual 5062 Go Back Previous Next Assembly 17 HTU covers 1 5 6 8 9 11 13 12 7 2 10 4 3 ...

Page 657: ...1 1 HTU right bottom cover HTU right bottom cover removal on page 4 315 6 40X7280 1 1 HTU front standard bin cover HTU front standard bin cover removal on page 4 294 7 40X7274 1 1 HTU outer front cover AIO only HTU outer front cover removal AIO only on page 4 310 8 40X7279 1 1 HTU front redrive cover HTU front redrive cover removal on page 4 293 9 40X7286 1 1 HTU top redrive cover HTU top redrive ...

Page 658: ...7 42 Service Manual 5062 Go Back Previous Next Assembly 18 HTU left interior 1 5 8 6 2 4 7 9 3 3 3 ...

Page 659: ... sensor removal on page 4 309 4 40X7324 1 1 Drive motor gears parts pkt M6 e clip 4 mm e clip Redrive pulley Pulley gear Idler roller HTU transport gear removal on page 4 330 5 40X7288 1 1 HTU belts pulley parts pkt HTU drive belt removal on page 4 290 and HTU timing belts rear removal on page 4 326 6 40X4626 1 1 HTU bin full send card HTU card bin full send card and lens removal on page 4 288 7 4...

Page 660: ...7 44 Service Manual 5062 Go Back Previous Next Assembly 19 HTU right interior 1 3 5 6 7 8 10 12 13 11 15 14 19 20 2 2 9 4 16 17 18 ...

Page 661: ...ns removal on page 4 287 10 40X5544 1 1 HTU bin full receive PCBA HTU card bin full receive card and lens removal on page 4 287 11 40X7310 1 1 HTU output bin divert solenoid HTU output bin solenoid removal on page 4 304 12 40X7281 1 1 HTU locking lever HTU locking lever removal on page 4 295 13 40X7311 1 1 HTU stop diverter HTU stopper diverter removal on page 4 325 14 40X7309 1 1 HTU output optio...

Page 662: ...7 46 Service Manual 5062 Go Back Previous Next Assembly 20 HTU with hole punch complete 1 ...

Page 663: ...catalog 7 47 5062 Go Back Previous Next Assembly 20 HTU with hole punch complete Index P N Units mach Units FRU Description Removal procedures 20 1 40X7235 1 1 Redrive unit with hole punch total assembly N A ...

Page 664: ...7 48 Service Manual 5062 Go Back Previous Next Assembly 21 HTU with hole punch covers 1 5 7 9 10 12 14 13 8 2 11 4 6 3 ...

Page 665: ...t bottom cover HTU right bottom cover removal on page 4 315 6 40X7299 1 1 Chad hopper HTU right bottom cover removal on page 4 315 7 40X7280 1 1 HTU front standard bin cover HTU front standard bin cover removal on page 4 294 8 40X7274 1 1 HTU outer front cover AIO only HTU outer front cover removal AIO only on page 4 310 9 40X7279 1 1 HTU front redrive cover HTU front redrive cover removal on page...

Page 666: ...7 50 Service Manual 5062 Go Back Previous Next Assembly 22 HTU with hole punch left interior 1 6 9 8 2 5 10 11 3 3 3 4 7 13 12 ...

Page 667: ... removal on page 4 283 5 40X7324 1 1 Drive motor gears parts pkt HTU transport gear removal on page 4 330 6 40X7288 1 1 HTU belts pulley parts pkt HTU drive belt removal on page 4 290 and HTU timing belts rear removal on page 4 326 7 40X7327 1 1 Punch motor HTU punch motor removal on page 4 334 8 40X4626 1 1 HTU bin full send card HTU card bin full send card and lens removal on page 4 288 9 40X730...

Page 668: ...r path MPF sensor Tray 1 machine side Duplex motor Staging motor Thermistor redrive HVPS cable Option bottom Ground Duplex door beacon side Ref edge ground Blower right side waste Duplexer Waste toner full 40X7169 1 OP panel cables parts packet including Front host USB Card reader Panel USB User interface card 40X7170 1 Beacon cables parts packet including Waste toner Bin full output beacon Front ...

Page 669: ...er sensor cable Jam latch cable Jam access door sensor cable Jam access door senor 2 cable Jam door LED cable N A 40X7273 1 Mailbox cable parts pack Bin full sensor cable Exit tray LED cable Tray LED cable Jam door LED cable Option to printer cable N A 40X7325 1 Tamper full cable N A 40X7154 1 Output options relocation kit N A 40X7249 1 Stapler unique cables 10P stapler unit cable 12P stapler tamp...

Page 670: ...card NS 40X4827 1 1 MarkNet N8130 10 1000 F adapter NS 40X5301 1 1 256MB DDR DRAM DIMM NS 40X5302 1 1 512MB DDR DRAM DIMM NS 40X5303 1 1 1GB DDR DRAM DIMM NS 40X5704 1 1 256MB NAND flash card NS 40X5969 1 1 Korean font card NS 40X5970 1 1 Simplified Chinese font card NS 40X5971 1 1 Traditional Chinese font card NS 40X5972 1 1 Japanese font card NS 40X6337 1 1 Arabic font card NS 40X7058 1 1 160GB ...

Page 671: ...J0944 ITU autoconnect cable Right frame System board connector JITM1 See ITU autoconnect removal on page 4 78 40X7167 10J0930 BLDC K ITU cable EP drive System board connector JKI1 See EP drive assembly removal on page 4 56 Note Use cable ties to attach the toroids to the new cables as you replace them 10J0931 BLDC Y fuser cable EP drive System board connector JYF1 10J0932 BLDC C M cable EP drive S...

Page 672: ... sensor plate assembly removal on page 4 108 2 Remove the LVPS exit duct to route the cable through the hole in the lower frame See LVPS exit duct removal on page 4 89 10J0933 Autocomp W2W cable Behind Tray 1 between MPF redrive gears and rear frame System board connector JTRAY1 See MPF drive assembly removal on page 4 106 10J0935 Duplex motor cable Left access door System board connector JDUPL1 S...

Page 673: ...paper path reference edge See Staging paper path reference edge assembly removal on page 4 142 10J0951 Paper path redrive sensor cable Paper path redrive System board connector JRDR1 See Paper path redrive assembly with sensors removal on page 4 117 10J0953 Blower right side waste cable Behind blower on top frame under printhead access cover System board connector JBLW1 See Printhead access cover ...

Page 674: ...See Top cover removal on page 4 30 10J0960 Front door beacon cable Waste toner left cover See Waste toner left cover removal on page 4 34 40X7171 10J0974 Weather station compensation thermistor On LVPS System board connector JCCT2 See step 5 of Low voltage power supply LVPS removal on page 4 86 10J1370 Fuser thermal guide assembly Behind fuser See Fuser thermistor removal on page 4 70 Cable locati...

Page 675: ...tion during reassembly Sizes are as close to actual as possible as long as the printout is not scaled or resized Screw identification table P N Screw type Location Qty 10B1580 6 Panhead Main fan to exit cooling fan duct 2 LVPS fan to LVPS exit duct 2 10J1046 3 x 5 mm Pads to bottom plate 6 Bottom plate to cartridge rails 2 10J1733 M3 5 x 10 mm Flathead ITU DS roller plate to paper path staging ass...

Page 676: ...frame 3 Ground cables to frame 4 LVPS to frame 3 Media tray rails to bottom plate 1 per rail 2 Post to HVPS board and frame plate above it 2 Rear cover to system board cage and frame 2 Rear upper cover to rear cover 2 Redrive motor to frame 2 Right cover to lower front frame 1 System board cage to support 1 Top cover to top frame 3 88A0231 M3x5 taptite 2000 sheet bracket to frame 4 2000 sheet cont...

Page 677: ...ports on system board to cage 2 88A0233 M3 x 8 Taptite 550 sheet bottom cover to 550 sheet drawer 2 88A0312 M02 9X06 ACR2 Panhead 550 sheet controller card assembly to 550 sheet drive assembly 4 2000 sheet elevator home sensor to frame 1 2000 sheet jam clearance sensor to frame 1 88A0313 Plastite M2 9 x 8 mm PAN Beacon cover to frame 1 2000 sheet controller card assembly to controller card housing...

Page 678: ... frame 3 Left cover to top cover and left frame 2 Left frame cable cover 1 Logo panel to top cover 3 Lower left cover to frame 2 LVPS exit duct to frame 2 LVPS to frame 2 Media rails left and right to front lower frame 2 MPF breakaway assembly front 3 MPF breakaway assembly rear 2 MPF cable cover to lower frame 2 MPF connector cover to duplex assembly 3 MPF drive assembly to frame 3 Operator panel...

Page 679: ...x 11 mm Duplex unit to left access door 1 88A0442 M3x5 2 T TITE SEMS 2000 sheet drive assembly to 2000 sheet drawer 3 2000 sheet left side cover to 2000 sheet drawer 7 2000 sheet pick assembly to 2000 sheet drawer 5 2000 sheet rear cover to 2000 sheet drawer 2 2000 sheet right side cover to 2000 sheet drawer 7 1126827 E clip M2 Left access door rear piston to door assembly 1 1126829 E clip M4 Fuse...

Page 680: ... Back Previous Next 1126830 E clip M5 Bellcrank daturn front and rear 2 MPF pivot shaft 2 MPF pulley 1 Spur 17T Helicai gear 2 1126831 E clip M6 MPF redrive gear 2 Screw identification table continued P N Screw type Location Qty ...

Page 681: ... of the pages available in various menus While they are as close as possible to what you will see variations in printing may result from individual user printer settings media and printer alignment Print tests Print Quality Pages Title page total of five From the Diagnostics menu select PRINT TESTS Print Quality Pages ...

Page 682: ...A 2 Service Manual 5062 Go Back Previous Next Print Quality Pages Page 1 total of five ...

Page 683: ...Appendix A Print samples A 3 5062 Go Back Previous Next Print Quality Pages Page 2 total of five ...

Page 684: ...A 4 Service Manual 5062 Go Back Previous Next Print Quality Pages Page 3 total of five ...

Page 685: ...Appendix A Print samples A 5 5062 Go Back Previous Next Print Quality Pages Page 4 total of five ...

Page 686: ...A 6 Service Manual 5062 Go Back Previous Next Registration and alignment Quick Test Page From the Diagnostics menu select REGISTRATION Quick Test ...

Page 687: ...Appendix A Print samples A 7 5062 Go Back Previous Next Printhead mechanical alignment test page From the Diagnostics menu select MISC TESTS Printhead Inst ...

Page 688: ...A 8 Service Manual 5062 Go Back Previous Next Printhead electronic alignment test page Magenta one of two From the Diagnostics menu select Alignment Menu select a color Quick Test ...

Page 689: ...Appendix A Print samples A 9 5062 Go Back Previous Next Printhead electronic alignment test page Magenta two of two ...

Page 690: ...A 10 Service Manual 5062 Go Back Previous Next Printhead linearity test page From the Diagnostics menu select Alignment Menu select a color Linearity Quick Test ...

Page 691: ...42 cartridge memory block parts catalog 7 8 cartridge metering cable removal 4 46 cartridge rail removal 4 47 cartridge rails parts catalog 7 6 Color Adjustment 3 28 Color Alignment 3 29 Color Trapping 3 27 Configuration ID 3 23 configuration menu 3 26 accessing 3 6 Auto Align Adj 3 29 Black Only Mode 3 27 Color Adjustment 3 28 Color Alignment 3 29 Color Trapping 3 27 Disk Encryption 3 29 Download...

Page 692: ... 23 Serial Number 3 23 REGISTRATION 3 10 diagnostics menu accessing 3 6 Diagnostics Mode ALIGNMENT MENU 3 11 Disk Encryption 3 29 Diverter Test 3 19 Download Emuls 3 28 DRAM Test 3 14 Drift Sensors 3 12 DUAL DIODE ADJUST 3 9 duplex assembly removal 4 53 Duplex Quick Test 3 16 Duplex Top Margin Offset 3 16 duplex unit parts catalog 7 4 E E clip identification 7 59 Energy Conserve 3 28 Engine Settin...

Page 693: ...al 4 11 low voltage power supply removal 4 86 lubrication fuser drive assembly 6 3 redrive parts packet 6 2 lubrication specifications 6 1 LVPS parts catalog 7 14 LVPS exit duct parts catalog 7 14 removal 4 89 LVPS fan parts catalog 7 14 removal 4 90 M main cooling duct parts catalog 7 14 main fan parts catalog 7 14 removal 4 92 Mechanical Test 3 19 media specifications characteristics 1 10 recomm...

Page 694: ... 2 2 PPDS Emulation 3 28 preventive maintenance 6 1 print quality background 2 31 blank page 2 33 blurred or fuzzy print 2 34 characters have jagged or uneven edges 2 34 colors not properly aligned 2 35 dark print 2 41 horizontal banding 2 36 horizontal lines 2 36 incorrectly colored line on page 2 37 light colored line on page 2 37 light print 2 41 media damage 2 38 missing image at edge 2 34 mot...

Page 695: ...ar upper cover 4 22 redrive motor 4 135 right cover 4 24 sensors D1 D2 fuser bubble 4 137 sensors input S1 narrow media near narrow media 4 138 speaker 4 139 staging deflector assembly 4 140 staging paper path reference edge assembly 4 142 standard media tray 4 150 system board 4 151 system board cage with board 4 155 system board shield 4 27 toner cartridge rail 4 47 top cover 4 30 waste toner co...

Page 696: ... belt 4 290 drive gear spring 4 291 engagement roller 4 292 exit roller 4 293 front redrive cover 4 293 front standard bin cover 4 294 HTU to printer cable 4 327 locking lever 4 295 locking lever card 4 297 lower redrive guide 4 297 option hook 4 300 option roller 4 302 outer front cover removal 4 310 output bin 4 303 output bin extension 4 303 output bin solenoid 4 304 output bin wire stop 4 305 ...

Page 697: ...66 tray empty 2 169 tray jam indicator 2 171 tray linking 2 171 service error 900 xx System software error 2 132 service errors 100 199 2 60 900 999 2 62 service tips identifying system board cabling 5 1 setting printer alignment 3 11 SIZE SENSING 3 28 speaker parts catalog 7 2 removal 4 139 specifications acoustics 1 5 dimensions 1 4 electrical 1 4 environment 1 5 memory configuration 1 7 operati...

Page 698: ... Next waste toner cover removal 4 34 waste toner full sensor removal 4 162 waste toner gears parts catalog 7 14 waste toner left cover parts catalog 7 2 waste toner sensor removal 4 159 waste toner tray bracket parts catalog 7 6 removal 4 163 ...

Page 699: ...40X4622 Rear tamper motor assembly 7 27 40X4623 Tamper drive belt 7 27 40X4624 Tamper recoil spring 7 27 40X4626 HTU bin full send card 7 43 7 51 40X4626 Send PCBA transparency detect 7 51 40X4626 Sensor bin full send 7 25 40X4633 Bin full sensor 7 37 40X4635 Deflector gate solenoid 7 37 40X4647 Output bin LED bracket 7 37 40X4819 Serial interface card 7 54 40X4823 Parallel 1284 B SERI adapter 7 5...

Page 700: ...40X6919 IPDS SCS card 7 54 40X6920 PRESCRIBE card 7 54 40X6967 550 sheet tray option 7 17 40X6968 2000 sheet high capacity feeder media tray option 7 21 40X6969 2000 sheet high capacity feeder lift drive motor assembly 7 23 40X6970 2000 sheet high capacity feeder left cover 7 23 40X6971 2000 sheet high capacity feeder right cover 7 23 40X6972 2000 sheet high capacity feeder rear cover 7 23 40X7051...

Page 701: ...152 MPF drive assembly 7 15 40X7153 Left access door pistons parts pack 7 13 40X7154 Output options relocation kit 7 53 40X7155 Exit cooling duct assembly 7 15 40X7156 Duplex assembly 7 5 40X7157 Belts parts packet 7 5 40X7158 Staging paper path assembly 7 7 40X7160 Paper pick mechanism assembly 7 9 40X7161 Waste toner tray bracket 7 7 40X7162 Waste toner gears parts packet 7 15 40X7163 Sensors pa...

Page 702: ... 40X7260 Backup roll plate 7 37 40X7261 LED jam cover 7 35 40X7262 Output bin deflector 7 37 40X7263 Top output bin roller 7 37 40X7264 1 thru 4 output bin roller 7 37 40X7265 Pass thru sensor 7 37 40X7266 Output bin paper bail 7 35 40X7267 Output bin extension cover 7 35 40X7268 Bin full flag 7 37 40X7269 Feed motor with bracket 7 37 40X7270 Rear cover 7 35 40X7271 Controller card 7 37 40X7272 To...

Page 703: ...verter 7 45 40X7312 HTU lower redrive guide 7 43 7 51 40X7313 HTU access door output option position sensor 7 45 40X7314 HTU input 2nd output sensor 7 43 7 51 40X7315 HTU bin full send rec lens 7 43 7 51 40X7315 HTU bin full send receive lens 7 45 40X7316 HTU drive gear spring 7 43 7 51 40X7317 HTU transport motor 7 45 40X7318 HTU exit roller 7 45 40X7319 HTU upper exit shaft 7 45 40X7320 HTU cabl...

Page 704: ...I 14 Service Manual 5062 Go Back Previous Next ...

Page 705: ...e Port USB Port K M C Y Fuser Drive Assembly ITU Motor EP Drive Assembly Paper Pick Mechanism LVPS Fan JL1 JDP1 8 1 2 3 4 5 6 7 9 JDUPL1 1 2 3 4 5 6 1 2 3 4 5 JWTB1 Optional Hard Drive JCVR1 1 2 3 4 5 JPP2 JIOPT1 Thermistor LVPS FG Power Switch Input Option Waste Toner Full Sensor Duplex Unit Door LED Paper Path Sensor MPF Sensor Motor Motor Paper Path Staging Duplex Motor Staging Motor Staging De...

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